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Department of Technical Education Diploma Course in Automobile Engineering Fourth Semester Subject: Auto Electrical and Electronic System

Contact Hrs / Week: 4 Hrs Contact Hrs / Semester: 64 Hrs. TOPIC ANALYSIS Chapter No. Contents PART - A 1 2 3 4 5 6 7 8 9 10 Introduction : Basics of Electronics : Battery Charging system PART - B Starting system Ignition system PART - C Lighting system Electrical accessories Miscellaneous electrical equipments Test and Revision Total 5 6 4 6 64 12 15 10 145 9 12 23 30 2 5 8 7 5 12 20 18 No. of Hrs. Weightage of marks

GENERAL EDUCATIONAL OBJECTIVES 1 2 3 4 5 6 7 8 Understand the electrical system Understand the basics of Electronics Know the construction and working of battery Know the battery charging system and recharging Know the starting system Know the ignition system Know the lighting system in the vehicle Know the various electrical accessories and gauges

CONTENT DETAILS Introduction : Different electrical systems in Automobile & their requirements. Earth and Insulated return system, Merits & Demerits of positive & negative earth system. Electrical & Electronics symbols Basics of Electronics : Semiconductors-properties, N-type,P-type ,PN-junction, as a Diode, Crystal diode Rectifier- half wave, full wave,center tap,as a Bridge type .filters circuits zener diode, zener diode as voltage regulators of diodes Transistors:- NPN, PNP transistor, working. Transistor as an amplifier, Transistor as an switch Battery : Purpose, types, construction & working of lead acid and alkaline batteries. Comparison between lead acid and alkaline batteries- Cell voltage- Battery capacity- Battery efficiency battery ratings- battery charging- types of charging- battery testing battery defectsMaintenance of batteries- maintenance free batteries Charging system : DC Generators: Purpose-Construction & working Circuit diagram, various components- their functions Regulators AC Generators : Purpose types, Construction & working Circuit diagram, various componentstheir functions Regulators Comparison between DC generators & AC Generators Starting system : Necessity- circuit diagram- various components & their functions - special features of series motors, construction & working of series & series shunt wound motorsnecessity of drive arrangements- types- bendix, overrunning clutch, axial sliding armature type, Solenoid switches used in starting systemIgnition system : Purpose, Types Coil ignition system : Construction and working of ignition system , construction & working of Ignition coil, distributor, CB point, condenser.. Cam angle, Ignition timing, Ignition advance mechanism-centrifugal and vacuum types. Magneto ignition system : Construction and working of ignition system , types Electronic ignition system : Construction & Working of electronic ignition system and their types.- CDI ignition system- Distributor less Ignition system- Merits & demerit of electronic ignition system over conventional type Spark plug- constructional details and classification, heat range- reach.-Spark plug gap & its importance - Specification of spark plug Lighting system: Various lighting circuits : Head light, parking light, turn-indicators , brake light, reverse light , top or doom light. Head lamp-types and constructional details, Bulbs classification- fuses- HT and LT cables , cable color code, wiring harness, cable connector, head light alignment. Electrical accessories fuel gauges-bimetallic and balancing coil type, Coolant temperature gauge, Oil pressure guage, speedometer- Odometer , wind screen wipers & circuits, Electric horns, horn switches & relays.

Miscellaneous electrical and electronic equipment.: tachometer, heaters, remote door locks, window actuators, seat adjuster, anti-theft lock, central locking system. Know the special electrical devices. SPECIFIC INSTRUCTIONAL OBJECTIVES:

Introduction 1.1 State the various electrical systems in Automobile & purpose of each system. 1.2 Explain the Earth & Insulated return system with circuit diagram 1.3 State the merits & demerits of positive & negative earth return system. 1.4 List the Electrical & Electronics symbols w.r.t Auto electrical system

Basics of Electronics 2.1 Sketch & Explain the semiconductor with examples.(Germanium & silicon ) 2.2 State the properties of semiconductors. 2.3 Sketch &Explain P-type,N-type semiconductor. 2.4 Sketch &Explain PN-junction 2.5 Sketch &Explain semiconductor Diode(crystal diode) 2.6 Sketch &Explain Diode as a rectifier. 2.7 Sketch &Explain Diode as a half wave, full wave & bridge rectifier 2.8 Sketch &Explain the full wave rectifier with capacitor filter circuit. 2.9 Explain zener diode. 2.10 Sketch &Explain the working of zener diode as a voltage regulator. 2.11 Explain LED & photo diode. 2.12 Define Transistor. 2.13 Sketch &Explain NPN & PNP Transistor. 2.14 Sketch &Explain Transistor as an amplifier 2.15 Sketch &Explain Transistor as a switch. Battery system in Automobile 3.1 Know the purpose of Batteries in Automobiles 3.2 List the different types of batteries 3.3 Explain the construction and working of lead acid battery 3.4 Explain the construction and working of Alkaline battery 3.5 List the difference between lead acid & Alkaline battery. 3.6 Explain the terms Battery cell voltage, Battery capacity, Battery efficiency, Battery ratings. 3.7 Explain the different types of Battery ratings. 3.8 Explain the different methods of charging 1 Normal Charging 2 Quick charging 3 Trickle charging

3.9 Explain the following tests on lead acid battery 1. Specific gravity test 2. High rate discharge test 3. Cadmium test 3.10 Explain the defects in batteries like Sulphation, Plates decay, Cracking, corrosion, sedimentation & loss of electrolyte. 3.11 Explain the maintenance procedure of a lead acid batteries. 3.12 Explain Maintenance-free batteries used in Automobiles. 4 Charging system and regulation 4.1 Know the purpose of D.C Generator. 4.2 Explain the circuit diagram of charging system using D.C Generator & functions of each component 4.3 Explain the construction & working of D,C Generator 4.4 Explain the construction and working of voltage regulator 4.5 Explain the construction and working of current regulator 4.6 Explain the construction and working of Cut-out relay. 4.7 Mention the purpose of Alternator. 4.8 Explain the circuit diagram of charging system using Alternator & functions of each component 4.9 Explain the construction & working of Alternator. 4.10 Explain the construction and working of Electronic voltage regulator. 4.11 List the difference between D.C generator & Alternator. 4.12 List the advantages of Alternator over D.C generator. Starting System 5.1 Know the necessity of starting system in Automobile. 5.2 Explain a circuit diagram of starting system and functions of each components. 5.3 Explain briefly, Why the series motors are used in Starting system. 5.4 Explain the construction & working of Series wound motor 5.5 Explain the construction & working of Series shunt wound motors 5.6 Explain the necessity of Drive mechanism in starter. 5.7 List the different types of Drive mechanisms. 5.8 5.9 5.10 5.11 6 Explain the construction and working of bendix drive . Explain the construction and working of Over running clutch drive Explain the construction and working of Axial sliding armature drive Explain the construction and working of solenoid switch used in starting system.

Ignition System 6.1 Explain the necessity of Ignition system 6.2 List the types of Ignition system. 6.3 Explain the working of Coil ignition system and functions of each components. 6.4 Explain the construction and working of ignition coil 6.5 Explain the construction and working of distributor.

6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21

Explain the construction and working C.B point & Condenser. Explain Cam angle & Ignition timing. List the different types of advance mechanisms in distributor Explain the construction and working of Centrifugal spark advance mechanism. Explain the construction and working of vacuum spark advance mechanism. List the types of Magneto Ignition system Explain the working of Magneto ignition system. (Rotating magnet type) Explain the construction & working of Transistor assisted Ignition system. Explain the construction & working of CDI Ignition system. Explain the construction & working of Distributor less Ignition system. List the merits & demerits of Electronic ignition system over Conventional Ignition system Mention the classification of spark plug. Explain the construction & working of a spark plug. Explain the terms : Heat range, Reach, Cold plug, hot plug Explain Spark plug gap & its importance. Explain the specification of spark plug.

Lighting System 7.1 Explain with circuit diagram the following circuits : a) Head light b) Parking c) Side indicator d) Brake light e) Reverse gear light f) Top or doom light circuit 7.2 Explain the construction of Head light assembly 7.3 Classify the bulbs used in Automobile. 7.4 Explain the following a) Dim & Dip switch b) HT & LT cables c) Fuses d) Cable colour codes e) Wiring harness f) Cable connectors 7.5 Explain the Alignment of Head light with necessary sketch

Electrical Accessories 8.1 Explain with circuit diagram the following circuits : a) Fuel gauge b) Coolant temperature gauge c) Oil Pressure gauge d) Wind screen Wiper e) Horn 8.2 Explain the construction & working of the following a) Speedometer Odometer

b) c) d)

Wind screen Wiper Electric Horn Relay

Miscellaneous Electrical & Electronic Equipment 9.1 Explain the construction & working of the following a) Engine Tachometer b) Heaters c) Remote Door locks d) Power window e) Anti-theft lock f) Central locking system

Reference Books 1. Diesel Engineering Electricity & Electronics Principals of Electrical Engineering & Electronics A system approach to Automotive Technology The Automobile Engineering Automobile Electrical Equipment Automobile Electrical Equipment Automobile Electrical Engg. Automobile Engineering Vol-2 The Automobile Engineering JOSEPH BELL V. K MEHTA & ROHIT MEHTA JACK ERJAVEC HARBAN SINGH REYATH W. H. CROUSE KOHLI N. R. KATAWATE KIRPAL SINGH K.M GUPTHA

Department of Technical Education Diploma Course in Automobile Engineering Fourth Semester Subject: Auto Electrical and Electronics systems. Time : 3 hours Model Question Paper Note: a) Answer question No.1 which is compulsory. b) Answer any two full questions from each part A,B and C respectively. ( 1x5) 5 Max. Marks: 100

Fill in the blanks :

1. The capacity of the battery is measured in ________ 2 Series wound starter motor produces high torque at ______ speed. 3. ________ diode is used as a voltage regulator in alternator charging system. 4. To make & brake the circuit, _________ is used in Electronic ignition system. 5. The individual cell voltage in Alkaline batteries is ______ volts b. Explain Maintenance-free batteries used in Automobiles PART A 2 a. b.. c. a b. c. a. b. c Define Transistor Sketch &Explain P-type semiconductor Sketch &Explain Transistor as an amplifier Sketch &Explain Diode as a half wave rectifier Write the chemical reaction of battery during charging and discharging. List the difference between lead acid & Alkaline battery Mention the purpose of Alternator Explain the circuit diagram of charging system using D.C Generator & functions of each component Explain the construction and working of Cut-out relay 2 5 8 5 5 5 2 8 5

3.

PART B 5 6 7 a. b. a. b. a. b. Explain briefly, Why the series motors are used in Starting system Explain the construction and working of Over running clutch drive Explain the construction and working of solenoid switch used in starting system Explain the working of Coil ignition system and functions of each components Explain the construction and working of Centrifugal spark advance mechanism Explain the construction & working of CDI Ignition system. PART C 8. a. b c a. b Explain the Head light circuit diagram Explain Dim & Dip switch. List the different types of bulbs used in Automobile Explain with circuit diagram the Fuel gauge Explain with a neat sketch the construction & working of a Wind screen wiper 5 5 5 5 10 5 10 6 9 6 9

10 a b c.

Write short notes on the following Power window Anti-theft lock Central locking system

( 3x5)

15