Está en la página 1de 63


A chronological history
The electrical and electronic systems of the motor vehicle are often the most feared, but at the
same time can be the most fascinating aspects of an automobile. The complex circuits and
systems now in use have developed in a very interesting way. For many historical developments
it is not possible to be certain exactly who invented a particular
component, or when, as developments were taking place. It is interesting to speculate on who
we could call the founder of the vehicle electrical system. Michael Faraday of course deserves
much acclaim, but then of course so does Ettiene Lenoir and so does Robert Bosch and so does
Nikolaus Otto and so does Perhaps we should go back even further to the ancient Greek
philosopher Thales of Miletus who, whilst rubbing amber with fur, discovered static electricity.
The Greek word for amber is elektron.
1742 Andreas Gordon constructed the first static generator.
1769 Cugnot built a steam tractor in France made mostly from wood.
1800 The first battery was invented by Alessandro Volta.
1830 Sir Humphery Davy discovered that breaking a circuit causes a spark.
1860 Lenoir built an internal-combustion gas engine.
1860 Lenoir developed in cylinder combustion.
1860 Lenoir produced the first spark-plug.
1870 Otto patented the four-stroke engine.
1879 Hot-tube ignition was developed by Leo Funk.
1888 Professor Ayrton built the first experimental electric car.
1894 The first successful electric car.
1899 First speedometer introduced (mechanical).
1901 The first Mercedes took to the roads.
1905 Miller Reese invented the electric horn.
1908 Electric lighting appeared, produced by C.A. Vandervell.
1912 Bendix invented the method of engaging a starter with the flywheel.
1920 Duesenberg began fitting four-wheel hydraulic brakes.
1921 The first radio set was fitted in a car by the South Wales Wireless Society.
1922 Lancia used a unitary (all-in-one) chassis construction and independent front suspension.
1928 Cadillac introduced the synchromesh gearbox.
1931 Smiths introduced the electric fuel gauge.
1936 An electric speedometer was used that consisted of an AC generator and voltmeter.
1936 Positive earth was introduced to prolong spark-plug life and reduce battery corrosion.
1937 Coloured wires were used for the first time.
1939 Car radios were banned in Britain for security reasons.
1950 Dunlop announced the disc brake.
1951 Buick and Chrysler introduced power steering.
1951 Development of petrol injection by Bosch.
1954 Flashing indicators were legalized.
1960 Alternators started to replace the dynamo.
1965 Development work started on electronic control of anti-locking braking system (ABS).
1965 Negative earth system reintroduced.
1967 Electronic speedometer introduced.
1972 Dunlop introduced safety tyres, which seal themselves after a puncture.
1990 Fibre-optic systems used in Mercedes vehicles.

2001 Global positioning systems start to become a popular optional extra.

2002 Full X-by-wire concept cars produced.
2003 Ford develop the Hydrogen Internal Combustion Engine (H2ICE).


Charging systems
Introduction:The current demands made by modern vehicles are considerable. The
charging system must be able to meet these demands under all operating conditions and still fast
charge the battery. The main component

of the charging system is the alternator.

Figure 1 Common charging system schematic. Note that not all vehicles are
equipped with an ammeter in the circuit.
The alternator generates AC but must produce DC at its output terminal as only DC can be used
to charge the battery
and run electronic circuits.
The charging system must meet the following criteria.
Supply the current demands made by all loads.
Supply whatever charge current the battery demands.
Operate at idle speed.
Supply constant voltage under all conditions.
Have an efficient power-to-weight ratio.
Be reliable, quiet, and have resistance to contamination.
Require low maintenance.
Provide an indication of correct operation.

Basic principles of charging system

Figure 2. Vehicle charging system

The charging system has three blocks
- The Alternator
- The Battery
- The Vehicle Loads
When the alternator voltage is less than the battery voltage, the direction of the current flow
is from battery to vehicle loads ( in this case Engine becomes slow or not running). The
alternator diodes prevent current flowing into the alternator.
When the alternator voltage is greater than the battery voltage, the direction of the current
flow is from the alternator to vehicle loads and the battery.
Note: From this, it is clear that the alternator o/p voltage must be greater than the battery
voltage all times, when Engine is running.
14.2 0.2v is accepted charging voltage for a12v system.

Vehicle electrical loads

The loads placed on an alternator can be considered as falling under three separate headings:
continuous, prolonged and intermittent.
The Table below shows typical power requirements for some common vehicle components.
-------------------------------------------------------------------------------------------------------------------Continuous loads
Power (W)
Current at 14V
Fuel injection
Fuel pump
-------------------------------------------------------------------------------------------------------------------Total 180 13.0 6.5

Prolonged loads
Power (W)
Current at 14V
-------------------------------------------------------------------------------------------------------------------Side and tail lights
Number plate lights
Headlights main beam
Headlights dip beam
Dashboard lights
Total (Av. main & dip)
-------------------------------------------------------------------------------------------------------------------Intermittent loads
Power (W)
Current at 14V
Brake lights
Front wipers
Rear wipers
Electric windows
Radiator cooling fan
Heater blower motor
Heated rear window
Interior lights
Rear fog lights
Reverse lights
Auxiliary lamps
0 8.0
Cigarette lighter
Headlight wash wipe
Seat movement
Seat heater
Sun-roof motor
Electric mirrors

Definition of Alternator:
Alternator is device and it converts a mechanical energy into an alternative electrical energy.

Definition of Rectifier:
Rectifier is a device; it converts an alternative electrical energy into unidirectional electrical energy.

Three-phase bridge rectifier

It consists of three positive diodes and three negative diodes. The output
produced is shown is shown compared with the three phase signals.
A further three diodes are often included in a rectifier pack. These are usually
small than the main diodes and are only used to supply a small current back
to the field windings in the rotor. The extra diodes are auxiliary field ( giving
support to the main field) or excitation diodes.

Mechanical regulator principle

Regulators can be mechanical or electronic, and the electronic regulators are now almost
universal on modern cars.
The mechanical regulators connected across the output terminals of the alternator. The
magnetism produced in this winding is proportional to the output voltage. A set of normally
closed contacts is attached to an armature, by means of a spring. The supply to the field
windings is via these contacts. If the o/p voltage rises more than pre-set level and opens the
contacts. This makes switch off the field current and causes the alternator voltage to fall. As the
o/p voltage falls below a pre-set (14v) level, the spring will close the regulator contacts and
allow the supply to pass through.
The problem with mechanical regulator is the wear on the contacts and other moving parts.

Hybrid IC regulator circuit

The hybrid system involves the connection of discrete components on a ceramic plate using film
techniques. The main part of the regulator is an integrated circuit containing the sensing elements
and temperature compensation
components. The IC controls an output stage such as a Darlington pair. This technique produces
a very compact device. A heavy duty zener diode is connected to protect all electronic
The graph shows how the IC regulator response changes with temperature. This change is
important to ensure correct charging under summer and winter conditions. When a battery is
cold, the electrolyte resistance increases. This means a higher voltage is necessary to cause the
correct recharging current.

Figure shows how the regulator response changes with temperature

Charging circuits

Fig. Example charging circuits

For many applications, the charging circuit is one of the simplest on the vehicle. The main output
is connected to the battery via a suitably cable. And the warning light is connected to an ignition
supply on one side and to the alternator terminal at the other. If the wires are kept as short as
possible, this will reduce voltage drop in the circuit. This reduced voltage should be less than
Some systems have an extra wire from the alternator to sense battery voltage directly. An
ignition feed may also be found and this is often used to ensure instant excitement of the field
windings. A wire from the engine management to alternator is used to send a signal to increase
engine idle speed if the battery is low on charge.

The charging circuits with graphical representation for

winter Commuting

Alternator testing

Consider two conditions; the first scenario is the traffic jam, on a cold night, in the rain! This can
involve long periods when the engine is just idling, but use of nearly all electrical devices is still
required. So the battery state of charge will be about 35% less than its original level.
The second scenario, the car has been parked in the open on a frosty night. The engine is started,
seat heaters, heated rear window and blower fan are switched on whilst a few minutes are spent
scraping the screen and windows. All the lights and wipers are now switched on. The seat heaters
and heated rear window can generally be assumed to switch off automatically after about 15
minutes. In this condition the state of charge will be about 10% less.
If the situations were repeated, then the battery would soon be incapable of starting the engine.
The above problem can little overcome by following five options:
1. Fitting a more powerful alternator.
Power management system.
Two-stage alternator drive mechanism or increased alternator speed.
Increased engine idle speed.
Dual voltage systems.

Operating principles of a power management system

It is an intelligent power management system. This technique works by switching off headlights
and fog lights when the vehicle is not moving. The cost of this system may be less than
increasing the size of the alternator.
A speed sensor signal is used via an electronic processing circuit to trigger a number of relays.
The relays can be used to interrupt the chosen lighting circuits. An override switch is provided,
for use in exceptional conditions.

A two-speed drive technique which uses a ratio of 5 : 1 for engine speeds under 1200 rev/min
and usually about 2.5 : 1 at higher speeds. The two-speed drive is only at the prototype stage at

Smart charging
Bringing together alternator output control, electrical power distribution and mechanical power
distribution. This is known as intelligent or smart charging.

Block diagram showing smart charge system

The principle of open loop control charging is that the alternator regulator and the power train
control module (PCM) communicate. This Communication is by pulse width modulated (PCM).
This signal is used in both directions. It is a constant frequency square wave with a variable
on/off ratio or duty cycle.
The PCM determines the set voltage point (regulated voltage) and transmits this to the regulator
using a specific duty cycle signal. PCM can calculate a more accurate figure for battery
temperature because it has sensors measuring

Two signals with different pulse width modulation (PCM)

The local interconnect network (LIN) is a protocol and communicate between intelligent
actuators and sensors. The controller area network (CAN) protocol is used where large
bandwidth is not necessary. LIN protocol is used for body systems such as door locks and seat


Starting Systems
The starting system includes the battery, starter motor, solenoid, ignition switch, and in some
cases, a starter relay. An inhibitor (neutral safety) switch is included in the starting system circuit
to prevent the vehicle from being started while in gear.
Figure shows A typical starting system converts electrical energy into mechanical energy to turn
the engine. The components are: battery, to provide electricity to operate the starter; ignition
switch, to control the energizing of the starter relay or solenoid; starter relay or solenoid, to make
and break the circuit between the battery and starter; starter, to convert electrical energy into
mechanical energy to rotate the engine; starter drive gear, to transmit the starter rotation to the
engine flywheel.

The important requirements of starting system

An internal combustion engine requires the following criteria in order to start and continue
1. Combustible mixture.
2. Compression stroke.
3. A form of ignition.
In order to produce the first three, the minimum starting speed (100 rev/min) must be achieved.
To produce this minimum speed, it is again dependent on a number of factors.

Rated voltage of the starting system.

Lowest possible temperature at which it must still be possible to start the engine
Engine cranking resistance. In other words the torque required to crank the engine at its
starting limit temperature
Battery characteristics.
Voltage drop between the battery and the starter.
Starter-to-ring gear ratio.
Characteristics of the starter.
Minimum cranking speed of the engine at the starting limit temperature.

Graphical representation of Starter torque and engine cranking torque

Figure shows how, as temperature decreases, starter torque also decreases and the torque
required to crank the engine to its minimum speed increases.
Block diagram of Starting system as part of the complete electrical

Criteria of Starting system

The starting system of any vehicle must meet a number of criteria
Long service life and maintenance free.
Continuous readiness to operate.
Robust, such as to withstand starting forces,vibration, corrosion and temperature cycles.
Lowest possible size and weight.
Starter system general layout

The minimum cranking speed varies for the particular engine. Some typical values are given in
Table for a temperature of -20 C.

Minimum cranking
speed (rev/min)
------------------------------------------------------------------------------------------------Reciprocating spark ignition
Rotary spark ignition
Diesel with glow plugs
Diesel without glow plugs
-----------------------------------------------------------------------------------------------The rated voltage for cars is 12VTrucks and buses are generally 24 V. A battery of maximum
capacity for the starter, which has a 20% drop in capacity at -20 C. A cable with a resistance of
1m connected between starter and battery. These criteria will ensure the starter is able to
operate even under the most adverse conditions. The rated power of the motor corresponds to the
power drawn from the battery. The battery should have less copper losses,
iron losses and friction losses.
Equivalent circuit for a starter system

Figure shows an equivalent circuit for a starter and battery. This indicates how the starter output
is very much determined by line resistance and battery internal resistance. The lower is the total
resistance, the higher the output from the starter. There are two other considerations 1. The
location of the starter on the engine is usually pre-determined. 2. But the position of the battery
must be considered. If the battery is closer to the starter the cables will be shorter. Otherwise a
long distance requires more cross sectional area to reduce the resistance.

Basic Starting system circuits

A basic simple starting system is shown in figure.

The starter is usually operated by a spring-loaded key switch.
The same switch also controls the ignition and accessories.
The supply flows via a relay in many cases, causes the starter solenoid to operate.
And this in turn, by a set of contacts, controls the heavy current.
An extra terminal on the starter solenoid provides an output when cranking, which is
usually used to bypass a dropping resistor on the ignition or fuel pump circuits.

Types of starter motor


Inertia starters
Pre-engaged starters
Permanent magnet starters
Heavy vehicle starters
Integrated starters
6. Electronic starter control
Necessity of starter motor
It is necessary to connect the starter to the engine ring gear only during the starting phase. This is
required in all standard vehicles. If the connection remained permanent, the excessive speed take
place in starter .This would be destroy the motor almost immediately.

Pre-engaged starter circuit

Pre-engaged starters are fitted to the majority of vehicles in use today. They provide a positive
engagement with the ring gear.

Basic operation:
A solenoid has two windings, the hold-on winding and the pull-in winding. When the key switch
is operated, a supply is made to terminal 50 on the solenoid. This energizes the solenoid. But the
pull-in winding has a very low resistance and hence a high current flows. This winding is
connected in series with the motor circuit. Hence the current flows through the motor and
rotate slowly.
At the same time, the solenoid attracts the plunger. And pushes the pinion into mesh, with the
flywheel ring gear. plunger in position as long as the solenoid is supplied.
When the engine is starts, the key is removed. The pinion and plunger returns to their rest

Permanent Magnet Starters:

It has less weight and smaller in size as compared to conventional
The reduction in weight provides, reducing fuel consumption.
They are available for use on spark ignition engines up to about 2 litre
The principle of operation is similar as that of pre-engaged starter
Only the difference is that the field windings and pole shoes are
replaced by permanent magnets.
Permanent magnets provide constant excitation, speed and torque.

It is also known as an integrated starter alternator damper [ISAD].

It consists of an electric motor, which functions as a control element

between the engine and the transmission.
It can also be used to start the engine and deliver electrical power to
the batteries.
It is noise less and has cranking speeds of 700 rev/min even at -20c.
It is still possible to crank at about 400 rev/min.


The electronic starter incorporates a static relay and solenoid switch on
its board. This prevent cranking when the engine is running
The starter can be simultaneously shut off to reduce wear and noise
generated by the free-wheel phase.
Thermal protection of the components allows optimization of the
components to save and to give short circuit protection.
Electrical protection also reduces damage from misuse or system
Modulating the solenoid current allows mechanical parts allowing a
softer operation and weight reduction.

Starter installation:
Starters are generally mounted in a horizontal position next to the
engine crankcase with the drive pinion in a position for meshing with
the flywheel or drive plate ring gear.
The starter can be secured in two ways: either by flange or cradle
Flange mounting is the most popular technique used on small and
medium sized vehicles.
It will reduce the effect of vibration.(mounted on rear of the starter)
Cradle mounting is used in larger vehicle fixed with 3 large bolts.
In both cases the starters must have some kind of of pilot often a ring
machined on the drive end bracket.


Ignition systems
The fundamental purpose of the ignition system is to supply a spark inside
the cylinder, near the end of the compression stroke, to ignite the
compressed charge of airfuel vapour.

For a spark to jump across an air gap of 0.6mm under normal atmospheric
conditions (1 bar), a voltage of 23 kV is required. For a spark to jump across
a similar gap in an engine cylinder, having a compression ratio of 8 : 1,
approximately 8 kV is required. For higher compression ratios and weaker
mixtures, a voltage up to 20 kV may be necessary. The ignition system has to
transform the normal battery voltage of 12 V to approximately 820 kV and,
in addition, has to deliver this high voltage to the right cylinder, at the right

Factors to be considered while design of an ignition


Combustion chamber design.

Airfuel ratio.
Engine speed range.
Engine load.
Engine combustion temperature.
Intended use.
Emission regulations.

Types of ignition system

Voltage source




Mechanical Electronic Electronic

Mechanical Mechanical Electronic


Inductive Inductive Inductive


Advance angle (timing)

For optimum efficiency the ignition advance angle should be such as to
cause the maximum combustion pressure to occur about 10 after top dead
centre (TDC). The ignition timing is dependent on two main factors, engine
speed and engine load. An increase in engine speed requires the ignition
timing to be advanced. The cylinder charge, of airfuel mixture, requires a
certain time to burn (normally about 2ms). At higher engine speeds the time
taken for the piston to travel the same distance reduces. Advancing the time
of the spark ensures full burning is achieved.
A change in timing due to engine load is also required as the weaker
mixture used on low load conditions burns at a slower rate. In this situation,
further ignition advance is necessary. Greater load on the engine requires a
richer mixture, which burns more rapidly. In this case some retardation of
timing is necessary.

Fuel consumption and Exhaust emissions

The ignition timing has a significant effect on fuel consumption, torque,

drivability and exhaust emissions.
The three most important pollutants are hydrocarbons (HC), carbon
monoxide (CO) and nitrogen oxides (NOx).
The HC emissions increase as timing is advanced.
NOx emissions also increase with advanced timing due to the higher
combustion temperature.
CO changes very little with timing and is mostly dependent on the air
fuel ratio.
The change in timing to improve exhaust emissions will increase fuel
With the leaner mixtures now prevalent, a larger advance is required to
compensate for the slower burning rate. This will provide lower
consumption and high torque but the mixture must be controlled

Figure : Effect of changes in ignition timing at a fixed engine speed

List of Conventional ignition components

1. Spark plug
2. Ignition Coil
3. Ignition Switch
4. Ballast Resister
5. Contact Breakers
7. HT Distributor
8. Centrifugal Advance
9. Vaccum Advance
Explination of each components of Contact Break System with block

Spark plug
Seals electrodes for the spark to jump across in the cylinder. Must withstand
very high voltages, pressures and temperatures.
Ignition Coil
Stores energy in the form of magnetism and delivers it to the distributor via
the HT lead. Consists of primary and secondary windings.
Ignition switch
Provides driver control of the ignition system and is usually also used to
cause the starter to crank.
Ballast resistor
Shorted out during the starting phase to cause a more powerful spark. Also
contributes towards improving the spark at higher speeds.
Contact breakers (breaker points)
Switches the primary ignition circuit on and off to charge and discharge the
Capacitor (condenser)
Suppresses most of the arcing as the contact breakers open. This allows for a
more rapid break of primary current and hence a more rapid collapse of coil
magnetism, which produces a higher voltage output.
HT Distributor
Directs the spark from the coil to each cylinder in a pre-set sequence.
Centrifugal advance
Changes the ignition timing with engine speed. As speed increases the
timing is advanced.
Vacuum advance
Changes timing depending on engine load. On conventional systems the
vacuum advance is most important during cruise conditions.

Plug leads (HT)

HT, or high tension (which is just an old fashioned way of saying high
voltage) components and systems, must meet or exceed stringent ignition
product requirements, such as:

Insulation to withstand 40000V systems.

Temperatures from 40C to 260C (40F to 500F).
Radio frequency interference suppression.
160000km (100000 mile) product life.
Resistance to ozone, corona, and fluids.
10-year durability.

Ignition coil cores

The disadvantages of Mechanical Ignition system

1.Mechanical contact breakers have limited life.
2.Current flow in the primary circuit is limited to4A or damage the contacts.
3.The ignition timing must stay in tune for a long period of time.

Necessity of Electronic Ignition

Fig. shows the circuit of a standard electronic ignition system

Electronic ignition is now using because the conventional mechanical system
has some major disadvantages.
_ Mechanical problems with the contact breakers, not the least of which is
the limited lifetime.
_ Current flow in the primary circuit is limited to about 4 A or damage will
occur to the contacts
or at least the lifetime will be seriously reduced.
_ Legislation requires stringent emission limits,which means the ignition
timing must stay in tune for a long period of time.
_ Weaker mixtures require more energy from the spark to ensure successful
ignition, even at very high engine speed.
These problems can be overcome by using a power transistor to carry out
the switching function and a pulse generator to provide the timing signal.
Very early forms of electronic ignition used the existing contact breakers as
the signal provider. This was a step in the right direction but did not
overcome all the mechanical limitations, such as contact bounce and timing
slip. Most (all?) systems nowadays are constant energy, ensuring high
performance ignition even at high engine speed.

Dwell systems
The term dwell is the measure of time taken by the ignition coil is
charging or when the primary current flowing through ignition coil. The dwell
in mechanical systems is simply the time during which the contact breakers
dwell is now expressed as a % of one charge discharge cycle.
Constant dwell electronic ignition systems are now replaced by constant
energy systems.

Hall Effect principle


If a certain type of crystal is carrying a current in a transverse

magnetic field then a voltage will be produced at right angles to the supply
the magnitude of the voltage is proportional to the supply current and
to the magnetic field strength. The Hall Effect can also be used to detect
current flowing in a cable.

Hall Effect Pulse Generator

As the central shaft of the distributer rotors, the vanes attached under
the rotor arm alternately cover and uncover the hall chip. The number of
vanes corresponds to the number of cylinders. The width of vanes
determined by constant dwell system. The result of this produces almost a
square wave output. This square wave can be used to switch further
electronic circuits

Fig: A Hall effect sensor output will switch between 0 V and about 7V

Current Limiting and Closed Loop Dwell

Fig: Closed loop dwell control system

Closed loop control

Primary current limiting ensures no damage can be caused to the
system by excessive primary current. (No damage can be cause to the
system by excessive primary current. This primary current must be limited
but also forms a part of a constant energy system.)
1. The primary current is allowed to build up to its pre-set maximum as
soon as possible and
2. Then be held at this value
During the construction of an amplifier this pre-set value will be considered.
The combination of this technique and dwell angle control is known as closed
loop control. The actual value of the primary current is fed back to the
control stages.
A very low resistance, high power precision resistor is used in this
circuit. This resistor is connected in series with the power transistors and the
ignition coil. A voltage sensing circuit connected across resistor. The
transistor will be activated at a pre-set voltage and causes the output stage
to hold the current at a constant value. Stationary current cut off is for when
the ignition is on but the engine is not working.

Capacitor Discharge Ignition ( C.D.I


Fig: CDI system

The CDI system works by first stepping up the battery voltage to about
400v (DC) using an oscillator and a transformer followed by a rectifier. The
capacitor is charging towards this high voltage and discharge through the
primary winding of a coil at the point of ignition. This is done by a thyristor
switch. The rapid discharge of capacitor at primary will produce a very high
voltage across the secondary winding. This voltage has a very fast rise time
compared with the conventional system. Typically the rise time for CDI is 310 kv/s. but the conventional pure inductive system has 300-500v/s. CDI
ensures that even a carbon or oil fouled plug will be fired.

Programmed Ignition (or) Electronic

Spark Advance (ESA)
programmed ignition system is also called electronic spark advance
(ESA). It will operate digitally. Information about the operating requirement of
a engine is programmed and stored into the memory inside the electronic
control unit. The data stored in ROM are obtained accurately to test the
engine dynamometer and used for further development under various
operating conditions. Programmed ignition or ESA can be a separate system
or be included as a part of the fuel control system.

Advantages of Programmed Ignition (or)

Advantages of Electronic Spark Advance
1. The ignition timing can be accurately matched for all operating conditions
2. The coolant temperature and ambient air temperature control inputs can
be utilized.
3. Starting is improved and fuel consumption is reduced, emissions and idle
control is better.
4. Other inputs can be taken into account such as engine knock
5. The number of wearing components in the ignition system is considerably

Fig:Programmed ignition system diagram

Engine Temperature Coolant Sensor

A thermister is used for coolant temperature measurement. It is used for the
operation of the temperature gauge and provide information to the fuel
control system. A separate memory map is used to correct the basic timing
settings. The timing may be retarded when the engine is cold to assist in
more rapid warm up.

Detonation knock sensor

Combustion knock can cause serious damage to an engine if sustained for
long periods. This knock or detonation is caused by over-advanced ignition
To achieve the efficient timing advance, the data stored in the basic
timing map. The data must be close to the knock limit of the engine.
Piezoelectric accelerometer sensor is used to provide a margins for error. It is
fitted in the engine block between cylinders two and three on in-line four
cylinder engines. vcc engines requires two sensors one on each side.
The knock or detonation is caused due to over advanced ignition timing may
damage an engine. To avoid this occurrence, we must achieve an efficient
timing advance. The data of knock limit will be stored in the basic timing
a piezoelectric accelerometer sensor is fitted in the engine block

between cylinder 2 and 3 on in line 4 cylinder engines. This sensor provides

margins for error.

The ECU responds to the knock sensor signals, and sets a few degrees on
each side of TDC (about 2o to 1o). This prevents clatter from the value
mechanism being interpreted as knock. An unwanted noise is filtered by
ECU. The detected detonation will reduce the ignition timing on 4 cylinders.

Distributer less Ignition (DIS)

Fig: Distributer less Ignition

The DIS system consists of three main components
1.The electronic modules
2. A crankshaft position sensor
3. The DIS coil
A various pressure sensor is integrated in the module. The crankshaft
position sensor (reluctance sensor) is positioned against the front of the fly
wheel or against a reluctor wheel just behind the front of the crankshaft


the tooth pattern consists of 35 teeth. These are spaced at 10o

intervals with the gap where the 36th tooth would be. The missing tooth is
positioned at 90o BTDC for the cylinders 1 and 4. The low tension winding is
supplied with battery voltage to a center terminal. The of the winding is
then switched to earth in the module. The high tension windings are
separate cylinders 1 and 4 or 2 and 3.

Direct Ignition
Direct ignition system is the follow on form of distributorless ignition. This
system utilizes an inductive coil for each cylinder. These coils are mounted
directly on the spark plugs.
the use of an individual coil for each plug ensures that the rise time.
This ensures that a very high voltage, high energy spark is produced. This
high vltage about 40 kv provides efficient combustion process under cold
starting conditions. Direct ignition systems use capacitor discharge ignition.

Properties of Electrode Material

1.High thermal conductivity
2.high corrosion resistance
3.high resistance to burn-off
4.nickel material is used in its construction
5.chromium, manganese, silicon and magnesium alloys are used
6.thermal conductivity is 200w/mk

Electronic fuel control

The combustion process is started by heating the fuel above its ignition
temperature in the presence of oxygen under the influence of heat. The
chemical bonds of the fuel are split iif complete combustion takes place. The
elements carbon (C), hydrogen (H) and sulphur (S) react with O2 to form CO2,
water H2O, SO2 and less degree of SO3.

Electronic Fuel Control System

1. The electronic control system consists of various engine sensors,
electronic control unit(ECU), fuel injector assemblies and related wiring.
2. The ECU determines precisely how much fuel needs to be delivered by the
injector by monitoring the engine sensors.
3. The ECU turns the injectors on for a precise amount of time referred to as
injection pulse width or injection duration to deliver the proper air/fuel ratio
to the engine.

Basic Electronic Fuel System Operation

Air enters the engine through the air induction system where it is
measured by the air flow meter. As the sir flows into the cylinder, fuel is
mixed into the air by the fuel injector. Fuel injectors are arranged in the
intake manifold behind each intake valve. The injectors are electrical
solenoids which are operated by the ECU. When the injector is turned ON, it
opens spraying atomized fuel at the back side of the intake valve.

As fuel is sprayed into the intake air stream, it mixes with the incoming
air and vaporizes due to the low pressures in intake manifold. The ECU
signals the injector to deliver just enough fuel to achieve an ideal air/fuel
ratio of 14.7:1 often referred to as stoichiometry. The precise amount of fuel
delivered to the engine is a function of ECU control. ECU determines the
basic injection quantity based upon measured intake air volume and engine
Injection quantity will vary depending on the engine operating
conditions. The ECU monitors variables such as coolant temperature, engine
speed, throttle angle and exhaust oxygen content and makes injection
correction which determine final injection quantity.

Single Point Injection: Advantages

1. Only one injection valve
2. No reaction of the system pressure depending on the inlet manifold
3. Instead of an air volume meter, only a throttle potentiometer is used.
4. Larger distribution between the heat stressed parts, thus lower vapor
development, lower supply pressure, more reasonably priced fuel supply
5. regulated exhaust gas decontamination with fewer components.

Multi Point Fuel Injection

System generally delivers a more accurate and equal mass of fuel to
each cylinder than a carburetor can, thus improving the cylinder to cylinder
distribution. Exhaust emissions are cleaned because the more precise and
accurate fuel metering reduces the concentration of toxic combustion
products, leaving the engine, and because exhaust clean up devices such as
the catalytic convertor can be optimized to operate more efficiently.

A single high intensity spark of high temperature passes between the
electrodes of the spark plug leaving behind it a thin thread of flame is called

Combustion Process in a Spark Ignition

Engine (or) Spark Ignition Engine
Combustion Process

Figure shows the speed at which fuel will oxidize or burn

Combustion is the process of burning. For combustion to occur fuel, air and
heat must be present together. (or) combustion is the chemical reaction of a
particular substance with an oxidant. If not enough oxygen is present or the
fuel/air mixture is insufficient then the burning of gases are particularly
cooled below the ignition temperature and combustion process stays

The combustion can be considered in two stages:1. Growth of a self-propagating flame

2. Spread through the combustion chamber
The first process is chemical and depends on the nature of the fuel. The
temperature and pressure at the time and the speed at which the fuel will
oxidize or burn is shown in the figure.
combustion appears as the interval from the spark (A) to the time when an
increase in pressue due to combustion can first be detected(B). with the
combustion under way, the pressure rises within the engine cylinder from (B)
to (C) very rapidly approaching the constant volume process of the fourstroke cycle, while (C) represents the peak cylinder pressure and the
completion of flame travel. All available heat has not been liberated due to
re-association but burning continues throughout expansion stroke.

The detonation phenomenon is the limiting factor on the output and
efficiency of the spark ignition engine. The mechanism setting up within the
engine cylinder, a pressure wave travelling against the cylinder walls sets
the vibration and this produces a high pitched ping sound.
the detonation pressure wave passes through the burning mixture at a
very high velocity and the cylinder walls emit the ringing knock. Detonation
is seldom dangerous in small engines. This may damage the engine because

the noise in engine at higher speeds and higher loads will dominant the ping.
Mixing water, or methanol and water, with the fuel can reduce detonation.

A damaging engine condition wherein the air/fuel mixture ignites
spontaneously due to hot spots in the combustion chamber. Causes include
engine overheating, spark plugs that have the wrong heat range (too hot).
Sharp edges on the combustion chamber, low octane gasoline, a lean fuel
mixture r carbon build up in the combustion chamber. Pre-ignition can burn
holes in pistons and contributes to detonation.

Engine Fueling
operating conditions

Fig:Composition exhaust

The ideal air/fuel ratio is about 14.7:1. This theoretical amount of air required
to burn the fuel completely. It is given a lambda () value of 1.
= actual air quantity theoretical air quantity
To improve an engine performance, drivability, consumption an emissions.
The air/fuel ratio can be altered during the following conditions.
cold starting
a richer mixture is required to improves drivability
load or accelerating
a richer mixture to improve performance
light loads (cruise)

a weaker mixture for economy

over run
very weak mixture to improve emissions and economy

Figure shows theoretical results of burning a hydrocarbon fuel and actual

combustion results

Fuel Injection
Fuel injection is a system for admitting fuel into an internal combustion
The basic principle of fuel injection is that if petrol I supplied to an
injector (electrically controlled valve) at constant differential pressure, then
the amount of fuel injected will be directly proportional to the injector open

Typical Control Layout for a Fuel

Injection System

Block diagram
Air enters the engine through the air induction system where it is measured
by the air flow meter. Air mixed into fuel supplied by the fuel injector to the
cylinder. An engines power can be increased or decreased by the restriction
of inlet gases and managed by throttle. ( throttle is the mechanism by which
the flow of fluid in managed by construction or obstruction). When the
injector is turned on, it opens spraying atomized fuel at the back side of the
intake valve.
The ECU signals the injector to deliver just enough fuel to achieve an
ideal air/fuel ratio of 14.7:1. The ECU determines the basic injection quantity
based upon measured intake of air volume and engine speed. Injection
quantity will vary depending on engine operating conditions. The ECU
monitors variables such as coolant temperature, engine speed, throttle
angle, and exhaust oxygen content and makes injection corrections which
determine final injection quantity.

Single Point Injection

1. Only one injection valve.
2. No regulation of the system pressure depending on the inlet manifold
3. Instead of an air volume meter only a throttle potentiometer.
4. Larger distance between the heat stressed parts. Thus: Lower vapor development and lower supply pressure
fuel supply pump

Fig: Fuel injection, single point

Multi Point Injection

A multi point fuel injection system generally delivers a more accurate and
equal mass of fuel to each cylinder than can a carburetor. Thus improving
the cylinder- to-cylinder distribution. Exhaust emissions are cleaner because
the more precise and accurate fuel metering reduces the concentration of
toxic combustion products leaving the engine and because exhaust clean up
can be optimized to operate more efficiently.

Fig: Fuel injection, multipoint

Block Diagram of Inputs and Outputs

Common to most fuel injection system
Components of a fuel injection system

Fig:Components of a fuel injection system common to all engines

Combination Relays:-

It has two relays, one will control the fuel

pump and another will control injection system

Air Flow Sensor:-

It provides the information about the quantity of air

and engine load.

Engine Speed Sensor: - This provides speed data but also engine
position to some extent. A series resistor is used to prevent high voltage
surges from reaching the ECU.

Temperature Sensor: - Thermistor provides engine coolant

temperature information.

Throttle position sensor: -

It consists of the two switch types,

which provides information that the throttle is at idle, full load or anywhere
else between.

Injector Resistors: - these resistors were used in some systems

where the resistors coils where very low. A lower inductive reactance in the
circuits allows faster operation of the injectors.

Lambda Sensor: - It provides the information about exhaust gas

oxygen content.

Fuel Pressure Regulator: -

this device maintain a constant

differential pressure across the injector.

Cold start injector and thermo-time switch: - An extra

injector was used along with thermo-time switch to control both engine
temperature and a heating winding heat.

Idle or fast idle control actuator: - bimetal or stepper motor

actuator are used. The air that it allows through is set by its open/close
ratio .

Fuel injector: - they are two types

1. Pinter and
2. Disc injectors.
they are simple solenoid-operated valves that produce a finely atomized
spray pattern.

Fig: Block diagram of a typical electronic diesel control system:-

Fuel pump: - it ensures a constant supply of fuel to the fuel rail. It must
maintain a pressure of about 3 bar.
ideal valves for fuel quantity and timing are stored in memory map in the
ECU. The injected fuel quantity is calculated from the accelerometer position
and the engine speed.
the start of injection is determined from the following: 1. Fuel quantity
2. Engine speed
3. Engine temperature
4. Air pressure
the ECU compare start of injection with actual delivery from a signal
produced by the needle motion sensor in the injector. Solenoid controls the
exhaust gas recirculation. This control as a as a function of engine speed,
temperature and injected quantity.
the ECU also controls the stop solenoid and glow plugs via a suitable relay.

Electronic unit injection (EUI) diesel fuel

Advantages:1. Lower emissions:through the use of higher injection pressure( up to 2000bar) lower emissions
of particulates and NOx are achieved together with a reduction in the levels
of noise.
2.Electronic fuel quantity and timing control: precise electronic control also assits in the reduction of emissions.
3. Shot to shot fuel adjustment: this feature also provides a very quick transient response improving vehicle
4. Control of all engine functions: through a series of sensors connected to the ECU, the EUI system ensures
that all the engine functions consistently.
5. Electronically controlled pilot injection: a new feature developed to meet tighter NOx emissions standards without
loss of fuel consumption. Fuel injection also reduces combustion noise.
6. Communication with other systems: ECU, the EUI system can communicate with other vehical systems such as
ABS, transmission and steering.
7. Cylinder cut-out: this is used as a diagnostic aid and offers potential for fuel economy at idling
and low loads.
8. Reliability and durability: -

the EUIs reliability is proven under field conditions.

9. Full diagnostics capability: fault codes can be stored and diagnostic equipment connected.

Common rail fuel injection system: the system that consists of a common pressure accumulator called the rail
which is mounted along the engine block and fed by a high pressure pump.
The pressure level of the rail is electronically regulated by a combination of
metering on the supply pump and fuel discharges by a high pressure
the pressure accumulator operates independently at engine speed or load
A series of injectors is connected to the rail and each injector is operated
and closed by a solenoid driven by ECU.

Advantages: compact design: the compact design of the injector outline enables the Diesel common rail
(DCR) system to be used on 2 and 4 valves per cylinder engine.
Modular system: with one electronically driven injector per engine cylinder, the system is
modular and can be used on 3, 4, 5 and 6 cylinders engines.
Low drive torque: as the pumping of the pressure rail is not phased with the injection, the
common rail system requires a low drive torque from the engine.
Independent injection pressure: the injection pressure is independent of the engine spped and load, so
enabling high injection pressure at low speed if required.

Lower NOX emissions: injection sequences that include periods both pre and post. The main
injection can be utilized to reduce emissions.
Noise reduction and NOX control: the inclusion of pilot injection results in a significant reduction is engine
Full electronic control: accurate fueling and timing can be controlled by ECU. Also can be interfaced
with other vehical functions.

Main components of common rail fuel

injection system: -

common pressure accumulator ( the rail)

high pressure regulators
high pressure supply pump
electronic solenoids
electronic control unit
filter unit

Engine management system: a stoichiometric mixture is the working point that modern engine
management systems employing fuel injection attempt to achieve in light
load cruise situations for gasoline fuel. The stoichiometric air-fuel mixture is
approximately 14.7:1, i.e. the approximate mass of air is 14.7, mass of fuel
is 1. Any mixture less than 14.7 to 1 is a lean mixture vehicals using an

oxygen sensor or other feedback loop to control fuel to air ratios.


Engine management systems

GOI gasoline direct injection

Main issues of engine control: - (combined ignition

and fuel management)

Ignition timing
Dwell angle
Fuel quantity
EGR ( exhaust gas recirculation)
Canister purge
Idle speed

Representation of complete engine control as

the standard functional system: -

An engine management system can be represented by the standard three

stage model
1. Input sensors
2. ECU
3. Output actuators with feedback
this feedback have common features related to lambda control knock and
idle speed

General block diagram of an ignition and fuel

control system (or) engine management
system: -

This simplified engine management system consists series of less common

inputs and outputs
1. Variable inlet tract: the length of the inlet tract determines the velocity of the intake air in
particular, the propagation of the pressure waves set up by the pumping
action of the cylinders.
2. Variable value timing: with the widespread use of twin cam engines, one cam for the inlet valves
and one for the exhaust valves. It is possible to vary the value overlap while
the engine is running.
3. Combustion flame and pressure sensing:the sensors will provide instantaneous closed loop feedback about the
combustion process. This will be important with lean burning engines.
4. Wide range lambda sensors: the lambda sensors provide excellent closed control of the air-fuel ratio of
5. Injectors with air shrouding: if high speed air is introduced at the tip of an injector, the disposal of the fuel
is considerably improved. Droplet size can be reduced to below 50m during
idle conditions. The emission control system improves the engine

performance and reduce the air pollution. It consists several following


Exhaust emission control: the exhaust emission control is mainly dependant on the following:1. Engine design
2. Combustion chamber design
3. Compression ratio
4. Valve timing
5. Manifold designs
6. Charge stratification
7. Warm up tome
8. Exhaust gas recirculation
9. Ignition systems
10. Thermal after-burning
11. Catalytic converters

Engine management: many design details of an engine have a marked effect on the production of
pollutant emissions, keeping this in mind, it will be clear that the final design
of an engine is a compromise between conflicting interests.

Combustion chamber design: the main source of hydrocarbon emissions is unburnt fuel that is in contact
with the combustion chamber walls. For this reason the surface area of the
walls should be kept as small as possible and should maintain the least
complicated shape. A good swirl of the cylinder charge facilitates more rapid
burning. A good swirl in the area of the spark plug ensures a mixture quality
that is easier to ignite. The spark plug must be well positioned in the center
of the combustion chamber. This reduces the knock by reducing the distance
the flame frount has to travel.

Compression ratio: the higher the compression ratio, the higher the thermal efficiency of the
engine and therefore the better the performance and fuel consumption. The
two main drawbacks to higher compression ratios are increased emissions
and increased tendency to knock.
The problem with emissions is due to the high temperature which in
turn causes greater production of NOX. The increase in temperature makes
the fuel and mixture more likely to self ignite, causing a higher risk of

combustion knock.

Manifold designs: gas flow within the inlet and exhaust manifolds is a very complex subject.
The main cause of this complexity is the transient changes in flow that are
due not only to changes in engine speed but also to the pumping action of
the cylinders. This pumping action causes pressure fluctuations in the
the volumetric efficiency can be attained, if the manifolds and both
induction and exhaust systems reflect the pressure back. Many vehicles are
now fitted with adjustable length induction tracts. Longer tracts are used to
lower engine speeds and shorter tracts at higher engine speed.

Charge stratification: if the charge mixture can be inducted into the cylinder in such a way that a
richer mixture is the proximity of the spark plug, then overall the cylinder
charge can be much weaker. This can bring great advantages in fuel
consumption but the production of NOX can still be a problem.
Many lean burn engines use a form of stratification to reduce the
chances of misfire and rough running.

Warm up time: a significant quantity of emissions produced by an average vehicle is created

during the warm up phase. suitable materials and care in the design of
cooling system can reduce this problem.
some engine management systems even run the ignition timing
slightly retarded during the warm up phase to heat the engine more quickly.

Exhaust gas recirculation (EGR): this technique is used primarily to reduce peak combustion temperatures
and hence the production of nitrogen oxides NOx . EGR can be either internal
due to valve overlap or can be an external via a simple arrangement of pipes
and a valve. A proportion of exhaust gas return to the inlet side of the
engine. A ROM is used in ECU to control EGR. This ensures that drivability is
not affected and also that the rate of EGR is controlled. If the EGR rate is too
high, then the production of hydrocarbon (HC) increases as shown in the

Drawback of EGR system is that they can become restricted by exhaust

residue over a period of time, thus changing the actual percentage of
recirculation. However, valves are now available that reduce this particular

Catalytic converters : automotive emissions are controlled in three-way catalyst (TWC) :1. One is to promote more complete combustion so that there are less by
2. The second is to reintroduce excessive hydrocarbon back into the engine

for combustion.
3. The third is to provide an additional area for oxidation or combustion to
occur. This additional area is called as a catalytic converter. (catalyst is a
substance used to speed up a chemical process).
4. As HC or CO in the exhaust are passed over the catalyst. It is chemically
oxidized or converted to carbon dioxide and water, i.e.
2C2H6 + 2CO 4CO2 +6H2O
5. As the converter works to clean the exhaust, it develops heat. The dirtier
the exhaust, the harder the converter works and the more heat that is
6. Platinum promotes the oxidation of HC and CO and rhodium helps the
reduction of NOx.
7. The main reactions in the cat are as follows:
2CO + O2 2CO2
2C2H6 + 2CO 4CO2 + 6H2O
2NO + 2CO N2 + 2CO2

Closed loop lambda control: -

Figure shows the fuel metering with closed loop control.

Current regulations have almost made mandatory closed loop control of airfuel mixture in conjunction with a three-way catalytic converter. It should
have a valve of lambda is 1 compulsory for all operating conditions
lambda control is a closed loop feedback system. The signal from a lambda
sensor in the exhaust can directly affect the fuel quantity injected.

Operation: -

Graph shows the effect of lambda control and a three-way catalyst (TWC).
The lambda sensor produces a voltage that is proportional to the oxygen
content of the exhaust. Oxygen content of the exhaust is proportional to the
air-fuel ratio. The ideal setting of lambda voltage is 450mv. If the ECU is
below this value (weak mixture), the quantity of fuel injected is increased
slightly. If the signal voltage is above the threshold (rich mixture), the fuel
quantity is reduced. This alternation in the mixture must not be too sudden
as it could cause the engine to buck. To prevent this, the ECU contains an
integrator which changes the mixture over a period of time.

Dead Time: a delay exists between the mixture formation in the manifold and the
measurement of the exhaust gas oxygen is called dead time. Due to the
dead time, the mixture cannot be controlled to an exact value of

Control of diesel emissions: 1. Introduction: Exhaust emissions from diesel engines have been reduced considerably
a. changes in the design of combustion chambers and injection
b. accurate control of start of injection and spill timing
c. electronic control

Exhaust gas recirculation: -

it is same as the petrol engines EGR is employed primarily to reduce NO X

emissions by reducing the reacting temperature in the combustion chamber. The
higher EGR is increased hydrocarbons and soot is produced.


Intake air temperature: a. the intercooler is fitted in turbocharged engines.

b. this reduces the temperature and will again reduce the production of NO X.


catalytic converter: -

a. reduces a hydrocarbons emissions

b. have less effect on nitrogen oxides because diesel engines are always run
with excess air to ensure more efficiency burning of the fuel.

Filters: to reduce the emissions of particular matter (soot) filters can be used.

Complete vehicle control systems: -

Fig: representation of a full vehicle control system.

Chassis electrical system

Anti-Lock Brakes (ABS): the abs is a four wheel system that prevents wheel lock-up by automatically
modulating the brake pressure during an emergency stop. By preventing the wheels
from locking, it enables the driver to maintain steering control and stop in the
shorter possible distance under most conditions. (During normal braking, the ABS
and non-ABS brake pedal feel will be the same ).
During the ABS operation, a pulsation can be felt in the brake pedal
accomplished by a fall and then rise in the brake pedal height and a clicking sound.
There are number of consequences: 1. Braking distance increases
2. Steering control is lost
3. Abnormal tire wear.

Block diagram of anti-lock brake system:

An ABS includes a central ECU, four wheel speed sensors and at least two hydraulic
valves within the brake hydraulics. The ECU constantly monitors the rational speed
of each wheel, i.e., if it detects a wheel rotating significantly slower than the others
(a condition indicative of impending wheel lock), it actuates the valve to reduce
hydraulic pressure to the brake at the affected wheel. Thus reducing the braking
force on that wheel. Then turns faster. If the ECU detects a wheel turning
significantly faster than the other brake hydraulic pressure to the wheel is increased
so the braking force is re-applied slowing down the wheel.
actual explanation: -

it consists of a input wheel speed sensor, the main output brake system pressure
control. The task of the control unit is to compare signals from each wheel sensor to
measure the acceleration or deceleration of individual wheels. From there data and
pre-programmed look up tables, brake pressure to one or more of the wheels can be
regulated. Brake pressure can be reduced, held constant or allowed to increase. The
maximum pressure is determined by the drivers pressure on the brake pedal.

Explain the function of control variable sensor of

ABS system: Pedal pressure:- determined by the driver
2. Brake pressure: 1.

a. under normal braking, this is proportional to pedal pressure

b. under control of the ABS, it can be reduced, held or allowed to increase.

Controlled variable: -

a. this is the actual result of changes in brake pressure (or)

b. the wheel speed that allows acceleration, deceleration and slip to be
4. Road/vehicle conditions: -disturbances such as the vehicle load, the
state of the road, tire condition and brake system condition.

ECU calculations from the wheel speed

sensors: 1.

Vehicle reference speed: -

Determined from the combination of two diagonal wheel sensor signals. After
the start of braking the ECU uses this value as its reference.

Wheel acceleration or deceleration: This is live measurement that is constantly changing.


Brake slip: -

Although this cannot be measured directly, a value can be calculated from

the vehicle reference
speed. This figure is then used to determine when/if ABS
should take control of the brake pressure.

Vehicle deceleration: -

During brake pressure control, the ECU uses the vehicle reference speed as
the starting point and decreases it in a linear manner. The rate of decrease is
determined by the evaluation of all signals received from the wheel sensors.

ABS components: it consists of three main components as follows:1. Wheel speed sensor
2. Electronic control unit (ECU)
3. Hydraulic modulator

Wheel speed sensor: most of these devices are simple inductance sensors and works in conjunction with
a toothed wheel. They consist of a permanent magnet and a soft iron rod around
which is wound a coil of wire. As the toothed wheel rotates, the changes in
inductance of the magnetic circuit generate a signal. The frequency and voltage of
which are proportional to the wheel speed. The frequency is the signal used by the
electronic control unit. The coil resistance is 1k and the co-axial cable prevent
interference affecting the signal.

Electronic control unit:the function of the ECU is to take in information from the wheel sensors and
calculate the best course of action for the hydraulic modulator. The heart of the ECU
consists of two microprocessors, which run the same program independently of
each other.
The following list forms the self test procedure of each other: 1. Currently supply
2. Exterior and interior interfaces
3. Transmission of data
4. Communication between the two microprocessor
5. Operation of valves and relays
6. Operation of fault memory control
7. Reading and writing functions of the internal memory
all this takes about 300s.

Hydraulic modulator: it has three operating positions: 1. Pressure build up brake line open to the master cylinder

2. Pressure reducing brake lines open to the accumulator

3. Pressure holding brake line closed
the values are controlled by electrical solenoids which have a low
inductance so they react very quickly. The more only runs when ABS is

Active suspension: conventional suspension systems are always a compromise between soft
springs for comfort and harder springing for better cornering ability. A
suspension system has to fulfil four main functions: 1. Adsorb bumps
2. Manage nose dive when braking
3. Prevent roll when cornering
4. Control body movement

this means that some functions have to be compromised in order to fulfill

others to a greater extent.

Operation of active suspension: active suspension allows the best by replacing the conventional springs with
double-acting hydraulic units. These are controlled by an ECU which receives
the signal from various sensors. Oil pressure in excess of 150 bar is supplied
to the hydraulic units from a pump.
A servo valve controls the oil, which is arguably the most critical

Benefits of active suspension: 1. Improvements in ride comfort, handling and safety.

2. Predictable control of the vehicle under different conditions
3. No change in handling between laden load and unladed.

Fig: block diagram of active suspension system

Functions of various sensor and actuators

used in chassis system: 1.

Load sensor: - a load cell is used to determine whether actual load is

positioned on each hydraulic ram


Displacement and vertical acceleration: - this sensor can

take a number of forms, as simple as a variable resistor or a more accurate
and sensitive linear sensor such as the LVDT.





Lateral and longitudinal acceleration : - acceleration can be

determined from a pendulum type sensor using strain gauges linked to a
mass, or devices similar to an engine knock sensor
Yaw transducer: -yaw can be determined from lateral acceleration. If
the sensor is mounted at the front and rear of the vehicle.
Steering position: -the rate of change of steering position is
determined from a rotary position sensor. This device can be a light beam
and detector type or similar. If the rate of change of steering position is
beyond a threshold, the system will switch to a harder suspension setting.
Vehicle speed: - the speed of the vehicle is taken from a standard type
sensor as used for operating the speedometer.
Throttle position: - a potentiometer gives the data of accelerometer or
decelerates, allowing the suspension to switch to a harder setting when
Driver mode selection: - a switch is provided allowing the driver to
chose soft or hard settings. Even if the soft setting is selected, the system will
switch to hard under certain operational conditions.

Traction control: -

Figure shows electronic traction control system

Electronic traction control has been developed as a supplement to ABS. this control
system prevents the wheels from spinning when moving off or when accelerating
sharply while on the move. In this way, an individual wheel which is spinning is
braked in a controlled manner. If both or all of the wheels are spinning, the drive
torque is reduced by means of an engine control function. Traction control is a
combination of ABS. this is because many of the components required are the same
as for the ABS.

Achievements of the traction control: 1. Mainly stability

2. Reduction of yawning moment reactions.

3. Provide optimum propulsion at all speeds.

4. Reduce driver workload.

Advantages of traction control: 1.


Improved tactile force

Better safety and stability on poor surfaces
Less driver stress
Longer tire life
No wheel spin on turning and cornering

Manual transmission: there is no clutch pedal in an automatic transmission car. There is no gear shift. In
automatic transmission both torque converter and a manual transmission with its
clutch are included.

Automatic transmission: the main aim of electronically controlled automatic transmission (ECAT) is to
improve conventional automatic transmission in the following ways:1.gear changes should be smoother and quicker
2. Improved performance
3. Reduced fuel consumption
4. Reduction of characteristic changes over system life
5. Increased reliability

Block diagram of ECAT system: -

The gear changes and lock-up of the torque converter are controlled by hydraulic
pressure. In an ECAT system, electrically controlled solenoid valves can influence
this hydraulic pressure. It consists of a ECU that is in communication with the
engine control ECU by a CAN (controller area network). The system as a whole
consists of a number of sensors providing data to the ECO which in turn is able to
control a number of actuators or o/p devices.

Electronic clutch: Graph

It was developed for racing vehicles to improve the getaway performance. It is

developed with greater throttle opening, the strategy to prevent abuse and drive
line damage. The electrical control of the clutch release bearing position. This is by
solenoid actuator, which can be modulated by signals from the ECU. This allows the
time to reach the ideal take off position to be reduced. And ability of the clutch to
transmit torque to be improved. Therefore, the whole efficiency of the system can
be increased.

Electronic power steering: There are three electronic power steering techniques
1. Replacing the conventional system pump with an electric motor while the ram
remains same.

the pump will run only when needed.

this gives some saving in the fuel consumption
and allows the drive belt arrangement at the front of the engine to be
2. A drive motor which directly assists with the steering and has no hydraulic

it is now most components

an electric motor acts directly on the steering via an epicyclical gear
this completely replaces the hydraulic pump and servo cylinder
this eliminates the fuel penalty of the conventional pump
simplifies the drive arrangements
3. Active steering: this is also known as drive-by-wire technique

steering wheel is replaced by joy stick

an array of sensors determines the required output
two electro hydraulic control valves operate via the control unit
the ECU filters out spurious data from the sensors and provides a
feedback to the joystick in order to maintain driver feel

Block diagram of active steering system: -

Fig: Active power steering

Comfort and safety in vehicles: Electric seat adjustment: seat adjustment is achieved by using a number of motors to allow
positioning of different parts of the seat movement is possible in the
following ways: 1. Front to rear
2. Cushion height rear
3. Cushion height front
4. Back rests tilt
5. Head rest height
6. Lumber support

explanation: this system uses four positioning motors and one smaller motor to operate a
pump. The pump controls the lumber support bag. A rocker-type switch is
used to control each motors via two relays. Nine relays are used for each
motor and 1 for control of the main supply.

Explanation of electric seat adjustment by

the help of diagram of position memory
circuits: -

Explanation: when the seat position is set some vehicles have set position memories to
allow automatic repositioning. This is often combined with electric mirror
adjustment. As the seat is moved a variable resistor mechanically link to the
motor is also moved. The resistance valve provides feedback to ECU. This
adjusts the motor voltage is proportional to the seat position. This analogue
voltage converted into digital and stored in digital memory. When the driver
presses a memory recall switch, the motor relays are activated by the ECU.

Door locking circuit: when the key is turned in the drivers door lock, all the other doors on the
vehicle should also lock. This can be achieved by motors or solenoids. If the
system can only be operated from the drivers door key, then an actuator is
not required in the doors. All the doors need an actuator, if the system can
be operated from either front door or by remote control. Alarm systems often
lock all the doors as the alarm is set.

Fig: door lock circuit.

Explanation: the main control unit contains two change over relays which are actuated by
either the door lock switch (or) if fitted with the remote infrared key. The
motor for each door lock are simply wired in parallel and all operate at the
same time. Most door actuators are now small motors which via a suitable
gear reduction, operate a linear rod in either direction to lock or unlock the
doors. A simple motor reverse circuit is used to achieve the required action.

Block diagram of door locking circuit: -

Infrared central door locking is controlled by a small hand held transmitter

and an infrared sensor receiver unit as well as a decoder in the main control
unit. When transmitter switch is pressed, a complex code of excess of 50,000
is transmitted. This code is converted in an electrical form and sends to the
ECU. If received code is either locked or unlocked. If an incorrect code is read
on three consecutive occasions when attempting to unlock the doors, then
the infrared system will switch itself off until the door is opened by the key.

Electric window operation: -

Electric window system is operated under the following modes

1. One shot up or down
2. Inch up or down
3. Lazy lock
4. Back-off
when a window is operated in one-shot or one-touch mode, the window

is driven in the chosen direction until either the switch position is reversed;
the motor stalls or the ECU receives a signal from the door lock circuit. The
problem with this is that if a child should be trapped in the window, there is a
serious risk of injury. To prevent this, the back-off feature is used. An extra
commutator is fitted to the motor, then ECU will reverse the motor until the
window is fully open. In inch up or down mode, the ECU count the pulses
received and determine the window position. The lazy lock feature allows the
car to the fully secured by one operation of a remote infrared key. This is
done by the link between the door lock ECU and the window and sun-roof

Main components of air bag: 1.


Driver and passenger air bags

Warning light
Passenger seat switches
Pyrotechnic inflator
Crash sensor
Electronic control unit




Driver and passenger air bags: the air bag is made of a nylon fabric with a coating on the inside.
Prior to inflation of air bag is folded up under suitable padding that
has specially designed break lines built-in. holes are provided in the
side of the air bag to allow rapid deflation after deployment. The
drivers air bag has a volume of about 60 liters and the passengers
airbag has about 160 liters.
Warning light: this gives an indication of a potential malfunction pyrotechnic
inflator and igniter can be considered together. The inflator in the
case of the driver is located in the center of the steering wheel. It
contains a number of fuel tablets in a combustion chamber. The
igniter consists of charged capacitor which produces the ignition
spark. The fuel tablets burn very rapidly and produce a given
quantity of nitrogen gas at a given pressure. This gas is forced into
the airbag through a filter and bag inflates. Breaking through the
padding in the wheel center. After deployment, a small amount of
sodium hydroxide will be present in the airbag and vehicle interior.
Passenger seat switch: the use of a switch on the passenger side to prevent deployment
when not occupied.
The crash sensor: this may be mechanical or electronic. This can be described as an


Crash sensor: this prevents deployment in the event of a faulty main sensor

Block diagram of an airbag circuit: -

Seat-belt tensions: taking the stack out of a seat-belt in the event of an impact is a good
contribution to vehicle passenger safety. The decision to take this action is
the same as for the airbag inflation. The two main types of tensioners are: 1. Spring tension
when the explosive charge is fired, the cable pulls a lever on the seat belt
reel, which in turn tightens the belt. The unit must be replaced once
deployed. This feature is sometimes described as anti submerging.

Car navigation system: this system consists of the base unit, a monitor, an antenna, a remote
control and CD-ROM discs.

Explanation: on your own way, you can set the input of your destination. The system
search in a variety of ways by address, street name, category or memory
point. Destinations can be alphabetical input or a common destination like
airports or hotels. Pop-up allow you to chose spellings of destinations
memory inputs. The system calculates the best route to your destination
according to your instructions. You can choose whether to go via motor way
or normal streets and also include local points (like restaurants or fuel
stations) or exclude. Alternate route can set if that route traffic is more, cross
border route can also be specified.

Global positioning system (GPS): the system was developed by the American department of defense. An
encrypted code allows a ground location to be positioned to within a 50
meters. The GPS satellite sends out synchronized information 50 times a
second. Data on orbit position time and identification signals are transmitted.
The navigation computer receives signals from up to 8 satellites. The time
taken for the signals to reach the vehicle is calculated at the same time.
From this information, the computer can calculate the distance from each

satellite. The current vehicle position can then be determined using three coordinates. Imagine the three satellites forming a triangle. The position of the
vehicle within that triangle can be determined. If the distance from each
satellite is known.

Advantages of GPS: 1.

Fast speed
Leads you in right direction
Helps improve mapping skills
Has panic buttons built in
You can be found easier if in danger or in accident
Plugs into your car cigarette lighter