Automotive Handbook

Description

The latest edition of the leading automotive engineering reference In the newly revised Eleventh Edition of the Bosch Automotive Handbook, a team of accomplished automotive experts delivers a comprehensive and authoritative resource for automotive engineers, designers, technicians, and students alike. Since 1936, the Bosch Automotive Handbook has been providing readers with of-the-moment coverage of the latest mechanical and research developments in automotive technology, from detailed technical analysis to the newest types of vehicles. This newest edition is packed with over 2,000 pages of up-to-date automotive info, making it the go-to reference for both engineers and technicians. It includes detailed and simple explanations of automotive technologies and offers over 1,000 diagrams, illustrations, sectional drawings, and tables. Readers will also find: 200 pages of new content, including the electrification of the powertrainAdditional coverage on new driver assistance systems and the automated detection of vehicles’ surroundingsUpdates on the on-board power supply for commercial vehiclesNew discussions of autonomous vehicles, as well as additional contributions from experts at automotive manufacturers, universities, and Bosch GmbH Perfect for design engineers, mechanics and technicians, and other automotive professionals, the latest edition of the Bosch Automotive Handbook will also earn a place on the bookshelves of car enthusiasts seeking a quick and up-to-date guide to all things automotive. 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