MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS AUTOMOTIVE ENGINEERING TECHNOLOGY REPAIR AND UPGRADE TEACHING MODELS OF AUTOMOTIVE BODY ELECTRICAL SYSTEMS INSTRUCTOR: NGUYEN QUANG TRAI, MSE. STUDENTS: NGUYEN PHUNG TRUNG NGUYEN NGUYEN THANH TIEN SKL012554 Ho Chi Minh City, January 2024 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION GRADUATION PROJECT REPAIR AND UPGRADE TEACHING MODELS OF AUTOMOTIVE BODY ELECTRICAL SYSTEMS NGUYEN PHUNG TRUNG NGUYEN Student ID: 19145157 NGUYEN THANH TIEN Student ID: 19145124 Major: AUTOMOTIVE ENGINEERING Supervisor: NGUYEN QUANG TRAI, MSE Ho Chi Minh City, January 2024 ĐÀO TẠO QUỐC TẾ Điện Tử Ô Tô Table of contents Table of contents. i Table of figures. iv Table of tables.
ix CHAPTER 1: OVERVIEW OF THE TOPIC. Reason for choosing the topic. 1 CHAPTER 2: THEORETICAL BASIS. Overview of lighting system.
Tail light system. Indicator light system. Braking light system. Some wiring diagram of lighting system on vehicle.
Overview of power door lock and power window system. Structure and operation. Some wiring diagram of door lock and power window system on vehicle. Overview of wiper and washer system.
Structure and working principle. Some wiring diagram of wiper and washer on vehicle. 44 CHAPTER 3: MODEL REDESIGNING AND UPGARDING. Material selection for the model.
Selection of frame materials. Selection of materials to make device mounting board for the model. Design and implementation of models. Training model PABE - 2.
Main devices of PABE - 2. Lighting system of PABE - 2. Power door lock and power window system of PABE - 2. Wiper and washer system of PABE - 2.
Others device of PABE - 2. The training model PABE – 2. 87 CHAPTER 4: PRACTICE INSTRUCTION (FOR INSTRUCTOR). Practice sheet no.
Practice sheet no. 108 * Pan 7 and Pan 1 for examination. 110 * Pan 2 for examination. 112 * Pan 3 for examination.
114 * Pan 4 for examination. Practice sheet no. Practice sheet no. Practice sheet no.
Practice sheet no. Practice sheet no. 133 CHAPTER 5: PRACTICE SHEET (FOR STUDENT). Practice sheet no.
Practice sheet no. 156 * Pan 1 for examination. 157 * Pan 2 for examination. 158 * Pan 3 for examination.
159 * Pan 4 for examination. Practice sheet no. Practice sheet no. Practice sheet no.
Practice sheet no. Practice sheet no. 178 iii Table of figures Figure 2. 1: Location of components in lighting and signal systems.
3: XENON – HID headlight. 6: Fog light on vehicle. 7: Tail light on vehicle. 8: Indicator light on vehicle.
9: Braking light on vehicle. 10: 2018 Mazda CX-5’s headlight wiring diagram. 11: hondacivic hatchback 2016+ ewd brake light. 12: Porsche Cayenne’s headlight wiring diagram with DRL.
13: Mechanical door lock system. 14: Electric door lock system inside the car. 15: Door lock system with remote key. 16: Door lock system with mobile application.
17: Two types of power window. 18: The cable mechanism of power window system. 19: The appearance of cable type 15. 20: The structure inside of motor.
21: 2018 Mazda CX-5’s power liftgate wiring diagram. 22: 2016 Innova’s door lock wiring diagram. 23: Front windshield wiper system. 24: Construction of wiper motor.
25: Working principle of wiper motor. 26: Front/rear washer motor. 27: Combined operation of washer and wiper. 28: Porsche Cayenne’s wiper and washer wiring diagram.
29: 2019 Honda Civic’s windshield wiper and washer. 30: 2019 Honda Civic’s rear window wiper and washer. 1: Hyundai Grand I10/Xcent 2018. 3: Board milky white mica.
4: Frame size for PABE – 2. 5: Layout design for main model board. 6: Layout design for left side model. 7: Layout design for right side model.
8: Layout for trouble activating board. 9: Layout design for nameplate. 10: Main layout of model after completing. 14: Connector view of BCM.
15: Connector view of Multifunction SW. 16: Layout of SJB. 17: Power distribution to SJB. 18: Power distribution from SJB to BCM.
20: Headlight wiring diagram. 21: Tail light, position light, license light wiring diagram. 23: Power door lock wiring diagram. 24: Power window wiring diagram.
27: Wiper and washer wiring diagram. 28: Frame size for PABE – 2. 29: Main layout for PABE – 2. 30: Nameplate of PABE – 2.
31: Main layout of PABE – 2. 3: The connection between all devices. 4: Electrical circuit of Power Window without auto. 7: The connection between all devices.
8: Electrical circuit of Power Window with auto. 11: The connection between all devices. 12: Electrical circuit of Power Door Lock controlled by relays. 14: Door Lock pins.
15: Electrical circuit of Power Door Lock controlled by Door Lock Module 132 Figure 4. 17: The first port of BCM. 18: The second port of BCM. 19: Circuit in BCM.
20: Electrical circuit of Power Door Lock controlled by BCM. 1: Power supply for SJB wiring diagram. 2: Power distribution from SJB to BCM. 3: Headlight wiring diagram redesign.
4: Tail light, position light, fog light, brake light, reverse light wiring diagram redesign. 5: Power door lock wiring diagram redesign. 6: Power window wiring diagram redesign. 7: Wiper and washer wiring diagram redesign.
10: Drawings for students to design connection circuits. 13: Drawings for students to design connection circuits. 16: Drawings for students to design connection circuits. 18: Door Lock pins.
19: Drawings for students to design connection circuits. 21: The first port of BCM. 22: The second port of BCM. 23: Circuit in BCM.
24: Drawings for students to design connection circuits. 176 vii Table of tables Table 3. 1: Types of lights in the lighting system. 2: Relays and switches of lighting system.
3: Some devices of door lock and power window system. 5: Main device on PABE – 2. 1: Measure the voltage of body electrical systems. 2: Measure the voltage of power supply.
1: Measure the voltage of body electrical systems. 2: Measure the voltage of power supply. 141 viii Preface Today, automotive technology is increasingly developing and has outstanding achievements. Increasing consumer demand requires automobile manufacturers to continuously upgrade and improve safety and comfort systems to meet the needs of users.
In today's vehicles, intelligent and electrically controlled systems are gradually replacing mechanical systems. Realizing that the lighting, door lock control, power window, wiper and washer system is a necessary and convenient safety system, the group choose the topic. This is a topic very close to the reality of the production and repair of vehicles. The graduation project includes five chapters: + Chapter 1: Overview of the topic.
+ Chapter 2: Theoretical Basis. + Chapter 3: Model redesigning and upgrading. + Chapter 4: Practice instruction (For instructor). + Chapter 5: Practice sheet (For student) + Chapter 6: Conclusions.
Our team would like to express our sincere thank Ho Chi Minh City University of Technology and Education for helping us to gain a lot of useful knowledge in our major (Automotive engineering technology). In particular, we would like to express our deep gratitude to the lecturer – Nguyen Quang Trai to help us finish the graduation project. During our working time with you, we have gained a lot of new knowledge, and an effective and serious learning spirit. These are definitely valuable knowledge and preparation for us to do well in our future jobs.
However, due to limited knowledge and the difficult ability to absorb reality, our team has tried our best, but surely the report cannot avoid shortcomings and many gaps. I hope you will consider and comment to make my group's report better. I wish you good health, happiness, and success in your glorious career of growing people. Our team sincerely thank you! ix CHAPTER 1: OVERVIEW OF THE TOPIC 1.
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. Repair and upgrade model.
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. 1 CHAPTER 2: THEORETICAL BASIS 2. 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. Tail lights, which are red in color, are illuminated along with the headlights. They function to notify other drivers that the vehicle is decelerating or coming to a halt.
Tail light assemblies often include stop lights, rear marker lights, and turn signals. Additionally, fog lights are also available to provide illumination during foggy weather conditions. 1: Location of components in lighting and signal systems The lighting and signal system has the following basic components: 1. Headlights, front fog lights.
Rear lights, rear fog lights. Light and brightness control switch: Turn signal switch, front and rear fog light switch. Turn signals and warning lights. Danger light switch.
Turn signal flasher.