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Kms4wssystem 170623171501 PDF
Kms4wssystem 170623171501 PDF
Kms4wssystem 170623171501 PDF
A PROJECT REPORT
ON
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Submitted by:
NAMES USN
KHADEER SAB (3BK13ME035)
BET’S
BASAVAKALYAN-585327
CERTIFICATE
1.
2.
ACKNOWLEDGEMENT
It is our proud privilege and duty to acknowledge the kind of help and guidance
received from several people in preparation of this report. It would not have
been possible to prepare this project in this form without their valuable help, co-
operation and guidance.
We express our sincere gratitude to our guide, Asso. Prof. RAVI KIRANAGI
Department of Mechanical Engineering, Basavakalyan Engineering College,
Basavakalyan, for guiding us in investigations for this project and in carrying
out experimental work. Our numerous discussions with his were extremely
helpful. We hold his in esteem for guidance, encouragement, involvement and
inspiration received from him.
Our sincere thanks to Asso. Prof. RAVI KIRANGI and Prof. SHIVARAJ
BHALEKAR project co-ordinator for having supported the work related to this
project. Their contributions and technical support in preparing this project and
greatly acknowledged. So, our sincere thanks to all teaching and non teaching
faculty for supporting directly or indirectly to us.
Place: Basavakalyan
Date:
Project Associates
1. INTRODUCTION
2. PRINCIPLE
The steering mechanism consists of rack and pinion arrangements which are
used to turn the wheels in the front. And a bevel gear arrangement is made just
after the steering and power is transmitted through the transfer shaft to the gear
box assembly. Then power is transmitted to the rear wheels. Layout/Operation
of the system: Two subsystems: Rack and pinion for front and rear, identical
geometry and components. Steering column is fitted with 3 bevel gears meshes
and transmits power to front and rear rack and pinion. As steering wheel is
turned the entire rotation is transferred to front rack and pinion and only half of
the rotation is transferred to rear rack and pinion.
2. Steering ratio
The steering ratio is the ratio of number of degrees of turn of the steering wheel
to the number of degrees the wheels turn. In cars, the ratio is between 12:1 and
20:1. For example, if one complete turn of the steering wheel, 360 degrees,
causes the wheels to turn 24 degrees, the ratio is then 360:24=15:1. A higher
steering ratio means that the steering wheel is turned more to get the wheels
turning, but it will be easier to turn the steering wheel. A lower steering ratio
means that the steering wheel is turned less to get the wheels turning, but it will
harder to turn the steering wheel. Larger and heavier vehicles will often have a
higher steering ratio.
3. Turning radius
The turning radius of a vehicle is the radius of the smallest circular turn (i.e. U-
turn) that the vehicle is capable of making. There is no hard and fast formula to
calculate the turning circle but an approximate value can be obtained using the
formula:
Turning circle radius = Track/2 + Wheel base/sin (Average steer angle)
4. Steering geometry
Steering geometry is the geometric arrangement of the parts of a steering system
and the value of the lengths and angles within it. Steering geometry changes due
to bumps in the road may cause the front wheels to steer in a different direction
together or independent of each other. Combined with the cars improved
steering geometry, a wide wheel and large footprint will notably improve
handling and grip.
3. BACKGROUND THEORY
The most effective type of steering, this type has all the four wheels of
the vehicle used for steering purpose. In a typical front wheel steering
system the rear wheels do not turn in the direction of the curve and thus
curb on the efficiency of the steering. Normally this system is not been
the preferred choice due to complexity of conventional mechanical four
wheel steering systems. However, a few cars like the Honda Prelude,
Nissan Skyline GT-R have been available with four wheel steering
systems, where the rear wheels turn by an angle to aid the front wheels in
steering. However, these systems had the rear wheels steered by only 2 or
3 degrees, as their main aim was to assist the front wheels rather than
steer by themselves. With advances in technology, modern four wheel
steering systems boast of fully electronic steer-by-wire systems, equal
steer angles for front and rear wheels, and sensors to monitor the vehicle
dynamics and adjust the steer angles in real time. Although such a
complex four wheel steering model has not been created for production
purposes, a number of experimental concepts with some of these
technologies have been built and tested successfully.
Usually in vehicles during turning, the tires are subject
to the forces of grip, momentum, and steering input when making a
movement other than straight ahead driving. These forces compete with
each other during steering manoeuvres. With a front-steered vehicle, the
rear end is always trying to catch up to the directional changes of the
front wheels. This causes the vehicle to sway. When turning, the driver is
putting into motion a complex series of forces. Each of these must be
balanced against the others. The tires are subjected to road grip and slip
angle. Grip holds the car’s wheels to the road, and momentum moves the
car straight ahead. Steering input causes the front wheels to turn. The car
momentarily resists the turning motion, causing a tire slip angle to form.
Once the vehicle begins to respond to the steering input, cornering forces
are generated. The vehicle sways as the rear wheels attempt to keep up
with the cornering forces already generated by the front tires. This is
referred to as rear-end lag because there is a time delay between steering
input and vehicle reaction. When the front wheels are turned back to a
straight-ahead position, the vehicle must again try to adjust by reversing
the same forces developed by the turn. As the steering is turned, the
vehicle body sways as the rear wheels again try to keep up with the
cornering forces generated by the front wheels.
4. THE CONCEPTS
The Four Wheel Steering System consists of rack and pinion mechanism
assisted by bevel gears of which is connected to front pinion, steering rod in
which input is given by the driver and another will be connected to rear pinion.
Rear wheel system consists of two racks with two pinions. One of the racks will
be in front of the rear wheel axis and the other will be at the front axis. Also at
any point in the system, one of the rack & pinion assembly will be engaged with
the other being disengaged. At lower speeds, the pinion will be in contact with
rear rack so as to keep the wheels motion out of phase while for higher speeds
pinion will be in contact with front rack of rear steering system, giving in phase
motion to wheels. This position of the rear pinion on the rack is controlled by a
steering mechanism. The angle turned by rear wheels will not be as high as that
of front wheels because the function of rear steering system is to assist the
motion of front wheels and not provide its own direction. This change of angle
is obtained by changing gear ratio of rack and pinion.
5. LITERATURE REVIEW
Cot Ø – cot θ = c / b
Slow and High Speed Modes
At Slow Speeds rear wheels turn in direction opposite to that of front wheels.
This mode is used for navigating through hilly areas and in congested city
where better cornering is required for U turn and tight streets with low turning
circle which can be reduced as shown in Fig 2.
At High Speeds, turning the rear wheels through an angle opposite to front
wheels might lead to vehicle instability and is thus unsuitable. Hence the rear
wheels are turned in the same direction of front wheels in four-wheel steering
systems. This is shown in Fig 3.
The 4WS system performs two distinct operations: in- phase steering, whereby
the rear wheels are turned in the same direction as the front wheels, and
counter phase steering, whereby the rear wheels are turned in the opposite
direction. The 4WS system is effective in the following situations:
Lane Changes
Gentle Curves
Junctions
Narrow Roads
U-Turns
Parallel Parking
U-Turns
By minimizing the vehicle’s turning radius, counter-phase steering of the
rear wheels enables U-turns to be performed easily on narrow roads.
In a straight-mechanical type of 4WS, two steering gears are used-one for the
front and the other for the rear wheels. A steel shaft connects the two steering
gearboxes and terminates at an eccentric shaft that is fitted with an offset pin.
This pin engages a second offset pin that fits into a planetary gear. The
planetary gear meshes with the matching teeth of an internal gear that is secured
in a fixed position to the gearbox housing. This means that the planetary gear
can rotate but the internal gear cannot. The eccentric pin of the planetary gear
fits into a hole in a slider for the steering gear. A 120-degree turn of the steering
wheel rotates the planetary gear to move the slider in the same direction that the
front wheels are headed. Proportionately, the rear wheels turn the steering wheel
about 1.5 to 10 degrees. Further rotation of the steering wheel, past the
120degree point, causes the rear wheels to start straightening out due to the
double-crank action (two eccentric pins) and rotation of the planetary gear.
Turning the steering wheel to a greater angle about 230 degrees, finds the rear
wheels in a neutral position regarding the front wheels. Further rotation of the
steering wheel results in the rear wheels going counter phase with regard to the
front wheels. About 5.3 degrees maximum counter phase rear steering is
possible. Mechanical 4WS is steering angle sensitive.
In the hydraulic four-wheel-steering system, the rear wheel turns only in the
same direction as the front wheels. This system limits rear wheel movement to
5.5 degrees in either the left or right direction. A two-way hydraulic cylinder
mounted on the rear stub frame turn the wheels. Fluid for this cylinder is
supplied by a rear steering pump that is driven by the differential. The pump
only operates when the front wheels are turning. When the steering wheel is
turned, the front steering pump sends fluid under pressure to the rotary valve in
the front rack and pinion unit. This forces fluid into the front power cylinder,
and the front wheels turn in the direction steered. The fluid pressure varies with
the turning of the steering wheel. The faster and farther the steering wheel is
turned, the greater the fluid pressure. The fluid is also fed under the same
pressure to the control valve where it opens a spool valve in the control valve
housing. As the spool valve moves, it allows fluid from the rear steering pump
to move through and operate the rear power cylinder. The higher the pressure on
the spool, the farther it moves. The farther it moves, the more fluid it allows
through to move the rear wheels.
In this system, a speed sensor and steering wheel angle sensor feed information
to the electronic control unit (ECU). By processing the information received,
the ECU commands the hydraulic system to steer the rear wheels. At low speed,
the rear wheels of this system are not considered a dynamic factor in the
steering process. At moderate speeds, the rear wheels are steered momentarily
counter 45 phase, through neutral, then in phase with the front wheels. At high
speeds, the rear wheel turns only in phase with the front wheels. The ECU must
know not only road speed, but also how much and quickly the steering wheel is
turned. These three factors - road speed, amount of steering wheel turn, and the
quickness of the steering wheel turn - are interpreted by the ECU to maintain
continuous and desired steer angle of the rear wheels. The yoke is a major
mechanical component of this electro-hydraulic design. The position of the
control yoke varies with vehicle road speed. The stepper motor moves the
control yoke. A swing arm is attached to the control yoke. The position of the
yoke determines the arc of the swing rod. The arc of the swing arm is
transmitted through a control arm that passes through a large bevel gear.
Stepper motor action eventually causes a push-or-pull movement of its output
shaft to steer the rear wheels up to a maximum of 5 degrees in either direction.
The electronically controlled, 4WS system regulates the angle and direction of
the rear wheels in response to speed and driver's steering. This speed-sensing
system optimizes the vehicle's dynamic characteristics, thereby producing
enhanced stability.
7.3 Tire:
A tire (British tyre) is a ring of material that covers the rim of a wheel. Most
road vehicles and many other vehicles use rubber tires. Tires help vehicles to
move smoothly. Tires need to be changed after their treads wear away. Driving
with worn tires is very dangerous. It can cause the tire to explode and the driver
to lose control. Tires are made of different types of rubber. Tires made of harder
rubber are made for long lasting performance, like long-distance truck carriers.
They come in different sizes and have different tread patterns. There are many
different sizes of tires. On car and truck tires, they are marked with 3 numbers
and might look like: 225/60R16.
Example
Tire size: 225/60R16
Tire width = 225mm
Sidewall height = 135mm (225 * .60 = 135)
Wheel diameter = 16 inches
Fig.7.3: Tire
7.7 Steering:
Steering is the collection of components, linkages, etc. which allows any vehicle
(car, motorcycle, bicycle) to follow the desired course. The primary purpose of
the steering system is to allow the driver to guide the vehicle. Four-wheel
steering is a system employed by some vehicles to improve steering response,
increase vehicle stability while maneuvering at high speed, or to decrease
turning radius at low speed.
fig.7.7: Steering
7.8 Chain:
A chain is typically made of metal. A chain may consist of two or more links.
Those designed for transferring power in machines have links designed to mesh
with the teeth of the sprockets of the machine, and are flexible in only one
dimension. They are known as roller chains, though there are also non-roller
chains such as block chain.
Fig.7.8: chains
In this type of steering system, we can steer a front wheel, as well as the rear
wheel of the vehicles simultaneously. This steering mainly includes two types
of steering:
Front wheels and rear wheels are steered in the same direction and are parallel
to each other. This type of system is very useful during lane changing. Front
wheels are steered in the direction opposite to that of the rear wheel. This
steering system reduces the space required by the vehicle during turning as
compared to that of the two wheel steering system. The present “Four Wheel
Steering” works mechanically with help of linkages. The system utilizes a
manual manipulator to control and direct the articulation (left and right turning)
of rear wheels. The system operates in three phases: Negative, Neutral and
Positive.
At lower speeds, rear wheel turns in opposite direction from the front
wheel. This is negative phase. At moderate speed, the rear wheel remains
straight or neutral.
At higher speed, the rear wheel are in the positive phase turning in the
same direction as the front wheels.
9. TYPES OF STEER
9.2 Over-Steer
Over steer is defined when the slip angle of front wheels lesser than the slip
angle of rear wheels.
10. OPERATIONS
10.1 Welding:
10.2 Cutting:
Cutting is the separation of a physical object, into two or more portions, through
the application of an acutely directed force. Cutting is a compressive and
shearing phenomenon, and occurs only when the total stress generated by the
cutting implement exceeds the ultimate strength of the material of the object
being cut. Cutting has been at the core of manufacturing throughout history. For
metals many methods are used and can be grouped by the physical phenomenon
used.
10.3 Grinding:
A grinding machine, often shortened to grinder, is any of various power tools or
machine tools used for grinding, which is a type of machining using an abrasive
wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a
small chip from the work piece via shear deformation. Grinding is used to finish
work piece that must show high surface quality (e.g., low surface roughness)
and high accuracy of shape and dimension. As the accuracy in dimensions in
grinding is of the order of 0.000025 mm, in most applications it tends to be a
finishing operation and removes comparatively little metal, about 0.25 to
0.50 mm depth. However, there are some roughing applications in which
grinding removes high volumes of metal quite rapidly. Thus, grinding is a
diverse field.
10.4 Drilling:
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross -
section in solid materials. The drill bit is usually a rotary cutting tool, often
multipoint. The bit is pressed against the work piece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge
against the work piece, cutting off chips (swarf) from the hole as it is drilled. In
rock drilling, the hole is usually not made through a circular cutting motion,
though the bit is usually rotated. Instead, the hole is usually made by
hammering a drill bit into the hole with quickly repeated short movements. The
hammering action can be performed from outside of the hole (top-hammer drill)
or within the hole (down-the-hole drill, DTH). Drills used for horizontal drilling
are called drifter drills.
For building of prototype model, the designed model is considered along with
that a frame is built to support the steering, suspension and seat.
The frame is designed considering the wheelbase and track width of Maruti
Suzuki 800 and also it has to support for the suspension part as the suspension is
welded to the frame, seat is also welded to the frame, the support structure for
steering column and rack body is welded to the frame. The frame also takes the
road load and load of the driver, so considering all the factors the frame is
designed and developed.
35 cm
65cm
140cm
12. CALCULATIONS
Fig.12.1: Steering angles position of instantaneous centre for turning radius 4.4m.
Now considering the same steering angles for front and rear tires, we reduce in
the turning radius of the vehicle but keeping the wheelbase and track width
same as the benchmark vehicle.
Calculation for turning radius for same steering angles.
To find turning radius, R
R2 = A22 + L2 cot2δ…………………… (8)
Where δ = Total steering angle of the vehicle.
To find δ
cotδ = (cotδi + cotδo) / 2…………….. (9)
Where δi = total inner angle of the vehicle.
δo = total outer angle of the vehicle.
cotδ = 1.032.
From equation 8
R = 2596 mm.
Further calculation for C1 and C2 from equation 3 and 4
considering turning radius as 2596 mm.
C1 = 780.82 mm.
C2 = 1394.17 mm.
1) Deformation analysis
2) Stress analysis
15. COMPARISON
16. ADVANTAGES
3. High speed straight line stability: The vehicle’s straight –line stability
at high speed is improved. Negative effects of road irregularities and
crosswinds on the vehicles stability are minimized.
17. DISADVANTAGES
3. The system is not stable at high speed gets overpowered and topple in
some cases.
19. APPLICATION
20. CONCLUSION
22. REFERENCES