A TECHNICAL REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (S.I.W.E.S) UNDERTAKEN AT . 4TH ROUNDABOUT, LEKKI-EPE EXPRESSWAY, VI, LAGOS. BY OLADEJI ADEOLA ISMAIHIL 100403071 DEPARTMENT OF ELECTRICAL / ELECTRONICS ENGINEERING FACULTY OF ENGINEERING UNIVERSITY OF LAGOS. INSTITUTION BASED SUPERVISOR: ENGR. OKEWOLE F. O. SUBMITTED IN PARTIAL FUFILMENT OF THE AWARD OF BACHELOR OF SCIENCE (B. Sc.) IN ELECTRICAL / ELECTRONICS ENGINEERING. FROM: AUGUST 2014 TO JANUARY 2015 SIWES TECHNICAL REPORT CERTIFICATION This is to certify that Oladeji Adeola Ismaihil of Matric number 100403071 compiled this report based on his twenty-four weeks Student Industrial Working Experience Scheme (S.I.W.E.S.) carried out at Germaine Auto Centre. 4th Roundabout Lekki-Epe Expressway, V.I. Lagos. ……………………………….. Name of Student ……………………… Signature and Date ........................................................ Name of Industry Based Supervisor ……………………. Signature and Date ………………………………… Name of Academic Supervisor ……………………… Signature and Date OLADEJI ADEOLA .I. 100403071 Page | 1 SIWES TECHNICAL REPORT DEDICATION This report is dedicated foremost to God Almighty for his favor, mercy and grace upon my life especially during my 6 months SIWES programme at Germaine Auto Centre. I would also like to dedicate it to my parents and siblings for their love and support and everyone else that contributed towards making my SIWES training a fun and successful one. OLADEJI ADEOLA .I. 100403071 Page | 2 SIWES TECHNICAL REPORT ACKNOWLEDEGEMENT My appreciation goes to the Industrial Training Fund for their foresight in putting this program in place and also to the Electrical / Electronics Engineering Department, University of Lagos, Akoka for providing a platform on which I was engaged on the training. I am grateful to Germaine Auto Centre for providing me with such an opportunity to be exposed to world class engineering services in the automobile industry. I also want to say a big thank you to my industry based Mr Idowu Amoo and to my direct boss Mr Azeez also to Mr lateef, Jessica, Mr Jamiu, Mr segun and every personnel of the Japanese Department especially the Light Truck section for welcoming me into the Truck family with open hands. To Mr Isaiah, Mr Seun and Mr Keneth of the IT department, thank you all for taking me in like a brother. To Mr Lawal, Mr Paul and everyone in the Material and Spare parts department. God bless you all. To my co-interns Emmanuel, Magnus, Nuah, Abiodun, Josh and Onyekachi thank you all for making my stay at GAC an exciting and blissful one. To my parents and siblings thank you all for your moral and financial support. I cannot wish for a better family. I am deeply indebted to God Almighty, the giver of all wisdom, knowledge and understanding, without whom I would have achieved nothing at all. Finally to my Institution based supervisor Engr. Okewole F. O. for his support and to my other friends and colleagues. Thank you all. I am highly grateful. OLADEJI ADEOLA .I. 100403071 Page | 3 SIWES TECHNICAL REPORT ABSTRACT This Industrial Report presents the experience garnered during my six months of Industrial training undertaken at Germaine Auto Centre, Lekki – Epe Expressway, VI, Lagos. My training was on Diagnosis / Electrical Technician in Light Truck Section and Technical Support, Troubleshooting of PC (personal computer) with other Networking Infrastructures in IT Department. I acquired practical knowledge on how to Repair, Replace and Install Electrical Systems and I also assisted in providing the operational units the functionality they need. This report discusses the technical skills gained during the training period and justifying the relevance of the scheme in equipping students with needed technical competence to thrive in the real world. OLADEJI ADEOLA .I. 100403071 Page | 4 SIWES TECHNICAL REPORT TABLE OF CONTENT Title Page Certification…………………………………………………………………………………….1 Dedication ……………………………………………………………………………………...2 Acknowledgement ……………………………………………………………………………..3 Abstract ………………………………………………………………………………………...4 Table of Content ……………………………………………………………………………….5 List of Tables …………………………………………………………………………………..7 List of Figures ………………………………………………………………………………….7 Chapter 1 Introduction to Training Program …………………………………….................................1 1.0 Purpose of Training ……………………………………………………………………8 1.1 Company’s profile…………. ……………………………………………………….....9 Chapter 2 The Training Program ……………………………………………………………………... 2 2.0 Description of Work done …………………………………………………………….13 2.1 Automotive Electrical System…………………………………………………………14 2.10 Starting System ……………………………………………………………………….14 2.11 Charging System ……………………………………………………………………...14 2.12 Digital (programmed) ignition system ………………………………………………..17 2.12 Lighting System ……………………………………………………………………....17 2.13 Audio System ………………………………………………………………………...18 2.14 Sensors and Actuators ………………………………………………………………..19 OLADEJI ADEOLA .I. 100403071 Page | 5 SIWES TECHNICAL REPORT Chapter 3 Repair and Maintenance Processes………………………………………………………….3 3.0 Safety Information……………………………………………………………………..23 3.1 Tools Required………………………………………………………………………...23 3.2 Checking the Battery……………………………………………………………….....24 3.3 Grounding Problems…………………………………………………………………..25 3.4 Checking and replace of fuses/Relays…………………………………………….......25 3.5 Low Voltage…………………………………………………………………………..26 3.6 Using Diagnostic Machines……………………………………………………….......27 3.7 The ‘six steps’ Approach………………………………………………………….......29 Chapter 4 4.0 Work experienced in IT. Department…………………………………………………30 Chapter 5 Observations and Contributions ……………………………………………………………5 5.0 Observations …………………………………………………………………….........34 5.1 Contributions …………………………………………………………………………35 5.2 Relevance of experience gained to classroom knowledge……………………………35 Chapter 6 Conclusion and Recommendation………………………………………………………….6 6.0 Conclusion ……………………………………………………………………………36 6.1 Recommendation …………………………………………………………………….36 6.2 Challenges encountered during period of Training………………………………......36 References …………………………………………………………………………………...37 OLADEJI ADEOLA .I. 100403071 Page | 6 SIWES TECHNICAL REPORT LIST OF TABLES Table 1.0: The colour codes in the various servicing sections Table 3.0: Maximum acceptable voltage drops for automotive electrical system Table 4.0: Motherboard components. LIST OF FIGURES Figure 2.0: Light Truck section Figure 2.1: Typical example of a Light Truck Figure 2.2: Starter Figure 2.3: Description of a Starter Figure 2.4: Alternator Figure 2.5: Battery Figure 2.6: Digital ignition system Figure 2.7: Lighting system Figure 2.8: An optoelectronic sensor Figure 2.9: Knock sensor on Engine Figure 2.10: A typical injector for a multiple-point injector system Figure 3.0: Some tools Used Figure 3.1: Inspecting the Battery Voltage Figure 3.2: Engine Fuse/Relay box Figure 3.3: Checking the Voltage drop Figure 3.4: Diagnosing process Figure 3.5: Display of Trouble codes on IT2 machine Figure 3.6: AUTOBOSS machine Figure 3.7 Techstream software Figure 4.0: Backing Up the Company’s document for the day Figure 4.1: PC troubleshooting process Figure 4.2: System Unit Figure 4.3: Motherboard Figure 4.4: RAM Figure 5.0: Caution Sign OLADEJI ADEOLA .I. 100403071 Page | 7 SIWES TECHNICAL REPORT CHAPTER 1 INTRODUCTION TO TRAINING PROGRAM 1.0 PURPOSE OF TRAINING The Students Industrial Work Experience Scheme (SIWES) was initiated in 1973 by the Industrial Training Fund (ITF). This was to update practical knowledge of students in the Universities, Polytechnics and Colleges of Technology. It was aimed at bridging the gap between the theoretical knowledge acquired in classes and technical knowledge in the industries by providing students with the opportunities to apply their educational knowledge in real work situations. Over the years, SIWES has contributed immensely to building the common pool of technical and allied skills available to the Nigerian economy which are needed for the nation’s industrial development. Furthermore, the place and relevance of SIWES is underscored by the fact that the schemme contributes to improving the quality of technical skills generally available in the pool from which employers source technical manpower. It also gives students the opportunity to blend theoretical knowledge acquired in the Classroom with practical hands-on application of knowledge required to perform work in the industry. Also, it prepares students for employment & makes the transition from school to the world of work easier after graduation. I undertook my SIWES training at Germaine Auto Centre which is located at 4th Roundabout Lekki – Epe Expressway, V.I. Lagos State which Lasted from August 05, 2014 to January 30, 2015. (24 weeks). OLADEJI ADEOLA .I. 100403071 Page | 8 SIWES TECHNICAL REPORT 1.1 COMPANY’S PROFILE: Germaine Auto centre is a subsidiary of Germaine group of companies, located at the 4th Roundabout of Lekki – Epe Expressway. It is an indigenous automobile company; and has three accredited automobile dealerships of some major brands in the country namely: Toyota, Kia and Peugeot franchises. It is equipped with the latest technology available in developed parts of the world for the service and maintenance of customer’s cars, light trucks and commercial buses. The company was founded in 1996 by its current Chairman/CEO (Mr. Jerry Chukwueke). Germaine’s modern hi-tech tools, equipment and technology are only comparable with what can be found in Europe or U.S.A. its service centres are the first of its kind in the sub-region. It has a staff strength of approximately 500. 1.2 COMPANY’S MISSION STATEMENT Germaine’s mission is the continuous building of the Great Germaine People who in turn must deliver Great Service to ensure a Great Company. “Great People! Great Service!! Great Germaine!!!” 1.3 CORPORATE GOAL Germaine’s objective is to deliver an amazing experience to every of its retail and corporate client. It is redefining the automobile market by operating highly efficient, full-fledged, franchised dealerships. With an unsurpassed advantage of having invested in ultra-modern equipment, tools and expertise blended with innovative response to the needs of its clients. It is also positioned to provide logistics solution tailored to meet the needs of its respective clients, thereby delivering “Peace of Mind” to its customers. OLADEJI ADEOLA .I. 100403071 Page | 9 SIWES TECHNICAL REPORT 1.4 THE COMPANY’S SCOPE OF WORK In areas of specialization Germaine Auto Centre Limited has the capacity of providing the following services: - Sales - Service and Maintenance - Body and Paint job - Quality control - Provision of authentic Spare parts for vehicles - Logistics solutions for projects Germaine Auto centre is made up of six (6) major departments. They are: 1. Sales Department 2. Service Department 3. Body and Paint Department 4. Spare parts Department 5. Quality control Department 6. Maintenance Department OLADEJI ADEOLA .I. 100403071 Page | 10 SIWES TECHNICAL REPORT 1.5 COMMAND STRUCTURE OF THE SERVICE/SALES DEPT. CHAIRMAN / CEO Executive Director (Parts Service) Executive Director (Sales and Marketing) General Manager (Parts Service) Ass. Gen. Manager (Sales) Senior Manager (Sales) Senior Manager Spare Parts Senior Workshop Manager Spare Parts Store Manager Senior Workshop Manager Health and Safety Engineer (H.S.E) Section Manager Quality Control Manager Assistant Section Manager Senior Technician Junior Technician OLADEJI ADEOLA .I. 100403071 Page | 11 SIWES TECHNICAL REPORT 1.6 WORK FLOW IN THE SEVICE SECTION Customer Service Advisor Service Advisor Store Manager Quality Control Technician Workshop Technician Some of Germaine’s corporate customers include, but are not limited to: - Halliburton Energy - Chevron - German Embassy - Addax Petroleum - Hewlett Packard - Global Communications Network - Central Bank of Nigeria etc. just to name a few. OLADEJI ADEOLA .I. 100403071 Page | 12 SIWES TECHNICAL REPORT CHAPTER 2 THE TRAINING PROGRAM 2.0 DESCRIPTION OF WORK DONE At Germaine Auto centre service section, because of the large number of staffs in this department and the varying sections. The nature of work carried out here will not allow identity cards to be worn while working. So colour codes are assigned to each workshop personnel according to his/her section; also to distinguish rank/hierarchy in the workshop in each section, the type of clothing worn by personnel is also of importance. The junior and immediate senior technicians wore overalls, while the master technicians and section manager/supervisor wore coats. SECTION COLOUR CODE Japanese Section Blue and Red overall with white stripes Kia Section Red Overall Peugeot Section Blue Overall Multi-Spec Section Blue and Black Overall Table 1: Showing the colour codes in the various servicing sections During my stay in Germaine Auto Centre, for the first five months, I was assigned to the service department as a Diagnosis / Electrical Technician in the Japanese section, more specifically the Light Truck section. The vehicles serviced here, as the name indicates are light trucks. Figure 2.0: Light Truck Section OLADEJI ADEOLA .I. Figure 2.1: Typical Example of Light Truck 100403071 Page | 13 SIWES TECHNICAL REPORT 2.1 AUTOMOTIVE ELECTRICAL SYSTEMS 2.10 STARTING SYSTEM Since the engine cannot be started by itself, external power is required to generate the first combustion to start it. To start the engine, the starter rotates the crankshaft via the ring gear. The starter is required to generate extremely large torque from the limited power from the battery and should be compact and light as well. For this reason, a DC (direct current) series motor* is used for the starter. To start the engine, the crankshaft has to rotate faster than the minimum cranking speed. The minimum cranking speed required to start the engine differs depending on the engine's construction and operating conditions, but it is generally 40 to 60 rpm for a gasoline engine and 80 to 100 rpm for a diesel engine. Figure 2.2: A Starter Figure 2.3: Description of a Starter I did troubleshooting on several cars having starting problems, by checking the battery, starter and the ignition switch using Multi-meter. I observed that most time the battery terminal was not connected firmly, and also observed that the battery is not connected to the ground (i.e. to the vehicle metal sheet) or has removed. I also learned how to do overhauling on the starter 2.11 CHARGING SYSTEM Function of charging system Vehicle is equipped with many electrical devices to drive safely and comfortably. The vehicle requires electricity not only while driving but also while it stops. Therefore, the vehicle has a battery for a power supply and a charging system to generate electricity by the engine running. The charging system supplies electricity to all the electrical devices and charges the battery. OLADEJI ADEOLA .I. 100403071 Page | 14 SIWES TECHNICAL REPORT Charging system mainly consists of the following devices. Alternator : While the engine is running, this generates a nearly equal amount of electricity to operate the electric devices used for the vehicle and to charge the battery Figure 2.4: Alternator. The function of alternator The alternator plays a major role in the charging system. Alternator has three functions of generating electricity, rectifying current and regulating voltage. (1) Generation Transmitting the engine revolution to the pulley via the v-ribbed belt turns the electro magnetized rotor, generating alternating current in the stator coil. (2) Rectification Since the electricity generated in the stator coil is alternating current, this cannot be used for the DC electric devices installed on the vehicle. To use the alternating current, the rectifier is used to rectify the alternating current into direct current. (3) Regulation of voltage IC regulator regulates the generated voltage to make the voltage constant even when the alternator speed or the amount of current flowing into the electric devices fluctuates Regulator (Built in Alternator): This is a device to regulate the generated voltage in order to make it constant even when the alternator speed changes or current volume that flows into the electric devices fluctuates. Battery: This is a power source when the engine stops and it supplies electricity to the electric devices to start the engine or when the alternator does not generate electricity. However, electricity generated by the alternator is charged to the OLADEJI ADEOLA .I. 100403071 Page | 15 SIWES TECHNICAL REPORT battery once the engine starts running. Figure 2.5: A Battery Charge warning light : This informs of the malfunction in the charging system Ignition switch : This starts the engine, causing the alternator to generate electricity I learned how to inspect the charging system. In No-Load Test (inspect charging circuit without load) and Load Test (inspect charging circuit with Load). In the IC regulator type alternator, No-Load Test specified value of the regulated voltage is between approx. 13.5V and 15.1V (when the engine speed is 2,000 rpm). If the measurement result is outside the specified value, the alternator may have a problem. If the value is higher than the maximum limit, the problem is in the IC regulator. While the value is lower than the minimum limit, the problem could be in a component of the alternator except for the IC regulator I Noticed That, In the load test, when the electric load is applied, whether the alternator can output according to the load is checked by measuring the output current. The important point in this test is applying heavy load as much as possible. If electrical load is insufficient even if the alternator is normal, it may not exceed 30A of specified value (when the engine speed is 2,000 rpm). Therefore, if the output current is 30A maximum, it is necessary to increase electrical load and inspect again. The measurement result is less than the specified value, the alternator can be judged faulty. In this case, the possibility of a malfunction is at the part that has a generating function or rectifying function OLADEJI ADEOLA .I. 100403071 Page | 16 SIWES TECHNICAL REPORT 2.12 DIGITAL (PROGRAMMED) IGNITION SYSTEM. Programmed ignition makes use of computer technology and permits the mechanical, pneumatic and other elements of the conventional distributor to be dispensed Figure 2.6: A digital ignition system The control unit (ECU or ECM) is a small, dedicated computer which has the ability to read input signals from the engine, such as speed, crank position, and load. These readings are compared with data stored in the computer memory and the computer then sends outputs to the ignition system. 2.13 LIGHTING SYSTEM. Lights used for vehicles are classified according to the purpose: for illumination, signaling or informing. For example, headlights are used for illumination to see at night, turn signal lights for signaling to other vehicles or pedestrians, and taillights for informing of the vehicle's own presence or position. Besides the general lighting system, vehicles are equipped with systems with various functions depending on the areas or grades. OLADEJI ADEOLA .I. 100403071 Page | 17 SIWES TECHNICAL REPORT Figure 2.7: Lighting System 2.14 AUDIO SYSTEM The construction of the car audio varies depending on the models and grades. In some cases, the customer may select the components from the dealer options, generally, there are the following components. Radio: The antenna picks up the radio wave transmitted from the radio broadcast station and converts it into the sound signal and sends to the amplifier. Almost all the recent radios can receive AM/FM broadcast and have an electronic tuner Tape player/CD player: A tape player reads the analog signal recorded on magnetic tape and sends the sound signal to the amplifier. This device has an auto reverse function, auto pick up function, etc. A CD player reads the digital signal recorded on the optical disc, performs D-A (Digital-Analog) conversion and sends the sound signal to the amplifier. Since digital signal is used, the sound of CD is clearer than that of tape player. This can speedily select songs, which is one advantage of the CD player. OLADEJI ADEOLA .I. 100403071 Page | 18 SIWES TECHNICAL REPORT Amplifier: The amplifier amplifies (expands) the signal from the radio, tape player, CD player, etc., and sends the signal to the speakers. Speaker: The speaker converts the electrical signal amplified at the amplifier into the (sound) air vibration. To listen to the sound in stereo, there must be at least two speakers. I also work on : WIPER AND WASHER SYSTEM The wiper and washer system is a system that keeps the view clear by removing raindrops on the windshield glass and the back window glass when it rains. Used with washer, the system can clear dirt from the windshield glass. For these reasons, this is an essential system for driving vehicles safely. Recently, some models have functions in which the wiper speed changes in response to the vehicle speed, and the wiper automatically operates when it rains. DOOR LOCK CONTROL SYSTEM The door lock control system does not simply lock/unlock the doors by mechanical operation, but also controls the electric motor according to the operation of the door lock control switch and key. The system also has key confine prevention function, two-step unlock function and security function. The functions covered by the system vary depending on the model, grade and area. WIRELESS DOOR LOCK REMOTE CONTROL SYSTEM The wireless door lock remote control system is a system that sends out signals from the transmitter that is built in the key or key holder to lock/unlock the doors even when away from the vehicle. When the door control receiver receives the signal sent out by the transmitter, it sends the operation signal to the integration relay. The integration relay controls the door lock motors upon receiving the operation signal. In addition to this function, the integration relay has automatic lock function, repeat function, answer back function, and other functions. The functions of the wireless door lock remote control system vary depending on the models, grades and areas. 2.15 SENSORS AND ACTUATOR SENSORS: Sensors are the components of the system that provide the inputs that enable the computer (ECM) to carry out the operations that make the system function correctly. In the case of vehicle sensors it is usually a voltage that is represented by a code at the computer’s processor. If this voltage is incorrect the processor will probably take it as an invalid input and record a fault. The fact that the controller itself receives an incorrect sensor signal normally means that the sensor and/or the circuit that connects it to the controller is not working properly and, as with many other parts of electronic systems, it may not be the sensor itself that is at fault. However, it is probable that a fault code has been produced that says ‘sensor fault’. This just means that the sensor signal that reached the controller was defective. It is quite possible that the sensor is functioning correctly, but the circuit connecting it to the ECM is defective. There is, therefore, OLADEJI ADEOLA .I. 100403071 Page | 19 SIWES TECHNICAL REPORT good reason for knowing how sensors work, what type of performance they give when they are working properly, and how to check their performance so that efficient diagnosis and repair can take place. Type of Sensors Electromagnetic sensors: Electromagnetic sensors are often used to sense the speed and/or angular position of a rotating object. Two common uses are: (1) crankshaft position for ignition and fuel injection control; and (2) road wheel rotational speed relative to vehicle frame for anti-lock braking (ABS) and traction control (TCS). The interactions between electricity and magnetism are used in various ways to produce the desired sensing effect. However, the two types of sensor that are widely used in vehicle systems: variable reluctance and Hall type sensors Optical sensors: When light is directed onto semiconductor materials, energy is transferred to the semiconductor and this produces changes in the electrical behaviour of the semiconductor. This effect is used in optoelectronic devices, either as a photodiode, or as a phototransistor. Figure 2.8: An optoelectronic sensor Variable resistance type sensors: When an engine is idling the exhaust gas scavenging of the cylinders is poor. This has the effect of diluting the incoming mixture. The ECU must detect when the throttle is in the idling position, so that alteration of the air–fuel ratio can occur to ensure that the engine continues to run smoothly. At full engine load and full throttle, the mixture (air–fuel ratio) needs enriching, so the ECU also needs a signal to show that the throttle is fully open. These duties are performed by the throttle position switch. Temperature sensors: A commonly used device used for sensing temperature is the thermistor. A thermistor utilizes the concept of negative temperature coefficient. Most electrical conductors have a positive temperature coefficient. This means that the hotter the conductor gets the higher is its electrical resistance. This thermistor operates OLADEJI ADEOLA .I. 100403071 Page | 20 SIWES TECHNICAL REPORT differently; its resistance gets lower as its temperature increases and this is a characteristic of semiconductor materials. There is a well-defined relationship between temperature and resistance. This means that current flow through the thermistor can be used to give an accurate representation of temperature Combustion knock sensors: A knock sensor that is commonly used in engine control systems utilizes the piezoelectric generator effect, i.e. the sensing element produces a small electric charge when it is compressed and then relaxed. Materials such as quartz and some ceramics like PZT (a mixture of platinum, zirconium and titanium) are effective in piezoelectric applications. In the application shown, the knock sensor is located on the engine block adjacent to cylinder number 3 (Fig. 5.10). This is the best position to detect vibrations arising from combustion knock in any of the four cylinders. Figure 2.9: Knock sensor on Engine. OLADEJI ADEOLA .I. 100403071 Page | 21 SIWES TECHNICAL REPORT ACTUATORS Actuators normally rely on one of two electrical devices for their operation; they are either operated by a solenoid or by an electric motor. Solenoid-operated actuators are normally controlled in one of two ways. One is the duty cycle method, where the solenoid is switched on for a percentage of the time available, e.g. 20 or 80%. This means that pulses of varying width can be used to provide the desired result. The other method of solenoid control is known as pulse width modulation (PWM). Here the solenoid current is switched on and off at frequencies that change to suit operating requirements. Electric motors that are used in actuators may be stepper motors, or reversible permanent magnet d.c. motors. A stepper motor can be made to provide small movements of valves by pulsing the current supply. Some stepper motors rotate 7.5Ž per step, which means that a full rotation of the motor shaft takes 48 steps. A common form of stepper motor uses two sets of windings. Current in one set of windings drives the motor shaft forward and when this is switched off and current is applied to the other set of windings, the motor shaft rotates in the reverse direction. This means that accurate control over the position of a valve can be achieved because the control computer determines the valve position by counting the number of pulses applied to the stepper motor windings. A selection of commonly used actuators of both types is covered below. Tests on vehicle systems should be approached with caution. It is dangerous to make assumptions, and it is vitally important that you should either be familiar with the product that you are working on, or have to hand the necessary data that relates to the product. Figure 2.10: A typical Injector for a multiple-point injector system OLADEJI ADEOLA .I. 100403071 Page | 22 SIWES TECHNICAL REPORT CHAPTER 3 Repair and Maintenance Processes Electrical systems are complex, and some problems, like issues with the onboard computer, may need to be serviced at a repair shop or dealership.. 3.0 SAFETY INFORMATION Working with the electrical system in a vehicle is generally quite safe. Automotive electrical systems run at 12V, which does not pose a danger of shocks or electrocution. However, many electrical components are easily damaged, so care should be taken when handling them. Introducing incorrect voltages or currents can break many systems. One part of the electrical system that is potentially dangerous is the high-voltage side of the ignition coil, which should not be serviced while power is applied. Additionally, electric or hybrid-electric vehicles use many high-voltage batteries and powertrains, which are dangerous and potentially fatal if mishandled. 3.1 TOOLS REQUIRED The simplest tool that can be used in electrical diagnosis is 12 volts test light.. This light can be used to check if power is being received at any point in a circuit, which can be handy for simple or quick tests. However, test lights do not provide very much information. A digital multimeter or DMM, has two probes that can be connected to a circuit to test voltage, amperage, resistance, continuity, and more. With a DMM, most electrical problems can be diagnosed. Basic electrical and automotive tools, such as wire cutters, wrenches, and screwdrivers, are used to service automotive electrical systems. Figure 3.0: Some tools Used. OLADEJI ADEOLA .I. 100403071 Page | 23 SIWES TECHNICAL REPORT 3.2 CHECKING THE BATTERY Battery problems are the most common cause of electrical issues in vehicles. To test a battery, connect a multi-meter in voltage mode across the terminals of the battery. A fully charged battery should read 12.6V, while a halfway-charged battery will be around 12.4V. A battery that shows 0V is dead and needs to be charged. One common problem is loose or corroded connections at the battery post, which can cause intermittent problems or prevent starting. Cleaning the posts and connections with a wire brush and tightening them will solve these problems. A battery that frequently goes dead might simply be old, and can be tested at an auto-parts store. A good battery that still goes dead is an indication of an electrical problem. With the car off, disconnect the negative battery cable and connect the multi-meter in amperage mode in between the negative battery post and the cable. A reading of more than 50mA indicates a parasitic load somewhere in the system that is draining the battery. Disconnect fuses one by one from the fusebox while checking the reading. When the system that is draining the battery is disconnected, the multimeter reading will drop to below 50mA. Figure 3.1: Inspecting the battery voltage OLADEJI ADEOLA .I. 100403071 Page | 24 SIWES TECHNICAL REPORT 3.3 GROUNDING PROBLEMS Another common problem in automotive electrical systems is improper grounding connections. In a vehicle, the metal body of the car serves as a ground, and connects each component back to the negative post on the battery. Each component and system is connected to by a grounding connector, which is generally an O-ring connected to a screw post. Vibration from driving can cause these connections to become loose over time, which opens the circuit, causing failure or intermittent issues. Cleaning and tightening these connections solves most grounding issues. 3.4 CHECKING AND REPLACING FUSES/RELAYS If a system, such as the radio or headlights, suddenly stops functioning, it is likely that a fuse has blown. Fuses are located at the fuse box, underneath the dash on the driver’s side, or in the power center under the hood. Each should have a diagram showing which fuse goes with which system. Fuses protect electrical systems and components by opening when too much current is flowing in the circuit. When a fuse blows, the wire connecting each side burns open, disconnecting the circuit. Replacing blown fuses with a new fuse of the same amperage rating reconnects the circuit. If a fuse has blown, it is likely that the problem is a short or overload in the circuit or component the fuse is protecting. If this is the case, replacing the fuse only fixes the problem temporarily. Figure 3.2: Engine Fuse/Relay Box OLADEJI ADEOLA .I. 100403071 Page | 25 SIWES TECHNICAL REPORT 3.5 LOW VOLTAGE Dim headlights, slow starting, and other problems of degree are usually due to low voltage. Under voltage occurs when a component is still receiving power, but not at the voltage it requires for proper operation. Under voltage is usually caused by a connection, switch, or ground wire using, or dropping, more voltage than it should. Ideally, these circuit components should have zero resistance and thus drop no voltage, but in reality, each component drops a small amount. In proper condition, these voltage drops are small, and do not add up to a significant problem. However, corroded connections, undersized wires, worn-out switches, and other problems can quickly add up to an under voltage situation. Test voltage drop by placing the probes of a multimeter on either side of a component. Figure 3.3: Checking the Voltage Drop. OLADEJI ADEOLA .I. 100403071 Page | 26 SIWES TECHNICAL REPORT The following table describes the maximum acceptable voltage drops for automotive electrical system components. Component Max. Acceptable Voltage Drop Connection 0.00V Wire or cable 0.20V Switch or relay 0.3V Ground connection 0.10V Table 2: Maximum acceptable voltage drops for automotive electrical system If voltage drops exceed these levels, the component needs to be repaired or replaced. For connections and grounds, this is usually as simple as cleaning them with a wire brush and securing. Wires that drop voltage are usually worn out, corroded, or undersized for their application. Switches and relays that drop voltage generally need to be replaced. 3.6 USING DIAGNOSTIC MACHINES I was responsible for checking faulty indicated light on the instrumental meter (i.e. cluster) and using Techstream software, Intelligent Tester II or AutoBox machine to diagnose the faulty indicated light, depending on the model of light Truck vehicles that came into the workshop. I learnt how to use the diagnostic machine listed above to diagnose both mechanical and Electrical trouble codes and also using ALLDATA repair manual to interpret the trouble codes I also learnt how to Program Electrical control unit (ECU) using Techstream software and Intelligent Tester II after replacing it. After Overhauling of engines or servicing of Vehicles, the Diagnosis Technician is responsible for clearing the maintenance and malfunction light on cluster I zero point calibration using Intelligent Tester II, after changing the ABS (anti-lock braking system) Master. I did Diagnosis on VSC light showing on cluster (Instrumental panel). Using IT2 machine. OLADEJI ADEOLA .I. 100403071 Page | 27 SIWES TECHNICAL REPORT Figure 3.4: Diagnosing Process Figure 3.5: Display of Trouble codes IT2 machine Figure 3.6: AUTOBOSS machine Figure 3.7: Techstream software OLADEJI ADEOLA .I. 100403071 Page | 28 SIWES TECHNICAL REPORT 3.7 The ‘Six Steps’ Approach. At this stage it is important to emphasize the need to be methodical. A simple, but effective approach to diagnostic work is known as the ‘six-steps’ approach. This six-step approach may be recognized as an organized approach to problem solving, in general. As quoted here it may be seen that certain steps are recursive. That is to say that it may be necessary to refer back to previous steps as one proceeds to a solution. Nevertheless, it does provide a proven method of ensuring that vital steps are not omitted in the fault tracing and rectification process. The six steps are: 1. Collect evidence; 2. Analyze evidence; 3. Locate the fault; 4. Find the cause of the fault and remedy it; 5. Rectify the fault (if different from 4); 6. Test the system to verify that repair is correct Skills acquired for effective diagnosis The skills I learnt has vehicle technicians, during diagnostic work on vehicle electronic systems, consist of many elements. The most important of these may be classed as ‘key skills’. These key skills may be summarized as follows. Use of appropriate ‘dedicated’ test equipment effectively. Make suitable visual inspection (assessment) of the system under investigation. Make effective use of wiring diagrams. Use of instruction manuals effectively. Use multimeters and other (non-dedicated) equipment effectively. Interpret symptoms of defective operation of a system and, by suitable processes, trace the fault and its cause. Work in a safe manner and avoid damage to sensitive electronic components. Fit new units and make correct adjustments and calibrations. Test the system, and the vehicle for correctness of performance OLADEJI ADEOLA .I. 100403071 Page | 29 SIWES TECHNICAL REPORT CHAPTER 4 4.0 WORK EXPERINCED IN I.T. DEPARTMENT For the Last month of my industrial training at Germaine Auto Center I was Transfer to Information technology Department. In IT department I was basically involved in providing the infrastructure for automation, the governance for the use of the network and operating systems, and assistance in providing the operational units the functionality they need. 4.1GOVERNANCE: Providing the operating parameters for individuals' and operating units use of the IT systems, networks, architecture, etc. (This includes responsibility for conventional IT security and data assurance). 4.2 INFRASTRUCTURE: Providing the operating network and circuitry and all equipment needed to make the IT system work in accordance with an established operating standard and system "size." 4.3 FUNCTIONALITY: Providing the capacity for operating applications development, storing and securing the electronic information the organization owns, and providing direct operating assistance in software use and data management to all functional areas in the organization. OLADEJI ADEOLA .I. 100403071 Page | 30 SIWES TECHNICAL REPORT Figure 4.0: backing up the company’s document for the day. I also Learnt how to troubleshoot PC (Personal computer) and Laptops that’s not working . Figure 16: PC troubleshooting process. 4.4 OVERVIEW OF SYSTEM UNIT Figure 4.1: System Unit The System unit is the main component of a PC which houses other devices necessary for other devices to function. It is comprised of chassis and the internal component of a PC such as motherboard, processor, memory module, disk drive, ISA and PCI slots, cooling devices and port for connecting external devices. OLADEJI ADEOLA .I. 100403071 Page | 31 SIWES TECHNICAL REPORT Motherboard Layout Motherboard or system board is a printed circuit board that serves as the backbone to the entire computer system. It houses the processor, memory and expansion slots. The type of motherboard has a great effect on system speed and upgrade capability. Figure 4.2: Motherboard S/n 1 2 3 4 5 6 7 8 9 10 Component ISA expansion slots(2) PCI expansion slots(3) PCI Express expansion slots Audio Ports(Speaker and Microphone Parallel and serial I/O ports USB ports PS/2 ports ROM BIOS chip CMOS battery SATA connector S/n 11 12 13 14 15 16 17 18 Component PATA Hard disk Connector Floppy disk connector ATX power connector DIMM system memory slots CPU LGA socket CPU voltage regulators Chipsets Chipset under heat sink Table 3: Motherboard components. System clock System clock synchronizes the operation of all part of the PC and produce a basic timing signal for the CPU. Clock speed are measured in Megahertz (MHz) or gigahertz (GHz). Memory PC memory can be categorized as RAM or ROM, each of which perform different functions within the PC. A motherboard will generally have between 2 and 4 slots for installation of system RAM. It also houses a ROM BIOS chip. Types of Memory System RAM System ROM OLADEJI ADEOLA .I. 100403071 Page | 32 SIWES TECHNICAL REPORT System RAM Random Access Memory (RAM) is the working memory of the PC. Program code is loaded into RAM so that it can be accessed and executed by the processor. RAM also holds data (for example, the contents of a spreadsheet or document), while it is being modified. System RAM is normally DIMMs (Dual-in-line memory modules) memory modules fitted to motherboard sockets. Types of RAM Dynamic Random Access Memory (DRAM) Static Random Access Memory (SRAM) Figure 4.3: RAM Dynamic Random Access Memory DRAM is used as the main or system memory of a PC. It stores the operating system, application programs, and data while they are running. DRAM stores each data bit as an electrical charge within a single bit cell. A bit cell consists of a capacitor to hold a charge (the cell represents 1 if there is a charge and 0 if there is not) and a transistor to read the contents of the capacitor. Static Random Access Memory (SRAM) Static RAM stores data in an electronic circuit called a flip-flop. SRAM is approximately four or five times faster than DRAM. OLADEJI ADEOLA .I. 100403071 Page | 33 SIWES TECHNICAL REPORT CHAPTER 5 OBSERVATIONS AND CONTRIBUTIONS 5.0 OBSERVATIONS - As a student my first observation was the cognition of the difference between the school environment and the labour market, as it is a different ball game entirely. - I also observed that safety was paramount and it could easy be seen as the primary goal of every staff of the company and not only the technicians. As safety equipments and instructions were always put in place or made available at strategic locations within the company. From the workshop to the service desks to the customer care centres to the offices to the receptions. Figure 5.0: Caution Sign - Neatness was also a key attribute as even though the job is usually seen as a dirty job, technicians were always admonished to be as neat as possible in their dressing and in carrying out their duties. This was further encouraged by rewarding technicians that could fully adhere to this. - The hospitality shown to customers was of another level as customers were treated with so much care and respect. From provision of free breakfast and lunch, to a brief internal training, to free medical checkup the customers were always made to feel at ease. - From internal training given by the HSE department to external training at companies like Mandilas and TNL (Toyota Nigeria Limited). Training was made an integral part of the company policy as it was made compulsory for every of the company’s personnel especially the workshop staff, and on occasions of external training the participants were tested and certified after successful testing. OLADEJI ADEOLA .I. 100403071 Page | 34 SIWES TECHNICAL REPORT - Communication played a vital role in the successful execution of jobs, from among personnels in a section to departments communicating with other departments present in the company and also customers with company’s personnel. Good flow of information was required and as a result most jobs that were returned or problematic, come about as a result of poor communication between parties. 5.1 CONTRIBUTIONS My contributions were shown in my work done and services given as a Diagnosing / Electrical technician in the company, which was basically diagnosing and repair of electrical components of automobiles. I majorly help in tracing the electrical fault using the vehicle manual’s to read the electrical circuit and also I was able to maximize the job efficiency and work output in my section, because after a couple of months my section supervisor gave me the access to work directly with the spare parts and material store department, thereby speding up the job completion process, as he wasn’t always around to attend due to official reasons. I was also able to revive the job registration process as it was slightly overlooked prior to my attachment because of the magnitude of work in the section, but after successfully reviving it, it became useful in double-checking the vehicles that came into the section and technicians that worked on them. 5.2 RELEVANCE OF EXPERIENCE GAINED TO CLASSROOM KNOWLEDGE The relevance of the experience gained can be linked to the following courses; EEG 201 FUNDAMENTALS OF ELECTRICAL ENGINEERING EEG 203 SIGNALS & SYSTEMS THEORY EEG 205 – PHYSICAL ELECTRO.ICS EEG 204 SWITCHING AND LOGIC SYSTEMS EEG 305 ELECTRONIC CIRCUITS 1 EEG310 ELECTRICAL DRIVE EEG308 POWER ELECTRONICS EEG307 INSTRUMENTATION AND MEASUREMENT 1 EEG314 LOGIC DESIGN OF DIGITAL SYSTEMS EEG 411ELECTRICAL MACHINES THEORY EEG403 COMMUNICATION SYSTEMS EEG405 CLASSICAL CONTROL SYSTEM ANALYSIS. OLADEJI ADEOLA .I. 100403071 Page | 35 SIWES TECHNICAL REPORT CHAPTER 6 CONCLUSION AND RECOMMENDATION 6.0 CONCLUSION My 6 months industrial attachment as a junior technician at Germaine Auto Centre was a huge success and a great time of acquisition of knowledge and skills. Through my training I was able to appreciate my chosen course of study even more, because I had the opportunity to blend the theoretical knowledge acquired from school with the practical hands-on application of knowledge gained here to perform very important tasks that contributed in a way to my productivity in the company. My training here has given me a broader view to the importance and relevance of Electrical / Electronics Engineers in the immediate society and the world as a whole, as I now look forward to impacting it positively after graduation. I have also been able to improve my communication and presentation skills and thereby developed good relationship with my fellow colleagues at work. I have also been able to appreciate the connection between my course of study and other disciplines in producing a successful result. 6.1 RECOMMENDATION I use this means to make the following recommendations concerning the training of students in Industrial Attachments. i. I would like to recommend that the Engineering curriculum in the University of Lagos be adjusted such as would provide going on industrial attachments for a longer period of time as opposed to 6 months or making the program to occur twice throughout an engineering degree program. ii. Allowances should be paid to students during their programme just like NYSC and not after. This would help them a great deal to handle some financial problems during their training course. 6.2 CHALLENGES ENCOUNTERED DURING PERIOD OF TRAINING I wasn’t allowed to drive cars after repair. So I could not do active test using Diagnostic machines on my own. And I was not allow to go out to repair car. I was restricted to the workshop. OLADEJI ADEOLA .I. 100403071 Page | 36 SIWES TECHNICAL REPORT REFERENCES “Guide to successful participation in SIWES” by Engr. Olusegun A.T Mafe, 2009 Company Profile. Germaine Auto Centre. Retrieved from www.germaineng.com/newsite APPENDIX ECU ECM ABS TCS VSC IT2 OLADEJI ADEOLA .I. Electrical Control Unit Electrical Control Module Anti- Lock Braking System Traction Control System Vehicle Stability Control Intelligent Tester II 100403071 Page | 37