MODULE IV

MULTI POINT FUEL INJECTION

Common rail fuel injection system
Turbo charger
Turbochargers are installed on an engine to put
more and denser air into the engine combustion
chambers. Because of this increased volume and
weight of compressed air more fuel can be scheduled
to produce more horsepower from a given size
engine. A turbocharger very simply is an air pump
designed to operate on the normally wasted energy
in engine exhaust gas.
Working
 The heat energy and pressures in the engine exhaust gas is
utilized to drive the turbine wheel. The housing acts as a nozzle
to direct the exhaust gas flow to the turbine wheel blades, which
drives the shaft wheel assembly. Since the compressor wheel is
directly coupled to the shaft, it rotates at the same speed as the
turbine wheel. Clean air from the air cleaner is drawn into the
compressor housing and wheel where it is compressed and
delivered through a crossover pipe to the engine air intake
manifold.

Advantages
 [Link] increases the volumetric efficiency of the
engine.
 [Link] increases the output power produced.
 [Link] reduces the intake of fuel or air-fuel mixture.
 [Link] allows the engine to work smoothly in various ambient
conditions.
 [Link] kinetic energy of exhaust gases is fed back to the engine
and used beneficially.
Intercooler
 Some times an intercooler is also used in between the supercharger
and the engine. The purpose is to cool the mixture which has become
hot on account of compression in the super charger. The volumetric
efficiency obviously is decreased at higher temperatures which is
again increased by cooling of the mixture in the intercooler.

 The design of intercooler is such that the air to be cooled is passed

through the outer tube and the refrigerant passes through the inner
tube of the two concentric tubes arrangement fitted in the
arrangement of fins. When the air conditioning system (AC) is
running, the hot air can give its heat to both, the refrigerant and the
cold air passing through the fins of the intercooler. When the AC is
not running, the hot air from the turbocharger can give its heat to the
cold air passing through the fins and will work as the normal
intercooler. In winters, the intercooler will work as a normal
intercooler and in summers, it will be assisted by the air conditioning
system of the vehicle.
Electronic ignition system
AIR SUSPENSION SYSTEM
 A layout of air suspension system is shown
below.- An air compressor is used to compress
the atmospheric air to 240 Mpa An
accumulator tank is used to maintain this
pressure, which provided with a safety
[Link] high pressure air goes through the
lift control valve and the leveling valves, to the
air springs. The lift control valve is operated
manually by means of a handle on the control
panel
 POWER STEERING
Benefits of power steering are mentioned below:
 Effortless steering
 Quick and precise response
 It absorbs road shocks
 It furnishes controllability and greater safety under critical
situations
Hydraulic Power Steering System
 In this type of power steering system as we discussed above the
hydraulic force is used to multiply the steering input force in order to
smoothen the steering of the front wheels, this hydraulic force is
generated by a series of components that includes hydraulic cylinder,
rotator hydraulic pump, hydraulic lines, highly compressed hydraulic
fluid and a coupling mechanism that can couple this hydraulic system
with rack of the steering system.

WORKING
 When the driver provides input by rotating the steering wheel, the
hydraulic pump driven by the engine starts pumping the highly
compressed hydraulic fluid through lines.
 The hydraulic pressure produced by the pump enters the hydraulic
cylinder which in turn applies pressure over the cylinder’s piston.
 The piston which is under high pressure starts moving from one end to
the another which in turn pushes the further fluid through lines, with
this movement of piston the input force applied by the driver is
multiplied several times.
 This high pressure fluid sent by the hydraulic cylinder then applies the
pressure to the attached pinion through the coupling mechanism which
in turn applies high force to the rack gear and the steering action in the
front wheels takes place.
Electric Power Steering System
 When the driver gives input through the steering wheel the
electronic sensors attached to the steering column reads the
input and sent them to the electric control unit of the vehicle.
 The ECU of the vehicle analyses these inputs and sent the
voltage signal to the electric motor placed at the end of the
steering column whose gear is in constant mesh with the pinion
gear.
 Due to these voltage signals sent by the ECU the motor which is
driven by the battery of the vehicle starts and provides the
particular torque according to the value of the voltage signals
received
 After the motor starts the gear which is in constant mesh with
the pinion gear starts transmitting the multiplied torque to the
pinion gear which in turn applies this torque to the rack through
which it is attached.
 With this torque applied by the pinion over rack , rack moves
which in turn steer the front wheels (with the help of the tie
rods attached) as per the requirement.
 central locking
 Cars can be fitted with an electronic locking system which is connected to the
car’s alarm system. To lock the car from the inside, the driver uses the key to
lock one of the front doors and all the doors lock automatically. The driver can
lock or unlock all doors by locking or unlocking the driver’s side door lock
manually or by pressing the lock and unlock buttons on the key fob or
dashboard.
 Every key has a unique code which is matched with the code in the alarm
system. Once the key is used to lock the car, an immobiliser goes off in the
engine. Only when the onboard computer detects the same code from the car
key will it unlock the immobiliser in the engine. When the immobiliser is on
the engine of the car will not start.
 Central locking systems evolved to systems that could be operated with a
remote. That had buttons on a remote attached to the key. The car can be
locked or unlocked with the remote. Some remotes have a button to set off the
car alarm. Car remotes are extremely useful for locating your car in a car park.
People lock and unlock their cars with the remote and the sound and blinking
lights help you locate your car. These remote locking systems work on the
principle of radio waves.
Power Windows:
 Power windows are controlled by switches and wires and are powered by battery or
electricity. Power windows do not function if the ignition of the car is not turned on.
Unlike the traditional windows, power windows do not have manual handles. They do
not work manually. The basic power windows generally have control of all the four
windows and can be controlled by the driver.

The power windows come with some unique features that make them more user-
friendly and convenient. These features can be summed up as follows:

 Automatic Down: This is a very common feature in almost all power windows. This
feature allows the user to make the windows go all the way down by just tapping the
button once. The system uses a circuit to monitor the amount of time that the switch was
held down. If the switch is held down for less than a second, the window goes down all
the way to hit the limit switch and stops there. In case the button is held down for a
longer time, the circuit analyses the time and stops rolling the window down as soon as
the button is released.

 Automatic Up: This feature is not very common as it has certain complications. The
automatic up works in the same way as the automatic down. But, the automatic up
feature poses a risk. While the window goes up, if anything gets in the way of the
window, like a child’s hand or a pet dog or cat’s paw, it is highly likely to injure them. As
the window won’t stop until it hits the limit switch, it engages a risk of an accident. The
only way out of this problem is the introduction of another circuit into the system, that
can monitor the speed at which the window rolls up. As the speed is slowed down due to
an obstruction, the circuit reverses the power back to the motor and the window goes
down.
Electronic Control Module
 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.
Components of ECU

 An ECU consists of a number of functional blocks:

 1. Power Supply – digital and analog (power for analog sensors)
 2. MPU – microprocessor and memory (usually Flash and RAM)
 3. Communications Link
 4. Discrete Inputs – On/Off Switch type inputs
 5. Frequency Inputs – encoder type signals (e.g. crank or vehicle speed)
 6. Analog Inputs – feedback signals from sensors
 7. Switch Outputs – On/Off Switch type outputs
 8. PWM Outputs – variable frequency and duty cycle (e.g. injector or ignition)
 9. Frequency Outputs – constant duty cycle (e.g. stepper motor – idle speed
control)
 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. 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.
 PROTECTION SYSTEM IN AUTOMOBILES
1. Air bag
 An airbag is a part of the safety restraint system in cars. Airbags are gas-
inflated cushions ,that rapidly fill with gas when an accident happens.
That way they can prevent injuries that occur when the driver hits a hard

MAIN PARTS AND WORKING OF AN AIRBAG

 Bag. Made of thin nylon fabric,folded into a steering wheel or dashboard
or more recently the door or seat.
 Sensor. Tells the bag to inflate
 Inflation system. The rapid pulse of hot nitrogen gas to inflate the bag.

WORKING
 During collision, a mechanical switch is flipped and an electrical contact
takes place. Sensors send an electric current to the inflation system.
Inflation system contains sodium azide and potassium nitrate. Electric
current heats the filament which ignites the capsule containing Nitrogen
gas. The gas expands quickly and inflation of air bags takes place, which
literally bursts from its storage site in the steering wheel.
2. ANTI LOCK BRAKING SYSTEM (ABS)
3. SELF INFLATING TYRES
[Link] OVER PROTECTION SYSTEM
5. ELECTRONIC STABILITY CONTROL (ESC)
[Link] spot detection
 Blind spot A blind spot in a vehicle is an area around the vehicle that cannot be
directly observed by the driver while at the controls, under existing
circumstances. Blind spots exist in a wide range of vehicles: cars, trucks,
motorboats, sailboats. and aircraft. Blind spots can be caused by the window
pillars, headrests, passengers, and other objects.

Blind spot detection

 Blind Spot Detection systems warn a driver that a vehicle is in his or her blind
spot –areas to the side and rear of the vehicle outside the driver’s view. So that
accidents can be avoided, and due to it changing of lane will be easier and safely
 Sensors (camera, ultrasonic, or radar) monitor the sides and rear of the vehicle
for vehicles (including motorcycles) approaching from behind and alert the
driver with lights mounted in either the side-view or rear-view mirrors, or the
door. If you switch on a turn signal showing intent to make a lane change, and a
vehicle is present in the blind spot, the system may warn you with red or yellow
flashing icons and/or audio alerts, or by vibrating the steering wheel or the
driver’s seat.

WORKING OF SENSORS
 These sensors continuously monitor the velocity and direction of the vehicle to
obtain a digital picture of the vehicle's environment. The warning indicator is
switched on when the vehicle approaches the blind spot. The system also emits
an audio alarm to give an additional warning.
7. parking aid with ultra sonic sensors