Bosch has just produced its five millionth Electronic Stability Program (ESP) system, as it races to meet rapidly increasing demand from Europe’s car manufacturers. Since it started production of ESP in 1995, Bosch produced three million systems by the end of 2000 and the last two million were built in 2001 alone.

Bosch expects its sales of ESP to reach ten million by mid-2003.

ESP is no longer the preserve of the premium end of the car market. This year, ESP will be available on the new Toyota Corolla, the new Nissan Primera and the new VW Polo.

A progression from previous technologies ABS and traction control, ESP works by taking information from sensors around the car, which monitor for signs of a potential swerve or skid. It then sends commands to the ESP hydraulic modulator and engine management system to proactively brake individual wheels and reduce engine power respectively to stabilise the vehicle.

For example, if a rear-wheel-driven vehicle is about to ‘lose’ its rear end, ESP simultaneously reduces the engine power and brakes the wheels using differing, precisely computed pressures to keep the vehicle on track.

ESP also delivers benefits in non-emergency situations; a Cornering Brake Control function selects separate and optimum braking pressures for each of the inside and outside wheels to increase directional stability during normal braking through a corner.

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Commenting on the attributes of ESP, Stefan Mischo, developer of brake control systems at Bosch said: “Errors aside, every driver is sooner or later confronted with critical driving situations, such as an obstacle appearing suddenly out of nowhere or icy patches on the street. Even at ‘appropriate’ driving speeds, the driver can lose control of the vehicle as a result of quick avoidance manoeuvres, and attempts to regain control by counter steering can easily grow into a severe problem even for experienced drivers.

“Of course ESP cannot overcome the laws of physics. However, through targeted intervention the system can do everything physically possible to prevent the vehicle from skidding – much better by far than even the most experienced driver.”

Two years ago, the Institute for Vehicle Safety in the Association of German Insurance Businesses analysed the causes of accidents with serious or fatal injuries. The analysis revealed that 60 percent of all accidents with fatalities were caused by side-impact crashes. In 30 to 40 percent of all fatal accidents, the vehicle began to skid due to excessive speed, exaggerated steering reaction or driving error.

Accident researcher, Prof. Klaus Langwieder, explains: “In contrast to the deformation zones in the front and rear end, a passenger car offers fewer options when it comes to side impact protection – this is evidenced by the large numbers of seriously injured or killed people in side collisions.”

ESP marks the start of an era of ‘Brake-by-Wire’, whereby braking is performed through electronics instead of the traditional hydraulic system, bringing a number of crucial benefits. For example ‘Brake Assist’ automatically increases the brake pressure up to the limit when the brake pedal is sharply pressed by the driver, shortening braking distance by a few decisive metres.

The world’s first example of Brake-by-Wire for passenger cars is an electro-hydraulic brake, called SBC, which has recently debuted in the Mercedes SL.