Isuru Gunasekara | Automobile

Automobile For Technical College Students

TUTORIAL 1

Automobile
Course

“Isuru Gunasekara
Automobile”
Isuru Gunasekara
Mechanical Engineer - NDT | DTET
Automobile Electrical & Hybrid Training Instructor
6year Experienced Teacher with NVQ-V | SLQL3
Mechatronic System Engineering UoM, HND Electrical & Electronics IVQ FLITS
Diploma in Psychology & Psychological Counselling SITC campus

ISURU GUNASEKARA Diploma in Human Resources and Management & Administration SITC campus
Certified in LEAN Six Sigma Green Belt Program Asian Aviation Center
Diploma in Productivity and Quality Improvement IQPC Asian Aviation Center

AUTOMOBILE TECHNOLOGY
Eng. Tech. ECSL AMIAESL
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 Isuru Gunasekara | Automobile
AT UTOMOBILE
ECHNOLOGY
By
ISURU GUNASEKARA
Technical Training & Educational School | TTES
Automobile Technology Workbook Tutorial 1
Copyright © 2024 By Isuru Gunasekara
All Right Reserved
2023 Nov

Content Editing and Graphical Designing:

Kaveesha Gunasekara

www.ttes.lk

Technical Training & Educational School

Isuru Gunasekara

Scan to Join the Telegram channel

077 676 59 58 | 077 176 59 58 Isuru Gunasekara Automobile

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ම ෝටර් රථ කාර්ික ශිල්පය Automobile Mechanic
✔️ Cooling system,

✔️ Lubricating system,

✔️ Conventional petrol and diesel system,

✔️ Conventional ignition system,

✔️ Diesel and petrol engines,

✔️ Transmission system,

✔️ Propeller shaft final and axle shafts,

✔️ Braking system,

✔️ Steering system,

✔️ Suspension system,

✔️ Wheel alignment and balancing,

✔️ Service Storage battery,

✔️ Service Electronic fuel ignition and Electronic Ignition system,

✔️ Service chassis Electronic and Passenger safety,

යන පද්ධතියත් පිළිබඳව අධයයන කිරීමට ලැබේ.

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ම ෝටර් රථ විදුලි කාර්ික ශිල්ී Automobile Electrician
✔️ Maintain and service storage battery

✔️ Repair and maintain Starting system

✔️ Repair and maintain Charging system

✔️ Repair and maintain Ignition system

✔️ Electronic control Ignition system and Injection system

✔️ Electrical accessory

✔️ Passenger and vehicle safety system

✔️ Maintain Lighting system

✔️ Wiper and Horn system

✔️ Heating and Ventilation and Car air conditioning system

✔️ Install passenger entertainment system

යන පද්ධතීන් පිළිබඳව අධයයනය කිරීමට ලැබේ. එබමන්ම බමෝටර් රථ විදුලි කාර්ික ශිල්පී
පාඨමාලාව යටබත් බමෝටර් රථ වායු සමීකරණ පද්ධති පිළිබඳවද හැඳින්ීමක් සිදුවන අතර
එහිදී එම පද්ධතිය විදුලි පද්ධතියට සම්බන්ධයක් පවතින බැවින් ඒ සඳහා අවශ්‍ය දැනුම
ලබා දීම සිදුබේ.

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ම ෝටර් රථ වායුසමීකරණ ශිල්ී
Automobile Air Condition Mechanist
✔️ Inspection Automobile Air conditioner system and servicing

✔️ Prepare estimate for installation modification and upgrading

✔️ Repair and servicing Ac system

✔️ Install and modify AC system

✔️ Refrigerant recovery and Re-cycling

යන පද්ධතීන් පිළිබඳව අධයයනය ලැබීමට හැක. එබමන්ම වායු සමීකරණ පද්ධතිය

බමෝටර් රථ විදුලි පද්ධතියට සම්බන්ධව පවතින බැවින් විදුලි පද්ධතිබේ පවතින යම් යම්
ක්‍රියාකාරීත්වයන්ද අධයයනය කිරීමට සිදුබවයි.

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ම ෝටර් රථ ටින්කර් ශිල්ී Automobile Tinker
• Assess damage to automobile chassis and body and provide estimates for repairs
Align and repair automobile chassis
• Perform repairs to automobile bodywork

• Repair automobile fittings

• Perform welding operations on automobiles

• Prepare automobile body surfaces for painting

• Remove and fix glass items to automobiles

ම ෝටර් රථ පින්තාරු ශිල්ීන් Automobile Painter

• Prepare estimates for painting automobiles
• Paint an undamaged automobile body or part thereof
• Paint a repaired automobile body or part thereof
• Paint a rusted automobile body or part thereof
• Paint plastic bumper and accessories

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බමම එක් එක් පාඨමාලාව හැදෑරීමක් මගින් ලබන කුසලතාවය සහතිකව පත්‍රයක් මගින්
සහතික කරන අතර බම් සඳහා ජාතික වෘත්තීය හා කාර්ික පුහුණුව අධිකාරිය යටබත්
ජාතික වෘත්තීය සුදුසුකම් මට්ටම් ලබාදීමක් සිදු වන අතර බමම පාඨමාලාවන්
පූර්ණකාලීනව බලස හැදෑරීමට සිදුබවයි.

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Advance Automobile Technology
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Electric and Hybrid Vehicles:
The electric vehicle (EV) market has been expanding with improved battery technologies, increased driving
ranges, and faster charging capabilities.

Many automakers were investing in hybrid and plug-in hybrid vehicles, combining internal combustion engines
with electric propulsion.

Autonomous and Semi-Autonomous Driving:

The development of self-driving cars was a major focus. Companies were working on advanced driver-
assistance systems (ADAS) and autonomous driving features.

Technologies such as radar, lidar, cameras, and advanced sensors were integrated into vehicles to enhance
safety and enable autonomous capabilities.

Connected Vehicles:
Cars were becoming increasingly connected to the internet, allowing for features like real-time traffic updates,
remote vehicle monitoring, and over-the-air software updates.

Vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2I) communication were being explored to improve
traffic flow and overall road safety.

Advanced Materials and Lightweighting:

The use of advanced materials, such as carbon fiber and aluminum, was becoming more common to reduce
vehicle weight and improve fuel efficiency without compromising safety.

3D printing and other advanced manufacturing techniques were being explored for creating complex and
lightweight components.

Energy Efficiency and Sustainable Practices:

Automakers were increasingly focused on making vehicles more energy-efficient and environmentally friendly.

Sustainability efforts included using recycled materials in manufacturing, reducing waste, and exploring
alternative energy sources.

Advanced Driver Assistance Systems (ADAS):

ADAS features were becoming more prevalent, including adaptive cruise control, lane-keeping assist, automatic
emergency braking, and parking assistance.

These systems were designed to enhance driver safety and provide a stepping stone toward fully autonomous
driving.

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Augmented Reality (AR) and Heads-Up Displays (HUD):
AR technology was being integrated into vehicles to provide drivers with real-time information, such as
navigation prompts and safety alerts, displayed directly on the windshield.

HUD systems were becoming more advanced, projecting relevant information onto the driver's field of view.

Cybersecurity:
With the increasing connectivity of vehicles, there was a growing emphasis on cybersecurity to protect cars
from potential cyber threats.

Car Scanning and Diagnosis

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OBD-II (On-Board Diagnostics) Scanning:
Modern vehicles are equipped with an OBD-II port that allows for the connection of a scanning tool. This tool
can read diagnostic trouble codes (DTCs) generated by the vehicle's onboard computer. Mechanics and car
owners use OBD-II scanners to identify issues with the engine, transmission, emissions system, and other
components.

Diagnostic Scanning for Troubleshooting:

Car scanning may involve using specialized diagnostic tools and software to identify and troubleshoot issues
within a vehicle's electronic systems. This can include checking sensors, actuators, and other components for
proper functioning.

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What is the difference between micro, mild, full
and plug-in hybrid electric vehicles?
Most of the vehicles in use worldwide are still powered by internal combustion engines (ICE), either
gasoline/petrol or diesel. A Hybrid Electric Vehicle (HEV) has at least two sources of power for propulsion:
the internal combustion engine and an electric motor.
There are three main reasons for which automotive manufacturers are developing and selling HEVs:

▪ reduction of the CO2 emissions (by reduction of the fuel consumption)

▪ reduction of exhaust gas toxic emissions
▪ improvement of the powertrain dynamics (by increasing total power and torque)
The powertrain of a HEV is quite complex because it contains all the components of an ICE vehicle plus
most of the components of a pure electric vehicle (EV). Also, depending on the level of hybridization, it needs
two energy sources, the fuel tank for the engine and a battery for the electric machine.

If we have an ICE vehicle, in order to transform it into a HEV, we need to add:

▪ a high voltage battery (between 200 and 400 V)

▪ a power electronics controller (inverter)
▪ an electric machine
▪ a DC-DC converter

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The main disadvantages of a HEV are: it’s adding more weight to the vehicle due to additional electric
components, it’s more difficult to build and the total price of purchasing and ownership increases (compared
to a ICE vehicle).
In most of the HEVs the electric propulsion is done using permanent-magnet electric machines. The main
advantages of an electric machine, compared to an ICE, are:
▪ constant high torque at low speeds
▪ very high efficiency
▪ instant torque delivery
▪ energy recuperation capability

1. 1.8 L internal combustion engine and electric drive unit

2. lithium-ion high voltage battery system

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Compared with a conventional powertrain, by putting together an electric machine with an ICE we get the
following advantages:
▪ by providing torque assistance with the electric motor, the ICE can work in the most fuel efficient
point (speed and torque)
▪ the ICE can be downsized, retaining in the same time a constant overall torque and power of the
powertrain, thanks to the electric motor assistance
▪ the kinetic energy of the vehicle during braking can be recovered and stored in the high voltage
battery, with the help of the electric machine operating as a generator
▪ the torque response of the powertrain can be improved, because of the instant torque delivery of
the electric motor
▪ the gear ratios of the transmission can be lowered, to keep the engine at lower speed operating
points (better fuel efficiency), because the electric motor can deliver instant torque request from the
driver

Having two sources of power, the hybrid control system needs to decide what is the torque split between the
ICE and electric machine, depending on the driver input and vehicle operating state.

A hybrid electric vehicle can perform at least one or more of the following functions:
▪ engine idle stop/start
▪ electric torque assistance (fill and boost)
▪ energy recuperation (regenerative braking)
▪ electric driving
▪ battery charging (during driving)
▪ battery charging (from the grid)

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A hybrid electric vehicle it’s also called a Full Hybrid Electric Vehicle (FHEV), in order to make a distinction
with the other types of hybrid electric vehicles (mild and plug-in).

Image: Full Hybrid Electric Vehicle (FHEV) modes

Legend:
ENG – internal combustion engine
MOT – electric motor (machine)
TX – transmission
BATT – high voltage battery
PE – power electronics module (MOT controller)

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Idle stop/start function
When the vehicle is stationary, the stop/start (S&S) function switches off the
internal combustion engine, without the intervention of the driver (through the
ignition key). This function reduces the overall fuel consumption of the vehicle.
When the driver shows the intention to drive (clutch pedal pressed or brake pedal
released) the engine is restarted automatically.
Most of the vehicles with idle stop/start function have also some sort of energy
management function, which optimizes the consumption of the low voltage (12
V) battery energy. In a conventional ICE vehicle, without any energy management, the primary function of
the low voltage battery is to generate the electrical energy required for the engine to start. After the engine is
running, the electrical energy for all the electrical consumers is supplied by the alternator (generator), which
is putting a load torque on the engine.
If the vehicle has an energy management function, even if the engine is running, the battery supplies electrical
energy to the consumers. In this way, the alternator doesn’t have to produce electrical energy, the load
torque of the alternator is nearly zero, and the fuel consumption is reduces. Further, the battery is recharged
when the engine is working in the most fuel efficient points or when the vehicle is braking (through energy
recuperation).

An example for idle stop/start and energy management functions is the Renault engine 1.6 dCi. It comes with
an Energy Smart Management (ESM) function which allows energy created under braking and deceleration
to be stored in the low voltage battery, helping to further reduce fuel consumption.
Vehicles that have idle stop/start and energy management functions are called Micro Hybrids.
Electric torque assistance
The electric motor can provide additional torque to the wheel, improving the overall torque response of the
powertrain. There are two types of torque assistance:

▪ torque fill
▪ torque boost
When the drive is pressing the accelerator pedal, it requests more torque from the powertrain. An internal
combustion engine (especially diesel) has a certain delay in delivering the requested torque. The torque
response delay of the internal combustion engine has several causes:

▪ the inertia of the air in the intake manifold

▪ the mechanical inertia of the moving parts
▪ the torque limitation (to prevent smoke in the exhaust)
In these situations, called torque transients (engine is changing the operating point), the electric motor can
assist, providing additional torque, which compensates for the engine torque response delay. This function
is called torque filling.

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An internal combustion engine has a maximum torque capability, which depends on the engine speed. By
adding the electric motor torque, additional to the engine torque, the maximum overall torque of the
powertrain is increased (positive offset). This function is called torque boost and can be supplied only for a
short duration of time (order of seconds) due to battery depletion.
The function of electric torque assistance is usually provided by mild hybrid electric vehicles (MHEV), full
hybrid electric vehicles (FHEV) and plug-in hybrid electric vehicles (PHEV).
When both, the engine and the electric motor, are providing torque for vehicle acceleration, the vehicle is
in hybrid/parallel mode.
Energy recuperation (regenerative braking)
When the driver is pressing the brake pedal, the vehicle needs to slow down. Basically we need a braking
torque at the wheels in order to reduce the vehicle speed. The total required braking torque at the wheels
can be achieved in several ways:

▪ only through the foundation brakes (hydraulic brakes)

▪ through the foundation brakes plus the powertrain
If the vehicle has a conventional powertrain, only with internal combustion engine, when the driver brakes,
the fuel injection is interrupted (fuel-cut) and the engine overruns (engine braking). The amount of engine
brake is equal with the total torque losses of the engine (friction torque + pumping losses + auxiliary devices).

1. 48V electric machine

2. 48V lithium-ion battery
3. 12V battery
4. DC-DC converter (bidirectional)
5. 12V electrical system

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