Vehicle Control & Safety Systems

Dr. Yehia Eldrainy

Historical development of automotive electronics
Vehicle subsystems
Vehicle Systems and components

1- Chassis or Body
This basic structure of an automobile supports many other
systems described herein, as well as passengers and loads. It is
supported by the suspension, which connects it to the axles and
the wheels. The design of the chassis also affects vehicle
dynamics, aerodynamic drag, fuel efficiency, and passenger
comfort. The current trend is toward lighter body structures,
including the more efficient use of lighter-weight materials that
nonetheless are durable and crashworthy.
2- Engine
This component provides the power for moving a vehicle as well
as operating various subsystems. The most prevalent of the many
engine designs is the piston-type, spark-ignited, liquid-cooled,
internal combustion engine with four strokes per cycle and
gasoline fuel. Engine controls, which improve engine performance
in various ways, are used widely. Many new engine technologies
(e.g., homogeneous-charge compression-ignition, electric, hybrid,
and fuel-cell) also are being developed.
Vehicle Systems and components

3- Drive Train or Powertrain

This system consists of the engine, transmission, driveshaft,
differential, and driven wheels. The transmission is a gear system
that adjusts the ratio of wheel speed to engine speed to achieve
near-optimum engine performance. Automatic transmissions
already are commonplace, and electronic transmission-control
systems and continuously variable transmissions (CVT) are being
introduced. A driveshaft is used in front-engine, rear-wheeldrive
systems to transmit the engine power to the drive wheels. The
differential provides not only the right-angle transfer of the
driveshaft rotary motion to the wheels but also a torque increase
through the gear ratio, thereby allowing the driven wheels to turn
at different speeds (e.g., when turning a corner). The wheels and
pneumatic tires provide traction between the vehicle and the road
surface. Traction-control systems have been developed to provide
good traction under a variety of road-surface conditions.
Vehicle Systems and components

4- Steering
Steering allows a driver to change the orientation of a vehicle’s
front wheels to control the direction of forward motion. A rack-and-
pinion steering system design is typical in many modern
automobiles. Power-assisted steering is now commonplace and
four-wheel-steering (4WS) vehicles are emerging.
5- Suspension
The two major functions of the suspension system are to (1)
provide a smooth ride inside the automobile, and (2) maintain
contact between the wheels and the road surface. An independent-
strut–type suspension design is common. A semirigid axle
suspension system also is typical on the rear wheels of front-
wheel-drive (FWD) vehicles. The suspension design also
influences vehicle dynamics. Active and semi-active suspensions,
which use electronic controls, are currently available on some
vehicles.
Vehicle Systems and components

6- Brakes.
The brakes are the means for bringing a vehicle to a stop. Two
common designs are drum and disk brakes. Antilock brakes,
which use electronic controls to limit wheel slip, are now common
on many commercial vehicles.
7- Instrumentation
A modern vehicle includes many electronic sensors, actuators,
and other instrumentation. In today’s cars, there are more than two
dozen sensors in the powertrain alone. Most vehicles also now
include dozens of microprocessors (e.g., for electronic engine
control and diagnostics). Technologies such as the global
positioning system (GPS) are starting to be used in automobiles.
The average value of automotive electronics per vehicle, which
was less than $100 in the 1960s, reached approximately $1,000 in
1990 and more than $2,000 by 2000 (Ford 1986). Due to increasing
power needs, today’s 14-volt (V) electrical systems (with a 12-V
battery) eventually may be replaced with a 42-V system (with a 36-
V battery).
Automotive Control Systems

The control functions in an automobile can be grouped as follows:

1- Powertrain control
2- Vehicle control
3- Body control

1- Powertrain control
It consists of engine- and transmission-control systems. The
engine-control systems may include fuel-injection control,
carburetor control, ignition or spark-timing control, idle-speed
control, antiknock-control systems, and exhaust-gas recirculation
(EGR) control.
The goal of engine-control systems is to ensure that an engine
operates at near-optimal conditions at all times. Electronic
transmission control is used primarily in automatic transmissions.
Transmission-control systems determine the optimal shift point
for the torque converter and the lockup operation point based on
throttle-angle and vehicle-speed measurements.
Automotive Control Systems

Often, a single electronic control unit (ECU) handles both engine

and transmission control functions. Four-wheel drive (4WD)
systems are used (1) to obtain the optimal torque–transmission
ratio, (2) in braking and acceleration, and (3) between the front and
rear wheels. This optimal ratio depends on the vehicle forward
velocity.

2- Vehicle control systems

They include suspension control, steering control (e.g., 4WS),
cruise control, braking control (e.g., antilock brake systems
[ABS]), and traction control. These systems improve various
vehicle functions including response, steering stability, ride, and
handling; many were introduced in recent decades or are currently
being developed.
Automotive Control Systems

3- Body control
It refers to systems such as automatic air conditioning, electronic
meters, multi-instrument displays, energy control systems,
security systems, communication systems, door-lock systems,
power windows, and rear-obstacle detection. The intent of these
systems is to increase driving comfort and convenience and to
improve the value of the automobile. These features often are
perceived immediately by drivers as a benefit and typically are
introduced first in luxury vehicles.
Automotive Control Systems

EGO = Exhaust Gas Oxygen Sensor

 Vehicle Systems and components

Vehicle frame and body:

The purpose of a vehicle’s
frame is to support the body,
engine, and other
components. Vehicle Frame

The frame itself is supported

by the wheels and tires
through the vehicles
suspension system.

The engine: Battery

When you start your car: (a) power from your battery is Spark Plug
used to operate a small electric motor called the starter
motor, (b) the starter motor turns the flywheel and
crankshaft of the engine so that the engine can attain
sufficient momentum and speed to start and run on its
own, (c) delivering rotational power to the crankshaft
which supplies power to the remainder of the power
train. Engine
Vehicle Systems and components

The engine:
This power is ignited by exploding
gas inside cylinders which drives
pistons up and down, through
connecting rods. Inside the pistons
a mixture of compressed air and
gas is delivered to the cylinders by
a carburetor and intake manifold or
a fuel injection system.
The moving parts of the engine must
be lubricated. Oil which accumulates
in your engine’s oil pan is pumped by
the oil pump through an oil filter and
then through tubes that deliver the oil
to the moving parts to be lubricated.

Oil and Oil Filter

Vehicle Systems and components

The fuel system:

Fuel and air is delivered to the
engine through components
which include: (a) the fuel tank
which is used to store the gas,
(b) a fuel pump which pumps the
gas from the tank through a fuel
line and furl filter to a carburetor
or fuel injection system.

This fuel injection system or

carburetor delivers the proper mix of
air and gas to the cylinders by means
of an intake manifold after passing
through an air cleaner.
Vehicle Systems and components
In a front wheel drive
vehicle, the power is
The power train system:
transmitted from the engine
A vehicle’s power train consists through a combination
of components that generate and transmission-differential and
transmit power to the wheels. then to the front wheels.
In a rear wheel vehicle automatic
vehicle, it includes: (a) the engine
which generates the force, (b) the
transmission which adjusts and
Differential
controls the engine’s RPM and
changes the gears, (c) the drive
shaft which transmits forces from
Drive shaft
the transmission to the rear of the
Transmission
vehicle into the differential which
allows the axels and back wheels In a four-wheel drive vehicle,
to turn. power is transmitted from the
transmission to a transfer case
which can transmit power to
either the rear wheels only or to
both the rear and front wheels.
Vehicle Systems and components

The exhaust system:

After gas is exploded in one of
the cylinders it is released into
an exhaust manifold which
Muffler
collects it and passes it to a
catalytic converter which
Exhaust Pipes
chemically reduces the
quantity of harmful pollutants.
The gases are then passed by
exhaust pipes through a muffler
and resonator which reduce the
noise.
The gasses are then moved to the
tailpipe which vents the hot gases Keep your exhaust system in
away from the vehicle. good working order by noticing
changes in noise, fumes, and
rattling. These all signal problems.
Eventually all vehicles need
replacement exhaust components.
Vehicle Systems and components
The cooling system:
Heat caused by the friction of moving
engine parts and the explosion of
gasoline is removed through the
vehicles cooling system.
In this system, heat is absorbed by
coolant flowing through passages
inside the engine. The coolant is a
mixture of water and chemicals that
protect the cooling system from
corrosion, lubricate the water pump,
and prevent freezing.
It is stored in the radiator which
transfers the heat to the outside
environment.
The radiator is cooled by
a fan, and most have a
recovery tank to capture
coolant as it expands due
to the heat, and returns it to
the radiator when it cools.
Radiator
This coolant also allows
your engine to heat up
to its proper operating
temperature and is
controlled by a heat sensing
valve called a thermostat.
Vehicle Systems and components

The electrical system:

The battery is your vehicle’s primary
source of electrical power. When you
turn on your ignition switch to start
your car, electricity is used to close
another switch called a solenoid that
transmits the large amount of current
needed to turn the starter motor.
Once your engine is running, power
is generated by the alternator, which
also keeps your battery charged.
Then there is a voltage regulator,
distributor, and coil which controls
the amount of electricity needed by
the spark plugs.
Electricity is distributed
throughout your vehicle by
various electrical circuits for
lighting, computers, radio,
interior cooling, heating, etc.
These circuits have fuses
to disable a circuit that is
drawing too much current
so as to prevent a fire and
protect the components
that the circuit serves.
Vehicle Systems and components

The steering system:

When you turn the
A vehicle’s steering wheel is attached to a
steering column or shaft which terminates steering wheel in a
in the steering box. Inside the steering power steering system,
box, the turning motion of the column is the hydraulic fluid is
translated into lateral motion which is compressed inside
passed on to the wheels through a series
of components which include ball joints,
a cylinder.
the steering arm, and steering knuckle.
In power steering systems, turning the
steering wheel actuates a hydraulic
system which amplifies the force
necessary to rotate and move the
linkages leading to the wheels.
With power steering there should be no
“free play” in the wheel.
This compressed fluid
is then transmitted by
hydraulic lines to a piston
which amplifies the force
making it easier to turn
the wheels.
Vehicle Systems and components
There are are different
The suspension system: designs for suspension
The purpose of your vehicle’s systems involving various
suspension system is to connect linkages, struts, joints,
the wheels to the frame and body
torsion bars, and so on.
and keep the movement of your
wheels from being transmitted
fully to the body of the vehicle.
This allows you to maintain
control of the car in turns, when
you hit potholes, and on rough
roads. It makes riding in the car
more comfortable.
Coil Springs and Shock Absorbers

As the up and down movement of your wheels is absorbed by the

springs in your suspension system, your shock absorbers keep
the springs from continuing to bounce.
Vehicle Systems and components

The braking system:

There are two independent braking Hydraulic fluid is stored in
systems in your vehicle, the service a brake reserve normally
brakes and the parking brake (also located in the engine
referred to as the emergency brake). compartment.
The service brakes are used to slow
your vehicle while you are driving.
The parking brake can also be used to
slow your vehicle in an emergency, but
is mainly used to hold your vehicle in
one place while stopped or parked.

When you press your brake pedal, a piston in your master cylinder
forces the brake fluid through the hydraulic lines to pistons in the
wheel cylinders at the wheels where additional pistons provide the
force to apply your brakes.
Vehicle Systems and components

The braking system:

There are two types of brakes:
(a) drum brakes and (b) disc brakes
Drum brakes slow your vehicle by
the friction of a brake shoe pushing
against the drum which is rotating with
the wheel.
Disc brakes slow your car by the
friction of a caliper pressing against a
disc which is rotating with the wheel.
Your parking brake uses
a cable to engage the
brakes or clamp down
on the drive shaft, and
will function even if your
service brakes fail.

Both drum and disc brakes convert friction force to heat and if the
brakes get too hot, they cease to work because they cannot dissipate
enough heat.
For both types of brakes, your stopping time is roughly proportional
to the square of your speed. So, if you double your speed you
increase your stopping distance by four times!
Vehicle Systems and components

The braking system: The purpose of the antilock braking

Brakes will only slow your car while
there is friction between the moving
parts of your brakes.
If the wheels are locked as in the
case of a skid, the drums or discs
are not moving and there will be no
friction.
With ABS: wheels do not lock up…you have steering control.
system is to prevent the brakes
from locking by first sensing that
they are locking then automatically,
rapidly releasing and applying
pressure. If you do not have
antilock brakes, you can avoid
having your brakes lock manually,
rapidly releasing and then reapplying
pressure to your brake pedal.

Let’s now
consider
driver
controls

Without ABS: wheels lock up…no steering control.

Vehicle Systems and components

Driver Controls:

The next several slides presents the most common driver

controls used in modern passenger vehicles. You should go into
your vehicle, identify them, know where they are typically
located, and what their purpose is. It is important to know their
location so as not to be distracted looking for them when driving.
Driver Controls:

Item Typical Location Purpose Comments

Driver Controls:

Item Typical Location Purpose Comments

Driver Controls:
Item Typical Location Purpose Comments
Driver Controls:
Item Typical Location Purpose Comments
Driver Controls:

Item Typical Location Purpose Comments

Driver Controls:

Item Typical Location Purpose Comments

Driver Controls:

Item Typical Location Purpose Comments

Driver Controls:

Item Typical Location Purpose Comments

Vehicle Systems and components

The instrument panel: lights, gauges and chimes:

Certain gauges and lights are more important than others.

An easy way to remember the most important one is to learn:
“boil, oil, and coil.”
The first and most important is the temperature or “boil”. When this warning
light is on or the gauge moves into the red, it means the temperature of the
engine is too high and the engine will overheat soon.
The proper
response is to pull
over and turn off
Question: What should
the engine so it can
you do if this needle
cool down. It would
goes into the red zone?
be good to then get
your cooling
system checked.
Red zone
Vehicle Systems and components

The instrument panel: lights, gauges and chimes:

Certain gauges and lights are more important than others.

An easy way to remember the most important one is to learn:
“boil, oil, and coil.”
Next, is the oil gauge or warning light. It signifies that the oil level is low.
Without oil, the parts that need lubrication would heat up, expand and not
move freely. This will cause permanent damage to the engine.

Question: What should The proper response

you do if this needle is to check and add oil
gets any lower? to the recommended
level. The vehicle
It’s a good idea to should be checked
frequently check your out to find out why
oil level anyway. the oil level was low.
Vehicle Systems and components

The instrument panel: lights, gauges and chimes:

Certain gauges and lights are more important than others.

An easy way to remember the most important one is to learn:
“boil, oil, and coil.”
“Coil” relates to the battery or alternator light or voltage gauge. If trouble is
indicated, it means the battery is not being charged. This is the least urgent
of the three warnings. The problem will eventually bring things to a stop,
but it does not require immediate or emergency attention.
The proper response
Question: What should is to get the system
you do if this needle checked out. It could
drops into the red zone? be a bad battery,
alternator, or other
Generally the needle
of a well charged related electrical
battery will be in the problem.
Red zone
center of the gauge.
 Safety is important to …
Consumers Governments Manufacturers
• Consumers regularly look • NHTSA NPRM for ESC • Safety products and
for vehicle safety • NHTSA side impact features help differentiate
information before making protection (FMVSS214) vehicles
their purchase decision • Occupant sensing • Adopting voluntary safety
• J.D. Power lists safety as (FMVSS208) standards in response to
the most desired aspect of • TREAD Act - tire market demand and
vehicle features pressure monitoring and regulatory trends
• Safety awareness levels rollover testing • Advertising and marketing
increasing along with • Fuel economy heavily focused on safety
aging U.S. population message
• Pedestrian protection
SHOPPING FOR A SAFER CAR
If you're like most people shopping for a new car,
safety ranks high among your purchase
considerations. Every new passenger vehicle must
meet federal standards specifying minimum safety
levels, but this doesn't mean all cars are equally
safe. There still are important safety differences…
(Insurance Institute For Highway Safety)

36
 Definition of Automobile Safety

37
Steady Evolution of New Products
Just as the vehicles we drive have evolved over the years… OSS (Occupant
Braking Steering Safety Systems)
• Two and four • Hydraulic power • Driver and
1980s wheel anti-lock assisted rack & passenger
braking pinion steering airbags
• Single stage
inflators

• Traction control • Electro-hydraulic • Side impact

1990s • Electric and steering
mechanical brake • Speed
airbags
• Enhanced airbag
assist proportional control units
steering

• Electronic stability • Electrically • Rollover curtain

control powered airbags with up
Today • Active rollover steering to 3 rows of
mitigation • Integrated protection
• Hill hold braking and • Dual stage and
steering cold gas inflators
systems

38
 Active and Passive Safety Technologies
Driver Assist Systems
Airbags Adaptive Cruise Control
Driver & Passenger Airbags Lane Guide Systems
Self Adapting Vent Collision Warning
Active Venting Steering Wheel Systems
Low Risk Deployment Touch Sensor in Steering Wheel Rim
Knee & Side Airbags Vibrating Steering Wheel
Curtain/Rollover Airbags Illumination Technology
Contactless Horn System
Seat Belt Systems Path-free use of Horn
Active Control Retractor
Steering Wheel with Integrated Microphone
Seat Belt Retractors
Electrical Connections
Load Limiters
Fixed Driver Airbag Module
Buckle Pretensioners
Active Buckle Lifter
EnTire Solution
Direct Tire Pressure Monitoring
- Products from JV with Michelin

Linkage & Suspension Systems

Steering Systems Active Dynamic Control
Speed Proportional Steering Control Arms
Electrically Powered Hydraulic Steering Ball Joints
Electrically Powered Steering Column Drive Stabilizer Links
Electrically Powered Steering Rack Drive Tie Rods
Active Steering Modules

Braking Systems
Anti-Lock Braking (ABS)
Safety Electronics Traction Control
ECU and Remote Sensors Electronic Stability Control (ESC)
Vision System Slip Control Boost
Pedestrian Protection Electric Park Brake
Weight Sensing System Integrated Park Brake
Calipers
Actuation
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Advanced Technologies Integrated Safety
Systems

Lane Guidance

Lane Departure Warning Collision Warning and

Preparation

Steering Torque Control

with Electronic Stability Rollover Prevention and
Control Mitigation
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