Chapter 1 - Automotive Electrical System

CHAPTER 1 : AUTOMOTIVE ELECTRICAL SYSTEMS AND CIRCUITS
1
SUB-CHAPTER
1.1 Understand the electrical system approach
AUTOMOTIVE 1.2 Understand electrical wiring, terminals and

ELECTRICAL switching
SYSTEMS AND 1.3 Understand circuit diagram and symbols

CIRCUITS
1.4 Understand vehicle smart wiring system
Electrical systems approach
Vehicle system approach
What is a system???
- describe a collection of related
components, which interact as a
whole
- ‘A group of devices serving a
common purpose’
- Once a complex set of interacting parts has been
systemized, the function / performance of each part can
be examined in more detail.
- The links & interactions between various sub-systems
are very important consideration.
- Example:
‘how the power requirements of the vehicle lighting
system will have an effect on the charging system
operation’
- Solution:
It has subdivided from the whole, consideration should
be given to the inputs & outputs.
-Many of the complex electronic system on a vehicle
done this recommended approach which consider the
‘ECU’ of the system as the control element, and looking
at its inputs & outputs.
Open loop & close loop systems
Open loop system - is designed to give the required

output whenever a given input is applied.
(no feedback is required for the system to operate)
Closed loop system - is identified by a feedback loop.

(a possibility of applying corrective measures if the output
is not quite what is desired)
- the feedback can be in many forms
= air-cond system – turning the button up / down
= voltage regulator in alternator – using simple wire
- many complex vehicle system are represent as block
diagram.
- the inputs supply information to an ECU then controls
the system outputs
Electrical wiring, terminals &
switching
Cables construction
Cables use in motor vehicle applications are almost
copper strands insulated with PVC.
Advantages of copper:-
 very low resistivity – 1.7 x 10-8 Ωm
 ideal properties – ductility & malleability
Advantages of PVC:-
 very high resistance – 1015Ωm
 very resistant to petrol, oil, water & other contaminants
switching
Cables construction
- Cable size depends on the current drawn
(larger cable, smaller voltage drop, = heavier)
switching
Cables construction
- the supply to a component must not be less than 90%
of the system supply.
- we can calculate voltage drop in a cable as follows:
P
current – I 
VS
I l
volt drop – Vd  I = current (A)
A
I l P = power rating (W)
cable cross-section - A Vs = system supply (V)
Vd Vd = volt drop (V)
ρ = resistivity of copper (Ωm)
l = length of cable (m)
A = cross-sectional area (m2)
switching
Cables construction
Example:-
Calculate the ideal copper cable size(area) required for a
fuel pump circuit. The pump drawn 8A from a 12V
battery. The maximum allowable volt drop is 0.5V.
(ρ = 1.7 x 10-8 Ωm, l = 1m)
Answer:-
272nm2 ~ 0.272mm2
switching
Cables construction
- Some typical sizes & uses of cable
switching
Color code & terminal designations
- A number of color code & terminal designation system
is used for standardization.
- Just for learning purpose, lets look three reference
system:
 British Standard system (BS AU 7a: 1983)
 European Standard system
 Terminal Designation system (DIN 72 552)
switching
Harness design
The wiring harness has been developed from a
loom just a few wires to over 1000 separate wires.
Modern vehicles tend to have wiring harnesses
constructed in a number of ways.
There were three type of harness construction
which are:-
 PVC wound harness (figure 4.6)
 Cable side by side & plastic welded to a backing strip
(figure 4.7)
 PVC tube & tape harness (figure 4.8)
switching
Harness design – PVC wound harness
- the tape is non-adhesive which allow the wires to retain
some flexibility.
switching
Harness design – cable side by side
- this method allows the loom to be run in narrow areas.
switching
Harness design – PVC tube & tape harness
- this method has the advantage of being harder wearing
& can also be waterproof (if suitable sealing)
switching
Harness design
When deciding on the layout of a wiring loom, many
issues must be considered as follows:
 cable runs must be as short as possible
 the loom must be protected against physical damage
 the number of connections should be kept to a
minimum
 modular design may be appropriate
 accident damage areas to be considered
 production line techniques should be considered
 access must be possible to main components & sub-
assemblies for repair purposes
switching
Harness design
The overall layout of a loom on a vehicle will follow one of
two patterns:
 ‘E’ shape
 ‘H’ shape
switching
Harness design
Figure shows a more realistic representation of the
harness layout in the level of complexity & number of
connection points involved.
switching
Printed circuits
- used on the rear of the instrument pack & other similar
places.
- allows these components to be supplied as complete
units & reduce the amount and complexity of the
wiring.
- construction:-
o using thin copper layer (bonded to a plastic sheet)
o required circuit print on to the copper using some
material (wax)
o unwanted copper can be etched away with an acid
wash
switching
Printed circuits
switching
Fuses & circuit breakers
Circuit protection required to protect the electrical
wiring of a vehicle.
Simple definition – it is a deliberate weak link in the
circuit.
Operation:-
- overload occurs = the fuse melt & disconnect the circuit
before any serious damage is caused.
Types:-
 glass cartridge
 ceramic
 blade – most popular (simple construction, reliability
against premature failure - vibration)
switching
switching
Fuses are rated with a continuous &
peak current value.
Continuous Value
- the current the fuse will carry
without risk of failure
Peak Value (double C.V)

- the current the fuse will carry for
a short time without failing
switching
Circuit breaker are commonly used in heavy vehicle
It has the same rating & function as a fuse.
Advantage – can be reset

Disadvantage – much higher cost
It use a bimetallic strip that will bend & open a set of

contact when it is subjected to excessive current.
A latch mechanism prevents the contacts from losing

again until a reset button is pressed.
switching
Termination
- Various types of terminals are available & have
developed from early bullet-type connectors into the
high quality waterproof systems now in use.
switching
Termination
- Many multiway connectors employ some kind of latch
to prevent individual pins working loose.
switching
Termination
- For high quality electrical connectors, the contact
resistance of a terminal must be kept to a minimum.
- This is achieved by ensuring a tight join with a large
surface area in contact & by using a precious metal
coating (contain silver).
-- notes that; many connectors are only designed to be
removed a limited number of times before
deterioration in effectiveness.
-- reason; to reduce the cost of manufacture but can
cause problem on old vehicles.
Many forms of terminal are available for after sales repair

with more success than other. (figure 4.15)
switching
Switches
Definition – ‘a device for breaking & making the
conducting path for the current in a circuit’
Can be considered in two parts:-
Mechanical
Contacts
Arrangement
Perform the Moves the

electrical contacts
connection
switching
Switches
Figure show one common method of sliding contacts
switching
Switches
Some characteristics of the contacts requirement:-
 resistance to mechanical & electrical wear
 low contact resistance
 no build up of surface films
 low cost
Materials:-
 copper
 phosphor bronze
 brass
 beryllium copper
 silver / silver alloys
 gold (very special applications)
switching
Switches
The electrical life of a switch is dependent on:-
 its frequency of operation
 the on–off ratio of operation
 the nature of the load
 arc suppression & other circuit details
 the amount of actuator travel used
 ambient temperature & humidity
 vibration levels
switching
Switches
Terms used to describe switch operation:-
 Free position – position of the actuator when no force is
applied
 Pretravel – movement of the actuator between the free &

operating position
 Operating position – position the actuator takes when

contact changeover takes places
 Release position – actuator position when the mechanism

resets
switching
Switches
Terms used to describe switch operation:-
 Overtravel – movement of the actuator beyond the
operating position
 Total travel – sum of pretravel & overtravel
 Actuating force – force required to move the actuator from

the free to the operating position
 Release force – force required to allow the mechanism to

reset
switching
Switches – temperature, pressure & inertia
- radiator cooling fan – operates by bimetal strip which
bend due to temperature & causes a set of contacts to
close
switching
- air conditioning system – used to monitor over-
pressure, operates by pressure on diaphragm
switching
- fuel injection pump – used to switch off the supply in
the event of an impact to the vehicle
Circuit diagrams and symbols
1. Electrical circuit
2. Conventional circuit diagram
3. Layout or wiring diagram
4. Terminal diagrams
5. Current flow diagrams
1. Electrical circuit
a) Circuit principle
 Conductor or cable arrangement to carry a current
from voltage supplier to the electric component
b) Simple circuit
 A closed connection allow the perfect current flow. It
must consist of voltage supplier (V), electric current (I)
and resistance (R)
c) Direction of current flow
 current flows from the positive (+) terminal to the
negative (-) terminal through the circuit.
2. Conventional circuit diagram
 Shows the electrical connections of a circuit
 but makes no attempt to show the various parts in any
particular order or position.
3. Layout or wiring diagram
 An attempt to show the main electrical components in
a position similar to those on the actual vehicle.
 Showing to the complex circuits and the number of
individual wires, some manufacturers now use two
diagrams
 One to show electrical connections and the other to
show the actual layout of the wiring harness and
components.
5. Terminal diagrams
 shows only the connections of the devices and not any
of the wiring.
 The terminal of each device, which can be represented
pictorially, is marked with a code.
 This code indicates the device terminal designation, the
destination device code and its terminal designation
and, in some cases, the wire colour code
5. Current flow diagrams
 The idea is that the page is laid out such as to show
current flow from the top to the bottom.
 These diagrams often have two supply lines at the top
of the page marked 30 (main battery positive supply)
and15 (ignition controlled supply).
 At the bottom of the page is a line marked 31 (earth or
chassis connection).
Vehicle smart wiring system
 the revolutionary new electrical system
 All the components had to be able to communicate and
‘understand’ one another’s language as well as being
integrated in one system
 many cars have advanced electrical systems – but it uses
the multiplex system for communications
 The electrical system is designed as a communication
network of 18 computers with central control units and no
fewer than 24 modules for most electrical functions. These
modules function like computers and control the electrical
functions in the car whenever necessary
 Multiplex technology involves only two cables. One of
them is able to carry all the signals in the system at the
same time. The other is the electrical cable, which
carries the necessary power. These cables run around
the entire car and are known as the databus. The
information travels in digital packages.
 All the small network modules are able to recognize
‘their’ signal for action and do as they are told.
 When the signal ‘open left front window’ arrives, for
example, only one module (in the front door) reacts to
it, receives it and transmits an ‘order’ to the electric
motor to lower the window. Signals are able
continuously to alert and activate the different
modules as a result of the capacity of the system,
which also operates at two speeds depending on the
function. The engine and transmission management
uses a high-speed databus, whereas all the other
functions use a slightly slower data bus.
 The benefits of the multiplex system are considerable:
 fewer cables and connections in the car;
 improved reliability;
 communication between all the components;
 software adaptations;
 easier and improved opportunities for the retro-
installation of electrical functions.
 The system also has the benefit of self-diagnosis for all
functions, including engine management, making the
OBD (on-board diagnostics)

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Chapter 1 - Automotive Electrical System

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CHAPTER 1 : AUTOMOTIVE ELECTRICAL SYSTEMS AND CIRCUITS

1.1 Understand the electrical system approach

AUTOMOTIVE 1.2 Understand electrical wiring, terminals and

SYSTEMS AND 1.3 Understand circuit diagram and symbols

Open loop system - is designed to give the required

Closed loop system - is identified by a feedback loop.

Peak Value (double C.V)

Advantage – can be reset

It use a bimetallic strip that will bend & open a set of

A latch mechanism prevents the contacts from losing

Many forms of terminal are available for after sales repair

Perform the Moves the

 Pretravel – movement of the actuator between the free &

 Operating position – position the actuator takes when

 Release position – actuator position when the mechanism

 Total travel – sum of pretravel & overtravel

 Actuating force – force required to move the actuator from

 Release force – force required to allow the mechanism to

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