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“ABSTRACT”
There have been major developments in the field of two wheelers with
One of the major aspect of the vehicle that is responsible for making vehicle
This project was undertaken with an objective to test the average of vehicle
flexible features. By standing the vehicle on main stand and within 10-15 min. we can find
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Two Wheeler Mileage Testing Machine
“INTRODUCTION”
We, the final year production engineering students have designed and
fabricated a very useful project namely "Two wheeler mileage testing machine".
employed at two wheeler service stations, as well as manufacturers and Pre delivery
Mileage is as important term used with respect to any vehicle Mileage is the
average distance traveled by a vehicle consuming one litre of fuel. As far as economy is
1) The manufacturer must know the fuel efficiency of vehicle at standard conditions as
2) In the service station, after the service of vehicle it is necessary to know the average of
the vehicle .Instead of, leaving it to customer to run it until one litre of fuel is burnt
certain specified conditions i.e. creating on road load conditions, the mileage is known to
us. The creation of loads includes the load of vehicle, driver, load due to air resistance,
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Two Wheeler Mileage Testing Machine
At present, the service station persons, use the mileage testing machine for
which the vehicle is made to run on the roads. Whereas in this project the machines
calculates the mileage, making the vehicle on the service table itself.
The cost of machine is so low that even a small service station owner can
For good mileage the running of the vehicle should be perfect for the setting
of running the service run has to rely on the customer information. So accordingly he
carries the running adjustment. On vehicle by using trial and error method. The results, he
implement the same practically. This is an attempt for service station to be aware of
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Two Wheeler Mileage Testing Machine
& equipment.”
conceived product, as it facilities or aids of to judge the market for our product and its
future existence. It determines who and where the customer is what are his needs and
wants, what will lay for it. Market research also uncovers the future of existing product and
For the part 5 decades, market research has got immense popularity and has
3. Data collection from existing and future consumers about their needs / requirements.
So, in the view of aforesaid important points, it is quite evident that for
launching /marketing a new concept in the market, survey research is very essential.
machine is concern, we conducted a through survey in Akola and the adjoining areas.
From this survey we concluded that our product (i.e. M.T.M/c) has got immense scope in
market as it has got distinctive features for its promotions. The main advantage with our
product lies within that, it can efficiently test the average or mileage of any two wheeler
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Two Wheeler Mileage Testing Machine
(Automobile) when erected on its main stand that too with just 25-50 ml of fuel and takes a
few minutes to do the job. In our market survey, we went to various show rooms of two
wheelers like Bajaj (Krishna Motors), Hero Honda (Baheti Sales & Service) TVS (Prakash
Enterprises) and a few service station. Except the Bajaj Show room, none of them had this
facility for mileage testing. Their managers /owners should a great interest in our project
and they were all convinced with our new design features and various modifications mode
in the existing machine available in market. The main disadvantages with the equipment
or machine available in market lies in its big size difficult in operation, high noise and low
transmission ratio. We in our project have tried to minimize all these draw backs by
redesigning the whole structure, making suitable adjustment to reduced noise and increase
transmission ratio.
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Two Wheeler Mileage Testing Machine
"BASIC PRINCIPLE"
The basic principle of two-wheeler mileage testing machine is that the rear
wheel of the vehicle is placed in touch with the first idler. This idler will rotate due to
friction between the idler and tyre. This first idler revolution is transferred. On second
idler via belt and pulley arrangement. The r.p.m. of the rear wheel of the vehicle. The
loading conditions are created by encovering the second idler with belt and spring weight
arrangement on it. The r.p.m. of the second idler is calculated with the help of
speedometer assembly mounted on shaft of second idler. So that we can take the readings
of the distance traveled and also the fuel consumption is known to us. So average output
Distance traveled
Average =
Fuel consumed
The care of rolling resistance, air drag resistance and gradient resistance are
The quantity fuel supplied can be measured using a measuring bottle of 100
ml. Hence if all variables are known to us. Average output of vehicle under loading
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Two Wheeler Mileage Testing Machine
road wheels. Varying at different engine speed and gear position it is mainly required to
overcome the force opposing motion of vehicle. The resistance to the motion of the
vehicle is called as tradre resistance. It is the sum of the three resistance that obstruct the
ii)Gradient resistances.
1)Rolling Resistances :-
surface the load on each tyre inflation pressure and type of tyre treated.
2)Frictional Resistances :-
Frictional resistances to the motion of the vehicle reduce the speed and also
f = 66.6 + 0.012 W
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Two Wheeler Mileage Testing Machine
These transmission losses are generally 10% in direct gear 15.20% in low
gear. For calculating performances tractive force should be emitted at efficiency at 90%
for top gear and 80-85% for low gear. This also includes temp losses and the losses
occurring in oil churning in the closely desired gear box and contended rear axle. For
private car's it is 89-95%. The friction losses in the tyre in about two third of total losses in
the chasis.
The air and wind resistances for two wheelers are negligible. Generally it
depends on speed of vehicle, wind velocity, size and shape of the body of the vehicle.
A = Projected area in m2
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Two Wheeler Mileage Testing Machine
“DESIGN”
DESIGN OF SHAFT :-
The heaviest two wheeler vehicle in Indian Market "Enfield Bullet" 500cc
= 255 kg.
= 510 kg.
= 255 kg.
= 127.5 kg
B.H.P. = 18 x 2 = 36 H P
= 26856 W
∴ P = 26.85 k w
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Two Wheeler Mileage Testing Machine
= 127.5 × 9.81
= 1250.77 N
2πNT
P=
60
2 × π × 6000 × T
26.85 × 10 3 =
60
T = 42.74 N.m
= 171.3 Nm
M = 171.3 Nm
Now ,
Te = M 2 + T 2
= (171.3) 2 + (42.74) 2
Te = 177.21 Nm
Taking fs = 56 N/mm2
π
Te = fsd3
16
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Two Wheeler Mileage Testing Machine
16 × τ e
∴ d3 =
π × fs
16 × 177.21 × 10 3
=
π × 56
d = 25.25 mm
Say 30 mm
Design of Idler
B = 1.1b + (15) mm
= 1.1 × 137 + 15
= 166 mm
S = 0.005 × 137 + 3 mm
=3.68 mm say 5 mm
4) Diameter of Hub d1 = 2 × d
= 2 × 30
= 60 mm
= 2 × 30
L = 60 mm
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Two Wheeler Mileage Testing Machine
Design of pulleys :-
Function :- The power from first idler to second is transmitted with the help of pulleys and
belt.
N1 d1
N2 =
d2
420 × 630
=
137
N2 = 193 1.38
N2 = 1931.38 = 4.59
N1 420
∴Diameter of pulley B = d4 = N 2 d3
N4
= 1931.38 × 65
420
= 282.38mm
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Two Wheeler Mileage Testing Machine
For Scooter :-
N1′ × n 1
RPM of Idler will be N ′2 =
D2
580 × 480
=
137
= 2032 rpm
N ′ 2032
=
N 1′ 580
= 3.5
N ′3 D 3
∴ D4 =
N ′4
2032 × 65
∴ D4 =
580
Design of Key
We know
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Two Wheeler Mileage Testing Machine
Fs = 40 N/mm2
Fc = 80 N/mm2
T = 42.74 Nm
= 42740 N mm
l = 80 mm
W = 8 mm
D = diameter of shaft
= 25 mm
T = l× W × Fs × d/2
42740 = 80 × 8 × Fs × 25/2
42740 × 2
∴ Fs =
80 × 8 × 25
Fs = 5.34
∴ Design is safe.
We know Fc = 90 N/mm2
t = 6 mm
π d
T= × d 2 × stress ×
4 2
t d
= L × × f C2 ×
2 2
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Two Wheeler Mileage Testing Machine
T
∴ for = t d
L× ×
2 2
4×T
=
L× t×d
4 × 42740
=
80 × 6 × 25
= 14.24 N/mm2
∴ Design is safe.
T×2
(iii) Resisting Area =
Fs × d
d1 = Bolt diameter
π 2 T×2
× d1 =
4 Fs × d
2 2×T× 4
d1 =
π × fs × d
2 × 42740 × 4
=
π × 40 × 25
2
d 1 = 108.83mm
d1 = 10.43 mm ≅ 12 mm (say)
∴ Design is safe
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Two Wheeler Mileage Testing Machine
π d
× d 2 × fc r ×
4 2
T×2
fc r =
Re sisting area × d
42740 × 2
=
π
× 12 2 × 25
4
fcr = 30 N/mm2
Design is safe
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Two Wheeler Mileage Testing Machine
Materials Required
Angle 2 50 × 50 × 5 200
Angle 1 350
50 × 50 × 5
2. Square pipe 2 22 × 25 × 2 460
Square pipe 4 90
35 × 35 × 3
3. Round pipe 1 φ 25 355
1 φ230
1
φ65
7. V-belt 1 B-56
8. Flat belt 1 2" 1800 mm
9. Spring 1 0 -100 Kg.
10. Petrol pipe 1 - 2 ft.
11. Measuring bottle 1 100 ml.
12. Plywood 1 355 × 300 × 6mm
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Two Wheeler Mileage Testing Machine
Fabrication
FRAME STRUCTURE :-
Two 860 mm angles are welded with four rectangular pipes of size 35 × 35
× 3 mm and length 90 mm at the four corners of the angles at bottom for preparing base
stand. The slots of size 102 mm × 38 mm are made in the angles at required places before
from the back side of the frame which has a provision of hole for tightening of bolt.
A piece of angle of same size and length 350 mm. Is welded at a distance of
Two pieces of same size angles and length 185 mm are then welded with the
Rectangular pipe 25 mm × 25 mm × 2 mm
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Two Wheeler Mileage Testing Machine
mm are welded vertically on the angles which are on ground as shown fig.
After that the two pieces of same pipes of same size and of length 460 mm
are welded with the vertical pipes in inclined manner and the other end is welded with the
The pipe of φ25 mm. and length 355 mm are then welded with the topmost
After than one more pipe of same diameter is welded in between the two
of lathe. One end is drilled to depth of 5 mm. After applying grease over the hole,
tailstock is held tightly with the hole, to eliminate the vibrations in shaft at the time of
revolving. The chuck is made to run at 430 rpm and after adjusting centre, the shaft is turn
to 30 mm diagram. Then the shaft is cut down to a length of 490 mm. A slot for key is
made in the shaft from one side. A tapped hole of φ10 mm is drilled on the shaft for fixing
After that the idler and pulley is assembled with the shaft.
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Two Wheeler Mileage Testing Machine
A mild steel round bar of φ35 mm and length 510 mm is mounted on chuck
of lathe. One end is drilled from one side of 5 mm depth. After applying grease over the
hole, tailstock is held tightly with the hole, to eliminate the vibrations in shaft at the time of
revolving. The chuck is made to run at 430 rpm and after adjusting centre, the shaft is
turn to 30 mm dia. Then shaft is cut down to a length of 490 mm. A slot for key is made
in the shaft from one side. A tapped hole of φ10 mm is drilled in shaft for fixing of drum at
Assembly
The prepared angle frame is placed on ground. After that firstly all the 4
pedestal bearings are fitted on the angles in their decided places, the upper cover of the
bearings is removed. After that the first idler, pulley of φ65 which is already fitted on shaft
is placed on the first two bearings which is then tightened by upper cover, by greasing
Then the second shaft on which 2 pulleys of φ280 mm, φ230, one idler
drum of φ237 of length 130 and the speedometer worm wheel is already fixed is placed on
the second 2 bearings, in required position. After that upper cover of bearing is tightened
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Two Wheeler Mileage Testing Machine
The V-belt is then fixed on the pulleys of φ65 and φ280 with required
tension in belt. After that one end of the flat belt which is attached by a bolt is tighten by
the nut by inserting into the bottom hale. By taking the another end of the belt over the
second idler and forwarded over the upper bar of frame and then it is inserted from the
upper hook of spring weight and tightened by nuts and bolts. The lower hook of the spring
to be fixed, is fitted to frame by screws. The remaining two plywood pieces are then fixed
Then the total frame is coloured using primer (red oxide) over it. Hence the
machine.
2 Idlers C.I. φ137 and length 160 mm Knurling on lathe m/c
3 Frame Structures :-
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Two Wheeler Mileage Testing Machine
Rubber
9 Screw, Nuts and bolts M.S. Readymade
10 Pipe M.S. Cutting and welding
11 Bearings Standard No. Mounting on a shaft
6206
12 Speedometer _ Readymade
Test Procedure
First of all, the vehicle is led on middle (main) stand. It's carburetor is made
empty and dry. 50 ml petrol is poured in the bottle and it's pipe is connected to input of
carburetor.
After that according to calculations loads are applied on belt over second
idler. Now the vehicle is started after touching it's rear wheel to first idler. The initial
meter reading is noted and vehicle is made to run at speed between 40 to 50 km/h. During
this time throttle for acceleration is kept constant. After the petrol in vehicle is finished it
will experience jerks, switch off the vehicle at this time. Take the second meter reading.
Hence,
For Scooter
procedure is followed.
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Two Wheeler Mileage Testing Machine
Performance
Test no - 1
Model :-
Reg. No :-
Fuel taken :-
Load applied :-
Initial reading :-
Later reading :-
Mileage :-
Test No. – 2
Model :-
Reg. No :-
Fuel taken :-
Load applied :-
Initial reading :-
Later reading :-
Mileage :-
Test No - 3
Model :-
Reg. No :-
Fuel taken :-
Load applied :-
Initial reading :-
Later reading :-
Mileage :-
Test No – 4
Model :-
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Two Wheeler Mileage Testing Machine
Reg. No :-
Fuel taken :-
Load applied :-
Initial reading :-
Later reading :-
Mileage :-
Advantages
4) Low vibrations.
5) Low cast.
7) Compact in shape
8) Low weight.
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Two Wheeler Mileage Testing Machine
Disadvantages
Applications
Estimation
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Two Wheeler Mileage Testing Machine
1) Drive steadily at the optimum speed i.e. at 40-50 Kmph you will surprise to find that
your frames time does not increase significantly, sudden start and stop and go driving
waste fuel.
2) Use brake Springly. A good drive anticipates stop. When your slime on the brake.
3) Let go off your clutch unnecessary use of the clutch leads to loss power.
4) Clean air filter regularly. Dust leads to rapid wear of engine components and increase
fuel. Consumption choked exhaust parts and silence make you engine struggle to
5) When your tyre pressure under inflated tyre increase rolling resistance and petrol
consumption. Test show that under inflation of tyre by 25% cause a 5% increase in
6) Stop fuel leaks, check your fuel task, carburettor and fuel lines daily for leaking fuel.
Loss of one drop of fuel per second amounts to nearly 2000 litre per day.
7) Key off the engine if you want to stop more than 2 minutes for example at railway
crossing.
8) Keep your engine in good condition. Test on a large number of vehicle show that you
can save over 6% of fuel. If your engine emits smoke, check it immediately at a
reputed garage.
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Two Wheeler Mileage Testing Machine
9) Use superior 27 oil for lubrication. Mix superior 27 oil consuming to intentional
API/TC Specification.
10) The Speedometer cable is to be oiled and all the bearings are to be Greased
periodically.
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Two Wheeler Mileage Testing Machine
“FUTURE SCOPE”
We can also attach exhaust gas analyser for analysing the exhaust gases, in
this way we can also control pollution. Hence, mileage as well as (PUC) can be made
known simultaneously.
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Two Wheeler Mileage Testing Machine
“BIBLIOGRAPHY”
1. Machine design
2. Automobile Engg.
4. Auto India
…. Nov.2001
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