University of Gondar (UoG)

Institute of Technology
Mechanical Engineering Department
Automotive Electrical and Electronics System
(MEng 5381)

Chapter 6
Fundamentals of
Automotive Electronics
Prepared by: Melkamu G.

2015 E.C.
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 Outline
 Basics of Electronics
 Semiconductors (Diodes & transistors)
 Integrated circuits
 Microcomputer
 Sensors and Actuators
 Sensors: types and function of different sensors
 Actuators: solenoids, stepper motors, relays
 Electronic Fuel Injection (EFI) System
 Components of EFI
 Operation of EFI
 Types of EFI (Indirect and Direct fuel injection)

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 Basics of Electronics
What is Electronics?
 Electronics is the science or technology that deals with the functions of
electrons, as well as the development and application of parts, circuits,
and devices involving this technology.
Semiconductors
 What is semi-
conductor?
 The two most
commonly used
semiconductor
materials are
germanium
(Ge) and silicon
(Si).

3
Cont…
 However, in their pure state, these are not suitable for practical use.

 For this reason, they must be doped; that is, slight amounts of impurities
must be added to enhance their practical use.

Characteristics of a semiconductor

 As its temperature increases, its electrical resistance decreases.

 Its electrical conductivity increases when mixed with certain other

substances.

 Its electrical resistance changes when exposed to light, magnetism, or

mechanical stress.

 It emits light when voltage is applied to it.

 Semiconductors can be divided into two types: N- type and P-type.

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Cont…
N-type semiconductors
 consists of a silicon (Si) or germanium
(Ge) base or substrate, which has been
doped with a slight amount of arsenic
(As) or phosphorus (P) in order to
provide it with many free electrons.
 The "n" of an n-type semiconductor
stands for "negative".
P-type semiconductors
 consists of a silicon (Si) or germanium
(Ge) substrate that has been doped
with gallium (Ga) or indium (In) to
provide "holes", which can be thought
of as "missing" electrons, and hence as
positive charges flowing in a direction
opposite that of free electrons.
 The "p" of a p-type semiconductor
stands for "positive".
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Cont…
Diode
What is diode?
 A diode is an electrical one-way check valve made by combining a P-type
material and an N-type material.
 There are several types of diodes: Ordinary rectifying diode, Zener diode,
LED (Light-Emitting Diode), Photodiode and etc.

The diagrams show how an electrical current flows through a diode.

 Ordinary Diode: An ordinary diode allows a current to flow only in one
direction from the p-side to the n-side. A minimum voltage (about 0.3V for
Silicon diode and 0.7V for Germanium diode) is required for a current to
flow from the p-side to the n-side. 6
Cont…
Ordinary diode provides rectification.
 Half-wave rectification
 Full-wave rectification

Application example:
Ordinary rectifying diodes
are used as rectifiers for
alternators.

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Cont…
 Zener Diode: in addition to allow current flow in forward direction, it also
allows current flow in the reverse direction under certain conditions. In the
reverse direction, a current exceeding a predetermined voltage flows
through a Zener diode. This is called a Zener voltage, which remains
practically constant regardless of the amperage of the current.
 Application example: Zener diodes are used for various purposes, in an
automotive it uses voltage regulator for an alternator.

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Cont…
 LED (Light-Emitting Diode): is a p-n joining diode, which is the same as
an ordinary diode. It emits light (in various colors, such as red, yellow, and
green) when a current passes through it in the forward direction.
LEDs have the following characteristics:
 Smaller heat generation and longer life than ordinary light bulbs.

 Emit bright light with low power consumption.

 React with low voltage (quick reaction speed).

Application example: LEDs are used in high-mount stop (brake) lights and
indicator lights, etc.

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Cont…
 Photodiode: The photodiode is a p-n joining
diode that consists of a semiconductor and a
lens. If a reverse direction voltage is applied
to a photodiode that is exposed to light, a
reverse current will flow. The photodiode can
determine the amount of the light by detecting
the amperage of the reverse current when the
reverse voltage is applied.
 Application example: Photodiodes are used in
the solar sensors for air conditioners, etc.

Transistors
What is transistor?
 Ordinary Transistors: contains three layers consisting of a p-type
semiconductor sandwiched between two n-type semiconductors, or an n-
type sandwiched between two p-type semiconductors.
 A transistor performs Amplification and Switching functions.
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Cont…
 An electrode is attached to each substrate layer: B (base), E (emitter), and
C (collector).

 Basic operation: In an n-p-n transistor, when current IB flows from B to

E, then current IC flows from C to E. In a p-n-p transistor, when current IB
flows from E (emitter) to B (base), then current IC flows from E to C.

 The current IB is called the base current, and current IC is called the
collector current. Therefore the current IC will not flow unless the current
IB flows.

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Cont…
 In an ordinary transistor, as shown in the graph on the left, portion "A" can
be used as a signal amplifier and portion "B" can be used as a switch.

 Application example: Transistors are used in numerous circuits. It uses for

vehicle speed sensor and injector.
 Phototransistor: When the phototransistor receives light while power (+)
is applied to its collector and ground (-) is applied to its emitter, a current
flows through the circuit.

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Cont…

 The amperage of the current varies by the amount of light that shines on
the phototransistor.

 Therefore, the light that shines on the phototransistor has the same
function as that of the base current of an ordinary transistor.
Application example: In automobiles, phototransistors
are used in deceleration sensors, etc.
 Thermistor: is a type of semiconductor whose
electrical resistance changes with changes in
temperature. It can determine the temperature by
detecting resistance.
 Application example: In automobiles, thermistors are
used in the water temperature sensor and intake air
temperature sensor, etc.
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Cont…
Integrated Circuits (ICs)
 An ICs is a combination of several thousand electrical circuits containing
transistors, diodes, capacitors, resistors, etc., built into or onto a several
millimeter-square silicon chip, and placed in a ceramic or plastic package.

 A single IC can have several special abilities and functions.

Advantages ICs over non-integrated circuits

 Having considerably reduced contact junctions resulting in reduced

failures.

 They are much smaller, lighter and production costs are much lower.

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Cont…

 Analog signal: Analog signals change continuously and smoothly over

time. Thus, the general characteristic of an analog signal is that its output
changes in proportion to its input.

 Digital signal: Digital signals change (ON and OFF) intermittently over
time.

 Logic Circuits: The circuits in a digital ICs are called logic circuits or
digital circuits, and are made up of combinations of different types of so
called gates, such as NOT, OR, NOR, AND, and NAND gates.

 A truth table represents the relationship between digital signal inputs and
outputs in a table format. In a truth table, 1 represents the presence of a
voltage, and 0, its absence.

Reading assignment: the symbol and the truth table of each gates.
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Cont…

Microcomputer

 A microcomputer receives signals from input devices, processes those

signals, and controls output devices.

 At Toyota, a microcomputer is called an ECU (Electronic Control Unit).

 In vehicle systems, input devices

are sensors, and output devices
are actuators.
 A microcomputer consists of a CPU
(Central Processing Unit), various
memory devices, and an I/O (input/
output) interface.

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 Sensors and Actuators
Sensors
 Sensors are devices used to convert the measurand, such as:
temperature, pressure, speed, position, etc., into either digital or analog
electrical signals and send to the ECU.

Sensors can be classified as:

Resistive Sensors: Voltage Generating Sensors:

 potentiometers  piezo electric

 thermistors  zirconia-dioxide
 magnetic inductance
 piezo resistive

Switch Sensors:
 phototransistors and LED  G-sensors (Air Bag Impact Sensors)
 speed sensors
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Cont…
Resistive Sensors
 A resistive sensor reacts to changes in mechanical conditions through
changes in its resistance.

 A potentiometer is a variable resistor with three terminals: one for power

input, one for a ground and one to provide a variable voltage output.

 The movable contact slides across the resistor to vary the resistance and
as a result varies the voltage output of the potentiometer.

 The output becomes higher or lower depending on whether the movable

contact is near the resistors supply end or ground end.

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Cont…
 The vane type air flow meter on an EFI uses a potentiometer to converts
the air flow meter vane opening angle to a voltage and sends it to the
Electronic Control Unit (ECU). This signal allows the ECU to determine the
volume of air that is entering the engine.

 Some models also use a potentiometer as the throttle position sensor

(TP).

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Cont…

 Thermistors are variable resistors whose resistance changes in relation

to temperature.

 The thermistor has two terminals, one for power and one for ground. A
reference voltage is supplied to one terminal through a fixed series resistor
located inside the computer. The other terminal of the thermistor is
connected to ground, usually back through the computer.

 The computer monitors the voltage after the internal fixed resistor and
compares this voltage to the reference voltage to determine the
temperature of the thermistor.

 The relationship between the two voltages changes as the temperature of

the thermistor changes.

 It is used for engine coolant temperature (ECT) sensor, intake air

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temperature (IAT) sensor and etc.
Cont…
 A piezo resistive sensor is a resistor circuit constructed on a thin silicon
wafer.
 Used for manifold pressure sensor (MAP) which monitors the air intake
volume for electronic fuel injection (EFI).

 A change in the intake manifold pressure causes the shape of the silicon
chip to change, with the resistance value of the chip fluctuating in relation
to the degree of deformation.
 An integrated circuit converts the fluctuation
to a voltage signal that is sent to the ECU,
where the air-fuel ratio is regulated.
 Another use for this same type of sensor is to
sense turbocharger boost.

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Cont…

Voltage Generating Sensors

 These sensor generates its own voltage signal in relation to the

mechanical condition it monitors. This signal in turn relays to the computer
data about the condition of the system it controls.

 Piezo electricity is generated by pressure on certain crystals, such as

quartz, which will develop a potential difference, or voltage, on the crystal
face. When the crystal flexes or vibrates, an AC voltage is produced.
 Knock sensors contain a piezo electric element which,
when deformed by cylinder block vibration caused by
knocking, generates a voltage and sending the signal
to the ECU that engine knock is occurring.
 The ECU in turn retards the ignition timing
to stop the knocking. 22
Cont…
Zirconia-Dioxide (Oxygen Sensors)
 The oxygen sensor (O2S), located in the exhaust manifold, senses
whether the air-fuel ratio is rich or lean, and sends signals to the ECU
which in turn makes minor corrections to the amount of fuel being
metered.

 It also used for the three-

way catalytic converter to
function properly.
 There are two kinds of
oxygen sensors: zirconia
and Titania.

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Cont…

 Magnetic inductance sensors consist of a coil of wire around an iron

core plus a permanent magnet.

 The magnet can be either stationary or movable. If the magnet is the

moving member, as it passes the coil the magnetic lines of force cut
through the coil and a voltage is produced.

 It is commonly used for speed sensor.

 The G signal and NE signal are
generated by the pickup coil, in which
the camshaft position sensor (CMP)
or crankshaft position sensor (CKP), and the signal plate
or the timing rotor. The information from these two signals
is combined by the engine ECU to comprehensively
detect the crankshaft angle and engine speed. 24
Cont…
Switch Type Sensors
 Switch sensors toggle a voltage from the computer high or low, or supply
an "on" or "off" voltage signal to the computer.

 This type of sensor may be as simple as a switch on the brake pedal or as

complex as a phototransistor speed sensor.

 Phototransistor and LED: When combined with a LED and a rotating

slotted wheel in a vehicle speed sensor, a phototransistor can supply
vehicle speed data to a computer.

 This type of sensor is also used as

a G Sensor or deceleration sensor.

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Cont…

 Reed switches are a special kind of electrical switch, actuated (turned on

and off or change over) by magnetism.

 The reed switch is commonly used as a speed sensor or position sensor.

 It consists of a set of contacts that open when adjacent to a magnet. In the

speed sensor application, the magnet is attached to the speedometer
cable and rotates with the cable. Each time one of the poles of the magnet
passes the switch the contacts open and then close.

 A voltage is supplied to one contact on the switch and the other contact is
connected to ground.
 Each time the points close, the
voltage is pulled down to 0 volts,
just like the phototransistor speed
sensor. 26
Cont…

Sensors ECU Actuators

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Cont…
 In

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Cont…
Actuators
 Actuators are electromechanical devices that convert an electrical signals
from the ECU into mechanical action.

 This mechanical action can then be used to open and close valves, control
vacuum to other components, or open and close switches.

Actuators can be classified as:

 Solenoids (Fuel Injectors)

 Stepper Motors

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Cont…

 Stepper Motor are digital actuators, they are either on or off.

 They move in fixed increments in both directions, and can have over 120
steps of motion.

 Used to enable the ECU to control idle speed. In most fuel injection
systems, it controls an idle air bypass built into the throttle body.
 In an idle speed control valve (ISCV),
(located in the air intake chamber) a
stepper motor is built into the ISCV
where it rotates a valve shaft either in or
out.
 This in turn increases or decreases the clearance between the valve and
the valve seat, thereby regulating the amount of air allowed to pass
through. 30
Cont…

 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.

 Solenoids are controlled two ways: pulse width or duty cycle. Pulse width
control is used when the frequency is not consistent. Duty cycle control is
used when the frequency does remain constant.

 Idle speed control valves can be constructed with a solenoid instead of a

stepper motor.

 Solenoid valves are also used in electronically controlled transmissions.

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Cont…

Actuators

Injector ISC
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Cont…
The major actuators in a computer-controlled engine include the following
components:
 Evaporative Emission (EVAP) Canister Purge Valve
 EGR Flow Solenoids
 Fuel Injectors
 Ignition Module
 Idle Speed Controls
 Motors: Using electrical relays, the computer is used to trigger the
operation of electric motors, such as the fuel pump.

Electronic throttle control assembly 33

 Electronic Fuel Injection (EFI) System
What is EFI?
 Electronic Fuel Injection System (EFI) is an electronically controlled
system used to provide an atomized fuel to the incoming air during the
intake stoke of SI engines.

 This ensures accurate control of air-fuel mixture and hence better

performance with lower emission.

 In an EFI system, the computer calculates

the amount of intake air based on MAP
and rpm input signals or mass air flow
(MAF) system.

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Cont…
Components of EFI

Multi-Point Injection (MPI) type

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Cont…
 Fuel injectors are electromechanical devices that meter and atomize fuel
so it can be sprayed into the intake manifold.

 Most injectors consist of a solenoid, a needle valve, and a nozzle.

 When the solenoid winding is energized, it
creates a magnetic field that draws the
armature back and pulls the needle valve from
its seat.
 Fuel then sprays out of the nozzle.
 When the solenoid is de-energized, the
magnetic field collapses and a helical spring
forces the needle valve back on its seat,
shutting off fuel flow.

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Cont…
 Idle speed control is a function of the ECM.
 Inputs: The ability of the fuel injection system to control the air-fuel ratio
depends on:
 its ability to properly time the injector pulses with the compression
stroke of each cylinder and,
 its ability to vary the injector “on” time, according to changing engine
demands.
 Both tasks require the use of sensors that monitor the operating conditions
of the engine.
 The major sensors in EFI engine include the following:

 MAF Sensor  ECT Sensor

 MAP Sensor  TP Sensor
 Oxygen Sensors (O2S)  CKP Sensor
 IAT Sensor  CMP Sensor

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Cont…
Operation of EFI
 All fuel injection systems operate in response to inputs.

 However, the ECM’s programming allows it to define the conditions and

establish a summary of those conditions. The ECM then controls the
delivery of fuel according to that mode of operation.

 Different EFI systems have different operational modes, but most have
starting, run, clear flood, acceleration, and deceleration.

 Starting Mode: When the ignition switch is initially moved to the start
position, the ECM turns on the fuel pump for about 2 seconds. When the
ECM receives a good signal from the CKP sensor, it energizes the fuel
pump to allow for starting. Once the engine is cranking, the ECM sets the
injectors’ pulse width according to inputs from the MAF, IAT, ECT, and TP
sensors. 38
Cont…
 Run Mode: Once the engine has started and is running above a
predetermined speed, the system will operate in open loop.
 In open loop, the ECM sets injector pulse width according to MAF, IAT,
ECT, and TP sensor signals. The system stays in open loop until the ECM
receives good signals from the O2S and a predetermined engine
temperature has been reached.
 Once these conditions have been met, the system moves into closed loop.
 In closed loop, the ECM adjusts the pulse width according to inputs from
a variety of sensors, but primarily the O2S.
 Clear Flood Mode: When an engine floods, the excess fuel must be
pumped out of the cylinders by fully depressing the accelerator pedal and
cranking the engine to start it. When the ECM detects a wide-open throttle,
it will go into the acceleration enrichment mode for 3 seconds. If the
throttle is held open and the engine’s speed is below a predetermined
rpm, the system will return to the start mode.
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Cont…
 Acceleration Mode: Based on signals from the TP and MAF sensors,
when intake air increases due to the throttle is opened, the ECM increases
the injectors’ pulse width. The pulse width change is calculated by the
ECM according to inputs from the CKP, MAP, ECT, MAF, and TP sensors.

 Deceleration Mode: Inputs from the MAF and TP sensors are also used
by the ECM to detect deceleration. During deceleration, the ECM reduces
injector pulse width.

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Cont…
Types of EFI System
a. Indirect injection (Jetronic)
 Throttle Body Injection (TBI): TBI system also called Single-point
injection (SPI).
 The throttle body unit is mounted directly to the intake manifold.
 Four-cylinder engines have a single throttle body assembly with one
injector and throttle plate, whereas V6 and V8 engines are usually
equipped with dual injectors and two throttle plates with a common throttle
shaft.
 The throttle body assembly contains a pressure regulator, injector or
injectors, TP sensor, idle speed control motor, and a throttle shaft and
linkage assembly.
Dis-advantage of TBI
 not as efficient as port injection systems.
 Fuel is not distributed equally to all cylinders.
 There is also a potential problem of fuel condensing and forming puddles
in the manifold when the manifold is cold.
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Cont…

Single-Point Injection (SPI) : Component Parts

42
Cont…
 Port Fuel Injection (PFI): uses one injector for each cylinder.
 They are mounted in the intake manifold near the cylinder head.
 Can be either multiport injection (MPI) systems or sequential fuel injection
(SFI) systems; each is defined by injector control.
 Due to OBD-II regulations, MPI systems are no longer used; rather, all
engines are now fitted with SFI systems.
 In MPI systems, the injectors were grouped together and the injectors in
each group fired at the same time. Some MPI systems fired all of the
injectors simultaneously.
 Sequential Fuel Injection systems control each injector separately so that
it injects just before the intake valve opens. It is the most accurate and
desirable method of regulating port injection.

43
Cont…

multiport injection (MPI) systems

sequential fuel injection (SFI) systems

44
Cont…

Multi-Point Injection (MPI): Component Parts.

45
Cont…
b. Gasoline Direct-Injection Systems (Motronic)
 In GDI system the fuel is highly pressurized when it is sprayed into the
cylinders.

 To prevent the heat from igniting the fuel in the injector (mostly solenoid
injectors), the injectors are designed to completely seal after the fuel is
sprayed.

 The ECM controls the pulse width and timing of each injector, whereas
adjustments of pulse width are made
according to inputs from the MAF and IAT
sensors.
 Fuel is injected before or after the intake
valve is closed, depending on the
operational mode. 46
Cont…

Combined Ignition and Injection System (ME-Motronic)

47
Cont…

Gasoline Direct Injection (GDI) System

48
Cont…
Operation Gasoline Direct-Injection Systems
 Most direct-injection systems can operate in three distinct modes: lean
burn, stoichiometric, and full power. Each of these modes has different air-
fuel ratios, injection timing, and pump pressures.
 Lean Burn Mode: The engines run in the lean mode when the vehicle is
cruising with a very light load. In addition to a reduction in fuel
consumption, exhaust emissions are also lowered. A small amount of fuel
is sprayed near the spark plug when the piston has nearly completed its
compression stroke but before ignition occurs. There is enough fuel
around the spark plug to cause combustion.
 Stoichiometric Mode: During medium-load operation, the system
operates in the stoichiometric mode. The air-fuel ratio is near
stoichiometric and the fuel is injected during the intake stroke.
 Full-Power Mode: The full-power mode is used during heavy loads and
hard acceleration. The air-fuel mixture is slightly richer than stoichiometric
and the fuel is again injected during the intake stroke.

Question: Does lean or riche mixture cause engine overheating?

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Cont…
Advantages of EFI
 Accurate AF Ratio (with uniform distribution) throughout all engine
operating conditions.
 Excellent fuel Economy with Improved Emissions Control.
 Superior throttle response (with rapid throttle movements) and power.
 Improved cold engine start ability and operation.
Light and Medium-Duty Diesel Fuel Injection
 Most late-model diesel injection systems are very similar to GDI systems.
 Nearly all of today’s diesel systems have a common rail injection system in
which the injectors are totally directly controlled by the ECM.
 However, some diesel engines use a mechanical-type system and only the
fuel pressure and emission controls are regulated by the ECM.
 To meet OBD standards, diesel control systems use many of the same
inputs as a gasoline engine (such as the MAP, IAT, MAF, TP, CKP, and
CMP sensors).

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END OF CHAPTER 6,7& 8

THANK YOU !!!

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