San Joaquin County Office of Education Career & Technical Education Automotive Engineering ~ Course Outline Automotive Engineering Course Outline Classroom Lab 1 Orientation and Safety 5 5 • Introduction to Automotive Engineering • Safety Unit: Review of equipment usage, lab procedures, safety rules, emergency guidelines, and Occupational Safety Hazards Association (OSHA) rules 2 Introduction to Engine Design 15 25 • Internal Combustion Engine (ICE) unit: Study internal combustion engine (ICE) physics of operation and discuss how science and mathematics are used in the design process, chemical bonding, performance modification, inspection and diagnosis of mechanical failure. • Engine Testing Unit: Examine the relationship between horsepower, torque, speed, and fuel consumption, plus interpret charts, graphs, and other data depicting mechanical power. • Emissions Control Unit: Analysis of particulate matter emissions (CO, CO2, NOX, HC, SO2, and DPM) caused by gasoline and diesel engines. Study early and late model automobile emission control components effectiveness in reducing pollutants, as well as how ICE modifications contribute to ultra-low-engine emission standards. • Digital Engine Control Unit: Study the relationship between mechanical components managed by networked computers. Understand the data generated by input and output sensors responsible for engine management control. Students will partake in the following hands-on tasks Disassembly of an internal combustion engine (ICE) in 02/09/2016 San Joaquin County Office of Education Career & Technical Education Automotive Engineering ~ Course Outline order to identify components, physical operation, and critical measurements, as related to: air and fuel volume efficiency, degrees of crankshaft and camshaft rotation in relation to maximum power, compression ratio and energy of fuel, cubic centimeters of combustion chamber and the effect on stoichiometric air/fuel ratio. Examine the relationship of cubic feet a minute of air flow to cylinder head valve and seat size. Research how air blowers provide additional power. Determine torque and horsepower derived from calculations made in prior activity Measure engine emissions with the use of an analyzer and compare to state and federal air quality standards Demonstrate how an ICE causes each of the emissions measured Identification of engine digital controls and the sub- systems managed by single computers and networks Communicate with computers and retrieve data to analyze feedback and output sensor signals. Use interactive controls to test the movement of actuators and retrieve diagnostic codes 3 Transmission, Electrical, Electric and Hybrid Vehicle 15 35 • Transmission Unit: Research the affect that gear ratios have on torque multiplication and the role of hydraulics and fluid coupling in transmissions. • Automotive Electrical and Electronic Unit: Identify and research DC and AC circuits, wiring systems, electromagnetic devices, module communication, and computer area network operation. Diagnose electrical systems with testing equipment, mathematical formulas, and wiring schematics. • Electric Vehicle Battery/fuel-cell EV packages Unit: Examine configurations of electric vehicles and motorized propulsion systems powered by hydrogen fuels cells and battery technologies. Study the fundamentals of regenerative braking, power sources (hydrogen fuel cells, ultra-capacitors, and ultra-high- speed flywheels) and energy storage (batteries). • Hybrid Vehicle Unit: Research hybrid vehicle designs and concept of hybrid electric drivetrains 02/09/2016 San Joaquin County Office of Education Career & Technical Education Automotive Engineering ~ Course Outline Students will partake in the following hands-on tasks Disassembly of a transmission, identification of the components, and demonstration of power flow, in order to determine the ratio of each gear and the affect it will have on engine speed Identification of components used in an electric car. Determine how to convert an automobile with an ICE to full electric and hybrid. Determine wattage, horsepower, battery capacity, and distance with mathematical formulas. Develop a wiring schematic of the electric vehicle conversion design that will meet engineering standards. Identification of: charging, starting, wiring, instrumentation, communication, safety, comfort, and lighting systems. Use electrical measurement equipment and tools to demonstrate the different signals, voltage, and current produced by the components. Disassembly of an electric starter motor to study the principle of electromagnetism and research how this theory is used in regenerative 4 Suspension, Steering, Brake, Tire and Wheel 10 25 • Suspension Unit: Examine front and rear suspension system design and operation. Inspect and diagnose component failure and analyze the affect it would have on alignment angles, braking, and vehicle stability. • Steering Unit: Examine steering system design and operation. Inspect and diagnose component failure and analyze the affect it would have on alignment angles, braking, and vehicle stability. • Braking Systems Unit: Research and examine the construction and components of passenger car braking systems, characteristics of the braking process, Society of Automotive Engineering requirements, electro- hydraulically actuated brakes, and interaction between the road surface, tire, and brake • Tire and Wheel Unit: Study the characteristics of tires and vehicle handling. Investigate the relationship 02/09/2016 San Joaquin County Office of Education Career & Technical Education Automotive Engineering ~ Course Outline between size and MPH calculation. Students will partake in the following hands-on tasks The identification of suspension and steering components of various designs and determine the function of each component and how they operate together in the chassis. Conduct measurements of wheel base, track, turning radius, toe, camber, caster, steering axis inclination, and ride height to determine if degrees of angles meet engineered specifications. Identify brake system components and research the effectiveness of electro-hydraulic devices in stopping distance reduction and vehicle stability improvement. Determine hydraulic force needed to stop a vehicle with a specified brake surface area, vehicle weight, and tire design. Identify materials used in tires and wheels. Research the handling characteristics of different tire designs. Demonstrate the effect of different tire sizes on odometer accuracy 5 Structural Design, Aerodynamics, and Vehicle Safety 15 30 • Structural Design Unit: Study vehicle structure types and materials incorporated into vehicle design. Identify structural changes due to front, mid, and rear engine placement. Investigate structural collapse and its influence upon safety. • Vehicle Safety Unit: Examine vehicle safety system operation, structural safeguards, and warning systems. Inspect and test the electronic and mechanical operation of seatbelts and supplemental restraints. • Aerodynamics Unit: Study the effects of aerodynamic forces, drag, drag reduction, stability and cross-winds on the performance of automobiles. Research how different automobile designs can affect aerodynamics Students will partake in the following hands-on tasks Locate and name key structural components and 02/09/2016 San Joaquin County Office of Education Career & Technical Education Automotive Engineering ~ Course Outline supports on a specified automobile. Identification of all safety sensors, microprocessors, air bags, pre-tension seatbelts, and standard seatbelts. Research and determine criteria established by engineers in order for crash sensors to trigger air bag deployment. Study the effect of air drag on various automobile designs by building small scale models that will be tested and the results analyzed 2nd Year – Classroom/Lab 55 120 Total Hours 180 02/09/2016 .