Vishwakarma Institute of Technology: A Seminar Report On

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BANSILAL RAMNATH AGARWAL CHARITABLE TRUST`S

VISHWAKARMA INSTITUTE OF TECHNOLOGY


PUNE-37

(An Autonomous Institute Affiliated to University of Pune)

A seminar
report on

“SELF-
HEALING
POLYMER
TECHNOLOGY”

Submitted By

ATUL K. SHINDE
( TE-V_01 )

Under The Guidance of

Prof. M.V.WALAME

Department of Mechanical Engineering


2014-2015
BANSILAL RAMNATH AGARWAL CHARITABLE TRUST`S

VISHWAKARMA INSTITUTE OF TECHNOLOGY


PUNE-411 037

(An Autonomous
Institute Affiliated to
University of Pune.)

CERTIFICATE
This is to certify that the Seminar titled “SELF-HEALING POLYMER

TECHNOLOGY” has been completed in the academic year 2014 – 2015, by Mr. ATUL

K. SHINDE in partial fulfillment of Bachelor’s Degree in Mechanical Engineering as

prescribed.

PROF. M.V.WALAME PROF. H.G.PHAKATKAR


(Guide) (H.O.D. - Mechanical Dept.)

Place : Pune Examiner


Date :
MAGIC BODY CONTROL

ABSTRACT

Mercedes-Benz is defining a level of ride comfort with Magic Body Control, the world’s
first suspension system with “eyes”. Magic body control combines the advantages of the
active suspension system active body control (ABC) with the globally innovative road
surface scan function - a stereo camera that scans the road ahead and registers the road
surface and its condition.Premiered in 2013 in the flagship S-Class, this pioneering
technology features a highly-sensitive sensor system that scans the road ahead for bumps
or potholes and then adjusts the car’s suspension accordingly.

Magic Body Control is the next generation of Active Body Control. Created with the help
of ZF, the system of bushings atop the strut towers neutralizes wheel and body
movements at two different frequencies. Daimler's testing indicates that MBC reduces 80
percent of unsavory suspension reverberations. It will show up on the S-Class and CL-
Class.
INTRODUCTION

Mercedes-Benz is presenting a new innovation in the new S-class, the world’s first car
capable of detecting road surface undulations in advance.

Mercedes' current ABC system uses a hydraulic piston to act on each steel coil spring to
quickly and independently adjust the suspension on each wheel in reaction to the road
surface, and it does a fine job keeping the ride smooth and occupants unjostled. But the
key term there is “reaction”—the suspension deals with the bumps after the wheel has
encountered them. What if the car knew what was coming in advance, with absolute
certainty and down to every imperfection? The oil flow at each corner could be adjusted
so accurately that any surface flaw could be practically neutralized.

That's exactly what Magic Body Control intends to do. A camera situated at the top of the
windshield scans the road ahead, analyzing its flaws and blemishes, and feeds that data
directly to the ABC system's control unit. The camera scans the area 15 to 45 feet in front
of the car, and it can detect and measure imperfections as small as 0.4 to 0.8 inch. In
doing so, the system knows exactly what the tires will encounter just fractions of a
second into the future. The series-production use of a camera to gather road data is
different from the laser-based approach used on the F700 concept, where the technology
was called pre-scan. The camera also feeds information to the distronic cruise control.

Mercedes launched their magic body control in 2013 which will be seen in new S-class
and CL-class.

SUSPENSION
Suspension is the system of springs, shock absobers and linkages that connects a vehicle
to its wheels and allows relative motion between the two. Suspension systems serve a
dual purpose — contributing to the vehicle's road holding/handling and braking for good
active safety and driving pleasure, and keeping vehicle occupants comfortable and
reasonably well isolated from road noise, bumps, and vibrations,etc. These goals are
generally at odds, so the tuning of suspensions involves finding the right compromise. It
is important for the suspension to keep the road wheel in contact with the road surface as
much as possible, because all the road or ground forces acting on the vehicle do so
through the contact patches of the tires. The suspension also protects the vehicle itself and
any cargo or luggage from damage and wear. The design of front and rear suspension of a
car may be different.

SUSPENSION IN MAGIC BODY CONTROL

Magic Body Control is based on the ABC(Active Body Control) suspension featuring
active suspension which improves both comfort and driving dynamics.

ACTIVE SUSPENSION
The active suspension and adaptive suspension/semi-active suspension are types of
automotive suspensions that controls the vertical movement of the wheels relative to the
chassis or vehicle body with an onboard system, rather than in passive suspensions where
the movement is being determined entirely by the road surface. Active suspensions can be
generally divided into two main classes: pure active suspensions and adaptive/semi-active
suspensions. While adaptive suspensions only vary shock absorber firmness to match
changing road or dynamic conditions, active suspensions uses some type of actuator to
literally raise and lower the chassis independently at each wheel.

These technologies allow car manufacturers to achieve a greater degree of ride quality
and car handling by keeping the tires perpendicular to the road in corners, allowing better
traction and control. An onboard computer detects body movement from sensors
throughout the vehicle and, using data calculated by opportune control techniques,
controls the action of the active and semi-active suspensions. The system virtually
eliminates body roll and pitch variation in many driving situations including cornering,
accelerating, and braking.

HYDRAULIC ACTUATED .
Hydraulically actuated suspensions are controlled with the use of hydraulic
servomechanisms. The hydraulic pressure to the servos is supplied by a high pressure
radial piston hydraulic pump. Sensors continually monitor body movement and vehicle
ride level, constantly supplying the computer with new data. As the computer receives
and processes data, it operates the hydraulic servos, mounted beside each wheel. Almost
instantly, the servo-regulated suspension generates counter forces to body lean, dive, and
squat during driving maneuvers.

In practice, the system has always incorporated the desirable self-leveling suspension and
height adjustable suspension features, with the latter now tied to vehicle speed for
improved aerodynamic performance, as the vehicle lowers itself at high speed
Computer Active Technology Suspension (CATS) co-ordinates the best possible balance
between ride quality and handling by analyzing road conditions and making up to 3,000
adjustments every second to the suspension settings via electronically controlled
dampers.

MAGIC BODY CONTROL


MAGIC BODY CONTROL is based on the ABC (Active Body Control) suspension
featuring active suspension which improves both comfort and driving dynamics.
Magic body control combines the advantages of the active suspension system Active
Body Control (ABC) with the globally innovative road surface scan function – a stereo
camera that scans the road ahead and registers the road surface and its condition.
The system is thus able to recognize an uneven road surface before you come to drive
over it, thus enabling the suspension to adjust itself in order to counteract, as far as
possible, the undulations in the road.

Magic body control ensures a unique synthesis of comfort and agility. Regardless of
whether the surface of the road you are driving on is smooth or damaged: you glide
quietly and serenely over the asphalt.
The basis of the new system is provided by the Active Body Control (ABC) active
suspension, which works to hold the vehicle body steady. It can actively regulate the
suspension strut forces – and does so for each wheel separately. This dampens the
vibrations of your car, while bodywork oscillations caused during steering, braking or
accelerating can be almost completely eliminated. This technology is also able to hold
your car in its lane much better in critical wind conditions.
The suspension also recognizes the car's load and adjusts its level accordingly. Depending
on circumstances, the ground clearance can be increased by up to 40 mm - for example in
wintery road conditions. Complementing this system is the new road surface scan
function. A stereo camera positioned at about the height of the interior mirror measures
the road surface ahead of you and sends the data recorded to the control unit for the
suspension, where they are evaluated. The active suspension then takes just fractions of a
second to adjust itself to the condition of the road. The result is very agile, precise and yet
still comfortable handling, on an apparently ultra-smooth road surface.
WORKING

It starts with analyzing the prevailing driving situation. In order to assess the prevailing
driving situation, a microprocessor analyses the signals from the lateral, longitudinal and
vertical acceleration sensors and from the pressure sensors assigned to each spring strut.
The level of the body is determined by the level sensors on the control arms of the front
and rear axles. The four spring struts are fitted with hydraulic cylinders to enable the
force in each spring strut to be adjusted individually. As a result, the vertical, rolling and
pitching movements to which the body can be subjected are almost completely
compensated for. The control unit receives information on the current driving conditions
from various acceleration sensors and compares it with the data from the pressure sensors
in the spring strut and the level sensors on the control arms. Subsequently the system
calculates control signals for the servo-hydraulic valves on the front and rear axle, in
order to meter the flow of oil appropriately. The engines pressure supply system provides
the servohydraulic valves with hydraulic pressure of up o 200 bar. The constantly
available pressure and the employed accumulators enable active body control to respond
to initial signs of body movement in a fraction of second.

Together with the information on the driving conditions, the control unit continually
calculates the best control strategy for dealing with unevenness in the road. Based on this,
the active suspension is able to make damping harsher or softer within fractions of a
second in advance and individually for each separate wheel, and increase or decrease the
load on each wheel via the active hydraulics.
ACTIVE BODY CONTROL -

Active Body Control, or ABC, is the Mercedes-Benz brand name used to describe
fully Active suspension, that allows control of the vehicle body motions and therefore
virtually eliminates body roll in many driving situations
including cornering, accelerating, and braking.

In the ABC system, a computer detects body movement from sensors located throughout
the vehicle, and controls the action of the active suspension with the use of hydraulic
servomechanisms. The hydraulic pressure to the servos is supplied by a high pressure
radial piston hydraulic pump. A total of 13 sensors continually monitor body movement
and vehicle level and supply the ABC controller with new data every ten milliseconds.
Four level sensors, one at each wheel measure the ride level of the vehicle, three
accelerometers measure the vertical body acceleration, one acceleration sensor measures
the longitudinal and one sensor the transverse body acceleration. At each hydraulic
cylinder, a pressure sensor monitors the hydraulic pressure. As the ABC controller
receives and processes data, it operates four hydraulic servos, each mounted in series on a
spring strut, beside each wheel. Almost instantaneously, the servo regulated suspension
generates counter forces to body lean, dive and squat during various driving maneuvers.
A suspension strut, consisting of a steel coil spring and a shock absorber are connected in
parallel, as well as a hydraulically controlled adjusting cylinder, are located between the
vehicle body and wheel. These components adjust the cylinder in the direction of the
suspension strut, and change the suspension length. This creates a force which acts on the
suspension and dampening of the vehicle in the frequency range up to five hertz.
The system also incorporates height adjustable suspension, which in this case lowers the
vehicle up to 11 mm (0.43 in) between the speeds of 60–160 km/h (37–99 mph) for
better aerodynamics, fuel consumption, and handling.

The ABC system also allows self leveling suspension, which raises or lowers the vehicle
in response to changing load (i.e. the loading or unloading of passengers or cargo). Each
vehicle equipped with ABC has an “ABC Sport” button that allows the driver to adjust
the suspension range for different driving style preferences. This feature allows the driver
to adjust the suspension to maintain a more level ride in more demanding driving
conditions. The first complete and ready-for-production version of ABC was introduced
in 1999 on the top-of-the-line Mercedes-Benz CL class, the Mercedes-Benz CL112 of
1991 however already featured a prototype version of ABC.
COMFORT AND SPORT MODE

At the touch of a button: individual suspension and transmission characteristics


The new CL-Class features an S/C/M button in the centre console with which the driver
is able to modify the overall characteristics of the coupe from comfortable to sporty:

Comfort: In this mode the automatic transmission changes the gears at lower engine
speeds, and the CL coupe moves off in second gear. The ABC suspension operates in
Comfort mode, comfortably smoothing out uneven road surfaces and bumps.

Sport: The automatic transmission makes full use of the engine speed range in this
setting. The ABC suspension operates in Sport mode as well, with a stiffer damping effect
on uneven surfaces and bumps. The characteristic map of the accelerator is also modified,
so that the engine responds more rapidly when acceleration is required.

Manual: The automatic transmission is operated manually using gearshift buttons on the
steering wheel, with significantly reduced gearshift times compared to the Sport mode.
The suspension configuration selected by Active Body Control is the same as in Sport
mode, as is the characteristic map of the accelerator.
If the CL-Class is travelling on poor roads which make a higher ground clearance
advisable, the driver is able to raise the suspension by 45 millimetres at the touch of a
button. When travelling at high speed in Sport mode, ABC automatically lowers the
suspension by up to ten millimetres to reduce aerodynamic drag and lower the fuel
consumption.

ROAD SURFACE SCAN

ROAD SURFACE SCAN uses a stereo camera positioned behind the windscreen. "It
measures the road up to 15 m in front of the vehicle and with a height measurement
accuracy of more than around 3 mm". This provides a precise picture of the road surface
profile. Together with the information on the driving conditions, the control unit
continually calculates the best control strategy for dealing with unevenness in the road.
Based on this, the active suspension is able to make the damping harsher or softer within
fractions of a second in advance and individually for each separate wheel, and increase or
decrease the load on each wheel via the active hydraulics. This can help to reduce vehicle
body movements significantly. Since ROAD SURFACE SCAN is a camera-based
system, it is able to function during the day in conditions of good visibility and on
suitably surfaced roads as well as at speeds up to 130 km/h.
.

DISADVANTAGES

Yet this brand of Magic has its limitations: it only works during the day, foul weather can
cause the system to pack up (if the camera gets blocked by snow, for instance) and it's
really most effective over large disturbances like the aforementioned speed bump, as it's
not yet quick-witted enough to catch subtler potholes and such. Oddly, it also only works
with ABC set to Comfort Mode – if you choose Sport you're on your own. Most of the
time, the system feels like a conventional luxury car, which is to say very well behaved,
but not entirely sporty.

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