AUTO- ELECTRONIC

AND AUXILIARY
SYSTEMS
AET 06210
 LECTURE 01
 Introduction

 Identification of the Automotive

Sensors Systems

 Basic Principles of Sensors Systems

 Automotive
Electronics
•Automotive electronics are any electrically-
generated systems used in road vehicles.

•Automotive electronics originated from the

need to control and manage Engines.

•The first electronic pieces were used to

control engine functions and were referred to
as engine control units (ECU).

•A modern car may have up to 100 ECU's and a

commercial vehicle up to 40.
 What is an ECU
• In the Automobile industry an electronic control unit
(ECU) is an embedded electronic device, basically a
digital computer, that reads signals coming from
sensors placed at various parts and in different
components of the car and depending on this
information controls various important units e.g.
engine and other automated operations within the car
among many.
• The ECU receives inputs from a wide variety of sensors
and switches.
• The ECU send the calculated signals to the actuators
KUVUKA SALAMA MAKUTANO YA
BARABARA YENYE ALAMA
ECU(Electronic Control Unit) and its mount location
 Types of ECU
•ECM - Engine Control Module
•EBCM - Electronic Brake Control Module
•PCM – Power train Control Module
•VCM - Vehicle Control Module
•BCM - Body Control Module
 What an ECU does
The ECU uses closed-loop control, a control
scheme that monitors outputs of a system to control
the inputs to a system, managing the emissions and
fuel economy of the engine (as well as a host of other
parameters).

Gathering data from dozens of different sensors, the

ECU performs millions of calculations each second,
including looking up values in tables, calculating the
results of long equations to decide on the best spark
timing or determining how long the fuel injector is
open.
 Applications
• Depending upon the nature of the circuit the Engine
mappings can change completely. On slower and
twister tracks, the engine control system will help the
driver have more control on the throttle input by
making the first half of the pedal movement very
sensitive.
• The ECU plays a very important role of aiding the
engine management, which controls ignition system,
fuel injection system and emission controls.
• Therefore, the ECU receives inputs from a wide variety
of sensors and switches and send the calculated
signals to the actuators
 Engine Management
The computer (ECU) control the following
engine system.

• Fuel injection control system (EFI)

• Idle air control system (ISCV)
• Ignition control system (ESA)
• Related engine and emission control (EGR)
• Failsafe and back-up system
• Self diagnosis (OBD1 & OBD2)
Types Of Automotive Sensors
KUVUKA SALAMA MAKUTANO YA
BARABARA YENYE ALAMA
KUVUKA SALAMA MAKUTANO YA
BARABARA YENYE ALAMA
 ENGINE SENSORS

ENGINE SENSORS
◦ Mass Air Flow Sensor
◦ Oxygen Sensor
◦ Throttle Position Sensor
◦ Crankshaft Position Sensor
◦ MAP Sensor
◦ Engine Coolant Temperature Sensor
 1. Mass Air Flow (MAF) Sensor
• A mass air flow sensor (MAF) is used to
find out the mass flow rate of air entering
a fuel-injected internal combustion engine.
• The air mass information is necessary for
the engine control unit (ECU) to balance
and deliver the correct fuel mass to the
engine.
• Air changes its density as it expands and
contracts with temperature and pressure.
 1. Mass Ai…
• In automotive applications, air density
varies with the ambient temperature,
altitude and the use of forced induction,
which means that mass flow sensors are
more appropriate than volumetric flow
sensors for determining the quantity of
intake air in each piston stroke
MAF Sensor
MAF SENSOR
MAF SENSOR
 2. Manifold Absolute Pressure (MAP)
Sensor
• The intake manifold pressure sensor measures the intake
manifold vacuum that exists in the intake manifold after
the throttle.
• The measured values of the intake manifold pressure
sensor and the intake air temperature sensor are
required to calculate the intake air mass.
• Depending on the injection system, the intake manifold
pressure sensor and the intake air temperature sensor
may be installed together as one unit.
• The intake manifold pressure sensor may be installed
directly into the intake manifold or attached in the
vicinity.
 2. Manifold Abso……
• A fully functioning MAP sensor is necessary
to maintain the right combination of
acceleration, fuel economy, emissions and
engine smoothness.
• When the throttle is wide open and air is
rushing into the intake manifold (causing a
drop in pressure), the MAP sensor signals the
engine computer to send more fuel.
• When the throttle closes, pressure rises and
readings from the MAP sensor tell the
computer to reduce the amount of fuel going
into the engine.
MAP SENSOR
 3. Throttle Position Sensor
• The throttle position sensor monitors how far open the
throttle valve (or blade) is open, which is determined
by how far down the accelerator pedal has been
pushed.
• The throttle position controls the amount of air that
flows into an engine’s intake manifold; when it’s
opened wide more air flows in; when it’s nearly closed,
little air flows in.
• The position of the throttle and how quickly it’s
opening or closing is transmitted to the engine control
module, and that information is among the factors the
computer uses to decide how much fuel is injected into
the engine and the spark timing.
 3. Throt…..
• The TPS is usually mounted on the throttle
body (the housing that contains the throttle
valve).
• When a TPS malfunctions it can trigger a
“check engine” warning light or cause the
engine to idle roughly, surge, hesitate or stall
because the engine control module doesn’t
know what the throttle position is and can’t
correctly set the fuel mixture or ignition
timing.
 4. Camshaft Position Sensor
• The camshaft sensor enables the engine
control to determine the exact position of the
crankshaft drive.
• This information is required to calculate the
ignition point and injection point, among
other things.
• The task of the camshaft sensor is to work
with the crankshaft sensor to define the exact
position of the crankshaft drive.
• Through the combination of both sensor
signals, the engine control unit knows when
the first cylinder is in the top dead point.
 4. Cam…
• This information is needed for three purposes:
i. For the start of injection during sequential injection.
ii. For the actuation signal of the solenoid valve for the
pump-nozzle injection system.
iii. For cylinder-selective knocking control.

• The camshaft sensor works according to the Hall principle.

It scans a ring gear on the camshaft.
• The rotation of the ring gear changes the Hall voltage of the
Hall IC in the sensor head.
• This change in voltage is transmitted to the control unit and
evaluated there in order to establish the required data.
4. Camshaft po….
Camshaft position sensor
 5. Crankshaft Position Sensor
• The crankshaft sensor is one of the key providers of
information of the engine control.
• It detects the speed and position of the crankshaft and
forwards this information to the engine control in the
form of an electrical signal.
• The function of crankshaft sensors is to measure the
crankshaft's speed and position.
• They are most commonly installed near to the flywheel
ring gear.
• There are two designs:
I. Inductive sensors
II. Hall generators
5. Crankshaft Position Sensor
 6. Car Knock Sensor
• The knock sensor monitors the combustion
process in the engine. Its signal helps the engine
control to prevent knocking combustion and
therefore protect the motor/engine control.
• The knock sensor is located on the outside of the
engine block. It is intended to record knocking
noise in all engine operating states in order to
prevent engine damage.
• The knock sensor "listens out for" the structure-
borne vibrations from the engine block and
converts these into electrical voltage signals.
 6. Car Knock s….

• The signals are filtered and evaluated in the

control unit.
• The knocking signal is assigned to respective
cylinder.
• If knocking occurs, the ignition signal for the
respective cylinder is adjusted in the "late"
direction until knocking combustion no
longer occurs.
 7. Oxygen Sensor
• This sensor is used in the mechanism serving for air
fuel ratio measurement, it is installed in the exhaust
system of the vehicle, attached to the engine's
exhaust manifold, the sensor measures the ratio of
the air-fuel mixture.
7. Oxygen Sensor
 8. Coolant Temperature Sensor
(ECTS)
• An engine coolant temperature sensor or ECT
measures the temperature of the liquid coolant.
• A typical engine cooling temperature sensor is a
Negative Temperature Coefficient (NTC) thermistor,
which means its electrical resistance decreases when
the temperature increases.
• The tip of the ECT sensor protrudes into one of the
cooling system passages and is immersed in coolant.
• The sensor works with the vehicle’s ECU, continually
monitoring the coolant temperature to make sure the
engine is running at the optimum temperature
 8. Coolant Temp…
• To get an accurate reading of the current engine
temperature, the ECU sends a regulated voltage to the
CTS.
• The resistance of the sensor varies with temperature,
this is how the ECU can monitor temperature changes.
• The ECU uses this reading to calculate the coolant
temperature, and from there adjusts the fuel injection,
fuel mix, and ignition timing, and controls when the
electric cooling fan is switched on and off.
• This information is also used to send an accurate reading
of the engine temperature to a gauge on the dashboard.
 9. Intake Air Temperature Sensors
(IAT)
• The Intake Air Temperature sensor (IAT) has
been utilized as an Engine Control Unit (ECU)
input signal from the very first EFI systems to
the currently used systems, as a requirement
for calculating the Air Mass volume for the
incoming air charge.
• This is, to assist in determining the correct
engine fuel requirement to suit the operating
air temperature.
• This type of sensor can be installed alone or
 9. Intake Air Temperature….
• A two wire NTC (Negative Temp Coefficient)
thermistor device that produces a resistance
change in accordance to the exposed air
temperature that it monitors.
• This may be located in the intake air tube
between the air filter box and the throttle
body.
SPEED SENSORS
Speed sensors are machines used to detect the
speed of an object, usually a transport vehicle.
They include:
 Wheel speed sensors
 Speedometers
 Pitometer logs
 Pitot tubes
 Airspeed indicators
 Piezo sensors (e.g. in a road surface)
 LIDAR
 ANPR (where vehicles are timed over a fixed
distance)
WHEEL SPEED SENSOR

A wheel speed
sensor or vehicle
speed sensor (VSS) is
a type of tachometer.
It is a sender device
used for reading
speed the of
rotation.
a
wheel vehicle's
usually It
consists
toothed of a ring
and
pickup.
SPEEDOMETER

A speedometer is a device that

measures the instantaneous speed of a
land vehicle.
The various types of speedometers include:
 Eddy current speedometer
 Electronic speedometer
 Bicycle speedometer
PIEZOELECTRIC SENSORS
A piezoelectric disk generates a
voltage when deformed (change in
shape is greatly exaggerated)
A piezoelectric sensor is a device
that uses the piezoelectric effect to
measure pressure, acceleration,
strain or force by converting them to
an electrical signal.
In the automotive industry,
piezoelectric elements are used to
monitor combustion when
developing internal
engines. combustion
LIDAR
LIDAR (Light Detection And Ranging) is an
optical remote sensing technology that measures
properties of scattered light to find range and/or
other information of a distant target.
The prevalent method to determine distance to an
object or surface is to use laser pulses.
Like the similar radar technology, which uses
radio waves, the range to an object is determined
by measuring the time delay between transmission
of a pulse and detection of the reflected signal.
TYPES OF VEHICLE SENSORS

◦ Rain Sensor
◦ Parking sensor
◦ Air Conditioning Sensor
◦ Oil sensor
◦ Fuel gauge
◦ Radar gun
◦ Water Sensor
RAIN SENSORS

Automotive rain sensors detect rain falling on the windshield of a

vehicle. One of the more common rain sensor implementations
employs an infrared light that is beamed at a 45-degree angle
onto the windshield from inside the car. If the glass is wet, less
light makes it back to the sensor, and the wipers turn on.
PARKING SENSORS
Parking sensors are
proximity sensors for
road vehicles which
can alert the driver to
unseen obstacles
during
manoeuvres. parking
The ultrasonic sensors
are currently available
in several brands of
cars. Some systems
are also available as
additional upgrade kits
for later installation.
OIL SENSORS
Oil sensors and oil analyzers
are used in automotive or
industrial
machinery applications to
sense oil levels, and check for:
 Contamination
 Particulates
 Viscosity
 Temperature

Oil sensors and oil analyzers

are also known as ferrography
instruments.
FUEL GAUGE

A fuel gauge is an instrument used to indicate the level of

fuel contained in a tank. As used in cars, the gauge
consists of two parts:
 The sensing unit
 The indicator
 Actuators
What is an actuator?

 Actuators are devices used to produce action or motion.

 Input(mainly electrical signal , air, fluids)

 Electrical signal can be low power or high power.

 Actuators output can be position or rate i. e.

linear displacement or velocity
Classification of Actuators
Pneumatic

Hydraulic

Electrical/
Electronic
Pneumatic Actuators
 Pneumatic Actuators
 A set of devices into with one or more pneumoengines, which
are determined to start mechanisms or some other objects by
means of pressed working gas is called pneumatic actuator, or
pneumoactuator.
 The devices intended for transformation of potential and
kinetic energy of the stream of compressed gas in mechanical
energy of the output link that can be, for example, a rod of the
piston, a shaft of the turbine or the case of the jet device is
called pneumatic engines of the automated actuator.
 They are devices providing power and motion to automated
systems, machines and processes.
 A pneumatic cylinder is a simple, low cost, easy to install
device
that is ideal for producing powerful linear movement.
Types of Pneumatic Actuator
 Pneumatic actuators are made in a wide variety of sizes,
styles and types including the following :

1. Single acting with and without spring return

2. Double acting
Single acting spring return
 Single acting cylinders have a power stroke in one direction
only
 Normally in

 Normally out
 Double acting
 Double acting cylinders use compressed air to power both the
outstroke and instroke.
 Superior speed control is possible
• Non cushioned cylinders are suitable for full stroke working at
slow speed.
• Higher speeds with external cushions.
Hydraulic Actuator
Introduction
 A hydraulic drive system is a drive or transmission
system that uses pressurized hydraulic fluid to drive
hydraulic machinery.

 The term "hydraulic actuator" refers to a device controlled

by a hydraulic pump.

 A familiar example of a manually operated hydraulic

actuator is a hydraulic car jack. Typically though, Principle
Used in Hydraulic Actuator System
 Hydraulic Actuator
Parts of a typical
cylinder
Working of Hydraulic Actuators
Hydraulic actuators or hydraulic cylinders
typically involve a hollow cylinder having a
piston inserted in it. An unbalanced pressure
applied to the piston provides force that can
move an external object. Since liquids are
nearly incompressible, a hydraulic cylinder can
provide controlled precise linear displacement
of the piston. The displacement is only along
the axis of the piston.
The piston forms sealed, variable-volume
Working of Hydraulic Actuators
Hydraulic actuators or hydraulic cylinders
typically involve a hollow cylinder having a
piston inserted in it. An unbalanced pressure
applied to the piston provides force that can
move an external object. Since liquids are
nearly incompressible, a hydraulic cylinder can
provide controlled precise linear displacement
of the piston. The displacement is only along
the axis of the piston.
The piston forms sealed, variable-volume
Classifications of Hydraulic Actuator
 Cylinders are typically classified by operating principle or by
construction type
◦ Single-acting or double-acting
◦ Tie rod, mill, threaded end, or one piece
 Single-acting cylinders exert force either on extension or
retraction.
 They require an outside force to complete the second motion
 Double-acting cylinders generate force during both extension
and retraction
◦ Directional control valve alternately directs fluid to opposite
sides of the piston
◦ Force output varies between extension and retraction
 Hydraulic Actuator
Single-and Double-Acting
Cylinders

Single-acting Double-acting
Electrical
 Introduction
 An electrical motor is an Transducer & an Actuator because it
converts electrical current into a large magnetic field which then
turns a shaft. (Mechanical energy)

 All electric motors use electromagnetic induction to generate a

force on a rotational element called the rotor.

 The torque required to rotate the rotor is created due to the

interaction of magnetic fields generated by the rotor, and the part
surrounding it, which is fixed, and called the stator.
Classification of Electrical
Actuators

Solenoid

Electrical Motors
Stepping Motors
  Electrically actuated system are very widely used in control system

Working Principle of motor

Every motor works on the principle that when a current-carrying

conductor is placed in a magnetic field, it experiences a mechanical force.

 There are three types of motor used in control system

 D.C. motor

 A.C. motor

 Stepper motor
 A.C. motor

 Stepper motor

A stepper motor is an electromechanical device which converts electrical pulses

into discrete mechanical movements.

 Permanent magnet type

 Variable reluctance type

 Hybrid type
 Pierre and Jacques Curie discovered the piezoelectric effect in 1880.

 The application of an electric field to a piezoelectric crystal leads to a

physical deformation of the crystal.

 Piezoelectric materials are: Quartz, Ceramics, PZT(lead zirconate

titanade).
 Advantages
 short response time.
 An ability to create high forces.
 A high efficiency and a high mechanical durability.
 Disadvantage
 Have small strains. (0.1-.2%)
 High supply voltage needed.(60-1000V)
 Large hysteresis.(actuator doesn’t go back to exactly
where it started).
 Piezoelectric Stack Actuators
 Produce linear motion.
 used with temperature
Heaters -

sensors And temperature controller

to control the temperature in automated moulding
Equipment and in soldering operation.

Lights - Lights are used on almost all machines to indicate the

machine state and provide feedback to the operator.
 LED
 LCD’s
 Gas plasma display
 CRT

Sirens/Horns - Sirens or horns can be useful for unattended or

dangerous machines to make conditions well known.