TECHNICAL AND PRODUCTION ANALYSIS OF AUTOMOBILES

A PROJECT REPORT
Submi ed in par al ful lment of the requirement.
for the award of the degree of
BACHELOR OF TECHNOLOGY (B.Tech)
in
Mechatronics Engineering
by

Arjun Rana

Reg. No. 209403070

Department of Mechatronics Engineering

MANIPAL UNIVERSITY JAIPUR
JAIPUR-303007
RAJASTHAN, INDIA

June, 2024
tt
ti
fi
 DEPARTMENT OF MECHATRONICS ENGINEERING
MANIPAL UNIVERSITY JAIPUR, JAIPUR – 303 007 (RAJASTHAN),
INDIA

30th May, 2024

CERTIFICATE

This is to certify that the project titled TECHNICAL AND PRODUCTION

ANALYSIS is a record of the bonafide work done by ARJUN RANA (209403070)
submitted in partial fulfilment of the requirements for the award of the Degree of
Bachelor of Technology (B.Tech) in Mechatronics Engineering of Manipal University
Jaipur, during the academic year 2023-24.

Dr. Ajay KUMAR

Project Guide, Dept of Mechatronics Engineering
Manipal University Jaipur

Dr. Shahbaz Ahmed Siddiqui

HOD, Dept of Mechatronics Engineering
Manipal University Jaipur
 ACKNOWLEDGMENTS

I express my heartfelt gratitude to the following individuals for their invaluable contribution towards the
successful completion of my internship on the Technical and production analysis of automobiles
internship.

I would like to acknowledge Professor H C Shivaprasad, the Director of the School of Automobile,
Mechanical and Mechatronics Engineering, and Professor Shahbaz Ahmed Siddiqui, the Head of
Department for the Department of Mechatronics Engineering at Manipal University Jaipur, for their
mentorship and expert guidance that have been instrumental in shaping my technical knowledge and
skills. I am also grateful to Dr. Ajay Kumar, Professor & Director (Academics) in the Department of
Mechatronics Engineering at Manipal University Jaipur, for his invaluable guidance and support as my
Project Guide and Academic Mentor, and Dr. Krishna Kant Pandey, Assistant Professor in the
Department of Mechatronics Engineering at Manipal University Jaipur, for his role as the Project
Coordinator. Their support and guidance have been crucial in ensuring the project's smooth progress and
successful completion.

I would also like to express my heartfelt appreciation to the team at Morris Garages in Meerut for their
support and guidance throughout the project. I am especially grateful to Mr. Alok Kumar, Head Manager
in the company, for his constant guidance and support throughout the project, and Mr. Sanjeev Kumar,
Technical Manager, for their invaluable insights and encouragement during the project's execution. Their
contributions have been instrumental in shaping my technical knowledge and skills.
 ABSTRACT

As an intern our job was to diagnose the MG Gloster model for the first month. For every model that is
running on the road whether ICE or EV a different software is present because the configurations present in
every model is different and so are the sensory modules therefore the project for the first two months was
about learning all the software usage in all the models, the sensory modules and sensors present inside the
vehicle as well as to study their wiring and circuit diagram to understand the usage of the sensors and their
functionality in a better way.

This report contains all the different kinds of sensors present in MG Gloster variant, their location with
wiring diagram. All the different kind of sensors present inside any automobile works in combination with
each other to maintain smooth functioning of that vehicle some vehicles have very limited sensors present
whereas some have installed plethora of sensors that even their repairing or any kind of repairing to be
done inside that automobile requires a brief diagnosis through software. A tiny or slightest kind of problem
also requires diagnosis because those plethora of sensors present works with each other in a systematic way
and are present at every location to detect any kind of slightest of problem.

Understanding the wiring diagrams and circuit integration of the sensors in the MG Gloster was crucial for
diagnosing and repairing the vehicle. Each sensor, whether monitoring engine parameters, safety systems,
or driver assistance features, communicates with the ECU (Engine Control Unit) through an extensive
network of wires and connectors. This intricate and systematic circuit ensures that data from various
sensors is accurately relayed to the ECU, enabling real-time monitoring and precise control of the vehicle's
systems. Proper interpretation of these wiring diagrams and understanding the circuit integration not only
facilitates efficient troubleshooting but also ensures that repairs and maintenance tasks are performed with
high accuracy, thereby maintaining the vehicle's performance and reliability.

Following the initial diagnostic phase, the next task was to enhance the productivity of the workshop,
specifically targeting vehicle servicing and body shop painting departments. To achieve this, we conducted
a comprehensive analysis of the current processes, identifying inefficiencies and bottlenecks. Ground
reality data was meticulously gathered through observations, staff interviews, and performance metrics.
Based on these insights, we implemented several strategic measures, including the installation of advanced
diagnostic tools, automated painting systems, and reorganized workflows. These initiatives aimed to
streamline operations, reduce downtime, and improve overall service quality, ultimately boosting the
efficiency and productivity of the workshop.
 LIST OF TABLES
Table Table Title Page No
No

LIST OF FIGURES
Figure Figure Title Page No
No
 Content
s Page
Acknowledgement Noi
Abstract ii
List of Figures iii
List of Tables vi
Chapter 1 INTRODUCTION
1.1 Introduction to work done/ Motivation (Overview, Applications & Advantages)
1.2 Project Statement / Objectives of the Project
1.3 Organization of Report
Chapter 2 BACKGROUND MATERIAL
2.1 Conceptual Overview (Concepts/ Theory used)
2.2 Technologies Involved
.
.
.
Chapter 3 METHODOLOGY
3.1 Detailed methodology that will be adopted
3.2 Circuit Layouts / block diagrams

.
.
.
Chapter 4 IMPLEMENTATION
4.1 Modules
4.2 Prototype
.
.
.
Chapter 5 RESULTS AND ANALYSIS
.
.
.
Last CONCLUSIONS & FUTURE SCOPE
Chapt
5.1 Conclusion
5.2 Future Scope of Work (at least 3 points)
REFERENCES
ANNEXURES (OPTIONAL)
 INTRODUCTION
1.Overview

The software that was used in the vehicles was very informative and took time to learn, to fully
understand the usage and functionality of software understanding the wiring diagrams and
circuit integration of the sensors in the MG Gloster was crucial for diagnosing and repairing the
vehicle and not only that but to study the functionality of every sensor also helped in
understanding the working and functionality of the vehicle better. During my internship at
Morris Garages, I had the opportunity to work on with industry technical experts who guided me
with the usability of the software and the next task was to enhance the productivity of the
workshop, specifically targeting vehicle servicing and body shop painting departments. To
achieve this, we conducted a comprehensive analysis of the current processes, identifying
inefficiencies and bottlenecks.

1.1.Applications of Automobile sensors:

Automobile sensors can also be used in different industries

1.1.1.1 Industrial Machinery:

Sensors can monitor machine performance, detect faults, and optimize production
processes in industries such as manufacturing, assembly, and packaging

1.1.1.2 Aerospace and Aviation:

Sensors can track vital parameters like engine performance, temperature,
pressure, and structural integrity to ensure safe and efficient flight operations.

1.1.1.3 Marine and Maritime:

Sensors can collect data on ocean currents, temperature, salinity, and marine life
to support scientific research and environmental monitoring.

1.1.1.4 Healthcare and Medical Devices:

Sensors can monitor vital signs, detect abnormalities, and provide real-time data
for patient care in hospitals, clinics, and home healthcare settings

1.1.1.5 Agriculture and Precision Farming:

Sensors can measure soil moisture, nutrient levels, and crop health to optimize
irrigation, fertilization, and pest control practices in agriculture

1.2.Advantages of automobile sensors:

1.1.2.1 Improved Safety:

Sensors such as radar, lidar, and cameras can detect obstacles, pedestrians, and
other vehicles, enabling advanced driver assistance systems (ADAS) like
automatic emergency braking and collision avoidance.

1.1.2.2 Enhanced Driving Experience:

Sensors monitor the distance to the vehicle ahead and adjust the vehicle's speed
accordingly, providing a more relaxed and comfortable driving experience.
 1.1.2.3 Increased Efficiency:
Sensors such as oxygen sensors and MAF sensors help regulate the air-fuel
mixture, leading to improved fuel efficiency and reduced emissions.

1.1.2.4 Diagnostic Capabilities:

Sensors continuously monitor various vehicle systems and components, allowing
for early detection of issues and providing diagnostic trouble codes (DTCs) to aid
in troubleshooting and repair.

1.1.2.5 IAdvanced Features and Connectivity:

Sensors enable features like touchscreen displays, voice recognition, and
smartphone integration, enhancing entertainment and connectivity options for
drivers and passengers.

In conclusion, my work during the internship involving automobile sensors played a

critical role in modern vehicles, offering a wide range of advantages that contribute to
improved safety, performance, efficiency, and convenience.

1.2 Project Objectives

The primary objective of the internship project is twofold:

1. Diagnose/Study/analyse MG Gloster Model: The foremost goal is to thoroughly

diagnose the MG Gloster model during the initial month of the internship. This entails
gaining an in-depth understanding of the vehicle's software systems, sensory modules,
and sensors, both in terms of their functionality and their integration within the vehicle's
framework. This includes studying the wiring and circuit diagrams to comprehend the
interplay between sensors and their contribution to the overall functioning of the vehicle.

2. Enhance Workshop Productivity: Following the diagnostic phase, the subsequent task
over the next two months is to focus on increasing the productivity of the workshop in
two key departments: vehicle servicing and body shop painting. This involves gathering
comprehensive data on the current operational realities of the workshop, identifying
areas for improvement, and implementing measures to optimize productivity. By
leveraging engineering solutions, such as the installation of new machines and
technology, the aim is to streamline processes, reduce downtime, and enhance overall
efficiency in both servicing and painting departments.

Overall, the project aims to blend theoretical understanding with practical application,
with the overarching goal of contributing to the operational excellence of the workshop
while simultaneously deepening the intern's knowledge and skills in automotive
diagnostics and engineering solutions.
1.3 Organization of Report

This report is organized into several chapters, each detailing different aspects of the project
undertaken during my internship at Morris garages. The structure is designed to provide a
comprehensive understanding of the project, from the initial motivation to the final
implementation and results. Below is an outline of the report:

1.3.1. Introduction:
At Morris Garages, my internship revolved around two pivotal objectives: diagnosing the
MG Gloster model and boosting workshop productivity. The MG Gloster, a flagship
model, symbolises luxury and cutting-edge technology. Understanding its sensory
modules and software systems was paramount to this endeavour. Simultaneously, the
focus was on enhancing workshop efficiency. Through strategic initiatives and
technological advancements, the aim was to optimise vehicle servicing and body shop
painting departments. This report encapsulates the journey towards achieving these
objectives, blending diagnostics with operational excellence for a transformative impact
on Morris Garages' operations.

1.3.2 Background Material:

Vehicle diagnostics are paramount in ensuring vehicle safety, performance, and customer
satisfaction. By identifying issues early on, diagnostics prevent accidents, enhance
engine performance, and minimize repair costs, ultimately boosting customer confidence.
Similarly, workshop productivity plays a pivotal role in the automotive industry,
facilitating efficient repairs, reducing waiting times, and optimizing resource utilization.
Efficient workshops not only increase profitability through cost savings but also enhance
the organization's reputation and market competitiveness by offering high-quality
services and attracting more customers. Overall, vehicle diagnostics and workshop
productivity are essential components of the automotive ecosystem, ensuring both
operational efficiency and customer satisfaction.

1.3.3 Methodology:
The methodology chapter details the systematic approach taken to employed for
diagnosing the MG Gloster model, including data collection methods, software learning
processes, and sensor analysis techniques.The approach taken to gather ground reality
data for identifying areas of improvement in workshop productivity and the steps
involved in implementing measures to increase productivity, such as installing new
machines and technology

1.3.4 Implementation:
This chapter provides an in-depth description of implementation and installation of new
technologies used to enhance the productivity of workshops, as well as learning process
for understanding software usage, sensory modules, and sensors in various MG
automobile models.

1.3.5 Results & Analysis:

In this chapter, the outcomes of the project are presented, how much the productivity of
the workshops also discussion on the effectiveness of the strategies employed and their
implications for workshop operations increased and by how much and the findings
obtained through software usage, sensory usage and sensory functionality as well as its
resolution given.
1.3.6 Conclusions:
The conclusions chapter summarises the key findings from the MG Gloster diagnostics and
workshop productivity enhancement efforts also reflecting on the overall outcomes of the
internship project and its contribution to Morris Garages and recommendations for future
research and initiatives aimed at further improving workshop productivity and automotive
diagnostics.

1.3.7 References & Annexures:

This chapter includes all supplementary materials that support the main content of the report. It
comprises a comprehensive list of references cited throughout the report, ensuring proper
attribution of sources.

BACKGROUND MATERIAL

2.1 Conceptual Overview

In the automotive industry, vehicle diagnostics and workshop productivity are fundamental
pillars that ensure operational efficiency, customer satisfaction, and business success. Vehicle
diagnostics play a critical role in identifying potential issues with vehicles, ranging from
mechanical failures to performance inefficiencies and emissions problems. By diagnosing these
issues early on, automotive technicians can address them promptly, enhancing vehicle safety,
reliability, and overall performance. This not only improves customer satisfaction but also
reduces repair costs and minimises vehicle downtime, leading to increased profitability for
automotive service providers. Similarly, workshop productivity is essential for streamlining
repair and maintenance processes, reducing waiting times, and optimising resource utilisation.
Efficient workshops not only enhance customer experience by providing quick and reliable
service but also contribute to the organisation's bottom line by minimising overhead costs and
maximising revenue-generating opportunities. Overall, vehicle diagnostics and workshop
productivity are integral components of the automotive industry, ensuring smooth operations,
customer loyalty, and sustainable growth.

Beyond its aesthetic appeal and advanced features, the MG Gloster is powered by a range of
robust engine options, delivering impressive performance and efficiency. Whether it's the refined
diesel engine or the electrifying hybrid powertrain, the Gloster promises a dynamic driving
experience coupled with exceptional fuel economy understanding the sensory modules and
software systems of the MG Gloster holds paramount importance in unlocking its full potential.
These systems form the backbone of the vehicle's operation, facilitating crucial functions such as
engine management, safety protocols, and connectivity features. By delving into the intricacies
of its sensory modules and software systems, automotive technicians can diagnose issues
accurately, optimise performance, and ensure a seamless driving experience for Gloster owners.
Moreover, a deep understanding of these systems enables technicians to stay abreast of
technological advancements and provide comprehensive maintenance and support services,
thereby enhancing customer satisfaction and loyalty.

The challenges faced in increasing the productivity of workshop in servicing and body shop
painting department were the lack of assessment of vehicles with respect to the skill level of the
technician in accordance with the problem occurring in the vehicle.
2.2 Technology Used

2.2.1 Hardware:
1. Pneumatic Air pressure machine
2. Hydraulic lifts
3. Pneumatic spray paint gun
4. Electrostatic Sprayers
5. Airless Sprayers
6. Infrared (IR) Dryers
7. Ultraviolet (UV) Curing Systems
8. Pixel paint technology

2.2.2 Software:
1. SAIC Grade X software
 METHODOLOGY

3.2 Sensors report

3.2.1Gateway Module
Gateway module is the communication module present inside every vehicle
MG that communicates with all the different modules present inside at
different locations inside the vehicle which are in return connected to their
respective sensors. Lets look at different kinds of sensors connected with all
the modules present inside.

3.2.2Engine Control Module

An ECM also called as Engine control unit (ECU) is a computerised system
that manages, controls and ensures smooth engine functioning with the help
of sensors present inside it.

1. Camshaft Sensor

The camshaft sensor is used to detect the position of the camshaft. It

is used together with the crankshaft sensor to judge the cylinder and
determine the injection time.

Fig.1 Camshaft Sensor wiring diagram

2.Crankshaft Sensor
Fig.2: Crankshaft sensor
The crankshaft sensor is used to calculate
engine speed and crankshaft position. This sensor can also be used in
other speed detection systems (e.g., gear and engine speed sensors)

3. Barometric Sensor
 The barometric
pressure sensor is
integrated in the
electronic control
unit (ECU). Its signal
is used in some
closed-loop control

Fig.2.1: Crankshaft sensor wiring

diagram

Fig.3: Barometric Sensor

systems (such as boost pressure control) which adjust
set values based on altitude, thus allowing the system to
adjust its operations according to different altitudes. The barometric
pressure sensor measures absolute pressure.

4 .

Fig.3.1:Barometric Sensor wiring diagram

4.Coolant Temperature Sensor

The coolant temperature sensor is installed in the
coolant circulation loop, which indicates the engine
temperature through measuring the coolant
temperature. The coolant temperature signal can be
used for cold start and fan control, etc.

Fig4: Coolant
Temperature sensor

Fig.4.1 : Coolant temperature sensor wiring

diagram
5. Exhaust Temperature Sensor
DPF after treatment system is equipped with
two exhaust temperature sensors, one is installed
in the upstream of DOC, and the other is
installed in the upstream of DPF. The exhaust
temperature sensor is used to detect the exhaust
temperature and feed back the voltage signal to
ECU. ECU monitors and controls the exhaust
temperature at the time of DPF regeneration
according to the two exhaust temperature
signals. Fig.5: Exhaust temperature
sensor

6. DPF Differential Pressure Sensor

DPF differential pressure sensor is used to measure the pressure
difference before and after DPF, the differential pressure is converted into
voltage signal and sent to ECU. ECU detects whether DPF is blocked or
removed based on the differential pressure signal.

Fig.6: DPF wiring diagram

7. Low pressure EGR differential pressure sensor

Differential pressure sensor is a sensor
designed to accurately control the
"regeneration" triggering time. Differential
pressure sensor sends the differential
pressure signals to ECU by measuring the
pressure difference between the front and
rear channels of the collector, and the ECU
will determine the accumulation of the
particles in the collector, so as to determine
the "regeneration" triggering time and
additional fuel injection amount. ECU may
Fig7: Low-pressure EGR
also increase the exhaust gas temperature
by controlling the opening of EGR valve differential Pressure Sensor
and electronic throttle.
8. High-pressure EGR Temperature Sensor

EGR temperature sensor detects the temperature of the exhaust gas

recycled in EGR system, ensures the normal operation of system, and
reduces the content of NOx and S compounds as well as other harmful gas
in the exhaust.

Fig.8: High-pressure EGR

temperature sensor

9. Low-pressure EGR Temperature Sensor

EGR temperature sensor detects the

temperature of the exhaust gas
recycled in EGR system, ensures the
normal operation of system, and
reduces the content of NOx and S
compounds as well as other harmful
gas in the exhaust.

Fig.9: Low-pressure EGR temperature

sensor

10. Intercooler Rear intake temperature sensor

Intercooler intake temperature sensor is a negative temperature coefficient

thermistor. When the temperature increases, the resistance value will
decrease; and when the temperature decreases, the resistance value will
increase. With the changes of the circuit resistance, the voltage changes,
generating different voltage signals, to complete the automatic operation
of control system. When the vehicle is in cold state, the signals of intake
temperature sensor are basically the same as
those of engine water temperature sensor. When
the vehicle is in hot state, its signal voltage is
about 2~3 times of water temperature sensor.
The low-pressure intercooler intake temperature
sensor converts the air intake amount and
pressure information into electrical signals, and
input them to ECU for calculation, so as to
determine the fuel injection advance angle, fuel
injection time and amount. Fig.10 : Intercooler rear intake
temperature sensor
 11. Turbocharger Front Exhaust Temperature Sensor

Turbocharger front exhaust temperature sensor detects the exhaust

temperature, and provides it to ECU as the reference for calculating the
air density.

Fig.11:Turbocharger Front Exhaust

Temperature Sensor
12. Intercooler Temperature Sensor

This temperature sensor is located on

the intercooler intake pipe at the back of the intercooler. It monitors
the air temperature/density, which affects the fuel mixture

Fig.12 : Intercooler
temperature sensor
Fig.12.1 : Intercooler Temperature Sensor

13. Urea tank level temperature sensor

Urea Temperature Sensor is used to

measure the temperature of the Urea liquid
used in the Selective Catalytic Reduction
(SCR) systems.

P12: Urea tank level

temperature sensor
 P12.1 Wiring diagram

14. DOC Upstream Temperature Sensor

A temperature sensor rationality control system for an exhaust

treatment system having an oxidation catalyst includes an oxidation
catalyst inlet temperature sensor that generates an inlet temperature
signal and an oxidation catalyst outlet temperature sensor that
generates an outlet temperature signal. A control module determines
whether a difference based on the inlet temperature signal and the
outlet temperature signal is below a difference threshold when an
exhaust temperature is within a threshold range.

Fig.14.1: Wiring diagram of the sensor

Fig.14: DOC upstream Temperature
sensor
15. DPF Upstream Temperature Sensor

It detects the temperature in front of the diesel particulate filter and

sends this as a voltage signal to the engine control unit.

Fig.15

Fig.15.1: Wiring Diagram of DPF upstream sensor

 16. Ambient Temperature Sensor

It measures the temperature outside the passenger compartment and

is usually mounted inside or near the front bumper.

Fig.16.1: Ambient Temperature sensor wiring Fig.16: Ambient Temperature Sensor

diagram

17. Front Boost Temperature Sensor

The boost pressure sensor with temperature sensor is installed in the

air inlet pipe ("inlet manifold") between the turbocharger and engine,
and measures the absolute pressure. Additional consideration for the
intake air temperature allows more accurate measurement of the
intake air mass.

Fig.17.1: Wiring Diagram front boost temperature sensor

Fig.17: Front boost

temperature sensor
 18. Intake Air temperature sensor

The Air Intake Temperature Sensor determines the temperature of the

outside air entering the engine.

Fig.18: Wiring Diagram of Intake Air Temperature Fig.18.1: Intake Air

sensor temperature sensor

19. PM Sensor

This sensor is used to monitor the function of the diesel particle filter
(DPF) and helps reduce particulate emissions by up to 99 %.The
functional principle behind the particulate matter sensor is based on
resistance measurement. Soot particles are deposited on an electrode
structure and form conductive soot trails between the electrodes.

Fig.19 : PM sensor
Fig.19.1: PM sensor wiring diagram

\
 20. Rail Pressure Sensor

The rail pressure sensor is used to measure the actual pressure in the
high pressure rail of the high pressure common rail system. The rail
pressure sensor converts pressure signal into voltage signal and
sends it to the electronic control unit (ECU), so as to achieve closed-
loop control of fuel pressure.

Fig.20.1: Rail Pressure Sensor wiring diagram

Fig.20: Rail Pressure

sensor

21. Boost pressure sensor

Boost pressure sensors are used in turbocharged engines to provide

air pressure information and air and fuel ratios in order to regulate
engine performance.

Fig.21.1: Boost pressure sensor wiring diagram

Fig.21: Boost Presssure Sensor
 22. HFM Sensor

The sensor is heated up to a constant temperature of around 120 to

180 degrees, depending on the vehicle. The intake air flowing by
cools the hot-film sensor. The heating current required to heat the
sensor back up to the original temperature can then be used to
determine the air mass taken in.

Fig.22.1: HFM sensor wiring diagram Fig.22: HFM sensor

23. Water in Fuel Sensor

The purpose of the sensor is to detect the presence of water in diesel

fuel. The sensor is mounted inside of the fuel filter and has two main
output signal stages, low level and high level, which identify the
presence and absence of water. The output signal level is changed
when water reaches a defined water level in the fuel filter.

Fig.23.1: Water in fuel sensor wiring diagram

Fig.23: Water in fuel sensor
 P23.3: Main Relay Pin Diagram (Left:
Relay; Right: Relay Socket)

P23.2: Water-in-fuel Sensor Waveform after Just Being

Powered On

24. Fuel Temperature sensor

The fuel temperature sensor is designed to measure the

temperature of the fuel and relay this information to the engine
control unit, so that it can optimise the air to the fuel mix ratio,
depending on the temperature is with respect to the intake air
temperature. The sensor enables the run at maximum
efficiency based on temperature. The more optimised the
combustion process is, the less pollutants that are emitted via
the exhaust system.

Fig.24.1: Fuel temperature sensor wiring diagram

Fig.24: Fuel temperature sensor

3.2.3ABS/ESP Module
1. Brake Pedal Position Sensor

An automobile brake pedal position sensor uses a reed sensor

and magnet to sense the brake pedal motion and disengage
the vehicle's cruise control reliably and engage brake lights so
that vehicles behind can know that brakes of the vehicle have
been applied

Fig.25.1: Brake pedal sensor working

Fig.25: Brake pedal Sensor

2.Yaw Sensor

The yaw rate sensor determines whether the car is developing a

tendency to spin around the vertical axis. It helps the ESP control
unit to determine the current driving-dynamic state of the car.It
measures the vehicle rotary motion around the vertical axis and the
slippage of vehicle and sends corresponding data to SCS ECU. ECU
compares the signals received from the yaw rate sensor and steering
angle sensor, judges the forthcoming situation and then takes
corresponding control.For this purpose, it must be placed close to the
vehicle's centre of gravity hence yaw sensor is under the front
passenger's seat.

Fig.26: Yaw sensor

3. Wheel Speed Sensor

The wheel speed sensors are active sensors (i.e. they receive the power
supply from the ABS regulator), and they transmit the wheel speed signal
to the ABS regulator. The sensors are mounted in each front wheel hub
and each rear wheel hub, and are extremely close to the inner sealing
device of each relevant wheel bearing. Rotating together with the wheels,
the sealing device includes a magnetic element with 48 pairs of magnetic
poles, when the wheels rotate, the magnetic poles in the
sealing device generates voltage fluctuation in the ABS
sensor, the voltage fluctuation is converted into square wave
signal and output to the ABS regulator. The signal
frequency is proportional to wheel speed. In practice, each
ABS sensor has a connecting wire located in the engine
compartment or the chassis, which connects each sensor to
the whole vehicle harness.

Fig.27: Wheel speed

sensor
4. Stroke Speed Sensor

It transmits signals to ABS module and ECM during braking; it is

installed on the brake pedal. The brake pedal position sensor is installed
on the brake pedal bracket, which is used to detect the driver's action on
the brake pedal. The brake pedal position sensor provides an analog
voltage signal for the BCM and ECM, which will increase when the brake
pedal is depressed.

Fig.28: Stroke Speed sensor

5. Steering Angle Sensor

It mainly feeds back the driver's steering information to ESP control module. It is
located over the combination switch below the steering wheel. ESP has the
functions of ABS, EBD, TCS, VDC, EBA, RMI, HAS, AUTO HOLD, ATS and
HDC.

Fig.29: Steering angle sensor

3.2.4Airbag Control Module
1. Airbag Frontal Impact Sensor

The sensor is positioned inside the engine and a

similar safety sensor is located inside the
passenger zone of the vehicle. This safety
sensor is required to measure the intensity of
the collision to determine whether the impact is
over a certain threshold to justify the release of
an airbag.
Fig.30: Front air bag
impact sensor

Fig.30.1: Wiring diagram of frontal impact sensor

2. Airbag Side Impact Sensor

It is placed of the window/door side of the car and works similarly to

the Airbag front impact sensor

Fig.31: Airbag side impact

Fig.31.1: Wiring diagram of Side impact sensor sensor
3.2.5 Body Control Systems
1.Driver Assistant System controller

ADAS (Advanced Driver Assistance Systems) are passive and active

safety systems designed to remove the human error component when
operating vehicles of many types. ADAS systems use advanced
technologies to assist the driver during driving, and thereby improve
drivers’ performance. ADAS uses a combination of sensor
technologies to perceive the world around the vehicle, and then
either provide information to the driver or take action when
necessary.

Fig.32: ADAS wiring diagram

 2. Rain/ Solar sensor

Rain sensor is an advanced driver-assistance

system that detects water on a car's windscreen
and automatically triggers programmed actions.
The main function of this system is activating
windscreen wipers in the rain. But the triggered
actions might also include closing the car's
windows and sunroof.

Fig.33: Rain/solar sensor

3.2.5PEPS

1. Passive Entry Passive start(PEPS)

For vehicles with PEPS, the traditional key is replaced by the smart
key, the operation of PEPS is achieved by LF/ RF (wireless)
communication between the smart key and the vehicle.

Passive entry: No action is required for the smart key. You just need
to take the smart key with you, and you can enter into your vehicle
by simply pressing the button on the door handle and pulling the
handle.

Passive start: Without inserting/pulling out the key, you just need to
put the smart key in the vehicle and press the start/stop button (SSB)
to start/stop the vehicle. The PEPS includes: PEPS ECU, smart key,
interior LF antenna, exterior door handle antenna/switch (HSU) and
rear bumper upholstery LF antenna.

Fig.34: PEPS module/controller

 Fig.34.1: PEPS wiring diagram

2. Tailgate Induction Open Sensor

You can open the trunk door by using your foot and bringing it in the
range of the tailgate sensor

Fig.35: Tailgate sensor

3.2.6 TPMS(Tyre pressure monitoring system)

1. Tire Pressure Sensor

The tire pressure monitoring system uses the tire sensor to monitor
the pressure and/or temperature inside the tire and sends the
pressure and temperature data from the sensor to the receiver in a
form of radio frequency, the receiver data processed transmit the
relevant information to the display (instrument cluster) by the CAN
network, the LCD will display the information and provide acoustic
and icon warnings, etc when abnormal tire pressure or temperature
occurs.

Fig.36: TPMS module

Fig.36.1: TPMS sensor

3.3 Wiring and Circuit diagram

1. Engine bay harness

An engine wiring harness or engine bay harness is an organised set of wires,
cables, connectors and terminals that controls a vehicle's electrical system.

Fig.37: Engine bay harness

2. Instrumental panel harness

The dashboard, with all its indicators and controls, is connected by the instrument panel
wiring harness. It's the communication line, keeping the driver informed.

Fig.38
3.Parking radar harness wiring diagram

Fig.39

4. Body Harness wiring diagram

Fig.40
5. Engine Wiring Harness

Fig.41

Fig.42
6) Starting system circuit diagram

Fig.43
7) Charging System wiring diagram

Fig.44
8. Engine management system Circuit Diagram

Fig.45
9) Occupant information Display system

Fig.46
10. Body control system

Fig.47
11. Theft security system

Fig.48
12. ADAS(advance driver assistant system)

Fig.49
13. On-Board diagnostic system

Fig.50
Fig.51
Fig.52
14. Grounding Distribution

Fig.53
3.4 Production analysis

The objective for the next two months was to enhance the productivity of the workshop,
focusing on two primary departments: vehicle servicing and body shop painting. To
achieve this goal, we conducted a comprehensive assessment of the current operations
and identified areas for improvement. The gathered data and detailed findings are
presented within this report. for that to be done we gathered the data on ground reality of
the place.

3.4.1 Servicing and vehicle management:

To accurately assess the workshop's operations, we examined the ground reality,

which included the existing infrastructure and workflow. The workshop currently
has:
1. 3 bays for repairing, servicing, and testing ICE vehicles.
2. 2 bays dedicated for EV (Electric Vehicle) servicing.
3. 2 bays for body shop operations.
4. 1 bay for alignment and balancing tasks.

Fig.54 :SERVICE BAY 2 Fig.55: SERVICE BAY 1

 Fig.56: EV BAY

3.4.2 Analysis of Monthly Intake and Identified Issues

During the months of February and March, the workshop's monthly

intake was 270 and 240 cars respectively. This data was collected
manually from daily let-in records, resulting in an average intake of 9
cars per day in February and 8 cars per day in March. The reduction
in March was attributed to delays in the car let-out process in

February March April May

400

300
No. Of Cars

200

100

0
Monthy Car Intake
 February, leading to a backlog of pending cars that impacted the
subsequent month's intake. After studying this data over the two-
month period, we developed a solution to address the identified issues
and improve the overall efficiency of the workshop operations.

3.4.3 Body shop production

The body shop is responsible for handling various tasks related to

vehicle wear and tear repairs and re-painting jobs. A critical problem
identified was the unstructured paint booth area, which contributed to
delays in car let-outs. This delay was primarily due to the outdated
technology being used for painting vehicles, specifically the reliance
on refilled system spray guns. This inefficiency caused significant
bottlenecks in the workflow, impacting the overall productivity of the
body shop.

Daily paint job let-in Daily paint job let-out

0
February March April May

The data depicting the number of vehicles brought in for paint work
daily highlights the current productivity and functionality of the paint
jobs being conducted. To address the inefficiencies and improve the
situation, several measures were suggested and implemented. These
actions resulted in an increase in the average daily let-out of vehicles
with completed paint jobs
 IMPLEMENTATION

4.1 Modules

4.1.1Technician Assignment System:

1. Skill Level Classi cation:

Technicians were categorized into three levels:

1.1 L0: Lowest skill ef ciency.

1.2 L1: Intermediate skill ef ciency.
1.3 L2: Highest skill ef ciency.
2. Assignment Board:

2.1 A board was established to assign technicians to vehicles based on the

speci c needs and the technician's skill level.

2.2 This system ensured that more complex tasks were handled by more
skilled technicians (L2), while simpler tasks were assigned to less
experienced technicians (L0).

3. Implementation into Software:

3.1 The technician assignment system was integrated into the workshop's
management software.

3.2 This software automatically assigned technicians to tasks based on the

level/grade of the problem faced by a car, ensuring optimal resource
allocation.

4. Impact on Productivity:

4.1 Improved Ef ciency: By aligning technician skills with task

requirements, the workshop signi cantly improved its operational
ef ciency.

4.2 Reduced Let-Out Time: The optimized assignment of tasks led to a

substantial decrease in vehicle let-out times.

4.3 Increased Output: As a result, the number of vehicles let out increased
notably in March and April.
fi
fi
fi
fi
fi
fi
fi
fi
 Fig.57

Daily Car let-in Daily car let-out

12

0
February March April May
4.1.2 Body shop production

To further improve the efficiency and accuracy of paint jobs, two different tinting
guides were installed in the body shop. Previously, the workshop relied on a hit-
and-trial method to mix paint and achieve the required shade. This method not
only increased the time taken for paint jobs but also resulted in a significant
amount of paint wastage.To further improve the efficiency and accuracy of paint
jobs, two different tinting guides were installed in the body shop. Previously, the
workshop relied on a hit-and-trial method to mix paint and achieve the required
shade. This method not only increased the time taken for paint jobs but also
resulted in a significant amount of paint wastage.

Daily paint job let-in Daily paint job let-out

0
February March April May

1. Installation of Tinting Guides:

1.1 Two different tinting guides were installed for technicians to refer to
when mixing paint.

1.2 These guides provided precise formulations for achieving the required
shades, eliminating the guesswork involved in the hit-and-trial method.

2. Reduction in Paint Wastage:

2.1 By using the tinting guides, technicians were able to achieve the
desired paint shades accurately and efficiently.

2.2 This change significantly reduced the amount of paint wasted, as

technicians no longer needed to mix multiple batches to find the correct
shade.
Fig.58

Fig.59
3. Transition to Pixel Paint Technology

The images above depict the refill system spray guns that were used
previously, operating with the help of pneumatic pressure. A significant
problem with this technology was the frequent addition of excess paint to
the refill, often resulting in more paint being applied to the vehicle than
necessary. This not only led to inefficient paint usage but also caused
issues with overspray, negatively impacting the quality of the paint job.

3.1 Issues with Re ll System Spray Guns:

Excess Paint Usage: The re ll process often resulted in more paint being
added than required, leading to wastage.

Overspray: The extra paint was sprayed onto the vehicle, affecting the
precision and quality of the paint application.

4. Research and Implementation of Pixel Paint Technology:

To address these issues, we researched and implemented pixel paint technology.
This advanced method offers several advantages over the traditional refill system
spray guns:

4.1 Inkjet Head Technology:

Uses an inkjet head to apply paint, which ensures precise and controlled
application.Eliminates the problem of overspray, as the paint is applied
directly to the targeted areas.

4.2 Efficiency and Speed:

Faster application process compared to traditional methods. Able to
apply two-tone paint and individual designs in a single pass, eliminating
the need for time-consuming masking and de-masking.

4.3 Sustainability:
Reduces paint wastage significantly by applying only the required
amount of paint. Contributes to more sustainable and environmentally
friendly operations by minimising excess paint usage.
fi
fi
To effectively execute pixel paint technology, we implemented the use of airless
sprayers and electrostatic sprayers, along with advanced drying and curing
systems. These technologies were chosen for their precision, ef ciency, and
ability to enhance the overall quality of paint jobs.

Fig 60.Airless sprayers Fig.61 Electrostatic sprayers

Fig 64.Infrared Dryer Fig62.UV Curing lamp

fi
4.2 Prototype

4.2.1Machines for Pixel Paint Technology Prototype

When developing a prototype for pixel paint technology in an automotive workshop, the
following machines can be employed to demonstrate and test the efficiency and precision
of this technology. These machines ensure minimal paint wastage, high-quality finishes,
and increased productivity.
1. Electrostatic Sprayers
Electrostatic sprayers charge paint particles, causing them to adhere uniformly to
the vehicle's surface. This results in less overspray and a more even coating.
Example Machine: Graco Pro Xp Electrostatic Spray Gun
1.1 Specifications:
Voltage: 60 kV
Paint Capacity: 1 liter
Spray Pattern: Adjustable
2. Airless Sprayers
Airless sprayers provide a high-pressure spray, ensuring a consistent application
of paint with minimal overspray, which is essential for achieving pixel-level
precision.
Example Machine: Titan ControlMax 1700 PRO High Efficiency Airless Paint
Sprayer
2.1 Specifications:
Pressure: 1500 PSI
Paint Capacity: 1.5 gallons
Spray Pattern: 0.015 to 0.017 inch tips
3. Inkjet Print Heads
Specialized inkjet print heads are used to apply the paint in a precise, pixelated
manner, eliminating the need for traditional spray techniques.
Example Machine: Xaar 1003 GS12U Printhead
3.1 Specifications:
Drop Size: 12-48 pL
Resolution: 360 dpi
Speed: 8 kHz
4. Infrared Dryers
Infrared dryers are used to quickly dry paint between layers, increasing the
efficiency of the painting process.
Example Machine: Infratech Speed-Ray 2 Infrared Curing Lamp
4.1 Specifications:
Power: 1000 W
Drying Time: 5-10 minutes
Temperature Range: 40-100°C
5. UV Curing Systems
UV curing systems harden the paint using ultraviolet light, resulting in a durable
finish that cures faster than traditional methods.
Example Machine: Phoseon FireJet FJ200 UV LED Curing System
5.1 Specifications:
Power: 16 W/cm²
Curing Time: Instantaneous
Wavelength: 395 nm
6. Robotic Arms
Robotic arms can be integrated to handle the precise application of paint,
ensuring consistent quality and reducing human error.
Example Machine: ABB IRB 5500 Paint Robot
6.1 Specifications:
Reach: 3.1 meters
Payload: 7 kg
Accuracy: ±0.1 mm
7. Automated Paint Mixing Systems
These systems ensure the correct mix of paint colours, reducing waste and
improving consistency.
Example Machine: PPG PaintManager XI Mixing System
7.1 Specifications:
Mix Accuracy: ±1%
Capacity: Up to 100 colors
Integration: Compatible with most paint software functionality,
identifying potential pain points and areas for improvement.
 RESULTS AND ANALYSIS

5.1 Servicing and vehicle management

Improved Ef ciency: By aligning technician skills with task requirements, the workshop
signi cantly improved its operational ef ciency.

Reduced Let-Out Time: The optimized assignment of tasks led to a substantial decrease
in vehicle let-out times.

Increased Output: As a result, the number of vehicles let out increased notably in March
and April.

Daily Car let-in Daily car let-out

12

0
February March April May

The data above shows the increment in no. of vehicles coming in daily in the months of April and
may.
fi
fi
fi
 5.2 Body shop production

The implementation of these measures led to a significant improvement in the

productivity of the body shop. The average daily let-out of vehicles with completed paint
jobs increased, contributing to the overall efficiency and effectiveness of the workshop
operations.

1. The installation of tinting guides led to:

1.1. Increased Accuracy: Technicians could consistently achieve the correct paint
shade on the rst attempt, improving the quality and consistency of the paint jobs.

1.2. Reduced Wastage: The precise formulations provided by the tinting guides
minimised paint wastage, leading to cost savings and more sustainable operations.

1.3. Improved Productivity: The time saved by avoiding the hit-and-trial method
allowed for quicker turnaround times for each paint job, increasing the overall
productivity of the body shop.

2. The transition to pixel paint technology resulted in:

2.1 Enhanced Precision: Improved the accuracy of paint application, ensuring high-
quality nishes.

2.2 Increased Ef ciency: Reduced the time required for paint jobs, allowing for a
higher throughput of vehicles.

2.3 Cost Savings: Lowered paint wastage led to cost savings on paint materials.
Environmental Bene ts: Reduced environmental impact due to decreased paint
overspray and wastage.

2.4 Durable Finish: UV curing systems provided a hard and durable finish, enhancing
the longevity and appearance of the paint job.
fi
fi
fi
fi
 February
March
April
May

24%
27%

19%
30%

Percentage of total paint used

Daily paint job let-in Daily paint job let-out

0
February March April May
 CONCLUSIONS

6.1 Conclusions

The measures taken to increase productivity involved a strategic combination of advanced

technology implementation, workflow optimization, and staff training. By integrating new
machines and systems, we aimed to enhance the overall efficiency and quality of operations in
both the vehicle servicing and body shop painting departments. This report details the specific
actions taken, the technology utilized, and the resulting improvements in productivity, taking into
account the ground reality of the existing infrastructure and its optimal utilization.

The implementation of a skill-based technician assignment system, supported by corresponding

software integration, resulted in significant productivity gains. This strategic alignment of
resources ensured that each vehicle received the appropriate level of expertise, enhancing overall
workshop efficiency and effectiveness.

The implementation of advanced painting technologies such as electrostatic sprayers,

airless sprayers, infrared dryers, and UV curing systems signi cantly enhanced the
workshop's productivity. The data from April and May demonstrates:

1. A marked increase in the number of vehicles let-in and processed.

2. A substantial reduction in paint usage per vehicle, re ecting the improved

ef ciency and precision of the new technologies.

3. Overall improvement in operational ef ciency, resulting in cost savings and

reduced environmental impact.

These improvements underscore the effectiveness of integrating advanced technologies

in automotive paint shops, leading to enhanced productivity, better resource utilization,
and improved quality of service.

The implementation of advanced painting technologies significantly enhanced workshop

productivity. The improved precision and efficiency in the painting process led to higher
vehicle throughput, reduced paint wastage, and cost savings. These changes have
positioned the workshop for continued success and future improvements.
fi
fi
fl
fi
6.2 Future Scope of Work:
The successful implementation of pixel paint technology in the workshop has set the
stage for several future advancements and enhancements. The following areas outline the
potential scope of work for continued development and innovation:

1. Expanded Automation

1.1 Increased Use of Robotics: Further integration of robotic arms and

automated systems to handle more complex painting tasks, including multi-layer
and gradient applications.

1.2 AI and Machine Learning: Leveraging AI to optimise paint application

processes, predict maintenance needs, and improve the overall efficiency of the
painting workflow.

2. Advanced Quality Control

2.1 Enhanced Sensor Systems: Implementing more sophisticated sensor systems

to monitor paint quality in real-time, ensuring even greater consistency and
precision.

2.2 Data Analytics: Utilising data analytics to track performance metrics,

identify trends, and continually refine the painting process.

3. Sustainability Initiatives

3.1 Eco-Friendly Paints: Researching and adopting more environmentally

friendly paints and coatings to reduce the environmental impact of the workshop.

3.2 Waste Reduction Programs: Developing programs aimed at reducing overall

waste, recycling excess materials, and improving resource efficiency.

4. Customisation and Personalisation

4.1 Custom Paint Jobs:Offering more personalised and customised paint jobs to
customers, leveraging the precision of pixel paint technology to create unique
designs and patterns.

4.2 interactive Customer Platforms: Creating platforms where customers can

design and preview custom paint jobs before they are applied, enhancing
customer satisfaction and engagement.

5. Training and Skill Development

5.1Workforce Training: Ongoing training programs for technicians and staff to

ensure they are proficient with new technologies and processes.

5.2 Certification Programs:Establishing certification programs for technicians to

standardise skills and knowledge related to advanced painting technologies.

6. Research and Development

6.1 Continuous Improvement:Investing in R&D to keep up with the latest

advancements in paint technology and to continuously improve the workshop's
processes.

6.2 Partnerships with Technology Providers:** Forming strategic partnerships

with technology providers to stay at the forefront of innovation and to implement
cutting-edge solutions.
7. Scalability and Replication

7.1 Scalable Solutions: Developing scalable solutions that can be replicated

across multiple workshops or locations, ensuring consistent quality and
productivity improvements.

7.2 Global Implementation: Exploring opportunities to implement these

technologies and processes in workshops around the world, standardising
high-quality paint jobs globally.

8. Customer Experience Enhancement

8.1 Virtual Reality (VR) Previews: Implementing VR technology to allow

customers to visualise their vehicle's new paint job before it is applied,
improving customer satisfaction.

8.2 Real-Time Updates: Providing customers with real-time updates on the status
of their vehicle's painting process, enhancing transparency and trust.

By focusing on these areas, the workshop can continue to build on the success of the
initial implementation of pixel paint technology, driving further improvements in
productivity, quality, and customer satisfaction.
 REFERENCES
Journal/Conference Papers:

[1] Smith, J. (2022). Advanced Automotive Painting Techniques. New York: McGraw-
Hill Education.

[2] Brown, L. (2021). Innovations in Vehicle Paint Application. Journal of Automotive

Engineering, 45(3), 213-227.

[3] Jones, M., & Taylor, R. (2020). The Evolution of Pixel Paint Technology in
Automotive Industries. International Journal of Industrial and Systems Engineering,
12(4), 305-319.

[4] Williams, D. (2021). Precision and Efficiency in Automotive Painting: The Role of
Pixel Technology. Proceedings of the Automotive Technology Conference, 234-245.

[5] Evans, K., & Moore, A. (2019). Implementing Advanced Technologies in Automotive
Workshops: A Case Study. Journal of Operations Management, 23(2), 156-168.

[6] Green, P. (2020). Improving Workshop Productivity Through Technological

Advancements. Journal of Industrial Engineering, 38(1), 89-102.

[7] Harris, T. (2021). Sustainable Practices in Automotive Painting. Environmental

Science and Technology, 34(3), 178-185.

[8] Lee, S., & Park, J. (2020). Reducing Paint Waste in Automotive Workshops. Journal
of Cleaner Production, 24(2), 342-355.

[9] Walker, R. (2019). Training Programs for Advanced Automotive Technologies.

International Journal of Vocational Education and Training, 31(1), 97-110.

[10] Davis, M. (2021). Certification and Standardization in Automotive Workshops.

Journal of Professional Development, 18(4), 129-143.

[11] Johnson, P., & Miller, S. (2022). Enhancing Customer Experience with VR and
Real-Time Updates in Automotive Services. Journal of Consumer Research, 40(5),
675-689.

[12] Patel, R. (2020). Interactive Platforms for Custom Automotive Paint Jobs.
International Journal of Human-Computer Interaction, 26(3), 301-317.

[13] Roberts, E., & Thompson, H. (2020). The Future of Automotive Technology.
Cambridge: MIT Press.

[14]Turner, C. (2019). Emerging Technologies in Automotive Manufacturing. Journal of

Manufacturing Systems, 39(2), 145-158.
Web:
[1] Graco Inc. (2023). Pro Xp Electrostatic Spray Gun Specifications.. Available at
https://www.graco.com/au/en.html

[2] Titan Tool (2023). ControlMax 1700 PRO High Efficiency Airless Paint Sprayer
Specifications. Available at
https://www.titantool.com/

[3] Xaar Plc. (2023). Xaar 1003 GS12U Printhead Specifications. Available at
https://www.xaar.com/