Abstract:
Basic electrical learning in vocational high schools
requires practical media that can connect theoretical
concepts with actual vehicle electrical systems. Limited
teaching aids at SMK Muhammadiyah Kawali have
constrained practical activities related to vehicle lighting and
battery charging systems. This study aims to design and
produce a simple, safe, easy-to-operate, and learning
oriented teaching aid for basic automotive electrical systems.
An engineering design method was employed through needs
identification, literature study, alternative design selection,
design
modeling, technical calculations, fabrication,
preparation of standard operating procedures, and functional
testing. The teaching aid uses a 12 V DC source with major
components consisting of a 12 V 35 Ah battery, headlights,
turn signals, brake lights, reverse lights, position lights,
switches, relays, fuses, a regulator, an alternator, and an
electric motor. The first design alternative was selected
because it was simpler, more economical, structurally rigid,
and more mobile. The final teaching aid measures 700 mm ×
600 mm × 800 mm and uses a 30 × 30 mm hollow steel frame
with a thickness of 1.5 mm. The theoretical lighting load is
450 W with a current requirement of 37.5 A when all loads
operate simultaneously; therefore, the lighting functions are
operated alternately. The charging system uses a 12 V
alternator with an 8 A output, corresponding to a theoretical
power of 96 W. Functional testing showed that the lighting
components could operate and the charging system increased
battery voltage to approximately 14 V. The teaching aid is
equipped with operating and assembly procedures as well as
a practical module, supporting its use as a learning medium
for basic vehicle electrical practice.
