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Chassis Handbook - Fundamentals, Driving Dynamics, Components, Mechatronics, Perspectives
Preface
5
Contributors
6
Contents
8
1 Introduction and Fundamentals
23
1.1 History, Definition, Function, and Significance
24
1.1.1 History
24
1.1.2 Definition and Scope
29
1.1.3 Purpose and Significance
30
1.2 Chassis Design
31
1.2.1 Vehicle Classification
31
1.2.2 Powertrain Configurations
32
1.2.3 Chassis Composition
35
1.2.4 Trends in Chassis Composition
35
1.3 Chassis Layout
37
1.3.1 Chassis Requirements
38
1.3.2 Layout of Suspension Kinematics
40
1.3.3 Suspension Kinematics
40
1.3.3.1 Suspension Parameters Relative to Vehicle
40
1.3.3.2 Roll and Pitch Center
42
1.3.3.3 Wheel Travel
42
1.3.3.4 Wheel Travel Parameters
43
1.3.3.5 Steering Kinematic Parameters
46
1.3.3.6 Kinematic Parameters of Current Vehicles
50
1.3.3.7 Wheel Travel Curves
50
1.3.3.8 Wheel Kinematic Calculation Software
53
1.3.4 Elastokinematics and Component Compliances in Suspension Design
53
1.3.5 Target Parameter Values
54
1.3.6 Suspension Composition
55
2 Driving Dynamics
57
2.1 Driving Resistances and Energy Requirements
57
2.1.1 Driving Resistances
57
2.1.1.1 Rolling Resistance
57
2.1.1.2 Effect of Road Surface on Rolling Resistance FR,Tr
62
2.1.1.3 Aerodynamic Drag FA
65
2.1.1.4 Climbing Resistance FC
66
2.1.1.5 Inertial Resistance FI
67
2.1.1.6 Total Driving Resistance
68
2.1.2 Crosswind Response Behavior
68
2.1.3 Performance and Energy Requirements
71
2.1.4 Fuel Consumption
72
2.2 Tire Traction and Force Transfer to the Roadway
74
2.2.1 The Physics of Tire Traction and Force Transfer
76
2.2.1.1 Acceleration and Braking
79
2.2.1.2 Cornering
80
2.2.2 Detailed Tire Forces
85
2.3 Longitudinal Dynamics
87
2.3.1 Acceleration and Braking
87
2.3.1.1 Anti-Dive
87
2.3.1.2 Anti-Lift (Anti-Squat)
88
2.3.1.3 Load Changes During Straightline Driving
89
2.4 Vertical Dynamics
89
2.4.1 Springs
89
2.4.1.1 Spring Ratio
90
2.4.1.2 Natural (Eigen) Frequencies
90
2.4.2 Vibration Dampers
91
2.4.3 Excitations from the Roadway
92
2.4.3.1 Harmonic Excitations
92
2.4.3.2 Periodic Irregularities
93
2.4.3.3 Stochastic (Random) Irregularities
93
2.4.3.4 Spectral Density of Road Surface Irregularities
94
2.4.3.5 Measured Road Surface Irregularities
95
2.4.4 Tires as Spring/Damper Elements
95
2.4.5 Suspension Models
96
2.4.5.1 Single-Mass System
96
2.4.5.2 Dual-Mass System
97
2.4.5.3 Expansion of the Model to Include Seat Suspension Effects
97
2.4.5.4 Single-Track Suspension Model
98
2.4.5.5 Two-Track Suspension Model
99
2.4.6 Parameter Variation
101
2.4.7 The Roadway/Vehicle Connection
103
2.4.7.1 Spectral Density of Vehicle Body Accelerations
104
2.4.7.2 Spectral Density of Dynamic Wheel Loads
106
2.4.8 Human Oscillation Evaluation
106
2.4.9 Conclusions from the Fundamentalsof Vertical Dynamics
108
2.5 Lateral Dynamics
108
2.5.1 Handling Requirements
108
2.5.2 Steering Kinematics
109
2.5.2.1 Static Steering Layout
109
2.5.2.2 Dynamic Steering Layout
110
2.5.3 Vehicle Modeling
111
2.5.3.1 Simple Single-Track (Bicycle) Model
111
2.5.3.2 Simple Vehicle Dynamics
112
2.5.3.3 Understeer and Oversteer
115
2.5.3.4 Expanded Single-Track Model with Rear-Wheel Steering
116
2.5.3.5 Nonlinear Single-Track Model
117
2.5.3.6 Analysis of Transient Behavior Using the Simple Single-Track Model
119
2.5.3.7 The Vehicle as Part of a Closed-Loop System
121
2.5.3.8 Dynamic Behavior of the Vehicle as Part of a Closed-Loop System
122
2.5.3.9 Slip Angle Compensation Using Rear-Wheel Steering
125
2.5.3.10 Investigation of Frequency Response for Varied Vehicle Configurations
127
2.5.3.11 Dual-Track Model
128
2.5.3.12 Parameter Variation
131
2.6 General Vehicle Dynamics
135
2.6.1 Interactions between Vertical, Longitudinal, and Lateral Dynamics
135
2.7 Chassis Control Systems
140
2.7.1 Definition of Terms
140
2.7.2 Limitations of the Passive Vehicle – Basic Goal Conflicts
140
2.7.3 The Driver-Vehicle Control Loop
141
2.7.4 Division of Chassis Control Systems into Domains
142
2.7.4.1 Longitudinal Dynamics
142
2.7.4.2 Lateral Dynamics
143
2.7.4.3 Vertical Dynamics
143
2.7.5 Requirements for Chassis Control Systems
143
2.8 Handling Characteristics
144
2.8.1 Handling Evaluation
144
2.8.2 Driving Maneuvers
146
2.8.3 Parameter Range of Maneuvers
146
2.8.4 Tuning Procedures
149
2.8.4.1 Tuning Procedures forSteady-State Steering Behavior
149
2.8.5 Subjective Handling Evaluation
149
2.8.5.1 Evaluation Methods and Representation
152
2.8.5.2 Acceleration (Driveoff) Behavior
152
2.8.5.3 Braking Behavior
152
2.8.5.4 Steering Behavior
154
2.8.5.5 Cornering Behavior
156
2.8.5.6 Straightline Driving Behavior
156
2.8.5.7 Ride Comfort
158
2.8.6 Objective Handling Evaluations
159
2.8.6.1 Measurement Parameters
159
2.8.6.2 Acceleration (Driveoff) Behavior
159
2.8.6.3 Braking Behavior
160
2.8.6.4 Steering Behavior
161
2.8.6.5 Cornering Behavior
163
2.8.6.6 Straightline Driving Behavior
165
2.8.6.7 Ride Comfort
167
2.9 Active and Passive Safety
167
3 Chassis Components
170
3.1 Chassis Structuring
170
3.1.1 Classification by Function
170
3.1.2 Modular Chassis Structure
171
3.1.3 Chassis Components
171
3.2 Drivetrain
172
3.2.1 Configurations
172
3.2.2 Axle Drives
172
3.2.2.1 Differentials
172
3.2.2.2 Locking Differentials
172
3.2.2.3 Active Differentials
174
3.2.2.4 Torque Vectoring
174
3.2.3 Four-wheel-drive (All-wheel-drive)
175
3.2.4 Control Strategies
176
3.2.5 Half-shafts
177
3.3 Wheel Brakes and Braking
178
3.3.1 Fundamentals and Requirements
178
3.3.2 Types of Braking Systems
179
3.3.2.1 General Requirements
180
3.3.3 Legal Regulations
181
3.3.4 Brake System Design
181
3.3.4.1 Brake Force Distribution
181
3.3.4.2 Dimensioning
183
3.3.5 Braking Torque and Dynamics
183
3.3.5.1 Braking Torque
183
3.3.5.2 Braking Dynamics
184
3.3.6 Brake System Components
185
3.3.6.1 Brake Calipers
185
3.3.6.2 Brake Discs
189
3.3.6.3 Brake Linings
190
3.3.6.4 Drum Brakes
190
3.3.6.5 Brake Fluid
193
3.3.6.6 Brake Force Booster
193
3.3.6.7 Tandem Master Cylinder
194
3.3.6.8 Human-Machine Interface (HMI)
194
3.3.7 Electronic Braking Control Systems
198
3.3.7.1 Brake Assistant (MBA, EBA, HBA)
198
3.3.7.2 Wheel Speed Sensors
201
3.3.7.3 Electronic Braking System Functions
202
3.3.7.4 Electrohydraulic Brake (EHB)
208
3.3.7.5 Electromechanical Brake (EMB)
209
3.3.7.6 Networked Chassis
211
3.4 Steering Systems
212
3.4.1 Requirements and Designs
212
3.4.2 Hydraulic Rack and Pinion Steering
215
3.4.2.1 Technology and Function
215
3.4.2.2 Design and Components
218
3.4.3 Steering Tie Rods
221
3.4.4 Steering Driveline and Steering Column
224
3.4.4.1 Components and Function Modules
224
3.4.4.2 Design and Testing
226
3.4.4.3 Crash Requirements and Energy Absorption Mechanisms
227
3.4.4.4 Future Prospects and Modularization
230
3.4.5 Electromechanical Steering Systems
230
3.4.5.1 Design Concepts
230
3.4.5.2 Configuration and Advantages
233
3.4.6 Active Steering and Superposition Steering
236
3.4.6.1 Functional Principles and Configuration
236
3.4.6.2 Functions – Present and Future
238
3.4.7 Rack and Pinion Power Steering with Torque and Angle Actuators
240
3.4.8 Rear-wheel and Four-wheel Steering Systems
241
3.4.9 Steer-by-wire and Single-wheel Steering Systems
243
3.4.9.1 System Configuration and Components
244
3.4.9.2 Technology, Advantages, Opportunities
246
3.5 Springs and Stabilizers
247
3.5.1 The Purpose of the Spring System
247
3.5.2 Design and Calculation of Steel Springs
247
3.5.2.1 Leaf Springs
248
3.5.2.2 Torsion Bar Springs
251
3.5.2.3 Stabilizers
252
3.5.2.4 Coil Springs
260
3.5.3 Spring Materials
268
3.5.4 Steel Spring Manufacture
270
3.5.4.1 Hot Forming
270
3.5.4.2 Heat Treating Hot Formed Springs
272
3.5.4.3 Cold Forming
272
3.5.4.4 Shot Peening
273
3.5.4.5 Plastification
274
3.5.4.6 Corrosion Protection
274
3.5.4.7 Final Inspection and Marking
275
3.5.5 Roll Control Using Stabilizers
275
3.5.5.1 Passive Stabilizers
275
3.5.5.2 Switchable Off-Road Stabilizers
276
3.5.5.3 Switchable On-Road Stabilizers
276
3.5.5.4 Semi-Active Stabilizers
276
3.5.5.5 Active Stabilizers
278
3.5.6 Springs for use with AutomaticLeveling Systems
278
3.5.6.1 Purpose and Configurations
278
3.5.6.2 Leveling Using a Gas Spring
279
3.5.7 Hydropneumatic Springs
282
3.5.7.1 Self-Pumping Hydropneumatic Spring/Damper Elements
282
3.5.8 Air Springs
285
3.6 Damping
287
3.6.1 The Purpose of Damping
287
3.6.2 Telescopic Shock Absorber Designs
291
3.6.2.1 Twin-Tube Shock Absorbers
291
3.6.2.2 Monotube Shock Absorbers
292
3.6.2.3 Comparison of Damper Types
292
3.6.2.4 Special Designs
293
3.6.3 Coilover Shock Absorber and Strut
293
3.6.4 Shock Absorber Calculations
295
3.6.5 Additional Damper Features
296
3.6.5.1 Rebound and Compression Bump Stops
296
3.6.5.2 Stroke-Dependent Damping
298
3.6.5.3 Amplitude-Selective Damping
300
3.6.6 Damper End Mounts
301
3.6.7 Semi-Active Damping and Spring Functions
302
3.6.8 Alternative Damping Concepts
306
3.6.8.1 Magneto-Rheological (MRF) Dampers
306
3.6.8.2 Conjoined Damping
307
3.6.8.3 Load-Dependent Damping (PDC)
307
3.7 Wheel Control
308
3.7.1 Purpose, Requirements, and System Structure
308
3.7.2 Suspension Links: Purpose, Requirements, and System Structure
309
3.7.2.1 Control Arms (Control Links)
310
3.7.2.2 Support Links
311
3.7.2.3 Auxiliary Links
311
3.7.2.4 Suspension Link Requirements
312
3.7.2.5 Suspension Link Materials
312
3.7.2.6 Suspension Link Manufacturing Processes
313
3.7.2.7 Manufacturing Methods for Aluminum Suspension Links
319
3.7.2.8 Configuration and Optimization of Suspension Links
321
3.7.2.9 Integration of the Joints into the Link
321
3.7.3 Ball Joints
322
3.7.3.1 Purpose and Requirements
323
3.7.3.2 Types of Ball Joints
323
3.7.3.3 Ball Joint Components
324
3.7.3.4 Bearing System (Ball Race, Grease)
327
3.7.3.5 Sealing System (Sealing Boot, Retaining Ring)
330
3.7.3.6 Suspension Ball Joints
333
3.7.3.7 Preloaded Ball Joints
334
3.7.3.8 Cross Axis Ball Joints
335
3.7.4 Rubber Bushings
337
3.7.4.1 Purpose, Requirements, and Function
337
3.7.4.2 Types of Rubber Bushings
339
3.7.5 Pivot Joints
341
3.7.6 Rotational Sliding Joints (Trunnion Joints)
342
3.7.7 Chassis Subframes
343
3.7.7.1 Purpose and Requirements
343
3.7.7.2 Types and Designs
343
3.8 Wheel Carriers and Bearings
346
3.8.1 Types of Wheel Carriers
346
3.8.2 Wheel Carrier Materials and Manufacturing Methods
348
3.8.3 Types of Wheel Bearings
349
3.8.3.1 Bearing Seals
352
3.8.3.2 Lubrication
352
3.8.3.3 ABS Sensors
353
3.8.4 Wheel Bearing Manufacturing
355
3.8.4.1 Rings and Flanges
355
3.8.4.2 Cages and Rolling Elements
356
3.8.4.3 Assembly
356
3.8.5 Requirements, Design, and Testing
356
3.8.5.1 Bearing Rotational Fatigue Strength
358
3.8.5.2 Component Strength and Tilt Stiffness
360
3.8.5.3 Verification by Testing
362
3.8.6 Future Prospects
363
3.9 Tires and Wheels
367
3.9.1 Tire Requirements
367
3.9.1.1 Properties and Performance
367
3.9.1.2 Legal Requirements
369
3.9.2 Types, Construction, and Materials
370
3.9.2.1 Tire Types
370
3.9.2.2 Tire Construction
371
3.9.2.3 Tire Materials
371
3.9.2.4 The Viscoelastic Properties of Rubber
372
3.9.3 Transmission of Forces between the Tire and the Road Surface
373
3.9.3.1 Supporting Force
373
3.9.3.2 Adhesion Behavior and Lateral Force Buildup
374
3.9.3.3 Tangential Forces: Driving and Braking
375
3.9.3.4 Sideslip, Lateral Forces, and Aligning Moments
375
3.9.3.5 Sideslip Stiffness
376
3.9.3.6 Tire Behavior under Slip
378
3.9.3.7 Tire Uniformity
379
3.9.4 Tire Simulation Models
379
3.9.4.1 Tire Models for Lateral Dynamics
379
3.9.4.2 Tire Models Using Finite Elements (FEM)
381
3.9.4.3 Tire Models for Vertical Dynamics
381
3.9.4.4 Tire Vibration Modes
382
3.9.4.5 Cavity Natural Frequencies
382
3.9.4.6 Full Tire Models
383
3.9.5 Modern Tire Technologies
385
3.9.5.1 Tire Sensors
385
3.9.5.2 Run-Flat Tires
387
3.9.5.3 Tires and Control Systems
388
3.9.5.4 High Performance (HP) and Ultra High Performance (UHP) Tires
389
3.9.6 Vehicle Testing and Measurement
390
3.9.6.1 Subjective Test Procedures
390
3.9.6.2 Objective Test Procedures for Longitudinal Adhesion
391
3.9.6.3 Objective Test Procedures for Lateral Adhesion
392
3.9.6.4 Acoustics
393
3.9.7 Laboratory Testing and Measurement Methods
393
3.9.7.1 Basic Tire Test Rig Designs
393
3.9.7.2 Strength Tests
394
3.9.7.3 Measuring Tire Characteristics Using a Test Rig
394
3.9.7.4 Measuring Tire Characteristics Using a Vehicle-Mounted Test Rig
394
3.9.7.5 Measuring Tire Rolling Resistance
395
3.9.7.6 Measuring Uniformity and Geometry
395
3.9.7.7 Roadway Measurement and Modeling
397
3.9.7.8 Power Loss Analysis
397
3.9.7.9 Tire Temperature Measurement
398
3.9.8 The Future of Tire Technology
399
3.9.8.1 Material Developments
399
3.9.8.2 Energy Saving Tires
399
4 Axles and Suspensions
403
4.1 Rigid Axles
405
4.1.1 The De Dion Driven Rigid Axle
407
4.1.2 Rigid Axles with Longitudinal Leaf Springs
407
4.1.3 Rigid Axles with Longitudinal and Lateral Links
408
4.1.4 Rigid Parabolic Axles with a Central Joint and Lateral Control Links
409
4.2 Semi-Rigid Axles
409
4.2.1 Twist Beam Axles
410
4.2.1.1 Torsion-Type Twist Beam Axles
411
4.2.1.2 Standard Twist Beam Axles
411
4.2.1.3 Coupling-Type Twist Beam Axles
412
4.2.2 The Dynamic Twist Beam Axle
412
4.3 Independent Suspension
413
4.3.1 Independent Suspension Kinematics
413
4.3.2 The Advantages of Independent Suspension
415
4.3.3 Single-Link Independent Suspension Systems
415
4.3.3.1 Trailing Link Independent Suspension
416
4.3.3.2 Semi-Trailing Link Independent Suspension
417
4.3.3.3 Screw-Link Independent Suspension
418
4.3.4 Two-Link Independent Suspension
418
4.3.4.1 Lateral-Longitudinal Swing Axles
418
4.3.4.2 Trapezoidal Link with One Lateral Link (Audi 100 Quattro)
419
4.3.4.3 Trapezoidal Link with One Flexible Lateral Link (Porsche Weissach Axle)
419
4.3.5 Three-Link Independent Suspension
419
4.3.5.1 Central Link Independent Suspension
419
4.3.5.2 Double Wishbone Independent Suspension
420
4.3.6 Four-Link Independent Suspension
422
4.3.6.1 Rear Axle Multi-Link Independent Suspension
422
4.3.6.2 Multi-Link Suspension with Two Lower Two-Point Links
423
4.3.6.3 Trapezoidal (Integral) Link Suspension
423
4.3.6.4 Two Longitudinal and Two Lateral Links
424
4.3.6.5 One Longitudinal and Three Lateral Links
424
4.3.6.6 One Diagonal and Three Lateral Links
425
4.3.7 Five-Link Independent Suspension
426
4.3.7.1 Five-Link Front Suspension (SLA with two Decomposed 3-Point Links)
426
4.3.7.2 Five-Link Rear Suspension
426
4.3.8 Strut-Type Suspension Systems
427
4.4 Front Axle Suspension
430
4.4.1 Front Axle Suspension System Requirements
430
4.4.2 Front Axle Components
432
4.4.3 Front Axle Suspension Types
432
4.4.3.1 McPherson with Upper Strut Brace
432
4.4.3.2 McPherson withOptimized Lower Control Arm
432
4.4.3.3 McPherson withDecomposed Lower Control Arm
432
4.4.3.4 McPherson with Two-Piece Wheel Carrier
433
4.4.3.5 Double Wishbone with Decomposed Control Arms
433
4.5 Rear Axle Suspension
434
4.5.1 Rear Axle Suspension Requirements
434
4.5.2 Rear Axle Components
434
4.5.3 Rear Axle Suspension Types
434
4.5.3.1 Non-Driven Rear Axles
434
4.5.3.2 Driven Rear Axles
434
4.5.4 ULSAS Rear Axle Benchmark
435
4.6 Design Catalog for Axle Type Selection
436
4.7 The Chassis as a Complete System
436
4.7.1 Front / Rear Axle Interaction
436
4.8 Future Suspension Systems
438
4.8.1 Axles of the Past 20 Years
438
4.8.2 Relative Popularity of Various Current Axle Designs
438
4.8.3 Future Axle Designs (Trends)
438
5 Ride Comfort and NVH
441
5.1 Fundamentals: NVH and the Human Body
441
5.1.1 Concepts and Definitions
441
5.1.2 Sources of Vibrations, Oscillations, and Noise
442
5.1.3 Limits of Human Perception
443
5.1.4 Human Comfort and Well-Being
444
5.1.5 Mitigation of Oscillation and Noise
445
5.2 Bonded Rubber Components
446
5.2.1 Bonded Rubber Component Functions
446
5.2.1.1 Transferring Forces
446
5.2.1.2 Enabling Defined Movements
446
5.2.1.3 Noise Isolation
447
5.2.1.4 Vibration Damping
448
5.2.2 The Specific Definition of Elastomeric Components
449
5.2.2.1 Force-Displacement Curves
449
5.2.2.2 Damping
449
5.2.2.3 Setting
450
5.3 Engine and Transmission Mounts
451
5.4 Chassis and Suspension Mounts and Bushings
455
5.4.1 Rubber Bushings
455
5.4.2 Sliding Bushings
456
5.4.3 Hydraulically-Damped Bushings (Hydro Bushings)
457
5.4.4 Chassis Subframe Mounts
460
5.4.5 Upper Strut Bearings and Damper Mounts
461
5.4.6 Twist Beam Axle Mounts
463
5.5 Future Component Designs
464
5.5.1 Sensors
465
5.5.2 Switchable Chassis Mounts
465
5.6 Computation Methods
466
5.7 Acoustic Evaluation ofBonded Rubber Components
467
6 Chassis Development
469
6.1 The Development Process
469
6.2 Project Management (PM)
475
6.3 The Planning and Definition Phase
475
6.3.1 Target Cascading
476
6.4 The Concept Phase
477
6.5 Computer-Aided Engineering
477
6.5.1 Multi-Body Simulation (MBS)
478
6.5.1.1 MBS Chassis and Suspension Models in ADAMS/Car
478
6.5.1.2 CAD Chassis Models and Multi-Body Systems
478
6.5.1.3 Multi-Body Simulation with Rigid and Flexible MBS
479
6.5.1.4 Multi-Body Simulations Using Whole-Vehicle, Chassis, and Axle Models
480
6.5.1.5 Effects of Manufacturing Tolerances on Kinematic Parameters
481
6.5.2 Finite Element Method (FEM)
482
6.5.2.1 Classification of Analyses
482
6.5.2.2 Strength Analyses
483
6.5.2.3 Stiffness Analyses
483
6.5.2.4 Natural Frequency Analyses
483
6.5.2.5 Service Life and Durability Analyses
484
6.5.2.6 Crash Simulations
484
6.5.2.7 Topology and Shape Optimization
484
6.5.2.8 Simulations of Manufacturing Processes
486
6.5.3 Whole-Vehicle Simulations
486
6.5.3.1 Vehicle Handling and Dynamic Simulations
486
6.5.3.2 Kinematics and Elastokinematics
486
6.5.3.3 Standard Load Cases
487
6.5.3.4 MBS Model Verification
488
6.5.3.5 NVH
488
6.5.3.6 Loads Management (Load Cascading from Systems to Components)
490
6.5.3.7 Whole-Vehicle Durability Simulations
494
6.5.3.8 Whole-Vehicle Handling Fingerprint
494
6.5.3.9 Specification of Elastokinematics Using Control-System Methods
495
6.5.4 3D Modeling Software (CAD)
496
6.5.5 Integrated Simulation Environment
497
6.5.5.1 Kinematic Analysis Using ABE Software
497
6.5.5.2 The Virtual Product Development Environment (VPE)
500
6.6 Series Development and Validation
502
6.6.1 Design
502
6.6.1.1 Component Design
503
6.6.1.2 Package Volume
504
6.6.1.3 Failure Mode and Effects Analysis (FMEA)
505
6.6.1.4 Tolerance Investigations
505
6.6.2 Validation
505
6.6.2.1 Prototypes
505
6.6.2.2 Validation Using Test Rigs
505
6.6.2.3 Roadway Simulation Test Rig
508
6.6.3 Whole-Vehicle Validation
509
6.6.4 Optimization and Fine-Tuning
510
6.7 Development ActivitiesDuring Series Production
510
6.8 Summary and Future Prospects
511
7 Chassis Control Systems
513
7.1 Chassis Electronics
513
7.2 Electronic Chassis ControlSystems
513
7.2.1 Domains
513
7.2.2 Longitudinal Dynamic Control Systems – Wheel Slip Regulation
514
7.2.2.1 Braking Control
514
7.2.2.2 Electronically-Controlled Center Differentials
514
7.2.2.3 Torque-On-Demand Transfer Cases
514
7.2.2.4 Electronically-ControlledAxle Differentials
515
7.2.2.5 Axle Drive for Lateral Torque Distribution
516
7.2.3 Lateral Dynamic Control Systems
517
7.2.3.1 Electric Power Steering Systems (EPS)
517
7.2.3.2 Superimposed Steering
518
7.2.3.3 Active Rear-Wheel Steering
518
7.2.3.4 Active Rear-Axle Kinematics
519
7.2.4 Vertical Dynamic Control Systems
519
7.2.4.1 Variable Dampers
519
7.2.4.2 Active Stabilizers
521
7.2.4.3 Active Leveling Systems
521
7.2.5 Safety Requirements
522
7.2.6 Bus Systems
523
7.2.6.1 CAN
523
7.2.6.2 FlexRay
523
7.3 System Networking
523
7.3.1 Vehicle Dynamic Control (VDC)
523
7.3.2 Torque Vectoring
525
7.3.3 Vertical Dynamic Management
526
7.4 Functional Integration
526
7.4.1 System Architecture
526
7.4.2 Standard Interfaces
527
7.4.3 Smart Actuators
528
7.5 Chassis Control System
528
7.5.1 Simulation Models
529
7.5.2 Hardware-in-the-Loop Simulation
530
7.6 Mechatronic Chassis Systems
531
7.6.1 Longitudinal Dynamics
531
7.6.1.1 Powertrain Systems
532
7.6.1.2 Braking Systems
534
7.6.2 Lateral Dynamics
536
7.6.2.1 Front-Wheel Steering Systems
536
7.6.2.2 Rear-Wheel Steering Systems
537
7.6.2.3 Roll Stabilization Systems
540
7.6.2.4 Active Kinematics
543
7.6.3 Vertical Dynamics
546
7.6.3.1 System Requirements
546
7.6.3.2 Classification of Vertical Dynamic Systems
546
7.6.3.3 Damping Systems
547
7.6.3.4 Active Leveling Systems
551
7.6.3.5 Current Active Spring Systems
552
7.6.3.6 Fully Active Integrated Suspension Systems
555
7.6.3.7 Pivots (Bushings, Joints, Mounts)
557
7.7 X-by-wire
559
7.7.1 Steer-by-wire
559
7.7.2 Brake-by-wire
560
7.7.2.1 Electrohydraulic Braking (EHB)
561
7.7.2.2 Electromechanical Braking(EMB) Systems
561
7.7.2.3 The ContiTeves Electromechanical Brake
562
7.7.2.4 Radial (Full-Contact) Disc Brakes
562
7.7.2.5 Wedge Brake
564
7.7.3 Leveling-by-wire
565
7.8 Driver Assistance Systems
565
7.8.1 Braking Assistance Systems
565
7.8.1.1 Safety-Relevant Braking Assistance
566
7.8.1.2 Comfort-Oriented Braking Assistance
567
7.8.1.3 Braking Assistance System Requirements
567
7.8.2 Distance Assistance Systems
568
7.8.3 Steering Assistance Systems
569
7.8.3.1 Steering Assistance Using Adaptive Assistance Torques
569
7.8.3.2 Steering Assistance Using Additional Steering Torque
569
7.8.3.3 Steering Assistance Using a Supplemental Steer Angle
570
7.8.3.4 Summary
571
7.8.4 Parking Assistance Systems
571
7.8.4.1 Introduction
571
7.8.4.2 Parking Space Recognition
571
7.8.4.3 Parallel Parking
573
7.8.4.4 Steering Actuators
574
8 The Future of Chassis Technology
577
8.1 Chassis System Concepts – Focus on Customer Value
577
8.1.1 Choosing Handling Behavior
577
8.1.2 Diversification of Vehicle Concepts – Stabilization of Chassis Concepts
579
8.1.2.1 Front Suspension as of 2004
579
8.1.2.2 Rear Suspension as of 2004
580
8.1.3 The Future of Chassis Subsystems and Components
580
8.1.3.1 The Future of Axle Drive Units
580
8.1.3.2 The Future of Braking Systems
581
8.1.3.3 The Future of Steering Systems
581
8.1.3.4 The Future of Suspension Spring Systems
581
8.1.3.5 The Future of Dampers
581
8.1.3.6 The Future of Wheel Control Components
581
8.1.3.7 The Future of Wheel Bearings
581
8.1.3.8 The Future of Tires and Wheels
581
8.2 Electronic Chassis Systems
581
8.2.1 Electronic Assistance Systems and Networking
581
8.2.2 Networking Chassis Control Systems
582
8.2.2.1 Peaceful Coexistence
582
8.2.2.2 Integral Control
583
8.2.2.3 Networked Control
583
8.2.2.4 Performance / Efficiency
584
8.2.2.5 System Safety
584
8.2.2.6 The Development Process
584
8.2.2.7 Data Transmission Requirements
585
8.2.2.8 Summary
585
8.3 The Future of X-by-Wire Systems
585
8.4 Intelligent and Predictive Future Chassis Systems
586
8.4.1 Sensors
587
8.4.2 Actuators
587
8.4.3 Predictive Driving
588
8.5 Hybrid Vehicles
590
8.6 The Rolling/Driving Chassis
591
8.7 The Vision of Autonomous Vehicle Control
592
8.8 Future Scenarios for Vehicle and Chassis Technology
593
8.9 Outlook
596
Index
599
All prices incl. VAT