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1
SUB-CHAPTER
What is a system???
- describe a collection of related
components, which interact as a
whole
- ‘A group of devices serving a
common purpose’
Electrical systems approach
Vehicle system approach
- Once a complex set of interacting parts has been
systemized, the function / performance of each part can
be examined in more detail.
- The links & interactions between various sub-systems
are very important consideration.
- Example:
‘how the power requirements of the vehicle lighting
system will have an effect on the charging system
operation’
Electrical systems approach
Vehicle system approach
- Solution:
It has subdivided from the whole, consideration should
be given to the inputs & outputs.
-Many of the complex electronic system on a vehicle
done this recommended approach which consider the
‘ECU’ of the system as the control element, and looking
at its inputs & outputs.
Electrical systems approach
Open loop & close loop systems
Advantages of copper:-
very low resistivity – 1.7 x 10-8 Ωm
ideal properties – ductility & malleability
Advantages of PVC:-
very high resistance – 1015Ωm
very resistant to petrol, oil, water & other contaminants
Electrical wiring, terminals &
switching
Cables construction
- Cable size depends on the current drawn
(larger cable, smaller voltage drop, = heavier)
Electrical wiring, terminals &
switching
Cables construction
- the supply to a component must not be less than 90%
of the system supply.
- we can calculate voltage drop in a cable as follows:
P
current – I
VS
I l
volt drop – Vd I = current (A)
A
I l P = power rating (W)
cable cross-section - A Vs = system supply (V)
Vd Vd = volt drop (V)
ρ = resistivity of copper (Ωm)
l = length of cable (m)
A = cross-sectional area (m2)
Electrical wiring, terminals &
switching
Cables construction
Example:-
Calculate the ideal copper cable size(area) required for a
fuel pump circuit. The pump drawn 8A from a 12V
battery. The maximum allowable volt drop is 0.5V.
(ρ = 1.7 x 10-8 Ωm, l = 1m)
Answer:-
272nm2 ~ 0.272mm2
Electrical wiring, terminals &
switching
Cables construction
- Some typical sizes & uses of cable
Electrical wiring, terminals &
switching
Color code & terminal designations
- A number of color code & terminal designation system
is used for standardization.
- Just for learning purpose, lets look three reference
system:
British Standard system (BS AU 7a: 1983)
European Standard system
Terminal Designation system (DIN 72 552)
Electrical wiring, terminals &
switching
Harness design
The wiring harness has been developed from a
loom just a few wires to over 1000 separate wires.
Modern vehicles tend to have wiring harnesses
constructed in a number of ways.
There were three type of harness construction
which are:-
PVC wound harness (figure 4.6)
Cable side by side & plastic welded to a backing strip
(figure 4.7)
PVC tube & tape harness (figure 4.8)
Electrical wiring, terminals &
switching
Harness design – PVC wound harness
- the tape is non-adhesive which allow the wires to retain
some flexibility.
Electrical wiring, terminals &
switching
Harness design – cable side by side
- this method allows the loom to be run in narrow areas.
Electrical wiring, terminals &
switching
Harness design – PVC tube & tape harness
- this method has the advantage of being harder wearing
& can also be waterproof (if suitable sealing)
Electrical wiring, terminals &
switching
Harness design
When deciding on the layout of a wiring loom, many
issues must be considered as follows:
cable runs must be as short as possible
the loom must be protected against physical damage
the number of connections should be kept to a
minimum
modular design may be appropriate
accident damage areas to be considered
production line techniques should be considered
access must be possible to main components & sub-
assemblies for repair purposes
Electrical wiring, terminals &
switching
Harness design
The overall layout of a loom on a vehicle will follow one of
two patterns:
‘E’ shape
‘H’ shape
Electrical wiring, terminals &
switching
Harness design
Figure shows a more realistic representation of the
harness layout in the level of complexity & number of
connection points involved.
Electrical wiring, terminals &
switching
Printed circuits
- used on the rear of the instrument pack & other similar
places.
- allows these components to be supplied as complete
units & reduce the amount and complexity of the
wiring.
- construction:-
o using thin copper layer (bonded to a plastic sheet)
o required circuit print on to the copper using some
material (wax)
o unwanted copper can be etched away with an acid
wash
Electrical wiring, terminals &
switching
Printed circuits
Electrical wiring, terminals &
switching
Fuses & circuit breakers
Circuit protection required to protect the electrical
wiring of a vehicle.
Simple definition – it is a deliberate weak link in the
circuit.
Operation:-
- overload occurs = the fuse melt & disconnect the circuit
before any serious damage is caused.
Types:-
glass cartridge
ceramic
blade – most popular (simple construction, reliability
against premature failure - vibration)
Electrical wiring, terminals &
switching
Fuses & circuit breakers
Electrical wiring, terminals &
switching
Fuses & circuit breakers
Fuses are rated with a continuous &
peak current value.
Continuous Value
- the current the fuse will carry
without risk of failure
Mechanical
Contacts
Arrangement
Materials:-
copper
phosphor bronze
brass
beryllium copper
silver / silver alloys
gold (very special applications)
Electrical wiring, terminals &
switching
Switches
The electrical life of a switch is dependent on:-
its frequency of operation
the on–off ratio of operation
the nature of the load
arc suppression & other circuit details
the amount of actuator travel used
ambient temperature & humidity
vibration levels
Electrical wiring, terminals &
switching
Switches
Terms used to describe switch operation:-
Free position – position of the actuator when no force is
applied