REV- Automotive Electrical and Electronics lab NHIT/AE&E/AEPC504/05

THE NEW HORIZONS INSTITUTE OF TECHNOLOGY

DEPT. OF AUTOMOBILE ENGINEERING
Automotive Electrical & Electronics - (3rd year, 5th sem)
Experiment no – 06

Name of the Experiment: To study, testing and sketching the wiring diagram of electronic control module
(ECM OR ECU) with different sensors and actuators.

Objective: To understand the function of an electronic control unit and different types of the sensors its
position and working of a car body.

Purpose of ECM of an Automobile:

Quite simply put ECU is a device that controls all the electronic features in a car. This may range
from fuel injection to maintaining perfect cabin temperature to controlling braking and
suspension. Some vehicles have multiple ECU controlling different features while some have a
single one controlling everything.

Working of an ECU is actually not complicated as one might assume. It is an electronic

device which has base numbers and parameters filled in its memory. With multiple
sensors around a vehicle feeding the ECU data it can manage and control the electronic
systems efficiently by giving orders to improve their output.

Let’s take an example of how ECU controls something by looking at how airbags are
deployed during an accident.

The car has sensors located around itself called the crash sensors which inform the ECU
when a crash has occurred. The ECU then measures the speed of the vehicle when it
undergoes accident and then using its onboard memory compares the data of whether it
should launch the airbags or not. If the data provides enough reason the ECU deploys the
airbags. Note that all this happens in mere milliseconds.

That covers how an ECU works let us take a look at what happens if it is faulty and even
worse when it breaks down.
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Types of Automotive Sensors and Actuators:

There are various kinds of sensors used in automotive or electric vehicles to read the real-time
signals and take necessary actions to manage in-vehicle functions such as ignition time, ABS,
speed control, etc. The types of automotive sensors and actuators are:
 01. Engine speed sensor
 02. Wheel speed sensor
 03. Vehicle speed sensor
 04. Throttle position sensor
 05. Temperature sensor
 06. Mass airflow (MAF) rate sensor
 07. Exhaust gas oxygen concentration sensor
 08. Crankshaft angular position/RPM sensor
 09. Manifold Absolute Pressure (MAP) sensor
 10. Accelerometer (knock sensors)
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Functions of sensors:

Engine Speed Sensor:

An engine speed sensor is needed to provide input for the electronic controller for several functions. The
reluctance sensor can be used to measure engine speed. The four tabs will pass through the sensing coil once
for each crankshaft revolution.

We count the pulses of voltage from the sensing coil in one minute and divide by four, we will know the
engine speed in revolutions per minute (RPM). An electronic circuit is used to start and stop the counter
circuit. The counter can be used to count the number of pulses through a special signal processing circuit.

Wheel speed sensor:

Used in ABS, Odometer. Contactless – Magnetic or optical method. Magnetic method – Hall effect. The
sensor provides square wave output whose frequency is proportional to the wheel speed.

Wheel-speed sensor using Hall technology incorporates the Hall-sensing element, signal amplifier, and signal
processing all on a single chip. It consists of a transistor whose base is excited by the magnetic effect. The
circuit is exposed to the changing magnetic field of the rotating encoder, which is either a multipole or a steel
wheel. In the case of a steel wheel application, a magnet placed inside the sensor is needed. Changing the
magnetic field around the Hall element induces an alternating voltage across the same.

Vehicle Speed Sensor:

The ECM (Engine control module) uses this information to modify engine functions such as ignition timing,
air/fuel ratio, transmission shift points, and to initiate diagnostic routines. Used in ABS (wheel speed sensor),
speedometer, and cruise control system. The Vehicle Speed sensor or VSS measures transmission/transaxle
output. The Vehicle Speed sensor is typically located at the transmission or transaxle. The speed sensor can
be implemented magnetically or optically.

Throttle Position Sensor:

A variable that must be measured for electronic engine control is the throttle plate angular position. The
throttle plate is linked mechanically to the accelerator pedal. The throttle plate restricts the airflow into the
intake manifold When the driver depresses the accelerator pedal, this linkage causes the throttle plate angle
to increase, allowing more air to enter the engine and thereby increasing engine power. Most throttle angle
sensors are essentially potentiometers.

This potentiometer can be used to measure any angular rotation, in particular the throttle angle. The only
disadvantage to the potentiometer for automotive applications is its analog output. For digital engine control,
the voltage v(a) must be converted to digital format using an analog-to-digital converter.

Temperature Sensor:
Temperature is an important parameter throughout the automotive system. In an electronic fuel control
system, it is vital to know the temperature of the coolant, the temperature of the inlet air, and the temperature
of the exhaust gas oxygen sensor.

Consists of a thermistor mounted in a housing that is designed to be inserted into the coolant stream. This
housing is typically threaded with pipe threads that seal the assembly against coolant leakage. A thermistor is
REV- Automotive Electrical and Electronics lab NHIT/AE&E/AEPC504/05

made of semiconductor material whose resistance varies inversely with temperature. For example, at –40˚C a
typical coolant sensor has a resistance of 100,000 ohms. The resistance decreases to about 70,000 ohms at
130˚C.

The correct operation of an electronically controlled engine requires a measurement of the mass flow rate of
air (Rm) into the engine. This requires a sensor that can sense the airflow rate into the intake manifold of the
engine. The sensor is normally mounted as part of the air cleaner assembly.

Air Flow Rate Sensor:

The correct operation of an electronically controlled engine requires a measurement of the mass flow rate of
air (Rim) into the engine. This requires a sensor that can sense the airflow rate into the intake manifold of the
engine. The sensor is normally mounted as part of the air cleaner assembly.

Rhw is a heated filament resistor. The resistance of the filament changes as the temperature of the filament
changes. This is used in Wheatstone’s network. The output of this n/w is given to a differential amplifier.
The resulting analog output is fed to the V/F converter.

The film element is electrically heated to a constant temperature above that of the inlet air. As air flows
across the hot film, heat is carried away from the film by the moving air. The amount of heat carried away
varies in proportion to the mass flow rate of the air. The heat lost by the film to the air tends to cause the
resistance of the film to vary, which unbalances the bridge circuit, thereby producing an input voltage to the
amplifier. This voltage is given to a V/F converter – a variable-frequency oscillator whose frequency is
proportional to the input voltage.

Exhaust Gas Oxygen Concentration Sensor:

Feedback control for fuel delivery is based on maintaining the air/fuel ratio at stoichiometry (i.e., 14.7:1 –
torque reaches a maximum for this ratio). In order to burn completely 1 kg of fuel, we need 14.7 kg of air.
The amount of oxygen in the exhaust gas is used as an indirect measurement of the air/fuel ratio. Also known
as lambda sensor.

Crankshaft Angular Position/RPM Sensor:

Crankshaft position measured directly using magnetic phenomena. This sensor consists of a permanent
magnet with a coil of wire wound around it. A steel disk that is mounted on the crankshaft (usually in front
of the engine) has tabs that pass between the pole pieces of this magnet. This sensor is of the magnetic
reluctance type and is based on the concept of a magnetic circuit. Reluctance – opposition to magnetic flux.

A magnetic circuit is a closed path through a magnetic material. The magnetic circuit here is the closed path
through the magnet material and across the gap between the pole pieces. When a tab on the steel disk passes
through the gap, the flow of the magnetic flux changes significantly. The reluctance of a magnetic circuit is
inversely proportional to the magnetic permeability of the material along the path.

The magnetic permeability of steel is a few thousand times larger than air; therefore, the reluctance of steel is
much lower than air. The steel has a lower reluctance than air, and the “flow” of magnetic flux increases to a
relatively large value. This rate of change of flux induces a voltage across the coil. A peak in voltage
indicates a tab crossing the pole piece as shown.

Manifold Absolute Pressure (MAP) Sensor:

The MAP sensor measures the absolute pressure inside the intake manifold of the engine. MAP Sensor-
Silicon diaphragm diffused strain gauge.

Piezoresistivity occurs in certain semiconductors so that the actual resistivity (a property of the material)
changes in proportion to the strain (fractional change in length). The strain induced in each resistor is
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proportional to the diaphragm deflection, which, in turn, is proportional to the pressure on the outside surface
of the diaphragm. This pressure is the manifold pressure. Wheatstone bridge is used for measurement of
strain.

Accelerometer (knock sensors):

Another sensor having application in closed-loop engine control is the so-called knock sensor. This sensor is
employed in closed-loop ignition timing to prevent undesirable knock. Knock can be described generally as a
rapid rise in cylinder pressure during combustion. It occurs most commonly with high manifold pressure and
excessive spark advance. Knocking has to be detected and prevented so as to
minimize engine and valve damage.

One way of controlling knocking is to sense when knocking begins and then retard the ignition until the
knocking stops. A knock sensor using magnetostriction to sense or detect knock. Other sensors use
piezoelectric crystals or the piezoresistance of a doped silicon semiconductor. Magnetostriction is a
phenomenon whereby the magnetic properties (magnetic susceptibility or permeability) of a ferromagnetic
material change depending on stress.

The forces associated with knock cylinder pressure are transmitted through the mounting frame to the
magnetostrictive rods. When sensing knock, the magnetostrictive rods, which are in a magnetic field, change
the flux field in the coil due to knock-induced forces. This change in flux produces a voltage change in the
coil. This voltage is used to sense excessive knock. Possible measures to overcome knocking are retarding
the timing, adding fuel, reducing boost pressure, etc. The frequency of knock is specific and depends on the
bore (piston) diameter of the engine. DSPs improve the SNR (signal-to-noise ratio) to detect knock.

Experimental table : N.A.

Precaution: N.A
Calculation: N.A.

DISCUSSION:
 REV- Automotive Electrical and Electronics lab NHIT/AE&E/AEPC504/05

Q 1. Briefly explain OBD Technology.

Q2. What do you know GPS system?