Course Title: Introduction to Automobile Mechatronics

Duration: 2 Weeks (Monday – Friday)

Target Audience: Auto technicians, engineering students, or individuals seeking foundational knowledge in modern vehicle electronic systems.

Week 1: Fundamentals of Automotive Electronics and Components

Day 1: Introduction to Mechatronics & Basic Electrical Principles

• • Morning (Theory):
    • What is Mechatronics? (Integration of Mechanical, Electrical, Electronic, Computer Systems)
    • Evolution of Electronics in Vehicles.
    • Basic Electrical Concepts: Voltage, Current, Resistance (Ohm’s Law).

• Series and Parallel Circuits.
• Introduction to Automotive Wiring Diagrams: Symbols and Reading

      Basics.

Afternoon (Practical)

• Using a Multimeter: Measuring Voltage, Current, Resistance,

      Continuity.

• Building simple series/parallel circuits on a breadboard.
• Identifying basic electrical components.

Day 2: Automotive Electrical Systems & Basic Electronics

Morning (Theory):

• • • The Vehicle Battery: Types, Testing, Maintenance.
    • Starting System: Components (Starter Motor, Solenoid) and Operation.
    • Charging System: Alternator, Voltage Regulator, Operation.
    • Basic Electronic Components: Diodes, Transistors, Relays – Function and Testing.

Afternoon (Practical):

• • • Battery testing procedures.
    • Testing relays and diodes using a multimeter.
    • Tracing simple starting and charging circuits on training boards/vehicles.

Day 3: Automotive Sensors – The Inputs

Morning (Theory):

• • • Role of Sensors in Mechatronic Systems.
    • Types of Sensors:
      • Position Sensors (Throttle Position Sensor – TPS, Crankshaft/Camshaft Position Sensor – CKP/CMP).
      • Temperature Sensors (Engine Coolant Temp – ECT, Intake Air Temp – IAT).
      • Pressure Sensors (Manifold Absolute Pressure – MAP, Fuel Rail Pressure).
      • Speed Sensors (Wheel Speed Sensors – WSS, Vehicle Speed Sensor – VSS).
      • Oxygen Sensors (O2S) / Air-Fuel Ratio Sensors (AFRS).

Afternoon (Practical):

• • • Identifying various sensors on training engines/vehicles.
    • Testing common sensors (e.g., TPS, ECT) using a multimeter (resistance/voltage checks).
    • Introduction to sensor signal types (Analog vs. Digital).

Day 4: Automotive Actuators – The Outputs

Morning (Theory):

• • • Role of Actuators in Mechatronic Systems.
    • Types of Actuators:
      • Solenoids (Fuel Injectors, Purge/Vent Solenoids, Transmission Solenoids).
      • Motors (Throttle Body Motor, Fuel Pump, Wiper Motor, Radiator Fan Motor).
      • Ignition Coils.

Afternoon (Practical):

• • • Identifying various actuators on training engines/vehicles.
    • Testing basic actuators (e.g., checking injector coil resistance, activating a relay/solenoid).
    • Understanding Pulse Width Modulation (PWM) concept for actuator control.

Day 5: Introduction to ECUs and Microcontrollers

Morning (Theory):

• • • What is an Electronic Control Unit (ECU) / Module?
    • Basic ECU Architecture: Microprocessor, Memory (ROM, RAM, EEPROM), Inputs, Outputs.
    • How ECUs process sensor data and control actuators (Input -> Process -> Output).
    • Overview of different modules in a modern car (ECM, TCM, BCM, ABS Module etc.).

Afternoon (Practical/Demo):

• • • Locating different ECUs in vehicles.
    • Demonstration of ECU communication (basic concept using a scan tool).
    • Discussion on ECU power and ground requirements.
    • Introduction to software and firmware in ECUs.

Week 2: System Integration, Diagnostics, and Future Trends

Day 6: On-Board Diagnostics (OBD-II)

Morning (Theory):

• • • History and Purpose of OBD-II.
    • The Diagnostic Link Connector (DLC): Location and Pinout.
    • Understanding Diagnostic Trouble Codes (DTCs): P, B, C, U codes; Pending vs. Confirmed.
    • Freeze Frame Data.
    • Readiness Monitors.

Afternoon (Practical):

• • • Connecting a generic OBD-II Scan Tool.
    • Reading and clearing DTCs.
    • Viewing Live Data PIDs (Parameter IDs) – e.g., Engine RPM, Coolant Temp, Throttle Position.
    • Interpreting basic Freeze Frame data.

Day 7: Vehicle Networking – CAN Bus

Morning (Theory):

• • • Need for Networking in Vehicles.
    • Introduction to Controller Area Network (CAN) Bus: Architecture (High-Speed, Low-Speed/Fault-Tolerant).
    • How modules communicate: Messages, Identifiers, Data Frames.
    • Other network types (briefly): LIN, FlexRay, Ethernet.

Afternoon (Practical/Demo):

• • • Identifying CAN Bus wiring (twisted pair).
    • Measuring CAN Bus voltage levels (basic check with multimeter).
    • Demonstration of network communication using a capable scan tool (viewing module lists, communication status).
    • Basic CAN Bus troubleshooting concepts (shorts, opens, termination resistors).

Day 8: Engine Management Systems (EMS) Overview

Morning (Theory):

• • • Role of the Engine Control Module (ECM/PCM).
    • Key Inputs (CKP, CMP, MAP, ECT, IAT, TPS, O2S).
    • Key Outputs (Fuel Injectors, Ignition Coils, Throttle Actuator).
    • Fuel Trim (Short Term Fuel Trim – STFT, Long Term Fuel Trim – LTFT) – basic concepts.
    • Ignition Timing Control.

Afternoon (Practical/Demo):

• • • Using a scan tool to view key EMS live data PIDs.
    • Observing sensor data changes and their effects (e.g., revving engine, watching RPM and injector pulse width).
    • Demonstration of basic fuel trim interpretation.

Day 9: Chassis Control Systems & Intro to xEV

• • Morning (Theory):
    • Anti-lock Braking System (ABS): Components (Wheel Speed Sensors, Hydraulic Unit, ABS Module) and Operation.
    • Electronic Stability Program (ESP) / Traction Control System (TCS): Integration with ABS, additional sensors (Steering Angle, Yaw Rate).
    • Brief Introduction to Hybrid (HEV) and Electric Vehicle (EV) Mechatronics: High Voltage Systems, Battery Management Systems (BMS), Inverters, Electric Motors (concepts only, emphasizing safety).

Afternoon (Practical/Demo):

• • • Identifying ABS/ESP components on a vehicle.
    • Using a scan tool to read wheel speed sensor data.
    • Discussion and demonstration of High Voltage safety procedures for HEV/EV (visual identification, safety disconnects). (Safety focus is paramount here).

Day 10: Integrated Diagnostics & Future Trends

• • Morning (Theory):
    • Systematic Diagnostic Approach: Verify Complaint, Check Basics, Retrieve DTCs, Analyze Data (Scan Tool, Multimeter, Scope Basics), Isolate Fault, Repair, Verify Repair.
    • Introduction to Oscilloscopes in Automotive Diagnostics (viewing sensor signals).
    • Future Trends: ADAS (Advanced Driver-Assistance Systems), Vehicle-to-Everything (V2X), Over-the-Air (OTA) Updates, Increased Electrification.
  • Afternoon (Review & Assessment):
    • Q&A Session covering all topics.
    • Short written assessment or practical skills evaluation (e.g., retrieving codes, testing a sensor).
    • Course feedback and closing remarks.