AUTOMOTIVE

ELECTRONICS
Subject code: (404190)

Unit 4: Electronic Control Unit Design

Critical review of microprocessor, microcontroller and
digital signal processor development (overview of
development within the automotive context).
Architecture of 8 /16 bit microcontrollers with
emphasis on Ports, Timer/Counters, Interrupts, Watchdog timers, PWM, Memory requirement and Usage.
High-level language programming: Effective use of C
programming with particular reference to: Operatorsincluding bit wise, Control constructs, Pointers.
Real-Time Program Design: Pointers to physical addresses and
linking, Input and Output device programming, Timers and
interrupts, latency.
Program Development: Software development
strategies, Compiling and linking, Software testing
and debugging, Use of a professional development
system (Use of Embedded C)

Unit 5:
Automotive Communication Systems
Communication interface with ECUs: Interfacing techniques
and interfacing with infotainment gadgets.
Relevance of internet protocols, such as TCP/IP for automotive
applications.
Wireless LANs standards, such as Bluetooth, IEEE802.11x.
Communication protocols for automotive applications.
Automotive Buses: Use of various buses such as CAN, LIN,
FlexRay, Recent trends in Automotive buses (Such as OBDII, MOST,
IE, IELLI, D2B, and DSI).
Application of Telematics in Automotive: Global Positioning
Systems (GPS) and General Packet Radio Service (GPRS), for
use in an automotive environment.
Higher End Technology: Comparative study and applications of ARM
Cortex:-A series/M-series, ARM 9 and ARM11.
Current developments and issues.

Unit 6:
Diagnostics and Safety in Automotive

Fundamentals of Diagnostics:
Basic wiring system and Multiplex wiring system.
Preliminary checks and adjustments.
Self Diagnostic system.
Fault finding and corrective measures.
Electronic transmission checks and Diagnosis.
Diagnostic procedures and sequence.
On board and off board diagnostics in Automotive.
Safety in Automotive: Safety norms and standards.
Passenger comfort and security systems.
Electromagnetic environment and Automotive EMC
Standards.
SAE and IEEE Standards. Future trends in Automotive
Electronics.

Automotive Multiplex Wiring

Multiplexing :
In-vehicle networking
involving time division is also
known as multiplexing. Its a
method of transferring data
among distributed electronic
modules via serial data bus.

Benefits of Multiplexing

 Multiplexing Standards are also

appearing in automotive
applications.
SAE J1939
OSEK from the German automotive
consortium
SDS from Honeywell
DeviceNet from Allen-Bradley

Diagnostics
Introduction
Finding the problem when complex automotive
systems go wrong is easy. Well, it is easy if you have
the necessary knowledge. This knowledge is in two
parts:
1. an understanding of the system in which the problem
exists,
2. the ability to apply a logical diagnostic routine.
It is also important to be clear about two definitions:
Symptom(s) what the user of the system (vehicle or
whatever) notices,
Fault the error in the system that causes the
symptom(s).

The theory of
diagnostics
One theory of diagnostics can be
illustrated by the following example. After
connecting a hosepipe to the tap and
turning on the tap, no water comes out
of the end. Your knowledge of this system
tells you that water should come out
providing the tap is on, because the
pressure from a tap pushes water
through the pipe, and so on. This is
where diagnostic skills become essential.

To diagnose the fault following stages are now

required.
1. Confirm that no water is coming out by looking down
the end of the pipe!
2. Does water come out of the other taps, or did it come
out of this tap before you connected the hose?
3. Consider what this information tells you, for example,
the hose must be blocked or kinked.
4. Walk the length of the pipe looking for a kink.
5. Straighten out the hose.
6. Check that water now comes out and that no other
problems have been created.
The procedure just followed made the hose work but it is
also guaranteed to find a fault in any system.

 The skill is to be able to apply the same logical

routine to more complex situations
The routine can be summarized by the following
six steps.
1. Verify the fault.
2. Collect further information.
3. Analyze the evidence.
4. Carry out further tests to locate the fault.
5. Fix the fault.
6. Check this and other associated systems for
correct operation.
Steps 3 and 4 will form a loop until the fault is
located. Remember that with a logical process

 Diagnosis requires a logical step by

step procedure that establishes the
cause of the problem.

Diagnostic Sequence of
events
Diagnosis complaints should follow a
systematic sequence of events which
resolves the customers concern.
1. Verify the Customer Complaint
( Is there enough information? )
2. Fluid Checks.
( Ensure the proper level and
condition of the fluid.)

3. Test Drive
[Perform only if possible]
4. Road Test
[if required]
5. Diagnostic Trouble Codes
[ The ECM monitors the sensors and
solenoids and sets a trouble code in
memory.]

6. Preliminary Checks and

Adjustments
[ Verifies communication between
the various parts]
7. Diagnostic Tester Usage
[ Analyzing the test drive results.]

Diagnosis
Mechanical

Mechanical diagnostic techniques

Check the obvious first !
Start all hands on diagnostic routines with hand
and eye checks.
In other words look over the vehicle for obvious
faults
If the engine is blowing blue smoke out of the
exhaust consider the worth of tracing the cause of
a tapping noise in the engine!
When an engine will not start check that there is
fuel in the tank!

 Noise, vibration and harshness

The main areas of the vehicle that produce NVH
are:
tyres;
engine accessories;
suspension;
driveline.

The five most common sources of non-axle

noise are exhaust, tyres, roof racks,
trim and mouldings, and transmission.

 The five most common sources of

non-axle noise are exhaust, tyres,
roof racks, trim and mouldings,
and transmission.

Road test
Normal driving speeds of 20 to
80 km/h (15 to 50 mph)
Acceleration/deceleration
High speed
Engine rev/min sensitive
Noise and vibration while turning

Electrical diagnostic techniques

Check the obvious first!
diagnostic routines with hand and eye
checks.
A misfire may be caused by a loose plug lead
it is easier to look for this than interpret the
ignition waveforms on a scope.
If the ABS warning light stays on look to see
if the wheel speed sensor(s) are covered in
mud or oil.
{anti-lock braking system (ABS, from
German: Antiblockiersystem)}

Generic electrical testing procedure

On-board diagnosis
Each microprocessor-based electronic subsystem
has the capability of performing some limited
self-diagnosis.
A subsystem can, for example, detect a loss of
signal from a sensor or detect an open circuit in
an actuator circuit as well as other failures.
As long as the subsystem computer is still
functioning it can store fault codes for
detected failures.
Such diagnosis within a given subsystem is
known as on-board diagnosis.

 However, a higher level of diagnosis than

the on-board diagnosis is typically done
with an external computer-based
system that is available in a service shop.
Data stored in memory in an on-board
subsystem are useful for completing
diagnosis of any problem with the
associated subsystem.
Such diagnosis is known as off-board
diagnosis and is usually conducted with a
special-purpose computer.

Diagnostic System in

Fault codes
Fast and slow:
Most modern vehicle management
systems carry out self-diagnostic
checks on the sensors and actuators
that connect to the vehicle ECU(s). A
fault in one of the components or its
associated circuit causes a code to
be stored in the ECU memory.
The codes may be described as fast
or slow.

 Some ECUs produce both types. An LED,

dash warning light, scope or even an
analogue voltmeter can be used to read
slow codes.
Normally, slow codes are output as a series
of flashes that must then be interpreted by
looking up the code in a fault code table.
The slow codes are normally initiated by
shorting two connections on the diagnostic
plug and then switching the ignition on.

 Fast codes can only be read by using

a fault code reader or scanner. Future
ECUs will use fast codes.

Fault code lists are available in publications

Fault Code Display

Clearing Fault codes

Fault codes can be cleared from the
ECU memory in two ways:
using the facilities of a fault code
reader (scanner) to clear the
memory;
disconnecting the battery earth lead
for about two minutes (does not
always work however).

Concept behind Onboard

Diagnostics
On-board digital systems can also store
diagnostic information wherever a failure or
partial failure occurs in a component or
subsystem.
The relevant information can then be stored in a
memory (e.g., RAM) that retains the information
even if the car ignition is switched off.
Then, when the car is delivered to a repair
station (e.g., at the dealer), the technician can
retrieve the diagnostic information electronically.

Trends
the trend in automotive maintenance is
for the automobile manufacturer to
distribute all required documentation,
including parts lists (with figures) as well
as repair procedures in electronic format
via a dedicated communication link (e.g.,
via satellite) or via CD supplied to the
mechanic.
The repair information is then available to
the technician at the repair site by use of
a PC-like workstation.

History:
The timing light
and traditional
engine analyzer
are not enough for
diagnosis of engine
problems.
(Refer: William
Ribbens)

 The use of on-board diagnostics can easily be

illustrated by outlining typical procedures and
using the Cadillac system as an example
system. Although display of the fault codes
varies from car to car, in each case the codes
must be readable as a numeric code.
A typical method involves flashing the
Check Engine light. The mechanic enters
the display mode and then counts the number
of times that this light is flashed, in two-digit
groups. For example, a fault code 24 would be
given by 2 flashes then 4 flashes. After a short
time interval the next code would similarly be
flashed in two-digit sequence. At one time
Cadillac used the environment controller to
display a two-digit code.