ESP ( E lectronic S tability P rogram)

ESP GENERAL ABS in add on design (Integrated type) - - Brake booster & Tandem master cylinder - - Wheel brakes (disc or drum) - - HECU - - Wheel sensors with tone wheels

Traction Control System (BTCS/FTCS ) This system is an extension of the well-known ABS function to incorporate BTCS (Brake Intervention Traction Control System) and FTCS (Full Traction Control System) which controls engine torque. ESP GENERAL

ESP (Electronic Stability Program) Combines the ABS and TCS components with additional sensors monitoring yaw, lateral acceleration and the drivers intention (steer angle sensor). * ESPAYC AYC * ESP: ABS + TCS + AYC (Active Yaw Control) ESP GENERAL

APPLICATION January 2004 ABS/TCS04.02~ (JOB #1) ESP04.09~ (R/C)

ESP CONTROL UNIT [ESP unit installation] Function of ESPCM - - Control of braking force / traction force/ yaw moment - - Failsafe function - - Self diagnosis function - - Interface with the external diagnosis tester Specification - - Operating voltage range : DC 10 ~ 16V - - Operating temperature range : -40 ~ Consumption current a. BAT 1 Max: 30A(ABS/TCS), 40A(ESP) b. BAT 2 Max: 30A

Electronic ESP Control Unit ESP CONTROL UNIT A : INLET VALVE (FR) B : INLET VALVE (RL) C : INLET VALVE (RR) D : INLET VALVE (FL) E : OUTLET VALVE (FR) F : OUTLET VALVE (RL) G : OUTLET VALVE (RR) H : OUTLET VALVE (FL) I : ELECTRIC SHUTTLE VALVE (ESV-R) J: ELECTRIC SHUTTLE VALVE (ESV-L) K:TRACTION VALVE(TCR) L: TRACTION VALVE(TCL) M: MOTOR(+) N: MOTOR(GND)

BASIC FUNCTIONS OF ESP In the event of understeering Without control Control RR wheel braking Generated Moment Normal direction

BASIC FUNCTIONS OF ESP In the event of oversteering FL wheel braking Non-control Control Normal direction Generated Moment

In the hydraulic control unit of the MGH-25 ESP system, pump valve block Are grouped together in one housing, forming one compact unit with the electric motor. HYDRAULIC CONTROL UNIT Peculiar things to MGH-25 ESP hydraulic are that shuttle valve is changed to solenoid type from hydraulic type and TC valve is repositioned. This is because ESP system controls the brake pressure of 4 wheels respectively while driving unlike the TCS which controls the brake pressure of 2 driving wheels in operation.

Suction (right side of pump) The pump piston moves to the left and the suction valve opens and brake fluid is sucked in. Pressure increase (left side of pump) The left piston moves to the left and the pressure valve opens and pressure is built up. Motor pump HYDRAULIC CONTROL UNIT Suction Dump

HYDRAULIC CONTROL UNIT Shuttle valve The valve type is changed to the solenoid valve type for MGH-25 ESP. When the ESP is in operation, the brake fluid should be supplied to the motor pump from the M/C via the shuttle valve to generate the brake pressure. This solenoid valve is closed and blocks the passage when a brake pedal is applied. Traction Control valve (TC valve) While TCS or ESP in operation, TC valve is closed and the generated pressure by motor delivers to wheel cylinders without returning to the master cylinder. TC valve includes a relief valve and a check valve. When excessive pressure is supplied from the motor, relief valve is opened and the pressure is relieved.

Hydraulic circuit of MGH-25 ESP HYDRAULIC CONTROL UNIT Shuttle Valve

Hydraulic flow In braking position In this position, the inlet valve and the TCS valve are open, the outlet valve and the electrically operated shuttle valve remain closed. HYDRAULIC CONTROL UNIT Shuttle valve TCS valve Outlet valve Inlet valve Motor

Hydraulic flow In ESP control position (pressure increase) The on/off booster builds up a pressure of approximately 10 bar in order to enable the ESP pump to suck brake fluid at low temperatures. In this position, the inlet valve is driven in a pulsed cycle. The TCS valve is closed. The outlet valve remains closed. The electrically operated shuttle valve is opened. The hydraulic pressure is led to the wheel brakes which are to be applied for a brief period of time. HYDRAULIC CONTROL UNIT Shuttle valve TCS valve Outlet valve Inlet valve Motor

INPUTS AND OUTPUTS

ESP COMPONENTS [ESP Components]

Layout CAN COMMUNICATION

[CAN-LOW][CAN-HIGH] Output signal CAN COMMUNICATION

ACTIVE WHEEL SPEED SENSOR - Type: Hall Effect - Output signal: Digital (Open Collector Type circuit integrated) - Good characteristics against temperature variation and noise - Low RPM Detection: 0 RPM can be detected - Air gap sensitivity: stable output pulse against air-gap change - -Supplying power: DC 12V

Construction & Principle [Principle of Active Wheel Speed Sensor] ACTIVE WHEEL SPEED SENSOR

14mA 7mA Output Current [Output Current] ACTIVE WHEEL SPEED SENSOR

YAW RATE SENSOR & LATERAL G SENSOR Operating Voltage: 5 ±0.25 V Operating Temperature : - 40 ~ 85 G-Sensor Range : ~ 1.5 g Yaw-Sensor Range: - 75 ~ +75 ˚/sec Zero Output Voltage: 2.5 V Output Voltage Range: 0.5 ~ 4.5 V Specification

Sensor Location [Sensor Connector] [Sensor Location] YAW RATE SENSOR & LATERAL G SENSOR

[Output Characteristics of Acceleration] [Output Characteristics of Yaw Rate] Sensor characteristics * Driving through a left curve leads to a more positive output signal YAW RATE SENSOR & LATERAL G SENSOR

Sensor Output [Reference voltage of the sensor] [Output of Yaw Rate] Left turn Right turn YAW RATE SENSOR & LATERAL G SENSOR

Sensor Output [Output of Lateral G - 90˚ left][Output of Lateral G - 90˚ right]

STEERING ANGLE SENSOR Application - Location: Inside steering wheel - Calculate the steering amount and direction - 3 Input Signals (ST 1, ST 2, ST N) - ST N detects the neutral position of steering wheel

Specification - Sensor type : Photo interrupt type - Sensor output type : Open Collector Type - Output pulse quantity :45pulse (Pulse cycle 8°) - Duty ratio : 50±10% - Phase difference of outputs : 2.0 ±0.6° - Supply voltage :IGN1(8~16V) - Output voltage :1.3V OL2.0V, 3.0V OH4.1V - Maximum rotational velocity : 1,500°/s STN STEERING ANGLE SENSOR

Steering angle sensor output (while turning right) [ST1, ST2][ST1, STN] ST1 ST2 ST1 STN STEERING ANGLE SENSOR

Steering angle sensor output (while turning left) [ST1, ST2][ST1, STN] ST1 ST2 ST1 STN STEERING ANGLE SENSOR

Steering angle sensor (When the sensor connector is open) [Diagnostic trouble code][Current data] STEERING ANGLE SENSOR

PRESSURE SENSOR Application Sense the drivers braking intentions (braking while an ESP intervention is in progress) Design The sensor consists of two ceramic disks, one of which is stationary and the other movable. The distance between these disks changes when pressure is applied. Installation The sensors are mounted on the TMC (primary circuits)

Function The pressure sensors operate on the principle of changing capacitance. The distance (s) between the disks and, thus, the capacitance changes when pressure is applied to the movable disk by a braking intervention. The characteristic of the sensor is linearized. The fluid displacement of the sensor is negligible. Max. measurable pressure: 170 bar Specification Operating Voltage: 5± 0.5 V Pressure Range: 0 ~ 170 bar Maximum Pressure Limit: 350 bar Operational Temp.: - 40 ~ 125 Accuracy: ± 3 % s s1s1 PRESSURE SENSOR

Output Characteristics t Output](V)Upper fault area lower fault area zero point [Sensor characteristics] PRESSURE SENSOR

ESP SWITCH The ESP switch deactivates the ESP and TCS functions. This facilitates - rocking to free the vehicle in deep snow or loose surface material - driving with snow chains - operation of the vehicle on a brake test bench The ABS function is fully maintained. With the ESP switch, the ESP system can only be deactivated when the vehicle is stationary or traveling at low speed. The system cannot be deactivated while an ESP intervention is in progress.

WARNING LAMP CONTROL a) EBD W/L control b) ABS W/L control c) TCS/ESP OFF W/L control d) TCS/ESP Function Lamp control a) b) c)d)

a) EBD warning lamp ON - During the initialization phase after IGN ON. (continuously 3 seconds) - When the Parking Brake Switch is ON or brake fluid level is low - When the EBD function is out of order - During diagnostic mode - When the ECU Connector is seperated from ECU. a) b) c)d) WARNING LAMP CONTROL

b) ABS warning lamp ON - During the initialization phase after IGN ON. (continuously 3 seconds) - In the event of inhibition of ABS functions by failure - During diagnostic mode - When the ECU Connector is seperated from ECU. a) b) c)d) WARNING LAMP CONTROL

c) TCS/ESP OFF warning lamp ON - Ring the initialization phase after IGN ON. (continuously 3 seconds) - In the event of inhibition of TCS/ESP functions by failure - When driver turns off the TCS/ESP function by on/off switch - During diagnostic mode a) b) c)d) WARNING LAMP CONTROL

4) TCS/ESP function lamp Control - During the initialization phase after IGN ON. (continuously 3 seconds) - When the TCS/ESP control is operating. (Blinking - 2Hz) a) b) c)d) WARNING LAMP CONTROL

kph Sensor H/W Air-gap Check Air-gap Check(10kph or more) Speed Jump Check (100g, 25km/h for 7ms) Wrong Exciter Check Long Term ABS Mode Check (ABS operation for 36 s) 7 Min. ABS operating speed (7kph) 25 Speed Jump Check (40g, 10km/h for 7ms) DIAGNOSIS Wheel Sensor Check Flow

DIAGNOSIS 012kph Initial check(3sec) Sol coil open/short to GND, Short to battery, Fuse open: Error after 56msec Fuse open, Motor short to GND, Motor Open: Error after 200msec Motor lock check : Motor voltage check for 84msec after Motor PWM operation Motor short to battery: Error after 49msec Motor Relay Open: Error after 49msec Motor & Solenoid Check

DIAGNOSIS DTC List

DIAGNOSIS DTC List

ABS/TCS WIRING DIAGRAM [ABS][TCS]

ESP WIRING DIAGRAM