CONTENT 1. Introduction 2. What is ABC? 3. History and Development 4. System Overview 5. System Design 6. Hydraulic Components 7. Electrical Components 8. System Functions
By John Kungu Kihara
CONTENT 9. Advantages and Disadvantages 10. Safety and Precaution
By John Kungu Kihara
1. INTRODUCTION I. What is Suspension? II. How a shock absorber works (Hydraulic Damper) III. Vehicle Body Movements IV. Active and Passive Suspension
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I. What is Suspension? • Suspension is the system of springs, shock absorbers and linkages that connect a vehicle to its wheels and allows relative motion between the two. • This system must support road handling and ride quality; which are odds with each other
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II. How a Shock Absorber Works • A shock absorber controls the spring oscillation by converting kinetic energy to heat energy thus reduce the springs’ oscillation. • Oil contained in one side of the cylinder is passed through constricted pores and valves to the other cylinder via a piston. • They work in two cycles; Rebound or Compression Bump or Extension
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III. Vehicle Body Movements • As a vehicle moves, its body experiences different types movements from different axis • These body movements occur about the following axis; ‒ Longitudinal Axis – Motive force, Braking force and Friction force ‒ Transversal Axis – Centrifugal force, Wind force and Lateral force ‒ Vertical Axis – Wheel load acting of road surface
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Body Roll • This is the tipping movement about the longitudinal axis either to the left or right. • When a vehicle is taking a turn, the load tends to be transferred to the outside of a turn.
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Yawing • This is the rotational motion of the vehicle about its vertical axis .
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Diving and Squatting • Diving is a movement experienced when the brakes are applied and weight is transferred from the rear of the vehicle to the front causing the front to pitch forward. • Whenever accelerated, the vehicle has a tendency to pitch up and the rear end is pushed down. This is known as squatting. • This happens because of change of inertia.
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Bouncing • Bouncing is the up and down movement of the vehicle on the vertical axis.
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IV. Active and Passive Suspension ACTIVE SUSPENSION • This is a type of suspension that controls the vertical movement of the wheels relative to the vehicle body, with aid of a system.
PASSIVE SUSPENSION • This is a type of suspension system where the vertical movement of the wheels is determined by the road surface. • This is the conventional suspension system.
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By John Kungu Kihara 2. WHAT IS ABC? I. Definition II. Functions
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I. Definition • Active Body Control or ABC is a name used to describe hydraulic fully active suspension. • ABC allows control of the vehicle body motions and therefore virtually eliminates vehicle body movements in many driving situations including cornering, accelerating and braking.
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II. Functions • The primary functions of a suspension system include; ‒ Maximizing the contact between the tires and road surface. ‒ Providing good steering stability and handling ‒ Evenly support the weight of the vehicle.
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• The ABC has the following additional functions; ‒ Level adjustment enables manual and speed-dependent automatic raising/lowering of the vehicle ‒ Ensures vehicle level remains constant but independently adjusting both the front and rear axles ‒ A load comparison function enables a system adjustment to adapt to the handling of the load
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By John Kungu Kihara 3. HISTORY AND DEVELOPMENT I. When it all began II. Types and names given to these systems
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I. When it all began • With Mercedes Benz launching the 1963 600 with the air suspension and the 1974 450SEL 6.9 with the hydropneumatic suspension, Mercedes Benz continued experimenting for the ultimate suspension with good handling and ride comfort. • In 1996, Daimler Benz unveiled the Mercedes Benz F 200 coupe concept at the Paris Motor Show. • This was the first car to have the ABC but since it was a concept car, they later released a production version at the Geneva Motor Show in 1999
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• The Mercedes Benz CL-Class C215 was the first production car to have the Active Body Control.
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II. Types and names given to these systems • 1955 Citroën DS had hydropneumatic suspension designed by Paul Magès - the first car with height adjustable suspension and self- levelling suspension. • 1962 Mercedes-Benz W112 platform featured an air suspension on the 300SE model and the 1963 Mercedes-Benz 600 model • 1975 Mercedes-Benz 450SEL 6.9 with fully hydropneumatic suspension similar in technology, but not geometry, to Citroën design • 1979 Mercedes-Benz W126 then new S class had even more sophisticated height adjustable suspension and self-levelling suspension. By John Kungu Kihara • 1984 Mercedes-Benz W124 selected models of E class had this technology (rear only hydraulic suspension) height adjustable suspension and self-levelling suspension • 1999 Mercedes-Benz CL-Class C215 introduces Active Body Control. • 2007, the Mercedes-Benz F700 concept introduced the PRE- SCAN suspension, an early prototype road scanning suspension, using lidar sensors, based on Active Body Control
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• 2013 the new Mercedes-Benz S-Class (W222) introduced the series production version of PRE-SCAN, but with a stereo camera instead of laser projectors and called it Magic Body Control • 2014 the new C217 S-Class Coupe introduced an update to Magic Body Control, called Active Curve Tilting
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4. SYSTEM OVERVIEW • Mercedes Benz are notorious for their smooth ride quality. Bumps and potholes just don’t bother passengers in Mercedes vehicles like they do in other cars. • Since suspension is a matter of compromise, best ride quality led to sloppy handling in corners and agile handling led to poor ride quality. • So, how does Mercedes Benz do it?
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SYSTEM OVERVIEW… • A computer detects body movement and controls the action of the active element with hydraulic servomechanism • The hydraulic pressure to the servo is supplied by a high pressure radial piston pump • More than 13 sensors monitor body movements and vehicle level and supply the ABC Control unit with new data every 10 milliseconds • The struts have hydraulic cylinders that react to bumps making the assembly to be shorter or longer. This causes the tire and wheel to move without the body moving as much. By John Kungu Kihara By John Kungu Kihara 5. SYSTEM DESIGN • For vehicles with the Active Body Control, each wheel is mounted to a suspension strut consisting of a vibration damper and a helical spring. • The plunger is a dynamically adjustable hydraulic cylinder which is able to generate forces which counteract wheel or body movements. • To do this, the plunger moves the base of the helical spring and changes the tension. • The Active Body Control is fully a hydraulic system that has electrical system incorporated to aid functionality of the system. • Therefore, the components are divided into hydraulic and electrical
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By John Kungu Kihara 6. HYDRAULIC COMPONENTS I. Hydraulic Pump II. Strut III. Oil Reservoir IV. Oil Cooler V. Pressure Reservoirs VI. Valve Units VII.Pressure Supply Valve Unit VIII.Pulsation Damper By John Kungu Kihara HYDRAULIC COMPONENTS… IX. Return Flow pressure reservoir X. Bleed Screws
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I. Hydraulic Pump • The hydraulic pump is a radial piston type pump used to generate hydraulic pressure in the system. • It is directly driven by the engine via a single belt along with the power steering pump. • The hydraulic fluid is suctioned from the oil reservoir then pumped to the circuit at a pressure of 180 to 200 bars. • The pump’s maximum delivery rate is approximately 11 litres per minute.
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• Its located on the left side of the engine close to the power steering pump
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Suction Restrictor Valve • This is a hydraulic component installed in the hydraulic pump and is actuated by a PWM signal from the ABC Control Unit. • Its main function is to regulate the intake quantity of the hydraulic oil to be pumped via a bore thus regulating the pressure • This valve is closed when de-energized.
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II. Strut • A strut is simply an assembly of a hydraulic damper and coil spring. The coil spring supports the weight of the vehicle and absorbs large bumps while the main function of the damper is to dampen vibration. • However, the struts found in vehicles with ABC are slightly modified and have a hydraulic cylinder at the top along with hydraulic oil connection. • The hydraulic cylinder can have different volumes of oil to bring about variance in the length of the suspension strut
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Strut… • The ABC strut carries out suspension, damping, ride height regulation and ride height adjustment.
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III. Oil Reservoir • The hydraulic oil reservoir is mounted in the engine compartment on the inner wing and is filled with special oil. • A dip stick is included for checking the oil level and the reservoir also houses a return-flow filter with a pressure bypass valve.
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IV. Oil Cooler • The hydraulic oil cooler is located in front of the right air conditioner condenser. • Its located upstream to the oil reservoir in the return line circuit and prevents the oil from being too hot • The hydraulic oil is however suitable for extreme conditions and situations.
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V. Pressure Reservoir • The vehicle has one pressure reservoir on each axle. The front pressure reservoir is located under the car towards the front and the rear pressure reservoir is located at the rear. • They contain a gas chamber separated from the oil by a diaphragm. The reservoirs absorb pressure pulses and provide a small store of hydraulic pressure for after the engine is switched off.
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VI. Valve Units • The front valve unit is located in the front left wheelhouse and the rear valve unit is located in the left vehicle floor in front of the rear axle with the fuel package. • In operation, both work identically and control the flow of oil to and from the suspension strut hydraulic cylinders. • They are both visible from under the vehicle
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Valve Units… • Each valve unit assembly contains four solenoid-operated valves. Two per suspension strut. • All valves can be operated separately and when without voltage, they are closed. • They also have an integrated pressure limiting valve.
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Operation of Valve Units Blocking Valve • One valve is a straight forward blocking valve. Its either open or closed • The blocking valve is closed when de-energized. It additionally prevents the struts from leaking incase there is a leakage or pressure loss in the system
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Operation of Valve Units 3-Position Type • The other valve is a three-position type valve. The valve is actuated using PWM signals
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Operation of 3- Position Valve When the valve is moved to this position, it allows oil under pressure to flow from the supply line into the suspension strut hydraulic cylinder.
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Operation of 3- Position Valve Moving it to this position, it allows oil to flow out of the hydraulic cylinder and back into the return line
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Operation of 3- Position Valve In this position, the valve closed off the flow of oil to the hydraulic cylinder in the strut. When de-energized, all valves are closed and oil can neither enter nor leave the cylinders.
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VII. Pressure Supply Valve Unit • The pressure supply valve unit is located on the right of the vehicle floor behind the front axle carrier. • It regulates the hydraulic pressure in the system and has an integral emergency relief valve. • It also has a pressure sensor to monitor the hydraulic pressure.
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VIII. Pulsation Damper • The pulsation damper is located on the end of the valve unit and it reduces pressure pulses in the hydraulic circuit
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IX. Return Flow Pressure Reservoir • The return flow pressure reservoir is similar to the pulsation damper and the pressure reservoirs. • It contains a gas chamber and diaphragm and its task is to reduce pressure peaks in the hydraulic return line. • Its mounted close to the rear axle valve unit.
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X. Bleed Screw • The two screws in the front axle line and the two screws in the rear axle allow hydraulic pressure to be released from the system for repair purposes. • They also provide a means to bleed the system of any air if necessary.
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7. ELECTRICAL COMPONENTS • If you imagine the hydraulic components as muscles, then the electrical components are like the nerves. • They monitor the vehicle suspension movements and decide on the counteractive action to take. • They include: I. ABC Control Unit II. Pressure sensor III. Valve unit with Pressure sensor IV. Level sensor By John Kungu Kihara ELECTRICAL COMPONENTS… V. Lateral and Longitudinal acceleration sensor VI. Body acceleration sensor VII. Level adjustment button VIII. Comfort/Sport Switch IX. Spring travel sensor X. Instrument cluster XI. Steering angle sensor XII. Wheel speed sensor XIII. Oil Temperature Sensor XIV. Brake light switch By John Kungu Kihara I. ABC Control Unit • The ABC control unit is the brain of the system. It collects data from the vehicle sensors and driver’s switches. It then generates output commands form the actuators. • The control unit receives some input signals directly and others like those from the drivers switches are received via the CAN. • It is located between the steering column and left side of the instrument cluster
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INPUT SIGNALS • Calculation of body vertical acceleration - Body acceleration sensors signal • Calculation of vehicle speed - Wheel rpm signal - Rpm status signal • Calculation of valve control -Front left axle, front right axle level signals -Rear left and right axle level signal -Front left and right axle suspension strut movement signal -Rear left and right axle suspension strut movement signal By John Kungu Kihara • Calculation of longitudinal and lateral acceleration - Longitudinal acceleration sensor signal - Lateral acceleration sensor signal • Calculation of pitch motion - Longitudinal acceleration sensor signal • Calculation of rolling motion - Lateral acceleration sensor signal
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• Calculation of ABC suction restrictor valve actuation - System pressure signal • Calculation of vehicle level - Wheel-wise level sensors signal • Information signals (operation) - Comfort and Sport switch signal - Level regulation switch signal - Door contact, luggage compartment switch signal, remote control
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II. Pressure Sensor • The pressure sensor is located in the pressure supply valve unit. It informs the ABC control unit on the hydraulic system’s operation pressure. • There are also more pressure sensors integrated in both valve units. The diaphragm found in the sensor is what is used along with silicon semiconductors, to record the pressure. • The output signals from the semiconductor are processed on a printed circuit board integrated in the sensor housing.
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III. Level Sensor • The level sensor records the height of the body in respect to the road surface. The ABC control unit uses their signal to calculate the overall length of the suspension struts. • They are found adjacent to each suspension strut and are operated via a linkage by the movement of the suspension.
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Level Lowering during idle time • It is possible that the vehicle level will sink after a certain period. However, this sinking is still within tolerances with the following factors: (i) Due to temperature differences If the vehicle is stopped with a heated ABC system, the oil will cool, resulting in a volume change in the enclosed oil. This volume change can result in a uniform sinking by up to 20 mm, depending on the temperature difference. (ii) The vehicle may uniformly sink by up to 30 mm within a 4- week idle time period. By John Kungu Kihara IV. Lateral and Longitudinal Acceleration Sensor LATERAL ACCELERATION SENSOR • Lateral acceleration is a transverse force which occurs in curves. The lateral acceleration sensor is located in the interior on the left side of transmission tunnel. • The lateral acceleration sensor records lateral acceleration of the vehicle body.
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LONGITUDINAL ACCELERATION SENSOR • Longitudinal acceleration is the rate of change in a straight line. The longitudinal acceleration sensor is located on the right hand footwell on the cross member under the front seat. • The longitudinal acceleration sensor records longitudinal acceleration.
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How it works • An acceleration sensor is basically an accelerometer. The accelerometer is a device that is used to measure rate of change of velocity by using mass. • Some use the piezoelectric effect. They contain small piezo crystal structures that get stressed by accelerative forces, which cause voltage to be generated.
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V. Body Acceleration Sensors • The body acceleration sensors measure the vertical rate of change of the vehicle body with two of them at the front and one at the rear. • The two at the front are located on either side of the engine compartment close to the top of the suspension strut towers. • The rear body acceleration sensor is located in the trunk on the right inner spring tower.
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VI. Level Adjustment Button • The level adjustment switch is located on the dash panel and enables the driver to raise the vehicle above the normal level, in two stages. • Its signals are evaluated by the upper control panel control unit then the signals are sent to the COMAND control unit via the interior CAN. • The COMAND control unit the sends the signal via interior CAN to central gateway control unit. From there, the signal is sent to the ABC control unit via CAN C.
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Level Adjustment Button… • If pressed once, the level rises by 25mm and if pressed twice, it rises by another 25mm
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VII. Comfort/Sport Switch • The comfort/sport switch is located next to the level adjustment button on the dash panel • The switch instructs the ABC control unit to select the either the comfort or sport damping settings. • Its signals are evaluated by the upper control panel control unit then the signals are sent to the COMAND control unit via the interior CAN. • The COMAND control unit the sends the signal via interior CAN to central gateway control unit. From there, the signal is sent to the ABC control unit via CAN. • The ABC then chooses a map based on the drivers demand. By John Kungu Kihara VIII. Spring Travel Sensor • The spring travel sensor, located in the piston rod of each suspension strut identifies whether the spring is compressing or expanding by measuring the position of the piston rod. • The sensor output values are always normalized to maximum to reduce variations.
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How The Spring Travel Sensor Works • A wire that is designated as a waveguide (a) is surrounded by a movable position magnet (f). • The position to be measured is marked by the current location of the position magnet. The position magnet generates a longitudinal magnetic field (b) at its position in the waveguide.
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How The Spring Travel Sensor Works… • All material that is located between the magnet and the waveguide (piston rod) must be antimagnetic. • A short current pulse (e) is sent through the waveguide for measurement. This results in a second magnetic field (c) appearing radially around the waveguide.
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How The Spring Travel Sensor Works… • A new direction of magnetizing results at the location of the position magnet by overlaying the longitudinal magnetic field (from the position magnet) and the vertical radial magnetic field (from the current pulse). • The effect of this is a short-term distortion of the waveguide, which triggers a torsion pulse (d).
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How The Spring Travel Sensor Works… • The torsion pulse undulates with a fixed dispersion speed towards the end of the waveguide where a torsion wave receiver (g) is located. • The position of the magnet is determined by the runtime of the torsion wave between the exciting current pulse and the receiver pulse.
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How The Spring Travel Sensor Works… • The torsion pulse converter sends the measured results to the ABC control unit in the form of an electrical signal. • The real plunger travel on the front axle and rear axle is different and always less than the measuring range of the plunger travel sensors. • The control unit has to take the actual possible adjusting range into consideration during plunger movement.
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IX. Instrument Cluster • The digital instrument cluster is a set of instrumentation displayed with a digital readout. • The instrument cluster is located in the interior of the vehicle, behind the steering wheel.
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X. Steering Angle Sensor • The steering angle sensor is integrated in the steering column module (SCM) and has its own CAN bus interface. • The sensor detects the momentary steering wheel position and passes it over the CAN bus to the control unit. • The control unit needs the angle to determine the lateral acceleration working on the vehicle and to identify steering criteria.
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XI. Wheel Speed Sensor • The wheel speed sensor informs the ABC control unit of the vehicle’s speed via CAN bus. However, this information is passed through the ESP control unit first. • The speed-dependent level lowering function is determined by the information received from the wheel speed sensor.
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XII. Oil Temperature Sensor • The PTC oil temperature sensor is used to monitor the hydraulic oil in the hydraulic circuit. Its located in the return circuit upstream the oil cooler.
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XIII. Brake Light switch • The brake switch is used to inform the ABC system via the CAN C, of the drivers intent to slow down. • Brake applications influence the pitch motion that the ABC counters.
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8. SYSTEM FUNCTIONS I. Automatic Ride Height Control II. Manual Ride Height Control III. Self Levelling IV. Sleep Mode V. Pitching VI. Rolling VII. Bouncing VIII. Sport Mode By John Kungu Kihara General Functionality • A radial piston pump is used for the pressure supply. The hydraulic fluid is sucked from the oil reservoir. A suction restrictor valve fitted to the pump regulates the intake volume and thus the pressure. • The oil quantity is determined in dependence of the vehicle situation. • The oil is conveyed to the pressure supply valve unit from the pump. A pulsation damper fitted to this valve unit compensates the vibrations of the hydraulic system. • A pressure limiting valve in the valve unit prevents a pressure rise above 200 bar. Pressure peaks are fed directly in the return line and eliminated. By John Kungu Kihara General Functionality… • After the pressure supply valve unit, the pressure is fed to the ABC front and rear axle valve units. There, the oil is fed to the hydraulic cylinders in the suspension struts as required. • Two pressure reservoirs ensure the system pressure demands will be easily met at any time. • Surplus oil flows back through the return line via an oil cooler and an oil filter into the oil reservoir. • There is a return flow reservoir fitted in the return line to take the oil flowing back and for the reduction of pressure peaks.
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General Functionality… • A preload valve is fitted in the return line which ensures a minimum pressure of 10 bar in the return when the engine is running. • When the engine is stationary the pressure falls to 0 bar and takes place via a bypass bore (approx. 5-10 minutes).
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I. Automatic Ride Height Control • The vehicle’s ride height may vary automatically depending on the speed. • The distance that the vehicle body is lowered or raised is dependent on vehicle speed and the setting of the drivers level control switch. • As the vehicle speed increases, the vehicle body is lowered and is raised once the vehicle slows down • This improves the handling of the vehicle and reduces air resistance thus better fuel economy. By John Kungu Kihara Normal Setting
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II. Manual Ride Height Control • The driver has the ability to raise the level of the car in two stages for poor road conditions. • This function can allow the automatic ride height control to take place, but it will behave in a slightly different manner • The level switch aids this control and has LEDs that illuminate to inform the driver if the car is raised.
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By John Kungu Kihara III. Self Levelling • Change in load of a vehicle usually results in a change to the vehicles ride height but with ABC, the characteristic is eliminated due to the self levelling function • The car not only self levels at the rear, but at the front and from side to side too.
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UNLOADING • Removing load caused the spring of the strut to expand again and rear of the vehicle to rise. • The movement of the vehicle body is detected and reported to the ABC control unit. • Oil is then allowed to return from the hydraulic cylinders of the strut until the vehicles correct level is restored.
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LOADING • Loading the vehicle causes it to lower and the springs to be compressed because of the weight • The level sensors detect this movement and report it to the ABC control unit. • Oil is then pumped to the relevant hydraulic cylinders to increase the volume and the vehicle is pushed up to its original level
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IV. Sleep Mode • When the engine is switched off, the ride height previously set by the driver is recorded in the ABC control unit. • After a minute or so, the ABC switches to sleep mode to ensure the battery doesn’t drain and from there on, only a limited number of operations are made possible
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• Sleep mode can be woken up by signals from: Keyless Go Remote Control Luggage compartment lid Door switches
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V. Pitching • The term pitching refers to a vehicles tendency to dive during braking and squat during acceleration. • This happens because weight is transferred from the front to the back or vice versa and compresses the springs • However, ABC eliminates this phenomenon
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Braking • As the vehicle brakes, the rear struts start to expand and the front struts compress. • The instant this starts to occur, the ABC control unit detects the movement by means of signals from the sensors and from additional information from different systems like brake moment via the CAN bus • To counteract this, the ABC must add oil to the front struts and release oil in the rear struts.
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Valve Operation Front
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Valve Operation Rear
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VI. Rolling • Assuming the vehicle is taking a left turn bend, the vehicle will roll to the right • What do you think will happen?
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VII. Bouncing • The tendency for the vehicle to bounce as a result of rough road surfaces is reduced with ABC • As the road wheel passes over a bump, the spring is first compressed as it absorbs the shock. • The spring needs to release its energy by expanding and as it starts to expand to push the car upwards, the ABC control unit detects this movement • The control unit then operated the respective cut off valve and the 3-position valve is operated to release oil from the hydraulic cylinder of the strut By John Kungu Kihara Bouncing… • As the spring compresses, the vehicle body would drop. • Before the vehicle drops, the ABC control unit detects the start of the body movement and operates the 3-position valve to allow oil into the hydraulic cylinder of the strut • The vehicle thus remains level and bouncing is virtually eliminated. • However, ABC can only reduce body oscillations of up to 5Hz and oscillations above this are dealt with by the lower spring in the struts By John Kungu Kihara VIII. Sport Mode • The ABC system allows the driver to choose between two settings. Comfort Sport • These settings are selected by the sport switch located on the dashboard • Activation of this switch changes the characteristics of the ABC control unit and uses a different map that changes the parameters for the operation of the front and rear valve assemblies.
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• In sport mode, suspension movements become stiffer and are better suited to a dynamic driving style
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By John Kungu Kihara Lock Position • This is a function of the ABC control unit that prevents the actuation of the hydraulic plungers. • The lock position is not activated via a locking switch, but by software that detects relief on the wheel. • Once detected, the plunger check valves are closed and the plunger valves no longer actuated once lock position is set by the control unit. • The lock position is automatically deleted by the control unit under specific conditions (e.g. vehicle speed > 0 km/h) and the normal function scope started again. By John Kungu Kihara 9. ADVANTAGES AND DISADVANTAGES ADVANTAGES • Higher driving safety and ride comfort • Adjustment of the suspension and damping to the road condition and driving style. • Better vibration comfort • Smaller vertical body movements due to road influences. • Reduced roll and pitch motion of the bodywork. • Low air resistance and thus lower fuel consumption. • Less lift on the front axle when accelerating By John Kungu Kihara ADVANTAGES AND DISADVANTAGES… DISADVANTAGES • High initial cost • Malfunctioning can lead to a big collapse • Require super quick micro computers
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By John Kungu Kihara 10. SAFETY AND PRECAUTION I. How to check and correct fluid level II. Emergency Mode Buffer III. Lock position
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I. CHECK AND CORRECT FLUID LEVEL • Level adjustment switch in "normal level” position • Ignition OFF • Remove the cover with oil dipstick (2a), read the oil level after a rest period of approx. 5 minutes. • If the oil level is too low, determine the cause and correct the problem. • Correctly adjust the oil level. • Funnel with filter may not be used to fill other operating fluids. To avoid damage to the ABC system caused by contamination, the funnel with filter must be stored in a closed cabinet. Correct measurement of the fluid level is possible only if vehicle is unloaded and ready to drive. By John Kungu Kihara II. Emergency Mode Buffer • Emergency mode buffers are available to maneuver vehicles with a suspension system in the event of sinking (leakage).
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III. Additional things to note • When the driver switches the ignition on, LEDs in both the sport mode switch and level control come on to indicate to the driver that the system is functional • Oil is maintenance free • Uses same oil as power steering • Thoroughly clean component before opening • Check oil level before carrying out any repair procedure • Relieve hydraulic pressure before opening any connection