Automotive Electrical Systems

BTAE 404
Recommended Books:
1) 2)
1)

Kohli P.L., Automotive Electrical Equipment ", Tata McGraw-Hill. W.H. Crouse, Automobile Electrical Equipment ", McGraw Hill Book Co. Inc.
C.P.Nakra, Basic Automotive Electrical Systems, Dhanpat Rai and sons

Lecture by : Jagwant Singh Assistant Professor Department of Automobile Engineering Gulzar College of Engineering , Khanna

Lecture 1 Introduction to Automotive Electric Systems

Introduction

Current and Voltage are two different but related aspects of electricity. Voltage is the electrical potential difference between two points while current is the rate of flow of electric charge across a certain element. OHMs Law:

Ohm's law states that the current through a conductor between two points is directly proportional to the potential difference across the two points.

V=IR

HT Leads
High tension leads or high tension cables (or spark plug wires or spark plug cables) are the wires that connect a distributor and ignition coil to each of the spark plugs in some types of internal combustion engine. "High tension lead" or "cable" is also used for any electrical cable carrying a high voltage .

HT Leads

Insulated Return Systems

As Shown in figure , Connections for the Lamp and Battery with Feed wire and return wire The RED wire is called Feed Wire . To Complete the circuit , the Black cable joining the lamp to the battery acts as a return for the Supply Current

The Term insulated return is used whenever an insulated cable provides the return path for the current.

Earth Return System

In this case the vehicle frame provides the return path for the current

Earth Return System

Advantages of this system are :

Reduced cost Lighter weight of wires Simpler Circuit Layout

Extra Precautions must be taken with this system to prevent cutting of feed wire rubber insulation by a sharp part of the vehicles frame or body, if this occurs the supply current will be conducted to body so, A fire can be started Most of the vehicles have an earth return system , the exceptions are the special purpose vehicles such as petrol tankers that have a high fire risk, that use the insulated return system

Earth Polarity

Earth polarity means that which pole of battery or Electrical system is connected to body of vehicle (to ground).

In Case , Negative Terminal of the battery connected to the frame , that arrangement is called Negative Earth system. This is Commonly used on the majority of modern vehicles However , some older cars were built with a "positive earth" electrical system, in this case the positive terminal of the battery is bonded to the chassis and the negative terminal for the live.

Negative earth was adopted globally by automobile manufacturers for the sake of standardization. It was due to the introduction of radios in automobiles that may have seen negative earth automobiles being favored. It was also that positive earth vehicles rusted quicker (Cathode Sacrificial Protection).

Circuit Faults
Failure of electrical system is often caused by a circuit fault . Two common faults are considered are : Open Circuit Short Circuit

Open Circuit

A complete enclosed Circuit is needed if current is to flow around the system. An open circuit exists when the circuit is interrupted either intentionally or un-intentionally may be due to Wire breakage

Short Circuit

When the feed or switch wire insulation is damaged and the conductor wire touches the metal frame , which is negative .All the current will take this easy path to return to battery . This alternative path offers the current a short path back to battery , so the term Short Circuit is used to describe this condition. This short path have very low resistance . When short circuit occurs the very high current flow ( because no current is consumed in other work ,so all the battery current return back to battery)That results will soon make the cable glow RedHot . This melts the plastic covering of the cable and often starts a fire . Some circuit-protection devices such as a fuse is needed if this danger is to be avoided

Fuse

Fuse is a type of low resistance wire that acts as a sacrificial device to provide overcurrent protection, of either the load or source circuit. Its essential component is a metal wire or strip that melts when too much current flows, which interrupts the circuit in which it is connected. Short circuit, overloading, mismatched loads or device failure are the prime reasons for excessive current

Fig: Fuse Symbols

Automotive Fuses

Automotive fuses are a class of fuses used to protect the wiring and electrical equipment for vehicles. They are generally rated for circuits no higher than 24 volts direct current Types

Blade type Bosch type

Lucas type
Glass Tube type Limiter type

Blade type Fuse

Blade fuses (also called spade or plug-in fuses), with a plastic body and two prongs that fit into sockets, are mostly used in automobiles. Each fuse is printed with the Rated Current in Amperes on the top. These types of fuses come in four different physical dimensions:

Low-profile mini (APS / Micro) Mini (APM / ATM) Regular (APR / ATC / ATO) Maxi (APX) heavy-duty.

Blade type Fuse

Size Groups
Dimensions L W H 10.9 3.81 8.73 mm 10.9 3.6 16.3 mm 19.1 5.1 18.5 mm 29.2 8.5 34.3 mm

Blade Size
Low-Profile Mini Mini Regular

Blade Group
APS, ATT APM, ATM APR, ATC (Closed), ATO (open)

Common Ratings
2, 5, 7.5, 10, 15, 20, 25, 30 2, 3, 4, 5, 7.5, 10, 15, 20, 25, 30 1, 2, 3, 4, 5, 7.5, 10, 15, 20, 25, 30, 35, 40 20, 25, 30, 35, 40, 50, 60, 70, 80, 100, 120

Maxi

APX

Bosch type Fuse

Bosch type fuses (also known as torpedo, ATS, or GBC type fuses) are used in old automobiles. The physical dimension of this type of fuse is 625 mm with conical ends. Bosch type fuses usually use the same color coding for the rated current

Color coding

Color Yellow White Red (or Green) Blue Grey

Ampere 5 8 16 25 40

Lucas type Fuse

Lucas type fuses are used in old British-made or assembled automobiles. The physical length of this ceramic type of fuse is either 1 inch or 1.25 inch, with conical ends.

Glass Tube type Fuse

North-American built old automobiles had electrical systems protected by glass cartridge fuses rated 32 volts and current ratings from 4 amperes to 30 amperes. The fuse dimensions and characteristics are standardized by the Society of Automotive Engineers standard J554. All fuses are 1/4 inch diameter, and the length varies according to the rating of the fuse. A 4 Amp fuse is 5/8 of an inch long, a 20 Amp fuse is 1 inches long, and a 30 amp fuse is 1716 inches long.