8

Contents

Contents
Basicprinciplesofphysics
Quantities and units
SI units
Legal units

Further units

Natural constants
Basic equations used in mechanics
Rectilinear and rotary motion
Transmission of force

Friction
Vibrations and oscillations

Terms
Equations

Vibration reduction
Modal analysis

Acoustics
General terminology
Measured quantities for noise
emissions

Measured quantities for noise
immissions (noise protection)
Perceived sound levels

Hydrostatics

Density and pressure

Buoyancy

Fluid mechanics

Basic principles

Basic equations of
fluid mechanics

Discharge from a pressure vessel
Resistance of bodies submerged
in a fluid flow

Thermodynamics

Enthalpy (heat content)

Laws of thermodynamics
Changes of state for gases

Electrical engineering
Electromagnetic fields

Electric field

Direct current and direct voltage
Time-dependent current

Magnetic field

Magnetic field and electric current
Wave propagation
Electric effects in metallic
conductors

22
22
24
30
33
34
34
34
37
40
40
42
43
44
46
46
48
49
50
52
52
52
53
53
54
54
55
56
56
58
59
60
60
60
62
65
66
70
74
77

Electronics
80
Basic principles of semiconductor
technology
80
Discrete semiconductor devices 83
Monolithic integrated circuits
95
Microprocessors in the ECU
96
Electrochemistry

99
Electrolytic conduction and
electrolysis

99
Applications

100
Mathematicsandmethods
Mathematics

Number systems
Functions

Equations in the plane triangle
Complex numbers
Mathematical signs and symbols
Greek alphabet

Finite-element method
Applications

FEM examples

Control engineering
Terms and definitions

Control-engineering transfer
elements
Designing a control task
Adaptive controllers
Materials
Chemical elements

Designations

Periodic table of elements

Substances

Substance terminology

Substance parameters



Properties of solids
Properties of liquids
Properties of water vapor
Properties of gases
Materials
Material groups

EN metallurgy standards

Properties of metallic materials
Casting and steel materials

Nonferrous metals, heavy metals
Nonferrous metals, light alloys
Sintered metals

Magnetic materials
Solders and filler materials

Electrical properties of materials

104
104
104
106
107
107
107
108
108
111
116
116
117
118
120
122
122
125
126
126
126
128
132
133
134
135
135
139
144
144
149
150
151
154
163
166

Contents
Properties of non-metallic materials
Insulating materials
Ceramic materials
Laminates

Plastic molding compounds

Plastic codes with chemical
names and trade names

Automotive paints
Heat treatment of metallic materials
Hardness

Heat-treatment processes
Thermochemical treatment
Corrosion and corrosion protection
Corrosion processes
Types of corrosion
Corrosion testing
Corrosion protection
Deposits and coatings
Deposits

Diffusion coatings
Conversion coatings
Operatingfluids
Lubricants
Terms and definitions
Engine oils

Transmission lubricants
Lubricating oils

Lubricating greases
Fuels

Characteristics

Gasolines

Diesel fuels

Alternative fuels

Properties of liquid fuels
and hydrocarbons
Properties of gaseous fuels
and hydrocarbons
Brake fluids

Coolants

167
167
168
170
171
178
180
182
182
186
191
194
194
196
197
200
203
203
207
207

208
208
213
216
217
218
220
220
221
224
228
234
235
236
238

Machineparts
Springs
Basic principles

Metal springs

Sliding bearings

Features
Hydrodynamic sliding bearings
Sintered metal sliding bearings
Sliding-contact bearings
Roller bearings

Applications

General principles
Selection of roller bearings
Calculation of load capacity
Gears and tooth systems
Overview of gears
Starter-tooth designs
American gear standards
Calculation of load-bearing
capacity
Gear materials

Belt drives
Friction belt drives
Positive belt drives
Chain drives

Overview

Chain designs

Sprockets

Chain-tensioning and
chain-guide elements

9
240
240
241
246
246
246
251
252
255
255
255
256
258
260
260
264
265
266
269
270
270
274
278
278
278
280

281

Joiningandbondingtechniques
Detachable connections

Positive or form-closed joints

Frictional joints
Threaded fasteners
Snap-on connections on
plastic components
Permanent joints

Welding
Soldering

Adhesive technologies

Riveting
Penetration clinching

282
282
286
292
302
304
304
308
309
310
312

10

Contents

Vehiclephysics
Basic terms of automotive
engineering
314
Basic terms of vehicle handling 314
Motor-vehicle dynamics
324
Dynamics of linear motion
324
Adhesion to road surface
329
Accelerating and braking
331
Actions: Reaction, braking
and stopping
331
Passing (overtaking)
333
Fuel consumption
335
Dynamics of lateral motion
338
Special operating dynamics for
commercial vehicles
344
Operating-dynamics test
procedures as per ISO
348
Aerodynamics

354
Aerodynamic parameters
354
Vehicle wind tunnels
355
Vehicle acoustics

360
Exterior noise measurements and
statutory limits for motor vehicles 360
Engineering acoustics
361
Sound design

362
Internal-combustionengines
Internal-combustion engines
366
Thermal engines

366
Cycles
368
Real cycles

373
Design and operating principle 442
Mixture formation, combustion,
emissions
376
Gasoline engine

376
Diesel engine

386
Mixed forms and alternative
operating strategies
391
Charge cycle and supercharging 392
Gas exchange

392
Variable valve timing
395
Supercharging processes
399
Exhaust-gas recirculation
403
Reciprocating-piston engine
404
Components

404
Reciprocating-piston engine types 418
Crankshaft-assembly design
419
Tribology and friction
427
Empirical values and
data for calculation
431
Wankel rotary engine
442
Design and operating principle 442
Properties of a rotary engine 445

Engine cooling

Air cooling

Water cooling

Intercooling (charge-air cooling)
Oil and fuel cooling
Cooling-module technology

Cooling-system technology

Intelligent thermal management
Exhaust-gas cooling
Engine lubrication

Force-feed lubrication system
Components

Air filtration
Air impurities

Air filters (air cleaners)

Turbochargers and superchargers
Superchargers
(mechanically driven)

Pressure-wave superchargers
Exhaust-gas turbochargers

Complex supercharging systems
Exhaust-gas system
Design and purpose
Exhaust manifold
Catalytic converter
Particulate filter

Mufflers
Connecting elements

Acoustic tuning devices

Commercial-vehicle exhaust-gas
systems
Emission-controland
diagnosislegislation
Emission-control legislation
Overview

CARB legislation
(passenger cars/
light commercial vehicles)
EPA legislation
(passenger cars/
light commercial vehicles)
EU legislation
(passenger cars/
light commercial vehicles)
Japanese legislation
(passenger cars/
light commercial vehicles)
US legislation
(heavy commercial vehicles)
EU legislation
(heavy commercial vehicles)
Japanese legislation
(heavy commercial vehicles)

446
446
446
450
451
452
453
453
455
456
456
456
459
459
459
462
462
465
467
475
480
480
481
482
483
483
485
486
487

488
488
490
493
495
498
499
500
502

Contents
S test cycles
U
(passenger cars/
light commercial vehicles)

European test cycle
(passenger cars/
light commercial vehicles)

Japanese test cycle
(passenger cars/
light commercial vehicles)
Test cycles for heavy
commercial vehicles
Exhaust-gas measuring techniques
Exhaust-gas test on chassis
dynamometers

Exhaust-gas measuring devices
Diesel smoke-emission test

Evaporative-emissions test

Diagnostics

Introduction

Monitoring in driving mode

On-Board Diagnostics (OBD)
OBD functions

OBD requirements for
heavy commercial vehicles

Workshop diagnostics

ECU diagnostics and
Service Information System

Managementfor
spark-ignitionengines
Management for
spark-ignition engines
Description of the engine
management system
System overview
Versions of Motronic
Cylinder charge

Component parts
Controlling the air charge
Fuel supply
Fuel supply and delivery with
manifold injection
Fuel supply and delivery with
gasoline direct injection
Evaporative-emissions
control system

Fuel filter
Electric fuel pump
High-pressure pumps for
gasoline direct injection
Fuel rail
Fuel-pressure regulator
Fuel-pressure attenuator

503
505
506
507
510
510
513
516
518
520
520
520
522
526
529
531
533

534
534
535
539
542
542
543
546
546
547
549
550
551
553
557
558
558

Mixture formation

Basic principles

Mixture-formation systems
Intake-manifold injection
Gasoline direct injection
Mixture-formation components
Ignition

Basic principles

Moment of ignition
Ignition systems

Ignition coil

Spark plug

Catalytic exhaust-gas treatment
Catalytic converter
control
Alternativegasoline-engine
operation
LPG operation

Applications
Design
LPG systems

Engines fueled by natural gas
Applications

Design
Components

Managementfordieselengines
Management for diesel engines
Description of the engine
management system
Electronic Diesel Control
Fuel supply system
(low-pressure stage)
Fuel supply and delivery
Fuel filtering

Common-rail injection system
System overview
Injectors
High-pressure pumps
Rail

Time-controlled single-cylinder
pump system

Unit-injector system for
passenger cars

Unit-injector system for
commercial vehicles
Unit-pump system for
commercial vehicles
Components

11
559
559
560
561
563
565
570
570
571
575
577
581
586
586
590

592
592
592
594
596
596
596
599
602
602
603
606
606
610
612
612
616
621
625
626
626
627
628
629

12

Contents

Diesel distributor injection pumps

Axial-piston distributor pumps
Radial-piston distributor pumps
Fuel-injection system
Start-assist systems
Preheating systems
Exhaust-gas treatment
Catalytic converters
Particulate filter

Alternativedrives
Hybrid drives

Features
Functions

Functional classification
Drive configurations
Control of hybrid vehicles
Regenerative braking system
Fuel cells for the vehicle drive
Functioning principle
Functioning principle of the
fuel-cell system

Functioning principle of the
drivetrain

630
630
633
635
636
636
639
639
642

646
646
647
648
649
654
657
658
658

Drivetrain
Drivetrain
Overview

Drivetrain elements
Power take-up elements

Multi-speed gearbox
Manually shifted transmissions
Automatic transmissions

Continuously variable
transmissions

Final-drive units

All-wheel drive and transfer case
Chassissystems
Chassis systems

Basic principles

Suspension

Basic principles

Types of spring

Suspension systems
Shock absorbers and
vibration absorbers

Shock absorbers

Vibration absorbers
Wheel suspensions
Basic principles

Kinematics and elastokinematics
Basic categories of wheel
suspensions

660
662
664
664
666
667
669
670
672
678
679
682
684
684
694
694
697
702
706
706
713
714
714
714
716

Wheels

Passenger-car wheels

Commercial-vehicle wheels

Tires

Tire categories

Tire design

Tire designation

Tire applications

Tire traction

Tire-pressure monitoring system
Steering
Definitions for motor-vehicle
steering systems
Steering-system requirements
Types of steering box

Power-assisted steering systems
for passenger cars
Power-assisted steering systems
for commercial vehicles

Brake systems

Definitions and principles

Legal regulations
Structure and organization of
brake systems

Brake systems for passenger cars
Service brake system

Electromechanical parking
brake system

Electrohydraulic brake
Purpose and function

Design
Operating principle
Brake systems for commercial
vehicles
System overview
Components of commercial-
vehicle brake systems

Electronically controlled
brake system

Continuous-operation brake
systems
Wheel brakes

Disk brakes

Drum brakes

Chassiscontrolandactivesafety
Antilock braking system

Function and requirements

Operating principle
ABS system variants
ABS versions

Antilock braking system for
commercial vehicles

722
722
728
732
732
732
734
737
738
746
748
748
748
750
751
757
760
760
765
774
776
776
778
780
780
782
782
784
784
787
794
798
802
802
804
806
806
806
810
812
814

Contents
Traction control system
Function and requirements

TCS control loops
Driving-dynamics control system
Function
Requirements

Operating principle
Typical driving maneuver

Structure of the overall system
System components
Special Electronic Stability
Program for commercial vehicles
Supplementary functions
(automatic brake-system
operations)

Integrated driving-dynamics
control systems

Overview

Functions

System architecture
Vehiclebodies
Road-vehicle systematics

Classification

Vehicle bodies, passenger cars
Main dimensions
Body design

Aerodynamics

Aeroacoustics

Body

Safety
Vehicle bodies,
commercial vehicles
Classification

Light utility vans

Medium- and heavy-duty
trucks and tractor units

Buses
Passive safety in trucks

Lighting equipment

Functions

Regulations and equipment

Light sources

Main-light functions
Main-light functions for Europe
Main-light functions for the USA
Definitions and terms

Technical design variations of
headlamps

Installation and regulations
for signal lamps

Technical design variations
for lamps
Headlight leveling control

Headlamp adjustment

818
818
818
822
822
823
824
824
825
834
837
842
846
846
846
849

Automotive windshield and

window glass

The material properties of glass
Automotive glazing
Functional design glazing

Windshield, rear-window and
headlamp cleaning systems

Windshield wiper systems

Rear-window wiper systems

Windshield and rear-window
washer systems

Headlamp washer systems
Passivesafety
Occupant-protection systems
Seat belts and seat-belt
pretensioners
Airbag
Rollover protection systems
Components

Further developments

868
868
869

Automotiveelectrics
Vehicle electrical systems

Electrical power supply

Electrical-system structures

Electrical-system parameters
Electrical energy management
Starter batteries

Requirements

Battery design

Charging and discharging

Battery characteristics

Battery types

Using the battery
Electrical machines
Systematics of rotating electrical
machines

Direct-current machines

Asynchronous machine

Synchronous machine

Three-phase current system

899
903
907
908

920
920
926
927
927

928
931
934
934
936

Vehiclesecuritysystems
Locking systems

Function
Structure (side door as example)
Double-locking functions

Technology

Theft-deterrent systems

Regulations

System design

888

914
914
915
916

928

852
853
854
854
856
857
859
860
864

869
872
874
876
876
877
878
879
882
885
887

13

938
938
939
941
945
946
946
946
948
948
953
955
957
962
962
963
964
965
966
968
970
970
970
975
977
982

14

Contents

Alternators

986
Electric power generation
986
Operating conditions
991
Efficiency

992
Types of claw-pole alternator 993
Starting systems

996
Starter
996
Triggering the starter
1000
Actuators
1002
Overview

1002
Electrodynamic and
electromagnetic converters
1002
Piezo actuators

1005
Fluid-mechanical actuators
1007
Wiring harnesses and
plug-in connections
1008
Wiring harnesses
1008
Plug-in connections
1010
Electromagnetic compatibility (EMC)
and interference suppression
1014
Requirements

1014
Sources of interference
1014
Potentially susceptible devices 1017
Interference coupling
1018
Electrostatic discharge
1019
Measuring technology
1020
Regulations and standards
1021
Symbols and circuit diagrams
1022
Circuit symbols

1022
Circuit diagrams

1029
Terminal designations
1041
Automotiveelectronics
Automotive software engineering 1044
Motivation

1044
Design of software
in motor vehicles
1045
Important standards for software
in motor vehicles
1045
The development process
1048
Quality assurance in
software development
1052
Sequences of software
development in motor vehicles 1052
Modeling and simulation
of software functions
1054
Design and implementation
of software functions
1057
Integration and testing of
software and ECUs
1058
Calibration of software functions 1060
Outlook
1061

Automotive networking
1064
Bus systems

1064
Technical principles
1065
Buses in motor vehicles
1071
CAN
1071
FlexRay
1075
LIN

1079
Ethernet, IP

1082
PSI5

1083
MOST bus

1085
Architecture of electronic systems 1090
Overview

1090
Architecture methods
of electronic systems
1093
Sensors
1100
Basic principles

1100

1105
Position sensors
Speed and rpm sensors
1121
Acceleration and
vibration sensors
1126
Pressure sensors
1130
Flowmeters

1134
Gas sensors, concentration
sensors
1137
Temperature sensors
1140
Force and torque sensors
1143
Optoelectronic sensors
1150
Sensors for driver-assistance
systems
1154
Mechatronics

1164
Mechatronic systems and
components

1164
Development methodology
1165
Outlook
1168
Comfortandconvenience
Passenger-compartment
climate control

1170
Climate-control requirements 1170
A/C-unit design and operating
principle
1170
Climate-control systems
1173
Climate control for hybrid and
electric vehicles

1174
Auxiliary heater systems
1176
Comfort and convenience systems
in the door and roof areas
1180
Power-window systems
1180
Roof systems

1181
Comfort and convenience functions
in the passenger compartment
1182
Electrical seat adjustment
1182

Contents
Userinterfaces,telematicsand
multimedia
Display and control

1184
Interaction channels
1184
Instrumentation

1185
Radio and TV reception in
motor vehicles

1192
Wireless signal transmission
1192
Radio tuners

1195
Traffic telematics

1199
EU recording equipment
1200
Legal regulations
1200
Design variations
1200
Driver-assistancesystems
Driver-assistance systems
Parking systems

Parking aid with ultrasonic
sensors
Parking aid assistant
Vehicle navigation

Navigation systems
Functions of navigation
Digital map

Adaptive Cruise Control
Function
Design and function
Control algorithms
Area of application and further
development

Predictive emergency-braking
systems
Video-based driver-assistance
systems
Lane departure warning
and lane keeping support
Road-sign recognition
Night-vision systems
Applications

Far-infrared systems
Near-infrared systems
Appendices
Technical terms
Abbreviations

1202
1206
1206
1209
1210
1210
1210
1213
1214
1214
1214
1216
1217
1220
1222
1222
1223
1224
1224
1224
1225
1228
1258

15

Revised &
Updated

established 1950
Automotive Reference

BentleyPublishers
.com

Bosch Automotive Handbook

8th Edition

Price: $49.95
Bentley Stock No: H016
Publication Date: 2011.jun.1
ISBN: 978-0-8376-1686-5
Vinyl cover, 4 1/2 in. x 7 in.
Case quantity: 1
1256 pages
Over 1000 technical photos and illustrations

All about automotive engineering in a pocketbook

Robert Bosch GmbH published the first incarnation of the Automotive
Handbook in 1932. The original preface to this edition introduced the
book as follows: These Technical Tables are an attempt to give users
of our products a small, handy collection of the interesting formulas,
values, and figures - drawn mainly from automotive technology -that
are otherwise scattered across various magazines. Three years later,
the Technical Tables were renamed the Automotive Handbook.

Contents - central themes

Basic principles: physics, materials, machine parts, joining and
bonding techniques
Vehicle physics: basic terms of automotive engineering,
motor-vehicle dynamics, vehicle acoustics
Internal-combustion engines: gasoline engine, diesel engine,
turbochargers and superchargers, exhaust-gas system
Emission-control and diagnosis legislation
Management for spark-ignition engines: manifold injection,
gasoline direct injection, alternative gasoline-engine operation
Management for diesel engines: common rail
Alternative drives: hybrid drive, fuel cell
Chassis systems: suspension, wheel suspensions, steering, brake
systems
Active safety: antilock braking system, driving-dynamics control
system
Lighting equipment
Automotive electrics: vehicle electrical systems, starter batteries,
electrical machines, alternators
Automotive electronics: automotive networking, buses, architecture
of electronic systems, sensors
Driver-assistance systems: parking systems, vehicle navigation,
Adaptive Cruise Control, night-vision systems

Sample page spreads

from the Bosch
Automotive Handbook

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA

Tel: 617-547-4170 Toll Free: 800-423-4595 Fax: 617-876-9235
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