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Introduction to Automotive Electrical and Electronic Systems

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Rajesh Murukesan
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INTRODUCTION TO AUTOMOTIVE ELECTRICAL AND
ELECTRONICS
Rajesh Murukesan and Solomon Newayjida

First edition, 2018

All rights reserved. No part of this book may be reproduced in any form,
by mimeograph or any other means, without permission in writing
from the author.

Aba Minch University reserves the right to reprint this edition in

Federal Democratic Republic of Ethiopia

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Contents

CHAPTER 1 – AUTOMOTIVE ELECTRICAL WIRING

1.1 INTRODUCTION ......................................................................................13
1.1.1 Insulated Return System..........................................................................13
1.1.2 Earthed Return System (Single Wire System) ................................13
1.2 AUTOMOTIVE WIRE...............................................................................14
1.3 FUSES AND CIRCUIT PROTECTION DEVICES .................................16
1.3.1 Blade Fuses:...................................................................................................16
1.3.2 Circuit Breakers ...........................................................................................17

Circuit Protectors ...................................................................................................18

1.3.4 Fusible Links .................................................................................................18
1.3.5 Mega Fuses.....................................................................................................19
1.3.6 Terminals and Connectors ......................................................................19
1.4 WIRING HARNESS ..................................................................................21

CHAPTER - BATTERIES
2.1 INTRODUCTION ......................................................................................26
2.1.1 Types of Cell ..................................................................................................27
2.1.2 Types of lead-acid batteries ...................................................................28
2.2 MOTOR VEHICLE BATTERIES .............................................................28

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 2.2.1 Battery Current ............................................................................................29
2.2.2 Selection of Battery ....................................................................................30
2.2.3 Battery Location ..........................................................................................31
2.3 LEAD-ACID BATTERY.............................................................................31
2.3.1 Construction of Lead-Acid Battery ......................................................31
2.4 CHEMICAL ACTION ................................................................................39
2.5 CHARACTERISTICS OF LEAD-ACID BATTERY ................................41
2.5.1 Effects of Temperature on Batteries ...................................................42
2.6 CYCLES Vs LIFE ........................................................................................43
2.7 BATTERY CAPACITY / RATING ...........................................................43
2.8 BATTERY EFFICIENCY ...........................................................................45
2.9 BATTERY TESTS ......................................................................................45
2.10 MAINTENANCE OF THE BATTERY ..................................................52
2.11 CHARGING AND DISCHARGING CHARACTERISTICS OF LEAD-
ACID BATTERY................................................................................................52
2.12 BATTERY CHARGING...........................................................................53
2.12.1 Factors Affecting Charging ...................................................................55
2.12.2 Battery Charging Methods ...................................................................55

CHAPTER 3 - STARTING SYSTEM

3.1 INTRODUCTION ......................................................................................58
3.1.1 Starting System Terminology.................................................................60
3.1.2 Condition at Starting .................................................................................60
3.1.3 Types of motor .............................................................................................61

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 3.2 SERIES MOTOR AND ITS CHARACTERISTICS .................................63
3.3 BEHAVIOUR OF STARTER DURING STARTING ...............................64
3.2.1 Requirements of Cranking Motor ........................................................65
3.3.2 Cranking Motor Capacity .........................................................................66
3.3.3 Performance Characteristics of a Starter Motor ............................66
3.3.4 Selection of Cranking Motors.................................................................68
3.4 CONSTRUCTION ......................................................................................69
...................................................................70
3.5 OPERATING PRINCIPLE ........................................................................72
3.6 STARTER DRIVE UNITS .........................................................................72
3.6.1 Manually operated [Pedal Shift] over running clutch type
starting mechanism ..............................................................................................74
3.6.2 Inertia type starting mechanism .........................................................75
3.6.3 Pre-engagement/Positive Engagement ORC type starting
mechanism ................................................................................................................78
3.7 STARTER SWITCHES ..............................................................................80

CHAPTER 4 - CHARGING SYSTEM

4.1 INTRODUCTION ......................................................................................83
4.1.1 D.C Generator [Dynamo]..........................................................................84
4.1.2 Shunt wound generator ...........................................................................85
4.1.3 Characteristics of Dynamo ......................................................................86
4.1.4 Armature Reaction and Control............................................................89

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 4.2 BATTERY CHARGING .............................................................................90
4.2.1 Cut out relay ..................................................................................................90
4.2.2 Regulator ........................................................................................................91
4.3 ALTERNATOR ...........................................................................................93
4.3.1 Introduction ..................................................................................................93
4.4 ALTERNATOR COMPONENTS ..............................................................93
4.5 VOLTAGE REGULATOR ...........................................................................97
4.5 ALTERNATOR CHARACTERISTICS .....................................................99

CHAPTER 5 - AUTOMOTIVE LIGHTING SYSTEM AND ACCESSORIES

5.1 INTRODUCTION ......................................................................................101
5.2 INTERIOR LIGHTING .............................................................................102
5.3 EXTERNAL LIGHTS – REGULATION [US] .........................................106
5.4 HEAD LAMP ..............................................................................................107
5.4.1 Light Filament .....................................................................................107
..........................................................................................................109
5.4.3 Headlight lenses ..........................................................................................113
5.4.4 Headlight Aiming and Levelling............................................................114
5.5 TYPES OF HEAD LAMP UNITS .............................................................117
5.5.1 Sealed beam headlights............................................................................117
5.5.2 Semi-sealed headlamps............................................................................119
5.6 HEAD LAMP DESIGNS ............................................................................119
5.7 LED LIGHTING SYSTEM ........................................................................121

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 5.8 HEAD LIGHT DAZZLING AND PREVENTIVE METHODS ..............121
5.9 ELECTRONIC DASHBOARD INSTRUMENTS ....................................123
5.10 HORN .......................................................................................................127
5.10.1 Simple Horn ................................................................................................127
5.10.2 Wind tone horn .........................................................................................129
5.10.3 Air horn ........................................................................................................129
5.11 WIND SHIELD WIPER SYSTEM.........................................................130
5.12 TURN INDICATOR ................................................................................132

CHAPTER 6 - IGNITION AND INJECTION SYSTEM

6.1 IGNITION SYSTEMS ................................................................................134
6..1.1 Requirements of the ignition system ................................................134
6.1.2 Types of Ignition System..........................................................................135
6.1.3 BATTERY COIL [CONVENTIONAL] IGNITION SYSTEM .............135
6.1.4 MAGNETO–IGNITION SYSTEM ........................................................138
6.1.5 TRANSISTORIZED POINT IGNITION SYSTEM.............................141
6.1.6 BREAKER-LESS IGNITION SYSTEM ................................................143
6.1.7 DISTRIBUTOR–LESS IGNITION SYSTEM ......................................144
6.1.8 CAPACITIVE-DISCHARGE IGNITION SYSTEM .............................145
6.2 IGNITION TIMING ...................................................................................147
6.3 IGNITION ADVANCE MECHANISMS ...................................................147
6.3.1 Centrifugal Advance Mechanism ..........................................................148
6.3.2 Vacuum Advance Mechanism ................................................................149

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6.4 FULL ELECTRONIC IGNITION SYSTEM .............................................151

6.5 SPARK PLUG .............................................................................................152
6.5.1 Construction of Spark Plug .....................................................................153
6.6 ELECTRONICALLY CONTROLLED CARBURETTED ENGINE .......156
6.7 FUEL INJECTION......................................................................................157
6.8 WORKING OF ELECTRONIC MPI SYSTEM ........................................162
6.9 ELECTRICAL FUEL LIFT PUMPS .........................................................165
6.9.2 Rotary Vane Pump ......................................................................................167

CHAPTER 7 - INTRODUCTION TO AUTOMOTIVE SENSORS

7.1 INTRODUCTION ......................................................................................168
7.1.1 Types Of Sensor ...........................................................................................169
7.2 MASS AIR FLOW FOR ENGINE .............................................................172
7.2.1 Speed-Density Method .............................................................................173
7.2.2 Hot wire type Mass Air Flow [MAF] sensor.....................................174
7.3 EXHAUST GAS OXYGEN SENSOR.........................................................176
7.4 THROTTLE POSITION SENSOR ...........................................................178
7.5 ENGINE SPEED / CRANK SHAFT ANGULAR POSITION................179
7.5.1 Magnetic Reluctance Position Sensor ................................................180
7.5.2 Optical Crankshaft Position Sensor .....................................................182
7.5.3 Hall-Effect Position Sensor .....................................................................183
7.6 KNOCK SENSOR .......................................................................................184
7.7 MANIFOLD ABSOLUTE PRESSURE [MAP] SENSOR ......................184