TEAM ID- 841427

Report on Skill based training as Internship at

International Automobile Centre of Excellence

An INTERNSHIP REPORT

Submitted by
LAKSHYA SINGH
220230119024

In partial fulfilment for the award of the degree of

BACHELORS OF ENGINEERING
in
Mechanical Engineering Department
Dr. S. & S. S. Gandhy Government Engineering College, Surat.

Gujarat Technological University, Ahmedabad

[July 2025]

Gujarat Technological University i DGGEC, Surat

TEAM ID- 841427

DR. S. & S. S. Ghandhy

GOVERNMENT ENGINEERING COLLEGE
MAJURA GATE, SURAT.

CERTIFICATE
This is to certify that the internship report submitted along with
the project entitled Skill Based Training as Internship at iACE
Ahmedabad has been carried out by Lakshya Singh under my
guidance in partial fulfilment for the degree of Bachelor of
Engineering in Mechanical Engineering, 7𝑡ℎ semester of
Gujarat Technological University, Ahmedabad during the
Academic year 2025- 2026.

Dr. Dimple N Gandhi Dr. Ratnesh K. Shukla

Internal Guide Head of the Department

Gujarat Technological University ii DGGEC, Surat

TEAM ID- 841427

INDUSTRY CERTIFICATE

Gujarat Technological University iii DGGEC, Surat

TEAM ID- 841427

DR. S & S S Gandhy

GOVERNMENT ENGINEERING COLLEGE
MAJURA GATE, SURAT.

DECLARATION

I hereby declare that the Internship report submitted along with the

Internship entitled “Report of Skill based training at International

Automobile Centre of Excellence” submitted in partial fulfilment for

the degree of Bachelor of Engineering in Mechanical Engineering to

Gujarat Technological University, Ahmedabad, is a Bonafide record of

original project work carried out by me at DR. S. & S. S. GHANDHY

GOVERMENT ENGINEERING COLLEGE, SURAT under the

supervision of Dhruv Ranpura and that no part of this report has been

directly copied from any other source, without providing due reference.

Lakshya Singh

Gujarat Technological University i DGGEC, Surat

TEAM ID- 841427

ACKNOWLEDGEMENT
I would like to highly acknowledge and pay respect to all associates with

project at different stages in presenting the reports of internship. I

express sincere thanks to Principal Dr. Sanjay R. Joshi sir, of Dr S & SS.

Ghandhy Government Engineering College, Surat for suggesting &

arranging best possible for us. Our sincere thanks to the Head of

Mechanical Engineering Department Dr. Ratnesh Shukla sir for his kind

help in the project. I am also thankful to my guide Dr. Dhruv Ranpura

sir for their valuable tips during the course of this study. The internship

work is the most practical and existing of my learning experience which

could be assets for me in my future career. It is my sincere duty to thank

all those people who helped me directly and indirectly in this internship.

I would like to express my sincere gratitude to my institute mentor, for

giving me opportunity to do an internship within the organization and

for his careful and precious guidance which was extremely valuable for

my study, both theoretically and practically. I also express my heartfelt

thanks GUJARAT TECHNOLOGICAL UNIVERSITY and GUJARAT

KNOWLEDGE SOCIETY(GKS) for arranging and sponsoring skill-

based training as an alternate of internship.

Thank You,

Gujarat Technological University ii DGGEC, Surat

TEAM ID- 841427

ABSTRACT
This report is to summarize the learning of my summer
training/Internship that I have carried out at International
Automobile Centre of Excellence. The International
Automobile Centre of Excellence (iACE), Gandhinagar, serves
as a national hub for automotive skill development, training,
and [Link] purpose of training at an automobile institute
is to get hands-on experience and skill development in vehicle.
It offers exposure to industry operations, networking
opportunities, and customer service experience. Students learn
problem-solving, industry standards, and gain insights into
potential career paths. The experience enhances resumes, may
lead to job opportunities, and fosters personal growth.

Gujarat Technological University iii DGGEC, Surat

TEAM ID- 841427

LIST OF FIGURES
Sr. No. Figure Page No.
3.1 iACE Logo 4
3.2 Tie ups with other universities 5
3.3 Workshop Layout 5
4.1 Engine mounted 8
4.2 Automobile Bodies 9
4.3 Monocoque 9
4.4 Body on Frame 9
4.5 I.C Engine 10
4.6 Cooling System 11
4.7 Lubrication System 12
4.8 Air Intake System 13
4.9 Turbocharger 14
4.10 Air flow Routing through Turbocharger 14
4.11 Fuel Feed System 15
4.12 HVAC System 16
5.1 Cylinder Block 19
5.2 Piston 19
5.3 Cylinder Head 20
5.4 Crankshaft 21
5.5 Camshaft 21
5.6 Valves 22
5.7 Spark Plug 22
5.8 Fuel Injector 23
5.9 Connecting Rod 23
5.10 Timing Belt/ Chain 24
5.11 Oil Pump 24
5.12 Flywheel 25
5.13 Pleated Air Filter 25
5.14 Throttle valve 26
5.15 Exhaust Manifold 26
5.16 EGR 26

Gujarat Technological University iv DGGEC, Surat

TEAM ID- 841427

5.17 Tapet 26
5.18 End bearing 28
6.1 Mechanical Brakes 30
6.2 Hydraulic / Pneumatic brake 30
6.3 Drum brake and Disc brake 30
6.4 ABS 34
7.1 Symbols of electrical components 37
8.1 Temperature sensor 38
8.2 Inductive sensor 38
8.3 ABS wheel speed sensor 39
8.4 Knock sensor 39
Synchronous motor v/s Asynchronous 41
9.1
motor
9.2 Brushed motor and BLDC motor 42
9.3 Stepper motor 43
10.1 Engine check light 45
10.2 Diagnosis Pad 45
OBD diagnostics trouble code 46
10.3
Identification
11.1 EV Powertrain components 47
11.2 HV Drivetrains layout 49
11.3 Toyota Prius 50
12.1 Two Post lift 52
12.2 Casing of Timing chain 53
12.3 Overhead camshaft 53

Gujarat Technological University v DGGEC, Surat

TEAM ID- 841427

LIST OF TABLES
Table 4.1 Automobile bodies.………………………………….. 9
Table 6.1 Types of Brake………………………………………. 30
Table 6.2 Difference b/w Disc and Drum brake….……………. 32
Table 6.3 List of components with function…………………… 33
Table 6.4 Types of ABS………………………...……………… 34
Table 8.1 Application of sensor…….…………..……………… 41

Gujarat Technological University vi DGGEC, Surat

TEAM ID- 841427

LIST IN ABBREVIATIONS USED

Term / Abbreviation Full Form / Meaning
International Automobile
iACE
Centre of Excellence
Internal Combustion
ICE
Engine
EV Electric Vehicle
HEV Hybrid Electric Vehicle
Plug-in Hybrid Electric
PHEV
Vehicle
ECU Electronic Control Unit
OBD On-Board Diagnostics
Heating, Ventilation, and
HVAC
Air Conditioning
ABS Anti-lock Braking System
Electronic Stability
ESP / ESC
Program / Control
TC / TCS Traction Control System
Advanced Driver
ADAS
Assistance Systems
Revolutions Per Minute
RPM
(engine speed)

Gujarat Technological University vii DGGEC, Surat

TEAM ID- 841427

TABLE OF CONTENTS
CHAPTER TITLE PAGE NO.
1 ABOUT INTERNSHIP 1
1.1 GTU curriculum 1
1.2 Objectives of Internship 1
1.3 Course outcome 2
1.4 Scope of Internship 2

2 ABOUT MY TRAINING DOMAIN 3

2.1 Introduction to Automobile/I.C.E 3
2.2 Scope of Automobile Field 3

3 OVERVIEW OF ORGANIZATION 4
3.1 Introduction to International Automobile Centre 4
of Excellence
3.2 Tie ups with other institutes 5
3.3 Workshop layout 5

4 AUTOMOTIVE SYSTEM 6
4.1 Introduction 6
4.2 Types of Automobile Bodies 7
4.3 Car structure 9
4.4 Brief on system 10
4.5 Subsystem 18

5 ENGINE & ITS COMPONENTS 20

Key components of an internal combustion
5.1 20
engine and their functions:
5.2 Tapet 27
5.3 Main bearing & big end bearing selection 29

6 BRAKES & ABS 30

6.1 Automotive brakes 30

Gujarat Technological University viii DGGEC, Surat

TEAM ID- 841427

6.2 ABS 32

7 AUTOMOTIVE ELECTRICAL
36
FUNDAMENTALS
7.1 Basic of Electrical circuit 36
7.2 Automotive electrical Fundamental 37

8 AUTOMOTIVE SENSORS 39
8.1 Working of sensors 39
8.2 Application of sensors 40

9 ELECTRICAL DRIVES 42
9.1 Types of motor 42

10 ON-BOARD DIAGNOSTICS 45
10.1 Introduction 45
10.2 Components of OBD system 45
10.3 Fault diagnosis process 45
10.4 Common fault diagnosed by process 47

11 HYBRID AND ELECTRIC VEHICLE 48

11.1 Electric Vehicle(EV) 48
11.2 Hybrid vehicle (HVs) 48
11.3 Different layouts of drivetrains in EV &HV 49

12 CASE STUDY 52
12.1 Case Study 1 52
12.2 Case Study 2 52
12.3 Case Study 3 53
CONCLUSION 55
REFERENCES 56

Gujarat Technological University ix DGGEC, Surat

TEAM ID- 841427

CHAPTER 1

ABOUT INTERNSHIP

1.1 GTU – Curriculum

The internship/skill-based training program is a requirement by Gujarat

technological university aimed at enabling students gains an experience of how
to link classroom concepts into the working environment on-campuses with
challenges, dynamics, techno logical advancements, professional ethics and
sector integration

1.2 Objectives of Internship/training

 To create competent professionals for the industry.

 To provide possible opportunities to learn, understand and sharpen the

real time technical / managerial skills required at the job
 To give exposure of the current technological developments relevant to
the subject area of training to the students.
 To learn applying the technical knowledge in real industrial situations
 To give exposure to the students about responsibilities and ethics of the
engineer.
 To understand role and responsibility of engineer in the service and
maintenance field.
 Understand operations and procedures in servicing a vehicle.
 Develop technical skills in vehicle maintenance
 Enhance problem-solving abilities.

Gujarat Technological University 1 DGGEC, Surat

TEAM ID- 841427

 To understand role and responsibility of engineer in the service and

maintenance field
 To strengthen industry institute linkage and increase employability of
the students.
 To understand the social, economics and administrative considerations
that influences the working environment of industrial organizations.

1.3 Course Outcome

Upon completion of this course students are able to:

1. Get exposure to the industrial environment, which cannot be simulated in

the classroom and hence creating competent professionals for the industry.
2. Get possible opportunities to learn, understand and sharpen the real time
technical or managerial skills required at the job(s).
3. Gain experience in writing technical reports / projects a presentation of it.
4. Learn and gain exposure to the engineer’s responsibilities and ethics.
5. Understand the social, economic and administrative consideration that
influence the working environment of industrial organizations.

1.4 Scope of Internship/training

 The opportunity to learn more about yourself

 An internship provides real life experience
 Get connected and develop your professional network.
 Transition into a full-time position.
 Opportunity to learn our skills.
 Communicate with experienced human resources.

Gujarat Technological University 2 DGGEC, Surat

TEAM ID- 841427

CHAPTER 2

ABOUT MY TRAINING’S DOMAIN

2.1 Introduction to Internal combustion Engine / Automobile

The IC (Internal Combustion) engine and automobile field is a cornerstone of

modern transportation, driving innovation in technology, engineering, and
mobility solutions. At its core, the IC engine refers to the power plant that propels
most vehicles on the road today, utilizing the controlled combustion of fuel and
air to generate mechanical energy.

The automobile industry encompasses a vast array of sectors, including vehicle

design, manufacturing, sales, and maintenance, with a primary focus on creating
safe, efficient, and reliable transportation solutions for consumers. Over the years,
this field has witnessed remarkable advancements in fuel efficiency, emissions
control, safety features, and autonomous driving technologies, all aimed at
improving the driving experience and addressing environmental concerns.

2.2 Scope of Automobile Field

The automobile sector encompasses vehicle manufacturing, research and

development, supply chain management, sales and distribution, aftermarket
services, emerging technologies, environmental sustainability, regulatory
compliance, transportation services, and global market dynamics. It drives
economic growth and technological innovation worldwide.

Gujarat Technological University 3 DGGEC, Surat

TEAM ID- 841427

CHAPTER 3

OVERVIEW OF ORGANIZATION

3.1 Introduction to International Automobile Centre of

Excellence
International Automobile Centre of Excellence (iACE), is an apex body for
skill development in the automotive sector, utilising modern technology &
systems. The centre caters to the entire value chain of the Automotive
Industry encompassing both Manufacturing & Servicing.

The International Automobile Centre of Excellence (iACE), is incorporated

as a 'Section 08 Company' under the Companies Act 2013, by Government
of Gujarat in collaboration with Maruti Suzuki India Limited (MSIL) with
50% equity stake each.

The centre is a world class institute catering to 'end to end' training,

development and research needs of the automobile ecosystem in India. The
centre hosts the latest 'state-of-the-art' infrastructure & technical labs to
provide hands on learning experience. The institute draws upon the expertise
of industry- academia collaborations with leading Indian & Foreign Partners
for Knowledge & Technological relevance of Industrial Learning.

Figure: 3.1 iACE Logo

Gujarat Technological University 4 DGGEC, Surat

TEAM ID- 841427

3.2 Tie up with another institute

Figure 3.2 Tie ups with other universities

3.3 Layout of workshop

Figure:3.3 Layout of workshop

Gujarat Technological University 5 DGGEC, Surat

TEAM ID- 841427

CHAPTER 4
AUTOMOTIVE SYSTEM (AN OVERVIEW)

4.1 Introduction
 The automotive system is a combination of mechanical, electrical, and
electronic components that enable vehicle operation.
 It consists of various interconnected subsystems working together for
mobility, performance, safety, and comfort.
 Major systems include:
o Powertrain system (engine, transmission)
o Steering and suspension system
o Braking system
o Cooling and lubrication system
o Air intake and exhaust system
o HVAC system
o Electrical and electronic control systems
 Modern vehicles are equipped with autotronics — a blend of automotive
and electronics for smart functionalities.
 Automotive systems are designed for:
o Efficient fuel usage
o Emission control
o Driver and passenger safety
o Enhanced driving comfort
 With technological advancements, vehicles now integrate:
o Sensors and actuators
o Embedded software and microcontrollers
o IoT and wireless communication
 The evolution of automotive systems has led to:
o Electric Vehicles (EVs)

Gujarat Technological University 6 DGGEC, Surat

TEAM ID- 841427

o Hybrid powertrains
o ADAS (Advanced Driver-Assistance Systems)
o Autonomous driving technologies
 The automotive system today is a result of interdisciplinary engineering —
combining mechanics, electronics, and data-driven control.

Figure:4.1 Engine mounted on vehicle

4.2 Types of Automobile Bodies

BODY TYPE DESCRIPTIO MAIN TYPICA
N FEATURE L USE
COUPE A 4-door car with a Comfortable, Family car,
separate trunk good boot urban use
space
SEDAN A 2-door car with a Sleek roofline, Sporty urban
sporty design compact cabin drive
HATCHBACK Small car with rear 3 or 5 doors, City driving,
door that swings compact economical
upward
PICKUP Vehicle with open Strong chassis, Utility, goods
cargo bed cargo capacity transport

Gujarat Technological University 7 DGGEC, Surat

TEAM ID- 841427

OFF-ROAD Built for rough High ground Adventure,

terrains clearance, rural travel
rugged build
SPORT High-performance, Aerodynamic, Racing,
stylish car fast enthusiasts
acceleration
MICRO Ultra-compact Minimal seats, City
vehicle small engine commuting,
solo rides
VAN Box-shaped vehicle Sliding doors, Family or
for multiple high roof cargo
passengers or cargo transport
CONVERTIBL Car with retractable Stylish, open- Leisure
E roof air driving drives
CROSSOVER Mix between sedan Higher stance, Urban + light
and SUV compact SUV off-road
features
SUV (SPORT Large vehicle with Tall body, Family,
UTILITY off-road and utility 4WD option rugged
VEHICLE) capabilities terrain
WAGON Like a sedan but Large boot, Travel,
extended rear family cargo,
oriented families
MUSCLE American high- Large engine, Classic car
power performance 2-door lovers,
cars performance
ROADSTER 2-seat, open-top Lightweight, Enthusiasts,
sports car fast sporty leisure

Gujarat Technological University 8 DGGEC, Surat

TEAM ID- 841427

CABRIOLET Another name for Soft/hard top Style-

convertible retractable focused
(especially in driving
Europe)
LIMOSUINE Extra-long luxury Partitioned Events, VIP
vehicle cabin, transport
chauffeur-
driven
FORMULA 1 Single-seater open- Aerodynamics Professional
wheel race car , high-speed racing
design
Table:4.1 Types of automobile bodies

Figure 4.2 Different automobile bodies

4.3 Car structure

 Automotive structures are primarily classified into Monocoque and
Body-on-Frame types. The monocoque structure integrates the body
and chassis into a single unit, offering high structural rigidity, reduced
weight, and ease of manufacturing. This design is commonly used in

Gujarat Technological University 9 DGGEC, Surat

TEAM ID- 841427

modern passenger cars and hatchbacks due to its efficiency and safety
benefits.
 In body-on-frame construction, the vehicle body is mounted on a
separate chassis frame. This configuration ensures greater durability,
superior load-bearing capacity, and ease of repair, making it suitable for
heavy-duty vehicles such as trucks, SUVs, and off-road applications.

Figure:4.3 Monocoque Figure: 4.4 Body on frame

4.4 Brief n System

4.4.1 Power generation system
The power generation system in an automobile is responsible for
converting chemical energy from fuel into mechanical energy that
drives the vehicle. This is primarily achieved through the internal
combustion engine (ICE) or electric motor in case of electric vehicles
(EVs). The system forms the core of the powertrain and includes
various components that work together to generate, manage, and
transmit power to the wheels.
Key Elements of the Power Generation System (ICE-based):

 Fuel System: Delivers fuel to the engine for combustion.

 Air Intake System: Supplies oxygen necessary for fuel combustion.
 Internal Combustion Engine: Burns the air-fuel mixture to produce
thermal energy.
 Piston-Crank Mechanism: Converts thermal energy into mechanical
rotary motion.
 Exhaust System: Expels combustion gases from the engine.

Gujarat Technological University 10 DGGEC, Surat

TEAM ID- 841427

Figure:4.5 An I.C. Engine

4.4.2 Cooling system

 The cooling system is essential for maintaining the engine’s optimal

operating temperature.
 It prevents overheating caused by the intense heat generated during fuel
combustion.
 A coolant fluid (usually a mixture of water and antifreeze) circulates
through engine passages.
 Heat from the engine is absorbed by the coolant and transferred to the
radiator.
 The radiator releases this heat into the atmosphere using air flow and a
cooling fan.
 Key components include: radiator, water pump, thermostat, coolant
reservoir, hoses, and cooling fan.
 Regulates thermal efficiency, improves engine longevity, and reduces
the risk of thermal damage.
 Maintains stable engine performance across varying load and
environmental conditions.

Figure: 4.6 Cooling system in an I.C. Engine

Gujarat Technological University 11 DGGEC, Surat

TEAM ID- 841427

4.4.3 Lubrication system

 The lubrication system plays a critical role in minimizing friction and

wear between moving engine parts.
 Lubricating oil is circulated under pressure to create a protective film
between components such as the crankshaft, piston, camshaft, and
bearings.
 This oil film prevents metal-to-metal contact, reducing mechanical wear
and operating noise.
 The system also helps in dissipating heat generated due to internal
friction.
 Impurities, sludge, and metal debris are removed through the oil filter,
keeping the oil clean.
 Key components include: oil pump, oil filter, oil pan, lubrication
passages, and pressure relief valve.
 Ensures smooth engine operation, enhances fuel efficiency, and increases
engine lifespan.
 Reduces the risk of mechanical failure caused by overheating or
component seizure.

Figure: 4.7 Lubrication system

Gujarat Technological University 12 DGGEC, Surat

TEAM ID- 841427

4.4.4 Air intake system

 The air intake system is essential for managing the engine’s

breathing process.
 It draws atmospheric air, filters it, and delivers it to the combustion
chamber.
 An air filter removes dust, dirt, and contaminants to prevent engine
damage.
 The filtered air is routed through intake manifolds to each cylinder.
 Sensors and actuators (e.g., MAF, MAP, throttle body) regulate
airflow and support accurate air–fuel mixture control.
 Maintains optimal combustion efficiency, improving power output
and fuel economy.
 Helps in controlling emissions by ensuring a balanced and clean
intake.
 Consistent airflow contributes to engine stability under different
driving conditions.

Figure:4.8 Air Intake system

4.4.5 Air intake system with turbocharger (overview)

When a turbocharger is installed in the air intake system, the process

of supplying air to the engine is significantly enhanced to increase
engine power output and efficiency.

Gujarat Technological University 13 DGGEC, Surat

TEAM ID- 841427

 The turbocharger is a forced induction device that compresses the

incoming air using a turbine-driven compressor, thereby increasing
the air density entering the combustion chamber.
 This enables more oxygen to be packed into each intake cycle,
allowing more fuel to be burned and thus increasing power output
without increasing engine size.
 The system uses exhaust gases from the engine to spin a turbine
wheel, which in turn drives the compressor wheel on the intake side.
 Compressed air is then passed through an intercooler to reduce its
temperature before it enters the intake manifold, ensuring better
combustion efficiency and preventing engine knocking.
 The turbocharged air intake system generally consists of:
 Air filter – filters incoming air
 Compressor (turbocharger) – compresses and increases air
pressure
 Intercooler – cools the compressed air
 Throttle body and intake manifold – directs air into the
cylinders
 Additional sensors like the Mass Air Flow (MAF) and Manifold
Absolute Pressure (MAP) sensors are used to monitor and adjust air–
fuel ratios precisely.
 This system enhances engine efficiency, performance, and torque,
particularly at higher altitudes or under load conditions.

Gujarat Technological University 14 DGGEC, Surat

TEAM ID- 841427

Figure:4.9 Turbocharger Figure: 4.10 Airflow routing through turbocharger

4.4.5 FUEL FEED SYSTEM

 The fuel feed system delivers fuel from the tank to the engine for
combustion.
 It ensures a steady and controlled supply of fuel under varying engine
loads and speeds.
 Major components include:
o Fuel Tank – stores the fuel safely.
o Fuel Pump – draws fuel from the tank and pressurizes it.
o Fuel Filter – removes impurities and particles from the fuel.
o Fuel Lines – transport fuel to the engine.
o Fuel Injectors / Carburettor – deliver fuel into the combustion
chamber in atomized form.
 Modern systems use electronic fuel injection (EFI) for precise fuel
delivery and better efficiency.
 Maintains the ideal air-fuel ratio, improving combustion, power
output, and fuel economy.
 Prevents engine knocking, misfires, and reduces exhaust emissions.

Gujarat Technological University 15 DGGEC, Surat

TEAM ID- 841427

 Proper fuel feed system operation is critical for engine performance,

reliability, and safety.

Figure:4.11 Fuel feed system

4.4.6 HVAC system

 Overview of the HVAC (Heating, Ventilation, and Air Conditioning)

system provided, focusing on its role in maintaining thermal comfort
inside the passenger compartment.
 Functioning and layout of key HVAC components explained:
o Compressor – for refrigerant compression
o Condenser – for heat dissipation
o Expansion valve – for pressure regulation
o Evaporator – for heat absorption
o Blower fan – for air circulation
o Cabin air filter – for air purification
 Refrigerant flow cycle discussed in case study, highlighting phase
changes involved in heat exchange.
 Different refrigerants studied:
o R-12 – older, ozone-depleting (phased out)
o R-134a – commonly used in modern vehicles
o R-1234yf – environmentally friendly, used in newer systems

Gujarat Technological University 16 DGGEC, Surat

TEAM ID- 841427

 Emphasis placed on energy efficiency, defogging, air quality, and

overall climate control performance.
 Practical relevance of HVAC integration within vehicle architecture
and its contribution to passenger comfort and safety highlighted.

Figure:4.12 HVAC system

4.5 Subsystem
In automobiles, subsystems are specialized units or systems that work
together to ensure the vehicle operates efficiently, safely, and comfortably.
Each subsystem is responsible for a specific set of tasks. Below is a list of
major automobile subsystems along with their key functions:

1. Powertrain Subsystem
 Components: Engine, transmission, clutch, driveshaft, differential,
axles.

 Function: Converts fuel into mechanical power and delivers it to the

wheels. It governs acceleration, speed, and torque delivery.
2. Chassis and Suspension Subsystem
 Components: Frame, suspension, steering system, wheels, tires.
 Function: Supports vehicle weight, provides ride comfort, absorbs
shocks, and maintains contact between tires and road.
3. Braking System
 Components: Brake pedal, master cylinder, disc/drum brakes, ABS,
callipers, brake lines.

Gujarat Technological University 17 DGGEC, Surat

TEAM ID- 841427

 Function: Slows down or stops the vehicle by applying friction to the

wheels.
4. Electrical & Electronics Subsystem
 Components: Battery, alternator, starter, ECU, sensors, actuators,
wiring.
 Function: Powers lights, infotainment, sensors, ignition, and onboard
computer systems.
5. Cooling System
 Components: Radiator, coolant, water pump, thermostat, fan.
 Function: Maintains engine temperature within optimal range to prevent
overheating.
6. Fuel System
 Components: Fuel tank, fuel pump, injectors/carburettor, fuel filter, fuel
lines.
 Function: Stores and delivers the correct amount of fuel to the engine
for combustion.
7. Air Intake & Exhaust System
 Components: Air filter, intake manifold, turbocharger (if any), exhaust
manifold, catalytic converter, muffler.
 Function: Supplies clean air to the engine for combustion and expels
exhaust gases safely.
8. Transmission System
 Components: Gearbox, clutch, differential.
 Function: Transfers engine power to the wheels at varying torque and
speed levels.
9. Body and Interior System
 Components: Doors, dashboard, seats, infotainment, HVAC,
instrument cluster.
 Function: Ensures passenger comfort, convenience, and vehicle
aesthetics.
10. Safety Systems

Gujarat Technological University 18 DGGEC, Surat

TEAM ID- 841427

 Components: Seat belts, airbags, ABS, traction control, ADAS

(Advanced Driver Assistance Systems).
 Function: Enhances occupant safety and vehicle control during
emergencies.
11. Telematics & Infotainment System
 Components: GPS, touchscreen display, audio system, vehicle-to-cloud
interfaces.
 Function: Provides navigation, entertainment, and connectivity
services.
12. Lighting & Signalling System
 Components: Headlights, tail lights, turn signals, hazard lights.
 Function: Ensures visibility and communicates driving intentions to
other road users.

Gujarat Technological University 19 DGGEC, Surat

TEAM ID- 841427

CHAPTER 5

ENGINE AND ITS COMPONENTS

5.1 Key components of an internal combustion engine and their

functions:
1. Cylinder Block:

Figure:5.1 Cylinder block [2]

 It is generally made up of Cast Iron or Aluminium Alloy (Al-Si

Alloys)
 Function: The main structure housing the cylinders where
combustion occurs. It provides the foundation for other engine
components and contains coolant passages for heat dissipation.
2. Pistons:

Figure:5.2 Piston [2]

 The piston is generally made up of Aluminium Alloy (most

common), Cast Iron (less common, mainly older or low-speed
engines), Forged Aluminium Alloy (used in performance or racing

Gujarat Technological University 20 DGGEC, Surat

TEAM ID- 841427

engines) and Steel Pistons (emerging in high-efficiency diesel

engines).
 Function: Move up and down within cylinders, driven by combustion
pressure, converting the force into rotational motion via the
connecting rod and crankshaft.

3. Cylinder Head:

Figure:5.3 Cylinder head [2]

 Made up of: Aluminium Alloy (most common in modern engines)

and Cast Iron
 Function: Seals the top of the cylinders, containing valves, spark
plugs (in gasoline engines), or fuel injectors (in diesel engines), and
facilitates combustion by housing the combustion chamber.

Gujarat Technological University 21 DGGEC, Surat

TEAM ID- 841427

4. Crankshaft:

Figure:5.4 Crankshaft [2]

 Function: Converts the linear motion of pistons into rotational

motion, which is transferred to the transmission to drive the vehicle’s
wheels.

5. Camshaft:

Figure:5.5 Camshaft [2]

Gujarat Technological University 22 DGGEC, Surat

TEAM ID- 841427

 Function: Controls the opening and closing of intake and exhaust

valves via lobes, ensuring proper timing for air/fuel intake and
exhaust gas expulsion.

6. Valves (Intake and Exhaust):

Figure:5.6 Valve [2]

 Function: Intake valves allow the air-fuel mixture into the cylinder;
exhaust valves release combustion gases, regulating the engine’s
breathing process.

7. Spark Plug (Gasoline Engines):

Figure: 5.7 Spark Plug [2]

 Distance between centre and ground electrode (e.g., 0.6 – 1.1 mm).

Gujarat Technological University 23 DGGEC, Surat

TEAM ID- 841427

 Voltage required to jump the spark gap. Typically, 12,000 V to

45,000 V, can go up to 60,000 V in modern ignition systems.
 Function: Ignites the air-fuel mixture in the cylinder by producing a
spark, initiating combustion.

8. Fuel Injector (or Carburettor in older engines):

Figure:5.8 Fuel injector [2]

 Function: Delivers precise amounts of fuel into the cylinder or intake
manifold for combustion, ensuring efficient fuel use.

9. Connecting Rod:

Figure: 5.9 Connecting rod [2]

Gujarat Technological University 24 DGGEC, Surat

TEAM ID- 841427

 Function: Links the piston to the crankshaft, transferring the piston’s

motion to rotate the crankshaft.

10. Timing Belt/Chain:

Figure: 5.10 Timing Belt/ Chain [2]

 Function: Synchronizes the crankshaft and camshaft, ensuring
valves open and close at the correct time relative to piston
movement.

11. Oil Pump:

Figure:5.11 Oil Pump [2]

 Function: Circulates oil to reduce friction, cool moving parts, and
extend engine life.

Gujarat Technological University 25 DGGEC, Surat

TEAM ID- 841427

12. Flywheel:

Figure: 5.12 Flywheel [2]

 Stores energy during the power stroke and releases it during the
non-power strokes (intake, compression, exhaust) to keep the
crankshaft rotating smoothly.
 Minimizes fluctuations in crankshaft speed by smoothing out the
jerky nature of combustion. Especially useful in single-cylinder
engines.

13. Air Intake System (Air Filter, Throttle):

Figure:5.13 Pleated Air Filter

 Remove debris larger than 10 microns.

Gujarat Technological University 26 DGGEC, Surat

TEAM ID- 841427

Figure: 5.14 Throttle valve

 Function: Supplies clean air to the engine for combustion, with the
throttle controlling airflow to regulate engine power.

14. Exhaust System (Exhaust Manifold, Catalytic Converter):

Figure:5.15 Exhaust Manifold [2] Figure:5.16 EGR [2]

 Function: Channels exhaust gases out of the engine and reduces

emissions through the catalytic converter.

5.2 Tapet

Figure:5.17 Tapet

Gujarat Technological University 27 DGGEC, Surat

TEAM ID- 841427

Function of Tappet:
The tappet transmits the rotational motion of the camshaft into the
reciprocating motion required to open and close the engine valves. It acts
as an intermediate link between the cam lobe and the valve stem (directly
or via pushrods and rocker arms in OHV engines).
Key Roles:
 Converts rotary camshaft motion to linear valve motion
 Maintains correct valve timing
 Helps maintain valve clearance
 Reduces wear between camshaft and valve assembly
Construction of Tappet:
The tappet is generally a cylindrical or bucket-type component made of
hardened steel or alloy steel with good wear and fatigue resistance.
Main Components:
1. Body:
o Cylindrical and hollow or solid
o Slides inside a bore in the engine block
o Contacts the cam lobe directly
2. Contact Surface (Base):
o Flat or slightly convex
o Faces the cam lobe
o Heat-treated to resist wear

Types of Tappets:
 Solid (Mechanical) Tappet
 Hydraulic Tappet (most common in modern engines)
 Roller Tappet (reduces friction with roller bearing at cam contact)

Material Used:

Gujarat Technological University 28 DGGEC, Surat

TEAM ID- 841427

 High carbon steel, chilled iron, or chromium alloy steel

 Often case hardened to resist wear at high RPM

5.3 Main bearing & big end bearing selection

Engine main bearings and big end bearings are crucial for engine
performance and longevity.

 Main Bearings: Support the crankshaft and maintain its

alignment. They must be selected based on engine specifications,
including size, load capacity, and material.

Proper selection ensures minimal friction and optimal rotation, preventing

wear and overheating.

 Big End Bearings: Located at the connecting rods, they handle

forces from the pistons. Selection depends on the engine’s
power output and operating conditions. They must match the
crankshaft and connecting rod dimensions precisely to avoid
excessive play or friction, which could lead to engine failure.

Both types of bearings should be chosen according to manufacturer

specifications and performance requirements for reliability and efficiency.

Figure: 5.18 Bearings used in connecting rods

Gujarat Technological University 29 DGGEC, Surat

TEAM ID- 841427

CHAPTER 6

BRAKES AND ABS

6.1 Automotive brakes
1. Working Principle of Brakes
The basic function of an automotive brake is to reduce the speed or stop
the vehicle by applying frictional force to the moving parts of the wheel.
 When the brake pedal is pressed, it transmits force through
mechanical, hydraulic, pneumatic, or electrical means.
 This force activates brake pads or shoes, which press against a
rotating part (disc or drum).
 The kinetic energy of the moving vehicle is converted into heat
energy by friction, slowing the vehicle.

2. Types of Brakes (Based on Various Classifications)

A. Based on Actuation Method

Type Description

Mechanical Uses rods, cables, and levers to transmit pedal force.

Brake Common in hand/parking brakes.

Hydraulic Uses brake fluid pressure. Common in passenger

Brake vehicles.

Pneumatic
Brake (Air Uses compressed air. Common in trucks and buses.
Brake)

Electromagnetic Uses magnetic field to generate resistance. Found in

Brake hybrid/electric vehicles.

Table:6.1 Types of brake

Gujarat Technological University 30 DGGEC, Surat

TEAM ID- 841427

Figure:6.1 Mechanical brake Fig: 6.2 Pneumatic/Hydraulic brake

B. Based on Construction
1. Disc Brake
 Construction:
 Rotor (Disc): Mounted on the wheel hub.
 Calliper: Contains pistons and brake pads.
 Brake Pads: Friction material that presses against the disc.
 Working:
 When brake fluid pressure is applied, the calliper pistons
push the pads against the disc.
 The resulting friction slows the rotation of the wheel.
 Applications: Front brakes of most cars, some use on all wheels.

Figure:6.3 Disc Brake and Drum Brake

Gujarat Technological University 31 DGGEC, Surat

TEAM ID- 841427

2. Drum Brake
 Construction:
o Brake Drum: Rotates with the wheel.
o Brake Shoes: Semi-circular friction surfaces.
o Wheel Cylinder: Contains pistons that push the shoes
outward.
o Return Springs: Pull shoes back after braking.
 Working:
o Hydraulic pressure forces the shoes outward, pressing
against the inner surface of the rotating drum.
o Friction slows or stops the wheel.
 Applications: Rear wheels in small vehicles, parking brakes.
3. Difference between Disc brake and Drum brake
Feature Disc Brake Drum Brake

Friction Inside of the

Outside of the rotor
Surface drum
Heat Poor (enclosed
Better (open to air)
Dissipation system)
Maintenance Easier More complex
Rear wheels,
Common Use Front wheels
handbrakes
Prone to brake
Performance High braking efficiency
fade

Table:6.2 Difference b/w Disc and Drum brake

6.2 ABS
The Anti-lock Braking System (ABS) is a safety system in vehicles that
prevents the wheels from locking during emergency or hard braking,
ensuring that the driver maintains steering control while braking.

Gujarat Technological University 32 DGGEC, Surat

TEAM ID- 841427

1. Purpose of ABS
 Prevent wheel lock-up.
 Maintain traction between tires and road.
 Allow controlled and stable braking, especially on wet, icy, or
slippery roads.
 Reduce braking distance in some conditions.
 Enhance overall vehicle safety and control.

2. Components of ABS
Component Function
Wheel Speed Monitor the speed of each wheel. Detect if a
Sensors wheel is about to lock up.
Electronic Processes input from sensors. Commands the
Control Unit hydraulic modulator to reduce pressure if
(ECU) locking is detected.
Hydraulic
Controls brake fluid pressure to each wheel
Modulator /
using valves and pumps.
Control Unit
Valves Regulate pressure to the brake lines. Usually in
three stages: open, hold, release.
Pump Restores pressure lost during modulation to
maintain braking force.
Table:6.3 List of Components
3. Working Principle of ABS
Step-by-Step Process:
1. Normal Braking:
o Brake pressure is applied equally to all wheels.
o Wheels rotate normally.
2. Wheel Lock Detection:
o Ifone or more wheels begin to decelerate faster (about to lock),
speed sensors detect it.
o The signal is sent to the ABS ECU.
3. Brake Pressure Modulation:

Gujarat Technological University 33 DGGEC, Surat

TEAM ID- 841427

o The ECU commands the modulator to release brake pressure

slightly on the affected wheel.
o It may rapidly apply and release pressure (pulsating effect) several
times per second (up to 15–20 times/sec).
4. Maintained Steering Control:
o Since wheels don’t lock, the vehicle can still steer during braking,
avoiding obstacles.
[Link] of ABS
Type Details
1-Channel, Used in motorcycles or old rear-wheel-drive
1-Sensor vehicles; one sensor controls both rear wheels.
3-Channel, Two front wheels and one sensor for both rear
3-Sensor wheels.
4-Channel, Independent control and sensing for all four wheels
4-Sensor (most accurate and modern setup).
2-Channel One sensor and valve for each axle (found in some
ABS budget cars).

5. Advantages of ABS
 Prevents wheel lock-up.
 Maintains steering control during braking.
 Reduces the chance of skidding and accidents.
 Effective on wet or slippery surfaces.
 Compatible with EBD, ESC, and TCS systems.

6. Limitations / Disadvantages
 In gravel, sand, or deep snow, ABS may increase stopping distance.
 Slightly more complex and costlier than conventional brakes.
 Can give false sense of security to inexperienced drivers.
 Requires maintenance and calibration.

Gujarat Technological University 34 DGGEC, Surat

TEAM ID- 841427

7. Use Case Example

Suppose a car is moving at 60 km/h and a dog suddenly crosses the road.
If the driver brakes hard, ABS ensures that:
 The wheels do not lock.
 The driver can steer away from the obstacle.
 Braking is applied optimally to all wheels without skidding.

8. Additional Features in Modern ABS Systems

 EBD (Electronic Brakeforce Distribution) – Distributes brake
force according to load.
 Brake Assist (BA) – Adds pressure during panic braking.
 Hill Start Assist, Traction Control, and ESC often work
alongside ABS.

Figure: 6.4 ABS

Gujarat Technological University 35 DGGEC, Surat

TEAM ID- 841427

CHAPTER 7

AUTOMOTIVE ELECTRICAL
FUNDEMENTALS

7.1 Basics of Electrical Circuits

An electrical circuit is a path through which electric current flows. It
typically consists of various components like resistors, capacitors,
inductors, and power sources (batteries or generators). Here's a brief
overview:

Components:
 Resistors: Limit the flow of electric current.
 Capacitors: Store electrical energy temporarily and release it when
needed.
 Inductors: Store energy in a magnetic field when electric
current passes through. Power Sources: Provide the necessary
voltage to drive the current.

Types of Circuits:

 Series Circuit: Components are connected end-to-end,

providing a single path for current flow. The total resistance is
the sum of individual resistances.
 Parallel Circuit: Components are connected across common
points, offering multiple paths for current. The total resistance is
reduced, calculated using the reciprocal sum of individual
resistances.

Ohm's Law:
Fundamental relationship in electrical circuits, defined as V = I*R
where,
V stands for Voltage
I stand for current
R stands for Resistor

Gujarat Technological University 36 DGGEC, Surat

TEAM ID- 841427

Kirchhoff's Laws:
 Kirchhoff's Current Law (KCL): The total current entering a
junction equals the total current leaving the junction.
 Kirchhoff's Voltage Law (KVL): The sum of all voltages around a
closed loop is zero.

AC vs. DC:
 Direct Current (DC): Electric current flows in one direction. Common
in batteries.
 Alternating Current (AC): Electric current changes direction
periodically. Common in household power supplies.
 Understanding these basics is essential for analyzing and designing
electrical circuits, ensuring they operate safely and effectively.

7.2 Automotive Electricals Fundamental

Automobile electrical fundamentals cover various key components and
systems essential for vehicle operation:

 Battery: Provides electrical energy to start the engine and power

accessories when the engine is off.

 Alternator: Charges the battery and powers the electrical system

when the engine is running.

Fig:7.1 Alternator Figure:7.2 Starter motor

 Starter Motor: Engages the engine flywheel to start the combustion

process.

Gujarat Technological University 37 DGGEC, Surat

TEAM ID- 841427

 Ignition System: Generates and delivers high-voltage spark to

ignite the fuel-air mixture in the engine cylinders.

 Electrical Wiring: Connects all electrical components and systems,

ensuring proper power distribution.

 Fuses and Relays: Protect electrical circuits from overload and

control circuit operations.

 Lights and Signals: Includes headlights, tail lights, turn signals, and
dashboard indicators for visibility and safety.

 Sensors: Monitor various vehicle parameters (like temperature,

speed, and pressure) and send signals to control units for appropriate
responses.

Figure:7.1 Symbols of electrical components

Gujarat Technological University 38 DGGEC, Surat

TEAM ID- 841427

CHAPTER: 8
AUTOMOTIVE SENSORS
8.1 Working of Sensors
Introduction:
Sensors in automotive systems are essential components that detect
physical conditions and convert them into electrical signals, enabling
electronic control units (ECUs) to make real-time decisions for optimal
vehicle operation.
Working Principle:
Most automotive sensors operate on one of the following basic
principles:
 Resistive (e.g., Thermistor for temperature sensing)

Figure: 8.1 Temperature sensor

 Inductive (e.g., Crankshaft position sensor)

Figure:8.2 Inductive sensor

 Hall Effect (e.g., Wheel speed sensor)

Gujarat Technological University 39 DGGEC, Surat

TEAM ID- 841427

Fig: 8.2 ABS wheel speed sensor

 Capacitive (e.g., Rain sensor)

 Piezoelectric (e.g., Knock sensor)

Fig: 8.3 Knock sensor

 Optical (e.g., Ambient light sensor)

General Sensor Working Process:
1. Detection: The sensor detects a physical quantity (e.g.,
temperature, pressure, speed).
2. Signal Conversion: The detected signal is converted into an
analog or digital electrical signal.
3. Signal Conditioning: The signal is amplified or filtered for
clarity.
4. Output Transmission: The conditioned signal is transmitted to
the ECU.
5. Action by ECU: The ECU processes the data and initiates control
actions (e.g., fuel injection timing, ABS activation, etc.).

8.2 Applications of Automotive Sensors

Gujarat Technological University 40 DGGEC, Surat

TEAM ID- 841427

Automotive sensors are widely used across different systems to enhance

safety, efficiency, performance, and comfort. Here are the major areas
of application:
System Sensor Type Function/Application
Oxygen (O2), Controls air-fuel ratio,
Engine
MAF, MAP, ignition timing, and engine
Management
Knock, TPS performance

Speed sensor, Ensures smooth shifting

Transmission
Gear position and prevents gear
Control
sensor mismatch

Wheel speed
Braking sensor (ABS), Activates ABS, monitors
System Brake pad wear brake pad condition
sensor
Cabin
Climate Adjusts AC settings for
temperature,
Control passenger comfort
Sunlight sensor
Detects collisions and
Airbag crash
Safety deploys airbags, detects
sensor, Seat
Systems presence for seatbelt
occupancy sensor
warnings
Steering angle Supports electronic
Chassis
sensor, Yaw rate stability control (ESC) and
Control
sensor traction control
Fuel level sensor,
Monitors fuel availability
Fuel System Fuel pressure
and delivery pressure
sensor
Enables lane assist,
Driver Radar, Ultrasonic,
adaptive cruise control,
Assistance LiDAR, Camera-
parking assist, and
(ADAS) based sensors
collision avoidance
Battery Current, Voltage,
Ensures proper
Management Temperature
charge/discharge cycles
(EVs) sensors

Gujarat Technological University 41 DGGEC, Surat

TEAM ID- 841427

CHAPTER 9

ELECTRIC DRIVES

9.1 Types of motor

I. Based on Power Source
1. AC Motors (Alternating Current Motors)
Operate on AC supply.
a) Synchronous Motor
 Rotor rotates at synchronous speed (same as stator's rotating
magnetic field)
 Needs external DC excitation
 Applications: Power factor correction, high-precision machines

Figure:9.1 Synchronous motor and Asynchronous motor

b) Induction Motor (Asynchronous Motor)

 Rotor lags behind the stator field (slip occurs)
 Most common motor type in industry
 Types:
o Single-phase: Fans, pumps, home appliances
o Three-phase: Industrial machinery, compressors

2. DC Motors (Direct Current Motors)

Operate on DC supply.

Gujarat Technological University 42 DGGEC, Surat

TEAM ID- 841427

a) Brushed DC Motor
 Uses carbon brushes and commutator
 Simple design, easy speed control
 Applications: Toys, small tools, automotive windows

Figure: 9.2 Brushed DC motor and BLDC motor

b) Brushless DC Motor (BLDC)

 No brushes, uses electronic commutation
 High efficiency, long life
 Applications: Drones, EVs, cooling fans
c) Shunt Motor
 Field winding connected in parallel with the armature
 Constant speed under varying load
d) Series Motor
 Field winding in series with the armature
 High starting torque, variable speed
 Application: Trains, elevators, hoists

II. Based on Operation Principle

1. Stepper Motor

Gujarat Technological University 43 DGGEC, Surat

TEAM ID- 841427

 Moves in discrete steps

 Precise control of angular position
 Applications: CNC, 3D printers, robotics

2. Servo Motor
 Controlled by PWM signals for position control
 Includes encoder/feedback system
 Applications: Robotics, automation, antennas

III. Special Purpose Motors

1. Linear Motor
 Provides motion in a straight line instead of rotary
 Applications: Maglev trains, actuators
2. Universal Motor
 Operates on AC or DC
 High speed, lightweight
 Applications: Mixers, power tools, vacuum cleaners
3. Hysteresis Motor
 Smooth, noiseless operation
 Used in electric clocks, record players

Fig: 9.3 Stepper motor and Servo motor

Gujarat Technological University 44 DGGEC, Surat

TEAM ID- 841427

CHAPTER 10

FAULT DIAGNOSTICS

10.1 INTRODUCTION

On-Board Diagnostics (OBD) systems are integral to modern

vehicles, allowing for real-time monitoring and diagnosis of
various vehicle subsystems. Initially introduced to control vehicle
emissions, OBD systems have evolved to provide comprehensive
diagnostic information, enhancing vehicle performance, safety,
and reliability. Fault diagnosis in OBD systems involves
identifying, isolating, and rectifying issues within the vehicle's
electronic and mechanical systems.

10.2 Components of OBD Systems

1. Sensors: Monitor various parameters such as engine temperature,

oxygen levels, speed, and fuel mixture.
2. Electronic Control Unit (ECU) : The central processing unit that
receives input from sensors, processes data, and controls
actuators.
3. Actuators: Devices like fuel injectors and spark plugs that execute
commands from the ECU.
4. Diagnostic Trouble Codes (DTCs) : Codes generated by the
OBD system indicating specific faults or issues.

10.3 Fault Diagnosis Process

1. Detection: The OBD system continuously monitors sensors

and compares their readings against predefined thresholds.
When a parameter exceeds its threshold, the system flags a

Gujarat Technological University 45 DGGEC, Surat

TEAM ID- 841427

potential issue.

2. Code Generation: Upon detecting an anomaly, the ECU

generates a DTC, which is stored in the vehicle's memory. Each
DTC is a standardized code that corresponds to a specific fault.

3. Notification: The driver is alerted via the Malfunction Indicator

Lamp (MIL) or "Check Engine" light on the dashboard. This
prompts further investigation using an OBD scanner.

Fig:10.1 Engine check light

4. Scanning: A mechanic or technician connects an OBD scanner

to the vehicle's OBD port to retrieve stored DTCs. The scanner
displays the codes along with descriptions of the corresponding
issues.
5. Diagnosis: The technician interprets the DTCs to identify the
root cause of the problem. This involves understanding the
system's operation, analysing sensor data, and using diagnostic
flowcharts and repair manuals.

Figure:10.2 Diagnosis Pad

Gujarat Technological University 46 DGGEC, Surat

TEAM ID- 841427

6. Repair and Verification: After diagnosing the fault, the

necessary repairs or replacements are made. Post-repair, the OBD
system is scanned again to ensure the issue is resolved, and the
MIL is reset.

Figure:10.3 OBD2 Diagnostics trouble identification

10.4 Common Faults Diagnosed by OBD Systems

1. Emission Control: Issues with components like the catalytic converter,

oxygen sensors, and EGR valve.

2. Engine Performance: Problems with fuel injectors, ignition coils, and

mass airflow sensors.

3. Transmission: Faults in transmission solenoids, sensors, and fluid

levels.

4. Fuel System: Issues with fuel pressure, pump performance, and

injector circuits.

5. Electrical Systems: Problems with wiring, battery voltage, and sensor

connections.

Gujarat Technological University 47 DGGEC, Surat

TEAM ID- 841427

CHAPTER 11

HYBRID & ELECTRIC VEHICLE

11.1 Electric vehicles (EVs):

 The system uses a battery pack and an electric motor instead of an ICE.
 Electricenergy is drawn from the battery and converted into mechanical
energy using motor windings and magnetic fields.
 Regenerative braking systems may also contribute to energy recovery.

Figure: 11.1 EV Powertrain Components

11.2 Hybrid vehicles (HVs):

 Combines an Internal Combustion Engine (ICE) and an Electric

Motor to generate power.
 ICE produces mechanical power and can also charge the battery.
 Electric Motor/Generator works in two modes:
 Motor Mode: Drives wheels using battery power.
 Generator Mode: Recovers energy via regenerative braking.
 Battery Pack stores electrical energy and supplies power to the
motor.
 Power Control Unit (PCU) regulates power flow between ICE,
motor, and battery.
 DC-DC Converter provides 12V supply to accessories.

Gujarat Technological University 48 DGGEC, Surat

TEAM ID- 841427

 Onboard Charger (in plug-in hybrids) charges the battery using

external power.
11.3 Different layouts of drivetrains in EV &HV
A. EV Drive train layouts
1. Single Motor, Front-Wheel Drive (FWD)
 Description: One electric motor power the front wheels.
 Advantages:
o Simple design
o Lower cost
o Efficient for urban driving
 Example Vehicles: Nissan Leaf
2. Single Motor, Rear-Wheel Drive (RWD)
 Description: One motor drives the rear axle.
 Advantages:
o Better weight distribution
o Enhanced handling for sporty vehicles
 Example Vehicles: BMW i3
3. Dual Motor, All-Wheel Drive (AWD)
 Description: One motor on each axle for AWD.
 Advantages:
o Superior traction and performance
o Better torque vectoring and acceleration
 Example Vehicles: Tesla Model S, Rivian R1T
4. In-Wheel Motor Drive (Each Wheel Motor)
 Description: Motors are placed directly in each wheel hub.
 Advantages:
o Excellent torque control
o No need for transmission, driveshaft, or differential

Gujarat Technological University 49 DGGEC, Surat

TEAM ID- 841427

 Challenges: Higher unsprung weight, complex cooling

 Example Vehicles: Concept cars like Lordstown Endurance

B. Hybrid Vehicle (Hv) Drivetrain Layouts

1. Series Hybrid Drivetrain
 Working: Engine generates electricity → Electric motor drives
wheels.
 Engine does not directly power the wheels.
 Advantages:
o Simple mechanical layout
o Efficient in city driving
 Example: BMW i3 REx, Fisker Karma
2. Parallel Hybrid Drivetrain
 Working: Both engine and electric motor drive the wheels.
 Advantages:
o Efficient at highway speeds
o Good fuel economy
 Example: Honda Insight (older generations)
3. Series-Parallel (Power-Split) Hybrid Drivetrain
 Working: Combines both series and parallel modes using planetary
gearsets.
 Highly flexible power delivery
 Advantages:
o Optimized for various driving conditions
o Smooth transition between EV and ICE

Gujarat Technological University 50 DGGEC, Surat

TEAM ID- 841427

 Example: Toyota Prius, Ford Escape Hybrid

Figure: 11.2 HV Drivetrain layout

4. PHEV Drivetrain
 Working: Same as series-parallel but includes a larger battery
& external charging.
 Can run longer in pure electric mode.
 Example: Toyota Prius Prime, Chevrolet Vol

Figure:11.3 Toyota Prius/ example of phev

Gujarat Technological University 51 DGGEC, Surat

TEAM ID- 841427

CHAPTER 12

CASE STUDY
12.1 CASE STUDY 1
On-Board Diagnostics
As part of the Autotronics training module at iACE, Gandhinagar, a
comprehensive demonstration on On-Board Diagnostics (OBD) was
conducted under the guidance of an experienced mentor. The session
focused on showcasing how modern vehicles employ electronic control
units (ECUs) and diagnostic protocols to monitor, detect, and report faults
in real-time. A live OBD-II scanner was connected to the vehicle’s
diagnostic port (DLC - Data Link Connector), allowing the participants to
observe the retrieval of Diagnostic Trouble Codes (DTCs), both active and
stored. The demonstration included interpreting alphanumeric fault codes,
checking live data streams, and understanding freeze-frame data related to
engine load, coolant temperature, oxygen sensor output, and fuel trim
levels.

12.2 CASE STUDY 2

As part of the practical training session, a passenger vehicle was lifted using
a two-post hydraulic lift by a group of six students. After ensuring the
vehicle was securely positioned, all four wheels were removed with the
help of a pneumatic impact wrench to provide access to the disc brake
assemblies. The brake rotors and pads were then inspected to evaluate their
remaining thickness. A Micrometre was used for measuring the rotor
thickness, while a standard brake pad gauge was employed to assess the
brake pad wear. The obtained values were documented and compared with
the manufacturer's permissible limits to determine their serviceability. The
entire task was carried out systematically, with responsibilities shared
among the group members. Through this activity, practical exposure to
brake system maintenance, wear measurement, and safety evaluation
procedures was gained.

Gujarat Technological University 52 DGGEC, Surat

TEAM ID- 841427

Figure:12.1 Two post lift

12.3 CASE STUDY 3

Engine Assembly and Disassembly
As part of the hands-on training at iACE, Gandhinagar, a detailed case
study was carried out on the disassembly and reassembly of an inline 4-
cylinder diesel engine equipped with a turbocharger and an overhead
camshaft (OHC). The engine provided for the session had its coolant and
engine oil already drained, allowing the team to directly proceed with the
mechanical disassembly. The process began with the removal of external
components such as the air intake system, turbocharger, exhaust manifold,
alternator, and starter motor. With these components cleared, attention was
turned to the camshaft cover, which was unbolted to access the overhead
camshaft and its timing mechanism. The cylinder head bolts were carefully
loosened in a crisscross pattern to prevent distortion, and the cylinder head
was safely removed. Internally, the pistons and connecting rods were
extracted by rotating the crankshaft to bottom dead centre and detaching
the connecting rod caps. The crankshaft was then removed by unbolting the
main bearing caps. During reassembly, all parts were thoroughly inspected,
cleaned, and reinstalled in the reverse order, with proper lubrication and
adherence to torque specifications. A bore gauge was used to measure the

Gujarat Technological University 53 DGGEC, Surat

TEAM ID- 841427

inner diameter of each cylinder at various depths and orientations to detect

wear, ovality, or taper. This step ensured that the cylinder bores met
acceptable tolerance limits before piston reinsertion. The activity not only
reinforced knowledge of diesel engine architecture and turbocharged
systems but also emphasized the importance of precision tools in engine
inspection and rebuilding.

Figure:12.2 Casing of timing chain Fig:12.3 Overhead camshaft

Gujarat Technological University 54 DGGEC, Surat

TEAM ID- 841427

CONCLUSION

The internship at ice, Gandhinagar, covering both Automotive Systems and

Autotronics modules, offered a well-rounded and practical understanding
of modern automobile engineering. Each module was carefully structured
to bridge theoretical knowledge with hands-on application.
In the Automotive Systems module, essential mechanical aspects such as
engine assembly and disassembly, coolant system servicing, and brake pad
and rotor thickness measurement were explored in detail. These activities
enhanced mechanical skills and provided real-time exposure to vehicle
maintenance procedures and component functionality.
The Autotronics module focused on the growing integration of electronics
in vehicles. Training sessions involved working on powertrain sensor
boards and German-engineered sensor systems (LN), which deepened
understanding of real-time data acquisition, signal processing, and sensor
behaviour. Additionally, a demonstration of On-Board Diagnostics (OBD)
by the mentor enabled practical insights into fault detection and
troubleshooting through electronic control systems. Together, both
modules provided a comprehensive view of how mechanical systems and
electronics converge in modern vehicles. This internship has significantly
strengthened the foundation in automotive engineering, while also
fostering critical thinking, system-level understanding, and hands-on
technical expertise—skills vital for a future in the evolving automotive and
mobility industry.

Gujarat Technological University 55 DGGEC, Surat

TEAM ID- 841427

REFERENCES
[1] Ganesan, V. (2012). “Internal Combustion Engines.” McGraw Hill Education.
[2] U.S. Department of Defense. (2014). Chapter 3: Construction of an internal
combustion engine (NAVEDTRA 14264A). Defense Media Activity
[3] Robert Bosch GmbH. (2004). “Automotive Handbook.” 6th Edition.

Gujarat Technological University 56 DGGEC, Surat