Bosch Automotive Handbook

1.1 Quantities and units......Page 3
1.2 Conversion of units......Page 12
1.3 Vibration and oscillation......Page 26
1.4 Basic equations used in mechanics......Page 36
1.5 Strength of materials......Page 50
1.6 Acoustics......Page 64
1.7 Heat......Page 74
1.8.1 Quantities and units......Page 81
1.8.2 Direct current (DC)......Page 85
1.8.3 Alternating current (AC)......Page 91
1.8.4 Magnetic field......Page 97
1.8.5 Ferromagnetic materials......Page 100
1.8.8 Electric effects in metallic conductors......Page 106
1.8.7 Magnetic field and electric current......Page 103
1.8.9 Gas and plasma discharge......Page 110
1.9 Electronics......Page 0
1.9.1 Fundamentals of semiconductor technology......Page 111
1.9.2 Discrete semiconductor devices......Page 115
1.9.3 Monolithic integrated circuits......Page 123
1.9.4 Film and hybrid circuits, MCM......Page 129
1.9.5 Circuit-board technology, SMT......Page 131
1.9.6 Micromechanics......Page 133
1.9.7 Mechatronics......Page 136
1.9.8 Analog/digital conversion......Page 137
1.10.1 Basics......Page 140
1.10.2 Position sensors (displacement/angle)......Page 144
1.10.3 RPM and velocity sensors......Page 153
1.10.4 Acceleration/vibration sensors......Page 159
1.10.5 Pressure sensors......Page 162
1.10.6 Force/torque sensors......Page 166
1.10.7 Flow meters......Page 170
1.10.8 Concentration sensors......Page 174
1.10.9 Temperature sensors......Page 177
1.10.10 Sensors for other applications......Page 182
1.11 Actuators......Page 185
1.12 Electrical machines......Page 197
1.13 Technical optics......Page 205
2.1 Mathematics......Page 216
2.2 Quality......Page 226
2.3 Technical statistics......Page 234
2.4 Reliability......Page 247
2.5 Control engineering......Page 250
2.6 Data processing in motor vehicles......Page 256
3.1 Chemical elements......Page 260
3.2 Terminology, parameters......Page 264
3.3 Material groups......Page 268
3.4 Properties of solids......Page 275
3.5 Properties of metallic materials......Page 283
3.6 Lubricants......Page 318
3.7 Fuels......Page 331
3.8 Antifreez and brake fluid......Page 343
3.9 Names of chemicals......Page 347
3.10 Corrosion and Corrosion protection......Page 351
3.11 Heat treatment of metallic......Page 367
3.12 Hardness......Page 376
4.1 Tolerances......Page 383
4.2 Sliding bearings and rolling bearings......Page 389
4.3 Spring calculations......Page 399
4.4 Gears and tooth systems......Page 407
4.5 Belt drives......Page 422
4.6 Basic principles of threaded fasteners and threads......Page 429
5 Joining and bonding techniques......Page 441
6 Sheet-metal processing......Page 450
7 Tribology......Page 455
8.1 Road-going vehicle requirements......Page 463
8.2 Basic requirement for fuels......Page 466
8.3.1 Dynamics of linear motion......Page 469
8.3.2 Adhesion to road surface......Page 479
8.3.3 Accelerating and braking......Page 481
8.3.4 Stopping distance......Page 484
8.3.5 Passing (overtaking)......Page 487
8.3.6 Dynamics of lateral motion......Page 490
8.3.7 Cornering behavior......Page 494
8.3.8 ISO procedures for evaluating vehicle handling......Page 496
8.3.9 Special operating dynamics for commercial vehicles......Page 504
8.3.10 Requirements for agricultural tractors......Page 509
8.4 Environmental stresses on automotive equipment......Page 513
9.1 Operating concepts and classifications......Page 517
9.2 Cycles......Page 519
9.3.1 Operating concept......Page 522
9.3.2 The spark-ignition (Otto) engine......Page 526
9.3.3 The diesel engine......Page 534
9.3.4 Hybrid processes......Page 542
9.3.5 Gas exchange......Page 544
9.3.6 Supercharging processes......Page 551
9.3.7.1 Engine types......Page 558
9.3.7.2 Crankshaft-assembly operation and dynamic properties......Page 561
9.3.7.3 Balancing of masses in the reciprocating-piston engine......Page 566
9.3.7.4 Free forces and moments......Page 570
9.3.7.5 Main components of reciprocating-piston engine......Page 573
9.3.8 Cooling......Page 581
9.3.9 Lubrication......Page 582
9.3.10 Empirical values and data for calculation......Page 584
9.4 Reciprocating-piston engine with external combustion (Stiring engine)......Page 597
9.5 Wankel rotary engine......Page 600
9.6 Gas turbine......Page 603
10.1 Air cooling and Water cooling......Page 606
10.2 Intercooling......Page 611
10.3 Oil and fuel cooling......Page 612
10.4 Intelligent thermomanagement......Page 614
11 Fuel filters......Page 615
12.1 Air filters......Page 618
12.2 Turbochargers and superchargers for internal-combustion engines (self-charging)......Page 621
12.3 Exhaust systems......Page 631
13.1 Requirements......Page 636
13.2 Cylinder charge......Page 638
13.3 Fuel delivery with electric fuel pump......Page 641
13.4 A/F-mixture formation......Page 645
13.5 Carburetors......Page 648
13.6.1 Systems for external A/F mixture formation......Page 652
13.6.2 Single-point injection system......Page 655
13.6.3 Multipoint injection systems......Page 658
13.7.1 Ignition......Page 671
13.7.2 Ignition coil......Page 677
13.7.3 Ignition systems......Page 685
13.7.4 Knock control......Page 698
14.1 System overview......Page 701
14.2 ME-Motronic......Page 703
14.3 MED-Motronic......Page 714
15 Engine-test technology......Page 718
16.1 LPG system......Page 721
16.2 Natural-gas operation of spark-ignition engines......Page 725
16.3 Operation on alcohol......Page 727
16.4 Operation on hydrogen......Page 728
17.1 Combustion products......Page 731
17.2 Emissions control......Page 733
17.3 Lambda closed-loop control......Page 738
17.4 Testing exhaust and evaporative emissions......Page 743
17.5 Exhaust emission test cycles......Page 746
17.6 Exhaust-gas analyzers......Page 751
17.7 Current emissions limits......Page 753
18.1 Fuel metering......Page 755
18.2 In-line fuel-injection pump (PE)......Page 758
18.3 In-line control-sleeve fuel-injection pump......Page 769
18.4.1 Mechanically controlled......Page 771
18.4.2 EDC rotating-solenoid actuator......Page 774
18.4.3 EDC solenoid-controlled......Page 776
18.4.4 Solenoild-controlled axial-piston distributor pumps......Page 778
18.4.5 Solenoild-controlled distributor pumps with integral ECU......Page 780
18.5 Time-controlled single-cylinder pump systems......Page 781
18.6 Common-rail (CRS)......Page 786
18.7 Injection-pump test benches......Page 788
18.8 Motor testers for diesel engines......Page 790
18.9 Nozzles and nozzle holders......Page 791
19.1 Mixture formation, combustion......Page 800
19.2 Emissions control......Page 801
19.3 Emissions testing......Page 803
19.4 Test cycles and exhaust-emission limits......Page 804
19.5 Smoke emission test equipment......Page 808
20.1 Sheathed-element glow plugs......Page 811
20.2 Glow-control unit......Page 814
21.1 Starters......Page 816
21.2 Starter protection......Page 822
22.1 Electric drives......Page 823
22.2 Barreries......Page 824
22.3 Drivetrains......Page 827
23 Hybrid drives......Page 831
23.1 Hybrid drive designs......Page 833
24.1 Fuel cells......Page 835
24.2 Design variations of Fuel cells......Page 836
24.3 Fuel conditioning......Page 837
24.4 Thermodynamics and kinetics......Page 838
24.5 Fuel cells in motor vehicles......Page 840
25.1 Basics......Page 842
25.2 Power take-up elements......Page 846
25.3.1 Multi-speed gearbox......Page 851
25.3.2 Manually-shifted transmissions......Page 853
25.3.3 Automatic transmissions......Page 856
25.3.4 Electronic transmission control......Page 860
25.3.5 Continuously-variable transmissions......Page 862
25.4 Final-drive units......Page 864
25.5 Differential......Page 866
25.6 All-wheel drive and transfer case......Page 867
25.7 TCS traction control......Page 868
26.1 Suspension......Page 876
26.2 Suspension linkage......Page 886
26.3 Wheels......Page 891
26.4.1 Tires......Page 898
26.4.2 Tire designation symbols......Page 902
26.4.3 Tire traction......Page 907
26.5 Steering......Page 914
27.1 Definitions, principles......Page 923
27.2 Legal regulations......Page 932
27.3 Design and components of a braking system......Page 936
27.4 Braking-system design......Page 939
27.5 Brake-circuit configurations......Page 941
27.6 Brake systems for passenger cars and light utility vehicles......Page 943
27.7.1 Principle, system variants......Page 949
27.7.2 ABS versions......Page 953
27.7.3 ABS components......Page 963
27.8 Electohydraulic brake (EHB)......Page 967
27.9.1 Systme and configuration......Page 969
27.9.2 Automatic loade-sensitive device for braking-force metering......Page 973
27.9.3 Wheel brakes......Page 975
27.9.4 Parking brake system......Page 979
27.9.5 Components for compressed-air brakes......Page 986
27.10 ABS for commercial vehicles......Page 994
27.11 ELB for commercial vehicles......Page 1000
27.12 Brake test stands......Page 1006
28.1 Principles......Page 1008
28.2 Vehicle handling......Page 1011
28.3 ESP control systems......Page 1012
28.4 System realization......Page 1019
29 Adaptive cruise control (ACC)......Page 1022
30.1 Overview......Page 1025
30.2 Classificaiton......Page 1027
31.1 Main dimensions......Page 1029
31.2 Body structure......Page 1035
31.3 Body materials......Page 1037
31.4 Body surface......Page 1039
31.5 Body finishing components......Page 1041
31.6 Safety......Page 1044
31.7 Calculations......Page 1051
32.1 Commercial vehicles......Page 1054
32.2 Delivery trucks and vans......Page 1055
32.3 Medium and heavy-duty trucks and tractor vehicles......Page 1057
32.4 Buses......Page 1060
32.5 Passive safety in commercial vehicles......Page 1063
33.1 Functions, definitions, regulations......Page 1065
33.2.1 European system......Page 1070
33.2.2 American system......Page 1083
33.2.3 European regulations......Page 1085
33.2.4 Headlamp aiming devices......Page 1089
33.2.5 North American regulations......Page 1091
33.2.6 Headlight leveling control......Page 1092
33.2.7 Headlamp cleaning systems......Page 1094
33.2.8 Fog lamp......Page 1095
33.2.9 Auxiliary driving lamps......Page 1098
33.3 Lights and lamps......Page 1099
34.1 Acoustic signaling devices......Page 1111
34.2 Theft-deterrent systems......Page 1113
35.1 Windshield wiper systems......Page 1118
35.2 Rear-window cleaning systems......Page 1122
35.3 Headlamp cleaning systems......Page 1123
35.4 Wiper motors......Page 1124
35.5 Washing systems......Page 1126
35.6 Automotive windshield and window glass......Page 1127
36.1 Systems deriving heat from the engine......Page 1130
36.2 Air conditioners......Page 1133
36.3 Auxiliary heater installations......Page 1136
37.1 Instrumentation......Page 1137
37.2 Automotive sound systems......Page 1145
37.3 Parking systems......Page 1152
37.4 Trip recorders......Page 1157
37.5 Navigation systems......Page 1160
37.6 Traffic telematics......Page 1164
37.7 Mobile radio......Page 1167
37.8 Vehicle information system......Page 1170
38.1 Safety in motor vehicles......Page 1171
38.2 Occupant safety systems......Page 1172
38.3 Rollover protection systems......Page 1180
38.4 Outlook......Page 1182
39.1 Power windows......Page 1184
39.2 Power sunroof......Page 1187
39.3 Seat and steering-column adjustment......Page 1188
39.4 Central locking system......Page 1190
40.1 Basics......Page 1192
40.2 Gear pumps and gear motors......Page 1196
40.3 Piston pumps and motors......Page 1198
40.4 Electrohydraulic pumps and small units......Page 1200
40.5 Valves......Page 1201
40.6 Cylinders......Page 1207
40.7 Tractor hydraulics......Page 1208
40.8 Hydraulic accumulators......Page 1213
40.9 Auxiliary drives......Page 1214
40.10 Hydrostatic fan drives......Page 1215
40.11 Hydrostatic drives......Page 1217
41 Automotive pneumatics......Page 1220
42.1.1 General symbols......Page 1223
42.1.2 Circuit diagrams......Page 1226
42.1.3 Schematic diagrams......Page 1227
42.1.4 Section designation and device identification......Page 1234
42.2 Assembled-representation diagrams......Page 1244
42.3 Calculation of conductor sizes......Page 1250
42.4 Connectors......Page 1253
42.5.1 Energy supply......Page 1257
42.5.2 Starter batteries......Page 1264
42.5.3 Alternators......Page 1274
42.5.4 Controller Area Network (CAN)......Page 1286
42.5.5 CARTRONIC......Page 1291
42.6 Electromagnetic compatibility (EMC) and interference suppression......Page 1296
43 Alphabets and numbers......Page 1305
44 Index......Page 1308