Contents

Preface .......................................................................................................... xiii

Introduction ..................................................................................................... xv

Chapter 1: The Systems Approach to Control and Instrumentation ........................ 1

Chapter Overview .......................................................................................................1
Concept of a System ...................................................................................................2
Block Diagram Representation of a System .......................................................... 3
Analog (Continuous Time) Systems ....................................................................... 5
Linear System Theory: Continuous Time ..................................................................5
First-Order System .................................................................................................. 9
Second-Order System ........................................................................................... 11
Steady-State Sinusoidal Frequency Response of a System .....................................16
State Variable Formulation of Models .....................................................................17
Control Theory ..........................................................................................................20
Open-Loop Control ............................................................................................... 20
Closed-Loop Control ............................................................................................ 21
Stability of Control System ......................................................................................28
Root-Locus Techniques ........................................................................................ 29
Robustness of Control-System Stability ............................................................... 31
Closed-Loop Limit-Cycle Control ............................................................................34
Instrumentation .........................................................................................................35
Measurement ......................................................................................................... 36
Issues ..................................................................................................................... 36
Systematic Errors .................................................................................................. 37
Basic Measurement System ......................................................................................39
Sensor .................................................................................................................... 40
Random Errors ...................................................................................................... 42
Signal Processing .................................................................................................. 45
Filtering .....................................................................................................................45
Filter-Design Techniques ...................................................................................... 46

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Chapter 2: Discrete Time Systems Theory ......................................................... 51

Digital Subsystem .....................................................................................................55
Sinusoidal Frequency Response ...............................................................................56
Discrete Time Control System .................................................................................63
Closed Loop Control .................................................................................................68
Example Discrete Time Control System ..................................................................72
Summary ...................................................................................................................77

Chapter 3: Electronics Fundamentals ................................................................ 79

Semiconductor Devices ............................................................................................80
Diodes ................................................................................................................... 83
Rectifier Circuit ..................................................................................................... 85
Transistors .................................................................................................................87
Field-Effect Transistors ......................................................................................... 96
Integrated Circuits .....................................................................................................99
Operational Amplifiers ...........................................................................................100
Use of Feedback in Op Amps ................................................................................101
Summing Mode Amplifier .................................................................................. 103
Phase-Locked Loop ................................................................................................104
Sample and Zero-Order Hold Circuits ............................................................... 106
Digital Circuits ........................................................................................................111
Binary Number System ...........................................................................................113
Logic Circuits (Combinatorial) ..............................................................................114
NOT Gate ............................................................................................................ 114
AND Gate ........................................................................................................... 115
OR Gate .............................................................................................................. 117
Combination Logic Circuits ............................................................................... 117
Logic Circuits with Memory (Sequential) .............................................................119
ReS Flip-Flop ..................................................................................................... 119
JK Flip-Flop ........................................................................................................ 119
Synchronous Counter ..............................................................................................120
Register Circuits .................................................................................................. 121
Shift Register ...................................................................................................... 122
Integrated Circuits ...................................................................................................124
The Microprocessor ................................................................................................124

Chapter 4: Microcomputer Instrumentation and Control ................................... 127

Microcomputer Fundamentals ................................................................................128
Digital versus Analog Computers ...................................................................... 128
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Parts of a Computer ............................................................................................ 129

Microcomputers versus Mainframe Computers ................................................. 130
Programs ............................................................................................................. 130
Microcomputer Tasks ..............................................................................................131
Microcomputer Operations .....................................................................................132
Buses ................................................................................................................... 132
Memory Read/Write ........................................................................................... 133
Timing ................................................................................................................. 134
Addressing Peripherals ....................................................................................... 135
CPU Registers .........................................................................................................135
Accumulator Register ......................................................................................... 136
Condition Code Register ..................................................................................... 136
Microprocessor Architecture .............................................................................. 138
Reading Instructions ...............................................................................................140
Initialization ........................................................................................................ 141
Operation Codes .................................................................................................. 141
Program Counter ................................................................................................. 142
Branch Instruction ............................................................................................... 143
Jump Instruction .................................................................................................. 144
Jump-to-Subroutine Instruction .......................................................................... 144
Example Use of a Microcomputer .........................................................................147
Buffer .................................................................................................................. 147
Programming Languages ........................................................................................148
Assembly Language ............................................................................................ 148
Logic Functions .................................................................................................. 150
Shift ..................................................................................................................... 150
Programming the AND Function ....................................................................... 152
Masking ............................................................................................................... 153
Shift and AND .................................................................................................... 153
Use of Subroutines .............................................................................................. 153
Microcomputer Hardware .......................................................................................154
Central Processing Unit ...................................................................................... 154
Memory: ROM .................................................................................................... 155
Memory: RAM .................................................................................................... 156
I/O Parallel Interface .......................................................................................... 156
Digital-to-Analog Converter ............................................................................... 156
Analog-to-Digital Converter ............................................................................... 159
Sampling ............................................................................................................. 162
Polling ................................................................................................................. 162
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Interrupts ............................................................................................................. 163

Vectored Interrupts .............................................................................................. 163
Microcomputer Applications in Automotive Systems ...........................................164
Instrumentation Applications of Microcomputers .................................................166
Digital Filters ...................................................................................................... 168
Microcomputers in Control Systems ......................................................................170
Closed-Loop Control System ............................................................................. 171
Limit-Cycle Controller ....................................................................................... 171
Feedback Control Systems ................................................................................. 171
Table Lookup ...................................................................................................... 173
Multivariable and Multiple Task Systems .......................................................... 175

Chapter 5: The Basics of Electronic Engine Control .......................................... 177

Motivation for Electronic Engine Control .............................................................178
Exhaust Emissions ..................................................................................................178
Fuel Economy .........................................................................................................179
Federal Government Test Procedures .....................................................................180
Fuel Economy Requirements .............................................................................. 181
Meeting the Requirements .................................................................................. 183
The Role of Electronics ...................................................................................... 184
Concept of an Electronic Engine Control System .................................................184
Inputs to Controller ............................................................................................. 187
Output from Controller ....................................................................................... 188
Definition of Engine Performance Terms ...............................................................193
Torque ................................................................................................................. 193
Power ................................................................................................................... 196
Fuel Consumption ............................................................................................... 198
Engine Overall Efficiency ................................................................................... 200
Calibration ........................................................................................................... 201
Engine Mapping .................................................................................................. 201
Effect of Air/Fuel Ratio on Performance ........................................................... 202
Effect of Spark Timing on Performance ............................................................ 203
Effect of Exhaust Gas Recirculation on Performance ....................................... 204
Exhaust Catalytic Converters .................................................................................206
Oxidizing Catalytic Converter ............................................................................ 206
The Three-Way Catalyst ..................................................................................... 207
Electronic Fuel-Control System .............................................................................209
Engine Control Sequence ................................................................................... 212
Open-Loop Control ............................................................................................. 213
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Closed-Loop Control .......................................................................................... 213

Closed-Loop Operation ....................................................................................... 215
Analysis of Intake Manifold Pressure ....................................................................219
Measuring Air Mass ........................................................................................... 220
Influence of Valve System on Volumetric Efficiency ........................................ 223
Idle Speed Control ..................................................................................................224
Electronic Ignition ..................................................................................................230

Chapter 6: Sensors and Actuators .................................................................. 233

Automotive Control System Applications of Sensors and Actuators ....................234
Variables to be Measured .................................................................................... 236
Airflow Rate Sensor ............................................................................................ 236
Pressure Measurements ....................................................................................... 242
Engine Crankshaft Angular Position Sensor ...................................................... 245
Magnetic Reluctance Position Sensor ................................................................ 247
Hall-Effect Position Sensor ................................................................................ 259
Optical Crankshaft Position Sensor .................................................................... 263
Throttle Angle Sensor .............................................................................................265
Temperature Sensors ...............................................................................................268
Typical Coolant Sensor ...........................................................................................268
Sensors for Feedback Control ................................................................................270
Exhaust Gas Oxygen Sensor ............................................................................... 270
Oxygen Sensor Improvements ............................................................................ 274
Knock Sensors ........................................................................................................276
Automotive Engine Control Actuators ...................................................................279
Fuel Injection ...................................................................................................... 284
Exhaust Gas Recirculation Actuator .................................................................. 286
Variable Valve Timing ............................................................................................288
VVP Mechanism Model ..................................................................................... 290
Electric Motor Actuators ........................................................................................292
Brushless DC Motors .......................................................................................... 301
Stepper Motors .................................................................................................... 304
Ignition System .......................................................................................................304
Ignition Coil Operations ..................................................................................... 305

Chapter 7: Digital Powertrain Control Systems ............................................... 309

Introduction .............................................................................................................310
Digital Engine Control ............................................................................................310
Digital Engine Control Features .............................................................................312
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Control Modes for Fuel Control .............................................................................316

Engine Start ......................................................................................................... 317
Open-Loop Mode ................................................................................................ 317
Acceleration/Deceleration ................................................................................... 317
Engine Crank ...................................................................................................... 319
Engine Warm-Up ................................................................................................ 320
Open-Loop Control ............................................................................................. 322
Closed-Loop Control .......................................................................................... 323
Acceleration Enrichment .................................................................................... 328
Deceleration Leaning .......................................................................................... 328
Idle Speed Control .............................................................................................. 329
Discrete Time Idle Speed Control ..........................................................................329
EGR Control ...........................................................................................................335
Variable Valve Timing Control ...............................................................................337
Electronic Ignition Control .....................................................................................343
Closed-Loop Ignition Timing ............................................................................. 347
Spark Advance Correction Scheme .................................................................... 353
Integrated Engine Control System ..........................................................................354
Secondary Air Management ............................................................................... 354
Evaporative Emissions Canister Purge ............................................................... 355
Automatic System Adjustment ........................................................................... 356
System Diagnosis ................................................................................................ 356
Summary of Control Modes ...................................................................................357
Engine Crank (Start) ........................................................................................... 357
Engine Warm-Up ................................................................................................ 357
Open-Loop Control ............................................................................................. 357
Closed-Loop Control .......................................................................................... 358
Hard Acceleration ............................................................................................... 358
Deceleration and Idle .......................................................................................... 359
Automatic Transmission Control ........................................................................ 359
Torque Converter Lock-Up Control ................................................................... 366
Differential and Traction Control ....................................................................... 366
Hybrid Electric Vehicle Powertrain Control ...................................................... 368

Chapter 8: Vehicle-Motion Controls ................................................................ 381

Representative Cruise Control System ...................................................................382
Digital Cruise Control ........................................................................................ 390
Hardware Implementation Issues ....................................................................... 394
Throttle Actuator ................................................................................................. 396
Cruise Control Electronics ......................................................................................400
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Stepper Motor-based Actuator Electronics ........................................................ 401

Vacuum-Operated Actuator ................................................................................ 403
Advanced Cruise Control ................................................................................... 406
Antilock Braking System ........................................................................................410
Tire-Slip Controller ............................................................................................. 420
Electronic Suspension System ................................................................................420
Variable Damping via Variable Strut Fluid Viscosity ........................................ 442
Variable Spring Rate ........................................................................................... 443
Electronic Suspension Control System .............................................................. 444
Electronic Steering Control ....................................................................................446
Four-Wheel Steering ...............................................................................................449
Summary .................................................................................................................457

Chapter 9: Automotive Instrumentation and Telematics .................................... 459

Modern Automotive Instrumentation .....................................................................460
Input and Output Signal Conversion ......................................................................463
Multiplexing ........................................................................................................ 465
Multirate Sampling ............................................................................................. 468
Advantages of Computer-Based Instrumentation ..................................................469
Display Devices ......................................................................................................470
LED ..................................................................................................................... 474
LCD ..................................................................................................................... 476
Transmissive LCD .............................................................................................. 480
VFD ..................................................................................................................... 480
Flat Panel Display ...................................................................................................483
Fuel Quantity Measurement ...................................................................................491
Coolant Temperature Measurement ........................................................................497
Oil Pressure Measurement ......................................................................................498
Vehicle Speed Measurement ...................................................................................500
High-Speed Digital Communications (CAN) ........................................................502
CAN Network ..................................................................................................... 504
Trip Information Computer ....................................................................................507
Telematics ...............................................................................................................510
GPS Navigation ......................................................................................................511
The GPS System Structure .....................................................................................516
Automotive Diagnostics ..........................................................................................519

Chapter 10: Diagnostics and Occupant Protection ............................................ 521

Electronic Control System Diagnostics ..................................................................522
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Service Bay Diagnostic Tool ..................................................................................524

Onboard Diagnostics ...............................................................................................525
Model-Based Sensor Failure Detection ..................................................................526
Diagnostic Fault Codes ...........................................................................................529
Onboard Diagnosis (OBD II) .................................................................................543
Model-Based Misfire Detection System .................................................................544
Expert Systems in Automotive Diagnosis ..............................................................555
Occupant Protection Systems .................................................................................561
Glossary ....................................................................................................... 569
Quiz questions .............................................................................................. 573
Index ........................................................................................................... 589