DR.Eng Mohd Harly, B,Eng,M.

Eng
B2B Consultant Malaysia

System Description of ESP

5 PILLAR TRANSPORT SAFETY
KEPRES NO 4/2014

POLRI BAPPENAS
PILAR 1 DEPKES
SAFETY MANAGEMENT

PILAR 4 DRIVER
LOW ENFORCEMENT

PILAR 5
KEMENHUB HEALING PASKA ACCIDANCE

PILAR 3
SAFER VEHICLE
PU
PILAR 2
SAFER ROAD
 PREVENTIVE CURRENCY AFTER

Traction Control-KERS
(Smart Over Taking)
Antilock Brake System Crash Fast Evacuation
(Stopping Distance) Smart Healing
Rolling ITS based Emergency
ESP(DSC) & 4 WS
(Under/over-steer)
Active Safety Belt
Active Suspension & ESP Smart Accidence
(Rolling , Sliding) Multi Air Bag Investigation

VNS(GPS) & Early Warning System Poltran Smart Box

Smart Body Damper
(Driver Information System)
DR.Eng Ir Harly, M.Eng 2/24/2015 3
BRAKE FORCE
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

MAX

MAX
NILAI LONGITUDINAL FRICTION CONSTANT 0-1 (0%-100%)
TERGANTUNG DARI
1). MATERIAL & PROFILE DR.Eng Mohd Harly, B,Eng,M.Eng
2). PROSENTASE SLIP B2B Consultant Malaysia
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

PROSENTASE SLIP & SKID

WHEEL SPEED = VEHICLE SPEED ==== NO SLIP / NO SKID

WHEEL SPEED < VEHICLE SPEED ==== SLIP IN %

WHEEL SPEED > VEHICLE SPEED ==== SKID IN %

 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
KESEIMBANGAN GAYA DAN MOMEN KENDARAAN MODEL RIGID
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Sensor Steering Sensor Sensor Sensor

angle spedometer centrifugal yawing rate

ARAH KENDARAAN YANG DI RESPONSE ARAH KENDARAAN

INGINKAN SESUNGGUHNYA ATAU KONTROL
( ARAH STEADY STATE VARIABLE
ACKERMAN)

UNIT KONTROL ESP

( melihat kondisi arah 50 kali setiap detik )

Impuls tekanan PADA

MASTER RODA CENTRIFUGAL FORCE
DAN GYROSCOPIC
MOMENT
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

BL ESP Specification
▶ System
- BOSCH ESP 5.3
- 4Sensor 4Channel
- BRAKE Line : X Split
- ABS with ESP Control
▶ Hydro-Electronic Control Unit (HECU )
- Hydraulic Modulator : Size(84 X 118 X 170mm), Weight(2.6Kg)
- Motor : Large Size(180W)
- Solenoid Valve : Sol-Sol Type(Inlet/Outlet)
- ECU : Attached ECU
▶ Wheel Speed Sensor
- Inductive Sensor(Passive Type)
- Minimum P-P voltage : 120mV (2.75KPH)
▶ Acceleration Sensor & vehicle rotation sensor
- Offset Voltage : 2.5V
- Operating voltage : 4.5V ∼ 5.5V
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
BL ESP Specification
Vehicle Rotation 8 ~ 16V
Dynamic
Acceleration Lat. -40℃ ~ 120 ℃
sensors
Acceleration Lo. -13.5V
Weight 2.7 Kg
Charger
Pump capacity 4.8 cc/sec
pump
Power consum. 230W
Inlet Valve (EV) : 8.54Ω ± 0.5Ω
Solenoid
Resistance Outlet Valve (AV) :4.29Ω ± 0.25Ω
Valve
EV AV
Operating 45A or less
Return current (10.5V ± 0.5V , 23 ℃ ± 5 ℃)
Pump
Motor 145A or less
Max. current
(16V ± 0.1V , 23 ℃ ± 5 ℃) PUMP MOTOR
Wheel Coil resistance 1600Ω ± 10% - Air Gap
Speed Insulation resist. 1MΩ Front : 0.3~1.2 mm
Sensor Tone wheel 48 EA Rear : 0.3~1.2 mm
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

HECU
▶ESP 5.3 model
RR RL MC2 MC1

ECU housing
FR

ECU connector
FL

Connecting bolt
Pump Motor

Return pump
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

HECU Location
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

HECU Appearance
ECU connector

▶Top view
Motor Power line

▶ESP 5.3 Damping

Chamber

Accumulator
▶Bottom view
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

ABSCM Housing

▶ Never Disassemble HECU

▶ valve seat coil assembly

a b c d a Inlet valve (RR)

b Inlet valve (FL)
e f g h c Inlet valve (FR)
d Inlet valve (RL)
e Outlet valve (RR)
f Outlet valve (FL)
g Outlet valve (FR)
h Outlet valve (RL)
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
BL BOSCH 5.3 ABS DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
 DR.Eng Mohd Harly, B,Eng,M.Eng
HYDRAULIC UNIT ESP B2B Consultant Malaysia
 DR.Eng Mohd Harly, B,Eng,M.Eng
HYDRAULIC UNIT ESP B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
 DR.Eng Mohd Harly, B,Eng,M.Eng
ESP CONTROL SUB SYSTEM B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
BL BOSCH 5.3 ABS DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Hydraulic Unit (Modulator)

▣ Normal Condition

LFEV/RFEV/LREV/RREV NO
Solenoid Valve
LFAV/RFAV/LRAV/RRAV NC

Pump Motor OFF

LF : LEFT WHEEL OF FRONT LR : LEFT WHEEL OF REAR

RF : RIGHTWHEEL OF FRONT RR : RIGHT WHEEL OF REAR

EV : INLET VALVE NO : NORMAL OPEN

AV : OUTLET VALVE NC : NORMAL CLOSE
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
Normal Brake pressure from the M/C directly delivers to wheel cylinders
ABSCM does not operate
condition Normal braking without the operation of NO, NC valves

EV OPEN (OFF)
Solenoid valve
AV CLOSE (OFF)

PUMP MOTOR OFF

D D
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
Pressure Stiff braking pressure → reduced friction, Wheel Lock-up tendency
ABSCM reduces the brake pressure of corresponding wheels
Dump Pump Motor dumps brake pressure to the M/C side

EV CLOSE (ON)
Solenoid valve
AV OPEN (ON)

PUMP MOTOR ON

D D
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Pressure To make a proper decision of wheel rotation while pressure dump

or pressure increase mode
Hold To hold the brake pressure of wheel cylinder

EV CLOSE (ON)
Solenoid valve
AV CLOSE (OFF)
PUMP MOTOR ON

D D
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Pressure If a frictional force between tire and road surface increases,

ABSCM increases brake pressure again
Increase
EV OPEN (OFF)
Solenoid valve
AV CLOSE (OFF)
PUMP MOTOR ON

D D
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Valve/Pump motor relay fuse

VALVE, MOTOR RELAY FUSE

 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Acceleration Sensor
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

EBD(Electronic Brake-force Distribution)

1. EBD Modulation

2. Advantage of EBD

3. EBD Failure Matrix(Rev. 4)

 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

EBD Modulation
* EBD control example
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

EBD Curve
Brake-force
Ideal brake force
rear axle 0.9G line
distribution (Laden)
0.8G line

μ=0.9, locking line rear

w heels ① Range w here only rear axle locks
in case of ABS/EBD disabled

Zcrit Rear w heel brake force w ith

EBD control a P-valve at μ=0.9 condition.

w ith P-valve

μ=0.9, locking line front

w heels
Ideal brake force
distribution (Unladen)
Brake-force
front axle
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Advantages of EBD

- (load sensitive) proportioning valve may be omitted

- increase of rear axle contribution to brake-force

- Approach to ideal brake-force distribution

(straight-ahead and bend driving)

- Adaptive to different loading conditions

- Constant brake-force distribution during vehicle live time

- Monitoring of EBD-function

- Minimal extension of ABS hardware required

 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

*1) thresholds hard-

ware depended
low voltage 9,4V > Uz > 6,9V Power-supply *1)
Failure Matrix of EBD Rev.4

<- reversible

G-Switch
ABS disabled, EBD enabled(Keep Alive Function)

WSS

BLS

MR
PM

VR
second failure

<- reversible

WSS-failure low-frequency (FFZ)

ABS and EBD disabled

WSS-failure non-ohm (FDFP)

WSS-failure high-frequency
ABS and EBD enabled

X not possible

over-voltage >17,4 V
low voltage <6,9 V

WSS-failure ohm

2 WSS-failures

sensor failure
first failure

BLS-Failure

interruption
that always
leads to keep

sticking
failure
failure
alive function
.
Power-supply reversible -> low voltage 9,4V > Uz >X6,9V
X X*1)
WSSwheel speed sensor ohm
non-ohm (FDFP)
2 WSS-failures
reversible -> high-frequenzy
BLS brake light switch X
PM pump motor failure X X
MR motor relay failure X X
VR ventil relay sticking X X
G-Switch sensor failure X
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

ABS & EBD Warning Lamp

Illuminate for 3
EBD & Parking brake lamp seconds after ABS Warning Lamp
IG key ON

• ECU Failure • Wheels sensor failure (Open or short) •

• Solenoid Valve Failure Pump Motor & Valve Fuse Open
• Paring Brake • Low / High Voltage
• Lacking of Brake Oil • While diagnosis
• Short ’ G Bar failure • Short ’ G Bar failure
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Function of ABS & EBD Warning Lamp Relay

1. ABS & EBD Warning Lamp(Passive Type)

2. ABS External Wiring Diagram

3. ABSCM Connector

4. Pin Assignment
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

ABS & EBD Warning Lamp(Passive Type)

 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

ABS External Wiring Diagram

 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia
60A

Wiring Diagram 17

18
10A
15
Ignition EBD
Switch 21
HAS 19
Stop 20
ABS
Switch
14

Stop 11
Lamp
diagnosis

Signal ground
30
Acceleration longitudinal A BSC M
10
Sensor V(5V)
28
TOD
Signal 13
4WD ECU
16

7
FL
6
5
FR
W heel 4
S peed 9
S enso r RL
8
2
RR
1
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

ABSCM Connector

15 UZ 26 --- 31 ---
15 31
26 14 BLS
14 30 25 --- 30 AGND
25 13 TOD
13 29 24 --- 29 ---
24 12 ---
12 28 23 --- 28 UST
23 11 DIAGK
11 27 22 --- 27 ---
22 10 AL
10 21 EBVSILA
21 9 DFRL
9 20 ABSSILA
20 8 MDFRL
8 19 SGND
7 DFFL
7 19
6 MDFFL 18 UB-VR
6
5 DFFR
5 18
4 MDFFR 17 UB-MR
4
17 3 ---
3
2 DFRR 16 MGND
2
16 1 MDFRR
1
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Pin Assignment

1 WSS - RR(－) 14 Brake lamp switch

2 WSS - RR(＋) 15 ECU power (IG)
3 16 Ground
ABS & EBD 경고등
- motor
4 WSS - FR(－) 17 Power - relay
5 WSS - FR(＋) 18 Power - relay
6 WSS - FL(－) 19 Ground - ECU
7 WSS - FL(＋) 20 ABS warning lamp
8 WSS - RL(－) 21 EBD warning lamp
9 WSS – RL(＋) 28 AL – input voltage
10 AL sensor output 30 AL - ground
11 Diagnosis - K line
12
13 TOD
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Troubleshooting

1. DTC list

2. System failure diagnosis

3. Air Bleeding

4. Hi-Scan Pro
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Troubleshooting

DTC list

DTC Description W/L Check point

C0800 High voltage (over 16V) O Battery voltage, Wire, Fuse
C0800 Low voltage (8V or less) O Battery voltage, Wire, Fuse
C0035 WSS FL - Continuity O WSS, Conn., Wire Harness
C0035 WSS FL - Plausibility O Wire check, Short, Air gap, Tooth
C0040 WSS FR - Continuity O WSS, Conn., Wire Harness
C0040 WSS FR - Plausibility O Wire check, Short, Air gap, Tooth
C0045 WSS RL - Continuity O WSS, Conn., Wire Harness
C0045 WSS RL - Plausibility O Wire check, Short, Air gap, Tooth
C0050 WSS RR - Continuity O WSS, Conn., Wire Harness
C0050 WSS RR - Plausibility O Wire check, Short, Air gap, Tooth
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Troubleshooting
DTC list
DTC Description W/L Check point
C0930 Acceleration sensor O Plug Conn., Sensor failure, Wire open
C0060 Solenoid Valve - LF(AV) O Short, MV line open
C0065 Solenoid Valve - LF(EV) O Short, MV line open
C0070 Solenoid Valve - RF(AV) O Short, MV line open
C0075 Solenoid Valve - RF(EV) O Short, MV line open
C0080 Solenoid Valve - RL(AV) O Short, MV line open
C0085 Solenoid Valve - RL(EV) O Short, MV line open
C0090 Solenoid Valve - RR(AV) O Short, MV line open
C0095 Solenoid Valve - RR(EV) O Short, MV line open
C0110 Motor pump O Motor or Relay circuit failure
C0121 Valve Relay O Valve relay failure
 DR.Eng Mohd Harly, B,Eng,M.Eng
B2B Consultant Malaysia

Troubleshooting

DTC list

DTC Description W/L Check Point

C0161 Brake Switch X SW failure, Brake lamp
C0245 WSS frequency error O Poor Tooth Gear or damage
C0550 ECU malfunction O ECU failure