Advanced Vehicle Control Systems Ø S. Balachandran Ø Vice President
AGENDA Ø About WABCO India Company proprietary & confidential Ø Commercial vehicle brakes system trend Ø Introduction to ABS & advantages over conventional braking Ø Electronic Braking System (EBS) Ø Full Air Brake Controls with ABS/ESC vs. EBS/ESC Ø Electronically controlled air suspension Ø Modular Door Control Systems – MTS Ø Tire Pressure Monitoring - TPM Ø Automatic Manual Transmission – AMT Ø Driver assistance systems From Brake Controls to Vehicle Dynamic Controls 2
WABCO INDIA LIMITED Sundaram – Clayton Limited was established in 1962 as a joint venture Company proprietary & confidential with Clayton Dewandre UK ( Now WABCO Vehicle Control Systems) ØThe Brakes Division of Sundaram-Clayton Limited has now become a separate company, WABCO-TVS (INDIA) Limited. On 3 rd Jun’ 09 WABCO raised its ownership position to 75% equity investment and balance to public ØOn 2 nd Aug 2011, WABCO-TVS (INDIA) LIMITED was renamed as WABCO INDIA LIMITED ØWABCO INDIA has three manufacturing sites (located at Chennai, Jamshedpur and Mahindra City) … over 40 years of service to the Indian automotive industry 3
ABOUT WABCO INDIA LIMITED Sales of Company proprietary & confidential MARKET LEADER in Indian Medium and Heavy Commercial Vehicle industry 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 4
WABCO INDIA JOURNEY New plant at Jamshedpur New Plant at Mahindra city ABS Introduction by OEMs Focus on Exports Products meeting global standards F&S Super platinum ABS Products for Stallion vehicles (Army application) High pressure compressors F&S Super platinum Air dryer, Automatic brake adjustment and Load sensing valve TPM award ACMA award Deming prize TPM Kick-off Japan Quality Medal A successful journey 5 Company proprietary & confidential • •
HISTORY OF WABCO IN INDIA / ASIA Shanghai (90) Hong Kong (3) Seoul, Pyungtaek (90) Tokyo, Kawagoe (80) Chennai (1, 400) Singapore (7) Melbourne (3) 1977 1986 1990 1996 2001 2005 2006 2007 2008 2009 > JV w/ Sundaram Clayton Ltd, India Technical Licensing in China APAC HQ in Hong Kong JV in Jinan, China Factory in Pyungtaek Korea APAC HQ moved to Shanghai QD Factory Jamshedpur Mahindra WC WABCO Official Factory in takes Factory in Inauguration India majority India control 6 Company proprietary & confidential Qingdao Jinan (340) (280)
CUSTOMER VALUES § WABCO is working on global TECHNOLOGY trends relevant to our customers We have a clear path to enhance VEHICLE EFFICIENCY and Company proprietary & confidential § 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 7
Increasing mobility Availability of natural resources Growing need for Growing demand for environmental care safety and security Shift of economic power among regions Truck/Bus-Specific Trends Stability control Fuel Efficiency Energy Recovery Weight Reduction Braking control systems ABS Suspension control ADAS 8 Company proprietary & confidential BRINGING VALUE TO CUSTOMERS
PRODUCT PORTFOLIO % 2010 -11 Sales Vacuum products 2% Air Processing 12% Repair kit sales 10% Conventional Brake Controls 21% Exports (Inter-company) 12% Brake Chambers & Actuators 22% Exports (Aftermarket) 1% Company proprietary & confidential Air Compressors 13% Anti-Lock Braking System (ABS) 7% 2010 -11 sales : Rs 899 Cr 9
WABCO - The Supplier of Control Systems for Commercial Vehicles Clutch Servo Air Dryer / APU Air Compressor Front Brakes Gear Box Controls Complete Air Brake System or ABS / ASR EBS with Stability Control Retarder Control Central Board Computer Reservoirs Suspension Controls • Pneumatic Rear Brakes • Electronic • with / w/o Shock Absorber Control 10 Company proprietary & confidential Temperature Control
Commercial Vehicles – Braking System Trend ACC ESC Car –like feel Braking Technology Varying road conditions Adjusting lining wear Varying load conditions Fail-safe Increasing vehicle speeds 30 -80 kmph 1940 1950 EBS ABS/ASR Automatic Slack Adjuster Load Sensing Valve Dual line air brake Single line air brake 1960 1970 1980 1990 Focus on ADAS beyond 2011 2000 2010 11 Company proprietary & confidential Stability
Company proprietary & confidential Typical Dual Brake System layout Hand brake Spring Brake Acctuator For Hand brake 12
Company proprietary & confidential System Function – Hand brake Able to stop the vehicle by Hand brake when both Service circuits failed. 13
Benefits of Hand brake system Company proprietary & confidential Ø Able to stop the vehicle by Hand brake when both Service circuits failed. Ø During vehicle parking Hand brake ensure the locking of the rear wheels Ø Driver can operate the vehicle when foot brake fail, by operating hand brake as service brake. 14
For parking & emergency braking Spring Brake Chamber Wind off condition Company proprietary & confidential Ensure the spring brake chambers in wind in condition Spring Brake Chamber Wind in condition 15
Company proprietary & confidential ABS System Reliable ABS Portfolio 16
Company proprietary & confidential ABS Schematic Layout – 4 S/4 M 17
ABS ADVANTAGE Air Brake with ABS • Improved stopping distances especially in dry/slippery roads • Wheel locking while panic braking or in slippery road conditions can lead to accidents. • Wheel locking avoided. An important safety Criterion to prevent accidents. • Tyre life reduced due to wheel locking • Experienced driver for driving on extreme road conditions Company proprietary & confidential • Sub-optimal stopping distances on dry/slippery roads • 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 18
Company proprietary & confidential Electronic Braking System - EBS back up Axlemodulator valve ABS solenoid valve Proportional Relay Valve EBS ECU Brake signal transmitter WABCO EBS Components - 4 S/4 M 19
4 S/4 M for 4 x 2 Vehicles (1) brake signal transmitter (BST) with 2 integrated sensors and switches (2) central electronic -control -unit (central module CM) (3) electro pneumatic proportional relay valve (PRV) (4) axle modulator with integ rated ECU (5) two ABS solenoid valves (6) ESC-module (7) steering wheel sensor (8) electro pneumatic trailer control valve (9) back up valve (10) wheel speed sensor front axle (11) wheel speed sensor driven axle 20 Company proprietary & confidential The electropneumatic circuit consists of
Why EBS? Shorter brake distance Shorter pneumatic pipes Electro pneumatic brake control Higher pressure in brake system Pipe connections are electrically controlled Better diagnosis Self test Fault memory Simplified brake check Installation advantages Less pneumatic and electric connectors No additional components if ESC is installed Cost benefit for the OEM and end user Less lining wear Less system cost Less service cost Functions due to parameter setting Company proprietary & confidential Advantages of EBS vs. ABS Improved brake pedal feeling Pedal feeling similar to Cars Deceleration control instead of brake pressure control New functions w/o additional valves Hill Start Funtion Brake Assist Brake management EBS provides advantages for all customer 21
Company proprietary & confidential Stability Controls – RSC & ESC 22
Philosophy of RSC is to reduce vehicle speed there by preventing vehicle roll over Ø Ø 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 23 Company proprietary & confidential Roll Stability Control
ABS based Roll Stability Control ( RSC ) - Components RSC Company proprietary & confidential – Accelerometer integrated in ABS ECU (or ESC Module) – ATC valve for drive axle braking – RSC valve for trailer braking 24
Directional Stability Control < Identification of unstable driving conditions : directional instability Under steering Company proprietary & confidential Over steering ESC brake application Ø Reduction of engine torque to slow down vehicle Ø Selective braking of single wheels to compensate deviation from stable driving conditions How does ESC work at critical vehicle yaw ? 25
ABS based ESC add. components ESC components • • • black/white Steering Angle Sensor • Valves for trailer braking Pressure Sensor for driver brake demand • ATC valve for drive axle braking Solenoid Valve for front axle braking ESC Module Company proprietary & confidential • controlled For ABS additional valves needed 26
EBS based ESC add. components ESC components front axle braking • • ATC valve for drive axle braking Valves for trailer braking X • Pressure Sensor for driver brake demand X X Company proprietary & confidential • Solenoid Valve for • Steering Angle X X black/white Sensor • ESC Module controlled Easy ESC extension with EBS 27
Company proprietary & confidential Electronically controlled air suspension ECAS 28
ECAS - Electronically Controlled Air Suspension - ECAS consists of Electronic Control Unit Remote Control Unit Height Sensors Pressure Sensors Solenoid Valve Blocks Company proprietary & confidential – – – 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 driver’s seat 29
Air Suspension (ECAS) electronically controlled Supply height sensor Company proprietary & confidential Nominal level solenoid valve ECU bellow ECU 30
Company proprietary & confidential MODULATOR DOOR CONTROL SYSTEMS (MTS) 31
MODULATOR DOOR CONTROL SYSTEMS (MTS) Ø Purpose up to five doors of different construction of inward pivot / outward pivot doors and pneumatic / electrically driven doors Ø MTS components Ø Electronics (for pneumatic or electrical doors) Ø Sensors for swinging doors Ø Door control valve Ø Door cylinder Ø Emergency valve with switch Ø Pressure switch 32 Company proprietary & confidential • The function of MTS is to actuate and monitor with identical devices
FEATURES OF MTS Ø Proven system >Doors controlled by MTS main pneumatic-functions in series application since 20 years System focus on safety for passengers, drivers and workshop peoples Ø Further increase of safety by connection of additional equipment (sensitive edges, light barriers…) easily possible Ø One solenoid-valve to control opening and closing of the door including damping and the safety-function “powerless”. Ø Door system connected to the vehicle at the first door only optional by: Ø conventional wiring or Ø CAN - data bus (according ISO 11898) Ø Reduced wiring due to internal data bus between the door ECUs. It is possible to link up to 5 doors 33 Company proprietary & confidential Ø
Tire pressure Monitoring ( TPM) 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 34 Company proprietary & confidential The function of TPM is to monitor the tyre pressure
Wheel Modules Data on Integrated Multi-function Display SAFETY Correct Tire Pressures ECONOMY Less fuel consumption Electronic Control Unit (ECU) Simple System Structure 35 Company proprietary & confidential Components in the TPM system
36 Company proprietary & confidential Automated Manual Transmission (AMT)
Company proprietary & confidential TRANSMISSION SYSTEMS Different types of Transmission systems 37 37
WABCO Opti. Drive system overview Value to Customer ● Easily adaptable to existing trucks and transmissions ● Lower development cost ● Shorter time to market Description WABCO Opti. Drive'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 ● 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 Standardization and Modularity to shorten time to market 38 Company proprietary & confidential Opti. Drive. TM BENEFITS 38
Passive Speed Sensor Company proprietary & confidential WABCO AMT system overview XY-Actuator Shift Lever Unit incl. TCU Pneumatic Clutch Actuator Active Speed Sensor SYSTEM CONTENT 39 39
WABCO AMT system overview SLU Company proprietary & confidential XY-Actuator Inductive Speed Sensor PCA SYSTEM CONTENT Active Speed Sensor 40 40
Company proprietary & confidential EVOLUTION OF ACTIVE SAFETY ABS control ESC stabilize anticipate ADAS Demo on ADAS From controlling –to anticipating 41
Driver Assistance Systems Technology and WABCO Headliner Cluster Camera • Lane Departure Warning & Lane Keeping Support • support of long range sensor Long Range 77 GHz Radar or Infrared Laser Sensor < < Lane Departure Warning Side Sensors 24 GHz Radar or ultrasonic <Blind spot detection ACC Collision Warning Collision Mitigation Autonomous Emergency Braking 42 Company proprietary & confidential Products
BENEFITS WORKING WITH WABCO Company proprietary & confidential § 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 43 43
PASSION 44 Company proprietary & confidential
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