Automotive Handbook

Cover
Title Page
Copyright Page
Foreword to the 11th Edition
Contents
Motor vehicles
Overall motor-vehicle system
Definition of motor vehicle
Functional units of a motor vehicle
Classification of motor vehicles
Basic principles
Quantities and units
SI units
Legal units
Further units
Natural constants
Mathematical signs and symbols
Greek alphabet
Basic principles of mechanics
Rectilinear and rotary motion
Statics
Calculation of strength
Friction
Fluid mechanics
Hydrostatics
Flow mechanics
Vibrations and oscillations
Terms
Equations
Vibration reduction
Modal analysis
Acoustics
General terminology
Measured quantities for noise emissions
Measured quantities for noise immissions
Perceived sound levels
Optical technology
Electromagnetic radiation
Geometric optics
Wave optics
Lighting quantities
Laser technology
Optical fibers/waveguides
Thermodynamics
Basic principles
Laws of thermodynamics
Equations of state
Changes of state
Cycles and technical applications
Heat transfer
Electrical engineering
Basic principles of electricity
Electrical quantities in an electric circuit
Conductors, nonconductors, semiconductors
Laws
Electric power and work
Time-dependent current
Electric field
Magnetic field
Electromagnetic fields
Power in the alternating-current circuit
Wave propagation
Electric effects in metallic conductors
Electronics
Basic principles of semiconductor technology
Discrete semiconductor devices
Monolithic integrated circuits
Basic principles of electrical machines
Energy conversion
Systematics of rotating electrical machines
Definition of geometric quantities
Direct-current machines
Asynchronous machine
Synchronous machine
Switched reluctance motor
Electronic motors
Energy-efficiency classes
Three-phase current system
Chemistry
Elements
Chemical bonds
Substances
Substance concentrations
Reaction of substances
Electrochemistry
Mathematics and methods
Mathematics
Numbers
Functions
Equations in the plane triangle
Complex numbers
Coordinate systems
Vectors
Differential and integral calculus
Linear differential equations
Laplace transform
Fourier transform
Matrix calculus
Technical statistics
Descriptive statistics
Probability calculus
Characteristic value in quality assurance and in quality management
Finite-element method
Application
FEM examples
Control engineering
Terms and definitions
Control-engineering transfer elements
Designing a control task
Adaptive controllers
Artificial intelligence
Introduction to AI
Machine learning
Representation of information
Planning
IT security of AI systems
Materials
Materials
Material parameters
Material groups
Metallic materials
EN metallurgy standards
Magnetic materials
Nonmetallic inorganic materials
Composite materials
Plastics
Heat treatment of metallic materials
Hardness
Heat-treatment processes
Thermochemical treatment
Corrosion and corrosion protection
Corrosion processes
Types of corrosion
Corrosion testing
Corrosion protection
Deposits and coatings
Deposits
Coatings
Machine parts Tolerances
Form deviations
Geometrical Product Specifications
Axles and shafts
Function and application
Dimensioning
Design
Springs
Basic principles
Metal springs
Friction bearings
Features
Hydrostatic friction bearings
Hydrodynamic friction bearings
Self lubricating bearings made of metal
Self lubricating bearings made of plastic
Rolling bearings
Application
General principles
Selection of rolling bearings
Calculation of load capacity
Seals
Seal technology
O-ring
Molded seal
Flat seals
Sealing caps
Radial shaft seal
Pneumatic seals
Two-component seals
Rod and piston sealing systems
Elastomer materials
Joining and bonding techniques
Detachable connections
Positive or form-closed joints
Frictional joints
Threaded fasteners
Snap-on connections on plastic components
Permanent joints
Welding
Soldering
Adhesive technologies
Riveting
Penetration-clinching processes
Vehicle physics
Vehicle motion
Coordinate system
Degrees of freedom of vehicle motion
Running resistances
Total running resistance
Individual running resistances
Motor-vehicle dynamics
Characteristics of vehicle dynamics
Dynamics of linear motion
Dynamics of lateral motion
Dynamics of vertical motion
Special operating dynamics for commercial vehicles
Driving-dynamics test procedures
Assessment of vehicle handling
Driving-dynamics test procedures as per ISO
Energy demand for drives
Fuel consumption of internal-combustion engines
Fuel consumption of hybrid vehicles
Range and consumption of electric vehicles
Well-to-Wheel analysis
Vehicle aerodynamics
Aerodynamic forces
Tasks of vehicle aerodynamics
Vehicle wind tunnels
Vehicle acoustics
Legal requirements
Development work on vehicle acoustics
Sources of noise
Sound design
Operating fluids
Lubricants
Terms and definitions
Engine oils
Transmission oils
Lubricating oils
Lubricating greases
Coolants for internal-combustion engines
Requirements
Composition of coolants
Types of radiator protection agents
Brake fluids
Requirements
Characteristics
Chemical composition
Fuels
Overview
Characteristics
Gasoline (petrol)
Diesel fuel
Methane
Liquefied petroleum gas
Hydrogen
Electricity-generated regenerative fuels
Ethers
Urea/water solution
Refrigerants for air-conditioning systems
Development up to today
Alternative possibilities
Drivetrain
Drivetrain with internal-combustion engine
Drivetrain elements
Functions of the drivetrain
Tractive-force curves
Drive types
Power take-up elements and vibration isolation
Single clutch
Dual clutch
Hydrodynamic torque converter
Vibration isolation
Step-up gear units
Components in manually shifted transmissions
Manually shifted transmissions
Automated manual transmissions
Dual-clutch transmissions
Automatic planetary transmissions
Continuously variable transmissions
Commercial-vehicle transmissions
Differentials
Final-drive differentials
Electronic transmission control
Functions and requirements
Transmission-control components
Shift-point control
Hydraulic control
Electrohydraulic actuators
Internal-combustion engines
Internal-combustion engines
Thermal engines
Mixture formation, combustion, emissions
Gasoline engine
Diesel engine
Mixed forms and alternative operating strategies
Charge cycle and supercharging
Charge cycle
Variable valve timing
Supercharging processes
Exhaust-gas recirculation
Reciprocating-piston engine
Components
Reciprocating-piston engine types
Crankshaft-assembly design
Tribology and friction
Empirical values and data for calculation
Exhaust-gas emissions
Historic measures
Constituents of engine exhaust gas
Basic principles of catalytic exhaust-gas treatment
Catalytic processes for exhaust-gas treatment
Belt drives
Friction belt drives
Positive belt drives
Chain drives
Overview
Timing chains
Sprockets
Chain-tensioning and chain-guide elements
Engine cooling
Air cooling
Water cooling
Intercooling (charge-air cooling)
Exhaust-gas cooling
Oil and fuel cooling
Modularization
Intelligent thermal management
Engine lubrication
Forced-feed lubrication system
Components
Thermal management
Air-intake systems and intake manifolds
Overview
Passenger-car air-intake system
Passenger-car intake manifolds
Motorcycle intake manifolds
Commercial-vehicle air-intake system
Commercial-vehicle intake manifolds
Turbochargers and superchargers
Superchargers (mechanically driven)
Exhaust-gas turbochargers
Complex supercharging systems
Exhaust-gas system
Purpose and design
Exhaust manifold
Catalytic converter
Particulate filter
Mufflers
Connecting elements
Acoustic tuning devices
Commercial-vehicle exhaust-gas systems
Management for spark-ignition engines
Management for spark-ignition engines
Description of the engine management system
System overview
Motronic versions for passenger cars
Motronic versions for motorcycles
Cylinder charge
Component parts
Control of cylinder charge
Recording of air charge
Cylinder shutoff
Fuel supply
Fuel supply and delivery with intake-manifold injection
Fuel supply and delivery with gasoline direct injection
Evaporative-emissions control system
Gasoline filter
Electric fuel pump
High-pressure pumps for gasoline direct injection
Fuel rail
Fuel-pressure regulator
Fuel-pressure attenuator
Mixture formation
Basic principles
Mixture-formation systems
Intake-manifold injection
Gasoline direct injection
Fuel injectors
Ignition
Basic principles
Moment of ignition
Ignition systems
Ignition coil
Spark plug
Catalytic exhaust-gas treatment
Catalytic converter
λ control
Particulate filter for gasoline engines
Motor sport
Requirements
Components
ECUs
Pure motor-sport developments
Gasoline-engine operation with alternative fuels
LPG operation
Applications
Design
LPG systems
Components
Engines fueled by natural gas
Applications
Design
Components
Engines fueled by alcohol
Applications
Ethanol as an alternative fuel
Flex-fuel concepts for the markets
Flex-fuel components
Management for diesel engines
Electronic Diesel Control
Description of the engine-management system
Requirements
Operating principle and architecture
Data processing
Application
Low-pressure fuel supply
Fuel supply and delivery
Diesel filter
Common-rail fuel-injection system
System overview
Injectors
High-pressure pumps
Rail
Time-controlled single-cylinder pump systems
Unit-injector system for passenger cars
Unit-injector system for commercial vehicles
Unit-pump system for commercial vehicles
Electronic control
Diesel distributor injection pumps
Axial-piston distributor pumps
Radial-piston distributor pumps
Fuel-injection system
Start-assist systems for diesel engines
Preheating systems for passenger cars and light commercial vehicles
Flame start systems for commercial-vehicle diesel engines
Grid heater for commercial-vehicle diesel engines
Exhaust-gas treatment
Catalytic oxidation
Filtration of particulates
Catalytic reduction of nitrous fumes
On-Board Diagnostics (OBD)
Electrification of the drive
Electrification of the drive
Features
Components of the electrified drive
Electrified ancillary systems
Regenerative braking system
Thermal management for electric vehicles
Charging infrastructure for electrified vehicles
Control of electric drives
Drivetrain of an electric vehicle
Vehicle control unit for electric vehicles
Further applications of the VCU for electric vehicles
Hybrid drives
Motivation
Functionalities of hybrid drives
Classification of hybrid drives
Classification based on drive structure
Incorporating the transmission in the hybrid drive
Control of a hybrid drive
Hybrid vehicle
Vehicle control unit for hybrid vehicles
Drivetrain operating strategy for hybrid vehicles
Electric final-drive unit
Functional component integration
Vehicle integration and interfaces
Performance classes and performance characteristic
Adaptation for application
Electric drives with fuel cell
Features
Design and operating principle of the fuel cell
Functioning principle of the fuel-cell system
Fuel cell in the drivetrain
Electromobility for two-wheelers
Features
System architecture
Emission-control and diagnosis legislation
Emission-control legislation
Overview
Emission-control legislation for passenger cars and light commercial vehicles
Test cycles for passenger cars and light commercial vehicles
Emission-control legislation for heavy commercial vehicles
Test cycles for heavy commercial vehicles
Emission legislation for motorcycles
Exhaust-gas measuring techniques
Exhaust-gas testing
Exhaust-gas measuring devices
Diesel smoke-emission test
Evaporative-emission test
Diagnostics
Monitoring in driving mode
On-board diagnostics
OBD functions
OBD requirements for heavy commercial vehicles
On-board diagnostics for motorcycles
ECU diagnostics and Service Information System
Chassis systems
Chassis systems
Overview
Basic principles
Characteristics
Suspension
Basic principles
Types of spring
Suspension systems
Shock absorbers and vibration absorbers
Shock absorbers
Vibration absorbers
Wheel suspensions
Basic principles
Kinematics and elastokinematics
Basic categories of wheel suspensions
Wheels
Function and requirements
Structure
Design criteria
Designation for passenger-car wheels
Materials for wheels
Manufacturing processes
Wheel design variations
Stress and testing of wheels
Tires
Function and requirements
Tire construction
Tire inflation pressure
Tire tread
Force transmission
Tire grip
Rolling resistance
Tire designation
EU tire label
Winter tires
Development of a tire
Tire tests
Tire-pressure monitoring systems
Rotary seal for tire-pressure control
Steering
Purpose of automotive steering systems
Steering-system requirements
Types of steering box
Power-assisted steering systems for passenger cars
Power-assisted steering systems for commercial vehicles
Brake systems
Definitions and principles
Legal regulations
Structure and organization of brake systems
Brake systems for passenger cars and light commercial vehicles
Subdivision of passenger-car brake systems
Components of the passenger-car brake system
Electrohydraulic brake
Integrated power brake
Brake systems for commercial vehicles
System overview
Components of commercial-vehicle brake systems
Electronically controlled brake system
Continuous-operation brake systems
Wheel brakes
Disk brakes for passenger cars
Disk brakes for commercial vehicles
Drum brakes
Chassis control
Wheel-slip control systems
Function and requirements
Control systems
ABS/TCS systems for passenger cars
ABS/TCS systems for commercial vehicles
Driving-dynamics control system
Function
Requirements
Operating principle
Typical driving maneuver
Structure of the overall system
System components
Special driving-dynamics control system for commercial vehicles
Automatic brake-system operations
Motorcycle Stability Control
Application
Riding physics of a two-wheeler
Motorcycle ABS
Motorcycle Traction Control
Integrated driving-dynamics control systems
Overview
Functions
System architecture
Vehicle bodies
Vehicle bodies, passenger cars
Introduction
Milestones in automobile history
Definitions
Vehicle body and vehicle segments
Vehicle systems
Interface management in complete-vehicle development
Process of vehicle-concept development
Sectional elaboration of the vehicle concept
Current trends of vehicle-concept development
Vehicle bodies, commercial vehicles
Classification of commercial vehicles
Light utility vans
Medium- and heavy-duty trucks and tractor units
Buses
Active and passive safety in commercial vehicles
Lighting equipment
Functions
Regulations and equipment
Light sources
Motor-vehicle bulbs
Main-light functions
Main-light functions for Europe
Main-light functions for the USA
Definitions and terms
Technical design variations of headlamps
Additional headlamps
Light functions
Installation and regulations for signal lamps
Technical design variations for lamps
Headlamp leveling control
Headlamp adjustment
Automotive glazing
The material properties of glass
Automotive windshield and window glass
Functional design glazing
Windshield, rear-window and headlamp cleaning systems
Front wiper systems
Rear wiper systems
Windshield and rear-window washer systems
Headlamp cleaning systems
Comfort and convenience
Passenger-compartment climate control
Climate-control requirements
Design and operating principle of the A/C unit
Climate-control systems
Climate control for hybrid and electric vehicles
Cabin filters
Auxiliary heater systems
Comfort and convenience systems in the door and roof areas
Power-window systems
Sunroof systems
Comfort and convenience functions in the passenger compartment
Electrical seat adjustment
Electrical steering-wheel adjustment
Safety systems in the motor vehicle
Safety systems in the motor vehicle
Phases of vehicle safety
Active safety
Passive safety
Legal regulations and consumer tests
Occupant-protection systems
Functions
Retention systems and actuators
Occupant sensing
Integral-safety systems
Overview
Solution approaches
Outlook
Vehicle security systems
Locking systems
Task and design
Access authorization
Lock design
Requirements
Lock layout
Safety functions
Development history
Vehicle access by means of digital key
Anti-theft systems
Electronic vehicle immobilizer
Theft-alarm system
Automotive electrics
12 V vehicle electrical systems
Function and requirements
Power of the consumers in the 12 V vehicle electrical system
Design and operating principle
Interaction of the components
Electrical-system structures
Electrical-system parameters
Electrical energy management
Vehicle electrical systems for commercial vehicles
Requirements of truck electrical systems
Schematic design of truck electrical systems
Electrical-system concepts for highly and fully automated driving functions
12 V starter batteries
Requirements
Battery design
Charging and discharging
Battery characteristics
Battery types
Using the battery
Alternators
Electric power generation
Alternator design
Voltage regulation
Characteristic alternator values
Operating conditions
Efficiency
Alternator versions
Starters for passenger cars and light commercial vehicles
Application
Requirements
Starter design and operation
Configuration of a starter
Triggering the starter
Starters for heavy commercial vehicles
Application
Power requirements
Operating principle
Special requirements for commercial-vehicle starters
Wiring harnesses and plug-in connections
Wiring harnesses
Plug-in connections
Electromagnetic compatibility
Requirements
Interference emission and interference immunity
EMC-oriented development
EMC measuring techniques
EMC test methods
EMC simulation
Legal requirements and standards
Symbols and circuit diagrams
Circuit symbols
Circuit diagrams
Terminal designations
Electrics for electric and hybrid drives
Vehicle electrical systems for hybrid and electric vehicles
Vehicle electrical systems for mild- and full-hybrid vehicles
Vehicle electrical systems for externally rechargeable hybrid and electric vehicles
Charging strategy
Electrical machines for motor-vehicle propulsion
Requirements
Design
Types of electrical machines
Influencing factors on operational performance
Losses in electrical machines
Cooling of the electrical machine
Inverters for electric drives
Area of application
Function and circuitry
Activation and control
Software and functional safety
Equipment mechanics
DC-DC converters
Application
Non-isolating DC-DC converters
Isolating DC-DC converters
On-board charger
Application
Requirements
Charging power
Basic design and operating principle
Batteries for electric and hybrid drives
Requirements
Storage technologies
Basic structure of a battery system
Components of a lithium-ion battery system
Charging method for lithium-ion batteries
Recycling of lithium-ion vehicle batteries
Supercapacitors
Application
Electric double-layer capacitors
Hybrid supercapacitors
Automotive electronics
Electronic control unit (ECU)
Functions
Requirements
ECU components
Data processing
Assembly and connection technology
Software
Application
Functional safety
EOL programming
Mechatronics
Mechatronic systems and components
Development methodology
Outlook
Automotive software engineering
Motivation
Design of software in motor vehicles
Important standards for software in motor vehicles
The development process
Quality assurance in software development
Workflows of software development in motor vehicles
Modeling and simulation of software functions
Design and implementation of software functions
Integration and testing of software and ECUs
Calibration of software functions
Outlook
Architecture of electronic systems
General
Development of E/E architectures
Summary and outlook
Vehicle communication networks
Bus systems
Technical principles
Buses in motor vehicles
CAN
FlexRay
LIN
Ethernet
PSI5
MOST
Serial Wire Ring
Automotive sensors
Automotive applications
Basic principles of classic sensors
Position and angular-position sensors
rpm sensors
Oscillation gyrometers
Flow meters
Acceleration and vibration sensors
Pressure sensors
Temperature sensors
Torque sensor
Force sensor
Gas and concentration sensors
Optoelectronic sensors
Infotainment
Infotainment and cockpit solutions
History
Infotainment systems
Smartphone connection to the infotainment system
Display and control
Interaction channels
Instrumentation
Display types
Voice control
Radio and TV reception in motor vehicles
Wireless signal transmission
Radio tuners
Traffic telematics
Transmission paths
Standardization
Information recording
Driver assistance and sensors
Driver-assistance systems
Introduction – driver assistance
Ultrasonic sensor system
Ultrasonic sensor
Distance measurement with ultrasound
Radar-sensor system
Application
Radar principle
Variants of radar sensors
Homologation
Lidar-sensor system
Functions and applications
Operating principle
Properties and use
Measurement principles
Methods for increasing the number of pixels
Video sensors
Application
Image sensor
Objective
Computer vision
Sensor-data fusion
Introduction
Sensors
Fusion types
AI-based sensor-data fusion
Driver-assistance systems
Vehicle navigation
Navigation systems
Functions of navigation
Digital map
Night-vision systems
Applications
Far-infrared systems
Near-infrared systems
Parking and maneuvering systems
Application
Ultrasonic parking aid
Ultrasonic parking assistant
Video systems
Adaptive Cruise Control
Function
Design and function
Control algorithms
Area of application and functional expansions
Current ongoing developments
Information and warning systems
Rearview-camera system
Multi-camera system
Digital exterior-mirror system
Road-sign recognition
Driver-drowsiness detection
Rear cross-traffic warning
Turn collision warning for trucks
Moving-off information system for heavy commercial vehicles
Wrong-way driver warning
Lane assistance
Lane departure warning
Lane-keeping support
Lane centering assist for heavy trucks
Emergency lane-keeping support for heavy trucks
Roadworks assistant
Bottleneck/constriction assistant
Lane-change assistant
Blind-spot assistant
Lane-change assistant
Evasive steering support
Further developments
Emergency-braking systems
Emergency-braking systems in longitudinal traffic
Maneuver emergency braking
Automatic emergency braking for unprotected road users
Intersection assistant
Motivation
Left-turn assistant
Cross-traffic assistant
Traffic-light and stop-sign assistants
Intelligent headlamp control
Motivation
System designs
Advanced rider-assistance systems for two-wheelers
Adaptive cruise control
Forward collison warning
Blind-spot detection
Interior-monitoring systems
Camera-based interior monitoring
Future of automated driving
Future of automated driving
Automation levels
Obstacles to automated driving
Stages on the road to autonomous driving
Appendices
Technical terms
Abbreviations
EULA