Automotive Mechatronics Course

Lesson 1 • Safety and Workshop Practices

Covers electrical, chemical, and mechanical hazards specific to automotive environments. Establishes safe habits required before any hands-on lab activity.

Lesson 2 • Units, Measurements, and Physical Laws

Reviews SI units, fundamental physical laws, and measurement principles relevant to automotive systems. Ensures accurate interpretation of sensor data and component specifications.

Lesson 3 • Vehicle Architecture Overview

Maps the major subsystems of a modern vehicle and their interdependencies. Builds the system-level thinking required for all subsequent diagnostic and design work.

Lesson 1 • Batteries and Charging Systems

Explains lead-acid and lithium battery chemistry, state of charge, and charging system operation. Connects battery health to reliable ECU and sensor performance.

Lesson 2 • DC Circuit Analysis

Applies Ohm's law and Kirchhoff's laws to series, parallel, and combination circuits. Directly supports diagnosis of automotive lighting, motor, and relay circuits.

Lesson 3 • Electrical Fault Diagnosis

Introduces systematic fault finding using multimeters, test lights, and wiring diagrams. Develops the diagnostic mindset applied in all later electronic system chapters.

Lesson 4 • Automotive Wiring and Connectors

Identifies wire gauges, insulation types, connector families, and terminal designs used in vehicles. Enables correct repair and fabrication of automotive harnesses.

Lesson 1 • Engine Management Sensors

Details crankshaft position, MAP, MAF, oxygen, and temperature sensors used in engine control. Links sensor accuracy to fuel, ignition, and emissions performance.

Lesson 2 • Sensor Operating Principles

Classifies sensors by physical principle and output signal type. Establishes the signal vocabulary used when analysing ECU inputs throughout the course.

Lesson 3 • Chassis and Safety Sensors

Examines wheel speed, steering angle, yaw rate, and acceleration sensors used in ABS and stability systems. Connects sensor accuracy to active safety system performance.

Lesson 4 • Actuator Types and Control

Covers DC motors, stepper motors, solenoids, and servo actuators used across vehicle systems. Explains how ECUs command actuators using duty cycle and current control.

Lesson 1 • ECU Software and Control Strategies

Covers real-time operating systems, task scheduling, and closed-loop control algorithms used in ECUs. Explains how software translates sensor data into actuator commands.

Lesson 2 • ECU Hardware Architecture

Describes microcontroller cores, memory types, and I/O interfaces inside an automotive ECU. Provides the hardware context needed to understand software and communication chapters.

Lesson 3 • Engine Control Unit Operation

Traces fuel injection, ignition timing, and idle control strategies within the engine ECU. Connects ECU logic to measurable engine performance and emissions outcomes.

Lesson 4 • ECU Programming and Flashing

Covers software update procedures, bootloader operation, and programming precautions. Prepares learners to safely perform ECU reflashing in a workshop environment.

Lesson 1 • LIN, MOST, and FlexRay Protocols

Compares LIN for low-speed body functions, MOST for multimedia, and FlexRay for safety-critical systems. Identifies appropriate protocol selection based on bandwidth and determinism needs.

Lesson 2 • Network Fundamentals and Topologies

Introduces bus, ring, and star topologies and the role of network communication in modern vehicles. Sets the foundation for understanding specific protocol chapters.

Lesson 3 • Automotive Ethernet and Emerging Protocols

Covers 100BASE-T1 and 1000BASE-T1 Ethernet for high-bandwidth ADAS and camera data. Positions Ethernet within the evolving vehicle network architecture.

Lesson 4 • Network Fault Diagnosis and Analysis

Applies bus analysers, oscilloscopes, and scan tools to locate open, short, and node faults. Reinforces systematic diagnosis skills across all network types covered.

Lesson 1 • Powertrain Fault Diagnosis

Applies live data analysis, actuator tests, and mechanical verification to powertrain fault isolation. Synthesises skills from all previous chapters into a structured diagnostic workflow.

Lesson 2 • Engine Management System Integration

Examines how fuel, ignition, and emission subsystems interact under ECU coordination. Builds on ECU and sensor chapters to analyse complete engine management behaviour.

Lesson 3 • Dual-Clutch and CVT Systems

Explains dual-clutch transmission mechatronics and continuously variable transmission belt-pulley control. Highlights unique diagnostic challenges compared with conventional automatics.

Lesson 4 • Automatic Transmission Control

Covers hydraulic, electronic, and mechatronic automatic transmission operation and shift logic. Connects transmission control to engine torque management for smooth power delivery.

Lesson 1 • Active Suspension and Ride Control

Examines electronically controlled dampers, air suspension, and active roll control system operation. Highlights sensor fusion and real-time control demands of adaptive suspension.

Lesson 2 • Electronic Power Steering Systems

Covers column-assist and rack-assist EPS motor control, torque sensing, and steering feel tuning. Links EPS to lane-keeping and parking assist system integration.

Lesson 3 • Chassis System Calibration and Verification

Applies scan tool calibration routines, steering angle sensor reset, and road test verification. Ensures all chassis safety systems meet performance and safety requirements after service.

Lesson 4 • Electronic Stability and Traction Control

Explains yaw rate, steering angle, and lateral acceleration inputs used to compute stability corrections. Demonstrates how ESC integrates with ABS and engine torque reduction.

Lesson 1 • High-Voltage System Architecture

Maps high-voltage bus topology, isolation monitoring, and interlock circuits in hybrid and electric vehicles. Establishes the safety and system knowledge required for all HV work.

Lesson 2 • HV System Diagnosis and Safe Service

Applies HV-rated tools, isolation testers, and scan data to diagnose battery, inverter, and motor faults. Enforces safe de-energisation and verification procedures throughout.

Lesson 3 • Battery Management Systems

Covers cell chemistry, state of charge estimation, thermal management, and cell balancing in traction batteries. Connects BMS accuracy to range, performance, and battery longevity.

Lesson 4 • Hybrid Control Strategy and Energy Management

Details parallel, series, and power-split hybrid operating modes and energy management logic. Shows how the hybrid control unit optimises fuel and electric energy use.