Introduction to Brake Control Systems e-Seminar

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In this e-seminar, James Walker, Jr. delves into brake control technology. Starting with the fundamentals of the tire-road interface, this course introduces participants to brake control system mechanization, system sensor needs, and the basic control strategies employed by anti-lock braking systems (ABS), traction control systems (TCS), electronic stability control systems (ESC), and their derivatives.

Limiting factors and compromises that must be made in the design and development of brake control systems are covered through a brief review of hydraulic brake system functionality, the friction circle concept, and the fundamentals of longitudinal and lateral vehicle dynamics. Brake control system integration with other vehicle on-board technologies are also discussed.

Based on the popular classroom seminar, the nine and a half hour course is divided into 13 modules accompanied by a handbook. Walker revisits key concepts in a summary at the end of the course to reinforce learning and retention.

Major topics include:

• Tire-Road Interface Characteristics [Total Run Time: 32 minutes]
  • Calculate longitudinal tire slip and explain its significance
  • Define the mu-slip relationship and illustrate this relationship graphically
  • Compare tire longitudinal force vs. lateral slip capacity
  • Construct the friction circle for a generic application
• Hydraulic Brake System Overview [Total Run Time: 1 hour, 34 minutes]
  • Explain the functionality of brake systems
  • Identify the components that comprise brake systems
  • Estimate the contribution of each of the individual components
  • Graphically illustrate the underlying fundamental relationships
  • Predict how these concepts apply to brake control systems
• Stability, Steerability, Stopping Distance [Total Run Time: 12 minutes]
  • Define stability, steerability, and stopping distance
  • Illustrate stability, steerability, and stopping distance using mu-slip curves
  • Compare stability, steerability, and stopping distance using the friction circle
• Mechanization of ABS [Total Run Time: 50 minutes]
  • Analyze ECU mechanizations and principles of basic operation
  • Identify HCU components and their functional requirements
  • Explain the ABS hold, release, and apply functions
  • Compare diagnostic strategies and warning lamp implementations
• ABS Sensor Overview [Total Run Time: 30 minutes]
  • Define the role of sensors in brake control system design
  • Compare and contrast wheel speed sensor technologies
  • Evaluate brake apply state sensor needs and interface requirements
  • Explain the need for longitudinal accelerometers in select applications
• ABS Performance [Total Run Time: 1 hour, 9 minutes]
  • Define the objectives of ABS and basics of wheel control
  • Analyze ABS control parameters on homogeneous surfaces
  • Explain the unique needs for ABS control during splits and transitions
  • Illustrate control considerations for ABS during dynamic maneuvers
• DRP Performance [Total Run Time: 43 minutes]
  • Calculate rear wheel proportioning as it relates to weight transfer
  • Explain the role of the hydraulic proportioning valve
  • Define basic DRP performance parameters and metrics
  • Compare and contrast DRP benefits and trade-offs
• Mechanization of TCS and ESC [Total Run Time: 30 minutes]
  • Define the additional ECU functionality required for TCS and ESC
  • Identify select HCU components required for TCS and ESC
  • Explain the HCU pressure build sequence required for TCS and ESC
• TCS and ESC Sensor Requirements [Total Run Time: 18 minutes]
  • Define the additional role of sensors for TCS and ESC implementation
  • Compare and contrast steering angle sensors technologies
  • Evaluate brake pressure sensor needs and interface requirements
  • Explain the need for lateral accelerometers and yaw rate sensors
• TCS Performance [Total Run Time: 56 minutes]
  • Define the objectives of TCS and the various strategies involved
  • Explain the basics of TCS wheel control and how it differs from ABS
  • Analyze TCS performance under various conditions
  • Illustrate control considerations for TCS based on driveline architecture
• ESC Performance [Total Run Time: 40 minutes]
  • Define the objectives of ESC and the various strategies involved
  • Explain the basics of ESC wheel control and how it differs from ABS/TCS
  • Analyze understeer and oversteer correction techniques
  • Illustrate control considerations for ESC based on driveline architecture
• Special Conditions and Considerations [Total Run Time: 26 minutes]
  • Define special needs for brake control systems during off-road operation
  • Explain control considerations possible in a high-performance environment
  • Project the impact of vehicle modifications on brake control system operation
• Advanced Integration [Total Run Time: 38 minutes]
  • Define and discuss adaptive cruise control
  • Explain the concept and implementation of panic brake assist
  • Evaluate the limitations of brake control system tire inflation monitoring
  • Identify the interfaces necessitated by brake-by-wire technology

About the Instructor: James Walker, Jr.
James Walker, Jr. is currently a Principal Engineer specializing in chassis, brake, and electronic brake control systems at Carr Engineering, Inc. His prior professional experience includes brake control system development, design, release, and application engineering at Kelsey-Hayes, Saturn Corporation, General Motors, Bosch, Ford Motor Company, and Delphi.

Mr. Walker created scR motorsports consulting in 1997, and subsequently competed in seven years of SCCA Club Racing in the Showroom Stock and Improved Touring categories. Through scR motorsports, he has been actively serving as an industry advisor to Kettering University in the fields of brake system design and brake control systems. Since 2001, he has served as a brake control system consultant for StopTech, a manufacturer of high-performance racing brake systems.

In addition to providing freelance material to multiple automotive publications focusing on chassis and brake technology, Mr. Walker is the author of High-Performance Brake Systems: Design, Selection, and Installation. In 2005, he was presented with the SAE Forest R. McFarland Award for distinction in professional development and education and in 2010, he was awarded the SAE Master Instructor designation. Mr. Walker obtained his B.S.M.E. in 1994 from GMI Engineering & Management Institute.

Is this e-Seminar for You?
This course was developed for engineers involved in all disciplines related to the design or development of vehicle braking systems, vehicle dynamics, powertrain systems, or chassis/suspension systems. A basic knowledge of college algebra, college physics, and a familiarity with vehicle foundation brake system functionality is required.

Individuals new to the field of brake control systems will benefit most from the material; this course is not intended for individuals with significant background in, or experience with, brake control systems. In addition, please note that because of proprietary considerations this class does not provide details of algorithm design, algorithm performance, or algorithm application.

This course has been approved by the Accreditation Commission for Traffic Accident Reconstruction (ACTAR) for 10 Continuing Education Units (CEUs). Upon completion of this e-seminar, accredited reconstructionists should contact ACTAR, 800-809-3818, to request CEUs. As an ACTAR approved course, the fee for CEUs is reduced to $5.00.

About e-Seminars
SAE "e-Seminars" are electronically delivered seminars featuring full-motion video illustrated with synchronized presentation slides. e-Seminars are based on some of SAE's most highly attended and rated classroom seminars.

Convenient & Portable Learning
Convenient and portable, SAE e-Seminars offer a new way to receive the same instruction as live classroom learning without the expense of travel and time away from the workplace. Using a laptop or PC with an Internet connection, you can view individual modules at your own pace, at times convenient to you. You can even e-mail your questions to SAE for instructor reply.

• 365 days of access (from date of purchase) to the 9.5 hour course
• Links to streaming video modules
• Course Handbook (downloadable, .pdf's, subject to DRM)
• Online Pre-test (self-test, immediate results)
• Online Post-test (submit to SAE)
• 1.0 CEUs*/Certificate of Achievement (with satisfactory post-test score)

Equipment Requirements

• Windows 2000, XP, 7 (Not currently supported by Windows Vista)
• Pentium III PC
• Minimum 128 MB RAM; recommended 256 MB RAM
• Internet Explorer 6.0 & above browser (Mozilla Firefox, Google Chrome, and Unix/Linus based browsers are not currently supported)
• Adobe Flash Player 8.0 & above
• Broadband-128Kbps and above
• 1024 X 768 Screen Resolution
• Sound Card/Speakers

Available in Single-User packages. Quantity discounts for three or more students and Site License options also are available - complete a Corporate Learning Solutions Request Form for a quote.

For more detail, email CustomerService@sae.org; or call
1-877-606-7323 (U.S. and Canada) or 724-776-4970 (outside US and Canada).