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29 de novembro de 2016 | 1 Sistemas Automóveis Safety Systems Mário Alves ([email protected])

Automotive Systems course (Module 10) - Active and Passive Safety Systems for road vehicles

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Page 1: Automotive Systems course (Module 10) - Active and Passive Safety Systems for road vehicles

29 de novembro de 2016 | 1

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Safety Systems

Mário Alves ([email protected])

Page 2: Automotive Systems course (Module 10) - Active and Passive Safety Systems for road vehicles

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Outline

• Definition of active/passive safety

• Examples of active and passive safety systems

• Road accident statistics

• Safety regulations

• Active safety

• brake, traction, stability, steering, cruise control systems

• Passive Safety

• programmed structural deformation, Supplemental Restraint

Systems (SRS) (airbags + seat belt pre-tensioners)

• Glossary

• Recommended references

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Definitions

• Automobile safety

• scientific domain that is related to the study, design, construction and

regulation of technology to minimize the occurrence and

consequences of road traffic accidents

• Active safety systems

• help preventing accidents

• they control the dynamics of the vehicle

• Passive safety systems

• help mitigating the consequences of accidents

• they protect occupants and pedestrians

http://www.livelifedrive.com/news/guide-choosing-

safe-car-buy/28101

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Examples of active safety systems

• Typical • Anti-lock Braking System (ABS)

• Traction Control System (TCS)

• Stability Control system (ESP)

• Emerging • cruise control (ACC)

• steering control

• suspension control

• road sign detection

• Intelligent Speed Assistance (ISA)

• Autonomous Emergency Braking (AEB)

• cross-traffic assist

• blind spot detection

• lane departure warning

• light Source recognition

• pedestrian detection

• vision enhancement (night/augmented vision, adaptive headlights)

https://www.autoliv.com/ProductsAndInnovations/ActiveSafetySystems

http://eandt.theiet.org/magazine/2014/10/car-safety.cfm?origin=EtOtherStories

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Examples of passive safety systems

• Typical

• seatbelts

• airbags

• body structure with programmed deformation

• retractable steering column

• head restraints

• seats with “anti-submarine” effect

• fuel cut-off

• Emerging

• automatic emergency call (eCall)

• automatic message to an emergency call centre in case of a crash

• …

http://www.euroncap.com/en/vehicle-safety/the-rewards-explained/ecall/

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Classification of safety systems

http://www.eetimes.com/document.asp?doc_id=1272754

• Classification

• Active

• Collision mitigation

• Vehicle control

• Passive

• Passive safety

• Driver support

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Road accident statistics

https://en.wikipedia.org/wiki/Road_traffic_safety

http://etsc.eu/transport-safety-performance-in-the-eu-a-statistical-overview/

2001 data

2012 data

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Safety regulations

• Euro NCAP (New Car Assessment Programme)

• objective and independent assessment of the safety performance of

new vehicles on the European market

• It scores vehicle safety performance in four main areas

• Adult Occupant Protection (AOP)

• Child Occupant Protection (COP)

• Pedestrian Protection (PP)

• Safety Assist (SA)

http://ae-plus.com/news/euro-ncap-sets-out-its-roadmap-for-2020-tests

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Safety regulations

• The overall number of deaths on European roads has

continued to decrease over the last decade

• thanks to a wider adoption safety systems

• more robust and forgiving to human mistakes

• Trend is for

• crash avoidance

• pedestrian protection

http://www.euroncap.com/en/vehicle-safety/the-ratings-explained/pedestrian-protection/aeb-pedestrian/

http://euroncap.blob.core.windows.net/media/16472/euro-ncap-2020-roadmap-rev1-march-2015.pdf

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Safety regulations

• Safety (star) rating

• determined from a series of vehicle tests, designed and carried out by

Euro NCAP

• represent, in a simplified way, important real life accident scenarios

that could result in injured or killed car occupants or other road users

• From 2016, Euro NCAP allows two star ratings for the same

vehicle

• a base rating that indicates the safety of the car fitted only with safety

equipment which is standard on the model range throughout EU28;

• and, if the manufacturer wishes, a second rating for the car fitted with

a ‘safety pack’ which may be offered as optional

http://euroncap.blob.core.windows.net/media/16472/euro-ncap-2020-roadmap-rev1-march-2015.pdf

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Safety regulations

• Safety (star) rating

• 5 stars safety

• overall good performance in crash protection; well equipped with robust crash avoidance technology

• 4 stars safety

• overall good performance in crash protection; additional crash avoidance technology may be present

• 3 stars safety

• average to good occupant protection but lacking crash avoidance technology

• 2 stars safety

• nominal crash protection but lacking crash avoidance technology

• 1 star safety

• marginal crash protection

http://www.euroncap.com/en/about-euro-ncap/how-to-read-the-stars/

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Safety vs. Autonomous systems

http://www.telegraph.co.uk/finance/newsbysector/industry/

engineering/11502870/Will-Britain-be-in-the-driving-seat-for-autonomous-cars.html

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Safety vs. Autonomous systems

http://www.telegraph.co.uk/finance/newsbysector/industry/engineering/11502870/Wi

ll-Britain-be-in-the-driving-seat-for-autonomous-cars.html

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Active Safety: “all-in-one” holistic perspective

• Braking control

• ABS: controls per-wheel brake fluid pressure when braking to maintain directional stability, ensure steerability, and reduce stopping distance

• EBD: controls distribution of brake fluid pressure to the front and rear wheels according to vehicle load, road surface, and vehicle speed conditions, preventing lock-up of rear wheels

• EBA/AEB: helps the driver in emergency situations, increasing braking fluid pressure

• Traction control

• optimizes traction according to road and driving conditions to improve starting and acceleration performance and safety

• Stability control

• suppresses over-steer and under-steer tendencies when turning by controlling engine output and braking of each wheel to assure driving safety

• Speed/cruise control

• keeps the vehicle’s pre-set speed and distance/time gap from vehicles ahead

• Steering control

• adjusts steering ratio depending on the driving situation

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: “all-in-one” holistic perspective

http://www.pakwheels.com/forums/news-articles-motorists-

education/150007-esc-esp-dsc-tcs-vids

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Active Safety: braking control

• Anti-Lock Braking System (ABS)

• prevents the wheels from locking when braking so that the vehicle

maintains the steer-ability, directional stability and road adhesion

during vehicle deceleration

• it dynamically maximizes

braking force, according

to wheel slip

• maximum wheel friction

is achieved when wheels

slip around 20%

http://the-contact-patch.com/book/road/c0816-stopping

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Active Safety: braking control

• Braking force changes according to road conditions

• braking force greatly depends on road pavement material and

weather-related conditions

• braking force is related to wheel-road friction (coefficient)

http://pubs.sciepub.com/ajvd/2/1/2/

https://www.researchgate.net/publication/269274084_Road_surface_condition_detection_based_on_road_surface_temperature_and_solar_radiation

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Active Safety: braking control

• ABS is now mandatory for motorcycles

• new European rules to make motorcycles safer and greener have

been defined in 2012

• ABS mandatory for all motorcycles that have an engine displacement

greater than 125 cc, while ABS or combined brake systems (CBS)

could be fitted to smaller ones (under 125 cc), including scooters

• they apply to all two-, three- and quad-wheel vehicles, from 2016

onwards

http://www.bosch-

motorcycle.com/en/de/fahrsicherheit_fuer_zweiraeder/motorrad_abs/gesetzgebung/legislation.html#

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Active Safety: braking control

• Basic diagram and operation

• ABS ECU compares wheels & vehicle speed

• it controls brake fluid flow from the master cylinder to the brakes,

through solenoid valves (hydraulic unit)

• it modulates the braking pressure of

each wheel

http://www.rx7club.com/3rd-generation-specific-1993-2002-16/how-fd-anti-

lock-brakes-abs-controlled-978049/

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Active Safety: braking control

• ABS operation – pressure increase phase

• the driver presses the brake pedal

• no wheel slipping occurs

• the ABS solenoid valves are open (inactive)

• brake fluid hits the brakes

• this is “normal braking”, i.e. the

ABS takes no control action

over the brakes

• (red represents brake fluid

under high pressure)

http://www.techtalk.ie/technical_articles/blue-print-instruction-on-abs-

system-diagnostics-part-3/

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Active Safety: braking control

• ABS operation – pressure hold/retention phase • driver keeps pressing the brake one or more wheels at risk of locking

• ECU senses that a wheel is rotating much slower than it should

• the solenoid valve of the slow wheel is moved upwards to block the hydraulic pipe from the master cylinder

• the pressure produced up to this point at the wheel brake is maintained (held) at that level – driver has now little influence on the brake pressure

• pump runs for preparing the next phase (note that the pump is housed in the modulator assembly itself)

• the wheel speed should be maintained at a point just before the onset of skidding, providing maximum braking force

• (purple represents brake fluid under average pressure)

http://www.techtalk.ie/technical_articles/blue-print-instruction-on-abs-

system-diagnostics-part-3/

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Active Safety: braking control

• ABS operation – pressure reduction phase

• if the wheel slows excessively and still skids, brake pressure must be

reduced

• a higher current (5 A) is sent to the solenoid valve, opening it fully

• brake fluid is pumped to the reservoir, reducing the pressure at the

brake and allowing the wheel to

speed up, regaining grip

• (green represents brake fluid

under low pressure)

http://www.techtalk.ie/technical_articles/blue-print-instruction-on-abs-

system-diagnostics-part-3/

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Active Safety: braking control

• ABS control cycle

• pressure regulation actuation occur 15-20 times per second

(every 50-70 ms)

• pressure increase,

hold, reduction,

depends on diff

BTW vehicle and

wheel speeds

• braking pressure

varies accordingly

http://www.rx7club.com/3rd-generation-specific-1993-2002-

16/how-fd-anti-lock-brakes-abs-controlled-978049/

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Active Safety: braking control

• ABS components

• (brake pedal/handle)

• (master cylinder, pipes)

• (disk/drum brakes)

• wheel speed sensors (one per wheel)

• ABS unit (AKA ABS module) – 1 for all or 1 rear + 1 front

• ECU

• hydraulic pump/modulator

• solenoid valves

• 1 per wheel: 3-position reduction-hold-increase valves or

• 2 per wheel: 2-position opened/closed valves – one inlet valve and one outlet valve

• sensors (pressure, temperature)

http://www.techtalk.ie/technical_articles/blue-print-instruction-on-abs-

system-diagnostics-part-3/

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Active Safety: braking control

• ABS unit 1. Pump motor fastening bolt (x2)

2. Pump motor

3. Guide sleeve

4. Pump/valve housing

5. Outlet valves (x4)

6. Inlet valves (x4)

7. Printed circuit board with

semiconductor relay

8. ABS control unit

9. ABS control unit cover

10. ABS control unit fastening bolt (x4)

11. Pressure sensor (only ABS 8.0/ESP)

12. USV valve (x2)

13. ASV/HSV valve (x2)

14. Pressure control valve (x2)

http://workshop-manuals.com/vauxhall/corsa-c/h__brakes/abs_8/description_and_operation/anti-

lock_braking_system_(abs_8.0_and_abs_8.0_esp)/

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Active Safety: braking control

http://www.autozone.com/repairinfo/repairguide/repairGuideContent.jsp?pageId=0996b43f80378880

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Active Safety: braking control

http://www.autozone.com/repairinfo/repairguide/repairGuideContent.jsp?pageId=0996b43f80378880

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Active Safety: braking control

• Wheel speed sensors

• inductive, magnetoresistive, Hall

http://www.brakeandfrontend.com/wheel-speed-sensors-abs-and-tcs-signal-use/

http://www.kstuned.com/products/speed-sensor-bracket-abs

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Active Safety: braking control

• Acura RSX

http://www.wiringdiagrams21.com/2012/11/14/acura-rsx-abs-modulator-system/

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Active Safety: braking control

• Bosch ABS 8.0

http://www.ls1gto.com/forums/showthread.php?t=417188 http://workshop-manuals.com/skoda/fabia-

mk1/chassis/abs_adr_tcs_edl_esp/hydraulic_control_unit_(abs_systems_bosch_8.0)_brake_servo_unit/master_brake_cylinder/removing_and_installing_the_hydraulic_control_unit_rhd_version/

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Active Safety: braking control

• Evolution of Bosch car ABS

http://forum.monzeiros.com/viewtopic.php?t=24151

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Active Safety: braking control

• Evolution of Bosch motorcycle ABS

http://www.ashonbikes.com/content/bosch-abs-testing

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Active Safety: braking control

• Electronic Brake Distribution (EBD)

• detects the slip ratio between the front and rear wheels from the ABS

wheel-speed sensor signals

• if the slip ratio of the rear wheels as compared to the front wheels is

larger than the fixed limit, the ABS unit reduces brake pressure to the

rear wheels

• brake pressure distribution is constantly optimized according to

vehicle load, road surface conditions and vehicle speed

• if ABS control conditions are met during EBD control, EBD control

is stopped and ABS control is given priority

http://www.thaimazda3.com/svmanual/esicont/en/srvc/html/B3E041343750T08.html

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Active Safety: braking control

https://www.obd-codes.com/faq/ebd-explained.php

http://www.pakwheels.com/forums/news-articles-motorists-education/150007-esc-esp-dsc-tcs-vids

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Active Safety: braking control

1. Speed

2. EBD initial control value

3. ABS initial control value

4. Vehicle speed

5. Rear wheel speed

6. Front wheel speed

7. High

8. Time

9. Rear solenoid valve control

10. Brake fluid pressure

11. Pressure reduction

12. Pressure maintained

13. Pressure increase

14. EBD control area

15. ABS control area

16. Front brake fluid pressure

17. Rear brake fluid pressure

http://www.thaimazda3.com/svmanual/esicont/en/srvc/html/B3E041343750T08.html

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Active Safety: traction control

• Steerability is important also when accelerating

http://www.bobbellnissan.com/blogs/729/you-auto-know-mondays-great-car-ownership-tips/nissan-

and-kia-traction-control-tips-when-to-turn-it-off/

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Active Safety: traction control

• Braking/Traction force coefficients are almost symmetrical

http://www.rx7club.com/3rd-generation-specific-1993-2002-16/how-fd-anti-lock-brakes-abs-

controlled-978049/

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Active Safety: traction control

• Traction Control System (TCS)

• ABS, TCS and SCS systems share the same (4) wheel speed sensors.

• TCS requires two additional solenoids in the hydraulic modulator

assembly; these solenoids isolate the brake circuits to the drive

wheels from the non-drive wheels during wheel spin

• electric pump + accumulator are used to apply the wheel brake on the

wheel that has lost its traction

• if one of the wheels loses traction, TCS applies pressurized fluid to

its brake

http://www.rx7club.com/3rd-generation-specific-1993-2002-16/how-fd-anti-lock-brakes-abs-

controlled-978049/

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Active Safety: stability control

• SCS = ESP = VSA = ESC = VDC = VSC = …

http://www.hirscheautomotive.com/acronyms.html

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Active Safety: stability control

• Understeering and oversteering situations

http://www.hirscheautomotive.com/acronyms.html

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Active Safety: stability control

• Basic operation

• dynamic behavior of the vehicle is perceived via several sensors

• vehicle speed (m/s)

• engine speed (RPM)

• wheels speed (individually)

• yaw (AKA attitude, rotation) sensor

• lateral acceleration sensor

• drivers’ steering intentions measured via a steering-angle sensor

• located in the steering column, it measures the direction the driver intends to aim the car

• if there are differences between the direction of the steering wheel and the direction the car, DSC takes control actions

• it controls brakes (individually) and accelerator

shared with ABS/TCS

exclusive for DSC

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Active Safety: stability control

• Bosch DSC III (v5.7)

• rotation rate sensor (yaw)

and lateral acceleration

sensor have been combined

into one unit located under

the drivers seat under the

carpet

http://www.bimmerfest.com/forums/showpost.php?p=4205801

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Active Safety: stability control

• Mazda 6 2014

• ABS +

• TCS +

• EBD +

• SCS

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

1. During normal braking

• solenoid valves are not energized (all of them are off), so they are

open

• brake pedal is depressed brake fluid pressure is transmitted from

the master cylinder, through the inlet solenoid valves, and then to the

caliper piston

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

1. During normal

braking

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

2. During ABS and EBD control

• when wheel lock-up is about to occur

• the linear control solenoid valves are not energized

• the inlet and outlet solenoid valves are energized and controlled

in three pressure modes (increase, reduction or maintain),

thereby adjusting brake fluid pressure

• brake fluid during pressure reduction is temporarily stored in the

reservoir and afterwards the pump motor operates the pump to return

the fluid to the master cylinder

• the following figure shows these conditions:

• right front wheel pressure increased

• left front wheel pressure maintained

• both rear wheels pressure reduced

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

2. During ABS

and EBD

• right front wheel

pressure increased

• left front wheel

pressure maintained

• both rear wheels

pressure reduction

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

3. During TCS control

• when a driving wheel spin is detected, the linear control solenoid

valves are energized, switching the hydraulic circuits

• at the same time, the pump motor is actuated to operate the pump,

thereby increasing pressure by supplying brake fluid pressure to the

front caliper piston of the slipping driving wheel

• after a pressure increase, brake fluid pressure is adjusted using the

three pressure modes (reduction, maintain, increase) so that the target

wheel speed is obtained.

• the following figure shows a control of right front wheel spin (during

pressure increase mode)

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

3. During TCS

control

• control of right

front wheel spin

(during pressure

increase mode)

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

4. During DSC control (to suppress oversteer tendency)

• when a large oversteer tendency is determined, the linear control

solenoid valves are energized, switching the hydraulic circuits

• at the same time, the pump motor is actuated to operate the pump,

thereby increasing pressure by supplying brake fluid pressure to the

outer front caliper piston

• also at this time, the inlet solenoid valve of the inner rear wheel is

energized and the hydraulic circuit of this wheel is closed.

• after a pressure increase, brake fluid pressure is adjusted using the

three pressure modes (reduction, maintain, increase) so that the target

wheel speed is obtained

• the following figure shows a left turn (during pressure increase

mode)

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

4. During DSC

control

(to suppress

oversteer

tendency)

• left turn

(during pressure

increase mode)

• brakes

RF wheel

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

5. During DSC control (to suppress understeer tendency)

• when a large understeer tendency is determined, the linear control

solenoid valves are energized, switching the hydraulic circuits

• at the same time, the pump motor is actuated to operate the pump,

supplying brake fluid pressure from the reservoir to the inner rear

caliper piston

• also at this time, the inlet solenoid valve of the outer front wheel is

energized and the hydraulic circuit of this wheel is closed.

• after a pressure increase, brake fluid pressure is adjusted using the

three pressure modes (reduction, maintain, increase) so that the target

wheel speed is obtained.

• the following figure shows control during a left turn during pressure

increase mode

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

5. During DSC

control

(to suppress

understeer

tendency)

• left turn

(during pressure

increase mode)

• brakes

LR wheel

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

• Mazda 6 2014

• control block

diagram

http://nema.club/2014wsm/service%20highlights/books/n6w04/html/id041500103300.html

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Active Safety: stability control

http://www.automotiveitnews.org/articles/share/384781/

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Active Safety: steering control

• Automatic steering control

• traditionally, the driver’s steering angle input it is directly transferred

to the wheels using a predetermined steering ratio

• power steering systems assist the driver by adding torque to the input

thus reducing driver effort, and these systems can be hydraulic or

electric motor driven

• active steering systems use electronic controls to adjust the steering

ratio depending on the driving situation

http://www.cvel.clemson.edu/auto/AuE835_Projects_2013/Pachahara_project.html

http://www.bosch-automotive-steering.com/en/products/car-steering-systems/active-steering.html

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Active Safety: steering control

• Automatic steering control

• planetary gearset is the “heart” of the system

• δs = steering wheel angle, δm = electric motor angle, δp = pinion angle

• id = ratio between steering wheel and pinion

• im = ratio between motor shaft and pinion

• the system responds in a fraction of a second

http://www.cvel.clemson.edu/auto/AuE835_Projects_2013/Pachahara_project.html

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Active Safety: steering control

• BMW automatic steering system (planetary gearset-based)

http://www.mwerks.com/artman/publish/bmw_news/printer_136.shtml

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Active Safety: steering control

• Audi dynamic steering (harmonic drive-based) • an electric motor turns an elliptical inner rotor which, via a ball bearing,

alters the shape of a thin sunwheel connected to the steering input shaft.

• At the vertical axes of the ellipse, the sunwheel meshes with the teeth of an annulus or ring gear, which acts on the steering output shaft.

• When the inner rotor is turned, the main axis of the ellipse changes, and with it the extent of gear tooth meshing.

• Since the sunwheel has fewer teeth than the annulus, there is relative movement between them – the superimposed movement used to alter the effective steering ratio.

http://mag.ebmpapst.com/en/industries/automotive/audi-a4-the-adaptive-steering_1321/

http://www.audi-technology-portal.de/en/chassis/wheel-suspension-steering/dynamic-steering

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Active Safety: steering control

• Lexus automatic steering

system (harmonic drive-

based)

• gearbox built into the steering

column, between the steering wheel

and the pinion gear

• unlike BMW’s active steering

system (employs a planetary

gearbox), Lexus’s Variable Gear

Ratio Steering (VGRS) uses a wave

generator and a flexible gear

• Lexus claims its system is more

accurate and quicker than others

http://jckronbauer.blogspot.pt/2012/05/lexus-variable-gear-ratio-steering.html

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Active Safety: adaptive speed/cruise control

• Adaptive Cruise Control (ACC) market forecast

• …

http://www.marketsandmarkets.com/Market-Reports/blind-spot-detection-adaptive-cruise-control-

system-market-117989633.html

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Passive Safety: programmed structural deformation

• Deformable steering column/wheel

http://www.volvocars.com/us/cars/new-models/xc60/specifications

http://www.mazda.com/en/innovation/technology/safety/passive_safety/steeringsystem/

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Passive Safety: Supplemental Restraint Systems (SRS)

http://www.nissan-global.com/EN/TECHNOLOGY/OVERVIEW/srs.html

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Passive Safety: Supplemental Restraint Systems (SRS)

http://www.toyota-global.com/innovation/safety_technology/safety_technology/technology_file/passive/airbag.html

• SRS airbags

• supplement the seat belt to enhance passenger safety upon collision

• by increasing the time during which the force is applied

• by spreading the force over a wider area of the body

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Passive Safety: Supplemental Restraint Systems (SRS)

• Infineon

• …

http://www.infineon.com/cms/en/applications/automotive/safety/airbag-restraint/

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Passive Safety: Supplemental Restraint Systems (SRS)

• Dainese D-air®

• J-KIT • Electronic system cover

• Airbag

• Electronic system and batteries

• Gas generators

• Electronic system housing

• Wave back protector

• Kidney belt

• M-KIT (J-KIT + the following)

2 – ECU and system management

and monitoring unit with GUI

3 – 2 three-axis accelerometers

mounted on the front fork

(one on each leg)

4 – skid sensor mounted under

the seat

http://www.dainese.com/br_en/d-air/street/

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Passive Safety: Supplemental Restraint Systems (SRS)

http://www.mazda.com/en/innovation/technology/safety/passive_safety/pre_load_seatbelt/

• SRS belt pre-tensioners and load limiters

• a pretensioner retracts the seatbelt when a collision occurs, to restrain

occupants quickly and reducing the amount they are thrown forward

in a frontal crash

• a load limiter helps protect occupants from seatbelt-inflicted injury;

upon a crash, the pretensioner restrains the occupant until certain

amount of force is applied; at this point, the load limiter releases the

belt gradually for not exerting too much force on the occupant’s chest

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Glossary (English/Portuguese)

• …

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Recommended references

• http://euroncap.blob.core.windows.net/media/16470/ratings-group-report-2015-version-

10-with-appendix.pdf

• …