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Automobile Engineering Lecture Notes-4 To Final Year Students by Kiranmedesign PDF
Automobile Engineering Lecture Notes-4 To Final Year Students by Kiranmedesign PDF
ENGINEERING
BY
KIRAN KUMAR.K
Lecturer
Mechanical Engineering Department
College of Engineering and Technology
Eritrea Institute of Technology, Mainefai, Asmara,Eritrea.
e-mail: kiranmedesign@gmail.com
kiranmek3@gmail.com
CONTENTS
Starting system
Over running clutch
Chasis
Springs
Shock absorbers
Body terminology
Front/back wheel drives
Wheels
Tyres
Battery
DC Generators/Regulators
STARTING SYSTEM
System by means of which an engine is cranked for
starting purposes
Components
Starting motor or Self starter
Motor unit
D.C.Motor
Drive unit Transmits the torque developed by starting motor to the engine
flywheel
Bendix drives (Inertia drive)
Overrunning clutch
Storage battery
Starter switch
BENDIX DRIVE
Inertia drive
Bendix drive
STARTING SYSTEM
STARTING SYSTEM
SOLENOID SHIFT
CHASSIS
Machine portion Chassis
Carriage portion - Body
Automobile =
Chassis
Body
CHASSIS - COMPONENTS
Frame
Springs, shock absorber, axles, wheel
Power unit or Engine
Transmission system (Propeller shaft, Differential, axle shafts)
Steering, brakes, accelerator
Fuel tank
Battery
Lamps, gauges,switches etc.
CHASSIS - CLASSIFICATION
Conventional control chassis
Engine mounted in front of drivers cabin
Full forward control chassis
Completely mounted inside drivers cabin
Semi forward control chassis
Engine mounted half in drivers cabin and other half in front
FRAME
Provides support for the engine, body wheels, power train members
Made of box, tubular and channel members
Frame is extremely rigid and strong
Engine is insulated from the frame by means of a rubber pad
SPRINGS
COIL SPRING
LEAF SPRING
Leaf spring is made up of a series of flat steel plates of graduated length
,placed one on top of another .
The plate are held together at the centre by a centre bolt which passes
trough holes in the leaves
Clips are placed at intervals to keep the leaves in alignment
One end of spring is mounted on the frame with a simple pin, while other
end connection is made with a shackle
Materials
Chrome vanadium steel (C,Mn,Si,Ni,Cr,Va)
Silico Manganese steel (C,Mn,Si,Cr)
Carbon steel (C,Mn,Si)
Helper springs
TORSION BARS
Springing action is produced by torsion or a twisting effort
Made of heat treated alloy spring steel.
Amount of energy stored per unit weight of material is nearly same as for
coil springs
Used with independent suspension
Light as compared to leaf springs and also occupies less space
With no load
With load
SHOCK ABSORBERS
Springing device must be a compromise between flexibility and stiffness.
Friction between leaves of spring provides the damping
But damping characteristics do not remain constant lubrication
conditions
Principle of operation of Shock absorber
Resistance to the motion of piston
An advantage of the double-tube damper is that the oil displaced from the
main tube into the outer one carries heat with it, which is then readily
conducted away. This tends to keep all the fluid at a moderate
temperature.
SUSPENSION SYSTEM
All parts which perform the function of isolating the automobile from the
road shocks are collectively called a suspension system
Objectives
To prevent the road shocks from being transmitted to the vehicle
components
To safeguard the occupants from the road shocks
To preserve stability of the vehicle
INDEPENDENT SUSPENSIONS
The elastic energy stored per unit spring weight stored in a coil /torsion bar is
greater than in case of leaf springs
In case of independent suspensions unsprung weight is reduced,which
ultimately reduce tyre scrub and hence increases tyre life
With independent suspension ,steering geometry is not altered with spring
deflection as in the case of rigid axle suspension
The sprung mass is that part of the vehicle supported by the springs - such
as the body, the frame, the engine, and associated parts.
Unsprung mass includes the components such as wheels, tires, brake
assemblies, and any part of the steering and suspension not supported by
the springs.
As the unsprung weight increases roughness of ride also increases
Unsprung mass
WISHBONE TYPE
UNIVERSAL
JOINTS
VARIABLE VELOCITY JOINTS
Rzeppa
Tracta
Bendix Weiss
In Variable joints the driving and driven shafts do not turn at the same speed
through each part of the revolution although they turn at same rpm
Speed variation and vibration causes steering difficulty and excessive tyre
wear
Bendix Weiss
Tracta U/Joint
AIR SUSPENSION
Conventional springs replaced by air bags or air spring assemblies
Maruti 800
Engine : Type4 stroke cycle, water cooled
No. of cylinders 3
Piston displacement : 796 cc
Maximum output (Std.,AC) 37 bhp at 5000 rpm Maximum torque (Std.,AC) 59
Nm at 2500 rpm
Power Transmission Std., AC4-forward, all synchromesh,
1 reverse
Steering
: Rack & pinion
Suspension : FrontMcPherson strut & coil spring RearCoil spring with gas
filled shock absorbers
Brakes
: Front - Disc & Rear - Drum
Tyres
: Tyre size (Radial)
Capacity : Fuel tank capacity 28 liters (BS III)
Maruti Swift
Rear: Coil Spring, Gas filled shock absorbers with three link rigid and
isolated trailing arm
Power Steering Type: Electronic Power Steering (EPS)
INDICO CS (PETROL)
BODY TERMINOLOGY
CLASSIFICATIONS BY SHAPE
There are various styles of bodies available in the market for passenger cars
today. There exists no hard rules for the classifications and new segments and
sub segments keep emerging as we will see. However, following are the broad
Hatchback
Sedan/Notchback
MPV/MUV
SUV/Offroad
Estate/
Station wagon
Hatchback
Hatchbacks are vehicles with a separate engine area, and passenger area, the luggage area is
enclosed with the passenger area behind the rear seats.
Hatchback can have 4 passenger doors (5 door hatchback) as all do in India or 2 passenger
doors (3 door hatchback) e.g. Zen Export model.
Examples in India: Maruti 800, Alto, Zen, Wagon R, Palio etc.
Sedan/Notchback
Saloons are basically vehicle with an engine area, passenger area, and boot
area, all separate, and with 4 doors.
Examples in India
Esteem, Baleno, Accent, Sienna, Ikon, Corsa, Vectra, Camry
Estate/Station Wagon
Estates or Station wagons are modified saloon vehicles by combining the boot with
passenger area & extending it till the roof .
This makes the boot larger and makes it convenient to carry big objects.
Examples in India: Altura, Weekend, Swing, Marina
MPV/MUV
MPV (multi purpose vehicles) or MUV (Multi utility vehicles) can have the engine, passenger
area and boot area enclosed together, like Omni & Versa.
Or they can have the engine area separate and the passenger and boot area enclosed.
MUV/MPV can also have Third row of seating.
They are also taller and generally more spacious.
Examples in India: Omni, Versa, Innova, Sumo
These vehicle have large tyres, higher seating, higher ground clearance. The
engine area is separate and the passenger and boot area are enclosed together.
These vehicle are either equipped with 4 wheel drive or has as an option of 4
wheel drive.
Examples in India: XL-7, Gypsy, Pajero, Safari, Scorpio
FWD GEARBOX
Neutral
FWD GEARBOX
1st Gear
FWD GEARBOX
2nd Gear
FWD GEARBOX
3rd Gear
FWD GEARBOX
4th Gear
FWD GEARBOX
5th Gear
FWD GEARBOX
Reverse
Disadvantages
With powerful engines, increasing influence on steering;
Engine length limited by available space;
Engine gearbox unit renders more difficult the arrangement of the
steering package;
Poorer drive-off capacity on wet and icy roads and on inclines
There is a complex front axle, so inner drive shafts need a sliding CV
joint
Higher tyre wear in front, because the highly loaded front wheels
are both steered and driven;
Complex gear shift mechanism which can also be influenced by
power plant movements.
Advantages of front-mounted
engine, rear-mounted drive design
No restriction on engine length, making it particularly suitable for more powerful
vehicles (in other words for engines with 812 cylinders).
Insulation of engine noise is relatively easy.
Under full load most of the vehicle mass is on the driven rear axle (important for
estate cars and trailers
Simple and varied front axle designs are possible irrespective of drive forces.
Uncomplicated gear shift mechanism
Sufficient space for housing the steering system in the case of a recirculating ball
steering gear.
Good cooling because the engine and radiator are at the front; a power-saving
fan can be fitted.
Disadvantages
Complex rear independent wheel suspension with chassis subframe,
differential gear case and axle drive causing restrictions in boot size
The need for a propshaft between the manual gearbox and differential
and, therefore, a tunnel in the floor pan is inevitable, plus an unfavourable
interior to vehicle
WHEELS
WHEELS
Wire spoked wheels Hub, spokes/wires,rim,tyre,tube,
tube valve, flap
Steel disc wheels
- Rim,ring,tyre,tube,tube valve, flap
Light alloy wheels
Aluminium or Magnesium alloy
Magnesium alloy wheels weighs about 50 % of a steel wheel and about
70% of an Aluminum alloy wheels
Reduced unsprung weight
Light alloys are better conductors
Magnesium alloys have high impact anf fatigue strength so that they
can withstand vibrations and shocK loading better
Higher cost
WHEELS
TYRES
Function
Interpose a cushion between the road and car wheels - shocks
To carry load of the vehicle
Provide frictional contact between wheels and road, so that good
traction is secured
Desirable tire properties
Load carrying capacity
Must be of max. strength to take weight ,road shocks etc.
Must be strong enough to resist local deformation
Cushioning
Should be able to absorb high frequency vibration set up by the road surface
Wheel balance
Must be properly balanced
Non skidding
Good thread pattern giving nice gripping
TUBE
Tube flexible
Amount of air pressure depends on the type of tire and operation
Passenger cars : 22 30 psi
Trucks & buses : 100 psi
Importance of maintaining tyre pressure
Under inflation severe flexing of tire plies, side walls, excessive heat,
premature failure
Over inflation overloads the components of the tyre, causes excessive tread
wear and hard riding
CARCASS TYPE
Cross ply or bias ply
Ply cords are woven at an angle (30 40) to the tyre axis
Two layers run in opposite direction
Radial ply
Ply cords run in radial direction
Number of break strips in circumferential direction to provide lateral stability
Due to the highly flexible sidewalls ,their bulge appears due to which tyre
seems to be under inflated
TUBELESS TYRE
No separate tube
Advantages
Tubeless Tyre
Tubeless Tyre
Tubeless tyres are tyres wherein there is no tube, the air is held between the tyre and the rim. The
advantages of this are: Incase of a puncture, the air does not rapidly escape through the valve hole as the valve is fitted to the rim,
the air if at all only escapes slowly. The chances of a blow out are also minimal.
The ride & handling is also marginally better.
The mileage too increases slightly.
And the only care one has to take is when changing a tyre or repairing, is the work should be done on a
machine not a local hammer
TYRE SECTION
Aspect ratio = Tyre section height/ Tyre section width
Lower aspect ratio
Better load carrying capacity
TYRE CODIFICATION
2
155/65 R13
Tyres size is usually identified by a code that looks like the number alongside.
3
The significance of these numbers is as below:
1. Tyre width in mm
2. Aspect Ratio (Height/Width)
3. R for radial tyre
4. Rim Diameter in Inches.
TYRE DESIGNATIONS
Tire Size : 8 x 15 (m xn)
n : Diameter of the rim, m : m inches larger in radius than rim
Width, speed rating,diameter
(SR upto 170kmph, HR upto 210 kmph, VR above 210 kmph),
145 SR -13
Width, rim diameter, ply rating
9.00 20 -12
Load/size relationship, tyre construction, aspect ratio, Rim size in inches
FR 78 -15
WHEEL BALANCING
Regular tyre maintenance and wheel alignment reduces fuel consumption and
prevents undue tyre wear.
Worn shock absorbers and weak springs can also contribute to the waste of fuel.
Correctly aligned wheels extend tyre life and improve fuel efficiency
They also help safe steering of the vehicle and comfortable ride
Wheel out of balance leads to hard steering, rough riding and rapid tire wear
Static balance & Dynamic balance
STATIC BALANCE
A wheel that is statically out of
balance is heavier in one section than
in another.
A statically balanced wheel may not
be dynamically balanced
DYNAMIC BALANCE
To check dynamic balance ,the wheel is spun and indicating device in the
wheel balancer indicates the place and appx. amount the dynamically out
of balance.
Dynamic unbalance causes the wheels to wobble at or above a particular
speed.
No more than 8 ounces should be added to a rim
Lighting system
Ignition system
Starting system
Generator
Purpose of Battery
Discharging : The battery can make the electrical energy from the
chemical energy.
Charging : It can also store the electrical energy as the chemical
energy .
The requirements for the battery :
* It should be small in size and light in weight.
* It should have long lifetime.
* It should be endure against the hard vibrating conditions.
* It should have large capacity and it should have cheap cost.
The lead peroxide (PbO2) is used for the anode, the discharge
lead (Pb) is used for the cathode and the dilute sulfuric acid
(H2SO4) solution is used for the electrolyte.
BATTERY
Electrolyte
Sulfuric acid
Battery case
Moulded from ebonite
Or bituminous
CHEMICAL REACTIONS
H2SO4 = H2 (pos) + SO4 (neg.)
H2 +PbO2 = H2O +PbO (Pos)
PbO +SO4 = PbSO4 (Pos)
Pb +SO4 = PbSO4
Charged
Lead
Peroxide
PbO2 +
Pos
(Neg.)
Discharged
Sulfuric Spongy
Lead
Water Lead
Energy
acid
lead
Sulfate
Sulfate
2H2SO4 + Pb
= PbSO4 + 2H2O + PbSO4 + Q
Electrolyte Neg.
Pos.
Water
Neg.
PbO2
Electrolyte
+
Lead
peroxide
2H2SO4
Cathode
+
Dilute
sulfuric acid
Pb
Anode
Discharge
lead
PbSO4
Electrolyte
+
Lead
sulfate
2H2O
Cathode
+
PbSO4
Water
Lead
sulfate
Electrolyte
Cathode
PbSO4
Lead
peroxide
Electrolyte
+
2H2O
Water
Cathode
+
PbSO4
Lead
sulfate
Anode
PbO2
Lead
peroxide
2H2SO4
Dilute
sulfuric
acid
Pb
Discharg
e lead
The lead in the lead peroxide is combined with the sulfuric acid
to form the lead sulfate.
The discharge lead of the cathode is converted into the lead
sulfate as the anode.
Full charge
charge
charge
Very little life
Completely discharged
Suction type
gravimeter
Scale
Float
Suction
tube
BATTERY CAPACITY
Maximum current that a cell can furnish is dependent on the area of plate
surface in contact
Standard Capacity rating (SAE )
20 hour rating in ampere hours (quantity of energy furnished by a current
of 1 amp for 1 hour)
Indicates the lighting ability of the battery
Discharging the battery at a current rate equal to 1/20 of the
manufacturer's ampere hour rating
6 V, 120 amp hour 6 amp for 20 hrs before its terminal voltage drops to
5.25 V
12 amp 10hrs
3 amp 40hrs
20
Hours
100
10
Hours
92
9.2
5 Hours
3 Hours
1 Hour
80
75
68
16.0
25.0
68.0
BATTERY LIFE
Depends on the material
Way of use
Overcharging Faulty regulator/generator dry battery
Under charging Sulfated Sulfate crystals causes plates to buckle
and break
Mechanical breakage
Excessive loads Starting motor
Addition of distilled water
BATTERY CHARGING
Charging methods
Slow charge method Small current for long time
Quick charge method Large current for short time
Battery charging
Quick charge
CHARGING CIRCUIT
Responsible to keep the battery charged for regular supply of electric
current to various electrical systems.
DC Generator
Battery
Ampere-meter
Cut out/Voltage/Current Regulator
Necessity of regulators
DC GENERATORS
REGULATORS
The value of the dynamo voltage at which the cut out contact close is
usually between 12.7 to 13.3 V
VOLTAGE REGULATOR
Causes generator to provide a charging rate in reverse ratio to the state of charge of battery
Variable resistance increases or decreases the effective resistance in generator field
Battery (full charge) & No electrical load resistance remains in the generator field
Battery (Partial charge) & with load resistance is kept only for a small portion of time
CURRENT/VOLTAGE REGULATOR
CURRENT/VOLTAGE REGULATOR
CURRENT/VOLTAGE REGULATOR
CURRENT/VOLTAGE REGULATOR
When the load requirement is high and the battery is low, the current
regulator operates to prevent the generator output from exceeding the
safe maximum
When load requirement is reduced and the battery come up to charge,
Voltage regulator operates
Current and voltage regulator will not operate simultaneously.
EMISSIONS
Hydrocarbon (HC)
- H2O + CO2 (By Oxidation)
Carbon monoxide (CO) - CO2
( By oxidation)
Soot (Particulate matters) CO2 (By oxidation)
NOx
- N2 + O2 ( By reduction)
Temperature
Oxygen content
Reaction time
EMISSION CONTROL
Engine modification
Diesel Particulate Filters (DPF)
Exhaust gas recirculation
Catalytic convertors
Fuel additives
Ce2O3 + 0.5O2
Hydrocarbon combustion:
(2x+y)CeO2 + CxHy
Cerium oxide has excellent catalytic activity due to its ability to act as oxygen
2Ce2O3 + CO2
2CeO2 + N2
The soot formed in the engine together with the lubricating oil forms
deposits inside the engine , leading to friction losses
Due to lower Cerium oxide Carbon activation temperature carbon
deposits are oxidized
Cleaner engine
Efficient operation
Lower fuel consumption
Catalytic activity of cerium oxide is strongly dependent on particle size
and surface area
Hence nanoparticles of cerium oxide ( high surface to volume ratio) is
an excellent fuel additive.
Year
Norms
CO%
HC
NOx
1983
<2%
< 1200ppm
Carburetor
1993
1 0.5 %
< 1200ppm
Carburetor with
Catalytic Converter
1997
Euro I
1 0.5 %
< 1200ppm
1999
Euro II
< 0.5 %
< 300ppm
Mpfi
2005
Euro III
< 0.5 %
< 300ppm
Remarks
TURBOCHARGER
If the traction between the tire contact patch and the road is not enough to act against the
vehicles momentum, the wheels lock up and hence skid on the road.
Vehicle Braking
without ABS
Vehicle Braking
with ABS
ABS controls braking pressure applied to each wheel by taking wheel speeds into
consideration.
This avoids the immediate lock up of the wheels while hard braking.
Hence the skidding of the wheels on the road is controlled, where the traction is
less.
By keeping the wheels from skidding while you slow down, anti-lock brakes benefit
in two ways:
Components of ABS
Warning lamp
Location of Components
Functions of Components
ABS CONTROLLER
And Controls:
The solenoid valves (8 Nos)
Pump Motor Assembly
Then it increases the pressure until it sees the deceleration again. It can do
this very quickly, before the tire can actually significantly change speed.
The result is that the tire slows down at the same rate as the car, with the
brakes keeping the tires very near the point at which they will start to lock
up.
contd.
contd.
contd.
Functions of Components
contd.
3.HALL element
4.Sensor rotor
5.ABS control module
6.Sensor power
7.Current signal
8.Wave generation circuit
9.CPU
Schematic Diagram
Without ABS
With ABS
COMPRESSOR
Compressor draws off gaseous refrigerant from the evaporator and
compress it. This causes the refrigerant gas temperature and pressure to
rise rapidly.
CONDENSOR
Condenser through which the heated refrigerant gas gives off heat to the
engine cooling air. The refrigerant gas cools off and once again becomes
liquid
EXPANSION DEVICE
A device to eject the receiver dryer passed liquid refrigerant from fine
holes for sudden expansion to produce atomized refrigerant of low
pressure and low temperature
EVAPORATOR
In which the released refrigerant expands and flows through the
evaporator tubes.this removes heat from the air blowing across the fins
and tubes and evaporates, causing the temperature inside the vehicle
gradually to be lowered
CRDI VS DDIS
Injection Quantity
Injection Begin
Injection Pressure
For every injector there is a
9 Digit specific IMA (injection mean adoption)
Emission Legislation
Higher Power and Torque
Fuel Efficient
Smoother drivability
Cost effective
Code. Which is required to be registered in the ECM, while replacing the injector.
MM =
Magneti
Marelli
MM =
Magneti
Marelli
Cylinder
head
Back leak
connector
HP outlet
connector
Inlet
connector
Shaft