Bosch Professional Automotive Information Konrad Reif Ed. Fundamentals of Automotive and Engine Technology Standard Drives · Hybrid Drives · Brakes · Safety Systems Bosch Professional Automotive Information 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. Konrad Reif Editor Fundamentals of Automotive and Engine Technology Standard Drives, Hybrid Drives, Brakes, Safety Systems Prof. Konrad Reif Duale Hochschule Baden-Württemberg Friedrichshafen, Germany reif@dhbw-ravensburg.de ISBN 978-3-658-03971-4 ISBN 978-3-658-03972-1 (eBook) DOI 10.1007/978-3-658-03972-1 Library of Congress Control Number: 2014942447 Springer Vieweg © Springer Fachmedien Wiesbaden 2014 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 is part of Springer Science+Business Media www.com Foreword V ▶ Foreword Hybrid drives and the operation of hybrid vehicles are characteristic of contemporary automotive technology. Together with the electronic driver assistant systems, hybrid technology is of the greatest importance and both cannot be ignored by today’s car drivers. This technical reference book provides the reader with a firsthand compre- hensive description of significant components of automotive technology.
All texts are complemented by numerous detailed illustrations. 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 Electronics provides the book in the series “Bosch Professional Automotive Informa- tion” which contains necessary fundamentals, data and explanations clearly, system- atically, currently and application-oriented. The series is intended for automotive professionals 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. VI Contents ▶ Contents 2 History of the automobile 78 Transmissions for Motor Vehicles 2 Development history 78 Transmission in the Drivetrain 4 Pioneers of automotive technology 80 Transmission Requirements 6 Robert Bosch’s life’s work (1861–1942) 81 Manual Transmission 82 Automated Shift Transmission (AST) 8 History of the diesel engine 86 Dual-Clutch Transmission (DCT) 9 Rudolf Diesel 88 Automatic Transmission (AT) 10 Mixture formation in the first 96 Continuously Variable Transmission (CVT) diesel engines 102 Toroid Transmission 11 Use of the first vehicle diesel engines 14 Bosch diesel fuel injection 104 Motor-vehicle safety 104 Safety systems 18 Areas of use for diesel engines 106 Basics of vehicle operation 18 Suitability criteria 18 Applications 114 Basic principles of vehicle dynamics 21 Engine characteristic data 114 Tires 117 Forces acting on a vehicle 22 Basic principles of the diesel engine 124 Dynamics of linear motion 22 Method of operation 126 Dynamics of lateral motion 25 Torque and power output 128 Definitions 26 Engine efficiency 29 Operating statuses 130 Car braking systems 33 Operating conditions 130 Overview 35 Fuel-injection system 132 History of the brake 36 Combustion chambers 138 Classification of car braking systems 140 Components of a car braking system 40 Basic principles of diesel fuel injection 141 Brake-circuit configuration 40 Mixture distribution 42 Fuel-injection parameters 142 Vehicle electrical systems 51 Nozzle and nozzle holder designs 142 Electrical energy supply in the passenger car 52 Basics of the gasoline (SI) engine 146 Electrical energy management 52 Method of operation 148 Two-battery vehicle electrical system 56 Cylinder charge 149 Vehicle electrical systems for commercial 60 Torque and power vehicles 62 Engine efficiency 152 Wiring harnesses 64 Specific fuel consumption 154 Plug-in connections 66 Combustion knock 158 Overview of electrical and electronic 68 Inductive ignition system systems in the vehicle 68 Design 158 Overview 69 Function and method of operation 71 Ignition parameters 161 Control of gasoline engines 75 Voltage distribution 76 Ignition driver stage 172 Control of Diesel engines 77 Connecting devices and interference suppressors 180 Lighting technology Contents VII 194 Electronic stability program 240 Regenerative braking system 240 Strategies of regenerative braking 202 Adaptive cruise control 244 Workshop technology 210 Occupant-protection systems 244 Workshop business 248 Diagnostics in the workshop 218 Hybrid drives 250 Testing equipment 218 Principle 252 Brake testing 219 Operating modes 258 Fuel-injection pump test benches 221 Start/stop function 260 Testing in-line fuel-injection pumps 222 Degrees of hybridization 264 Testing helix and portcontrolled distributor 224 Drive configurations injection pumps 268 Nozzle tests 231 Operation of hybrid vehicles 231 Hybrid control 270 Index 232 Operating strategies for hybrid vehicles 234 Operating-point optimization 237 Design of the internalcombustion engine VIII Authors ▶ Authors History of the automobile Overview of electrical and electronic systems Dipl. Karl-Heinz Dietsche in the vehicle, Control of gasoline engines, Dietrich Kuhlgatz Control of Diesel engines, Lighting technology, Electronic stability program (ESP), Adaptive History of the diesel engine cruise control (ACC), Occupant-protection Dipl. Karl-Heinz Dietsche systems Dipl.
Bernhard Mencher, Areas of use for diesel engines Dipl. (BA) Ferdinand Reiter, Dipl. Joachim Lackner, Dipl. Andreas Glaser, Dr.
Herbert Schumacher, Dipl. Walter Gollin, Dipl. (FH) Klaus Lerchenmüller, Dipl. Felix Landhäußer, Basic principles of the diesel engine Dipl.
Doris Boebel, Automotive Lighting Dr. Thorsten Raatz, Reutlingen GmbH, Dipl. Michael Hamm, Automotive Lighting Reutlingen GmbH, Basic principles of diesel fuel injection Dipl. Tilman Spingler, Automotive Lighting Dipl.
Jens Olaf Stein, Reutlingen GmbH, Dipl. Frank Niewels, Dipl. Thomas Ehret, Basics of the gasoline (SI) engine Dr. Gero Nenninger, Dr.
Dirk Hofmann, Prof. Peter Knoll, Dipl. Bernhard Mencher, Dr. Werner Häming, Dipl.
Hybrid drives Dipl. Michael Bildstein, Inductive ignition system Dr. Karsten Mann, Dipl. Transmissions for Motor Vehicles Operation of hybrid vehicles D.
Grauman, Regenerative braking system Dipl. Laux, Strategies of regenerative braking Dipl. Michael Bildstein, Dr. Karsten Mann, Motor-vehicle safety Dr.
Workshop technology Basic principles of vehicle dynamics Dipl. Stephan Sohnle, Dipl. Rainer Rehage, Rainer Heinzmann, Car braking systems Rolf Wörner, Dipl. Günter Mauderer, Hans Binder.
Vehicle electrical systems Dipl. Clemens Schmucker, and the editorial team in cooperation with the Dipl. (FH) Hartmut Wanner, responsible in-house specialist departments of Dipl. (FH) Wolfgang Kircher, Robert Bosch GmbH.
(FH) Werner Hofmeister, Unless otherwise stated, the authors are all Dipl. employees of Robert Bosch GmbH. Basics 2 History of the automobile Development history History of the automobile Mobility has always played a crucial role in powered by the internal-combustion engine. the course of human development.
In al- Public opinion remained divided, however. most every era, man has attempted to find While the proponents of the new age lauded the means to allow him to transport people the automobile as the epitome of progress, over long distances at the highest possible the majority of the population protested speed. It took the development of reliable against the increasing annoyances of dust, internal-combustion engines that were op- noise, accident hazard, and inconsiderate erated on liquid fuels to turn the vision of motorists. Despite all of this, the progress a self-propelling “automobile” into reality of the automobile proved unstoppable.
In the begin- ning, the acqui- Daimler Motorized Development history sition of an au- Carriage, 1894 tomobile repre- (Source: It would be hard to imagine life in our mod- sented a serious DaimlerChrysler Classic, ern day without the motor car. Its emergence challenge. Corporate Archives) required the existence of many conditions A road network without which an undertaking of this kind was virtually nonexistent; repair shops were would not have been possible. At this point, unknown, fuel was purchased at the drugstore, some development landmarks may be worthy and spare parts were produced on demand by of note.
They represent an essential contribu- the local blacksmith. The prevailing circum- tion to the development of the automobile: stances made the first long-distance journey by 쐌 About 3500 B. Bertha Benz in 1888 an even more astonishing The development of the wheel is attri- accomplishment. She is thought to have been buted to the Sumerians the first woman behind the wheel of a motor- 쐌 About 1300 ized vehicle.
She also demonstrated the relia- Further refinement of the carriage with bility of the automobile by journeying the then elements such as steering, wheel suspen- enormous distance of more than 100 kilome- sion and carriage springs ters (about 60 miles) between Mannheim and 쐌 1770 Pforzheim in south-western Germany. Steam buggy by Joseph Cugnot The first journey with an 쐌 1801 In the early days, however, few entrepreneurs engine-powered vehicle Étienne Lenoir develops the gas engine – with the exception of Benz – considered is attributed to Joseph Cugnot (in 1770). 쐌 1870 the significance of the engine-powered vehi- His lumbering, steam- Nikolaus Otto builds the first four-stroke cle on a worldwide scale. It was the French powered, wooden internal-combustion engine who were to help the automobile to great- three-wheeled vehicle ness.
Panhard & Levassor used licenses for was able to travel for In 1885 Carl Daimler engines to build their own automo- all of 12 minutes on a Benz enters the biles. Panhard pioneered construction fea- single tankful of water. annals of his- tures such as the steering wheel, inclined tory as the in- steering column, clutch pedal, pneumatic The patent issued to Benz ventor of the tires, and tube-type radiator. on January 29, 1886 was first automo- In the years that followed, the industry not based on a converted bile.
His patent mushroomed with the arrival of companies carriage. Instead, it was a marks the be- such as Peugeot, Citroën, Renault, Fiat, Ford, totally new, independent ginning of the Rolls-Royce, Austin, and others. The influ- construction (Source: rapid develop- ence of Gottlieb Daimler, who was selling DaimlerChrysler Classic, ment of the his engines almost all over the world, added Corporate Archives) automobile significant impetus to these developments.), Fundamentals of Automotive and Engine Technology, DOI 10.1007/978-3-658-03972-1_1, © Springer Fachmedien Wiesbaden 2014 History of the Automobile Development history 3 More than 15 million Taking their original design from coachbuild- WWII had a sig- units were produced of ing, the motor cars of the time would soon nificant influence the Model T, affection- evolve into the automobiles as we know them on the develop- ately called “Tin Lizzie”. However, it should be noted that each ment of smaller This record would be automobile was an individual product of cars.
The Volks- topped only by the purely manual labor. A fundamental change wagen model Volkswagen Beetle in the 1970s came with the introduction of the assembly that came to be line by Henry Ford in 1913. With the Model T, known as the (Photos: Ford, he revolutionized the automobile industry in “Beetle” was designed by Ferdinand Porsche Volkswagen AG) the United States. It was exactly at this junc- and was manufactured in Wolfsburg.
At the ture that the automobile ceased to be an arti- end of the war, the demand for cars that were cle of luxury. By producing large numbers small and affordable was prevalent. Respond- of automobiles, the price of an automobile ing to this demand, manufacturers produced dropped to such a level that it became accessi- automobiles such as the Goliath GP 700, ble to the general public for the first time.