8th Edition

Automotive Handbook

Autom

otive Hand

book

All about automotive engineering in a pocketbookThe 8th edition has been revised and extended.

Automotive Handbook

Reference handbook for academic and personal use.

ISBN 978-0-7680-4851-3

Contents – central themes Basic principles: physics, materials, machine parts,

joining and bonding techniquesVehicle physics: basic terms of automotive engineering,

motor-vehicle dynamics, vehicle acousticsInternal-combustion engines: gasoline engine, diesel engine,

turbochargers and superchargers, exhaust-gas systemEmission-control and diagnosis legislationManagement for spark-ignition engines: manifold injection,

gasoline direct injection, alternative gasoline-engine operationManagement for diesel engines: common railAlternative drives: hybrid drive, fuel cellChassis systems: suspension, wheel suspensions, steering,

brake systemsActive safety: antilock braking system, driving-dynamics

control systemLighting equipmentAutomotive electrics: vehicle electrical systems,

starter batteries, electrical machines, alternatorsAutomotive electronics: automotive networking, buses,

architecture of electronic systems, sensorsDriver-assistance systems: parking systems, vehicle navigation,

Adaptive Cruise Control, night-vision systems

About the Bosch GroupBosch is one of the world’s leading suppliers to the automotive industry. The large number of applications for patents and utility models is impressive proof of the company’s leading position in automotive engineering.

8  Contents

Electronics 80Basicprinciplesofsemiconductortechnology 80Discretesemiconductordevices 83Monolithicintegratedcircuits 95MicroprocessorsintheECU 96Electrochemistry 99Electrolyticconductionandelectrolysis 99Applications 100

Mathematics and methodsMathematics 104Numbersystems 104Functions 104Equationsintheplanetriangle 106Complexnumbers 107Mathematicalsignsandsymbols 107Greekalphabet 107Finite-elementmethod 108Applications 108FEMexamples 111Controlengineering 116Termsanddefinitions 116Control-engineeringtransferelements 117Designingacontroltask 118Adaptivecontrollers 120

MaterialsChemicalelements 122Designations 122Periodictableofelements 125Substances 126Substanceterminology 126Substanceparameters 126Propertiesofsolids 128Propertiesofliquids 132Propertiesofwatervapor 133Propertiesofgases 134Materials 135Materialgroups 135ENmetallurgystandards 139Propertiesofmetallicmaterials 144Castingandsteelmaterials 144Nonferrousmetals,heavymetals 149Nonferrousmetals,lightalloys 150Sinteredmetals 151Magneticmaterials 154Soldersandfillermaterials 163Electricalpropertiesofmaterials 166

Contents

Basic principles of physicsQuantitiesandunits 22SIunits 22Legalunits 24Furtherunits 30Naturalconstants 33Basicequationsusedinmechanics 34Rectilinearandrotarymotion 34Transmissionofforce 34Friction 37Vibrationsandoscillations 40Terms 40Equations 42Vibrationreduction 43Modalanalysis 44Acoustics 46Generalterminology 46Measuredquantitiesfornoiseemissions 48Measuredquantitiesfornoiseimmissions(noiseprotection) 49Perceivedsoundlevels 50Hydrostatics 52Densityandpressure 52Buoyancy 52Fluidmechanics 53Basicprinciples 53Basicequationsoffluidmechanics 54Dischargefromapressurevessel 54Resistanceofbodiessubmergedinafluidflow 55Thermodynamics 56Enthalpy(heatcontent) 56Lawsofthermodynamics 58Changesofstateforgases 59Electricalengineering 60Electromagneticfields 60Electricfield 60Directcurrentanddirectvoltage 62Time-dependentcurrent 65Magneticfield 66Magneticfieldandelectriccurrent 70Wavepropagation 74Electriceffectsinmetallicconductors 77

00-04-U327E_Inhalt.indd 8 21.03.11 16:17

Contents 9

Propertiesofnon-metallicmaterials 167Insulatingmaterials 167Ceramicmaterials 168Laminates 170Plasticmoldingcompounds 171Plasticcodeswithchemicalnamesandtradenames 178Automotivepaints 180Heattreatmentofmetallicmaterials 182Hardness 182Heat-treatmentprocesses 186Thermochemicaltreatment 191Corrosionandcorrosionprotection 194Corrosionprocesses 194Typesofcorrosion 196Corrosiontesting 197Corrosionprotection 200Depositsandcoatings 203Deposits 203Diffusioncoatings 207Conversioncoatings 207

Operating fluidsLubricants 208Termsanddefinitions 208Engineoils 213Transmissionlubricants 216Lubricatingoils 217Lubricatinggreases 218Fuels 220Characteristics 220Gasolines 221Dieselfuels 224Alternativefuels 228Propertiesofliquidfuelsandhydrocarbons 234Propertiesofgaseousfuelsandhydrocarbons 235Brakefluids 236Coolants 238

Machine partsSprings 240Basicprinciples 240Metalsprings 241Slidingbearings 246Features 246Hydrodynamicslidingbearings 246Sinteredmetalslidingbearings 251Sliding-contactbearings 252Rollerbearings 255Applications 255Generalprinciples 255Selectionofrollerbearings 256Calculationofloadcapacity 258Gearsandtoothsystems 260Overviewofgears 260Starter-toothdesigns 264Americangearstandards 265Calculationofload-bearingcapacity 266Gearmaterials 269Beltdrives 270Frictionbeltdrives 270Positivebeltdrives 274Chaindrives 278Overview 278Chaindesigns 278Sprockets 280Chain-tensioningandchain-guideelements 281

Joining and bonding techniquesDetachableconnections 282Positiveorform-closedjoints 282Frictionaljoints 286Threadedfasteners 292Snap-onconnectionsonplasticcomponents 302Permanentjoints 304Welding 304Soldering 308Adhesivetechnologies 309Riveting 310Penetrationclinching 312

00-04-U327E_Inhalt.indd 9 21.03.11 16:17

10  Contents

Vehicle physicsBasictermsofautomotiveengineering 314Basictermsofvehiclehandling 314Motor-vehicledynamics 324Dynamicsoflinearmotion 324Adhesiontoroadsurface 329Acceleratingandbraking 331Actions:Reaction,brakingandstopping 331Passing(overtaking) 333Fuelconsumption 335Dynamicsoflateralmotion 338Specialoperatingdynamicsforcommercialvehicles 344Operating-dynamicstestproceduresasperISO 348Aerodynamics 354Aerodynamicparameters 354Vehiclewindtunnels 355Vehicleacoustics 360Exteriornoisemeasurementsandstatutorylimitsformotorvehicles 360Engineeringacoustics 361Sounddesign 362

Internal-combustion enginesInternal-combustionengines 366Thermalengines 366Cycles 368Realcycles 373Designandoperatingprinciple 442Mixtureformation,combustion,emissions 376Gasolineengine 376Dieselengine 386Mixedformsandalternativeoperatingstrategies 391Chargecycleandsupercharging 392Gasexchange 392Variablevalvetiming 395Superchargingprocesses 399Exhaust-gasrecirculation 403Reciprocating-pistonengine 404Components 404Reciprocating-pistonenginetypes 418Crankshaft-assemblydesign 419Tribologyandfriction 427Empiricalvaluesanddataforcalculation 431Wankelrotaryengine 442Designandoperatingprinciple 442Propertiesofarotaryengine 445

Enginecooling 446Aircooling 446Watercooling 446Intercooling(charge-aircooling) 450Oilandfuelcooling 451Cooling-moduletechnology 452Cooling-systemtechnology 453Intelligentthermalmanagement 453Exhaust-gascooling 455Enginelubrication 456Force-feedlubricationsystem 456Components 456Airfiltration 459Airimpurities 459Airfilters(aircleaners) 459Turbochargersandsuperchargers 462Superchargers(mechanicallydriven) 462Pressure-wavesuperchargers 465Exhaust-gasturbochargers 467Complexsuperchargingsystems 475Exhaust-gassystem 480Designandpurpose 480Exhaustmanifold 481Catalyticconverter 482Particulatefilter 483Mufflers 483Connectingelements 485Acoustictuningdevices 486Commercial-vehicleexhaust-gassystems 487

Emission-control and  diagnosis legislationEmission-controllegislation 488Overview 488CARBlegislation(passengercars/lightcommercialvehicles) 490EPAlegislation(passengercars/lightcommercialvehicles) 493EUlegislation(passengercars/lightcommercialvehicles) 495Japaneselegislation(passengercars/lightcommercialvehicles) 498USlegislation(heavycommercialvehicles) 499EUlegislation(heavycommercialvehicles) 500Japaneselegislation(heavycommercialvehicles) 502

00-04-U327E_Inhalt.indd 10 21.03.11 16:17

Contents 11

UStestcycles(passengercars/lightcommercialvehicles) 503Europeantestcycle(passengercars/lightcommercialvehicles) 505Japanesetestcycle(passengercars/lightcommercialvehicles) 506Testcyclesforheavycommercialvehicles 507Exhaust-gasmeasuringtechniques 510Exhaust-gastestonchassisdynamometers 510Exhaust-gasmeasuringdevices 513Dieselsmoke-emissiontest 516Evaporative-emissionstest 518Diagnostics 520Introduction 520Monitoringindrivingmode 520On-BoardDiagnostics(OBD) 522OBDfunctions 526OBDrequirementsforheavycommercialvehicles 529Workshopdiagnostics 531ECUdiagnosticsandServiceInformationSystem 533

Management for  spark-ignition enginesManagementforspark-ignitionengines 534Descriptionoftheenginemanagementsystem 534Systemoverview 535VersionsofMotronic 539Cylindercharge 542Componentparts 542Controllingtheaircharge 543Fuelsupply 546Fuelsupplyanddeliverywithmanifoldinjection 546Fuelsupplyanddeliverywithgasolinedirectinjection 547Evaporative-emissionscontrolsystem 549Fuelfilter 550Electricfuelpump 551High-pressurepumpsforgasolinedirectinjection 553Fuelrail 557Fuel-pressureregulator 558Fuel-pressureattenuator 558

Mixtureformation 559Basicprinciples 559Mixture-formationsystems 560Intake-manifoldinjection 561Gasolinedirectinjection 563Mixture-formationcomponents 565Ignition 570Basicprinciples 570Momentofignition 571Ignitionsystems 575Ignitioncoil 577Sparkplug 581Catalyticexhaust-gastreatment 586Catalyticconverter 586λcontrol 590

Alternative gasoline-engine  operationLPGoperation 592Applications 592Design 592LPGsystems 594Enginesfueledbynaturalgas 596Applications 596Design 596Components 599

Management for diesel enginesManagementfordieselengines 602Descriptionoftheenginemanagementsystem 602ElectronicDieselControl 603Fuelsupplysystem(low-pressurestage) 606Fuelsupplyanddelivery 606Fuelfiltering 610Common-railinjectionsystem 612Systemoverview 612Injectors 616High-pressurepumps 621Rail 625Time-controlledsingle-cylinderpumpsystem 626Unit-injectorsystemforpassengercars 626Unit-injectorsystemforcommercialvehicles 627Unit-pumpsystemforcommercialvehicles 628Components 629

00-04-U327E_Inhalt.indd 11 21.03.11 16:17

12  Contents

Dieseldistributorinjectionpumps 630Axial-pistondistributorpumps 630Radial-pistondistributorpumps 633Fuel-injectionsystem 635Start-assistsystems 636Preheatingsystems 636Exhaust-gastreatment 639Catalyticconverters 639Particulatefilter 642

Alternative drivesHybriddrives 646Features 646Functions 647Functionalclassification 648Driveconfigurations 649Controlofhybridvehicles 654Regenerativebrakingsystem 657Fuelcellsforthevehicledrive 658Functioningprinciple 658Functioningprincipleofthefuel-cellsystem 660Functioningprincipleofthedrivetrain 662

DrivetrainDrivetrain 664Overview 664Drivetrainelements 666Powertake-upelements 667Multi-speedgearbox 669Manuallyshiftedtransmissions 670Automatictransmissions 672Continuouslyvariabletransmissions 678Final-driveunits 679All-wheeldriveandtransfercase 682

Chassis systemsChassissystems 684Basicprinciples 684Suspension 694Basicprinciples 694Typesofspring 697Suspensionsystems 702Shockabsorbersandvibrationabsorbers 706Shockabsorbers 706Vibrationabsorbers 713Wheelsuspensions 714Basicprinciples 714Kinematicsandelastokinematics 714Basiccategoriesofwheelsuspensions 716

Wheels 722Passenger-carwheels 722Commercial-vehiclewheels 728Tires 732Tirecategories 732Tiredesign 732Tiredesignation 734Tireapplications 737Tiretraction 738Tire-pressuremonitoringsystem 746Steering 748Definitionsformotor-vehiclesteeringsystems 748Steering-systemrequirements 748Typesofsteeringbox 750Power-assistedsteeringsystemsforpassengercars 751Power-assistedsteeringsystemsforcommercialvehicles 757Brakesystems 760Definitionsandprinciples 760Legalregulations 765Structureandorganizationofbrakesystems 774Brakesystemsforpassengercars 776Servicebrakesystem 776Electromechanicalparkingbrakesystem 778Electrohydraulicbrake 780Purposeandfunction 780Design 782Operatingprinciple 782Brakesystemsforcommercialvehicles 784Systemoverview 784Componentsofcommercial-vehiclebrakesystems 787Electronicallycontrolledbrakesystem 794Continuous-operationbrakesystems 798Wheelbrakes 802Diskbrakes 802Drumbrakes 804

Chassis control and active safetyAntilockbrakingsystem 806Functionandrequirements 806Operatingprinciple 806ABSsystemvariants 810ABSversions 812Antilockbrakingsystemforcommercialvehicles 814

00-04-U327E_Inhalt.indd 12 21.03.11 16:17

Contents 13

Tractioncontrolsystem 818Functionandrequirements 818TCScontrolloops 818Driving-dynamicscontrolsystem 822Function 822Requirements 823Operatingprinciple 824Typicaldrivingmaneuver 824Structureoftheoverallsystem 825Systemcomponents 834SpecialElectronicStabilityProgramforcommercialvehicles 837Supplementaryfunctions(automaticbrake-systemoperations) 842Integrateddriving-dynamicscontrolsystems 846Overview 846Functions 846Systemarchitecture 849

Vehicle bodiesRoad-vehiclesystematics 852Classification 853Vehiclebodies,passengercars 854Maindimensions 854Bodydesign 856Aerodynamics 857Aeroacoustics 859Body 860Safety 864Vehiclebodies,commercialvehicles 868Classification 868Lightutilityvans 869Medium-andheavy-dutytrucksandtractorunits 869Buses 872Passivesafetyintrucks 874Lightingequipment 876Functions 876Regulationsandequipment 877Lightsources 878Main-lightfunctions 879Main-lightfunctionsforEurope 882Main-lightfunctionsfortheUSA 885Definitionsandterms 887Technicaldesignvariationsofheadlamps 888Installationandregulations forsignallamps 899Technicaldesignvariations forlamps 903Headlightlevelingcontrol 907Headlampadjustment 908

Automotivewindshieldandwindowglass 914Thematerialpropertiesofglass 914Automotiveglazing 915Functionaldesignglazing 916Windshield,rear-windowandheadlampcleaningsystems 920Windshieldwipersystems 920Rear-windowwipersystems 926Windshieldandrear-windowwashersystems 927Headlampwashersystems 927

Passive safetyOccupant-protectionsystems 928Seatbeltsandseat-beltpretensioners 928Airbag 931Rolloverprotectionsystems 934Components 934Furtherdevelopments 936

Vehicle security systemsLockingsystems 938Function 938Structure(sidedoorasexample) 939Double-lockingfunctions 941Technology 945Theft-deterrentsystems 946Regulations 946Systemdesign 946

Automotive electricsVehicleelectricalsystems 948Electricalpowersupply 948Electrical-systemstructures 953Electrical-systemparameters 955Electricalenergymanagement 957Starterbatteries 962Requirements 962Batterydesign 963Charginganddischarging 964Batterycharacteristics 965Batterytypes 966Usingthebattery 968Electricalmachines 970Systematicsofrotatingelectricalmachines 970Direct-currentmachines 970Asynchronousmachine 975Synchronousmachine 977Three-phasecurrentsystem 982

00-04-U327E_Inhalt.indd 13 21.03.11 16:17

14  Contents

Alternators 986Electricpowergeneration 986Operatingconditions 991Efficiency 992Typesofclaw-polealternator 993Startingsystems 996Starter 996Triggeringthestarter 1000Actuators 1002Overview 1002Electrodynamicandelectromagneticconverters 1002Piezoactuators 1005Fluid-mechanicalactuators 1007Wiringharnessesandplug-inconnections 1008Wiringharnesses 1008Plug-inconnections 1010Electromagneticcompatibility(EMC)andinterferencesuppression 1014Requirements 1014Sourcesofinterference 1014Potentiallysusceptibledevices 1017Interferencecoupling 1018Electrostaticdischarge 1019Measuringtechnology 1020Regulationsandstandards 1021Symbolsandcircuitdiagrams 1022Circuitsymbols 1022Circuitdiagrams 1029Terminaldesignations 1041

Automotive electronicsAutomotivesoftwareengineering 1044Motivation 1044Designofsoftwareinmotorvehicles 1045Importantstandardsforsoftwareinmotorvehicles 1045Thedevelopmentprocess 1048Qualityassuranceinsoftwaredevelopment 1052Sequencesofsoftwaredevelopmentinmotorvehicles 1052Modelingandsimulationofsoftwarefunctions 1054Designandimplementationofsoftwarefunctions 1057IntegrationandtestingofsoftwareandECUs 1058Calibrationofsoftwarefunctions 1060Outlook 1061

Automotivenetworking 1064Bussystems 1064Technicalprinciples 1065Busesinmotorvehicles 1071CAN 1071FlexRay 1075LIN 1079Ethernet,IP 1082PSI5 1083MOSTbus 1085Architectureofelectronicsystems 1090Overview 1090Architecturemethodsofelectronicsystems 1093Sensors 1100Basicprinciples 1100Positionsensors 1105Speedandrpmsensors 1121Accelerationandvibrationsensors 1126Pressuresensors 1130Flowmeters 1134Gassensors,concentrationsensors 1137Temperaturesensors 1140Forceandtorquesensors 1143Optoelectronicsensors 1150Sensorsfordriver-assistancesystems 1154Mechatronics 1164Mechatronicsystemsandcomponents 1164Developmentmethodology 1165Outlook 1168

Comfort and conveniencePassenger-compartmentclimatecontrol 1170Climate-controlrequirements 1170A/C-unitdesignandoperatingprinciple 1170Climate-controlsystems 1173Climatecontrolforhybridandelectricvehicles 1174Auxiliaryheatersystems 1176Comfortandconveniencesystemsinthedoorandroofareas 1180Power-windowsystems 1180Roofsystems 1181Comfortandconveniencefunctionsinthepassengercompartment 1182Electricalseatadjustment 1182

00-04-U327E_Inhalt.indd 14 21.03.11 16:17

Contents 15

User interfaces, telematics and  multimediaDisplayandcontrol 1184Interactionchannels 1184Instrumentation 1185RadioandTVreceptioninmotorvehicles 1192Wirelesssignaltransmission 1192Radiotuners 1195Traffictelematics 1199EUrecordingequipment 1200Legalregulations 1200Designvariations 1200

Driver-assistance systemsDriver-assistancesystems 1202Parkingsystems 1206Parkingaidwithultrasonicsensors 1206Parkingaidassistant 1209Vehiclenavigation 1210Navigationsystems 1210Functionsofnavigation 1210Digitalmap 1213AdaptiveCruiseControl 1214Function 1214Designandfunction 1214Controlalgorithms 1216Areaofapplicationandfurtherdevelopment 1217Predictiveemergency-brakingsystems 1220Video-baseddriver-assistancesystems 1222Lanedeparturewarningandlanekeepingsupport 1222Road-signrecognition 1223Night-visionsystems 1224Applications 1224Far-infraredsystems 1224Near-infraredsystems 1225

Appendices Technicalterms 1228Abbreviations 1258

00-04-U327E_Inhalt.indd 15 21.03.11 16:17

8th Edition

Automotive Handbook

Autom

otive Hand

book

All about automotive engineering in a pocketbookThe 8th edition has been revised and extended.

Automotive Handbook

Reference handbook for academic and personal use.

ISBN 978-0-7680-4851-3

Contents – central themes Basic principles: physics, materials, machine parts,

joining and bonding techniquesVehicle physics: basic terms of automotive engineering,

motor-vehicle dynamics, vehicle acousticsInternal-combustion engines: gasoline engine, diesel engine,

turbochargers and superchargers, exhaust-gas systemEmission-control and diagnosis legislationManagement for spark-ignition engines: manifold injection,

gasoline direct injection, alternative gasoline-engine operationManagement for diesel engines: common railAlternative drives: hybrid drive, fuel cellChassis systems: suspension, wheel suspensions, steering,

brake systemsActive safety: antilock braking system, driving-dynamics

control systemLighting equipmentAutomotive electrics: vehicle electrical systems,

starter batteries, electrical machines, alternatorsAutomotive electronics: automotive networking, buses,

architecture of electronic systems, sensorsDriver-assistance systems: parking systems, vehicle navigation,

Adaptive Cruise Control, night-vision systems

About the Bosch GroupBosch is one of the world’s leading suppliers to the automotive industry. The large number of applications for patents and utility models is impressive proof of the company’s leading position in automotive engineering.