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Technicaltraining.Productinformation.
BMWService
G12ChassisandSuspension
Generalinformation
Symbolsused
Thefollowingsymbolisusedinthisdocumenttofacilitatebettercomprehensionortodrawattentiontoveryimportantinformation:
Containsimportantsafetyinformationandinformationthatneedstobeobservedstrictlyinordertoguaranteethesmoothoperationofthesystem.
Informationstatusandnational-marketversions
BMWGroupvehiclesmeettherequirementsofthehighestsafetyandqualitystandards.Changesinrequirementsforenvironmentalprotection,customerbenefitsanddesignrendernecessarycontinuousdevelopmentofsystemsandcomponents.Consequently,theremaybediscrepanciesbetweenthecontentsofthisdocumentandthevehiclesavailableinthetrainingcourse.
Thisdocumentbasicallyrelatestolefthanddrivevehicles.Furtherdifferencesmayariseastheresultoftheequipmentspecificationinspecificmarketsorcountries.
Additionalsourcesofinformation
Furtherinformationontheindividualtopicscanbefoundinthefollowing:
• Owner'sHandbook• IntegratedServiceTechnicalApplication.
Contact:[email protected]
©2015BMWAG,Munich
ReprintsofthispublicationoritspartsrequirethewrittenapprovalofBMWAG,Munich
TheinformationcontainedinthisdocumentformsanintegralpartofthetechnicaltrainingoftheBMWGroupandisintendedforthetrainerandparticipantsintheseminar.RefertothelatestrelevantinformationsystemsoftheBMWGroupforanychanges/additionstothetechnicaldata.
Contact:SebastianRiedelTel.:+49(0)8938265044E-mail:[email protected]
Informationstatus:June2015BV-72/TechnicalTraining
G12ChassisandSuspensionContents1. Introduction.............................................................................................................................................................................................................................................1
1.1. Developmentcode...............................................................................................................................................................................................11.2. Chassisandsuspensioncomparison....................................................................................................................................11.3. Overviewofchassisandsuspension.....................................................................................................................................2
1.3.1. Highlights..........................................................................................................................................................................................3
2. Axles.....................................................................................................................................................................................................................................................................52.1. Frontaxle............................................................................................................................................................................................................................5
2.1.1. Versionsofthefrontaxlesupport..............................................................................................................82.1.2. NotesforService..................................................................................................................................................................8
2.2. Rearaxle...........................................................................................................................................................................................................................112.2.1. NotesforService.............................................................................................................................................................12
3. AirSuspension.............................................................................................................................................................................................................................163.1. Airsupplysystem.............................................................................................................................................................................................19
3.1.1. Technicaldata........................................................................................................................................................................233.1.2. Solenoidvalveblock...................................................................................................................................................24
3.2. Airsuspensionstrut......................................................................................................................................................................................253.3. Rideheightsensor..........................................................................................................................................................................................273.4. Operatingstrategy...........................................................................................................................................................................................29
3.4.1. High level.......................................................................................................................................................................................333.4.2. Normal level..............................................................................................................................................................................343.4.3. Sport level....................................................................................................................................................................................35
3.5. NotesforService...............................................................................................................................................................................................363.5.1. Liftingthevehicle............................................................................................................................................................363.5.2. Transportmode...................................................................................................................................................................373.5.3. Bleedingtheairsuspension...........................................................................................................................373.5.4. Fillingtheairsuspension....................................................................................................................................37
3.6. Systemwiringdiagram.............................................................................................................................................................................38
4. Brakes............................................................................................................................................................................................................................................................404.1. Servicebrakes........................................................................................................................................................................................................42
4.1.1. Brakedesign............................................................................................................................................................................424.1.2. Pedalmechanismmounting...........................................................................................................................43
4.2. Parkingbrake............................................................................................................................................................................................................444.2.1. Functions.......................................................................................................................................................................................474.2.2. Braketeststand.................................................................................................................................................................48
4.3. Serviceinformation.........................................................................................................................................................................................494.3.1. Servicebrakes.......................................................................................................................................................................494.3.2. Parkingbrake..........................................................................................................................................................................50
G12ChassisandSuspensionContents5. Wheels/Tires.................................................................................................................................................................................................................................51
5.1. Puncturedetectionsystems............................................................................................................................................................525.2. TirePressureMonitorRDCi.............................................................................................................................................................52
5.2.1. Wheelelectronics............................................................................................................................................................54
6. DrivingStabilityControl.............................................................................................................................................................................................566.1. DynamicStabilityControl(DSC)...............................................................................................................................................59
6.1.1. Hydrauliccircuitdiagram.....................................................................................................................................616.1.2. Functions.......................................................................................................................................................................................626.1.3. Systemwiringdiagram............................................................................................................................................64
6.2. Steering.............................................................................................................................................................................................................................666.2.1. Steeringwheel.....................................................................................................................................................................676.2.2. Steeringcolumnadjustment.........................................................................................................................686.2.3. Versionoverview................................................................................................................................................................696.2.4. IntegralActiveSteering..........................................................................................................................................716.2.5. Serviceinformation.......................................................................................................................................................786.2.6. Systemwiringdiagram............................................................................................................................................80
6.3. ElectronicDamperControl(EDC)...........................................................................................................................................856.3.1. Shockabsorberdesign..........................................................................................................................................856.3.2. Systemoverview...............................................................................................................................................................876.3.3. Electricalshockabsorbercontrol...........................................................................................................89
6.4. Anti-rollbar..................................................................................................................................................................................................................926.5. Standardsuspension...................................................................................................................................................................................94
6.5.1. Chassisandsuspensionsetup..................................................................................................................946.6. ActiveComfortDrive....................................................................................................................................................................................95
6.6.1. Predictivecontrol.............................................................................................................................................................986.6.2. Electricactiverollstabilization(EARSV).................................................................................1026.6.3. Controlstrategy..............................................................................................................................................................1096.6.4. Systemwiringdiagramofelectricactiverollstabilization
EARSV...........................................................................................................................................................................................112
G12ChassisandSuspension1.Introduction
1
1.1.DevelopmentcodeThenewBMW7SeriesG12willbelaunchedonthemarketfromOctober2015.
Intermsofthechassisandsuspension,thenewBMW7Seriesoffersincreasedcomfortwithoutanycompromisesindrivingdynamics.
1.2.ChassisandsuspensioncomparisonComponent F01/F02 G12Frontaxle Double-wishbonefrontaxle Double-wishbonefrontaxleFrontsuspension Steelsprings AirsuspensionFrontdamping ElectronicDamperControl
(EDC)ElectronicDamperControl(EDC)
Anti-rollbar,front Conventionalorhydraulicactivestabilizer(ARS)
Conventionalorelectricalactivestabilizer(EARSV)
Rearaxle Five-linkrearsuspension Five-linkrearsuspensionRearsuspension Steelspringsorrearair
suspension(optionalequipmentintheF01)
Airsuspension2axle
Reardamping ElectronicDamperControl(EDC)
ElectronicDamperControl(EDC)
Rearanti-rollbar ConventionalorhydraulicactivestabilizerARS
ConventionalorelectricalactivestabilizerEARSV
Frontbrake Brakediscsuptodia.348mm Brakediscsuptodia.395mmRearbrakes Brakediscsuptodia.345mm Brakediscsuptodia.370mmParkingbrake Drumbrakeswith
electromechanicalparkingbrakeEMF
Discbrakeswithcombinedbrakecaliperfortheelectricparkingbrake
Wheels/tires Run-flattires(RSC) NormaltiresTirePressureMonitor(RDC) RDC RDCiSteering ElectronicPowerSteeringor
IntegralActiveSteeringElectronicPowerSteeringorIntegralActiveSteering
G12ChassisandSuspension1.Introduction
2
1.3.Overviewofchassisandsuspension
OverviewofchassisandsuspensionintheG12
Index Explanation1 Airsuspensionstrut,frontaxle2 12Vbattery(forEARSV)3 Brakeservo4 Steeringcolumnadjustment5 Steeringwheel6 Airsuspensionstrut,rearaxle7 Five-linkrearaxle(HA5)8 Rearaxleslipanglecontrol(HSR)(optionalequipment)9 ElectricactiverollstabilizationrearEARSV(optionalequipment)10 Pressureaccumulator2liters11 Airsupplysystemoftwo-axleridelevelcontrol12 Pressureaccumulator4liters13 Discbrakewithintegratedparkingbrakefortherearaxle
G12ChassisandSuspension1.Introduction
3
Index Explanation14 DynamicStabilityControl(DSC)15 Discbrakeforfrontaxle16 Double-wishbonefrontaxle17 ElectricactiverollstabilizationfrontEARSV(optionalequipment)18 ElectronicPowerSteering(electromechanicalpowersteering)(EPS)
ThefollowingtableshowsacomparisonofthechassisandsuspensionontheG12.
G12Rear-wheeldrive Four-wheeldrive
Wheelbase 3210mm 3210mm
Turningcircle* 12.8m 12,9m
Groundclearance 135mm 135mmMaximumvehicleheight 1505mm 1505mmMinimumvehicleheight 1475mm 1475mmVehicleheightatnormallevel 1485mm 1485mmVehicleheightathighlevel 1505mm 1505mmVehicleheightatsportlevel 1475mm 1475mm
*Theturningcirclevaluesrefertovehicleswithbasicsteering.
1.3.1.HighlightsThefollowingtableshowsthedifferentequipmentspecificationsintheareaofthechassisandsuspensionfortheG12.
Systems Basicchassisandsuspension
IntegralActiveSteering
ActiveComfortDrive
ElectronicPowerSteering(EPS) XEPSwithvariablerackgeometry XRearaxleslipanglecontrol(HSR) XTwo-axleridelevelcontrol XElectronicDamperControl(EDC) XFrontaxleanti-rollbar XRearaxleanti-rollbar XElectricactiverollstabilizationfront(EARSV)
X
Electricactiverollstabilizationrear(EARSV)
X
G12ChassisandSuspension1.Introduction
4
Systems Basicchassisandsuspension
IntegralActiveSteering
ActiveComfortDrive
Wheelaccelerationsensors
X
StereoKAFAScamera XAuxiliarybattery(12 V) X
Thefollowingoptionalequipmentisavailableinadditiontothebasicchassisandsuspension:
• IntegralActiveSteering• ActiveComfortDrive
Bothequipmentoptionscanbecombinedwitheachotherandareavailableforalldrivevariants(alsoxDrive).Itwaspossibletoreducethecarbondioxideemissionsandincreasethecontroldynamicsthroughcompleteelectrificationofthetwooptionalequipmentsystems.Inthecustomer'sperception,thisisexpressedinalowerfuelconsumptionwithincreasedcomfortaswellasasportierdrivingfeeling.
Thedrivercaninfluencethecontrolcharacteristicsofthedifferentsuspensioncontrolsystemsbymeansofthedrivingexperienceswitch.FurtherinformationonthisisprovidedintheTechnicalTrainingManual“G12DriverAssistanceSystems”.
G12ChassisandSuspension2.Axles
5
2.1.FrontaxleThedouble-wishbonefrontaxleoffersoptimumalignmentofthecamberofthefrontwheelsinrelationtotheroadwayineverydrivingsituation.Duringthecompressionandreboundmovements,awheelthereforealwayshasexactlythecambervaluethatguaranteesoptimumtransferofcorneringforcesinrelationtotheroadway.Thisensuresexcellenttirecontactwiththeroadandthetireisabletotransferhighlateralforces.Theattainablehighlateralaccelerationforcesarethuspossiblewithouttheotherwisenecessaryfirmchassisandsuspensionsetup.
Withthedouble-wishbonefrontaxle,theshockabsorberdoesnotperformanywheelcontroltasks.Thismeansthattheshockabsorberarepracticallyfreeoflateralforcesandcanreactsensitivelytoroadbumps.
Sincethedouble-wishbonefrontaxlehasasmallkinematicleverarm,disturbancevariablessuchasroadjointsorpotholesgenerateonlyasmalltorqueaboutthesteeringaxis.
Thesumofalladvantagesmeansthatthedouble-wishbonefrontaxlemakesitpossibletoresolvetheconflictofgoalsbetweencomfortandsportiness.
G12ChassisandSuspension2.Axles
6
OverviewoffrontaxleonG12withxDrive
Index Explanation1 Supportbearingonairsuspensionstrut2 ActuatorforElectronicDamperControl(EDC)3 Wishbone,bottom4 Steeringbox5 Crossmember6 Universaljointofsteeringshafttosteeringgear7 Castsidesection8 Strut
G12ChassisandSuspension2.Axles
7
Index Explanation9 Serviceopening10 Rearstiffeningplate11 Steeringshaft12 Universaljointofsteeringshafttosteeringcolumn13 Trianglewishbone,top14 Sidemember15 Swivelbearing16 Wheelbearingunit17 Trackrodhead18 Trailinglink19 Transversetube20 Frontserviceflap21 Lever22 Castcorner23 Castcornerconnection24 Springstrutholder
Inordertoachievethelowestpossiblevehicleweight,thefrontaxlecomponentsaremadealmostcompletelyfromaluminium.
Thedesignofthedouble-wishbonefrontaxleoffersthefollowingadvantages:
• Highagilityduetoabsorptionofhighlateralaccelerationforces.• Outstandingrollstabilizationwhencorneringwithoutanyreductioninridecomfort.• Comfortable,goodspringresponseoftheaxleandgooddirectionalstability.• Highcomfortduetominimuminfluenceofdisturbancevariables.
Inadditiontoensuringdrivingdynamicsandridecomfort,thedouble-wishbonefrontaxlealsoperformsvariouscrashfunctions.Thefrontaxlesupportispartofthecrashstructureofthebodyandformsanadditionalloadpath.Thisensuresthattheincreasedrequirementsrelatingtopedestrianprotectionaremet.
Drivingwithoutastiffeningplateisnotpermittedduetotheresultantlackofvehiclestability.
G12ChassisandSuspension2.Axles
8
2.1.1.VersionsofthefrontaxlesupportTwodifferentfrontaxlesupportsareuseddependingonthevehicleequipment.
VersionsofthefrontaxlesupportintheG12
Index ExplanationA Rear-wheeldrivesDriveB All-wheeldrivexDrive
2.1.2.NotesforServiceTwodifferentwishbonesareavailabletoServiceforcambercorrection.
CambercorrectionbyupperwishboneintheG12
G12ChassisandSuspension2.Axles
9
Index ExplanationA Cambercorrectionbyupperwishbone+30minB Cambercorrectionbyupperwishbone-30min
Inordertoavoiddamagetotheballbearingontheupperwishbone,itmustbeensuredwhenperformingdisassemblyorassemblyworkthatthedeflectionangleoftheballjointdoesnotexceedavalueof55°.
Thefollowingtableshowswhenwheelalignmentisnecessaryonthefrontaxlewhenacomponentisreplaced.
Replacementofacomponentonthefrontaxle
Wheelalignmentrequired
Frontaxlesupport YESSteeringbox YESWishbone,bottom YESRubbermountforwishbone,bottom YESTrailinglink NORubbermountfortrailinglink NOTrianglewishbone,top NORubbermountforupperwishbone NOTrackrod YESSwivelbearing YESWheelbearing NOAirsuspensionstrut NOSupportbearing NO
Thefollowingtableshowswhenwheelalignmentisnecessaryonthefrontaxlewhenacomponentisundone.
Undoingthescrewconnectionatthefrontaxle
Wheelalignmentrequired
Frontaxlesupporttobody NOSteeringboxtofrontaxlesupport YESBottomwishbonetofrontaxlesupport YESBottomwishbonetoswivelbearing NOTrailinglinktofrontaxlesupport NOTrailinglinktoswivelbearing NOUpperwishbonetobody NO
G12ChassisandSuspension2.Axles
10
Undoingthescrewconnectionatthefrontaxle
Wheelalignmentrequired
Upperwishbonetoswivelbearing NOTrackrodtosteeringbox NOTrackrodendtotrackrod YESTrackrodendtoswivelbearing NOSpringstruttobottomwishbone NOSupportbearingtobody NOBottomsteeringshafttosteeringbox NOUppersteeringshafttosteeringcolumn NO
G12ChassisandSuspension2.Axles
11
2.2.Rearaxle
OverviewofrearaxleintheG12
Index Explanation1 Supportbearing2 Airsuspensionstrut3 Frontrubbermount4 Rearrubbermount5 Airdeflector
G12ChassisandSuspension2.Axles
12
Index Explanation6 Cambercontrolarm7 Wishbone8 Camberlink9 Wheelbearingunit10 Wheelcarrier11 Trailingarm12 Controlarm13 Compressionstrut14 Axlesupport
Thefive-linkrearaxleoftheG12ischaracterizedbyprecisewheelguidance,whichcomesintoitsowninvariousdrivingsituations,suchasduringloadreversalsorthetransitionfromcorneringtostraight-aheaddriving.Inaddition,thefive-linkrearaxleoffersveryhighcomfortincombinationwithsportydrivingdynamics.
Itwaspossibletoresolvethisconflictofgoalsbymeansofthefollowingmeasures:
• Doubleflexiblerear-axlerubbermounts• Highstructuralrigidityoftherearaxlesupport• Largesupportareaoftherearaxlesupport
Itwaspossibletokeeptheunsprungmassesofthefive-linkrearaxlelowthroughtheuseofanaluminiumwheelcarrieraswellasvariousforgedaluminiumandsheetsteelcontrolarms.
Cleverdefinitionofthekinematicpointsaswellasprecisedesignoftheballjointsandrubbermountsresultinalargespringtravelrangeincombinationwithoptimumwheelguidance.Thesmallactingleverarmsensureparticularlygoodinsensitivitytobumpsintheroad.Theextremelyrigidcontrolarmsaswellasthetorsion-freerearaxlesupportandbodyconnectionsrealizedbymeansofcompressionstrutsresultinextremelyprecisewheelguidance.
Theairdeflectorsunderthecontrolarmsminimiseswirlandthusincreasetheefficiencyofthevehicle.
2.2.1.NotesforServiceThefollowingtableshowswhenwheelalignmentisnecessaryontherearaxlewhenacomponentisreplaced.
Replacementofacomponentontherearaxle
Wheelalignmentrequired
Rearaxlesupport YESRubbermountforrearaxlesupport YESCambercontrolarm YESCamberlink YESTrailingarm YES
G12ChassisandSuspension2.Axles
13
Replacementofacomponentontherearaxle
Wheelalignmentrequired
Wishbone YESBalljointinthewheelcarrier YESControlarm YESWheelcarrier YESWheelbearing NOAirsuspensionstrut NOSupportbearing NO
Thefollowingtableshowswhenwheelalignmentisnecessaryontherearaxlewhenacomponentisundone.
Undoingacomponentontherearaxle WheelalignmentrequiredRearaxlesupporttobody YESFrontcompressionstruttobody NOCamberlinktorearaxlesupport YESCambercontrolarmtowheelcarrier YESCamberlinktorearaxlesupport YESCamberlinktowheelcarrier NOTrailingarmtorearaxlesupport YESTrailingarmtowheelcarrier YESControlarmtorearsuspensionsubframe YESControlarmtohubcarrier NOWishbonetorearaxlesupport NOWishbonetowheelcarrier NOAirsuspensionstruttowheelcarrier NOSupportbearingtobody NO
G12ChassisandSuspension2.Axles
14
Rearaxlepositioning
ComparisonofrearaxleontheF01/F02withtheG12
Index ExplanationA RearaxleoftheF01/F02B RearaxleoftheG121 Body2 Centeringmountingforrearaxlesupport3 Mountingforrearaxlesupport4 Rearaxlesupport5 Rubbermountoftherearaxlesupport
OntheG12,nocenteringmountingsareusedonthebodyforalignmentoftherearaxle.Thismakesitpossibletoensureduringassemblythattherubbermountsoftherearaxlearescrewedtothebodycompletelywithoutanytension.Bumpsintheroadareisolatedandarenottransmittedtothebodyduetodirectcontactoftherubbermounts.
Newspecialtoolsareusedforremovalandassemblyoftherearaxlesupport.Therearaxlesupportisheldinthecorrectpositionforinstallationbymeansof2guidepins.Forthedetailedprocedure,refertothecurrentrepairinstructions.
G12ChassisandSuspension2.Axles
15
CenteringtoolforremovingandinstallingtherearaxleintheG12
Index Explanation1 Centeringpinforlongitudinalandtransversedirections(x-andyaxes)2 Centeringpinforlongitudinaldirection(y-axis)
Basicalignmentoftherearaxlesupportisensuringbythecentringpinforlongitudinalandtransversedirections.Duetothepermittedproductiontolerancesoftherearaxlesupport,thesupportispositionedonlyinlongitudinaldirectionbythesecondcentringpin.
Anincorrectprocedureforpositioningtherearaxlesupportcanleadtoproblemsduringwheelalignment.
G12ChassisandSuspension3.AirSuspension
16
Inordertoguaranteeuniformridecomfortindependentlyoftheloadstatus,theG12isequippedasstandardwithairsuspensiononthefrontandrearaxles.Thetwo-axleridelevelcontroloftheG12isofferedonlyincombinationwithelectricallycontrolledshockabsorbers.
Theairsuspensionincreasestheridecomfort.Thesystemperformsadjustmentmainlyatstandstill,e.g.inordertocompensateforachangeinheightduetothevehicleload.Theinertiaofthesystemmeansthatitcannotreacttodrivingdynamicsdisturbancevariables,whichmayoccurwhenthevehicleisdrivenquicklyontwistingroads.Dynamiccontrolwhendrivingservesonlytocompensateforchangesinheightduetoafallingfueltankvolumeaswellastemperaturechangesoftheairintheairsuspensionstruts.
Theairsuspensionoffersthefollowingadvantages:
• Increaseindrivingsafety,sincetheself-levellingsuspensionautomaticallykeepstheheightofthevehiclebodyatapredefinednominalride-levelinallloadstates.
• Highridecomfortduetoautomaticadaptationoftheoscillationbehaviortothevehicleweight.• Increasedcustomerbenefitthroughmanualleveladjustmentbymeansoftherideheight
selectionswitch.
G12ChassisandSuspension3.AirSuspension
17
Systemoverviewoftwo-axleridelevelcontrolintheG12
Index ExplanationA Compressedairline,frontright(colorcodeblack)B Compressedairline,rearright(colorcodeblue)C Compressedairline,rearleft(colorcodered)D Compressedairline,frontleft(colorcodegreen)E Compressedairlineforpressureaccumulator(colorcodeyellow)1 Airsuspensionstrut,frontright2 EDCvalve,frontright(ElectronicDamperControl)3 Rideheightsensor,frontright4 Rearrightpowerdistributionbox5 Relayforairsupplysystem
G12ChassisandSuspension3.AirSuspension
18
Index Explanation6 VerticalDynamicsPlatform(VDP)(centralcontrolunit)7 Airsuspensionstrut,rearright8 Positivebatteryterminaldistributor9 Airsuspensionstrut,rearleft10 Pressureaccumulator2liter11 Pressureaccumulator4liter12 Airsupplysystem13 Rideheightselectionswitch14 Airsuspensionstrut,frontleft
ThecentralcontrolunitforcontrollingtheairsuspensionistheVerticalDynamicsPlatform(VDP).TheVerticalDynamicsPlatform(VDP)controlunitreadsinthecurrentrideheightvaluesbymeansofthe4rideheightsensors.TheVerticalDynamicsPlatform(VDP)activatesthesolenoidvalvesofthesolenoidvalveblockinordertoperformcontrolactions.
Controlactionsatstandstillandatlowvehiclespeeds(0–20km/h/0–12mph)areachievedbyusingthestoragevolumeofthetwopressureaccumulators.Forcontrolactionswhendriving(>20km/h/>12mph),therequiredcompressedairisnottakenfromthepressureaccumulator,butisgeneratedbythecompressorandforwardeddirectlytothecorrespondingairsuspensionstruts.Inexceptionalsituations,thecompressorcanalsobeswitchedonwhenthevehicleisatstandstill.
Theincreaseinvolumeintheairsuspensionstrutliftsthevehiclebody.Achievementofthenominalride-levelheightisdetectedbythe4rideheightsensorsandactivationofthecorrespondingsolenoidvalvesisinterrupted.Three-pointcontrolisusedforprocessinginordertoavoidfrequentre-adjustment.Therearaxleiscontrolledindividuallybymeansofbothrideheightsensors.Inthecaseofthefrontaxle,thecorrespondingrideheightisadjustedonthebasisofameanvalue.
Thecompressedairlineshavedifferentcolorsinordertoavoidconfusionduringservicingworkonthesolenoidvalveblock.Thefollowingtablecontainsanoverviewofthecolorcodes.
Colorcode ComponentYellow PressureaccumulatorBlack Airsuspensionstrut,frontrightGreen Airsuspensionstrut,frontleftBlue Airsuspensionstrut,rearrightRed Airsuspensionstrut,rearleft
G12ChassisandSuspension3.AirSuspension
19
3.1.AirsupplysystemTheairsupplysystemismadeupofthefollowingcomponents:
• Electricalcompressor• Solenoidvalveblock• Holderwithvibrationdamper
Theairsupplysystemhasthetaskofgeneratingtherequiredcompressedairandcoordinatingtheairflowsbetweentheelectricalcompressor,pressureaccumulatorsandthe4airsuspensionstrutscorrespondingtotherequirements.ThecalculationsrequiredforthisareperformedbytheVerticalDynamicsPlatform(VDP).
Forpackagereasons,thesystemcomprisestwoseparatepressureaccumulatorswithatotalvolumeof6litersandamaximumstoragepressureof17.5bar.Atotalvolumeof105litersisavailabletothesystematmaximumpressure.
AirsupplysystemoftheG12
G12ChassisandSuspension3.AirSuspension
20
Index Explanation1 Pressureaccumulator2liters2 Airintakehose3 Electricalcompressor4 Holderwithvibrationdamper5 Solenoidvalveblock6 Pressureaccumulator4liters7 Compressedairlineforpressureaccumulator2liters8 Compressedairlineforpressureaccumulator4liters9 Compressedairlineforairsupplytosolenoidvalveblock10 Ventilationtoatmosphere11 Connectionforairintakehose12 Housingcoverforaircleaner61 Plug-incontactforelectricalaircompressor62 Plug-incontactforelectricaldrainsolenoidvalve63 Plug-incontactforsolenoidvalveblock64 Plug-incontactoftemperaturesensor
Theelectricalcompressorisswitchedviaarelay.TherelayisactivatedbytheVerticalDynamicsPlatform(VDP).Inordertopreventvibrationsfrombeingtransmittedintothevehicleinteriorwhenthecompressorisrunning,theairsupplysystemissecuredtothevehiclebodybymeansofaholderwithvibrationdampers.
Topreventthedriverfrombeingirritatedbythestart-upnoisesofthecompressor,thisisswitchedonalmostexclusivelywhiledriving.Thecompressorcanalsobeswitchedonatvehiclestandstillifthefollowingpreconditionsareallmet:
• VehicleconditionResiding/Awake• Sufficientvehiclevoltage• Rideheight–40mmoftheinitializesvalue• Insufficientpressureinthepressureaccumulatorforcontrol
Theintakeairiscleanedbytheaircleanerupstreamofthecompressoranddriedbytheairdrierdownstreamofthecompressor.Cleaningisnecessarysothatthevalvesareprotectedagainstsoiling.Thewaterisextractedfromtheairinordertoprotectthevalvesagainsticingatlowambienttemperatures.Ifthevalvesweretofreezeduetoexcessivelyhighairhumidityintheairsupplysystem,thiswouldmeanthatlevelcontrolbytheairsuspensionwouldnolongerbepossible.Toavoidthis,theairdrierispermanentlycleanedordried.
Thegranulateintheairdrierabsorbsmoistureathighpressureandgivesthisoffagainatlowpressure.Themoistureisextractedfromtheairwhenairflowsthroughthegranulatewhenfillingthesystem.Whenthevehicleheightislowered,theexcessairwithlowpressureisroutedthroughtheairdrier.Thestoredmoistureisthengiveofftotheairagainasitflowspast.Thispermanentregenerationoftheairdrierensuresfault-freeoperationofthesystemwithouttheneedformaintenancework.
G12ChassisandSuspension3.AirSuspension
21
Pneumaticconnectionsincompressedairsystemsareusuallyprovidedwithstandardisednumbers.Thisservesthepurposeofdifferentiationandisintendedtoexcludethepossibilityoftheconnectionsbeingmixedup.Thefollowingtableprovidesanoverviewofthestandardizednumbercodes.
Numbercode Meaning0 Intakeairconnection1 Energysupply2 Energyoutlet3 Atmosphere
G12ChassisandSuspension3.AirSuspension
22
Thefollowinggraphicshowsaschematicillustrationoftheairsupplysystem.
SchematicillustrationoftheairsupplysystemintheG12
Index ExplanationA AircompressorB SolenoidvalveblockC FillingD Draining
G12ChassisandSuspension3.AirSuspension
23
Index Explanation1 Airfilter2 Electricmotor2.1 Energyoutlet,output1(airsuspensionstrut,frontleft)2.2 Energyoutlet,output2(airsuspensionstrut,frontright)2.3 Energyoutlet,output3(airsuspensionstrut,rearleft)2.4 Energyoutlet,output4(airsuspensionstrut,rearright)2.5.1 Energyoutlet,pressureaccumulator12.5.2 Energyoutlet,pressureaccumulator23 Pneumaticdischargevalvewithpressurerelieffunction4 Airdrier5 Non-returnvalve6 Electricaldrainsolenoidvalve7 Temperaturesensor8 Electricalsolenoidvalveofpressureaccumulators9 Electricalsolenoidvalveforrearleftairsuspensionstrut10 Electricalsolenoidvalveforrearrightairsuspensionstrut11 Electricalsolenoidvalveforfrontrightairsuspensionstrut12 Electricalsolenoidvalveforfrontleftairsuspensionstrut13 Pressuresensor
3.1.1.Technicaldata
Compressor Drainsolenoidvalve
Temperaturesensor
Solenoidvalveblock
Supplyvoltage
12V 12V 5 V 12V
Pickupcurrentpervalve
— 0.82A6 — 0.8-1.0A
Holdingcurrentpervalve
— 0.55A6 — 0.55A6
Maximumstartingcurrent
110A6 — — —
G12ChassisandSuspension3.AirSuspension
24
Compressor Drainsolenoidvalve
Temperaturesensor
Solenoidvalveblock
Maximumcontinuouscurrent
35A6 2.5A6 — 3.1A6
Dynamicpressurecontrol
22.5 bar — — —
Resistance — 9Ω 5kΩat25°C/77°F
6.8kΩ
3.1.2.Solenoidvalveblock
SolenoidvalveblockoftheairsupplyintheG12
Index Explanation2.1 Energyoutlet,output1(airsuspensionstrut,frontleft)2.2 Energyoutlet,output2(airsuspensionstrut,frontright)2.3 Energyoutlet,output3(airsuspensionstrut,rearleft)2.4 Energyoutlet,output4(airsuspensionstrut,rearright)2.5.1 Energyoutlet,pressureaccumulator2l2.5.2 Energyoutlet,pressureaccumulator4l63.1 Activationofsolenoidvalveforfrontleftairsuspensionstrut63.2 Activationofsolenoidvalveofpressureaccumulators63.3 Activationofsolenoidvalveforrearleftairsuspensionstrut63.4 Activationofsolenoidvalveforfrontrightairsuspensionstrut63.5 Ground
G12ChassisandSuspension3.AirSuspension
25
Index Explanation63.6 Ground63.7 Sensorground(pressuresensor)63.8 Activationofsolenoidvalveforrearrightairsuspensionstrut63.9 Sensorvoltagesupply(pressuresensor)63.10 Sensorsignaloutput(pressuresensor)
Thedifferentelectricalsolenoidvalvesarelocatedinthesolenoidvalveblock.Theseareusedtoforwardthecompressedairtothedifferentcomponentsoftheairsuspension.TherequiredcalculationsforcontroloftheelectricalsolenoidvalvestakeplaceintheVerticalDynamicsPlatform(VDP)controlunit.
Thefollowingcontrolspeedscanbeachievedforaxle-basedchangesintherideheightbythesystem:
• Controlviathepressureaccumulators~10mm/s• Controlviatheelectricalcompressor~2mm/s
Anadvantageoftheinstallationpositionofthepressuresensoristhatthefillingpressuresofthepressureaccumulatorsandairsuspensionstrutscanbereadinwithonlyonesensordependingonactivation.
Whentheelectricalsolenoidvalveofthepressureaccumulatorsisactivated,apressuresensorsuppliesinformationaboutthecurrentfillingpressureofthesystemtotheVerticalDynamicsPlatform(VDP)controlunit.Ifthestoredpressureisnotsufficientforapendingchangeinrideheight,theVerticalDynamicsPlatform(VDP)controlunitswitchesonthecompressorforpressurebuild-up.However,thecompressorisswitchedononlysubjecttocertainpreconditionswhenthevehicleisatstandstillsothatcomfortisnotimpaired(seeAirsupplysystem).
Intheeventofactivationofthesolenoidvalvesforoperationoftheairsuspensionstruts,thepressuresensorsuppliesthefillingpressuresofthecorrespondingairsuspensionstruts.
3.2.AirsuspensionstrutTheheightofthevehiclebodyisautomaticallycontrolledviathepressureintheairsuspensionstrutinallloadstates.Thispreventsthevehiclebodyfromsinkingwhenthevehicleisloaded.Theairsupplyfortheairsuspensionstrutsisprovidedbyanelectricallydrivencompressorand2airaccumulators.Theairsuspensionthusfunctionsindependentlyoftheoperatingconditionofthecombustionengineandcanalsocompensateunevenloading(e.g.slopingload)byindividualwheelcontrolontherearaxle.
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AirsuspensionstrutsonfrontandrearaxlesintheG12
Index ExplanationA Airsuspensionstrutonthefrontaxle(illustrationfromall-wheeldrive)B Airsuspensionstrutonrearaxle1 Pot,upperpart2 Pot,lowerpart3 Gaiter4 Dustboot5 ControlvalveoftheElectronicDamperControl(EDC)6 Dampertube7 Electricalconnectionfordamperadjustment8 Pneumaticconnectionwithintegratedresidualpressureholdingvalve
Ontheairsuspensionstrut,thecoilspringisreplacedbyaU-typebellows.Theairispressedintotheairsuspensionstrutviaacompressedairconnection.TheU-typebellowsoftheairsuspensionstrutunrollsasaresultofthepressureincreaseandraisesthevehiclebody.Whentheairsuspensionstrutisvented,thepressurefallsandtheU-typebellowsrollsupagainsothatthevehiclebodyislowered.
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27
Thereisaresidualpressureholdingvalveinsidethepneumaticconnectionstopreventcompletepressurereductionintheairsuspensionstrut.Aresidualpressureof1.8–2.7barisheldwhenthecompressedairlinesareremoved.
Thepneumaticconnectionswithintegratedresidualholdingvalveontheairsuspensionstrutcannotbereplacedseparately.Theairsuspensionstrutwillbedamagedifitisattemptedtoremovedthepneumaticconnectionswithintegratedresidualpressureholdingvalve.
Airsuspensionstrut,frontaxle
Airsuspensionstrut,rearaxle
Airvolumeinnormalposition 2.87L 2.85LCompressiontravel 65mm 86mmReboundtravel 76mm 106.4mmFillingpressureondelivery 1.8-2.7bar 1.8-2.7bar
3.3.Rideheightsensor
RideheightsensorintheG12
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Index Explanation1 Holder2 Articulatedrodwithballsocket3 Deflectionlever4 Rideheightsensor
TheVerticalDynamicsPlatform(VDP)controlunitreadsinthecurrentrideheightvaluesofthevehiclebodybymeansofthe4rideheightsensors.Themaximummeasuringrangeoftherideheightsensoris70°.Theoutputisananaloguevoltagesignalbetween0.5Vand4.5V.
Therideheightsensorhasthefollowingelectricalconnections:
• Voltagesupply(5V)• Groundconnection• Signaloutput(0.5–4.5V)
RideheightsignaloftherideheightsensorsintheG12
Index ExplanationV VoltageinVW Angle
Afterrenewalofoneormorerideheightsensors,theservicefunctionforrideheightadjustmentmustbeperformedusingtheBMWdiagnosissystemISTA.
TherideheightvaluesarestoredintheBodyDomainController.Theyarealsousedforleveladjustmentoftheheadlights.
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3.4.Operatingstrategy
InputandoutputdiagramoftheairsuspensionintheG12
Index Explanation1 VerticalDynamicsPlatform(VDP)2 Compressor3 Solenoidvalveblock4 Drivingexperienceswitch5 Doorcontactswitch6 Rideheightselectionswitch7 Temperaturesensor(insidethecompressor)
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Index Explanation8 Pressuresensor(insidethesolenoidvalveblock)9 Rideheightsensor10 Vehicleelectricalsystemvoltage11 Vehiclespeed
ConfigurationoptionsoftheairsuspensionintheG12
Index ExplanationA NormallevelorSportlevelactivatedB Highlevelactivated1 SPORTbuttononthedrivingexperienceswitch2 Rideheightselectionswitch
Therideheightcanbeadjustedmanuallybymeansoftherideheightselectionswitchandthedrivingexperienceswitch.Threedifferentrideheightsareavailable.
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RideheightsoftheG12
Index ExplanationA Sportlevel(-10mm)B Normallevel(+/-0mm)C Highlevel(+20mm)
Situation Highlevel Normallevel SportlevelRideheight +20mm +/–0mm -10mmRideheightactivation
Rideheightselectionswitch
— 1)Drivingexperienceswitch2)Drivingspeed> ~ 140km/h/> ~ 87mph
Speed 0–40km/h/0–25mph
0~140km/h/0~87mph
1)0km/h–finalspeed2)~140km/h/~ 87mph–finalspeed
Thefollowingprerequisitesmustbemetinordertoperformmanualadjustmentintherideheightbymeansoftherideheightselectionswitch:
• DrivingreadinessResiding/Awakeordrivingbetween0–40km/h/0–25mph• Sufficientvehiclevoltage• Doorsclosed• Pressureaccumulatorwithsufficientfillingpressure
(onlyrelevantfordrivingreadinessResiding/Awake)
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ThefollowinggraphicshowstheoperatingstrategyoftheairsuspensionintheG12.
OperatingstrategyoftheairsuspensionintheG12
Index ExplanationA Highlevel(+20mm)B Normallevel(+/-0mm)C Sportlevel(-10mm)H Rideheightofthevehiclebodyv Vehiclespeed1 RideheightselectionswitchsettoHighlevel2 DrivingexperienceswitchinComfortposition3 DrivingexperienceswitchinSportposition
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3.4.1.Highlevel
OperatingstrategyoftheairsuspensionintheG12atHighlevel
Index ExplanationA Highlevel(+20mm)B Normallevel(+/-0mm)C Sportlevel(-10mm)H Rideheightofthevehiclebodyv Vehiclespeed1 RideheightselectionswitchsettoHighlevel2 DrivingexperienceswitchinComfortposition3 DrivingexperienceswitchinSportposition
Inthespeedrangebetween0–40km/h/0–25mph,theHighlevel(+20mm)canbeactivatedmanuallyviatherideheightselectionswitch.Thisrideheightsettingisintendedtoallowthedrivertodriveovershouldersorrampswithalargegradientanglewithoutdamagingthevehicleduetotheincreasedgroundclearance.Thefollowingrideheightsaresetautomaticallyifthisspeedrangeisexceeded.
1 IfthedrivingexperienceswitchisinComfortposition,therideheightisloweredtoNormallevel(+/-0mm).
2 IfthedrivingexperienceswitchisinSportposition,therideheightisloweredtoSportlevel(-10mm).
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Whenadrivingspeedof~140km/h/~87mphisexceeded,thevehiclebodyisautomaticallyloweredfromNormalleveltoSportlevel(-10mm)independentlyoftherespectiveswitchsettings.LoweringtoSportleveloffersthefollowingadvantages:
• Lowvehiclecenterofgravityandthusincreaseddrivingdynamics.• Improvedaerodynamicsandthuslowerfuelconsumption.
3.4.2.Normallevel
OperatingstrategyoftheairsuspensionintheG12atNormallevel
Index ExplanationA Highlevel(+20mm)B Normallevel(+/-0mm)C Sportlevel(-10mm)H Rideheightofthevehiclebodyv Vehiclespeed1 RideheightselectionswitchatNormallevel2 DrivingexperienceswitchinComfortsetting
Normallevel(+/-0mm)canbesetbymeansofthefollowingswitchpositions.
• RideheightselectionswitchinNormalposition.• DrivingexperienceswitchnotinSportposition.
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Whenadrivingspeedof~140km/h/~87mphisexceeded,thevehiclebodyisautomaticallyloweredfromNormalleveltoSportlevel(-10mm)independentlyoftherespectiveswitchsettings.LoweringtoSportleveloffersthefollowingadvantages:
• Lowvehiclecenterofgravityandthusincreaseddrivingdynamics.• Improvedaerodynamicsandthuslowerfuelconsumption.
3.4.3.Sportlevel
OperatingstrategyoftheairsuspensionintheG12atSportlevel
Index ExplanationA Highlevel(+20mm)B Normallevel(+/-0mm)C Sportlevel(-10mm)H Rideheightofthevehiclebodyv Vehiclespeed1 RideheightselectionswitchatNormallevel2 DrivingexperienceswitchinSportsetting
Sportlevel(-10mm)canbesetbymeansofthefollowingswitchpositions.
• RideheightselectionswitchinNormalposition.• DrivingexperienceswitchinSportposition.
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Sportlevel(-10mm)offersthehighestdrivingdynamicsofallrideheightsduetothelowvehiclecenterofgravity.Thefuelconsumptionalsofallsduetotheimprovedaerodynamics.
3.5.NotesforServiceComplete(100%)tightnessoftheairsuspensioncannotbeguaranteedduetothenumerousflexiblecompressedairlineswiththecorrespondingcompressedairconnections.Adefinedlowlossofcompressedairisthereforepermissible.IfthevehicleisparkedatNormallevel,therideheightmaybeloweredbyuptoamaximumof–2mmafter24hours.Thismeansthattherideheightmaybeloweredbyupto-60mmforavehiclethathasbeenparkedfor30dayswithouttherebeingafaultcausedbyaleak.
SideviewoftheG12withairsuspensionloweredtomaximumextent
Sincecomponentsdonotallleaktothesameextentfortolerancereasons,itisalsopossiblethatthevehiclewillbeslopingatanangleafteraprolongedstandstilltime.
LowandslopingvehiclepositionsareautomaticallycompensatedbytheairsuspensionafterdetectionofthevehicleconditionResiding/Awake.Forthispurpose,themissingcompressedairisforwardedtothecorrespondingspringstrutsbythepressureaccumulator.Ifthefillingpressureofthepressureaccumulatorsistoolow,thelackofairiscompensatedbyswitchingontheelectricalcompressor.
Thefollowingscenariosforactivationoftheelectricalcompressorarepossible:
1 Iftherideheightislessthan–40mm,thecompressorwillbeswitchedononlywhentheengineisrunning.
2 Iftherideheightismorethan–40mmandthevehicleelectricalsystemhassufficientvoltage,thecompressorwillalreadybeswitchedonwhenthevehicleconditionResiding/Awakeisdetected.
3.5.1.LiftingthevehicleTheairsuspensionhasajackdetectionfunction.Thispreventscontrolactionoftheairsuspensionwhenthevehicleislifted.
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3.5.2.TransportmodeTheairsuspensionisintransportmodewhennewvehiclesaredelivered.Achangeintherideheightisnotpossible.TransportmodemustbedeletedusingtheBMWdiagnosissystemISTAduringthepre-deliverycheck.Thedifferentrideheightsoftheairsuspensioncanbeselectedonlyaftersuccessfulstart-upoftheairsuspension(transportmodedeleted).
3.5.3.BleedingtheairsuspensionWhenworkingoncomponentsoftheairsuspensionsystem,itisnecessarytodepressurizethesystembeforeundoingthevariouscompressedairlines.ThiscanbedoneusingtheBMWdiagnosissystemISTAbymeansofableedingroutine.Here,thevarioussolenoidvalvesoftheairsuspensionstrutsandtheelectricaldrainsolenoidvalveareactivatedsimultaneously.Inordertoprotectthevalvesagainstoverheating,thebleedingroutinecannotbeperformedanarbitrarynumberoftimesinsuccession.However,thefunctionisavailableagainafteradefinedwaitingperiod.
Inordertoavoiddamagetotheairsuspensionstruts,thevehicleshouldberaisedslightlyusingavehiclehoistduringthebleedingroutine.
However,itisnotrecommendedtocompletelyliftthevehicleduringthebleedingroutineasthishamperscompleteemptyingofthecompressedairfromtheairsuspensionstruts.
3.5.4.FillingtheairsuspensionThesystemisfilledautomaticallyviathevehicle'selectricalcompressorassoonasthemarginalconditionsforthisaremet.InordertoperformaleakagetestoftheairsuspensioninService,theelectricalcompressorcanbeswitchedonmanuallytofillthesystemusingtheBMWdiagnosissystemISTA.Iftheairsuspensionisfilledseveraltimes,theelectricalcompressormaybeswitchedofftopreventthecompressorfrombeingdamaged.
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3.6.Systemwiringdiagram
Systemwiringdiagramofthetwo-axleridelevelcontrolintheG12
G12ChassisandSuspension3.AirSuspension
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Index Explanation1 Rideheightsensor,frontleft2 EDCvalve,frontleft(ElectronicDamperControl)3 EDCvalve,frontright(ElectronicDamperControl)4 DSCrideheightsensor,frontright5 Powerdistributionbox,frontright6 BodyDomainController(BDC)7 Rearrightpowerdistributionbox8 VerticalDynamicsPlatform(VDP)9 Rideheightsensor,rearright10 EDCvalve,rearright(ElectronicDamperControl)11 Relayforairsupplysystem12 Positivebatteryterminaldistributor13 Compressor14 Solenoidvalveblock15 Airsupplysystem16 EDCvalve,rearleft(ElectronicDamperControl)17 Ride-heightsensor,rearleft18 CrashSafetyModule(ACSM)19 Rideheightselectionswitch20 DynamicStabilityControl(DSC)
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ThefollowinggraphicprovidesanoverviewofthebrakesystemoftheG12.
OverviewofbrakesystemintheG12
Index Explanation1 Plug-incontact,wheel-speedsensor,frontright2 EMFactuator(electromechanicalparkingbrake)3 Plug-incontact,wheelspeedsensor,rearright4 Plug-incontact,brakepadwearsensor,rearright5 Plug-incontact,wheelspeedsensor,rearleft6 Brakedisc,rearaxle7 Brakecaliper,rearaxle8 Auto-Holdbutton9 Parkingbrakebutton10 DSCbutton11 Bearingsupport,pedalmechanism12 Brakeservo13 Brakefluidexpansiontank14 DynamicStabilityControl(DSC)
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Index Explanation15 Brakecaliper,frontaxle16 Brakedisc,frontaxle17 Plug-incontact,wheel-speedsensor,frontleft18 Plug-incontact,brakepadwearsensor,frontleft
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4.1.Servicebrakes
4.1.1.BrakedesignInordertoenhancethevisualappearanceofthebrakes,Blackpaintedcalipersareoptionalinthe“AutobahanPackage”(ZAN).
Versions Frontaxle RearaxleStandardcaliper
AutobahnPackagewithBMWlogoprint
MSport
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4.1.2.Pedalmechanismmounting
MountingofthepedalmechanismonthebrakeservolinkageintheG12
Index ExplanationA BrakeservolinkageB Pedalmechanism1 Ballhead2 Plasticclip
AmodifiedmountingisusedintheG12betweenthepedalmechanismandthebrakeservolinkage.Here,theballheadofthebrakeservolinkageisengagedinaplasticcliponthepedalmechanism.
Anewspecialtoolisneededtoreleasethisconnection.
Partnumber83302409646
Specialtoolforremovingthepedalmechanism
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Whenremovingthepedalmechanism,alwaysobservetheinstructionsinthecurrentrepairinstructions.
4.2.ParkingbrakeTheBMWE65/E66(BMW7Seriesfrom2001–2008)wasthefirstproductionvehicleintheworldwithanelectromechanicalparkingbrakeEMF.ThiswasfollowedbymanyotherBMWmodelswithdifferentelectricalparkingbrakesystems.
Thefollowingadvantagesresultfromtheuseofsuchasystem:
• MorestoragespaceduetoomissionofaparkingbrakeleverandparkingbrakeBowdencable.• Contactpressureofbrakepadscorrectlyadjustedatalltimes.• Variousadditionalfunctionstoassistthedriver(e.g.automaticreleasewhendrivingoff).• Higherbrakingpowerofauxiliarybrakesystem.
Thefollowing2differentelectricalsystemsarecurrentlyusedatBMW:
• Electromechanicalparkingbrake=Cablepullsystemviaduo-servoparkingbrake(Küstersystem).
• Electricparkingbrake=Combinedbrakecaliper(TRW/Continentalsystem).
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Thefollowinggraphicshowsacomparisonofthetwosystems.
SystemcomparisonoftheelectromechanicalparkingbrakeintheF01/F02withtheelectricparkingbrakeoftheG12
Index ExplanationA F01/F02(BMW7Seriesfrom2008–2015)B G12(BMW7Seriesfrom2015)1a DSCcontrolunit(DynamicStabilityControl)1b DSCcontrolunitwithintegratedparkingbrakefunction
(DynamicStabilityControl)2 Instrumentpanel(KOMBI)3 Parkingbrakebutton4 Electricparkingbrakeviaactuatoratcombinedbrakecaliper
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Index Explanation5 Electromechanicalparkingbrakeviaduo-servoparkingbrake6 Electromechanicalparkingbrakeactuatorunitwithintegrated
controlunit(electromechanicalparkingbrake)BDC BodyDomainControllerZGM Centralgatewaymodule
IncontrasttothecablepullsystemintheF01/F02,theelectricparkingbrakesystemwithacombinedbrakecaliperfamiliarfromthesmallerseriesisusedintheG12.
Previously,theparkingbrakewasrealizedbymeansofaduo-servoparkingbrakeintheheavyupperclassvehicles.Theadvantageofthissystemisthehighself-lockingforceofthebrakepadswhentheparkingbrakeisapplied.
Duetotheincreaseinthepreloadforcesofthecombinedbrakecaliperwithelectricparkingbrake,itwaspossibletodispensewiththepreviouslyusedcablepullsystemintheG12.OmissionoftheassociatedcomponentsisbeneficialforweightreductionandalsofortherepairfriendlinessoftheG12.
TheelectricparkingbrakeoftheG12isdifferentiatedaboveallbythefactthatthereisnoseparatecontrolunit.TheelectricparkingbrakeisactivatedviathecontrolunitoftheDynamicStabilityControl(DSC).Thereisaparkingbrakebuttononthecenterconsoleforactivatingordeactivatingtheelectricparkingbrake.ThedriverisinformedaboutthecurrentsystemstatusviatheinstrumentclusterKOMBI.
Thebrakepadisappliedwithapreciselycalculatedpreloadforceviatwoactuatorsscrewedontothebrakecalipers.AtemperaturemodelisstoredintheDSCcontrolunitwhichmakesitpossibletodrawconclusionsaboutthebrakedisctemperatures.Asthecontactpressuredecreaseswhenthebrakediscscooldown,thesystemmustadjustthebrakepadsasappropriate,particularlyifthebrakediscsarehot.Thetimeandfrequencyoftheadjustmentvariesdependingontheinitialtemperaturecalculated.
Whentheelectricparkingbrakeisopened,theactuatorsaremovedbackonlyuntilthebrakepadshavereachedtheircorrectlysetclearance.Duetothisreadjustmentfunction,theactuatorsmustbemovedbackbeforeexchangingthebrakepadsinService.Forthedetailedprocedure,refertothecurrentrepairinstructions.
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ActuatorforelectricparkingbrakeintheG12
Index Explanation1 Beltdrive2 Planetarygears3 Spindlenut4 Brakecaliper5 Electricmotor(DC)
Thereisanelectricmotorwithbeltdriveandplanetarygearonthehousingofthecombinedbrakecaliperwithelectricparkingbrake.Whentheelectricmotorisactivated,theforceistransmittedviathebeltdriveandplanetarygeartothespindlenut.Thespindlenutgeneratestherequiredstroketoapplythebrakepad.ThecontrolunitoftheDynamicStabilityControlcandeterminethepreloadforceonthebasisoftheriseincurrentoftheelectricmotor.
Whencarryingoutservicingwork,anextendedspindlenutcanbetravelledbacktoitsinitialpositionasfollows:
• Specialtoolformechanicallyturningback• Servicefunction“Workshopmode”intheBMWdiagnosissystemISTA
4.2.1.Functions
Dynamicemergencybraking
Iftheparkingbrakebuttonisoperatedduringthejourneyaboveadefineddrivingspeed,theDSCunitinitiatesadynamicemergencybrakingoperation.Apressurebuild-upoccursinall4wheelbrakesduetoactivationofthe6-pistonpumpandthechangeovervalvesintheDSCunit.Thesliplimitsofallwheelsaremonitoredwiththeassistanceofthefourwheelspeedsensorstoensureastablebraking
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operationuntilthevehiclecomestoastandstill.Thetwoactuatorsoftheelectricparkingbrakeareactivatedassoonasthevehiclecomestoastandstill.Thevehicleisthensecuredtopreventitfromrollingawayonlybymeansoftheparkingbrake.
Automaticreleaseoftheparkingbrake
Thisfunctionallowsthedrivertodriveoffwhentheparkingbrakeisactivatedwithoutoperatingtheparkingbrakebuttontoreleasethebrake.
Prerequisitesforreleasingtheelectricparkingbrake:
• Driver'sdoorisclosed• VehicleconditionDRIVING• Electricparkingbrakeactuated• Drivepositionengaged• Acceleratorpedaloperated
4.2.2.BraketeststandTheDynamicStabilityControl(DSC)hasarollermodesothatthebrakingpoweroftheelectricparkingbrakecanbecheckedonabraketeststand.Whenrollermodeisactivated,thevehicleisbrakedviatheactuatorsoftheelectricparkingbrakewhentheparkingbrakebuttonispressed.ADSCpressurebuild-upinthe4wheelbrakesdoesnottakeplace.Thismakesitpossibletodeterminethebrakeforcesoftheelectricparkingbrake.
IntheG12,rollermodeisautomaticallydetectedonthebasisofaplausibilitycheck(wheelspeedcomparison).Thedetectiontakesamaximumof5seconds(canberecognizedbyslowflashingoftheredparkingbrakeindicatorlight).
Afteractivationofteststandmodethesystemisinteststandmode.Thisconditionisacknowledgedbytheindicatorlightoftheparkingbrakestartingtoflashatafrequencyof1Hz.Theparkingbrakecanbeappliedin5stagesusingtheparkingbrakebutton.Inthiscase,thebrakingvariesbetweentheminimumbrakingpowerinthefirststageandthemaximumbrakingpoweroncetheparkingbrakebuttonhasbeenpressedfivetimes.Ifthebuttonisoperatedcontinuously,thesystemincreasesthebrakingpowerautomaticallyincrementallyuptothemaximumbrakingpower.Theflashingfrequencyoftheparkingbrakeindicatorlightchangesfrom1Hzto3Hzwhentheparkingbrakebuttonispressedinteststandmode.
Thefollowingpointsmustbeobservedduringthetest:
• Donotpresstheaccelerator• DrivepositionN(neutral)• Donotpressthefootbrake
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4.3.Serviceinformation
4.3.1.ServicebrakesThestatusofthebrakepadscannotbereadoutpermanentlyviatheCentralInformationDisplay(CID).
ThefollowinggraphicshowsthevehiclestatuswithoutandwithinformationaboutthestatusofthebrakepadsontheCentralInformationDisplay(CID).
CIDmessageonvehiclestatusintheG12
Index ExplanationA BrakepadwearsensorwithinlimitsB Brakepadwearsensoroutsidelimits1 Vehiclestatus2 OKEngineoil3 OKBrakefluid4 OK§vehicleinspection5 OKVehiclecheck6 Brakepadsrear(padwearshortlybeforethewearlimit)
TheG12isequippedwithaone-stagebrakepadwearsensor.Novehiclestatusaboutthecurrentstatusofthebrakepadsisoutputaslongasthissensorhasnotbeengroundbythebrakedisc.
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Beforethewearlimitofthebrakepadisreached,thesensorwireoftheone-stagebrakepadwearsensoriscutthroughbytherotatingbrakediscwhiledriving.Asfromthispoint,thevehiclestatusofthebrakepadscanbecheckedontheCentralInformationDisplay(CID).Theremainingdistanceuntilthewearlimitofthebrakepadisreachedis4000-5000km/2500-3100miles,dependingondrivingstyle.
Inaddition,thedriverisinformedabouttheconditionofthebrakepadsbymeansofthefollowingwarnings.
Remainingdistance YellowCheckControlmessage
RedCheckControlmessage
<2000km/<1200miles X0km/0miles X
Thecurrentrepairinstructionsmustalwaysbeobservedinordertoavoidinterferencenoisesafterbrakepadreplacement.
4.3.2.Parkingbrake
Replacingbrakepads
Inordertoreplacethebrakepadsoftherearparkingbrakecalipers,itisfirstnecessarytoturnbackthedrivespindleinthebrakecaliper.ThiscanbedoneeithermanuallyusingaspecialtoolorusingtheBMWdiagnosissystemISTA.TheparkingbrakebuttonisblockedtopreventuseafteractivationofworkshopmodeviatheBMWdiagnosissystemISTA.Thispreventsinjuryduringthebrakeservice.Theparkingbrakebuttonisenabledagainatthestartofdrivingorafterexitingworkshopmode.
Afterenablingviathespeedthresholdof3km/h/1.8mph,theparkingbrakemustbere-initializedbybuttonoperation(apply/releasebrake).
Emergencyrelease
Itispossibletomechanicallyturnbackthedrivespindletoreleasetheparkingbrakeafterremovingtheactuatorhousingfromthebrakecaliper.Topreventaccidents,thevehiclemustfirstbesecuredtopreventitfromrollingaway.
Emergencyreleaseoftheelectricparkingbrakeispermittedonlybycorrespondinglytrainedpersonnel.
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TheG12willbeequippedinthestandardequipmentconfigurationwithrun-flattires.Asparewheelisavailableasoptionalequipment.
Components Standardequipment OptionalequipmentRun-flattires XSparewheel(OE300) X
TiresoftheG12
Index ExplanationA Tireswithoutemergencyrunningproperties(NotforUS)B Run-flattires
Intheeventoftirepressurelossinarun-flattire,thecustomercanstilldriveatarestrictedspeed(max.80km/h/50mph)foraremainingdistancethatisdependentonthevehicleload.Onvehicleswiththeoptionalchassisandsuspensionpackage“ActiveComfortDrive”,thevehicleweightisautomaticallydistributedviatheactiveelectricstabilizerswhendrivingwithanunpressurisedrun-flattiresothattheunpressurisedwheel(<0.5bar)isrelievedtothemaximumpossibleextentandtheintactwheelsloadedcorrespondingly.Thisensuresthatthemaximumpossibleremainingdistancecanbedriven.Themaximumpermittedremainingdistancewithmediumloadis80kilometres/50miles.
Furtherinformationonthefunctionoftheactiveelectricstabilizerisprovidedinthesection“AutobahanPackage”.
Adamagedrun-flattirecanalsobereplacedbyatirewithoutemergencyrunningpropertiesintheeventoftirefailure.However,thetirewithoutemergencyrunningpropertiesmustbereplacedattheearliestopportunitybyarun-flattire.
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5.1.PuncturedetectionsystemsDependingoncountry,theG12isequippedwiththefollowingsystemsforpuncturedetection:
• Tirepressurecontrol(RDC)
5.2.TirePressureMonitorRDCi
SystemoverviewoftirepressurecontrolRDCiintheG12
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Index Explanation1 Wheelelectronics,frontright2 CentralInformationDisplay(CID)(displayoftirepressurespossible)3 Wheelelectronics,rearright4 Remotecontrolreceiver(FBD)5 Wheelelectronics,rearleft6 Instrumentpanel(KOMBI)7 DynamicStabilityControl(DSC)8 Wheelelectronics,frontleft
TheG12isequippedwiththeRDCialreadyfamiliarfromtheF15.TheRDCiisasystemwhichperformsdirectmeasurementandwhichdeterminestherealtirepressuresbymeansofwheelelectronicsineachwheel.UnlikewiththeRDClow,aseparateRDCcontrolunitisnotrequiredfortheRDCi.ThefunctionsoftheRDCiareintegratedintotheDynamicStabilityControl(DSC)controlunit.Theremotecontrolreceiver(FBD)actsasareceiverforthesentreportsofallwheelelectronics.ItthenforwardsthisinformationviabustotheDSCcontrolunit.
ThepreviousRDCisystemsweresuppliedbyContinental.ThesystemsupplieroftheRDCiintheG12isthecompanySchrader.Inordertoensurefault-freeoperationofthesystem,itisessentialthatonlySchraderwheelelectronicsareused.Itisnotpossibletoassumeanyliabilityformalfunctionswiththird-partywheelelectronics.
OntheG12,theresttimesrequiredbythesystembeforethenewwheelelectronicscanbetaught,havechanged.Previously,avehiclewithRDCihadtobestationaryforanuninterruptedperiodofatleast8minutesindependentlyoftheterminalstatusbeforetheDSCcontrolunitacceptedtheIDsofthenewwheelelectronics.
OntheG12,thevehicleconditionisdecisiveforthetimesrequiredbythesystembeforetheIDsofnewwheelelectronicsareacceptedandtaught.Thefollowingtableprovidesanoverviewofthedifferentconditions.
Vehiclecondition 5minutes 17minutesResiding/Awake XDriving X
SothatnewwheelelectronicscanbetaughtbytheDynamicStabilityControl(DSC),astandingtimeofatleast5minutes(Residing/Awake)or17minutes(driving)mustbeobservedafterawheelexchange.
Ifthestandingtimeofatleast5minutes(Residing/Awake)or17minutes(driving)wasnotreachedbeforestartingajourneywithnewwheelelectronics,aCheckControlmessagewillbedisplayedtothedriverafteracertaintime.Inthiscase,thevehiclemustonlyremainstationaryforanuninterruptedperiodoflongerthan5minutesinResiding/Awakemodeor17minutesinDrivingmode.ThenewwheelelectronicswillthenbeautomaticallytaughtbythecontrolunitoftheDynamicStabilityControl(DSC).
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ThevehiclecanalsobeinthevehicleconditionDrivingwhentheenginehasbeenswitchedoffbytheautomaticenginestart-stopfunctionMSA.
Thesystemmustbere-initializedintheeventofchangesinthetirepressuresaswellasafterwheelexchange.InitializationofthenewtirepressurescanbeperformedusingthecontrollerontheCentralInformationDisplay(CID).
5.2.1.Wheelelectronics
WheelelectronicsfromSchraderintheG12
Thewheelelectronicsareinthefollowingmodes,dependingonthesystemstatus:
• Sleepmode• Teach-inmode• Readinessmode
TherearealsochangesinthetransmissionmodesoftheSchraderwheelelectronicsincomparisonwiththetransmissionmodesofthewheelelectronicsfromContinental.Inordertoguaranteethelongestpossiblebatterycapacity,thewheelelectronicsrequirelongerstandingtimesbeforetheyswitchtoteach-inmode.
After15minutesinrestmode(wheelstandstill),thewheelelectronicsstarttotransmitinteach-inmodeassoonastheyareacceleratedtoaspeedfasterthanaround20km/h.Inteach-inmode,thereportsaresenttotheDSCcontrolunitevery15secondsforapproximately9minutes(40reports).Transmissioninteach-inmodeallowstheDSCcontrolunittocalculatetheinstallationpositionoftherespectivewheelelectronics.Thewheelelectronicswillstarttotransmitinreadinessmodeifawheel
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setwaschangedfromonevehicletoanotherwithoutthewheelsethavingbeeninrestmode(wheelstandstill)foranuninterruptedperiodofmorethan15minutes.Teachingofthewheelelectronicsisnotpossibleinreadinessmode.
Balancingofthewheelsetshortlybeforefittingonthevehicleisnotaproblem.Sinceonlyasmallnumberofreportsaretransmittedinteach-inmodeduringbalancing,theremainingreportsaresufficienttoreliablyteachthewheelelectronics.
ThebatterystatusofthewheelelectronicscanbereadoutviatheBMWdiagnosissystemISTA.Theremainingbatterylifeisspecifiedinpercent.
DetailedinformationontheoperatingprincipleoftheRDCiisprovidedintheTrainingReferenceManual“I01CompleteVehicle”.
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BusoverviewG12
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Index ExplanationACC ActivecruisecontrolACSM CrashSafetyModuleAHM Trailermodule(NotforUS)AMPT AmplifierTop(tophighfidelityamplifier)ASD ActiveSoundDesignBDC BodyDomainControllerCON ControllerDDE DigitalDieselElectronics(NotforUS)DME DigitalMotorElectronicsDME2 DigitalEngineElectronics2DSC DynamicStabilityControlEARSVH ElectricactiverollstabilizationrearEARSVV ElectricactiverollstabilizationfrontEGS ElectronictransmissioncontrolEPS ElectromechanicalPowerSteeringFLA High-beamassistantFLER FrontalLightElectronicsRightFLEL FrontalLightElectronicsLeftFZD RooffunctioncenterGWS GearselectorHEADUNIT HeadunitHKARearclimatecontrol
Automaticrearair-conditioningandheating
HKFM TailgatefunctionmoduleHSR RearaxleslipanglecontrolIHKA Integratedautomaticheating/airconditioningKAFAS Camera-baseddriversupportsystemsKOMBI InstrumentpanelLEM LightEffectManagerNFC NearFieldCommunicationNVE NightVisionElectronicsPCU PowerControlUnitPMA ParkingmanoeuvringassistantRFK ReversingcameraRSE RearSeatEntertainment
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Index ExplanationRSL RadarSensorLeft(avoidanceassistant)RSR RadarSensorRight(avoidanceassistant)SAS OptionalequipmentsystemSCR SelectiveCatalyticReductioncontrolunit(NotforUS)SMBF Seatmodule,passengerSMBFH Seatmodule,passenger,rearSMFA Seatmodule,driverSMFAH Seatmodule,driver,rearSPNMHL SeatpneumaticsmodulebackleftSPNMHR SeatpneumaticsmodulebackrightSWW Lanechangewarning(main)SWW2 Lanechangewarning(secondary)TCB TelematicCommunicationBoxTRSVC ControlunitforrearviewcameraandSideViewVDP VerticalDynamicPlatformVM VideoModule(NotforUS)VTG VTGcontrolunitWCA WirelesschargingtrayZGM Centralgatewaymodule
ThecontrolunitsthatarerelevanttodrivingdynamicsareinterconnectedviatheFlexRaybus.Thisbusischaracterizedaboveallbyitshighdatatransferrateof10MBit/s.
Themostimportantsystemsandtheirfunctionsaredescribedinmoredetailbelow.
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6.1.DynamicStabilityControl(DSC)AlongsidetheVerticalDynamicsPlatform(VDP)controlunit,theDynamicStabilityControl(DSC)representsthecoreelementofthedrivingdynamicscontrolsystemsusedtoincreaseactivesafety.Itoptimizesdrivingstabilityinalldrivingconditionsandalsotractionwhendrivingoffandaccelerating.Italsoidentifiesunstabledrivingconditionssuchasundersteeringoroversteeringandhelpsmaintainthevehicleonasteadycourse.
InstallationpositionofDynamicStabilityControl(DSC)intheG12
Index ExplanationA DSCunit1 DSCcontrolunit2 BrakelineconnectionsattheDSChydrauliccontrolunit3 Returnpump4 Bracket
TheDynamicStabilityControl(DSC)islocatedinthefrontlowerareaofthevehicle.ThemanufacturerdesignationisTRWDSC-EBC460.Duetothedifferentconnectiondiametersofthebrakelines,channelconfusionofthevarioushydrauliclinesisnotpossible.
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DSCunitintheG12
Index ExplanationA DSChydraulicunitB DSCcontrolunit1 Pressuresensors2 Hydraulicdampingelements3 Returnpumpactivation4 Solenoidvalves(12x)5 Controlunitconnector6 Solenoidvalvecoils(12x)
TheDSCcontrolunitandtheDSChydrauliccontrolunitarescrewedtogether.TheDSCcontrolunitcanbereplacedindividuallytoreduceservicingcosts.
Inolderseries,thedifferentdrivingdynamicssystemsareconnectedviatheIntegratedChassisManagement(ICM)controlunit.ThecontrolunitoftheDynamicStabilityControl(DSC)intheG12hasanadditionalstorageelement(blackbox)inwhichsomeofthefunctionsoftheIntegratedChassisManagement(ICM)arestored.Thedifferentdrivingdynamicscontrolsystemsarecoordinatedperfectlybymeansofthealgorithmsstoredintheblackbox.
Thefunctionsofthetirepressurecontrol(RDC)andelectricparkingbrake(EPB)wereintegratedintheDSCcontrolunit.
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6.1.1.Hydrauliccircuitdiagram
HydrauliccircuitdiagramofTRWDSC-EBC460
Index ExplanationA InstalledonlyonhybridversionB OnlyforoptionalequipmentactivecruisecontrolwithStop&Gofunction1 Hydraulicdampingelements2 6-pistonpump3 DSCpressuresensor4 Brakemastercylinder5 Brakefluidexpansiontank6 Brakeservo7 BrakepedaltravelsensorAV Exhaustvalves
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Index ExplanationEV IntakevalvesHL RearaxleonleftHR RearaxleonrightTV SeparatorvalvesUPS ChangeovervalvesVL FrontaxleonleftVR Frontaxleonright
DifferentDSCversionsareuseddependingonthedrivetypeandequipmentrange.Inthehybridversion,thereisanadditionalbrakepedaltravelsensoronthefootbrakelever.
Ifthevehicleisequippedwiththeoptionalequipment“ActivecruisecontrolwithStop&Gofunction”,thereare2additionalpressuresensorsinthehydraulicunit.
6.1.2.FunctionsThefollowingtableprovidesanoverviewofthedifferentfunctionsoftheDSCunit.
Function ExplanationAntilockBrakeSystem(ABS)
Preventsblockingofindividualwheelswhenbrakingthroughtargetedmodulationofthebrakepressures.Vehiclesteerabilityismaintained.
DynamicStabilityControl(DSC)
Ifthevehiclestartstoundersteeroroversteer,itisstabilizedbytargetedbrakeinterventionsatindividualwheels.
DynamicTractionControl(DTC)
ThisisaspecialmodeoftheDynamicStabilityControl(DSC).IninteractionwithASCandDSC,thismodefeaturesextendedinterventionthresholdsandpermitsanevensportierdrivingstylewithoutinterventionsonnormalsurfacesaswellasmaximumpropulsiononloosegroundsuchassnow,sandorcoarsegravel.
CorneringBrakeControl(CBC)
Preventsthevehiclefromturninginwhenitisbrakedlightlyunderhighlateralaccelerationforcesbymeansofasymmetricalcontrolofthebrakepressure.Thecorneringstabilityisimproved.
AutomaticStabilityControl(ASC)
Preventsthedrivewheelsfromspinningbytargetedbrakingofthesewheelsandadaptationofthedrivetorquedeliveredbytheengine.Vehiclepropulsionisoptimizedasaresultanddrivingstabilityismaintained.
DynamicBrakeControl(DBC)
Intheeventofpanicbrakinginitiatedbythedriver,thesystemsupportsthedriverbyautomaticallyimmediatelyapplyingthemaximumbrakepressuretoensurethebestpossibledeceleration.
AutomaticDifferentialBrake(ADB-X)
Replicatesthefunctionofadifferentiallock.Ifawheeldisplaysatendencytospin,thiswheelisautomaticallybrakedsothatpropulsioncanstillbeachievedviatheotherwheelofthedrivenaxle.
Trailerstabilizationcontrol
Automaticallydetectswhenavehiclewithtrailerisstartingtosnake,stabilizestheoutfitbytargetedbrakeinterventionsandsimultaneouslydeceleratesittoanuncriticalspeedforsnaking.
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Function ExplanationBrakestandby Buildsupamoderatebrakepressureinthesystemwhenthedrivertakes
hisfootofftheacceleratorpedalveryquickly.Thebrakepadsareappliedslightlyasaresult.Thebrakingeffectthenactsmorequicklyifthedriverthenperformspanicbraking.
Drybyapplyingbrake Dependingonoperationofthewiper,appliesthebrakepadsgentlyatintervalsinordertodrythebrakediscs.Thebrakingeffectissignificantlyimprovedbythiswhenthevehicleisbraked.
Fadingsupport Supportsthedriverwhenbrakingifthebraketemperaturehasbecomeveryhighduetoanextremedrivingstyleandthedesireddecelerationcanbeachievedonlybyapplyingahigherbrakeforce.
Drive-offassistant Holdsthevehicleforapproximately1.5sonuphillgradientswhenthedriverreleasesthebraketodriveoff.Thisallowsthedrivertodriveoffcomfortablywithoutthevehiclerollingawayonitsown.
AutomaticHold Automaticallyholdsthevehicleafterithascometoastandstillwithoutitbeingnecessarytostillpressthebrakewhenthedrivepositionisselected.Thebrakeisautomaticallyreleasedwhentheacceleratorpedalispressedandthevehicledrivesawaynormally.Thefunctioncanbeswitchedonandoffbymeansofabutton.
Ifatrailertowhitchisretrofitted,thefunction“trailerstabilizationlogic”mustbeencodedintheDSCcontrolunit.
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6.1.3.Systemwiringdiagram
SystemwiringdiagramfortheDynamicStabilityControl(DSC)intheG12
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Index Explanation1 Brakepadwearsensor,frontleft2 Wheel-speedsensor,frontleft3 Powerdistributionbox,enginecompartment4 Wheel-speedsensor,frontright5 Powerdistributionbox,frontright6 BodyDomainController(BDC)7 Rearrightpowerdistributionbox8 Wheelspeedsensor,rearright9 Brakepadwearsensor,rearright10 Actuator,electricparkingbrakerearright11 Actuator,electricparkingbrakerearleft12 Wheelspeedsensor,rearleft13 CrashSafetyModule(ACSM)14 ButtonforelectricparkingbrakeandforAutomaticHoldfunction15 DSCbutton16 Brakelightswitch17 Steeringcolumnswitchcluster18 Instrumentpanel(KOMBI)19 Brakefluidlevelswitch20 DynamicStabilityControl(DSC)
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6.2.Steering
OverviewofsteeringintheG12
Index Explanation1 Steeringwheel2 Uppersteeringcolumnwithsteeringcolumnadjustment3 Controlunitforsteeringcolumnadjustment4 Lowersteeringcolumnwithslidingpiece5 Trackrodend6 Trackrod7 Steering-torquesensor8 EPScontrolunit(ElectronicPowerSteering)9 ElectricmotorforEPS(ElectronicPowerSteering)
Inelectricsteeringsystems,thesupporttorqueisgeneratedbymeansofanelectricmotor.
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Inadditiontothepuresupportfunction,thefrontwheelscaninprinciplebemadetoperformanysteeringmovementindependentlyofthemanualtorqueappliedatthesteeringwheel.ThissystemisthereforeaprerequisiteforrealizationofalargenumberofassistancefunctionssuchastheParkingManoeuvringAssistant(PMA).
TheElectronicPowerSteering(EPS)permitsareductionintheaveragefuelconsumptionofapproximately0.3lper100km/62miles.Afurtheradvantageisthatnooilisneededforsteeringassistance.
6.2.1.SteeringwheelItispossibletochoosebetween3differentsteeringwheeldesigns.
SteeringwheelversionsintheG12
Index ExplanationA SportssteeringwheelwithshiftpaddlesB LuxurysteeringwheelC Standardsteeringwheel(NotforUS)
Intheluxuryversion,theleatherrimfeaturesawoodinlayleathersteeringwheel.Thedrivercanoperatethevariousassistanceanddriverinformationsystemsbymeansofthemultifunctionswitches.
Steeringwheeldiameterofthedifferentversions:
• Sportssteeringwheel=382mm• Luxurysteeringwheel=384mm(NotforUS)• Standardsteeringwheel=385mm(NotforUS)
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Additionalfunctionsareoptionallypossible:
• Heatedleatherrim.• Transmissionofhapticvibrations(steeringwheelvibration)
Forassistancesystemssuchaslanedepartureorlanechangewarning.• Hands-Offdetection
Forthetrafficjamassistantfunction.• Shiftpaddles
ForthemanualshiftfunctionwiththeautomaticSporttransmission(SA2TB).
6.2.2.Steeringcolumnadjustment
SteeringcolumnadjustmentintheG12
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Index Explanation1 Electricmotor2 Spindle3 Controlunitforsteeringcolumnadjustment4 Steeringshaft
Thesteeringcolumnwithelectricallongitudinalandheightadjustmentallowsthedrivertoassumeanoptimumsittinganddrivingpositionthroughseamlessadjustmentofthesteeringwheelposition.
Adjustmentrange:
• Heightadjustment=+/-20mm• Forward/backadjustment=-20mm/+40mm
6.2.3.VersionoverviewTheG12isequippedwiththefollowingdifferentsteeringsystems:
• Standardsteering12V• IntegralActiveSteering12V• IntegralActiveSteering24V
Components Standardsteering12V
IntegralActiveSteering12V
IntegralActiveSteering24V
ElectronicPowerSteeringwithnormalrackgeometry
X
ElectronicPowerSteeringwithvariablerackgeometry
X X
12 Vbattery X X X12Vauxiliarybattery XPowerControlUnit(PCU)(DC/DCconverter150W)
X
Rearaxleslipanglecontrol(HSR)
X X
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Thefollowinggraphicshowstheinstallationpositionsofthedifferentsystemcomponents.
OverviewofthesteeringsystemsoftheG12
Index Explanation1 ElectromechanicalPowerSteering1a Conventionalrackgeometry(standardsteering)1b Variablerackgeometry(IntegralActiveSteering)2 PowerControlUnit(PCU)(onlyfor24Vsteering)3 Rearaxleslipanglecontrol(HSR)(IntegralActiveSteering)4 12Vauxiliarybattery(onlyfor24Vsteering)5 Separatingelement(onlyfor24Vsteering)6 12 Vbattery7 DynamicStabilityControl(DSC)
Withthestandardsteering,theG12isequippedwithconventionalelectromechanicalpowersteering(12V)withnormalrackgeometry.
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TheoptionalequipmentIntegralActiveSteeringnownolongerconsistsofanactivesteeringsystemwithvariableratiotransmission,buthasbeenreplacedbyanelectromechanicalpowersteeringsystemwithvariablerack(sportsteering)aswellasrearaxleslipanglecontrol(HSR).Dependingontheaxleloadsofthefrontvehicleend,a12Vor24Vsteeringsystemisused.Therearaxleslipanglecontrol(HSR)alwaysoperateswitha12Vvoltage.
ThefollowingtableprovidesanoverviewofthedifferentvoltagelevelsoftheelectricsteeringintheoptionalequipmentIntegralActiveSteering.
Model Engine Rear-wheeldrivewithIntegralActiveSteering
All-wheeldrivewithIntegralActiveSteering
740i B58 12V —750(x)I N63 24 V 24 V
6.2.4.IntegralActiveSteering
Frontaxle
Ratioofthevariablerackgeometry(OEIntegralActiveSteering)intheG12
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Index ExplanationA Moreindirectsteeringgearratiointhecenterpositionof
thevariablerack(0°-45°)B Transitionalrange(45°-130°)C Directsteeringgearratiooutsidethecenterpositionof
thevariablerack(>130°)X Steeringanglein°y Steeringgearratioinmm/steeringwheelturn1 Variablerackgeometry(IntegralActiveSteering)
ThevariablesteeringgearratiointheoptionalequipmentIntegralActiveSteeringisaccomplishedbythegeometry/pitchofthetoothedgearoftherack.Aroundthecenterpositionofthesteeringgear,thesteeringsystembehavesaccuratelywithsteadydirectionalstability.Asthesteeringanglemovesawayfromthecenterposition,theratiobecomesincreasinglymoredirect.
SteeringangleoftheIntegralActiveSteeringonthefrontaxleoftheG12
Index ExplanationA Moreindirectsteeringgearratio(variablerackgeometry)B Directsteeringgearratio(variablerackgeometry)
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Rearaxle
Rearaxleslipanglecontrol(HSR)intheG12
Index Explanation1 Trackcontrolarmmounts2 Electricmotor3 HSRcontrolunit(rearaxleslipanglecontrol)4 Spindlepositionsensor(PLCDsensor)5 Permanentmagnet6 Carrierplate
Therearaxleslipanglecontrol(HSR)mountedontherearanglepermitsamaximumsteeringangleoftherearwheelsof+/-3°.Asaresult,itwaspossibletoreducetheturningcirclebyapproximately1mincomparisonwithvehicleswithoutrearaxleslipanglecontrol(HSR).Therearaxleslipanglecontrolisavailablefromaspeedofapproximately5km/h/3mphuptothemaximumspeed.
TherequesttoadjustthesteeringangleattherearaxleisissuedbytheDynamicStabilityControl(DSC).Aspindledriveinsidethecomponentisrotatedviatheelectricmotor.Thisproducesalinearmovementatthetwotrackcontrolarms.Usingthepositionsensor,thecontrolunitoftherearaxleslipanglecontrol(HSR)candeterminethelineardisplacementandthuscalculatethesteeringangleofthetworearaxlewheels.
Thespindledriveoftherearaxleslipanglecontrol(HSR)isself-inhibiting.Thismeansthatthevehiclehastheidenticaldrivabilitytoavehiclewithoutrearaxleslipanglecontrol(HSR)intheeventofsystemfailure.
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Aspecialfixtureisrequiredforalignmentinordertoassemblethecarrierplates.ThisisnotavailableinService.Forthisreason,thecarrierplatesontherearaxleslipanglecontrol(HSR)mustnotbeundone.Ifthisisnotobserved,thewheelalignmentontherearaxlewillbecomeincorrectlyadjusted.
Thecarrierplatesoftherearaxleslipanglecontrol(HSR)mustnotbeundoneinService
Operatingstrategy
InputandoutputdiagramoftheIntegralActiveSteeringintheG12
Index Explanation1 DynamicStabilityControl(DSC)2 Rearaxleslipanglecontrol(HSR)3 Yawrateandlateralacceleration(ACSM)4 Wheelspeeds5 Steeringangle(EPS)
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OperatingstrategyoftheIntegralActiveSteeringintheG12
Index ExplanationA OppositesteeringB Parallelsteering
Inthespeedrangeuptoapproximately60km/h/37mph,therearaxleslipanglecontrol(HSR)steersintheoppositedirectiontothesteeringanglesofthefrontaxlesteering.Thispermitsincreasedvehiclemanoeuvrability.
Asfromthespeedrangeofapproximately60km/h/37mph,therearaxleslipanglecontrol(HSR)steersinthesamedirection.Thisimprovesthedirectionalstabilityofthevehicle.
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Drivingdynamicscontrolinterventionswhencornering
Whenchanginglanesquickly,allvehicleshaveatendencytoproduceasignificantyawresponseandcansometimesstarttooversteer.IftheDynamicStabilityControl(DSC)detectsadeviationbetweenthedriverwishandvehicleresponse,thevehicleisstabilizedbymeansofasteeringinterventionattherearaxle.Thespeedofthestabilizinginterventionissuchthatitishardlydiscerniblebythedriver.ItispossibletolargelydowithoutdeceleratingDSCbrakeinterventions.Asaresult,thevehicleismorestableandthedrivingdynamicsarepreserved.
PossibledrivingdynamicsinterventionsoftheDSCandIntegralActiveSteeringwhencornering
Index ExplanationA Preventionofundersteerbybrakeinterventionsatindividualwheels(DSC)B Preventionofundersteerbysteeringinterventionsattherearaxle(HSR)M Yawmomentactingonthevehicleduetoaninterventionbythedriving
dynamicscontrol1 Courseofanundersteeringvehicle2 Courseofavehiclewithneutraldrivability3 Individualbrakemodulation(DSC)4 Steeringinterventionattherearaxle(HSR)
Ifthedriverunderestimatesabendwhendrivingrapidly,hemaybesurprisedbysuddenundersteer.Therearaxleslipanglecontrol(HSR)canalsoperformacorrectiveinterventioninundersteersituationsandthusadditionalincreasesactivesafety.
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Drivingdynamicscontrolondifferentsurfaces
Hardbrakingmanoeuvresonroadwaysthatareslipperyononesidemakethevehicleyawtothevehiclesidewithmoregrip.Intheeventofemergencybraking,thedriverofaconventionalvehiclemusttakecorrectiveaction.Withthisso-calledµ-splitbraking,theDynamicStabilityControl(DSC)providesastabilizingyawmomentviaasteeringinterventionattherearaxle.
µ-splitbrakingmanoeuvreswithdifferentdrivingdynamicssystems
Index ExplanationA VehiclewithoutDSCB VehiclewithDSCC VehiclewithDSCandrearaxleslipanglecontrol(HSR)
(optionalequipmentIntegralActiveSteeringSA2VH)
FurthertoA)WithoutDSC
WhenbrakingwithavehiclewithoutDSC,maximumbrakeforceissupportedonthedrysideoftheroadandonlylowbrakeforceonthewetoricyside.Ananti-clockwiseyawmomentisproducedwhichcanleadtothevehicleskiddingtotheright.
FurthertoB)WithDSC
WhenbrakingwithavehicleequippedwithDSC,thebrakeforcesatthewheelsaremeteredsothattheyawmomentactingonthevehicleisreduced.Thevehiclethereforeremainscontrollable.Thestoppingdistancemaybeincreasedslightly.
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FurthertoC)WithDSCandrearaxleslipanglecontrol(HSR)
WhenbrakingwithavehicleequippedwithDSCandrearaxleslipanglecontrol(HSR)(optionalequipmentIntegralActiveSteeringSA2VH),theDSCcontrolunitcalculatesthesteeringanglefortherearwheels.Theactuatorsoftherearaxleslipanglecontrol(HSR)convertthecalculatedsteeringangleintoanactivesteeringangleatbothrearwheels.Theresultantstabilizingyawmomentallowsthemaximumbrakeforcestobeappliedinordertoachievetheshortestpossiblestoppingdistance.Theperfectinteractionofsteeringandbrakeinterventionthereforeincreasesactivesafetyandenhancesthedrivingdynamicsofthevehicle.
6.2.5.ServiceinformationIntheeventofarepair,thesteeringgearcanbefullylowered.Thiseliminatestheneedforcomplexaxledisassemblyandrepaircostsarereducedsignificantly.
Steeringangle
Thesteeringangleiscalculatedbythecontrolunitoftheelectromechanicalpowersteeringusingtherotoranglesensor.Intheeventofalossofthevoltagesupply,thisstoredvalueislostandmustbetaughtagain.Thiscanbedonestaticallybyturningthewheelstotherightandleftwiththeenginerunningordynamicallywhendrivingslowly.
Drivingwithsnowchains
SettingmenufordrivingwithsnowchainsintheG12
Index ExplanationA SnowchainmodedeactivatedB Snowchainmodeactivated
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Inordertoavoiddamagetothewheelarcheswhendrivingwithsnowchains,therearaxleslipanglecontrol(HSR)mustbefixedinstraight-aheadposition.ThedrivercandothismanuallyusingthecontrollerontheCentralInformationDisplay(CID).Themaximumpermittedspeedis50km/h(31mph)hisspeedisexceeded,therearaxleslipanglecontrol(HSR)switchesonagainautomatically.
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6.2.6.Systemwiringdiagram
24Vsteering
Systemwiringdiagramfor24VsteeringintheG12
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Index Explanation1 DynamicStabilityControl(DSC)2 Wheel-speedsensor,frontleft3 Enginecontrolunit(DME)4 ElectronicPowerSteering(electromechanicalpowersteering)(EPS)5 Steering-torquesensor16 Steering-torquesensor27 Wheel-speedsensor,frontright8 Powerdistributionbox,frontright9 BodyDomainController10 Wheelspeedsensor,rearright11 Rearrightpowerdistributionbox12 PowerControlUnitPCU(DC/DC150W)13 Separator14 12Vauxiliarybatteryfor24Vsteering15 Positivebatteryterminaldistributor16 Wheelspeedsensor,rearleft17 CrashSafetyModule(ACSM)18 Brakelightswitch19 Steeringcolumnswitchcluster(SZL)20 Instrumentpanel(KOMBI)
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Rearaxleslipanglecontrol(HSR)
Systemwiringdiagramforrearaxleslipanglecontrol(HSR)intheG12
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Index Explanation1 DynamicStabilityControl(DSC)2 CrashSafetyModule(ACSM)3 BodyDomainController(BDC)4 Rearrightpowerdistributionbox5 Positivebatteryterminaldistributor6 Rearaxleslipanglecontrol(HSR)
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Electricallyadjustablesteeringcolumn
SystemwiringdiagramforelectricallyadjustablesteeringcolumnintheG12
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Index Explanation1 Powerdistributionbox,frontright2 BodyDomainController(BDC)3 Steeringcolumnswitchcluster(SZL)4 Buttonforsteeringcolumnadjustment5 Memoryswitch6 Controlunitforsteeringcolumnadjustment7 Electricmotor(DC)8 Electricmotor(DC)
6.3.ElectronicDamperControl(EDC)Inordertomeetthehighcustomerdemandswithrespecttocomfortanddrivingdynamics,theG12isequippedasstandardwithElectronicDamperControl(EDC).Theelectronicallycontrolledshockabsorbersformaunitwiththerespectiveairsuspensionstrutandcannotbereplacedseparately.Thereare2electriccontrolvalvesoneachshockabsorberwhichallowthecompressionandreboundstagesoftheregulatedshockabsorberstobeadjustedseparatelyfromeachother.Thismakesitpossibletoperfectlycounteractthevibrationsofthebodyandwheels.Thisincreasessafety,comfortanddrivingdynamics.
6.3.1.ShockabsorberdesignTheshockabsorbersaresingle-tubegas-filledshockabsorbers.Thegascushionconsistsofnitrogenatapressureof16.5bar.Thisispressedtogetherandthuscompressedfurtherbytheoildisplacedwhenthepistonrodisretracted.Thehighgaspressurepreventsfoamingoftheoilunderalloperatingconditionsandthusguaranteesoptimumshockabsorberoperation.Inaddition,thehighgaspressureensuresthatthepistonrodispressedoutwithaforceofapproximately400N(~40kg).Compressionoftheshockabsorberbyhandisthereforehardlypossible.
Thefollowinggraphicshowstheinternaldesignofanelectricallyregulatedshockabsorber.
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DesignofEDCshockabsorberintheG12
Index Explanation1 Pistonrod2 Workingchamber3 Overflowduct4 Controlvalve,compressionstage5 Comfortvalve,compressionstage6 Comfortvalve,reboundstage7 Controlvalve,reboundstage8 Gaspressurechamber
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Index Explanation9 Dividingpiston10 Balancingchamber11 Bottomvalve12 Workingchamber13 Workingpiston
Inordertopermitasportydrivingstyleongoodroadswhilestillabsorbingbumpsonroughroadsurfacesascomfortablyaspossible,theoilflowinsidetheshockabsorbercanbevariablyadjusted.Thechangesintheoilflowchangetheforcesactingontheshockabsorber.
Theshockabsorberhas2controlvalves,whichallowseparateadjustmentofthedampingforceforrebound(reboundstage)andcompression(compressionstage).
Thecontrolvalvesadjustthedampingforcebychangingarestrictorcross-sectionthroughwhichanoilflowispressed.Thefollowingrelationshipexistsbetweentherestrictorcross-sectionanddampingforce:
• Largerestrictorcross-section=lowdampingforce.• Smallrestrictorcross-section=highdampingforce.
Therestrictorcross-sectionandthusthedampingforcecanbeadjustedseamlessfewmilliseconds.
Compressionstage
Duringcompression,theshockabsorberispushedtogethertelescopicallyandoperatedintheso-calledcompressionstage.
Rebound
Duringrebound,theshockabsorberisextendedtelescopicallyandoperatedintheso-calledreboundstage.
6.3.2.SystemoverviewThedrivingexperienceswitchisusedtoconfiguretheshockabsorberadjustmentsetting.Itispossibletochoosebetweenasportilyfirmorcomfortablysoftchassisandsuspensionsetup.Thefollowingtableprovidesanoverviewofthesettingoptions.
Drivingmode CharacteristicsCOMFORTPLUS ComfortableComfort/ECOPRO BalancedSport Sports
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SystemoverviewoftheElectronicDamperControl(EDC)
Index Explanation1 ElectronicPowerSteering(electromechanicalpowersteering)(EPS)2 Controlvalvesforshockabsorberadjustment,frontright3 Rideheightsensor,frontright4 Controlvalvesforshockabsorberadjustment,frontleft5 Rideheightsensor,frontleft6 DynamicStabilityControl(DSC)7 BodyDomainController(BDC)8 AdvancedCrashSafetyModule(ACSM-High)9 Drivingexperienceswitch10 VerticalDynamicsPlatform(VDP)11 Rideheightsensor,rearright12 Controlvalvesforshockabsorberadjustment,rearright13 Ride-heightsensor,rearleft14 Controlvalvesforshockabsorberadjustment,rearleft
TheElectronicDamperControl(EDC)comprisesthefollowingcomponents:
• 4electricallycontrolledshockabsorberswith2controlvalveseach• VerticalDynamicsPlatform(VDP)controlunit• 4rideheightsensorsfordeterminationofwheelmovement• Sensorclusterfordeterminationofbodymovement(lift,pitchandroll)
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TheVerticalDynamicsPlatform(VDP)controlunitusesvariousdatasuchasbodymovement,transverseandlongitudinalacceleration,steeringangleandtheroadconditiontocalculatewheel-individualcontrolcommandsfortheelectricalcontrolvalvesintheshockabsorbers.Inthisway,thedampingforceoftheindividualshockabsorbersiscontinuouslychangedapproximately100timespersecond.Thismeansthatdemand-basedadjustmentofthedampingforceisalwayspossiblecorrespondingtothedrivingsituation.
Fewervehiclebodymovementsarepermittedifasportierdrivingmodeisselected.Theshockabsorbersareadjustedtoahardsettingmorequicklyandmoreoften.Thisautomaticallyresultsinalossofcomfort.
Inthestandardequipmentconfiguration,informationabouttheverticalbodymovements(pitch,rollandlift)ismadeavailablebytheCrashSafetyModuleACSM-High.Theretractionandextensionspeedsoftheshockabsorbersaredeterminedbymeansoftherideheightsensors.
Ifthevehicleisequippedwiththeoptionalequipment“ActiveComfortDrive”(SA2VS),thereareadditionalwheelaccelerationsensors.TheseareusedamongotherthingsformorepreciseregulationoftheElectronicDamperControl(EDC).
Thefollowingtableshowsthedifferentcomponentsuseddependingonthechassisandsuspensionpackage.
Component Basicchassisandsuspension
ActiveComfortDrive
Wheelaccelerationsensors — XACSM-High X —ACSM-Low — X
Amoredetaileddescriptionoftheoptionalequipment“ActiveComfortDrive”(SA2VS)isprovidedinalaterchapter.
6.3.3.ElectricalshockabsorbercontrolThecontrolvalvesofthereboundandcompressionstagesareactivatedviapulse-widthmodulatedsignalsfromtheVerticalDynamicsPlatform(VDP)controlunit.Thecontrolvalvesareopeninde-energizedcondition.Theshockabsorberisinthemaximumsoftsettinginthiscondition.
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Controlofthecompressionstage
ControlofcompressionstageontheshockabsorberoftheG12
Index ExplanationA ShockabsorbermovementB Oilflow1 Mainvalve,compressionstage2 Workingpiston3 Mainvalve,reboundstage4 Bottomvalve5 Gaspressurechamber6 Controlvalve,reboundstage7 Comfortvalve,reboundstage8 Comfortvalve,compressionstage9 Controlvalve,compressionstage
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Whenthepistonrodisretracted,theoilvolumedisplacedbytheretractingpistonispressedthroughthebottomvalveintothecompensatingreservoirandgeneratesadampingforceatthebottomvalveintheprocess.Theoilvolumedisplacedbytheworkingpistonispressedthroughthecomfortandcontrolvalveofthecompressionstageandthuspassesfromtheworkingchamberbelowtheworkingpistonintotheworkingchamberabovethepiston.Therestrictorcross-sectioninthecontrolvalveadjuststhedampingforce.Theoilflowisforcedthroughthemainvalvewhenthecontrolvalveisclosed.Themaximumpossibledampingforceisthenset.
Controlofthereboundstage
ControlofreboundstageontheshockabsorberoftheG12
Index ExplanationA ShockabsorbermovementB Oilflow1 Mainvalve,compressionstage2 Workingpiston3 Mainvalve,reboundstage
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Index Explanation4 Bottomvalve5 Gaspressurechamber6 Controlvalve,reboundstage7 Comfortvalve,reboundstage8 Comfortvalve,compressionstage9 Controlvalve,compressionstage
Whenthepistonrodisextended,thegaspressureforcesthenecessarycompensationvolumeoutofthecompensatingchamberthroughthebottomvalveintotheworkingchamberbelowtheworkingpiston.Theoilvolumedisplacedbytheworkingpistonispressedthroughthecomfortandcontrolvalveofthereboundstageandthuspassesfromtheworkingchamberabovetheworkingpistonintotheworkingchamberbelowthepiston.Therestrictorcross-sectioninthecontrolvalveadjuststhedampingforce.Theoilisforcedthroughthemainvalveofthereboundstagewhenthecontrolvalveisclosed.Themaximumpossibledampingforceisthenset.
6.4.Anti-rollbarThefollowinganti-rollbarsareusedontheG12dependingonthevehicleequipment:
• StandardequipmentConventionalanti-rollbaronfrontandrearaxles.
• Optionalequipment(“ActiveComfortDrive”SA2VS)ElectricactiverollstabilizationonfrontandrearaxleEARSVV/EARSVH.
ComparisonofconventionalandactiverollstabilizationinstationaryconditionoftheG12
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Index ExplanationA ConventionalpassiverollstabilizationB Activerollstabilizationaq LateralaccelerationFq Transverseforceh Distancebetweenrollaxisandcenterofgravity(leverarm)Ma MomentofactivestabilizerMw RollmomentRA RollaxisSP centerofgravityφ Rollangle
Whencornering,thelateralacceleration(aq)actsatthevehiclecenterofgravity(SP).Thebodyrollsabouttherollaxis(RA),whichisdefinedbythekinematicsofthefrontandrearaxles.Thisresultsintherollangle(φ).
Onvehicleswiththeoptionalequipment“ActiveComfortDrive”(SA2VS),therollmoment(Mw)canbecompensatedsolelybytheactivestabilizersuptoacertainlateralacceleration.Arollangle(φ)buildsuponlywhentherollmoment(Mw)exceedsthecounter-torque(Ma)setbytheactivestabilizer.
Thefollowingdiagramshowsacomparisonofthedifferentrollanglesofbothanti-rollbarsasafunctionofthelateralacceleration.
Rollanglediagramoftheconventionalanti-rollbarandactivestabilizer
Index ExplanationA ConventionalrollstabilizationB Activerollstabilizationaqin[m/s²] Lateralaccelerationinmetrespersecondsquaredφin[°] Rollangleinangulardegrees
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6.5.Standardsuspension
Conventionalanti-rollbarintheG12
Index Explanation1 Rearaxleanti-rollbar2 Frontaxleanti-rollbar
Asstandard,conventionalanti-rollbarsonthefrontandrearaxlesreducetherolltendencyofthebodyduringfastcorneringorfastavoidancemanoeuvres.However,therearealsocomfortlossesinthecaseofone-sidedroadbumpsduetothetorsionspringcharacteristicsofaconventionalanti-rollbar.Ifaconventionalanti-rollbarisexcitedbyapulseatawheelononeside,thisleadstospringoscillationsoftheanti-rollbarsothatthewheelattheotherendoftheanti-rollbaralsoperformsor"copies"theseoscillations.Sincetheanti-rollbarispivot-mountedonthebody,thedriveralsofeelstherolloscillationscausedbythisso-called"copying".
6.5.1.ChassisandsuspensionsetupVehicledrivabilitywhencorneringcanbegreatlyinfluencedbyanti-rollbarsonthefrontandrearaxles.Adecisivefactorhereistherollmomentratiobetweenthefrontandrearvehicleaxles.Thisratiodependsontherespectiveanti-rollbarmomentsofthetwoaxles.
Thefollowingtableprovidesanoverviewofthepossiblerollmomentratiosandtheresultanthandlingofthevehicle.
Anti-rollbar Rollmomentratio Understeer OversteerFrontaxlesoft/rearaxlehard
<50% X
Frontaxlehard/rearaxlesoft
>50% X
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Thefollowinggraphicshowsthepercentagedistributionoftheanti-rollbarmoments(rollmomentratio)ofthefrontandrearaxleswhenconventionalanti-rollbarsareused.
Percentagedistributionoftheanti-rollbarmomentsonavehiclewithconventionalanti-rollbars
Index ExplanationA UndersteeringrollmomentratioMkin[%] Momentdistributionofconventionalanti-rollbarsinpercentvin[km/h] Drivingspeedinkilometersperhour1 Conventionalanti-rollbaronthefrontaxle2 Conventionalanti-rollbarontherearaxle
Withaconventionalanti-rollbar,therollmomentratioisoptimallyadaptedtotherespectivevehicle.Itisaimedtoachievehandlingwithslightundersteer.Fornormaldrivers,anoversteeringvehicleismoredifficulttocontrolthananundersteeringvehicle.
6.6.ActiveComfortDriveThepreviouslyknownoptionalequipmentAdaptiveDriveisreplacedintheG12bytheenhancedsuspensioncontrolsystem“ActiveComfortDrive”.
Thevariousdrivingdynamicscontrolsystemsarenetworkedtogetherintheoptionalchassisandsuspensionpackage“ActiveComfortDrive”inordertoachieveperfectdrivingdynamicscombinedwithhighridecomfort.InformationisreadinfromalargenumberofsensorsbytheVerticalDynamicsPlatform(VDP)controlunitandthecorrespondingcontrolcommandsareoutputtothedifferentactuators.Theaimistoabovealldetectroadbumpsandobstaclesaheadasearlyaspossibleandtoderiveappropriatecounter-measures.
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Thefollowinggraphicprovidesanoverviewoftheoverallsystem.
Systemoverviewoftheoptionalchassisandsuspensionpackage“ActiveComfortDrive”intheG12
Index Explanation1 ElectricactiverollstabilizationfrontEARSVV(optionalequipment
“ActiveComfortDrive”SA2VS)2 ElectronicPowerSteering(electromechanicalpowersteering)(EPS)3 Wheelaccelerationsensor,frontright(optionalequipment
“ActiveComfortDrive”SA2VS)4 Controlvalvesforshockabsorberadjustment,frontright5 Rideheightsensor,frontright6 Wheelaccelerationsensor,frontleft(optionalequipment
“ActiveComfortDrive”SA2VS)7 Controlvalvesforshockabsorberadjustment,frontleft8 Rideheightsensor,frontleft9 12Vbattery(optionalequipment“ActiveComfortDrive”SA2VS)10 DynamicStabilityControl(DSC)11 BodyDomainController(BDC)12 Stereocamera(optionalequipment“ActiveComfortDrive”SA2VS)13 AdvancedCrashSafetyModule(ACSM-Low)14 Drivingexperienceswitch15 VerticalDynamicsPlatform(VDP)16 Rideheightsensor,rearright17 Controlvalvesforshockabsorberadjustment,rearright
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Index Explanation18 Wheelaccelerationsensor,rearright(optionalequipment
“ActiveComfortDrive”SA2VS)19 Ride-heightsensor,rearleft20 Controlvalvesforshockabsorberadjustment,rearleft21 Wheelaccelerationsensor,rearleft(optionalequipment
“ActiveComfortDrive”SA2VS)22 Electricactiverollstabilizationrear(EARSVH)(optionalequipment
“ActiveComfortDrive”SA2VS)23 PowerControlUnit(PCU)(optionalequipment
“ActiveComfortDrive”SA2VS)
Theoptionalchassisandsuspensionpackage“ActiveComfortDrive”hasthefollowingadditionalcomponents:
• Wheelaccelerationsensorsonall4wheelcarriers• Electricactivestabilizersonthefrontandrearaxles• Anadditional12VbatteryaswellasaDC/DCconverter• Astereocamerainthewindscreen
Wheelaccelerationsensorsareusedintheoptionalchassisandsuspensionpackage“ActiveComfortDrive”forthefollowingreasons:
• Moreprecisedisturbancevariablecontroloftheelectricactivestabilizers(EARSV)possible.Avoidanceofso-calledcopyingfromonewheeltotheotherintheeventofroadbumps.
• PreciseregulationoftheElectronicDamperControl(EDC)ispossiblethroughdetectionofthewheelmovementviathewheelaccelerationsensorsandthebodymovementviatherideheightsensors.ProcessingofthetwoinformationsourcesallowsuseofasimplifiedcontrolunitversionoftheCrashSafetyModule(ACSM-Low).
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6.6.1.Predictivecontrol
Predictivecontroloftheoptionalchassisandsuspensionpackage“ActiveComfortDrive”intheG12
Index Explanation1 Satellite2 Navigationdata3 Stereocamera(KAFAScamera3)4 Controllableshockabsorber,frontleft5 Electricactiverollstabilizationfront(EARSVV)6 Controllableshockabsorber,frontright7 DynamicStabilityControl(DSC)
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Index Explanation8 Controllableshockabsorber,rearright9 VerticalDynamicsPlatform(VDP)controlunit10 Electricactiverollstabilizationrear(EARSVH)11 Controllableshockabsorber,rearleft
Inordertopreparethechassisandsuspensionforthedifferentroadconditionsasearlyaspossible,thefollowingdataisreadinfromvariouscontrolunitsandprocessedtoallowpredictivecontrol:
• IfADAPTIVEdrivingmodehasbeenactivatedviathedrivingexperienceswitch,theDynamicStabilityControlcontrolunitprocessesthenavigationdatatoanalysestherouteandinfluencesthedrivingprogramtobeactivatedifnecessary.Ifthevehicleisapproachingasharpbendathighspeed,forexample,theDynamicStabilityControl(DSC)activatesSportmodewithoutanyactiononthepartofthedriver.TheVerticalDynamicsPlatform(VDP)readsinthisinformationandactivatesthecorrespondingchassiscomponentsforSportmode.Conversely,anautomaticchangeindrivingprogramfromSporttoComfortisalsopossible.Ifthevehicleexitsatwistingsectionofroadthroughwhichithasbeendrivenatspeedandthendrivesatconstantspeedonastraightsection,thisresultsinautomaticchangeovertotheComfortdrivingprogram.Thismeansthattheoptimumdrivingmodewithrespecttocomfort(Comfort)anddrivingdynamics(Sport)isautomaticallysetwithoutmanualoperationofthedrivingexperienceswitchdependingonthedrivingstyleandprobableroute.Routeguidanceneednotbeactivatedforthis.
• TheVerticalDynamicsPlatform(VDP)readsintheinformationofthestereocamerainthewindscreenindependentlyoftheselecteddrivingmodeandprocessesthis.
Inaddition,alargequantityofadditionalinformationsuchasthedrivingstyleanalysisisreadinbytheVerticalDynamicPlatform(VDP)controlunitandusedforpredictivecontrolofthestandardElectronicDamperControl(EDC)aswellastheelectricactivestabilizers(EARSV).
Obstaclescanthereforebeovercomepredictivelyandwithevenmorecomfort.Thedriverisevenlessawareofbumps.Thebodyofthevehicledoesnothavetomoveverticallytothesameextentsincethechassisandsuspensionreactintelligentlyandpredictivelytoroadbumps.
Theoptionalchassisandsuspensionpackage“ActiveComfortDrive”thereforeoffersthefollowingadvantages:
• Reducedcompressionandrebound(EDC).• Reducedpitchmovement(EDC).• Fasterdecayofvehiclebodyreverberations(EDC).• Highdrivingdynamicswhencorneringthankstoactiverollstabilization(EARSV).• Highcomfortforstraight-aheaddrivingduetodecouplingofanti-rollbarhalves
andthusavoidanceofroadbump"copying"(EARSV).
Thefunctionsofthechassisandsuspensionpackage"ActiveComfortDrive”areavailableindifferentformsinthefollowingpositionsofthedrivingexperienceswitch.
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Drivingexperienceswitchposition
ElectricactiverollstabilizationEARSV
ElectronicDamperControl(EDC)
COMFORTPLUS Balanced ComfortableComfort/ECOPRO Balanced BalancedSport Sporty Sporty
Asaresultofintelligentnetworkingofthesystems,failureofonesensorsystem,e.g.thestereocameraduetopoorvisibility,canbesufficientlycompensatedbytheotheravailablesensors.Theridecomfortanddrivingdynamicsthusremainataveryhighlevelunderallconditions.
Thefollowinggraphicshowsaninputandoutputdiagramofthevariouscomponentsforcontroloftheoptionalchassisandsuspensionpackage“ActiveComfortDrive”intheG12.
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Inputandoutputdiagramoftheoptionalchassisandsuspensionpackage“ActiveComfortDrive”intheG12
Index Explanation1 VerticalDynamicsPlatform(VDP)2 Electricactiverollstabilizationfront(EARSVV)3 Electricactiverollstabilizationrear(EARSVH)4 ElectronicDamperControl(EDC)(4x)5 Steeringangle(EPS)6 Navigationdata7 Wheelspeeds(DSC)
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Index Explanation8 Wheelaccelerations9 Rideheights10 Drivingmode11 Roadprofile(stereocamera)12 Lateralandlongitudinalaccelerationandyawrate(ACSM-Low)13 Vehiclespeed
6.6.2.Electricactiverollstabilization(EARSV)Asthefirstvehiclemanufacturerworldwide,BMWuseselectricactivestabilizersinsteadofthepreviouslyusedhydraulicactivestabilizers.Theelectricactivestabilizersintheoptionalequipment“ActiveComfortDrive”(SA2VS)reducetherolltendencyofthebodyinbendsbytargetedapplicationofmechanicalmomentsonthestabilizerhalvesbymeansofanelectricmotor.
Thefollowinggraphicshowsaschematicsystemcomparisonbetweentheactivehydraulicstabilizerandtheactiveelectricstabilizer.
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Schematiccomparisonofhydraulicactivestabilizerandelectricactivestabilizer
Index ExplanationA HydraulicactivestabilizerARS(F01/F02)B ElectricactivestabilizerEARSV(G12)1 Engineoilcooler2 Hydraulicactivestabilizerfront(ARS)3 Expansiontank4 Hydraulicpump5 Valveblock6 VerticalDynamicsManagementcontrolunit(VDM)7 Hydraulicactivestabilizerrear(ARS)8 Electricactiverollstabilizationfront(EARSVV)9 12Vbattery(vehicleelectricalsystemsupport)
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Index Explanation10 Vehicleelectricalsystem11 PowerControlUnitPCU(DC/DCconverter500W)12 VerticalDynamicsPlatform(VDP)controlunit13 Electricactiverollstabilizationrear(EARSVH)
Electrificationoftheactivestabilizeroffersthefollowingadvantages:
• Simpleintegrationin“fullhybrid”drivesystemsActiverollstabilizationispossibleduringpurelyelectricdriving.
• Simpledecouplingofthestabilizerhalvesduringstraight-aheaddrivingImprovedridecomfortduetopreventionofroadbump"copying"
• IncreasedefficiencyEnergyisrequiredexclusivelyduringthecontrolactionsanddoesnotneedtobekeptpermanentlyavailablelikeinahydraulicsystem.Self-aligningforceswhichactontheelectricmotorinthestabilizercanbepartiallyconvertedintoelectriccurrentandfedbackintothevehicleelectricalsystem.
SystemoverviewofelectricactiverollstabilizationEARSV
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Index Explanation1 Electricactiverollstabilizationfront(EARSVV)2 Wheelaccelerationsensor,frontright3 12Vbatteryinenginecompartment(vehicleelectricalsystemsupport)4 Wheelaccelerationsensor,rearright5 VerticalDynamicsPlatform(VDP)6 Rearrightpowerdistributionbox7 PowerControlUnit(PCU)(DC/DCconverter500W)8 Electricactiverollstabilizationrear(EARSVH)9 Wheelaccelerationsensor,rearleft10 Wheelaccelerationsensor,frontleft
Aparticularadvantagewhichcontributesabovealltoincreasingridecomfortisthepreventionofso-called"copying".Whenthevehicleisdrivingstraight-aheadanddrivesoverroadbumps,electricactiverollstabilizationEARSVpermitspracticallyfulldecouplingoftheleftandrightsidestothatcopyvibrationsarealmostexcluded.Theelectricactivestabilizersthereforecompensateforthedisadvantagesofconventionalanti-rollbars.
Thefollowingvariablesaremainlyusedforcalculationoftherequiredactivationoftheelectricactivestabilizers.
• Currentlateralandlongitudinalacceleration• Vehiclespeed• Steeringangle• Wheelacceleration• Rideheights
Theincipientrollmoment(Mw)israpidlycounteractedbyfastprocessingofthedataandactivationofelectricactiverollstabilization(EARSV).
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SectionalviewofanelectricactivestabilizerintheG12
Index Explanation1 Groundconnection2 Electricalconnection3 Controlunit(EARSVV/EARSVH)4 Electricmotor5 Planetarygear(three-stage)6 Decouplingelement7 Anti-rollbarlink8 Torquesensor
TheactivestabilizersreceivethecontrolrequestfromtheVerticalDynamicsPlatform(VDP)controlunit.Thebustelegramsarereadinandprocessedbythecontrolunitsofthetwoactivestabilizers(EARSVV/EARSVH).Thetwostabilizerhalvesaretwistedwithrespecttoeachotherbyactivationoftheelectricmotor.Centralenergyconversiontakesplaceinthepermanentlyexcitedsynchronousmotor,whosedirectionofrotation,torqueandspeedarecontrolledviathesetrotatingfield.
Powertransmissiontakesplaceviathethree-stageplanetarygear,whichconvertsthetorqueoftheelectricmotortotherequiredstabilizeroutputtorsiontorquewitharatioof1:158.Amaximumstabilizertorsiontorqueof750NmiscurrentlyimplementedintheG12.Thesystemisdesignedforsignificantlyhighertorsiontorquesinordertoalsopermitcompensationofsuperpositioneffectsduetoroadbumps.
Theelastomerdecouplingelementbetweentheplanetarygearandstabilizertorsionspringhasthetaskofdecouplinghighlydynamic,low-amplitudeexcitationsfromtheroad.Thisthusmakesafurthercontributiontomeetingthehighcomfortgoals.
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Atorquesensorinsidethecomponentprovidesfeedbackonthecurrentcontroltorquestothecontrolunit.Aplausibilitycheckofthedataallowsvariousfaultstobedetectedandthenstoredintheformofafaultcodeentry.However,repairofthecomponentisnotpossible.Theactiveelectricstabilizermustbereplacedasacompleteunitintheeventofamechanicalcomponentdefect.
Sincetheelectricactivestabilizerwillbeavailableinothervehiclemodelsinfuture,thecontrolunitmustbetaughtfortherespectivevehiclebymeansofversionencodingafterinstallation.Thisensuresthattheelectricactivestabilizerprovidesthecorrectcontroltorquesforthevehicleinquestion.
Technicaldata
Thefollowingtableprovidesanoverviewofthetechnicaldataoftheelectricactivestabilizer.
ElectricactiverollstabilizationEARSV TechnicaldataWeight 14 kg/30lbsMaximumcontrolunittemperature 120 °C/248°FMaximumelectricmotortemperature 160 °C/320°FMaximumelectricmotortorque 7.5Nm/5.5ft-lbsMaximumstabilizertorque 750Nm/553ft-lbsMaximumcurrentconsumption 120AMaximumcurrentoutput -100A
Thevaluesformaximumcurrentconsumptionandmaximumcurrentoutputarethevaluesthatarepossibleforshort-timeoperation.
CurrentconsumptionandcurrentoutputoftheelectricactivestabilizerintheG12
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Theabovegraphicshowsthecurrentconsumptionandoutputoftheelectricactivestabilizerforadrivingmanoeuvrewithapproximately30 %energyrecovery.Itmustbenotedthatthisdiagramisjustasnapshotrepresentation.Dependingonthedrivingmanoeuvre,theactivationpowerandenergyrecoveryoftheelectricactivestabilizermaydifferconsiderably.
FunctiondiagramoftheDC/DCconverterintheG12
Index ExplanationA 12VvehicleelectricalsystemB Consumesofelectricactivestabilizers1 Startermotor2 Alternator3 12 Vbattery4 Consumersofthe12Vvehicleelectricalsystem5 PowerControlUnit(PCU)(DC/DCconverter500W)6 12Vbatteryinenginecompartment(vehicleelectricalsystemsupport)7 Electricactiverollstabilizationfront(EARSVV)8 Electricactiverollstabilizationrear(EARSVH)
Inordertoensurethattheconsumersofthe12VvehicleelectricalsystemintheG12arenotinfluencedbythehighloadcurrentsofthetwoelectricactivestabilizers,thestabilizershavebeenisolatedfromthebasisvehicleelectricalsystembymeansofaDC/DCconverter(500W).
Therequireenergyforactivationisprovidedbyanadditional12Vbatterylocatedintheenginecompartment.Thismeansthatotherconsumersarenotaffectedbythehighenergyconsumption.
Thebatteryisanauxiliarybatterwhichsuppliesthevehicleelectricalsystemwithpowerdependingonthevehicleequipment.Forthisreason,thebatterymayalsobepresentevenifthevehicleisnotequippedwithelectricactivestabilizers.
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6.6.3.ControlstrategyVehicledrivabilitywhencorneringcanbegreatlyinfluencedbyanti-rollbarsonthefrontandrearaxles.Adecisivefactorhereistherollmomentratiobetweenthefrontandrearvehicleaxles.Thisratiodependsontherespectiveanti-rollbarmomentsofthetwoaxles.
Thefollowingtableprovidesanoverviewofthepossiblerollmomentratiosandtheresultanthandlingofthevehicle.
Anti-rollbar Rollmomentratio Understeer OversteerFrontaxlesoft/rearaxlehard
<50% X
Frontaxlehard/rearaxlesoft
>50% X
Thefollowinggraphicshowsthepercentagedistributionofthestabilizermoments(rollmomentratio)oftheactivestabilizersonthetwovehicleaxles.
Characteristiccurveofactivestabilizeronfrontandrearaxles
Index ExplanationA UndersteeringrollmomentratioB NeutralrollmomentratioMain[%] Momentdistributionofactivestabilizersinpercentvin[km/h] Drivingspeedinkilometersperhour1 Activestabilizeronthefrontaxle2 Activestabilizerontherearaxle
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Theactivestabilizerallowstherollmomentratiotobeadaptedtotherespectivedrivingsituationinordertoincreasethedrivingdynamics.Therollmomentratiois50 : 50(neutral)inthelowerspeedrange(0 ~ 50km/h).Therollmomentratioisadjustedtowardsundersteerwithincreasingspeed.
Applicationofrollmomentsviatheactivestabilizerinfluencesthecorneringforcesthatcanbetransferredbythetires.
Thefollowinggraphicshowsthemaximumcorneringforcesthatcanbetransferredwhencorneringasafunctionoftheappliedstabilizermoments.
Diagramofapositiverollmomentratiothroughcontrolvia2activestabilizers
Index ExplanationA LargemomentoftheactivestabilizeronthefrontaxleB LowmomentoftheactivestabilizerontherearaxleC IncreaseintransferablecorneringforceatthewheelD ReductionintransferablecorneringforceatthewheelE ResultanttransferablecorneringforceatthewheelsofanaxleFS TransferablecorneringforceatthewheelFN VerticalwheelforceHL Forceofactivestabilizeratrearleftwheel
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Index ExplanationHR ForceofactivestabilizeratrearrightwheelMa ActivestabilizermomentVL ForceofactivestabilizeratfrontleftwheelVR Forceofactivestabilizeratfrontrightwheel
Whencornering,acounter-torque(Ma)isappliedbytheactivestabilizerstocounteracttheactingrollmoment(Mw).Themoments(Ma)applieddependingontheactionoftheactivestabilizerseitherincreaseorreducethetirecontactforcesofthedifferentwheels.
Ifawheelisloadedwithaparticularlyhighforcebytheactivestabilizer,itstransferablecorneringforceincreasesduetothehighertirecontactforce.Incontrast,theloadontheoppositewheelisrelieved,anditscorneringforceisthusreducedduetothelowertirecontactforce.Theresultanttirecontactforcescharacterisethetransferablecorneringforcesofthewheelsonanaxle.
Sincethereductioninthetransferablecorneringforcesoftherelievedwheelisproportionatelyhigherthantheincreaseinthetransferablecorneringforcesoftheloadedwheelasaresultofincreasingactivestabilizerforce,thismeansthatthereisareductionintheresultantcorneringforceofthewheelsonthisaxle.
Inthedirectcomparisonofthetwoaxlesintheabovediagram,itcanbeseenthattherearaxlecantransferahigherresultanttransferablecorneringforcethanthefrontaxle.Inthelimitrange,thevehiclewouldthereforepushoverthefrontwheels,i.e.understeer.
Itiseasierforaninexperienceddrivertoregaincontroloverthevehicleagaininthissituationthanifthevehicleweretooversteer(vehicleskidsattherearaxle).
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6.6.4.SystemwiringdiagramofelectricactiverollstabilizationEARSV
SystemwiringdiagramofelectricactiverollstabilizationEARSVintheG12
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Index Explanation1 Wheelaccelerationsensor,frontleft2 Electricactiverollstabilizationfront(EARSVV)3 Powerdistributionbox,enginecompartment4 Wheelaccelerationsensor,frontright5 12Vbatteryinenginecompartment(vehicleelectricalsystemsupport)6 BodyDomainController(BDC)7 Powerdistributionbox,frontright8 VerticalDynamicsPlatform(VDP)9 Wheelaccelerationsensor,rearright10 Rearrightpowerdistributionbox11 Electricactiverollstabilizationrear(EARSVH)12 Wheelaccelerationsensor,rearleft13 KAFAScameracontrolunit14 Stereocamera
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