Understanding automotive electronics : An engineering perspective

Understanding Automotive

Electronics

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Understanding Automotive

Electronics

An Engineering Perspective

Eighth edition

William B. Ribbens

Department of Electrical Engineering and Computer Science,

University of Michigan, Ann Arbor, MI, USA

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correcting errors, this book would not have been completed.

I dedicate this work to her.

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Contents

CHAPTER 1 Overview ..................................................................................................... 1

CHAPTER 2 Electronic Fundamentals ........................................................................ 23

Semiconductor Devices............................................................................................ 24

Diodes ................................................................................................................... 27

Zener Diode .......................................................................................................... 29

Electro Optics ........................................................................................................... 30

Photo Conductor ................................................................................................... 31

Photo Diode .......................................................................................................... 32

Light Generating Diode........................................................................................ 34

Laser Diode........................................................................................................... 34

Rectifier Circuit........................................................................................................ 35

Communications Applications of Diodes ............................................................ 37

Transistors............................................................................................................. 37

Field-Effect Transistors ........................................................................................ 45

FET Theory .............................................................................................................. 47

FET Amplifier ...................................................................................................... 50

Integrated Circuits .................................................................................................... 52

Operational Amplifiers ......................................................................................... 53

Use of Feedback in Op-Amps.................................................................................. 54

Summing Mode Amplifier ....................................................................................... 56

Comparator ........................................................................................................... 57

Zero-Crossing Detector ........................................................................................ 58

Phase-Locked Loop .............................................................................................. 58

Sample and Zero-Order Hold Circuits................................................................. 60

Zero-Order Hold Circuit....................................................................................... 63

Bidirectional Switch ............................................................................................. 64

Digital Circuits ......................................................................................................... 66

Binary Number System ............................................................................................ 68

Logic Circuits (Combinatorial)................................................................................ 69

AND Gate ............................................................................................................. 70

OR Gate ................................................................................................................ 70

NOT Gate.............................................................................................................. 70

Boolean Algebra ................................................................................................... 71

Exemplary Circuits for Logic Gates .................................................................... 71

Combination Logic Circuits ................................................................................. 75

Logic Circuits with Memory (Sequential)............................................................... 77

R-S Flip-Flop........................................................................................................ 77

vii

JK Flip-Flop.......................................................................................................... 78

D Flip-Flop ........................................................................................................... 79

Timer Circuit ........................................................................................................ 80

Synchronous Counter ............................................................................................... 83

Register Circuits ................................................................................................... 83

Shift Register ........................................................................................................ 84

Digital Integrated Circuits........................................................................................ 86

The MPU .................................................................................................................. 87

CHAPTER 3 Microcomputer Instrumentation and Control....................................... 89

Microcomputer Fundamentals.................................................................................. 91

Digital Computer .................................................................................................. 91

Parts of a Computer.............................................................................................. 91

Microcomputers versus Mainframe Computers................................................... 92

Programs ............................................................................................................... 93

Microcomputer Tasks............................................................................................... 93

Microcomputer Operations....................................................................................... 94

Buses..................................................................................................................... 94

Memory-Read/Write............................................................................................. 94

Timing................................................................................................................... 96

Addressing Peripherals ......................................................................................... 96

CPU Registers .......................................................................................................... 97

Accumulator Register........................................................................................... 98

Condition Code Register ...................................................................................... 98

Microprocessor Architecture .............................................................................. 100

Reading Instructions............................................................................................... 100

Initialization........................................................................................................ 102

Operation Codes ................................................................................................. 102

Program Counter................................................................................................. 102

Branch Instruction .............................................................................................. 104

Jump Instruction ................................................................................................. 105

Jump-to-Subroutine Instruction.......................................................................... 105

Example Use of a Microcomputer......................................................................... 107

Buffer .................................................................................................................. 107

Programming Languages........................................................................................ 108

Assembly Language ........................................................................................... 109

Logic Functions .................................................................................................. 109

Shift..................................................................................................................... 110

Programming the AND Function in Assembly Language................................. 111

Masking............................................................................................................... 112

viii Contents

Shift and AND.................................................................................................... 113

Use of Subroutines ............................................................................................. 113

Microcomputer Hardware ...................................................................................... 114

Central Processing Unit...................................................................................... 114

Memory: ROM ................................................................................................... 115

Memory: RAM ................................................................................................... 115

I/O Parallel Interface .......................................................................................... 115

Digital-to-Analog Converter............................................................................... 116

Analog-to-Digital Converter............................................................................... 118

Sampling ............................................................................................................. 120

Polling................................................................................................................. 121

Interrupts............................................................................................................. 121

Vectored Interrupts ............................................................................................. 122

Microcomputer Applications in Automotive Systems .......................................... 122

Instrumentation Applications of Microcomputers................................................. 124

Digital Filters...................................................................................................... 126

Microcomputers in Control Systems ..................................................................... 128

Closed-Loop Control System ............................................................................. 128

Limit-Cycle Controller ....................................................................................... 128

Feedback Control Systems ................................................................................. 128

Table Lookup...................................................................................................... 130

Multivariable and Multiple Task Systems ......................................................... 132

AUTOSAR ............................................................................................................. 133

CHAPTER 4 The Basics of Electronic Engine Control ........................................... 135

Motivation for Electronic Engine Control............................................................. 136

Exhaust Emissions.................................................................................................. 136

Fuel Economy......................................................................................................... 137

Federal Government Test Procedures.................................................................... 137

Fuel Economy Requirements ............................................................................. 140

Meeting the Requirements.................................................................................. 141

The Role of Electronics...................................................................................... 141

Concept of an Electronic Engine Control System................................................. 142

Inputs to Controller ............................................................................................ 144

Output from Controller....................................................................................... 145

Basic Principle of Four-Stroke Engine Operation ............................................. 146

Definition of Engine Performance Terms.............................................................. 150

Torque................................................................................................................. 150

Power .................................................................................................................. 153

Fuel Consumption............................................................................................... 154

Contents ix

Engine Overall Efficiency.................................................................................. 156

Calibration .......................................................................................................... 156

Engine Mapping ................................................................................................. 157

Effect of Air/Fuel Ratio on Performance........................................................... 157

Effect of Spark Timing on Performance............................................................ 158

Effect of EGR on Performance .......................................................................... 159

Exhaust Catalytic Converters................................................................................. 161

Oxidizing Catalytic Converter ........................................................................... 161

The Three-Way Catalyst .................................................................................... 162

Electronic Fuel Control System ............................................................................. 164

Engine Control Sequence ................................................................................... 166

OL Control.......................................................................................................... 167

CL Control.......................................................................................................... 167

CL Operation ...................................................................................................... 169

Analysis of Intake Manifold Pressure.................................................................... 172

Measuring Air Mass ........................................................................................... 173

Influence of Valve System on Volumetric Efficiency ...................................... 175

Idle Speed Control.................................................................................................. 176

Electronic Ignition.................................................................................................. 181

CHAPTER 5 Sensors and Actuators.......................................................................... 183

Automotive Control System Applications of Sensors and Actuators ................... 184

Variables to be Measured................................................................................... 185

Airflow Rate Sensor ........................................................................................... 186

Pressure Measurements ...................................................................................... 191

Engine Crankshaft Angular Position Sensor...................................................... 194

Magnetic Reluctance Position Sensor................................................................ 195

Hall-Effect Position Sensor ................................................................................ 205

Optical Crankshaft Position Sensor ................................................................... 208

Throttle Angle Sensor ............................................................................................ 211

Temperature Sensors .............................................................................................. 213

Typical Coolant Sensor .......................................................................................... 214

Sensors for Feedback Control ................................................................................ 215

Exhaust Gas Oxygen Sensor .............................................................................. 215

Oxygen Sensor Improvements ........................................................................... 220

Knock Sensors ........................................................................................................ 221

Angular Rate Sensor............................................................................................... 223

LIDAR .................................................................................................................... 227

Digital Video Camera ............................................................................................ 229

x Contents

Flex-Fuel Sensor..................................................................................................... 235

Oscillator Methods of Measuring Capacitance.................................................. 239

Acceleration Sensor............................................................................................ 244

Automotive Engine Control Actuators .................................................................. 247

Fuel Injection...................................................................................................... 251

Exhaust Gas Recirculation Actuator .................................................................. 253

Variable Valve Timing........................................................................................... 254

VVP Mechanism Model ..................................................................................... 257

Electric Motor Actuators........................................................................................ 258

Two-Phase Induction Motor............................................................................... 263

Brushless DC Motors ......................................................................................... 266

Stepper Motors ....................................................................................................... 268

Ignition System....................................................................................................... 268

Ignition Coil Operations..................................................................................... 269

CHAPTER 6 Digital Powertrain Control Systems .................................................... 271

Introduction ............................................................................................................ 272

Digital Engine Control ........................................................................................... 272

Digital Engine Control Features ............................................................................ 274

Control Modes for Fuel Control ............................................................................ 277

Engine Start ........................................................................................................ 278

Open-Loop Mode................................................................................................ 278

Acceleration/Deceleration .................................................................................. 278

Idle Mode............................................................................................................ 279

Engine Control Configuration............................................................................ 279

Engine Crank ...................................................................................................... 281

Engine Warm-Up................................................................................................ 281

Open-Loop Control............................................................................................. 283

Closed-Loop Control .......................................................................................... 284

Acceleration Enrichment .................................................................................... 288

Deceleration Leaning.......................................................................................... 289

Idle Speed Control.............................................................................................. 289

Discrete Time Idle Speed Control ......................................................................... 291

EGR Control........................................................................................................... 294

Variable Valve Timing Control ............................................................................. 296

Turbocharging ........................................................................................................ 302

Direct Fuel Injection .............................................................................................. 306

Flex Fuel................................................................................................................. 308

Electronic Ignition Control .................................................................................... 309

Closed-Loop Ignition Timing............................................................................. 312

Spark Advance Correction Scheme ................................................................... 317

Contents xi

Integrated Engine Control System ......................................................................... 318

Secondary Air Management............................................................................... 319

Evaporative Emissions Canister Purge .............................................................. 319

Automatic System Adjustment........................................................................... 319

System Diagnosis................................................................................................ 320

Summary of Control Modes................................................................................... 321

Engine Crank (Start)........................................................................................... 321

Engine Warm-Up................................................................................................ 321

Open-Loop Control............................................................................................. 322

Closed-Loop Control .......................................................................................... 322

Hard Acceleration............................................................................................... 322

Deceleration and Idle.......................................................................................... 323

Automatic Transmission Control ....................................................................... 323

Torque Converter Lock-Up Control................................................................... 329

Differential and Traction Control ...................................................................... 329

Hybrid Electric Vehicle Powertrain Control...................................................... 331

CHAPTER 7 Vehicle Motion Controls....................................................................... 343

Representative Cruise Control System .................................................................. 344

Digital Cruise Control ........................................................................................ 351

Hardware Implementation Issues ....................................................................... 354

Throttle Actuator ................................................................................................ 356

Cruise Control Electronics ..................................................................................... 359

Stepper Motor-based Actuator Electronics ........................................................ 360

Vacuum-Operated Actuator................................................................................ 362

Advanced Cruise Control ................................................................................... 364

Antilock Braking System ....................................................................................... 368

Tire Slip Controller ............................................................................................ 377

Electronic Suspension System ............................................................................... 377

Variable Damping via Variable Strut Fluid Viscosity ...................................... 395

Variable Spring Rate .......................................................................................... 396

Electronic Suspension Control System.................................................................. 397

Electronic Steering Control................................................................................ 398

Four-Wheel Steering CAR..................................................................................... 401

Summary................................................................................................................. 408

CHAPTER 8 Automotive Instrumentation ................................................................. 409

Modern Automotive Instrumentation..................................................................... 410

Input and Output Signal Conversion ..................................................................... 413

Multiplexing........................................................................................................ 415

Multirate Sampling............................................................................................. 416

xii Contents

Advantages of Computer-Based Instrumentation.................................................. 419

Display Devices...................................................................................................... 419

Galvanometer-Type Display............................................................................... 420

Electro Optic Displays........................................................................................ 423

Light-Emitting Diode ......................................................................................... 424

Liquid-Crystal Display ....................................................................................... 426

Transmissive LCD.............................................................................................. 428

Vacuum-Fluorescent Display ............................................................................. 429

Alpha-Numeric Display...................................................................................... 431

Flat Panel Display Instrument Clusters.............................................................. 434

Pictorial Display Capability of FPD .................................................................. 441

Digital Maps ....................................................................................................... 442

Touch Screen ...................................................................................................... 443

Measurement Examples ......................................................................................... 447

Fuel Quantity Measurement ............................................................................... 447

Coolant Temperature Measurement....................................................................... 452

Oil Pressure Measurement ..................................................................................... 454

Vehicle Speed Measurement.................................................................................. 456

Trip Information Function of the System.............................................................. 457

CHAPTER 9 Vehicle Communications...................................................................... 461

IVN ......................................................................................................................... 462

CAN........................................................................................................................ 464

CAN Bus Transceiver......................................................................................... 467

CAN Electronic Circuits .................................................................................... 469

Arbitration on CAN............................................................................................ 472

Local Interconnect Network (LIN) ........................................................................ 472

FlexRay IVN .......................................................................................................... 474

FlexRay Transceiver Circuit .............................................................................. 477

MOST IVN............................................................................................................. 478

Vehicle to Infrastructure Communication ............................................................. 481

Vehicle-to-Cellular Infrastructure .......................................................................... 482

Quadrature Phase Shifter and Phase Modulation (QPSR) .................................... 487

Short-Range Wireless Communications ................................................................ 488

Satellite Vehicle Communication .......................................................................... 490

GPS Navigation ...................................................................................................... 493

The GPS System Structure................................................................................. 500

Safety Aspects of Vehicle-to-Infrastructure Communication ............................... 503

Contents xiii

CHAPTER 10 Electronic Safety-Related Systems..................................................... 505

Airbag Safety Device ............................................................................................. 505

Blind Spot Detection .............................................................................................. 512

Automatic Collision Avoidance System................................................................ 515

Lane Departure Monitor......................................................................................... 521

Tire Pressure Monitoring System .......................................................................... 522

Enhanced Vehicle Stability.................................................................................... 524

CHAPTER 11 Diagnostics............................................................................................. 533

Electronic Control System Diagnostics ................................................................. 534

Service Bay Diagnostic Tool ................................................................................. 536

Onboard Diagnostics .............................................................................................. 536

Model-Based Sensor Failure Detection ................................................................. 538

General Model-Based Diagnostics......................................................................... 539

Diagnostic Fault Codes .......................................................................................... 543

Onboard Diagnosis (OBD II)................................................................................. 555

Misfire Detection................................................................................................ 555

Model-Based Misfire Detection System................................................................ 555

Expert Systems in Automotive Diagnosis ............................................................. 567

CHAPTER 12 Autonomous Vehicles............................................................................ 573

Automatic Parallel Parking System ....................................................................... 575

Autonomous Vehicle Block Diagram.................................................................... 581

Appendix A: The Systems Approach to Control and Instrumentation ............................................ 595

Appendix B: Discrete Time Systems Theory ................................................................................... 641

Appendix C: Dynamics in Moving Coordinate Systems.................................................................. 665

Appendix D: FDI Feedback Matrix Design...................................................................................... 669

Appendix E: Coordinate Transformation.......................................................................................... 673

Appendix F: GPS Theory.................................................................................................................. 677

Index .................................................................................................................................................. 683

xiv Contents