Automobile Electrical and Electronic Systems

476 Pages·2004·8.54 MB·English

by  Tom Denton

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Automobile Electrical and Electronic Systems
Third edition
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Automobile Electrical and Electronic
Systems
Third edition
Tom Denton
BA,AMSAE,MITRE,Cert.Ed.
Associate Lecturer, Open University
AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD
PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO
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Elsevier Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
200 Wheeler Road, Burlington, MA 01803
First published in Great Britain in 1995 by
Arnold, a member of Hodder Headline plc.
Second edition, 2000
Third edition, 2004
Copyright © 1995, 2000, 2004, Tom Denton. All rights reserved
The right of Tom Denton to be identified as the author of this work has been asserted
in accordance with the Copyright, Designs and Patents Act 1988
No part of this publication may be reproduced in any material form (including photocopying
or storing in any medium by electronic means and whether or not transiently or incidentally
to some other use of this publication) without the written permission of the copyright holder
except in accordance with the provisions of the Copyright, Designs and Patents Act 1988
or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham
Court Road, London, England W1T 4LP. Applications for the copyright holder’s written
permission to reproduce any part of this publication should be addressed to the publisher.
Permissions may be sought directly from Elsevier’s Science and Technology Rights Department
in Oxford, UK: phone: ((cid:2)44) (0) 1865 843830; fax: ((cid:2)44) (0) 1865 853333;
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British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
ISBN 0 7506 62190
For information on all Butterworth-Heinemann publications
visit our website at: www.bh.com
Composition by Charon Tec Pvt. Ltd
Printed and bound in Great Britain
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Contents
Preface ix
Introduction to the third edition x
Acknowledgements xi
1 Development of the automobile electrical system 1
1.1 A short history 1
1.2 Where next? 8
1.3 Self-assessment 10
2 Electrical and electronic principles 11
2.1 Safe working practices 11
2.2 Basic electrical principles 11
2.3 Electronic components and circuits 18
2.4 Digital electronics 26
2.5 Microprocessor systems 30
2.6 Measurement 35
2.7 Sensors and actuators 36
2.8 New developments 50
2.9 Diagnostics – electronics, sensors and actuators 52
2.10 New developments in electronic systems 54
2.11 Self-assessment 55
3 Tools and test equipment 57
3.1 Basic equipment 57
3.2 Multimeters 59
3.3 Specialist equipment 61
3.4 Dedicated equipment 66
3.5 On-board diagnostics 68
3.6 Case studies 69
3.7 Diagnostic procedures 72
3.8 New developments in test equipment 77
3.9 Self-assessment 80
4 Electrical systems and circuits 82
4.1 The systems approach 82
4.2 Electrical wiring, terminals and switching 83
4.3 Multiplexed wiring systems 91
4.4 Circuit diagrams and symbols 97
4.5 Case study 98
4.6 Electromagnetic compatibility (EMC) 100
4.7 New developments in systems and circuits 103
4.8 Self-assessment 108
5 Batteries 110
5.1 Vehicle batteries 110
5.2 Lead-acid batteries 111
5.3 Maintenance and charging 112
5.4 Diagnosing lead-acid battery faults 113
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vi Contents
5.5 Advanced battery technology 115
5.6 Developments in electrical storage 119
5.7 New developments in batteries 124
5.8 Self-assessment 127
6 Charging systems 128
6.1 Requirements of the charging system 128
6.2 Charging system principles 129
6.3 Alternators and charging circuits 130
6.4 Case studies 136
6.5 Diagnosing charging system faults 139
6.6 Advanced charging system technology 139
6.7 New developments in charging systems 143
6.8 Self-assessment 148
7 Starting systems 149
7.1 Requirements of the starting system 149
7.2 Starter motors and circuits 151
7.3 Types of starter motor 155
7.4 Case studies 161
7.5 Diagnosing starting system faults 165
7.6 Advanced starting system technology 165
7.7 New developments in starting systems 167
7.8 Self-assessment 168
8 Ignition systems 170
8.1 Ignition fundamentals 170
8.2 Electronic ignition 174
8.3 Programmed ignition 180
8.4 Distributorless ignition 184
8.5 Direct ignition 185
8.6 Spark-plugs 185
8.7 Case studies 189
8.8 Diagnosing ignition system faults 195
8.9 Advanced ignition technology 196
8.10 New developments in ignition systems 197
8.11 Self-assessment 197
9 Electronic fuel control 199
9.1 Combustion 199
9.2 Engine fuelling and exhaust emissions 205
9.3 Electronic control of carburation 208
9.4 Fuel injection 210
9.5 Diesel fuel injection 214
9.6 Case studies 219
9.7 Diagnosing fuel control system faults 236
9.8 Advanced fuel control technology 236
9.9 New developments 237
9.10 Self-assessment 238
10 Engine management 240
10.1 Combined ignition and fuel management 240
10.2 Exhaust emission control 244
10.3 Control of diesel emissions 248
10.4 Complete vehicle control systems 248
10.5 Case study – Mitsubishi GDI 251
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Contents vii
10.6 Case study – Bosch 258
10.7 Diagnosing engine management system faults 271
10.8 Advanced engine management technology 274
10.9 New developments in engine management 282
10.10 Self-assessment 289
11 Lighting 291
11.1 Lighting fundamentals 291
11.2 Lighting circuits 299
11.3 Gas discharge and LED lighting 299
11.4 Case studies 302
11.5 Diagnosing lighting system faults 310
11.6 Advanced lighting technology 310
11.7 New developments in lighting systems 312
11.8 Self-assessment 315
12 Auxiliaries 317
12.1 Windscreen washers and wipers 317
12.2 Signalling circuits 321
12.3 Other auxiliary systems 322
12.4 Case studies 324
12.5 Diagnosing auxiliary system faults 328
12.6 Advanced auxiliary systems technology 329
12.7 New developments in auxiliary systems 330
12.8 Self-assessment 331
13 Instrumentation 333
13.1 Gauges and sensors 333
13.2 Driver information 337
13.3 Visual displays 339
13.4 Case studies 343
13.5 Diagnosing instrumentation system faults 346
13.6 Advanced instrumentation technology 346
13.7 New developments in instrumentation systems 348
13.8 Self-assessment 355
14 Air conditioning 356
14.1 Conventional heating and ventilation 356
14.2 Air conditioning 358
14.3 Other heating systems 360
14.4 Case studies 361
14.5 Diagnosing air conditioning system faults 365
14.6 Advanced temperature control technology 366
14.7 New developments in temperature control systems 367
14.8 Self-assessment 368
15 Chassis electrical systems 370
15.1 Anti-lock brakes 370
15.2 Active suspension 374
15.3 Traction control 375
15.4 Automatic transmission 377
15.5 Other chassis electrical systems 379
15.6 Case studies 383
15.7 Diagnosing chassis electrical system faults 391
15.8 Advanced chassis systems technology 393
15.9 New developments in chassis electrical systems 395
15.10 Self-assessment 401
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viii Contents
16 Comfort and safety 403
16.1 Seats, mirrors and sun-roofs 403
16.2 Central locking and electric windows 405
16.3 Cruise control 407
16.4 In-car multimedia 409
16.5 Security 416
16.6 Airbags and belt tensioners 418
16.7 Other safety and comfort systems 421
16.8 Case studies 425
16.9 Diagnosing comfort and safety system faults 436
16.10 Advanced comfort and safety systems technology 437
16.11 New developments in comfort and safety systems 439
16.12 Self-assessment 441
17 Electric vehicles 443
17.1 Electric traction 443
17.2 Hybrid vehicles 446
17.3 Case studies 446
17.4 Advanced electric vehicle technology 453
17.5 New developments in electric vehicles 455
17.6 Self-assessment 456
18 World Wide Web 457
18.1 Introduction 457
18.2 Automotive technology – electronics 457
18.3 Self-assessment 458
Index 459
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Preface
In the beginning, say 115 years ago, a book on vehicle Current and older systems are included to aid the
electrics would have been very small. A book on reader with an understanding of basic principles.
vehicle electronics would have been even smaller! To set the whole automobile electrical subject in
As we continue our drive into the new millennium, context, the first chapter covers some of the signif-
the subject of vehicle electrics is becoming ever icant historical developments and dares yet again to
larger. Despite the book likewise growing larger, some speculate on the future …
aspects of this topic have inevitably had to be glossed What will be the next major step in automobile
over, or left out. However, the book still covers all of electronic systems? I predicted that the ‘auto-PC’
the key subjects and students, as well as general read- and ‘telematics’would be key factors last time, and
ers, will find plenty to read in the new edition. this is still the case. However, as 42V systems come
This third edition has once again been updated on line, there will be more electrical control of
and extended by the inclusion of more case studies systems that until recently were mechanically or
and technology sections in each chapter. Multiple hydraulically operated – steer-by-wire, for exam-
choice questions have also been added to most chap- ple. Read on to learn more …
ters.Subject coverage soon gets into a good depth; Also, don’t forget to visit http://www.automotive-
however, the really technical bits are kept in a sepa- technology.co.uk where comments, questions and
rate section of each chapter so you can miss them contributions are always welcome. You will also
out if you are new to the subject. find lots of useful information, updates and news
I have concentrated, where possible, on underlying about new books, as well as automotive software
electrical and electronic principles. This is because and web links.
new systems are under development all the time. Tom Denton, 2004