Autotronics and EV

Practical No.4
Name: Shubham Dharmraj Chougule
Roll No: 4344, PRN: 0220200041

Aim: - Diagnostic trouble code for ABS System, Steering system, Airbag
Objective: -

1) To understand and classify braking systems

2) To recognize Diagnostic trouble code for ABS System
3) To discuss various steering system and their importance EGR and Purge Controller
4) To understand airbag function and sensors

Diagnostic trouble code for ABS System: -

1] Introduction ABS System: Commonly known as ABS, or sometimes anti-skid braking systems,
anti-lock braking systems help prevent car and motorcycle wheels locking up and improve
steering control whilst braking. Today, anti-lock braking is now standard on virtually all new
cars and motorcycles and is used not only to aid steering whilst braking but also to help with
traction control. ABS operates by preventing the wheels from locking up during braking, thereby
maintaining tractive contact with the road surface and allowing the driver to maintain more
control over the vehicle.

The primary purpose of ABS is not actually to help cars stop faster. But to help drivers maintain
control of their vehicles in heavy braking situations. In ideal conditions vehicles equipped with
ABS generally experience shorter stopping distances than those without. Decreased stopping
distance is not guaranteed by ABS and is a secondary effect. ABS is also used as a form of
traction control in a range of modern cars. ABS is used to help restore grip to wheels that slip, by
slightly applying the brake. Although this shouldn't be confused with actual traction control
systems (TCS) that are used to prevent wheel spins during acceleration. TCS works by shifting
torque through differentials to wheels that the ECU deems to have better traction in comparison
with a wheel that is slipping.

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2] Types of brakes:

Brakes are perhaps the most important safety feature of any vehicle. There are two kinds of
service brakes, or the brakes that stop your vehicle while driving: disc and drum brakes.
Additionally, almost all vehicles come with emergency brakes and anti-lock brakes.
 Disc Brakes
Disc brakes consist of a brake rotor which is attached directly to the wheel. Hydraulic pressure
from the master cylinder causes a calliper (which holds the brake pads just outside the rotor) to
squeeze the brake pads on either side of the rotor. The friction between the pads and the rotor
causes the vehicle to slow and stop.
 Drum Brakes
Drum brakes consist of a brake drum attached to the inside of the wheel. When the brake pedal
contracts, hydraulic pressure presses two brake shoes against the brake drum. This creates
friction and causes the vehicle to slow and stop.
 Emergency Brakes
Emergency brakes, also known as parking brakes, are a secondary braking system that work
independent of the service brakes. While there are many different kinds of emergency brakes (a
stick lever between the driver and passenger, a third pedal, a push button or handle near the
steering column, etc.), almost all emergency brakes powered by cables which mechanically apply
pressure to the wheels. They are generally used to keep a vehicle stationary while parked, but can
also be used in emergency situations if the stationary brakes fail.

 Anti-Lock Brakes
Anti-lock braking systems (ABS) are found on most newer vehicles. If the stationary brakes are
applied suddenly, ABS prevent the wheels from locking up in order to keep the tires from
skidding. This feature is especially useful when driving on wet and slippery roads.

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3] ABS System working principle and important Sensors:

ABS works by releasing and then reapplying or 'pumping' the brakes to a motorcycle wheel or
car wheels in heavy braking situations. Sensors on each wheel are used to detect 'locking' or
when a wheel stop moving and starts to skid. Although not all ABS systems are the same, with
some only preventing wheels on the rear axle from locking up. When a lock-up is detected, ABS
pumps the brakes, 100's of times a second. This stops the wheel or wheels from skidding and
helps keep the driver in control of the vehicle. So essentially, ABS works in three stages:

1. Brake pedal is pushed

2. Wheel sensors detect skidding or 'locking'
3. ABS pumps the brakes

The four major components of a typical anti-lock braking system are:

 Speed sensors - These sensors monitor how fast the wheel or wheels are rotating
 Valves - Valves in the brake line allow, block and release pressure on the brakes by
assuming three different positions
 Pump - These pumps are filled with hydraulic fluid and apply pressure to the brake
drums or callipers on demand
 Controller - The electronic control unit (ECU) is the brain of the ABS and uses data
from the sensors to determine whether or not to pump the brakes

Important ABS Sensors

Wheel speed sensor:

An anti-lock brake sensor or ABS sensor is a type of tachometer that measures the rotational
speed of a wheel and passes it to the car's Engine Control Module (ECM). The ABS sensor is
also called the wheel speed sensor or ABS brake sensor. Since all the wheels do not turn at the
same speed, the ABS sensors report the speeds of all the four wheels to the ECM, based on
which the ECM determines if the wheels are locking up. The application of the ABS brake is
quicker than manual brakes. Due to this, when the ABS is engaged, it emits a grinding noise in
some automobiles.

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There are different types:

 ABS Hall with magnetic coding ring.

 Magneto-resistive ABS sensor.
 ABS Hall sensor with permanent magnet.

ABS Hall with magnetic coding ring

In this case, the toothed wheel is replaced by a coding ring with 48 pairs of magnets with
alternating polarity (N/S). This magnetic ring is fitted within the wheel bearings. The sensor has
three elements of measurement which give the final signal.

Magneto-resistive ABS sensor (AMR)

Base on anisotropic magnetoresistance, that is a property of certain materials in which the

electric resistance depends on the angle between the electric current and the direction of
magnetization. These sensors are very precise and can determine the rotation speed and the
direction (this is very useful for the hill-start assist control, HAC).

ABS Hall sensor with permanent magnet

This sensor uses a permanent magnet and the magnetic coding ring is not necessary. This
magnet is located behind the semiconductor. This allows for the use these types of sensors in
transmissions with toothed wheels

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5] Diagram/Sketch:

6] Reasons of ABS System fail:

1. Breaks in wiring/sensor winding due to excessive vibration
2. Internal short circuits Autotronics and EV 5
3. Increased wheel bearing clearance
4. Damage during replacement of other braking components

• Malfunctioning in ABS
When you turn on your car for the first time, the ABS light turns on. It starts up because the main
computer is checking to see if the system is functioning properly. The light goes off when the
system passes the test. If the ABS light comes on at any other time, there may be an issue with
the main computer or there may be an issue with the ABS system. A short causes some system
lights to turn on and off.

• Malfunctioning ABS Sensor:

The brakes' ABS sensors might get somewhat dirty because they are there. Road filth causes the
sensors to start acting strangely when it accumulates on them. The faults cause the main
computer to get error signals, which then turn on the ABS dashboard warning light. The issue is

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resolved by cleaning the sensors. You will need to have the ABS sensors replaced if the sensors
are too dirty to clean.

• Malfunctioning ABS Controller:

Lastly, the ABS controller keeps track of the wheels' rotational speed. With more wheel
rotations equalling faster driving, this enables the controller to activate the ABS system as
necessary. Your vehicle's anti-lock brake system will fail if the controller malfunctions or dies
entirely, which is never a good thing, especially if you're travelling on rainy roads.

7] Diagnostic trouble code for ABS System (Error code):

C0060: Left front ABS solenoid 1 circuit malfunction
C0065: Left front ABS solenoid 2 circuit malfunction
C0070: Right front ABS solenoid 1 circuit malfunction
C0075: Right front ABS solenoid 2 circuit malfunction
C0080: Left rear ABS solenoid 1 circuit malfunction
C0085: Left rear ABS solenoid 2 circuit malfunction
C0090: Right rear ABS solenoid 1 circuit malfunction

C0095: Right rear ABS solenoid 2 circuit malfunction

B] Drive Mechanism - Steering System in Automobiles

1] Different Steering Systems:

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 Turntable Steering or Centre Pivot Steering:

Once the front wheels are turned, then the whole front axle is turned about the central pivot. In
this case, the perpendicular of all the wheels meet at a particular point during the turning.
Therefore, the turning is safe and the wheels roll quite freely.

 Ackerman Steering or Side Pivot Steering:

Mostly the front axle is pivoted on the either side of the axle as the wheels are mounted on
the stub axles. This is why the stub axles are turned by the steering arms and are connected to the
tie rod.

 Recirculating-ball steering 
Recirculating-ball steering is used on many trucks and SUVs today. The linkage that turns the
wheels is slightly different than on a rack-and-pinion system. The recirculating-ball steering gear
contains a worm gear. This block has gear teeth cut into the outside of it, which engage a gear
that moves the pitman arm (see diagram above). The steering wheel connects to a threaded rod,
similar to a bolt, that sticks into the hole in the block. When the steering wheel turns, it turns the
bolt. Instead of twisting further into the block the way a regular bolt would, this bolt is held fixed
so that when it spins, it moves the block, which moves the gear that turns the wheels

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
 Rack and Pinion Steering System:

In most of the cars and SUVs on today’s road consists of a rack and pinion steering system. This
system is responsible for converting the rotational motion of the steering wheel into the linear
motion which turns the wheels and guides the path. This system involves a
circular gear which locks the teeth on a bar. This transforms the big rotations of the steering
wheel into small, accurate turns of the wheels which gives a solid and direct feel to the steering.
The recirculating ball mechanism has the advantage of a much greater mechanical advantage, so
that it was found on larger, heavier vehicles while the rack and pinion was originally limited to
smaller and lighter ones; due to the almost universal adoption of power steering, however, this is
no longer an important advantage, leading to the increasing use of rack and pinion on newer
vehicles.

 Parallelogram Steering System:

The typical steering system used on passenger cars and light trucks is called a parallelogram
system because all the pivot points are paralleled. This allows each wheel to be flexible and to
travel independently. The conventional parallelogram system consists of the following:

 pitman arm
 idler arm
 tie-rod ends
 centre link
 adjusting sleeves

Another steering system design typically used in many General Motors vehicles is also a
parallelogram system. This system uses two idler arms and a drag link.

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 Power assisted steering:

Power assisted steering helps the driver of a vehicle to steer by directing some of its power to
assist in swivelling the steered road wheels about their steering axes. As vehicles become heavier
along with increase in tyre width and diameter, the effort needed to turn the wheels about their
steering axis increases. To alleviate this auto makers have developed power steering systems: or
more correctly power-assisted steering also for off road vehicles like tractors.

There are two types of power steering systems;

(i) Hydraulic power steering (HPS)

(ii) Electric or electronic power steering (EPS).)

i Hydraulic power steering (HPS)

The power steering is added with some more parts and components to the rack and pinion system
which makes it simplified and easy to use. In most of the cases the pump, pressure tubes, rotary
control valve, fluid lines and a hydraulic piston are the common parts of a power steering system.

The main work of the pump is to, pump the fluid around the place where it is required. The
rotary control valve is the valve which ensures that the movement of fluid is only performed
once the driver is actually steering the car. The hydraulic piston keeps moving, depending upon
the fluid line which brings the high-pressure fluid. This movement of the piston on the rack
makes it easier for the driver as it usually applies force that is necessary to steer the car.

ii Electric Power Steering (EPS):

Computer-controlled electric power rack steering systems are used on some vehicles (Fig. 12.7).
These systems use a small electric motor within the housing to assist in moving the rack. Some
include a recirculating ball steering gear. Computer-controlled electric systems typically use
inputs from the antilock brake wheel speed sensors, steering angle and steering effort sensors,
and other inputs to provide the proper amount of steering assist.

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2] Starter Motors:
A starter or starter motor is an electrical device that used to rotate (crank) internal combustion
engines so as to initiate the engine’s operation under its own power. As soon as the engine begins
to run, it got disconnected from the engine, which now relies on the combustion process. The
component is mounted on the engine’s gearbox housing, and the starter motor gear meets
flywheel’s teeth.
Being an electrical component, a starter consists of a powerful DC (Direct Current) electric
motor and a solenoid. The solenoid receives positive power direct from the battery and hearth
current from the engine body. In order to turn the engine, a 12-volt battery must be used to run
the starter. This means the battery has to be sufficient enough to power the device. In the most
situation where the starter motor clicks but won’t start, the issue is either from the battery or
starter itself.

Parts of Starter Motor:

Below are starter motors parts and their functions:

Armature:
An armature is an electromagnet component that is mounted on the driveshaft or bearings for a
guide. It is made of a laminated soft iron core which is wrapped with numerous conductor loops
or windings.

Commutator:
A commutator is a section of the shaft at the rear of the housing on which brushes run to conduct
electricity. It is made of two plates mounted to the axle of the armature, the plates provide
connections for the coil of the electromagnet.

Brushes:
Brushes are parts that run on a section of the commutator at the rear of the housing. it rubs the
commutator and conducts electricity.

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Solenoid:
The solenoid features two coils of wire that are wrapped around the core. This solenoid serves as
a switch that connects and close the electrical connection between the starter motor and the
vehicle’s battery.

Plunger:
The function of a plunger in a starter motor is to push forward so the pinion can be engaged.

Lever Fork:
The lever fork is connected to the plunger which makes them push forward together to engage
the pinion.

Pinion:
A pinion is a small mechanism containing gear and springs. It engages immediately the engine
started, by extending the gear to the flywheel teeth. The flywheel is the source of engine rotation.

Field Coils:
The field coils are held in housing with screws as it consists of two or more coils connected in
series. These coils receive power from the battery that converts them into an electromagnet that
turns the armature. This creates a magnetic field around the armature.

C] Airbag system
1] Airbag working principle with Sketch:

An airbag is an inflatable safety device designed to protect the occupants of a car in case of a
collision. The airbags are part of an occupant restraint system and are also referred to as air
cushion restraint system. Airbags supplement the basic protection offered by seat belts. They are
also referred to as airbag supplemental restraint system due to this very reason. The effectiveness
of the airbags directly depends on the seatbelt. The seatbelt has to hold the occupant in the car in
place during the impact to ensure maximum efficiency of the airbag. In the event of an accident,
the airbag fills up very quickly and provides a cushion for the people in the car to ensure they are
protected during the crash.

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 The airbags generally consist of a diagnostic monitoring unit, a steering wheel connecting
coil, an air bag module, an indicator lamp, and crash sensors. All of these parts are
interconnected and are powered by the battery in the car.
 A backup power is provided for the airbags to function even after the battery has been
disconnected. Components required for the operation of airbags are generally dormant for
years. An internal self-test is performed during each startup to ensure the airbags are
functional.

 The airbag system has a crash sensor that makes sure the airbags do not inflate when the car
goes over a pothole, a bump, or even in the case of minor collision.

Working Principle:

1. The crash sensors present in the front of the car detects sudden decelerations and sends
electrical signals to activate an initiator.
2. A thin wire provided in the initiator heats up and penetrates the propellant chamber. This
results in the chemical propellant inside the inflator to undergo a rapid chemical reaction. This
reaction is often referred to as a pyrotechnic chain.
3. This reaction produces nitrogen gas that fills the air bag. This expanding gas inflates the airbag
in less than one-twentieth of a second.
4. This opens up the plastic module cover and inflates it in front of the person seated in the car.
The bag is inflated for just one-tenth of a second and deflated three-tenths of a second after
impact.
5. The inner side of the airbag is provided with a coating of cornstarch or talcum powder which is
released from the bag as it is opened.

2] Reasons of ABS System fail:

• Depleted Airbag Backup Battery: If your vehicle's battery is dead, it may have also depleted
the backup battery that powers the airbags. It may fix itself once the battery is fully charged again.
• Faulty Sensors: Your vehicle has several sensors connected to different components. The
sensors link directly to the car's computer system to recognize and notify the driver of potential
problems. Sensors can fail or be tripped on accident to cause the airbag warning light to come on.
The sensors will need to be inspected, and the system will need to be restored.

3] Important Sensors of Airbag system:

1. Mass-Type Sensor: An impact sensor is normally fitted to the front of the vehicle as this is
where a collision is likely to occur. The sensor is positioned inside the engine and a similar
safety sensor is located inside the passenger zone of the vehicle. This safety sensor is required to

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measure the intensity of the collision to determine whether the impact is over a certain threshold
to justify the release of an airbag.

2. Roller-Type Sensor: The roller-type sensor consists of a weight connected to a coil spring
component. Like the mass type sensor, during impact with an oncoming vehicle, the metal
weight is forced forward which alters the tension on the coil spring to manipulate the electrical
circuit that closes off the sensor contact. It is important to note that the impact and safety sensors
must activate and close off at the same time to allow for the deployment of the airbag.

3] Diagnostic trouble code for Airbag System (Error code):

B1933 is a diagnostic trouble code (DTC) for "Air Bag Passenger Circuit Open". This can
happen for multiple reasons and a mechanic needs to diagnose the specific cause for this code to
be triggered in your situation

Conclusion: - In this practical we have studied about active and Passive type of automotive
safety and control systems such as ABS system, types brakes, Important sensors in the ABS
systems. Main reasons for failing ABS system and error codes. Steering systems, starter motor
and last one is airbag system including working, sensors and error codes.

Reference: -
https://www.trackdays.co.uk/news/anti-lock-braking-system-abs/
https://www.atlantictireonline.com/4-types-of-car-brakes/
https://engineeringlearn.com/steering-system-types-function-components/
https://studentlesson.com/starter-motor-definition-functions-parts-types-working/
https://www.bankbazaar.com/insurance/motor-insurance-guide/airbag-system-in-your
car.html#:~:text=An%20airbag%20is%20an%20inflatable,protection%20offered%20by
%20seat%20belts.

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