New Generation and Hybrid Vehicles

(AENG 6310)
Automotive Computer Controlled
System
Department of Mechanical Engineering
School of Mechanical, Chemical and Materials engineering
Feb, 2023
Outline

• UNIT III VEHICLE OPERATION AND CONTROL

• Computer Control for( pollution, noise and for fuel economy etc…..)

• Transducers and Actuators

• Information Technology for receiving proper information and operation of the

vehicle like optimum speed and direction.

 Objectives
At the end of this presentation the students will be able to:

• Discuss the need for computer controlled Engine systems

• Understand transducers application areas and common

actuators in automotive engineering

• Explain the communication and network technologies of

modern vehicles

• Appreciate the application of computer controlled systems

of of modern vehicles
 Discussion questions
• Explain the three factors that led car manufacturers to
the wide spread of computers in automobiles engine.

• What is a green house effect?

• What is/are controlled in gasoline EFI?

• Discuss the techniques employed on automobiles to

overcome pollutant gases.
ECU/ECM
• Changes in electronics technology and manufacturing methods take place rapidly and
for some years now, microcontrollers (mini-computers) have formed the heart of many
of the control systems found on motor vehicles
• Microcontrollers, in common with other computers, contain a control unit and
presumably in order to avoid any possible confusion
• Terminologies used for the control unit
• black box
• Electronic Control Unit (ECU)
• Electronic Control Module (ECM) or control module
Environmental aspects
• When we think about the globe we live in, it is surrounded
by different layers of atmosphere.
> Troposphere
> Stratosphere
> Mesosphere
> Ionosphere
Layers of atmosphere
Solar Radiation
Electromagnetic spectrum
• Green house effect is the rise in temperature that the
earth experiences.

• Some green house gases occur naturally in the

atmosphere while others result from human
activities.
Naturally occurring green house gases are:
• Water vapor
• Carbon dioxide
• Methane
• Nitrous oxide
• Ozone (to some extent)
Very powerful green house gases, not naturally occurring
include:
• Hydro fluorocarbons (HFCs)
• PERFLUOROCARBONS (PFCs)
• Sulfur hexafluoride (SF6)
 Global warming
These green house gases result in global warming.
Some of the impacts of global warming may include:
• Stronger storms
• Migration of agricultural zones
• Spreading of tropical diseases
• Melting of ice caps
Environmental pollution
• Environmental pollution is defined as “the contamination of the
physical and biological components of the earth/atmosphere system
to such an extent that normal environmental processes are
adversely affected. (From: Environmental Management, 2017)

• pollution of air, water, and land. Environmental pollution is of

different types namely air, water, soil, noise and light-weight. These
cause damage to the living system. How pollution interacts with
public health, environmental medicine and the environment has
undergone dramatic change. (Environmental solutions, by Dr. Yashpal Singh Narwaria)
Pollutants
• Pollution is one of the most serious problems facing humanity and
other life forms on our planet today.

• Pollutants, can be either foreign substances/energies or naturally

occurring contaminants.

• Pollution can take the form of chemical substances or energy, such as

noise, heat or light.
Different types of pollution include:

• Air pollution. (gases, and particulate matters)

• Noise pollution. (NVH)
• Water pollution.
• Soil pollution.
• Radioactive pollution.
Air Pollution
• Air pollution refers to the release of pollutants into the air that are
detrimental to human health and the planet as a whole.
• Air pollution is a mixture of solid particles and gases in the air.
• Car emissions, chemicals from factories, dust, and pollen and mold
spores may be suspended as particles.
• Ozone is a major part of air pollution in cities. When ozone forms air
pollution, it's also called smog.
• Some air pollutants are poisonous.
• Air pollution occurs when harmful or excessive quantities of substances
are introduced into Earth's atmosphere.
• Sources of air pollution include gases, particulates, and biological
molecules.
Exhaust emissions
The six major exhaust gas compositions (of automobile)

♦Oxygen (O2)
♦Hydrocarbons (HC)
♦Water vapor (H2O)
♦Carbon monoxide (CO)
♦Carbon dioxide (CO2)
♦Oxides of nitrogen (NOx)
• Among these, CO, HC and NOx are harmful gases for living things
• More over, CO2 has a green house effect which leads to global
warming.
1. NOx – is irritant gas, it irritates respiratory system and damages lung
tissues.
• Produced due to rise in combustion temperature.

2. HC – causes irritation of mucus membrane.

Caused by >any electrical malfunctioning.
>lack of mechanical integrity
>an exceedingly rich mixture and etc.

3. CO – reduces the ability of the blood to absorb oxygen.

* is extremely dangerous (0.3 % by volume in the air can prove fatal
with in 30 minutes).
Caused by – an overly rich air fuel ratio.
Techniques used to overcome these gases
1. Stoichiometric air fuel ratio – minimizes CO, HC, NOx, by
maximizing CO2 and H2O production.
2. Exhaust gas recirculation system (EGR) – reduces NOx.
3. Altering ignition timing (retarding) – for reduction of
NOx.
4. Using catalytic converters
5. Air management valve – responsible for controlling air
injection.
Therefore
• Today’s cars are desired to meet three major
goals below.

Low exhaust emission

Good fuel economy

Excellent driving performance under all driving conditions.

• Many factors are important in achieving this aim;
improvement in the mechanical design of the engine such
as shape of combustion chamber, location of the spark plug
and number of intake valves are very significant.
• However, precise control of the air/fuel ratio and spark
timing have considerably very high importance in
maximizing an engine's power and its efficiency; at the
same time to reduce its emissions
• For modern engines this task is now considered to be
beyond the capabilities of simple mechanical control
systems and electronic engine management must be used.
 Therefore, application of
computer controlled systems
is indispensable!!!
 Classification
• Vehicle electronic control systems can be broadly classified as:
• Electronic engine management

• Electronic body management

• Electronic motion control system

• Electronic drive management

• Vehicle networking technology

1. Electronic engine management

• Gasoline engine management

• EFI
• ESA
• ISC
• Diesel engine management
• Conventional diesel EFI
• Common rail system
2. Electronic body management
• Commonly encountered systems include:
1. Driver information system ( instrumentation &
infotainment )
2. Auxiliary body electronics.
3. Vehicle security systems
4. Supplementary restraint systems (SRS or ‘air-bag’).
5. Air-conditioning
3. Electronic vehicle motion control
1. Cruise control
2. Anti-lock braking system
3. Traction control system (TCS)
4. Electronic stability program (ESP)
5. Electronic controlled suspension
6. electronic power steering
7. Electronic 4 wheel steering (E4WS)
8. Engine drug torque control
4. Electronic drive management

• ECT

• Electronically controlled 4wd

• Automatic freewheeling hub

• Differential and antilock braking hubs

5. Vehicle networking technology

• LIN bus technology

• CAN bus technology
• MOST, Flexyray and etc.
•Discussions & questions?
 Summary questions
1. Tell your friend the three factors that led car manufacturers to the wide
spread of computers in automobiles engine.

2. Discuss the techniques employed on automobiles to overcome pollutant

gases.

3. What do you think the reason for global warming?

4. What is the green house effect?

5. What is the purpose of catalytic converter?

6. Discuss the environmental pollution and air pollution.

Outline

• UNIT III VEHICLE OPERATION AND CONTROL

• Computer Control for( pollution, noise and for fuel economy etc…..)

• Transducers and Actuators

• Information Technology for receiving proper information and operation of the

vehicle like optimum speed and direction.

 Discussion questions
• Recall definition of sensors
• How can you classify sensors?
• What is a voltage divider? wheat stone bridge?
• Can you explain the working principle of pressure sensors?
• sketch and explain potentiometer?.
• Explain what a piezoresistive and piezoelectric materials
are.
• Which sensors are considered as a basic sensor? In
gasoline engine? in diesel engine?
Definition
• Sensors are transducers that change physical quantity in to
electrical quantity

• Sensors have the task of recording the operating statuses in

electronically controlled systems and converting them into
electrical signals.
Classification of sensors
Sensors are distinguished according to:
• Operating principle (e.g. inductive, capacitive, optical,
thermal, resistive, etc)
•Type of output signal (e.g. analogue, digital)
• Number of integration levels
• Function (e.g. calculation of speeds, temperatures,
pressures), based on assignment and application.
•Type of characteristic curve (e.g. linear, non-linear)
• Active or passive.
Classification by Operating principle
• Variable resistors (pot, thermistors, etc)
• Piezoelectric principle
• Piesoresistive principle
• Capacitive principle
• Electromagnetic (induction principle)
• Hall effect
• Photo couplers
• switches
Classification based on type of output
signals
Sensors out put signal can be:
a) Analog - an analog signal voltage is continuously variable
with in a given range and time is used for the voltage to
change.

b) Digital - digital signals also vary but not continuously, and

time is not needed for the change to occur.
Example of analogue sensors
• Induction sensors
• Temperature sensors (thermistors)
• Flow meters
• Knock sensors
• Etc
Example of digital sensors
• Switches
• Hall sensors
• Photo couplers
• Etc.
Sensor classification (assignment and application)
• Sensors can be classified according to very different
standpoints. With regard to their use in motor vehicles,
they can be categorized as follows.
– Functional sensors (e.g., pressure sensor, temperature
sensor, air-mass sensor), primarily for open- and closed-loop
control functions.
– Sensors for safety (passenger protection: airbag and
driving-dynamics control) and protection (theft deterrence).
– Sensors for vehicle monitoring (on board diagnostics,
consumption and wear quantities) and for providing
information to driver and passengers.
Group of sensors by functional category
Eye breaker exercise
• Case 1 switch off, case 2 switch on
• Write voltage readings for V1 through V5, take R=3 ohm,
time 4 minutes
Voltage divider

• voltage divider is a simple linear circuit that produces an output

voltage (Vout) that is a fraction of its input voltage (Vin).
Additional illustrations of voltage dividers
Application examples
• You want a circuit which will deliver a HIGH voltage when
hot conditions are detected (a fire alarm? )
• How could you make a sensor circuit to detect
temperatures less than 4°C to warn motorists that there
may be ice on the road?
Sample application
 Wheatstone bridge
• Wheatstone bridge is constructed by connecting two
voltage dividers in parallel. If the output voltage of both
voltage dividers are equal we call the bridge is in a balanced
state.
• It's less obvious that you should be thinking about two
voltage dividers, but once you know, the action of the
circuit is easy to follow.
Applications of voltage dividers
Constant current type hot wire air flow meter
 Piezoelectric principle
Piesoresistive principle
Both piezo-resistive and piezoelectric materials ca be
arranged in bridge form
Definition of Piezoresistive Sensing
• Also called strain sensors or strain gauges.
• A strain gauge is a device used to measure how much a
component distorts under loading.
• The electrical resistance of a sensing material changes
as a result of applied strains.
• A strain gauge is a conductor or semiconductor material
that can be directly fabricated on the sensor itself or
bonded with the sensor.
• In macroscopic systems, such as strain sensors in
machine tools, aircraft, strain gauges are most likely
bonded onto parts.
Stress-strain relation
What is a gauge factor? Take as home work
Electromagnetic (induction principle)
 Electromagnetic induction

• B  where
A
• is flux density in in [v.s/m2]
B
• is a magnetic flux

• is effective magnetic field cross-sectional area
A

where
Uo  N
induced
t voltage
U o number of turns
N change in flux
 rate of change
t
• Also U  N = 1
N * *   N * nwhere
* n is number of
t minute,tas n changes, U also changes
o
revolution per o
• where is magnetomtive force or
magnetic

potential difference

• RmagRmag 
is reluctance or magnetic resistance
But where l is magnetic path length and μ
is permeability.
l
R 
• A is cross=sectional area of magnet
A
mag

• Consequently Uo changes.
• Therefore, as changes,
 Rmag also changes that in turn
change the , Consequently Uo changes. On the

other hand, as n changes, the frequency and rate of
change of flux changes, consequently the magnitude of
the induced voltage.
• But which value is preferred as a signal?
• The voltage or the frequency? Reading
assignment.
Capacitive sensor

Sensor is adjusted so that it

does not ‘see’ the wall of the
vessel.
Basic Principles
• Sensing
• capacitance between moving and fixed plates change as
• distance and position is changed
• media is replaced
• Actuation
• electrostatic force (attraction) between moving and fixed
plates as
• a voltage is applied between them
• Two major configurations
• parallel plate capacitor (out of plane)
• interdigitated fingers - IDT (in plane)
 Basic Principles
• Parallel Plate Capacitor
• Comb Drive Capacitor
 Basic Principles
• Parallel plate capacitor

Fringe electric field (ignored in first order analysis)

Equations without considering fringe electric

field.
In FEM analysis, fringe effect can be adapted
 Con…
• Forces of capacitor actuators
• Stored energy

• Force is derivative of energy with

respect to pertinent dimensional
variable

• Plug in the expression for capacitor

• We arrive at the expression for force

Hall effect principle
Photo coupler type
Switch or reed switch
Integration levels.
• This means that several steps, which are required before the
signal is utilized in the control unit, have already been
executed within the sensor housing.
• For sensors in the 3rd integration level, for example, the
information is recorded by the sensor and converted into an
electrical voltage.
• This is prepared, e.g. amplified and then digitised.
• The signal is then processed in evaluation electronics until it
can be used directly in the control unit.
• A high level of integration leads to the following advantages:
•The sensor can serve several control units by transferring the
signal via a bus system.
•The signal only has to be prepared once for use in several
control units.

The signal is relatively interference-proof due to the

digitisation.
Control units can be more easily adapted to different sensors,
as the signal is prepared in the sensor
The sensor signal information can be called up by the control
unit as required.
• SE- Sensors, sc-Signal conditioning, AD-Analogue-digital
converter, Ecu-Electronic control unit, MC -Microcomputer
Examples of conventional
• Switches such as point type TPS
• Temperature sensors
• Potentiometers

• Disadvantage: Sensors in the 2nd and 3rd integration

levels can no longer be checked using standard workshop
instruments, such as multimeter or oscilloscope.
• They can only be checked using an engine analyzer
Examples of sensors in the
2nd or 3rd integration level
Angle sensors
• These are used to determine the rotational angle of shafts.
• The Hall principle is usually used to do this. One or more
Hall lCs are fitted so that they are penetrated by
corresponding magnetic fields when the shaft rotates.
• From the generated Hall voltages, the microprocessor
integrated in the sensor calculates the angle of rotation and
pre pares the signal for transfer to the CAN bus.
 Common automotive sensors
https://ackodrive.com/car-guide/different-
• Air flow meter types-of-car-sensors/
• Manifold pressure sensor
• Throttle position sensor
• accelerator pedal position sensor
• Crank shaft position and engine speed sensor
• Water and intake air temperature sensor
• Oxygen sensor
• Vehicle speed sensor
• Knock sensor and etc.
• Sensors for driver-assistance systems (ultrasonic sensors,
radar and other complex sensors which cannot be
compared with the classic sensors.
 Air flow measurement
• The amount of air supplied to the engine must be
measured in order to control the combustion process.
• The air-mass flow is the most important load variable in
gasoline engines;
• The air is not drawn in continuously by the engine, but
rather in time with the opening of the intake valves. For
this reason, the air flow pulses strongly – particularly with
the throttle valve wide open
 Air flow measurement
• There are two methods of sensing incoming, engine air flow
• Speed density
https://www.mathworks.com/help/autoblks/
• Mass air flow ug/compression-ignition-engine-speed-
density-breathing-model.html
• The Control module uses intake air flow measurement
information for
• Barometric pressure readings
• Fuel delivery calculation
• Spark calculations
• Diagnostics
• Transmission shift https://www.mathworks.com/help/autoblks/
ug/spark-ignition-engine-simple-speed-
density-breathing-model-1.html
 Types of flow meters in Automotive
● Vane/FLAP type (VAF)

● Optical Karman vortex type (VAF)

● Hot wire type (MAF)

• The first two measures intake air amount by volume but

hot wire type measures air mass.
Vane Type
Flap/vane type
 OPERATION
• The principle used here is the measurement of force
exerted in the sensor flap by the air passing through it .
 Electrical circuitry
• There are two types of vane type air flow meter. These
differ in the nature of their electrical circuitry, but the
components for the two types are the same.
• Type 1 – Vs will indicate the exact opening angle of the
measuring plate, and there fore the intake air volume.
• Type 2 – intake air volume =(VB-E2) / Vc-Vs
Optical Karman Vortex Type
• This type of air flow meter directly senses the intake
air volume optically.
Electrical circuit
Hot wire type air flow meter

• The hot wire type measures the mass airflow, and so such
compensation is not needed
 MAF
• Construction
• Honeycell screen
• Break up incoming air turbulence
• Carrier assembly
• Holds the sensing circuit
• Sandwiched between the flow body and diffuser
• [Thermistor]
• Measures the temperature of the incoming air
• Electronic module
• Sends digitized signal to ECM
sensor assembly (1), sensor element (2), partial
airflow measuring tube (3), and integrated
evaluation electronics (4).
OPERATING PRINCIPLE

• If a heated metal wire (hot wire) is exposed to airflow, its temperature

drops as the heat is removed from the wire.
• Resistance varies with temperature
• Temperature of the conductor (sensor
element) is maintained at constant calibrated
temperature.
• As air passes the heated conductor
• Heat is carried away by the passing air
• More current is required to maintain the pre
set temperature
• The current is translated in to voltage signal
ELECTRICAL CIRCUITRY
• Constant current type
• Constant temperature type -
MAF sensor with back stream detection (hot
film)
• Center element is heated by a centrally mounted heater resistor
• Evaluation electronics
• Two temperature dependent resistors
• Upstream
• Downstream
• With the engine stalled
• Temperature is the same on each side of the heating zone and resistance
values are identical
sensor element

Downstream
resistor

heater resistor
Upstream resistor diaphragm
• A diaphragm (1) on the sensor element (2) is heated by a
centrally
• mounted heater resistor (3), which is held at a constant
temperature.
• The temperature drops sharply each side of the heating
zone.
• Temperature of the diaphragm is registered to the
evaluation electronics by two temperature-dependent
resistors located on the upstream (4) and downstream (5)
side of the resistor.
• Upstream resistor is cooled
• Resistance of the element decreases
• Then as the air flows over the heating zone the air
temperature is increased
• The heated air then passes over the downstream
resistor
• Resistance of the element is higher
• This temperature differential is used to calculate the air
mass flow and is independent of absolute temperature.
• The differential is directional and enables the MAF to
detect direction of the incoming air.
 More on hot wire flow meter
The hot wire is made from for example
platinum whose electrical resistance R
increases with temperature. The wire
heats up when a current IH is passed
through it.
It is cooled when it is in an air flow. The
cooling process reduces the resistance of
the wire and increases the electric current
to produce an equilibrium between the
input power Pel and the power PV output
by the flow:
Manifold Pressure Sensor dec27
• This sensor detects the pressure variation of the intake
manifold and converts it to the voltage signal.
Detailed wiring diagram (GM)
• The ECU then calculates the basic injection volume and
the basic ignition advance angle on the basis of this
signal
• The ECU uses speed density formula to calculate air
density inside cylinder
Air density in cylinder = EP * EGR * VE * MAP
AT
• Where MAP - manifold absolute pressure, VE=volumetric
efficiency,
• EP=engine parameters (engine speed, eng. Temperature,
TP),
• EGR=EG flow,
• AT= air temperature
THROTTLE POSITION SENSOR
The throttle position signal is used for
• fuel cut off control (during deceleration or braking) and
• increasing the fuel volume during acceleration.
• (Additionally, this signal is used for automatic
transmission control also.)
Types
• On-Off Type

• Linear type

• Hall element type

Accelerator Pedal Position Sensor
• The accelerator pedal position sensor converts the amount
that the accelerator pedal is depressed (angle) to an
electrical signal that is sent to the engine ECU.
• In addition, to ensure reliability, this sensor outputs signals
from two systems with differing output characteristics.
• The TP sensor 1 signal voltage range is from about 0.7-4.3
volts as the throttle plate is moved from 0 percent to wide
open throttle (WOT).
• The TP sensor 2 voltage range is from about 4.3-0.7 volts
as the throttle plate is moved from 0 percent to WOT
• The ECM performs monitoring diagnosis checking the
voltage levels of both APP sensors, both TP sensors, and
the throttle actuator control motor circuit.
• It also monitors the spring return rate of both return
springs that are located inside the throttle body assembly
• This diagnosis is performed at different times based on
whether the engine is running, or not running.

• Every ignition cycle, the ECM performs a quick throttle

return spring test to make sure the throttle plate can
return to the 7 percent rest position from the 0 percent
position.

• This is to ensure that the throttle plate can be brought to

the rest position in case of an actuator motor circuit
failure.
Electrical circuitry

Linear type
Hall type App
G and NE Signal Generators
• The information from these two signals is combined by
the engine ECU to comprehensively detect the
crankshaft angle and engine speed.
• These two signals are not only very important to the
EFI systems but to the ESA system as well.
CKP and CMP
In distributor type
Electrical circuitry
Water Temperature Sensor/ Intake Air
Oxygen sensors
• Zirconia element type (narrow range)

• Titania element type (also used in early 90s)

• Broadband type (common this days)

Location
Oxygen Sensor (Zirconia element)
• To maximize the exhaust purification function of the engine
with TWC (Three-Way Catalytic Converter), the air-fuel
ratio must be kept within a narrow range around the
theoretical air-fuel ratio.
Electrical circuitry
Titania element type
• This oxygen sensor consists of a semiconductor element
made of titanium dioxide (TiO2, which is, like ZrO2, a kind of
ceramic).
• This sensor uses a thick film type titania element formed on
the front end of a laminated substrate to detect the oxygen
concentration in the exhaust gas.
OPERATION:
• The properties of titania are such that its resistance
changes in accordance with the oxygen concentration of
the exhaust gas.
• This resistance changes abruptly at the boundary between
a lean and a rich theoretical air-fuel ratio, as shown in the
graph.
Air-fuel (A/F) Ratio Sensor(broadband)
• The old O2 sensors can not measure how rich or lean the
air/fuel ratio is
• Conventional oxygen sensors are such that the output
voltage tends to change drastically at the boundary of the
theoretical air-fuel ratio.
• As with the oxygen sensor, the air-fuel ratio sensor detects
the oxygen concentration in the exhaust gas.

• In comparison, the air-fuel ratio sensor applies a constant

voltage to obtain a voltage that is nearly proportional to the
oxygen concentration.
• This improves the air-fuel ratio detection accuracy.
Con…
Operation
• A detection circuit in the ECM detects the change and
strength of the current flow and output the voltage
signal relatively proportional to the exhaust oxygen
content
• NB this voltage signal can only be measured by using the
diagnostic tester or OBD II compatible scan tool.
• The A/F sensor current can not be accurately measured
directly.
• The A/F sensor is designed so that at stoichiometry, there is
no current flow and voltage output by the detection circuit
is 3.3v
• A rich mixture which leaves a very little oxygen in the
exhaust stream, produces a negative current flow. The
detection circuit will produce a voltage below 3.3v.
• A lean mixture, which has more oxygen in the exhaust
stream, produces a positive current flow. The detection ckt
now produces
HINT
• Think of the A/F sensor as a generator capable of changing
polarity. When the fuel mixture is reach, the A/F generates
current in the negative direction. As the mixture gets leaner,
the A/F sensor generates in the positive direction. At
stoichiometric point there is no current flow.
• The detection ckt measures the direction and how much
current is being produced.
 Vehicle Speed Sensor

• The speed sensor detects the actual speed at which the

vehicle is running. The sensor outputs the SPD signal, and
the engine ECU uses this signal mainly to control the ISC
system and the air-fuel ratio during acceleration or
deceleration as well as other uses.
• The MRE (Magnetic Resistance Element) types are the main
type of speed sensor used, but recently many models use
the SPD signal from the ABS ECU.
MRE type
Reed switch type & Photo coupler type
Electromagnetic pickup type
Knock Sensor
STA (Starter) signal
NSW (Neutral Start Switch) signal
• This signal is only used in vehicles with an automatic transaxle, and is
used to detect the shift lever position.
• The engine ECU uses this signal to determine if the shift lever is in the
"P" or "N" position, or other position.
• The NSW signal is mainly used to control the ISC system.
A/C (Air Conditioner) signal
• The A/C signal differs depending on the vehicle model, but it
detects if the magnetic clutch of the air conditioner or the
air conditioner switch is ON.
• The A/C signal is used by the ignition timing control during
idling, ISC system control, fuel cut-off, and other functions.

Electrical load signal

• The electrical load signal is used to detect if the headlights,
rear window defogger, or other devices are ON.
Electrical circuitry
Variable Resistor

• The variable resistor is used to change the air-fuel ratio during idling
and to adjust the idling CO.
• The variable resistor is installed in models without an oxygen sensor
or air fuel ratio sensor.
• When the idle mixture adjusting screw is turned to the R direction,
the contact inside the resistor moves to increase the VAF terminal
voltage.
• Conversely, when the screw is turned to the L direction, the VAF
terminal voltage is decreased. When the VAF terminal voltage
increases, the engine ECU slightly increases the fuel injection volume
to make the air-fuel mixture a little richer.
Electrical circuitry
ACTUATORS AND THEIR
CONTROL CIRCUIT
Common automotive actuators
• Fuel pump
• Injectors
• Idle speed control valve
• Igniter
• Check engine lamp
• Oxygen sensor heater
• EGR valve
• Relays
• various types of electric motors,
Relays and Solenoids
Solenoids
• Solenoids: solenoids are digital actuators. One
terminal is attached to battery voltage while
the other is attached to the computer which
opens and closes the ground circuit as needed.
• When energized, the solenoid may extend a
plunger or armature to control functions such
as vacuum flow to various emission-related
systems or fuel injection.
• Most actuators are solenoids.
 Fuel pump control

The following types of fuel pump control are in use at

present:
1. ON-OFF control
- by fuel pump switch at the air flow meter
- by Engine ECU
2. ON-OFF control with speed
- by engine ECU and fuel pump control relay and
resistor
- By engine ECU and fuel pump ECU
ON-OFF control by Engine ECU (old)
operation
• Engine stop, ignition ON:

• Engine cranking :

• Engine started:

• Engine stopped:
ON-OFF control by fuel pump switch at the air
flow meter

Flap type air flow meter

ON-OFF control by Engine ECU (recent)
•Operation
Ignition switch ON
Ignition switch START
Engine running
ON-OFF control with fuel pump speed control
Some models control the fuel pump speed using the
fuel pump ECU instead of the circuit opening relay,
fuel pump control relay and resistor.
Two speed control with fuel pump ECU
Three speed fuel pump control
DLC 1
Fuel pump shut-off system
• Some vehicles have a mechanism where the fuel pump
control stops the fuel pump in the following conditions to
maintain safety.
1. When an airbag inflates:- the engine ECU will do the job
2. When vehicle crashes:- inertia switch will perform the job
• When the SRS of driver's, front passengers, or side airbag
inflates, the fuel cut-off control stops the fuel pump.
• When the engine ECU detects an airbag inflation signal
from the center airbag sensor assembly, the engine ECU
turns off the circuit opening relay to stop the fuel pump
operation.
• After the fuel cut-off control operates, the fuel cut-off
control can be cancelled by turning the ignition switch OFF,
causing the fuel pump to re-operate.
• When the vehicle crashes or roll over the fuel pump inertia
switch will turn off the pump to minimize fuel leakage.
Fuel pump cut-off by ECU
By inertia switch
Injector
• The injector is an electro-magnetically operated nozzle,
which injects fuel in accordance with signals from the ECU.
• Internal resistance of injectors: there are two types of
injector, which differ in their internal resistance value.
• High-resistance type: approximately 13.8 Ohms.
• Low-resistance type: approximately 1.5-3 Ohms.
Fuel Injection- solenoids

Figure : Schematic Drawing of Fuel Injector

Types of Fuel injection methods
• a) Simultaneous fuel injection:
• b) Group injection:
• c) Sequential fuel injection (Independent)
A. Injector control circuitry for high resistance
injectors
B. Injector control circuitry for low resistance injectors
C. INJECTOR DRIVE METHOD
CURRENT CONTROL METHOD

• improved injection response

• reduced ineffective injection duration.
Fuel injection duration and injection timing control
• The Engine ECU calculates the basic fuel injection
duration in accordance with two signals:
1. Intake air amount signal
2. Engine speed

It bases its calculations on a program stored in its memory.

Fuel Injector Signal

PWM-control
Piezo injector for common rail system (diesel)
• Extremely compact for high-precision injection
Fuel Injection Duration Control
• Determined by changing the injector injection duration.
1. The basic injection duration (by intake air and the engine speed
signals).
2. The corrective injection durations
• There are following corrections:
Start enrichment
Warm-up enrichment
Air-fuel ratio feedback correction (some models only)
Acceleration enrichment
Fuel cut-off
Power enrichment
Other corrections
Idle speed control (ISC)
• The ISCV is a device that controls the amount of the intake
air during idling using the signal from the engine ECU and
controls the idling speed.
• There are two types of ISCV as follows.
1. Type that bypasses the throttle valve and controls the
amount of the intake air:
2. Type that controls the amount of the intake air using the
throttle valve:
1. Type that bypasses the throttle valve and controls the
amount of the intake air:

• Because the throttle valve is completely closed during idling,

the ISCV bypasses the required air volume during idling.
This type controls the
idle speed by means
of the ISC valve to
change the volume of
air flowing through
the throttle valve by
pass in accordance
with signals from the
ECU.
Type 1 (ISCV)

• There are four types of ISC valve:

• Duty-control ACV (air control valve)
• Rotary solenoid type
• Stepper motor type
• On-off control VSV (Vacuum switching valve)
1. Duty control ACV type
 Duty ratio  Ontime
ontimeofftime

In actual operation current

to the coil is switched
on & off each 100 m sec
Rotary solenoid type
operation
Full electrical circuitry of rotary type
 3. stepper motor type
The step motor utilizes the principle of
pulling and rebounding of the permanent
magnet (rotor) when a magnetic field is
generated by electricity flowing in the
coil.
 Stepper motor
• Essentially, stepper motors are digital actuators; in other
words, they are either on or off.
• They move in fixed increments in both directions, and can
have over 120 steps of motion.
Eg. they are commonly used to enable the ECU to control idle
speed. In most fuel injection systems, the stepper motor
controls an idle air bypass built into the throttle body.
 Con…
• A stepper motor is a positioning device that increments its
shaft position in direct proportion to the number of current
pulses supplied to its windings.

• A digital positioning system without any position or speed

feedback is thus easily implemented at a much lower cost
than with other types of motors, simply by delivering a
counted number of switching signals to the motor.
4. On-off control VSV (Vacuum switching valve)
2. Type that controls the amount of the intake air using the
throttle valve:

• With this type, the throttle valve proper controls the

amount of the intake air during idling.
• This system is called ETCS-i (Electronic Throttle Control
System-intelligent), and conducts other control functions in
addition to amount of the intake air control during idling.
Electronic Throttle Actuator
Control (TAC)

The TAC system eliminates:

• the mechanical link

between the accelerator
pedal and the throttle plate.

• the need for a cruise control

module and idle air control
motor.
• The following is a list of TAC system components:
1) The accelerator pedal assembly includes the following components:
– The accelerator pedal.
– The accelerator pedal position (APP) sensor.
– The APP sensor 2.
2) The throttle body assembly includes the following components:
– The throttle position (TP) sensor 1.
– The TP sensor 2.
– The throttle actuator motor.
– The throttle plate.
3) The engine control module (ECM).
GM electronic throttle
control
(ETC) wiring diagram
O2 sensor heaters (GM)
Heater for A/F sensor (Toyota)
Exhaust Gas Recirculation Actuator
References
• Toyota training manuals
• GM training manuals
• Automotive power electronics, a book by the Power Semiconductor
Applications Laboratory, of the Philips Semiconductors product
division, Hazel Grove
• Understanding Automotive electronics, book by William B. Ribbens,
PhD.
Reading assignment on the following topics. Any one who submit a
comprehensive note or slides on one of the topics has a bonus mark. The
sources shall be valid.
• Air suspension
• Closed loop suspension, compensated suspension,
• Anti-skid braking system, retarders, regenerative braking, safety gauge air
bag-
• Crash resistance,
• Aerodynamics for modern vehicles, safety systems, materials and
standards.
• Preparation and maintenance of proper road network
• National highway network with automated roads and vehicles
• Satellite control of vehicle operation for safe and fast travel, GPS.