description

Gomponent

UW01- Fundamentals
of electricity
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Gomponent
description
UW 01 - Fundamentalsof electricity
fudmedby:|mpim/Edfujl9'u07/ve€d:1

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 description
Component
UW01 - Fundamentals
of electricity

1. Introductionto electricity/ electronics

1.1Definitions

>1.1.1Voltage
Anelectdcal
voltageisproduced between twopoints(e.9.theterminals ifthercarea different
ona battery)
number ateachofthese
ofeleclrons poinb.
Themagnitude inelectrons
ofthisdifierence determinesthesizeofthevoltage.

Charge separationinthevoltagesourc€(fig'l) results

inthegenerationofanelectrical
voltage.
Forexam-
ple,thechemical insidea dlargingbattery
reaction causes negatively
charged to
electrons migraie
tolhe
negativeterminal.
Thismeans lhereisa shortageandsuelusofelectrons atthepositive
andnegative respectively.
lerminals
Thisresultsina voltage
diference between thetwopoles. Thehigherthecharge thehigherthe
differenlial,
diferenceinvoltage(potential
difference).

1 ' ., t-.t l- d.rg rdc It J

Fig.1:Voltagegenerated
by chargeseparation

voltageis produced
Electrical thesedifferent-sized
in an attemptto compensate charges.
Voltagecausescurrentto flow.
Theunitof voltageU is givenin Volt(V).

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>1.1.2Current
attemptto compensate
Electrons voltagedifferences.
Curentcanonlyflowin closedcircuits.Voltagecauseselectricalcurrentto flow.

Electrical movementof freeelectrons.

currentis the dlrectional
Closinga circuitby applyinga voltageforcesall freeelectronsto movein a certain
Thiscauseselectricalcurrentto flowfromthe negativeterminalthroughthe
direction.
loadsandwiresto the positiveterminal.Electronsperformelectricalwork.

,;r -r - r -rtr,I-
.:lr *

Convenlionalcunentflow

Fio.2: Flow ofelecttonsin an electricalcitcuil

Everyelect calcircuitmusthave:
. Voltagegenerator
. LOaO
. Wres

lMovementof eLectrons+

Fig.3: Electrical
circuit

Note;
Othercomponents suchas switches,relaysor fusesmightalsobe included.
Switchesaredrawnin thelrnon-actuated state.
Fusesarefittedto protectelectricalcircuitsagainstshort-circuits
andoverload.

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current",currentflowsfromthe positiveto
Accordingto the definitionof "conventional
thenegative terminal.
The unitof currentstrengtht is givenin Ampere(A).

il Conventional

I
-__>

Fig.4: Batteryas an electrcnPumP

DirectCurrent"DC"flowsin onlyone directionthrougha circuit.
Thecurrentis steadyprovidingvoltageandresistance are constant;
'rl
II

E
Time [ -------->-
5: Diroctcurrent

curentAC alwayschangesin its magnitude

Alternating anddirection:
Movement
of electrons

IVlovement
ol elechons

Period

Fig.6:Altemating
c!nent
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>1.1.3Electricalresistance
Electronsdo notflowfreelywhena voltageis appliedto an electricalconductor.
Depending materialshavedifferentnumbersof freeelectrons.
on theircomposition,
Consequently thesematerialsprovide whichopposethe
differentlevelsof resistance
current.The movementof electronsis thereforesloweddownat differentrates.

Obstruction of theflowof electronsis referredto as electricalresistance.

The unitof resistance R is givenin Ohm(O).
=
(1 Ohm= 1 o 1 VoltAmpere = 1VA).

Thereare differenttypesof resistors:

. Fixedresistors
. Variableresistors
' Potentiometers (resistors
witha slidingcontact)

-G --z-
reslsrcr resistorwith vadable
taps resistor

li
I
--f --r- --G
resistorwiih tully-variable step-cnange
slidingcontact resistorwith resistorwith
slidingcontact slidingcontact
Fig. 7: Resisiorsymbols

Unwantedresistance:
' Poorlysolderedconnections
. Badpluggedcontacts
. Faultywiresandconnections
. Rustedgroundconnections
(corrosion
resistance)

Resistancedesignations:
500R = 500f)
0R5 = 0.5o
2OK = 200000
1K5 = 1 , 5 K o= 1 5 0 0 K o

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>1.1.3Ohm'slaw
TheappliedvoltageU in a closedcircuitwillcausea currentlto flowthroughresistorR
(fiSl).
Theratioof voltageU to currentI determinesthe resistanceR.
Thislaw is namedafterits discovererGeorg Simon Ohm,namely"Ohm'slaw".

Derivation:
Fora constantresistance,currentwill increaseas the voltageincreases.
Thismeansthal cunentI andvoltageU are proportional to one another(U - l).
Fora constantvoltageU, currentwilldecreaseas resistance R increases.
Thismeansthatcunentlandresistanc€ R areinversely to oneanother(l - 1/R).
proportional
Combiningtheaboveresults in thedellnition of Ohm'slaw (U=R-l).

Unit; R = V
o

in an eleclrical
Fig.8: Vadables circuil

theequation:
The followingaid can be usedto remember

Note:
Simplyuseyourfingerto coverthe desiredsymbol!

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Measurement
examples:

Resist-
ance
UinV 0 2 6 B i0

R , = 2 Q Irin A 0 I 2 e 4 5

R z =1 Q Irin A n 2 + o 8 10
Fig.9:Currentversusvollage

Voltage
BinO 0 z b 8 i0
Short-
Ur=5V I . , i n A circuit z,a 1 , 2 5 0,83 0,675 U,C

Short-
Uz=1ov Irin A circuit 2,5 1,66 t,Jc 1,0
Fig.10:Currentversusresistance

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>1.1,4Resistornetworks
Seriesresistors:

R1 R2 R3

Fig.11:Seriesnetwork

Seriesnetworksserveas voltagedividers.
Pre-resistors
are requiredwhenconnecting LEDs(e.9.witha nominal ol2.4V)to
voltage
the 24Von-boardsupplyon mobilecranes.

Thefollowinglawsapply:
| - t - t -
Thesamecurrentflowsthroughall the resistofs.

Ubt= Ur+ U, +... Thetotalvoltageis the sumof all partialvoltages.

R.. = R,+ R,+... is the sumof all partialresistances.

Thetotalresistance

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Parallelresistors:

l',
Fig. 12:Parallelnetwork

Parallelnetworksserveto dividethe current.

Thefollowinglawsapply:

l,"c= lr + lr+ ... All the resistorshavethe samevoltage.

U,.,= U,= U,= ... Thetotalcurrentis the sumof all partialcurrents.

1,/R*=t76,*17*,*... Thereciprocal isthesumofall recipro-

of thetotalresistance
catedoartialresistances.

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1.2Measuremeni
technology

>1.2.1Typesof measurement
inslruments
Thereare twotypesof measurement
instruments:
. Analogue multimeter
. Digitalmultimeter

Analoguemultimeter:

,.t,.
_-.--;;-- .f
'; ,,r''= -ll;:t

Fig.13:Analoguemultimeter

Connections:
COM: groundconnection
v/o: voltageand resisiancemeasurement
currentmeasurement inAmpere-range
currentmeasurement in milli-Ampere
range

Advantages: Disadvantages:
. Rapidchanges
in measured
vari . Whenusing
dursn drv vdrry nEcr r. movingcoilmechanisms,it is only
. If correctlyused,often possibleto measureDCvoltageand
moreaccurate. current.
. Measurement rangemustalwaysbe
manually selected.

Note:
Themeasurement leadsmustbe re-plugged
depending
on thevariable beingmeasured.
Alwaysselectthehighest
measurement rangewhenmeasuring an unknown variable.
Thenselectthemeasurement rangewheretheneedleis in theupperthirdof thescale.

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1,2.1Typesof measurementinstrumenls
Digitalmultimeter:

Fig. 14: [.4etrixMX22 Fig.15:chauvin

AmouxMM3000 Fig.16:chauvin
Arnoux
Conpa2010

Connections:
coM: grounoconneqton
V/O: voltageand resistance
measurement
currentmeasurement in Ampere-range
mA: cun-entmeasurement range
in milli-Ampere

Advantages: Disadvantages:
. Rapidindication of measuredvalues . Difficultto noticemeasurement
. The measurement rangeis often ran9ecnanges.
automaticallyselectedby the
measurement instrument.
. On someinstruments the measured
valuescanbe storedor
transferredto a PC for further
analysis.

Note:
leadsmustbe re-plugged
Themeasurement depending
on the variablebeingmeasured.

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>1.2.2Using measurementinstruments
Measuring
electricalvoltages:
Theelectricalvoltageis measuredusinga voltmeter. Thevoltmeter(fig 1) is switchedin
parallelto thevoltagesourceor load.A voltmeteralwaysmeasuresthe voltagedifference
betweentwo measurement points.ThetypeofvoltageAC- or DC must - be selected.

I
lu

Fig.17rVoltagemeasurement

Fig.18:Voltage
measurement
Note:
Thevoltageacrosseachloadcanbe individually measured. probes
The measurement
mustbe applieddirectlyin frontof and behindthe loads(fig2).
Caution:
to V and COMrespectively
Theredandblackleadsmustbe connected whenmaking
voltagemeasurements.
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Measuringelectricalcu enls:
Electrical currentis measuredusingan ammeter. Theammeteris placedin the circuit,t . e .
it is switchedin seriesin eitherthe supplyor returnlineto the load.

.<-

Fig.19:Currentmeasurement

Fig,20:Currentmeasurement
Caution:
to mA(orA) andCOMrespectively
The redand blackleadsmustbe connected when
makinocurrentmeasurements.

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Resistancemeasurements:
Theresistance usinoa director indirectmeasurement
valueis determined

measurements
Directresistance eitherrequirethe circuitto be interrupted
or the compo-
nentto be removed.Thistypeof measurement is veryimprecise-

Fio,21: Directresistance
measurement

Indirectmeasurements are basedon voltageandcurrentmeasurements at the resistor.

Theresistanceis calculatedfromthe measuredvaluesusingohm's law.

Therearedifferentootionsfor oerformino
an indirectmeasurement;

l u t p
I
measurement
Fig.22:Indirectresjstance / voltageerrorcircuit

Fig.23: Indirectresislance
measurement/
curentenorcircuit
Caution:
The redand blackleadsmustbe connected
to R andCOI\4respectively
whenmaking
resistance
measurements.
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Componentdescription

UW04- Driveunit /
dieselengine

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Glossary:
pressure
Absolute pressure
sensor:Theabsolute sensoralwaysrelatesitsmeasurement
to a referencepoinl

AGR: Exhaustrelurn

ECU: ControlUnit(enginecontrolunit)
Electronic

EDC: ElectronicDieselControl
(injection
systemfor Dieselengines)

OT Topdeadcenter

PLD: Pumplinanozzle

pressure
Relative pressure
sensor: A relative thepressure
sensormeasures difference
betweentwotestvalu€s

UT Bottomdeadcenter

ZMEi Unilto bs measured

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UW04 - Driveunit / dieselengine

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 Componentdescription
uw04-
1. Inlineengine
>1.1General
Inlineengineis the namegivento an enginewhosecylindersare arrangedin a line.

>1.2Motordesignation

I Model
emissions
Optimised
Supplementarydesignation
Numberof cylinders
Production
series
Dieselengine

Supplementarydesignations:
NA Suctionengine
TB Turbo-charged engine"slightlycharged"
T Turbo-charged engine
Tl Turbo-charged enginewithchargeair cooling
S Short(shortpistonstroke)
L Long(longpistonstroke)

Model:
injectionpump
Distributor-type
-
MW-/ P3000 Injectionpump
A3 P7'100- Injectionpump
M P7100- lnjection pump+ EDC
(EDC= Electronic DieselControl)with LH ECUl
A5 PistonvalveinjectionpumpEDCwith LH ECU4or ECUS
A6 PLD(PumpLineNozzle)withLH ECU-UP/cR
A7 CR (CommonRail)withLH ECU-UP/CR

Typedesignations
for inlineengines:
.D924
.D926
.D846
.D934
.D936

Distinguishingcharacteristicsof inline engineswhich can be determinedfrom their

type designation:
Productionseries+ no.of cylinders= 3-digit!
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>1.3Layout
Overview:
Rockerlever
Injectionnozzle Intakevalve Pushrod

Dipstick

Oilfilter

Piston

lnjection
pump

Connecting
roo

Crankshaft

Oilpan

Plunger Camshaft Starter

motor

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>1.4Installedenginetypes

D846- A5 / 6 CylinderDieselInlineEngine:

FSC(FuelService
Center)
. Suctionfilter
. Finefilter
. Manualdelivery
Exhaustgas
pump

Flameglowplug

EnginecontrolunitECU5

generator

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D846- A7 / 6 CylinderDiesetInlineEngine:

FSC{FuelService
Centef)
. Suciionfilter

. IVanual
delvery
pump

Enginecontrolunil
ECU UP/CR

High-pressure
pump(railpump)
air
Compressed
pump
FueldeTivery

Exhaustwatercooler Flameglowplug

Oilfilier
Gene€tor

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UW04 - Driveunit / dieselengine

D924- A4 / 4 CylinderDieselInlineEngine(ow engine);

EnginemntroluniiECU1

Fuelpreliminary
filterunit

Fuelllnefilter

EnginecontrolunitECU4
D926- A5 / 6 CylinderDieselInlineEngine:

Heatingflange

FLrel
finefilter

Oilfilter Fuelpreliminary
filterunit

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D934-A6 / 4 CylinderDieselInlineEngine(ow engin€):

Enginecontrolunit
Fuelfinefilter ECUUP/CR Oilfilter

Plug-inpr.rmps

Coolant
pump

Fuelprelimin
filterunil
Fueldeliverypun
Starter
molor
pressedair
compressor
Oilcooler
Exhauslgas
turbocharger

D936-AO / 6 CylinderDiesellnline Engine:

Engine
control
unit
ECU UP/CR

Fuelfinefilter

Fu€lpreliminary
filtorunit

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2. V-engine
>2.1General
givento an enginewhosecylindersare anangedin a V-for-
V-engineis the designation
matron-

>2.2 Motordesignation

Model
emissions
Optimised
Supplementarydesignation
Numberof cylinders
Production
series
Dieselengine

Supplementarydesignations:
TB Turbo-charged engine"slightlycharged"
T Turbo-charged
engine
Tl enginewithchargeair cooling
Turbo-charged
Model:
A3 - P7800- Injectionpump
A4 - P7800- Injectionpump
+ EDC(electronicdrivecontrol)
A5 - H-RP43 - Pistonvalveinjectionpump
+ EDC(electronicdrivecontrol)
A7 - CR (CommonRail)withLH ECU-UP/CR
Typedesignationfor V-engines:
.D9306
.D9308
.D9406
.D9408
.D9508

Distinguishingcharacteristicsof V-engineswhich can be determinedfrom their

type designation:

series+ no.of cylinders= 4-digit!

Production

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>2.3Layout
Overview:
Oilseparator
Pushrod pump
Injection Rockerlever
Plunger lntakevalve Dipstick

Rockerlever

Outletvalve

Injection
nozzle
Piston

Camshaft

Oilcooler

Connecting
rod
Crankshaft

Oilfilier

Oilpan
Exhaust
9as
turbocharger
Connecting
rod Injectionnozzle
Startermotor

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2.4Installedenginetypes

D9406-A5 / 6 CylinderDieselV-Engine:
EnginecontrolunitECU4

Fuelfine filter

Generator Coolantpump

D9408- A5 / 8 CylinderDieselV-Engine;
Oilfilter

Engineconlrcl unitECU4
Coolantpump

Fuelflnefilter Fuelprcliminary
filterunit

Air conditio-
nrngsysiem
Generalor

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D9508- A7 / 8 CylinderDieselV-Engine:
Oil separalor Heatingflange Exhaust
gas
turbochargef
Enginecontrolunit
Actuatingcylinder ECUUP/CR
exhaustflap
(enginebrake)

Generalor
Aircondilioning High-pressure
compressor pump
FSC(FuelService
Center)

D9508- A7 / 8 CylinderDieselV-Engine:
Heatingflange
Exhaustgas Enginecontrolunit
Oilseparator turhochaQer ECUUP/CR

Oilseparator

Oil filter

Starter
motor
Coolantpurnp Airconditioning
compressor FSC (FuelSer-
Generator vice Center)

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