NEGROS ORIENTAL STATE UNIVERSITY
Bayawan-Sta. Catalina Campus
COLLEGE OF INDUSTRIAL TECHNOLOGY
AUTOMOTIVE ELECTRICITY AND ELECTRONICS
MODULE 1 IN AUTO 201 (Automotive Electricity and Electronics)
Preparede by:
Junryl S. Español
Instructor
Contact Info:
Facebook Account: (Lyrnuj Cidroz) [Link]
Number: 09675203978
MODULE 1
Automotive Electricity and Electronics
Introduction
Working with the electrical systems can be challenging, yet very rewarding; however, it can also be
very frustrating at times. For many people, learning electrical systems can be a struggle. It is my hope
that I am able to present the material to you in such a manner that you will not only understand
electrical systems but will excel at it. There are many ways the theory of electricity can be explained,
and many metaphors can be used. Some compare electricity to a water flow, while others explain it in
a purely scientific fashion. Everyone learns differently. I am presenting electrical theory in a manner
that I hope will be clear and concise.
COURSE LEARNING OUTCOMES
Upon completion of this module, the students will be able to understand and describe:
■ The importance of learning automotive electrical systems.
■ The role of electrical systems in today’s vehicles.
■ The interaction of the electrical systems.
■ The purpose of the starting system.
■ The purpose of the charging system.
■ The role of the computer in today’s vehicles.
■ The purpose of vehicle communication networks.
■ The purpose of various electronic accessory systems.
■ The purpose of passive restraint systems.
■ The purpose of alternate propulsion systems.
Contents of the Module
This module contains the following lessons:
Lesson 1: The Importance of Electricity in Automobile
Lesson 2: Types of Signal and Communication System
Directions on how to use this module Properly
In order to benefit profoundly from this module, please be guided by all the key points presented
below.
1. This lesson contains two (2) lessons. Each lesson is explained substantially. Read the
explanations thoroughly so that you would understand the lesson entirely.
2. On the first page of each lesson, you will find the specific learning outcome (SLOs) of
each lesson. SLOs are knowledge and skills you are expected to acquire at the end of the
lesson. Read them heartily.
3. You must answer the learning Activities / Exercises (LAEs). The LAEs are designed to
help you acquire the SLOs.
4. Feel free to chat, call, text or send me an email if you have questions, reactions or
reflections about the module’s contents or activities.
5. The practice Task/Assessment and assignment shall be checked by me.
LESSON 1 – Automotive Electrical System
Specific Learning Outcomes:
1. Explain the basic role and function of electricity in automobiles.
2. Discuss the different automotive electrical systems.
3. Explains the different parts and functions of each system.
The Importance of Electricity in Automobile
In the past, electrical systems were basically stand-alone. For example, the ignition system was only
responsible for supplying the voltage needed to fi re the spark plugs. Ignition timing was controlled
by vacuum and mechanical advance systems. Today there are very few electrical systems that are still
independent. Today, most manufactures network their electrical systems together through
computers. This means that information gathered by one system can be used by another. The result
may be that a faulty component may cause several symptoms. Consider the following example. The
wiper system can interact with the headlight system to turn on the headlights whenever the wipers are
turned on. The wipers can interact with the vehicle speed sensor to provide for speed-sensitive wiper
operation. The speed sensor may provide information to the antilock brake module. The antilock
brake module can then share this information with the transmission control module, and the
instrument cluster can receive vehicle speed information to operate the speedometer. If the vehicle
speed sensor should fail, this could result in no antilock brake operation and a warning light turned
on in the dash. But it could also result in the speedometer not functioning, the transmission not
shifting, and the wipers not operating properly.
Automotive Starting System
Starting system - is a combination of mechanical and electrical parts that work together to start the
engine. The starting system is designed to change the electrical energy, which is being supplied by
the battery, into mechanical energy. For this conversion to be accomplished, a starter motor is used.
The basic starting system includes the following components (Figure 1-1):
1. Battery. 5. Starter motor.
2. Cable and wires. 6. Flywheel gear
3. Ignition switch. 7. Starting safety switch
4. Relay / Solenoid
Starter motor (Figure 1-2) - requires large amounts of current (up to 400 amperes) to generate the
torque needed to turn the engine. The conductors used to carry this amount of current (battery cables)
must be large enough to handle the current with very little voltage drop. It would be impractical to
place a conductor of this size into the wiring harness to the ignition switch. To provide control of the
high current, all starting systems contain some type of magnetic switch. There are two basic types of
magnetic switches used: the solenoid and the relay.
Ignition switch - is the power distribution point for most of the vehicle’s primary electrical systems.
The ignition switch is spring loaded in the start position. This momentary contact automatically
moves the contacts to the RUN position when the driver releases the key. All other ignition switch
positions are detent positions.
Neutral safety switch - is used on vehicles equipped with automatic transmissions. It opens the
starter control circuit when the transmission shift selector is in any position except PARK or
NEUTRAL. Vehicles equipped with automatic transmissions require a means of preventing the
engine from starting while the transmission is in gear. Without this feature, the vehicle would lunge
forward or backward once it was started, causing personal or property damage. The normally open
neutral safety switch is connected in series into the starting system control circuit and is usually
operated by the shift lever (Figure 1-3). When in the PARK or NEUTRAL position, the switch is
closed, allowing current to flow to the starter circuit. If the transmission is in a gear position, the
switch is opened and current cannot flow to the starter circuit.
Many vehicles that are equipped with manual transmissions use a similar type of safety switch. The
start/clutch interlock switch is usually operated by movement of the clutch pedal (Figure 1-4).
Charging System
The automotive storage battery is not capable of supplying the demands of the electrical systems for
an extended period of time. Every vehicle must be equipped with a means of replacing the energy
that is being drawn from the battery.
Charging system - is used to restore to the battery the electrical power that was used during engine
starting. It is the vehicle’s charging system that generates the current to operate all of the electrical
accessories while the engine is running. The purpose of the charging system is to convert the
mechanical energy of the engine into electrical energy to recharge the battery and run the electrical
accessories. When the engine is first started, the battery supplies all the current required by the
starting and ignition systems.
As illustrated in Figure 1-5, the entire charging system consists of the following components:
1. Battery.
2. AC generator or DC generator.
3. Drive belt.
4. Voltage regulator.
5. Charge indicator (lamp or gauge).
6. Ignition switch.
7. Cables and wiring harness.
All charging systems use the principle of electromagnetic induction to generate the electrical power.
Voltage regulator - controls the output voltage of the AC generator, based on charging system
demands, by controlling field current. The battery, and the rest of the electrical system, must be
protected from excessive voltages. To prevent early battery and electrical system failure, regulation
of the charging system is very important. Also, the charging system must supply enough current to
run the vehicle’s electrical accessories when the engine is running.
Lighting System
Lighting system - consists of all of the lights used on the vehicle (Figure 1-6). This includes
headlights, front and rear park lights, front and rear turn signals, side marker lights, daytime running
lights, cornering lights, brake lights, back-up lights, instrument cluster backlighting, and interior
lighting.
The lighting system of today’s vehicles can consist of more than 50 light bulbs and hundreds of feet
of wiring. Incorporated within these circuits are circuit protectors, relays, switches, lamps, and
connectors. In addition, more sophisticated lighting systems use computers and sensors. Since the
lighting circuits are largely regulated by federal laws, the systems are similar among the various
manufacturers. However, there are variations that exist in these circuits. With the addition of solid-
state circuitry in the automobile, manufacturers have been able to incorporate several different
lighting circuits or modify the existing ones. Some of the refinements that were made to the lighting
system include automatic headlight washers, automatic headlight dimming, automatic on/off with
timed-delay headlights, and illuminated entry systems. Some of these systems use sophisticated body
computer–controlled circuitry and fibre optics. Some manufacturers have included such basic circuits
as turn signals into their body computer to provide for pulse-width dimming in place of a flasher unit.
The body computer can also be used to control instrument panel lighting based on inputs that include
if the side marker lights are on or off. By using the body computer to control many of the lighting
circuits, the amount of wiring has been reduced. In addition, the use of computer control of these
systems has provided a means of self-diagnosis in some applications. Today, high-density discharge
(HID) headlamps are becoming an increasingly popular option on many vehicles. These headlights
provide improved lighting over conventional headlamps.
Instrument Panel
Instrumentation systems (Figure 1-7) - monitor the various vehicle operating systems and provide
information to the driver about their correct operation. Warning devices also provide information to
the driver; however, they are usually associated with an audible signal. Some vehicles use a voice
module to alert the driver to certain conditions.
Electrical Accessories
Electrical accessories - provide for additional safety and comfort. There are many electrical
accessories that can be installed into today’s vehicles. These include safety accessories such as the
horn, windshield wipers, and windshield washers. Comfort accessories include the blower motor,
electric defoggers, power mirrors, power windows, power seats, and power door locks.
Automotive Horns
Horn - a device that produces an audible warning signal (Figure 1-8). Automotive electrical horns
operate on an electromagnetic principle that vibrates a diaphragm to produce a warning signal. This
vibration of the diaphragm is repeated several times per second. As the diaphragm vibrates it causes a
column of air that is in the horn to vibrate. The vibration of the column of air produces the sound.
Windshield Wipers
Windshield wipers - mechanical arms that sweep back and forth across the windshield to remove
water, snow, or dirt (Figure 1-9). The operation of the wiper arms is through the use of a wiper
motor. Most windshield wiper motors use permanent magnet fields, or electromagnetic field motors.
Electric Defoggers
Defoggers - heat the rear window to remove ice and/or condensation. Some vehicles use the same
circuit to heat the outside driver-side mirror. When electrons are forced to flow through a resistance,
heat is generated. Rear window defoggers use this principle of controlled resistance to heat the glass.
The resistance is through a grid that is baked on the inside of the glass (Figure 1-10). The system may
incorporate a timer circuit that controls the relay.
Power Mirrors
Power mirrors are outside mirrors that are electrically positioned from the inside of the driver
compartment. The electrically controlled mirror allows the driver to position the outside mirrors by
use of a switch. The mirror assembly will use built-in, dual-drive, reversible permanent magnet (PM)
motors.
Power Windows
Power windows are windows that are raised and lowered by use of electrical motors. Many vehicle
manufacturers have replaced the conventional window crank with electric motors that operate the
side windows. The motor used in the power window system is a reversible PM or two-field winding
motor.
The power window system usually consists of the following components:
1. Master control switch. 3. Individual window drive motors.
2. Individual control switches.
Electric Door Locks
Electric door locks use either a solenoid or a permanent magnet reversible motor to lock and unlock
the door. Many vehicles are equipped with automatic door locks that are activated when the gear shift
lever is placed in the DRIVE position. The doors unlock when the selector is returned to the PARK
position.
LESSON 2 - Automotive Electronic System
Specific Learning Outcomes
1. Familiarized the different Automotive electronic systems
2. Enumerate the different components and functions of each system
3. Explain the function of the Electronic Control module
Electronic Control Modules (ECM)
Electronic Control Module (computer) – an electronic device that stores and processes data and is
capable of operating other devices (Figure 1-11). The use of computers on automobiles has expanded
to include control and operation of several functions, including climate control, lighting circuits,
cruise control, antilock braking, electronic suspension systems, and electronic shift transmissions.
Some of these are functions of what is known as a body control module (BCM). Some body
computer–controlled systems include direction lights, rear window defogger, illuminated entry,
intermittent wipers, and other systems that were once thought of as basic. A computer processes the
physical conditions that represent information (data).
The operation of the computer is divided into four basic functions:
1. Input. 3. Storage.
2. Processing. 4. Output.
Vehicle Communication Networks
Most manufacturers now use a system of vehicle communications called multiplexing (MUX) to
allow control modules to share information (Figure 1-12). Multiplexing provides the ability to use a
single circuit to distribute and share data between several control modules throughout the vehicle.
Because the data is transmitted through a single circuit, bulky wiring harnesses are eliminated.
Vehicle manufacturers will use multiplexing systems to enable different control modules to share
information. A MUX wiring system uses bus data links that connect each module. The term bus
refers to the transporting of data from one module to another. Each module can transmit and receive
digital codes over the bus data links. The signal sent from a sensor can go to any one of the modules
and can be shared by the other modules.
Electronic Accessory Systems
With the growing use of computers, most systems can be controlled electronically. This provides for
improved monitoring of the systems for proper operation and the ability to detect if a fault occurs.
The systems that are covered in this book include the following:
1. Electronic Cruise Control Systems
Cruise control - is a system that allows the vehicle to maintain a pre-set speed with the driver’s foot
off of the accelerator. Most cruise control systems are a combination of electrical and mechanical
components.
2. Memory Seats
Memory seat - feature allows the driver to program different seat positions that can be recalled at the
push of a button. The memory seat feature is an addition to the basic power seat system. Most
memory seat systems share the same basic operating principles, the difference being in programming
methods and number of positions that can be programmed. Most systems provide for two seat
positions to be stored in memory.
An easy exit feature may be an additional function of the memory seat that provides for easier
entrance and exit of the vehicle by moving the seat all the way back and down. Some systems also
move the steering wheel up and to full retract.
3. Electronic Sunroofs.
Some manufacturers have introduced electronic control of their electric sunroofs. These systems
incorporate a pair of relay circuits and a timer function into the control module. Motor rotation is
controlled by relays that are activated according to signals received from the slide, tilt, and limit
switches.
4. Anti-theft Systems
Anti-theft system is a deterrent system designed to scare off would-be thieves by sounding alarms
and/or disabling the ignition system. Figure 1-13 illustrates many of the common components that are
used in an antitheft system. These components include:
1. An electronic control module.
2. Door switches at all doors.
3. Trunk key cylinder switch.
4. Hood switch.
5. Starter inhibitor relay.
6. Horn relay.
7. Alarm.
In addition, many systems incorporate the exterior lights into the system. The lights are flashed if the
system is activated. Some systems use ultrasonic sensors that will signal the control module if
someone attempts to enter the vehicle through the door or window. The sensors can be placed to
sense the parameter of the vehicle and sound the alarm if someone enters within the protected
parameter distance. Doors when the required conditions are met. Many automobile manufacturers are
incorporating automatic door locks as an additional safety and convenience system. Most systems
lock the doors when the gear selector is placed in DRIVE, the ignition switch in RUN, and all doors
are shut. Some systems will lock the doors when the gear shift selector is passed through the
REVERSE position, while others do not lock the doors unless the vehicle is moving 15 mph or faster.
The system may use the body computer or a separate controller to control the door lock relays. The
controller (or body computer) takes the place of the door lock switches for automatic operation.
Keyless Entry
Keyless entry system - allows the driver to unlock the doors or the deck lid (trunk) from outside of
the vehicle without the use of a key. The main components of the keyless entry system are the control
module, a coded-button keypad located on the driver’s door (Figure 1-14), and the door lock motors.
Some keyless entry systems can be operated remotely. Pressing a button on a hand-held transmitter
will allow operation of the system from distances of 25 to 50 feet (Figure 1-15). Recently, most
manufacturers have made available systems of remote engine starting and keyless start. These are
usually designed into the function of the remote keyless entry system.
Passive Restraint Systems
Federal regulations have mandated the use of automatic passive restraint systems in all vehicles
sold in the United States after 1990. Passive restraints are ones that operate automatically, with no
action required on the part of the driver or occupant.
Air bag systems
Air bag - are on all of today’s vehicles. The need to supplement the existing restraint system during
frontal collisions has led to the development of the supplemental inflatable restraint (SIR) or air bag
systems (Figure 1-16). A typical air bag system consists of sensors, a diagnostic module, a clock
spring, and an air bag module. Figure 1-17 illustrates the typical location of the common components
of the SIR system.
Alternate Propulsion Systems
Due to the increase in regulations concerning emissions and the public’s desire to become less
dependent on foreign oil, most major automotive manufacturers have developed alternative fuel or
alternate power vehicles. Since the 1990s, most major automobile manufacturers have developed an
electric vehicle (EV). The primary advantage of an EV is a drastic reduction in noise and emission
levels. General Motors introduced the EV1 electric car to the market in 1996. The original battery
pack in this car contained twenty-six 12-volt batteries that delivered electrical energy to a three-phase
102-kilowatt (kW) AC electric motor. The electric motor is used to drive the front wheels. The
driving range is about 70 miles (113 km) of city driving or 90 miles (145 km) of highway driving.
EV battery limitation was a major stumbling block to most consumers. One method of improving the
electric vehicle resulted in the addition of an on-board power generator that is assisted by an internal
combustion engine, resulting in the hybrid electric vehicle (HEV). Basically, the hybrid electric
vehicle relies on power from the electric motor, the engine, or both (Figure 1-18). When the vehicle
moves from a stop and has a light load, the electric motor moves the vehicle. Power for the electric
motor comes from stored energy in the battery pack. During normal driving conditions, the engine is
the main power source. Engine power is also used to rotate a generator that recharges the storage
batteries. The output from the generator may also be used to power the electric motor, which is run to
provide additional power to the powertrain. A computer controls the operation of the electric motor,
depending on the power needs of the vehicle. During full throttle or heavy load operation, additional
electricity from the battery is sent to the motor to increase the output of the powertrain.
Fuel cell – powered vehicles have a very good chance of becoming the drives of the future. They
combine the reach of conventional internal combustion engines with high efficiency, low fuel
consumption, and minimal or no pollutant emission. At the same time, they are extremely quiet.
Because they work with regenerative fuel such as hydrogen, they reduce the dependence on crude oil
and other fossil fuels.
A fuel cell–powered vehicle (Figure 1-19) is basically an electric vehicle. Like the electric vehicle, it
uses an electric motor to supply torque to the drive wheels. The difference is that the fuel cell
produces and supplies electric power to the electric motor instead of batteries. Most of the vehicle
manufacturers and several independent laboratories are involved in fuel cell research and
development programs. A number of prototype fuel cell vehicles have been produced, with many
being placed in fleets in North America and Europe.
Things to Remember:
Air bag systems Electric vehicle (EV)
Antitheft system Electrical accessories
Automatic door locks (ADL) Fuel cell
Charging system Electric defoggers
Electronic Control Module (ECM) Windshield wipers
Cruise control Heated windshield
Voltage regulator Hybrid electric vehicle (HEV)
Horn Intelligent windshield
Ignition switch Keyless entry system
Wiper systems Neutral safety switch
Lighting system Vehicle instrumentation system
Instrument Panel Starting system
Memory seat Power windows
Multiplexing Power mirrors
Network Power door locks
Passive restraint systems
■ the starting system is a combination of mechanical and electrical parts that work together to start
the engine.
■ the charging system replaces the electrical power used by the battery and to provide current to
operate all of the electrical accessories while the engine is running.
■ the lighting system consists of all of the lights used on the vehicle.
■ Vehicle instrumentation systems monitor the various vehicle operating systems and provide
information to the driver.
■ Electrical accessories provide additional safety and comfort.
■ Many of the basic electrical accessory systems have electronic controls added to them to provide
additional features and enhancement.
■ Computers are electronic devices that gather, store, and process data.
■ Most vehicles use a multiplexing system to share information between computer systems.
■ the memory seat feature allows the driver to program different seat positions that can be recalled at
the push of a button.
■ Some manufacturers have introduced electronic control of their electric sunroofs. These systems
incorporate a pair of relay circuits and a timer function into the control module.
■ Antitheft systems are deterrent systems designed to scare off would-be thieves by sounding alarms
and/or disabling the ignition system.
■ Automatic door locks is a passive system used to lock all doors when the required conditions are
met. Many automobile manufacturers are incorporating the system as an additional safety and
convenience feature.
■ Passive restraints operate automatically, with no action required on the part of the driver or
occupant.
■ Electric vehicles powered by an electric motor run off a battery pack.
■ the hybrid electric vehicle relies on power from the electric motor, the engine, or both.
■ A fuel cell–powered vehicle is basically an electric vehicle, except that the fuel cell produces and
supplies electric power to the electric motor instead of batteries.
Learning Activities / Exercises
INSTRUCTIONS:
1. Write your answers on a SHORT BOND PAPER (Answers Only) with your Name, Section
and Module number.
2. All answers must be HAND WRITTEN
3. Take a CLEAR PICTURE of your answer sheets (names must be included).
4. Send the pictures taken to me by PRIVATE MESSAGE via FACEBOOK MESSENGER.
5. To those who can’t comply through online, put your answer sheets in a small brown envelop
with your Name, Subject and Section then submit it to NORSU GATE DROP BOX addressed
to CIT.
Essays: In your own words and understanding, answer the following:
1. Describe your level of comfort concerning automotive electrical systems.
2. Explain why you feel it is important to understand the operation of the automotive electrical
system.
3. Explain how the use of computers has changed the automotive electrical system.
4. Explain the difference between an electric vehicle and a fuel-cell vehicle.
5. Explain the basics of HEV operation.
6. What is the purpose of the keyless entry system?
7. What safety benefits can be achieved from the automatic door lock system?
8. What is the purpose of the starting system?
9. What is the purpose of the charging system?
10. What is the function of the air bag system?
Fill in the Blanks: Write the correct answers on your answer sheets.
1. Today, most manufactures ________ their electrical systems together through computers.
2. Vehicle instrumentation systems ________the various operating systems and provide information
to the driver about their correct operation.
3. A ________ is an electronic device that stores and processes data.
4. The starting system is designed to change the _________ energy into mechanical energy.
5. The feature is an additional function of the memory seat that provides for easier entrance and exit
of the vehicle.
6. The _______ is the power distribution point for most of the vehicle’s primary electrical systems.
7. The _______ system is a deterrent system.
8. The purpose of the charging system is to convert the ____________energy of the engine
into ________ energy.
9. __________ restraints operate automatically with no action required on the part of the driver.
10. The ___________ uses an on-board power generator that is assisted by an internal combustion
engine.
Multiple-Choice: Write the corresponding letter of the correct answer on your answer sheet.
1. Electric vehicles power the motor by:
A. A generator.
B. A battery pack.
C. An engine.
D. None of the above.
2. The charging system:
A. Provides all electrical energy to operate the electrical system while the engine is running.
B. Restores the energy to the battery after starting the engine.
C. Uses the principle of magnetic induction to generate electrical power.
D. All of the above.
3. The memory seat system:
A. Operates separately of the power seat system.
B. Requires the vehicle to be moving before the seat position can be recalled.
C. Allows for the driver to program different seat positions that can be recalled at the push of
a button.
D. Can only be equipped on vehicles with manual position seats.
4. The following are true about the easy exit feature EXCEPT:
A. It is an additional function of the memory seat.
B. the driver’s door is opened automatically.
C. the seat is moved all the way back and down.
D. the system may move the steering wheel up.
5. The following are components of the starting system EXCEPT:
A. The flywheel ring gear.
B. Neutral safety switch.
C. Harmonic balancer.
D. Battery.
6. Which of the following is the most correct statement?
A. Automotive electrical systems are interlinked with each other.
B. All automotive electrical systems work the same on every vehicle.
C. Manufactures are required by Federal legislation to limit the number of computers used on
today’s vehicles.
D. All of the above.
7. Automotive horns operate on the principle of:
A. Induced voltage.
B. Depletion zone bonding.
C. Frequency modulation.
D. Electromagnetism.
8. The purpose of multiplexing is to:
A. Increase circuit loads to a sensor.
B. Prevent electromagnetic interference.
C. Allow computers to share information.
D. Prevent multiple system failures from occurring.
9. The following are true about the air bag system EXCEPT:
A. It is an active system.
B. It is a supplemental system.
C. It is mandated by the federal government.
D. Deployment is automatic.
10. Alternate propulsion systems include:
A. Electric vehicles.
B. Hybrid vehicles.
C. Fuel cell vehicles.
D. All of the above.
References:
1. Willam H. Crouse , Donald L. Anglin (2013), Automotive Mechanics 10th Edition,
Mamillan/McGraw-Hill
2. [Link]
[Link]
3. [Link]
4. Tom Denton (2004), Automobile Electrical and Electronic Systems 3rd edition, Elsevier
Butterworth Heinmann, Amsterdam Boston Heidelberg London
5. James D. Halderman (2002), Automotive Electricity and Electronics
6. James D. Halderman (2017),Automotive Electricity and Electronics 5th edition, Pearson
