MODULE CODE: CNOT 16.1
A. CONTENT
1. Functions, classification and requirements of batteries.
1.1. Tasks :
The starter battery has the following tasks:
- Start the engine
- Supply power to electrical loads when the engine stops or at low rpm. Stabilize voltage in the circuit and store electrical energy.
1.2. Classification
On cars, there are two types of batteries that can be used to start: acid batteries and alkaline batteries. But the most popular so far is still acid batteries, because compared to alkaline batteries, they have a higher electromotive force of each pair of plates, have a small internal resistance and ensure good starting mode, although alkaline batteries also have many advantages.
1.3. Requirements:
The battery must meet the following requirements:
-Able to start the engine, small voltage drop
-Must provide a stable voltage
- Withstand vibration, shock, and environmental temperature conditions (the best environmental temperature for acid batteries is 30 0 – 35 0 C).
- Long usage time.
1.
2. Structure and operation of batteries 2.1. Structure
Figure 4.1 . Battery structure
a.Cylinder shell
Made of ebonite or hard rubber, the inside is divided into separate compartments by sealed partitions. At the bottom of each compartment there are ribs (supports) to support the electrodes to avoid precipitation causing short circuit of the electrodes. There are holes on the top. On the normal shell there are two lines to indicate low (lower) and high (upper) levels outside the shell.
Figure 4.2 Battery case
b.Pole: A frame cast from an alloy of lead and antimony (Pb-Sb) to increase rigidity and rust resistance. This alloy has a small expansion coefficient and low melting point compared to pure lead.
The negative electrode is made from lead powder and H 2 SO 4 solution plus about 3% of the expander (the expander is usually the salt of organic acid). The negative electrode frame is usually thin because of its low resistance and less rust, especially the two outer plates are even thinner because it only works on one side. The expander is mainly to increase the porosity of the electrode.
The positive electrode is made from lead oxides Pb3O4 or Pb02 . The resistance of PbO2 is very large (10,000 times that of pure lead), so the positive electrode is thickened to limit its resistance. In a battery compartment, the positive and negative electrodes are placed alternately and separated by a separator. There is always one more negative electrode than positive electrode in a battery compartment.
Figure 4.3 Pole block
c. Partition
Used to prevent the positive and negative plates from short circuiting, and at the same time minimize the effects of peeling during use. It has insulating properties but must not prevent the electrolyte solution from circulating to the plates, and must not contain
harmful impurities. The partition is usually made of plastic, fiberglass pressed with plastic, wood... Each partition is about 1.5 - 2.4 mm thick and has two sides: smooth side and corrugated side.
The smooth side is the side that is mounted with the negative electrode. The wavy side is mounted facing the positive electrode to facilitate the solution to penetrate the positive electrode.
d. Cap, button and bridge:
The cover is usually made of plastic, and can be made as a separate cover for each compartment or as a general cover for the entire battery. The advantage of a separate cover is that it is easy to repair when one or more single battery compartments are damaged.
Button: in each compartment there is usually a hole to pour the electrolyte solution, check the solution level as well as the solution concentration. It is covered with a button to prevent dirt and foreign objects from entering as well as limit the solution from leaking out. On each button there is a vent hole so that the air in the tank compartment can escape.
Bridge: is a lead bar to connect two adjacent single batteries in series.
Figure 4.4 Battery button
e. Battery terminals: There are three types of battery terminals used: top, side, and L-type. The top terminal is the most common type used in automobiles. The side terminal is a General Motors specialty, and the L-type is used on ships.
Figure 4.5. Battery terminals
g. Electrolyte:
The electrolyte in a battery is a mixture of 36% sulfuric acid (H 2 SO 4 ) and 64% distilled water (H 2 O). The electrolyte solution in today's batteries has a specific gravity of 1.270 (at 20 0 C) when fully charged. Specific gravity is the weight of a volume of liquid compared to the weight of water for the same volume. The higher the specific gravity, the thicker the liquid.
A hydrometer is used to measure the specific gravity of the electrolyte solution. The electrolyte in a charged battery is stronger and heavier than the electrolyte in a discharged battery.
Figure 4.6. Electrolyte
2. 2. Operating principle
Two dissimilar metals placed in an acid solution will generate a voltage between the two poles. The positive pole is made of lead oxide (PbO 2) , the negative pole is made of lead (Pb). The electrolyte is a mixture of sulfuric acid (H 2 SO 4 ) and water (H 2 O). They form an element of the cell.
Figure 4.7. Battery operation Figure 4.8. Discharge and charge process Figure 4.9. Battery voltage
Batteries store electricity in the form of chemical energy. Through chemical reactions, batteries generate and release electricity for the needs of the electrical system and electrical equipment. When the battery loses chemical energy during this process, the battery needs to be recharged by a generator. By the reverse current passing through the battery, the chemical process is restored, thus charging the battery. The charging and discharging cycle is repeated continuously and is called the battery cycle.
Each cell has a voltage of approximately 2.1V regardless of the size and number of plates. A car battery has 6 cells connected in series, producing a voltage of 12.6V.
Electrochemical processes in batteries
In batteries, two characteristic reversible chemical processes occur, charging and discharging, and are expressed in the following equation:
PbO 2 + Pb + 2H 2 SO 4 2PbSO 4 + 2H 2 O
During the discharge process, the two electrodes PbO 2 and Pb turn into PbSO 4 . Thus, during discharge, sulfuric acid is absorbed to form lead sulfate, and water is produced, thus, the concentration of H 2 SO 4 solution decreases.
The change in electrolyte concentration during discharge and charging is one of the signs to determine the discharge level of the battery in use.
2.3. Battery charging methods
+ Charging with constant voltage: In this charging method, all batteries are connected in parallel with the charging source and ensure that the charging source voltage ( U ng ) is 2.3V - 2.5V on a single battery with the condition that U ng > U a .
+ Constant current charging method: In this method, the charging current is kept at a constant value throughout the charging time by changing the resistance value of the potentiometer R. Normally, people charge with a current with intensity I n = 0.1Q dm .
+ Two-step charging method: In this method, the battery is first charged with 0.1I dm when the battery starts to boil, then reduced to 0.05I dm . The two-step charging method ensures that the battery is fully charged and does not get hot.
+ Mixed charging method: First, charge by constant voltage method and then charge by constant current method. Can charge quickly for batteries that are completely discharged, but must reduce charging time.
3. Phenomenon, cause of damage and solution
Status
Phenomena | Reason | Fix | |
1 | Battery quick dry water charge | Overcharge | Charge until the battery is full. electricity is fine |
2 | Self-discharging battery | The lid surface is dirty or wet. | Use Na2co3 solution to clean . vase face |
3 | Sulfated | - The concentration and temperature of the electrolyte water is too high. - Due to the phenomenon of self-destruction Prolonged Discharge | Charge at half strength for 60 to 100 hours |
4 | The pole is warped. | - Overcharge with high current. - Concentration and temperature water charge is too high. | Pour the correct concentration solution, and charge with the correct intensity. |
Maybe you are interested!
-
Motor electrical maintenance and repair - Automotive Technology - College Part 2 - Da Nang Vocational College - 11 -
Diesel engine maintenance and repair - Automotive Technology Profession For College Level Part 1 - 1 -
Car body electrical practice - 8
zt2i3t4l5ee
zt2a3gs
zt2a3ge
zc2o3n4t5e6n7ts
If the voltage is out of specification, replace the wire or connector.
If the voltage is within specification, install the front fog light relay and follow step 5.
Step 5 Check the front fog light switch
- Remove the D4 connector of the fog light switch
- Use a multimeter to measure the resistance of the front fog light switch.
Measurement location
Condition
Standard
D4-3 (BFG) -D4-4 (LFG)
Light switchFront Fog OFF
>10kΩ
D4-3 (BFG) -D4-4 (LFG)
Front fog light switchON
<1 Ω
- Standard resistor
D4 connector is located on the combination switch assembly.
If the resistance is out of specification, replace the combination switch (the fog light switch is located in the combination switch).
If the resistance is within specification, follow step 6.
Step 6 Check wiring and connectors (front fog light relay-light selector switch)
- Disconnect connector D4 of the combination switch assembly
- Use a voltmeter to measure the voltage value of jack D4 on the wire side.
Measurement location
Control modecontrol
Standard
D4-3 (BFG) - (-) AQ
TAIL
11 to 14 V
D4 connector for the wiring of the combination switch assembly
If the voltage does not meet the standard, replace the wire or connector.
If the voltage is within standard, there may have been an error in the previous measurements.
Step 7 Check the front fog lights
- Remove the front fog light electrical connector.
- Supply battery voltage to the fog lamp terminals
Jack 8, B9 of front fog lamp on the electrical side
blind first.
Power supply location
Terms and Conditions
Battery positive terminal - Terminal 2Battery negative terminal - Terminal 1
Fog lightsbefore morning
- If the light does not come on, replace the bulb.
If the light is on, re-plug the jack and continue to step 8.
Step 8 Check wiring and connectors (relay and front fog lights)
- Disconnect the B8 and B9 connectors of the front fog lights.
- Use a voltmeter to measure voltage at the following locations:
Measurement location
Switch location
Terms and Conditions
B8-2 - (-) AQ
Electric lock ON TAIL size switchFog switch ON
11 to 14 V
B9-2 - (-) AQ
Electric lock ONTAIL size switch Fog switch ON
11 to 14 V
B8 and B9 connectors on the front fog lamp wiring side
Voltage is not up to standard, repair or replace the jack. If up to standard, there may have been an error in the measurement process.
2.2.4. Procedure for removing, installing and adjusting fog lights 1. Procedure for removing
- Remove the front inner ear pads
Use a screwdriver to remove the 3 screws and remove the front part of the front inner ear liner
-Remove the fog light assembly
+ Disconnect the connector.
+ Use a screwdriver to remove 3 screws to remove the fog light cover
2. Installation sequence
-Rotate the fog lamp bulb in the direction indicated by the arrow as shown in the figure and remove the fog lamp from the fog lamp assembly.
-Rotate the fog light bulb in the direction indicated by the arrow as shown in the figure and install the light into the fog light assembly.
- Use a screwdriver to install the fog light cover
-Install the electrical connector
Attention: Be careful not to damage the plastic thread on the lamp assembly.
- Install the front inner ear pads
Use a screwdriver to install the front inner bumper with 3 screws.
3. Prepare the vehicle to adjust the fog light convergence. Prepare the vehicle:
- Make sure there is no damage or deformation to the vehicle body around the fog lights.
- Add fuel to the fuel tank
- Add oil to standard level.
- Add engine coolant to standard level.
- Inflate the tire to standard pressure.
- Place spare tire, tools and jack in original design position
- Do not leave any load in the luggage compartment.
- Let a person weighing about 75 kg sit in the driver's seat.
4. Prepare to check the fog light convergence
a/ Prepare the vehicle status as follows:
- Place the car in a dark enough place to see the lines. The lines are the dividing line, below which the light from the fog lights can be seen but above which it cannot.
- Place the car perpendicular to the wall.
- Keep a distance of 7.62 m between the center of the fog lamp and the wall.
- Park the car on level ground.
- Press the car down a few times to stabilize the suspension.
Note: A distance of approximately 7.62 m is required between the vehicle (fog lamp center) and the wall to adjust the convergence correctly. If the distance of 7.62 m cannot be achieved, set the correct distance of 3 m to check and adjust the fog lamp convergence. (Since the target area varies with the distance, please follow the instructions as shown in the figure.)
b/ Prepare a piece of thick white paper about 2 m high and 4 m wide to use as a screen.
c/ Draw a vertical line through the center of the screen (line V).
d/ Set the screen as shown in the picture. Note:
- Keep the screen perpendicular to the ground.
- Align the V line on the screen with the center of the vehicle.
e/Draw the reference lines (H, V LH and V RH lines) on the screen as shown in the figure.HINT:
Mark the center of the fog lamp on the screen. If the center mark cannot be seen on the fog lamp, use the center of the fog lamp or the manufacturer's name mark on the fog lamp as the center mark.
H line (fog light height):
Draw a line across the screen so that it passes through the center mark. Line H should be at the same height as the center mark of the fog light bulb.
Line V LH, V RH (center mark position of left fog lamp LH and right fog lamp RH):
Draw two lines so that they intersect line H at the center marks.
5. Check the fog light convergence
a/ Cover the fog lamp or remove the connector of the other side fog lamp to prevent light from the unchecked fog lamp from affecting the fog lamp convergence test.
b/ Start the engine.
c/ Turn on the fog lights and make sure that the dividing line is outside the standard area as shown in the drawing.
6. Adjust the fog light convergence
Use a screwdriver to adjust the fog light to the standard area by turning the toe adjustment screw.
Note: If the screw is adjusted too far, loosen it and then tighten it again, so that the last rotation of the light adjustment screw is clockwise.
3. Self-study questions
1. Describe the operating principle of the lighting system with automatic headlight function
2. Describe the operating principle of the lighting system with the function of rotating headlights when turning
3. Draw diagram and connect lighting system on Hyundai Porter car
4. Draw diagram and connect lighting system on Honda Accord 1992
5. Draw the lighting circuit on a 1993 Toyota Lexus
LESSON 3 MAINTENANCE AND REPAIR OF SIGNAL SYSTEM
I. IMPLEMENTATION GOAL
After completing this lesson, students will be able to:
- Distinguish between types of signals on cars
- Correctly describe common symptoms and suspected areas causing damage.
- Connecting signal circuits ensures technical requirements
- Disassemble, install, check, maintain and repair the signal system to ensure technical requirements.
- Ensure safety in work and industrial hygiene
II. LESSON CONTENT
1. General description
The signal system equipped on cars aims to create signals to notify other vehicles participating in traffic about the vehicle's operating status such as: stopping, parking, braking, reversing, turning...
Signals are used either by light such as headlamps, brake lights, turn signals….. or by sound such as horns, reverse music….
Just like the lighting system. A signal system circuit usually consists of: battery, fuse, wire, relay, electrical load and control switch. Only some switches of the signal system are on the combination switch. The switches of other signals are usually located in different locations such as in the gearbox or brake pedal……
2. Maintenance and repair
2.1. Turn signals and hazard lights
The installation location of the turn signal is shown in Figure 3.1. The turn signal control switch is located in the combination switch under the steering wheel. Turning this switch to the right or left will make the turn signal turn right or left.
The hazard light switch is used when the vehicle has a problem while participating in traffic. When the hazard light switch is turned on, all the turn signals on the vehicle will light up at a certain frequency. The hazard light switch is usually placed separately from the turn signal switch (some old cars integrate the hazard and turn signal switches on the same combination switch cluster).
Figure 3.1 Turn signal switch Figure 3.2 Hazard switch
The part that generates the flashing frequency for the lights is called a turn signal relay. The turn signal relay usually has 3 terminals: B (positive power supply); E (negative power supply); L (providing the turn signal switch to distribute to the
lamp)
2.1.1. Circuit diagram
To generate the frequency for the turn signal, a turn signal relay is used in the turn signal circuit. The current from the turn signal relay will be sent to the turn signal switch assembly to distribute the current to the turn signal lights for the driver's purpose.
Figure 3.3. Schematic diagram of a turn signal circuit without a hazard switch
1. Battery; 2. Electric lock; 3. Turn signal relay; 4. Turn signal switch; 5. Turn signal lamp; 6. Turn signal lamp; 7. Hazard switch
Figure 3.4 Schematic diagram of turn signal circuit with hazard switch
1. Battery; 2. Combination switch cluster; 3. Turn signal;
4. Turn signal light; 5. Turn signal relay
Today's cars no longer use three-pin turn signal relays (B, L, E) but use eight-pin turn signal relays (figure 3.5) (pin number 8 is used for hazard lights).
For this type, the current supplying the turn signal lights is supplied directly from the turn signal relay to the lights.
div.maincontent .p { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; margin:0pt; } div.maincontent p { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; margin:0pt; } div.maincontent .s1 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 13pt; } div.maincontent .s2 { color: black; font-family:"Times New Roman", serif; font-style: italic; font-weight: normal; text-decoration: none; font-size: 14pt; } div.maincontent .s3 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; } div.maincontent .s4 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 13pt; } div.maincontent .s5 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 13pt; vertical-align: 1pt; } div.maincontent .s6 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 11pt; } div.maincontent .s7 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; vertical-align: -9pt; } div.maincontent .s8 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 11pt; } div.maincontent .s9 { color: #008000; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; } div.maincontent .s10 { color: black; font-family:"Times New Roman", serif; font-style: italic; font-weight: normal; te -
Maintenance and repair of internal combustion engines Rural Electromechanical Profession - Lao Cai Community College - 21 -
Maintenance and repair of asynchronous motors Rural Electromechanical Profession - Lao Cai Community College - 12
4. Battery maintenance and repair
4.1. Testing process
a. Quick dry battery charge:
Status
Job Description | Tool | Technical requirements | |
1 | Check for cracked and broken battery terminals | If so, replace the battery. | |
2 | Check battery terminals for corrosion | Use a metal brush |
to scrub again | |||
3 | Check for dirt and acid on the battery surface. rule | Add distilled water when need not overflow | |
4 | Check the electrolyte level in battery | ||
5 | Check the electrolyte solution for cloudiness. or discoloration | Replace the battery if Have |
b. Check the density
Status
Job Description | Tool | Technical requirements | |
1 | Open the battery cover | Wear eye protection fit | |
2 | Squeeze the suction bulb of the hydrometer and insert The suction head goes into the compartment closest to the positive terminal. | Hydrometer | |
3 | Aspirate electrolyte solution to float Inside probe up. | Slowly release the suction cup, | |
4 | Read specific gravity only on the probe | Green solution: battery is fully charged Dark blue solution: Battery needs charging Light yellow solution: damaged battery, need to replace. | |
6 | Record the value and repeat the process. present to the remaining compartments | ||
7 | Compare the difference in proportions of the compartment | Difference not exceeding over 0.05 |