repair and upgrade teaching models of automotive body electrical systems

Some wiring diagram of door lock and power window system on vehicle ..... 23: Power door lock wiring diagram .... 4: Tail light, position light, fog light, brake light, reverse light wir

OVERVIEW OF THE TOPIC

Reason for choosing the topic

In an era where the automotive industry is growing and changing constantly, mechanical control systems are gradually being replaced by electrical controls

Therefore, our group implements the topic: REPAIR AND UPGRADE TEACHING

MODELS OF AUTOMOTIVE BODY ELECTRICAL SYSTEMS to improve degraded models and contribute to improving the understanding of automotive electronic and electrical systems.

Research purposes

In order to understand the structure and operating principle of the lighting, door lock control, power window, wiper and washer systems

Design troubleshooting, practice sheets then apply it to tasks such as diagnosing, maintaining, and repairing cars in the future.

Research subjects

Lighting, door lock control, power window, wiper and washer systems.

Research scope

Structure and working principle of lighting, door lock control, wiper and washer systems of Hyundai Grand I10/Xcent 2018.

Research method

With the goal of REPAIR AND UPGRADE TEACHING MODELS OF

AUTOMOTIVE BODY ELECTRICAL SYSTEMS, the main research method is the method of researching Then, we repair and upgrade the model base on the knowledge that we study and reuse equipment in old model to meet the initial objectives

THEORETICAL BASIS

Overview of lighting system

The car's lighting system comprises lights and signals located at the front, back, and sides of the vehicle These lights indicate the vehicle's presence on the road In addition, modern cars are also fitted with devices that enhance visibility, particularly in inclement weather such as storms or foggy conditions

+ Lights the roadway for the driver

+ Vehicles on the road are indicated by light signals

+ Information about the vehicle's size, structure, and license plate is reported

+ In low light conditions, the lighting system also enhances the visibility of the vehicle It alerts other drivers and pedestrians to the presence and direction of travel of the vehicle

+ Signals when the vehicle turns around, turns left or right when braking, backing up and when stopping

+ Car parts are illuminated when being necessary such as the engine, cockpit, passenger compartment, and luggage compartment

+ The lighting system also makes the vehicle more visible, especially in low light conditions It gives warning to other drivers and pedestrians of a vehicle's presence and direction of travel

Classification of lights used on vehicles consists of two main categories: lighting system and signal lighting system

The lighting system comprises of various lights, such as head lights, which include both low beam and high beam options These lights are essential for providing visibility to the driver during nighttime Headlights are specifically designed to illuminate the space in front of the vehicle The requirements for headlights, including intensity, lighting area, lighting angle, and lighting limit, will be clearly specified in the subsequent section

On the other hand, the signal lighting system encompasses different lights with specific functions Turn signals are used to indicate when a vehicle is turning or giving a warning

Size lights are employed to indicate the dimensions of the vehicle, while brake lights signal when the vehicle is braking

Illuminated with headlights, red tail lights signal vehicle deceleration or upcoming stops Tail light assemblies incorporate various elements, including stop lights, rear marker lights, and turn signals For enhanced visibility in fog, fog lights are often included within the assembly.

Figure 2 1: Location of components in lighting and signal systems

The lighting and signal system has the following basic components:

2 Rear lights, rear fog lights

3 Light and brightness control switch: Turn signal switch, front and rear fog light switch

4 Turn signals and warning lights

10 Headlight lighting angle control switch

11 The actuator controls the headlight illumination angle

Headlights play a vital role in the lighting system of any vehicle as they are accountable for providing illumination to the road ahead Over the course of history, different types of headlights have been created

Halogen bulbs are one of the most commonly used automotive headlights on the market This type of bulbs uses a tungsten filament, which is heated at a temperature of 2,500 degrees Celsius to produce light In addition, the bulb is also added with some gases such as argon and nitrogen to increase lighting efficiency With a color temperature of about 3,500 degrees K, halogen lamps give off a yellow light

Low cost and long bulb life The average life of Halogen headlights is about 1,000 hours and has a capacity of about 55 W in normal lighting conditions This type of bulbs has the ability to illuminate quite well when going through areas with fog or heavy rain

Compared with other lamps, Halogen lamps emit large heat, consume a lot of power, but the luminous efficiency is not high Most of the energy is converted into useless heat instead of light Halogen bulbs over a period of use at high temperatures cause the tungsten to evaporate and settle on the glass layer, causing the bulb to perforate At that time, the lighting function of the bulb is considered to be no longer available Therefore, with the present time and the future, Halogen is being considered as an obsolete ball in car headlights

Xenon headlights, also known as HID (High Intensity Discharge) are high intensity lighting systems Born in 1991, but in recent years, Xenon lamps have been widely used on midsize cars

Xenon headlights feature a quartz glass lens that evenly distributes light The heart of the headlight lies in the xenon gas bulb, which emits a brilliant white light when an electric current flows through it This light is significantly more intense (2-3 times stronger) than that produced by halogen lamps Notably, the color temperature of xenon headlights ranges from 4,300 to 5,500 degrees K, resulting in a white light that closely resembles natural sunlight.

With vehicles using these lights, the driver's visibility is always improved Besides, xenon headlights only need about 35 W of power to operate and have a lifespan of about

The production and maintenance costs of Xenon lamps are quite high when they are composed of many components such as converging lenses, xenon bulbs and ballasts This is the reason that limits the appearance of Xenon headlights on many models Besides, Xenon headlights have a rather slow glow time, when the lights are turned on, they will be green, then about 3-5 seconds, the lights will turn white and reach the highest luminous intensity The glare of this type of light is also easy to interfere with oncoming vehicles

LED stands for "Light-Emitting Diode" which is understood as "light-emitting diode" This type of lamp is used by semiconductor chips that are only a few millimeters in size The movement of electrons produces light radiation with different colors

6 depending on the substance in the semiconductor chip Therefore, manufacturers can make LED lights with many different shapes to increase aesthetics but still ensure the ability to illuminate the vehicle The advantage of LED headlights is that they have a color temperature of 5,000 - 6,300 degrees K for white light Brightness can reach nearly 10,000 Lumen, this parameter is twice that of Xenon lamps

LED lights also have the advantage of fast lighting, do not consume much energy to activate They can help increase the reaction time of other drivers by 30% LED lamp life can be up to 15,000 hours

The limitation of this lamp is that it radiates a lot of heat, which easily increases the temperature of the semiconductor chip, affecting the neighboring details Therefore, LED lights are often built with a heat dissipation system, causing costs and costs to be pushed up In addition, compared to Xenon and Halogen lamps, the cost of LEDs is quite high

Laser headlights are the most modern and expensive lamps available today The luminous intensity of the Laser lamp is capable of shining up to 600m away compared to the 300m distance of the LED, but it only uses more than half of the power consumption compared to the LED In terms of structure, although called a laser light, the laser beam is not capable of illuminating objects Instead, the laser beam hits a lens containing yellow phosphorus gas This gas will emit a bluish-white light when excited by laser light

Has the ability to illuminate very far, using less power than LED, using on luxury car: Audi, BMW, Porsche, …

Overview of power door lock and power window system

In the evolving automotive landscape, the door lock system has emerged as a crucial safety feature As manufacturers strive to enhance safety, they have advanced the door lock system from rudimentary mechanical controls to sophisticated remote and smart key technologies These advancements have transformed automobiles into indispensable tools for personal mobility, while also placing a responsibility on manufacturers to ensure the well-being of their customers.

The power window system includes the following functions:

+ Manual open/close function: When the switch for the power window is pressed or pulled, the window will open or close until the switch is let go

+ One touch auto open/close function: When the power window switch is pushed or pulled fully, the window fully opens or closes

+ Window lock function: When the window lock switch is turned on, it prevents all windows, except for the driver's window, from being opened or closed

Jam protection function: The power window will automatically halt and lower by approximately 50 mm if any foreign object becomes trapped during the one-touch auto close action

Key-off power window function: This feature enables the functioning of the power window system for about 45 seconds once the ignition switch is turned to either the ACC or LOCK position, provided that the driver's door remains closed

Mechanical door lock systems, common in older vehicles, operate solely on mechanical mechanisms Users can open and lock these systems through two primary methods: inserting a key into an exterior door lock or rotating an interior knob within the vehicle's door.

Figure 2 13: Mechanical door lock system

Figure 2 14: Electric door lock system inside the car

Door lock system using remote key: Remote control door locking system is a system that sends remote control signals from the remote controller in combination with the key to control the opening and closing of the car when near or far from the vehicle

The electric door lock system, which is installed inside the car, utilizes an electric mechanism and electric motors for the purpose of conveniently opening and closing the car door This system is efficiently controlled through the utilization of push buttons, which are specifically located at the driver's door, allowing the individual to effortlessly unlock the door On the other hand, the door lock system that utilizes a remote key is a groundbreaking system that allows the individual to conveniently secure or unlock the vehicle door from a distance This sophisticated system operates by sending remote control signals from a remote-control device, thereby providing the user with the ease and convenience of effortlessly controlling the locking mechanism of the car door

Figure 2 15: Door lock system with remote key

The door lock system that utilizes a smartphone is an incredibly advanced and cutting-edge technological solution By means of the implementation of this system, individuals are capable of encountering a degree of convenience, comfort, and safety The integration of a sensor, which is seamlessly attached to the vehicle, allowing it to establish a wireless connection with a personal mobile phone for effortless identification purposes Consequently, users can effortlessly gain access to their vehicle without the need for traditional keys or physical interaction Additionally, one of the most extraordinary characteristics of this system is the capability for users to unlock their car doors simply by utilizing their own voice This voice recognition capability adds an additional layer of ease and convenience to the overall user experience Furthermore, its potential and versatility are so significant that it is predicted to be widely adopted and utilized in the future, the way individuals interact with their vehicles

Figure 2 16: Door lock system with mobile application

The basic from of the electric window operation is similar to many of the systems discussed so far in this module, that is, a motor reversing system either using relays or directly by a switch More sophisticated systems are now popular for reasons of safety as well as improved comfort The following features are now available from many manufacturers:

+ On touch up or down (Automatic function)

The power window system includes:

The feature that used to lift up and move down is called the window regulator There are two basic mechanisms of windows regulator that both use the spinning motion of motor The power window drive units include integral Hall-effect sensors to monitor motor speed during operation If a reduction in speed is detected the motor’s direction of rotation is immediately reversed The window closing force must not exceed 100N at a spring rate of 10M/mm The unit automatically overrides the force limitation function immediately before the window enters the door seal, allowing the motor to run to its end position and permitting complete closure of the window The window position is monitored over its entire range of movement

Figure 2 17: Two types of power window

In recent decades, the automotive industry has transitioned towards cable-driven window regulators due to several advantages These include the compact size, enabling enhanced safety in the form of additional crash protection and airbags within the door Furthermore, the lightweight nature of cable regulators contributes to improved fuel efficiency Additionally, the integrated assembly simplifies manufacturing processes, resulting in cost reductions However, it is noteworthy that cable regulators contain a greater number of components and exhibit a more complex design compared to the traditional scissor-type regulators.

Figure 2 18: The cable mechanism of power window system

Window regulators in the scissor style are an earlier feature that we primarily see on antique cars A major arm is attached to the window carriage/ tray on one end and to a big plate with gear teeth on the other end, and is made almost entirely of metal If a scissor assembly is power operated, an electric motor turns a worm gear that meshes with those teeth to move the arms In the absence of a power motor, a manual crank handle serves the sense function

Figure 2 19: The appearance of cable type 15

As they push or pull the window up or down, both arms travel on tiny wheels down a groove in the bottom of the window tray, and the main arm is crossed by a smaller secondary arm at a hinged center point When the wheels at the end of the arms wear out and break off, scissor type regulators can fail, allowing the glass to tilt at an angle within the door The entire mechanism generates noise and the glass rattles in a sloppy, unexpected manner when the middle hinge wears between the two bars as they scissor up and down

With each door, there is one motor equipped inside Window regulator is the mechanical assembly behind the door panel The window motor can not be repaired or maintenance, it is replaced instead

The control system for the door lock is operated by a combination relay that includes the following details:

1 The combination relay (ECU controls door lock) The combination relay receives signals from each switch and transmits lock (open) signals for each door lock cluster to drive the motor and control the door lock for each door

2 Door lock assembly the door lock cluster locks (unlocks) each door The doors can be locked (un)locked when the door lock control motor located inside is electrically activated

4 Key unlock warning switch the door unlock warning switch with the key determines whether the ignition key has been used Has the electric lock been inserted yet?

6 Door lock control switch (Electric window main switch)

The car door lock system relies on an electric motor to rotate a series of cylindrical gears, which decrease speed The final gear drives the rack base, connected to the rigid tie rod, converting rotational motion into linear motion This facilitates the movement of the locking pin When the door latch is raised, an automatic centrifugal clutch disconnects the gears from the electric motor, preventing further rotation.

When the gears are turned by the electric motor, the clutch links the small metal gear to the larger plastic gear, enabling the electric motor to engage the door latch If you raise the pin, all the gears will continue to turn, with the exception of the plastic gear that is firmly held by the clutch

Overview of wiper and washer system

Windshield wipers guarantee proper visibility in unfavorable weather situations like rain, fog, and snow They are occasionally employed on a vehicle in combination with a windshield washer system, which dispenses a cleaning solution or winter windshield washer fluid containing antifreeze, to aid in eliminating debris, snow, dust, dirt and ice from the windshield

Windshield wipers are a vital aspect of every vehicle, regardless of size It is responsible for removing water and debris from the windshield, which improves visibility for the driver while they are on the road Nowadays, windshield wipers are deemed a typical trait not only in cars, but also in trains, ships, and airplanes During rainy weather, the windshield wiper and washer system ensures a clear view by wiping away any precipitation from both the front and rear windshields Additionally, a glass washer component helps to remove dirt from the front windshield This part is crucial for upholding the safety of the vehicle while it is in motion certain vehicles have the capability to adjust the wiper angle to 110 degrees, depending on the specific vehicle

Figure 2 23: Front windshield wiper system

The windshield wiper and washer system plays a crucial role in ensuring clear visibility for drivers during inclement weather, particularly during rain This system consists of both wipers and washers, working in tandem to remove rainwater and maintain visibility The wipers effectively wipe away raindrops from the front and rear windshields, while the washers spray glass water to clear dirt and debris from the headlamps and windshield By effectively removing water and debris, the windshield wiper and washer system greatly enhances driver visibility, thereby improving traffic safety and enabling safer driving conditions.

39 Therefore, this is an essential tool for ensuring the security of cars during movement

In recent times, certain vehicle makes have the capability to adjust the wiper speed based on the car's velocity and also automatically turn on the wipers when it starts raining The car's wiper system should operate seamlessly, flexibly, and dependably, while also being able to adapt to different intensities of rainfall, whether it is heavy or light

The windshield wipers, three types are widely used

+ Conventional frame-style wiper: The conventional wiper, which is in the frame style, consists of a rubber that is hardened either by halogen or by ordinary rubber This rubber body is mounted on a metal frame The metal frame provides support to the rubber blade at every point where the windshield wiper comes into contact with the window Typically, the frame is tensioned by a spring, and instead of replacing the entire wiper unit, the rubber over the frame can be replaced This type of wiper is the most commonly used and is widely found in vehicles Furthermore, it is frequently the cheapest alternative accessible

+ Beam blades style wiper: the frame that holds the rubber design for the windshield wiper is made from a single piece of rubber with a steel spring integrated into it This design ensures that the wiper provides even pressure across the entire windshield, preventing any areas from being neglected Some wipers even incorporate a double layer of rubber or silicone, which enhances their performance and durability While the appearance of a wiper may not directly impact its functionality, many people choose the Beam blades style wiper for its sleek and attractive look In fact, the Beam blades style wiper often has a slightly better outer appearance compared to the traditional blade This style of wiper is gaining popularity, particularly due to the rise in curved windscreens in modern car models The more expensive versions of Beam blades are just as good, if not better, than the conventional blades However, the cheaper versions of Beam blades fail to meet the same standards and do not perform as effectively

+ Winter wipers: this particular type of wiper blade is specifically crafted to cater to individuals who reside in or frequently visit or drive through regions with extremely harsh winter climate The design of the winter wiper is characterized by a traditional blade style that is effectively encased in a protective rubber covering This unique construction is purposefully created to prevent the accumulation of ice and snow on the wiper blade Although winter wipers may not possess the same visual appeal as conventional or beam blades, nor boast optimal aerodynamics, solution for enduring the unforgiving winter weather conditions

The wiper motor is a type of DC motor with permanent magnet excitation The wiper motor consists of a motor and a gear transmission to reduce the motor output speed The wiper motor has 3 energizing brushes: low speed brush, high speed brush and a shared brush (for grounding) A cam switch is located in the gear so that the wiper stops in a fixed position at all times

Figure 2 24: Construction of wiper motor

A reverse electromotive force is generated in the armature winding when the motor rotates to limit the motor rotation speed

When current enters the armature winding from the low-speed brush, a large reverse electromotive force is generated As a result, the motor rotates at a low speed

When current enters the armature winding from the high-speed brush, a small reverse electromotive force is generated As a result, the motor rotates at high speed

2.3.3.2 Working principle of wiper motor

Figure 2 25: Working principle of wiper motor

This switch has a V-slotted cam disc and 3 contacts When the wiper switch is in the LO/HI position, battery voltage is applied to the circuit and current enters the wiper motor through the wiper switch causing the wiper motor to rotate However, at the time the wiper switch is off, if contact P2 is in the contact position but not in the groove position, the battery voltage is still applied to the circuit and current enters the wiper motor to contact P1 through contact P2 causes the motor to continue to rotate Then by rotating the cam disc makes contact P2 in the slotted position so that current does not enter the circuit and the wiper motor is stopped However, due to the inertia of the armature, the motor does not stop immediately and continues to rotate a little As a result, contact P3 crosses the conductive point of the cam disc Close the circuit as follows: Armature → Pole (+)1 of the motor → wiper switch → S pole of wiper motor → contact P1 → P3 → armature Since the armature generates reverse electromotive force in this closed circuit, electrical braking of the motor is produced and the motor is stopped at a fixed point

2.3.3.3 Washer motor a Front/rear washer motor

Figure 2 26: Front/rear washer motor

Pour the windshield washer fluid into the reservoir in the engine compartment The glass cleaner tank is made from a translucent plastic bottle and the glass cleaner is sprayed by the glass washer motor located in the container The windshield washer motor is impeller as used in the fuel pump

There are two types of windshield washer systems for cars with rear window washers: One has a common reservoir for both the front and rear washers, and the other has two separate tanks for the front and rear washers rear glass There is also one type that adjusts the nozzles for both the front and rear windows by means of a washer motor that controls the valves, and another with two separate motors for the front and rear washer placed in the container b Operation in combination with glass washing parts

Figure 2 27: Combined operation of washer and wiper

43 This type automatically controls the wiper mechanism when spraying glass cleaner after turning on the glass washer switch for a certain time, which is "the operation in combination with the glass washer" It is the operation so that the windshield wiper is sprayed on the front glass surface

2.3.4 Some wiring diagram of wiper and washer on vehicle

Figure 2 28: Porsche Cayenne’s wiper and washer wiring diagram

Figure 2 29: 2019 Honda Civic’s windshield wiper and washer

Figure 2 30: 2019 Honda Civic’s rear window wiper and washer

MODEL REDESIGNING AND UPGARDING

Hyundai I10/Xcent 2018

The hatchbacks remain the favorite family ride in a number of Asian countries Actually, they look for small cars with lesser fuel and maintenance expenses And even they look for small size based on the parking issues

In South Asia, you would find plenty of such hatchback based on cars And one of them is the Hyundai Xcent The Xcent was unveiled at the 2014 Auto Expo India as a step ahead of Accent Not to forget, the Accent is still alive but it is no more available in the South Asian market

The South Asian market needed something like a hatchback but in shape of a sedan that could offer the same specs like the i10 And the Xcent is very much successful to be a sedan version of the i10 While it is not purely based on the i10 But it is marketed in Mexico as the Grand i10 Sedan

By now the Xcent has received some basic improvement including some facial uplift and the interior improvisation Further, the model line includes plenty of trim levels And the cheapest among them is for $7,760 While the finest trim level begins from

The body shape does make Xcent a sedan But the driving experience is similar to the common South Asian hatchbacks The available drivetrains are even those that you could easily get in a hatchback

For the gasoline, you get the 1.2 L inline-four Kappa engine that you may even witness on the Hyundai hatchbacks Well, this fella is capable of generating 83 hp of power at 83 lb-ft of torque And it comes mated with the 5-speed manual transmission Further, a 4-speed automatic transmission is offered manually for the upper trim levels

While the diesel variants get the 3-cylinder 1.1 L U2 CRDi engine with just enough power to pull the body Well, this powertrain has been recently upgraded to offer some more power While in the past it was just like a liability With this engine, you get 72 hp of power producing 133 lb-ft of torque And it offers some good saving on fuel Even its CO2 emission is enough to keep the city clean Ahead of that, the diesel variant is available only with the 5-speed manual transmission

The Hyundai Xcent comes only with front-wheel-drive configuration And the handling column is pretty fine when you are driving at an average speed If you go fast, the Xcent would not really comprise well on its handling

0 – 62 MPH Top Speed Body Style MPG

The Xcent gets a few features to keep the occupant safe Well, they are the antilock braking system, dual frontal airbags, and the rear screen defogger Besides, it gets the option for the rearview camera as well While some good safety points include a hard structure that reduces the impact of the collision Ahead of that, there is nothing more included for the safety And the rest remains on the driver that how safe they could drive

Car choosing

We have developed a model of the door lock system, power window, lights, and wipers of the Hyundai Grand I10/Xcent 2018 This model emulates the operating principles of modern automotive systems It leverages diagnostic tools to gather vehicle data, facilitating an understanding of control methodologies Despite variations between models, the underlying principles remain similar, allowing for the utilization of replacement actuators to reduce expenses.

The model can fully perform the functions of 4 lighting systems, wipers, power window and door locks on Hyundai Grand I10/Xcent 2018, in addition to the model, there is also a troubleshooting and joints connector to facilitate the teaching and learning environment Besides that, we repair and upgrade the connection model of power window and door lock system.

Material selection for the model

The material chosen by the group to make the frame for the model is steel pipe CT3

∅20 with outstanding features such as:

+ High flexibility, easy to shape

+ The price is cheaper than other steels with the same characteristics

Because of the above advantages, CT3 steel is widely used in many areas

3.3.2 Selection of materials to make device mounting board for the model

In order to create newness and high aesthetics for the model, the team chose milky white mica resin as model frame face material For teaching models, our group selected the 5mm mica plate to ensure the solid support of the limb details

• Mica's glossy properties are iridescent, smooth and shiny surface

• Has good light penetration Various colors

• Mica has flexible properties, so it is easy to assemble, bend, and press at will

• High temperature resistance, anti-corrosion

• Does not conduct electricity or heat Water proof

Figure 3 3: Board milky white mica

Design and implementation of models

There are many software for design work, the team chooses Auto-cad software for main design because Auto-cad is accurate and easy to use, especially popular with engineering students

The model frame to be designed should have a solid structure and be suitable for the size of model table

Figure 3 4: Frame size for PABE – 2.75

56 The main layout of the board includes: location of systems equipment, symbols and names of devices, shape of cutouts for mounting devices, location of mounting holes and jack pin

The nameplate includes the modeling name, instructor

Figure 3 5: Layout design for main model board

Figure 3 6: Layout design for left side model

Figure 3 7: Layout design for right side model

Figure 3 8: Layout for trouble activating board

Figure 3 9: Layout design for nameplate

Figure 3 10: Main layout of model after completing

BCM and SJB is a place to process information of input signals such as door position, light signals, sensor signals, then control system outputs such as door lock mechanism, lights head, turn signal, windshield wiper, In addition, we can use it to customize the system as well as read its datas thanks to diagnosis device

Multifunction switch is the device is used to help the driver turn on functions such as lightings, wiper and washer,…These functions will be sent as a signal and ECU will handle then send to SJB Actuators will be activated

Figure 3 14: Connector view of BCM

Figure 3 15: Connector view of Multifunction SW

Figure 3 17: Power distribution to SJB

Figure 3 18: Power distribution from SJB to BCM

The vehicle's comprehensive lighting system comprises essential components including headlights for illumination, position lights for visibility, taillights for rear visibility, fog lights for enhanced visibility in adverse conditions, turn-signal lights for indicating direction changes, reverse lights for reversing maneuvers, brake lights for signaling braking, lighting switches for manual control, relays for power distribution, a reverse switch for gear detection, a hazard switch for indicating emergencies, and a brake switch for braking detection.

Table 3 1: Types of lights in the lighting system

Device Type of lights Color Quantity

Turn-signal lights Yellow 4 bulbs

Table 3 2: Relays and switches of lighting system

Brake switch Red 1 (drop type)

Reverse switch Red 1 (holding type)

Figure 3 21: Tail light, position light, license light wiring diagram

3.4.4 Power door lock and power window system of PABE - 2.75

Door lock and power window system on the model includes: Door lock/ unlock switch, door lock actuator, power window switch, power window actuators

Table 3 3: Some devices of door lock and power window system

Figure 3 23: Power door lock wiring diagram

Figure 3 24: Power window wiring diagram

3.4.5 Wiper and washer system of PABE - 2.75

The wiper and washer system on model includes: Wiper motor, washer motor, wiper and washer switch

Figure 3 27: Wiper and washer wiring diagram

Figure 3 28: Frame size for PABE – 2.34

Figure 3 29: Main layout for PABE – 2.34

Figure 3 31: Main layout of PABE – 2.34 after completing

Table 3 5: Main device on PABE – 2.34

PRACTICE INSTRUCTION (FOR INSTRUCTOR)

Practice sheet no.1 for PABE - 2.75

Day: / / Time: 60 minutes Start: _ End:

- Identify devices in the model

- Operate the system, test and confirm the operating principle Design electrical circuits suitable for the system under investigation

- To help students understand the basic operating principles of body electrical systems

- Help students master how to use VOM meters, measure and determine the pins of control switches and relays,

- Check before power on, correct polarity

- Do not perform any other power supply or connection operations on the model

Step 1: Receive the model from the lecturer

Step 2: Identify devices, check for abnormalities

Step 3: Check the battery voltage (12V) and power the model

Step 4: Confirm the operating principle

Step 5: Follow the instruction below

* Note: All terminals are compared to ground

Table 4 1: Measure the voltage of body electrical systems

Power window and power door lock SW IG: ON

Power window - LH IG: ON

Driver and RLH IG: ON

Passenger and RRH IG: ON

Table 4 2: Measure the voltage of power supply

Practice: Operate the system and identify troubles.

1 Turn on the pan switch 1 and identify the problems

Power window does not work

2 List the possible cause of these problems

3 Conduct an inspection, locate the damage, and mark on the circuit diagram

+ Check the voltage of pin 60 (I/P - LR): 12V

+ Check the voltage of pin 9 (Power window main SW)

4 Evaluation, Conclusion, Recommendation (If any)

Open between pin 60 of I/P - LR and pin 9 of power window main SW

101 + Check the voltage of pin 3, 30 (I/P - RT) and 7, 21 (I/P - LR): 0V

+ Check signal from hazard SW: measure the voltage of pin 23 (I/P – SB) and pin 1 of hazard SW or check continuity of pin 23 (I/P – SB) and pin of hazard SW

Open between pin 23 (I/P – SB) and pin of hazard SW So, SJB does not get the signal from hazard SW

High mode of headlights does not work

103 + Check the voltage of pin 3 of all relay

+ Check the voltage of pin 12, 13, 16, 26 (I/P - RT)

+ Check signal from hazard SW: measure the voltage of pin 21 (M04 - A) and pin 13 of multifunction SW or check continuity of pin 21 (M04 - A) and pin 13 of multifunction

Open between pin 21 (M04 - A) and pin 13 of multifunction SW

INT and LOW mode of wiper motor do not work

105 + Check the voltage of pin 3 (Multifunction SW)

+ Check the voltage of pin 4 (Multifunction SW) when SW turned to Low mode

+ Check the voltage of pin +1 of wiper motor

+ Check continuity between pin 4 (Multifunction SW) and pin +1 of wiper motor

Open between pin 4 (Multifunction SW) and pin +1 of wiper motor

Door lock does not work

+ Check the voltage of pin 40 I/P - RT

+ Check continuity between pin 1 (I/P - SA) and mass

+ Check signal from power window main SW: check continuity of pin 30 (I/P - RT) and pin 2 power window main SW

+ Check continuity between pin 5 (I/P - SA) and pin 1 (M04 - C)

Open between pin 5 (I/P - SA) and pin 1 (M04 - C)

Wiper and washer do not work

109 + Check voltage of pin 28 I/P - SB

No power supply for pin 28 I/P - SB Mean that, no power supply for wiper and washer motor, headlight

and Pan 1 for examination

1 Turn on the pan switch 7 or pan switch 1 for exam and identify the problems

+ Check all devices in headlight system first

+ Check the voltage of pin 16 (I/P - SB)

+ Check the voltage of pin 13 (M04 - A)

Open between pin 16 (I/P - SB) and pin 13 (M04 - A) Mean that, no IG power supply for BCM

for examination

1 Turn on the pan switch 2 for exam and identify the problems

Headlight LH does not work

+ Check signal from Multifunction SW to BCM

+ Check voltage of pin 12 and 13 I/P - RT

+ Check continuity pin 2 headlight LH and mass

Open between pin 2 headlight LH and mass

for examination

1 Turn on the pan switch 3 for exam and identify the problems

Door lock and door unlock do not work

+ Activate door lock and door unlock, hear that relay in SJB active

+ Check continuity pin 1 I/P - SA and mass

Open between pin 1 I/P - SA and mass

for examination

Practice No.3 Power Window without automatic function

Identify devices in the model

Identify the structure and function of necessary devices using for Power Window

Connect all the necessary components to operate the whole system

To help students are able to work in groups to discuss and solve automotive electrical problems

To help students master how to use VOM meters, measure and determine the pins of control switches and relays,

Design electrical circuits suitable for the system under investigation

To study about working principle of the Power Window system

Check before power on, correct polarity

Checking carefully the whole system before start operating

Step 2: Identify devices and the functional pins of each component

120 Step 3: Design the electrical circuit and connect all necessary devices

*Note: Power supply must be applied through relay

Figure 4 3: The connection between all devices

121 Figure 4 4: Electrical circuit of Power Window without auto

Step 4: Double check, connect to the battery and operate the system

Practice No.4 Power Window with automatic function

Figure 4 8: Electrical circuit of Power Window with auto

Practice No.5 Power Door Lock with Relays

Identify the structure and function of necessary devices using for Power Door Lock Connect all the necessary components to operate the whole system

To study about working principle of the Power Door Lock system

Figure 4 12: Electrical circuit of Power Door Lock controlled by relays

Practice No.6 Power Door Lock with Door Lock Module

Figure 4 15: Electrical circuit of Power Door Lock controlled by Door Lock Module

Practice No.7 Power Door Lock with BCM

Figure 4 17: The first port of BCM

Figure 4 18: The second port of BCM

Figure 4 20: Electrical circuit of Power Door Lock controlled by BCM

PRACTICE SHEET (FOR STUDENT)

Table 5 1: Measure the voltage of body electrical systems

Power window and power door lock SW IG: ON

Power window - LH IG: ON

Driver and RLH IG: ON

Passenger and RRH IG: ON

Table 5 2: Measure the voltage of power supply

Figure 5 1: Power supply for SJB wiring diagram

Figure 5 2: Power distribution from SJB to BCM

Figure 5 3: Headlight wiring diagram redesign

Figure 5 4: Tail light, position light, fog light, brake light, reverse light wiring diagram redesign

Figure 5 5: Power door lock wiring diagram redesign

Figure 5 6: Power window wiring diagram redesign

Figure 5 7: Wiper and washer wiring diagram redesign

for examination

Practice No.3 Power Window without automatic function

Figure 5 10: Drawings for students to design connection circuits

Practice No.4 Power Window with automatic function

Practice No.5 Power Door Lock with relays

Practice No.6 Power Door Lock with Door Lock Module

Practice No.7 Power Door Lock with BCM

Figure 5 21: The first port of BCM

Figure 5 22: The second port of BCM

CONCLUSIONS

After a period of implementation of the graduation project, the group has completed the model of the Lighting, Door lock, Power window, Windshield wipers and washer system of Hyundai I10/ Xcent 2018 and repair the training model Automotive power window and power door lock system During the process of researching and implementing the topic, the group has absorbed a volume of specialized knowledge about body electrical systems, thereby helping the members better understand about the electrical systems of modern vehicles The group has achieved some results as follows:

+ Building the theoretical basis of the model of the door lock, power window, lighting, wiper and washer system

+ Build a model about automotive body electrical system and repair - upgrade a model

+ Build practice sheets to help students practice about errors on the system

Thereby, teachers can use the model for teaching, helping students in the later class to have closer access to the body electrical systems of modern cars, closer to reality

1 PGS-TS Đỗ Văn Dũng (2007) “Giáo trình điện tử điện thân xe” Đại học sư phạm kỹ thuật TP HCM

2 PGS TS Đỗ Văn Dũng, Hệ thống điện và điện tử trên ô tô hiện đại – Hệ thống điện thân xe và điều khiển tự động trên xe ô tô, Nhà xuất bản ĐH quốc gia-2003

3 Tom Denton (2006) Automobile Electrical and Electronic Systems, Lighting (3rd edition) 291-317

4 2018 Hyundai Xcent Review - Global Cars Brands

Tiêu đề	Repair and Upgrade Teaching Models of Automotive Body Electrical Systems
Tác giả	Nguyen Phung Trung Nguyen, Nguyen Thanh Tien
Người hướng dẫn	Nguyen Quang Trai, MSE
Trường học	Ho Chi Minh City University of Technology and Education
Chuyên ngành	Automotive Engineering
Thể loại	Graduation Project
Năm xuất bản	2024
Thành phố	Ho Chi Minh City

Định dạng
Số trang	194
Dung lượng	14,36 MB

repair and upgrade teaching models of automotive body electrical systems

OVERVIEW OF THE TOPIC

Reason for choosing the topic

Research purposes

Research subjects

Research scope

Research method

THEORETICAL BASIS

Overview of lighting system

Overview of power door lock and power window system

Overview of wiper and washer system

MODEL REDESIGNING AND UPGARDING

Hyundai I10/Xcent 2018

Car choosing

Material selection for the model

Design and implementation of models

PRACTICE INSTRUCTION (FOR INSTRUCTOR)

Practice sheet no.1 for PABE - 2.75

Practice sheet no.2 for PABE - 2.75

and Pan 1 for examination

for examination

for examination

for examination

Practice sheet no.3 for PABE - 2.34

Practice sheet no.4 for PABE - 2.34

Practice sheet no.5 for PABE - 2.34

Practice sheet no.6 for PABE - 2.34

Practice sheet no.7 for PABE - 2.34

PRACTICE SHEET (FOR STUDENT)

Practice sheet no.1 for PABE - 2.75

Practice sheet no.2 for PABE - 2.75

for examination

Practice sheet no.3 for PABE - 2.34

Practice sheet no.4 for PABE - 2.34

Practice sheet no.5 for PABE - 2.34

Practice sheet no.6 for PABE - 2.34

Practice sheet no.7 for PABE - 2.34

CONCLUSIONS