Automotive

Electrical and
Electronics

A K BABU
Associate Professor
Department of Mechanical Engineering
PERI Institute of Technology
Chennai

KHANNA BOOK PUBLISHING CO. (P) LTD.

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 Price: ` 295.00

Automotive Electrical and Electronics

A K BABU

Copyright © Khanna Book Publishing Co. (P) Ltd.

This book is sold subject to the condition that it shall not, by way of trade or
otherwise, be lent, resold, hired out, or otherwise circulated without the publisher’s
prior consent in any form of binding or cover other than that in which it is published
and without a similar condition including this condition being imposed on the
subsequent purchaser and without limiting the rights under copyright reserved
above, no part of this publication may be reproduced, stored in or introduced into
retrieval system, or transmitted any form or by any means (electronic, mechanical,
photocopying, recording or otherwise), without the prior written permission of both
the copyright owner and the above mentioned publisher of this book.

ISBN: 978-93-82609-69-8

Edition: 2016

Published by:
KHANNA BOOK PUBLISHING CO. (P) LTD.
4C/4344, Ansari Road, Darya Ganj, New Delhi-110 002
Phone: 011-23244447-48 Mobile: +91-9910909320
E-mail: contact@khannabooks.com

Typesetted by:
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Printed in India by:

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 PREFACE

This book is designed for the core subject “Automotive Electrical

and Electronics” offered to the under graduate and post graduate
students of Automobile Engineering of various engineering colleges
and universities in India. My aim is to provide a broad understanding
of the many systems and component parts that constitute the vehicle
electrical and electronics in a detailed way. The book should also be
a valuable source of information and reference.
The book provides clear explanation of vehicle electrical and
electronic components and systems with unique illustrations, which
should be of value both to the students and to the experienced faculty
members. Each chapter takes the reader systematically through the
details of each component system. Key topics are emphasized and
are reinforced by numerous illustrations.
I hope that students and teachers enjoy reading this book and
that they find its contents informative and useful.

A K BABU
 Acknowledgement

Acknowledgements for this book are difficult to make because many

books and manuals have influenced me directly or indirectly in
its preparation. I express my grateful thanks to all those authors,
publishers and manufacturers.
I owe a huge thanks to Dr.V.Antony Aroul Raj, Easwari Engineering
College and Dr.G.Kumaresan, Institiute of Energy Studies, Anna
University for providing excellent support and advice.
I am grateful to my professor Dr.S. Parthasarathy, who never tired
of my requests, doubts and questions, and supported me throughout
this project.
I am grateful to my wife Sharmila Babu, who constantly encouraged
me for completing this book. I also thank my wonderful children
Vishal Surya S.B. and Harshitha S.B., for always making me smile
when I was writing this book.
I am grateful to my parents, Shri A.Krishnamoorthy and Srimati
K.Savithri, who put me in Engineering education.
I would really like to thank Khanna Publications for providing me
with the opportunity to become the lead author for this book.
 Contents

Preface v
Acknowledgement vii

1. Fundamentals of electricity 1
Electricity 1
Elements of electricity 3
Ohm’s law 4
Electric circuits 5
Dc measuring instruments 6
Actions of electric current 8
Voltage generation by electromagnetic induction 10
Voltage generation by electro-chemical cells 10
Voltage generation by heat (thermo element) 10
Voltage generation by light (photoelectric cells) 11
Voltage generation by pressure (piezo-electric effect) 11

2. Vehicle electrical system 12

Generation system 12
Starting system 13
Ignition system 13
Lighting system 14
Accessories 14

3. Battery 15
Vehicle battery 15
Functions 16
Principle 16
Construction of a lead-acid battery 17
Cell and battery arrangements 26
Electrochemical action 27
Alkaline battery 29
Sodium-sulphur battery 31
Aluminum-air battery 32
Performance characteristics of a lead-acid battery 32
Battery rating and capacity 38
Battery efficiency 40
Various tests on battery 41
Battery charging 45
Maintenance of batteries 51

4. Starting system 54
Starting requirements 56
Starter motor 59
 6 Automotive Electrical and Electronics

Requirements of starter motor 59

Principle 59
Starter construction 60
Conventional starter motor 62
Reduction type starter motor 63
Types of starter motor 65
Characteristics of starter motor 67
Starter drive mechanisms 70
Overrunning clutch 77
Starter switches 79
Starter solenoid 79
Starter relay 82

5. Charging system 85
Operation 86
Requirements 86
Generator 86
Direct-current (dc) generator 87
Regulator 89
Alternator 92
Construction 93
Principle of alternator 97
Advantages of alternator 97
Single-phase and three-phase alternators 98
Voltage regulator 99
Compensated voltage regulator 103
Regulator characteristics 104

6. Ignition system 109

Functions and requirements 109
Ignition energy 110
Principle of high voltage generation 110
Components of conventional ignition system 112
Ignition coil 113
Distributor 114
Conventional ignition systems 120
Comparison of battery ignition and magneto ignition 123
Ignition advance mechanisms 123
Spark plug 129
Ignition performance 131
Self-cleaning temperature 133
Pre-ignition temperature 133
Spark plug heat flow 134
Spark plug reach 134
Nose length and heat range 135
Projecting-electrode spark plugs 136
Platinum-tipped spark plugs 137
 Contents 7

7. Electronic Ignition system 141

Capacitive discharge ignition system 141
Solid state transistorized ignition system 142
Distributor less ignition (dli) system (fully electronic) 145
Triggering devices (signal generators) 146
Igniter 151
Digital ignition system 151
Electronic spark advance (esa) 158

8. Automotive wiring 160

Automotive wiring and circuits 160
Earth return system 160
Insulated earth return 161
Positive and negative earth systems 161
Wire 163
Wire gauge (wire size) 163
Metric wire system and american wire gauge (awg) system. 164
Necessities of selecting wire gauges 165
Current density 165
Measurement of the gauge of a cable 166
Colour coding of electrical wires 168
Wiring harness 168

9. Lighting system 172

Headlight 172
Signal lights 174
Interior lights 177
Low beam and high beam operation 178
Headlight aiming 180
Headlamp arrangement 183
Headlight dazzling 184
Methods to reduce dazzling 185
Directional warning lamps 187

10. Accessories 192

Dashboard instruments 192
Speedometer 193
Fuel gauge 200
Temperature gauge 206
Horn 208
Components of hot water heater 224

11. Electronic Engine management 233

Sensors in engine management 234
Mass air-flow sensor 235
Manifold pressure sensor 237
Position/speed sensors 239
 8 Automotive Electrical and Electronics

Throttle position sensor 242

Oxygen sensor (lambda sensor) 243
Temperature sensors 251
Detonation sensor 253
Electronic control unit (a microcomputer) 254
Actuators 255
Feedback carburetor 256
Electronically controlled gasoline injection system 258
Types of electronic fuel injection systems 258
Electronic fuel injection system for a diesel engine 263

12. Safety and Warning systems 268

Automobile safety 268
Airbag 268
Anti-lock brake system (abs) 269
Traction control system (tcs) or vehicle
stability assist (vsa) system 270
Tyre pressure monitoring systems (or)
deflation detection system 272
Electronic stability control 275
Adaptive cruise control 277
Emergency brake assist systems 277
Rearview cameras 278
Voice warning system 279
Travel information system 283
Keyless entry system 284

13. Vehicle electronics 286

Electronic dash board instruments 286
Electronic power steering 286
Vehicle cruise control 288
Vehicle navigation 288
Automatic air conditioner 289
Functional components 290
Sensors 290
Controllers 293
Actuators 294

Index 295

 U N I T

1 Fundamentals
of Electricity

The components of the automobile electrical system are of complicated

construction, but all of them are applications of the various actions made
possible by the flow of electricity. Before taking up the construction and
operation of these various electric components, the fundamentals of
electricity will first be reviewed.

ELECTRICITY
Electricity is a form of energy and is produced by the movement of
small atomic particles known as electrons. It can be easily transmitted or
converted to other forms, such as mechanical or heat energy. To transmit
electricity, conductors such as copper, steel, carbon or an electrolyte are
used. Insulators such as rubber, porcelain or bakelite are used to prevent
electrical leakage from conductors.
There are two kinds of electricity: static and dynamic. Dynamic
electricity can be further divided into direct current (DC) and alternating
current (AC).

Static electricity

Electricity Direct
current (DC)

Dynamic
electricity

Alternating
current (AC)
 2 Automotive Electrical and Electronics

Static Electricity
When a non-conductive substance such as a glass rod is rubbed with a
silk cloth, the surfaces of both the rod and the cloth become charged with
electricity, one positively and one negatively. Unless the two materials
touch, or are connected by a conductor, the electrical charge will remain in
the glass rod and silk cloth. Since it does not move, this type of electricity
is called static electricity.
Charged with
Glass rod static electricity
+ + + + +

– –
–
–
–
Silk cloth

Fig.1.1: Static electricity

In terms of free electron, static electricity refers to a state in which free

electrons are separated from their atoms and do not move about on the
surface of the substance.
Dynamic Electricity
Dynamic electricity refers to a state in which there is a flow of free electrons,
i.e. electrons that are separated from their atoms and moving about inside
the conductive substance.
– –
– –
+ –
–
– – –
– – –
– –
–
– – –
– –
0
–

Time

DIRECT CURRENT

– –
– –
– –
– –
– – – – –
– –
+ – –
–
–
– –

0
Time
_ – –
–
– – –
–
– – –
– –
– –
– – –
– –
– – –
– –

ALTERNATING CURRENT

Fig.1.2: Dynamic electricity

When the free electrons are moving in a constant direction, the state
of dynamic electricity is called direction current (DC). When the direction
of motion and the size of the current vary periodically with time, the state
of dynamic electricity is called alternating current (AC).
 Fundamentals of Electricity 3

ELEMENTS OF ELECTRICITY
The three elements of electricity are voltage, current and resistance.
Current
Electric current is a flow of electrons and is measured in amps, (short for
amperes). The amp is a measure of flow rate. In other words how much
electricity is flowing per second.

– – –

MOVING ELECTRONS

Fig.1.3: Current

1 amp = 6,240,000,000,000,000,000 electrons per second

In electronic circuits a current of one amp is quite large, so often
the milli-amp is used instead. A milli-amp (mA) is a thousandth of an
amp (A).
Voltage

– – –
– – – –
–
–
Voltage – – – –
– – –
– – – – –
–
–

Fig.1.4: Voltage

Electricity does not flow through a wire unless it is pushed. There

has to be an electrical pressure and this pressure is called voltage and is
measured in volts. The symbol is V. It is also called electrical pressure, and
electromotive force (emf). This pressure can be provided by a battery, or it
can be produced by a generator.
Resistance

– – – – –
–
– –
Voltage –
– – – –
–

Fig.1.5: Resistance
 4 Automotive Electrical and Electronics

The rate that the electrons pass around the circuit (i.e. the amount of
current) is dependent not only on the force (voltage) but also by how much
resistance there is in the circuit. Resistance is measured in ohms (W).
In the case of electricity, a same conductor will allow better current
flow when its diameter becomes larger due to less resistance. When it
becomes longer, its resistance increases so that the current gets weaker.
That is, the resistance of a conductor is directly proportional to its length
and inversely proportional to its cross-sectional area. Because in a car the
same 12V battery powers all circuits, the only way that current can vary is
by varying the resistance.
The conductor resistance normally changes with the temperature.
The resistances of metal conductors increase when the temperature rises,
but resistances of carbon and aqueous solutions decrease. The resistance
also varies with the conductor material. A good conductor will have small
resistance, whereas the resistance of insulating material will be enormous.

OHM’S LAW
Increase resistance

Water

Water pipe

Resistor

Current

Fig.1.6: Ohm’s law

In 1827, George ohm introduced simple mathematical formula, which

relates voltage, current, and resistance. This formula is called ohm’s law.
Ohm’s law says voltage is equal to current times resistance. A force of 1V
is required to push a current of 1A through a resistance of 1Ω .
V=I×R
Where, V = Voltage in volts
I = Current in amperes
R = Resistance in ohms