Automobile Electricals And Electronics

Automobile Electricals & Electronics Automobile and Mechanical Engineering Department Thapathali Campus Institute of Engineering Tribhuvan University by Sung C. Park WFK Advisor

CONTENTS I.

Introduction to Automobile Electrical & Electronic System (10hrs)

II.

Batteries and Starting System (6hrs)

III.

Charging System (6hrs)

IV.

Lighting System and Accessories (6hrs)

V.

Electronic Ignition System (4hrs)

VI.

Electronic Injection System (4hrs)

VII. Sensors, Actuators and Microprocessors in Automobiles (8hrs) VIII. Auxiliary Equipment (8hrs) IX.

EV(Electric Vehicle) (8hrs)

1. Introduction to Automobile Electrical & Electronic System

1-1. Electrical System : Purpose, Functions 1-2. Electronic System : Purpose, Functions

Electrical or Electronic ? ■ Electrical • Refer to wiring and electrical parts, such as generators, lights and voltage regulators • Need Multimeter, Volt/Ammeter to diagnosis ■ Electronic • Refer to Computers and other Black-Box type items used to control engine and vehicle systems • Need Scope, Scan Tool to diagnosis

1-1. Electrical System

1-1. Electrical System ■ Ohm’s Law V

I

R

P

I

V

1-1. Electrical System ■ Kirchhoff’s Law Current Law

i2 + i3 = i1 + i4 Current entering any junction is equal to current leaving that junction

Voltage Law

V1 + V2 + V3 - V4 = 0 Sum of all voltages around a loop is equal to zero

1-1. Electrical System ■ Serial, Parallel, Serial-Parallel Circuit Serial Circuit

Parallel Circuit

1-1. Electrical System Serial-Parallel Circuit

1-1. Electrical System ■ Electromagnetism  Self & Mutual - Induction Change in current through its circuit induce EMF(electromagnetic force) in conductor itself (self-induction) and in any nearby conductors (mutual-induction)

 Lenz’s law & Faraday’s Law  Lenz’s Law : Changing electric current through a circuit that contain inductance induce a proportional voltage, which oppose the change in current (self-inductance) Varying field in this circuit may also induce an EMF in neighbor circuit (mutual inductance)  Faraday’s Law : Time-varying magnetic field induce electromagnetic force (EMF) in nearby conductors

1-1. Electrical System Self-Induction

Mutual-Induction

1-1. Electrical System  Electrical Wiring Components – Relay Electric switch that allow small amount of current to control a high current circuit

1-1. Electrical System RELAY OPERATION

Load Circuit

Control Circuit

Relay De-Energized (OFF)

Relay Energized (ON)

1-1. Electrical System RELAY VARIATION

3 pin

4 Pin Mini Relay

5 Pin Mini Relay

4 pin

5 pin

4 Pin Micro Relay

5 Pin Micro Relay

1-1. Electrical System RELAY APPLICATION (example)

1-1. Electrical System  Electrical Components – Solenoid/Solenoid Valve Electromagnets with movable cores used to change electrical current flow into mechanical movement

1-1. Electrical System Solenoid Valve in LPG/CNG Vehicle

1-1. Electrical System Solenoid

Fuel Injector(2nd Gen.)

Starter Motor

1-1. Electrical System  Electrical Wiring Components – Capacitor (Condenser) Passive two-terminal electrical component that store electrical energy in electrical circuit

1-1. Electrical System

Distributor in Ignition System

Condenser

1-1. Electrical System Capacitor’s Capacitance in Series

Capacitor’s Capacitance in Parallel

1-1. Electrical System ■ Motor and Generator Fleming’s Left Hand Rule

MOTOR

Fleming’s Right Hand Rule

GENERATOR

1-1. Electrical System AC(ALTERNATING CURRENT)

AC Generator

AC Motor

1-1. Electrical System AC(Alternating Current)

1-1. Electrical System DC(DIRECTING CURRENT)

1-1. Electrical System DC(Directing Current)

1-1. Electrical System ■ Electrical Wiring

1-1. Electrical System Wiring Harness

1-1. Electrical System Terminal, Connector and Wire

1-1. Electrical System Electrical Wiring Digram Symbol

1-1. Electrical System Ex) Electrical Wiring Digram

Wire Color Code Connector

1-1. Electrical System How to read Wiring Digram

1-1. Electrical System ■ Electrical Circuit  DEFINITION OF CIRCUIT Complete path that electron travel from power source thru load and back to power source

 PARTS OF A COMPLETE CIRCUIT  Power Source Battery

 Protection Devices Fuse, Circuit breaker, Fusible link

 Circuit Control Devices Switch

 Power Path Insulated wire from battery to loads

 Loads(Resistance)

Motor, Light, Actuator…..

 Return Path(Ground) Insulated wire and body sheet metal of vehicle

1-1. Electrical System  Circuit Fault  OPEN CIRCUIT -

Not completed circuit or broken wire No current flow at all Circuit not to work Fuse will blow(open) when over current flow in circuit to protect system components

 SHORT TO VOLTAGE - One circuit is electrically connected to another circuit by fault in power side of circuit - Complete circuit in which current bypass some or all of resistance in circuit - Current flow in circuit - Affect more than one circuit

1-1. Electrical System  SHORT TO GROUND - Current bypass part of normal circuit and flow directly to ground - Normally ground return circuit is metal(vehicle frame, engine or body) - Result in blown fuse, damaged connector or melted wire

 HIGH RESISTANCE - Caused by corroded connector or loosen terminal - Result in slow operation of motordriven unit (windshield wiper or blower motor) - Dim light - “clicking” of relay or solenoid - No operation of circuit

1-1. Electrical System  Concept of Vehicle Main Electrical Circuit Starter

to start engine Engine Generator

Battery

Accessories

to run engine Ignition

1-2. Electronic System

1-2. Electronic System

CONDUCTOR

SEMI-CONDUCTOR

INSULATOR

1-2. Electronic System

N-Type Semiconductor

P-Type Semiconductor

1-2. Electronic System ■ Diode

1-2. Electronic System  Diode Rating  Maximum current flow in forward-bias direction, normally 1~5A

☞ Current Limitation

Forward-bias voltage required for diode range used in automobile between 1.5~2.2V, so a resistor(300~500 ohms) must be connected in series with every diode to control current flow across the P-N junction when a diode were connected across 12 voltage automotive battery

 PIV(Peak Inverse Voltage) or PRV(Peak Reverse Voltage) Rating of resistance to reverse-bias voltage

 Diode Voltage Drop Voltage drop across a diode : Ge diode 0.3~0.5V, Si diode 0.5~0.7V e.g.) 1N 4001-50 V PIV 1N 4002-100 V PIV 1N 4003-200 V PIV 1N 4004-400 V PIV 1N 4005-600 V PIV

1-2. Electronic System Rectifier Diode - Act as a form of current valve - Suitable for rectifying alternating current

Zener Diode - Operate with a reverse-bias current above Breakdown Voltage or Zener Region - Suitable for voltage regulator

LED(Light Emitting Diode)

- Radiate light when current flow through diode in forward-bias direction - LED emit in limited spectral range depending on choice of semiconductor e.g.) Gallium Arsenide : Infrared, Gallium Arsenide Phosphide : Red to Yellow, Gallium Phosphide : Green, Indium Gallium Nitride : Blue

1-2. Electronic System Photo Diode - Response to various wavelengths of light - Light energy strike diode, electrons are released and diode will conduct in forward-bias direction - Used in automatic headlight and steering wheel control for transmitting tuning, volume etc

Photoresistor - Change resistance wit presence or absence of Light Dark : High resistance Light : Low resistance - Used to control headlight dimmer relay and automotive headlight

1-2. Electronic System ■ Transistor

NPN

PNP

1-2. Electronic System  Basic Transistor Operation  Act as Electrical Switch in a circuit  Act as amplifier of Current in a circuit  Regulate Current in a circuit

1-2. Electronic System Bipolar Transistor

FET(Field Effect Transistor) - Used in most automotive application - Use less electrical current and rely on small voltage signal to control output - Constructed with MOS(Metal Oxide Semiconductor) material, which is highly sensitive to static electricity - Easily damaged when exposed to excessive current or high-voltage surge(spike) - PMOS(p-channel MOS), NMOS(nchannel MOS), CMOS(complementary* MOS) * pair PMOS and NMOS

1-2. Electronic System Phototransistor - Use light energy to turn on base of transistor - NPN transistor - Has large exposed base area to permit light - May or may not have a base lead

Thermistor - Thermistor heated, electrons gained energy are released, producing voltage - Contrary to typical conductor, thermistor’ s resistance is decreased as temperature increase, so called NTC(Negative Temperature Coefficient) - Used as temperature-sensing device for coolant and intake manifold air temperature

1-2. Electronic System Darlington Pair -Consist of two transistors wired together -Permit very small current flow to control large current (Amplifier circuit) -Used in electronic ignition system, computer engine control circuits etc.

SCR (Silicon Controlled Rectifiers) -Consist of two diodes connected end to end -If anode is connected to higher voltage source than cathode in circuit, no current will flow, but positive voltage source is connected to gate of SCR, then current can flow from anode to cathode. -Voltage applied to gate is used to turn SCR on, but if voltage source at gate is shut off, current will still continue to flow thru SCR until source current is stopped -Used for CHMSL(Center High-Mounted Stoplight) circuit

1-2. Electronic System Transistor Gate - Electronic circuit whose output depend on Location and Voltage of two inputs - AND Gate Require both transistors to be ON to get output - OR Gate Require either transistor to be ON to get output - NAND(Not-AND) Gate Output is ON unless both transistors are ON - NOR(Not-OR) Gate Output is ON only when transistors are OFF Typical AND Gate

OPA (Operational Amplifier) -Used in circuits to control and amplify digital signals -Used for motor control in climate control system (heating and air conditioning) airflow control door operation

1-2. Electronic System ■ DC-DC Converter  Electronic device used to transform one level DC voltage to another higher or lower level  Used in PCM circuit to convert 14V(battery voltage) to 5V(reference voltage or power voltage for many sensors in computer controlled engine management system)  Used in hybrid electric vehicle to transform 42V to 14V for accessories power voltage

1-2. Electronic System ■ Inverter  Electronic circuit that change DC (Direct Current) into AC (Alternating Current)  Switching transistors are turned on alternately for short pulse that produce a modified sin wave output  Inverter can convert DC power to AC power at required frequency and amplitude  Used in hybrid electric vehicle to change DC from battery to AC for use by electric motor

Typical Inverter Circuit

Modified sin wave

1-2. Electronic System ■ IC(Integrated Circuit)  Integration Level • SSI (Small Scale Integration)

- Up to several hundreds functional elements per chip - Mean chip surface area of 1 mm2

• MSI (Medium Scale Integration

- Several hundreds to 10,000 functional elements per chip - Mean chip surface area of 8 mm2

• LSI (Large Scale Integration)

- Up to 100,000 functional elements per chip - Mean chip surface area of 20mm2

• VLSI (Very Large Scale Integration) - Up to 1 million functional elements - Mean chip surface area of 30 mm2

• ULSI (Ultra Large Scale Integration)

- Over 1 million functional elements per chip - Surface area of up to 300 mm2 and the smallest structure sizes of less than 30 nm

1-2. Electronic System ■ Computer ECU(Electronic/Engine Control Unit) ECM(Electronic/Engine Control Module) ECA(Electronic/Engine Control Assembly) PCM(Power Control module)

INPUT

PROCESSING

OUTPUT

From SENSORS

CPU

To ACTUATORS

AD Convertor Speed Sensor Accessory Switch Pressure Senor Airflow Sensor Temperature Sensor Oxygen Sensor Position Senor

OUTPUT CONTROL

STORAGE MEMORY ROM(Read Only Memory) P(Programmable)ROM E(Erasable)PROM

RAM(Random Access Memory) KAM(Keep-Alive Memory) Nonvolatile RAM

Operate Actuator Network Communication Fuel Injector Transmission Shifting Blow motor Control Idle Speed Control

OUTPUT DRIVER LSD(Low Side Driver) HSD(High Side Driver)

PWM(Pulse-Width Modulation)

1-2. Electronic System ■ Network Communication & CAN  TYPE OF COMMUNICATION  Differential Difference in voltage is applied to two wires (twisted pair for reduce EMI(Electromagnetic Interference))

 Parallel Send and receive signal are on different wires

 Serial Data Data transmitted over one wire by series of rapidly changing voltage signals pulsed from low to high or from high to low

 Multiplexing Sending multiple signals of information at the same time over a signal wire and then separating signals at the receiving end

1-2. Electronic System

1-2. Electronic System  MODULE COMMUNICATION CONFIGURATION BUS LINK NETWORK  Also referred to as LINEAR BUS  Core element is single cable to which all nodes connecting  Easy to expanding  If a node fail, data from this node are not available in network, but remaining nodes can continue to exchange data  If central cable has a fault, network will fail completely

1-2. Electronic System STAR LINK NETWORK  Consist of a central node(hub), to which all other nodes are connected  Easy to expanding if free connection s are available  Data are exchanged via individual node connection with central star computer  Network performance is significantly determined by star computer  If a node fail, remaining network continue to be operational  If central node fail, entire network is not operational

1-2. Electronic System

Star Link Network

1-2. Electronic System RING LINK NETWORK  Each node is connected to its two neighbors  Data are transferred in only one direction form one station to next  Data are transferred repeatedly until reach intended destination  Once one station in single ring fail, data transfer is interrupted and network fail completely  Can also be structured in double ring, then data are transferred in both direction  In double ring topology, failure if one station or connection between two stations can be managed

1-2. Electronic System

Ring Link Network

1-2. Electronic System MESH LINK NETWORK

 Each node is connected to one or more further nodes  In event of failure of a node or connection, there are diversion along which data can be routed  Therefore have high failure tolerance  However, cost of networking and transferring are high

1-2. Electronic System HYBRIDLINK NETWORK

Star-Bus Networking

Star-Ring Networking

1-2. Electronic System  CAN(Controller Area Network)  BACKGROUND - Developed by Robert Bosch in 1993 - Approved by EPA(Environment Protection Agency) for vehicle diagnostics since 2003 and legal requirement for all vehicle since 2008

 FEATURES -

Faster than other BUS communication protocols Cost effective Less effected by EMI(Electromagnetic Interference) Message based rather than address based which make it easier to expand No wakeup needed because it is a two-wire system Support up to 15 modules plus a scan tool Use pins 6 and 14 in standard 16 pin OBD-II connector Apply 2.5 V on both wires H(High) go to 3.5 V when active L(Low ) go to 1.5 V when active

1-2. Electronic System

1-2. Electronic System  NETWORK COMMUNICATION CLASSIFICATION CLASS A

CLASS C+

Data Transfer Rates

up to 10 kbit/s

Application

Networking of actuators and sensors

Represented by

LIN, PSI5

CLASS B Data Transfer Rates

up to 125 kbit/s

Application

Complex mechanisms for error handling Networking of control units in comfort area

Represented by

Low-speed CAN(CAN-B)

CLASS C Data Transfer Rates

up to 1 Mbit/s

Application

Real-time requirements Networking of control units in drive and chassis area

Represented by

High-speed CAN(CAN-C)

Data Transfer Rates

up to 10 Mbit/s

Application

Real-time requirements Networking of control units in drive and chassis area

Represented by

FlexRay

CLASS D Data Transfer Rates

from 10 Mbit/s

Application

Networking of control units in area of telematics and multimedia

Represented by

MOST, Ethernet

2. Battery and Starting System

2-1. Purpose and Functions of Battery 2-2. Different Types of Battery 2-3. Principle, Rating, Testing and Charging of Battery 2-4. Starting System : Component, Working Principle, Circuit Diagram 2-5. Starter Motors : Types, Characteristics

2-6. Capacity Requirement 2-7. Drive Mechanism 2-8. Starter Switches

2. Battery and Starting System

2. Battery and Starting System ■ Function of Battery in Automobile

 Supply current for Starting Motor and Ignition System when engine is starting  Act as stabilizer and supply current to different electrical accessories (e.g., lights, radio, heater etc) when output from generator is not sufficient to handle electrical load

■ Type of Battery Dry Cell

Wet Cell

2. Battery and Starting System ■ Construction of Automotive Battery (Wet Cell)

2. Battery and Starting System ■ Battery Chemical Reaction DISCHARGING

CHARGING

2-1. Battery Chemical Reaction Starter Battery  ICE(Internal Combustion Engine)  Wet-Cell  Lead-Acid

Driver Battery  Hybrid Vehicle, EV  Dry-Cell  Ni-MH, Li-ion  BMS(Battery Management System)

2. Battery and Starting System ■ STARTING SYSTEM  Components  Battery  Ignition Switch  Fuse and Relay  Starter Solenoid  Starter Motor  Starter Drive

2. Battery and Starting System Starter Motor Operation

2. Battery and Starting System SERIE MOTOR Develop maximum torque at initial start and less torque as speed increase  Used for starter motor

SHUNT MOTOR Not decrease in torque at higher speed but not produce as high starting torque as that of SERIES MOTOR Used for small electric motor such as windshield wiper motor

2. Battery and Starting System COMPOUND MOTOR  Operating characteristic of SERIES MOTOR and SHUNT MOTOR  Used in most commercial automotive starter motor

PM(Permanent Magnet) MOTOR  Use permanent magnet to maintain constant field strength  Similar operating characteristics as SHUNT MOTOR  To compensate for lack of torque, use gear reduction

2. Battery and Starting System Starter Drive  Include small pinion gear that mesh with and rotate larger gear on engine flywheel or flex plate  To prevent damage to starter or engine, must be engaged slightly before starter motor rotate and disengaged after engine start  Gear ratio between engine ring gear and starter pinion 15:1 ~ 20:1  Overrunning Clutch Type of one-way clutch that allow starter to rotate engine but then freely if engine speed is greater than starter motor speed

2. Battery and Starting System Solenoid – Operated Starter

2. Battery and Starting System Solenoid – Operated Starter

2. Battery and Starting System Circuit of Solenoid – Operated Starter

3. Charging System

3-1. Purpose, Functions of Charging System 3-2. Charging System : Component, Working Principle, Circuit Diagram 3-3. Alternators and their Characteristics

3-4. Control Unit : Voltage Regulator

3. Charging System ■ Requirements of Charging System  Provide current to recharge battery and keep it fully charged  Develop electricity to power all electrical components  Provide voltage output slightly higher than battery voltage  Maintain voltage constant under all conditions  Change current output as per load due to electrical accessories  Be reliable and quiet in operation  Require least maintenance  Have maximum possible power to weight ratio

■ Type of Charging System  DC(Direct Current) – Dynamo  AC(Alternating Current) - Alternator

3. Charging System ■ Generating System Principle

3. Charging System ■ Generating System Principle

Three Winding

3. Charging System ■ Stator Winding

 WYE(Y) -Connected Stator

 DELTA(Δ) -Connected Stator

3. Charging System ■ Alternator Output Factors  Speed of Rotation  Number of Conductors  Strength of Magnetic Field

3. Charging System ■ Rectifier & Diode Trio  Rectifier is 6 Diodes Set (1 positive & 1 negative set for each of 3 stator windings) to convert alternating current to direct current  Diode Trio operate as one-way electrical check valve

Rectifier

Diode Trio

3. Charging System ■ Voltage Regulator

Alternator must produce electrical pressure (voltage) higher than battery voltage to charge battery, but excessive high voltage can damage battery, electrical components  Regulator simply open ground side of field circuit if voltage reach predetermined level, then close the circuit again as necessary to maintain correct charging voltage  Zener diode is major electronic component that block current flow until specific voltage is reached, then permit current to flow

3. Charging System ■ Alternator Construction of Alternator Stator

Stator Rotor(Armature) Rotor(Ar Voltage Voltage mature) Regulator Regulato r Bearing Bearin g Ring Split Split Ring

Housing Housi

ng

Bearing Bearin

g

Rectifier Rectifi

er Fan Fan

Fan Fan

3. Charging System

3. Charging System

3. Charging System ■ Charging System Circuit

3. Charging System

■ Typical Circuit of Alternator

4. Lighting System

4-1. Purpose, Types, Functions, Components & Circuit Diagram 4-2. Wiring Requirements

4. Lighting System ■ Functions of Lighting System  Lighting at Front End  Low-beam headlamp  High-beam headlamp  Fog lamp  Position/Clearance lamp (wide vehicle)  Auxiliary driving lamp  Turn-signal (Direction indicator) lamp  Parking lamp Headlamps  Daytime running lamp

Fog lamps

Side Turn lamps

4. Lighting System  Lighting at Rear End  Turn-signal (Direction indicator) lamp  Stop lamp  Clearance lamp (wide vehicle)  Tail lamp  Rear fog warning lamp High Mount Stop lamp  Parking lamp  License-plate lamp

Rear Combination lamps Rear Fog lamps

4. Lighting System  Lighting in vehicle Interior  Instrument lamp  Courtesy lamp

4. Lighting System ■ Bulb

 Thermal Radiator  Incandescent Bulb 1. 2. 3. 4.

Glass bulb Filament Lamp socket base Electrical connection

4. Lighting System  Gas-Discharge Lamp  H4 Halogen Lamp 1. 2. 3. 4. 5.

Glass bulb Low-beam filament with cap High-beam filament Lamp base Electrical connection

4. Lighting System  D2S Gas-Discharge Lamp

1. 2. 3. 4. 5. 6.

Glass capsule with UV shield Electrical lead Discharge chamber Electrodes Lamp base Electrical connection

4. Lighting System  D2R Gas-Discharge Lamp

1. 2. 3. 4.

UV inert-gas bulb Discharge chamber shutter Lamp base

4. Lighting System ■ HEADLIGHT

4. Lighting System ■ HEADLIGHT

4. Lighting System ■ HEADLIGHT

High Beam

Low Beam

4. Lighting System ■ Headlight Dimmer Switch

Low Beam Position

High Beam Position

4. Lighting System ■ HEADLIGHT  Bulb

 Halogen Sealed Beam  HID (high-Intensive discharge)  LED (Light Emitting Diode)

4. Lighting System ■Headlight Aiming

4. Lighting System ■Headlight Aiming

4. Lighting System ■Headlight Adjustment

Manual Headlamp Leveling

Automatic Headlamp Leveling

4. Lighting System ■ Lighting System Wire Diagram

4. Lighting System ■ BRAKE LIGHT  When brake is applied, brake switch is closed and brake lamp on  Recent third brake light, CHMSL(Center High Mounted Stop Light)  Normally use LED for faster illumination and longer service life

4. Lighting System ■ TURN SIGNAL  Turn Signal Flasher

Mechanical Type

Electronic Type

5. Electronic Ignition System

5-1. Purpose, Types, Functions, Components, Working Principle & Circuit Diagram 5-2. Spark Plugs and Its Types 5-3. Spark Advance Mechanisms

5-4. Different Types of Ignition Systems

5. Electronic Ignition System Function of Ignition System  To generate an electric spark that has enough heat to ignite air/fuel mixture in combustion chamber  To maintain the spark long enough to allow for combustion of all the air and fuel in cylinder  To deliver the spark to each cylinder so combustion can begin at the right time during combustion stroke of each cylinder

5. Electronic Ignition System Components of Ignition System  Power Source  Magneto  Capacitor  Battery

 Primary Coil  Break Point  Mechanical(Contact Breaker)  Electrical(Power TR, SCR)

 Secondary Coil  Distribution System  Mechanical(Distributor)  Electrical(Distributorless)

 Spark Plug

5. Electronic Ignition System

IGNITION SYSTEM

MAGNETO POWERED

BATTERY POWERED

with Breaker Point

without Breaker Point

with Breaker Point

without Breaker Point

Magneto Ignition System

Capacitor Discharge Ignition System

Battery Point Ignition System

Distributor Less Ignition System

5. Electronic Ignition System ■ Voltage Boosting Mechanism (Battery Point Ignition Type) Function

Component

Voltage Boost

Power Source

Battery

12V

Self-Induction

Primary Coil

Magnetic Field Corruption

Distributor( Contact Breaker) Power TR

Count Electromotive (Surge)

Primary Coil

Mutual Induction

Secondary Coil

200~300V

20,000~30,000V

5. Electronic Ignition System  DI (Distributor Ignition) System  Use battery power as primary source of electricity  Mostly gasoline engine for vehicles (old)

5. Electronic Ignition System Distributor

TEI Distributor

HEI Distributor

5. Electronic Ignition System Ignition Coil 1. Printed circuit board 2. Ignition driver stage 3. AAS(Activation Arc Suppression) Diode 4. Secondary winding body 5. Secondary wire 6. Contact plate 7. High voltage pin 8. Primary plug 9. Primary wire 10. I core 11. Permanent magnet 12. Core 13. Spring 14. Silicon jacket

5. Electronic Ignition System DI (Distributor Ignition) System

5. Electronic Ignition System EI (Electronic Ignition) System  Use battery power as primary source of electricity  DIS(Direct Ignition System) or DIS(Distributor-less Ignition System)  Mostly gasoline engine for vehicles (recent)

5. Electronic Ignition System EI (Electronic Ignition) System

5. Electronic Ignition System Waste Spark System

(COP)Coil on Plug System

5. Electronic Ignition System ■ Magneto Ignition System  No need of outside primary source of electricity such as battery  Mostly small gasoline engine such as lawnmower, chainsaw etc.

5. Electronic Ignition System ■ CDI(Capacitor Discharge Ignition) Ignition System  Thyristor or SCR(Silicon Controlled Rectifier)  Widely used in outboard motor, lawnmower, turbine –powered aircraft

5. Electronic Ignition System ■ Crankshaft & Camshaft Position Sensor  Magnetic Pulse Generator Type

5. Electronic Ignition System  Metal Detector Type

 Photoelectric Type

5. Electronic Ignition System  Hall Effect Type

5. Electronic Ignition System ■ Ignition Timing  Spark should occur after compression stroke with piston at TDC  This will change as engine speeds up because fuel can only burn at one rate of speed  Piston could move faster than fuel burns, which means piston could be gone from TDC before fuel can push down on piston

Spark must be timed earlier as engine speed increase

5. Electronic Ignition System Mechanical Ignition System Use in Distributor System

 Mechanical Timing Advance Uses centrifugal force to move some weights and cause shaft to move ahead of rotation and open points sooner

 Vacuum Timing Advance

Uses vacuum to pull on the breaker plate and cause points to open sooner

Computer Controlled Ignition System ECM(Engine Control Module) having a timing map with spark advance data for all combi nations of engine speed and engine load, control ignition timing

5. Electronic Ignition System ■ Spark Plug

5. Electronic Ignition System ■ Heat Rate and Flow Path of Spark Plug

5. Electronic Ignition System ■ Spark Plug Fouling

Worn

Normal Spark Plug

Cold or Carbon-fouled

5. Electronic Ignition System

Wet or Oil-fouled

No Gap

Pre-ignition Damaged

Splash-fouled

Over Heating

6. Electronic Injection System

6-1. Purpose, Types, Functions, Components, Working Principle & Periphery Diagram 6-2. Periphery Diagram of Mono & Multi Point Fuel Injection System (MPFI) 6-3. Periphery Diagram of Common Rail Direct Injection System (CRDi)

6. Electronic Injection System ■ Evolution of Fuel Delivery System for SI Engine

SPI

MPI

GDI

6. Electronic Injection System ■ Typical Electronic Injection System

6. Electronic Injection System ■ Electronic Fuel Delivery System for SI Engine

6. Electronic Injection System ■ Evolution of Fuel Delivery System in CI Engine Boosting Pressure

Maintain Pressure

High Pressure pump

Common Rail

Boosting Pressure

Maintain Pressure

Rotary Pump

Boosting Pressure

Maintain Pressure In-Line Pump

Distribution

Injection Control Quantity

Timing

ECM

Injector

Injection Control

Distribution

Quantity

Timing

Distributor

Distribution

Injection

Injection Injector

Injection Control

Quantity

Timing

Governor

Pump

Injection Injector

6. Electronic Injection System ■ Common Rail Direct Injection System (CRDi)

7. Sensors, Actuators & Microprocessors in Automobile

7-1. Basic Sensor Arrangements 7-2. Types of Sensors 7-3. Actuators 7-4. Electronic Control Unit : Microprocessors & Microcomputers 7-5. Controlled Devices

7. Sensors, Actuators & Microprocessors in Automobile ■Electronics in Modern Vehicle

7. Sensors, Actuators & Microprocessors in Automobile ■Automobile Sensors

7. Sensors, Actuators & Microprocessors in Automobile ■Basic Sensor & Actuator Arrangement

7. Sensors, Actuators & Microprocessors in Automobile ■ Open loop & Closed Loop Control System

7. Sensors, Actuators & Microprocessors in Automobile ■ Typical Automotive Closed Loop Control System CONTROL SYSTEM

FUEL INJECTOR SYSTEM

KNOCK CONTROL SYSTEM ABS CONTROL SYSTEM

INDIRECTLY CONTROLLED VARIABLE

DIRECTLY CONTROLLED VALIABLE

MANUPULATED VARIABLE

SENSOR

ACTUATOR

Air-fuel ratio

Exhaust oxygen content

Quality of injection fuel

Lamda sensor

Fuel Injector

Knock

Knock sensor output

Ignition timing

Pizoelectri c accelerometer

Ignition coil switch

Wheel speed

Brake time pressure

Magnetic Reluctance

ABS solenoid valve

Wheel slip limit

7. Sensors, Actuators & Microprocessors in Automobile ■ Type of Sensor  Position and Angular Position Senor  Wiper Potentiometer - Throttle valve angle sensor, Accelerator pedal sensor, Fuel level sensor

Wiper Potentiometer

7. Sensors, Actuators & Microprocessors in Automobile

Throttle Valve Sensor

Electric Circuit of Throttle Valve Sensor

7. Sensors, Actuators & Microprocessors in Automobile

Potentiometric Fuel Level Sensor Sensor

7. Sensors, Actuators & Microprocessors in Automobile  Magnetically Inductive Sensor - Position sensor for Transmission control

Position Sensor using eddy-current principle

7. Sensors, Actuators & Microprocessors in Automobile  Magnetostatic sensor - Hall sensor, Axle sensor, Accelerator pedal sensor

UH : Hall voltage RH : Hall coefficient d : Chip thicness

Hall Effect

7. Sensors, Actuators & Microprocessors in Automobile

Hall Sensor using spinning-current principle

7. Sensors, Actuators & Microprocessors in Automobile

Axle Sensor

7. Sensors, Actuators & Microprocessors in Automobile

Accelerator Pedal Sensor(Hall Angular Position)

7. Sensors, Actuators & Microprocessors in Automobile  Magnetoresistive sensor

Differential Magnetoresistive Sensor Sensor

7. Sensors, Actuators & Microprocessors in Automobile  AMR(Anisotropic Magnetoresistive effect) Sensor - Steering angle sensor AMR Basic Principle

7. Sensors, Actuators & Microprocessors in Automobile

AMR Steering Angle Sensor

7. Sensors, Actuators & Microprocessors in Automobile  GMR(Giant Magnetoresistive effect) Sensor

GMR Layer Structure

7. Sensors, Actuators & Microprocessors in Automobile  RPM Sensor  Hall Sensor - Crankshaft/Camshaft speed sensor - Wheel speed sensor - Speed sensor for transmission control

 AMR Sensor  GMR Sensor

7. Sensors, Actuators & Microprocessors in Automobile  Pressure Sensor  Diaphragm type sensor

 Strain-gage sensor

7. Sensors, Actuators & Microprocessors in Automobile  Absolute pressure sensor

7. Sensors, Actuators & Microprocessors in Automobile  Temperature Sensor  Type -Sintered-ceramic resistor (NTC) - Thin-film metallic resistor (PTC) - Thick-film resistor (PCT and NTC) - Monocrystalline silicon semiconductor resistor (PTC)

 Temperature Range in Vehicle Measuring Point

Range, C

Measuring Point

Range, C

Intake and charge air

-40 ~ 170

Engine oil

-40 ~ 170

Outside atmosphere

-40 ~ 60

Battery

-40 ~ 100

Passenger compartment

-20 ~ 85

Fuel

-40 ~ 120

Ventilation & heating air

-20 ~ 60

Tire air

-40 ~ 120

Evaporator(A/C)

-10 ~ 50

Exhaust emission

100 ~ 1000

Coolant

-40 ~ 130

Brake caliper

-40 ~ 2000

7. Sensors, Actuators & Microprocessors in Automobile  Temperature-Resistance Curve

7. Sensors, Actuators & Microprocessors in Automobile  Measurement Principle

7. Sensors, Actuators & Microprocessors in Automobile  Flow Meter  Pilot-tube flowmeter

7. Sensors, Actuators & Microprocessors in Automobile  Hot-wire air-mass meter

7. Sensors, Actuators & Microprocessors in Automobile  Hot-film air-mass meter

Sensor element of Hot-film air-mass meter

7. Sensors, Actuators & Microprocessors in Automobile

Section thru of Hot-film air-mass meter

7. Sensors, Actuators & Microprocessors in Automobile  Oscillation Gyrometer - Micromechanical yaw-rate sensor

- Surface-micromechanical yaw-rate sensor

 Acceleration and Vibration Sensor - Piezoelectric acceleration sensor - Micromechanical bulk silicon acceleration sensor - Surface-micromechanical acceleration sensor - Piezoelectric knock sensor

 Gas Concentration Sensor - Oxygen sensor - NOx sensor - Particulate sensor - Hydrogen sensor

7. Sensors, Actuators & Microprocessors in Automobile  Torque Sensor  Force Sensor  Optoelectronic Sensor - Dirt sensor - Rain sensor

 Ultrasonic Sensor - Sensors for parking aid system

 Radar Sensor - Sensors for ACC(Adaptive Cruise Control) system

 Lidar(Light Detection and Ranging) Sensor - Sensors ACC system

7. Sensors, Actuators & Microprocessors in Automobile ■ Engine Management Sensors (1) Measured Variable Intake Manifold Absolute Pressure

Mass airflow

Temperature

Direct/Indirect Measurement

Sensor Technology

Location

Indirect measurement of engine load or mass air-flow intake

Wheatstone bridge arrangement of thick film resistors bonded onto a thin alumina diaphragm

Direct and indirect measurement of fuel injector basic pulse width

Various forms including ‘flap’ type, ‘hot-wire’, Karman Within air intake vortex and thick-film diaphragm

Direct measurement at various locations

Thermister or thermocouple depending on temperature range

Within intake manifold

Intake air, outside air, catalytic converter, engine coolant, hydraulic oil

7. Sensors, Actuators & Microprocessors in Automobile ■ Engine Management Sensors (2) Measured Variable

Direct/Indirect Measurement

Engine speed and Direct crankshaft reference measurement position

Sensor Technology

Location

Magnetic reluctance or Hall effect device

Flywheel on end of engine crankshaft

Battery voltage

Direct measurement

Resistive attenuator

Throttle position

Direct measurement

Potentiometer

Knock (engine cylinder pressure oscillations during ignition)

Direct measurement

Piezoelectric accelerometer type

Direct measurement

Zirconia or Titania based exhaust gas oxygen sensors

Oxygen concentration in exhaust gas (Lambda sensor)

Accelerator pedal

Cylinder block or head Exhaust manifold (normal operation above 3000 C)

7. Sensors, Actuators & Microprocessors in Automobile ■ Chassis Control Sensors(1) Measured Variable

Direct/Indirect Measurement

Wheelspeed and engine speed, (ABS, Direct TCS and electronic measurement damping)

Steering wheel angle, (Electronic damping) Throttle position

Direct measurement

Sensor Technology

Magnetic reluctance or Hall effect device

Brake assembly and crankshaft flywheel respectively

Potentiometer or optical encoder

Steering shaft

Indirect measurement Potentiometer of vehicle accel.

Chassis and wheel acceleration, Direct (electronic damping)

Location

Piezoelectric accelerometer

Accelerator pedal

Engine compartment and wheel assembly

7. Sensors, Actuators & Microprocessors in Automobile ■ Chassis Control Sensors(2) Measured Variable

Direct/Indirect Measurement

Indirect Brake system measurement of pressure (electronic vehicle damping) deceleration Steering shaft torque (Electric power assisted steering)

Direct measurement

Sensor Technology

Location

Flexing plate sensor with strain gauges mounted on plate

Brake master cylinder

Optical device relying on steering shaft distortion under driver’s twisting action

Steering shaft

7. Sensors, Actuators & Microprocessors in Automobile ■ Safety and Onboard Navigation Sensors Measured Variable

Direct/Indirect Measurement

Sensor Technology

Location

Vehicle deceleration Direct (air-bag systems) measurement

‘G’ sensor (Piezoelectric accelerometer)

Single-point electronic sensing, location in dashboard or steering wheel

Wheelspeed and engine speed (Vehicle nav. Systems)

Magnetic reluctance or Hall effect device

Brake assembly

Direct measurement

7. Sensors, Actuators & Microprocessors in Automobile ■ Actuator  Electrodynamic & Electromagnetic Converters

Electromagnetic Priciple Force between pole faces

Electrodynamic Principle Force on moving charge (Lorenz force)

7. Sensors, Actuators & Microprocessors in Automobile  Piezo Actuators

Design of Piezo Actuator

Force/Stroke Characteristic Curve of Piezo Actuator

7. Sensors, Actuators & Microprocessors in Automobile  Fluid-mechanical Actuator

7. Sensors, Actuators & Microprocessors in Automobile ■ Microprocessor  ECM(Engine Control Module)  BCM(Body Control Module)  TCM(Transmission Control Module)  Anti-Lock Brake System(ABS) Control Module  Airbag Control Module  Power Distribution Box Module  Climate Control Module  Instrument Panel Control Module  Door & Security System Control Module

7. Sensors, Actuators & Microprocessors in Automobile

7. Sensors, Actuators & Microprocessors in Automobile ■ Block Diagram of Data Processing

7. Sensors, Actuators & Microprocessors in Automobile Automatic Clutch Control System

7. Sensors, Actuators & Microprocessors in Automobile ■ Sensor, Actuator & Microprocessor of SI Engine

7. Sensors, Actuators & Microprocessors in Automobile ■ Sensor, Actuator & Microprocessor of CI Engine

7. Sensors, Actuators & Microprocessors in Automobile ■ Basic Sequence of Electronic Diesel Engine

8. Auxiliary Equipment

8-1. Braking System (ABS & EBD) 8-2. Airbag Restraint System

8-3. Driver Assistance System 8-4. Anti-theft System 8-5. Windshild Wiper

8-6. Horn System 8-7. Miscellaneous Accessories

8-1. Braking System(ABS&EBD) ■ ABS(Anti-lock Braking System)  Prevent wheel from locking up (ceasing rotation)  Avoid uncontrolled skidding  Improve vehicle control  Decrease stopping distance on dry and slippery surfaces  However, increase braking distance on loose gravel or snow-covered surface, but still secure steering control

8-1. Braking System(ABS&EBD) ■ ABS(Anti-lock Braking System)

8-1. Braking System(ABS&EBD) ■ ABS(Anti-lock Braking System)

8-1. Braking System(ABS&EBD) ■ ABS COMPONENTS  Controller  BCM(Brake Control Module)

 Sensor

 Wheel speed sensor  Vehicle speed sensor

 Actuator

 hydraulic modulator  pump  valves

 ABS warning lamp

8-1. Braking System(ABS&EBD) ■ With & Without ABS

8-1. Braking System(ABS&EBD) ■ With & Without ABS

8-1. Braking System(ABS&EBD) ■ Typical Input and Output for Brake Control System

8-1. Braking System(ABS&EBD) ■ EBD(Electronic Brakeforce Distribution)  Automatically vary amount of force applied to each wheel based on road condition, speed, loading , etc  Apply more or less braking pressure to each wheel in order to maximize stopping power whilst maintaining vehicular control  Work in conjunction of ABS

☞ TCS(Tracking Control System) ESP(Electronic Stability Program)

8-1. Braking System(ABS&EBD) ■ Oversteering & Understeering

8-2. Electric Power Steering System ■ Advantage of EPS System  Improve fuel economy, 3~5%  Increase in usable power  Save vehicle weight and complexity in design  Improve cold weather starting performance  Make assembly and vehicle service easier

■ Type of EPS System  R-EPS : Rack-and-pinion  C-EPS : Column-mounted  P-EPS : Pinion-mounted

8-2. Electric Power Steering System ■ Construction of EPS System

8-2. Electric Power Steering System ■ EPS System Control  EPS Input and Output  PCM(Powertrain Control Module)  BCM(Body Control Module)  PSCM(Power Steering Control Module)  Steering shaft torque sensor  Steering wheel position sensor  Power steering motor  DIC(Driver Information Center)  Battery voltage

8-3. Airbag Restraint System ■ Typical Airbag System  Parts Involved

 Sensors  Airbag Inflator Module  Clockspring wire coil in steering column  Control Module  Wiring and connector

 Type of Airbag Inflator  Solid Fuel - Sodium azide pellet - When ignited, generate a large quantity of nitrogen gas

 Compressed Gas - Used in passenger side airbag and roof-mounted system - Use canister filled with argon gas , plus small of helium at 435 kPa

8-3. Airbag Restraint System ■ Airbag Sensor

 Magnetic Sensor Ribbon-type Crash Sensor

 Internal Sensor - Deceleration sensor built in inflator module

8-3. Airbag Restraint System ■ Airbag Electronic Block Diagram

8-3. Airbag Restraint System ■ Wire Diagram of Airbag Restraint System

Time Table for Airbag Deployment 1. Collision occur (0.0ms) 2. Sensor detect collision (16ms) 3. Airbag is deployed and seam cover rip (40ms) 4. Airbag is fully inflated (100ms) 5. Airbag deflated (250ms)

8-4. Drivers Assistance System ■ Vehicle navigation  GPS(Satellite Positioning System)  Accuracy (3~5m in plane, 10~20m in height)  Travel-Direction determination  Dead reckoning  Map matching

■ ACC(Adaptive Cruise Control)

■ Lane assistance  Lane departure warning  Lane keeping support  Roadwork assistance

■ Night vision system  FIR(Far-Infrared) system  NIR(Near-Infrared) system

8-5. Anti-Theft System ■ Anti-Theft System

8-5. Anti-Theft System ■ Anti-Theft System  Alarm Detector  Door and hood contact  Interior monitoring  Tilt sensor  Self-monitoring of alarm siren

 Alarm system control unit  Alarm siren  Intermittent sound signal - 25~30 s duration - 1800~3550Hz - 05 dB min.~118 dB max at 2m distance

 Visual flashing signal - 5 min max.

8-6. Windshield Wiper ■ Windshield Wiper

8-6. Windshield Wiper ■ Rain Sensor Operation

8-6. Windshield Wiper ■ Wire Diagram of Windshield Wiper

8-7. Horn System ■ Horn System

8-8. Miscellaneous Accessories ■ Miscellaneous Accessories  Power Seat

8-8. Miscellaneous Accessories ■ Miscellaneous Accessories  Power Seat

8-8. Miscellaneous Accessories ■ Miscellaneous Accessories  Power Window System Arm Window Lift

Flexible Cable Window Lift

1.Power window drive 4. Rod linkage 2.Guide rail 5. Drive cable 3.Drive 6. Quadrant gear

8-8. Miscellaneous Accessories Power Window Drive wi/ECU

1.Power window drive motor 2.Worm 3.Helical bevel gear 4.ECU

Power Window Control Unit

1.Microcomputer 2.Relay output stage 3.Control commands 4. Networking vis CAN 5. Hall sensor

9. EV(Electric Vehicle)

9. EV(Electric Vehicle) CLASSIFICATION OF ELECTRIC VEHICLE

ICE only

ICE

HYBRID

PLUG-IN ALL-ELECTRIC

9. EV(Electric Vehicle) ■ Hybrid Vehicle

9. EV(Electric Vehicle) Classifications of Hybrid Vehicle  Series Hybrid

9. EV(Electric Vehicle) Classifications of Hybrid Vehicle  Series Hybrid

9. EV(Electric Vehicle)  Parallel Hybrid

9. EV(Electric Vehicle)  Parallel Hybrid

9. EV(Electric Vehicle)  Series-Parallel Hybrid

9. EV(Electric Vehicle) ■ High-Voltage Batteries

9. EV(Electric Vehicle) High-Voltage Batteries  Nickel-Metal Hydride(NiMH)  Positive electrode : Nickel Hydroxide(Ni(OH)2)  Negative electrode : Metal Hydride  Electrolyte : KOH  Nominal voltage : 1.2 volt ADVANTAGE  High specific energy  Large surface area (increasing overall battery capacity)  Electrolyte not react with steel (can be housed in sealed steel)  Can be recycled (environment friendly)  Excellent cycle life  Durable and safe

DISADVANTAGE  High rate of self-discharge  Moderate level of memory effect  High cost

9. EV(Electric Vehicle)  Lithium-Ion(Li-Ion)  Positive electrode : Lithium Cobalt Oxide  Negative electrode : Carbon  Electrolyte : Organic solvent  Nominal voltage : 3.6 volt ADVANTAGE  High specific energy  Good high temperature performance  Low self-discharge  Minimum memory effect  High nominal cell voltage (allow for fewer battery cells to produce high voltage battery)

 Lithium Polymer  Nickel-Cadmium

DISADVANTAGE  High cost  Battery overheating (safety)

9. EV(Electric Vehicle) Secondary Batteries Comparison Type

Nominal Voltage (V/cell)

Theoretical Specific Energy (WH/kg)

Practical Specific Energy (WH/kg)

Major Issues

Lead-Acid

2.1

252

35

Heavy, Low cycle life, Toxic Material

Ni-Cd

1.2

242

50

Cost, Toxic material

NiMH

1.2

278~800

80

Cost, High self discharge rate, Memory effect

Li-Ion

3.6

766

120

Safety issue, Calendar life, Cost

Zn-Air

1.1

1,320

110

Low power, Limited cycle life, Bulky

Na-S

2.0

792

100

High temp. Battery, Safety, Low power electrolyte

Na-Ni-Cl

2.5

787

90

High temp. operation, Low power

9. EV(Electric Vehicle) High-Voltage Batteries

9. EV(Electric Vehicle) High-Voltage Batteries  Battery Cell, Module & Pack

9. EV(Electric Vehicle) High-Voltage Batteries

TESLA BATTERY SYSTEM

9. EV(Electric Vehicle) Charging System

9. EV(Electric Vehicle) Charging System

9. EV(Electric Vehicle) Charging System

9. EV(Electric Vehicle)  Drive-Line

9. EV(Electric Vehicle)  Drive-Line  In-Wheel Motor

9. EV(Electric Vehicle)  Drive-Line  In-Wheel Motor

THANKS/धन्यबाद्