CHAPTER 3 VEHICLE MECHATRAONIC SYSTEMS

3.1 Vehicle Mechatronic Systems

Engine Management Ignition Fuel

Suspension Brakes Anti-lock Brake Systems (ABS).

Transmission Air Bags Security Comfort, Communications and Entertainment Temp, Humidity Driver seat Radio volume Phone /cell volume

Driver Aids and Information Lights and wipers Warning and advice are provided Parking sensors Fuel consumption and average speed Cruise-control monitors GPS navigation systems

When an air bag is deployed, an automated call can be placed to an emergency processing centre and a conversation with the driver initiated so that emergency vehicles can be dispatched as appropriate.

3.2 Anti-lock Braking System (ABS)

Anti-lock Braking Systems (ABS) are sometimes called anti-skid brakes. Individual control the four brakes on a vehicle, which would clearly be impossible for a human driver. Stability of a vehicle and maintain steering response either very hard emergency braking normal braking under wet or icy conditions.

The braking distance required to bring a vehicle to a stop can also be reduced, but this is really a secondary bonus effect of the system.

3.3 Mechanism
A mechatronic system Wheel speed sensors Electro-hydraulic valves Central processing unit.

Constantly monitors the rotational speed of all four wheels When it detects one wheel slowing down faster than all the others, it reduces the braking force at that wheel by blocking or even reversing the flow of hydraulic fluid to the wheel. It is thus a system which if it malfunctioned, is capable of immobilizing the entire brake system of the vehicle. For this reason, it must clearly be regarded as safety critical.

3.4 Theory of Braking

At constant speed, the distance moved =circumference of the wheel When accelerating or braking, this simple relationship does not apply. There is relative movement between the tyre tread and the road =>> slip.

 When braking =>>brake slip. Under normal breaking, the amount of brake slip increases linearly as the braking force increases. This is known as the stable region Under hard breaking when the brake slip reaches a value of about 20%, the braking force stops increasing and thereafter actually decreases. This is the unstable region. When a wheel is fully locked (brake slip = 100%) =reduced to about 80% of its maximum value. Wet road conditions exaggerate the effect. ABS actions to keep the slip in the stable region for all wheels at all times. It does this by monitoring the relative speeds of all the wheels and comparing them with an average reference value obtained from diagonally opposite wheels. When it detects a wheel slowing down faster than it should, it momentarily holds or releases the brake pressure on that wheel. When a wheel enters the unstable region, the peripheral deceleration increases rapidly and this can be detected by the ABS controller. The normal peak coefficient of friction between a modern tyre and the road is about 1.0. Means that a vehicle can decelerate (and accelerate) at a maximum of about 1 g. If there was no brake slip, the perimeter of the wheel would also decelerate at about 1 g.

3.5 ABS zone

3.6 ABS systems logic

Phase 1 The wheel peripheral deceleration moves beyond the defined threshold (a) and the ABS valve is instructed to maintain brake pressure. Phase 2 The wheel perimeter velocity continues to reduce until it falls below a reference value which is based on extrapolation of previous vehicle speed. The valve shifts to pressure release mode. Phase 3 The brake pressure drops and the deceleration rate of the wheel also drops until it again rises above the threshold value (a). The brake pressure is then maintained. Phase 4 The wheel actually starts to accelerate again and eventually reaches a certain threshold (+A) Phase 5 The brake pressure is allowed to increase again until the acceleration again falls below the threshold (+A). Phase 6 The brake pressure is maintained until the acceleration drops to the lower threshold (+a). Phase 7 The wheel is now underbraked so the pressure is slowly ramped up until the deceleration drops below (a). Phase 8 The cycle is repeated from phase 3 until normal breaking is detected.

3.7 ABS Components

Hydraulic Control Valves One for Each Wheel These are 3-position valves :electrical solenoid to move between positions. 1: allows fluid to pass between the brake master cylinder and the wheel brake cylinder in the normal way 2:position (50% of maximum current) prevents movement of fluid between the brake master cylinder and the wheel brake cylinder. 3:(maximum current) connects the wheel brake cylinder to the fluid return line and with the aid of a pump, can reduce the brake pressure at the wheel.

(1) Damper (2) Throttle (3) Pump (4) 3/3 valve (5) Accumulator

Wheel Speed Sensors Electromagnetic proximity sensor fixed in a stationary position to the wheel hub. The sensor is positioned about 1 mm from a rotating toothed ring which is connected to the moving wheel shaft. Each time a tooth passes the sensor, a signal is sent to the ECU.

The Electronic Control Unit Input circuit conditions the signals from the wheel speed sensors and forwards them to one of two microcontrollers. Microcontrollers Two identical but separate integrated circuits. Each one connected to two diagonally opposite wheels. They process the wheel speed signals to decide on the appropriate ABS action. Commands are sent to an output circuit. Output circuits In response to commands from the microcontrollers, two-stage output circuits use power transistors to amplify the signals to provide enough current to energise the solenoids on the hydraulic valves.

3.8 ABS control unit

(1) Wheel-speed sensors (2) Battery (3) Input circuit (4) Digital controller

(5) LSI circuit {1} (6) LSI circuit {2} (7) Voltage stabilized memory (8) Output circuit

(9) Output circuit (10) Output stage (11) Solenoid valves (12) Safety relay

(13) Stabilized battery voltage (14) Indicator lamp

3.9 ABS Diagnostics

When first switching on the car ignition, the ABS controller will send signals to the four three-way valves and the wheel speed sensors. By monitoring the current consumed, the controller will be able to predict whether the hydraulic valve spools have stuck or if either a short or an open circuit exists in a component. In general, if a defect is discovered, the ABS system will be disabled and a warning light will be illuminated on the dashboard. When first pulling away, the output from the four wheel speed sensors is monitored and a reasonableness check applied. All defects and spurious behaviors are recorded in a fault memory within the controller for downloading when the vehicle is serviced.