MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS AUTOMOTIVE ENGINEERING TECHNOLOGY RESTORATION AND RESEARCH ON A COMBINED AIR CONDITIONER AND EFI ENGINE SYSTEM TEACHING MODEL INSTRUCTOR: VU DINH HUAN, MSC. STUDENTS: NGUYEN ANH VU PHAM XUAN BACH HO PHAM NAM PHONG SKL012556 Ho Chi Minh City, January 2024 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR INTERNATIONAL EDUCATION GRADUATION THESIS RESTORATION AND RESEARCH ON A COMBINED AIR CONDITIONER AND EFI ENGINE SYSTEM TEACHING MODEL NGUYEN ANH VU – 19145134 PHAM XUAN BACH – 19145190 HO PHAM NAM PHONG – 19145184 ADVISOR: MSC.VU DINH HUAN MAJOR: AUTOMOTIVE ENGINEERING TECHNOLOGY Ho Chi Minh City, January 8th, 2024 GRADUATION THESIS Advisor: MSc.Vu Dinh Huan ACKNOWLEDGEMENT This graduation project report represents the culmination of our academic endeavors, rigorous training, and immersion in the specialized educational environment provided by the Ho Chi Minh City University of Technology and Education. It stands as a testament to our dedication to acquiring knowledge and experience that will serve us in our future endeavors. We wish to extend our heartfelt gratitude to the University, particularly to MSc.
Vu Dinh Huan, for their unwavering commitment to excellence in education. Their dedicated instruction, guidance, and support have been instrumental in our academic journey. The University's provision of valuable resources, coupled with the impartation of essential knowledge and practical experiences, has significantly enriched our understanding and facilitated the completion of this report. Recognizing the inherent limitations of our current knowledge and experience, especially in the context of practical exposure during internships, we acknowledge that this report may contain imperfections.
Therefore, we earnestly welcome constructive feedback and insights from all stakeholders to address these limitations and further enhance our capabilities. In conclusion, we would like to express our sincere appreciation to all the faculty members of the Ho Chi Minh City University of Technology and Education who have supported and guided us throughout this educational journey. We extend our best wishes for your continued health, success, and dedication to shaping the future of aspiring professionals. Thank you sincerely, Nguyen Anh Vu Pham Xuan Bach Ho Pham Nam Phong i GRADUATION THESIS Advisor: MSc.Vu Dinh Huan ABSTRACT The growing demand for advanced automotive technologies requires the development and understanding of integrated systems such as combined air conditioning and EFI (Electronic Fuel Injection) engines.
The project seeks to recover and study a teaching model that illuminates the complex workings of this integrated system. The project adopted a systematic approach that involved restoring the teaching model to a working state. Detailed research methods, including literature review, component analysis and experimental setup, were used to explore and monitor air conditioner functions, operations and interactions. and EFI engine system.
After completion, the engine and air conditioning system were operating and stable. Research has revealed important insights into effective synchronization techniques between actuators and optimization of the integration of air conditioning systems with EFI engines. The restored teaching model serves as an important educational tool to understand the complexity and interdependence of combined air conditioning systems and EFI engines for students. ii GRADUATION THESIS Advisor: MSc.Vu Dinh Huan CONTENTS ACKNOWLEDGEMENT.
iii LIST OF FIGURES. xi LIST OF TABLES. xvii LIST OF ABBREVIATIONS AND SYMBOLS .xviii CHAPTER 1: OVERVIEW. Reasons to choose the topic.
Purposes of research. Object of research. Scopes of research. Target of research.
Structure of the thesis. 5 CHAPTER 2: OVERVIEW OF 2NZ-FE ENGINE. Introduction to 2NZ-FE engine. Effectiveness of the VVT-i System.
Camshaft Timing Oil Control Valve. 22 iii GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 2. Oil circuit specifications. System diagram and engine coolant specifications.
Fuel returnless system. 31 CHAPTER 3: ENGINE CONTROL SYSTEM. Engine control system diagram. Layout of Main Components.
Main components of Engine Control System. Mass Air Flow Sensor (MAF). Structure and Operating Principle. Diagnosis and Testing.
Engine Coolant Temperature sensor (ECT). 41 iv GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 3. Structure and Operating Principle. Diagnosis and Testing.
Structure and Operating Principle. Diagnosis and Testing. Crankshaft Position Sensor (CPS). Structure and Operating Principle.
Diagnosis and Testing. Camshaft Position Sensor (CPS). Structure and Operating Principle. Diagnosis and Testing.
Structure and Operating Principle. Diagnosis and Testing. Accelerator Position Sensor (APS). 58 v GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 3.
Structure and Operating Principle. Diagnosis and Testing:. Shape of Bobine and Igniter. Location of Ignition System.
System description, ignition signals. Diagnosis and Testing. Electronic Throttle Control System-intelligent (ECTS-i). Diagnosis and Testing.
Fuel Injnection System. Diagnosis and Testing. 73 CHAPTER 4: AIR CONDITIONING SYSTEM. Overview of car air conditioning systems.
Air conditioner install location. Classification of control methods. Automatic control method. 79 vi GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 4.
Components of the air conditioning system. Air conditioning system. Description of components. Principle of operation.
Working of Scroll Compressor. The connection of the compressor to the moving parts of the engine. Magnetic clutch components. Magnetic clutch structure.
Principle of operation of magnetic clutch. Principle of operation. Blower motor and fan. 98 vii GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 4.
Cooler thermistor sensor. A/C room temperature sensor. A/C ambient temperature sensor. Engine coolant temperature sensor.
Other Miscellaneous Components.Lines and Hoses. Overall Schematic of Air-conditioning Components and Controls. 110 CHAPTER 5: AUTOMATIC AIR CONDITIONING CAMRY 2002 SYSTEM. Automatic Air Conditioning system.
How to identify automatic systems. The components of automatic Air conditioning system:. Diagram wiring Air conditiong automatic system toyota camry 2002. System control method.
Compressor on/off controller. Blower control motor ( using mosfet). Idle speed controller (throttle compensation). Turning off control.
Controls A/C closed when the medium pressure is unstable. Detected that the compressor was stuck. 125 viii GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 5. Controls A/C closed when engine temperature is high.
Controls fan speed. Controls radiator fan. Controls condenser fan. 127 CHAPTER 6: CONSTRUCTION OF TEACHING MODEL.
Introducing Autodesk Inventor Professional software. Design the model frame on Inventor Professional. Rebuild frame mode. Design the control panel on the model.
Design control panel on autocad. Restore and check electrical circuits on the control panel. Construction of control panel. Rebuild the electronic fuel injection mechanical model with Toyota's automatic air conditioning system.
About the 2NZ-FE Toyota engine. Procedure proposed when diagnosing the engine. Procedures for checking engine control systems. Check the fuel system.
Air Intake system. Automatic air conditioning camry 2002. 146 Chapter 7: PRACTICAL EXERCISES APPLICATION ON THE MODEL. Practical about EFI engine on the model.
Check the resistance of the sensor. Check the voltage of details in engine. Practical about automotive air conditioning on the model. 157 ix GRADUATION THESIS Advisor: MSc.Vu Dinh Huan 7.
Practice refill the air conditioning system using R314a refrigerant. Load refrigerant into the air conditioning system. Practice check for refrigerant leaks in the system:. Practice observation and listening around the system.
Practical exercise on detecting damage to the air conditioning system using a gas pressure gauge. Proceed to checkout. The air conditioning system works stably. The system is clogged during the cooling cycle.
Air gets into the system. Air conditioning system compressor malfunction. The air conditioning system lacks gas. Practicce of measuring and checking voltage.
Proceed to checkout. Some common diseases in car air conditioning systems and fixes. 176 CHAPTER 8: CONCLUSIONS AND RECOMMENDATIONS. 180 x GRADUATION THESIS Advisor: MSc.Vu Dinh Huan LIST OF FIGURES Figure 1.
Control Panel Of Teaching Model. Electronic Throttle Control System intelligence. VVT-i System Diagram. A Block Diagram of a VVT-i System.
Camshaft Timing Oil Control Valve. Timing Advance Direction of VVT-I System. Timing Retard Direction of VVT-I System. Oil Circuit of Lubrication System.
Cooling System Diagram. Fuel Pump and Components. Fuel returnless system. Ignition System Diagram.
Ignition Coil with Igniter. Engine control system diagram. Layout of Main Components. Mass Air Flow Sensor (MAF) Shape.
Mass Air Flow Sensor’s Location. Mass Air Flow Sensor’s Wiring Diagram. Connection Port of MAF. Engine Coolant Temperature sensor’s shape.
ECT sensor’s Wiring Diagram. Connection Port of ECT. Knock Sensor’s shape. 43 xi GRADUATION THESIS Advisor: MSc.Vu Dinh Huan Figure 3.
Location of Knock Sensor. Knock Sensor’s Wiring Diagram. Connection Port of Knock Sensor. Shape of Crankshaft Position Sensor.
Crankshaft Position Sensor’s Location. Wiring Diagram of Crankshaft Position Sensor. CPS’s Connection Port. Camshaft Position Sensor’s shape.
Location of Camshaft Position Sensor. Camshaft Position Sensor’s Wiring Diagram. Connection port of CPS. Oxygen Sensor’s shape.
Oxygen Sensor’s Location. Wiring Diagram’s Oxygen Sensor. Connection Port of Oxygen Sensor. Location of Accelerator Position Sensor.
Wiring Diagram of APS. Structure & Operating Principle of APS. Connection Port of APS. Ignition Coil of Toyota.
Location of Ignition System. Wiring Diagram of Ignition System. Connection Port of Ignition System. Electronic Throttle Control System-intelligent (ECTS-i).
Throttle Position Sensor’s Wiring Diagram. Connection Port of Throttle body. Fuel Injection System’s Wiring Diagram. Connection Port of Injector.
Air conditioning system. Operating principle of the heater. Operating principle of the air cooling system. Font style air conditoning.
Rear style air conditoning. 78 xii GRADUATION THESIS Advisor: MSc.Vu Dinh Huan Figure 4. Dual style air conditoning. A/C unit control manual Cadillac.
A/C control unit automatic. The operation and parts air conditoner system. Parts of scroll compressor. Arrangment of fixed and orbiting scroll.
Scroll Compressor Animation. First revolution of shaft. Second revolution of shaft. Third revolution of shaft.
Two types connection of compressor belt. Magnetic Clutch Components. Structure compressor clutch. Magnetic compressor clutch.
Clutch structure in the compressor pulley. Structure of condenser. Distribustion refrigerant in condenser. Check sight glass.
Structure expansion valve. Expansion valve close. Expansion valve open. Folded wing style.
Diagram of operator refrigerant from liquid to gas state. Conventiona and skew condenser fan. Diagram wiring basic controler fan condenser. Blower motor and fan.
Diagram wiring blower control speed fan with transitor. Cooler thermistor sensor. A/C room temperature sensor. A/C ambient temperature sensor.
Engine coolant temperature sensor. Low and High presure lines model. Material of each layer of hoses. 103 xiii GRADUATION THESIS Advisor: MSc.Vu Dinh Huan Figure 4.
Low and high size charging port size. O-ring size measurement unit. R134 refrigerant air conditioning system. Glass , gloves and chemical-resistant mask.
Air conditioning automatic system. Diagram Refrigeration Cycle. The refrigeration process. Automobile A/C schematic arrangement.
Control components of automatic air conditioning systems. Diagram wiring Air conditiong automatic system toyota camry 2002. Diagram of controlling the compressor ON and OFF. Circuit diagram Blower control fan with fan resistor (mosfet type).
Idle speed controller. Diagram of thermistor type defrost control system. Structure and schematic control pressure switch. Compressor drive system diagram.
Position water temperature sensor in engine. Diagram control radiator fan. Cooling fan operation through ECT. Wiring diagram control of the condenser fan.
Autodesk inventor professional 2022 software. 3D design model framework in Inventor Professional. 2D design of the model frame. Disassemble and install the control parts to be cut.
Make a mark on the design cutout. Original image of the unbuilt model .