Bosch Automotive Handbook - 8th Edition - Table of Contents

Contents Basic principles of physics Quantities and units SI units Legal units Fur ther units Natural constants Basi Ba sic ceq equa uati tion onsu suse sed din inm mec echa hani nics cs Rectilinear and rotary motion Transmission of force Friction Vibrations and oscillations Terms Equations Vibration reduction Modal analysis Acoustics General ter minology Measuredquantitiesfornoise emissions Measuredquantitiesfornoise immissions (noise protection) Perceived sound levels Hydrostatics Density and pressure Buoyancy Fluid mechanics Basic principles Basicequationsof fluid mechanics Disch Dischar arge gef fro rom ma apr pres essu sure rev vess essel el Resistanceofbodiessubmerged in a fluid flow Ther modynamics Enthalpy (heat content) Laws of thermodynamics Changes of state for gases Electrical engineering Electromagnetic fields Electric field Dire Direct ctc cur urre rent nta and ndd diirect rectv vo oltag ltage e Time-dependent current Magnetic field Magnet Mag netic icfie field ldand andel elect ectric riccurr current ent Wave propagation Electriceffectsinmetallic conductors

22 22 24 30 33 34 34 34 37 40 40 42 43 44 46 46 48 49 50 52 52 52 53 53 54 54 55 56 56 58 59 60 60 60 62 65 66 70 74 77

Electronics 80 Basicprinciplesofsemiconductor technology 80 Disc Discre rete tes sem emic icon ondu duct ctor ord de evice vices s 83 Monolithic integrated circuits 95 Microprocessors in the ECU 96 Electrochemistr y 99 Electrolyticconductionand electrolysis 99 Applications 10 0 Mathematics and methods Mathematics Number systems Functions Equa Eq uati tion ons sin int the hep pla lane net tri rian angl gle e Complex numbers Mathem Mat hemati atical calsi signs gnsan ands dsymb ymbols ols Greek alphabet Finite-element method Applications FEM examples Control engineering Ter ms and definitions Control-engineeringtransfer elements Designing a control task Adaptive controllers  Materials Chemical elements Designations Periodic table of elements Substances Substance ter minology Substance parameters Propertiesofsolids Proper ties of liquids Proper ties of water vapor Proper ties of gases Materials Material groups EN metallurgy standards Properti rtieso sof metallicm cmateria rials Casting and steel materials Nonfe Nonferrou rrousm smeta etals, ls,he heav avyme ymetal tals s Nonf Nonfer erro rous usm met etal als, s,l lig ight hta all llo oys Sintered metals Magnetic materials Solders and filler materials

104 1 04 104 106 10 6 1 07 107 1 07 10 8 108 1 11 1 16 11 6 117 11 8 12 0 12 2 12 2 125 1 26 126 126 128 13 2 13 3 13 4 1 35 135 139 1 44 144 149 150 15 0 15 1 154 16 3

Propertiesof Propertiesofnon-me non-metalli tallicmate cmaterials rials Insulating materials Ceramic materials Laminates Plastic molding compounds Plasticcodeswithchemical names and trade names Automotive paints Heattreatm Heattreatmentof entofmeta metallic llicmateri materials als Hardness Heat-treatment processes Thermochemical treatment Corros Corrosion ionan andc dcorr orrosi osion onpro protec tectio tion n Corrosion processes Types of corrosion Corrosion testing Corrosion protection Deposits and coatings Deposits Diffusion coatings Conversion coatings Operating fluids Lubricants Ter ms and definitions Engine oils Transmission lubricants Lubricating oils Lubricating greases  Fuels Characteristics Gasolines Diesel fuels Alternative fuels Propertiesofliquidfuels and hydrocarbons Propertiesofgaseousfuels and hydrocarbons Brake fluids Coolants

167 167 168 1 70 171 178 18 0 182 18 2 1 86 1 91 194 1 94 196 197 20 0 203 2 03 207 207 2 08 208 21 3 216 21 7 2 18 2 20 2 20 221 224 2 28 23 4 23 5 236 23 8

Machine parts Springs Basic principles Metal springs Sliding bearings Features Hydr Hydrod odyn ynam amic ics sli lidi ding ngb bea eari ring ngs s Sint Sinter ered edm met etal als slilidi ding ngb bea earin rings gs Sliding-contact bearings Roller bearings Applications General principles Selection of roller bearings Calculation of load capacity Gears and tooth systems Over view of gears Star ter-tooth designs American gear standards Calculationofload-bearing capacity Gear materials Belt drives Friction belt drives Positive belt drives Chain drives Over view Chain designs Sprockets Chain-tensioningand chain-guide elements Joining and bonding techniques Detachable connections Positive or formrm-clo closed sed joints Frictional joints Threaded fasteners Snap-onconnectionson plastic components Permanent joints Welding Soldering Adhesive technologies Riveting Penetration clinching

24 0 2 40 241 24 6 2 46 246 24 6 251 25 1 2 52 25 5 2 55 2 55 25 6 25 8 260 260 26 4 26 5 266 269 27 0 27 0 2 74 27 8 27 8 27 8 28 0 2 81 2 82 28 2 28 6 29 2 3 02 3 04 30 4 3 08 309 3 10 3 12

Vehicle physics Basictermsofautomotive engineering 31 4 Basi Ba sic cte term rms sof ofv veh ehic icle leh han andl dlin ing g 31 314 4 Motor-vehicle dynamics 3 24 Dynamics of linear motion 324 Adhesion to road surface 329 Accelerating and braking 3 31 Actions:Reaction,braking and stopping 3 31 Passing (over taking) 33 3 Fuel consumption 33 5 Dynamics of lateral motion 3 38 Specialoperatingdynamicsfor commercial vehicles 344 Operating-dynamicstest procedures as per ISO 348 Aerodynamics 354 Aerodynamic parameters 3 54 Vehicle wind tunnels 35 5 Vehicle acoustics 3 60 Exteriornoisemeasurementsand statut statutoryl orylimi imits tsfo form rmoto otorv rvehi ehicle cles s 360 Engineering acoustics 36 1 Sound design 362 Internal-combustion Internal-combustion engines Internal-combustion engines 3 66 Ther mal engines 3 66 Cycles 368 Real cycles 37 3 Desi Design gna and ndo ope pera rati ting ngp pri rinc ncip iple le 442 44 2 Mixtureformation,combustion, emissions 376 Gasoline engine 3 76 Diesel engine 38 6 Mixedformsandalternative operating strategies  39 1 Char Charge gec cyc ycllean eand dsu supe perc rcha harg rgin ing g 392 39 2 Gas exchange 392 Variable valve timing 39 5 Supercharging processes 39 9 Exhaust-gas recirculation 40 3 Reciprocating-piston engine 404 Components 4 04 Reciprocating-pistonenginetypes 418 Crankshaft-assembly design 419 Tribology and friction 427 Empiricalvaluesand

Engine cooling Air cooling Water cooling Interco Int ercooli oling ng(cha (charge rge-ai -airco rcooli oling) ng) Oil and fuel cooling Cooling-module technology Cooling-system technology Inte Intell llig igen ent tth ther erma mal lma mana nage geme ment nt Exhaust-gas cooling Engine lubrication Force orce-f -fe eed edl lu ubri bricati cation ons sys yste tem m Components Air filtration Air impurities Air filters (air cleaners) Turboch urbocharg argers ersand andsu super percha charge rgers rs Superchargers (mechanically driven) Press ressur uree-w wavesu esupe perc rcha harg rger ers s Exhaust-gas turbochargers Comple Complexsu xsuper percha chargi rging ngsyst systems ems Exhaust-gas system Design and pur pose Exhaust manifold Catalytic conver ter Par ticulate filter Mufflers Connecting elements Acoustic tuning devices Commercial-vehicleexhaust-gas systems Emission-control Emission-control and diagnosis legislation Emission-control legislation Over view CARBlegislation (passengercars/ light commercial vehicles) EPAlegislation (passengercars/ light commercial vehicles) EUlegislation (passengercars/ light commercial vehicles) Japaneselegislation (passengercars/ light commercial vehicles) USlegislation

44 6 44 6 446 450 45 1 45 2 453 453 45 3 4 55 4 56 456 45 6 45 6 45 9 459 459 462 4 62 465 46 5 467 475 4 80 48 0 4 81 4 82 4 83 4 83 485 48 6 4 87

48 8 48 8 49 0 49 3 49 5 49 8

UStestcycles (passengercars/ light commercial vehicles) Europeantestcycle (passengercars/ light commercial vehicles) Japanesetestcycle (passengercars/ light commercial vehicles) Testcyclesforheavy commercial vehicles Exhaus Exhaust-g t-gasm asmeasu easuring ringte techn chniqu iques es Exhaust-gastestonchassis dynamometers Exhaust Exhaust-ga -gasm smeasu easuring ringde devic vices es Diesel smoke-emission test Evaporative-emissions test Diagnostics Introduction Monitoring in driving mode On-Board Diagnostics (OBD) OBD functions OBDrequirementsfor heavy commercial vehicles Workshop diagnostics ECUdiagnosticsand Ser vice Infor mation System Management for spark-ignition engines Managementfor spark-ignition engines  Descriptionoftheengine management system System over view Versions of Motronic Cylinder charge Component par ts Controlling the air charge Fuel supply Fuelsupplyanddeliverywith manifold injection Fuelsupplyanddeliverywith gasoline direct injection Evaporative-emissions control system Fuel filter Electric fuel pump High-pressurepumpsfor

503 505 5 06 5 07 510 510 513 516 5 18 5 20 5 20 52 0 522 5 26 529 531

Mixture for mation Basic principles Mixture-formation systems Intake-manifold injection Gasoline direct injection Mixt Mixtur uree-fforma ormati tion onc com ompo pone nent nts s Ignition Basic principles Moment of ignition Ignition systems Ignition coil Spark plug Catalytic exha xhaustst-gast streatment Catalytic conver ter  λ control

55 9 5 59 5 60 56 1 563 565 56 5 570 5 70 57 1 57 5 57 7 581 58 6 5 86 590

Alternative gasoline-engine operation LPG operation Applications Design LPG systems Engines fueled by natural gas Applications Design Components

59 2 59 2 5 92 594 5 96 5 96 596 59 9

533

534 53 4 535 539 542 542 54 3 5 46 5 46 5 47 5 49 55 0 55 1

Management for diesel engines Management for diesel sel engines Descriptionoftheengine management system Electronic Diesel Control Fuelsupplysystem (low-pressure stage) Fuel supply and deliver y Fuel filtering Common-rail injection system System over view Injectors High-pressure pumps Rail Time-controlledsingle-cylinder pump system Unit-injectorsystemfor passenger cars Unit-injectorsystemfor commercial vehicles Unit-pumpsystemfor commercial vehicles

60 2 602 60 3 606 6 06 61 0 61 2 612 61 6 62 1 62 5 626 6 26 6 27 6 28

Diese Diesel ldi distr strib ibut utor ori inj njec ecti tion onp pum umps ps Axia Axiall-pis -pisto ton nd distr istrib ibut utor orp pum umps ps Radi Radial al-p -pis isto ton ndi dist strib ribut utor orp pum umps ps Fuel-injection system Star t-assist systems Preheating systems Exhaust-gas treatment Catalytic conver ters  Par ticulate filter Alternative drives Hybrid drives Features Functions Functional classification Drive configurations Control of hybrid vehicles Regenerative braking syst syste em Fuel cells for the vehicle drive Functioning principle Functioningprincipleofthe fuel-cell system Functioningprincipleofthe drivetrain Drivetrain Drivetrain Over view Drivetrain elements Power take-up elements Multi-speed gearbox Manu Ma nual ally lys shi hift fted edt tra rans nsmi miss ssio ions ns Automatic transmissions Continuouslyvariable transmissions Final-drive units All-wh All-wheel eeldri drive vean andt dtran ransf sfer ercas case e Chassis systems Chassis systems Basic principles Suspension Basic principles Types of spring Suspension systems Shockabsorbersand vibration absorbers Shock absorbers Vibration absorbers

630 630 630 63 0 633 63 3 63 5 63 6 636 639 63 9 642 646 646 647 648 6 49 65 4 65 7 65 8 6 58 6 60 662 66 4 6 64 6 66 6 67 6 69 670 67 0 6 72 67 8 67 9 682 684 684 69 4 694 69 7 7 02 7 06 70 6 71 3

Wheels Passenger-car wheels Commercial-vehicle wheels Tires Tire categories Tire design Tire designation Tire applications Tire traction Tire Tire-p -pre ress ssur ure emo moni nito tori ring ngs sys yste tem m Steering Definitionsformotor-vehicle steering systems Steer teeriing ng-s -sys yste tem mre requ quiireme rement nts s Types of steering box Power-assistedsteeringsystems for passenger cars Power-assistedsteeringsystems for commercial vehicles Brake systems Definitions and principles Legal regulations Structureandorganizationof brake systems Brake Brakesy system stemsf sfor orpas passen senger gerca cars rs Ser vice brake system Electromechanicalparking brake system Electrohydraulic brake  Pur pose and function Design Operating principle Brakesystemsforcommercial vehicles System over view Componentsofcommercial- vehicle brake systems Electronicallycontrolled brake system Continuous-operationbrake systems Wheel brakes Disk brakes Drum brakes

72 2 722 728 7 32 73 2 73 2 7 34 737 7 38 746 74 6 748 7 48 748 74 8 7 50 751 757 7 60 76 0 76 5 774 776 7 76 7 78 78 0 780 78 2 7 82 7 84 784 787 7 94 7 98 8 02 8 02 80 4

Chassis control and active safety Antilock braking system 806 Function and requirements 8 06 Operating principle 8 06

Traction control system Function and requirements TCS control loops Driv Drivin ingg-dy dyna nami mics csc con ontr trol ols sys yste tem m Function Requirements Operating principle Typical driving maneuver Stru Struct ctur ure eof oft the heo ov veral erall lsy syst stem em System components SpecialElectronicStability Progr Program amfo forc rcomm ommerc ercial ialv vehi ehicle cles s Supplementaryfunctions (automaticbrake-system operations) Integrateddriving-dynamics control systems Over view Functions System architecture Vehicle bodies Road-vehicle systematics Classification Vehicle bodies, passen senger cars cars Main dimensions Body design Aerodynamics Aeroacoustics Body  Safety Vehiclebodies, commercial vehicles Classification Light utility vans Medium-andheavy-duty trucks and tractor units Buses Passive safety in trucks Lighting equipment Functions Regulations and equipment Light sources Main-light functions Main Ma in-l -lig ight htf fun unct ctio ions nsf for orE Eur urop ope e Main-l Main-ligh ightf tfunc unctio tions nsfo fort rthe heUSA USA Definitions and ter ms Technicaldesignvariationsof headlamps

8 18 818 818 822 82 2 8 22 82 3 82 4 8 24 825 82 5 834 837

Automotivewindshieldand window glass The Thema mate teria rial lpr prop operti erties eso of fgl glass ass  Automotive glazing Functional design glazing Windshield,rear-windowand headlamp cleaning systems Windshield wiper systems Rear-window wiper systems Windshieldandrear-window washer systems Headlamp washer systems

914 914 91 4 915 916 920 920 926 927 927

Passive safety Occupant-protection systems Seatbeltsandseat-belt pretensioners Airbag Rollover protection systems Components Fur ther developments

928 931 934 934 936

852 853 854 854 8 56 8 57 8 59 860 8 64

Vehicle security systems Locking systems Function Structur Structure( e(sid sided edoor ooras ase exam xample ple) ) Double-locking functions Technology Theft-deterrent systems Regulations System design

938 938 939 941 945 946 946 946

8 68 86 8 8 69

Automotive electrics Vehicle electrical systems Electrical power supply Electrical-system structures Electri ctric cal-syst ystem parameters Elec Electr tric ical ale ene nerg rgy ym man anag agem emen ent t Star ter batteries Requirements Batter y design Charging and discharging Batter y characteristics Batter y types Using the batter y Electrical machines Systematicsofrotatingelectrical machines Direct-current machines

84 2 846 846 846 849

8 69 87 2 87 4 8 76 876 8 77 878 879 882 88 2 885 8 87 8 88

928

948 948 953 955 957 95 7 962 962 963 964 965 966 968 970 970 970

Alter nators 98 6 Electric power generation 9 86 Operating conditions 99 1 Efficiency 99 2 Types of claw-pole alterna rnator 993 Star ting systems 9 96 Star ter 996 Triggering the star ter 1000 Actuators 1002 Over view 1002 Electrodynamicand electromagnetic converte rters 1002 Piezo actuators 1005 Fluid-mechanical actuators 1007 Wiringharnessesand plug-in connections 1008 Wiring harnesses 1008 Plug-in connections  1010 Electromagneticcompatibility(EMC) and interference suppressio sion 1014 Requirements 1014 Sources of interference 1014 Pote otenti ntiall allys ysusce uscepti ptibl bled edev evice ices s 101 1017 7 Interference coupling 1018 Electrostatic discharge 1019 Measuring technology 1020 Regulations and standards 1021 Symbols and circuit diagrams 1022 Circuit symbols 1022 Circuit diagrams 1029 Terminal designations 1041 Automotive electronics

Automotiveso Automoti vesoftwar ftwareeng eengineeri ineering ng 1044 Motivation 1044 Designofsoftware in motor vehicles 1045 Importantstandardsforsoftware in motor vehicles 1045 The development process 1048 Qualityassurancein software development 1052 Sequencesofsoftware deve de velop lopmen menti tinm nmoto otorv rvehi ehicle cles s 105 1052 2 Modelingandsimulation of software functions 1054 Designandimplementation of software functions 1057 Integrationandtestingof

Automotive networking Bus systems Technical principles Buses in motor vehicles CAN FlexRay LIN Ether net, IP PSI5 MOST bus Archit Architect ecture ureof ofel elect ectron ronic icsyst systems ems Over view Architecturemethods of electronic systems Sensors Basic principles Position sensors Speed and r pm sensors Accelerationand vibration sensors Pressure sensors Flowmeters Gassensors,concentration sensors Temperature sensors Force and torque sensors Optoelectronic sensors Sensorsfordriver-assistance systems Mechatronics Mechatronicsystemsand components Development methodology Outlook

10 6 4 1 06 4 10 6 5 1071 1 07 1 1 0 75 1 07 9 1 0 82 10 8 3 10 8 5 1090 109 0 1 0 90 1 0 93 1 10 0 11 0 0 1 1 05 1 1 21 1 1 26 11 3 0 1 1 34 1 1 37 1 14 0 11 4 3 1 15 0 1 1 54 1 1 64 1 1 64 1 1 65 1 16 8

Comfort and convenience

Passenger-compartment climate control 1 1 70 Clim Climat atee-co cont ntro rol lre requ quiireme rement nts s 1170 11 70 A/C-unitdesignandoperating principle 1 17 0 Climate-control systems 1 17 3 Climatecontrolforhybridand electric vehicles 1 17 4 Auxiliar y heater systems 11 7 6 Comfortandconveniencesystems in the door and roof areas 1 18 0 Power-window systems 1 1 80 Roof systems 11 8 1

User interfaces, telematics and multimedia Display and control Interaction channels Instrumentation RadioandTVreceptionin motor vehicles Wirel ireles ess ssi sign gnal alt trran ansm smiissio ssion n Radio tuners Traffic telematics EU recording equipment Legal regulations Design variations Driver-assistance Driver-assistance systems Driver-assistance systems Parking systems Parkingaidwithultrasonic sensors Parking aid assistant Vehicle navigation Navigation systems Functions of navigation Digital map Adaptive Cruise Control Function Design and function Control algorithms Areaofapplicationandfurther development Predictiveemergency-braking systems Video-baseddriver-assistance systems Lanedeparturewarning and lane keeping suppor t Road-sign recognition Night-vision systems Applications Far-infrared systems Near-infrared systems Appendices Technical ter ms Abbreviations

1 1 84 1 1 84 1 1 85 1 1 92 1192 11 92 1 19 5 11 9 9 1 20 0 12 0 0 1 2 00 1 2 02 1 2 06 1 20 6 1 2 09 12 10 12 1 0 12 1 0 12 13 1 21 4 12 1 4 12 1 4 12 16 1 2 17 1 22 0 1 22 2 1 2 22 1 22 3 12 2 4 1 22 4 1 22 4 1 2 25 12 2 8 1 2 58

R ev is ed & Updat ed

established 1950 Automotive Reference™

BentleyPublishers .com

Bosch Automotive Handbook  8th Edition Price: $49.95 Bentley Stock No: H016 Publication Date: 2011.jun.1 ISBN: 978-0-83 978-0-8376-1686-5 76-1686-5 Vinyl cover, 4 1/2 in. x 7 in. Case quantity: 1 1256 pages Over 1000 technical photos and illustrations

All about automotive engineering in a pocketbook Robert Bosch GmbH published the frst incarnation o the Automotive Handbook in 1932. The original preace to this edition introduced the  book as ollows: “These ‘Technical Tables’ are an attempt to give users o our products a small, handy collection o the interesting ormulas, values, and fgures - drawn mainly rom automotive technology -that are otherwise scattered across various magazines.” Three years later later,, the “Technical Tables” were renamed the “Automotive Handbook.” Contents - central themes

• Basic principles: physics, materials, machine parts, joining and  bonding techniques • Vehicle physics: basic terms of automotive engineering, motor-vehicle dynamics, vehicle acoustics • Internal-combustion engines: gasoline engine, diesel engine, turbochargers and superchargers, exhaust-gas system • Emission-control and diagnosis legislation • Management for spark-ignition engines: manifold injection, gasoline direct injection, alternative gasoline-engine operation • Management for diesel engines: common rail • Alternative drives: hybrid drive, fuel cell • Chassis systems: suspension, wheel suspensions, steering, brake systems • Active safety: antilock braking system, driving-dynami driving-dynamics cs control system • Lighting equipment • Automotive electrics: vehicle electrical systems, starter batteries, electrical machines, alternators • Automotive electronics: automotive networking, buses, architectu architecture re o electronic systems, sensors • Driver-assistance systems: parking systems, vehicle navigation, Adaptive Cruise Control, night-vision systems

Sample page spreads from the Bosch  Automotive Handbook 

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