Automotive Electrical and Electronic Systems -

ENME 5391
Department of Mechanical and Mechatronics Engineering
Dr. Rashad Mustafa

3/24/2022 1
 Schedule
Short history, development of electric and electronic
Introduction
system
Current output of the alternator, power outputs of the
Electrical power supply
consumers, charging the battery
in automotive
Batteries, Charging the batteries
Basic components to starting system
Engine starting systems
Starting systems, types of starters
Basic components to ignition system (Ignition switch, coil
transforms, switching device, spark plug, spark plug
Ignition systems
wire)
Ignition circuits
Automotive light sources, headlamp leveling control,
Lighting systems
adaptive lighting system
Electric heater control
Comfort systems
Electronically controlled air conditioning system,…
Active safety system: Electronic braking system (Antilock
braking system (ABS), Electronic stability program
Road safety systems (ESP), Traction control system (TCS)
Adaptive cruise system
Occupant protection system: (airbag, seat belt)
3/24/2022 2
 Schedule
Topics
Auxiliaries Windscreen wipers, parking system
Cross-system functions
Requirement for Bus systems
Communication systems
Classification of Bus systems
Applications in the vehicle
Engine control
Control systems
Control of automated transmission
Control area network (CAN) Bus, LIN Bus, Bluetooth,
Bus systems
MOST bus, TTP/C, FlexRay
Acoustic signaling devices
Central locking system
Vehicle security systems
Locking systems
Biometric systems
Diagnosis interfaces
On-board diagnostics Monitoring during vehicle operation
On-board diagnostics system
3/24/2022 3
 Chapter 1: Introduction
Automobile Electrical & Electronic Systems

3/24/2022 4
 Chapter 1: Introduction
Automobile Electrical System

Safety System: Comfort System:

- Radar Distance Warning/Regulation - Chassis control
- Headlight adjustment and cleaning - Heating, climate control
- Headlamp with gas discharge lamp - Seat adjustment with position
- Tyre pressure control memory
- Anti-lock braking system (ABS) - Central locking system
- Drive slip control (ASR) - Driving speed control
- System diagnosis - Rear area monitoring
- Wiper-wash control
- Load-dependent maintenance interval
display
- Monitoring systems for operating
materials and wear parts
- Release systems for airbags, belt
tensioners, anti-theft system
- Steering system for front and rear axle

3/24/2022 5
 Chapter 1: Introduction
Automobile Electrical System
Powertrain systems
- Electronic diesel control
- Idle Speed Control
- Lambda control
- Start Stop System
- Electronic transmission control
- Digital engine electronics, electronic
ignition system, injection systems
- Engine power control (electronic
accelerator pedal)
- Controller Area Network (CAN) ECU
coupling
3/24/2022
Commincation systems:
- Electronic voice output
- Function control by language
- Radio
- On-board computer
- Car phone
- Control and information system
- New display technologies
- Cable loom multiplex system
6
 Chapter 1: Introduction
Automobile Electrical System

3/24/2022 7
 Chapter 1: Introduction

Historical development of vehicle electronics:

Electric ignition on the engine of
the first Benz car in 1885

3/24/2022 H. Gaus; PKW-Konstruktion ll, Vorlesungsskript Universität Stuttgart 8

 Chapter 1: Introduction

Historical development of vehicle electronics:

1875 Low-voltage magnetic ignition device
1886 Benz tricycle with electric ignition
1902 High-voltage magnetic ignition device
1907 Speedometer
1908 Windscreen wiper (Prince Heinrich/Bosch)
1911 Electric starter (Kettering/Cadillac)
1913 Alternator, electric lighting system
1918 Brake light
1921 Bosch horn
1925 Two-Wire lamp (Osram)
1932 Car radio
1935 Electric preselection gearboxes
1950 Flashing light for direction indication
1957 Transistor car radio
1962 Three-phase generator with integrated silicon diodes
1965 Transistor ignition (contact controlled)
1967 First electronic fuel injection system (D-Jetronic)
1970 Computer diagnosis (VW) contactless magnetic high-voltage capacitor
ignition, First ABS (Teledix, Daimler-Benz)
3/24/2022 9
 Chapter 1: Introduction

Historical development of vehicle electronics:

1973 Halogen double wire lamp (H4)
1975 Digital instruments, On-board computer
1976 Lambda sensor for measuring oxygen in exhaust gas
1977 Driver guidance and information system
1978 ABS in production car (Bosch, Mercedes Benz)
1979 Motronic (central motor electronics), first use of a microcomputer
1980 Cylinder deactivation electronic heating and ventilation control
1983 Draft control for agricultural tractors Airbag (airbag as passive accident protection)
1984 ABS control unit with microcomputer (Teves, Bosch) automatic transmission with
electronic control
1985 Digital data bus (Controller Area Network CAN, Bosch)
1986 Electronic chassis control Rear axle steering (Mazda, Nissan) , Drive slip control ASR
1989 Navigation system
1991 Headlamp systems with gas discharge lamp
1994 Vehicle stabilization by brake intervention; with measurement of vehicle movement
(yaw angle speed and lateral acceleration)
1995 Route-seeking navigation systems for motor vehicles (with satellite navigation)

3/24/2022 10
 Introduction

Historical development of vehicle electronics:

Cable set and electric devices of a

Mercedes 170 V in 1946

Cable set and electrical

aggregates of a Mercedes
500 SL in 1989

Modern Vehicles

3/24/2022 11
 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 12
 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 13
 Chapter 1: Introduction

Requirements and development goals - Comfort

Driving comfort
 Vibration comfort of the entire vehicle
 Objectification of the vibration sensation
 Seat, foot and steering wheel vibrations
 Comfort on a "bad road“

 Structure vibrations
 Lift, pitch and roll oscillations as a function of "roadway", "load",
 "Gear shift," "driving maneuvers.“

 Vibration comfort in trailer

 Vibration behavior of the front and rear axle
 Powertrain vibrations
 Motor excitation (rotational uniformity, torque build-up, housing vibrations)
 Behavior of gearbox, cardan shaft, exhaust system

3/24/2022 14
 Chapter 1: Introduction

Requirements and development goals - Comfort

Operating comfort of the Primary operating devices
 Maneuverability
 Force-displacement behavior as a function of speed and lateral acceleration
 Accelerator
 Force-displacement and kick-down behavior
 Service brake
 Force-displacement behavior
 Parking brake
 Force-displacement behavior
 Release mechanism
 Clutch
 Force-displacement behavior during coupling and uncoupling
 Shift lever, selector lever
 Force-displacement behavior
 Precision
 Levers on steering column  Horn
 Turn signal
 Wiper Control
3/24/2022 15
 Chapter 1: Introduction

Requirements and development goals - Comfort

Operating comfort of the Secondary operating devices
 Purpose of the arrangement
 Haptic design
 Findability in darkness
 Force, displacement, noise, speed behavior
 Quality impression
 Seats, headrests
 Door actuation
 Fuel tank cap
 Heating and air conditioning system
 Other
 Navigation system
 Steering wheel adjustment
 Isolated compartment, sun visor

3/24/2022 16
 Chapter 1: Introduction

Requirements and development goals - Comfort

Climate Comfort
 Ventilation
 Flow rate distribution, speed
 Air quality

 Heating
 Temperature distribution in the interior
 Heating of the interior
 Windscreen defrosting
 Quality of temperature control

 Cooling
 Temperature distribution in the interior
 Quality of temperature control and humidity

3/24/2022 17
 Introduction

Requirements and development goals - Comfort

Acoustic Comfort
 Drive noises
 In traction and drag operation
 During load changes
 At constant speed
 Wind noises
 Tyre rolling noise as a function of
 Speed
 Road surface
 Tyre data
 Chassis noises
 Brakes, ABS  Opening, closing and other
 Shock absorber, steering operating noises
 Wheel bearing, axle suspension  Interior acoustics - sound
 slip control systems quality
 Noise from electrically driven aggregates
 Unwanted acoustic feedback (heating fan, air conditioning fan, fuel pump, ...)
 Desired acoustic feedback (central locking, window and seat adjustment, ...)
3/24/2022 18
 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 19
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
Exhaust emissions
 Fulfilment of the country regulations regarding

 Carbon monoxide (CO)

 Hydrocarbons (HC)
 Nitrogen oxides (NOx)
 Particle emission
 HC evaporation losses
 Catalyst conversion rate
 Exhaust gas behavior after cold start
 Long-term emission behavior

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 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
Noise Emissions
 ISO pass-by external noise level
 Meaning of the components
 Tyre/road noise
 Exhaust noise
 Drive noise

 Component noise
 Starting the engine
 Diesel cold start nailing
 Fuel pump
 Gearbox

3/24/2022 21
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
Vehicle-related measures to reduce emissions (consumption,
exhaust gas) Body
Engine - lightweight construction
- Warm-up optimization - cw optimization
- Efficiency optimisation
- Opt. powertrain
management

Chassis
- Reduction of rolling friction
- Electro-mechanical power
steering Powertrain
- (instead of hydraulic) - Ratio optimization
- Efficiency optimisation
Note:
The measures on the vehicle side to reduce emissions essentially
3/24/2022 mean minimizing friction in the powertrain and chassis! 22
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
New European Driving Cycle (NEDC)

Inner city cycle extra-urban cycle

Phase 1 Phase 2 Phase 3

Speed [km/h]

Time [s]
Cycle length: 11 km
Average speed: 32,5 km/h
Maximum speed: 120 km/h
Travel time 1170 s
3/24/2022 Source: EU Richtlinie 98/69/EC 23
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
Japan Test Cycles
11-mode cycle (cold test) 10/15-mode cycle (hot test)

Cycle length: 1,021 km Cycle length: 4.16 km

Number of cycles/test: 4 Number of cycles/test: 1
Average speed: 30.6 km/h Average speed: 22,7 km/h
Maximum speed: 60 km/h Maximum speed: 70 km/h

Speed [km/h] Speed [km/h]

60 60

40 40

20 20

0 0
0 50 100 0 200 400 600
Time [s] Time [s]
3/24/2022 Source: Ottomotor-Managemen 24
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
USA Test Cycles
Phase 1 Phase 2 Phase 3
Pause
City-Cycle (FTP 75)

Cycle length: 17.87 km

Speed,average: 34,1 km/h
Max Speed: 91,2 km/h
Travel time: 1877 s
(+ 600 s break)
0 500 1000 1500 2000
Time [s]

100
Extra Urban & Highway-
80
Cycle (HFEDS)
60
Speed [km/h]

Cycle length: 16.44 km

Speed ,average: 77,4 km/h 40
Max speed : 96,4 km/h
20
Travel time: 765 s
0
0 200 400 600 800
Time [s]Time [s]
3/24/2022 Source: http://www.metricmind.com 25
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility

3/24/2022 26
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility

NEDC

3/24/2022 27
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility

Volkswagen Emissions Scandal

3/24/2022 28
 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
Resource efficiency
 Component concept
 Lightweight construction, easy to repair
 Dismountable and separable, suitable for recycling
 Material concept
 Reusability, reduction of variety, recyclable secondary raw materials
 Energy concept
 Reduction of fuel and operating behavior
 Extension of maintenance intervals
 Minimization of waste disposal
 Combustion, landfilling
 Ecological balance
 Energy consumption, emissions over the service life
 Recycling rate

3/24/2022 Source: http://www.metricmind.com 29

 Chapter 1: Introduction Environmental
Requirements and development goals – Compatibility
Recycling ratio for end-of-life vehicles
Material Parts am
Anteil in car Recycling rate [%]
Auto [%] Recyclingquote
Steel
Stahl 53 98 -100
Cast Iron
Gußeisen 12,5 98 -100
Other metal
andere Metalle 5,2 95
Rubber
Gummi 5 95
Plastics
Kunststoffe 9 60
Glass
Glas 4 5-10
Other materials
andere Materialien 11,3 ~10
Totally
Insgesamt 100 ~75

3/24/2022 Source: http://www.metricmind.com 30

 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 31
 Chapter 1: Introduction
Requirements and development goals – Passives Safety
Occupant load
 Head injuries with
 Frontal, side, rear impact
 Rollover test (cross and
screw rollover)
 Acceleration of head, chest,
pelvis, foot at the limit of
 Frontal, side, rear,
rollover impact
 Force-displacement
boundaries
 Thigh force
 Breast deformation
 Impact occupant kinematics

3/24/2022 32
 Chapter 1: Introduction
Requirements and development goals – Passives Safety
Vehicle Body deformation
 Frontal crash
 Impact velocity (50 - 60 km/h)
 Impact angle (0° - 30°)
 Excess cover (40 % - 100%)
 Barrier: rigid, deformable,
with/without slip guard, centrally
positioned pile
 Side, rear crash, rollover
 Energy distribution
 Deformation characteristic curve
 Survival space (structural strength of the passenger cell)
 Displacement of steering column, pedal mechanism
 Intrusion of parts, door opening force

3/24/2022 33
 Chapter 1: Introduction
Requirements and development goals – Passives Safety

A variety of
airbags in modern
passenger cars

Front airbags with two-stage internal

four side bags and two window
pressure depending on accident
bags in the BMW 3 Series
severity
3/24/2022 34
 Chapter 1: Introduction
Requirements and development goals – Passives Safety
Fire Safety
 Sealing and protection of the fuel system
 Fire resistance of tank and interior materials
 Fire protection systems (Hand fire extinguishers)
 Switching off the fuel supply
 Short-circuit protection (battery arrangement, cable routing,
disconnection of the positive pole in the event of a crash)

3/24/2022 35
 Chapter 1: Introduction
Requirements and development goals – Passives Safety
Partner Protection
 Vehicle compatibility
 Geometry
 Force-displacement identification of the vehicle structure
 Pedestrian protection
 Deformation behaviour of vehicle front and accessories

3/24/2022 36
 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 37
 Chapter 1: Introduction

Requirements and development goals - Design

Objective criteria for good car design

Two sympathy carriers: The front of

the Minis and the facial expression of
an infant.

Attractiveness: Ford Fiesta orients

itself on the characteristics of
physiognomic attractiveness

Less attractive: The Toyota Auris is

based on physiognomic characteristics
that are not considered sympathetic.

3/24/2022 38
 Chapter 1: Introduction

Requirements and development goals - Design

Exterior
 Dimensioning proportions, shape
contexts, lines
 Body shape (wheel base, overhangs,
track, ...)
 Side wall, waistline
 Doors, door handles, gap width, joint
pattern
 Front design
 Radiator grille, headlights, bumpers,
 Front flap, windscreen
 Rear design
 tailgate, lights, bumper, exhaust pipe
 Wheel design
 Wheel diameter/wheel cut-out
 Wheel width/vehicle width Rim
shape, tyre shape
 Brake discs and caliper design
3/24/2022 39
 Chapter 1: Introduction

Requirements and development goals - Design

Interior
 Passenger compartment
 Dimensioning proportions, shaping, design, material
 Dashborad
 Operating elements
 Centre console
 Indicating instruments, seats
 Engine compartment design
 Luggage compartment design

3/24/2022 40
 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 41
 Chapter 1: Introduction
Requirements and development goals – Passives Safety

3/24/2022
https://www.youtube.com/watch?v=n8vf9EJBBfw 42
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
The 5 phases of an "accident" and the measures of
vehicle safety

Phase Situation Measure

I Normal (uncritical)
driving situation
"Active"
II Dangerous (critical) accident avoidance
driving situation

III Accident unavoidable Overlapping of "active" and

"passive" measures

IV Accident "passive"
accident Minimization
V Rescue

3/24/2022 43
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Elements and criteria for anthropometric (Human Body)
driver compartment design
Criteria
Driver-Vehicle Interface
 Sensibility, functionality
 Hand  Visibility
 Steering wheel (position, design)
 Position, accessibility
 Shift/ selector lever
 Design (optical, haptic)
 Parking brake
 Force-displacement curve
 Operating keys, buttons, sticks
 Acoustic, haptic feedback
 (for radio, telephone, etc.)
 Distance between controls
 Foot
 Pedals for:
 Brake
 Gas
 Clutch
 Parking brake

3/24/2022 44
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Visual Perception
 Direct view of the driver
 All-round visibility
 Windshield properties
 Windshield wiper
 Indirect view of the driver
 Interior and exterior mirrors
 Auxiliary systems (Cameras + Monitor)
 Display visibility
 Spatial arrangement
 Content, hierarchy
 Display accuracy
 Road Lighting
 Arrangement of luminaires
 Light distribution, light/dark boundary
 Lighting and visual assistance systems (light distribution and intensity
depending on traffic, driving speed and maneuvers)
 Visibility of the vehicle
 By day, by night, by bad weather
3/24/2022 45
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
All-round visibility in the vehicle

3/24/2022 Source FAZ, 46

 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Driving Performance
 Engine characteristics
 PMax, Mmax values
 Driving performance
 Acceleration times
 from 0 to 100 km/h
 from 0 to 100 m
 from 60 to 100 km/h
 Acceleration distance after 4 s
 Maximum speed vMax
 "customer-oriented" start-up
 Influence of outside temperature and altitude on driving
performance
 Response behavior of the vehicle
 Subjective impression
 Hill-climbing ability
 Start-up with mMax-vehicle, mTrailer,Max, ...
 Start-up after cold start
3/24/2022 Source FAZ, 47
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Cooling
 Allowable temperature collectives
 Coolant, engine oil
 Transmission oil, hydraulic oil
 Outdoor temperature compatibility of the equipment's
 Heat balance

3/24/2022 Source FAZ, 48

 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Traction
 Tensile force at different friction coefficients
 Right / left (μ-split)
 Front / rear

 Influence of
 Drivetrain concept
 Axle load distribution
 Blocking system

 Traction assistances
 Slip control systems

 Applied forces with

 Load changes
 Acceleration
 Traction / Drag
 Gear shifting
3/24/2022 Source FAZ, 49
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Traction

3/24/2022
https://www.youtube.com/watch?v=CwionwuuQQ0
Source FAZ, 50
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Driving dynamics characteristics
 Straight ahead travel
 Keeping track on level, uneven, undulating, transversely inclined road
surface
 Buoyancy and crosswind behavior
 Steering and concentration effort
 Load change, acceleration and aquaplaning behavior

 Curve and self-steering behavior with

 Stationary circle
 Lateral acceleration limit
 Over / understeering
 Load change reactions, aquaplaning

 Transient driving behavior

 Without driver influence (step response, ...)
 With driver influence (single-, double lane change, Elk test, …)

 Trailer operation
3/24/2022 Source FAZ, 51
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Slalom test – Not Passed

3/24/2022
https://www.youtube.com/watch?v=Um-XlKerWvA 52
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Slalom test – Passed

3/24/2022
https://www.youtube.com/watch?v=Er7r-9JWkIs&t=47s 53
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Elk “Moose” test

3/24/2022
https://www.youtube.com/watch?v=06y2ZRPglsI 54
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Braking Behavior
 Effect when driving straight ahead and in the curve
 Braking distance, deceleration
 Directional stability
 Influence of humidity, cold and corrosion
 Steering effort, vehicle reaction

 Braking effect of the parking brake

 Static (gradient / incline)
 Dynamic

 Emergency brake function (“Fail-Safe")

 Response
 Comfort behavior in case of wear and high temperature

3/24/2022 55
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Braking Behavior

3/24/2022
https://www.youtube.com/watch?v=_47utWAoupo 56
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Vehicle Control System
 Speed control
 Distance control
 Longitudinal dynamic control
 Brake force control (ABS)
 Traction control
 Lateral dynamic control
 Active axis kinematics
 Speed-dependent steering
 Driving dynamics control with engine and brake intervention
 Adaptive transmission control
 Roll stabilization
 Damping, Tyre Pressure Control
 Engine drag torque control

3/24/2022 57
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Driver Vehicle Interface
 Communication and entertainment systems (radio, telephone, fax,...)
 Vehicle condition monitoring
 On-board computer
 Service interval display
 Driver driving condition monitoring
 Detection of sleepiness condition
 Vitalizing capacity

3/24/2022 58
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Safety through DAS (Driver assistant system)
Cross Autonomous
Sensor CA
assistance
fusion Driving
CW
Passenger classification
Camera
inside Seat Occupant recognition
Attention Checks
LDW HC
Camera
Rear View Camera
outside
NiVi
Radar / ACC Stop & Go
Ultra- ACC BSD
ANB
Sound PDC Parking Assistance
EBV ABC TPM
Sensors ASR RSP BDC
for driving ESP
ABS HBA ESP+
condition
Side Airbag Pre-safe Pre-Crash Actions
Crash Active belts Automatic emergency call
sensors Airbag Active rollover protection
Laminated Glass EMB BbW(m.R.)
No Belt EML SbW(m.R.)
sensors crush zone
Safety compartment
1960 1980 2000 2020 Year
3/24/2022 59
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
ABC Active Body Control
ABS anti-lock braking system
ACC Adaptive Cruise Control
ANB Automatic emergency brake
ASR traction control
BbW/SbW Brake-by-Wire / Steer-by-Wire
(m.R.) (with mechanical drop back)
BDC Brake-Disc-Cleaning
BSD Blind spot-Detection
CA Collision Avoidance
CW Collision Warning
DbW Drive-by-Wire
EBV Electronic brake force distribution
EMB,EML Electromechanical brake, steering
ESP Electronic stability program
HBA hydraulic brake assistant
HC Heading Control
LDW Lane-Departure-Warning
NiVi Night Vision
PDC Park-Distance-Control
RSP Rollover-Stability-Program
TPM Tire Pressure Monitoring
TSP Trailer-Stability-Program

3/24/2022 60
 Chapter 1: Introduction
Driving dynamics /
Requirements and development goals - Active safety
Assistance Systems
 Present
 Brake assistant
 Heading control
 Lane change assistant
 Sleep warning
 ….

 Future
 Lane Monitoring "Lane Assistant
 Road condition detection for determining the adhesion
value
 Collision warning
 Speed monitoring (via traffic sign recognition)
 Electronic map with identification of accident routes
 ….
3/24/2022 61
 Chapter 1: Introduction

Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
3/24/2022 62
 Chapter 1: Introduction

Requirements and development goals - Economy

Energy costs
 Availability

 Type of energy source

 Gas
 Diesel/Gasoline
 Electric
 Hydrogen
 HC compounds (LPG, CNG, CH4, ...)

 Energy density (volumetric, gravimetric)

 Mileage

 Consumption
 Driving resistances
 Efficiency of the aggregates CNG: Compressed Natural Gas
3/24/2022 LPG: Liquefied Petroleum Gas 63
 Chapter 1: Introduction

Requirements and development goals - Economy

Historic vehicle fuel prices
Fuel Prices in $

3/24/2022 Quelle: Shell (www.shell.de), 2017 64

 Chapter 1: Introduction

Requirements and development goals - Economy

Inspection and repair costs

 Frequency

 Parts costs

 Labor cost

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Requirements and development goals - Economy

Fixed Costs
 Insurances
 Liability Insurance
 Comprehensive coverage
 Personal Injury protection

 Taxes
 Cars, CO2
 Mineral oil
 Duty

 Capital losses
 Purchase
 Residual value
 Depreciation (Each year, the price of the vehicle is reduced)
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Requirements and development goals - Economy

Fees

 Road use ( tolls )

 Technical supervisory association

 AU (Exhaust emission test)

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Requirements and development goals

Comfort
Environmental
Quality Compatibility

Economy 7
Passives
Criteria for Safety
vehicle
development

Driving
dynamics/
Active safety Design
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 Chapter 1: Introduction
Vehicle Testing and Validation

E0-Durability test (European Standard Test) 40.000 km

G0-Durability test (Global Standard Test) 42.800 km

Durability Road 100.000 km

Combined Powertain Test 95.000 km

• Durability Road 40.000 km
• High Speed Test 40.000 km
• City Test 10.000 km
• Winter Test 5.000 km

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 Chapter 1: Introduction
Internationales Technisches Entwicklungszentru
Vehicle Testing and Validation Test und Validierun
Testzentrum Dudenhofen
OPEL Testzentrum
Dudenhofen
Am Opel-Prüffeld 2
N
63110 Rodgau - Dudenhofen
 06106/281-0
06106/281-236

Schnellfahrbahn (4,8 km)

Schlammbad
Hochgeschwindigkeits-
Dauerversuch Bremsstopp

1. Kurzschluß Niedrig-
Rollenbahn Reibwert-
Bereich
2. Kurzschluß
Berg
Waldstr Heißboxen
ec ke
30%
20% Island Test
12%

anne
Hochgeschwindigkeits-
Bremsstopp

Splittw
Skidpad
Storch
baums (  100 m) Meßstrecke (1,3
chneis km)
3 e
US- 4
Schlaglöcher
Rampe Bahn-
10 übergang
9
trecke

Airbag- Misuse- 7
Testeinrichtungen 6 8 1 beheizt
2
5
Splitts

Verteilerkreisel Außengeräusch-
Salzwasserbad
meßstrecke
kleine (0,9 km)
HalleRampe 13°
Wasserbad
Verwaltung Rampe 16° Inspektionsplatz
Einsatzleitung
Interner Hochgeschwindigkeits-
Sicherheitsdienst Bremsstopp
Werkstatt
Klimakammer
Abgasgebäude
Freiluftrollen- Prüfstände Eingang
Tankstelle Besucherparkplatz
0 Konferenzraum 70
07.05.99/ Testzentrum Dudenhofen
3/24/2022
Pavillon
 Chapter 1: Introduction
Vehicle Testing and Validation

3/24/2022
https://www.youtube.com/watch?v=InOkUFDgjx0 71
 Chapter 1: Introduction

Requirements and development goals - Qaulity

Implementation quality
 Functional verification of
 Complete vehicle
 Subsystems (modules)
 In the vehicle and on the test bench
 Component parts
 Processing quality
 Auditing of assemblies
(body structure, paints,
engine compartment,
interior, ...)
 Radiation insensitivity
 Electromagnetic (EMV)

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Long-Term quality
 Failure behaviour of
 Component parts
 Systems
 complete vehicle
 Proof of reliability through
 Endurance testing
 Representation in the probability network
 Field analysis
 Customer satisfaction, ADAC breakdown statistics
 CSI (Customer Satisfaction Index), ...
 Corrosion protection quality
 Mechanical components (chassis, exhaust  Quality methods
system, brakes)  FMEA
 Body parts  FTA, …
 Electrical / electronic components
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Requirements and development goals - Qaulity

Life Cycle of vehicles in Germany
Car 11,8
11,9

Omnibuses 14,2
13,2

Motorcycle 13,8

Trailers 17,8

Trucks 21,6

Lorry 10,8

Other 15,9

Average 12,1

0 5 10 15 20 25

Year
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Requirements and development goals - Qaulity

ADAC - Breakdown statistics 2018: Causes
Manifold cracked, Battery defective,
catalytic converter discharged;
defective, suspension generator
broken, exhaust pipes / defective; drive
silencer corroded belt torn; starter
Exhaust system motor blocked;
General electrics cable
Others
disconnected;
16% 40% fuse blown

Immobiliser
Shift blocked; clutch 2,0% defective;
slipping; gear noise; marten bites on
clutch actuation 4,0% ignition cable;
defective; automatic control unit
transmission leaking 5,0% Ignition
defective; U-
system
Clutch/Gearbox contacts burnt;
10% spark plugs
8,0% Wheel wet
Cooling/ /tyres Engine
7,0% 8,0% Toothed belt or timing
Ventilation chain torn; marten bite on
Injection system intake system; oil pump
defective; too little oil;
Injection pump defective; air flow meter or air filter dirty; engine overheated
throttle cable torn or linkage jammed
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 Chapter 1: Introduction
Requirements and development goals - Qaulity
Quality of usage
 Under special conditions
 Extremely high/low temperatures
 Fluctuating fuel quality
 Air density, humidity
 Road condition
 High driving speed
 "Stop and go.
 Road salt, icing, snow dust
 Snow chain and studded tyre insert
 Flat tyre
 Waterproof and dustproof, wading depth
 vehicle pollution
 Anti-theft security
 Active protection (e.g. alarm system)
 Passive protection (e.g.. immobilizer)
3/24/2022
 For special driving situations
 Turning circle (right/left)
 Parking characteristics (visibility,
assessment of vehicle geometry)
 Driving on a ramp (overhang angle)
 Ground clearance (Curbside departure)
 Off-road capability (climbing ability, tilt
angle)
 With “Misuse“
 Curbside drive up/down, "bang" start
 Extremely long idle engine run when
stationary
 Improper towing, vehicle-lifting
 Shifting without clutch
 Driving with incorrect oil level, tyre
pressure
 Water passage, overloading
 High engine load with cold engine
 Creep speed with trailer on the
mountain
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Test im Death Valley (Nevada, USA)
Ø-Temperatur:e bis zu 50°C
Test Road 21 km with 7 % to 1200 m High

• Constant Driving Test: v = 40 km/h; 90 km/h, vMax in Pos. „D“ to 21 km

• Stop &Go- Cycle: Stop & Go Traffic under extreme conditions
3/24/2022 Source 25 Jahre Mercedes-Benz Prototypentest im Death Valley USA 77
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Testing under extreme conditions

Desert testing

Cold Chamber Test

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Source: Mercedes-Benz
 Chapter 1: Introduction

Requirements and development goals - Qaulity

EMC testing
• Testing of the immunity of cable harnesses and microprocessors, as well as electric motors
and digital instruments to electromagnetic interference fields
• Each component must first be checked individually, but then its effects on the entire vehicle
must also be checked.
• Test bench offers the possibility to simulate frequencies up to the gigahertz range
• Example: Noise from mobile phones in the radio loudspeakers

Integrated roller test bench

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Source: : Audi Presse Informationen
 Chapter 1: Introduction

Requirements and development goals - Qaulity

Service Friendly Design
 Vehicle cleaning
 Easy to clean
 vehicle outer skin
 Interior, luggage
compartment
 engine compartment
 Maintenance
 Diagnostic capability
 Expenditure (accessibility,
ease of assembly)
 Wear and spare parts
(availability)
 Weight distribution and
tipping safety of lifted
vehicles
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