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Bosch Professional Automotive
Information

Konrad Reif Ed.

Automotive
Mechatronics
Automotive Networking · Driving
Stability Systems · Electronics

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Bosch Professional Automotive Information

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Bosch Professional Automotive Information is a definitive reference for

automotive engineers. The series is compiled by one of the world´s largest
automotive equipment suppliers. All topics are covered in a concise but
descriptive way backed up by diagrams, graphs, photographs and tables
enabling the reader to better comprehend the subject.
There is now greater detail on electronics and their application in the motor
vehicle, including electrical energy management (EEM) and discusses the
topic of intersystem networking within vehicle. The series will benefit
automotive engineers and design engineers, automotive technicians in
training and mechanics and technicians in garages.

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Konrad Reif
Editor

Automotive Mechatronics
Automotive Networking, Driving Stability
Systems, Electronics

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Editor
Prof. Dr.-Ing. Konrad Reif
Duale Hochschule Baden-Württemberg
Friedrichshafen, Germany
[email protected]

ISBN 978-3-658-03974-5 ISBN 978-3-658-03975-2(eBook)

DOI 10.1007/978-3-658-03975-2

Library of Congress Control Number: 2014946887

Springer Vieweg
© Springer Fachmedien Wiesbaden 2015
This work is subject to copyright. All rights are reserved, whether the whole or part of the material is
concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting,
reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication
or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965,
in its current version, and permission for use must always be obtained from Springer. Violations are liable
to prosecution under the German Copyright Law.

The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply,
even in the absence of a specific statement, that such names are exempt from the relevant protective laws
and regulations and therefore free for general use.

Printed on acid-free paper

Springer Vieweg is part of Springer Science+Business Media

www.springer-vieweg.de

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Foreword V

▶ Foreword

As the complexity of automotive vehicles increases this book presents operational

and practical issues of automotive mechatronics. It is a comprehensive introduction
to controlled automotive systems and provides detailed information of sensors for
travel, angle, engine speed, vehicle speed, acceleration, pressure, temperature, flow,
gas concentration etc. The measurement principles of the different sensor groups are
explained and examples to show the measurement principles applied in different
types.

Complex technology of modern motor vehicles and increasing functions need a

reliable source of information to understand the components or systems. The rapid
and secure access to these informations in the field of Automotive Electrics and Elec-
tronics provides the book in the series “Bosch Professional Automotive Information”
which contains necessary fundamentals, data and explanations clearly, systemati-
cally, currently and application-oriented. The series is intended for automotive pro-
fessionals in practice and study which need to understand issues in their area of work.
It provides simultaneously the theoretical tools for understanding as well as the
applications.

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VI Contents

▶ Contents

2 Basics of mechatronics 165 Overview of the physical effects for sensors

2 Mechatronic systems and components 167 Overview and selection of sensor
4 Development methods technologies
6 Outlook
168 Sensor measuring principles
8 Architecture 168 Position sensors
8 Overview 195 Speed and rpm sensors
11 Vehicle system architecture 207 Acceleration sensors
212 Pressure sensors
18 Electronic control unit 215 Force and torque sensors
18 Operating conditions 224 Flowmeters
18 Design 230 Gas sensors and concentration sensors
18 Data processing 234 Temperature sensors
22 Digital modules in the control unit 244 Imaging sensors (video)
26 Control unit software
30 Software Development 246 Sensor types
246 Engine-speed sensors
44 Basic principles of networking 248 Hall phase sensors
44 Network topology 249 Speed sensors for transmission control
48 Network organization 252 Wheel-speed sensors
50 OSI reference model 256 Micromechanical yaw-rate sensors
52 Control mechanisms 259 Piezoelectric “tuning-fork” yaw-rate sensor
260 Micromechanical pressure sensors
56 Automotive networking 262 High-pressure sensors
56 Cross-system functions 263 Temperature sensors
57 Requirements for bus systems 264 Accelerator-pedal sensors
59 Classification of bus systems 266 Steering-angle sensors
59 Applications in the vehicle 268 Position sensors for transmission control
61 Coupling of networks 271 Axle sensors
61 Examples of networked vehicles 272 Hot-film air-mass meters
275 Piezoelectric knock sensors
70 Bus systems 276 SMM acceleration sensors
70 CAN bus 278 Micromechanical bulk silicon acceleration
84 LIN bus sensors
90 Bluetooth 279 Piezoelectric acceleration sensors
100 MOST bus 280 iBolt™ force sensor
111 TTP/C 282 Torque sensor
124 FlexRay 283 Rain/light sensor
136 Diagnosis interfaces 284 Two-step Lambda oxygen sensors
288 LSU4 planar wide-band lambda oxygen
144 Automotive sensors sensor
144 Basics and overview
147 Automotive applications 290 Electric Actuators
150 Details of the sensor market 290 Electromechanical actuators
151 Features of vehicle sensors 295 Fluid-mechanical actuators
152 Sensor classification 296 Electrical machines
154 Error types and tolerance requirements
155 Reliability 302 Electrohydraulic Actuators
158 Main requirements, trends 302 Application and Function

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Contents VII

302 Requirements 404 Hydraulic modulator

303 Design and Operating Concept 404 Development history
304 Actuator Types 405 Design
313 Simulations in Development 408 Pressure modulation

316 Electronic Transmission Control 412 Sensotronic brake control (SBC)

316 Drivetrain Management 412 Purpose and function
317 Market Trends 414 Design
318 Control of Automated Shift Transmission 414 Method of operation
AST
322 Control of Automatic Transmissions 416 Overview of common-rail systems
338 Control of Continuously Variable 416 Areas of application
Transmission 417 Design
340 ECUs for Electronic Transmission Control 418 Operating concept
347 Thermo-Management 422 Common-rail system for passenger cars
349 Processes and Tools Used in 427 Common-rail system for commercial
ECU Development vehicles

350 Modules for Transmission Control 430 High-pressure components of common-rail

350 Application system
351 Module Types 430 Overview
432 Injector
354 Antilock Braking System (ABS) 444 High-pressure pumps
354 System overview 450 Fuel rail (high-pressure accumulator)
356 Requirements placed on ABS 451 High-pressure sensors
357 Dynamics of a braked wheel 452 Pressure-control valve
358 ABS control loop 453 Pressure-relief valve
362 Typical control cycles
454 Electronic Diesel Control (EDC)
370 Traction Control System (TCS) 454 System overview
370 Tasks 456 Common-rail system for passenger cars
370 Function description 457 Common-rail system for commercial
372 Structure of traction control system (TCS) vehicles
373 Typical control situations 458 Data processing
374 Traction control system (TCS) for four 460 Fuel-injection control
wheel drive vehicles 468 Lambda closed-loop control for
passenger-car diesel engines
378 Electronic Stability Program (ESP) 473 Torque-controlled EDC systems
378 Requirements 476 Data exchange with other systems
379 Tasks and method of operation 477 Serial data transmission (CAN)
380 Maneuvers
388 Closed-loop control system and controlled 478 Active steering
variables 478 Purpose
478 Design
394 Automatic brake functions 480 Method of operation
394 Overview 481 Safety concept
396 Standard function 481 Benefits of active steering for the driver
398 Additional functions

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VIII Contents

482 Drive and adjustment systems 496 Electromagnetic compatibility (EMC) and
482 Power windows interference suppression
483 Power sunroofs 496 EMC ranges
484 Seat and steering column adjustment 497 EMC between different systems in the
vehicle
485 Heating, ventilation and air conditioning 504 EMC between the vehicle and its
485 Electronic heater control surroundings
485 Electronically controlled air conditioning 508 Guarantee of immunity and interference
system suppression

488 Vehicle security systems 510 Fault diagnostics

488 Acoustic signaling devices 510 Monitoring during vehicle operation
489 Central locking system (on-board diagnosis)
490 Locking systems 513 On-board diagnosis system for passenger
494 Biometric systems cars and light-duty trucks
520 On-board diagnosis system for heavy-duty
trucks

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Authors IX

 Authors

Basics of mechatronics Dipl.-Ing. Christian Gerhardt,

Dipl.-Ing. Hans-Martin Heinkel, Dipl.-Ing. Klaus Miekley,

Dr.-Ing. Klaus-­Georg Bürger. Dipl.-Ing. Roger Frehoff,

Dipl.-Ing. Martin Mast,

Architecture Dipl.-Ing. (FH) Bernhard Bauer,

Dr. phil. nat. Dieter Kraft, Dr. Michael Harder,

Dipl.-Ing. Stefan Mischo. Dr.-Ing. Klaus Kasten,

Dipl.-Ing. Peter Brenner, ZF Lenksysteme GmbH,

Electronic control units Schwäbisch Gmünd,

Dipl.-Ing. Martin Kaiser, Dipl.-Ing. Frank Wolf,

Dr. rer. nat. Ulrich ­Schaefer, Dr.-Ing. Johann ­Riegel.

Dipl.-Ing. (FH) Gerhard Haaf.

Electric Actuators
Basic principles of networking
Dr.-Ing. Rudolf Heinz,
Automotive networking
Dr.-Ing. Robert Schenk.
Bus systems
Dipl.-Ing. Stefan Mischo,
Electrohydraulic Actuators
Dipl.-Ing. (FH) Stefan Powolny,
Electronic Transmission Control
Dipl.-Ing. Hanna Zündel,
Modules for Transmission Control
Dipl.-Ing. (FH) Norbert Löchel,
Dipl.-Ing. D. Fornoff,
Dipl.-Inform. Jörn Stuphorn,
D. Grauman,
Universität Bielefeld,
E. Hendriks,
Dr. Rainer Constapel, Daimler AG Sindelfingen,
Dipl.-Ing. T. Laux,
Dipl.-Ing. Peter Häussermann,
Dipl.-Ing. T. Müller,
Daimler AG Sindelfingen,
Dipl.-Ing. A. Schreiber,
Dr. rer. nat. Alexander Leonhardi,
Dipl.-Ing. S. Schumacher,
Daimler AG Sindelfingen,
Dipl.-Ing. W. Stroh.
Dipl.-Inform. Heiko Holtkamp,
Universität Bielefeld.
Antilock Braking System (ABS)
Traction Control System (TCS)
Automotive sensors
Electronic Stability Program (ESP)
Sensor measuring principles
Automatic brake functions
Sensor types
Hydraulic modulator
Dr.-Ing. Erich Zabler,
Dipl.-Ing. Friedrich Kost
Dr. rer. nat. Stefan Fink­beiner,
(Basic Principles of Vehicle Dynamics),
Dr. rer. nat. Wolfgang Welsch,
Dipl.-Ing. Heinz-Jürgen Koch-Dücker
Dr. rer. nat. Hartmut Kittel,
(Antilock Braking Systems, ABS),
Dr. rer. nat. Christian Bauer,
Dr.-Ing. Frank Niewels and
Dipl.-Ing. Günter Noetzel,
Dipl.-Ing. Jürgen Schuh
Dr.-Ing. Harald Emmerich,
(Traction Control Systems, TCS),
Dipl.-Ing. (FH) Gerald Hopf,
Dipl.-Ing. Thomas Ehret
Dr.-Ing. Uwe Konzelmann,
(Electronic Stability Program, ESP),
Dr. rer. nat. Thomas Wahl,
Dipl.-Ing. (FH) Jochen Wagner
Dr.-Ing. Reinhard Neul,
(Automatic Brake Functions),
Dr.-Ing. Wolfgang-Michael Müller,
Dipl.-Ing. (FH) Ulrich Papert
Dr.-Ing. Claus Bischoff,
(Wheel-Speed Sensors),
Dr. Christian Pfahler,
Dr.-Ing. Frank Heinen and
Dipl.-Ing. Peter Weiberle,
Peter Eberspächer
Dipl.-Ing. (FH) Ulrich Papert,

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X Authors

Sensotronic brake control (SBC) Active steering

Dipl.-Ing. Bernhard Kant. Dipl.-Ing. (FH) Wolfgang Rieger,
ZF Lenksysteme, Schwäbisch Gmünd.
Overview of common-rail systems
High-pressure components of common-rail Drive and adjustment systems
system Dipl.-Ing. Rainer Kurzmann,
Electronic Diesel Control (EDC) Dr.-Ing. Günter Hartz.
Dipl.-Ing. Felix Landhäußer,
Dr.-Ing. Ulrich Projahn, Heating, ventilation and air conditioning
Dipl.-Inform. Michael Heinzelmann, Dipl.-Ing. Gebhard Schweizer,
Dr.-Ing. Ralf Wirth Behr GmbH & Co., Stuttgart.
(Common-rail system),
Ing. grad. Peter Schelhas, Vehicle security systems
Dipl.-Ing. Klaus Ortner Dipl.-Ing. (FH) Jürgen Bowe,
(Fuel-supply pumps), Andreas Walther,
Dipl.-Betriebsw. Meike Keller Dr.-Ing. B. Kordowski,
(Fuel filters), Dr.-Ing. Jan Lichtermann.
Dipl.-Ing. Sandro Soccol,
Dipl.-Ing. Werner Brühmann Electromagnetic compatibility
(High-pressure pumps), Dr.-Ing. Wolfgang Pfaff.
Ing. Herbert Strahberger,
Ing. Helmut Sattmann Fault diagnostics
(Fuel rail and add-on components), Dr.-Ing. Matthias Knirsch,
Dipl.-Ing. Thilo Klam, Dipl.-Ing. Bernd Kesch,
Dipl.-Ing. (FH) Andreas Rettich, Dr.-Ing. Matthias Tappe,
Dr. techn. David Holzer, Dr,-Ing. Günter Driedger,
Dipl.-Ing. (FH) Andreas Koch Dr. rer. nat. Walter Lehle.
(Solenoid-valve injectors),
Dr.-Ing. Patrick Mattes and the editorial team in cooperation with the
(Piezo-inline injectors), responsible in-house specialist departments of
Dipl.-Ing. Thomas Kügler Robert Bosch GmbH.
(Injection nozzles),
Dipl.-Ing. (FH) Mikel Lorente Susaeta, Unless otherwise stated, the authors are all
Dipl.-Ing. Martin Grosser, employees of Robert Bosch GmbH.
Dr.-Ing. Andreas Michalske
(Electronic diesel control),
Dr.-Ing. Günter Driedger,
Dr. rer. nat. Walter Lehle,
Dipl.-Ing. Wolfgang Schauer,
Rainer Heinzmann
(Diagnostics).

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Basics

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