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Advanced Vehicle Control Systems

S. Balachandran Vice President. Advanced Vehicle Control Systems. AGENDA. About WABCO India Commercial vehicle brakes system trend Introduction to ABS & advantages over conventional braking Electronic Braking System (EBS) Full Air Brake Controls with ABS/ESC vs. EBS/ESC

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Advanced Vehicle Control Systems

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  1. S. Balachandran Vice President Advanced Vehicle Control Systems

  2. AGENDA • About WABCO India • Commercial vehicle brakes system trend • Introduction to ABS & advantages over conventional braking • Electronic Braking System (EBS) • Full Air Brake Controls with ABS/ESC vs. EBS/ESC • Electronically controlled air suspension • Modular Door Control Systems – MTS • Tire Pressure Monitoring - TPM • Automatic Manual Transmission – AMT • Driver assistance systems From Brake Controls to Vehicle Dynamic Controls

  3. WABCO INDIA LIMITED Sundaram – Clayton Limited was established in 1962 as a joint venture with Clayton Dewandre UK ( Now WABCO Vehicle Control Systems) The Brakes Division of Sundaram-Clayton Limited has now become a separate company, WABCO-TVS (INDIA) Limited. On 3rd Jun’09 WABCO raised its ownership position to 75% equity investment and balance to public On 2nd Aug 2011, WABCO-TVS (INDIA) LIMITED was renamed as WABCO INDIA LIMITED WABCO INDIA has three manufacturing sites (located at Chennai, Jamshedpur and Mahindra City) … over 40 years of service to the Indian automotive industry

  4. ABOUTWABCO INDIA LIMITED MARKET LEADER in Indian Medium and Heavy Commercial Vehicle industry Sales ofRs. 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

  5. WABCO INDIAJOURNEY • 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 F&S Super platinum Air dryer, Automatic brake adjustment and Load sensing valve Products for Stallion vehicles (Army application) TPM award ACMA award High pressure compressors Deming prize TPM Kick-off Japan Quality Medal A successful journey

  6. HISTORY OF WABCOIN INDIA / ASIA Qingdao (340) Seoul, Pyungtaek (90) Jinan (280) Tokyo, Kawagoe (80) Shanghai (90) Hong Kong (3) Chennai (1,400) Singapore (7) Melbourne (3) 1977 1986 19901996 2001 20052006 2007 2008 2009 > APAC HQ moved to Shanghai QD Factory Official Inauguration Jamshedpur Factory in India WABCO takes majority control JV w/ Sundaram Clayton Ltd, India Technical Licensing in China APAC HQ in Hong Kong Factory in Pyungtaek Korea Mahindra WC Factory in India JV in Jinan, China

  7. CUSTOMER VALUES • WABCO is working on global TECHNOLOGYtrendsrelevant to our customers • We have a clear path to enhance VEHICLE EFFICIENCYand ENVIRONMENTAL SUSTAINABILITYby 20% • Our vision is to improve ADVANCED SAFETYand DRIVER EFFECTIVENESS,and reduce the number of commercial vehicle accidents by 50% by 2020 • We are involved in developing PRODUCTSand FUNCTIONALITIESto better meet these needs

  8. BRINGING VALUE TO CUSTOMERS Increasing mobility Availability of natural resources Growing need for environmental care Growing demand for safety and security Shift of economic power among regions Truck/Bus-Specific Trends Fuel Efficiency Stability control Braking systems control Energy Recovery ABS Suspension control Weight Reduction ADAS

  9. PRODUCTPORTFOLIO Vacuum products 2% Repair kit sales 10% Exports (Inter-company) 12% Exports (Aftermarket) 1% Air Compressors 13% Air Processing 12% Conventional Brake Controls 21% Brake Chambers & Actuators 22% Anti-Lock Braking System (ABS) 7% % 2010-11 Sales 2010-11 sales : Rs 899 Cr

  10. WABCO - TheSupplierofControlSystemsforCommercialVehicles Temperature Control Clutch Servo Air Dryer / APU Complete Air Brake System or ABS / ASR Air Compressor EBS with Stability Control Reservoirs Front Brakes Suspension Controls Central Board Computer Gear Box Controls • Pneumatic • Electronic • with / w/o Shock Absorber Control Retarder Control Rear Brakes

  11. ACC Stability ESC EBS Car –like feel Varying road conditions ABS/ASR Adjusting lining wear Automatic Slack Adjuster Braking Technology Varying load conditions Load Sensing Valve Fail-safe Dual line air brake Increasing vehicle speeds 30-80 kmph Single line air brake 2010 1940 1950 1960 1970 1980 1990 2000 Commercial Vehicles – Braking System Trend Focus on ADAS beyond 2011

  12. Hand brake Typical Dual Brake System layout Spring Brake Acctuator For Hand brake

  13. System Function – Hand brake Able to stop the vehicle by Hand brake when both Service circuits failed.

  14. Benefits of Hand brake system Able to stop the vehicle by Hand brake when both Service circuits failed. During vehicle parking Hand brake ensure the locking of the rear wheels Driver can operate the vehicle when foot brake fail, by operating hand brake as service brake.

  15. Spring Brake Chamber Wind in condition Spring Brake Chamber Wind off condition For parking & emergency braking Ensure the spring brake chambers in wind in condition  

  16. ABS System Reliable ABS Portfolio

  17. ABS Schematic Layout – 4S/4M

  18. ABSADVANTAGE Air Brake with ABS Air Brake • Sub-optimal stopping distances on dry/slippery roads • Wheel locking while panic braking or in slippery road conditions can lead to accidents. • Tyre life reduced due to wheel locking • Experienced driver for driving on extreme road conditions • Improved stopping distances especially in dry/slippery roads • Wheel locking avoided. An important safety Criterion to prevent accidents. • 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

  19. Electronic Braking System - EBS EBS ECU back up valve Axle-modulator ABS solenoid valve Proportional Relay Valve Brake signal transmitter WABCO EBS Components - 4S/4M

  20. The electropneumatic circuit consists of (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 ESC - module (6) (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 4S/4M for 4x2 Vehicles

  21. Why EBS? Advantages of EBS vs. ABS Shorter brake distance Shorter pneumatic pipes Electro pneumatic brake control Higher pressure in brake system Pipe connections are electrically controlled Installation advantages Less pneumatic and electric connectors No additional components if ESC is installed Improved brake pedal feeling Pedal feeling similar to Cars Deceleration control instead of brake pressure control Better diagnosis Self test Fault memory Simplified brake check Cost benefit for the OEM and end user Less lining wear Less system cost Less service cost Functions due to parameter setting New functions w/o additional valves Hill Start Funtion Brake Assist Brake management EBS provides advantages for all customer

  22. Stability Controls – RSC & ESC

  23. Roll Stability Control • Philosophy of RSC is to reduce vehicle speed there by preventing vehicle roll over • RSC controls the lateral acceleration • If the lateral acceleration exceedsa 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

  24. ABS based Roll Stability Control ( RSC ) - Components • RSC • Accelerometer integrated in ABS ECU (or ESC Module) • ATC valve for drive axlebraking • RSC valvefor trailerbraking

  25. Directional Stability Control • Identification of unstable driving conditions : Over steering Under steering directional instability ESC brake application • Reduction of engine torque to slow down vehicle • Selective braking of single wheels to compensate deviation from stable driving conditions How does ESC work at critical vehicle yaw ?

  26. Solenoid Valve for front axle braking Pressure Sensor for driver brakedemand Steering AngleSensor ESC Module ATC valve for drive axlebraking Valvesfor trailerbraking ABS based ESC add. components ESC components black/white controlled For ABS additional valves needed

  27. Solenoid Valve for front axle braking Pressure Sensor for driver brakedemand Steering AngleSensor ESC Module ATC valve for drive axlebraking Valvesfor trailerbraking EBS based ESC add. components ESC components X X X X X black/white controlled Easy ESC extension with EBS

  28. Electronically controlled air suspension ECAS

  29. ECAS - Electronically Controlled Air Suspension - • ECAS consists of • Electronic Control Unit • Remote Control Unit • Height Sensors • Pressure Sensors • Solenoid Valve Blocks • 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

  30. Air Suspension (ECAS) electronically controlled solenoid valve height sensor ECU Supply Nominal level bellow ECU

  31. MODULATOR DOOR CONTROL SYSTEMS (MTS)

  32. MODULATOR DOOR CONTROL SYSTEMS (MTS) • Purpose • The function of MTS is to actuate and monitor with identical devices up to five doors of different construction of inward pivot / outward pivot doors and pneumatic / electrically driven doors • MTS components • Electronics (for pneumatic or electrical doors) • Sensors for swinging doors • Door control valve • Door cylinder • Emergency valve with switch • Pressure switch

  33. FEATURES OF MTS • 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 • Further increase of safety by connection of additional equipment (sensitive edges, light barriers…) easily possible • One solenoid-valve to control opening and closing of the door including damping and the safety-function “powerless”. • Door system connected to the vehicle at the first door only optional by: • conventional wiring or • CAN - data bus (according ISO 11898) • Reduced wiring due to internal data bus between the door ECUs. It is possible to link up to 5 doors

  34. Tire pressure Monitoring ( TPM) • The function of TPM is to monitor the tyre pressure • 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

  35. Components in the TPM system Wheel Modules Data on Integrated Multi-function Display SAFETY - Correct Tire Pressures ECONOMY - Less fuel consumption Electronic Control Unit (ECU) Simple System Structure

  36. Automated Manual Transmission (AMT)

  37. TRANSMISSION SYSTEMS Different types of Transmission systems 37

  38. WABCO OptiDrive system overview Value to Customer • OptiDriveTM BENEFITS • Easily adaptable to existing trucks and transmissions • Lower development cost • Shorter time to market • 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 Description WABCO OptiDrive'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 Standardization and Modularity to shorten time to market 38

  39. WABCO AMT system overview Passive Speed Sensor XY-Actuator Shift Lever Unit incl. TCU Active Speed Sensor Pneumatic Clutch Actuator SYSTEM CONTENT 39

  40. WABCO AMT system overview SLU XY-Actuator Inductive Speed Sensor Active Speed Sensor PCA SYSTEM CONTENT 40

  41. EVOLUTION OF ACTIVE SAFETY ABS control ESC stabilize anticipate ADAS Demo on ADAS From controlling –to anticipating

  42. WABCO Driver Assistance Systems Technology and Products • Headliner Cluster • Camera • Lane Departure Warning & Lane Keeping Support • support of long range sensor Lane Departure Warning Side Sensors 24 GHz Radar orultrasonic • Blind spot detection Long Range 77 GHz Radar or Infrared Laser Sensor • ACC • Collision Warning • Collision Mitigation • Autonomous Emergency Braking

  43. BENEFITS WORKING WITH WABCO • 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

  44. PASSION

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