Bosch Automotive Handbook

1.1 Quantities and units......Page 3 1.2 Conversion of units......Page 12 1.3 Vibration and oscillation......Page 26 1.4 Basic equations used in mechanics......Page 36 1.5 Strength of materials......Page 50 1.6 Acoustics......Page 64 1.7 Heat......Page 74 1.8.1 Quantities and units......Page 81 1.8.2 Direct current (DC)......Page 85 1.8.3 Alternating current (AC)......Page 91 1.8.4 Magnetic field......Page 97 1.8.5 Ferromagnetic materials......Page 100 1.8.8 Electric effects in metallic conductors......Page 106 1.8.7 Magnetic field and electric current......Page 103 1.8.9 Gas and plasma discharge......Page 110 1.9 Electronics......Page 0 1.9.1 Fundamentals of semiconductor technology......Page 111 1.9.2 Discrete semiconductor devices......Page 115 1.9.3 Monolithic integrated circuits......Page 123 1.9.4 Film and hybrid circuits, MCM......Page 129 1.9.5 Circuit-board technology, SMT......Page 131 1.9.6 Micromechanics......Page 133 1.9.7 Mechatronics......Page 136 1.9.8 Analog/digital conversion......Page 137 1.10.1 Basics......Page 140 1.10.2 Position sensors (displacement/angle)......Page 144 1.10.3 RPM and velocity sensors......Page 153 1.10.4 Acceleration/vibration sensors......Page 159 1.10.5 Pressure sensors......Page 162 1.10.6 Force/torque sensors......Page 166 1.10.7 Flow meters......Page 170 1.10.8 Concentration sensors......Page 174 1.10.9 Temperature sensors......Page 177 1.10.10 Sensors for other applications......Page 182 1.11 Actuators......Page 185 1.12 Electrical machines......Page 197 1.13 Technical optics......Page 205 2.1 Mathematics......Page 216 2.2 Quality......Page 226 2.3 Technical statistics......Page 234 2.4 Reliability......Page 247 2.5 Control engineering......Page 250 2.6 Data processing in motor vehicles......Page 256 3.1 Chemical elements......Page 260 3.2 Terminology, parameters......Page 264 3.3 Material groups......Page 268 3.4 Properties of solids......Page 275 3.5 Properties of metallic materials......Page 283 3.6 Lubricants......Page 318 3.7 Fuels......Page 331 3.8 Antifreez and brake fluid......Page 343 3.9 Names of chemicals......Page 347 3.10 Corrosion and Corrosion protection......Page 351 3.11 Heat treatment of metallic......Page 367 3.12 Hardness......Page 376 4.1 Tolerances......Page 383 4.2 Sliding bearings and rolling bearings......Page 389 4.3 Spring calculations......Page 399 4.4 Gears and tooth systems......Page 407 4.5 Belt drives......Page 422 4.6 Basic principles of threaded fasteners and threads......Page 429 5 Joining and bonding techniques......Page 441 6 Sheet-metal processing......Page 450 7 Tribology......Page 455 8.1 Road-going vehicle requirements......Page 463 8.2 Basic requirement for fuels......Page 466 8.3.1 Dynamics of linear motion......Page 469 8.3.2 Adhesion to road surface......Page 479 8.3.3 Accelerating and braking......Page 481 8.3.4 Stopping distance......Page 484 8.3.5 Passing (overtaking)......Page 487 8.3.6 Dynamics of lateral motion......Page 490 8.3.7 Cornering behavior......Page 494 8.3.8 ISO procedures for evaluating vehicle handling......Page 496 8.3.9 Special operating dynamics for commercial vehicles......Page 504 8.3.10 Requirements for agricultural tractors......Page 509 8.4 Environmental stresses on automotive equipment......Page 513 9.1 Operating concepts and classifications......Page 517 9.2 Cycles......Page 519 9.3.1 Operating concept......Page 522 9.3.2 The spark-ignition (Otto) engine......Page 526 9.3.3 The diesel engine......Page 534 9.3.4 Hybrid processes......Page 542 9.3.5 Gas exchange......Page 544 9.3.6 Supercharging processes......Page 551 9.3.7.1 Engine types......Page 558 9.3.7.2 Crankshaft-assembly operation and dynamic properties......Page 561 9.3.7.3 Balancing of masses in the reciprocating-piston engine......Page 566 9.3.7.4 Free forces and moments......Page 570 9.3.7.5 Main components of reciprocating-piston engine......Page 573 9.3.8 Cooling......Page 581 9.3.9 Lubrication......Page 582 9.3.10 Empirical values and data for calculation......Page 584 9.4 Reciprocating-piston engine with external combustion (Stiring engine)......Page 597 9.5 Wankel rotary engine......Page 600 9.6 Gas turbine......Page 603 10.1 Air cooling and Water cooling......Page 606 10.2 Intercooling......Page 611 10.3 Oil and fuel cooling......Page 612 10.4 Intelligent thermomanagement......Page 614 11 Fuel filters......Page 615 12.1 Air filters......Page 618 12.2 Turbochargers and superchargers for internal-combustion engines (self-charging)......Page 621 12.3 Exhaust systems......Page 631 13.1 Requirements......Page 636 13.2 Cylinder charge......Page 638 13.3 Fuel delivery with electric fuel pump......Page 641 13.4 A/F-mixture formation......Page 645 13.5 Carburetors......Page 648 13.6.1 Systems for external A/F mixture formation......Page 652 13.6.2 Single-point injection system......Page 655 13.6.3 Multipoint injection systems......Page 658 13.7.1 Ignition......Page 671 13.7.2 Ignition coil......Page 677 13.7.3 Ignition systems......Page 685 13.7.4 Knock control......Page 698 14.1 System overview......Page 701 14.2 ME-Motronic......Page 703 14.3 MED-Motronic......Page 714 15 Engine-test technology......Page 718 16.1 LPG system......Page 721 16.2 Natural-gas operation of spark-ignition engines......Page 725 16.3 Operation on alcohol......Page 727 16.4 Operation on hydrogen......Page 728 17.1 Combustion products......Page 731 17.2 Emissions control......Page 733 17.3 Lambda closed-loop control......Page 738 17.4 Testing exhaust and evaporative emissions......Page 743 17.5 Exhaust emission test cycles......Page 746 17.6 Exhaust-gas analyzers......Page 751 17.7 Current emissions limits......Page 753 18.1 Fuel metering......Page 755 18.2 In-line fuel-injection pump (PE)......Page 758 18.3 In-line control-sleeve fuel-injection pump......Page 769 18.4.1 Mechanically controlled......Page 771 18.4.2 EDC rotating-solenoid actuator......Page 774 18.4.3 EDC solenoid-controlled......Page 776 18.4.4 Solenoild-controlled axial-piston distributor pumps......Page 778 18.4.5 Solenoild-controlled distributor pumps with integral ECU......Page 780 18.5 Time-controlled single-cylinder pump systems......Page 781 18.6 Common-rail (CRS)......Page 786 18.7 Injection-pump test benches......Page 788 18.8 Motor testers for diesel engines......Page 790 18.9 Nozzles and nozzle holders......Page 791 19.1 Mixture formation, combustion......Page 800 19.2 Emissions control......Page 801 19.3 Emissions testing......Page 803 19.4 Test cycles and exhaust-emission limits......Page 804 19.5 Smoke emission test equipment......Page 808 20.1 Sheathed-element glow plugs......Page 811 20.2 Glow-control unit......Page 814 21.1 Starters......Page 816 21.2 Starter protection......Page 822 22.1 Electric drives......Page 823 22.2 Barreries......Page 824 22.3 Drivetrains......Page 827 23 Hybrid drives......Page 831 23.1 Hybrid drive designs......Page 833 24.1 Fuel cells......Page 835 24.2 Design variations of Fuel cells......Page 836 24.3 Fuel conditioning......Page 837 24.4 Thermodynamics and kinetics......Page 838 24.5 Fuel cells in motor vehicles......Page 840 25.1 Basics......Page 842 25.2 Power take-up elements......Page 846 25.3.1 Multi-speed gearbox......Page 851 25.3.2 Manually-shifted transmissions......Page 853 25.3.3 Automatic transmissions......Page 856 25.3.4 Electronic transmission control......Page 860 25.3.5 Continuously-variable transmissions......Page 862 25.4 Final-drive units......Page 864 25.5 Differential......Page 866 25.6 All-wheel drive and transfer case......Page 867 25.7 TCS traction control......Page 868 26.1 Suspension......Page 876 26.2 Suspension linkage......Page 886 26.3 Wheels......Page 891 26.4.1 Tires......Page 898 26.4.2 Tire designation symbols......Page 902 26.4.3 Tire traction......Page 907 26.5 Steering......Page 914 27.1 Definitions, principles......Page 923 27.2 Legal regulations......Page 932 27.3 Design and components of a braking system......Page 936 27.4 Braking-system design......Page 939 27.5 Brake-circuit configurations......Page 941 27.6 Brake systems for passenger cars and light utility vehicles......Page 943 27.7.1 Principle, system variants......Page 949 27.7.2 ABS versions......Page 953 27.7.3 ABS components......Page 963 27.8 Electohydraulic brake (EHB)......Page 967 27.9.1 Systme and configuration......Page 969 27.9.2 Automatic loade-sensitive device for braking-force metering......Page 973 27.9.3 Wheel brakes......Page 975 27.9.4 Parking brake system......Page 979 27.9.5 Components for compressed-air brakes......Page 986 27.10 ABS for commercial vehicles......Page 994 27.11 ELB for commercial vehicles......Page 1000 27.12 Brake test stands......Page 1006 28.1 Principles......Page 1008 28.2 Vehicle handling......Page 1011 28.3 ESP control systems......Page 1012 28.4 System realization......Page 1019 29 Adaptive cruise control (ACC)......Page 1022 30.1 Overview......Page 1025 30.2 Classificaiton......Page 1027 31.1 Main dimensions......Page 1029 31.2 Body structure......Page 1035 31.3 Body materials......Page 1037 31.4 Body surface......Page 1039 31.5 Body finishing components......Page 1041 31.6 Safety......Page 1044 31.7 Calculations......Page 1051 32.1 Commercial vehicles......Page 1054 32.2 Delivery trucks and vans......Page 1055 32.3 Medium and heavy-duty trucks and tractor vehicles......Page 1057 32.4 Buses......Page 1060 32.5 Passive safety in commercial vehicles......Page 1063 33.1 Functions, definitions, regulations......Page 1065 33.2.1 European system......Page 1070 33.2.2 American system......Page 1083 33.2.3 European regulations......Page 1085 33.2.4 Headlamp aiming devices......Page 1089 33.2.5 North American regulations......Page 1091 33.2.6 Headlight leveling control......Page 1092 33.2.7 Headlamp cleaning systems......Page 1094 33.2.8 Fog lamp......Page 1095 33.2.9 Auxiliary driving lamps......Page 1098 33.3 Lights and lamps......Page 1099 34.1 Acoustic signaling devices......Page 1111 34.2 Theft-deterrent systems......Page 1113 35.1 Windshield wiper systems......Page 1118 35.2 Rear-window cleaning systems......Page 1122 35.3 Headlamp cleaning systems......Page 1123 35.4 Wiper motors......Page 1124 35.5 Washing systems......Page 1126 35.6 Automotive windshield and window glass......Page 1127 36.1 Systems deriving heat from the engine......Page 1130 36.2 Air conditioners......Page 1133 36.3 Auxiliary heater installations......Page 1136 37.1 Instrumentation......Page 1137 37.2 Automotive sound systems......Page 1145 37.3 Parking systems......Page 1152 37.4 Trip recorders......Page 1157 37.5 Navigation systems......Page 1160 37.6 Traffic telematics......Page 1164 37.7 Mobile radio......Page 1167 37.8 Vehicle information system......Page 1170 38.1 Safety in motor vehicles......Page 1171 38.2 Occupant safety systems......Page 1172 38.3 Rollover protection systems......Page 1180 38.4 Outlook......Page 1182 39.1 Power windows......Page 1184 39.2 Power sunroof......Page 1187 39.3 Seat and steering-column adjustment......Page 1188 39.4 Central locking system......Page 1190 40.1 Basics......Page 1192 40.2 Gear pumps and gear motors......Page 1196 40.3 Piston pumps and motors......Page 1198 40.4 Electrohydraulic pumps and small units......Page 1200 40.5 Valves......Page 1201 40.6 Cylinders......Page 1207 40.7 Tractor hydraulics......Page 1208 40.8 Hydraulic accumulators......Page 1213 40.9 Auxiliary drives......Page 1214 40.10 Hydrostatic fan drives......Page 1215 40.11 Hydrostatic drives......Page 1217 41 Automotive pneumatics......Page 1220 42.1.1 General symbols......Page 1223 42.1.2 Circuit diagrams......Page 1226 42.1.3 Schematic diagrams......Page 1227 42.1.4 Section designation and device identification......Page 1234 42.2 Assembled-representation diagrams......Page 1244 42.3 Calculation of conductor sizes......Page 1250 42.4 Connectors......Page 1253 42.5.1 Energy supply......Page 1257 42.5.2 Starter batteries......Page 1264 42.5.3 Alternators......Page 1274 42.5.4 Controller Area Network (CAN)......Page 1286 42.5.5 CARTRONIC......Page 1291 42.6 Electromagnetic compatibility (EMC) and interference suppression......Page 1296 43 Alphabets and numbers......Page 1305 44 Index......Page 1308