1.

Introduction to vehicle drive train

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 1.1 Introduction
• Power train
 Essentially the driveline and engine together, but may be train to
include other related parts of the vehicle such as the exhaust or
fuel system.
• Drive Train (Drive line)
 Power transmitting parts of a car between the flywheel and the
wheels.
• Power transmission has to take place between engine and driven
wheels.
• The torque of the engine is transmitted via:
 Clutch,
 Transmission,
 Drive shaft and
 Differential to the wheels.

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 1.2 the requirements for the drive TRAIN

1. Allow the vehicle to start from rest, with the engine running
continuously.
2. Let the vehicle stop by disconnecting the drive when
appropriate.
3. Enable the vehicle to start at varied rates under a controlled
manner.
4. Vary the speed ratio between the engine and wheels.
5. Allow this ratio to change when required.
6. Transmit the drive torque to the required wheels.

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1.3 Different engine and drive line-arrangements

Front engine with Rear engine with

Front engine with front wheel drive rear wheel drive
Rear wheel drive

4WD Truck 6WD, Truck

4 WD, Car

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 1.4. CLUTCH

 Clutch is a device to connect driving and driven shafts of a

machine, where the driven shaft can be disconnected almost
instantaneously from the driving shaft as desired by the
operator or driver.

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 Necessity of Clutch

 To connect a running engine smoothly and gradually to the

remainder of the transmission system.
 To permit gear changing when a vehicle is in motion.
 To allow the engine to continue running when a vehicle is
temporarily halted in gear with the clutch pedal depressed to
disengage.
 To provide positive linkage capable of transmitting maximum
engine torque.

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• Definition
– Transmission or Gearbox is an assembly of gears and shafts to
transmit the rotation and torque of the engine to the driveline or
final drive.
• Functions of Transmission
– To achieve the desired maximum vehicle speed.
– To be able to start, fully loaded in both forward and reverse
directions on a step gradient.
– To provide a means to vary the torque ratio & speed between the
engine and the road wheels as required.
– To provide a neutral position so that the engine and road wheel are
disconnected even with the clutch is in engaged position.
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 Types of Transmission

1. Manual Transmission
I. Sliding Mesh Gearbox
II. Constant Mesh Gearbox
i. With Dog Clutch
ii. With Synchromesh
2. Automatic Transmission (AT)
1) Fully hydraulic control
2) Electronic controlled AT (ECT)
3. Continuously variable transmission (CVT)

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 1.6 DRIVE SHAFT
• To transfers power (and torque) from output of gear box
to rear drive axle.

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 Purpose of drive shaft

• It drive shaft assembly must perform the following:

– Send turning power from the transmission to the rear axle
assembly.
– Flex and allow up-and-down movement of the rear axle
assembly.
– Provide a sliding action to adjust for changes in drive line
length.
– Provide a smooth power transfer.
– Light weight and strong enough.
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• Purposes:
– Transmit torque at a 90 degree angle from drive shaft to drive
axles.
– Provides a gear reduction between the drive pinion and drive
axles.
– Split driving torque between the two wheels.
– Allows drive wheels to turn at different speeds when turning
corners.
• The differential consists of two parts:
1. Final gears
2. Differential gears

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1. Final reduction
 Crankshaft rotation, after being modified by the transmission, is
further reduced by the final gear to obtain a greater torque.
2. Differentiation
 The differential gear assembly is designed to permit the inner
rear wheel to turn at a different speed than the other when the
vehicle is changing direction (cornering) so that wheels do not
slip.

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 1.8 TRANSAXLES
• A transaxle is a transmission and differential combination in a
single assembly.
• Transaxles are used in front-wheel (FF) or (RR) drive vehicles.
• A transaxle allows the wheels next to the engine to propel the
vehicle.

The location of typical front-wheel-drive power train components.

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 Vehicle manufacturers claim that a transaxle and front-wheel drive has
several advantages over a vehicle with rear-wheel drive.
– Improved efficiency and reduced drive train weight
– Improved traction on slippery surfaces because of increased weight
on the drive wheels
– Increased passenger compartment space (no hump in floorboard for
rear drive shaft)
– Less un-sprung weight (weight that must move with suspension
action), thereby providing a smoother ride
– Quieter operation since engine and drive train noise is centrally
located in the engine compartment
– Improved safety because of the increased mass in front of the
passengers

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 1. Main shaft
2. Input cluster gear shaft
3. 4th speed gears
4. 3rd speed gears
5. 2nd speed gears
6. Reverse gears
7. Reverse idler gears
8. 1st speed gears
9. 5th speed gear drive shaft
10. 5th speed gear
11. 5th gear driveshaft pinion gear
12. Main shaft pinion gear
13. Differential oil seals
14. CV shafts
15. Differential pinion gears
16. Differential side gears
17. Final drive ring gear
18. 1st/2nd synchronizer
19. 3rd/4th synchronizer
20. 5th synchronizer
A transaxle with three gear shafts
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 Automotive Design

 An Automotive design is the subject which includes the design

of all the parts of an automobile subjected to carry forces
without failure by transforming other forms of energy into
mechanical energy or
 by transmitting and modifying available energy to do some
particular kind of work.
 It starts from design of any small parts and ends with
designing of all kinds of automobile parts.

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 Automotive Design

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 Automotive Design
 During designing an automobile parts we will consider the
following points:
 Some aspects of design
 Need analysis
 Feasibility study
 Preliminary design
 Detailed design
 Modeling
 Creative design
 Design procedure
 Effects of design
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 Automotive Design
Some aspects of design:
 To the information in the best way possible into needed
devices or systems.
 A designer has a chance to choose the best out of the available
alternatives related to customers need.
Need analysis
 Design needs comes from the customers. Therefore, your first
work will be take any need and think about the way how to
solve or modify the problems.
 For solving the problem, considerable study is needed to
certain that the need does exists.

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 Automotive Design
Feasibility Study
 It’s feasibility must be check at various stages.
 Feasibility study is conducted through the analysis of several
workable alternate solutions, establishes the design concept as
some thing which can be realized and accepted.
Preliminary design:
 The purpose of preliminary design is to select the best solution
from the possible alternatives
 comparison has to be made in terms of certain criteria and
constraints already established during the earlier phases,
choice finally made in the preliminary design.

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 Automotive Design

Detailed Design

 Includes the finalization of the details and preparation of

working drawings, which can be handed over to the
manufacturer.
 in this phase, it may be necessary to construct a prototype of
the product in order to ensure that it lives up to the expected
standards.
 During this type of design, revision of a part of design may be
necessary keeping in view some operational maintenance and
other requirements.

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 Automotive Design
Creative Design

 Means a process of evolving a new device or process that can

better solve some need of mankind.
 A creative idea transcends the accepted, established order of
things, but the idea and its design should lead to something
practical and marketable.
 This types of design will focus on the following areas:
 Improvement of existing solutions
 Analysis of the particular problem
 Shaping and synthesizing of the parts

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 Automotive Design
Design Procedure
 A logical procedure of design may be adopted as follows:
 State the purpose of the title
 Draw the diagrams of the design in a simplified form
 Find the necessary calculations
 Select the suitable materials
 Find the factor of safety and allowable stress for a safe
working of a job.
 Consider manufacturing processes for manufacture.
 Make an assembly drawing of the design parts.
 make a detail drawing of each component of part showing:
dimension , manufacturing accuracy, surface finish and other
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data.
 Automotive Design
Effect on a Design
 The design of any job may be affected due to the several
reasons as follows:
 Manufacturing processes
 Material availability
 Modification based upon practical experience
 Appearance of the job
 Market value
 Labour cost
 Financial problems
 Due to the above problems, we have to change the design of a
particular design.
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 Automotive Design

Basic Requirements

 For designing a complete automobile parts, the designer must

consider the following points:
 Cost and Efficiency
 Rigidity and Strength
 Reliability and Durability
 Wear resistance
 Operational safety and Easy of assembly and disassembly

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 Automotive Design

Basic Requirements

 Weight and simplicity

 Size and shape
 Servicing, repair and maintenance
 Material availability
 Standardization
 Market value or demand
 It is not a hard and fast rule that all the factors must come into
consideration. But, since as a designer all should keep them in
mind while designing any automobile components.

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