1. Industrial Control
Behzad Samadi
Department of Electrical Engineering
Amirkabir University of Technology
Winter 2009
Tehran, Iran
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2. Car Suspension
Howstuffworks.com
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3. Shock Absorbers (Dampers)
Howstuffworks.com
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4. Shock Absorbers (Dampers)
Single tube:
1 Atmospheric pressure
2 Valve, soft spring
3 Valve, hard spring
4 Non-return valve
[Bosch, 2007]
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5. Shock Absorbers (Dampers)
Twin tube:
1 Atmospheric pressure
2 Reserve chamber
3 Base valve
Advantages: Insensitive to stone throw. Tube can be adapted to fit in
locations where space is limited. This shock-absorber type is short, as the
balance chamber is next to the working cylinder.
[Bosch, 2007]
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6. Shock Absorbers (Dampers)
Force velocity diagram
[Reimpell et al., 1995]
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7. Shock Absorbers (Dampers)
Force displacement diagram
[Reimpell et al., 1995]
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8. Level Control System
Air suspension:
1 Air connection
2 Steel spring
3 Auxiliary air-spring element
4 Gas volume
5 Shock absorber
[Bosch, 2007]
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9. Level Control System
Hydropneumatic suspension:
1 Fluid supply
2 Steel spring
3 Accumulator
4 Gas volume
5 Rubber diaphragm
6 Fluid
7 Hose
8 Shock absorber
System reacts to increased vehicle speed by reducing body ride height, resulting in
fuel savings
Increase in vehicle-body ride height on poor road surfaces
Enhanced stability in curves achieved through lateral blocking of the suspension
elements on a given axle
[Bosch, 2007]
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10. Roll Control System
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11. Semi-active Suspension System
Magnetorheological (MR) fluid:
MR damper:
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12. Steering System
Rack and pinion:
Howstuffworks.com
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13. Power Steering System
[Reimpell et al., 1995]Behzad Samadi (Amirkabir University) Industrial Control 13 / 86

14. Power Steering System
Power rack:
Howstuffworks.com
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15. Power Steering System
Rotary vane pump:
Howstuffworks.com
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16. Power Steering System
Electrohydraulic:
[Reimpell et al., 1995]
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17. Power Steering System
Electrohydraulic:
[Bosch, 2007]
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18. Electric Power Steering System
delphi.com
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19. Electric Power Steering System
delphi.com
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20. Steer by Wire
delphi.com
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21. Four Wheel Steering
delphi.com
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22. Brake System
cartechservice.com
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23. Vacuum Booster and Master Cylinder Assembly
[Limpert, 1992]
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24. Master Cylinder
Howstuffworks.com
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25. Vacuum Booster and Master Cylinder Assembly
carbibles.com
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26. Dual Hydraulic Circuit
carbibles.com
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27. Hydraulic Leverage
Howstuffworks.com
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28. Simple Brake System
Howstuffworks.com
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29. Brake System
Main factors affecting the overall gain:
Pedal conversion
Boost factor
Diaphragm surface area
Vacuum pressure
Surface area of master cylinder
[Bosch, 2007]
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30. Disk Brakes
carbibles.com
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31. Drum Brakes - Single Leading Edge
carbibles.com
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32. Drum Brakes - Double Leading Edge
carbibles.com
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33. Diagonally Split Circuit
conti-online.com
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34. Proportioning Valve
Load-sensitive brake force reducing valve:
The cut-in pressure is altered to correspond to the vehicle’s load by
means of a mechanical device which transmits the relative movement
between axle and vehicle body to the step-bore piston in the valve.
The force acting on the step-bore piston during braking is again
modified by the dynamic axle load transfer and thus influences the
braking force on the rear axle.
This guarantees maximum deceleration while at the same time largely
preventing locking of the rear axle and the resulting danger of
skidding.
conti-online.com
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35. Proportioning Valve
centricparts.com
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36. Air Brake System
Why air brakes?
Air brake systems are more tolerant to small leaks. The
smallest leak in a hydraulic system could result in brake
failure. An air brake system includes a compressor to
generate more compressed air as needed.
icbc.com
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37. Air Brake System
icbc.comBehzad Samadi (Amirkabir University) Industrial Control 37 / 86

38. Air Brake System
icbc.comBehzad Samadi (Amirkabir University) Industrial Control 38 / 86

39. Air Brake System
icbc.com
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40. Air Brake System
icbc.com
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41. Air Brake System
icbc.com
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42. Air Brake System
icbc.com
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43. Air Brake System
icbc.com
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44. Air Brake System
icbc.com
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45. Air Brake System
icbc.com
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46. Air Brake System
icbc.com
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47. Air Brake System
icbc.com
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48. Air Brake System
icbc.com
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49. Air Brake System
icbc.com
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50. Air Brake System
icbc.com
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51. Air Brake System
icbc.com
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52. Air Brake System
icbc.com
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53. Air Brake System
The compressor will continue to pump air, but all of its output will
take the path of least resistance and be vented at the line rupture.
icbc.com
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54. Air Brake System
icbc.com
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55. Air Brake System
icbc.com
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56. Air Brake System
icbc.com
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57. Air Brake System
icbc.com
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58. Air Brake System
icbc.com
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59. Air Brake System
icbc.com
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60. Air Brake System
icbc.com
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61. Air Brake System
icbc.com
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62. Air Brake System
icbc.com
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63. Air Brake System
icbc.com
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64. Air Brake System
icbc.com
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65. Air Brake System
icbc.com
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66. Air Brake System
icbc.com
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67. Air Brake System
Once the supply line is connected to the trailer, there needs to be a
way of directing air pressure to the trailer.
icbc.com
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68. Air Brake System
There are times when it may be benefi cial to apply only the trailer
brakes with out applying the tractor brakes, such as when coupling
the tractor to a trailer.
icbc.com
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69. Air Brake System
icbc.com
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70. Air Brake System
icbc.com
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71. Air Brake System
icbc.com
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72. Air Brake System
icbc.com
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73. Antilock Braking System (ABS)
Reduce stopping
distance
Maintain steerablity
Maintain lateral stability
bosch.de
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74. Antilock Braking System (ABS)
Maximize tire-road adhesion with wheel slip control
[Bosch, 2007]
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75. Antilock Braking System (ABS)
[Bosch, 2007]
Behzad Samadi (Amirkabir University) Industrial Control 75 / 86

76. Antilock Braking System (ABS)
ABS components:
Electronic Control Unit
Hydraulic Modulator
Wheel Speed Sensors
conti-online.com and bosch.de
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77. Antilock Braking System (ABS)
howstuffworks.com
Behzad Samadi (Amirkabir University) Industrial Control 77 / 86

78. Antilock Braking System (ABS)
ABS MK20: Samand, Peugeot, Citroen, VW,...
conti-online.com
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79. Antilock Braking System (ABS)
Bosch ABS5:
Hinten (rear), Vor (front), Richtig (right), Linke (left)
[Bosch, 2007]
Behzad Samadi (Amirkabir University) Industrial Control 79 / 86

80. Antilock Braking System (ABS)
ABS MK20:
Hinten (rear), Vor (front), Richtig (right), Linke (left)
[Bosch, 2007]
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81. Electronic Stability Program (ESP)
Vehicle lateral variables:
Yaw rate
Sideslip angle (β)
[Bosch, 2007]
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82. Electronic Stability Program (ESP)
bosch.de
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83. Electronic Stability Program (ESP)
[Bosch, 2007]
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84. Electronic Stability Program (ESP)
ESP components:
Wheel speed sensors (A)
Steering angle sensor (B)
Combined yaw rate
sensor/lateral
accelerometer (C)
Electronic Control Unit
(ECU) (D)
Hydraulic unit (E)
Motor (F)
Pressure sensor (G)
bosch.de and edmunds.com
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85. Electronic Stability Program (ESP)
[Bosch, 2007]
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86. Brake by Wire
Siemens VDO:
vdo.com
Behzad Samadi (Amirkabir University) Industrial Control 86 / 86

87. Bosch, R., editor (2007).
Bosch Automotive Handbook.
Wiley, 7 edition.
Limpert, R. (1992).
Brake Design and Safety.
Society of Automotive Engineers Inc.
Reimpell, J., Stoll, H., and Betzler, J. W. (1995).
The Automotive Chassis: Engineering Principles.
Arnold.
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