Advanced Vehicle Control Systems

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Advanced Vehicle Control Systems

• S. Balachandran
• Vice President

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AGENDA

• About WABCO India
• Commercial vehicle brakes system trend
• Introduction to ABS advantages over
  conventional braking
• Electronic Braking System (EBS)
• Full Air Brake Controls with ABS/ESC vs. EBS/ESC
• Electronically controlled air suspension
• Modular Door Control Systems MTS
• Tire Pressure Monitoring - TPM
• Automatic Manual Transmission AMT
• Driver assistance systems

From Brake Controls to Vehicle Dynamic Controls
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WABCO INDIA LIMITED

• Sundaram Clayton Limited was established in
  1962 as a joint venture with Clayton Dewandre UK
  ( Now WABCO Vehicle Control Systems)
• The Brakes Division of Sundaram-Clayton Limited
  has now become a separate company, WABCO-TVS
  (INDIA) Limited. On 3rd Jun09 WABCO raised its
  ownership position to 75 equity investment and
  balance to public
• On 2nd Aug 2011, WABCO-TVS (INDIA) LIMITED was
  renamed as WABCO INDIA LIMITED
• WABCO INDIA has three manufacturing sites
  (located at Chennai, Jamshedpur and Mahindra
  City)
• over 40 years of service to the Indian
  automotive industry

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ABOUT WABCO INDIA LIMITED
MARKET LEADER in Indian Medium and Heavy
Commercial Vehicle industry
Sales of Rs. 899 Cr in 2010-11, 50 growth
Over 2,400 EMPLOYEES, 200 ENGINEERS
3 MANUFACTURING LOCATIONS in India
MAJORITY CONTROL BY WABCO in Jun 2009
listed on NSE / BSE with the stock symbol
WABCOINDIA / 533023
Listed in stock exchanges in India
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WABCO INDIA JOURNEY

• New plant at Jamshedpur
• New Plant at Mahindra city
• ABS Introduction by OEMs
• Focus on Exports

Products meeting global standards
FS Super platinum
ABS
FS Super platinum
Air dryer, Automatic brake adjustment and Load
sensing valve
Products for Stallion vehicles (Army application)
TPM award
ACMA award
High pressure compressors
Deming prize TPM Kick-off
Japan Quality Medal
A successful journey
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HISTORY OF WABCO IN INDIA / ASIA
Qingdao (340)
Seoul, Pyungtaek (90)
Jinan (280)
Tokyo, Kawagoe (80)
Shanghai (90)
Hong Kong (3)
Chennai (1,400)
Singapore (7)
Melbourne (3)
1977 1986 1990 1996 2001 2005 2006
2007 2008 2009
gt
APAC HQ moved to Shanghai
JV w/ Sundaram Clayton Ltd, India
APAC HQ in Hong Kong
Technical Licensing in China
QD Factory Official Inauguration
WABCO takes majority control
Mahindra WC Factory in India
Factory in Pyungtaek Korea
Jamshedpur Factory in India
JV in Jinan, China
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CUSTOMER VALUES

• WABCO is working on global TECHNOLOGY trends
  relevant to our customers
• We have a clear path to enhance VEHICLE
  EFFICIENCY and ENVIRONMENTAL SUSTAINABILITY by
  20
• Our vision is to improve ADVANCED SAFETY and
  DRIVER EFFECTIVENESS, and reduce the number of
  commercial vehicle accidents by 50 by 2020
• We are involved in developing PRODUCTS and
  FUNCTIONALITIES to better meet these needs

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BRINGING VALUE TO CUSTOMERS
Shift of economic power among regions
Increasing mobility
Growing demand for safety and security
Growing need for environmental care
Availability of natural resources
Truck/Bus-Specific Trends
Fuel Efficiency
Stability control
Braking systems
control
Energy Recovery
ABS
Suspension control
Weight Reduction
ADAS
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PRODUCT PORTFOLIO
Vacuum products 2 Repair kit sales 10 Exports
(Inter-company) 12 Exports (Aftermarket) 1
Air Compressors 13 Air Processing
12 Conventional Brake Controls 21 Brake
Chambers Actuators 22 Anti-Lock Braking System
(ABS) 7
2010-11 Sales
2010-11 sales Rs 899 Cr
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WABCO - The Supplier of Control Systems for
Commercial Vehicles
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Commercial Vehicles Braking System Trend
Focus on ADAS beyond 2011
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Typical Dual Brake System layout
Spring Brake Acctuator For Hand brake
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System Function Hand brake
Able to stop the vehicle by Hand brake when both
Service circuits failed.
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Benefits of Hand brake system

• Able to stop the vehicle by Hand brake when both
  Service circuits failed.
• During vehicle parking Hand brake ensure the
  locking of the rear wheels
• Driver can operate the vehicle when foot brake
  fail, by operating hand brake as service brake.

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For parking emergency braking
Ensure the spring brake chambers in wind in
condition
?
?
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ABS System
Reliable ABS Portfolio
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ABS Schematic Layout 4S/4M
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ABS ADVANTAGE
Air Brake with ABS
Air Brake

• Sub-optimal stopping distances on dry/slippery
  roads
• Wheel locking while panic braking or in slippery
  road conditions can lead to accidents.
• Tyre life reduced due to wheel locking
• Experienced driver for driving on extreme road
  conditions

• Improved stopping distances especially in
  dry/slippery roads
• Wheel locking avoided. An important safety
• Criterion to prevent accidents.
• Increase in tyre life. COST SAVING to the end
  customer.
• System will assist less experienced driver on
  extreme road conditions

Demo on wheel locking
Demo Without ABS
Demo With ABS
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Electronic Braking System - EBS
EBS ECU
back up valve
Axle-modulator
ABS solenoid valve
Proportional Relay Valve
Brake signal transmitter
WABCO EBS Components - 4S/4M
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4S/4M for 4x2 Vehicles
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Why EBS?

• Advantages of EBS vs. ABS

Installation advantages Less pneumatic and
electric connectors No additional components if
ESC is installed
Shorter brake distance Shorter pneumatic
pipes Electro pneumatic brake control Higher
pressure in brake system Pipe connections are
electrically controlled
Improved brake pedal feeling Pedal feeling
similar to Cars Deceleration control instead of
brake pressure control
Better diagnosis Self test Fault
memory Simplified brake check

• Cost benefit for the OEM and end user
• Less lining wear
• Less system cost
• Less service cost
• Functions due to parameter setting

New functions w/o additional valves Hill Start
Funtion Brake Assist Brake management
EBS provides advantages for all customer
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• Stability Controls RSC ESC

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Roll Stability Control

• Philosophy of RSC is to reduce vehicle speed
  there by preventing vehicle roll over

• RSC controls the lateral acceleration

• If the lateral acceleration exceeds a certain
  level RSC controls the engine torque including
  its retarder and if necessary activates the drive
  axle brakes through the ASR differential brake
  valve and activates the brakes of trailer
  additionally through RSC valve

Demo on RSC
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ABS based Roll Stability Control ( RSC ) -
Components

• RSC
• Accelerometer integrated in ABS ECU (or ESC
  Module)
• ATC valve for drive axlebraking
• RSC valvefor trailerbraking

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Directional Stability Control

• Identification of unstable driving conditions

Over steering
Under steering
directional instability
ESC brake application

• Reduction of engine torque to slow down vehicle
• Selective braking of single wheels to compensate
  deviation from stable driving conditions

How does ESC work at critical vehicle yaw ?
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ABS based ESC add. components
ESC components

• Solenoid Valve for front axle braking
• Pressure Sensor for driver brakedemand
• Steering AngleSensor
• ESC Module

• ATC valve for drive axlebraking
• Valvesfor trailerbraking

black/white
controlled
For ABS additional valves needed
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EBS based ESC add. components
ESC components

• Solenoid Valve for front axle braking
• Pressure Sensor for driver brakedemand
• Steering AngleSensor
• ESC Module

• ATC valve for drive axlebraking
• Valvesfor trailerbraking

X
X
X
X
X
black/white
controlled
Easy ESC extension with EBS
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Electronically controlled air suspension ECAS
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ECAS - Electronically Controlled Air Suspension -

• ECAS consists of
• Electronic Control Unit
• Remote Control Unit
• Height Sensors
• Pressure Sensors
• Solenoid Valve Blocks

• Reasons for ECAS
• Simple installation / Few parts / Cost Reduction
• Improvement of Conventional Air Suspension
  Functions
• Safety Concept
• Less air consumption
• Kneeling down function
• Control from drivers seat

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Air Suspension (ECAS) electronically controlled
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MODULATOR DOOR CONTROL SYSTEMS (MTS)
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MODULATOR DOOR CONTROL SYSTEMS (MTS)

• Purpose
• The function of MTS is to actuate and monitor
  with identical devices up to five doors of
  different construction of inward pivot / outward
  pivot doors and pneumatic / electrically driven
  doors
• MTS components
• Electronics (for pneumatic or electrical doors)
• Sensors for swinging doors
• Door control valve
• Door cylinder
• Emergency valve with switch
• Pressure switch

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FEATURES OF MTS

• Proven system gtDoors controlled by MTS main
  pneumatic-functions in series application since
  20 years
• System focus on safety for passengers, drivers
  and workshop peoples
• Further increase of safety by connection of
  additional equipment (sensitive edges, light
  barriers) easily possible
• One solenoid-valve to control opening and closing
  of the door including damping and the
  safety-function powerless.
• Door system connected to the vehicle at the first
  door only optional by
• conventional wiring or
• CAN - data bus (according ISO 11898)
• Reduced wiring due to internal data bus between
  the door ECUs. It is possible to link up to 5
  doors

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Tire pressure Monitoring ( TPM)

• The function of TPM is to monitor the tyre
  pressure
• Method
• Indirect monitoring by analyzing signals from
  the ABS wheel speed sensor
• Small differences of tire circumference are
  accumulated by wheel module (sensor) and transmit
  to ECU through wireless which in turn display the
  Tyre pressure data on the display cluster located
  in the dash board.
• Benefits
• Maintaining the tyre pressure results in saving
  in fuel consumption

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Components in the TPM system
Wheel Modules
Data on Integrated Multi-function Display
SAFETY - Correct Tire Pressures ECONOMY - Less
fuel consumption
Electronic Control Unit (ECU)
Simple System Structure
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Automated Manual Transmission (AMT)
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TRANSMISSION SYSTEMS
Different types of Transmission systems
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WABCO OptiDrive system overview
Value to Customer

• OptiDriveTM BENEFITS
• Easily adaptable to existing trucks and
  transmissions
• Lower development cost
• Shorter time to market
• Full functionality including drive software
• Minimized space requirements at gearbox
• Reliable design based on long experience
• Development and Testing according to
  state-of-the-art specifications
• Offering full system development

Description
WABCO OptiDrive's high degree of modularity
significantly reduces the development time
required for application to transmission
vehicle platforms, enabling faster time to market
for vehicle and transmission manufacturers
Standardization and Modularity to shorten time to
market
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WABCO AMT system overview
SYSTEM CONTENT
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WABCO AMT system overview
SLU
XY-Actuator
Inductive Speed Sensor
Active Speed Sensor
PCA
SYSTEM CONTENT
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EVOLUTION OF ACTIVE SAFETY
ABS
control
ESC
stabilize
anticipate
ADAS
Demo on ADAS
From controlling to anticipating
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WABCO
Driver Assistance Systems Technology and Products

• Headliner Cluster
• Camera
• Lane Departure Warning Lane Keeping Support
• support of long range sensor

Lane Departure Warning

• Side Sensors
• 24 GHz Radar orultrasonic
• Blind spot detection

• Long Range
• 77 GHz Radar or
• Infrared Laser Sensor
• ACC
• Collision Warning
• Collision Mitigation
• Autonomous Emergency Braking

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BENEFITS WORKING WITH WABCO

• Experienced vehicle control transmission
  automation specialist
• Know-how across vehicle control systems
• Capability to offer a complete system out of one
  hand
• A more efficient and economic system development
• A simplified and streamlined project management
  through local support
• A product that is fully tested as a complete
  system
• A product that is tailored to your requirements

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PASSION