Industrial Control

Behzad Samadi
Department of Electrical Engineering
Amirkabir University of Technology

Winter 2009
Tehran, Iran

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Car Suspension

Howstuffworks.com

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Shock Absorbers (Dampers)

Howstuffworks.com

Behzad Samadi (Amirkabir University) Industrial Control 3 / 86

Shock Absorbers (Dampers)

Single tube:

1 Atmospheric pressure
2 Valve, soft spring
3 Valve, hard spring
4 Non-return valve

[Bosch, 2007]

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Shock Absorbers (Dampers)

Twin tube:

1 Atmospheric pressure
2 Reserve chamber
3 Base valve

Advantages: Insensitive to stone throw. Tube can be adapted to fit in

locations where space is limited. This shock-absorber type is short, as the
balance chamber is next to the working cylinder.
[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 5 / 86

Shock Absorbers (Dampers)

Force velocity diagram

[Reimpell et al., 1995]

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Shock Absorbers (Dampers)

Force displacement diagram

[Reimpell et al., 1995]

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Level Control System

Air suspension:

1 Air connection
2 Steel spring
3 Auxiliary air-spring element
4 Gas volume
5 Shock absorber

[Bosch, 2007]

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Level Control System
Hydropneumatic suspension:

1 Fluid supply
2 Steel spring
3 Accumulator
4 Gas volume
5 Rubber diaphragm
6 Fluid
7 Hose
8 Shock absorber

System reacts to increased vehicle speed by reducing body ride height, resulting in
fuel savings
Increase in vehicle-body ride height on poor road surfaces
Enhanced stability in curves achieved through lateral blocking of the suspension
elements on a given axle

[Bosch, 2007]
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Roll Control System

Behzad Samadi (Amirkabir University) Industrial Control 10 / 86

Semi-active Suspension System
Magnetorheological (MR) fluid:

MR damper:

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Steering System

Rack and pinion:

Howstuffworks.com

Behzad Samadi (Amirkabir University) Industrial Control 12 / 86

Power Steering System

Behzad Samadi
[Reimpell et al., (Amirkabir
1995] University) Industrial Control 13 / 86
Power Steering System

Power rack:

Howstuffworks.com

Behzad Samadi (Amirkabir University) Industrial Control 14 / 86

Power Steering System

Rotary vane pump:

Howstuffworks.com

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Power Steering System

Electrohydraulic:

[Reimpell et al., 1995]

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Power Steering System

Electrohydraulic:

[Bosch, 2007]

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Electric Power Steering System

delphi.com

Behzad Samadi (Amirkabir University) Industrial Control 18 / 86

Electric Power Steering System

delphi.com

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Steer by Wire

delphi.com

Behzad Samadi (Amirkabir University) Industrial Control 20 / 86

Four Wheel Steering

delphi.com

Behzad Samadi (Amirkabir University) Industrial Control 21 / 86

Brake System

cartechservice.com

Behzad Samadi (Amirkabir University) Industrial Control 22 / 86

Vacuum Booster and Master Cylinder Assembly

[Limpert, 1992]

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Master Cylinder

Howstuffworks.com

Behzad Samadi (Amirkabir University) Industrial Control 24 / 86

Vacuum Booster and Master Cylinder Assembly

carbibles.com

Behzad Samadi (Amirkabir University) Industrial Control 25 / 86

Dual Hydraulic Circuit

carbibles.com

Behzad Samadi (Amirkabir University) Industrial Control 26 / 86

Hydraulic Leverage

Howstuffworks.com

Behzad Samadi (Amirkabir University) Industrial Control 27 / 86

Simple Brake System

Howstuffworks.com

Behzad Samadi (Amirkabir University) Industrial Control 28 / 86

Brake System

Main factors affecting the overall gain:

Pedal conversion
Boost factor
Diaphragm surface area
Vacuum pressure
Surface area of master cylinder
[Bosch, 2007]

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Disk Brakes

carbibles.com

Behzad Samadi (Amirkabir University) Industrial Control 30 / 86

Drum Brakes - Single Leading Edge

carbibles.com

Behzad Samadi (Amirkabir University) Industrial Control 31 / 86

Drum Brakes - Double Leading Edge

carbibles.com

Behzad Samadi (Amirkabir University) Industrial Control 32 / 86

Diagonally Split Circuit

conti-online.com

Behzad Samadi (Amirkabir University) Industrial Control 33 / 86

Proportioning Valve

Load-sensitive brake force reducing valve:

The cut-in pressure is altered to correspond to the vehicle’s load by
means of a mechanical device which transmits the relative movement
between axle and vehicle body to the step-bore piston in the valve.
The force acting on the step-bore piston during braking is again
modified by the dynamic axle load transfer and thus influences the
braking force on the rear axle.
This guarantees maximum deceleration while at the same time largely
preventing locking of the rear axle and the resulting danger of
skidding.
conti-online.com

Behzad Samadi (Amirkabir University) Industrial Control 34 / 86

Proportioning Valve

centricparts.com

Behzad Samadi (Amirkabir University) Industrial Control 35 / 86

Air Brake System

Why air brakes?

Air brake systems are more tolerant to small leaks. The
smallest leak in a hydraulic system could result in brake
failure. An air brake system includes a compressor to
generate more compressed air as needed.
icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 36 / 86

Air Brake System

Behzad Samadi (Amirkabir University)

icbc.com Industrial Control 37 / 86
Air Brake System

Behzad Samadi (Amirkabir University)

icbc.com Industrial Control 38 / 86
Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 39 / 86

Air Brake System

icbc.com

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Air Brake System

icbc.com

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Air Brake System

icbc.com

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Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 43 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 44 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 45 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 46 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 47 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 48 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 49 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 50 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 51 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 52 / 86

Air Brake System

The compressor will continue to pump air, but all of its output will
take the path of least resistance and be vented at the line rupture.
icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 53 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 54 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 55 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 56 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 57 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 58 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 59 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 60 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 61 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 62 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 63 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 64 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 65 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 66 / 86

Air Brake System

Once the supply line is connected to the trailer, there needs to be a

way of directing air pressure to the trailer.
icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 67 / 86

Air Brake System

There are times when it may be benefi cial to apply only the trailer
brakes with out applying the tractor brakes, such as when coupling
the tractor to a trailer.
icbc.com
Behzad Samadi (Amirkabir University) Industrial Control 68 / 86
Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 69 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 70 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 71 / 86

Air Brake System

icbc.com

Behzad Samadi (Amirkabir University) Industrial Control 72 / 86

Antilock Braking System (ABS)

Reduce stopping
distance
Maintain steerablity
Maintain lateral stability

bosch.de

Behzad Samadi (Amirkabir University) Industrial Control 73 / 86

Antilock Braking System (ABS)

Maximize tire-road adhesion with wheel slip control

[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 74 / 86

Antilock Braking System (ABS)

[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 75 / 86

Antilock Braking System (ABS)

ABS components:
Electronic Control Unit
Hydraulic Modulator
Wheel Speed Sensors

conti-online.com and bosch.de

Behzad Samadi (Amirkabir University) Industrial Control 76 / 86

Antilock Braking System (ABS)

howstuffworks.com
Behzad Samadi (Amirkabir University) Industrial Control 77 / 86
Antilock Braking System (ABS)

ABS MK20: Samand, Peugeot, Citroen, VW,...

conti-online.com

Behzad Samadi (Amirkabir University) Industrial Control 78 / 86

Antilock Braking System (ABS)
Bosch ABS5:

Hinten (rear), Vor (front), Richtig (right), Linke (left)

[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 79 / 86

Antilock Braking System (ABS)
ABS MK20:

Hinten (rear), Vor (front), Richtig (right), Linke (left)

[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 80 / 86

Electronic Stability Program (ESP)

Vehicle lateral variables:

Yaw rate
Sideslip angle (β)

[Bosch, 2007]
Behzad Samadi (Amirkabir University) Industrial Control 81 / 86
Electronic Stability Program (ESP)

bosch.de

Behzad Samadi (Amirkabir University) Industrial Control 82 / 86

Electronic Stability Program (ESP)

[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 83 / 86

Electronic Stability Program (ESP)

ESP components:
Wheel speed sensors (A)
Steering angle sensor (B)
Combined yaw rate
sensor/lateral
accelerometer (C)
Electronic Control Unit
(ECU) (D)
Hydraulic unit (E)
Motor (F)
Pressure sensor (G)
bosch.de and edmunds.com

Behzad Samadi (Amirkabir University) Industrial Control 84 / 86

Electronic Stability Program (ESP)

[Bosch, 2007]

Behzad Samadi (Amirkabir University) Industrial Control 85 / 86

Brake by Wire

Siemens VDO:

vdo.com

Behzad Samadi (Amirkabir University) Industrial Control 86 / 86

 Bosch, R., editor (2007).
Bosch Automotive Handbook.
Wiley, 7 edition.
Limpert, R. (1992).
Brake Design and Safety.
Society of Automotive Engineers Inc.
Reimpell, J., Stoll, H., and Betzler, J. W. (1995).
The Automotive Chassis: Engineering Principles.
Arnold.

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