SENSOTRONIC

BRAKE SYSTEM

SENSOTRONIC

BRAKE SYSTEM

Sensotronic Brake System

2011

CONTENTS

S. NO 1 Introduction

TOPIC

PAGE NUMBER

2 to 4

Contribution of mec !tronic"

# to $

Com&onent" of SBC

$ to '

C !r!cteri"tic" !nd fe!ture" of SBC

( to 1$

)i"!d*!nt!+e" of SBC

1$ to 1,

C!r" -it SBC

1'

Bib.io+r!& /

1(

Department of mechanical and manufacturing

Page 2

Sensotronic Brake System

2011

Sensotronic Brake System

2011

Sensotronic Brake System

2011

CONTRIBUTION OF MECHATRONICS

Mechatronics - a new term is gaining popularity within the automotive industry and is rapidly developing into the catchword of a quiet technological revolution which in many fields stands century-old principles on their head. Mechatronics brings together two disciplines which in many cases were thought to be irreconcilable, namely mechanics and electronics. Hence automobile functions which hitherto worked purely mechanically and partly with hydraulic assistance will in future be controlled by high-performance microcomputers and electronically controllable actuators. hese either replace the conventional mechanical components or else enhance their function. he mechatronic interplay therefore opens up hitherto inconceivable possibilities to further raise the safety and comfort levels of modern passenger cars. !or e"ample# it was only thanks to mechatronics that an electronically controlled suspension system which instantly adapts to prevailing conditions when driving off, braking or cornering -- thus providing a totally new driving e"perience -became a reality. $n %&&& Mercedes-'en( launched this system under the name )ctive 'ody *ontrol +)'*, in the flagship *- coup., thereby signalling the advent of a new era of suspension technology. his electronically controlled suspension system has quickly been followed by the electronic brake system# Mercedes-'en( and 'osch have teamed up on this benchmark development pro/ect which will shortly enter into series production at the 0tuttgart automobile brand under the name 0ensotronic 'rake *ontrol -- or 0'* for short.

Department of mechanical and manufacturing

Page 1

Sensotronic Brake System

2011

$t turns the conventional hydraulic brake into an even more powerful mechatronic system. $ts microcomputer is integrated into the car2s data network and processes information from various electronic control units. $n this way, electric impulses and sensor signals can be instantly converted into braking commands, providing a marked safety and comfort gain for drivers.

1 Mercedes benz

*3MP3454 0 3! 0'*
0 'rake 3perating 6nit +'36, 0 7heel speed sensors 0 raction 0ystem Hydraulic unit

Department of mechanical and manufacturing

Page 8

Sensotronic Brake System

2011

BRAKE OPERATING UNIT (BUO

he 'rake 3perating 6nit +'36, consists of the following#

1 'rake fluid reservior 1 0'* pedal value sensor 1

andem master cylinder

1 'rake pressure simulator

2 BUO

PE!A" #A"UE SENSOR

0 $t contains two hall effect sensors. 0 *onverts pedal travel distance into electrical signal

Department of mechanical and manufacturing

Page 9

Sensotronic Brake System

2011

TRACTION SYSTEM HY!RAU"IC UNIT

$t contains 0'* control module , pressure reservoir and high pressure charge pump.

Department of mechanical and manufacturing

Page :

Sensotronic Brake System

2011

CHARACTERISTIC FEATURES AN! A!#ANTAGES OF SBC

0 E$ec%r&n'c br()e *ed($ # o turn to the technical side# when drivers hit the brake pedal today, their foot moves a piston rod which is linked to the brake booster and the master brake cylinder. ;epending on the pedal force, the master brake cylinder builds up the appropriate amount of pressure in the brake lines which - in a tried and tested interaction of mechanics and hydraulics - then presses the brake pads against the brake discs via the wheel cylinder. $n the Mercedes-'en( 0ensotronic 'rake *ontrol, by contrast, a large number of mechanical components are simply replaced by electronics. he brake booster will not be needed in future either. $nstead sensors gauge the pressure inside the master brake cylinder as well as the speed with which the brake pedal is operated, and pass these data to the 0'* computer in the form of electric impulses. o provide the driver with the familiar brake feel engineers have developed a special simulator which is linked to the tandem master cylinder and which moves the pedal using spring force and hydraulics. $n other words# during braking the actuation unit is completely disconnected from the rest of the system and serves the sole purpose of recording any given brake command. 3nly in the event of a ma/or fault or power failure inside the %2< vehicle battery does 0'* automatically use the services of the tandem master cylinder and instantly establishes a direct hydraulic link between the brake pedal and the front wheel brakes in order to decelerate the car safely.

Department of mechanical and manufacturing

Page &

Sensotronic Brake System

2011

0 *ress+re ,&d+$(%&rs -&r e(c. /.ee$ he central control unit under the bonnet is the centrepiece of the electrohydraulic brake. his is where the interdisciplinary interaction of mechanics and electronics provides its greatest benefits - the microcomputer, software, sensors, valves and electric pump work together and allow totally novel, highly dynamic brake management# $n addition to the data relating to the brake pedal actuation, the 0'* computer also receives the sensor signals from the other electronic assistance systems. !or e"ample, the anti-lock braking system +)'0, provides information about wheel speed, while 50P= makes available the data from its steering angle, turning rate and transverse acceleration sensors. he transmission control unit finally uses the data highway to communicate the current driving range. he result of these highly comple" calculations is rapid brake commands which ensure optimum deceleration and driving stability as appropriate to the particular driving scenario. 7hat makes the system even more sophisticated is the fact that 0'* calculates the brake force separately for each wheel. he high-pressure reservoir contains the brake fluid which enters the system at a pressure of between %>? and %8? bar. he 0'* computer regulates this pressure and also controls the electric pump which is connected to the reservoir. his ensures much shorter response times than on conventional brake systems.

Department of mechanical and manufacturing

Page %?

Sensotronic Brake System

2011

0 F+$$ br()e *&/er (0('$(b$e e0en /.en %.e en1'ne 's s/'%c.ed &--2 he hydraulic unit mainly comprises four so-called wheel pressure modulators. hey mete out the brake pressure as required and pass it onto the brakes. $n this way it is possible to meet the microcomputer2s stipulations while each wheel is slowed down separately in the interests of driving stability and optimum deceleration. hese processes are monitored by pressure sensors inside the wheel pressure modulators. 0 E,er1en1enc3 br()'n1 2 s%&*'n1 d'(%(nce red+ced b3 %.ree *ercen% he main performance characteristics of 0ensotronic 'rake *ontrol include the e"tremely high dynamics during pressure build-up and the e"act monitoring of driver and vehicle behaviour using sophisticated sensors. Mercedes-'en( is thus moving into new dimensions of driving safety. ake the e"ample of the emergency brake# 0'* already recognises the driver2s rapid movement from the accelerator onto the brake pedal as a clue to an imminent emergency stop and responds automatically# with the aid of the highpressure reservoir, the system increases the pressure inside the brake lines and instantly presses the pads onto the brake discs so that they can get a tight grip the moment the driver steps onto the brake pedal. )s a result of this so-called prefilling of the brake system, the stopping distance of an 0'*-equipped sports car from a speed of %2? km@h is cut by around three per cent compared to a car featuring conventional braking technology. hanks to electrohydraulic back-up, the performance of 'rake )ssist is also improved further. $f this system issues the command for an automatic emergency

Department of mechanical and manufacturing

Page %%

Sensotronic Brake System

2011

stop, the quick pressure build-up and the automatic prefilling of the wheel brakes leads to a shorter braking distance. 0 !r'0'n1 s%(b'$'%3 2 *rec'se br()'n1 ',*+$ses -&r *er-ec% ESP *er-&r,(nce $t is not /ust in emergency braking that 0ensotronic 'rake *ontrol proves its worth, but also in other critical situations - for e"ample, when there is a risk of swerving. 6nder such conditions, the system interacts with the 5lectronic 0tability Program +50P=, which keeps the vehicle safely on course through precise braking impulses at all wheels and@or by reducing engine speed. 0'* once again offers the benefits of greater dynamics and precision# thanks to the even faster and more accurate braking impulses from the 0'* high-pressure reservoir, 50P= is able to stabilise early and comfortably a vehicle which is about to break away. his is evident, for e"ample, from the results of the <;) lane-change test which suspension engineers use to simulate a quick obstacle-avoidance manoeuvre and to demonstrate the high capabilities of the 5lectronic 0tability Program. $n con/unction with 0'*, 50P= works even more effectively and significantly reduces vehicle swerving through quick and precise braking impulses. )t the same time the driver2s steering effort is reduced. hanks to 0'* and 50P= he or she will have even less difficulty keeping the car on course.

Department of mechanical and manufacturing

Page %2

Sensotronic Brake System

2011

0 Br()'n1 (% c&rners 2 1re(%er s(-e%3 %.(n)s %& 0(r'(b$e br()e *ress+re

5ven when braking in corners, 0'* also offers more safety than a conventional brake system. his is where the variable and targeted brake force distribution is of particular advantage to actively influence the car2s compliance steer. 7hile conventional brake systems always mete out the brake pressure equally to the inner and outer wheels, 0'* offers the possibility of assigning brake forces in a way appropriate to the situation. Hence the system will automatically increase the brake pressure at the outer wheels because the higher vertical forces also allow them to transfer greater brake forces. )t the same time the brake forces at the inner wheels are reduced to provide the higher cornering forces needed to stay on course. he result is a more stable braking behaviour along with optimum deceleration values.

Department of mechanical and manufacturing

Page %A

Sensotronic Brake System

2011

7ith the innovative 0ensotronic 'rake *ontrol Mercedes engineers still stick to the proven principle of a variable brake force control for the front and rear a"les. hey program the system in such a way that, when slowing down from a high speed, the larger part of the brake force continues to act on the front a"le. his prevents a potentially ha(ardous overbraking of the rear a"le. )gain 0'* is capable of adapting to the prevailing situation. )t low speeds or during partial braking, the system automatically increases the brake force share at the rear a"le to improve brake system response and achieve even wear and tear of the brake pads.

0 C&,-&r% 2 n& *ed($ 0'br(%'&n d+r'n1 d+r'n1 ABS &*er(%'&n 'oth the separation of the 0'* pedal from the rest of the brake system and the proportional pressure control using mechatronics serve to increase brake comfort - particularly during sharp deceleration or when the anti-lock braking system is operational. he usual vibration of the brake pedal when )'0 sets in does not occur, which, Mercedes engineers have found, is not only a comfort feature of the new system but also offers measurable safety benefits. heir research in ;aimler*hrysler2s 'erlin driving simulator has revealed that almost two thirds of all drivers are startled when )'0 pulsation sets in# they do not increase the brake force further and are even prone to taking their foot off the brake pedal for a short while, thereby lengthening the stopping distance of their vehicle - in the driving simulator by an average of 2.%? metres during )'0 braking from 8? km@h on a snow-covered road surface.

Department of mechanical and manufacturing

Page %>

Sensotronic Brake System

2011

0 SBC (dd &n -+nc%'&ns 2 s+**&r% s3s%e, %& red+ce dr'0er s%r('n 0ensotronic 'rake *ontrol offers additional advantages in everyday driving situations - when slowing down ahead of traffic lights, in the wet, in traffic /ams or hill starts# he so-called S&-%4S%&* -+nc%'&n of the 0'* software ensures particularly gentle and smooth stopping which provides significant comfort benefits particularly around town when you need to slow down frequently for traffic lights. )ll this is made possible by the higher-precision pressure control thanks to mechatronics. 3n a wet road surface the system metes out short brake impulses at regular intervals to ensure that the water film on the brake discs dries off and that 0'* can always operate with optimum effectiveness. his automatic dr34br()'n1 -+nc%'&n is activated at regular intervals when the car2s windscreen wipers are running. he driver does not even notice these ultra-precise brake impulses. he 0ensotronic 'rake *ontrol also incorporates a so-called Tr(--'c 5(, Ass's% function, which is activated using the cruise control stalk while the car is stationary. he benefit is that during stop-and-go traffic drivers only need to use the accelerator pedalB once they take their foot off the accelerator, 0'* slows down the car to standstill at a steady rate of deceleration. he raffic Cam )ssist facility can remain operational up to 8? km@h and switches off automatically at higher speeds.

Department of mechanical and manufacturing

Page %1

Sensotronic Brake System

2011

3n hills or steep drives the 0ensotronic 'rake *ontrol !r'0e4A/(3 Ass's% prevents the car from rolling backwards or forwards - stepping onto the brake pedal quickly but sharply is all it takes to activate the brake. $f the driver accelerates, the ;rive-)way )ssist releases the brake and allows the car to drive off smoothly. T.e -+%+re 2 SBC *(0'n1 %.e /(3 -&r (+%&,(%'c 1+'d(nce s3s%e,s he advent of electronics in brake technology opens up new and promising opportunities to Mercedes engineers - and not only in the disciplines of safety and comfort. hanks to 0'* they have also moved a considerable way closer to the realisation of their long-term ob/ective, namely to be able to automatically guide the cars of the future along the roads with the aid of video cameras, pro"imity radar and advanced telematics.

MA5OR !ISA!#ANTAGE OF SBC

S&-%/(re -('$+re 2 he technology eliminates the mechanical link between the driver2s brake pedal and the brakes, substituting an electrical link that actuates the brake calipers. *ustomer complaints were linked to the failure of software for the brake system. 7hen the system failed, the hydraulic system took over. 'ut that resulted in a longer stopping distance and additional brake pedal effort by the driver.

Department of mechanical and manufacturing

Page %8

Sensotronic Brake System

2011

D0tatistically, +the 0ensotronic 'rake *ontrol is, as good as our other braking systems and sometimes better,D the insider said. D'ut we cannot get the doubts out of customers2 heads.D Mercedes2 0- roadster and the low-volume 0-E Mc-aren and Maybach supercars will retain the brake system until the end of their life cycles. $t would be too costly to re-engineer those low-volume cars to accommodate a conventional system, a source said. 0ensotronic 'rake *ontrol was supposed to highlight Mercedes2 technology leadership. $nstead, it created a double blow to the brand2s image. $n May 2??>, Mercedes recalled 8:?,??? vehicles to fi" the comple" brake-bywire system. hen, in March 2??1, %.A million cars were recalled, partly because of further unspecified problems with the 0ensotronic 'rake *ontrol system. Mercedes dropped the 0ensotronic 'rake *ontrol system from the 5-*lass in Cune 2??8 when it introduced the car2s midterm face-lift. )t about the same time, the 5 *lass-derived *-0 also lost the system. 'oth cars now have a conventional hydraulic braking system. D6e c(n n&/ &--er ($$ %.e c&,-&r%s &SBC 'n ( c&n0en%'&n($ s3s%e,7D said a Mercedes insider. DSBC /(s ( 0er3 e8*ens'0e s3s%e,9: B+% %.e s&+rce ($s& (c)n&/$ed1ed %.(% c+s%&,ers .(d $&s% c&n-'dence 'n %.e s3s%e,9

Department of mechanical and manufacturing

Page %9

Sensotronic Brake System

2011

CARS 6ITH SBC 0 Mercedes 0- roadster +E2A?, 0 Mercedes 5-*lass sedan +72%%, and 5state +02%%, until mid 2??8 0 Mercedes 5-*lass >matic sedan +72%%, and >matic 5state +02%%, until mid 2??8 0 Mercedes 0-E +*%&&, 0 Maybach 19 and 82 +72>?, 0 Mercedes *-0 coupe +*2%&, until mid 2??8

Department of mechanical and manufacturing

Page %: