Automotive Electrical and Electronic Systems nandakumarmb@gmail.

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Questions and Answers for Chassis control system.

Below are the questions from the previous examination and also important from examination
point of view.

Note: some answers are elaborate for better understanding. Use your discretion and answer
depending on the marks and the questions.

1. Explain in brief the construction and working of ABS used in Automotive Vehicle. 08
marks Jan 2015, 05 marks July 2014,
What are the essential components of ABS. What are their function.05 marks July 2015
Locate them with the help of neat sketch. Or Explain the working of ABS with its
functional components with a neat sketch OR write a short note of ABS 5 marks Jan
2014

systems, however, there are three main

components.
 Wheel speed sensors.
 Electronic control unit.
 Hydraulic modulator

Wheel speed sensors

Most of these devices are simple
inductance sensors and work in
conjunction with a toothed wheel.
Theyconsist of a permanent magnet and a
soft iron rodaround which is wound a coil
of wire. As the toothed wheel rotates, the
changes in inductance of the
magneticcircuit generate a signal; the
frequency andvoltage of which are
proportional to wheel speed.The frequency
is the signal used by the electroniccontrol
Ans: There are a few variations between
unit. The coil resistance is of the order
manufacturers involving a number of
of1k_. Coaxial cable is used to prevent
different components. For the majority of
interferenceaffecting the signal.Some
systems now use ‘Halleffect’ sensors.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

Electronic control unit

The function of the ECU is to take in information from the wheel sensors and calculate the
best course of action for the hydraulic modulator. The heart of a modern ECU consists of two
microprocessors, which run the same program independently of each other. This ensures
greatersecurity against any fault, which could adversely affect braking performance because
the operationof each processor should be identical. If a fault is detected, the ABS disconnects
itself and operates awarning light. Both processors have non-volatile memory into which
fault codes can be written forlater service and diagnostic access. The ECU also has suitable
input signal processing stages and outputor driver stages for actuator control.
The ECU performs a self-test after the ignitionis switched on. A failure will result in
disconnectionof the system. The following list forms the self-test procedure.
 Current supply.
 Exterior and interior interfaces.
 Transmission of data.
 Communication between the two microprocessors.
 Operation of valves and relays.
 Operation of fault memory control.
 Reading and writing functions of the internalmemory.
All this takes about 300 ms.
Hydraulic modulator
The hydraulic modulator has three operating positions.
 Pressure build-up (brake line open to the mastercylinder.)
 Pressure reducing (brake line open to the accumulator)
 Pressure holding (brake line closed.)
The valves are controlled by electrical solenoids, which have a low inductance so they react
very quickly. The motor only runs when ABS is activated

2. Explain the five requirements of ABS system. 10 marks, Jan 2014

A good way of considering the operation of a complicatedsystem is to ask: ‘what must the
system beable to do?’ In other words, what are the requirements?These can be considered for
ABS under thefollowing headings.
Fail-safe system
In the event of the ABS system failing the conventionalbrakes must still operate to their full
potential.In addition, a warning must be given to thedriver. This is normally in the form of a
simplewarning light.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]
Figure:ABS can help maintain
steering control

Manoeuvrability must be
maintained
Good steering and road holding must
continue when the ABS system is
operating. This is arguably the key issue,
as being able to swerve around a hazard
whilst still braking hard is often the best
course of action.

Immediate response must beavailable

Even over a short distance the system must reactsuch as to make use of the best grip on the
road. Theresponse must be appropriate whether the driverapplies the brakes gently or slams
them on hard.

Operational influences
Normal driving and manoeuvring should produce no reaction on the brake pedal. The
stability and steeringmust be retained under all road conditions. The system must also adapt
to braking hysteresis whenthe brakes are applied, released and then re-applied. applied. Even
if the wheels on one side are on dry tarmac and the other side on ice, the yaw (rotation about
the vertical axis of the vehicle) of the vehicle must be kept to a minimum and only increase
slowly in order to allow the driver to compensate.
Controlled wheels
In its basic form, at least one wheel on each side of the vehicle should be controlled on a
separate circuit.It is now general for all four wheels to be separately controlled on passenger
vehicles.
Speed range of operation
The system must operate under all speed conditions down to walking pace. At this very slow
speed evenwhen the wheels lock the vehicle will come to rest very quickly. If the wheels did
not lock then, intheory, the vehicle would never stop!
Other operating conditions
The system must be able to recognize aquaplaning and react accordingly. It must also still
operate onan uneven road surface. The one area still not perfected is braking from slow speed
on snow. The ABS will actually increase stopping distance in snow but steering will be
maintained. This is consideredto be a suitable trade-off. A number of different types of anti-
lock brake systems are in use, but all try to achieve the requirements as set out above.

3. Explain with neat sketch, 3 channel Anti Lock Brake system used in Automotive
Vehcile. July 2015 10 marks

Ans: The control could be of 3 types.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

Four-channel, four-sensor ABS

This is the best scheme. There is a speed sensor on all four wheels and a separate valve for all four
wheels. With this setup, the controller monitors each wheel individually to make sure it is achieving
maximum braking force.

Three-channel, three-sensor ABS

This scheme, commonly found on pickup trucks with four-wheel ABS, has a speed sensor and a valve
for each of the front wheels, with one valve and one sensor for both rear wheels. The speed sensor
for the rear wheels is located in the rear axle.
This system provides individual control of the front wheels, so they can both achieve maximum
braking force. The rear wheels, however, are monitored together; they both have to start to lock up
before the ABS will activate on the rear. With this system, it is possible that one of the rear wheels will
lock during a stop, reducing brake effectiveness.

One-channel, one-sensor ABS

This system is commonly found on pickup trucks with rear-wheel ABS. It has one valve, which
controls both rear wheels, and one speed sensor, located in the rear axle.
This system operates the same as the rear end of a three-channel system. The rear wheels are
monitored together and they both have to start to lock up before the ABS kicks in. In this system it is
also possible that one of the rear wheels will lock, reducing brake effectiveness.
This system is easy to identify. Usually there will be one brake line going through a T-fitting to both
rear wheels. You can locate the speed sensor by looking for an electrical connection near the
differential on the rear-axle housing.

4. Explain the active suspension system with the help of a block diagram showing all
their functional components. Or

Whatis the importance of suspension system? How active suspension system is better
version of conventional suspension system. Explain with a neat sketch. Or

Explain with a block diagram the general layout of an active suspension system. 10
marks, 10 marks Dec 2013

Ans: Conventional suspension systems are always a compromise between soft springs for
comfort and harder springing for better cornering ability. A suspension system has to fulfil
four main functions.
 Absorb bumps.
 Manage nose dive(pitching)when braking.
 Prevent roll when cornering.
Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore
Automotive Electrical and Electronic Systems [email protected]
 Control body movement.
This means that some functions have to be compromised in order to fulfil others to a greater
extent
operation: Active suspension allows the best of both worlds. This is achieved by replacing
the conventional springs with double-acting hydraulic units. These are controlled by an ECU,
which receives signals from various sensors. Oil pressure in excess of 150bar is supplied to
the hydraulic units from a pump. A servo valve controls the oil, which is arguably the most
critical component.
The main benefits of active suspension are as follows.
 Improvements in ride comfort, handling and safety.
 Predictable control of the vehicle under different conditions.
 No change in handling between laden and unladen.

. A representation of an electronically controlled suspension system or Active suspension

system is shown in Figure.

The layout of the suspension system also

shows a simplified view of the hydraulic
unit. This is, in effect, a hydraulic ram and
can have oil under very high pressure fed
to the upper or lower chamber. The actual
operation of the whole system is as
follows. As a wheel meets a bump in the
road there is increased upward acceleration
and vertical load. This information is fed
to the ECU, which calculates the ideal
wheel displacement. A control signal is
now sent to the servo valve(s), which
control the position of the main hydraulic
units.

As this process can occur hundreds of times per second, the wheel can follow the contour of
the road surface. This cushions the vehicle body from unwanted forces. By considering
information from other sensors, such as the lateral acceleration sensor, which gives data
relating to cornering, and the longitudinal sensor, which gives data relating to braking or
acceleration forwards, the actuators can be moved to provide maximum stability at all times.
Active suspension looks set to have an easy ride in the future. The benefits are considerable
and, as component prices reduce, the system will become available on more vehicles. It is
expected that even off road vehicles may be fitted with active suspension in the near future

Sensors, actuators and system operation

To control the hydraulic units to the best advantage,the ECU needs to ‘know’ certain
information. Thisis determined from sensor readings from variousparts of the vehicle. A
number of sensors are usedto provide information to the suspension ECU.
Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore
Automotive Electrical and Electronic Systems [email protected]
Load sensor
A load cell used to determine whether actual load is positioned on each hydraulic ram.
Displacement and vertical acceleration
This sensor can take a number of forms, as simple as a variable resistor or a more accurate
and sensitive linear sensor such as the LVDT
Lateral and longitudinal acceleration
Acceleration can be determined from a pendulum type sensor using strain gauges linked to a
mass, or devices similar to an engine knock sensor.
Yaw transducer
Yaw can be determined from lateral acceleration if the sensor is mounted at the front or rear
of the vehicle.
Steering position
As well as steering position, rate of change of position is determined from a rotary position
sensor. This device can be a light beam and detector type or similar. If the rate of change of
steering position is beyond a threshold the system will switch to a harder suspension setting.
Vehicle speed
The speed of the vehicle is taken from a standard type sensor as used for operating the
speedometer.
Throttle position
Similar to the existing throttle potentiometers. This gives data on the driver’s intention to
accelerate or decelerate allowing the suspension to switch to a harder setting when
appropriate.
Driver mode selection
A switch is provided allowing the driver to choose soft or hard settings. Even if the soft
setting is selected, the system will switch to hard, under certain operational conditions

5. With a block diagram, explain the active body control system (ABC) 8 marks Jan
2015

Active Body Control, or ABC, is the Mercedes-Benz brand name used to describe hydraulic
fully active suspension, that allows control of the vehicle body motions and therefore
virtually eliminates body roll in many driving situations including cornering, accelerating,
and braking.
Repeat the answer of Active suspension system along with the above paragraph.

6. What is traction control system? Explain the function of essential components July
2014 and 2015

Ans: The steerability of a vehicle is not only lost when the wheels lock up on braking; the
same effect arises if the wheels spin when driving off under severe acceleration. Electronic
traction control has been developed as a supplement to ABS. This control system prevents the
wheels from spinning when moving off or when accelerating sharply while on the move. In
this way, an individual wheel, which is spinning is braked in a controlled manner. If both or
all of the wheels are spinning, the drive torque is reduced by means of an engine control
function. Traction control has become known as TCS, ASR(in German known as
Antriebsschlupfregelung) or TCR.
Traction control will intervene to achieve thefollowing:
 Maintain stability.
 Reduction of yawing moment reactions.
 Provide optimum propulsion at all speeds.
 Reduce driver workload.
The following list of advantages can be claimed fora good traction control system.
 Improved tractive force.
 Better safety and stability on poor surfaces.
 Less driver stress.
Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore
Automotive Electrical and Electronic Systems [email protected]
 Longer tyre life.
 No wheel spin on turning and cornering.
An automatic control system can intervene in many cases more quickly and precisely than the
driver of the vehicle. This allows stability to be maintained at time when the driver might not
have been able to cope with the situation.
Traction control is not normally available as an independent system, but in combination with
ABS. This is because many of the components required are the same as for the ABS. Traction
control only requires a change in logic control in the ECU and afew extra control elements
such as control of the throttle. Figure shows a block diagram of atraction control system.

Note the links with ABS and the engine control system.
Contol functions:
The following are controlled by the ECU to control traction
 Throttle
 Ignition
 Brakes

Figure 15.8 shows an ABS and traction control modulator, complete with an ECU.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

7. b. List out the various methods of traction control and compare them with suitable
graph for the prevention of spinning wheel. 04 marks Jan 2015
Contol functions:
The various methods to control traction are
1. Throttle
2. Ignition
3. Brakes
Note the links with ABS and the engine control system.

Figure shows an ABS and traction control modulator, complete with an ECU.

Control functions
Control of tractive force can be by a number of methods. Figure shows a comparison of three techniques used to
prevent wheel spin, throttle, ignition and brake control.
Throttle control
This can be via an actuator, which can move the throttle cable, or if the vehicle employs a drive-bywire
accelerator, then control will be in conjunction with the engine management ECU. This throttle control will be
independent of the driver’s throttle pedal position. This method alone is relatively slow to control engine torque.
Ignition control
If ignition is retarded, the engine torque can be reduced by up to 50% in a very short space of time.The timing is
adjusted by a set ramp from the ignition map value.
Braking effect
If the spinning wheel is restricted by brake pressure, the reduction in torque at the affected wheel is very fast.
Maximum brake pressure is not used, to ensure passenger comfort is maintained.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

16. Write a short note on a. Air bag b. seat belt tensioner c. Central locking.

Air Bag: A seat-belt, seat-belt tensioner and an airbag are, at present, the most effective
restraint system in the event of a serious accident. At speeds in excess of40 km/h the seat-belt
alone is no longer adequate. Research after a number of accidents has determined
that in 68% of cases an airbag provides a significant improvement.

Operation of the system

The sequence of events in the case of a frontal impact at about 35 km/h, as shown in Figure
is as follows.

Note to students:Sketch no 4 is sufficient to illustrate the use of Airbag.

1. The driver is in the normal seating position priorto impact. About 15 ms after the impact
the vehicle is strongly decelerated and the thresholdfor triggering the airbag is reached. The
igniter ignites the fuel tablets in the inflater.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]
2. After about 30 ms the airbag unfolds and the driverwill have moved forwards as the
vehicle’s crumplezones collapse. The seat-belt will have locked orbeen tensioned depending
on the system.
3. At 40 ms after impact the airbag will be fully inflated and the driver’s momentum will be
absorbed by the airbag.
4. About 120 ms after impact the driver will be moved back into the seat and the airbag will
have almost deflated through the side vents, allowing driver visibility.

Passenger airbag events are similar to the above description. A number of arrangements are
used with the mounting of all components in the steering wheel centre becoming the most
popular. Nonetheless, the basic principle of operation is the same. Consideration is being
given to the use of a seat switch on the passenger side to prevent deployment when not
occupied. This may be more appropriate to side-impact airbags mentioned in the next section.
Seat-belt tensioners
Taking the ‘slack’ out of a seat-belt in the event of an impact is a good contribution to vehicle
passenger safety. The decision to take this action is the same as for the airbag inflation. The
two main types of tensioners are:
 Spring tension.
 Pyrotechnic.
The mechanism used by one type of seat-belt tensioner is shown in Figure

When the explosive charge is fired, the cable pulls a lever on the seat-belt reel, which in turn
tightens the belt. The unit must be replaced once deployed. This feature is sometimes
described as anti-sub marining.

Q: Explain cruise control and their essential components with a block diagram.
Its difficult to keep going at the same speed ( predetermined speed ) since you loose sense of
the speed with windows closed. this effect quite significant when u have driven for a long
time.
The purpose of cruise control is to allow the driver to set the vehicle speed and let the system
maintain it automatically. The system reacts to the measured speed of the vehicle and adjusts
the throttle accordingly. The reaction time is important so that the vehicle’s speed does not
feel to be surging up and down. Other facilities are included such as allowing the speed to be
gradually increased or decreased at the touch of a button. Most systems also remember the
last set speed and will resume this again at the touch of a button.
Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore
Automotive Electrical and Electronic Systems [email protected]
To summarize and to add further refinements, the following is the list of functional
requirements for a good cruise control system.
 Hold the vehicle speed at the selected value.
 Hold the speed with minimum surging.
 Allow the vehicle to change speed.
 Relinquish control immediately the brakes are applied.
 Store the last set speed.
 Contain built in safety features.

The main components of a typical cruise control system are as follows

 Actuator: A motor can be used to control the throttle cable or, in many cases,
vacuum-operated diaphragm is used which is controlled by three simple valves.
 Speed sensor:This will often be the same sensor that is used for the
speedometer.
 Brake switch:This switch is very important, as it would be dangerous braking if
the cruise control system was trying to maintain the vehicle speed.
 Clutch or automatic gearbox switch: The clutch switch is fitted in a
similar manner to the brake switch. It deactivates the cruise system to prevent the
engine speed increasing if the clutch is pressed.
 Main switch and warning lamp:
 Set and resume switches:These are fitted either on the steering wheel or on
a stalk from the steering column. The ‘set’ button programs the speed into memory
and can also be used to increase the vehicle and memory speed. The ‘resume’ button
allows the vehicle to reach its last set speed or temporarily to deactivate the control.

What is adaptive cruise control?

One of the limitations of the conventional cruise control is that the driver has to take over
from the cruise control system on many occasions to speed up or slow down. Adaptive cruise
control can automatically adjust the vehicle speed to the current traffic situation. Figure
shows the operation of the system. The system has three main aims.
 Maintain a speed as set by the driver.
 Adapt this speed and maintain a safe distance from the vehicles in front.
 Provide a warning if there is a risk of collision.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

Explain the benefits of Total vehicle dynamics

It is apparent that more and more electronic systems are required to be in communication to
achieve optimum results. This is one of the driving forces behind data bus communications
because many of the sensors used by various systems are common. Data are used by each in a
slightly different way but many systems have an effect on others. Systems, which are now
quite common, that lend themselves to combined control, are as follows:
 Anti-lock brakes.
 Traction control.
 Active suspension.
 Four-wheel steering.
 Engine management.
 Automatic transmission.

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

Block diagram shows how the above systems could be linked together. When these systems
are working together, significant improvements in the operation of each can be produced.
Research is still to be carried out in this area and further significant benefits are still possible
in the future.

Q: What is drive by wire ? Explain with an example

Drive-by-wire technology involves the replacement of traditional mechanical systems for

steering, braking, throttle and suspension functions, with electronic controllers, actuators and
sensors. Electronic throttle control (ETC) replaces the throttle cables. These cables are
twisted steel wires to transmit foot pedal movement to the throttle body. An electronic link
replaces the traditional mechanical link, which communicates with an engine control module
(ECM).

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore

Automotive Electrical and Electronic Systems [email protected]

1. What is active safety?

2 What is passive safety?
3. ABS acronym stands for _____ _______ ________
4. The chemical used in air bags is ___________
5. Seat belts is an example for ______ safety.
6.What is the advantage of drive by wire for throttle control?
7. give an example for a drive by wire system?

Nandakumar M. B. Dept of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore