Automobile Electrical and Electronic Systems

740 Pages·2012·102.22 MB·English

by  Tom Denton

Automobile
Electrical and
Electronic Systems
Fourth Edition
(Automotive Technology: Vehicle Maintenance and Repair)
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Automobile
Electrical and
Electronic
Systems
Fourth Edition
Automotive Technology:
Vehicle Maintenance and Repair
T om Denton
BA FIMI MSAE

MIRTE Cert Ed
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Fourth Edition fi rst published in 2012
by Routledge
2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN
Simultaneously published in the USA and Canada
by Routledge
711 Third Avenue, New York, NY 10017
Routledge is an imprint of the Taylor & Francis Group, an informa business
© 1995, 2000, 2004, 2012 Tom Denton
The right of Tom Denton to be identifi ed as author of this work has been asserted by him in
accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form
or by any electronic, mechanical, or other means, now known or hereafter invented, including
photocopying and recording, or in any information storage or retrieval system, without permission
in writing from the publishers.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and
are used only for identifi cation and explanation without intent to infringe.
First edition published 1995 by Arnold, a member of Hodder Headline plc.
Third edition published 2004 by Elsevier
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging in Publication Data
[CIP data]
ISBN: 978-0-08-096942-8 (pbk)
ISBN: 978-0-080-96943-5 (ebk)
Typeset in Helvetica
by Refi neCatch Limited, Bungay, Suffolk
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C ontents
Preface xxiii
Acknowledgements xxv
Glossary of abbreviations and acronyms xxvii
Chapter 1 D evelopment of the automobile electrical system 1
1.1 A short history 1
1.1.1 Where did it all begin? 1
1.1.2 A chronological history 4
1.2 Where next? 12
1.2.1 Current developments 12
1.2.2 Auto-electrical systems in the next millennium 12
1.2.3 Automobile systems in the next millennium –
‘The modern driver’ 13
1.2.4 An eye on the future 15
1.2.5 The death of the car – Energise? 17
Chapter 2 E lectrical and electronic principles 19
2.1 Safe working practices 19
2.1.1 Introduction 19
2.1.2 Risk assessment and reduction 19
2.2 Basic electrical principles 19
2.2.1 Introduction 19
2.2.2 Electron fl ow and conventional fl ow 20
2.2.3 Effects of current fl ow 21
2.2.4 Fundamental quantities 22
2.2.5 Describing electrical circuits 22
2.2.6 Conductors, insulators and semiconductors 23
2.2.7 Factors affecting the resistance of a conductor 23
2.2.8 Resistors and circuit networks 23
2.2.9 Magnetism and electromagnetism 25
2.2.10 Electromagnetic induction 26
2.2.11 Mutual induction 26
2.2.12 Defi nitions and laws 26
2.3 Electronic components and circuits 29
2.3.1 Introduction 29
2.3.2 Components 29
2.3.3 Integrated circuits 33
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vi Contents
2.3.4 Amplifi ers 34
2.3.5 Bridge circuits 37
2.3.6 Schmitt trigger 37
2.3.7 Timers 38
2.3.8 Filters 38
2.3.9 Darlington pair 40
2.3.10 Stepper motor driver 40
2.3.11 Digital to analogue conversion 41
2.3.12 Analogue to digital conversion 42
2.4 Digital electronics 43
2.4.1 Introduction to digital circuits 43
2.4.2 Logic gates 43
2.4.3 Combinational logic 44
2.4.4 Sequential logic 45
2.4.5 Timers and counters 46
2.4.6 Memory circuits 47
2.4.7 Clock or astable circuits 49
2.5 Microprocessor systems 49
2.5.1 Introduction 49
2.5.2 Ports 49
2.5.3 Central processing unit (CPU) 50
2.5.4 Memory 50
2.5.5 Buses 50
2.5.6 Fetch–execute sequence 51
2.5.7 A typical microprocessor 51
2.5.8 Microcontrollers 53
2.5.9 Testing microcontroller systems 54
2.5.10 Programming 54
2.6 Measurement 55
2.6.1 What is measurement 55
2.6.2 A measurement system 56
2.6.3 Sources of error in measurement 56
2.7 Sensors 58
2.7.1 Thermistors 58
2.7.2 Thermocouples 59
2.7.3 Inductive sensors 60
2.7.4 Hall Effect 61
2.7.5 Strain gauges 62
2.7.6 Variable capacitance 63
2.7.7 Variable resistance 64
2.7.8 Accelerometer (knock sensors) 66
2.7.9 Linear variable differential transformer (LVDT) 68
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Contents vii
2.7.10 Hot wire air fl ow sensor 69
2.7.11 Thin fi lm air fl ow sensor 70
2.7.12 Vortex fl ow sensor 70
2.7.13 Pitot tube 71
2.7.14 Turbine fl uid fl ow sensor 71
2.7.15 Optical sensors 72
2.7.16 Oxygen sensors 72
2.7.17 Light sensors 73
2.7.18 Thick-fi lm air temperature sensor 74
2.7.19 Methanol sensor 74
2.7.20 Rain sensor 74
2.7.21 Oil sensor 75
2.7.22 Dynamic vehicle position sensors 75
2.7.23 Summary 76
2.8 Actuators 77
2.8.1 Introduction 77
2.8.2 Solenoid actuators 77
2.8.3 EGR valve 78
2.8.4 Motorized actuators 79
2.8.5 Stepper motors 80
2.8.6 Synchronous motors 84
2.8.7 Thermal actuators 84
2.9 Testing electronic components, sensors and actuators 84
2.9.1 Introduction 84
2.9.2 Testing sensors 85
2.9.3 Testing actuators 86
Chapter 3 T ools and equipment 87
3.1 Basic equipment 87
3.1.1 Introduction 87
3.1.2 Basic hand tools 87
3.1.3 Accuracy of test equipment 88
3.1.4 Multimeters 89
3.1.5 Logic probe 91
3.2 Oscilloscopes 93
3.2.1 Introduction 93
3.2.2 Waveforms 94
3.3 Scanners/Fault code readers and analysers 95
3.3.1 On-board diagnostics introduction 95
3.3.2 Serial port communications 95
3.3.3 OBD2 signal protocols 96
3.3.4 AutoTap OBD scanner 97
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viii Contents
3.3.5 Bosch KTS diagnostic equipment 99
3.3.6 Engine analysers 101
3.4 Emission testing 103
3.4.1 Introduction 103
3.4.2 Exhaust gas measurement 103
3.4.3 Exhaust analyser 104
3.4.4 Emission limits 106
3.5 Pressure testing 108
3.5.1 Introduction 108
3.5.2 Automotive pressure oscilloscope transducer 109
3.5.3 Breakout boxes 110
3.6 Diagnostic procedures 110
3.6.1 Introduction 110
3.6.2 The ‘theory’ of diagnostics 111
Chapter 4 Electrical systems and circuits 113
4.1 The systems approach 113
4.1.1 What is a system? 113
4.1.2 Vehicle systems 113
4.1.3 Open loop systems 114
4.1.4 Closed loop systems 114
4.1.5 Summary 115
4.2 Electrical wiring, terminals and switching 115
4.2.1 Cables 115
4.2.2 Colour codes and terminal designations 116
4.2.3 Harness design 119
4.2.4 Printed circuits 122
4.2.5 Fuses and circuit breakers 123
4.2.6 Terminations 125
4.2.7 Switches 127
4.3 Multiplexing 129
4.3.1 Limits of the conventional wiring system 129
4.3.2 Multiplex data bus 131
4.3.3 Overview 131
4.3.4 Controller Area Network (CAN) 133
4.3.5 CAN data signal 135
4.3.6 Local Interconnect Network (LIN) 139
4.3.7 FlexRay 141
4.4 Media oriented systems transport (MOST) 144
4.4.1 Introduction 144
4.4.2 MOST network 144
4.4.3 Protocol 145
Contents ix
4.4.4 MOST applications 146
4.4.5 Consumer device gateway 146
4.4.6 Summary 146
4.5 Automotive Ethernet 147
4.5.1 Introduction 147
4.5.2 Overview 147
4.6 Circuit diagrams and symbols 148
4.6.1 Symbols 148
4.6.2 Conventional circuit diagrams 148
4.6.3 Layout or wiring diagrams 148
4.6.4 Terminal diagrams 148
4.6.5 Current fl ow diagrams 150
4.7 Electromagnetic compatibility 150
4.7.1 Introduction 150
4.7.2 EMC problems 150
4.8 Central electrical control 153
4.8.1 Overview 153
4.8.2 Ford generic electronic module (GEM) 155
4.8.3 Communication between modules 161
4.8.4 Summary 166
4.9 Connected cars 166
4.9.1 Introduction 166
4.9.2 Smart cars and traffi c systems 166
4.9.3 Wi-Fi cars 169
4.9.4 Bluetooth 170
4.9.5 Applications (apps) 171
4.9.6 Vision enhancement 172
4.9.7 Self-help 173
4.9.8 Big brother 174
4.9.9 When computers go wrong 174
4.9.10 Summary 175
Chapter 5 Batteries 177
5.1 Vehicle batteries 177
5.1.1 Requirements of the vehicle battery 177
5.1.2 Choosing the correct battery 178
5.1.3 Positioning the vehicle battery 178
5.2 Lead-acid batteries 179
5.2.1 Construction 179
5.2.2 Battery rating 180
5.3 Maintenance, charging and testing batteries 182
5.3.1 Maintenance 182
5.3.2 Charging the lead-acid battery 182
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