AIN SHAMS UNIVERSITY

FACULTY OF ENGINEERING
AUTOMOTIVE ENGINEERING DEPARTMENT

MCT 311

‫مقدمة األوتوترونيكس‬
311 ‫همك‬

Prof. Dr. Moussa Said

Automotive Engineering Department
September 2019
 INTRODUCTION TO AUTOTRONICS (PART 1)
Contents

CHAPTER I: Ground Vehicle Types ………………………………………………………………… 2

CHAPTER II: Vehicle Main Systems………………………………………………………………… 17

CHAPTER III: Propulsion Systems …………………………………………………………………… 30

CHAPTER IV: Braking Systems………………………….………………………………………………… 45

CHAPTER V: Suspension Systems …………………………………………………………………….. 50

CHAPTER VI: Steering Systems ………………………………………………………………………….. 55
.

REFERENCES …………………………………….……………………………………………………...…………………… 70

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CHAPTER I: GROUND VEHICLE TYPES

1.1 Introduction

The Autotronics is referred to as modern automotive technology in

the field of automobile engineering. Significantly, it has many
applications in motor vehicles technology. Autotronics as an aspect
of automobile engineering presents basics, advantages, layout and
components and functional operation of various computer-
controlled motor vehicle systems. In addition, it clarifies how to
use recent diagnostic tools and equipment for fault finding and
analysis. It deals with computer-controlled motor vehicle systems
like; engine management, ABS (Anti Brake Skid), TCS (Traction
Control), SCS (Stability Control) and others. The self-diagnosis and
fault codes are also included.

Some of the modern cars are as much electronic as they are

mechanical, thus creating a new AUTOTRONIC area (AUTOmobile
+ elecTRONIC). A modern car has several control modules, which
monitor and manage most of the major systems in the vehicle. The
most common types are engine and drive line control, cruise
control, suspension control, anti-lock braking and airbag control,
climate control, GPS-based navigation system, stability
management system, instrumentation, infotainment, etc. Systems
such as steering systems, collision warning, voice recognition,
Internet access, night vision enhancement and collision avoidance
systems.

The modern automobile is a complex technical system employing

subsystems with specific design functions. Some of these consist of
thousands of component parts that have evolved from
breakthroughs in existing technology or from new technologies
such as electronic computers, high-strength plastics, and new
alloys of steel and nonferrous metals. Some subsystems have come
about as a result of factors such as air pollution, safety legislation,
and foreign competition. Fig. 1.1 shows a typical vehicle, indicating
the major functional components of an automobile.

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 Fig.1.1: The Major Functional Components of an Automobile.

1.2 History

TIMELINE:
• 1970’s: Introduction of electronics for engine controls.
• 1980’s: Anti-lock braking introduced.
• Early 1990’s: Airbags become standard.
• Late 1990’s: Rapid expansion of body electronics – seat
motors (body Computers), instrument panel lighting, auto
locking systems and keyless entry.
• Early 2000’s to date: infotainment, including sophisticated
audio and video ; Signals sent via satellite (such as the OnStar
System); GPS and mapping Capabilities; satellite radio.
• Late 2000’s: Steer-by-wire, wireless connectivity

1.3 Classification of Ground Vehicles

Vehicles can be classified into several types based on several

criteria. A brief classification of vehicles is:
➢ Based on Purpose
➢ Based on Load and Capacity
➢ Based on Number of wheels
➢ Based on Fuel source
➢ Based on the frame and Body Style
➢ Based on type of transmission

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 ➢ Based on the drive
➢ Based on Location of the Engine
➢ Based on Make and Model

1.3.1 Classification of Ground Vehicles Based on Purpose

Fig.1.2: Classification of Ground Vehicles Based on Purpose.

Fig 1.2 shows some of the types of vehicles classified based on

purpose of use. Figure 1.3 shows an overview of Automobiles

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1.3.2 Classification of Ground Vehicles Based on Load and Capacity.

➢ Heavy transport vehicle, e.g. trucks, buses

➢ Light transport vehicle, e.g. pickup, station wagon
➢ Light motor vehicle, e.g. cars, jeeps

1.3.3 Classification of Ground Vehicles Based on Number of wheels.

➢ Two-wheeler vehicle, for example : Scooter, motorcycle, scooter

➢ Three-wheeler vehicle, for example : Auto rickshaw, three-
wheeler scooter for handicaps and tempo
➢ Four-wheeler vehicle, for example : Car, jeep, trucks, buses
➢ Six-wheeler vehicle, for example : Big trucks with two gear axles
each having four wheels.

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1.3.4 Classification of Ground Vehicles Based on Fuel source

➢ Petrol vehicle, e.g. motorcycle, scooter, cars

➢ Diesel vehicle, e.g. trucks, buses
➢ Electric vehicle which use battery to drive.
➢ Hybrid vehicle which use two different drive sources, e.g. Petrol
and electricity.
➢ Gas vehicle, e.g. LPG and CNG vehicles, where LPG is liquefied
petroleum gas and CNG is compressed natural gas.
➢ Hydrogen Vehicles, Biofuel and Fuel cells

1.3.5 Classification of Ground Vehicles Based on the frame and

Body Style

➢ Sedan
➢ Hatchback car
➢ Coupe car
➢ Station wagon
➢ Convertible
➢ Van and mini vans
➢ Sport Vehicles (Racing)
➢ Sport Utility Vehicles (SUV)
➢ Special purpose vehicle, ambulance.

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1.3.6 Classification of Ground Vehicles Based on type of
Transmission

➢ Conventional vehicles with manual transmission, e.g. car with 5 gears.

➢ Semi-automatic, has no need for a clutch.
➢ Automatic : In automatic transmission, gears are not required to be
changed manually. It is automatically changing as per speed of the
automobile.

1.3.7 Classification of Ground Vehicles Based on the drive

➢ Driven sitting towards right or left side

• Left hand drive
• Right hand drive
➢ Driving Axle
• Front wheel drive
• Rear wheel drive
• Four Wheel drive
• All wheel drives

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1.3.8 Classification of Ground Vehicles Based on Position of the
Engine
a) Engine in Front
Most of the vehicles have engine in the front. Example : most of
the cars, buses, trucks.
b) Engine in the Rear Side
Very few vehicles have engine located in the rear. Example :
VW.

1.3.9 Classification of Ground Vehicles Based on Make and Model

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1.4 Design and Specifications of the Motor Vehicles

Integration of an automobile involves fitting together separate

parts to form a body and mounting these into a frame and/or onto
a chassis.

An automobile chassis basically comprises the following:

1. Body, Frame and/or Chassis: Forms the skeleton of the

vehicle.
2. Engine : Power train unit of the vehicle; which in the past has
been in large part, the internal combustion engine.
3. Transmission system : Aids in transferring the drive from the
engine to the wheels. Its main components are the clutch,
gearbox, final drive, and differential.
4. Suspension system : Used to connect the wheels to the body
or chassis frame.
5. Steering system:
6. Brakes
7. Electrical equipment
8. Interior Trims : Dashboard, Door pads, Roof upholstery, Seats
etc.

1.4.1 Body

➢ Made of steel, aluminum, fiberglass, plastic, or composite

materials
➢ Forms the outside of the vehicle
➢ Serves as an attractive covering for the chassis

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Unibody Construction: The frame is an integral part of the body. It
is usually called Monocoque Body.

Body-over-Frame Construction: The body bolts to a thick steel

frame. Usually used in Pickups.

1.4.1 Frame

• Strong metal structure that provides a mounting place for

other parts of the vehicle
• Body-over-frame construction

chassis parts and body bolt to the frame

• Unibody (unitized) construction

sheet metal body panels are welded together to form the body
and frame

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1.4.2 Chassis

➢ Consists of the vehicle’s frame and everything attached to it

except the body
➢ Includes the tires, wheels, engine, transmission, drive axle
assembly, and frame

The chassis is complete in itself as a road vehicle. It can drive and

control itself just as in case of a complete car and therefore, in many
motor works, the chassis is usually tested on the road before the
complete body of the vehicle is attached as the chassis alone can
behave as the propulsion means.

Specifications of the Motor Vehicles

Vehicle Identification Number

Vehicle Dimensions

Vehicle Parameters

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1.5 Components of Motor Vehicles

The auto components industry is predominantly divided into five

segments.
1. Engine parts
2. Drive transmission and steering parts
3. Suspension and brake parts
4. Electrical parts
5. Body and chassis

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Definition of a System

Group of related parts and assemblies that performs a specific job.

Example: The steering system is comprised of the steering wheel,
gears, swivel joints, and other assemblies and parts. Allows the
driver to turn the wheels when maneuvering the vehicle

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Definition of an Assembly

▪ Set of fitted parts designed to complete a function

Example: The engine is an assembly that converts fuel into
usable power to move the vehicle
▪ Technicians take assemblies apart and put them back together
during maintenance, service, and repair operations

Definition of a Part

▪ The smallest removable item on a car

▪ Not normally disassembled
▪ Electrical or electronic parts are often called components

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Example 1.1:
1) What are the functions of the chassis?
(a) To carry the weight of the vehicle and its passengers.
(b) To withstand the engine and transmission torque.
(c) To withstand the centrifugal force while cornering.
(d) All the above
2) Automobile body is made of:
(a) sheet metal or fiber glass
(b) iron (c) copper
(c) gun metal
3) The body is fixed to the chassis with the help of:
(a) I or U bolts
(b) rivet
(c) welding
(d) threaded bolt
4) Automobile body should fulfill which of the following
requirements?
(a) The body should be light.
(b) It should have a long fatigue life.
(c) Both (a) and (b)
(d) None of the above

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