BOSCH

Automotive Handbook

6 Table of Contents

Contents

Basic principles of physics Quantities and units

Sl units Legal units Systems of units not to be used

22 22 23 23

Quantities and units 24 Conversion of units 29

Basic equations used in mechanics 39 Symbols and units 39 Rectilinear and rotary motion 39 Laws of projectile motion 40 Free fall 40 Moments of inertia 41 Transmission of force 42 Friction 42

Vibrations and oscillations 44 Symbols and units 44 Terms 44 Vibration reduction 46 Modal analysis 48

Optical technology 49 Photometrie quantities and units 49 Electromagnetic radiation 49 Geometrical optics 50 Components 50 Light sources 51 Light and the physiology of vision 52 Laser technology 53 Optical fibers/waveguides 53 Holography 54 Display elements 55

Acoustics 56 Quantities and units 56 General terminology 56 Quantities for noise emission measurement 57 Motor-vehicle noise measurements and limits 58 Quantities for noise immission measurement 59 Perceived sound levels 60 Engineering acoustics 61

Hydrostatics 62 Symbols and units 62 Density and pressure 62 Buoyancy 62

Fluid mechanics 63 Symbols and units 63 Basic principles 63 Continuity equation 64 Bernoulli equation 64

Discharge from a pressure vessel 64 Resistance of bodies submerged in a fluid flow 65

Heat 66 Symbols and units 66 Enthalpy (heat content) 66 Heat transfer 66 Technical temperature measurement 68 Thermodynamics 69 Changes of State for gases 69

Electrical engineering 70 Quantities and units 70 Electromagnetic fields 70 Electric field 71 Direct current (DC) 72 Direct-current cireuits 73 Alternating current (AC) 75 Alternating-current cireuits 75 Three-phase current 77 Magnetic field 77 Ferromagnetic materials 79 The magnetic cireuit 80 Magnetic field and electric current 81 Electric effects in metallic conduetors 83 Gas and plasma discharge 85

Electronics 86 Basic principles of semiconduetor technology 86 Discrete semiconduetor devices 88 Monolithic integrated cireuits 92 Film and hybrid cireuits, MCM 97 Circuit-board technology, SMT 99 Micromechanics 100 Analog/digital conversion 102

Mechatronics 105 Mechatronic Systems and components 105 Development methodology 106 Outlook 108

Sensors 110 Basic principles 110 Sensor types 112

Actuators 140 Quantities and units 140 Electromechanical actuators 140 Fluid-mechanical actuators 145 Actuator Performance data 146

Electrical machines 149 Operating coneept 149 Direct-current machines 149 Three-phase machines 150

Table of Contents 7

Single-phase alternating-current machines 152 Duty-type ratings for electrical machines 152 Degrees of protection for electrical machines 153

Mathematics and methods Mathematics 154

Mathematical signs and Symbols 154 Useful numbers 154 Number Systems 154 Preferred numbers 155 Trigonometrie funetions 156 Equations for plane and spheheal triangles 157 Equations often used 157 Areas of plane surfaces 158 Volume and surface area ofsolids 159

Strength of materials 160 Symbols and units 160 Basic principles of material strength 161 Component stressing 163 Determining safety under static stress 175 Proof of safety under vibrating stress 178 Introduction to operational integrity calculation 186

Finite-element method (FEM) 190 WhatisFEM? 190 Areas of FEM application 191 Elements of FEM 194 Modeling and evaluation of results 196 FEM application examples 196

Quality 206 Quality management (QM) 206 Measuring and inspection equipment 210

Reliability 212 Reliability analysis and prediction 212 Reliability enhancement 213

Technical statistics 214 Purpose of statistics 214 Presentation of measured values 214 Evaluation of series of measurements 216 Weibull distribution of lifetimes 219 Statistical evaluation of test results 220 Measurement: basic terms 222

Control engineering Terms and definitions Control methods

223 223 225

Materials science Chemical elements 228

Designations 228 Periodic table of elements 231

Materials 232 Material terminology 232 Material Parameters 232 Properties of solids 234 Properties of liquids 238 Properties of water vapor 239 Properties of gases 240

Materials 241 Material groups 241 EN metallurgy Standards 245

Properties of metallic materials 250 Casting and steel materials 250 Vehicle-body sheet metal 254 Nonferrous metals, heavy metals 255 Nonferrous metals, light alloys 256 Sintered metals 257 Magnetic materials 260 Solders and filier materials 269 Electrical properties 272 Insulating materials 273

Properties of non-metallic materials 274

Ceramic materials 274 Laminates 276 Plastic molding Compounds 277 Plastic codes 284 Automotive paints 286

Corrosion and corrosion protection 288 Corrosion processes 288 Types of corrosion 290 Corrosion testing 291 Corrosion protection 294

Coating Systems 297 Coatings 297 Diffusion coatings 301 Conversion coatings 301

Tribology 303 Purpose and goals 303 Definitions 303 Tribological System 304 Types of wear 305 Manifestations of wear 305 Wear mechanisms 305 Wear quantities 305

8 Table of Contents

Tribological damage analysis Tribological test procedures Inhibiting wear

Lubricants Terms and definitions Engine oils Transmission lubricants Lubricating oils Lubricating greases

Fuels Characteristics Fuels for spark-ignition engines (gasoline/petrol) Diesel fuels Properties of liquid fuels and hydrocarbons Properties of gaseous fuels and hydrocarbons Alternative fuels

Antifreeze and brake fluid Brake fluids Coolants

Names of Chemicals

Machine parts Frictional joints

Basic principles Press fits (cylindrical interference fits) Tapered connections (tapered interference fits) Taper-Iock joints Clamp joints Keyed joints

Positive or form-closed joints Basic principles Feather-key and woodruff-key couplings Profiled shaft-hub connections Bolt and pin connections

Threaded fasteners Symbols and units Basics Threads Property classes Tightening threaded fasteners Fastener forces and torques Design of threaded fasteners Threaded fastener locking devices Thread selection

305 306 306 308 308 312 314 315 316 318 318

318 321

324

325 327 329 329 331 332

338 338

338

341 341 343 343 344 344

344 346 346 348 348 349 349 349 350 351 353

355 356

Springs 358 Symbols and units 358 Functions 358 Characteristic, work and damping 358 Spring combinations 359 Metal Springs 360

Fluid-film bearings and rolling-contact bearings 364

Characteristics 364 Hydrodynamic sliding bearings 364 Sintered-metal sliding bearings 368 Dry sliding-contact bearings 368

Rolling bearings 371 Characteristics 371 Parameters 371

Gears and tooth Systems 372 Quantities and units 372 Definitions 373 DIN gear qualities 375 Addendum-modification coefficient 376 Starter-tooth design 376 American gear Standards 377 Calculation of load-bearing capacity 378 Teeth calculations for bending and tooth fracture 380 Gear materials 381

Belt drives 382 Friction belt drives 382 Positive belt drives 385

Manufacturing processes Heat treatment of metallic materials 386

Hardening 386 Austempering 388 Draw tempering 388 Quench and draw 389 Thermochemical treatment 389 Annealing 391

Hardness 392 Hardness testing 392 Test procedure 392

Tolerances 397 Correlations 397 ISO System for limits and fits 397 Tolerances of form and position 397 Geometrical deviations 398 Surface parameters 398

Sheet-metal processing 400 Deep-drawing technology 400 Laser technology 402

Table of Contents 9

Joining and bonding techniques Welding Soldering Adhesive technologies Riveting Punch riveting Bonding and joining (pressurized clinching) Snap-on connections on plastic components

Influences in motor vehicles Road-going vehicle requirements Fuel consumption

Determining fuel consumption Effect of vehicle design on fuel consumption

Motor-vehicle dynamics Dynamics of linear motion Adhesion to road surface Accelerating and braking Actions: Reaction, braking and stopping Passing (overtaking) Dynamics of lateral motion Cornering behavior ISO procedures for evaluating vehicle handling Special operating dynamics for commercial vehicles Requirements for agricultural tractors

Environmental Stresses on automotive equipment

Climatic factors

Internal-combustion engines Internal-combustion engines

Operating concepts and classifications Cycles

Reciprocating-piston engines with internal combustion

Operating concept Engine types Definitions Crankshaft-assembly Operation and dynamic properties Balancing of masses in the reciprocating-piston engine Main components of reciprocating-piston engine Gas exchange

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417 418 418 423 424

426 428 430 435

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451 451 454 455

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Variable valve timing Supercharging processes Evaluating gas-exchange components Cooling Lubrication

The spark-ignition (Otto) engine Mixture formation Ignition Load control Power Output and economy

The diesel engine Mixture formation Diesel combustion process Combustion process

Hybrid engines Charge stratification Multifuel engines

Empirical values and data for calculation

Comparisons Engine Output, atmospheric conditions Definitions of power Calculation

Reciprocating-piston engine with external combustion (Stirling engine)

Operating concept and efficiency Design and operating characteristics

Wankel rotary engine Gas turbine

Operating concept, comparative cycle and efficiency

Engine peripherals Engine cooling

Air cooling Water cooling Intercooling (charge-air cooling) Oil and fuel cooling Cooling-module technology Cooling-system technology Intelligent thermomanagement Exhaust-gas cooling

Engine lubrication Force-feed lubrication System Components

Air filtration Air impurities Air filters (air cleaners)

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480 481 481 482 483 483 486 486 487 487 488 491 493 493 493

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496 497 498

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512 512 512 516 517 518 519 519 521 522 522 522 525 525 525

1 0 Table of Contents

Turbochargers and superchargers for internal-combustion engines 528

Superchargers (mechanically driven) 528 Pressure-wave superchargers 530 Exhaust-gas turbochargers 532 Multistage supercharging 537 Acceleration aids 538

Emission reduction Systems 540 Exhaust-gas recirculation System 540 Secondary-air injection 540 Evaporative-emissions control System 541 Crankcase Ventilation 542

Exhaust-gas Systems 544 Design and purpose 544 Manifold 545 Catalytic Converters 545 Particulate filters 546 Mufflers 547 Connecting elements 548 Acoustic tuning devices 549

Emission-control and diagnosis legislation Exhaust emissions 550

Combustion products 550 Properties of exhaust-gas components 550

Emission-control legislation 552 Overview 552 CARB legislation (passenger cars/light-duty trucks) 554 EPA legislation (passenger cars/light-duty trucks) 557 EU legislation (passenger cars/light-duty trucks) 559 Japanese legislation (passenger cars/light-duty vehicles) 562 U.S. legislation (commercial vehicles) 563 EU legislation (commercial vehicles) 564 Japanese legislation (commercial vehicles) 565 U.S.A. test cycles for passenger cars and light-duty trucks 566 European test cycle for passenger cars and light-duty trucks 568 Japanese test cycle for passenger cars and light-duty trucks 569 Test cycles for commercial vehicles 570

Exhaust-gas measuring techniques 572 Emissions testing on Chassis dynamometers 572 Exhaust-gas measuring devices 575 Diesel smoke emission test (opacity measurement) 579 Evaporative-emissions test 580

Diagnostics 582 Introduction 582 Self-diagnosis 582 On-Board Diagnosis (OBD) 584

Engine management for spark-ignition (Sl) engines Description of the engine management System 592 Cylinder Charge 593

Component parts 593 Controlling the air Charge 594 Air-system components 595

Fuel supply 596 Fuel supply and delivery with intake-manifold injection 596 Fuel supply and delivery with gasoline direct injection 597 Fuel supply and delivery components 599

A/F mixture formation 605 Basic principles 605 Mixture-formation Systems 606 Carburetors 607 Intake-manifold injection (external A/F mixture formation) 610 Gasoline direct injection (internal A/F mixture formation) 612 A/F mixture formation components 614

Ignition 618 Basic principles 618 Moment of ignition 619 Ignition Systems 623 Ignition components 625

Motronic engine-management System 634

Function 634 System overview 634 Versions of Motronic 635

Development of fuel-injection Systems 642

Overview 642 Mono-Jetronic 642 K-Jetronic 644 KE-Jetronic 646 L-Jetronic 648 LH-Jetronic 650

Table of Contents

Development of coil-ignition Systems

Conventional coil ignition (Cl) Transistorized ignition (Tl) Electronic ignition (El and DLI) Capacitor-discharge ignition (CDI)

Minimizing pollutants in the spark-ignition engine

Engine-design measures Reducing engine external interference Catalytic exhaust-gas treatment

Alternative spark-ignition engine Operation Engines fueled by LPG (liquefied petroleum gas)

Applications LPG Systems

Engines fueled by natural gas Applications Natural-gas Systems

Engines fueled by alcohol Applications System

Engines fueled by hydrogen Applications Hydrogen System

652 652 654

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661 662

668 668 669 671 671 671 673 673 673 674 674 675

Alternative drives Electric drives

Power supply Batteries Drivetrains

Hybrid drives Drive configurations Hybrid drive designs

Fuel cells Design variations Fuel conditioning Thermodynamics and kinetics Fuel cells in motor vehicles

Drivetrain Drivetrain

Quantities and units Function Design Drivetrain configurations Drivetrain elements Power take-up elements Multi-speed gearbox Manually shifted transmissions Automatic transmissions Electronic transmission control Continuously variable transmission (CVT) Final-drive units Differential

722 722 723 725 728 728 729 732 732 732 733 735

736 736 736 736 737 737 738 740 741 743 747

749 750 752

All-wheel drive and transfer case 753

Diesel-engine management Fuel supply (low-pressure stage) 676

Diesel fuel-injection System 676 Diesel fuel-supply components 678

Diesel fuel-injection Systems 682 Overview 682 In-Iine fuel-injection pump 685 In-Iine control-sleeve fuel-injection pump 693 Distributor injection pump 694 Time-controlled single-cylinder pump System 700 Common-rail System (CRS) 704 Injection System components 707 Start-assist Systems 713

Minimizing pollutants in diesel engines 716

Engine-design measures 716 Exhaust-gas treatment 716

Chassis Systems Suspension 754

Types of oscillation 754 Suspension design elements 756/762 Controlled Suspension Systems 756 Active Suspension 758 Shock absorbers 760 Vibration absorber 761

Suspension linkage 764 Kinematics 764 Basic types 765/766 Elastokinematics 765

Wheels 768 Overview 768 Passenger-car wheels 768 Commercial-vehicle wheels 770

Tires 772 Tire categories 772 Tire design 772 Tire designation Symbols 774

1 2 Table of Contents

Tire applications 777 Tire traction 778

Steering 786 Steering-system requirements 786 Steering behavior 786 Types of steering box 787 Steering kinematics 787 Classification of steering Systems 788 Hydraulic power-assisted steering 788 Electric power-assisted steering 789 Power-assisted steering for commercial vehicles 790

Electronic Stability Program (ESP) for commercial vehicles

Electronically controlled braking System (ELB) for commercial vehicles

Function System design ELB components Electropneumatic braking (operating concept) Control and management functions Monitoring and diagnostic functions

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874 Vehicle safety Systems Braking Systems

Definitions, Principles Legal regulations Design and components of a braking System Braking-system design Brake-circuit configurations

Braking Systems for passenger cars and light Utility vehicles

Components Vehicle stabilization Systems for passenger cars

Antilock braking System (ABS) Traction control System (TCS) Electronic Stability Program (ESP) for passenger cars Suppiementary functions (automatic brake-system Operations)

Electrohydraulic brakes (SBC) Purpose and function Design Operating concept

Braking Systems for commercial vehicles > 7.5 t permissible total weight

System and configuration Automatic load-sensitive braking-force metering Wheel brakes Parking-brake System Retarder braking Systems (additional retarding braking Systems) Components for compressed-air brakes

Vehicle stabilization Systems for commercial vehicles

Antilock braking System (ABS) Traction control System (TCS)

792 792 797

800 803 804

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Electronic commercial-vehicle brake management as the platform for driver-assistance Systems

Basic electronic braking System Subsystems

Vehicle bodies Road-vehicle systematics

Classification Vehicle bodies, passenger cars

Main dimensions Body design Aerodynamics Aeroacoustics Body structure Body materials Body surface Body finishing components Safety Calculations

Vehicle bodies (commercial vehicles)

Commercial vehicles Light commercial vehicles Medium- and heavy-duty trucks and tractor vehicles Buses Passive safety in commercial vehicles

Lighting Functions Regulations and equipment Definitions and terms Main headlamps, European System Main headlamps, European regulations Headlamps, U.S.A. Headlamps, U.S. regulations Headlamp leveling control, Europe

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884 885 886 886 888 888 890 891 893 894 894 896 901

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Table of contents 1 3

Headlamp cleaning Systems Fog lamps Auxiliary driving lamps Lights and lamps Tum-signal indicators Hazard-warning and turn-signal flashers Side-marker, clearance and tail lamps Parking lamps License-plate lamps Stop lamps Rear fog warning lamps Reversing lamps Daytime running lamps Other lighting devices Motor-vehicle bulbs

Automotive windshield and Window glass

The material properties of glass Automotive glazing Functional design glazing

Windshield and rear-window cleaning Systems

Windshield wiper Systems Rear-window wiper Systems Headlamp washer Systems Wiper motors Washing Systems

Passenger-compartment heating Ventilation and air conditioning (HVAC)

Function Systems deriving heat from the engine Air conditioners Auxiliary heater Systems Cabin filters for passenger cars

Automotive electrical Systems Vehicle electrical Systems

Electrical power supply in a conventional vehicle electrical System Future vehicle electrical Systems Influence on fuel consumption Starter batteries Alternators

Starting Systems Requirements Design factors Starter design and Operation Triggering the Starter

929 Symbols used in vehicle 930 electrical Systems 990 931 General Symbols 990 931 Circuit diagrams 995 934 Schematic diagrams 995

Section designation and 935 device identification 1005

Wiring diagram: 936 Detached representation 1007 937 Terminal designations 1008 937 Assembled-representation 937 diagrams 1010 937 Conductor dimensions 1014 938 Connectors 1018 938 Function and requirements 1018 939 Design and types 1018 939 Electromagnetic compatibility

(EMC) and interference 942 suppression 1020 942 Requirements 1020 943 Sources of interference 1020 944 Potentially susceptible devices 1023

Interference coupling 1024 946 Electrostatic discharge 1026 946 Measuring techniques 1026 949 Regulations and Standards 1027 950 950 951 Vehicle locking Systems

Locking Systems 1028 Function, structure,

952 952

952 953 956 959

960

960 963 966 967 974 984 984 984 984 988

operating principle Mechanical locking System Open-by-wire Electrical locking System

Central locking System Acoustic signaling devices

Applications Horns Fanfare horns

Safety and convenience Occupant safety Systems

Active and passive safety in motor vehicles Seat belts and seat-belt tighteners Front airbag Side airbag Components Rollover protection Systems Outlook

1028 1029 1030 1031 1032 1033 1033 1033 1033

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1 4 Table of Contents

Power Windows Power-window motors Power-window control

Power sunroof Seat and steering-column adjustment Biometrie Systems Driver-assistance Systems Adaptive Cruise Control (ACC) for passenger cars Adaptive Cruise Control (ACC) for commercial vehicles

Design and funetion Applications Control algorithms Outlook

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1060 1060 1060 1062 1062

Information and communication Data processing and communication networks in motor vehicles 1064

Requirements 1064 Electronic control unit (ECU) 1065 Architecture 1065 CARTRONIC 1066 Communication networks 1070 Controller Area Network (CAN) 1072

Instrumentation 1076 Information and communication areas 1076 Driver information Systems 1076 Instrument Clusters 1078 Display types 1080

Vehicle information System 1082 Trip recorders 1083

Applications 1083 Operating coneept 1083

Parking Systems 1086 Parking aid with Ultrasonic sensors 1086 Further development 1089

Analog Signal transmission 1090 Wireless Signal transmission, TV and radio broadeasting 1090 Information transmission using high-frequency waves 1091 Propagation of high-frequency waves 1091 Radio interference 1093 Signal-to-noise ratio 1093

Digital signal transmission 1094 Applications 1094 The Digital Audio Broadeasting (DAB) System 1094

Measures for reliable transmission in the mobile Channel 1095 The Digital radio broadeasting System (DRM) for the long, medium and short wavebands 1095

Automotive sound Systems 1096 Radio tuners 1096 Conventional tuners 1096 Digital reeeiver 1097 Reception quality 1098 Reception improvement 1098 Auxiliary equipment 1100 Vehicle antennas 1101

Mobile and data radio 1102 Telecommunications networks 1102 Components and strueture 1102 Mobile radiocommunications networks 1103 Data radio networks 1105

Mobile information Services 1106 Transmission Systems for mobile information Services 1106 Components 1107 Challenges 1108 Service classes 1109 Alternative mobile information Services 1110

Navigation Systems 1112 Position location 1112 Destination entry 1112 Route computation 1113 Route guidance 1113 Map display 1113 Road-map memory 1113

Traffic telematics 1114 Transmission paths 1114 Standardization 1114 Referencing 1114 Selection 1114 Decoding of traffic messages 1114 Telematics Services 1114 Dynamic route guidance 1115 Offboard navigation 1115 Information recording 1115

Fleet management 1116 Definition 1116 Services 1116 Transmission paths 1117 Standardization 1117

Multimedia Systems 1118 Multimedia broadeasting 1118 Mobile Internet 1118

Table of Contents 1 5

Development methods and processes Methods and tools

Function and requirements Model-based development of vehicle functions Software architecture and standardized Software components Modeling and Simulation of Software functions Rapid prototyping of Software functions Design and implementation of Software functions Integration and testing of Software and ECUs Calibration of Software functions

Sound design Definition Implementation

Vehicle wind tunnels Applications Aerodynamic Parameters Wind tunnel designs

Development methods and processes Environmental management

Overview Environmental policy Legal principles Organization and management tasks Suppliers and Service Providers Technical development Procurement of environment-friendly materials Production System monitoring Corrective measures Eco-management System audit Education and training

Workshop technology Vehicle System fest

Workshop equipment System fest using KTS fester Engine-test technology

Electrical tests Testing and charging Starter batteries Test technology for altemators Test technology for Starters

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1126 1128 1130 1130 1130 1134 1134 1134 1135

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1150 1152 1153

Headlamp adjustment, Europe Headlamp adjustment, U.S.A.

Testing diesel fuel-injection pumps Testing on test benches Testing in the vehicle

Brake testing Brake test Stands

German emissions inspection Regulations Test procedure Test equipment

Motorsports Motronic in motor racing Super Race Trucks

Automotive hydraullcs and pneumatics Automotive hydraulics

Quantities and units Terms and formulars Gear pumps Gear motors Piston pumps and motors Electrohydraulic pumps and small units Valves Cylinders Tractor hydraulics Hydraulic accumulators Auxiliary drives Hydrostatic fan drives Hydrostatic drives

Automotive pneumatics Operation of bus doors

Appendices International registration plates Alphabets and numbers Index of technical terms Abbreviations

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