Advanced Vehicle Control Systems

S. Balachandran

Vice President

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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

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WABCO INDIA LIMITEDSundaram – 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

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Sales of Rs. 899 Cr in 2010-11, 50% growth

MARKET LEADER in Indian Medium and Heavy Commercial Vehicle industry

Over 2,400 EMPLOYEES, 200 ENGINEERS

MAJORITY CONTROL BY WABCO in Jun 2009

ABOUT WABCO INDIA LIMITED

3 MANUFACTURING LOCATIONS in India

listed on NSE / BSE with the stock symbol WABCOINDIA / 533023

Listed in stock exchanges in India

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WABCO INDIA JOURNEY

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High pressure compressors

Deming prize

TPM Kick-off

ABS

Japan QualityMedal

Air dryer, Automatic brake adjustment and Load sensing valveProducts for

Stallion vehicles (Army application) ACMA award

F&S Super platinum

Products meeting global standards

• New plant at Jamshedpur• New Plant at Mahindra city• ABS Introduction by OEMs• Focus on Exports

TPM award

A successful journey

F&S Super platinum

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Melbourne (3)

Shanghai(90)

Qingdao(340)Jinan

(280)

Seoul, Pyungtaek (90)

Tokyo, Kawagoe(80)

Singapore(7)

Hong Kong(3)

Chennai(1,400)

1977 1986 1990 1996 2001 2005 2006 2007 2008 2009

APAC HQmoved to Shanghai

JV w/ SundaramClayton Ltd,India

>

APAC HQ in Hong Kong

Technical Licensingin China

JV in Jinan, China

QD FactoryOfficial Inauguration

WABCO takes majoritycontrol

Mahindra WCFactory inIndia

Factory in Pyungtaek Korea

JamshedpurFactory inIndia

HISTORY OF WABCO IN INDIA / ASIA

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CUSTOMER VALUES

WABCO is working on global TECHNOLOGY trends relevant to our

customers

We have a clear path to enhance VEHICLE EFFICIENCY and

ENVIRONMENTAL SUSTAINABILITY by 20%

Our vision is to improve ADVANCED SAFETY and DRIVER

EFFECTIVENESS, and reduce the number of commercial vehicle

accidents by 50% by 2020

We are involved in developing PRODUCTS and FUNCTIONALITIES to

better meet these needs

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Shift of economic power among

regions

Increasingmobility

Growing demand forsafety and security

Growing need for environmental care

Availability of natural resources

Truck/Bus-Specific Trends

ABScontrol

Fuel Efficiency

Energy Recovery

Weight Reduction

Stability control

Braking systems

Suspension control

ADAS

BRINGING VALUE TO CUSTOMERS

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PRODUCT PORTFOLIO

Air Compressors 13%

Air Processing 12%

Conventional Brake Controls 21%

Brake Chambers & Actuators 22%

Anti-Lock Braking System (ABS) 7%

Vacuum products 2%

Repair kit sales 10%

Exports (Inter-company) 12%

Exports (Aftermarket) 1%

% 2010-11 Sales

2010-11 sales : Rs 899 Cr

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WABCO - - The Supplier of Control Systems for Commercial Vehicles

Complete Air Brake System

orABS / ASR

Air Dryer / APU

Air Compressor

Front Brakes

Rear Brakes

EBS with Stability Control

ClutchServo

Suspension Controls• Pneumatic• Electronic

• with / w/o Shock Absorber Control

Temperature Control

Gear Box Controls

Retarder Control

Central Board

Computer

Reservoirs

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Increasing vehicle speeds

30-80 kmph

1940 1950 1960 1970 1980 1990 2000

Fail-safe

Car –like feel

Stability

Single line air brake

Dual line air brake

Load Sensing Valve

Automatic Slack Adjuster

ABS/ASR

EBS

Varying load conditions

Adjusting lining wear

Varying road conditions

Bra

king

Tec

hnol

ogy

2010

ESC

ACC

Commercial Vehicles – BrakingCommercial Vehicles – Braking System TrendSystem Trend

Focus on ADAS beyond 2011

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Typical Dual Brake System layout

Hand brake

Spring Brake Acctuator For Hand brake

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System Function – Hand brake

Able to stop the vehicle by Hand brake when both Service circuits failed.

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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.

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Spring Brake Chamber

Wind in condition

Spring Brake Chamber

Wind off condition

Ensure the spring brake chambers in wind in condition

For parking & emergency braking

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ABS System

Reliable ABS Portfolio

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ABS Schematic Layout – 4S/4M

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ABS ADVANTAGE

Air BrakeAir 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

Air Brake with ABS

Air Brake with ABS

• 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 With ABS

Demo Without ABS

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Axle-modulator

back up valve

ABS solenoid

valve

Proportional Relay Valve

EBS ECUBrake

signal transmitter

WABCO EBS Components - 4S/4M

Electronic Braking System - EBS

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2S / 2M

2S / 2M

SAS

CA

B

446 130 XXX 0

IIII II IIII IIIEPB 4S /4M

Optional

Optional / ESC

Optional / ESC

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4S/4M for 4x2 Vehicles

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 (6) ESC-module (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

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Why EBS?

Advantages of EBS vs. ABS

Better diagnosis

Self test

Fault memory

Simplified brake check

EBS provides advantages for all customer

Installation advantages Less pneumatic and electric connectorsNo additional components if ESC is installed

Shorter brake distanceShorter pneumatic pipesElectro pneumatic brake controlHigher pressure in brake systemPipe connections are electrically controlled

Improved brake pedal feelingPedal feeling similar to Cars Deceleration control instead of brake pressure control

New functions w/o additional valves

Hill Start Funtion

Brake Assist

Brake management

Cost benefit for the OEM and end userLess lining wearLess system costLess service costFunctions due to parameter setting

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Stability Controls – RSC & ESC

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Roll Stability Control

Philosophy of RSC is to reduce vehicle speed there by preventing vehicle roll over

If the lateral acceleration exceeds a 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

RSC controls the lateral acceleration

Demo on RSC

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ABS based Roll Stability Control ( RSC ) - ComponentsABS based Roll Stability Control ( RSC ) - Components

RSC– Accelerometer

integrated in ABS ECU (or ESC Module)

– ATC valve for drive axlebraking

– RSC valvefor trailerbraking

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How does ESC work at critical vehicle yaw ?

Directional Stability Control

Over steering Under steering

Reduction of engine torque to slow down vehicle

Selective braking of single wheels to compensate deviation from stable driving conditions

directional instability ESC brake application

Identification of unstable driving conditions :

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ABS based ESC add. components

• Solenoid Valve for Solenoid Valve for front axle brakingfront axle braking

• Pressure Sensor Pressure Sensor for driver brakefor driver brakedemand demand

• Steering AngleSteering AngleSensorSensor

• ESC ModuleESC Module

• ATC valve ATC valve for drive axlefor drive axlebrakingbraking

• ValvesValvesfor trailerfor trailerbrakingbraking

For ABS additional valves needed

ESC componentsESC components

black/whiteblack/white controlledcontrolled

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• Solenoid Valve for Solenoid Valve for front axle brakingfront axle braking

• Pressure Sensor Pressure Sensor for driver brakefor driver brakedemand demand

• Steering AngleSteering AngleSensorSensor

• ESC ModuleESC Module

• ATC valve ATC valve for drive axlefor drive axlebrakingbraking

• ValvesValvesfor trailerfor trailerbrakingbraking

Easy ESC extension with EBS

ESC componentsESC components

black/whiteblack/white controlledcontrolled

X

X X

XX

EBS based ESC add. components

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Electronically controlled air suspension ECAS

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ECAS- Electronically Controlled Air Suspension -

ECAS consists of– Electronic Control Unit

– Remote Control Unit

– Height Sensors

– Pressure Sensors

– Solenoid Valve Blocks

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

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

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Air Suspension (ECAS) electronically controlled

No

min

al l

evel

Supply

height sensor

bellow

solenoid valve

ECU

ECU

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MODULATOR DOOR CONTROL SYSTEMS (MTS)

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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

MODULATOR DOOR CONTROLSYSTEMS (MTS)

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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

FEATURES OF MTS

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Tire pressure Monitoring ( TPM) 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

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Components in the TPM system Components in the TPM system

Simple System Structure

SAFETY - Correct Tire Pressures

ECONOMY -Less fuel consumption

Electronic Control Unit (ECU)

Wheel Modules

Data onIntegrated

Multi-functionDisplay

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Automated Manual Transmission (AMT)

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TRANSMISSION SYSTEMS

Different types of Transmission systems

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38Standardization and Modularity to shorten time to market

Standardization and Modularity to shorten time to market

WABCO OptiDriveTM

GENERAL AMT BENEFITS

• Fuel saving up to 3%

• Maintenance cost savings

• Safer, improved gearshift operation

• Increase driver attention on road traffic

• Lower installation cost

• Reduced weight

SPECIFIC OptiDriveTM BENEFITS

• Easily adaptable to existing trucks and transmissions

• 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

Our Passion for your Vehicle Efficiency

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

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

Description

Value to Customer

WABCO OptiDrive system overview

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39SYSTEM CONTENT

Shift Lever Unitincl. TCU

Passive Speed Sensor

Active Speed SensorPneumatic Clutch

Actuator

1:1

XY-Actuator

1:1

WABCO AMT system overview

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PCA

XY-Actuator

Inductive Speed Sensor

Active Speed Sensor

SLU

WABCO AMT system overview

SYSTEM CONTENT

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EVOLUTION OF ACTIVE SAFETY

From controlling –to anticipating

ABS

ESC

ADAS

control

stabilize

anticipate

Demo on ADAS

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Driver Assistance Systems Technology and Driver Assistance Systems Technology and ProductsProducts

Headliner ClusterCamera• Lane Departure

Warning & Lane Keeping Support

• support of long range sensor

Long Range77 GHz Radar orInfrared Laser Sensor ACC Collision Warning Collision Mitigation Autonomous Emergency Braking

Side Sensors24 GHz Radar orultrasonic Blind spot detection

Lane Departure Warning

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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

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PASSION