DESIGN AND FABRICATION OF

POWER DEPLOYABLE RUNNING BOARD

A PROJECT REPORT

SUBMITTED BY
NITHEESH MOHAN (960614114065)

PRASHANTH.S.N (960614114067)

PRAVEEN.M.R (960614114068)

RAHUL RAJ (960614114070)

In partial fulfilment for the award of the degree

Of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DMI ENGINEERING COLLEGE

ARALVAIMOZHI-629 301

ANNA UNIVERSITY, CHENNAI-600 025

APRIL-2018
 ANNA UNIVERSITY, CHENNAI-600 025

BONAFIDE CERTIFICATE

This is to certify that this project report on “DESIGN AND FABRICATION OF POWER
DEPLOYABLE RUNNING BOARD " work is done by PRAVEEN.M.R(960614114068),
PRASHANTH.S.N(960614114067), RAHUL RAJ (960614114070), NITHEESH MOHAN
(960614114065), of mechanical department in partial fulfilment of the course work requirement for
the BACHELOR OF ENGINEERING degree examination during the year 2017-2018

SIGNATURE SIGNATURE

MR.C.MAHIL LOO CHRISTOPER,M.E MR.TAMILVAANAN.B ,M.E

Head of the Department, Project supervisor,

Assistant Professor, Assistant Professor,

Dept. of Mechanical Engg, Dept. of Mechanical Engg,

DMI ENGINEERING COLLEGE, DMI ENGINEERING COLLEGE

ARALVAIMOZHI-629301 ARALVAIMOZHI-629301

Anna University practical project viva voce held on ………………. 2018

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We reveal our prime gratitude to the Lord Almighty for giving in the confidence and strength for
successful termination of our project.

We wish to our deep sense of gratitude to our beloved chairman, REV.FT. J.E. ARUL RAJ and
managing trustee REV.Sr.XAVIER SELVI for this constant encouragement throughout the
course

We wish to express our deep sense of gratitude to our principal, Dr.A.ALBERT RAJ, M.E, Ph.D.
and our Administrator Rev.Sr.MATHALAI MARY for their stable and ethical support to finish
our project successfully

We express our deep sense of gratitude to our esteem HOD

Mr.C.MACHIL LOO CHRISTOPHER M.E, Department of Mechanical Engineering, and
our project supervisor Mr.B.TAMILVAANAN, M.E For his scintillating discussions and
encouragement towards our project work and for his excellent guidance and co-operation
during the project work .

It is pleasure to acknowledge our indebt to all the stuff members of our department who aided us
successfully to bring our project as effective one. Further thanks to non-teaching staff members for
extending the lab facilities. We thank our family members and friends for their honourable support.

ABSTRACT
The aim of the project is to Design and Fabrication of POWER DEPLOYABLE RUNNING BOARDS
an automatic extending Running board system in automobiles. In this project is In control apparatus
for an automobile and a method of controlling such A circular gear called "the pinion" engages
teeth on a linear "gear" bar called "the rack"; rotational motion applied to the pinion causes the rack
to move relative to the pinion, thereby translating the rotational motion of the pinion into linear
motion .Aside from making the vehicle more ergonomic and protecting it from minor damage, a
running board can also help keep the interior of the van or truck clean by serving as a doormat upon
which passengers can wipe their feet before entering easily.
This system consists of a sensor system which is used to detect the door open
or Running board automatic switch on. The automatic Running board system in automobiles
used to protect the car owners. Thus by means of this project we can establish an feet before
entering easily. This project has also a high advantage of simple in construction and easy
operation.

CONTENTS
CHAPTER Title Page No.
NO
ACKNOWLEDGEMENT I
ABSTARACT II
CONTENT iii
LIST OF TABLE iv
LIST OF FIGURE v
LIST OF SYMBOLS vi
 1 Introduction
1.1 Market size
8-10
1.2 Government initiatives
1.3 Manufacturing facilities
1.4 Need for automation

2 Literature review 11-12

3
Gears 13-25
3.1 History of gears
3.2 Classification of gears
3.2.1 Spur gears
3.2.2 Helical gears
3.2.3 Double helical gear or Herringbone gear
3.2.4 Internal gear
3.3 Rack and pinion
3.4 Frame
3.5 Straight bevel gear
3.6 Spiral bevel gear
3.7 Hypoid bevel gear
3.8 Worm gear
3.9 Spiral gear
3.10 Law of gearing
3.11 Meshing of gears
3.12 Applications of rack and pinion
3.13 Rack rail ways
3.14 Actuators

4 Power deploy
4.1 Automatic power deploy
4.2 Manual power deploy
4.3 Principles of D.C Machines
4.4 Homopolar machines
26-30
4.5 Hetropolar D.C machines

5 Motor 31-39
5.1 D.C motor
5.2 Electromaganetic motor
5.3 Brushed
5.4 Brushless
5.5 Ball bearing motor
5.6 Permanent magnet stator
5.7 Series connection
5.8 Shunt connection
5.9 Compound connection
6 Main component 40
6.1 Block diagram
6.2 Car door
6.3 Wiper motor
6.4 Mild steel 41-48
6.5 Rack and pinion
6.6 Battery
6.7 Running board
6.8 Micro controller

7 Working principle 49-50

Calculation
8 Advantages & Application 51-52

9 Result & Discussion 53-54

Conclusion & Future scope
REFERENCES
 LIST OF FIGURES

Fig No. Title Page No.

3 Gears 13
3.2.1 Spur gear 15
3.2.2 Helical gear 16
3.3 Rack and pinion 18
3.5&3.6 Straight&Spiral gears 19
3.8 Worm gear 20
4.4 Homopolar machines 27
4.5 Hetropolar machines 29
5.6 Series connection 35
5.7 Shunt connection 37
5.8 Compound connection 39
7.2 Wiper motor 41
7.7 Micro controller 48

LIST OF ACRONYMS, SYMBOLS AND ABBREVIATIONS

Sl. No. Symbol/Avv./Nom. Description

01 m mass

02 g Acceleration due to gravity

03 µ Coefficient of friction

04 v Velocity

05 fn Life time factor

06 tb Acceleration time

07 sb Safety coefficient

CHAPTER 1

1. INTRODUCTION
 The automotive industry in India is one of the largest in the world with an annual
production of 23.96 million vehicles in 2015–16, following a growth of 2.57 per cent over the last
year. The automobile industry accounts for 7.1 per cent of the country's gross domestic product .
The Two Wheelers segment, with 81 per cent market share, is the leader of the Indian Automobile
market, owing to a growing middle class and a young population. Moreover, the growing interest of
companies in exploring the rural markets further aided the growth of the sector. The overall
Passenger Vehicle segment has 13 per cent market share.

India is also a prominent auto exporter and has strong export growth expectations for the near
future. In 2014–15, automobile exports grew by 15 per cent over the last year. In addition, several
initiatives by the Government of India and the major automobile players in the Indian market are
expected to make India a leader in the Two Wheeler and Four Wheeler market in the world by
2020.

1.1 MARKET SIZE

The industry produced a total 14.25 million vehicles including PVs, commercial vehicles ,
four wheelers 2W in April–October 2015, as against 13.83 in April–October 2014, registering a
marginal growth of 3.07 per cent, year-to-year.
The sales of PVs grew by 8.51 per cent in April–October 2015 over the same period in the
previous year. The overall CVs segment registered a growth of 8.02 per cent in April–October 2015
as compared to same period last year. Medium and Heavy Commercial Vehicles registered very
strong growth of 32.3 per cent while sales of Light Commercial Vehicles declined by 5.24 per cent
during April–October 2015, year-to-year.
In April–October 2015, overall automobile exports grew by 5.78 per cent. PVs, CVs, 3Ws
and 2Ws registered growth of 6.34 per cent, 17.95 per cent, 18.59 per cent and 3.22 per cent,
respectively, in April–October 2015 over April–October 2014
1.2 GOVERNMENT INITIATIVES

The Government of India encourages foreign investment in the automobile sector and allows
100 per cent FDI under the automatic route.

Some of the major initiatives taken by the Government of India are:

The Government of India aims to make automobile manufacturing the main driver of "Make in
India" initiative, as it expects the passenger vehicles market to triple to 9.4 million units by
2026, as highlighted in the Auto Mission Plan 2016-26.
 In the Union budget of 2015-16, the Government has announced plans to provide credit of Rs
850,000 crore to farmers, which is expected to boost sales in the tractors segment.

The government plans to promote eco-friendly cars in the country—i.e. CNG-based vehicles,
hybrid vehicles, and electric vehicles—and also to make mandatory 5 per cent ethanol blending
in petrol.

1.3 MANUFACTURING FACILITIES:

The majority of India's car manufacturing industry is evenly divided into three "clusters".
Around Chennai is the southernmost and largest, with a 35% revenue share, accounting for 60% of
the country's automotive exports, and home of the operations of Heavy Vehicles Factory, (Engine
Factory Avadi, Ford, Hyundai, Renault, Mitsubishi, Nissan, BMW, Hindustan Motors, Daimler,
Caparo, ((Mini, and Datsun.

KERALA:

COMMERCIAL VEHICLES

Bharat Earth Movers Defense Products - produces Tatra Trucks 12x12, 10x10,8x8, 6x6, 4x4,
and variants

Kerala Automobiles Limited

TAMIL NADU:

Two wheelers

TVS Motor – Hosur

Royal Enfield – Chennai

India Yamaha Motor – Oragadam

PASSENGER VEHICLES

Ford India Private Limited – Maraimalai Nagar

Hyundai Motor India Limited – Sriperumbudur

 Mitsubishi – Tiruvallur

Renault Nissan Automotive India Private Limited

Nissan Motor India Private Limited – Oragadam

Renault India Private Limited

1.4 NEED FOR AUTOMATION:

This project is fully equipped by IR sensors circuit and extended activation circuit. It is a
genuine project which is fully equipped and designed for Automobile vehicles. This forms an
integral part of best quality. This product underwent strenuous test in our Automobile vehicles and
it is good.

Automation can be achieved through computers, hydraulics,extendeds, robotics, etc., of these

sources, extendeds form an attractive medium for low cost automation.

The main advantages of all extended systems are economy and simplicity. Automation
plays an important role in mass production.For mass production of the product, the machining
operations decide the sequence of machining. The machines designed for producing a particular
product are called transfer machines. The components must be moved automatically from the bins
to various machines sequentially and the final component can be placed separately for packaging.

Materials can also be repeatedly transferred from the moving conveyors to the work place
and vice versa. Nowadays almost all the manufacturing process is being atomized in order to
deliver the products at a faster rate. The manufacturing operation is being atomized for the
following reasons.

CHAPTER 2

LITERATURE REVIEW
By MICHEAL GRAYEN SAE certified mechanic and technical writer says that a running board
or footboard is a narrow step fitted under the side doors of a tram (cable car, trolley, or streetcar in
North America), car, or truck. It aids entry, especially into high vehicles, and is typical of vintage
trams and cars, which had much higher ground clearances than today's vehicles. It is also used as a
fashion statement on vehicles that would not otherwise require it. The origin of the name running
board is obscure; the first running boards predate automobiles and were installed on carriages as
early as the 17th century.

In the early 20th century, all automobiles were equipped with running boards. The necessity of
using them was caused by the fact that first cars were designed with a narrow, high body bolted to
the chassis. A running board served as a step to a vehicle's cabin, and sometimes could be wide
enough to serve as a place to sit or even lie down for an adult.

2.1 HISTORICAL BACKGROUND

During the 1920s and 1930s, car design was evolving rapidly to
become more sleek and aerodynamic, which largely eliminated the need for running boards. The
first automobile designed without running boards was the 1936 Cord. It changed the attitude
towards running boards for many years ahead.

Running boards may also be used to stand on while the vehicle is moving. The name running board
is also given to safety appliances for walking on top of rail cars.

In 1945, at the end of World War 2, car makers met pent-up demand by resuming manufacture of
their pre-war designs. By the end of the decade, cars (but not trucks) were done with running
boards. Compare this 1948 Ford with the 1949 Ford. Although the has a slim"running board", by it
was all slab-sided.

1979 Beetle Convertible Equipped With Running Boards

One significant hold-out was the Volkswagen Beetle. Designed before the war, the basic styling
never changed, and the running boards stayed until the end, which in the U.S. was represented by
the 1979 Beetle convertible.

Trucks always lagged behind their automotive brothers in the design department. Since "trucks"
were sold to farmers and laborers, they really didn't need to be designed. Trucks kept running
boards into the mid-1950s. Compare this 1954 Chevy pickup with running boards next to the 1956
version without.

1954 Chevy Pickup1956 Chevy Pickup

Note though, that the 1956 truck has a "step" behind the door to help one reach into the pickup bed.
It's almost a last vestige of a running board.

Running boards made a comeback as a practical matter. First, with the booming popularity of the
large SUV (Sport Utility Vehicle), these trucks were used to ferry families, friends, even paying
customers if used as limos. Since the SUVs sat higher off the ground than the typical car, some
riders needed help during entry and exit. The running board was the "stepping stone" to do just that.

Lincoln Navigator With Running BoardsChevy Tahoe 3 Door With Running Boards

Secondly, the craze toward "lifted" vehicles was a boom to those who wished to go off-roading in
their 4x4s. The increased ground clearance meant that boulders and streams could tackled more
easily. The trade-off was in the literal leap between the ground and the driver's seat. A running
board helped you get in and out, but ran the risk of becoming the truck's low point during off-road
excursions. But compared with tubular side bars, the running boards hugged the truck's rocker
panels and minimized the decrease in ground clearance.
Today, running boards are as much a style statement as they are a matter of practicality

2.2 CAR & RUNNING BOARD

A car, automobile, or auto is a wheeled, self-powered motor vehicle used for

transportation and a product of the automotive industry. Most definitions of the term specify that
cars are designed to run primarily on roads, to have seating for one to eight people, to typically have
four wheels with ((tyres, and to be constructed principally for the transport of people rather than
goods.

Cars did not become widely available until the early 20th century. One of the first cars that was
accessible to the masses was the 1908 Model T, an American car manufactured by the Ford Motor
Company. Cars were rapidly adopted in the United States of America, where they replaced animal-
drawn carriages and carts, but took much longer to be accepted in Western Europe and other parts
of the world.

The benefits may include on-demand transportation, mobility, independence,

and convenience. The societal benefits may include: economic benefits, such as job and wealth
creation from car production, sales and maintenance, transportation provision, society well-being
derived from leisure and travel opportunities, and The numbers are increasing rapidly, especially in
China, India and other newly industrialized countries.

2.3 RUNNING BOARD :

A running board is a narrow step fitted under the side doors of a car or truck. It aids
entry, especially into high vehicles, and is typical of vintage cars, which had much higher ground
clearances than today's vehicles. It is also used as a fashion statement on vehicles that would not
otherwise require it. The origin of the name running board is obscure; the first running boards
predate automobiles and were installed on carriages as early as the 17th century. Whether the
running board was named after the inventor or in reference to function is open to debate.

In the early 20th century, all automobiles were equipped with running boards.
 The necessity of using them was caused by the fact that first cars were designed with a narrow,
high body bolted to the chassis. A running board served as a step to a vehicle's cabin and was wide
enough to serve as a place to sit or even lie down for an adult.Running boards may also be used to
stand on while the vehicle is moving. The name running board is also given to safety appliances for
walking on top of rail cars.

RAILROAD USAGE:

The term also applied to the walkways on top of railroad boxcars. Originally, they were
used by brakemen to travel from car to car to apply hand-operated brakes. With the adoption of the
air brake this practice was abandoned. However the running board was still used as an observation
point to pass hand signals to the train engineer when cars were being switched. The increased use of
radio communication made this unnecessary. Today it is forbidden for anyone to be on top of a
freight car while the train is in motion. The term is also used to describe the continuous step below
all doors of classic trams on both sides as well as below the doors of old fashioned ((passenger cars.

2.4 FOOTPLATE:

The footplate of a steam locomotive is a large metal plate that rests on top of the frames
and is normally covered with wooden floorboards. It is usually the full width of the locomotive and
extends from the front of the cab to the rear of cab or coal bunker just above the buffer beam.The
footplate does extend beyond the front of the cab on some locomotives, but is then usually referred
to as the "running board/plate." The footplate is where the Driver and Fireman stand in the cab to
operate the locomotive, giving rise to the expression of working on the footplate for being in the
cab of a steam locomotive..

A engineer must be present on the footplate" or "an engineer footplated the locomotive after
trouble in its bogies was reported at an intermediate station". The word however is not used to refer
to the driving cab outside of context of someone riding it : the usage "the footplate is very
convenient for the loco pilot" is incorrect.The term foot plate can also be applied to the step along
the length of a classical tram on both sides.

CHAPTER - 3

GEARS
 Fig.3 Gears

Gears are toothed members which transmit power / motion between two shafts by
meshing without any slip. Hence, gear drives are also called positive drives. In any pair of gears,
the smaller one is called pinion and the larger one is called gear immaterial of which is driving the
other.

When pinion is the driver, it results in step down drive in which the output speed decreases and
the torque increases. On the other hand, when the gear is the driver, it results in step up drive in
which the output speed increases and the torque decreases.

3.1 HISTORY OF GEARS

Indian history as per our mythological stories is more than 12,000 years old. Since then people
living here have been striving to improve the living conditions. We also know that earlier people
were living in the caves and the doors of the caves were made of granite. How were these heavy
doors opened and closed? They were opened and closed by none other than a system with gear
mechanism, wheel, lever and rope drives.

However, the documented evidence has been lost due to destruction by the invaders and
improper storing of palm leaf literature. The guru Kula method of teaching and passing of the
information from mouth to ear procedure and keeping some of the advances as closely guarded
secret have resulted in poor dissemination of the knowledge and documentation. But, the
knowledge of gears has gone from India to east through some of the globe trotters from China as
back as 2600 years BC. They have used the gears then ingeniously in chariots for measuring the
speed and other mechanisms.

Leonard da Vinci used multitudes of gears in various mechanisms developed by him 500
A.D. Greek and Roman literatures show extensive usage of gears for forward motion. Toothed
gears used for the clocks of Cathedrals and other ecclesiastical buildings during the middle ages are
still preserved in many places. Salisbury cathedral still possesses the oldest clock in England made
in 1386. The Wells Cathedral clock made in 1392 is preserved in Science museum, South
Kensington. Though the iron gears have worn out to some extent, they still keep good timings.

German artist Albrecht Durer’s engravings show a vehicle designed for the Emperor
Maximilian I during 15th century . That vehicle was driven by worm gears on all four wheels. This
clearly shows that he knew the concept of gearing which helped him in sketching them accurately.
In 18th century, Industrial Revolution in England led to usage of cycloidal gears for clocks,
irrigation devices, water mills and powered machines. gives the glimpses of their contribution to
engine application. The industrialization of west made a big impact on gear technology which is the
key to the modern development and the gear technology is advancing rapidly. It is most unlikely
that gears are going to be replaced by any other component for their function in the near future.

3.2 CLASSIFICATION OF GEARS

Gears are classified according to the shape of the tooth pair and disposition into spur, helical,
double helical, straight bevel, spiral bevel and hypoid bevel, worm and spiral gears and this is
shown in

3.2.1 SPUR GEARS

 Fig.3.2.1 (spur gear)

Spur gears have their teeth parallel to the axis and are used for transmitting power between two
parallel shafts. They are simple in construction, easy to manufacture and cost less. They have
highest efficiency and excellent precision rating. They are used in high speed and high load
application in all types of trains and a wide range of velocity ratios. Hence, they find wide
applications right from clocks, household gadgets, motor cycles, automobiles, and railways to
aircrafts.

3.2.2 HELICAL GEARS

Fig 3.2.2 (Worm&Helical gear)

Helical gears are used for parallel shaft drives. They have teeth inclined to the axis. Hence for the
same width, their teeth are longer than spur gears and have higher load carrying capacity.

Their contact ratio is higher than spur gears and they operate smoother and quieter than
spur gears. Their precision rating is good. They are recommended for very high speeds and loads.
Thus, these gears find wide applications in automotive gearboxes as illustrated in Fig. Their
efficiency is slightly lower than spur gears. The helix angle also introduces axial thrust on the shaft.

3.2.3DOUBLE HELICAL GEAR OR HERRINGBONE GEAR

Double helical or Herringbone gears used for transmitting power between two parallel shafts. They
have opposing helical teeth with or without a gap depending on the manufacturing method
adopted,.Two axial thrusts oppose each other and nullify. Hence the shaft is free from any axial
force. Though their load capacity is very high, manufacturing difficulty makes them costlier than
single helical gear. Their applications are limited to high capacity reduction drives like that of
cement mills and crushers.

3.2.4 INTERNAL GEAR

Internal gears are used for transmitting power between two parallel shafts. In these gears, annular
wheels are having teeth on the inner periphery. This makes the drive very compact In these drives,
the meshing pinion and annular gear are running in the same direction

Their precision rating is fair. They are useful for high load and high speed application with
high reduction ratio. Applications of these gears can be seen in planetary gear drives of automobile
automatic transmissions reduction gearboxes of cement mills, step-up drives of wind mills. They
are not recommended for precision meshes because of design, fabrication, and inspection
limitations.

3.3 RACK AND PINION

 Fig 3.3 (Rack and Pinion)

Rack is a segment of a gear of infinite diameter. The tooth can be spur as in Fig. or helical as in
This type of gearing is used for converting rotary motion into translatory motion or visa versa.

A rack and pinion is a type of linear actuator that comprises a pair of gears which
convert rotational motion into linear motion. A circular gear called "the pinion" engages teeth on a
linear "gear" bar called "the rack"; rotational motion applied to the pinion causes the rack to move
relative to the pinion, thereby translating the rotational motion of the pinion into linear motion.

For example, in a rack railway, the rotation of a pinion mounted on a locomotive or a

railcar engages a rack between the rails and forces a train up a steep slope.For every pair of
conjugate involute profile, there is a basic rack. This basic rack is the profile of the conjugate gear
of infinite pitch radius.

A generating rack is a rack outline used to indicate tooth details and dimensions for the design
of a generating tool, such as a hob or a gear shaper cutter.

3.4 Frame

A frame is often a structural system that supports other components of a physical construction
and/or a boundary that limits the construction's extent.

In vehicles

• Frame (aircraft), structural rings in an aircraft fuselage

• Frame (nautical), the skeleton of a ship

• Bicycle frame, the main component of a bicycle, onto which other components are fitted

• Motorcycle frame, main component of a motorcycle, onto which other components are fitted

• Locomotive frame, a structure that forms the backbone of a railway locomotive

• Vehicle frame, to which everything on an automobile is mounted

3.5 STRAIGHT BEVEL GEAR

Straight bevel gears are used for transmitting power between intersecting shafts, . They can operate
under high speeds and high loads. Their precision rating is fair to good. They are suitable for 1:1
and higher velocity ratios and for right-angle meshes to any other angles. Their good choice is for
right angle drive of particularly low ratios.

Fig 3.5 (Straight&Spiral bevel gears )

However, complicated both form and fabrication limits achievement of precision. They should be
located at one of the less critical meshes of the train. Wide application of the straight bevel drives is
in automotivedifferentials, right angle drives of blenders and conveyors. A typical application of
straight bevel used in differential application is shown in Fig..

3.6 SPIRAL BEVEL GEAR

Spiral bevel gears shown in Fig. are also used for transmitting power between intersecting shafts.
Because of the spiral tooth, the contact length is more and contact ratio is more. They operate
smoother than straight bevel gears and have higher load capacity. But, their efficiency is slightly
lower than straight bevel gear. Usage of spiral bevel gears in an automobile differential is shown
Fig.

3.7 HYPOID BEVEL GEAR

These gears are also used for right angle drive in which the axes do not intersect. This permits the
lowering of the pinion axis which is an added advantage in automobile in avoiding hump inside the
automobile drive line power transmission. However, the non – intersection introduces a
considerable amount of sliding and the drive requires good lubrication to reduce the friction and
wear. Their efficiency is lower than other two types of bevel gears. These gears are widely used in
current day automobile drive line power transmission.

3.8 WORM GEAR

Fig 3.8 (Worm gear)

Worm and worm gear pair consists of a worm, which is very similar to a screw and a worm
gear, which is a helical gear as shown in Fig. 1.25. They are used in right-angle skew shafts. In
these gears, the engagement occurs without any shock. The sliding action prevalent in the system
while resulting in quieter operation produces considerable frictional heat.

High reduction ratios 8 to 400 are possible. Efficiency of these gears is low anywhere
from 90% to 40 %. Higher speed ratio gears are non-reversible. Their precision rating is fair to
good. They need good lubrication for heat dissipation and for improving the efficiency. The drives
are very compact.

Worm gearing finds wide application in material handling and transportation machinery,
machine tools, automobiles etc. An industrial worm gear box used for converting horizontal to
vertical drive

3.9 SPIRAL GEAR

Spiral Gear Spiral gears are also known as crossed helical gears, Fig. They have high helix angle
and transmit power between two non-intersecting non-parallel shafts. They have initially point
contact under the conditions of considerable sliding velocities finally gears will have line contact.
Hence, they are used for light

Fig 3.9

load and low speed application such as instruments, sewing machine etc. Their
precision rating is poor.
3.10 LAW OF GEARING

The fundamental law of gearing states that the angular velocity ratio between the gears
of a gear set must remain constant throughout the mesh. n order to maintain constant angular
velocity ratio between two meshing gears, the common normal of the tooth profiles, at all contact
points with in mesh, must always pass through a fixed point on the line of centers, called pitch
point.

3.11 MESHING OF GEARS

In order to have a more understanding of the conjugate action in gears and how the point
of contact moves during the mesh, an illustration is provided in flash

3.12 APPLICATIONS OF RACK AND PINION

Rack and pinion combinations are often used as part of a simple linear actuator, where the
rotation of a shaft powered by hand or by a motor is converted to linear motion.

The rack carries the full load of the actuator directly and so the driving pinion is usually
small, so that the gear ratio reduces the torque required. This force, thus torque, may still be
substantial and so it is common for there to be a reduction gear immediately before this by either a
gear or worm gear reduction. Rack gears have a higher ratio, thus require a greater driving torque,
than screw actuators. Most Stair lifts today are operating using the Rack & Pinion system.

A rack and pinion is commonly found in the steering mechanism of cars or other wheeled,
steered vehicles. Rack and pinion provides a less efficient mechanical advantage than other
mechanisms such as recirculating ball, but less backlash and greater feedback, or steering "feel".

The mechanism may be power-assisted, usually by hydraulic or electrical means.

 The use of a variable rack was invented by Arthur Ernest Bishop, in the 1970s, so as to
improve vehicle response and steering "feel," especially at high speeds. He also created a low cost
press forging process to manufacture the racks, eliminating the need to machine the gear teeth.

3.13 Rack railways

Rack railways are mountain railways that use a rack built into the center of the track and a
pinion on their locomotives. This allows them to work on steep gradients, up to 45 degrees, as
opposed to conventional railways which rely on friction alone for locomotion. Additionally, the
rack and pinion addition provides these trains with controlled brakes, and reduces the effects of
snow or ice on the rails.

3.14 Actuators

A rack and pinion with two racks and one pinion is used in actuators. An example is pneumatic rack
and pinion actuators that can be used to control valves in pipeline transport .

The actuators in the picture on the right are used to control the valves of large water pipeline.
In the top actuator, a gray control signal line can be seen connecting to a solenoid valve which is
used as the pilot for the actuator. The solenoid valve controls the air pressure coming from the input
air line.

The output air from the solenoid valve is fed to the chamber in the middle of the actuator,
increasing the pressure. The pressure in the actuator's chamber pushes the pistons away. While the
pistons are moving apart from each other, the attached racks are also moved along the pistons in the
opposite directions of the two racks. The two racks are meshed to a pinion at the direct opposite
teeth of the pinion. When the two racks move, the pinion is turned, causing the attached main valve
of the water pipe to turn.
 CHAPTER 4

POWER DEPLOY

4.1 AUTOMATIC POWER DEPLOY:

The running boards will extend down and out when the doors are opened.
Automatic power stow:
The running boards will return to the stowed position when the doors are closed. There will be
a two second delay before the running boards move in to the stowed position.

4.2 MANUAL POWER DEPLOY:

To manually operate the running boards, refer to Message center in the This feature can
manually set the running boards in the deployed (OUT) position for access to the roof. When
running boards are manually set in the deployed position, the boards will return to the stowed
position and enter automatic mode when the vehicle speed exceeds 5 mph (8 km/h).

4.3 PRINCIPLES OF D.C. MACHINES

D.C. machines are the electro mechanical energy converters which work from a d.c. source and
generate mechanical power or convert mechanical power into a d.c. power. These machines can be
broadly classified into two types, on the basis of their magnetic structure.

They are,
 1. Homopolar machines

2. Heteropolar machines.

These are discussed in sequence below.

4.4 HOMOPOLAR MACHINES

Homopolar generators Even though the magnetic poles occur in pairs, in a homopolar
generator the conductors are arranged in such a manner that they always move under one polarity.
Either north pole or south pole could be used for this purpose. Since the conductor encounters the
magnetic flux of the same polarity everywhere it is called a homopolar generator.

A cylindrically symmetric geometry is chosen. The conductor can be situated on the surface
of the rotor with one slip-ring at each end of the conductor. A simple structure where there is only
one cylindrical conductor with ring brushes situated at the ends. The excitation coil produces a field
which enters the inner member from outside all along the periphery.

The conductor thus sees only one pole polarity or the flux directed in one sense. A steady
voltage now appears across the brushes at any given speed of rotation. The polarity of the induced
voltage can be reversed by reversing either the excitation or the direction of rotation but not both.
 Fig 4.4 (Homopolar Machines)

The voltage induced would be very low but the currents of very large amplitudes can be
supplied by such machines. Such sources are used in some applications like pulse-current and MHD
generators, liquid metal pumps or plasma rockets. The steady field can also be produced using a
permanent magnet of ring shape which is radially magnetized.

If higher voltages are required one is forced to connect many conductors in series.
This series connection has to be done externally. Many conductors must be situated on the rotating
structure each connected to a pair of slip rings. However, this modification introduces parasitic air-
gaps and makes the mechanical structure very complex. The magnitude of the induced emf in a
conductor 10 cm long kept on a rotor of 10 cm radius rotating at 3000 rpm, with the field flux
density being 1 Tesla every where in the air gap, is given by

The voltage drops at the brushes become very significant at this level bringing down the efficiency
of power conversion. Even though homopolar machines are d.c. generators in a strict sense that they
’generate’ steady voltages, they are not quite useful for day to day use. A more practical converters
can be found in the d.c. machine family called ”hetero-polar” machines.

4.5 HETERO-POLAR D.C. MACHINES

 In the case of a hetero-polar generator the induced emf in a conductor goes through a
cyclic change in voltage as it passes under north and south pole polarity alternately. The induced
emf in the conductor therefore is not a constant but alternates in magnitude. Fora constant velocity
of sweep the induced emf is directly proportional to the flux density under which it is moving. If the
flux density variation is sinusoidal in space, then a sine wave voltage is generated. This principle is
used in the a.c generators.

In the case of d.c. generators our aim is to get a steady d.c. voltage at the terminals of the
winding and not the shape of the emf in the conductors. This is achieved by employing an external
element, which is called a commutator, with the winding.

Hetero-polar, 2-pole machine and one-coil armature. The ends of the coil are connected to a
split ring which acts like a commutator. As the polarity of the induced voltages changes the
connection to the brush also gets switched so that the voltage seen at the brushes has a
unidirectional polarity. This idea is further developed in the modern day machines with the use of
commutators. The brushes are placed on the commutator. Connection to the winding is made
 Fig 4.5 (Hetropolar Machines)

Hetero-polar d.c. machines through the commutator only. The idea of a commutator is an ingenious
one. Even though the instantaneous value of the induced emf in each conductor varies as a function
of the flux density under which it is moving, the value of this emf is a constant at any given position
of the conductor as the field is stationary. Similarly the sum of a set of coils also remains a constant.
This thought is the one which gave birth to the commutator.

The coils connected between the two brushes must be ”similarly located” with respect to
the poles irrespective of the actual position of the rotor. This can be termed as the condition of
symmetry. If a winding satisfies this condition then it is suitable for use as an armature winding of a
d.c. machine. The ring winding due to Gramme is one such. It is easy to follow the action of the d.c.
machine using a ring winding, hence it is taken up here for explanation.

CHAPTER 5

MOTOR

5.1 MOTOR :

A DC motor is any of a class of rotary electrical machines that converts

direct current electrical power into mechanical power. The most common types rely on the forces
produced by magnetic fields. Nearly all types of DC motors have some internal mechanism, either
electromechanical or electronic, to periodically change the direction of current flow in part of the
motor.

A DC motor's speed can be controlled over a wide range, using either a variable supply
voltage or by changing the strength of current in its field windings. Small DC motors are used in
tools, toys, and appliances. The universal motor can operate on direct current but is a lightweight
motor used for portable power tools and appliances. Larger DC motors are used in propulsion of
electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of power
electronics has made replacement of DC motors with AC motors possible in many applications.

The ends of the wire winding are connected to a commutator. The commutator allows each
armature coil to be energized in turn and connects the rotating coils with the external power supply
through brushes. Brushless DC motors have electronics that switch the DC current to each coil on
and off and have no brushes.

5.2 ELECTROMAGNETIC MOTORS

A coil of wire with a current running through it generates an electromagnetic field aligned
with the center of the coil. The direction and magnitude of the magnetic field produced by the coil
can be changed with the direction and magnitude of the current flowing through it.

A simple DC motor has a stationary set of magnets in the stator and an armature with one or
more windings of insulated wire wrapped around a soft iron core that concentrates the magnetic
field. The windings usually have multiple turns around the core, and in large motors there can be
several parallel current paths. The ends of the wire winding are connected to a commutator. The
commutator allows each armature coil to be energized in turn and connects the rotating coils with
the external power supply through brushes.

Since the series-wound DC motor develops its highest torque at low speed, it is often used in
traction applications such as electric locomotives, and trams. The DC motor was the mainstay of
electric traction drives on both electric and diesel-electric locomotives, street-cars/trams and diesel
electric drilling rigs for many years. The introduction of DC motors and an electrical grid system to
run machinery starting in the 1870s started a new second Industrial Revolution. DC motors can
operate directly from rechargeable batteries, providing the motive power for the first electric
vehicles and today's hybrid cars and electric cars as well as driving a host of cordless tools.

Today DC motors are still found in applications as small as toys and disk drives, or in large
sizes to operate steel rolling mills and paper machines. Large DC motors with separately excited
fields were generally used with winder drives for mine hoists, for high torque as well
as smooth speed control using thyristor drives. These are now replaced with large AC motors with
variable frequency drives.

If external power is applied to a DC motor it acts as a DC generator, a dynamo. This feature

is used to slow down and recharge batteries on hybrid car and electric cars or to return electricity
back to the electric grid used on a street car or electric powered train line when they slow down.
This process is called regenerative braking on hybrid and electric cars. In diesel electric
locomotives they also use their DC motors as generators to slow down but dissipate the energy in
resistor stacks. Newer designs are adding large battery packs to recapture some of this energy.

5.3 BRUSHED

A brushed DC electric motor generating torque from DC power supply by using an internal
mechanical commutation. Stationary permanent magnets form the stator field. Torque is produced
by the principle that any current-carrying conductor placed within an external magnetic field
experiences a force, known as Lorentz force. In a motor, the magnitude of this Lorentz force.Since
this is a single phase two-pole motor, the commutator consists of a split ring, so that the current
reverses each half turn.

The brushed DC electric motor generates torque directly from DC power supplied to the
motor by using internal commutation, stationary magnets (permanent or electromagnets), and
rotating electrical magnets.

Advantages of a brushed DC motor include low initial cost, high reliability, and simple
control of motor speed. Disadvantages are high maintenance and low life-span for high intensity
uses. Maintenance involves regularly replacing the carbon brushes and springs which carry the
electric current, as well as cleaning or replacing the commutator. These components are necessary
for transferring electrical power from outside the motor to the spinning wire windings of the rotor
inside the motor. Brushes consist of conductors.

5.4 BRUSHLESS
 Typical brushless DC motors use one or more permanent magnets in the rotor and
electromagnets on the motor housing for the stator. A motor controller converts DC to AC. This
design is mechanically simpler than that of brushed motors because it eliminates the complication
of transferring power from outside the motor to the spinning rotor.

The motor controller can sense the rotor's position via Hall effect sensors or similar devices
and can precisely control the timing, phase, etc., of the current in the rotor coils to optimize torque,
conserve power, regulate speed, and even apply some braking. Advantages of brushless motors
include long life span, little or no maintenance, and high efficiency. Disadvantages include high
initial cost, and more complicated motor speed controllers. Some such brushless motors are
sometimes referred to as "synchronous motors" although they have no external power supply to be
synchronized with, as would be the case with normal AC synchronous motors.

5.5 BALL BEARING MOTOR

A ball bearing motor is an unusual electric motor that consists of two ball bearing-type
bearings, with the inner races mounted on a common conductive shaft, and the outer races
connected to a high current, low voltage power supply. An alternative construction fits the outer
races inside a metal tube, while the inner races are mounted on a shaft with a non-conductive
section (e.g. two sleeves on an insulating rod). This method has the advantage that the tube will act
as a flywheel. The direction of rotation is determined by the initial spin which is usually required to
get it going.

5.6 PERMANENT MAGNET STATORS

A PM motor does not have a field winding on the stator frame, instead relying on PMs to
provide the magnetic field against which the rotor field interacts to produce torque. Compensating
windings in series with the armature may be used on large motors to improve commutation under
load. Because this field is fixed, it cannot be adjusted for speed control. PM fields (stators) are
convenient in miniature motors to eliminate the power consumption of the field winding. Most
larger DC motors are of the "dynamo" type, which have stator windings. Historically, PMs could
not be made to retain high flux if they were disassembled; field windings were more practical to
obtain the needed amount of flux. However, large PMs are costly, as well as dangerous and difficult
to assemble; this favors wound fields for large machines.

5.7 SERIES CONNECTION

A series DC motor connects the armature and field windings in series with a common D.C.
power source. The motor speed varies as a non-linear function of load

Fig 5.7 (Series connection)

torque and armature current; current is common to both the stator and rotor yielding current
squared behavior. A series motor has very high starting torque and is commonly used for starting
high inertia loads, such as trains, elevators or hoists. This speed/torque characteristic is useful in
applications such as dragline excavators, where the digging tool moves rapidly when unloaded but
slowly when carrying a heavy load.

A series motor should never be started at no load. With no mechanical load on the series
motor, the current is low, the counter-EMF produced by the field winding is weak, and so the
armature must turn faster to produce sufficient counter-EMF to balance the supply voltage. The
motor can be damaged by overspeed. This is called a runaway condition.

Series motors called universal motors can be used on alternating current. Since the armature
voltage and the field direction reverse at the same time, torque continues to be produced in the same
direction.
 However they run at a lower speed with lower torque on AC supply when compared to DC
due to reactance voltage drop in AC which is not present in DC.Since the speed is not related to the
line frequency, universal motors can develop higher-than-synchronous speeds, making them lighter
than induction motors of the same rated mechanical output. This is a valuable characteristic for
hand-held power tools. Universal motors for commercial utility are usually of small capacity, not
more than about 1 kW output.

However, much larger universal motors were used for electric locomotives, fed by special
low-frequency traction power networks to avoid problems with commutation under heavy and
varying loa

5.8 SHUNT CONNECTION

Fig 5.8 (Shunt connection)

A shunt DC motor connects the armature and field windings in parallel or shunt with
a common D.C. power source. This type of motor has good speed regulation even as the load
varies, but does not have the starting torque of a series DC motor. It is typically used for industrial,
adjustable speed applications, such as machine tools, winding/unwinding machines and tensioners.

5.9 COMPOUND CONNECTION

 A compound DC motor connects the armature and fields windings in a shunt and a series
combination to give it characteristics of both a shunt and a series DC motor.

This motor is used when both a high starting torque and good speed regulation is needed. The
motor can be connected in two arrangements:

cumulatively or differentially. Cumulative compound motors connect the series field to aid
the shunt

Diagram 4.5Compound connection

Fig 5.9 (compound connection)

field, which provides higher starting torque but less speed regulation. Differential compound
DC motors have good speed regulation and are typically operated at constant speed.
 CHAPTER 6

6.1 BLOCK DIAGRAM

Battery Switch Micro controller

Dc motor Door
Rack and pinion Extension

board

Opening
operation
 MAIN COMPONENTS

6.2 CAR DOOR

Fig 7.1 (Car door)

A car door is a type of door, typically hinged, but sometimes attached by other mechanisms such
as tracks, in front of an opening which is used for entering and exiting a vehicle. A vehicle door can
be opened to provide access to the opening, or closed to secure it. These doors can be opened
manually, or powered electronically. Powered doors are usually found on minivans, high-end cars,
or modified cars.
6.3 WIPER MOTOR

Fig 7.2( Wiper motor)

A windscreen wiper or windshield wiper (American English) is a device used to remove

rain, snow, ice and debris from a windscreen or windshield.

Almostall motor vehicles,including cars, trucks, train locomotives, watercraft with a

cabin and some aircraft, are equipped with such wipers, which are usually a legal requirement. A
wiper generally consists of a metal arm, pivoting at one end and with a long rubber blade attached
to the other. The arm is powered by a motor, often an electric motor, although pneumatic power is
also used in some vehicles. The blade is swung back and forth over the glass, pushing water or
other precipitation from its surface.

The speed is normally adjustable, with several continuous speeds and often one or more
"intermittent" settings. Most automobiles use two synchronized radial type arms, while many
commercial vehicles use one or more pantograph arms.

On some vehicles, a windshield washer system is also used. This system

sprays water or an antifreeze window washer fluid at the windshield using several nozzles. The
windshield washer system helps to remove dirt or dust from the windshield when it is used in
concert with the wiper blades. When antifreeze windshield washer fluid is used, it can help the
wipers to remove snow or ice.
 For winter conditions, some vehicles have additional heaters aimed at the windows or
embedded heating wire in the glass. These defroster systems help to keep snow and ice from
building up on the windshield. In rare cases, miniature wipers are installed on headlights.

6.4 MILD STEEL:

Steel is an alloy of iron and other elements, primarily carbon, that is widely used in
construction and other applications because of its high tensile strength and low cost. Steel's base
metal is iron, which is able to take on two crystalline forms (allotropic forms), body centered cubic
and face centered cubic (FCC), depending on its temperature.

It is the interaction of those allotropes with the alloying elements, primarily

carbon, that gives steel and cast iron their range of unique properties. In the body-centred cubic
arrangement, there is an iron atom in the centre of each cube, and in the face-centred cubic, there is
one at the center of each of the six faces of the cube. Carbon, other elements, and inclusions within
iron act as hardening agents that prevent the movement of dislocations that otherwise occur in the
crystal lattices of iron atoms.

The carbon in typical steel alloys may contribute up to 2.1% of its weight. Varying the
amount of alloying elements, their presence in the steel either as solute elements, or as precipitated
phases, retards the movement of those dislocations that make iron comparatively ductile and weak,
and thus controls its qualities such as the ((hardness, ductility, and tensile strength of the resulting
steel. Steel's strength compared to pure iron is only possible at the expense of iron's ductility, of
which iron has an excess.
 Steel was produced in bloomery furnaces for thousands of years, but its
extensive use began after more efficient production methods were devised in the 17th century, with
the production of blister steel and then crucible steel. With the invention of the Bessemer process in
the mid-19th century, a new era of mass-produced steel began. This was followed by Siemens-
Martin process and then Gilchrist-Thomas process that refined the quality of steel. With their
introductions, mild steel replaced wrought iron.
Further refinements in the process, such as basic oxygen steelmaking (BOS), largely
replaced earlier methods by further lowering the cost of production and increasing the quality of the
product. Today, steel is one of the most common materials in the world, with more than 1.3 billion
tons produced annually. It is a major component in buildings, infrastructure, tools, ships,
automobiles, machines, appliances, and weapons. Modern steel is generally identified by various
grades defined by assorted standards organizations.

6.5 RACK AND PINION

Fig 7.4 (Rack and pinion)

Rack is a segment of a gear of infinite diameter. The tooth can be spur as in Fig. or helical as in
This type of gearing is used for converting rotary motion into translatory motion or visa versa.

A rack and pinion is a type of linear actuator that comprises a pair of gears which
convert rotational motion into linear motion. A circular gear called "the pinion" engages teeth on a
linear "gear" bar called "the rack"; rotational motion applied to the pinion causes the rack to move
relative to the pinion, thereby translating the rotational motion of the pinion into linear motion.

6.6 BATTERY

An electric battery is a device consisting of one or more electrochemical cells with external
connections provided to power electrical devices such as flashlights, smartphones, and electric cars.
When a battery is supplying electric

Fig 7.5 (Battery)

power, its positive terminal is the cathode and its negative terminal is the anode. The terminal
marked negative is the source of electrons that when connected to an external circuit will flow and
deliver energy to an external device. When a battery is connected to an external circuit, electrolytes
are able to move as ions within, allowing the chemical reactions to be completed at the separate
terminals and so deliver energy to the external circuit.
It is the movement of those ions within the battery which allows current to flow out of the
battery to perform work. Historically the term "battery" specifically referred to a device composed
of multiple cells, however the usage has evolved to additionally include devices composed of a
single cell.
Primary (single-use or "disposable") batteries are used once and discarded;
the electrode materials are irreversibly changed during discharge. Common examples are the
alkaline battery used for flashlights and a multitude of portable electronic devices. Secondary
(rechargeable) batteries can be discharged and recharged multiple times using mains power from a
wall socket; the original composition of the electrodes can be restored by reverse current. Examples
include the lead-acid batteries used in vehicles and lithium-ion batteries used for portable
electronics such as laptops and smartphones.

6.7 RUNNING BOARD

A running board is a narrow step fitted under the side doors of a car or truck.
It aids entry, especially into high vehicles, and is typical of vintage cars, which had much higher
ground clearances than today's vehicles. It is also used as a fashion statement on vehicles that would
not otherwise require it. The origin of the name running board is obscure; the first running boards
predate automobiles and were installed on carriages as early as the 17th century.
Whether the running board was named after the inventor or in reference to function is open to
debate.all automobiles were equipped with running boards. The necessity of using them was caused
by the fact that first cars were designed with a narrow, high body bolted to the chassis. A running
board served as a step to a vehicle's cabin and was wide enough to serve as a place to sit or even lie
down for an adult.
Running boards may also be used to stand on while the vehicle is moving. The name running board
is also given to safety appliances for walking on top of rail cars.

6.8 MICROCONTROLLER
A microcontroller (or MCU for microcontroller unit) is a small computer
on a single integrated circuit. In modern terminology, it is a System on a chip or SoC. A
microcontroller contains one or more CPUs (processor cores) along with memory and
programmable input/output peripherals. Program memory in the form of Ferroelectric RAM, NOR
flash or OTP ROM is also often included on chip, as well as a small amount of RAM.
Microcontrollers are designed for embedded applications, in contrast to the microprocessors used in
personal computers or other general purpose applications consisting of various discrete chips.

Fig 7.7 (Micro controller)

Microcontrollers are used in automatically controlled products and devices,
such as automobile engine control systems, implantable medical devices, remote controls, office
machines, appliances, power tools, toys and other embedded systems. By reducing the size and cost
compared to a design that uses a separate microprocessor, memory, and input/output devices,
microcontrollers make it economical to digitally control even more devices and processes. Mixed
signal microcontrollers are common, integrating analog components needed to control non-digital
electronic systems.
 CHAPTER 7

7.1 WORKING PRINCIPLE

In the process of automatic, POWER DEPLOYABLE RUNNING BOARDS system

in automobiles .it consists of rack and pinion , car door, wiper motor, running board , battery and
electronic sensors. A rack and pinion arrangement connected to the running board and car door is
fixed on the stand.A rack and pinion is convert rotational motion into linear motion. Door will be
open.There are electronic sensors are used to detect the door with the help of IR sensor. When the
wiper motor connected to the Rack and pinion arrangements then the sensors senses the door open
level and send feedback signal to Micro controller for maintaining running board level of the door
open in the automobile. A wiper Motor is switch on the Movement a rack and pinion arrangement
is convert rotary motion into linear motion a running board automatically come outside.
. This system consists of a sensor system which is used to detect the door will be close . the
signal is given to MC system., thus the running board automatically enter inside. The automatic
Running board system in automobiles used to protect the car owners. Thus by means of this project
we can establish an Aside from making the vehicle more ergonomic and protecting it from minor
damage, a running board can also help keep the interior of the van or truck clean by serving as a
doormat upon which passengers can wipe their feet before entering easily. This project has also a
high advantage of simple in construction and easy operation.

7.2 CALCULATION

POSITION SIZE

Racks Helical m = 1.5

m=2
m=3
m=4
m=5
m=6
m=8
m = 10
m = 12
Racks Straight m=1
m = 1.5
m=2
m = 2.5
m=3
m=4
m=5
m=6
m=8
m = 10
m = 12
Integrated Racks m=2
m=3
m=4
p=5
mm p =
10 mm
p = 13.33 mm

Actual size of modular gearing according to DIN 867

The values given in the load table are based upon uniform, smooth operation, KHß=1.0
and reliable grease lubrication. Since, in practice, the applications are very diverse, it is
important to consider the given conditions by using appropriate factors S B, KA, LKHß
and fn (see below).

Formulas for Determining the Tangential Force

v
a =t [m/s²]
b

Fu = m · g + m · a (for lifting axle) [kN]

1000
Fu = m · g · μ + m · a (for driving axle) [kN]
1000
F = Fu Tab [kN]
u perm.
KA · SB · fn · LKHß

Formula dimensions see page ZD-3

The Condition Fu < Fu perm. Must be Fulfilled.

Load Factor KA
Drive Type of load from the machines to
be driven
Unifo Medium Heavy
rm Shocks Shocks

Uniform 1.00 1.25 1.75

Light Shocks 1.25 1.50 2.00

Medium Shocks 1.50 1.75 2.25

Safety Coefficient SB
The safety coefficient should be allowed for according to experience (SB = 1.1 to 1.4).

Life-Time Factor fn
considering of the peripheral speed of the pinion and lubrication.
Lubrication Continuous Daily Monthly
Peripheral Speed
of Gearing
m/sec m/min
0.5 30 0.85 0.95
1.0 60 0.95 1.10 from 3
1.5 90 1.00 1.20 to 10
2.0 120 1.05 1.30
3.0 180 1.10 1.50
5.0 300 1.25 1.90

Linear Load Distribution Factor LKHß

The linear load distribution factor considers the contact stress, while it describes
unintegrated load distribution over the tooth width (LKHß = KHß).

LKHß = 1.1 for counter bearing, e.g. Torque Supporter

= 1.2 for preloaded bearings on the output shaft e.g. ATLANTA HT, HP and E servo-worm
gear unit, BG bevel-gear unit

= 1.5 for unpreloaded bearings on the output shaft e.g. ATLANTA B servo-worm gear unit
 Calculation
Example
Values Given
x Travelling
Operation
Mass to be Moved m = 820 kg
Speed v = 2 m/s
Acceleration Time tb = 1 s
Acceleration Due g = 9.81 m/s2
to Gravity
Coefficient of μ = 0.1
Friction
Load Factor K = 1.5
A
Life-Time Factor fn = 1.05 (cont. lubrication)
Safety Coefficient S = 1.2
B
Linear LoadLKH = 1.5
1.5Distribution Factor
v 2
a = a = = 2 m/s2
tb 1

Fu = m·g·μ+m·a
1000
Fu = 820·9.81·0.1+820·2 = 2.44 kN
1000

Assumed feed force: rack C45, ind.

hardened, straight tooth, module 3,
pinion 16MnCr5, case hardened, 20
teeth, page ZB-40 with Futab = 11.5 Kn

Fu Tab
Fu zul./per. =
KA · SB · fn · LKH
;

= 11.5 kN = 4.05 kN
.
1.5·1.2·1.05·1.5

Condition
Fu zul./per. > Fu ; 4.05 kN > 2.44 kN = > fulfilled
Calculation Example

Values Given
x Lifting Operation
Mass to be Moved
M = 300 kg

Speed V = 1.08 m/s

T
Acceleration Time = 0.7 s
b
Acceleration Due to G = 9.81 m/s²
Gravity

Load Factor K = 1.2

A
Life-Time Factor F = 1.1 (Cont.
n Lubrication)
Safety Coefficient S = 1.2
B

Linear Load LKH

= 1.2 Distribution Factor

Calculation Process Results

 1.08
a = a = = 4 m/s²
tb 0.27

Fu = m·g+m·a Fu = 300·9.81+300·4 = 4.1 kN

1000 1000

Assumed feed force: rack C45, ind. hardened, helical,

module 2, pinion 16MnCr5, case hardened, 20 teeth, page ZA-31 with Futab = 12 kN
Fu Tab 11.5 kN
Fu zul./per. = ; Fu zul./per. =
KA · SB · fn · LKH 1.2·1.2·1.1·1.2
= 5.9 kN
Condition

Fu zul./per. > Fu ; 6.0 kN > 4.1 kN => fulfilled

 CHAPTER 8

8.1 ADVANTAGES

Higher productivity

Less opening time

Simple in construction

Increased overall vehicle customer safety

LOW cost

Less Maintenance
 8.2 APPLICATION

Power deployable running boards are used in all type automobiles like
cars,jeep,truck etc

FEATURES

A running board can be made of many materials. It can be diamond-plate steel,

rubber, plastic or fiberglass, or even a tube like structure that runs around the
perimeter of the vehicle (this is a popular feature on Jeeps.)

BENEFITS

Aside from making the vehicle more ergonomic and protecting it from minor
damage, a running board can also help keep the interior of the van or truck clean
by serving as a doormat upon which passengers can wipe their feet before
entering.

CHAPTER 10

RESULT AND DISCUSSION

Power deployable running board is advanced technology introduced in

automobile industry. The running board are automatically extension board is
kept under the car. The rack and pinion arrangement in the setup helps to make
easy to extension of board in forward and backward movement when the door
opening and closing operation. This make easy to getting in and out from a car.
The rack and pinion which converts the rotational motion applied to the pinion
causes the rack to move relative to the pinion ,there by translating the rotational
motion of pinion into linear motion .
 This system consist of sensor which detect
door opening and closing operation thus by means of this project we can
establish an feet before entering easily.

CONCLUSION AND FUTURE SCOPE

It is a time to replace an ordinary foot plate with

an automatic extension board .In future the automatic extension board in each
and every mid range cars not only in suv. The running board has increase the
value and look of an vehicle and satisfy customer.In foreign countries the
topmost industries like Toyota ,BMW,Ford has an vehicle with extension board
in future Indian automobile industry has to move in advanced technology so
there is a need and demand for running board .In future there is more
improvement done on power deployable running boardsuch as like replacing
board by tube step and xxx mod step etc.

REFERENCES

1. Production technology by P.C. Sharma

2. Todd, Robert H.; Allen, Dell K. Manufacturing

Processes Reference Guide

3. Industrial Press Inc., ISBN 0-8311- 3049-0,

4. Colvin, Fred H. (1947), Sixty Years with Men and

Machines, McGraw-Hill,

5. Floud, Roderick C. (2006) [1976], The British Machine

Tool Industry,

6. Hounshell, David A. : The Development of

Manufacturing Technology in the United States,

7. Noble, David F. (1984), Forces of Production: A Social

History of Industrial Automation