AP

1)Introduction to Automobile
Unit-
Syllabus:
Definition, Classification of Automobiles, Major Components of
Automobiles with their Function
,Adomobile:
and Location.
Significance of Vehicle Layout, Different types of Vehicle layouts (FEFWD, FERWD,
Vehicle Layout: Definition
12
RERWD, 4WD), Advantages, Disadvantages, Applications and Cormparisons.of Diferent types of vehicle

layouts.
Frame,
1.3 Function of Chassis, Frame and
Body Requirement of Chassis, Frame and Body, Load acting on
(Conventional, Unitized
Classification of Chassis Frames with advantages, disadvantages and applications

Body, Sub Frame). Basic Bady Nomenclature.

related with
1.4 Significance of Body Streamlining: Need and importance of aerodynarmic Aspects, Basic tems
Car Aerodynamics. (eg. Drag, Lit, Skin Friction, Form Drag, Wake, Coeficient of Drag)

1.5 Alternative Fuels: LPG and CNG: Need, Fuel Characteristics, Construction and Working, Advantages,
Limitations; Layout of Electric Vehicles: Need, Working. Advantages, Limitations. Hydrogen as fuel

1.1 Introduction to Automobile

Present age is called the age of "Automobile"' or self propelled vehicle. A vehicle producing power within itself for its
propulsion is known as self propelled vehicle e.g. moped, scooter, motorcycle, etc. Germany is the birth place of
automobile
as
The automobile is define a self propelled vehicle which will be run on the ground.
The firsi automobile
powered by steam engine as
built in France by Nicholas-Joseph Cugnot in 1769-70. It was a
three wheel vehícle having speed 2% miles/hour.
Olfver Evans in 1805, operated his Evans Amphibian for the first time in Philadelphia, America. This vehicie was
designed with four wheels and the body was in the forn of a flat boat. Two.outstanding successes in America were the
Stanley Steamer and the White Steam Car, introduced in 1895 and 1902 respectively. Both of these automobiles gave
excellent perförmance. The Stanley Steamer is credited with being the first self- propelled vehicle to attain a road speed
af 160 kmper hour.
The development of an internal combustion engine for antomobile was accelerated the change in the production of
vehicle. The first practical automobile fitted with I.C. engine which ran on city gas and was ignited by
clectric spark
plug by Belgium iventor Eienme Lenor in 1860. Inl 866 Nikofaus A. Otto and
Engen Langen of Germany, invented'a
four stroke engine which was, the predecessor of modem gasoline engine. again modificd by Gottlicb Daimler
It was
who substituted oil for gas. Gottlieb Daimler presented high speed LC. engine which revolutionized
a automotive
transportatio.

In 1896-97 Germany, France, England, America. considerable

work was carried for the development of gasoline
utomobiles and until 1910, the automobile was in the experimental
stage.
By the improvement in the roads, rapidity and economy
of motor transportation and the First World War were the main
factors which lead to the frther development automobile.
of an

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 Automobile Engineering (MSBTE Sem-V) 1-2 Introductionto Automobiles

we
The rapid industialization and development of an automobile gave birth for the growth. In India the first
imported inl898 and it is continue for about 50 years.
motor .car
Visveswaraya
Sir M. an made establishment of an automobile
industry in 1935.
The first automobile industry in India, Hindustan Motor Limited Kolkata, came in the
at year 1947and then Premier
Automobile Limited at Mumbai, in 1948. Initialy they manufacture
cars. Today there are lot of industries developed.
The govemment's liberalization policy and the transformation
of Indian economy from a protected one to a highly
competitive one has offered an unpredicted future of the Indian
Automobile Industries. The industry is certainly headine
for a tremendous growth, the number of anmual, sale of car and
jeep at domestic front is expected. The demand
raising at an average of 25%, compared to the previous is
coresponding period.
Indian automobile industry taking big leaps forward on fronts
3 in preparation for entering 21" century. These are
:
1 The technology gaps are being bridged not only between
India and the world but also between the
future. Almost every compay introducing present and the
a new engine which is smaller, powerful and lighter and more efficient.
2. The vehicle owners and users havea greater
choice of vehicles. So manufacturing company
needs and developing new models introducing look at the customer
new features.
3. Tbe vehicle manufacturers
are concentrating on their plant and the manufacturing
process is changing,with a view
to provde geater economy and eficiency
in production and better reliability, endurance and performance
vehicle. in

1.1:1 Classification of Automobiles:

MSBTE:W14 S:15,W15S-16,W-16,
W-17, S-18,S-19
te vanoustypes of automobile badie
(W-14,W-15W-17)
afeclassiication.ofautomobile
S15,S18,$19)
Cassify automobiles.
aHow Automobiles.areclassied S-16
The automobiles are classified W16)
as follows:

Classification of Automobiles

(a) According to use

b) According to capacity

c) According to fuel
used

0) According to wheels

(e) According to drive

(1) According
to transmission

o) According to suspension
system

h) According to engine fitting

)
Accarding to body construction

Fig.C1.1

Ted

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 Engineering (MSBTE Sem-V) 1-3 Introduction to Automobiles
Automobile

(a) According to use

Passenger Cars ) Goods Carriage

)
Special Purpose iv) Earth Moving
(i)
(v) Motor Cycle (Bikes) (vi Mopeds

(b) According to capacity

)Heavy transport vehicle eg. Trucks and buses.

Light transport vehicle e,g. Car,jep, minibus, matador.
(c) According to fuel used

)Petrol vehicle: Motor cycle, scooter etc.

() Diesel vehicle: Buses, trucks.

(i) Gas vehicle: Buses.

v)Solar vehicle Storage battery types.
(d) According to wheels

Two wheeler :eg. Scooter,motorcycle.

) Three whecler : e.g. Auto-rickshaw, tempo.
) Four wheeler: e.g. Car,jeep, tractor.

iv) Sixwheeler: Truck, buses.

e Accordingto drive

According to sitting(driver) arañgement:

(a) Left hand drive e-g. American
vehicle, oldIndian wehicles.
6)Righthand driveeg. Indian vehicle.
) Whetherthefront axle,rear axde or
bothaxle drive :
a) Eront wheel drive eg. Manuti Car
b) Rearwheel.drivee.g.Ambassador, premier.
(All wheel driveeg. Joep.
40According totransmission

) Coventional in which ordinary

crash type gear box
is usede.g All Indian car.
n) Semi-atomatic having two
pedal transmission
clutch control
using manual operation with standard gear
box and antomaic
üi) Fully automatic.
(g) According to suspension
system
Conventional (Rigid): Leaf
spring.
) Independent : Hydraulic
shock absorber.

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 Introduction to Automob
Engineering (MSBTE Sem-VI) 1-4
Automobile

(h) According to engine fitting

)Front engine.
(i) Rear engine.

(ii) Transverse under floor engine.

According to body construction

0
A. Passenger Cars

a) Sedan/Saloon b) Hardtop

c)Lit
e)Coupe
gConvertible
back (Hatchback)

.
d) Station Wagon

Limousine

h Estate Car
B. Heavy Vehicles/Trucks

a Tuck Punjab Body

b Truck Half Body
Truck Platform.Typa
dTruckith Trailer
e Dumpet Tanker

Car Jeep Pickup

O
Straight truck
Half body truck Platformtruck

Delivery van
Fanker.
Dumper trucks .

Station wagon
Bus
Trailer
Fig. 1.11:Types of automobile
1.1.2 Major Components bodies
of Automobile with
Their Function
and Location:
NNamemajor componentprautomooieand
MSBTE : W-14.W-11 S-18
state tne runcion any
QNameany sour majorcomponents of tourcomponents.
O
of automobile
and stäte theirfuncion W-1
Whatarethe
majorcomponents mountedd
on venicle
chassis State purpose
the of.eachcoponent $-1

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 Automobile Engineering (MSBTE Sem-V)
1-5 Introduction to Automobiles

An automoble is consist of substructure called chassis and superstructure as body.

Chassis is a main structure upon which all the major component or an automobile which are necessary
to propel the
vehicle are assembled.

Chassis comprises of everything of a vehicle except the body, cabin and equipment. The automobile
chasis consist of
following components.

Components of chassis

(1) Frame

(2) Engine

(3) Transmission system

(4) Suspension system

(a) Conventional system

H Independent systemn

(5) Controls

Ha) Steering system

6) Brake systern

c) Engine control .

(6)Electrica controks

Radiator
Fig: C1.2
) Frame
The frame is the main part
of the chassis on which Temaining parts
extremely rigid and strong so that of chassis àre mounted. The frame should be
if can withstand shocks, twists, stresses
vehicle is moving on road. Itis also and vibratons to which it is subjected while
called underbody.
The frame is supportedon the whecls
and tyre assemblies.
radius to front wheels. widens The frame is narrow the
It out at the rear sidé to provide in front for providing short furning
larger space in the body.
Ttis a skeleton to hold the major
unittogether. These
are of two types:
(a) The conventional pressed
steel frame to which
all mechanical
unit are attached.
(6) Integra or frameless
construction in which
body construction
decreases the weight perfom combine function of body and irame. So it
and save fuel consumption
damage occur during also reduces manufacturing
accident. cost.but. increases repair f

TechKare
0311atioos

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 Introduction to Automobiles
EAutomobile Engineering (MSBTE Sem-V) 1-6

Comparison of conventional chassis framed and frameless type chassis framed:

MSBTE: W1

med and frameless vehicle

W15

SE No
ramed yehich rameless velhicle
All mechaical units are attached to Performed combine function body and frame.

perforn function of only support (Frame).

side members
2. Longitudinal member and cross member Floor is strengthened but cross member and heavy

form the frame. are eliminated from body, which are welded together.

3. Heavy in weight used for truck and Buses. Light in weight used for small cars.

4. More fuel consumption. Less fuel consumption.

Manufacturing cost is more. Manifacturing cost is less.

6. Repair cost less due to higher impact Repair cost more due to lower impact resistance.
tesistance.

Stronger and Heavy construction. Results in a light but stiff construction.

Frame and Body are not integral structure. Frame and Body are integral structure for extra strength and
durability
9 Frane is up swept at rear and front to In sorme cases the sub frames are also used along with this type
accumulate movement of the axle.
of construction.
Eg. Tata, Ashok Leyland vehicles. Eg. Small and medium cars, small buses

10. During collision the body transfers the | During collisíon the body-crumbles,
thereby absorbíng the
shock due to impact and thus not safety to shock. duc to impact and
thus providing safety to t
the passengers. passengers.

11. Topless cars are simple to design. Topless carS are diticult to design.

(2) Engine

It is the powerhouse which develop and provides motive power to propelled

the vehicle for performing the vam
function of vehicle. It is located at the front,rear or in middle depending
on the type ofapplication of layout.
(3) Transmission system:

W-16
MSBTE: W-15,
OState functions of transmisslon system in automobile.

Write functions ofynyersatjointang sipjoint 16)

This system consists of clutch, gear box, universal
joint, propeller shaft, differential,
rear axle, wheel.
Functions:

(a). Clutch is used to connect or disconnect engineu

the engine power to road wheel
when desire. It is located an
the Transmission system.

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 Automobile Engineering (MSBTE Sem-VI) 1-7 Introduction to Automobiles

(b) Gearbor is used to obtain the various fixed torque ratio according to requirement. It also help to reverse ne
vehicle.

)Universal joint and propeller shaft: It is located between gear box and diíferential. It transmit the torqgu
from the gear box shaft to the final drive and also adjust the different inclination when vehicle come across a bunmp
or shock.

(d) Differential : It is located in the rear or front axle depending upon type of drive. It helps to tun the vehicie
through right angle and split the torque in equal proportion to the road wheel.

It is a weight carying portion whether it may be front or

rear loaded at intermediate point. It takes vertical
()Axle:
load due to weight of body, shock load during braking or driving, a torquë reaction due to driving and braking and

a side thrust during cornering.

cope with the
(9 Wheel and tyre : The wheels along with tyre has to take vehicle load, provide cushioning effect and
steering control.

(4) Suspension system

pitching. E
This system isolates the vehicle body from the road shock which are in the form of rolling, bouncing and
provides comfort to passenger and reduce the stress in frame. These are of two types

housing
(a) Conventional (Rigid) system: In which the leaf springs are attached to the rigid beam axle or to axle

(b)Independent system: Here no rigid axle beam and cach wheel is free to move vertically without any reaction on

theotherwheel.
(5). Controls

Vehicle inchudes steering system, braking system and engine

contro.

Steering system lt is used to change the direction of motion of the vehicle by turning the front wheet. The front
(a
driver.
wheels are linked to steering wheel which is operated by the
system
)Brake Ihis system provide safety to the vehidle by stoping quickly or slow dowin while going dowa
vehicle.
slope. The brakes are mounted on all the wheels of a
.

Enginè control :This control réfer to variation in the revolution of the engine shaft in accordance with demand of

fuel supply and accelerator pedal.

This system consist of following:

a) Supply system: Battery and dynamometer.

(b) The starting relay.

(0)Theignition system:Batery or magneto-ignition system.

() Other miscellancous system like driving light, signaling, reverse light, panel ight, wiper etc.

7). Radiator
It is a device used to re-cool the hot engine cooling water for recirculation purpose. The radiator is connected to engine
by hose pipe to allow the cooled water circnlation. It is located at the front or rear depending upon chassis
layout.

TechKaewledgi

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Automobile Engineering (MSBTE Sem-VI) Introductionto Automobiles
1-8

Transmission
Diferential
Distributor -Universal
joint
Frame

Waler pump r Propeller

Engine Sfhaft
Frot CReer
Radiator

Gear box Steering Wheet and tyre

wheel

Fig. 11.2: Layout of chassis frame and its maîn component

8) Body (superstructure)

Vehicle body is a superstructure. Body is either integral with the under

frame or bolted to the frame. The body and
chassis make complete vehicle.

A body consist of a doors, windows, engine cover,

roof, luggage, cover etc. Different type of body is attached to chassis
according to application.

The folowing conditions must be full filled by vehicle

body:
() Itmust be lighter.
6) If must have réasonable fatigue life.

()Should nothave too mnany and complicated components.

d) Must ensure a quite side and easy
entry and exit.
)II must withstand uniform induced
stresses.

1.2 Vehicle Layout

DeinitioH
:1is detined asthe location and arraingementof
lhemain coMpONent suchas
engnëand drve
It can be divided into thre categories
as Front whecl drive, Rear wheel
drive and four wheel
1.2.1 Significance of Vehicle dive.
Layout:
Normally automobile
manufacturers
overall best weight distribution
ted to make their vehicle have
an equal weight distribution
helps the car for
good at acceleration,
for each wheer
important role in weight
distribution.
braking and aya
steering. The different layoutspuay

It also help for handling characteristics

of vehicle. It also concentrates
the drive component
on one area
Enlist various types
of vehicle layauts. MSBTE:S15

S-15
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 Automobile Engineering (MSBTE Sem-V) 1-9 Introduction to Automobiles

1.2.2 Types of Vehicle Layout:

drive used are rear engine rear whel drive, front engine rear wheel drive, front engine
The vehicle based upon type of
drive which are discussed below:
front wheel drive and four wheel

Types of Automobile according

to Drive

1.FrontEngine Rear Wheel Drive

2 Front Engine Front Wheel Drive

3. Rear Engine Rear Wheel Drive

Drive
4.Mid-Engine, Rear Wheel
5FOur.Wheel Drive.

HBRear engine, alf wheel drive (4WD

() Front engine, al wheel dive (4WD

Fig.C1.3:Types of Automobile according to Drive

1. Front Engine Rear Wheel Drive (FERWD)

MSBTE W.15 S 16, S-17.W-17,W-18
w15.S-17,W.18
QWrte advantages of front engine and rear wieldrive
any four

Expain rear wieerdrive vehicle with iont and rear engihe S

disadvantag
16
QSketch and explain rear wheeldrive
chiassis layout of trontengine
the rear, a
Rear-vwheel drive places the engine in the front of thé vehicle and the driven wheels are located at
configuration known as front-engine, rear-wheel drive layout.
axle supported on leaf springs
In this layout a front mounted engine-clutch-gear box unit drives a beam type rear
through apropeller shaft with two universaljoints.
With tlie help coil springs,the front wheels are independently sprung, As shown în Fig. I.5.1,
this layout is one of the
of
oldest layout which remains unchanged for many years.:

Advantages:

Some of the advantages provided by this.system are:

dlin
good Banag
(a) Even weight distribution: Balanced weight distribution between the front and the rear wbeels providing
characteristics.
ches.
0) For easy front wheel stering movement engine occupies the reduod width between the wheel
C)Large luggage space is provided behind the rear seat.
(0) Maintcenace and accessibifity of engine, grar box is easy
and the control overtie acelerator,
cluten,

e)Radiator cvoling is natural (by air) so decreases

the power require for cooling

TedhKanaled
P1D1ieatie0

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 Automobile Engineering (MSBTE Sem-VI)
1-10 Introductionto Automobiles
) Better braking efficiency: The more even weight distribution helps prevent lockup
fom wheels becoming unloaded
under heavy braking.

Luggage spa0

Sleering"

Propeler sheft

Clutch
Enghe Gear box

Rear arle

Difererntial

Radiator

Col spring
Unlversal joint
Leaf sping

Fig. 1.21:Front Engine Rear Wheel

Drive
Disadvantages
. Reduces back seats leg room space.

2. A tunnel is needed for the propeller shaft.

3. Reduces bootspace.

4. Heavier and more expensive.

5. If stuck in mud or snow it is harder to drive away than in

a front wheel drive car.
2. Front Engine Front Wheel Drive (FEFWD)

a neat sketch of front engine frontwheel type MSBTE:W.16,S-17

aDraw yehicle layoiut and label it
(W-16)
QDraW generatayout of front engine front wreel dirive car. RKA i S-10
Engine, clutch, gearbox and final drive build together to form
a single integral assembly. Normally transversal engne
arrangement is used. Longitudinal-mounted engine is the other
possible layout. Weight
distribution tends to be moe
in
than 50% the front axle.

.In this arrangement the engine is fitted in the front of vehicle and drive is given
to the front wheel
.
The propeller shaft length is reduced or neglects the propeller shaft.

The drive is transferred from engine, situated at front end, to the gear box to the differential
with the help of geat dnive
The differential unit is placed in the front axle.

Y NIatig

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 (MSBTE Sem-VI) 1-11 Introduction to Automobiles
Automobile Engineering
Engine- f Final drve

Torque
Converter
Transaxle

Fig.1.2.2 Front Engine Front Wheel Dive

This arangement provides good grip with road

surface due to engine weight at the front.

Absence of propcller shaft can decrease the chassis

height.

propeller shaft in moderm vehicles, but there is

Note that for front engine, front wheel drive vehicle there generally no
is
on each side connecting whecls vith balk joints.
a transaxle with two half shafts laxles

Advantages
Having engine, cutch, gearbox and final-drive in the front makes the front heavy and this helps acceleration (f
compared with a rear engine, front wheel drive which does not exist).

This type of arrangement provides optimum passenger space and a ilat floor line resulting in a transverse under-floor
longitudinal engine position.

The propeller siaft length is recuced oir neglects the propeller shaft
to
Good gipwith road surface duer engine wcight at front
The chance of wtecl skiding and sliping is very much roducod.
Natural air-cooling of the radiator due to motion of vehicle.
it provide "under-steer
Power required for ihe cooling is reduced. When the vehicle is to be 'steer in' to the curve,
characteristics, which always is preferred. .

than over
More passenger room since the propeller shaft is eliminated. Tend to under-steer, which makes them safer
is the
steer (supposing an average driver and no traction-stability .control, under-steer is easier to notice and correct). It
cheapest, lightest and more compact'arangement.
Disadvantages

Traction is penalized when hill-climbing, weight moves backwards.

wheels to brake
Not efficient braking, when braking hardis casy to block the back wheels, it is like only having two
wilth, even though these have a lat of grip duc-to weight transfer to the front:
(accelerate, brake,
Steering radius is redaced because of drive shafts. The front wheels have to do almost all the work
steering).
Application of this layout

The vast majority of car manufäcturers, to say some examples: Ford, Audi, Seat, VW, 10yo1a.

undcr-steer characteristics, which is always prefered.

Justhy Most of the miodern.cars are front wheël drive

in a transverse unEO
* O aTangement provides optimum passenger space and a flat floor line resulting
longitudinal engine position.

The propeller shaft length

is reduced or neglects the propeller shat.
Good gip with road surface due to engine weight at front.
Techauledgi
PUDIIatiens

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 Automobile Engineering (MSBTE Sem-V) Introductionto Automobiles
1-12

The chance of whcel skidäing and slipping is very much reduced.

.Natural air-cooling of the radiator due to tnotion of vehicle.

Difference between Rear Wheel Drive and Front Wheel Drive

MSBTES19

frontrearwheeldrive withfront engineffont whieeldrive2

Compare front enginé e 19
SHNoFront Engine ront Whecf Drive WD);
Front Engine Rear WheetDrincRWD
FWD vehicles are propelled viz the front}RWD vehicles are propelled viathe rear wheels
wheels.

2 Ahe propeller shaft dength is reduced or Require longer propeller shaft-length.

negicts the propeller shaft.
3 FWD vehicles ofen havc more interior space RWD vehicles often have less interior space.compared
compared to RWD vehicles. FWD vehiles.
FWD vehicles are less balanced. RWD vehicles are more balanced.
5 FWD vehicles allow for less control. RWD vehicles allow for better controf.
6 FWD vehicles cannot be able to drift
RWD vehicles are able to drift, while FWD vehicles cammot
When the vehicle is to be 'steer in' to the For easy front whee steering movement engine occupies the
Curve, it provide 'under-steer' characteristics, | reduced width between the wheel arches.
which is always preferred
EWD vehicles are lighter compared to. RWD RWD vehicles are heavier compared to FWD vehicles.
vehicles.
9
Not efficient braking to block back wheel. Better :braking efticiency The more even weight
distribution helps prevent lockup from wheels becoming
unloadedunder heavy braking
10 No limitation on speed due to whirling of| Limitation on speed due to whirling
propeller shaft or sagging. of propeller shaft or
sagging:
3: Rear Engine Rear Whee Drve (RERVWDY

Fuellank
Spare wheel-

Cantrol rod
and cables

Catch
Rear drive
Gear box
Engini

Universal
Joints

Fig. 1.2.3 : Rear engine rear wheel drive

Pcatie9

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 Automobile Engineering (MSBTE Sem-VI) 1-13 Introduction to Automables

Advantages

1. Excelent traction is available while climbing hills.

2. A larger passenger space is available for the given length of body.
3. Very compact and acceible power and tramsmission asscmbly is provided.

4. Lot of weight at the back improves aceleration and braking, rear wheels and disc brakes can be designed.to. take a
bigger amount of braking due to the weight distribution to the rear end.
5. Passengcrs are comfortable from engine noise, heat and fumes.

Front of thevehicle provides good visibility and by designing the, body to aerodynamic shape gives good streaming
lining
Disadvantages

1At high. speed, relatively high proportions of weight at the rear axle will make the car unstable at spoed. There is a
strong tendency for the vehicle to over ster.

2.. The space at the front has to be reduced to allow for the steering lock of the front whoel

3. Space utilized for engine compartment is wasted.

Dificulties with the arrangement of the engine cooling system. Nátural coolingg of radíator is not possible. Power
requirement increases, Compact engine, clutch and gearbox make servicing more difficut.

5. The wheel gets turn too sharply due to tendency of the vehicle to over steer. This necessitates the turning of tihe steering
wheel in the opposite direction to make the correction by driver.

Mid-Engine Rear Wheel Drive

This type of engine layout plaçes the engine between the two axles and the rear wheels are driven. The weight is equally
distributed between front and rear wheet.

This type of engine layout places the engine between the two.axles and the rear wheels ane driven
Normally 50-50 weight distribution

Fig. 1.2.4: Mid-engine, alf wheel drive

Advantages

Good acceleration dúe to back weight transfer.

Good braking:
Neutral handling

Front of the car can be aerodynamically optimized.

Tech Khedj
catlos

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Automobile Engineering (MSBTE Sem-VI) 1-14 Introductionto Automot
moples

Disadvantages

When accelerating some steering is lost.

Takes a lot of space.

No back seats. Difficulties with the cooling system.

Application of this layout

Ferari F430
5. Four Wheel Drive (4WD)
MSBTE:S-15,S-18S-19
OExplain allwiheel drive ype
QDraw the layout of four wheel drive yehicle, State the advantages and dsadvantages
QDraW fOur wheler chassis layoutard show major components oni
S19
To increase maneuverability.of the vehicle required to travel on rough roads this four wheel drive is provided. In this
arrangement all the four wheels of the vehicle are driyen by the engine thus making the entire vehicle weight available
for traction.

CV.joint Front drive-axle

Propellor shat

Transfer case Differential

Engine

Clutch Rear dive axie -

Gear boX

Wheel-

Fig. 1.2.5 Four wheel drive

These four wheel, drive vehicles are very useful

on Hill station if one of the wheel slipping or skidding then fhe otre
axle wheel transmit the tractive force to the vehicle. The steering
of the four wheel drive is hard to operate coman
with other type of drive.
In this arrangement all the four wheels of the vehicle
are driven by the engine thus making
available for traction. the entire vehicle wE

Ditferental

Transfer cas
Diferenfial

Fig. 1.2.6:Line Diagram

of Four Wheel Drive
Working

When the engine is started the

power is transmitted to the rear
wheel.

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 (MSBTE_Sem-VI) 1-15
Automobile Engineering Introduction to Automobiles

of a transfer case is connected to the input shaft with the big input gear, but the other
hen the shifter
mechanisnm

4er mechaism B discomects the front output shaft from the rear output shaft: In this position, the two wheel drive
obtained.
with the high gear is

Similatly the situation of four wheel drive in low gear. Obviously, four wheel drive with low gear should be used
the main transmission. Also the transter case should be engaged with the stationary
uyariably with the low gears on
vehicle since these are not
provided with synchromesh devices.

Advantages
two-wheel-drive layout.
.Traction is nearly doubled compared to a
Handling characteristics in normal conditions can be configured to emulate FWD or RWD.
2
3. Gives sufficient power, this results in unparalleled acceleration and drivability on surfaces with less than ideal grip, and
superior engine braking on loose surfaces:

Disadvantages

. The mamufacturing cost of the vehicle ishigh. .

2 More conponent and complicate transmission

3 Increase power-train mass, rotational inertia and power transmission losses

4 Increased fuel consumption compared to 2WD.

(A) Rear engine, all wheel drive (4WD)

Similar characteristics as rear engine, rear wheel drive. And other additional as:."

Advantages.

1. Better weight distribution

2 More neutral reactions.

3. Better traction on bends and slippery surfaces.

Disadvantages

1. Heavier.

2 More expensive and diffcult to desigm and build.

(B) Front engine, all wheel drive (4WD)

Similar characteristics as the front engine, rear whel drive. And other additional as

Advantages

I. Better handling capacity.

2. Better acceleration.

Disadvantages

increases weight and manufacturing.cost compare with front engine layouts.

2 Loss of some space jn the back seats legs room

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 Introduction to Automobila
Automobile
Engineering(MSBTE Sem-V 1-16
Mount Engine Vehicle
erentiate between Front and Rear
Rear mountngine
No PEKN2 K
ront mountoine
Engine
and safer than1frontmount
faster
mount Travelling is less
Travelling is faster and safer as compare to rear
engine.
engine.
vehicles having less road adhesion
adhesion due to | This engine
2. his engine vehicles have good road
compared to front mount engine.
vehicle weight carrying on
driving whee.
large
passenger comfort due t
comfort compared to This engine provide better
3. This engine provide less passenger
reduce noise, heat and fumes.
rear mount engine. passena.
more passenger space as t provides less floor area result in more enger
4. It provides high floor results in propeller
space due to dispensing with shaft.
comparod to rear engine
Rear engine required powerfal fan.
Front engine vehicles provide natural air cooling
of weight
In this engine as compared to the rear engine. the| In this engine, the rearward concetration
vehicles are less affectedd
causes the vehicle more affected by side wind at
high speed causes vehicle to umstable resuit in over
steer.

1.2.4 Articulated Vehicles:

.These vehicles having a detachable trailer supported on a platform on the tractor unit are used to carry heavy load
which must not exceed gross train weight
Engine
Fifth wheel

Dead axle

Fig. 1.2.7:Articulated Vehicle

The traifer tractor commection

is also calfed the fifth wheel. It maximum
permitted laden length and weighit i5 1> uEneters
and 20 tonnes or less than four
wheel vehicle. No time will be waste
available. in loading or unloading as several trai
1.2.5 Heavy Commercial
Vehicles:
These heavy and robust vehicle used forhaulage
purpose are paweredby diesel engine.
is gross vehicle weight a
(gv.w.)ismore than tomes. required wheetsfir
carying heavy laads. Sometimes,
3 It twin tyres fitted side by siue
more axles are added for
very heavy loads.

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 Automobile Engineering (MSBTE Sem-V) 1-19 Introduction to Automobiles

6. Torque from the engine and transmission.

7. Longitudinal tensile forces from starting and acceleration, as well as compression from braking.

8. Sudden impacts from collisions.

9 Acrodynamic characteristic which determine the fucl consumption, spoed and stability in cross wind. The positve
pressure at front should be decreases and deflatcd smoothly for the prevention of cddies creations.
10. Reduction in body weight to improve capacity and fuel economy.

1.4 Requirements of Chassis, Frame and Body

MSBTE: W17

9 Stafe the various reguirements.of automobile.body

1. Space availability

There must be adequate space inside the body for the passenger and luggage both.

2. Stiffness

The car body may be considered a rigid beam which is supported on wheels at each end. The car body must have
sufficient stiffncss to prevent excesive sagging or bending in the middle.

3. Strength
subjected, which include the weig?ht
The body must be strong enough to withstand all types of foroes to which the car is
impact loads of
of the car, passengers and luggage, inertia, and side forces. It shonld also be able to.cope with

reasonable magnitude.

4. Protection against weather

protected from bad veather.
The design of the body must be such that the occupants and the luggage are

5. Torsional stiffness
roads.
The body should be sufficiently rigid so as to resist twisting movement on rough

6. Protection in accidents
that the driver is at
This is a very important parameter, consider in the. design car body. The body must be such
accident
maximum ease so that there are least changes of the accident talking place due to fatigue. However, in case the
taking place the body must protect the occupants.

7. Air lift or drag

with the square of the
The resistance of air during Tunning depends upon the body shape and size. It incTeases directly
vehicle speed. The shape ofthe body should be such that the air drag should be minimizes.

&.
Resistance to corrosion
The vehicle body is exposed to corrosion throughout its life. The body should be designed such that no mojsture shoud
be acumulated which causes rust The materials are used also be such that no corrosion takes place.

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 Introduction to Automobiles
Automobile Engineering (MSBTE_Sem-V 1-26 depend on acrodynamic
can be
fucl but it
it rarc 10 to 15% on engine reduces. It ale
2 The acrodynamic shapc can improve fuel conony So
well as life as the load
engine efficiency as flow over andunder and
components vehicle. Ii improves optimizing the air
C
increases speed of vehicle. It also improve cooling
cffect to the engine by
uniformly and properly
distriouion of air pressun
comfort due to
component. It improve the ride
ngine
over a car body.

Aerodynamics aspect W:16,S17:W17 S18,W-18, -19

.Need and Importance of S15,W15,S-16,
MSBTE WA4,
W-14, W-17, W.18
Importance of Aerodynamlc shape of car Doay S-15
Gve the
aerodynamic shape of body
Ustify W15
improves performance of venicle
Ustiy Aerodynamic shape of an automobile

State importance of aerodynamic body of car

(W-16,S-18, S19
State its advantages.
Whyaérodynamic shapes is important in autormobile bodies?
to aerodynamics.
State andexplain different forces.acting on the vehicle body related

reduce drag and wind nóise, minimze noise emission and preve
In automotive aerodynamics is the main aim to case
speed. Air is also considered as a fluid in this se.
undesirable lift forces and other causes of aerodynamic instability at high
aerodynamic characteristics. There are three forces actino
The body shape and size of the vehicle must have acceptable

on a vehicle

(1) Air drag force acting in a direction of vehicle motion.

Aerodynamic lift acting vertically upward

) Cross wind fore acting in lateral direction,

The aerodymamic aspects will be more expensive but lowering aerodynamic drag the fuel economy of the fastest vehick

can be improved.

(a) Aerodynamic drag

Acrodynamic means the behaviour of the air motion relative to

car body. Aerodynamic drag is also called as ar
resistance.

Total aerodyniamic drag of a vehicle include many factors

such as Form drag is also known
drag (576) is the drag caused by the separation
as pressure drag or profle
of the boundary layer from the surface and
separation. It is depend on the shape of body,
the wake created by te

Induced drag (8%) skin friction drag

(10%) arises from the friction
viscous drag in the boundary layer around
of the air against the surface and is caused by
the automobile body.
Interference drag (15%) is created
by mixing of airflow streamline
and cooling and ventilation
the region of turbulent flow downstream drag (10%A)The wake is
ofthe moving automobile body.
Total aerodynamic drag
(P)=Cp V
Where

Cdimensional dragcoeficient
p air densityin kg sec'/m
V velocity ofcar in m/sec

A projected area ofthe vehicle

from the front, m

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Autlombie Engineering (MSSTE Sem-V
1-29 Introduction to Automobies
1.8.2 Need:
.As a result gases from fosil fuel emision have causad and cortinuing to caused geat danage
to the atmosphere such
effect
as green house and acidie rain. Altermative füels wtich
are renewzble and eco friendly reduce
the dependency on
fossil fuels and they help to preserve the atmosphere by reducing
the emissicn levels. Tte burning
higher levels of C0, and other gases in atmospbere affecting of fosil fuels create
the green bouse effect The soareity coaveational
fuels, growiag emissions of combustion causing polhitants
of fosil
and their increasing costs will make
biomass sources more
attrective. The comvertional fuel as diesel exhaust
may cause kng cancer and other
repiratory diseaes The diesel
emission has been classitfied as human carcinogen.

1.8.3 Fuel characteristics of CNG and LPG:

.CNGis alled compressed natural gas, and it is mainly a methane gas which is compressed
240 bars. CNG obained from coal bed methane at pressure between 200t
and oil wells. CNG is
a good fuel substirure for vebicles. CNG is
lighter than the air.
LPG is called liquefied petroeum gas,
and it is a mixture of propane and butare
Hquefed st the temperature of 15 C
and a pressure betuween 1.7 to 7.5 bar. Propane
is atomatically generated from the gas
extracted. Propane is usualy used for heating, felds wiaie atural gas
coaking or agricultural uses LPG is heavier than
flarmmable. LPG vehicles the gas air, hence it is ighly
mixe reedily with air, allowing fer more complete combusion.
than Tegular gasoline, but LPG vehicles æve tower The fuel costs less
energy per mit voume, so its fuel ecoomy and efficieocy are
lower.
LPG vehicles give a longer engine life due its ciean
to buruing characteristics. LPGis a gas at room temperahure,
liquid when pressurized the required pressure varies according but a
to the composition of the mixtre). It is usualiy stored
at around 10 bar.

CNG fuel characteristics

CNGCharacteristi alne
Vapour density 0.68

Auto ignition 700 C

Octane rating 130

Boiling point (atm. pressure) 162 PC

Air fuel ration (weight) 1725

Chemical reaction with rubbe No

Strong pressure 20.6 MPa

Fuel air mixture.quality Good

Fuel air mixture Low

Flame speed (m/s) 0.63

Combustion ability with air 4-14%

Vaporisation energy (MJ/ m) 215-276

Many things are considered when determining the. viability of n alternative fiuel incuding emission, cast, fuel
availability, fuel consumption, safety, engine Tife, fueling facilities, weight, space requirement for fuel tanks and the
range of a fuly fueled vehicle.

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 onto
Introducuon10Automobiles
Autom

marginaly cheaper, cleanct

Automoble Englnorlng (MSBTE, Sem- 1-30 vehicle.CNGILPG is and
power the
CNGAPG engine uwses Compresed natral gs to
cnvronmentally-ftiendlly thnn ordlinary gasolinc or dienc.
situated in the tr nk.This
1.8.4 Tho CNG Engino and is tank
atached to the vehicie,
which has to be
The CNG engine usesnssecondficltnk gas used compressed. icle uusing any onefuel
vehicle
is usunllylarger in size, as it has to kecp
tha choice to run the
deiver has a
engine. Thò lhe difierent tanka
nks,dravinA
from engine to can allernute between
TThe pressure range may vary the car
i means that
dashboard. This
switeh on the
pressing a
fucl from either.

Working of CNG Englno gasoline and CNG vehicles.

the two, contains parts ofboth the gas compres
vehicle is combination of of tank is large to keep ressed.
CNG a size
A
situated in the trunk. The
separate fucl tunk switch
CNG engine uses a simply operating a
he vehicle using any one fuels by
series of highly pre.
The driver has a
choice to run the
the tank is sucked through a
compressed gas in
sclects the CNG tank, the
Once the driver
regulator.
amount of tucl nieeded by the
fuel injectiom
inie
lines until it reaches the
pressure on the gas to match the
regulator is to control the
The function of
cngine.
systcm of the vehicle move into the fuci inieri
level, the solenoid valve allows the gas to
reaches to acccptable
When pressure of gas
the proper proportion in engine.
system.and mixed with ait in downmward. This
to the engine. During
this the piston moves stob
into the suction manifold
This mixture is then enters required compression ratio
mixture is compressed to a wfi
suction stroke. The gas and air
is called as induction or chamber.
and it is ignited in the combustion
increases temperature and pressure
temperature and pressure which acts on piston t
combustion large amount of heat energy is released increasing
.Due to vehicle forward.
developing power which moves the
move the piston downward

Gas and air mixture Exhaust yalve

Compressed. Temp Diesel ignites pens on
and press nses. causng gas pward stroke
Pilot dlesel injecled expelling gases to
gnite and forces
through fuel valve piston down. atmosphere.

sasSand an
mixtureenters
cylinder via
inlet valve

1.Suction 2. Compression 3.Power 4. Exhaust

Fig 1.8.1

1.8.5 Liquid Petroleum Gas (LPG):

.LPG is obtained by refining of crude oil.

LPG contains propane and butane

and propylene and is most
pure.

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 Automobile Engineering (MSBTE_Sem-VI) 1-31
Introduction to Automobiles

As vaporization of propane occurs at atmosphere temperature and

pressure hence it burn move accurately in engine
cylinder.

Due to complete combustion emit less HC and CO and easy ta control exhaust cmission.

At normal temperature propane lires easily hence cold starting is easy and produces power without stumble..

The main difference between petrol and L.P.G is that the L.P.G is dry fuel and enters in engine cylinder in vapour state
while petrol enter in engine with fine tiny liquid droplets.

Regulator or reducer, also called as a vaporizer and is located in engine compartment and performs same functions as
that a carburetor in a gasoline engine.

It uses heat from the cooling fluids to vaporize the propane into gas form. It includes am electronic circuit that cuts the
flow of gas if the engine stops or stalls. The regulator is usually smaller than a regular carburetor.

Working of LPG:

The propane fucl system is a completely closed system that contains a supply of pressurized LPG.

Since the fuel is aready under pressure, no fuel pump is needed.

From the pressurized fuel tanks, the fuel flows to a vacuum filter fuel lock. This serves as a filter and a control allowing
the fuel to flow to the engine.

The gas (propane) supplied from the fuel tank through the reducer, in which the gas changes from the liquid to the
gaseous state, is injected into the air intake just before the turbo pump:

The mass flovw rate is adjusted by gas injector controlled by an electronic control unit(ECU), which adjusts the entire
system based on information obtained from load, RPM and temperature in the exhaust system.

Exhaust Gas temperature sensor. acts as.safety control, if the exhaust temperature rises, the system immediately reacts
by reducing gas fiow through the computer control, the engine is not at risk for knock combustion or abnormal wear i
comparison to an engine without an LPG system installed

A solenoid valve must be installed on the fuel line in between the tank and the engine. This valve cuts the filow of LPG
when the car is running on gásoline and when the engine is shut off It aso has a filter built in that removes any dirt that
may be in the füet.

The carburetor mixes gaseous propane with air.

Air flow itothe engine is controlled by a butterfly valvein the venturi.

micture is controlled by a fuel metering valye operated by a diaphragm, which is controlled by the pressure in the
The
intake manifold.

The idle system is an air bleed, similar

to a gasoline engine.
n ac,except for the fact that the propane carburetor does not require a fiel bowi, the two carburetor types are
basicallythe same:
Advantages:

MSBTE: W-14,S-16, W-16, S-17, S-18, W-18

State the advantages.of. LPG and CNG operatedengines W-14 W-16, S-17
22gyantageS.and disadvantages of L.GIGNengine.gMES
tate the advantages ofLPG
and CNG operated vehiciesS S18, W161

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 Introduction to Automobiles
FAutomobile Engineering (MSBTE Sem-V 1-32
1. The fuel cost is less.
dioxide (C0), unburned hydrocarbons,
Less pollution and more efficieney: It emits 99% less pollutants carbon
(SOx) and particulate matter t n petrof.
Carbon monoxide (CO), nitrogen oxides (NO,), sulphur oxides

3. It is safer for vehicle. The CNG fuel tank is made of thick wall % or % inch. So they can withstand dynamic exposion,
crashtest, direct gunfire
As it is lighter than air, CNG dissipates quickly and has a higher ignition temperature.

4. Increased life of lubricating oils, as CNG does not contaminate and dilute the crankcase. oil. No nced, of oil change
before 19300 km and reduce vehicle maintemance. Being a gaseous fiuel, CNG mixes easily and evenly in air.

CNG-powered vehicles have lower maintenance cost than ofher tydrocarbon-fuekpowered vehicles.CNG mainly
consist of methane with less percent of other hydrocarbon lke ethane, popane and hyutane. Less pollutant, does not
restrict vehicle performance and more coiomical than petrof

6. Due to its antiknock property, CNG can be used safely in engine with compression ratio as high as 12: 1 compare to
gasoline engine, Because CNG has a higher octane number than petrol, CNG engines.operate at higher compression
Tatio without knocking
. CNG fuel systems are sealed, preventing fiuel losses from spils or evaporation.
Disadvantages

The space required for CNG.cylinders and their weight about 300 pounds which
is more in most of the application.
2 While as compare to diesel engine compression
ratio of CNG is lower, so fuel efficiency of these engise is 10-28%
lower than diesel engine.

1.9 Electric Vehicles

1.9.1 Introduction:
In the electric car, the engine is replaced by an electric motor which
gives electrical energy from aset of þatteries.
electric vehicle also réfered to as an electric A
drive vehicle, uses one or more electic motors traction motors 10
propulsion. or

Three maintypes of electric vehicles exist,

(a) Directhy powered from an extermalpower station,
eg. clectric train.
(b) Powered by stored electriçity originally from
an extermal power sounce e.g. electric boats.
(c) Powered by an on-board electrical generator, such
as an engine (a hyhridelectric vehicle), celi.
orahydrpgen.
Electric vehicles inchude electric cars, electric
lorties, clectric aeroplanes,
electric boats, electric motony es ad
scooters and electric spacecraft.

1.9.2 Need

The fast.depletion of crude ail reserves, freqnent price coaventiona

hike and high atmospheric pollutionnorom the
automobile, it is the need to reduce ihe use operazlod
of conventional fuel the antomobile. So the hattery
electric and solarvehicle are the best altermatirve. The
in So of 1

se
vehicles
social and environmental impactsof electric and hybrid
include effects on mobility and travel, electricity supply consunption,
system operation, petroleum and on fuel
pollution and trafic noise.
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 Automobile Engineering (MSBTE Sem-VI)
1-33 Introductionto Automobiles
Hybrid electric vehicles (tHEVs)
are alternatives to conventional vehicles, and have a critical
role in migrating climate
change and saving oil resources.
Petroleum consumption for transportation
purposes will decline, but the benefits are
dependent on thetype fucl
of used to generate recharge clectricity.
Solar automobile uses solar batteries convert
to solar energy into electrical energy. Which can
motor to run the car. The conventional be used small electric
solar cell, or photovoltaic cell,is
an electrical device that converts the energy of
light directly into clectricity
by the photovoltaic cffect,
which is a physical and chemical phenomenon but delivers
power only about 0.5%
of the total light energy it absorbs. In
the electric car, the engine is replaced by electric motor
which fetes electrical energy from an
a set of batteries.
1.9.3 Working of Electric Vehicles:

The layout ofan electric vehicle shown

in Fig. 1.9.1.

Acceleration

Brake
Charger Drive Drive
Batery Matar iransmi
Whees

DCIDC
Gorverte

12 V

Fig 1.9.1.:Layout of an Electric Car

The battery used in electric car is lead-acid battery hose only disadvantage is relatively low specific energy
(27-33 Whkg)

Sodium- sulphur type with specific enengy 78-81 Whkg is a good alternatve but of very high cost amd its tise is yet

limited.

The drive controller takes powers from the batteries and delivers to motor.

The dive comtroler consists of twa variable resistars operated by acelerator pedal or brake pedal.

Accelerator pedal signa sent to drive controller through resistor to adjust the power to be delivered to the motor.

Two resistors (potentiometers)

are used for safety.
The drive controller gets signals from both
the potentiometers but operates only if the two signals ane equal
ne darve controller takes in about 300 volts DC from the battery set and coverted into maximum of 240 volts three
phaseAC tosend to the same
motor.

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Automobile Engineering (MSBTE Sem-VI)_ Introductionto Automobile
1-34

1.9.4 Advantages of Electric Vehicles:

Advantages of electric
vehicles

1. Rapid acceleration

2. Noise-free cperation

3. No exhaust fumes

4. High reliability
5, Easy maintenance

6. Regenerative braking

. No
loss of pawer in idling

8. Easy to drive

Fig.C1.5
1. Rapid acceleration.
2. Noise-free operation Electric
: vehicles typically have
whether it is at rest less noise pollutionthan an internal
or in motion. combustion engine veticle,
3.
No exhaust fumes:
Electric vehicles release
addition, is generally almost no any air polhutants
it easier to build pallution control at the place where they
systems into centralized.
are operated. In
umbers of cars. Electric vehicles power stations
emit no tailpipe CO,
or pollutants such as
than retrofit enomos
uSe. NO, NMHC, CO and PM at the
point of
Electric motors do
not require oxygen, unlike
internal combustion
High reliability : engines.
Due to absence of numerous
flywheels, starter motor, engine parts, such
distributer, spark as pistons, connecting
plugs, valve tappers roads, cams, valves,
5. Easy maintenance: ctc., electric car bas clute
Due to very small number high reliability..
of moving parts in electric
6. Regenerative braking: motor, the maintenance
When we take foot is much easie.
energy of motion off the accelerator
back into the battery. pedal, the motor
ABS brakes are automatically becomes a generator, *

climbing uphill is recovered suking

on the way down, rather applied in emergency stops. Energy
tham in sp
7. No loss of power buring up the brake
in idling : Electric motor linings.
in case of conventional does not need
vehicles. to idle and stops,
thus avoiding
the power loss during ra
8. Easy to drive: No clutch
operation or gear
šhifts are required.
1.9.5 Full power is available
Disadvantages ofElectric Vehicles as soon as you stepon pedal
. The range is limited
to about 100-150 km
the

becauseofthe
2 The top speed is quite
low (about 60 km per
hour).
need to recharge
the batteries.
3. Life of batteries is
quite short, which
expensive per kilometer means very
high
run compared to the conventional replacement costs. Thus
petrol engine
vehicle.
it is found that it 1s ch

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FAutomobile Engineering (MSBTE Sem-V})_ 1-35 Introduction to Automobles

1.9.6 Limitations of Electric Vehicles

1. High acceleration by high torque from the motor is lowered eficiency due to higher losses in the form of Joule heating
in the motor windings caused by the high electric current.

2 This cnergy loss increases fourfold as the input curent is doubled, so the practical limit for sustained torque from an
clectric motor depends on how well it can be cooled.during operation
3. There is always a compromise between torque and energy efficicncy. This linmits the top speed of electric vehicles
operating on a single gear due to the need to limit the requred torque aind maintain efliciency at low vehicle speeds

1.10 Hydrogen Fuel Cell

A fucl cell is a device which produce electrical power through a chemical reaction by' converting
a fuel (hydrogen) into
electricity. Although fuel cells and batteries are both considered
electrochemical cells and consist of similar structure,
finel.cells require a contimuous source
of fucl and oxygen to run similar to an internal combustion.engine needsa
continuous flow of gasoline or diesel.
A hydrogen fucl celt consists
of three main components an anade, the negative post of the fuel cell, athode the posifive
post of the fuel cell and an polymer electrolyte membrane to
create the chemical reaction detween hydrogen gas (tH
and oxygen gas (0,) as fuel

First, a hydrogen füel is channeled to the anode through

flow fields. Hydrogen atoms become ionized (stripped of
electrons), and carry only a positive charge. Then, oxygen enters
the fuel cell' at the cathode, where it combines with
electrons returning from the electrical circuit and the ionized hydrogen
atoms.
Here, the oxygen atom picks up the electrons, then it flow through the electrolyte combine with
to the hydrogen ion.
The combination ofoxygen and ionized hydrogen serve as the basis for the chemical reaction.
A polymer electrolyte membrane (Proton Exchange Membrane) permits thë appropriate ions
tó pass between the anode
and the cathode. If the electrolyte gave free control for all electrons or ions pass freely, it would
to disrupt the eh mical
reaction. At the end of the process the positively charged hydrogen doms react with the oxygen to form both
water and
lieat while creating an electrical charge.

Electric curent

Water and
Excess fuel heat out

HO

Fuel In Air In

Anode Cathoda
Polymer Electrolyte

Fig.1.10.1:Hydrogen Fuel Cell

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 Automobile Transmission
() SystemS
Unit-1
Syllabus:

2.1 Functton and Necessity of Clutch: Requirement of Clutch, Classification of Clutch, Working Principte Clutch,
of
Construction and Working o Single Plale (Colil Spring and Diaphragm), Multiplate Clutch
and Centrifugal Clutch.
22 Function and Necessity of Gear Box Manual Transmisslon: Clasification of Gear Box, Constructioni and
working of Constant Mesh arid Synchro Mesh Gear Box with power flow
diagrams.
2.3 Semi Automatic Transmission: Function, Construction and Working of Overdrive, Automatic Transmission:
Fluid Flywheel: Function, Construction and Working of Fluid Flywheet; Torque Converter: Function,
Construction and Working of Torque Converter, Epicyclic Gear Train: Function, Construcion
and Working of
Epicyclic Gear Tralin:

2.4 Propeller Shaft Assembly:: Function, Necessity and Types of Propeller Shaft, Funiction and necessity of
Universal and Slip Joint.

25 Final Drive: Function and Necessity of Final Drive, Difrental, Working Pinciple, Construction and Working ot
Differential.

Axdle, Function and Requirement ot Front Axde,

2.6 Axles:Significance of Live and Dead Types ot (Front) Stub axle,
Function, Construction and Workiñg of Semi Floating and Fully Floasting Rea Abxde.

2.1 Introduction

In order to propel the vehicie, a particular ype of speed and power changing device is required to transfer the power
developed by the engine to the driving whecl due to constantly changing requirement demanded on the engine and its
inherent limitation. These device are generally knoiwn as transmission. Transmission basically defined as an assembly
ofparts inclading the speed-changing gears and the propeler shaft by which the power is transmitted from an engine to
alive axle.
It includes all the companents between the engine and the road wheels used for transmission like clutch, gear box,
propeller shaft, differential andaxles.

2.1.1 Definition and Necessity for a Clutch:

MSBTE:S-15, W:17

hat iS cutch? State functions and dassification of friction clütches S15

QState hefunctions of dlutch. (W-17

on:Cluteh 1sa device used in transmussion system of a vehicle to transnmit the rotar no9
onesshaf
LOcated between
O Secona shaft of which as
are coincident with that of first Thus, the clutet. 15
the engine and the transmiSsion system.
the
power (Tarque) transtnits from the engine to the driving wheels through tne
iS engaged,

eticle moves. When the clutch is disengaged, the power is not transmitted to the driving wnet d e
the
vehicle stop, while
the engine is still unning.

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 Automobile Transmission Systems
Automobile Engineering (MSBTE Sem-VI) 2-2
disengaged during the gear, shiftina. 1while
engaged position. The clutch is
In a vehicle, the clutch is always in the operating clutch
by the peial
idling the engine. It should be disengage
stopping the vehicle or during braking and when
this avoids puting under strain on
sudden jerk motion of the vehicle and the
When clutch operated properly it prevents
remaining part of the power transmissio.
the engine amd the
transmission.
The clutch is located just behind the engine, betwecn

2.1.2 Requirements of Clutch:

The Main Requircments of Clutch are as follows:

I. It should be able to transmit maximum torque of the engine.

shocks.
2. t should be engage gradually to avoid sudden jerks or
during clatch operation.
3. It should be able to dissipate large amount of heat generated

4. R should be dynamically balane, för high specd engine.

during power transInission.
S. T should have suitable mechanism for damp vibration and rediuce noise

6 Size should be small and óccupies less space.

7. Easy for operating so that it can operate by small effort of drive.

8 It shoukd be lighter in weight.

2.1.3 Working Principle of Clutch:

A clutch is a mechanism'used to transmit the rotating motion of one shaft to another whicn desired and the axis of both
the shaft are coincident.

It works an the principle of friction. It comnect the engine shaft and gear box shaft. The transmission of power cam be
more roftating concentric surfaces, called as riction plate.
afected by iricion betwen two or The ficion plates cam be
presed firmly against one another by means
of axial force provided by spring and the pressure plate.

N pressuT

N RPM

(b)

Fig. 2.1.1

When it engaged, the clutch tends to otate as a single unit.

The rotating speed of the
depends upon the friction force which concentric surface or other sharts
is proportional to axial force applied by
spring. The torque (power) transmnud
by clutch is given by

= WR
T
Hence power transmitted
by clutch is depend upon the
coefficient of friction utch
plate (R). () of the material and radius Or C

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Automobile Engineering (MSBTE Sem-Vi 2-3 Automobile Transmissión Systems

2.1.4 Functions of Clutch:

MSBTES-16
QRStatepurpose and funclion of clutch in automobile, S-16

To permit engagement or disengagement of a gear whien the vehicle is stationary and the engine is running
2. To transmit the engine power to the road wheel smoothly without shocks to the transmission system while
setting the
vehicle in motion.

3. To permit the engaging of the gear when the vehicle

is in motion without damping the gear wheel.
2.1.5. Design Consideration of friction clutch:
1) The suitable máterial foming the contact surfaces should
be selected.
2) The moving parts of the clutch should
have low weight in order to minimize the inertia load, especially high speed
in
service
3) The clutch should not require any external force to maintain contact
of the frictional surface.
4 The clutch should have provisionfor facilitating repair
5) The ciutch should have provision for carrying away thie heat generated at
contact surfaces.
6) The provision for taking up wear of contact surface must be provided.

2.1.6 Selection of Clutch

The factors taken into consideration fordeciding type'
of clutci are listed belowi:
1)Torque: Required normal force, type of friction surfaces and number of surfaces
2). Rotation speed :t should be light, compact and intemally balanced
:
Available space Diamèter and height of clutch.
4) Frequency of operation: Type of joúrmey.as small travel, a simple engaging mechanisn, large cooling area, low
inertia.

2.2 Classification of Clutch

MSBTE:S-15
sific
te tne casSiicaton oincion Cucnes
Clutch

Positive tlutch Gradual engagement clutch

dog.clutch ar spline dutc
(in and out ype)

Electro magnetic Vacuum Hyraulic Fricion Fluid cutch or

clutch dutch clutth lutch Fuid tyowtreel dutch

Cona clutch Disc or plate clutch Semicerntfifugal Diaphram or Centriugal

cutch Coicar clutch
spring citch

Intermal Extemal Single plate Muld plate

Taper finiger Crow sping
Cone Cone CIuch. clutch type
type

Dry clutch Wet ctutch

Fig. C2.1
Techiaveledi
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 Engineering (MSBTE Sem-VI) 2-4 Automobile Transmissi
Automobile
Syste
2.2.1 Single Plate Clutch
MSBTE:S-16,W-16.
S.7
QDraw neat labelled sketch of single plate coil spring clutch of automóbile.

Q: Draw aneat labelled skelch of single plate clutch:

Q.Descnibe with neat sketch single plate cutchi

Q Explain the necessity and working ot single plate clutct with neat sket

Construction:

The part of single plate clutch shown in Fig 2.2.1.

It consist of flywheel, pressure plate, clutch plate with friction lining'faces called friction plate,
cutch pedal,
ball bearingamdclutch springs.
thas only one chutch plate, mounted on the hub which is splined internally and free to slides overthe clutch
th.
ust
n
sha
Fywheel is mounted on the crankshaft and rotates with
it.
The pressure plate is fixed to the flywheel through clutch
spring by means of þolts.
The springs are arranged circumferentially
to provide axia foreon pressute plate to keep the clutch in engage
as shown in Fig. 221 (a). posi

Thefriction plate held between flywheel and pressure plate having iiction facing on both side
to provide two z
friction surfaces for power transmission.

AAMAGS

Lautthpadai

Flywhee-

Fulcrum pn

Clutch sha
Engine shat

Bearing

Pressure plate

Cutch plate

AiAI Fiction ining

Cludch spring

Fig. 2.2.1a):
Single plate clutch

Td
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 Automobile Engineering (MSBTE_Sem-V) 2-5 Automobile Transmission
Systems

Working of Single Plate Clutch

hen hatch pedal is pressed the pressure plate iS moved to the nght (from Fig. 2.2.1 (a)) against the spring force and
this is achieved by means
of suitable imkage (not shown in Fig. 2.2.1a)) and thrust bearing.
Pressure plate

Fywheel

w Release lever
-Release
fever plate

Clutch shaft

ww
Cover
a
Fig. 2.2.1b): Simplifed diagrarh howing the working of singte plate clutch

Due to this movement of the pressure plate, the friction plate is releasod and clutch is disengaged and when pedal is
released tie pressure plate moves to left (from Fig 2.2.16)) due to clutch spring arranged circumferentially and thus
clutch again engaged
Advantages of Single Plate Clutch:
1. Gear changing is easicr than the cone elhutch because the pedal movement is less.
2 Itis more reliable because it does not suffcr from disadvantage of binding of cone.
Disadvantage of Sfnigfe Plate Ctutch:

The springs have to be more stiff kience greater force required by the driver for disengaged
Applicatton of Singte Piate Ctutch

This clutch is used in four wheelers like Truck, Jeep Fiat-1100, Ashok Leyland, Tata sierra etc.

Clutch
2.3 Diaphragim
MSBTE: W-17, W18.S19

GExplan wilh near sketch, the working ot a W17

ODraw.neat sketches for diaphragmspring type clutch in engage and disengage position Name the componerts 18)
construction and working of iaphragm ypepr clutch
aExplan S-19
In this clutch, in order to produce the required pressure for engaging it, a form of diaphragm or conical spring is
employed in place of coil springE

This type of clutch is quite advantageous because and the spring itself acts as a series of
itrequies no release leve
levers.

Some of the conical springs used even are not having the constant-rate characteristics.
.The presure of spring is always varying
this position.
It increases till the spring reaches to its flat positionm and decreases with the passing of
TerhKavaedg
ttiess
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 Automobile Transmission
2-6 Systems
Automobilo Engineering (MSBTE Sem-V)_
out of engagement as in en:
high a pedal pressure to hold the clutch case
In case of this clutch, the driver has not to cxert as
of a coil spring type.
to disengage the clutch, the spring pressure funb
In casc of a coil spring type of clutch, when the pedal is depressed arther
increases.
tapered finger type of diaphragm spring operating in a clutch
assembly.
In ig. 2.3.1 is shown in the
Flywheel Flywheel

Pressure plate assembly This section ofspring

moves back.
Rim

Rear plvot ring Pivot ting

Pressure plate

Dlaphragm spring This section ofspring

moves forward

Throwout bearing

Cover
Clutch plate Pivot ring
Pressure plate
Engaged Clutch plate
Disengaged.
Fig.23.1:Dlaphragm Clutch Operation
The spring is pivoting on the rear pivot rings
in its engaged position while holding itself
on the clutch cover.
In this position the pressure plate is
in contact with its outer rim. Therefore,
making a fim contact between the pressure sufficient pressure is exerted
plate'and clutch píate as well the
by the spring
as flywheel in this naturaconícal positiot
Now inorderto disengage the clutch,the pedal is depressed
The throughout bearing is moved toward the flywheel the
by linkage due to pedal depression.
As the spring is pivoting on thefront pivat ring therefore,
moves that portion the bearingcontactingthe
forward resulting the rim to inner portion of the conical spring
move backward.
The clutch disc gets released from
the contact with both
the driving members because
is removed the pressure pressure on the pla
The release levers would move towards the withdräwn
bearing,and.prevent
wearing down of the friction lining. the clutch from engaging füly due
To prevent the clutch slipping,
a free movement of about
bearing is provided 25 mm at the clutch pedal
or 1.5 mm at the
winr
2.3.1 Difference between Coil Spring
and Diaphragm Spring
Type Clutch:
MSBTE: W-
Diferentiate betweencoilspring
gAgM.cutch, fay four
STNo Coil sprina
Col spring clutch
Helical compression Diaphragmspring clutch
coi spring is used. Diaphragm conical spring is
used.
2 Release levers requires.
No release levers.
Non-unifomm pressure or on pressure
plate. Uniform pressure on pressure
plate.

TId

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 Engineering (MSBTE Sem-V) 2-7 Automobile Transmission Systems
Automobile

Sr.No. Coilspring chitch Diaphragm spring cliich

cffort for disengagement| Driver required less effort to disengagement of clutch.
Divcr required more
of clutch.
pressure constant.
During disengagement spring pressure.increase.| During disengagement spring
5.
Requircd more space. Compact in size required less space.
6.
Balancing is simple.
Balancing is complicated.

2.3.2 Multi-plate Clutch

MSSTE:S-15

Describe the working.of muit-plate dry clutch win

diagram, State.its.applications. S15
frictional plate (friction surface and clutch
single plate type clutch where increase the number of
t is a modification of
plate).
clutcht increased, the size remaining fixed:
this friction surface increasing, the torque transmission capacity of
Due to clutch.
rëduced for same power transmission as a single plate
Altematively the size of the clutch is
transport vehicles and racing cars where high torque transmited.
This type of clutch is used in heavy
limited.
This clutch is also used in scooter
and motor cycle as space available is

A systematic sketch of
multi-plate clutch is shown in Fig. 2.3.2(a).
- Flywhees Clutch pedal

Fulcrum pin
Pressure
plate

Spigotend

2ZZZZTTAE
-Springi
Bearing
Clutc shaf-
Friction Tiring
Clutch plates

(a)Multi-plateclutch

0 Plates with outer teeth (i) Plates with inner teeth

(b) Friction plates mult-plate
of clutch
Fig. 2.3.2: Multi-plate Clutch
rhknouledgi
Pbatlens

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 Automobile Transmission Systems
Automobile Engineering (MSBTE Sem-V)_ 2-8
two sets of
bearing and ciurcn pedal and
spigot.end with clutch spring, thrust
ot. 1lywheel, pressure plate,
Cnsist
Triction plate.
on splines on the pressue plate
flywheel and other one slides
One. set of friction plate slides in longitudinal
groove of
hub.

The friction plates are arranged altematively to each set:

pressure plate to move right (Grom
axial pressure acts on the
pressed, the
when the clutch pedal is
Fig. 232) and compressing the clutch spring at the spigot end.
disengaged.
Thus pressure on friction plate released and it is pressure plate to left
pressure plate to moves ihe
spring exert a pressure on the
When clotch pedal released the clutch
(fromFig. 2.32) and thus clatch again engaged
Number of pairs of contact surface= (n-1).
t'n'isthe number of friction plate in multi- plate clutch
Torgue transmitted by chutch = T=(n-1) 4WR.

Advantages of Mult-plate Ciutch:

1. Increase the amount of torque to be trinsmitted.

2 Decrease the pedal effort to operate the clutch.

3. Decrease the weight of the clutch.

4. Decrease the M.O.I. (Moment of Inertia) of the clutch.

5. Increase in better acccleration.

Disadvantages ot Mut plate Clutch:

t More number of friction plate

2. large anount of heat developed which may changes the properties of friction lining
3. Heavy

4. Too expensive
Applications of Muti-plate Clutch

1. Sport car, motor cycle

2. Heavy vehicle

3. Locomotives

Difference between single plate clutch and multi-plate

clutch:
SeNa Single Plate Cutch
Multi-plate clutch
Only one frction plate
Two sets of friction
plates (More than one)
2. Power transImission capacity
is more. Power transmission capacity
Iess.
3. Size is large
Size is small or compact

4 Springs are arranged círcumferentially.

| Only one spring located on spigot end
centrauy
2.3.3 Semi Centrifugal Clutch;

In this type of clutch light clutch spring

of sufficient strength
exering low pressure at iclingspeeds are
Also the pressure between the friction used.
plate is increased with
to the pressurerequirements the increase of speed
by means of centrifugal of rotation of the clutch in prop
weight attached to the
hinged lever at equal interval.
Trdi
featin

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 Automobile Engineering (MSBTE Sem-VI) 2-11
Automobile
Transm
transmission Systems
3) Fully automatic

There are two pedal i.c. for braking and for accelerating. Also an a selector mechanism
The following three different types of fully automatic transmission are in us
.
a. Hydramatic drive.

b. Controled-coupling hydramatic transmissions.

c. Three-speed hydramatic transmissions.

4) Continuously variable transmission

The transmission has continuously variable drive ratio

and uses belt, puileys and sensors
steady acceleration curve with no pause of gear rather than gearto maintain
change keeping constant power
range and inçrease
efficiency.
5) Dual-clutch transmission

2.5 Function and Necessity of Gear

Box

MSBTE:S-14, W-14.
QExplain the necessity of Gearbox in W-17
Automobiles
aStatethe nécessity bf transmissionsystemin
An Internal combustion engine
a
4W4
produces little power
at low speed and maximum power
the particular engine. at a gven specd depending
on

The gear box has a series

The automobile required high

.
Whenitdirectly coupled with gear box, a fixed roadspeed
ofgears and shaft to vary the
is provided to the vehicle
speed ofthe gear box output
shaft comparedto the engine
torque, when climbing speed.
speed. hils and when starting even- though
they are performed at low
On the other hand, when
runing at high speed on the straight
momentum and would level road, high torque is
t be more preferable to have
just thewheelalone turning at high speed.
not required because of
However, the torque which
the engine can produce is
torque necessary limited to such an amount that
for starting and for climbing the engine by itself cannot develop
hil..
The transmission acts
in accordance with the running condition.
When driving power is
required, it reduces
high running speed
the engine speed and transmitsstrongertorque
is desired, it transmits tò the driving road wheel and
high speed low-torque to the wbeels.

Power
available throtie
at.wheels goar-tul
road
Top level
vehicle

Powerof Maximum possible

road speed

Road speed kmhr

Fig. 2.5.1:Road speed km/hr

TedTnomledg
Pablicatias

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 Automobile Iransmission
Systems
Automoble Engineering (MSBTE Sem- 2-12
since cngine can nun in
one directiqn.
t&us0 serves to reverse the vehicle
position, without stopping the engine.
t also helps to kecp the vehicle in neutral speed, fuel economy, noise
Je
acceleration, ability to go up a slope, top
on
he vehicle perfomance is based to provide maximum acceleration at low speed by keeping the driving wbeel wheel
torque ng
durability. The gear box is designed

Output at the point of impending whel spi,

with-cube of speed When the power available matched with.power
The power required to drive the vehicle increases
roquired the ehicle moves forwand at constant speed.

2.6 Types of Gear Box

The gear box in automobile vehicle are classified are as followis:

Types of Gear Box

a) Selective gear transmigsion

1) Slicing mesh fype

2) Constant mesh type

3) Synchromesh type

9Three speed gear box

Four speed gear box

) Six speed gear box .

b) Planetary gear Transmission

1) Epi-cyclic gear type

2) Automatic
transmission

H0 Fluid type or Torque

converter

()Electic type
Twin topgear box

d)Pre-selective
gearbox

2.6.1 Fig.C2.3:7ypes
Constant Mesh of Gear Box
Gear Box

G Draw neat
labelled
sketchof
constar
Q Explanwithneat mesh gear
boxand explain MSBTE: S-16, S-17. W1
sketch wOrking working.
ot constant mesh
In this type of gear
box, all the
gear
box 19
gears on
The.twodog clutches the main shaft,
lay shaft are 17,N
are provided in constantlymeshing.
first gear and on main shaft,
reverse gear. one between
the clutch gear
and the second
gear andother etwcn
o

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Automobile
Engineering
(MSBTE
Sem-VI) 2-13 Automobile Transmission Systems
The main shaft
is splincd and
all the gear on
The two dogclutch
can slide on
the main shaft arc free to
rotatc.
the main shaft and
All the gear on lay
also as same
shaft (counter
rotate with
shaft) are rigidly fixcd
it
as enginc ty
spccd., fixcd with
with it and onc
onc gear on 14y
lay shaft is mesh with clutch shart geat

with tecth o
eth on OW gear) the Dog
low gear M clutch D, moves
toward by mean of gear shift lever,
it teeth arc engg
Gg
direction 1s moved
right (from
of rotation Fig. 2.6.1) and
is changeby gear L. mesh with teeth on M,
gear, a reverse gear is
00lau Ihe

Secondgear- LOw gear

Clutch gear Reyersa gear

Engime
shaf

Main shat

- Intemediate gear

Lay shaft

Fig. 2.6.1:Constant
mesh gear box
Second gear
Gear

Clutch gear- Reverse gear

i
Engine shaft
Main shat
Intermediate gear

Lay shaft

Fig. 2.6.2: Power flow diagram in first (Low) gear

Tehkaeuledge
9biltatians
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 2-14
ionSystema
Automobile Iransmission s
Automobile Engineering (MSBTE Sem-V)
Second gear
Reverse gear

Clutch pear

Main shaft
Engine shafl
Irntermediate gear

Lay shaft
B

in second gear
Fig. 26.3: Power flow diagram
Second gear-
Reverse gear

Clutch gear

Engine shat Main shat

-Intermediate gear

Layshat

Fig. 2.6.4:Power flow diagram in direct gear

Second gear Gear
Reverse gear
Clutch gear

-
Engine shaft-
Main shat
Intermediate gear

Layshaft

Fig. 2.6.5 Powerflow diagram

in reverse gear

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 rww
3"***w
toward right which mesh withthe
tch ID, is moves
dog clutch
hand scond gear
When left dogclutch D, movestoward left
ohtaining tthe direct gear by sclector (M,y.as
obtained for obtaincd. l cchanism
diræct gear is to meshwith
gear K, a teet
teth
on clutch a nstant mesh, they
box, hecause of are safe from
gear beingdamage
In this wihiiec.cngage and discngaged. and unpleasant
sound does not
occr ginding
follows:
power transmission is as
The
gear A
Clutch gearK-lay shaft -lay shaftgear Main shaft pear
Low gear: M, -dogD,-Main
o shan for
final dive
gear::Clutch gear K-gear A - gear gear M, -dog D,-Main shaft
Second forfinaldrive.
o
gear K- Dog D, ~main shaft for final drive
oTop gear: Ciutch
Intermediate
oReverse gear: Clhtch gear K- gear A-gear D- gear I-gear M, - Dog
Dg-Main shaft for
final dive.
skillful anding is necessary by drive so that speed
this gear box a of locking dogs and respectve
In effect a clash free gear change. gear on main shaft
remains ne to For obtaining same speed double declutching
is necessay.
Double Declutching

MSBTE: S-16,W-18

OEXpain needotdouble declutching

Rlain the concept.ot.couble .ectchng ralated to constant mesngeart

18)
gear bOx, 1or smooth engagement of the dog clutch, must be necessary keep
In constant mesh it to the speed of dog
clutch and gear on main shaft,must be equal.

For obtaining low gear, the speed of the ciutch shaft, main shaft and lay shaft gear must be increase and this is doneby
doubledeclutching..
First main chutch is disengaged and the gear are braught to
neutral position then engaged the chutch and press
gear then disengaged the cluteh and dog clutch moves to
accelerator pedal for increase the speed of the main shaft
required lower gear and engaged:

Thenclutch again emgagedi

hence it is called cdouble declutching.
this process clutch is disengaged twice
Asin dfiver has to wáait with the gear in
neutral il the main shaft speed is decrease
sufcienty
For obtaining higher gear the
for smooth engagement of the gear.

Advantages
gears are in constant nesh.
jts.operation, asall.the
gears are easier and quite in So we can have a
smooth and
Tnese having a smaller
diameter than the gear it controls.
mesh is
Z.he cutch used in constant
discngagement involved.
easy engagement and the dog clutches are
disengaging decreases
because althe teth of
duringengaging and same size.
Wear of dog teeth torque transmission
capacity than
ordinary gear of
the toeth of the gear wheels
Helical gear has high teeth and not to
4. occurs to the dog clutch
fauliy manipulation
damage that resuits from
.Any even ioss of
mechanical components and
Disadvantages damage lo
inappropriategear by mistake,
an
inexperienceddriver sélects
f an
control may occur.
TedKaeufedge
Blatlo

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 2-16
Automobile Engineering (MSBTE
Sem- MSBTE:W14 War
2.6.2 Synchromesh Gear Box -14, W-15is
operar
synchromesh
gearbox.
gearn cvery type of
by syne
RExplain with neal sketch, wokingof can be done types of nchromesh
so that lhis diterent
changing gear consequent damage, gaa
In order to sinmplifty lhe operalion of
the opertion and their
uy occumence or teeth clashes
wiuhout occurence
of
unskilled driver without and gearbbox output
shaft
chicle.
vehic engine driven
devic
evices are uscd in different type of motor
the speeds of
both the
clutches or equiva
ivalent meshin i
is to bring their dog unit
moving
a these
But the principle off all
devics
rotational speed
for i
gear which are to becngaged
eng to the same
shaft are im
constant.mesh
engagement readily and quietly. gear on main shaft, lay
box that the
similarwith constant
miesh gear
rotate as lay
shaft gear speed.
uS gcar box is
Th
gearon main shaft are
free to
fixed while friction after which
which these
t m
nc gear on lay shaft are
by
cqualises the spccdby
instead of dog, which
devicc is used
In this a 'synchromesh
having clutch gear B rotate
engaged smothly. the engine shaft T.
The systematic skeltch of
synchromesh is shown in Fig. 266.A
is
gear on lay . isthe
shaft. U. is th
a
on main shaft
and gear U,, U, U, and U, are the intermedi
speed, gear B, C D,E are
**

shaft which is spline internally.

gcar.
synchromesh member free to slide
on main
F and F,are the
teeth which fit onto extermal teeth of member F, andn
shape member having intemal
G, and G,are the ring
,
L and are dog teth on gear B, CD, E, T, and T, are
the ball supported by spring. S, amd S,are the fork

obtained low gear member F,

moves toward left (from Fig. 2.6.6) which causes the friction contact betwe
To thecoze
shape surface of gear D and member F

or
This ficion rubing makes the speod qual then member G, overide to left to engage with teeth K, and In
obiained., Similarly when member E, slides toyard igh, mesh with gear E, a everse gear is abtained.

Similarly for second gear the member F, and G, are slid to the ight so that finally the intemal teeth
withL, then the drive to main shaft from gear B-
on G. are
a engaed
U,-U gear C-G,-F,to spline.

Clutch shat

Main
shait

Fig.2.6.6(a):
Neutral
positilon

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 Automobile Engineering (MSBTE_ Sem-VI)
2-17
Automobile Transmission Systems
A direct gear is dbtained by sliding member P, toward left.

A synchronizer ring is provided betwecn the dog teeth K, and member F,

To push this ring in the proper direction, three guide bar are cqually spaced
along the circumference are provided. These
are retain in the placed by means of circlips.

This ring has dog teeth at its outer círcumíerence and is cut at three places
to provide space for guide bar.
.The widtt of each cut is equal to the width of the guide bar plus half
the pitch of the teeth of the symchronizer ring.
The synchronizer ring help to ovemide the ring gear when speed of member and gear is equalize and hence ring gear
moves to engage the required gear ratio.

(b)Direct gear position.

gear
Fig. 2.6.6:Syhchromesh box

Power Flow diagram:

Fig. 2.6.7: Power flow in first (Low) gear

A- Gear B-UU- Gear D- KzGFar Final drive

TechKnvulelgi
u tiins

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Automobile Automobile \ransmissiorn
Enginocring 2-18
Engineeting (MSBTE_ Sem-V
(MSD

GI

Fig.2.6.8:Power flow in second gear

Gear B-U-Ua-Ly-S Member
F-Final drve

S2

Fig. 2.6.9:Power flow

in reverse gear
Shaft A-Gear B-U-U-Us-Reversegear
E- Gear G2-Member F2- Final drive
Direct gear posiion
is shown in Fig. 2.6.66) of Synchromesh
gear box.
Advantages of Synchromesh
Gear Box:
1. Power tansmissioncapacity
in synchromeshgear box
is more as compare to Constant
2. Changing gear can be done MeshGear Bon.
by every type of operator,
their consequent damage. skilledor unskilled driver
withoutoccunence of ten
3. Noneed of double declutching.
Disadvantages of Synchromesh
Gear Box
1. Gear box is more expensive

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 Automobile Engineering (MSBTE Sem-V)
2-19 Automobile Transmission
Systerms
2. It is more bulky due to additional component.

Common features in a constant mesh and synchromesh gear

box
. All the gcars on the main shaft, lay shaft are in constantly meshing

2. The main shaft is splined and all the gear on the main shaft is free to rotate.

3 All the gear on. lay shaft (counter shaft) are rigidly fixed with it and one gear on lay shaft is mesh with clutch shaft gear

also as same as engine specd.

4 Gears on main shaft are fitted on bearings.

5 Synchromesh device and dog clutches are fitted, one between the clutch gear and the second gear and other between
first gear and reverse gear.

Differences in a constant mesh and synchromesh gear box

which these
in synchromesh gear box a two synchromesh devices are used which equalizes the speed by friction after
the speed
may be engaged smoothy. While fn a constant mesh two dog clutches are used which equalzes
mesh operation of double declutching is
2 In synchromesh gear box no need of double declutching while in a constant
necessary.
unskilled
gear this can be done by every type of operator, skilled or
3. In synchromesh gear box the operation of changing
driver without occurrence of teeth clashes and their consequent damage.
nubbing.surface, ball and spring and'a. synchronizer ring
having few teeth
4. Synchromesh device consist of cone shape
while a constant mesh dog clutch is provided with few teeth.
in

synchromesh gear box is more as

ompare to Constant Mesh Gear Box.
5. Power transmission capacity in
dog teeth which helps meshing of
gear box, the main shaft geai pròvided with two type of teeth one is
6. In synchromesh
lay shaft which received power from input
final drive and other mesh with gear on
gear and for power transmission to
shaft:
manual transmssion)
Semiautomatic transmission (Automated
2.7
the car handles manipulation
control also allowed for a sort of cross-breed transmission where
The creation of computer "clutchless
manualy if desired. This is sometimes called a
clatch automatically, but the driver can still select the gear
of the the driver to give full controt to the
"automated manual" transmission. Many of these transmissions alow
manual" or passenger,cars, have
mamual transmission "intermals", and when used in
computer. They are generally desigied using
gear sets.
synchromesh operated helical constant mesh
Easytronic, and Gartronic.
Specific type of this transmission includes:
used, each with its own clatch, so that
anly
sets of intermals which are aternately
A "dual-clutch" transmission uses two
the clotches are used doring the actual "gear
change"
Direct-Shift Gearbox..
Specifie type of this transmission includes :
switch gears.
which use the rotation of a drum to
There are also sequential transmissions
clutch. Torque converter is also
transmission is a combination of fluid coupling and a conventional
The semi automatic
automatic transmission was introdiuce in
models of semi automatic transmission. Chrysler semi
used in late some from the vacuum unit of the
In the first model, the power for shifting gear is obtained
1941by the Chrysler corporation. operate the automatic
by using hydraulic pressure from transmission gear pump to
engine manifold. Then it improves

shaft TeKnealedgu
Dtatlons
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 Autornobile Transmi
smission
2-20 Syse
Automobile Engineering (MSBTE Som-V
Direct-speed
dlutch sleeve Third speed gear
gear
Clutch D, First speed
Reversa gear
teeth
Main drive pinion

N Main shat
Clutch
cdutch
shaft E, Manual
sleeve

Counter shaf
cluster
drive gear B, Countersthaft gear
Free-wheling
unit
transmission power flow (Neutral)
Fig. 2.7.1:Semiautomatic
transmissiom
speed Chrysler semi automatic .Thech
2.7.1 shows arangement of
three forward and one reverse
Fig lay-shaft as in conventiana
the main driving gears which ther turn gear on nal ype
shaft is driven by engine and rotates
by one-way clutch or freewheelin
cluster is not integral with the lay-shaft gear, but driven ngunit.
lay-shaft gear
The (counter shaft) gear and
respectively are in constantly with their lay-shaft
The third and fist speed gear C and D
freely on the main shaft in neutral position.
contact with the dog clutch teei
The manual clutch sleeve Eis spline on the main šhaft and máke synchronized
mechanism lever.
gear Cand gear D when operated by the selector

The direct speed clutch sleeve Fis connected to the third speed gear C through.aspline and can engaged the clutch
tbe
of the main drive gear when moved' by the fork of the power unit
The power flow is shown by the arrows in Fig. 2.7.

2.3 Overdrive

MSBTE WSE W10

aDescribe the workingot bverdnive with neat sketch

W16,W-13
This is a device helps the propeller shaft to rotate
faster than the engine in the transmission.
Byemploying this engine speed can be reduce by 20 to 25% allowing
high crushing at low engine speed.
So advamtage of this is increase
to engine life, improve fuel consumption,
also reducenoise and vibration. increase
gear ratio available by fiting
it to intermediate gear. It
Itis generallyfittedon top gear.

It also fited on gear other

than top gear which
increase torque ratio.
e.g. in sports car.
It can be operated automatically
or manually.
It come into operation
at a particular speed
when operate automatically.
2.8.1 Construction
and Working of an
Overdrive
It consists of
an epicyclic
while the camier gear train in which
can be slide. sum gear is free
A free clutch to rotate on the
output shaft.
is also fitted on engine sshaft (input shaft) which is sp
input shaft. The
When the ring gear is mesh
sun gear is locked wiun un
Overdrive with the casingie.
is engaged. it became stationary,
the speed of the output cæ say s
shaft
incre
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 Automobile Engineering (MSETE_Sem-V). Automobile Transmission Systems
2-21
.When the sun gear is locked with the cafrier or the ring gcar, solid drive through the gear train is obtained.

Planel gear or -Freewheel

ring gear clutch

Sun
gear Output shaft
Input
shaft

Carier

Casing

TTTIIIL
Fig.2.8.1: An Overdrive
Thus depending upon the locking of sun gear with casing 'or carrier the overdive or direct drive is obtained.

.There is amother possible control of the mechanism there is a direcr drive through the free wheel clutch when the engine
develops the power.

When the accelerator pedal is brought to zero positioo and engine is iding, the output shaft wll tends to override the
input shaft.
The rollers of free wheel no longer remain wedge amd the vehicle frewheeis.
Thus for gear changing driver has to lift his foot off the accelerator pedal, clutch need not be aperated:
Advantages of Overdrive

1) lgives higher top gear ratio for better fucl conomy.

2) treduce engine wear and teair because of diven road speed, the engine speed is less,
3) Itis easy forengagement and disengagcment.
4) Aquarter running is provided by reduced engine speed
5) Less physical and mental fatigue on driver

6No shocks and jerks during driving-

7) Noiseless gear shifting.

2.9 Fluid Flywheel

2.9.1 Fluld flywheel or fluid coupling or fluid clutch

fiuid flywhee is mostly used in antomatic transmission system. It consist of two members the diving and tie
The
driven member. The two members are coupled through a fluid media. The driving member is fixed to engine flywhee
and driven member to transmission shaft. The two members do not have any direct contact with each other. The driven
member (runner) is free to slide on splines of the transmission shaft. The.two members are kept in an oil tight housing
which keep oil of suitable- viscosity up to a certain level. Both the members provided with radial rib in their facing
which face toward each other.

AS engine started, the driving member (impeller) beings to move inside the housing containing oil. Due to centrifugal
1orce the blade or ribs forces the oil outward radically. As the speed increases the centrifugal force the oil outward

raly as the speed increases the centrifugal forces increáses and the oil strikes the blades of the driven member and
between the both
along the same direction as a single unit. As engine speed decreases the oil filn
Ove
members is broken and the members are disengaged.

Techrouledgë
PuDItlons

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Autormobile Engineering (MSBTE_Sem-V) 2-27 Automobile Transmission
Systems
Let, T, = Number of teeth on sun gear

Tp Number of effective toeth on arm of planet carrier

The gear ratio of a pair of mating gear wheel with respect to the link carrying the axis of the gears is always
the same
whether hie link carying the axmis is fined or moving.

According to abave principle,

Speed of sun gear with respect to carrier

Gear ratio
Speed of planet gear with respect.to carrier
Reverse gear

Here the planet carier is held stationary the internal gear driven by sun gear to which power is applied.
gear
Reverse gear ratio=ethonthedriven
Teeth of driving gear

Teeth on internalgear
Teeth on sun geár

Applications of epicyclic gear train

) Cars that having automatic transmission.

G) Amy Tanks.

(in Wrist watches/walf ciocks

2.12 Propeller Shaft
Introduction

TtePropeller shalt is a diving shaft for connecting the transmision main of the outgut shaft to the diferential at the
ear axles It also caries the transmission main,or output shaft to the diferential for gotating rear whecis. Now the gear-box
or transmission and the engine are attached or bolited to the vehicle chassis orframe and rise or fall as one piece with it. The
rear axle housing (with wheel or differential) is attached to the frame
MSBTESW14:W16 S-17,W-17. S-18. W-18

Xpatn the necessiy.ofsiding joint anduniyersalont provided in propellec shait W14W 18)
Wite hindtons btunversaljoinand sipjont
16)
propy
ale tupciononiversal and sipjontusedin 17, W17S1)
Necessity of Slding joint

To accommodates change in length due to raad irregularities.

Necessity of Universal Jaint

he universal joint takes care of the variation in the inclination of the propeller shaft during up and down movement of
vehicle.

They also permit the motion to be transmitted from the gear box shaft to the bevel pinion shaft of the differential at all
times irrespective of the inclination of the propeller shaft.

of
hePrOpeller skatt connect the transuission shaft (gear box shaf), fo the bevel pinion shaft
dEfrereritial at the wheel axle is alšo caled as drive shafi
It

efaledgi
7PCtins

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 Automobile Transmission Systems
Automobile Engineering (MSBTE Sem-V) 2-28
2.12.1 Functions of the Propeller Shaft:
MSBTE
-14S16
W-14,S-16)
QState pDpellér.shaftshaft
wheels through the axle shaf
to the differential and them to the aft
uran smits rotary motion of the gear box output shaft
which is varying frequently
It transmits motion at an angle
between gear box and rear axle.
It adjusted the change in length
Propeller Shaft:
2.12.2 Construction and Working of (also called slip joint) .
flexible joint, namely a spline sleeve. t) and
stecl tube or hallow shaft and two type of
is made of
end. mm depending upon the tveof
two universal joint at each ranges from I.5 to 7.5 at
mm and the, thickness
ranges from 50 to 70
The diameter usually
application.
of the same size.
them lighter and stronger than a solid shaft
section makes
Tubular
Ttis also less expensive axle shaft deffected,or.changes its position due to spring
defilection
Don
comes across shock bump, the rar shaft of differential changes
When vehicle transvérsally, hence moving in a
circle so beve pinion es ts
and moves longitudinally and
Joint.
position. This care is taken by universal
propeller shaft during up and down movement of
variation in the inclination of the
The universal joint takes care of the
vehicle.
bevel pinion shaft of the differential at al
permit the motion to be transmitted from the gear box shaft to the
They also
propeller shaft
times irespective of the inclination of the
the rear axle movement.
adjust the length of the propeller shaft when demanded by
The slip joint serve to
and external spline o
sleeve attached to the universal joint at left
The slip joint is formed by the internal splines-on the
propeller shaft
truck and lng
shaft and the pinion shaft. of differeptial, is more as in
When the distance between the transmission.
chassis vehicles.
main propeler
connected to the gear box output shaft and other end to the
One or more intemediate propelier shaft is
SharL
Propeller shaft

Sliding
Universal joint
joint

Fig. 2.12.1:Propeller Shaft

The intermediate propeller shaft is supported in bearing unit fixed to frame.

speed is 0r
This arangement avoid sagging and whirl of propeller shaft at critical whirling speed. The whirling
the square of its length.

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 Automobile Engineering (MSBTE Sem-VI)
2-29 Automobile Transmission
Systems
Function of Universal Joint

Tfniversal joint allows transmission or power and rotary motion at an

angle which varies as a vehicle
encounters a
bump.

Function of Slip Joint

This joint allows variation in length of the propelle shaft when vehicle came across road iregularities.

2.12.3 Types of Propeller Shaft:

Types of Propeller shafts are

Types of
Propeller shaft

1.OpenType

2. Enclosed Type

Fig.c2.4: Types of Propeller shaft

1. The open type

like car is used this type of Propeller shaft.
In heavy commercial vehicle and light vehicle
universal joint one at each end.
Itistubular in cross section and is not enclosed. It is provided with two
sbaft and the other to the driving axle pinion
One of universal joint is attached to the gear-box main shaft or output
shaft
Propeller shaft which is comparatively longer is made up to two portions.
The Solid tube
Sip yoke

Fig. 2.12.2:Open type propeller shaft

2. The enclosed type

This propeller shaft is solid in cross section.

casing by a ball
which rigidly connected to gear box
Generaly it is enclosed in a tubular structure called torque tube
joint or large spherical bearing for resisting the torque reaction.
the
are resisted by this tube. Torque tube is
wnEn brakes are applied, the torque and twisting motion of rear axle casing
prevents the pw1sung
the axle housing and
D the reaction of the drive. A torque tube is a rigid extension of
VEn
of axle on its spring during power transmission to the rear axle.
sRubber element

Fig. 2.12.3: Enclosed propeller shaft

TechKared
llcatisns

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 Automobi ssion S
Automobile IransmissionSystetne
ngineering (MSBTE Sem-
34
2.14 Differential
one 8thai to drive
Definition Different arrangement of a gear that perimit
is defned as an may berotalingatunequal
speeds
ntial egiualtorgue,although the
three shafs
S
2.14.1 Need of Differential: MSBTERW5:S

W-15
the need of differential with neat sketch
State diferenualk
QWhy diferentialis needed ? Draw heat sketch of driving wheels, then both the whel
shaft is geared rigidly to both the
propeller
In an automobile vehicle, if the
rotated at the same speed.
when vehicle takes turn or on a
will be no any problem. But
When the vehicle is driven on straight road, there
trw b
will have to cover different distance i.e. outer wheel must
the vehicle
road, the right and left side wheel of
than the inner whecl.
and outer wheels, at one of the driving wheel will tends to slip on
theroad
When the propeller shaft drives the inner
in tum.
because of this tyre wear quickly caused
wheel skidding and wheel cannot controlled

214.2 Functions of the Differential:

MSBTE:S-16.W-13

a Expain wth neat sketch hefúnction of diferentiain rearaxe S16 W16

the power that received and sends the same throngh the two half axle shaft to the diving wheels
splits
the two wheels to turm by the
same amount when vehicle goes straight path.
Italows
I allow the diving whels to tum by diferent amount when vehicle goes on curved path and delivers same powezh
both the wheels.

The speed diference between the two wheel became possible because the two half axle shaft are not directly coupled b
the crown wheel but are drive through bevel pinion and side gears, This gear system constitute
a differential.
It transmit the torgue from the propeller shaft to the half axle shaft.

It provide permanent speed reduction and also

tun the drive round through 90'. The reduction provided is about 41
car and 10:1 in heavy vehicle. This is
done either in one or two steps. For less
reduction upto about 7:1 single reductie
is used. For higher reduction is achieved in
two step.
214.3 Construction and Working of
Diferential

MSBTE: W-14, S16,W-16,S-17 W-17.S

EXplain
erential withneat sketch:
C Draw neat labelled W-14
sketchofdifferential
and explain working.
State the (S14
needofdiferéntial: Explain with neatskelch working
hydiferentialisusëdin automobile ofdifferential (W-16,W-1
? Explain workingof differential
plainthe construction
and working of diferential
with simple
linesketch
a) Construction of diferential

The differential consists

of a crown wheel
(ring gear),
two type
of bevel gear, cage
and spider or cross
an

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 Automobile Engineering (MSBTE Sem-V)
2-35 Automobile Transmission Systems

Bevel pinion

Crown wheel Planet pinion

Sun gear

Half shat

Ate

Cage-

Fig.2.14.1:Differential
The road wheels are driven by two half axle shaft.

The side gear (planet gear) on the inner ends of each the half axle shaft.

The sun bevel gear and planet bevel gear are mesh with each other at right angle. The side gears are freely mounted on
the spider or cross arm. The cage together with the bevel pinions is secured in the differential cage is bolted to the
crown wheel of the final drive.
The diferential cage has a bearing at its centre. This bearing is mounted on the left half axle shaft. This arrangement
permits the differential cage to turn independently on the half axle shaft

The crown wheel is mesh with curved teth bevel pinion which is rotated by propeller shaft.

b) Operation.

The pinion, driven by the propeller shaft, rotates the crown wheel. Since the differential cage is attached to the crown
wheel it also rotate, when the cage rotate, the bevel pinion and the cross arm which caries them moves around the
circle with the differential cage
When the vehicle is driving on a straight level road, both the driving meet the same rolling resistanice. Hence, the load
on the planetary gear which mesh with the gear on one half axle shaft side gear will be same as those on the teth that
mesh with other ie gear. As such, the two bevel pinion do not rotate on the arms of the cross. In this case all the gear
will tends to turn as a single unit without any relati've motion between them. So the whole unit rotate as a same speed as
the crown wheel.

Differential Action

.When the vehicle takes a turm on curve surface. The inner wheel meets a higher resistance than the outer wheel and
resistance at the inner wheel (which is nearer to the center of curvature) is more
hence its rotation is slowed down. The
same amont of work in a shorter distance which they travels
because of these wheels are required to do the
turnm on their spindles. This turn causes
Now the tooth load became unequal. Because of this the bevel pinions tends to
turning of the
the bevel pinion roll around the planet gear on the one of the two half axle shaft. Due to this action more
restored.
outer side gear than inner side gear thereby accelerates the same until equilibrium is
travel more distance as
Thus outer side gear shaft tum more rapidly than the inner wheel shaft. So outer wheel has to
compared to inner wheel during the same interval of time
forward at N rpm as the outer
Due to differential action, the left wheel rotates back at n pm and right wheel will rotate
wheel will be (N + n) rpm and left
wheel has to cover more distance than inner wheel. Thus resultant speed of right
wheel will otate at (N-n).

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 Automobile Transmission
Automobile Engineering (MSBTE Sem-VI) 2-40 Systeme
protect them from dust, damage and wat
A housing completely encloses the short axle shaft and gearsthercby
vehicle from road viDrOn.
he rear axle housing is mounted on the leaf spring to prevent the

2.17.1 Rear Axle Shaft Supporting:

The live rear axle half shaft has to withstand the following loads.

() Shearing force due to weight of body.

(2) Side thrust caused by side forces during turning.
road wheel.
the spring seat and
6) Bending moment due to offset between
the tyres on the ground.
moment caused due to side forces and reaction by
9 Bending
wheel.
6) Driving torque transmitted to road
housing.
mounting of beaing in the axle
The rear axle are clasificd às pér the
MSBTE:S17

Working of any,
diferent types of real axle. Explain
ate
1. Semi -floating type

2 Ful loating Axcl

3. Three quarter floating axel

1. Semi-floating Type
MSBTEW5S17.S19
aExplain with neat sketch, full floating ype rear axle drive W15,819
Q State diferent types otreal axle. Explain working of ahy

In this type bearings are installed in between the axle housing and the axle shaft

Wheel is fitted directly to the flanged of wheel hub at outer end of shaft by bolts, while inner end
of the axle shat
splines to the diferential side gear.

It has to support the entire load as listed above (in section 2.17.1) like side thrust
and driving torque hence the diametr
of the shaft is larger for same torque output as compare to other type axle
of supporting.
The vehicle load is transmitted to the axle through the
casing and bearing which causes bending
and shearing of the
axle.

Itis simplest and cheapest than other type of axle

and widely used in cars.
Axde casing-

Wheel hub

Axde Shait

TIITI
Taperhub
Fig.2.17.1:Semi floating
axle

TedKan
Pe ti

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 (MSBTA
TE Sem-VI)
Engineening 2-41
Automobne tomobile Transmiss
ion Systems
TloatingAxle
Ful
2
Re Axle
Rear
Working of MSBTE
skeich used in Truck W-16,S-18
Descibe with neal
ful-loating axle and explainits
neat sketch
of eature. W-10
axle two taper roller bearings are used.
ne of
placed tuwcen the axlc housing
and he wheel
Bearingsare hub. Since the
load of the vehicle
housing. is supported completely
by the axle

Bearing

Axlecasing

Flange
Axle shaft

L
Wheel hub-
Bearing
lock nuts
Fig.2.17.2:Fullfloating
axle
The axle only transmits driving torqug. The
inner end of the axle is supported
have a flange to which wheel hub is bolted.
in side gear of differential
and outer end

.During repair the axle may be removed or replace from the housing
without disturbing the wheel
by removing the nut.
This type of axle is more expensive
and heavier than other axle. This type
is used in trucks or heavy commercial
vehicles.

2:17.2 Difference between Live Rear Axle

and Dead Rear Axle:

Hvea ae Ded
1 It is a rotary axle transtnit power or motion
to wheel..
It is a rigid axle transmit the weight of vehicle
part to road siurface.
2. II takes Bending movement,
torque reaction and diving | It takes only weight of body.
thrust. Reaction and weight
of body.
3. It is not directly fixed to suspension system but through
axle | It irectly fixed. to suspension system
housing.
depending upon type of drive.

L4. Forpowertransmission
it split into two half axle shaft. Itis a complete a straight axle.

echaeuledgi
atins
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 Automobile Control
Systems
Unit-1
Sylabus:

a Antomobile Braking System: Function and Requirement of

Braking System: Principle of Braking, Basic
Tems
related to Braking (Stopping Distance, Braking Efficlency, Fading of Brakes)

Braking System: Layou, Construction, Working of Drum,

32 Types of Disc, Hydraulic and Air Brakes.

33 Master Cyinder, Wheel Cylinder, Tandem Master Cylinder, Significance and general procedure of Bleeding of
Brake.

34 Review of Anti Lock braking System: Layout of ABS, Pressure Modulation, Types of ABS.

35 Automobile Steering System: Function and Requirements of Steering System: Basic Tems related to $teering
(Steering Ratio, Tuming Radius, Understeering and Oversteering), Basic Components of Steering Linkages.

36 Types of Stering Gear Boxes: Construction and Woiking of Rack and Pirion, Reciraulaing BallType Slering
Gear Box, Necestity and Principle of Power Stering, Construction and working of Hydtraulic and Electronic
Power Steering.

3.7 Steering Geometry : Necessity of Steering Geometry, Significance and ranges of Caster (Positive, Negative),

Camber (Positive, Negative), Toe-in, Toe out, King Pin Inlination (KPI}, Stering Axis Inclination (SA)

BRAKE

3.1 Introduction to Brake

stopping the vehicle within smallest
Brake is one of the most important device of a vehicle used for retarding or
The brakes also used to hold the vehicle at rest
possible distance, in consistent with safety and without wheel skidding.

on an inclined road against the pull of gravity.

both while remaining in action and this absorbed
energy
The brake absorbs either kinetic energy or potential energy or
engine is
de-accelerating a vehicle at a faster rate than the
appears in the form of heat. The brake must be capable of
engine power in its equivalent form.
able to accclerate it. Normally brakes absorb three times of

Functions of brake:
ASBTE:W-16

parking brakes
V-16)
D Cessity of braking system Whatis function.of

tis used as emergency of brake to avoid accident.

holds vehicle stationary on slope or steep road for parking
9) tcontrol the vehicle to be retained when descending a hill. wncc
in consistent
with safety and winour
possible distance,
ugskidding or stopping the vehicle within smallest

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 Systems
TAutomobile Engineering Control
(MSBTE
Automobile
Sem-V)
3-5

Wherc RT = Radius RT
of tyre,
Retarding forc on
road wheel(friction
between
road and tyre)

Where,
H Cocfficicnt offrictionbetween
WT tyre and road.
Normal force
on the tyre
3.1.4 Braking efficiency:

.Itis the ratio of retarding

force to the weight the
wheels to stop vehicle of vehicle. resistance applied at
or reduce the It mum retarding force of
is the maxim and
the componcnt of weight speed. It depends tyre surface
of vehicle on coeficient of friction between the road and
pends on coefic
the whecl.
If unity cofficient of firiction
is achieved,thetotal
then the 981m? e total retarding force produce at the wnewheel is equal to weight of vehicie
GT retardation is
brake is 100%. Ing eticiency is considered as 100% Thus therotical efficiency limit 1or
The checking of brake
without the
particular speed aid of proper testing equipment
from the moment stopping(5rakng
of application of the
brake is measured.
The instant when the brakes
exactly
difficult. Ciect take effect with maintaining vaiue atuthis moment is quite
maintaining the speed at exact value

Some other ditfficulties like variation

in gradient, iregularities applying brakes
stopping distance are libel in as well as wheel skidding aung
to arise.
The testing of brake is done either
by static brake testing machine or
by a decelerometer.
Wheels of the motor vehicle are
rest on the rollers of a static brake testing machine.
will be tuming. By rotating the roller the wneel

Now the brakes are appied and the resistance

to rotation at cach wheel is indicated. This method used only
speed without considering the road conditions. for low

A decelerometer is quite an accurate instrument which gives direct' reading of brake efficiency without
any
consideration of speeds.

This instrument is attached to a heavy block and placed on the floor of the car or mounted on a vehicle. A calibrated
scale visible through the window in the instrument will indicate the percentage brake efficiency.

Stoping distance required to bring the vehicle to dead stop' condition varies direculy to brake efficiency. When the
m/sec
brake force equal to weight of the vehicle or the rate of deceleration is 9.8
wheèl skiding when 80% efficiency on dry road is used on
.The efficiency is said to be 100 %. But the risk of front
slippery roads.
affected by condition of the brake. The stopping distance is also depends on the speed of
The brake efficiency is also
efficiency of the brake.
the driver's reaction as well as

Classification of Brakes
3.2
MSBTE: W-17

W-17)
classilicationotbrakes.and.braking systems

classificd as follows:
The brakes are

eelegi

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Automobile Engineering (MSBTE Sem-VI) 3-6 Automobile
ControlSr
Seta
Classificatlon of brakes

1. According to purpose
renetheeoenez

(a) Primary or service brake

(6) Secondary or parking brake

2. Accordingto location
H (a) At the transmission

(6) At the wheel

HO Two wheel brake

i)Four wheel brake

3. According to construction

H (a) Drum brake

Disc brake
6)
4. According to method of actuation
H(a) Mechanical brake

H (6) Hydraulic brake

H () Electrical brake

H ) Vacuum brake

(e) Air or pneunatic brake

5.Accordingto extra-braking effort

H (a) Servo-brake or power assisted brakes

b) Power brakes or power operated brake

6. According to application

H (a) Foot brake

(6) Hand brake

Fig.C3.2: Classification of Brakes

Te

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 Automobite Enginoering(MSBTE Sem-VI)

Hydraulic Brake 3-9 Automobile Control Systems

3.4

Explain raulic braking system

with neat
MSBTEWA5:S37
Whatarethe components.of sketch
hydrautlic braking W-15)
s
As compare to chanicalbrakes,
efficicnt, durable and
these brakes S17
simple in design. system
is silent, flexi
hydraulic lubricating. Also this system is highly
he braking system
based on pascal
without any loss. law which
states that the
fluid transmit pressu irection
This system is desi in such
nipeline to protect
a way that even
the entering brakes
NS are
of air in the aTt in released
system when po
position, a small pressure must
be maintann In
This system consist of master
cylinder,
cup of wheel cylinder
wheel cylinder, are kept expandea.
end of master cylinder.
steel pipe, flexiblet
When operator
se, brake linkage and a check valve att
pressed the brake
pedal, this force
is transmitted
.The piston in master cylinder
moves (to
to the piston in master cylinder
through linkag
covered, a further leftfrom Fig,
movement 34.1) by compressing
of piston build ng the reun spring. As bypass
up, the fluid check valve up pressure port is
deflect and in the compression chamber,
fluid under when sufficient
pressure in presSure 13 built
Du
As soon as the fluid enter the pipe line enters
in wheel cylinder, in wheel cylinder.
motion of piston exert a pressure
causes the brake on two piston to move
shoe expand the piston outward. This
creating tension outwar
The brake shoe lining press inretracting spring.
tightly against intemal
slow down or stop surface of brake
the rotation of drum drum. This fiction
between brake lining
hence vehicle slow and drum,
down or stopped.
As brake pedal rcleased,
the retracting spring
wheel cylinder pushes pul the brake shoe inward onginal
back. Due to this the position, this canses
brake fluid flow reverse the piston in
reservoir. in direction i.e. to the
master cylinder and
to fluid
As the pressure drop
in the fluid line the fluid check
valve at the end of
master cylinder closes.
Advantages of Hydraulic Brake

(1) An equal pressure is applied

at all point in the system, thus
equal effort can be applied
compensating. to each wbeel. This system
is self
(2) Even ifall the brake shoes are
not adjusted equally neár the drum, braking
effoit will be samie on all
(3) A differential braking action can the wheels.
be achieved by using different size of wheel cylinder
for front and rar.
(4) Less friction losses.

5) Asit is self lubrication, less wear and tear.

(6) Application of brake is very smooth.

(7) Minimum moving parts and less complicated linkage.

Disadvantages of Hydraulic Brake

(1) Any breakage or fault in the system causes pressure loss, affect the complete hydraulic system.
(2) If the brake fluid leak out on the brake shoe, they will be muined (destroyed).

3) Slightly leakage of air in braking system, imake it useles.

caulelgi
atless

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 Automobile Automobile
Engineering(MSBTE Sem-VI) 3-10 Control
Sysete
Brake shoas
Brake drum
Retracting
spring
ww Master wws Rear o
JMnder the vehicle
Front of Brakd
the vehicle pedal
Wheel
Pi5ton(G-Pivot cylinder
Pistons
Retum Fluid line
spring

Brake shoe

of Hydraulic Braking System

Fig. 3.41: Layout

3.4.1 Component of Hydraulic Brake System:

Component of Hydraulic
brake system

cylinder/Tanderm
(A) Master cylinder
master

e Wheel cylinder

(C)Fluid check valve

Fig. C3.4:Component of hydraulic brake system

(A) Master Cylinder

s16.S-17.S

QOravneat ebelled sketchof masteryinder cn ycraulc brake and explain working

Anconstucton and wonking of masteEEylinder

The master cylinder consist of two chamber a fluid reservoir and compression chamber.

A fluid reservoir contain oil or fluid with a Filler cap at top with small air vent to keep the brake fluid
at atmaspheic
pressure. Both the chamber are connected by two port

The smaller one is called intake port and larger one called compensating or bypass
port.
A piston operates in compression chamber.
There are number of holes in the piston head of the high
pressure side. The reduced diameter of piston is alwas
survunded by the fluid.
At the discharge end of the compression chamber fluid
check valve with a rubber cup inside. serve to retain
residual pressure in the brake line when brakes
It b
are in released condition.
A piston returm spring and to prevent
the leakage there are rubber seal
chamber.
on both ends of the piston in the compreso

When the brake pedal pressed,

the push rod moves toward
left by moving the piston against the spring forcCas
bypas port, a pressure built up in the
compression chamber va
deflected and the fluid under
pressure flows in the pipeline.
when sufficient pressure built up, the
tua cDsck

Tdn

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 (MSBTE Sem-VI)
Automobile Engineering 3-11
Automobile
ControlASystems
Air vent
Cap
IL
Fluid reservolr
=Body
Primary Stop
washer
seal
Compression- By pass
Circip
chamber Intake
Puah
rod

Fluid
check valvee
-Rubber
cup
L-piston
spring
rehum
L Secondary W seal
-Rubber
boot

Fig. 342: Master

cylinder
when the brake pedal release, the
spring pressure in the master
Fig. 3.4.2). cylinder moves the piston
toward ight (from
This same force of spring keep the
check valve pressed on
the compression chamber. its seat for sometime there
This delay causes vacuum compression by delaythe retum of fluid into
into the system. This vacuum in chámber and there may
is destroyéd by cnteting be chance of air leakage
piston which deflect rubber cup and the fluid from reservoir through
enter in compression chamber. intake port and holes in the
(5) Tandem Master Cylinder

In this separate luid lines go

to rear and front brake and
rear brakes will be still effective it is so arranged that if thefront
similarly if rear brake lincs brake lines are damaged, the
are defective, front brakes are
During normal working the brake fluid transmit to åpplied.
both front and rear brake when
brake lines are damaged, brake pedal pressed. Consider front
the piston 'b' will moves till
space between 'a' and
it comes up against stop after this
'c' pressure start building up in
'b'.and rear brake applied. Similarly when
space between piston rear brake line damage no pressure is build up
'a' and 'b'. So piston moves freely till comes in the
moves both it up against "b'. Further movement of brake pedal
a' and 'b' togcther thereby applying the front brake.

Fluid reservior
Intake Bypass
By pass Intake
port port port
pot

Push To front
brake

Piston (a)
To rear Piston ()
brake
Fig. 3.4.3
ecamde
PCata

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 Automobile Engineering (MSBTE Sem-VI) 3-14 Automobile
ControlSystema

3.6 Pneumatic or Air Braking System

MSBTE W-14,
W-17.S-18.Wa
Descibe pneumatic braking system with neat sketch and staté adyantag

Descrbe pneumatic braking system with neat and state its advantages W14
Draw the layout of air-braking system. Explain fits woiking

State the components of pneurmatic braking system wilh

r'suncion
An pncumatic braking system is
used in medium and heavy duty vehicles. This system
has following advantages
(1) The pressure on the pre-compressed
air allow any force required for braking
to developed very smal effort
by the driver to the brake pedal. aplied
apnlo

(2) The compressed air can used

be for many purposes like to inflate
the tyre, drive windshield wiper,
gear etc. actuate steering
steer

3) This system is most convenient for full trailers

and semi-trailers.
The layout of air braking system
shown in above Fig. 3.6.1(a).
reservoir, brake valve and brake It consists of air filter, air compressor,
chamber with steel tubes unloader valve
and flexible hoses.
Pressure P
gauge
ir
Compressor
seperator
s Unloadingg
valve
Air receiver

To
accessoriess
Brake
pedal
Hose
Brake valve
Brake chamber

Frort
Hose
Tee with quick Rear
relese valve
Compressed air Tubing tee
(9To 10 Kscm)
Hose

Hose Slack
adjuster

Fig. 3.6.1(a): Alr

braking system
The compressor is operated
by engine. The compressor
it to high pressure and discharge suck the air from atmosphere pressed
to the reservoir through through air filter and coug
oil separator.
The pressure gauge
is fitted to reservoir
air for several braking operation. to indicate the pressure
in the tank. The reservoir containenou compressed
The air from reservoir
tank is supplied
There is no braking cfíect until to brake valve and to otheracessories.
the brake pedal not pressed as
chamber. is brake valve prevent passag¢ Or the brake
the

T
PiCti

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 (MSBTE_Sem-VI)
Engineenng 3-15
Automobile Automobile
Breather hole Control
ystems

Diaphragm

Sprng
Compressed-
To
all brakes
Push rod

Pressure
chamber

Fig. 3.6.1(6): Brake chamber

valve
brake pedal is
presSed, the brake valve changes its position and brake open.
when
mpressedairfrom brake
valvefl to brake chamber acts on the flexible diaphragms in brake chamber.

pushestherods connected with the levers of brake gear cam. The cam tum and expend the brake shoe
The diaphragm
with make frictional contact with brake drum thus braking the wheels.

pedal is released, the supply of compressed air is cut off from the brake chamber and they are connected to
When brake
atmosphere.
are returned to their initial position and wheel nun fre.
The pressurefrom the chamber drops and brake shoes
braking force on shoe proportional to the
The brake valve is
equipped with servo-mechanism which ensure that the
the degree
force on the pedal and also
import relative reaçtion to the movement of the pedal. So driver can sense
applied

of brake
application.
valve is relieves the
compressor and reservoir air pressure line. The unloader
unloader valve is located between the
An unloader cut out pressure is obtained and seal the
reservoir.
compressor of its pumping load once the
upon the setting of the adjusting screw.
pressure depending
When the compressor is built up a
Thus allowing the compressor to
runm
atmosphere.
The umloadér then delivers the air
discharge by the compressor to the
supply of air.
light while the reservoir contains sufficient chassis andd
These are mounted on the
material entering the operating system.
foreign
The air filter prevents the dust and easily removed.
have a druin plug to allow the condensate to be

over mechanical brakes :

4.1 Advantages and disadvantages of airbrakes
Advantages

1. Quick braking effect.

Regquires less effort by the driver for braking.

reic.
. for inflate the tyre, drive
windshield wiper, actuale
siecning Bea

aur can be used

onvenicnt for full trailers and semi-trailerS.
Dsadvantages

Small leakage
of air causes brake failure
omplicate
in construction.
Requires analelgi
Air pressor, so cost is high. latiens

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 Sem-VI) 3-19
Engineering (MSBTE
Automobile le Automobile Control
Hydraulic and Pneumatic Braking System: Systems
Difference betwee
3.6.1
MSBTE: S-15,W-17,W-18
hydrauic
vdraulic bräking system ith pneumatic braking system.
befween
a
Compare S15, W-17,W.-18)
Hydraulic brake system
Sr. No.
2 Pheumatic brakesyster
will get relined of brake fluid leaks out of Brake shoe will not affected
Brake shoes due to leakage of air.
lining.
the brake

Large effort is required to diver to operate the,brake Less effort is required to driver
the to operate
2. brake pedal.
pedal
Brakc fluid is not useful for other
purpose. Air is used for inflate tyre, actuate
3.
steeringetc.
need of
compressor, air filter. Component like compressor air filter
4. No are essential.

Braking is less powerful. Quick braking effect (more powerful)

. Less frictional less as self lubricating. More frictional loss.

Simple in constriction and less moving part. Complicated in construction and more moving
"

1.
part
. No engine power required to run the system. Compressor consume engine power to operate the
sy'stem.

. |Less cost. More costly.

3.9 Comparison of Disc and Drum Brake

1 In disc brakes friction surfaces are directly exposed to the cooling air while in drum type brake, the friction occurs on
the intemal surfaces, from which is disipated only after it passed by conduction through the drunm.

2 In disc brake friction pad are flat while in drum brake friction lining are curve shape.
3.The desiga of disc brake is such that there is no loss of efficiency due to expansion. As in drum brakc system becamie
hol, expansion of a drum of internally friction surface apart, causing loss of effcctive pedal travel. One the other hand
brake dise expansion merely changes the relative position on the friction surfaces slightly without tending to increase
the clearance.

Drum brake

Disc brake

0.1 0.2 0.3 04 0.5 0.6

Coeffient of friction

Fig.3.9.1

FTechTaeuledgi
Pubiltatios
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 Automobile Contr ystens
Automobile Engineering (MSBTE Sem-V) 3-20
aPprOximately 20 g
counterpart-a saving ot being
conventional drum type
pot type disc brakes weighless than the
possible.
than drum brake.
.Disc brakes have better antifade characteristics surfaces can be sho
hown by plotting
changcs in the friction coefficicnt at
the rubbing brake .
6. The sensitivity of a brake to
factor against friction cofficient.
comparcd to drum brake i.e. 1:4. This means the pressure
frictional spot brakc is very less
7. Total arca of pads in
type.
intensity in disc brake is greater than drum MSBTE W-14, S15 W16 S-17.S-18, W-18,.S-19
w-14,S-15,W16,S17S18 N 18S
poiny
between Drum and Disc brake (any ejght
Diferentiate
Drum
brake
St No DiscBrake
Friction lining are curved shape.
Friction pads are flat.
Friction occur internally and heat dissipate by conducion
2. Friction surface directly exposed to air cooling.
and convection.

3. More efficiency. Loss of efficiency.

Light in weight (20 % less) Heavier in weight.

4
. Better and anti-fade characteristics. Poor anti-fade characteristics.

. Frictional area of pad is less. Friction area is more.

3.10 Steering System

MSBTE:S-15
QState the needotsteeringSyste
The steering system allows the driver to guide the moving vehicle
on road and turm it right or left as he desires.
During steering, the movement of the wheel
must be positive and exact and no wheel should slide on the road. Ths
aspect is influenced
by the steering linkage mechanism, tyre
and road conditions and vehicle
suspension system.
In order to maintain proper control throughout
its speed range with safety
bumps and bounce and provide in a straight ahead motion well as during
directional change with as
minimui effort of driver. Such mechanism
is known as steering mechanisn. is uised in a vehice
When a vehicle is moving on a road surface, the relative motion
of pure rolling This condition between the wheels
must be satisfied when and the road surface shoud be ou
the vehicle is moving
3.10.1 Purpose(Requirement) along straight or curved paths.
of Steering System

C What are 17:W-18

the reguirementsot MSBTE: S-14,W-15.S-16,
steering system
OSlateneedotpowersteeing
andexplain generallayout
QWhaare ha r t QenerallayoUtotn
otpowers S16
Listrequirements
ofsteeringsystem?
S
1. The steering mechanism W-18
should be
very accurate
2 It shouldmultiply the turning effort andcasy to
handle.
applied
on the steering
wheelby
the driver.

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 (14SBTE_Sen-V) 3-21
Engjineering Automcbile
Autormohilo Contro Syaterms
certain degrec ircvernible t the shocks on the road surface encountered
shoudbe ito a by the wheel
3. hands. are not
the dri ver 's
transmitted to
iem should have self-rightening
mechanism effct so
that when the driver release
The stcering the steering wheel
4. whoel should try to achicve straight ahcad position.
negotiating a turn, the after

3.10.2 Function of Steering System:

swinging the whecls to the left or right.

It helps in

stability.
2 t provides diretional
3. It helps in tuming the vehicle at the will of the driver.

4. It helps in controlling wear and tear of tyres.

5. t helps in achieving the self-rightening effects.

converts
ft the rotary movement of the steering wheel into an
angular turn of the front wheels.
1. It multiplics the driver effort by leverage to make it easy to turn the
wheel.
8. It absorbs the road shocks thereby preyent them to get transmitted
to the hands of the driver.
3.11 Basic term related to Steering
3.11.1 Steerlng Ratio (Reduction Ratio):

It is defined as the number of turn on the steering

wheel to produce one turn of the
steering gear cross shaft when
pitman arm is attached to it

The Steering ratio varies between 14:1

and 24:1 in case of passenger cars.
It grows with the size of the car, being low
for small, light car.

There are different types of gears

which have variable reduction ratio
by varying the pitch of the worm of cam
is flatter at the centre. so that it

Itislárger for straight ahead while for outer range

it is lower.
The gear ratio can be defined by considering
the turning of cross shaft.
It turns much less than the completing
the rotation in operation.
Therefore, gear ratio is the ratio between
numbers of degrees of rotation of the steering wheel
degrees through which and the numbers of
the cross shaft tums rotates.o
3.11.2 Turning radius:

The turning circle or turning

radius of a vehicle is the radius of smallest circular turn that a vehicle is capable ar when
a vchicle takes a u-turn. depend
It is on the maximum angle of the front wheel can tum and the wbeel base..
The radius of the circle on which
the outside front whecel moves. When the front wheel tum to extreme outer portion is
AnOwn as turning radius. It varies from Sm 8m
to for passenger can and upto I5m for bus and Truck. It is proportional
to wheel base
of the vehicle.
3.11.3 Understeering and Oversteering:
While taking tum,
the centrifugal force acts on the vehicle which produces side thrust.

ntnat force, the plane

achicved by the distortion
of the wheel must make some angle with the direction of motion of vehicle. Thiss
of tyre tread.
Tecaledg
tiess

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 Automobile Control Systen
Engineering (MSBTE Sem-VI 3-24
RAutomobile
causesthe turning 1

suspension. The link rod of the front

conventional rigid a
Fig. 3.11.3 shows stecring linkage for a
rod.
wheel through the steering arms and the track socket joint,, it is conside
The component a ball and
connected by ball joint.
The track rod and stecring arms are Tor wear and misadjust
expanding spring compansaies stment
in
joint is such that the
Wcar component. The design of ball

the system. inkage only one wheel is positively

also provided. In this steering roeie
length of the track rod is
A provision for change the
steered.

(b) Steering linkàge for independent

suspenslon
wheels relative
thewheels relati to each other,
regarding the motion of to ken
. In independent suspension, a provision has to be made

the steering geometry correctly at all ime. ck rod. In

actuate the two picce track In this
thie case
e
and a centrally idler arm both
track rods are provided
Fig. 3.11.4 shows two
the wheels are positively steered.

Tont Track rod

Relay rod
Shibade

Track rod
Pitman am
EFvéd to frame
emg box

Steering cotun

3.11.4:Steering linkage for independent

suspension
Fig.
due to
stub axles can move up or down independent of cach other whi
In case of independent suspension, the two ich
ends of the two track and arms is continuously varyng. On account of this a single trast
distance between ball joints
used, the center portion being called the relay rod.
rod cannot be used, instead three track rods are
ger
Relay rod is connected at one end to an idler amm supporied on body structure and to the drop arm of the steering
the other end through ball joints.

The relay rod is restricted to move in horizontal plane only. Movement in verical plane is provided by the outa
portion, viz, the tie rods about the end ball joints, in case of conventional igid axle suspension, the main atle bean
ensures the movement of stub axle in the horizontal plane only.

In this therefore, there is no vertical defiection of the suspension amd hence there is no change in effective traek mi
Iength

3.12 Types of Steering Gear Boxes

Worm and Worm sector/ wheel steering gear

.Wormand Nutsteering gear

Worm and roller type steering
gear
Rack and pinion steering
gear
Recirculated ball type
steering gear

Electronics and Hydraulic powersteering

gear

Tdlin
Pica

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 AutomobileEngineering (MSBTE_Sem-VI) 3-25 Automobile Control Systems
3.12.1
Rack and Pinion Steering Gear

MSETEHS-14WS15, Sal6,S17,WA17. S-18, S-19

ain with sketch working of rack and pinion type steering
gearbox used in Automobile,
With neat skelch, cxplain rking of rack and pinion (14
QWit type steering gear
(W.15
Daw neat labelled sketch of rack and pinion steering gear
(S-16)
neat sketch wnte construconana
Wih working of rack and pinion type steering
system.
Eyolain the working of rack
and pinionypesleering S17,S19
gearboxwith neat sketch Also state
o Explain working of acK and pinion fype steering gear system
ifs advantages (W17
S18)
The rack and pinion gear has become increasingly
popular for today's
smaller cars. It is simpler, more direct acting and
may be straight mechanical or power assisted in
operation.
In small car, this steering is quick and easy.
It provide maximum amount
the roads. There is no darmping out of road feel of road feel as the tyres meet irregularities in
as the tyres meet irregularities
in the roads. "
There is no damping out of road shock
and vibrations compare
to other type of steering system.
As gear ratio is limited to diameter of
steering wheel and pinion
force where as in large vehicle this can
gear so it can be used in small car and operated
be disadvantage hence re-circulating by light
ball type are found in trucks.
In this type of steering gear, a pinion is
mounted at the end
of the steering shaft. The pinion engages
is provided with ball joint at its each with the rack which
end in order to allow for rise
the and fall of wheel.
The rotary motion of the stecring wheel
is transmitted to the pinion.
The circular motion of pinion is converted
into the linear rack movement,
stub axle through ball which is further transmitted to
joint, tie rods the
to
This type of steering gear provides
sufficiently low gear reduction
for car and it is quite suitable even
vehicles if assisted with power. for heavier motor
It occupies very small space and
les number of linkages.
Rack and pinion steering gears used
is in Ambassador and Maruti 800 cars,
Maruti Swift
The rack and pinion gear design are
of two type

Types of rack and pinion

gear deslgn

1. Centre take off rack

2. End take off rack

Fig. C3.6

L Centre take off rack: In this tie rods are connected at the centre of the rack instead
of at the end. It has a large boot
that covers the centre part of the rack and pinioni housing. A slot in the
housing permit the inner tie rod ends
to move
with the rack. This type of design can be mounted high, saving space and reduces
the length of steering column.
2. End take off
rack: In this tie rod is connected at the end of the rack this is less affected by bump steer. When the toe
of wheel changes as they go over the bump, the vehicle is said to have bump steer.

TechKaewledg
P atieas

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 Automobile Control Systems
Automobile Engineering (MSBTE Sem-V) 3-26
Swivel pih
Wish bone
hr

Shb Pri
nde
Te rod

Bal jolnt W Tie rod

Tierod- Boot
Ball ont

Fig. 3.12.1(a):
Rack and Pinion Gear
Steering column

Universal:
joint
Spindle
Flexible-
Steering shaft
Clamps cOupling

Inputshaft
Steering gear

Tie rod

7 steering am

LTie rod L Spindle

Flexible rubber bellows

Fig. 3.12.1(b): Actual Rack and Pinion Gear system

Advantages
1. Stecring is quick and easy

2 No damping to steering wheel

3. Less effort required to drive

4. Operate easily on winding road

5. t provide maximum road feel on inregularities in the road

3.12.2 Recirculating Ball Type Steering Gear:
MSBTE: W16.W-13

Q. Describe with sketch working of recirculating

ball ype steering geat box
aU
liis an improved version of the worm and nut steering gear. It consists of worm at the end or rndAdi
a sici
mounted on worm with two set of balls worm.
in the grooves of the worm, in between the nut and
ousr
he function of ball is to reduce the friction 'between he
the worm and nut. The nut has a number
which mesh with the
teeth on worm wheel sector.
seemng
he drop am is mounted on sector. Which transfer caueste
wneel tum, the balls in the
the motion to steering arns througu
worm groove rolls, causes to nut slides on the worm.
r nut
wheel sector turm
at an angle and actuate
m fthe
wdet

the link rod through drop arm, resung

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 tornobile Engineering
(MSBTE_ Sem-Vi)
3-27
be adjusted
canbc adjuste with the help Automobile
the worm ControlSystems
The endplay of of adjuster nut
provided.
and hence the whecl sector can be positioned along A screw
is also provided
its axis
a by means of

Bal gulda

Ollo Wom

EEitT
Wheel sector

Cross shat

End play aduster

Drop am
Link rod

Fig. 3.12.2:Recirculated ball steering gear

312.3 Necessity and Principle of Power Steering:

MSBTE: S-14, W-14. S-15. S-16, W-16

Explain with neat sketch working of power steering S14, W14
0
0. Nowa day's power steering
issedinmost ofvyehicle.WhySate its advantages S15
Q. State need of power steernng and explain generallayout of power steerin9
(S16
Describe working of power.steering.with sker
W1
With increasingdemand for light control aligning tyre torque for keeping vehicle load acceptable, power steering has
become necessary in most of the vehicle.

In order to reduce the steering wheel turming effort, turn sharp cormer easily, negotiate winding roads and monocurve
the vehicle in confirmed space. The driver can sens and predetermine the approach of front wheel steering resistance to
stabilize the vehicle on turns or wind oad a power steering is used.
The construction of power steering is in such a way so that vehicle may be steered in the usual way when the engine is
not working or any break-down occur in the power source
power steering
The is of two type:

() Integral type
b) Linkage type
n beary duty (dump) trucks and power tractors the effort applied by the driver is inadequate to tum the wheels. In this
aca booster arrangement is incorporated in the steering system.
e booster is set into operation when the steering wheel is turned The ooster then takes over and does most of the
work for
and bydrauic
sg
ns system is called power steering and it uses compressed air, clectrical mechanisms
pressure.

A simplified sketch of Hydraulic

Power
e IS Used on the vast majority of power steering mechanism today.
siering with hydraulic
booster shown in Fig. 3.12.5.
When
thesteering arm.
The gWnecl is turned, the worm turms the sector of the worm wheel and the
arm high and the
turns the road wheel offered to turm the wheels is too
effortapplied by meansof o the drag link. If the resistance

e byt diver to the steering wheel is too weak, then the worm, like a screw in a nut will be displacea
e
ly together with
the distributor slide valve.
TechKneuledgë
Puatatlons

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 Sem-VI)
Engineering (MSBTE 3-29
nobile
Automobile Control
Systems
collects aformation from the torgquc sensor to neip determine how
ECU information from other much assistance
he also take other info areas such as the is needed by the diver.
modulemay traction control
system in order to get moret
The rcading. a
accuratc
it BCU) calculatcs
(LECU) calculates the assisting power
electronic control unit needed based on
the torque being applied the
The driver, the s wheel position and the vehicle's to
whecl by the speed. The ECU send
the varying curent to
ring
clectronic molor to
fes Stcering gear
rotates a stceri with an applied force that reduces
the torque required from
the driver.
send that data to the motor to push the rack left or right depending upon
module will then the direction of curent
The provide t
t he proper amount of rotation when steering
in order to
Tow

Advantages
pump, hose required.
construction as no hydraulic
required for steering.
effort is
2 Les
consumed only during steering.
Power is
3 resetting the selector switch.
assist can be changed by
Powcr
leakage is totally eliminated.
sProblem of fuid
consumed only while steering.
consumption and CO% emission as energy
A Less fuel

3.13 Steering Geometry

MSBTE: -15
pain toe in and toerouf wihrea
0Statelhe requiremenis.ol steerm
RANAN

firong
DefinitionThe angular relationship.anbrithe
frame 1s knounas steeriTg Eeomet
Necesity:
consequenty to steering
Suspension system can result in changes in wheel orientation relative to the ground and
The transmitted by the
vehicle: When these arise from vertical forces
efects unrelated to those initiated by the driver of the
sprung roll steer and fleribility in the
mass can induce
uT-prung mass they are called as bump steer effects. Roll of the
suspension mechanism can also give rise to compliance steer.
.
case/steering stability, ding
ge vanious factors entering into the front, end geometry
and influencing the steering

qualnty have direct effort on tyre wear. These factors are discussed as under.

Camber
S-17 W-17, W-18. S-19
W-15. S-16. W-16.
MSBTE: S-14, W-14, S-15.

Negativ mber
etern Cambea
Define camberangle
stateøftect
ene camberandits normaly
Apainwieefgeometryampe
the
or the
rear of the vehicle. If
nberis the angle from the front
of the wheel vertical, as viewed camber.
ans in
towards the Pne Telauve to from the vehicle, it has positive
chassis, it has negative camber; ifit leans away
OR
Camber
from front of vehicle.
rovided
may respect to the vertical ixis view
ront
bepositive or negative.
wheel tyre with
Camber is also called as vheel
rake'.
Techaraled
ltatie

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 Automobile Engineering(MSBTE Sem-V) Automobile Control Systems
3-30
Effect

When the whecl is tiltcd outward at the top camber is positive. Because of positive camber, the rolling radius at
utierent points of the tyre tread is different result of which the tyre tends to roll like truncatcd cone about the centre of
rotation, so tyre will wcar more on outside.
Negative camber will causes the wear of tyre more on inside. Initially positive camber is provided to the w v heels
so that
when the vehicle is loaded they automatically come to vettical position.
The tyre life will be maximum when camber angle is zero.
Amount: Camber should not be exceed 2°.
Tyre centre Vertical
ne
Camber

Left
front wheel

King pin

Fig.3.13.1: Camber angle

Significance

During turming the performance

of the suspension system is assume
negative camber angle. to by considering the vehicle operating at asightly
At this the chassis rolls in turning,
wheel is connected to the suspension deflect vertically
the chassis by number of links by some distance. As the
which must rotate
be subject to large camber changesas to allow for the wheel deflecton, the whel can
the suspension moves up
Camber angle alters
and dowm.
the handling characteristic
improves grip when cornering/
of a particular suspension
the vertical plane of the
tuming. This results the
tire rather than through
design; in particular, negalive
tire at a better angle to
the road, transmiting the forcesn
ca
a shearforce across
rubber tire tends to roll
on itself while comering. it. Another reason for negative cambcris that a
tyre had zero camber, reducing The inner edge of the contact
the area of the patch is to lift off of tneg
camber, maximizing contact patch. This effect is compensated for byY aPPapplying negaive
the contact patch area.
provided when the camber For maximum straight-line acceleration, ion will
be
angle is zero the greau
and the tread is flat
on the road.
(b) King pin or Swivel
pin or Steering
axis inclination
S-19
W-15. 5-118
ISBTE: S-09, W-09, S-14. S-15.
Deine KIngpin
incination,included
angleand it
EXplain
thetermKing pininclinati
pain wheelgeometry King
pinincination
Most of the steering
systems have
a kingpin which
is attached to steering knuckle to a support
ering knuckic

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 Automobile Engineering (MSBTE_Sem-V) 3-31
Automobile Control
Systems
Steering
King ph axis inclination
Indinaton

-Upper ball joirt

King
pin

Lower ball joint

wwwwwy
wwww

) King pin inclination (i) Steering Axis Inclination

Fig. 3.13.2

In some later design kingpin is replace by ball and socket joint. In this design, the steering knuckle and kmuckle support
are combined into'a single part. This part is called steering knuckle. No kingpin is used in this case

The stering knuckle is supported at the top and bottom by control arm.

Wheel Wheel Wheel

Kinig pin King pi King pin

wwwwwt ww.w

Tracive Road Tractive Road Road Tractve

forca resistance forca resistanca resistanca| forc

Fig. 3.13.3

Definton of Steering axis lInclination (SAI):

line drawn througn
SAI ángle is an imaginary
* LC 1DWard tilt of the suspension toward the centre
of the vehicle. The
centre of tyre
that run through the
PpCr strut and lower ball joint and another true vertical line
Definition of kingpin (KPI): the vehicle
viewed from the front of
steering axle when
of kingpin or
en tne vertical line and centre the
1s known as kingpin inclination or steering axis
inclination.
value is 5'. It reduces tyre wear
and helps to
provide

The kingpin ranges from 3.5° to 8.5 and its average vehicle is stationary.
"SPau nclination
ind
when the Tech neuledgi
effort particularly
steering stabilit It also reduces steering Catiens

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 3-32
Automobile Engineering (MSBTE Sem-VI)
produee.
when the
whecls are tumed and uces a
Effect: vehicle to rise
causing the
the effect of
Th SWIvel pin inclination has than 15
swivel pin
inclinations greater
noticeable self-centering effect for
to wheel. So as soon
Significance: moves up in relation n
causes the vehicle body st
king pin return the wheel to the
the inclination of tends to
When vehicle takes a tun, weight of the vehicle
turn is complete. The reduces steeing effort paricl
ularkly
as the steering wheel left after the provide steering stability. It also
reduces tyre wear and helps to
ahcad position. It
when the vehicle is stationary.
radius
pin) offset or scrub
Combine angle and Swtvel pin (king
() kingpin centre line. Combine angle is eul
between the wheel centre line and
It is the angle fomed in vertical plane to 10°.
inclination. The combine angle may be 9°
camber plus kingpin or steering axis with the gTDUnd i
patch and intersection of the kingpin
the tyre
The distance between the centre of positive camber or both reduce
scrub radius.
radiys. Kingpin inclination or
caled kingpin offset or scrub
wheel tends to toe-in.
(1 Ifthe scrub radius is negative the
wheel tends to toe-out.
(2) If the scrub radius is positive the
wheel is in straight position.
3) If the scrub radius is zero the steering.
position the steering is called Centre point
Without any tendency toe-in and toe-out: In this
12 mm.
The amount of scrub radius should be upto

Effect
offset, the
swivel-pin offset reduces steering effort because the wheel tends to roll during turning. With zero
The
significant
wheel is steered under these conditions there is
kingpin axis intersects the centre of the tyre contact patch. If the
is hat
tyre scrub at the front and rear of the contact patch leading to a
significant steering effort. The disadvantage of offset

longitudinal forces at the tyre contact patch due to braking, or striking a bump or
potholei transmitted through the stering

mechanism to the steering wheel.

Combined anige

Steering
axis

King pin

wwwwy

Fig. 3.13.4: Combine angle

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 Engineering (MSBTE
Sem-VI)
Automobile 3-33 Automobile Control Systems

(d) Caster
MSBTE:S14, W14 SE151S16/W16 S17. W-17, S-18: S-19

QDefine: Caster. 14515s7s19)

oDefine Negative caster
range of angle
0W-14
(S-16,W 16,W 17)
Define.caster, state eifecis on steering and give approximate
QExplain wheel geometry Caster S19)
angle between the king pin centre line and the vertical, in the plane of the wheel is called caster
angle.
.The
Caster is the slant of the steering axis as viewed from the side of the vehicle.
in some vehicles runs through the centre of the king pin and
The steering axis is the imaginary steering pivot line which
on other runs through the centres of the
upper and lower ball joint.

Caster Vertical

-Front Ieft wheel

King pin

ofFront
car

wwwwwwwiiiii iiiiN
Fig.3.13.5:Caster angle
Caster is positive when the top of the steering axis slants to the rear of the vehicle and negative when it leans to the
front.

When the caster is positive, the projected intersection of the steering axis is ahead of the tyre contact point.

Caster is negative when the top of the steeing axis leans to the front of the vehicle.

The steering axis intersection point is called leading point and the tyre ground contact point is called trailing point.
The positive caster is to provide directional stability. The greater the positive caster, greater is the stabilizing force.
Amount of caster about 3° gives good result.

Significance:.

stabilizing force. On
The positive caster is to provide directional stability. The greater the positive castor, greater is the
.
is raised, i.e. positive castor helps the
the fum for a positive castor the outer side of the vehicle is lower while inner one
centrifugal force in rolling out the vehicle. Negative castor tends to oll in the vehiclei. e. the centrifugal
force is counteract.
stability but effort require for steering and hold the vehicle on
The more positive caster is to provide gives more directional
pulling to one side when brakes are applied and
um increase. Incorrect caster can produce difficulties like hard steering,
range of t 1 degree. 3° gives good result caster tends to
shimmy. Amount óf caster will be 2° to 2.5° with a tolerance

changes the vehicle weight when it is not set at zero.

mled
Nties
PapliEat

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 Automobile Suspension,
(a
(4 Wheels and Tyress
Unit- IV

Syllabus System: Basic Tem

of Rigid Suspension erms
Function and Requirement
4.1 Automobile Suspension System:
Unsprung Welght, Spring Rate, Elastich
System: (Jounce, Rebound, Sprung and
Related with Suspension
Leaf Springs.
Types and Constructional Features of
Front Wheel Independent
Suspenslon System: Advantages of
4.2 Function and Requirement of Independent Type Suspension system.
Mac-Pherson Strut Type, Wishbone
Suspension, Construction and Working of
Working of Air Suspension, Function a nd
Air Suspension: Layout, Construction and
4.3 Shock Absorbers and
Construction and Working of Telescope
Types of Shock Absorber, Principle of Hydraulic Shock Absorber, pic

working of Gas Flled Shock Absorber.

Shock Absorber, Constructional Features and
Requirement of Wheel, Rim and Tyres: Types of Whees
4.4 Wheels, Rims and Tyres: Function, Necessity and
of Wheels, Aims and Tyres.
Rims and Tyres, Construction and Working of Different Types
affecting to Tyre Life, Tyre Wear and Rotaion
4.5 Tyre Economy: Consideration in Tyre Tread Design, Factors
Tyre Designation.
of Wheel Alignment, Purpose ot
4.6 Wheel Alignment and Balancing: Purpose of Wheel Alignrnent, Procedure
Dynamic Balancing.
Wheel Balancing, Significance of Static and Dynamic Balancing, Procedure for Static and

4.1 Need of Suspension System

MSBTE:S-14. W-14.S-17/W-18
W-14
Q Wby suspension is necessary inAutomobiles S4
Explajin need of suspension systemnaut obiles
Kplain necesIy oT Suspension sys
In order to provide comfortable ride to the passengers and avoid additional stresses in the vehicle frame.
nor
The vehicle should neither bounce or roll or sway the passengers when cormering pitch when accelermating, bru
or sudden lifting or dropping of the front wheel with respect to rear wheels.

Although some of the road imegularties and inequalities are absorbed by large tyre
ridealso
It is necessary to provide a suspension system for reducing the shocks to passengers and for comiora
reduce additional stresses in the automobile frame and body.
collectively caled a
All the parts which perform the function of isolating the auto are
obile from the road shock
suspension system.

A good suspension should have springiness and damping

The springiness is the elastic resistance to load while

damping is ability of absorbing snocA

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Automobile Engineeing (MSBTE Sem-VI) 4-2
Automobile Suspension,
Wheels and Tyres
4.1.1
Functions

thefunction of sUSpension system.and classify suspension svs

MSBTE: S15
State
1) act
To a$ a Safeguard for the occupants against road shocks and (S15
provide comfort ride.

nTo preserve the stability of the vehicle in olling, pitching, while in motion.
T minimise the effects of stresses due to road shock on
mechanismof a vehícle and
provide cushioning effect.
To provide the required height to body structure as well
as bear the torque and braking
reaction.
9 To keep the body perfecdly in level while travelling over the uneven road.

0 To provide good road holding while driving, cornering and braking.

n tisolate the automobile body from the road shocks which may be in the form
of bounce, pitch, roll or sway.
4.1.2 Requirements of Rigid Suspension System:

MSBTE: W-15. W-16

Q Enistany tour reguirements ofsuspensionš emgnt mobile W-15
Whatis the requirement o suspension
systemn Atütomóbile?
W16
The basic requirements of suspension system are listed below.

It must withstand Greater part of the extra weight of passengers and luggage has to be caried.
There should be have minimum deflection with the loads as well as the torque or turning forces imposed it.
on
It must be maintained wheels in the proper position with respect to road surface.

I should be posidion the axle for minimizing bouncing and associated vibrations to which is liable while moving
of,
braking and conering particularly.

It should be of low initial weight.

nPrevent transmission of 'road noise' to the vehicle body.
requires appropriate isolation in the suspension joints.
I
4.1.3 Basic Terms Related to Suspension:
when it comes across the bump
Jounce: It refers to the bounce or vertical movement of the vehicle suspension upward
or shock in the road.
the opposite direction of jounce. The
Rebound Rebound refers to the movement of the vehicle suspension in
:
rebound, or exteasion. When
and shock absorber is called
AOWward travel of the tyre and wheel hat extends the spring
the spring is deflected, it stores energy

SSprungandUnsprungMasses: design, is broken up into

two partsSprung and
the 'suspension
The Otal mass of a vehicle, for the purpose of
unsprung. main body
these items to the
suspension components that attach
consists of tyres, wheels and
Wgnt unsprung
chassis structure. the wheel ane
all items that move with
weight. In dynamic terms, suspension. The portions
ne Test of the vehicle is sprung bar which are attached to the
absorber and sway
portions of the shock
nis also includes sprung Tecae
tipa"
frame and body are
that are attached to the

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 Tyres
Automobile Suspension, Wheels and
NAutomobile Engineering (MSBTE _Sem-V)_ 4-3
heavier oncs.
with the ground more casily
components can be kept in contact tyre to the surface.
Light springs can retum the
whecls and related assembly must be stopped before the
Motion of the
control.
the less momentum there is to
Therefore, the lighter the components,
handling deteriorates.
weight, the suspension has to work harder and
With greater unspring smoother ride.
thus allows the use of softer springs, which make for a
Low unsprung mass absorbers, thus giving a better
weight can be controlled with springs and shock
With less unsprung weight, more
ridc quality.
handling and steering.
and unsprung weight
adverselyaffect ride,
Resonance duc to the sprung quality,
amplitudes and the lower the ride TOad

unsprung weight, the higher the hop and tramp

The higher the
holding and stability. dyanamic forces
vehicle during the steady aero to

It is defined as the amount of force acts on the

4. Spring rate :
the load is placed onto the spring.
spring, however, remains constant at
compress or deflect a spring. The rate of the
force applied (when it come across the bum)
measures of the deformation of an vehicle body when
It is the
Elasticity :
5.
suspension system.
In automobile it must be constant for

4.2 Types of Leaf spring

springs.
Following are the different types of leaf

1. Seml Eliptical Spring

in front and
Particularly in trucks, semi-elliptical springs are fitted
rear
These are usually used in all the vehicle.
semi-eliptical plate.
axles. The leaf springs are made of steel plates or flat
axle. Semi-
the independent suspension is fitted on the front
But in cars, they are fitted on the rear axle only and
the range of spring action and last for a
lomg
elliptical springs are cheaper and require less repairing. They increase

time.
full elliptical spring and fited wh
2 Quarter Eliptical Spring: This type of spring consists only a quarter portion of the
the frame by the bolt.
qu
3. Three Quarter Eliptical Spring: Three quarter elliptical spring i the combination of semi elliptical and
elliptical springs
One end o
4. Transverse Spring: Transverse spring in just like the semi elliptical spring but inverted in shape.
by the Dos
spring in joined with chassis frame by shackle, and the other end with the axle. It is also fixed with frame

thecentre.
opposiily,
5 Full Eliptical Spring :
Ful eliptical springs are consists of two semi elliptical springs joined together
do not maintain corect axle alignment.
frame
6. Platform Type Spring: Platiorm type springs consist of two semi-elliptical springs. They are fited wit
weight
by shackle at one side and the other side is fitted with an inverted semi eliptical spring, In this arangenu
of the car is divided into three points.

4.2.1 Construction and Working of Leaf Spring:

S-16,S18
MSBTE: S-14,

Descnbe with neat sketch the construction andworking of leat spring

Draw neat labelled sketch of rear leaf spring suspension
and explaD
QDraw neat sketch qf leafspring:Slateitsfunction:
licati

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 (MSBTE_Sem-V)
Engineering 4-4
Autorm
mabile obile Suspension,
Wheelsand Tyres
Al
Semi
clliptica lcaf
dly
springs are widely
used for suspension
in light and heavy commercial
vehicle. In
suspension. car these are used
rear
for lates or flat semi-clliptical plate.
are made of
leaf springs
The c ing over hclical spring is that the ends of the spring may
advantage ofl be guided along the
definite path asit
The structural member in addition to energy absorbing device,
deflecs to act as a
lateral load,ibrake torque, driving thrust and shocks.
spring cary
Thusleaf
plates called blade or laves.
number of semi elliptical
cons ists of
N
curvature or camber so that they tend to straighten under the load
leaves
e are given iinitially
aTe given
The ry in length and are held together
by a bolt passing through the centre acting as a beam of uniform
Theblades
strength.
"U bolts.
to the axle housing by means of
spring is clamped
The leaves has its end formed in the shape of an eye through which the bolts are
leave is known as master
The longest
spring to its support.
passed to secure the
material such as bronze or rubber. The other
shackle provided with bushing of anti-friction
eyes are attached to
The
leaves are
graduated leaves.
trimmed in various forms.
Ieaves, the ends of graduated leaves are
prevent digging in the adjacent
To twisting moment due to presence of stresses
has to withstand vertical bending load, side thrust and
.The master leaf to provide two full length
leaves and rest graduated leaves.
caused by these load so it is usual
that graduated leaves also shear the
intermediate position in the leagth of the spring so
Rebound clips are located at

stresses induced in the full length

leaves when the spring rebound.
(movement about vertical
suspension but they also increase tendency to jaw
provides a soft
Highly cambered spring when brake or accelerate
suddenly.
reduces tendency of the vehicle to dip (pitching),
spring
axis). Flat

Use of longer spring gives soft suspension. frequencies, wich

vibrate at differeat
than the front spring. This causes them to
longer
Generally rear spring are kept
prevent excessive bounce. Shackde-

Frame side member

Spring eye
U bolt -Rear axde
Rubber bush
Master leaf
Cip or stapP
(Rebound cip)
Central bolt

Fig. 4.2.1:Leaf spring

Advantages
separate linkage
without the need for a
tis simple position trailing arms and
andsstrong, acting as a linkage that holds the axle in eliminates the need for
2. Extra location. This
weight and costs axle
pan hard are reduced because of the rear TedKeulel
rod.

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 Automobile Engineering (MSBTE Sem-VI) Automobile Suspension, Wheels and Tyrea
4-7 yres
The suspension system is classified as:

Types of Suspension System

(1) Conventional or Rigid System

(2) Independent system

(3) Rear end suspension system

(a) Longitudinal leaf spring rear end sUspension

Transverse leaf spring rear end suspension

6)

C) Coil spring rear end suspension

(4) Front end independent suspension

a) Wishbone type or paralel link type

(6) Mac-pherson strut type

o)Verical guide type

H) Trailing link type

(e) Swing half axde type

5) Interconnected suspensions

la) Air or pneumatic suspension

system

H6) Hydro elastic suspension systerm

) Hydrogas suspension system

(6) Selfleveling suspension

system

Fig.C4.1:Classification
of Suspension Systems
The conventional system,
in which the road springs
are attached to a rigid beam axle. Applicabons-
The independent system
in which there is without ay
reaction on the no rigid axle beam
other wheel. and each wheel is free to movev
The suspension
system are againclassified
3. Rear end suspension as:
system
(a) Longitudinal
leaf spring rear
end suspension.
6) Transverse
leafspring
rear end suspension.
c) Coil spring
rear end suspension.
Application
:Motorcycle.

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Automobile Enginering (MSEBTE Sem:V) Automobile Suspension, Wheels andTyres
4-9
4.6 Types of Front Wheel Independent Suspensions
Types of front wheel
Independent suspenslons

(1) Mc-Pherson strut type or single

wishbone system

(2) Wishbone type or parallel ink type

r double wishbone fype

(3) Trailing link type

(4) Verical guide type

(5) Swing-half axle type8

Fig.C4.2: Types of front wheel independent suspenslons

4.6.1 Mac-Pherson Strut Type Suspension System:
MSBTE: W-14, S-14. S-15, W-15. S-17. W-17. W-18

With neat sketch explaln the workingot Mac Pherson ype suspensior system
Explain with neat sketch Mac-Pherson ype suspension
systemGve name this ype d
SUSDension syYstem is used Gve any two advantages otit

QDescribe the working of Mac Pherson.strütiype sSUSDension with reat sketch

Q Descnbe construcion of Macpherson suspension system with neat sket
Q. Describe construction of Mac Pherson suspension system
State its ady
A Mac-Pherson, cngineer introduces a single wishbone
with a telescopic strut type independent suspension
system
This system, consist of a telescopic strut type
shock absorber, a single arm and diagonal
a stay.
Body member

-Spring

Shock
absorber

-Strut contalning
shock absorber

-Shub axde

Wish bone am

Fig. 4.6.1: Mac-Pherson Strut

Suspension System
tiets
DIiea

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 Sem-VI)
Aulomobile
Engineering(MSBTE 4-10 Automobile Suspension, Wheels and
Tyres
is fixed to the underside of the cross member of body through
upperendof a stut a flexible mounting and a lower
.The the strut is fastened at the ttom by a joint to the lower wishbone arm.
part of carries the stub axle, on which wheel is mounted.
The lower
pat of the strut also
wheel is transmitted to the lower part of the strut and it turn the
rotary motionofthe stering whole unit
The
oressive coil spring with shock
absorber surround the upper part of the strut which takes care
helical o of the road
A absorbing the shock and
vibration bya protect the vehicle from the stresses transmitted to the body.
Dughs
ughness shocks and
Maruti-zen , Manuti-800, Maruti alto and Maruti swift.
1

Aplications:
App
Advantages

in construction.
1. Itis simple
constant.
Keep wheel camber
2
very easy.
3. Its maintenance is
follow the road iregularities.
moving parts help the wheel to
4 Is light
Disadvantages

1. Increases tyre wear.

Quality of ride depends upon

shock absorber.
2 accurately.
check steering angle
3. Special cquipment is required to

Cannot withstand heavy

load.
4
4.6.2 Wishbone Type Suspension System: MSBTE:S-16. W-16

m with
construction orking of Wishboné type suspension
pain suspen ejis advar
Desco thuicional Wishbone type

It consists of two wishbone arm pivoted to the frame.

length than lower arm.
The upper wishbone arm is shorter in
reduces the tyre wear.
constant, so avoid the tyre scrub and thus
track
This help to keep the wheel
. A small change in the camber does occur
with such arrangement.

suspension system is most popular.

The wishbone type independent member.
the lower wishbone and underside of the cross tne
The coil spring is located in between through which it goes to
member to the coil spring
body and the cross
u weight of vehicle is transmitted from the
lower wishbone member.
Wheel

Upper wishbone am
Cross am

Spring

Damper
Lower wishbone anm

system edlaiedge
4.6.2:Wishbonesuspension
PuDDiCatieas
Fig.

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 Automobile Suspension,Wheels
Wheels
andTyrea
Automobile Engineering (MSBTE Sem-VIl 4-11
cross member and too lower
lo wishbone men
the coil spring and is attached
to the
A shock absorber is placed inside transmit the vehicle load
adtothespring,bu
position the wheels and
Because of 'V' shape of
am, the wishbones not only
these also resist acceleration, braking
and side forces. upper arm (control a
move up, the lower ind movea
tended to
come across a bump and wheel is vibralions Set up in the coil spri
When the vehicle (damper) damps
the dueto
is compressed so shock absorber
up and the coil spring

road imegularities.

Advantages of Wishbone suspenslons wear.

scnub, reduces tye
constant, so it avoid tyre uneven surface or on the
this type wheel trackis stable on holeor
In vechicle is
independent, so vehicle is
Right and left side suspension of
2 to
transmts the vehicle load the s
digs.
positions the whels and
arm, the wishbone not only
Because of V shapeof
braking and side forces. better vehicle stability
also resists accleration, ground clearance and
Mac-Pherson, so less
compared to
requires less vertical spae
4t
5) Low sping rate.
deflection.
altering with spring
6) Steering geometry is not
Suspension
Suspension and Independent
Difference between Rigid Axle
ependent suspension
Rigid axle suspënsi
Sr There is no rigid axle
beam.
rigid beam axle.
The spring is attached to
without any Teaction
Each wheel move vertically
vertically having reaction |
2. Wheels moves (deflect) not tile and wheel remaine
other wheel. Or Axle does
on other wheel. Or
Axle tile and wheel no longer
vertical.
remains vertical.

Used for light vchicle like car at front

3. Used for heavy vehicle like, truck.

Less tyre scrub, increases tyre life.

More tyre scrub, reduces tyre life.

Steering geometry not alter.

5. Steering geometry alter/change.

spring rate
6. Provide slightly rigid suspension due to higher| Provide softer suspension due to low
spring rate. (stifness)

7 Wheels may wobble. No chances of wheel wobble.

8 Road adhesion less. Road adhesion more.

4.7 Air Suspension Spring

A volume of air enclosed either in a cylinder fitted with a piston or in a flerible bellows can be used as sprng
Under static load the air is compressed to a predetermined
pressure and subsequently motion 0r ue g
eith
increases and decreases the pressure and consequently
increases or decreases the force acting on pistOn.
Air springs are fairly widely employed
on vehicle whose laden and unladen
weights differ greauy.

91latiat

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 Automobile Suspension, Wheelsand
and7
Tyres
Automobile Engineering (MSBTE Sem-VI) 4-13

4.8 Air Suspenslon System MSBTE:W-15,S-16S-18.

WA

suspension with neat sketch. W15

OEXplain construction of alr
suspenslon system and name the com
QSketchlayout of an air
Howair suspension system works? Draw the layoul

aExplain air suspension with skétch

prove the
to improye riding comfort
the riding
employed in some tounst vehicles comf of
Now-a-days pneumatic suspension systems are the

passcnger.
Tfitting Alr bag Rear leveling
Check valve Filler
r bag valve
Alr Pressure
recelver regulator

Leveling
Tcheck valve
valve

Compressor

T httng-
A Tcheck valve
Air bag

Solenoid Air bag

Leveling valve'

Fig. 4.8.1a): Air suspension system

A line diagram of the air suspension system with air shown in Fig. 48.1(). I consists of four air bags as shown in
Fig 4.8.1b).
The elastic element consists of housing, diaphragm with suitable air inlet and piston group. The housing is linked with
the frame (sprung mass). The housing contains the piston group which is linked with unsprung mass (rear
and front
axle).

The housing and piston group are conmected by a metallic diaphragm for better sealing and reduce friction between
to
the members of clastic clements.

Each air bag is filled with compressed air. The sketch of air bag shown in Fig. 4.8.1(b).

The component of air suspension system are air filter,

compressor, air reservoir, relief valve, pressure regulator,
solenoid valve, levelling valve and
T check valve.
An air compressor is mounted on the vehicle frame supplies
high pressure air into the reservoir. The compressor sucs
the air from atmosphere through air filter.

The pressure in the reservoir is maintained

at about 20 kg/cm.

Housing

-
Fig.4.8.1b): Air bag
-Dlaphragm

Piston group

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 Automobile Engineering (MSBTE Sem-VI) 4-14 Automobile Suspension, Wheels and
Tyres

The compresscd air in the air bags support the weight

of vehicle whenever vehicle come across the bump of ne 0a
surface, the air inthe air bag compresse and absorbs the shocks.

Airis admitted into the four air bags through two circuits. In one circuit a pressure reduced
to 12 kg/cm" by pressure
regulator.

This pressure is kept in air bag through levelling valve if the

presure in one of the bag is low, the levelling arm moves
nd air is admitted into low pressure air bag through
inlet valve.
The outer circuit has air pressure of 20 kgf/cm". This circuit
pressure is used for additional loading of vehicle.
This can be achicved by special regulator, which keeps
the same distance between wheel and
frame under various loads.
This circuit maintain the vehicle level constant in
loadedor unloaded condition.
For this situation, the air at 20 kgflcm' pressure is admitted
into theleveling valve through solenoid
Also the air is quickly released by levelling
valve
valve whenever load decreased
is from coresponding air bag. This lowers
the air bag and hence the vehicle to the proper
level.
Advantages

1. Constant frequency of vibration.

2. Highly smooth run due to low rigidity.

3. Provide constant body height

under all static load taken
by elastic element.
4. Avoid change in head lamp alignment
due to varying load.
5. Longer service life.

Disadvantages

1. Complicated in design.

2 System is more costly.

3.. Risk ofbreakdown.
4. Freezing of moisture in air in cold weather.
5. Greater maintenance required.

4.9 Shock Absorber

For providing comfortable ride to the passengers and driver as well as reduce additional
stresses to vehicle frame. It is
necessary to provide a proper device in the suspension system for damping
out the effect of rmad imegularities, A
vehicle must be roll or bounce or sway during turming on good road condition.

The springing device must be a compromise betwen flexibility and stifiness. If it is igid, it
wil not absorb the shock
efficiently and if it is more flexible it will continue to bounce or vibrate cven afñter the bump has passed.

In leaf spring damping is provided due to friction but because of uncertainty in lubrication, friction between blade or
leaves vaies its damping characteristics due to this reason an adional damper (shock absorter) must be provided

The shock absorber or damper is a device which absorb shock energy by damping and dissipate into heat. So it serve to
control ampitude and frequency of bouncing. It cannot suppart weight and has zero resilience.
Thiere are many types of shock absorber operating on friction, on compressed air and hydraulically.
present.
The hydraulic shock absorber is the only type in common use at
restricting orifices as the shock absorber is operated by
The hydraulic shock absorber contain fluid that forces through
spring flexure.

le
Platloss

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 Engineering (MSBTE Sem-VI) Automobile Suspension,
Automobile 4-15 heels
W and Tyres
Principle of Hydraulic Shock Absorber

.When a fluid forces through restricting or small orifices it develop the resistance to the movement of the
luid
ft.
through the
the restricting orifices by absorbing shock energy of damping and control amplitude and frequency of bouncing
dissipate into heat.
h
and
of
It cannot support weight and has zero resilience. This effect quickly damped and spring oscillation
lation damping a

proportional to square of the speed. is

4.9.1 Telescopic Shock Absorber:
MSBTE:W-14, S-15,S-16:W-16,
W-17,S-18,S
Q. Explain the working of télescopic shox apeofter with neat ske
W44, SA8
Q.Describe with neat sketchwonking.ot telescopio shock
S15
Drawlabelled neat sketch.of teleéscopictype shock absorbe
Q Deschbe telescopic shock absorberwith sketc 15
0EXplain with neatsketch
Scopic shiockabsorber
Skelchtelescopic shock absorber and label ma
V-17

Construction

It consist of a cylinder to which head is welded

The head is screwed into the top end of the outer tube.
To the bottom end of the outer tube is welded with a pressed stecl
cap and eye or ring. This eye is connected to wheel
axle.
The piston slides inside the cylinder. This piston is secured to the piston
rod which at its upper end has an eye welded to
it. With this eye, the piston rod is attached to the frame of the vehicle
the outside part of the piston rod is protected by a
dust shield (cover) which is welded to the fixing eye.

A gland prevents oil leakage from where the piston rod passes through
the head.
The gland consist of a piston rod, oil seal, oil seal gasket, scal retainer,
oil seal spring and oil seal cup.
Any fluid scraped off by the gland packing passes down drain
a hole to the reservoir space between the cylinder and
outer tube.

The piston has two concentric rings of holes drilled through

it.
The outer ring of hole is covered at the top by a disc valve which
is held down by a star shape disc spring.
The inner ring hole is covered by disc valve from bottom by
the coil spring.
There is a foot valve assembly at the bottom of the cylinder.
The foot valve assembly is similar to that piston assu
sembly,

except that the lower disc valve which covers the inner
ring of holes is held up by a disc valve spring u
spring.

Bolh ends of the cylinder are completely filled by a

mixture of 609% transformer oil and 40% nurbine oil nd
the gp
pace

between the tube and cylinder.

Working:
be
When a vehicle come across the bump, piston nust
the bottom eye is moved upwards, then the fluid below the
displaced to the top
side of the piston.

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 (MSBTE_Sem-V) 4-16
AulomobileEngineenng Automo
A lluidwill pass through the outer ring of hole in the piston = Suspension
Wheels and
Tyres
by lifting the
The the piston is less duc to piston rod.
p disc against
the disc spring,
nlume above But the
bottom of the piston
such, fluid from the pet displaced through
As spacc betwecn the cylinder and outer
inner ing
of holes
entcr the rescvoir tube. in the foot valve
.Uppereye and

Piston rod
Gland

Head

Disc sping
Top discvalve
Piston

Coil spring
Outer tube
Bottom disc valve
Cylinder
Foot valve

Steelcap
with eye

Fig. 4.9.1:Telescopic
shockabsorber
So the fluid level in the reservoir
space will rise.
.The pressure set up in
the system will depend
upon the size of the passage
This will depend on open by valve in the piston
the square of the speed and foot valve.
at which the cylinder is moved
upward.
When the cylinder
moves downward, Fluid will
inner ring of hole
be displaced from the upper end of
in the piston by opening the cylinder to lower end through
the lower disc valve against coil the
spring
Because of the volume of the piston
rod that leaves the cylinder,
cylinder from the the fluid will be drawn into
reservoir space through the lower end ofthe
the outer ring of hole in the foot valve.
provide damping. This passing of fluid through opening

4.9.2 Gas Filled Shock Absorbers:

9as filled shock absorbers

work along the same principle as a conventional
gas cushion hydraulic shock absorber but also havea
that be compressed, therefore
creating space for the compressed oil.
De gas filled shock-ups
can be easily differentiated by 'Canister which holds the nitrogen gas inside
the conventional and atached to
spring loaded shock absorber.
0 canister is used to be filled with pressurized
Nitrogen gas, which further act as reservoir for both oil and Nítrogen
0e role of the Nitrogen gas is to keep the damping oil pressurized so that the gas molecules present in the oil
LIN bonded with the oil molecules and must not get loosen to bubbles/foam and hence prevent the Cavitation.
fom
Dgpston separates oil and gas, thus preventing hem from mixing. If the oil is displaced when the spring is
pressed, the piston compresses the gas cushion. When the spring then extends, the gas pushes the oil back, similar
aspmng. The gas pressure is very high and ensures that even the smallest movements are damped.

Techaaledgi
Pbilcatieas

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 _Sem-VI) 4-18
(MSBTE utomobile
Engineening
Autornabile Suspension,
heels andTyres
Wheel
Functionof
a) following functions
perform the
whecl must
The
the load
iicle, brake system mounting and
Ishould support the passengers.
1.
force, during turning called lateral load
shonld resisttheside
2 I torque and braking torque
also transmit engine driving totthe tyre while driving
The whecl
3. and braking
tractive load. called as
system of the vehicle.
4. It assists the steering

5. Ishould absorb the shock caused by road iregularities.

)Necesaity and Requirements of Wheel

To perform the above
functions, the wheel must be,

1. It should be strong enough to withstand the weight of the vehicle.

2 Ishould be perfectly balanced statically and dynamically.

3. i should be light in weight and easily remarkable.
4. It should be able to grip the road surface.

5. It should not detcriorates with weather condition

and age (cracking, corosion).
4.10.1 Types of Automobile Wheels

Three main types of wheels

are in use today:

Types of automoblle
wheels

1) Pressed steel disc wheel

(2) Wire or spoke wheels

(3) Light alloy casting wheels

Fig.C44:Types of Automobile Wheels

aConstruction andworking
of pressed steel disc wheel

MSBTEW16

ea skejC W16
Now-a-days these wheels
are widely usedfor cars.
The
are light, strong,
cheap and resistant to accidental damage.
PEOT Wheel consists of two
parts, namely rim and the disc member welded togetnet.
Whenthebeadof
the tyre is resting the well, edge of the rim.
in is possible to pass the tyre over the oppasite
t
0 seat of the rim where the beads are forced up the taper to
Wedon tyre rests has 5 to 15° taper so as the tyre is inflated, the
BNEa
wedge fit with tubeless tyre, the taper
helps to make a good seau

Tec armledg
tisss

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 Automobile Engineering (MSBTE Sem-VI) 4-21 Automobile
ension,
Wheels
Sizc of rim affcct braking, handling, acccleration, alignment and specdomcter calibration a Tyree
4.10.3 Requirements of Rims

It should have static strength.

It must have fatigue strength.

It must passess impact strength.

It must deform under alltype of load.

4.10.4 Types of Rims, their Construction and Working:

MSBTE:S14AV15.S.a

a State the types ofrims Drawany one type of.nm and write its construdti VI-A

e IStthe various types of rims üsed in automobiles and draW.neat sketchof any
Explain the ypes of WheeFims

Rim is well type of structure in which the tyre is contained.

The rims are gencrally of two types:

(1) Drop centre rim. (2) Flat base rim.

Drop centre rims ane generally used in two wheeler where as flat base rims are used in commercial vehicla i

made of steel or aluminum.

Also rim again classified into flat base three piece rim, semi drop centre and iat base divided type.
For ear
yre,wel
base or drop centre is the common tyre.

The tyre is pressed into the racess of the drop centre well for levcling in opposite sideover
o
the rim ílange. Aslight
is of 5P provided for riding up the bead due to air pressure in the tyre. t
Flat base three piece rim is a detachable flange rim. It is used vith stiff and heavy beads tyre fitted
on heavw whi
The flange is beld in position by a split lock ring similar to larger circlip. The lock ring may
be removed ater
poi ing
the flange toward the tyres.

Semi drop centre rim is a two piece rim. It is compromises between

well base and flat base rim. It is suitable for
vehicle. lit
Its removal is simplified by a split, detachable flange while the tyre
is locked to the rim by a slight taper, when the
tye
is removed the slight well may be used.
Flange

Well

Drop centre rim Semi-Drop centre

rim
rLoose
flange rLoose flange

(a) Two Piece

Fig. 4.104:Section (b) Three plece

of rim

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 Sem-Vi)
Engineening (MSBTE 4-22 mobile Suspension,
Automo ile Wheek and Tyres
di'vided sed mainly in military vehicle. Iit is made in two halves which
base arcbolted
Flat together by
adjacent to the
rim. aring
ofnut these nuts should never be moved.
changing wheel
;

For influenced by
diamcter is
wheel rim
The vehicle,
and weight of the
The size
1.
clearancc and
Theground
2 reguired for the brakes and
suspension components etc.
3. Space

4.11 Tyres
Functlons
Necessityand
link with road and vehicle.
necessary for safe driving as they are
Tyresare
illustrated in Fig. 4.11.1. A tyre is made from rubberized fabic piles over arubber liner
t's of the tyre are
are wrapped around a wire bead, which holds the tyre to the wheel rim.
the edees of the piles
compound tread and ditterent rubber a compound for the side walls. The tyre
.The fabric piles are covered with a rubbrinto a single unit and fom the tread design.
mould to vulcanize the parts
is cured in a
provided with an automobile wheel against shock.
Atyre is a cushion
must be large and strong to
support the load they are expected to cary.
.Tyre
tractive force on accelerating, comering and braking,
.They absorb shocks from road iregularities. They must develop
transmits driving and braking forces of the road.
It
stecring.
Provides comering power for smooth
Maintain steering and directional control.
4.11.1 Desirable Properties (Requirement) of Good
Tyres:
Propertles (requlrement)
of good tyres

1. Load carrying

2. Cushioning

3. Unifom wear

Balancing

5. Non skidding

6. Fuel or power consumption

Noise

Fig. C4.5: Properties of Good Tyres

1. Load
carrying
be strong to carry the vehicle load and also
altermate stress set
up
n cae
danage must
edlaetedgi
iltatisss

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 Automobile Suspension, Wheelo
Automobilo Engineering (MSSTE Sem VI) 4-23 andTyres
set up Dy tne road surface ane
vibration, shocks and impacts provide
Cushioning should be flexible to absorb
:II passengers.
Cushioning effect. So it must provide comfortable ride to
circumfcrence to provide a long nie.
niorm wear: Tyre must wear uniformly over its outer steeri
well as dyanamically. It
must respond accurately toto steering
: It must be balance statically as withou
alancing
deflcction by the ridge on the road.
all weathers condition providing gip
grin for
skidding: It should not skid
or slip on the road surface in traction,
Non
Comering, accclerating and braking without overheating.
. it must coisume minimum fuel and powe.
Fuel or power consumption: During rolling on road surface, to getfue
economy.

Noise :t must create minimum noise while rolling on road surface.

4.11.2 Types of Tyres:

In general, the tyres are clasified in two type:

Types of tyres

(a) Solid tyre

L6) Pneumatic or air fild tyre

1.Onthe basis of pressure and volume

H ) High pressure tyre

(i) Conventional tyre

(i) Super cushion tyre

H2.On the basis of construction

H) Tube tyre

.) Tubeless tyre

3.Carcass ypes
tyre

(a) Cross plytyre

H) Radial ply tyre

(c) Belled bias tyre

(a) Solid tyre: These
Fig.C4.6:Types
of Tyres
are oflimited use specially
6)Pneumatic or in industral applications.
air filled tyre
classified as : In this type
below. an air is acts
as a cushioning
1.
medium confined
On the basis of
pressure in an inner ubc. 1
and volume
)High pressure
tyre (Pressunre
Gi) Conventional upto4.2 Kg/cm)
tyze (Pressure
)Supercushiontyre range 1.68
Kgcm to2.8
(Pressure
range 1.4Kg/cm
Kgcm)
tol.68Kg/cm)

Tdla
icat

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 (MSBTE Sem-VI)
tomobile Engineering 4-24
A On the
basis of construction
Automobile Suspension,
Wheels and Tyres
2
)Tubetyre i) Tubeless tyre

Carcasstypes tyre:
3.
(b) Radial ply tyre
(Cross ply tyre
(C) Belted bias tyre

Tube Tyre
0
It is difional tyre. It encloses a tube in wnich air 1s forced to a high
pressure as a cushioning
emanufacturerd from ditferent parts medium.
ty that are moulded together
to form a complete structure. The
parts of tyre
are

) Liner (i) Tread layer

(Gi) Cord and piles (iv) Bead or rib

() Side wall (vi) Outer rubber covering.

Casing cushicn
Tread pattem
Tread nubber
Breakers

Undertread
Shoulder
Tube
Crown
Plies

-Rubber
Side wall

Filers
Chafers
Bead cindt-
Bead core
Heel of bead-
Rim
Flap
LValve
Bead seat
Toe of bead

(tube) tyre
Fig. 4.11.1::Cross section of a truck
vulcanization process in
is manufactured by
carcass or inner casing. The tyre
The liner and plies form together called as
form and characteristics.
which rubber is heated under pressure to obtain required

(1) Carcass construction and the

backbone of the tyre
the tyre. The carcass forms the
horseshoe-shaped inner lining of
LS 1S a
cord piles
tread, bead and walls all are moulded on to these overlapping plies, consist of
paralel
made from
wall rubber. It is
tyre without side
prvides strength and body to the a layer of rubber.
rayon, nylon, fiber glass, polyester, embedded in pressure acts evenly against
the intenor
rd of walls. Air
bounded to the side
are wound around the beads and
Sends
surface producing tension in the carcass.
the vehicle. The outer
rubber covering is moulded
weight of
and resist the
puEsSure carcass support
around the carcass.
the tyTe
number of plies in Kavualedge

ne ply rating indicate the approximate

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 Automo SuSpension,Whees
wheel
andyTea
4-25
(MSBTE
Sem-VI)
Engineering
Automobile
carcass.
side of the
(2) Liner
rubher on inncr
light laycr of
Liner is a thin air wheel rim. It hastheiggdäity
on to the
centralizes the cover and
(3) Bead locates and
tyre and
the inner edge ofthe
toms bead.
hisstrength required to support
the carcass.
circumfcentially
througlh the
wrapped with a fabric
moulded wires are
achicve this cndless wire core
is
the whecl im and the hold to
To fit around
stcel wires. These are
a bundle of
thin wheel rin
16 protect from leaving the By use
stretching and of
them. from
prevent the tyre
in nubber to
are embedded
These strength of bead
increascs.
heavicr gauge wire the
working ife
holding ability and
(4) Tread gripping, road
considerably influences the tyre's 1s
groove provide
ve to provide :
part of tyre design rolls. The tread rubber marimum
isa road surface when
the wheel
the vehicle on minimize noise.
helps to nun avoiding skidding, rigidity.
fnctional force giving good
traction and additional stability and
which give
circumferentially on outside
to compound of high resiet
stance
chamber is provided changes or convert to
Some separate piece of soft rubber which
assembled in a
The tread are
vulcanization.
wcar after

(5) Breaker
breaker.
are refered to as
two top plies of the tyre
The other plies.
are widely spaced as compared to
They from the road.
plices helps in spreading the shocks recived
These
(6) Side wallI
carcass between the
bead and the tyre tread.
covering of the
constitutes the outside nubber
This and the stiffness of the
tyre during deflection depends on the
thickme
provided to the carcass
The amount of protection
of side wall
different grade rubber. The
rubber has quality to absorb road sthock and
the tread and made of
It connects the bead to
protect cord and piles.
used is relatively porous in nature.
side walls are thinner and the rubber
The
which rolls on the rvad is made of synthetic
rubber and is called tread. At the inner edg
The outer portion of the tyre
steel wires.
beads are formed by reinforcing with

i) Tubeless Tyre
MSBTE: 9-18. W-18.S-19

Describe tubeless tyre withneatsketch

Stateadvantages and disadvantages of1ubeless yre

Tubeless tyre is a advance version of conventional tube tyre.

The basic difference is that tubeless tyre does not enclose a separate inner tube. In this type of tyre there 1s a spea
relaining bead arrangement.

This type of tyre is directly mounted on the rim.

.The air under pressure is filled in the tyre itself through a non retun valve
is fitted to the rim.
TedhKasuld
latis

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 (MSBTESem-VI)
Engineering 4-26 Automobile
obile Suspens
inflatable envclope made of outer cover with aspecial heels
toroidal innerlining.
air-tight card ffabric to retain the air. It d esnot andTyres
Misa pends upon emplay
and part which fit on the circumfcrence of anysealant
the air tight thewheel rim.It consist
iis of beeadcores
The wire.
strandofsteel made
that takes the load and consist
fCarcassis the main structurale ofnubberbounded
ofnumber
contact with rod surface cordsand
surface part that coome in made of synthetic bea
beads.
adis the
Tradi nubber,
an integral part whichaallows high pressure air in
return valve is one way.
Non
and runs coole than the tube tyre
tyre is lighter
Thetubel

Advantages
Advantages
of tubeless tyre

1. Simple assembly

2.improve safety

3. Beter cooling

4. Lesser unsprung weight

Fig.C4.7:Advantages oftubeless
tyre
, Simple assembly: The tubeless tyre are easier to fit and
no danger of puncture during
asembly.
, Tmprore safety: When punchured it deilects slowly in contrast to
tube tyre where air leaks
out fast. This is becanse
soft ining has self-sealing effect. of

Atemporary punctire repair can be made without removing the whel by

stopping the hole with special
a rubber plag
However tubeless tyre cannot be used in spoked wheels since in that case the rim is perforated
.The tubeless tyre should be inspected periodically and
all the förgein objects should be removed
If the objects are allowed to remain in the tubeless tyre they
tends to enlarge the puncture and upair became more
difficult. The chances of sudden tyre punchure leading
to acident are reduced.
4. Better cooling: Heat generated during running is directly
pass from the tyre to the surounding,
5. Lesser unsprung weight: The tubeless tyre
is lighter and runs cooler than the tube tye.
Arretaining- -Tread
Sinear

Carcass

Sleel wire-
bead

Vae
Ne c
cap

RUbber
Rubber sealed
valve

tyre
Fig.4.11.2:Tubeless Tedtaraled
llatie"

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 Automoble Suspension,
Automobile Enginering (MSBTE Som-VI) 4-27 Whel.

Disadvantages
Disadvantages of tubeless
tyre

1. Early replacement

2. Cost

puncture detection
3. Difficutt

Fig.C4.8:Disadvantages of tubeless tyre

1. Early replacement
tightness betuea
repair. Refitting over the rim, the air etween
Duc to frequcnt removal of tyre in case of puncture therim
and
tyre became weak.
2. Cost:

Duc to spocial air sealing the cost is 20 to 30% more.

3. Dilicult puncture detection

Since this tyre retain air even in case of puncture, so it is difficult to realise a puncture in the tyre.

4. Not suitable for spoke wheel.

(4) Comparison of Tubed Tyres with Tubeless Tyres

MSBTE:W-14,S-1

QCompare tubed yres with tube W 14,S1

Tubedtyres ubeless tyres

Suitable for the spoke wheel. Not suitable for spoke wheel.

. Chance of air leakage is more. Chance of air leakage is less.

3. Tube is provided inside the tyre.

Air retaining liner is provided inside
the tyre.
Air sealing quality is poor.
Better air scaling quality.

. Fitting of these tyres is difficult.

These are easier to fit.

6. Strength of these tyres

is more. Strength of these tyres
is less.
(a) Radial Ply Tyre

a Drawneatsketch ofredialply
tyrés and describetheir
MSBTE:S-15
construction
The radial ply tyre have
plies running from
bead to bead across
On the side walls the the crown at right angle
direction ofthese to rotation.
tyre tread there pies is radial and hence
are cord or breakers the name is radial ply
which run around
the circumíerence.
tyre. In between nese d

TedIesaled
Pbiiat
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 Automobile Engineering (MSBTE Sem-VI)
4-30
Automobile Suspension,
Wheels and Tyres
During
(vi) turning, a radial ply tyre has ICss tendency
to distort and lift off the
road from one side. Thus
contact of tyTe and hence less tendency to skid while there is better
comcring in radial tyre.

2.
Disadvantages of radial ply over cross ply tyre

1. Heavier stcering at low spccd.

2. Uncomfortable ride at low spced.

3. Instability during comering.

iference between radial ply and cross ply tyres

MSBTE S-17
S19
Diferent radial ply and cross ply.tyres
SS19)
ST.No. Cross ply tyres Radial ply tyres
Stiffness of tyre is more.
Stiffness oftyre is less.
2. Less comfortable due to more stiffness.
Gives comfort for speed 55 km/hr.

3. Tyre grip less on road

Fim frictional grip with road.
The first cost of cross-ply tyres is about 20% Costier than
cross ply tyre.
less than for radial-ply tyres.

5. Steering is easy.
Steering is harder.
. Less tread life. More tread life.

7. Plies are running diagonally opposite from

bead| Plies are running radially. straight from bead to bead.
to bead

8. Cross-ply tyres increase the amount of energy The more flexible

casing of adial-ply compared to
consumed while running, fuel consumption. cross-ply tyes reduces the amount of energy consumed
while running, so that saving in fuel consumption in the
order of 5% is achieved.

413 Tyre Economy: Considerationsin Tread Design

Tread is a pattern design which
is cut into the rubber andit helps to create traction between tyre and road.
ne main consideration in tread the design of treads is grip, noise and wear. These will be discussed in detail in the
following
paragraphs,
a) Grlp:

ne braking grip of a tyre depends upon two factors that are treads material and tread pattern.

d
r dry roads, the completely smooth tyre, no doubt, gives highest braking gip because it provides maximun
of contact with the road,
however, in case of wet road, its grip becomes almost neghgible.
Th
a particular tread pattern is afected mechanically as well as through road friction. For better mechanical
Tor
uct, the tread must provide suitable sharp edges that will engage with the road.
While for
a good
tood frictional contact, it is very importan that tyTe must provide drainage of the water on the
road,
aerwise
byre will aquaplane, that is float on the water film and loose contact with the ground.

Techalelgi
Pllcatioas

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 Automobile Suspension, Wheels a
Automobile Engineering (MSBTE Sem-VI) 4-31 andTyres
requirements. Sufficiently wide grooves at the middle.
.The various tread designs aim at saisfying these two basic deofthe
tread serve to drain the road watcr.
comparatively narrower grooves provide
It has been found through experimentation that more number of bete
better
drainage as compared to small number of very wide grooves

b) Nolse:

A part from the 'squeal' peculiar tyTe noise which depends upon the nature of the rubber oompound used for thebyte
ty
treads.

Various types of vibrations caused by the roughness of the road surface andor by the distortion of the tyre carasa
so
produce noise.

However, besides these, the type of tread pattern also contributes to tyre noise. It is seen that this source of noise
i
eliminated by providing intentional iregularities in the tread pattem by varying the size or shape of the tread biock
cks
slightly

cWear :
For less wear, the tyre tread must be such that the individual elements undergo miimum distortion during running

4:13.1 Factors Affecting Tyre Life:

MSBTE:S-15. W-16.S-19
Siovanoos tactosatointyelite
Q pan anyiourfactor affechngHTE
te
The life of tyre is greatly reduced by under inflection, rapid stop, fast acceleration, road surface, misalignment and
unbalance condition.

Tyres wear quickly on sand and gravel roads whereas the tyre life is promoted to its
maximum value by the concrete
and asphalt roads. In addition to normal wear caused by evenly and smoothly worm
tread.
The tyre life can be greatly influenced by the factors as explain below.

Factors affecting
tyre ife

1. Atmospheric condition

2. The road surface condition

3. The Route

4. Type of work.

5. Style of driving

6. Inflation Pressures
and Load

7.Correct alignment of
wheel

8.Proper maintenance

Fig.C4.9: Factors affecting tyre

life

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 (MSBTE_Sem-VI)
4-32
Engineenng Autormobile
Automobile Suspenslon,
heels andTyres
condition
Atmospheric
1. generateu docs not affcct by climate and seasonal condition but
The
heal
high
neraturc rubber gels softened result
tempcrature nubbe in decreases
it affects by the way
of heat dissipated
surounding.
ng. At the abrasive resistance causes
more thread
to
WCar.
ondition water acts as a lubricant to rubber which reduces
scason tyre wear but chances of puncture
In rainy' bber cut more
casily in wet condition as it depend on nature it is
unavoidable.
inereasesas
surface condition
The road
greatly abrasive than tarred road as it is made from varying size of stone.
Concra roads are Gravel road and extremely

smooth that
cffect wear.

The Route
3 roads tyre and tyrelife reduces while winding road on a hillya
areas, tyres wear much faster when to brakc,
On traight
suddenly and accelerate tinuously, even when speeds are relatively low.
changedirection

Type of work
4
ime :available
The time for cooling tyre is less on long and high sped runing. So continuous runing reduces tyre life and
unavoidable.
itis
driving
5 Style of
The tyre life decreases
with the increasc of car speed.
or turming greatly reduce the tyre life while maximum tyre life and economy
starts, quick stop, high speed running
.Fast
is promoted by conservative driving
habits but this can be avoidable.

Infiation Pressures and Load

in under inflated. The frequency of side wall deflection
The sidewall of tyre is deflected due to overload as same as
increases with increases in speed of vehicle result in more heat
generation causes more defilection. So tyre will damage

or fails if it allowed for longer period. So tyre failure depends

on amount of load, speed and distance traveled.
with the ground and the relationship betveen
The inflation pressure also influences on the tread which makes contact
uneven (and therefore, accelerated) tyre wear because the tread not
the tyre and the rim. Both these factors can increase

makes contact with the surface of the road across its full arca.
1. Correct alignment of wheel
treads is
the inner side of the tyre
and much camber the outer ribs will get warnt out. The wear on
EXCessIVe too due to
outer area of the treads is caused
y the negative camber. The excessive wear on both the inner and
excessive skidding
on turn.
excesive wear if ine
Du
scrubbing action on the road surface resulting in
toein l0e-out will affect the tyre life the
loe in or toe
out is not corect.

Unung /demounting of tyre causes bead damage exposing the bead wire.
.Propermaintenance
Wheel
alignment due to bad bump
t and balancing suspension settings which may change
413.2
Types of Tyre
Wear: NMSBTESW15:S-17|W:18

W-15)
Stateany
ght probable.causes s
of tyre wear and gve its remedies S-17, W-18)

OUr0pableprohsRA causes of tyre wear

De with
and give its remedies i172
ech.the effect of (i) Under inflation (2) Over Inaud TechKnauledgë
ICaleas
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 Automobile Suspension, Wheels and Tvrae
Automobile Engineering (MSBTE Sem-VI) 4-33
Types of tyre wear

(a) Under inflation

(6) Over inflation

(c) Poor alignment

()Wheel imbalance

(e) Fast turning on curve

( Incorrect toe

Fig. C4.10:Types of tyre wear

(a) Under inflation: Both edges wom, squealing on curves. Under-inflection is the most usual cause of reduce tyre
life
This causes the side of the tyres of its walls bend sharply as the wheel revolve. The cords eventually brake
and the tye
blows out with the further revolving of the wheel. Tyre wear at the centrally excessively
and less on outer edges.
Itis detrimental to life of tyre. It causes excessive flexing in irrepairable damage to the tyre carcass
or visible cracks on.
side wall, loose card inside casing

2) More tread wear on the side

3) Chances of rim bruises increases due
to decrease resistance of the tyre to deflection.

Crack
side wall

Fig.4.13.1:Underinflation
(b) Overinflation:

1. Rapid tyre wear at centre

only.
2. Abnormal stresses
and strain in treat
area causes separation
3. Decreases resistance of ply and tread cracking.
to skidding because
of reduction in contact
4. Poor alignment surface of tyre trade with roaa.
: One side wear, saw
toothed wear pattem.
5. Wheel imbalance:
Treads worn unevenly
6 with bold spots,
Fast tuming on cups or scallops.
curve: Front tyre
wear only.
7 Incorecttoe:
Feathered edge.

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 wheels and
Automobile SuspenSIon,

Engineering (MSBTE Sem-VI) 4-35

Automobile
(Designation of Tyre)
Specification of Tyre: MSBTE
S13
4.14

diflerent iype of yre wear

913
7 Explain diameter. They aremarked
a.How tyres are specified sectional width and m
nominal size oftheir
by the
tyres are specified and designated
The
1 Rim diameter
as P205/75 inches
in

P-Tyre type Aspect ratio

P-Passanger Sectional height
C-Commercial Sectional with
Constructional type
Sectional with typpe
P-Tyre
P-Passanger
C-Commercial

habit and vehicle

factor like tyre load. Intlation pressure, driving
detecrmined by
life and performance are
Tyre
maintenance

Example
ratio of 75 and
passenger car tyre with sectional width 205 mm having aspect
P20S/75R15 as specified above indicate

adial ply rating of 15 inch wheel diameter.

4.15 Wheel Alignment

MSBTE:S-14, S-15, WVA8

QDefine Wheel Alignment

Why wheel alignment is necessary

State the necessity of wheel aligoment. -17

Describe is procedure
State wheel balancing and wheel alignment
Definition The wheel alignnent meuns.correct adjustnment of the front twheels with respect pip h
and controlling steering movement to the wheel giung the directional stabilih tove
stecring and rediuces the wear tó amininum
enter and
The directional stability of vehicle means the condition that it possess if it can rin straight down on 1
leaves the circular path easily and resist road shock.

Purpose (Necessity) of Wheel Alignment

above
the
DuE to Tunning of vehicle over a period
of time on various road conditions leads to change in the seting
mentioned parameters.
vehicle8
In wheel alignment all these
parameters are set to their design values. Otherwise direu
nampered. Uneven tyre wear,
damage to various links of steering system may resut
in-toe-ou
loe
gnent
explained earlier
depends upon wheel
geometry ie. caster, camber, kingpin inclinao
in wheel geometry.
Tectlarada
bieotlee

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 Engineering (MSBTE Sem-VI) 4-36
omobile
Automobile Suspension,
Wheels and Tyres
allowing factors
affecis the whccl alignment:
Thei pertaining to wheel:
Factors
Balance of wheel (6) Inflation of tyre
(a)
Steening geometry
(c)
geometry
Steering
2
Camber 6) Caster
(a)
inclination (d) Toe-in and Toe-out
C)Kingpin
Steering linkage.
3.
Suspension system.
4.

415.1
Procedure (Checking9) of Wheel Alignment:

of wheel alignment, is to inspect the king pin inclination, camber and caster anges and toe-in.
De fint sep
Eor igid axle suspension system camber angle and king pin indention is fixed and caster angle can be adjusted by caster
plate.

Whereas for
vehicles having independent suspension system, the above mention angles are adjusted by a shim between

the lower and

upper arm brackets or by eccentric clamping bolts of the arm
used. This gauge
For inspection of camber, caster and king pin inclination, a specific type of standard ganges are

consists of two part-

Level and angle gauge,

)Tuntable.
Co. gives very acurate and precious reading used to measure toe-
One of them gauge is optical gauge of Dunlop Tyre
used in workshops.
in. Telescopic gauge is commonly

Rod-
Poinfer

Scale Pipe

Pipe adjusting srew

Fig. 4.15.1: Toe-in gauge

on
width. A vetical rod is mounted
This
of which one can be slide on another to adjust the
consists of two pipes,
rod s
requiremeat of wheel. The vertical
can be adjusted at any position on the pipe according to
andwith adjustable
PTOvided
pointer which moves up and down on rod.
To inspect n the pointers of the gauge touches with the front wheels,
measure and note the reading
on ine pipe.

the reading and

Similarly,
when the portion of the front wheels and note
of the gauge touches with the rear
pOinters
calculate
difference between the two readings gives the value of toe-in. edaeo
Dlatisos

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 Automobile Suspension,
Autormobile Enginaerlng (MSBTE Sem-VI) 4-37 Wheels
andTyres
4.16 Wheel
Balancingg
MSBTE W-14,S-14 S-15,W-17.
W-18,
necessary ?
S-19
Q. Why wheol balancing ls

.Explain what do you mean by whéel balanclng

QState the necessity of wheel balanicng.

Q. State wheel balancing and wheel alignment. Describe its procedure;
Wheol Balancing:

Definition: It is a process that ensures wheelspins triesyas tiev ar jittedkorn dvehice tn

not spinning properly then there are probtenis iugventire uear nhicte pulinon
ie a
bouncing ofä vehiele, uhel shm ete whicpejace do hen ihts don o
The method, of addition of small weight to the wheel rim to avoid wheel wobble and vibration
and easy to steer
for
for A:
it should be statically and dynamically balance. tis
Wheel balancing is the process of correcting the lateral run, radial run out
and addition of weight to
avoid uneven
u
distribution of the weight about the rotational axis of wheel

Purpose of Wheel Balancing (Necessity )

During the running of vehicle the tyres gets worn out and whecl rim gets bend or damaged.
There may be lateral nun out of wheels, Radial run out may be created due to tyre or rim out of conditions.
This leads to
uneven distribution of weight around axis of rolation
of whecl assembly. Because of this there is an unbalance
created
in the wheel assembly.

If this unbalance is not removed, then this may lead

to wobbling of front wheels, viþrations, tyre
wear, and may
adversely affect steering system assembly
parts. This can be avoided by balancing.
The balancing of a tyres whecl is most essential
to avoid the front wheel wobble. Which affects steering and increase
tyre wear rate. The factors affecting the
wheel balance are as follows
1. Lateral run out of the wheel.

2 Radial run out or run of round the

wheel, caused by tyre or rim
out
3. Uneven distribution of the weight
around the axis of rotation.
Therefore it must be necessary to
inspect the wheel centering, before
checking the wheel for balancing lateral n ou
which result of a wraped rim from
bumps and can be corrected by
arbor press.
The tyre must be removed to straighten
the wheel rim. Tum the wheel about
its axis and check the wheel insioe
retaining the tyre bead and the
rim well from ran out in excess i
of 1.5 mm.
General Procedure of Wheel Balancing:

Fll tyre with recommended tyre

pressure, check for tyre / wheel
damage don't use damaged rim for balancing
1. Mount wheel on balancing
Machine and lock it. Remove
2. old balance weights.
Set balance for size of
tyre and start the machine.
3. Read values of imbalance
on right and
left side of wheel on display.
4. Put respective weights
on both sides on marks.

ati"
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 Automobile Engneeing (MSBTE_Sem-VI) 4-38
Automobile Suspension,
Wheels and Tyres
Startbalancer again and check that reading is zero on both sides then the wheel
is balanced.
both sides is not zcro then repeat the procedure.
6 Ifr cnding on
Methods of wheel
Balancing:

416.1 Static Balance of Front Wheels:

MSBTES-183
the procedure of wheel balancing
oState
Thisncan be done with the
whecls installed on the vehicle
by using electronic balancer.
S-18
This gives remarkable advantage
balancing the wheellalong with theotherrotating masses. The procedure
of is as follows:

Lit
Ange
the front whels on hydraulic jack such that the whel is frely rotated.
spinner, which carries
the the balancer equipment, with its pulley in
) touch with the tyre tread, the wheel
should
bein straight ahead position.
( Move the balancer into position to point to strobe light at the w el.
fa Position the pickup magnet in contact with a clean tlat surface on the front suspension as closed
to the wheel as
possible.

(e) Apply the reference mark on the wheel cap on the tyre, consisting of a radial line. Use chalk or a length of tape.
(0 Shift the balancer switch to position 1 and wait some minutes to allow the warm up
of tubes if the pick up magnet is in
proper contact, the strobe light wil fash when the top of the tyre is tapped.

(c) Start the wheel by hand, snap on the switch of the spinrer motor and hold the spinner pulley against
the tyre tread to
Tevup' the wheel.

While spining, the following conditions are experienced

1. The flashing of the strobe light will make the reference mark on the wheel appear to fixed
be in the same position.
2. Watch the meter of electronic balancer. The needle will move on from zero position. When it reaches its highest
reading and starts moving back, pull the spinner away.

3. Inertia causes the wheel to keep turming, and the needle will rise
again. When meter needle shows its higher
Teading, note the position of the reference mark. Consider the reference mark as the hour hand of a clock. The
"time" the reference mark indicates the position
to remember.
(6) Repeat the above inspection
procedure and note maximum needle reading on meter dial
fhe needle still moves beyond green
area of meter dial, proceed as follows:
L Stop the wheel.

2 Move the wheel on same

reference mark position or time recorded at g.
S.Change or shiíft the balánce weight applied,
to wheel.
he check as directed previously.
TDeler needle
remains
If the wheel is still out of balance, proceed with the balance procedure, till the
in the green area of dial meter.
18.2 Dynamlc
Balance of Front Wheels
n the wheel
out approximately one
6) Positionthepickup half of their steering angle.
magt in contact with the
0 Spanthe
wheel
nagnet external front end of the brake housing flange at the wheel rotation axis.
and record the highest
balancing meter reading as well as coresponding position of reference mark as per static
procedure.

TechKaowledgi
7Plcatioos

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 Automobile Electrical
5 and Electronics System
Unit-V
Syllabus:
5.1 Introduction to Electrical-Electronic
System: Basic Electrical-Electronics Principles
(Curent, voge,
Resistance, Electricity, Magnetism,
Electromagnetism, Induction, Rectification,
etc) Basic Electricak Electronics
Components used in automobiles
with their conventional symbols.

52 Batteny: Function and Requirements

of Battery, Types of Battery, Principle of Lead Acid Battery, Construction
and Operation of Lead Acid Battery,
Significance of Battery Rating and Battery Capacity, Battery Open Voft
and Specific Gravity Test, Salient
Features of Maintenance Free Battery.
5.3 Starting System: Function and Requirement
of Starting System, Components of Starting System,
Construction and Working of Standard
Bendix Drive.

54 Charging System: Function and Requirement

of Charging System, Components of Charging System,
Construction and Working of Altemator.

55 lgnition System: Function and Requirement of Ignition System, Types of lgnition

System, Construction and
Working of Battery Ignition, Magneto lgnitilon and Electronic Ignition
System with advantages, disadvantages,
applications.

5.6 Lighting System: Function and Requirements of Lighting Systems, Types of Lights, Necessity
and Importance
of Cable Color Codes, Wiring Harmess.

5.7 Miscellaneous: A Brief Review of Different types of Gauges, Windscreen wiper, Function and Location of
Major Sensors and Actuators used in Automobile Electronics.

5.1 Introduction to Basic Electrical and Electronic

Electic curent is used for a number of purposes in the automobile, electric curent flows through different system to
fulfill the different objects of cranking the engine. For staring, for production of spark to burn the air fuel mixture in
SL engine, charging of batery, lighting the lamp, blowing the horm, electrical fuel pump, wind shield and many others
unit of automobile.
Electricity is the movement of electrons. Electrons create charge, which we can harméss to do work. They all operate
using the same basic power source
or more specifically, the charge they create:
The three basic principles explained using electrons,
points.
o Voltage is the difference in charge between two
flowing
o Current is the rate at which charge is
to charge (Current). Resistance is measured in ohms (Q). The
Resistance is a material's tendency resist
the
tlow of
o
the resistance.
higher the temperature, the higher
EICcincity is flowing through a conductor while a magnetic field is
Electricity and magnetism are very closely related.
or a it create electron flow inside of it, which can be
created around it. a magnet move near conductor in coil,
a
If
develop an electricity.

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 Automobile Electnicaland Electronics
5-2 onicsSystem
Sue
Automobile Engineering (MSBTE _Sem-VI)_
work or to generat
clectrical systems to do mechanical theelectricity
throughout automotive
This principal is used
that rnuns the vehicle. a conductor as a result c
an clectromotive force (em)
in
production of f achanging
Elcctromagnctic induction is the
magnctic ficld about the conductor. electromotive force across an electrical
is the production of an 1ga
Electromagnetic or magnetic Inductfon discovery of induction in
generally credited with the and James
ficld. Michael Faraday is
changing magnetic
law of induction.
Maxwell mathematically described it as Faraday's
Clerk Magnetic Lines
of Force

AAANAAL

---*-**
=-=-*=--*

Fig. 5.1.1

Rectification:
(DC).
altemating curent (AC) into direct curreat
Rectification is a process that converis
OR

altermating curent (AC), which

peniodically reverses direction, to direct
electrical device that converts
A rectifier is an rectification, since it "straightens"
the
direction. The process is known as
current (DC), which flows in only one
direction of current.
Vehicle
5.2 Electrical and Electronic Components of

components of Vehicle
Following are the Electrical and Electronic

Resistors 2. Capacitor

Semiconductor 4. Diodes
3.
Zener Diodes 6. Transistors
5.

Rclay 8. Solenoids
7.

Fuses 10. Starter

9.

Resistors
nerg)
opposes curent flow in a circuit. It is a two-terminal element, dissipates is
A Resistor is a passive element that
in the fom of heat. The resistor
will damage due to the overflow of electric
curent through it. Resistance
s t
resistance.
in units of ohms and
are not
Is function is to limit current 1low and and thereby voltage in circuits where full current flow and voiu
needed or desired.
etlaculndgi
ti

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 Automobile Engineering (MSBTE Sem-V) Automobile Electrical and Electronics
Syste
5-3
Provide fixed voltage drops.

The resistors
used in clectronic circuits are manufactured from small carbon rods, and the size of the re
determines its resistance.

Cutbon resistors havc

a negative temperature cocfficient (NTC) and this must be considered for some applications.
more stable tecmperature propertics and are constructed by depositing a layer of carbon onto n
Thin film resistors have
insulated former such as glass.

Resistor Variable Resistor

(Aheostst)

Variable Resistor Variable Resistor

(Potentiometer) (Preset)

Capacitor
2
store an electric charge. In its simple form it consists of two
plates separated by an
The function of capacitor is to
charge but
insulating material. The capacitor constitutes of
di-electrical materials having property to hold electrical
In automobile it is used for reducing
arcing acrOss
cannot flow the free electrons through these like air or paper.
contacts breaker point.
electrons are accumulated to one side start shifting to
the dielectric substance is connected to the voltage the
Where
another side which is called charging of capacitor.
difference of the capacitor. As
The charging continue till the applicd voltage across the source became equal to potential
circuit.
soon as circuit is off the suspended electrons continue to pass through the

capacitor

Variable
capacitor

The use of capacitor inIgnition system is to protect the piting of circuit breaker
point. If the area of the plates is A, the
distance between two plate is L, and then value of capacitance is C= AL.

3. Semiconductor:

These cannot provide a current flow when purë but when another small amount of
material is added to a semiconductor,

then it provide movement of clectron.

P-type.
Depending upon the type of impurity (material) added they are called as N-type or

material are poduced by doping sillcon or germanium with a element having five electron in
Naype semiconductor

beir outemost orbit E.g. Phosphorus, antimony or bismuth.

St
bimilarty P type semiconducior
is obtained by doping gérmanium or silicon in the element having three electron
Boron, aluminium in outermost orbit.

TechKanuledgi
Puslcatloas

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 Automobile Electrical and Electronics System
EAutomobile Engineering (MSBTE Sem-V)
54
4. Diodes
A Diode is an clectronic cathode. It allows clectronCurrent flow
compon with two terminals that are anode and from
IC to anoxde but it blocks another dircction means allowing current to flow in one direction only.
direction.
wil have low resistance in one direction and high resistance in another
Oe
The diodes are formed by combining P-1ype and N-type semiconductor.
Diode

Dioda

Battery

Battery

a) Forward bias (b) Reverse bias

Fig.5.2.1:Diodes
5. Zener diodes:

These are used for low voltage circuits, wave rectification circuits and so forth.
6. Transistors:
It is a semiconductor device which can be used as an electronic solid state switch or a current amplifier. Transistor are
made in three soction N and P type material. It may be PNP transistor or NPN transistor.
Central section is calied base and one end called emitter and other is called collector. Base control the current flow

NPN PNP Photo

Transistor Transistor Transistor
NPN type

ow Caurent
Base Bas
cument
CuTent

Emitar Base Collector Emiter Base Coletor

(a) NPN Transistor (6) PNP Transistor

Fig. 5.2.2: Transistors

oulsin
Transformer: It is used to produce AC power supply, energy is transferred in between primary and secou
the form of mutual inductance.

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 Electronics System
Automobile Engineering (MSBTE Sem-VI) 5-5 Automobile Electrical and

Transformer
circuit symbol

current circuit.
7. Relay: A Relay is an clectric switch that allows a small amount of curent to control a high
chanica
current flow into
8. Solenolds : Solenoids arc clectromagnetic switches with a movable core that converts
movement.
current and it is used to provue
9. Fuses: Fuses providc protection from high current. The fuse will fow suficient
over current protection.

Fuse circuit symbol

10. Starter :
when the igniton swi
Located on the back of the engine or the front of the transmission, the starter cranks the engine

is turned on.

Diodes

Diode

Zener Diode

Tunnel Diode

2. Capacitors capacitor

Variable
capacitor

3. Resistors
Resistor Variable Resistor
(Rheostst)

Variable Resistor Variable Resistor

(Potentiometer) (Preset)

4. Battery Circuit:

Fuse Circuit

Fuse circuit symbol

Tec Kauledgi
Y Pblltatiuns

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 utomobile EIectncal an0 Eiectronics
nicsSystem
Svs
Automobile Engineering (MSBTE Sem-V) 5-6

6. Transfomer

Transformer
circuit symbol

Transistors

Photo
NPN PNP
Transistor Transistor
Transistor

5.3 Battery
5.3.1 Functions and Requirements of Battery:
MSBTE W:14S16 S-17

(W-14)

QExplain the functionsof battery (S-16)

construction and working with neat.sketCI
Sate function of battery Explain its construction
the function of battery in
of lead acid tbattery.xplain is
an automobile: List the. main components
(S17
State neat sketch
ith
battery, engine cannot be started with
the
is main part of the electrical system in an automobile. Without
The battery the
starting motor.
starting motor, ignition system, head
battery supplies curent to various part of the automobile vehicle such as for
The
other accessories.
and tail light, brake light, to wiper and
construction since they have to withstand several vibration.
Vehicle batteries should have robust
different automobile
charging rate as well as heavy discharge convent required for
The battery must have the high
service.
engine.
starter motor and low current to ignition system to start and operate the
(1) Battery supply high current to

(2) It supplies cureat to

accessories which operate electrically.

and control the voltage regulation of electrical system

(3) It stores the electrical energy
the lights, instrument and other electrical accessories.
4) It must provide the power to operate

Principle
chemical eaergy
Generally a battery works on the principle of Elctro-hemical Reactions in which the conversion of
electical energy in bateries. I consisting of negative terminal is anods and positive terminal is the cathode underges
into
two or morc ions from the electrolyte combine with the anode to form a compound
an oxidation reaction: during discharge
Simultaneously, the cathode, undergoes a eduction reaction and deliver an electical
and release one or more electrons.
energy to an external devicc.

Kasledgi
Tech
PBIcstisus

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 Electronics System
Automobile Engineering (MSBTE Sem-VI) Automobile Electrical and
5-7
Types of Battery

. The typc of batteries are

1) Lcad-acid battery

2) Alkaline battery

i) Nickel iron type i) Nickel cadmium type

3) Zinc-air battery

4) ZEBRA Battery (Molten Salt Battery)

5)
Sodium-Sulphur Battery

6SwingCel
7) Lithium ion battery.

5.3.2 Lead-Acid Battery:

S-18
MSETE2S14, W-14, S-16, W-17

a State constrüction of lead acid Battery.

14
(W-14)
xplain is construction WIth neats
oListhe main components otlead acid battery S1,$1
working of lead acid battery wth neatsketch
O. Explain the construction and
Describe with neat sketch construction and working of lead
acid battéry W-17
device.
automobile vehicle. It is an electro-chemical
lead acid battery is widely used in
The current force through the battery
can produce current as a result of chemical reaction. A reverse
and
It has a voltage
and restore the battery material.
which cause chemical reaction
battery is explain below:
construction with component of lead acid
The
(A) Battery Construction

component:
It consist offollowing
Components of
battery

(a) Container

Grids and platess

(6)
(c) Separators

(d) Cell cover

Electrolyte
(e)
(0 Cell connectors

(g) Taper terminal

(h) Sealing compound

Fig. C5.1:Componenets of Battery

echanaledyi
Y lations

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Automobite Engineering (MSBTE Sem-VI)_ 5-10 =
Automobile Electrical and Electronics:
System

(0 Cell connectors
cover.
adjacent cell just above tne cell
LOr straps conncct the negati ve and positive terminal post of the

Each cell of a lead acid battery produce 2 vols

required for starting without overheating
LICOTS must be heavy enough to carry high current
(gTaperterminal
dimension. So that all positive and negative cable clamn
DxLCTy teminals are of special design made tapered to specific
will be fit

ne positive terminals are slightly larger in diameter at top than negative terminal.
(h) Sealing compound

having resistance to iow at hgh temperature

hey are blends of specially processed bituminous substance
and

resistance to crack at low temiperature.

5.33 Working (Operation) of Battery:

MASBTE: S-09.W-09

S-09, Was)
plan the working of batery, used in automobiles

charging or discharging
The working of the battery can be understood by knowing the changes taking place during the
of the battery.

Chemlcal reaction during charging and discharging

A fully charged lead-acid battery consists of lead peroxzide (PbO) as the positive plates, spongy lead (P) as te
negative plates and diluted sulphuic acid (HLS0,) and (H-0). The ilution of the electrolyte is at a relative density of
1.28. The lead is known as the active material.

When sulphuric acid is in an aqueous solution (mixed with water), it dissociates into charged ions H" and SO4

The spliting of the electrolyte into these parts is the reason that a charging or discharging current can flow through te
liquid
The chemical eaction takes place between the three chemicals in the battery. In presence of H,SO, the electrons from
one group of plate collect on the other group of plate.
The voltage of a cell is created due to the ions (charged particles) being forced into the solution from the electrodes by
the solution pressure. Lead will give up two positively charged atoms, which have given up two electons, into te
liquid

.This flow of clectrons is continuing until there is insufficient in balance of electron to create a 2 volts pressure berwen
two groups of plate.

This results in a pressure of 2 volts between the terminals of the battery cell. If two terminals are connected by a cunu
the clectron will flow.

After a certain amount of current has been withdrawn, the battery is discharged or dead.

When it is discharged, it is not capable of delivering any additional curent. It is then charged

The charging reaction at the negative electrode

PbSO4+ 2e+ 24. Pb+ H,S04

The reaction at the positive pole is:

PbO+ H2 SO,+22H*
PbsO 2+2H,0 -

naln
ed
Hlati

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 (MSBTE Sem-VI) Automobile Electrical and Electronics System
omobile Engineering 5-11
FAUnO
mical reaction takes place while the battery is charged and discharged:
Theche
2H,50, Pb Pbso + 2H,0 + PbSO Q
Pbo,
Lead-peroxide
Sulphuric acid Lead Lead Sulphate Water Lead Sulphate Energy

(
Electrolyte
Anode+ Charging -Cathode

2e Supply

H2SO4

so

4H
---
2H,0

Fig. 5.32: Lead acid battery charging

sulphate (S0,). The hydrogen
acid (H,SO) is split into hydrogen (H) and
discharging of battery the sulphuric (PbSO,) and water.
During combine with part of sulphuric acid to form lead sulphate
(PbO) which
liberate at the lead oxide During
lead sulphate (PbSO).
librated at the spongy lead plates (Pb) and combines with them to form
The sulphate is plates.
absonption of SO, by the sponge lead
process the electrolyte becomes dilute because of the
this plate again
The lead sulphate on the
charged, the chemical reaction shown above became reverse. electrolyte
When battery is sulphate on other plate is reduced to
spongy lead (Pb). Thus the
converts to lead peroxide and the lead

becomes concentrated because of

increase in H,SO4
chemical energy into electrical energy
electrical energy into chemical during charging and
Thus the battery converts

during discharging.

so

mmnunnnn4 Chargag
Dichargng

FIg. 5.3.3: Chemical

reaction in batteries

5331 Factors Affecting Battery Life

improper electrolyte Level

CoTosion of terminals and conductors

3. Overcharging

TeciKauledgi
P
Cations

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 Automobile Engineering (MSBTE Sem-VI) 5-12 Automobile Electnical and Electronics
System
4. Undercharge/ sulphation
5. Poor mounting
6. CyclingB

5.3.4 Methods of Rating of Battery (Characteristic of battery):

MSBTE S4:SI6:W-18.
S-19

9Definerating ofBattery S14)

Explain battery capacityand rating

QHow batteries are raled? Explain testing of lead acld battery. Elaborale procedure of festing. 16)
W-18
Axplain Fatng ofBaltery.recommended by SAE

The battery rating are recommended by Society of Automotive Engineers (SAE) and is defined as lighting
ability of
a
full charge battery.

(a) Ampere Hour Capacity

A battery's discharge rate capacity is usually expressed in ampere hours (Ah) and is determined by the current that
can
be supplied continuously before the voltage falls below a given value (usually 1.75 volts per cell) for a continuous discharge
period which is usually either 10 hours or 20 hours. Thus a battery rated at 40 Ah should be able to continuously provide
4
amperes for a period of 10 hours or 2 amperes for 20 hours if fully charged.

Types of Rating of
Battery

1) 20-hour rating

2) Cold rating

3) 25-ampere rating
4) Twenty minute rate

Fig. C5.2: Types of Rating of Battery

1) 20-hour rating (in ampere-hours)

equa
It indicates the lighting ability of a full charge battery. It is obtained by discharging the battery at a cument rite
1/20 of the manufacturer's ampere hour rating.
rate that 1.15 md
.The curent batery dielivers continuously for 20 hour after which cell voltage shonld not drop below
battery temperature is 80°F

2) Cold rating:

It gives an indication of the cold weather starting ability of the battery.

below 1 vol.
The number of minutes of a6 volt battery can deliver 300 ampere at 0°F before cell voltage drops

3) 25-ampere rating:
L75
voltag
t measures the battery performance at a moderate constant curent output at 80°F to a final limiting
voltucell. It is the ability of battery to cary electrical operating load when generator is not working
TeanledyiN
Blitatina

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 Artomobile Engineering (MSBTE Sem-VI)
5-13
Current: Automobile Electrical and Electronics Systemm
4Reserve
capacity is a system use now on all new
SA at 2980 K to a final batteries. This
volage of 1.75 V per is expressedlas
as a time in minutes for which the battery
cell. This provides
if the ging
charging system docs
does not work. Typically an indication of how lor
the car long the battery can run
a 44 Ah battery
has a reserve capacity
Twenty minute rate: of 60 minutes.
5)

Itis th amount of current a battery can deliver continuously

he
temperature of 27°C maintained during 20minutes without
15. A at the start of dropping the cell volagc below
the test
Example: A carbattery is rateda 300 CCA battery.
Bxplanation : It meansthat, the battery
is capable of supplying
300 ampe
amperes of current for a period of 30 seconds,
while maintaining at least7.2 volts across the terminals
of battery having tempera
a perature of -18C
(a) Coldcranking battery:
Battery is given a rating that inaicatcs their perfomance
at high curent output and low temperature.
means that a battery is capable of supplying at A rating of 170
A means a curent for one minute
at a temperature of 255K when cell voltage falls
14 volt. The overall power output of a battery is much more
when deliver for longer time because
reaction at a certain speed. of rate of chemical

r 2.2 A for 20 hrs.

25 Afor60 minutes
170 A for 1 minute

20 hrs.
Fig. 5.3.4

The above Fig. 5.3.4, shows comparišons of Discharge characteristics of Cold cranking battery, Reserve capacity,
Ampere Hour Capacity.

D) Internal Resistance:

.A perfect voltage in seies with a resistor is shown in figure. This

fig shows that the terminal voltage of a battery drops
when a load is placed across it. When a current is drawn from
the source a voltage drop across the internal resistance
and is calculated as

R U-V)/I
Where, U = open circuit voltage,

V on load voltage,
ana I Cument

-Intemal
resistanca

Load
Perfet
voltage
source

Fig. 5.3.5 Votage load connected in series.

Tedh
Taralei
atios

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 Automobile Electrical and Electronics System
Automobile Engineering (MSBTE Sem- 5-14

(c)SelfDischarge:
on temperature and
The battery will be discharge without the extemal source or circuit. It dischargc ratc depends it
increases with increases with it and the age of battery.
forms short
The sclf discharge rate is caused due to the change in chemical reaction process between the grid material

circuit betwecn antimony and active material ie. lead peroxide

5.3.5 Capacity of Battery OR Specification of Battery
MSBTE: S-14.S-16

O.Define Battery capacity 14 S16

The capacity of battcry has been defined as the amount of curent it can deliver.

The maximum amount of curent that a cell can furnish is dependent upon the following factors:

1) Number of plates

2) Area of plate

3) Temperature of electrolyte

4) Quanty of electrolyte.

About 1/10 m of the surface plate must be in contact with an electrolyte to produce 40 to 60 ampere of current. 6 volt

passenger car battery have 15, 17, 19 and 21 plates per cell, the 12 volt have 7,9, 1l and 13 plates per cell depending
upon the size of the battery.

There is always one more negative plate than positive plate.

5.3.6 Types of Battery Tests:

MSBTE:W5
aEnlitthediferenttestsofbattery Explainspeciticgravitytestofbateny
Types of battery tests

0 Specific Graviy Test

i) Open Circuit Voltage Test

(m) Light Load Test

(iv) High Discharge

Test

Cadmium Test

Fig.C5.3:Types of Battery Tests

0 Specific gravity test

This can be done by the use of 'hydrometer contained

in a syringe. The electrolyte is drawn up
into the syringe byu
bulb and the hydrometer float sink to a greater
electrolyte.
or lesser extent according to the amount
of sulphuric acid n
u
Teckled
t
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 Electronics Sv
Autormobile Electrical and
Automobile Enginering (MSBTE Sem-VI) 5-16

Gi) Open clrcuit voltage test

cireuit in Such a way that the
test conducted by use of voltmeter. The battery is connected in the
The open volt is the
and when Ine voltmeter gives the
with the help of voltmeter
posiuve teminal of battery to the negative terminal
indication of 2.1 volts then we say that the battery cellis about fully charged.
to a charge
voltage which is consider be equvalent
to
When the voltmeter indicates a charge of 0.01 volt of open circuit
gravity of an electrolyte
can be measured indirectly
of 0.010 in the specific gravity of the clectrolyte. Thus the specific
with a voltmeter also.

5.3.7 Salient features of Maintenance free battery:

and charge cycles.
Maintenance free battery is one that experiences little gasing during discharge
It docs not reguire addition of distiled water to the battery cells.
Generally they are provided with built-in charge indicator.
material is minimized.
These batteries resist overcharging at high temperature. Corrosion of the active

Construction:

The maintenance batterics have cell plates made of slightly äiferent material. Calcium or strontium is used to
fre
strengthen the plate grids instead of the antimony used in conventional batteries. These batteries use about 0.1%
calcium instead of antimony.

i) When overcharged, calcium will use only 1/3rd of the water that antimony does.
im) Maintenance free batteries are sealed except for small breather holes to prevent gas pressure build up in the case.

This is because the lead and calcium combination is susceptible to damage from even a small amount of dirt or grease.

5.4 Starting System

MSBTE D
SI1
Q.What are differentcomp
tomobile s1aring systEm
W10
OEXplain working ofstarting system

The starting or cranking system consist of a starting motor,

battery, control switch and interconnecting wiring.
performance of all these components must matched he
be against engine requirements for satisfactory
service.
The starting motors are mostly of direct current
series motor. These convert the electrical
to mechanical energy by rotating the armature shaft. energy supplied by the battergy

A drive mechanism couples the shaft through

a pinion and flywheel ring gear
of (a) Motor unit (6) Drive unit. to the engine. The starting motor cos

5.4.1 Requirements ofthe Starting

System:
An internal combustion engine
requires a combustible
mixture of air and fuel,
the minimum initial starting compression stroke for the
speed about 100
rpm in order
igniou
requirements are less for to start and continue running of a These

this minimum speed is

obtaining starting speed
to attain. This is where
the electic starter comes in. Theana
veicnentof
again dependent ona number
of factors, such as
)The rated voltage of the
starting system.
() The lowest possible temperature
at which the engine limit
temperature. can still be started. This
is known as
) The torque required to
crank the engine
at its starting limit
temperature (including
the inital stalleu rque)

TecKa
PB

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 (MS5IE_Sem-V 5-17 Automobile
gineering
Engine Electri
andElectronics
ALOmODIe characteristics. onicsSystem
battery
Thevolage dropå the battery and the starter.
rop between

Th The
startce to ring
gearratio.

oi characteristicsofthe star
starter.
The
i) ranking speed eof the engine at the starting limit
cranking
minimum temperature,
1he
i) possible. starter as an isolated component
within the vehicle
not consideration. electrical
ts irlaris ofprime
purcuar
n of
system
importance for

any vehicle must fulfil the following criteria

in addition
system.
The battery
in
starting to the eight factors
The functioning. listed above
for its
eficient
service life and low
maintenance needs,
A
Long
operate.
)Continuous readiness to

stness to withstand starting forces, vibration, corrosion and temperature

cycles
lowest possible size and weight.
The
Components and Functions of Automobile Starting
54.2 System:
Components of automobile
starting system

) Battery

) Starter motor

im) Solenoid switch

v) Starter drive

v) Staring safety switch

Fig.C54
Batery : It provides necessary current to solenoid and starting motor for engine cranking
motor: It receives current from battery and converts into mechanical motion, rotary mtion for
"ee engine.
cranking

Sol
SWitch: It acts as an clectromagnetic switch with a movable core that converts curent flow into mechanical
movement.

as soon. s
"ter drive :t couples
engine crankshaft
armature with the flywhel during cranking and disengages armature with flywhel
turns faster than the starter pinion.
)Starting
operation if the transmission is not in Park or neutral
y Switch :It prevents starter motor cranking
position.

Layout and Working of Starting System

he switch. When the
stem has starting contacts in the ignition
fio nuy used in passenger cars and other vehicles
ignition START, the starting contacts close.
key is turmed against force pass the ON position to
spring
Thisconnec the battery. After the engine start and the ignition key
istelease
nng
ne starting- motor solenoid or magnetic switch to
force returns it to the ON position. This opens
the starting contacts.
Tedarulelgi
atlens

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 Automobile Engineering (MSBTE Sem-VI)_ 5-18 Automobile Electrical
ar Electronics nd
Sptem
On starting motors used with overunning clutches, a solenoid is commonly used to produce the cluteh. dem
shifüng
actiom.
The solenoid contains a pair of winding that are connected to the battery when the starting suibat
chis closed.This
producs a magnetic field that puls a plunger in.
clutch on the armature shaft
The plunger movement cause a shift lever to move the overunning
To dstrbutor
batiery tenminad
Solenoid
Solenoid
Bulihead
Swith Connedtor
Hold in cod Contacds

Pinger
Shit lever

atery
Pinion grition and
Flyheel Stater SWich

Sht
Collar

Clutch Pinion
Cranking
Compression
motor
spmg Batery

Fig.5.4.1: Layout of Starting system circuit

the flywheel teeth. At the same time, the plunger movement

This shift the overunning clutch pinion into mesh with
forces a heavy switch to connect the starting motor directly to the battery. Now,
cranking begins. Fig. 5.4.1 shows the
sequence of action. Fig. 5.4.1 is a wiring diagram of a starting motor system.
to pull the plnger in.
The solenoid has two windings, a pull-in winding and a holdin winding. They work together
has a sliding pole
Fig. 5.4.1 starting system which uses a separate starter relay (magnetic switch). The starting motor
starting motors.
shoe that moves to shift the pinion into mesh. This action is perfomed by solenoid mounted on other
the starting-motor
This combination of windings provides sufficient magnetic strength to mesh the pinion and close
switch.
core Conscquendy, as te
After the pinion is meshed and the switch is closed, lss magnetism is nequired to held the in.
This reduces
switch closes, the pull-in-winding is shorted qut, since it is connected between the two solenoid terminals.
the load on the battery during cranking.

5.4.4 Bendix Drive:

MSBTE BSH145WE14W-15, S-16, W-16.S17AZ, SHEW-18.S19

Explainfünction of Bendik orive instaring systemNTn ane 14 W-14

Explain thefunction of Bendixdive
in
slarter system W15, S-17
nan wofkngo Bendix drive úsed in'stating sysiem with neat skeldh S-16, W-16

Explain with neat sketch Bendix dive used n staring system W-17
(S-18, W-18)
Explain the working ofBendix drve yWtineat sketch
Explain the construction andWorking of Berndit o 1
unun
This type of drive depends upon the inertia of the drive gear to produce meshing, Inertia is the property which all
have that resist any change in motion. When drive gear is stationary, it resist any force which tends to set it in motion

TechKaouledgi

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 Se
(MSBTESem-VI)
Engneering 5-19
omobile
ALICIO tomobile
to engage starter pinion with the flywhe Electrical
eis used andElectronics
withtthe armature starting Sy
fastening this unit motor shaft,
For partsare free from armature shaft and drivehead. thedriveheadiskeyed
, ther to theend
he ccted through
connccted through the springwhich
altached
of amature
shaftwhile
They
are only to thehead
andthesleeve
current passes into
Cum the starting motor the
armature carying
When the threaded sleeve.
beginto
tum at
pinion.
efect to th ful speedcausing
ming
, Although the
pinion is tume et itis moved forwardby
to its inertia of rest and unbalanced weight.
uc toits
thespiral thread
the transmission
of

iywheeldue tillitengaged
with the
is revented teethof
Furthermovement of pinion by a collar attached the
on thesleeve,
thee
engine flywheel, the flywheel rotate and because
mesh with engine starts, of thispinion
startrotating
Threaded as it is
dleeve Pinion gear
Spring
Drivehead
Armature
Shalft
ommutator
and
AmaTure

Coller

Balancing weight

Flywheel

Fig.5.4.2: Bendix drive

.The starter pinion and flywheel gear do not remain in mesh but are automatically disengaged by
soOn as the engine the Bendix drive as
start because in comparison to the rotation
of starting motor, the engine rotate the pinion much faster
after it start causing damage to the starter motor.

This disengagement is affected dlue to pinion rotation much faster

by the engine in comparison to the rotation of starting
motor at the time of engine actually start

Therefore the starting motor will be also protected due to pinion meshing
out of the 1lywheel gear because of its
SCTewing back on the spiral threaded slceve when the
starter switch is relcazed by the operator.

5.5 Charging system

5.5.1
Function and requirements of Charging system:
MSBTE W-14 S-15. W-16, S-18
(W14)
Sjatethe need of charging system.
IS15)
yis necessary to charge automobile batery
Statethe W16,S18)
ateithe needotcharging syster
well
curent to the starter at the time of starting as
The batter
direct current. The battery has to supply the
storage of
asto th
to the various accessories of automobile. depends upon state
current flow to battery
Generator constantly. The rate of charging
pro curent to charge battery
of charge of vides
battery. happen that run of vehicle is not
certain circumstances it
1fsufiei
batteryis
un down the charging rate will be
higher. Under
discharge due to frequent
use of starter, prolong
period of parking light

t to charg been
ON or age the battery which has car radio etc.
by the use of other accessories like,heater, blower, Tefaenledgi
Pliatisas

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Automobile Engnering (MSSTE Sem V) Automobile Electrical and Electronics System
5-20
always in charged condition there
Duc to prolonged use the charge of battery is decreased. Therefore to keep the battery
is a requirement of charging system.

Components of Charging System:

which ensures that battery remains in charged
Charging system is a part of a overall electrical system of motor vehicle
statc in any given situation. It comprises of following:-
phase recifier that is
Rectifier- It is full wave three
1) Battery: Gets charged as it avails DC supply from rectifier 2)
used in cvery vehicle
regulating ficld curent
3) Regulator: It regulates curent and voltage to the batery by
electrical energy as per
rotor-Converts mechanical energy made available by engine into
4) Altermator: Stator and
the principle of induction.
5) Relevant Electric circuit

5.5.2 Alternator:
MSBTE S16.W-17. S-19

advantages (S-18
Expain construcüonand working o.altenator state its
otaltematoEwith nedt sketch.
W-7,19
EXplain constructionand working
Alternators are much smaller,
alternator is used on vehicle to charge the battery and operate the electric circuits.
An
dynamo.
lighter in weight and produce more curent than
stationary set of winding. Solid state diodes used to
convert AC to DC
The altemator has a set of rotating pole and a
and brush assembly.
voltage. The alternator is made of stator, rotor, slip ring

5.5.2.1 Worling Principle:

generator.
Alternator operates on the same fundamental principles of electromagnetic induction as dc.
in the
which cuts a conductor induced a flow of electric curent
A rotating bar magnet furnishes the moving ficld
conductor. This is how the altermator produced.a current.

5.5.2.2 Aternator Components and their Funetion:

Components of
altermator

) Rotor

i) Stator

i) Stator vinding

) Field winding

v Brushes and Slip ring

vi) Housing

vi) Diode Rectifier Bridge

ii) Cooling Fan

Flg. C5.5

eliroth

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 (MSBTESem-VI)
Engineering 5-21
obile Automobile
Electrical
a Electronics
magnetic field when ficldwinding caries current. System
Treates

ides a path for

magnetic flu usinglaminatediron core
and holds stator
Stator. gener lectricity by cuting the rotor
winding.

Salorwinding
winding
:t generates the magnetic lines of flux.
magnetic flux.

: It
i The ovide a meams of maintaining
Slip ring: electrical continuity
Brushes and between stationary
s-battery and field winding through regulator. and rotating
rotora
e rotor and stator parts. It nolds rectifier and
supportsthe
Housing :t regulator.
Rectite Bridge : tis used to rectifier current output of AC generator.
Diode
i) Fan:It coolsthestator and rotor and diodes of altermator.
Coo
vij
Construction:
55.2.3

dan of an altemator is improved by placing the stator

operation
The and rotor assembly inside the iron frame
conducting path for the magnetic line or housing,
which provide a of force.

yoltage can be increased by increasing stator winding into number

of coil. A stator consisting
of one winding of
wire. Most altermator use three winding in y shape, called 3-phase.

.An altemalor consists of a rotor assembly (held winding), a stator assembly (arnature winding)
and a rectifier mounted
in a housing. But the main difference between the D.C. generator the amature rotate
and field winding is stationary
while in altemator ficld winding 1s rotated and the armature
conductor is stationary. This is called stator
as and field
winding called as rotor.

The housing made of two piece of die cast aluminium which is light in
weight and good heat dissipation property
bearing support the rotor assembly is mounted in the front and rear housing

Similarly stator is clamped in housing- The three windings are joined together at one end and
other end connected to
rectification asscmbly.

The field winding assembly consists of rotor shaft winding around an iron core, two pole pieces and slip rings. The
otor shaft is pressed into the core.

'The slip rings are held the two brushes by springs and are connected through a switch to the battery. The recifiers and
aodes ae presed in the slip ring end head or heat sink and are connected to the stator leads.
Working

aCn the field winding rotate a magnetic flux cut the magnetic lines produced by pole (N and S) and e.mí.is produced.
1his eamí.can be
colected by brushes from the slip rings. The nature of this e.mf. is A.C. So it is called altemator
OwCver curent generated in the coil is changed to direct curment D.C. by a
the alternating rectifier
just before output
and if generated in the coil.
OTEvolving a coil, a magnet (magnetic flux) is rotated inside the cirent can be
coil,

Thelarg
Volume of curent generated in the coil, the more coil will heat up due to current flow.

Forthisreason,,cooling is better if the coil is cquipped on the exterior of the generator.

altemators for automobile utilize generating coil (stator coil) with an internally rotating magnet (rotor
,all
col).

Tecfanlelgi
llatlas

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 Som-V 5-22 Automobile
(MSBTE El tricaland
Engineering Elertrorica.
From beatey
Automobilo Dodo Magnet Sptom
5tatcr

To
loctrc dr
Stp rthgs

-Diod

Fig. 5.5.1a): Working principle of alternator

bracket- 12-pole rotor and feld
Sip tng end
wirding assembly

Buit-in output- Fan

regulator Stator
Pulley
sink
in heat

Ball race
Cover Sip rings bearings

Brush gear- Rectifer pack Drive end bracket

exploded view
Fig.5.5.1(b): Alternator

Advantages of
Alternator

curTent.
(1) It limit its own

regulator required.
(2) No currecnt
running condition.
charge when vehicle is in
koeps the battery
3) t
Charging of Battery by
Alternator:
5.5.3 MSBTE: W14,W15.S18
W-14

constructional detall of charging

system used in automobile
S19
W-16,
Q.Explain the Automobile
Descnbe constnuction and operation of charging system used in
Q
turned ON, the iet rotor
generator. When the ignition switch is
charging circuit of A.C.
Fig 5.5.2 shows the produces the magnetic
field of the rotor.
regulator. This current
cuTent from the battery through
the voltage anged ino
altermating curent is enu
This
induced in the stator winding.
the roator is turned by the pulley, curent is
As
direct curent by rectifiers. vaue.
volliage a
used to limit the generator
ne voltlage depends upon the rotor speed. A voltage regulator is
barteny
volage generaled by the alternator is greater than battery
voltage, it will charge the
the

ctiani
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 Engineering (MSBT em-VI)
5-23
AutomobileElectrical
Stotor andElectronics
Rectifers
Wndings System
Heal sink

Baiery
thermal

Igition End frame

Ground wire-

Fuel
VoNiage-
regulator lgnition»

Rotor Amature

Rolor
windng

Fig.5.5.2: Charging circuit of A.C. generator (Altermator)

battery voltage then the battery wll be díscharged. This situation

than the battery
lessdhan will also ocur when the generator
If armature is
stationáry. To avoid this a cut-out is used to isolate the armature from the battery.

System
56lgnition
This is the system by
means of which spark is a provided in(S.) topetrol engine ignite the compressed air-fuel
mitur. Thissystem supplies a high-voltage surge ofcurent to prodace spark at the spark phug Ep.
according to the firing order of the engine to produce
The spark is produce at the exact time in the vañious cylinders
the combustion chamber.
maximum useful energy during the expansion of combustible gases within
transistor switching or it may use a capacity
ignition system may be of conventional design, it may use high-energy
The
discharge system.

5.61 Function and Requirement of lgnition System:

electrodes of the plugs at the comect timing.
L hshould provide good spark betwcen the
engine speed.
2 Itshould function efficiently over the entire range of

tshould be light, effective and reliable in service.

should be compact and easy to maintain. the spark discharge even
in lean
electrodes is required to affect
spark plug
large voltage across the
CnLy
mLxtures.
gap
combustible mixture across air
Suply energy required to ignite the engine load and
speca.
timing as per
be capable to advance or retard ignition position.
Id
&Efeciveto circuit at appropriate
time with
respect to crankshaft
ggertrigge the primary
S52 Types of Ignition Systems

0Batryignitionsystem
Conventional Transistor assistedd
(b)
Magneto ignition
system
9 Eectronic
ignition system
TechKaraledgi
9 Capacity
discharge system loatioas

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 Engineering (MSBTE Sem-VI) Automobile Electrical
Automobile 5-24 and ectronics
Systerm
1. Conventional

2. Distributor (Electronic)

(a) Mechanical and yacuum timing advance or (b) Eleetronic spark timing

3. Elcctronic (Distributor les)

Ignitlon Systems

Magneto ignition Coil ignition

system system

Electronic DistributorDistributor less Direct

Conventional CDI ignition
ignition igntion ignition

| Conventional coil Electronic Computer controlled

ignition system ignition system coil ignition system

The main task of an ignition system is to provide a precisely timed spark with suffcient current to ignite the
proper fel
to air mixture. Regarless of any type of system, any ignition must have the following elements:

() Adequate Electical Supply- this is the vehicle's batery, which supplies the initial
curent to startup the vehicle.
) An Tgnition Coil capable of augmenting 12 to 14 volts to 6,000 to 35,000 volts.

c)Distribution of secondary voltage.

(d) Electrical wiring to distribute secondary current from the ignition
coil to the spark plugs. Spark Plugs used to create the
spark that ignites the air/fuel mixture.

(1) Battery lgnition System

MSBTESS16. W-17
EXplain wilhneatsketch.theCrcuit diagram.atsparkignitiog
(S14
QExpain batter igpiian systëm o four cyinder

eExplain bøtteryjgniton systëm with

The battery ignition system consist of batery, ignition

switch, ignition coil with
a ballast resistor, distributor housing
contact breaker points, cam, condenser, rotor and advance
mechanism, spark plug and low
and high tension wiring.
The ignition coil consist of two coil, primary coil having 100
to 200 turn and secondary coil
having 20,000 urm.
The primary winding is connected to the battery through
an ignition switch and contact
breaker point
While secondary winding is connected to spark plug through
distributor.

Ted Ka
7
ilaties

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 ering(MSBTE Sem-VI) 5-25
tomobile. Automobile Electrical
Secondary and Electronics System
Wdg

Distrbutor
Sparkplug

Primary
Wdg

Ballast -D1
resister D
ignition switch Rotor
D4
Cam

Contacd breaken
2 Battery

Fig.5.6.1:Circuit diagram of
spark ignition system

resistor orovided in series with the primary winding to regulate primary curent and passes
ballast more curentin
A starting.
circuit during
prinary
speed operates
operates the
at camshaft speed r
the contact breaker and causes the breaker point
,Atating cam thecontact breaker point is closed, the current flow primary
to open and close.

gnition switch is ON and in winding and builds

When the
magnetic field
up a
contact breake
eaker point open, the cuTent flow in primary winding is stopped and the magnetic field
so as the
Assoon secondary winding and induce a voltage which is accomplished by
the a curent
collapse, cuts acrossi
primary winding and induced voltage in this as wel as in the secondury winding
magnetic field also cuts the
This action producing it. Thus effect of this is to slow down the build up
primary winding always opposes the
The voltage in
breaker point closes.
the primary winding when
of the curent
in
consequently lower voltage in secondary circuit,
to this continuous process a slow building up of the magnetic field
.Due causes sparking at breaker point. This arcing
increases wear and redoce the
Tesult slow collapse of magnetic field which

life of contact point.

the contact
condenser in primary winding across
prevent arcing and this can be achieve by using a
to
Itis necessary cument flow in primary winding is
stored and it become charged.
contact point open, the
reaker, when the
thus cause to quick collapse
of magnetic ficld
back into primary circuit in reverse direction,
immediately
t discharges plag through distibutor.
secondary circuit which supplies to the spark
md a high voltage is build up in
the ignition of charge in
occur acros the spark plug gas cansing
breakdown voltage a spark
ueis voltage is higher than
combustion chamber.

LIinitation
switching capability of the
in the curent
decrease due to limitations
v engine speed increase, the primary
voltage
he
breaker the
system. buildup of the current in
of the time available for
As the engine shorter because
increase, dwell period become
Ped
anary coil and
stored energy decreas. plug insulator
decrease.
side-tracking across the
Douctothe
highssource of system is sensitiveto because of continuously
Or iimpedance in the contact breaker point
lhcreased reliability of the
cureat causes rapid reduction in the life and
sabject es a rapia
dtoelectrical aswell as mechanical wear. TedKaenledge
Iatlans

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 domobile Engineering (MSBTE_Sem-Vn

A 5-27
Automobile Electrical
and Electronics System
Spark phugs
Distrttot

Cam

Rotating
magnet

Contact breaker

Fig.5.6.2: Magneto ignition

system (Rotating magnet
type)
Diference between Batery lgnition System and Magneto Ignition System:
MSBTE: S-15
system
OCompare batery ana magnelo.ignition

Batteryigniton system
Magheto ignition system
Current for primary circut is obtained from the| Current for primary circuit is generated by the magnelo.
battery.
A
2 good spark is obtained at spark plug at low During starting, quality of spark is por due to low speed,
speed. so extra battery is needed for starting.
Starting of engine is easier. Starting of engine is cifcult.
3.
battery needed, hence no prvblem of battery discharge.
Battery is most important, Impossible to start| No
engine when battery is discharge.

Require less space.

Require more space.

.
increase.
Spark intensity improve as the engine speed
intensity falls as the engine speed rises.
Spark
More costly.
Cost is less.
scooters etc.
Used in racing car, motor cycle,
L&Used in bus, cars, truck.
Electronic Ignition System
MSBTE S13.3W-14 W-16.S-18.
W-18. S-19

cropic (S13W-14)
elecropic igniton s neat sketch
Explain
(W16)
neat skE anito
with neatsketch electronic ignitlon system
(s-18, S.19)|
workingofelectronicignitionvstem
he y W-18)
ae dvantagesofelectronicignitionSystem.
ecaledgi
Publicatisns

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 (MSBT_Sem-VI) 5-28 Automobile
Engineenng Eled
Automobile alandElectronica
usc of brcake points to interupt
is the is
mechanical system
stem is the
-voltage Sydem
disadvantage of the subjcct to n chanical wecar high-curren
coil; the points are where they
, The
primary
windingofthe t the
the contact
o surfaces from the constant sparking.
ride
ntoogen thtongh
the burming atat andshut,
axidation and aa
vell as
to compensate for wear, : opening of thecontactbreak
ijustment
ngularadjus ich responitle
They
reguire mechanical variations is
subject to
timlng, is
for
spark contact servicing and to pr ide longer ignition system life
froquentibrcaker and be
avoid comsiste
necdto rease fuel consumption and
increa ocarbon emissions sisteacy
The avoiding the
power loss and from ok
thereby, theer
concepts using solid state d
fining, gnition system
new ignitio h aim atpartial
developmentof or totalsolution
led to the ntional ignition system. ation
conventio ts
cncountered with the
oblems
System
Electronics lgnition
Princlpleof
conventional point type lgnition System with a small dif
Electronics
Ignition system s
is similar to
tem is
Bectria
Electronic control unit which opens and close the primary circuit instead
provides with stead
ofcontact
Ignition system is
Contact breaker point
breaker point as in
contact breaker.
distributor instead of
used in the
system atimer is
h this tnggers the ignition module called electronic
be a pulse
generator or Hal-enect swucn wnich eloea
ignition
This timee may

Control unit

primary contain transistor circuit whose base cuent is tiggered OFF and ON by a timer nds.s result
This control unit

stopping of the primary curent

in the starting and

Electronic ignition system

Construction and Working of

Construcdion:

. Elctronics lmnition syatem is having

two circuits Primary and Secondary circuit. Battery. primary winding, ECU and

the timer forms primary circuit.

Whercas socondary winding, distributor and spark plug forms secondary circuit
A tinr is employed in the distibulor instead of contact breaker. This timer may be Pulse generator Or Hal- efiast
Switch which Thigers the Ignition
module also called as electronic control unit.
Working:

ms control unit primarily

contains transistor circuit
whose current is triggered off and on by in tho
stopping and timer wnicn resu
starting of the primary
circuit.
The secondarycircuit
worked in the similar manner
as in conventional contact
1. wbeathe magnetic breaker ype
field collapses
it induces curent
TEuls indevelopnent cuTent in
in the secondary winding having more number of turns.
of very high
voltage necessary n
to generate the spark
at the spank plug

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 Sem-VI)
Engineening
(MSBTE 5-29 Automobile
Electrical
nobile Electronic and Electronics
System
Ignition coil control unit
Switch
Spark plugs

Sensor coil
-Battery

Armature Distributor

Fig.5.6.3:Electronic ignitionsystem

Electronic Ignition
System
Aantages of
part, it
translate tthe control and reliability impossible to achicve any mochanical systenm.
No ine part,
moving

starding with cold engine. Fast

build up of output voltage
Better

possibility of arcing at spark plug. Spark plug fouling is greatly recdaced.

Is
timing.
Longer life due to stable
output voltage which is attainted in a very short time and with a very limited discharge, resulting
Podce a maxzimum
regular engine running, even with
dirty/foul spark plug and wide, plug gap.
in

C.B. point, Cam, etc. which expose to wear and tear.

Nochange in ignition timing due to absence of
1. High volage at secondary circuit throughout engine speed range.

Input current and output available voltage are constant over a wide speed range.

Disadvantagas of Electronic Ignition System.

This system is more costly due to more components.

2 Batery is necessary for starting.

Diference between Battery Ignition and Elecironic Ignition System

Elëctronicignition SYstem
NO. Battery ignition system
distributor.
Contact breaker is used in distributor A timer is used in the

Less cost. More costlier.

Compact, less space required

Require more space.
consistency of firing.
Power loss occurs. Avoid a power loss and

starting.
5. Battery required for
Battery is most important. Inmpossible to start engne
when battery discharge.

Spark intensity Spark intensity constant

falls.

5 LIghting
System
571
Introduction:
integrated to the front, rear,
signaling devices mounted or
BOs, 0 d automobile consists of lighting and
and
insomecases the
top of an automobile.
Ted Kaemledge
atlans

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 Electronics System
Automobile Electrical and
_Sem-V 5-30
Engineering(MSBTE
Automobile
System: safcly at night.
5.7.2 Function of Lighting operate the vehicle
to
illumination for the driver about the
the lighting system is to
provide
dri ver or peopie on the road
1) The purpose of information to other f travel. Beside this the
to convey direction and speed of
t
conspicuity of the vehicle and intended
2) To increase the travel and the
driver
vehicle presence, position
size, directionof vehicle.
dashboard and inside of the other dinvers and
pedestiane
illuminating instrument on the vehicie, alowing
visibility of the direction and sSpeed at
and increases the intentions regarding
roadway for the driver driver's
lights the and the
3This direction of travel,
vehicle's presence, position, size,
to sce a Emerpenr
movement in tratfic such as an
travel. priority of conveytn
warm drivers and indicate ambulance van used for ng
equipment to to an
4) The different lighting light with purple glass fitted
red
The blinker type of
vehicles usually cary.
patients

5.7.3
Requirement of Lighting System: withstandin
conditions of use and not
installed that under normal
light signaling devices shall be so
1. The lighting and
they may be subjected,
any vibration to which correctly.
that alignment can be easily set
Theilluminating lamps shall be so fitted
2 the vehicle shall be parallel
to horizontal bearing plane of the
signaling devices when fitted to
Reference axis of all light
vehicle.
specific instruction, with the vehicle unladen and
The height and alignment of lamps shall
be checked, in the absence of
4.
located on aflat horizontal surface;
symmetrically in relation to longitudinal median plane.
5. lamps constituting a pair shall be installed on the vehicle

6. The lighting fixtures housing and socket shall not be used as a ground returm
for any other electrical circuit.

5.7.4 Types of Lights

Modem vehicles uscs different types of lights for various purposes. The main lights are :

Types of lights used

for vehicles

1. Head lights

2.Parking lights

3. Direction-signal lights

4. Blinker lights

5. Stop lights

6. Back-up lights

7. Tail lights

8. Interior lights

Fig.C5.6

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 (MSBTE Sem-VI
utomobile Engineering 5-31 Automobile Electrical and Electronics System
Auno
function f head lights is to illuminate the highway road sufficiently to permit safc night driving. Generally
The hese
beams, one
o with high intensity to gives
ovided with two maximum illumination for night driving and other gives
seprovhe eround aand to the side of the road to minimize
ground
deflection to the glare when passing of cars on the road. Sometimes a
uscd which is of low intensity for city driving.
thirdbeam is
rdon to the head lights, low intensity parking lights are usually provided in the front of the car, either separate
,In o nat of the head lamps, and are used while the car is parking. For parking the car during dark, parking
3o
uils kent he
lightsare
d to provide a signal for other moving objects and thus avoid the accident.
kept ON

Direction-si lights known as "directionals", "blinkers", "indicators", or "lashers"

are blinking lamps mounted near
right front and rrear cormers of a vehicle, are
and used to indicate the direction in which the vehicle is to turn.
the left
give signal to the vehicles coming from the front or rear. In addition, some special signal
Thelights light are also used.

These
include a red signal light to indicate when the high beams of the head lamps are burning, to indicate when the
applied, to indicate that the oil pressurc is low, that the cooling water temperature
parking brake is is too high or too low
generator is not charging the battery.
or that the

Rack-up lights turns ON when the driver shifts into reverse. This closes a switch linked to the selector lever which
connects the back-up light to
the battery.
car is stalled on the highway or has pulled
.BEinker lights provide a means of signaling when the ofto the side.
biniing is much more noticable than a stcady light and provides a warmning to aproaching cars.
The
lights illaminate back of the car in
the night so that the other vehicles coming behind it are able to see it
,Tail
the night. Stop lights are also at the rear of the car and
,Tail lights are kept ON all the time when the car is running in
become ON when brakes are applied.
instrument panel lights, various
. To illuminate the Interior of the vehicle a various type of lights are used such as
Keyhole lights, map lights, radio dial lights, clock lights are also
warning indicator lights, and compartment lights.
provided in some cars.
Map-roadiog igh Glove bax light
instrumeni panel lights Dome or windshield
header ight fLuggage
compartnent
light
Underhaod light 7

Hoadihts Stop lights

-Tail Fghts
Backup ightss
License plate
ight
Comering lights and
ftront side marker Ights Ashtray lightsCourfesy Rear side
door lights marker íghts
Emergeny-repairs lighf
(With extension cord
into ighter socket)
Company)
lights on a vehicle (Ford Motor
Fig. 5.7.1: Interior and exterior
1. Head
Light
MSBTE W-11. W-13

W-11
the details of head lamp of vehicle with neatsketcn
Explain th
W-13)
pain the head lampof vehicle with a nealsketch
Head sealed beam type are mostly
filled type or sealed beam type. Now-a-days
Sed are either Incandescent gas
and a weaker low beam for city
driving.
beam for normal Geometry driving
A ghts are made to throw a high lamp system.
vehicles uses sealed beam head
of incandescent gas filled type. Now
elamps are

Tec Iavaleli
lcatiaas

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 Sem-VI) Automobile Electncal
¥Automobile Engineering (MSBTE 5-32 and Electronics
ronicss
System
Both lamps are alike and produce a straight hcad upper or "country' driving beam and a deflected
to er or "trafficC
beam in which the light from both beams deflected on one side of the road and slighuly dowinward
is
inimize
The traffic beam is affected by locating the traffic filament in a position slightly eccentric
ccentric with gare.
the center
cent of
the parabolic rcflector. the focus
of
The tungsten filamcnt is used in bulb of head lamp which turm white-hot when connected tobattery
and gives
Now-a-days halogen headlamps are used. These emit a whiter and brighter outlight
light than other sealed headlamn
A halogen headlamp has a smaller inner bulb filled with halogen
gas which protect tungsten
filament. The
airtight or hermetically sealed. The halogen lamp shown outercase
in Fig. 5.7.2(6).
is
Ught deflected
Pnsm by prism

Reflecor
Halogenifilled
inner bulb

-Dip flame Tungsten-

Manfilament
at focal point
lament
oT refector

A Strayight
Luight defiected
byPrism
Lens
(a) Head lamp main
and reflector (6) Construction of a halogen sealed-beam
headlamp
Fig.5.7.2
Aiming of headlight

The headlights must be aimed correctly

to the required direction to get proper
light on the road and to prevent
vehicle from accident. the

If the headlights are aimed too high or too low

they might blind an incoming
driver, causing the accident. Incomect
aiming of the headlight will not illuminate
the road properly:
1) A good main beam help the driver
for maintaining a rcasonable speed at
night.
2) To prevent dazzling of oncoming driver
of the approaching motor vehicle
by dipring the main beam.
3) To pickup the sides of the road side-illumination
should be provided.
4) To prevent dazzle to the oncoming
driver during particularly mistry
or hazy conditions the light about tne
horizontal should be cut off.

2 Tail Light and Stop Light

Each of these lights have their own function,

but forconvenience in design they
are usually assembled into a single

Karledg
Ted
ti

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 Sem-VI) 5-33
Engineering(MSBTE Automob
nobile Engin Electrical
ALUIOINODe
High beam
andtallights andEle
onics System

Instrument panel
ights

lnilon sirth
Light swteh and
rheostat
dinmer swtcth

Fig.&
.5.7.3: Headlight and tailligh wiring circuits, with headlights
on high beam
usually prescribe the stop light to be at least three times
Traffic laws larger than the tail
light.
light switch1may be of the hydraulic type or mechanical
The stop type operated directly
commonly used by the brake pedal,
being more the latte
.e msed to give an indication to the dver of other vehicle
stop light is us
is
The vehicle's speed and stop if required.
coming from the
back so that they
down his may slow

Tail ights are used to show red at the rear of the hicle. Tail light are kept
ON all the time when car
so that the other vehicles coming behind it anre able to see it
is nunning at night

Indicator Light

Direction indicator

DDrawa abelled sketchofndicator MSBTE:W1

igtt circuit Explaintits working
(W-11) W11)
Now in modem vehicles flasher type
direction indicator is used. These indicators
vehicle. In both circuit second are provided at front and rear of
filament of bulb or separate indicator lamp is used. These are independent
amp. from stop tail

When the brakes are being applied at same time direction indicators
are in operation with relay unit used. The
unit used in this
circuit is explained. flasher

Main amature- Setael core fSecondany

and contacts and coil amature and
pilot contacds

Ballast
resistor

Actuating wire-

To lamps P
From battery To pilot lamp
naSwitch
r relay

Fig.5.7.4: lasher unit circuit

Techneuledge
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 Automobile Electrical and Electronics:Systemm
Engineering (MSBTE Sem-V) 5-34 s
Automobile
Waming
light
Flasher
untt

LH.Front lamp
L BD
Light green
Green&
jbrawn
R.H.Front lamp

Green&
Green&
white
red

R.HRear kamp
LHRear lamp
indicator
Fig.5.7.5: Four lamp direction
will flow through the main armature
construction of a flasher unit is shown in Fig. 5.7.5. The current
An intemal through the flasher lamp filaments to.
resistors and the coil wound on the central core as well as
actuating wire, ballast left or the right.
switch is moved either to the
the earth, when the direction indicator
limitations but are kept to a low value by the ballast
lamps are not allowed to get illuminated due to the current
The
resistor. the suspended spring
armature to move inwards the core under
actuating wire will expand in length causing the lamp illuminated as
.The current. Therefore, when the contacts are
closed and
tension duc to heating.influence. of the
flashing
4. Turn Signal Light
automobile
vehicles and pedestrians in which direction the
purpose of the tum signal lights is to indicate the other
.The usually operated by a lever located under the steering
wheel.
is going to be turned. These lights are
that is automatically switched off when the
steering whecl is retumed to
Most of them are of the self-cancelling type
straight-ahead position.
is shown in Fig. 5.7.6. This was operated by a wire or
by clectromagnet.
The semaphore type used in the past
light blinks is mostly used at present. This type is
usually made to serve also as
The flasher type turn signal in which the
parking light.
times a minute.
when in operation, flashes on-and-off from 50 120
to
The flasher light
flasher lights are
An indicator light on the instrument or
clicking sound is normally provided to wan the driver that the
operating.
Bulb
Point-

Am

Switch
Magnet

Battery-

Fig. 5.7.6:Semaphore turn signal

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 (MSBTE_Sem-V) 5-35
Engineening Automobile
udomobile Electrical:
Electronics
Light System
Backup illuminating
indrcation or are
thescC in back of car when transmission
Thesegive is shifted into
reverse direction.
Impol nce
of Cable Color Used for Wiring
the Lighting
5.15 MSETE: S14.WSLHSA5AWEE System:
Ma6:SA7,WS17/
colour.codes
arious colour
various
ic
codes uged n wiring system. State its necacdh
S-18W518:S-19
aEnlist the
Codes usedin wiring svsterm
any four colour automobile. S-14)
Slate
Slate A

colour coding used automobile wirng system.

in (W-14)

ucodes colour.codes of wires

use
of
Wires used jn autornoDe
diferent winng system. S-15)
Wite 04-15,W-16,s-17,S18,
any four.colour codes usedin wiring system of automobile W-18, S19)
W.
W-17)
rrent to tthe various electncal units of an automobile
curent
To camry the and for identification
of cable, different colour
codes are used.
main colors namely, brown, yellow, white.
There are seven gren, blue, red and black. Their
applications being
has own as
lows and each color its identilication in the wiring of lighting
system.
Colour used for wiring
the lighting system

1. Brown

2 YelloW

3. White

4. Green and Light Green

Red

7.Black

Fig.C5.7
Brown

'tis denoted by capital letter B and small as Br,

r
Used for the
battery and generator circuit.
It goes rom the
battery or motor starter switch to the ammeter or control box and with compensated voltage control,
feeds hel box terminal.
ugnting and ignition switches, also the radio set, when fitted from the control
auxiliaries
1 USed for leads from the motor starter switch to the electric clock, inspection sockets and battery
are fed the electic horn, cigarctte lighter, interior lights etc.
Which
Yellow

Itis denotedby
capital letter Y.
Used for
the dynamo circuit.
control box terminal and the ignition waming light.
LOm the dynamo terminal to the corresponding TechMaledgi
YPcatiens

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Automobile Engineering (MSBTE_Sem-VI) 5-36 Automobile ElectricalandElectronics
System

White

.Itis denoed by capital letter W.

Uscd for the ignition cireuit and all electrical components that may be used while the igition is switched on btt do
&
not
require a fuse.

Eg. the electrical petrol pump, starter solenoid switch etc.

Green and Light Green

Itis denoted by capital leter G and Light Green by lg

Uscd for the auxiliary circuits fed through the ignition switch and
protected by the ignition autiliaries fuse, e
o he .
brake stop lamp, direction indicators, windscroen wiper etc.

Blue

Itis denoted by capital letter L

.
Used for the head lamp circuits and fed from the terminal on the lighting switch.

Eg.lighting switch to head lamp.

Red

Itis denoted by capital letter R.

Used for the side and tail lamp circuits and fed from the teminal on the lighting switch.

Included in circuits are fog lamps, panel lights and other lamps which are required only when the side lamps are in use

Black

Itis denoted by capital letter B.

Used for earthed circuit.

If, however a component is not earthed, a cable must be taken to a good carthing point on the chassis.

Sr No Code
Cólour Colour unction
01 Brown BR Battery circuit

02 Yellow Y Generation circuit

03 White W gnition circuit

04 Green G Auxiliary circuit

05 Blue BL Head lamp circuit

06 Red Side lamp and tail lamp

5.7.6 Wiring Harness MSBTE:S-14, W-14, W-17

pain ine ypical wiring diagram of automobile with

EXpláin Wire
harmess
nea
19 W-14

Describe wire haness: W-17

The group of wires are wrapped together to form wiring hamess. Most vehicles have several wiring harness whicn
throughout the body. Wiring harnesses connects the light with the battery and alternator. So the electrical system ol a
(wiring harness) has two main functions.

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itl

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 (MSBTE Sem-VI
mobile Engineering
5-37
electrical
clectrical eenergy to start Automobile
Electrical
supP!y
aly and operatc and ectronics
tmust the enginc.
System
power operate
) proVIdethe the ights, instrument
tmust andother
electrical accessories.
Wiring trough s lo antena
Relay module

lamp-outag
module
44 way conneclor
Radio
Instrument
panel cluster

BlOwer
motor

feed
To booy Grominet
To vacumAU
controler module(ATC)
To windshiekd washer
pump motor
4-way
To belower motor Connector
resistor block Diagnostic
To washer fiuid Connecior
To airbag
level sensor
dignostic module
To end erhood lamp
To keylght and
To multi function- key-inignition switch
Switch
To speed
controlgnition Switch

Fig.5.7.7: Wiring harness and connectors behind the instrument

panel

Windshield
Wiper motor Starter
Windshield relay
Acdutch
Grommets Cutout relay
wiper motor
connector
Low washer Fusible Radiator
fuid washer inks fan rele
Fue-pump
Washer
pump water relay

Engine
controler
Washer
reservoirK
Security alamm
hood ajar switch

Braka waming
Head lamp
lamp swilcn
ground
Map sensor Master
Cylinder

compartment
in the engine
Fig. 5.7.8:The wiring harness

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 Motor Vehicle
((6) Safety Act, Road
S
and Garage
Unit- VI Practices
Syllabus:

6.1 oduction and bjectives

of Motor Vehicle
Vehicle Rules11989.Types Act.
andSignificance Salient Features
Act (Motor Vehicle, Motor olTraffic of M. V. Act 1988 and Central
Cycle, HGV, Signs, Important Motor
Passenger, Accident). MGV, T
7 ransportTerms
(Definitions) in M.V.
LGV, Public
Senice Vehicle,
6.2 rganization Structure
Organization Transport Vehicle, Driver,
of MotorVehicle
(RTO) Department,
6.3 Passenger Comfort a
and Safety: Function Duties and Responsiblies
of RTO, AIMV.
Bags, Seat Bets, Collapsible and requirements
Steering Column. of Passenger
Automobile ger Safety System. Features
6.4 Maintenance of Air
Systems: Significance
65 Types of Maintenance, of Garage,
Need andimportance Workshop,Service
Station, Dealershup
of Record
86 Site selection and amenities/failities
Keeping, List
of Records to
Responsibilties required to be kept in Service Stations.
of ServiceManager, set up your. own
ServiceSupervisor, Garage/Service
Station, Role ano
6.1 Motor Vehicle Acts Customer
CareManager in SenviceStations.
and its Salient Features
Itis an Actto'consolidate'
and amend
1939 is applicable the lawsrelating to motor
and extends to whole vehícle. This
Act known as the
whenit wassuper of India. This Act enacted in 1939 Motor Vehiclé
sealed by motorvehicle had been amended Act of
act 1988 according from time to time until
Thenew motor
vehicle act 1988 effective totherequirements and 1988
necesities ofthe
amended uipto we.f. 1 july 1989 has replaced roads and vehicles.
2006 has nine chapters, the Motor Vehicle Act
135 sections and twelve of 1939 . This
the various
topics under thie following
schedules. The
ten chapters having Act as
hieadings: 135 sections
in all explain
Chapter
Preliminary
ChapterI1
Licensing of driversof motor vehicle
Chapter
Il Licensingof conductors of
stage carriages
ChapterIV
Registation of motor vehicle
Chapter V
Control oftransport vehicles
Chapter V
Special provisions relating to state transport underiaking
napter VII Construction, equipment and inaintenance of motor vehicle
Chapter
VIll- Control oftraffic
Chapter
1X Motor vehicle temporaily leaving or visiting lnlia
BaplerX Liability without fault in certain cases.
pler XI Insurance of motor vehicfe against third party nsks
Chapter
XII Claims Tribunals
Chapter
XII Offences, penaltúes and procedure
Chapter XIV
Miscellaneous.

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 Garage Practices
Automobile Engineering (MSBTE Sem-V) 6-8 Motor Vehicle Act, Road Safety and

Bi-cycles with pedal assistance

which are
power less than 0.25 kW, whose output is
u with an auxiliary electic motor having a thirty minute
progresively roduced and fimaly ent ofas thie vehicle rosches a speed of 25 km/t, or so0ner,ifthe oyelist stops
pedaling; and

cdthe rear.withsuitable brakes and retro-reflective devices, ie, one white refiector in the front and one red retcctor
Explan
Thethirty mimte power of the motor is defined in AlS: 049:.200s and method of verification is
AS: 041:2003, ill te coresponding BIS specificafions arc ofifed under the Bureau of Indian Slandards
in
Act, 1986 (63 of 1986).

oE means an agicultural machinery used

C
ravel and its
for soil prteparation having a single axle in which the direction o
control for field operation
is performed by the operator walking behind it. This equípment may or may not
kVE a Tding attaciment and when coupied
to a trailer can be used for the transportation of goads. Tbe maximum spee
OT DE power
tiller when coupled to trailer, shall
a not exceed 22km/h. The maximum haulage capacity of the PoweT
tiller coupled to trailer
a shall not exceed 15 tons.
6.9 Enforcement of Emission
Norms
EmissionStandard

EmIssio standards are requirements that set specific limits to

thie amouit of pollutants that car be released
environment Many emissions. standards focus on regulating nto the
polutants released by automobiles (motor cars,
powered vehicles but they can also and other
reglate emissions from industry, power plats, small equipment
such as lawmowers
and diesel generators. Frequent policy altermatives
to emissians standards are technology standards (which mandate
Standards generally regulate the emissions
of nitrdgen oxides (NO J,sulfür oxides, particulate matter (PM) or soot, carbon
monoxide (Co), or vofatile hydrocarbons.

6.10 Types and significance of Traffic Signs

Traffic signs that provide information: Informatory trafic signs provide information
to the driver via the boards.

Traffic signs act as silent conductors of the trafic on the road. Any person who holds
a driving licence and is eligible to
drive a vehicle should have proper kaowledge of trafiñic signs. The government has made it mandatory
for any persou who
wants to obtain a driving licence to be wel-versed with the traffic signs

Functions of traffic signs

Knowledge of traffic signs for any driver is necessary as tney pertom certam finctions which are essential for road
signs are:
safety. The functions performed by traffic
specific destination.
1. The distance left to cover to reacha
destination, if any.
2. Atermative routes to the specific nohlfe
as sehools, coleges, workplaces. ehike nlares
cautionary traftic signs are also displayed such
3. Locations on the
and restaurants.

E Trdlan
hiiCgtlo

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 Safety and Garage Practices
Automobile Motor Vehicle Act, Road
Engineering (MSBTE Sem-V 6-12

Part B:Cautionary.signs

8cm
Red border
45 cmy

-Centre white
or hollow

Explanatory
device
Plate while

45 cm NAll devices printed

black

Red border

Painted in 25 cm black and

white bands

Fig. 6.10.4
The signs of this part shall be used in conjuncion with a red triangular plate, the centre of which shall be either hollow
or painted white, in the manner indicated in the general design reproduced below.

Red borde

Red border

Red border
No. 2. Zig-Zagftef)
No. 2. Zig-Zag(Right)
No. 1. Rough road
Fig.6.10.5

E Tech Kaoutedge
Panitcati90

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 ineering (MS
Engineering (MSBTE Sem-V)
Homobile
6-13
Motor Vehicle Act, Road Safety and Garage Practices
Redborder
Redborder

No. 3. Cross road Red border

No. 4. Level
crossing
(Guarded) No. 5. Level crossing
(Unguarded)
Fig. 6.10.6
Red border

Red border
Red border
No.6. Right turm
.No.6. Left turn
No.7. Schoot
Fig. 6.10.7
Red border
Red border-

Red barder
No. 8. Dead end cross road' No.9. Side road[Right) No.9. Side roadLeft)

Fig.6.10.8

Red border

Red border Red border

No. 11.Pemy No. 12. Hair pin bend(Aight)
No. 10. Steep hill
Fig. 6.10.9

Red border-

-Aed border

red borders
No. 14. Narrow bridge
No. 13. Hair pin bend|Left)

Fig. 6.10.10

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 bile Engineering (MSBTE Sem-VI)
6-17 Motor Vehicle Act, Road Safety and Garage Practices
vehicle"
for vehicle" means a transport
pleaxy-motor vehicle or omnibus
(any vehicle constructed
six
personsexcluding the driver).
and run motor accident"
or adopted to cary than
o
Acident: "hit means an accident
arising out of the
identity whereot cannot be use of a motor vehicle or motor
ohicles the
he ascertained in spite
of reasonable efforts for the purpose;
scheme framed under section 163.
(c)"scheme meais
the
aanization Structure ofMotor Vehicle
(RTO) Department
612
department functions under
Transport t the provisions of section
213 ofMotor Vehicles Act, 1988. The Transport
nt primarily
is p
Departmentis established for enforcement the
of provisions of Motor Vehicles Act,1988.
cles Act,1989 and the nules framed under these two Acis.
The Transport Department is headed by the
,M Transpon
Commissioner (IC), He is asisted by Joint
Director and OSD specializing in Enforcement, Admimistration
the Head office.
andFina
in
Organization structure of Commissioner
of Transport
Ports and Transport
Department

Commissioner of
transport

Jointdirector
RUles and OSD-1 oSD-2 Account
Regulations o LTOffice (Estalblishment MVP Officer Field
Research
Cfficer
Modernization
Motor Vehicle Inquiy (Leal)Accounts Audit Officesl(Statisic)
Act. Check Posts Road $atety)Tax and Pemit) Planning)
and Enforcement)

RTO Offices ARTO Offices IMV Offices

Checkpcsts
(14 Offces) (12Oficas) (2 Ofices)

Pemanent Temporary
OSD-Officer on Special Duty offioes (3 offices
MVP-Motor Vehicle Prosecutor
RTO-Regional Transport Office/Officer
IMV- Inspector Motor Vehicle

&121 Regional Transport Ofice (RTO):

Officer. AIMV is an abbreviation for
Assistant Inspector of Motor
'RTO is an abbreviation for Regional Transport
Vehicles
the Government of India with a primary
Transport Office. It is an organization of
KLO is also called as the. Regional Union Teritories of India.
States and
DoUve to maintain the database of al the vehicles in different
Motor Vehicles.
execute the activities and the functions, as per the
ff every city andstate, there is a different RTO to
head of the departments in the specitic states.
A, 1983. And the Transpart Commissioner is the
which are allotted under specific series in a particular state. The
am is to ensure proper functioning of vehicles
Region Transport not taxed. The role also involves identifying the cars entering
onal Office identifies the vehicles that are
caught on
et Indian states. RTO also keeps a tab of vehicles exceeding the prescribed speed limit on the roads as

TechKnouledg
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 and arage Practices
Motor Vehicle Act, Road Satery
Automobile Engineering (MSBTE Sem-V) 6-18
the speed cameras drvimg licenses, tax
re-registration, transfer of ownership, I5sung
responsible for vehicle registration, and checks for
RIO or a state is certificates to transport vehicles
likewise. Furthermore, the RTO officer grants fitness
collection and the
the validity of the motor insurance policies. the RTO Eervices are
online. Nowadays, al
vehicle registration or do it
ofice physically for
uC in VISit the RIOofficial site of every state.
available online of the
AlMV:
6.12.2 Duties and Responsibility of RTO and as enforced by the
rules and the Motor Vehicles Act,
the central and state motor vehicle
npiement the provisions as per
Government

2. Conducting driving tests

licenses
3. Issuing and renewing the driving

4. Inspecting the vehicle insurance

5. Clearing the pollution test

duty
and road tax/excise
6. Collection road fund licenses
of
7. Vehicle registration
licenses
8. Granting international driving
public transport licenses
9. Providing freight and vehicles
database of the registered
10. Maintaining the
registrations
I1. Selling customized
loan transactions
12. Vehicle transfer
and registration of
rickshaw drivers
13. Providing badges to
the taxi and auto
vehicles
assessment of the accidental
14 Conducting the mechanical
transport vehicles
15. Issuing the fitness certificate to

Functions
and reports needed repairs.
lines and electric circuits,
1) Inspects truck accessories, air
malfunctions
and drives velhicle to detect
Examines vehicles for damage,
2) mechanical or electrical devices.
for wear, damage, or
improper adjustment, using
3) Tests vehicle components
rejection sticker to vehicles that fail.
sticker to vehicles that pass inspection, and
4) Applies inspection
for follow-up action by owner or police
5) Prepares report on each vehicle
delivered.
6) Prepares and keeps record of vehicles
truck trailer.
Positions trailer and drives car onto
owners having illegal equipment installed on vehicle.
8) Notifes authorities of

6.13 Passenger Comfort and Safety

and Sharpe increase in the vehicle sales, traffic
accident have become increg
With the development of society, technoiogy
technology automotive
frequently and serious. At the same time with the rapid development of science and
rapidly improve
he
increased road saieiy
acts are progressing in the right direction is the fact that due to
The proof that these regulatory ificant
This signi
volume of traffic tripled.
umber of fatal accidents in the last two decades has decreased, while the
Tedauin
7 Pubiicat

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 Enai
hile Engineering (MSBTE_Sem-VI)
AUTOMODle
6-23
Motor Vehicle Act,
Road Safety and Garage
Ensure Safety Pracices
. 2 PreventMalfunctioning
Performanc
1Increase Car 4 Ensure Fuel Efficiency
vehicle
5Prolong Lifeof 6 Reduce Polution

Low the Cost of Operation 8

1 Increase Resale
Value
Garage
Deryice Station
garage replaces and répairs are
in carried In service station fuel filling
and water servicing facilities are
on by the
skilled workers.
available. It has a small
workshop to provide repair for
particular make of vehícle.
I may have safes agency for
particular type of vehicle.

Petrol pump, washing bay, tyre and battery|All the equipment

2 in the garages plus small work shop tools,
servicing equipments are available VIZ. lathe, drilling machine,jigs and fixtures are available

Generally garage 1s located on main roads

Itis also locaáted on main roads or nearer to the highway.

6.15 Type ofMaintenance

There are four.types

of vehicle maintenance namely

Preventive maintenance
I
maintenance
2 Brake
schediule maintenance
Periodic maintenance (or)
4. Operation maintenance
road an some attention or
without breakdown or without giving trouble
Preventive maintenance: Prevention
1 Teduce or totally eliminate
preventive maintenance. It intends to
called as
maintenance taken to the vehicle is
reduces repair cost.
breakdownis accidents due to mechanical failures and
and
program leads to following advantages.
Agood preventive maintenance
vehicle
(a) Reduce the breakdown of
reduced breakdown
(b) Increased safety due to

c) Less expenses on repairs

spare parts
Good control on inventory of
required
) Lesser mumber of equipments are provided when a motor vehicle
maintenance is the attertion which is to be
Break down puncture, clectrical
Break down maintenance: during running These
faudts are started diffculties,
becomes immobilized due to faults created accidents etc.
overheating, fan beltings, breakage and
faults,
1anls, carburetors and fuel supply vehicle after
attention provided to motor
maintenance or operative maintenance is the
reriodic maintenance : Periodic quarterly, yearly
distance. These mantenance
may be done daily, weekly,
covered
operation for a specified time or
In garages this work is done on
the
2000 km, 4000 km, 8000 km of ruming.
after covering every 500 kn, 1000 km,
r so as to avoid road failhures and
to minimize break down
during use.
S O preset schedules
by the operator for
proper running of the vehicle is known as operation
Daily maintenance
peration maintenance : inflation, battery, brakes, clutch, smoke
proper working condition. Tire
Taintenance. It is needed to keep the vehicle in
maintenance daily.
and lights are checked in this
o07, staring system, ignition system

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 and Garage Practices
Engineering (MSBTE Sem-V) D-24 Motor Vehicle Act, Road Safery
Automobile

Advantages of good maintenance

1. Reduces the breakdown of vehicle

2. Increased safety due to roduced brcakdown

3. Less cxpenses on repairs

4. Increase the life of vehicle

spare parts
5. Good control on inventory of

6. To obtain the maximum, performance.

Need and importance of Record

Keeping:
6.15.1
on an individual vehicle. It
repair work performed
and
log is a historical record of the condition preventive maintenance,
A vehicle maintenance transport operators for
businesses to large
1s used by commercial
fleet owners ranging from small castings as
document both maintenance work/
Vehicle' mainteance logs can be used to
purposes.
Safcty, and record keeping
checks.
well as general vebicle inspection
running condition
comes to keeping it in good
I. Maintaining vehicle record is imperative when it
into big ones.
smallproblems before they escalate
2. tmakes it possible to take care of mumber or the
information and vehicle identification
information about make, model, insurance
3. Vehicles Record gives
VIN
Records Will Help to Keep Track.
4. Keeping Vehicle Maintenance
remind of repacement schedules.
information for a record of tyres. The type of tyre, mileage
5. tprovide
remind wheg to replaced again.
6. Aair and fuel line filter record will any
starting at purchase. A decreas in gas
mileage will be a good indication of
7. Keep detailed info on gas mileage
before they become a problem.
emerging maintenance issues that you can address
wihen your next change is due.
Type of oil used, date and mileage will help to keep track of
3. Write down all oil changes.
become unreadable.
Those little stickers in windshield may not last or
when to have old brake dust cleaned.
9. Record brake replacements.so when to keep an eye on wear or

10. This Helps with insurance or any vehicle issues that may have resulted from them.

II. t help for Schedule periodical maintenance

6.15.2 Listor record to be kept in service station:
The following record is should be Maintenance commonly caried out during a motor vehicle service include:

1. Changethe engine oil

2 Replace the oil filter

3. Replace the air filter

4. Replace the fuelfiler

5. Replace the cabin or alc filter

6. Replace the spark plugs

1. Check level and refill

bake fuid/clutch fluid

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 Automobile Engineering (MSBTE_Sem-V)
6-25 Motor Vehicle Act, Road Safety and Garage Practices
Pads/Liners,)
s/Liners, Brake Discs/Dnums
Check Brake
and replace
if worn out.
Coolant Hoses
Check
systems
Check the charging
10.
battery
Check the
I1.
Check evel and refill power steering fuid
12.
an refill Automatic/Manual Transmission
k level and
Chock
13. Fluid

Grease and lubricate components

14.

1nrnod and
replace the timing belt or timing
15.
chain if needed

Check condition ofthe tires

16.

17.
Check for proper operauon of all ights, wipers, etc.

Check for any Error codes in the ECU and take corective action.
18

19. Use
scan tool read trouble code.

VEHICLE MAINTENANCE LOoG

TOTAL
MAINTENANCE7n nG0 EAR 2003MAKE Dodge MODELB-3500UCENSE TEXASVIN NO
6100710
unkrow
0810
COsIS 098910091109 12 09 01 t0 02100310 0410 510
Erler Siarung venitaie
Mileage 15C00 21.000

at Mionta 21.000
Ertar Vehicle Mteago- at End
FVALEE PVALIEVALUEWALIE VALLE YALDE
Miontiy Mieage Tolals DO0 ALIE VALLE#VALUE 4VALUEVALUE
Total Mleage for Year
VALUE
Kalrtenance Cost Per
MieVALUE
VEHICLE WAINTENANCE COSTS
SERVICE
YPEOF
Oil& Fiter Change

Cnange s1000
AtFier
Fuel Fier Ghange

ransmission PdFLter
Enghe coolant
Cuoling System FUS
S400.00
r Hepair or Hepladement 2
e Rotabon or Eatanoe
Repacement $50.00
Hause
Brake flepat

nghe1ure Up,
Aligyemént
intd
POwerSrañngfBrake Fuid

COHeater Repai $3.00.0

6place Belts
Elaclncal Rapair
Bathery Repacernant

Batery Cables Terminals

Headighms ar Light Butbs

rdshiei Wiper sade

Wash& War
Miscelaneouis Service
S0080.00 $0.00S0.00 $0.00
ANENANCE COSTSs870.00s0.00$000 0 0

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EAtomobr
nhile
Engineering (MSBTE Sem-VI)
6-27
Motor Vehicle Act, Road Safety and Garage Practices

PrOvision of proper drainage

Prov
system
Samitation

Role And Responsibilities of Service Manager

6161 in service station

mabile service manager is responsible for directing

automobile
and coordinating all activities
An maintcnar of automotive equipments. involved in the acquisiton,
intenance
operationsand
mers and interactwith them to understand
customer
their vehicle problems.
Greet
vehic
yehicle with the technicIan and the customer to
the
Drivedhe gain firsthand knowledge ofthe vehicular
2 roblems,
estimat
mates including the services and repair
Preparethe cost costs and the cost of spare parts, if needed.

sdsin and manage a daily record of repairs and services of vehicles umdertaken and completed.
Mami
4
delivery fvehicles to customers on time.
Ensure
Handle.and manage soflytthe minor complaints and iitants with the customers.

Educate custome
tomers on maintaining their vehicles freefrom troubles and problems.
1.

pervise,
manage andImonitor-automotive service technicians and repairers.
8
needs in a cool, courteous and prompt manner.
a Handle customer inquiries and respond to their

ure10.
cUstomer satisfaction at the highest level
thirough effective šervices and repairs

service station
Role And Responsibilities of Service Supervisor
in
616.2

workers maintaining automobile.

responsibilities by overseeing skilled mechanics and
Performs supervisory
communicates with the superiors and
independently and in harmdhy with the automotive shop foreman and
Supervises
subordinates.
repairs and preventive
implements the smooth flow of general shop
Service supervisor organized the Schedules and
station
maintentance woskload for the service

Duties and Responsibilities of Service Supervisor

back repairs.
between customers and mechanics to eliminate in efficiency and come
L Service Supervisor communicates
repairs on buses and other light motorized equipment;
major and minor mechanical
Assign, supervise and participate in
diagmose diesel internal combustion
engine maintenance problems.
new techniques in mechanical repairs.
for employees with equipment suppliers for
Conduct in-service training programs
and schedule work flow of
and their assignment to personnel; plan, organize
arders
Delerine príoríty of work completion of work.
assigned personnel; assure timely
enployees as assigned; advise and assist
matches vehicles in system,
coordinates with parts person and updates
5.
oEVICe Supervisor ensures that parts
inventory
asinecessary.
maintenance recoris (hard copy
and computer).
EVICe Supervisor maintains preventive
or tools, toof room equipment, maintenance
and safety practices.

Supervisor must have an knowledge of

curent equipment and testers for effcient shop utilization.
ICe Estimat or services ae completed in a timely manner.
Tepair costs and makes sure that parts
10. Service or services are completed in a timely manner.
Ce Supervisor estimates repair costs and makes sure that paris
Supervi

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 Garage Practices
Automobile Engineering (MSBTE Sem-/) 6-28 Motor Vehicle Act, Road Safety and

6.16.3 Role and Responsibilities of Customer Care Manager in service station

at al times. Duies imcfude
CUstomer dervice Managers are responsible for ensuring that customers are satisfied
ot customer
service training staff members to provide the highest standards
Supervising and managing the customer team,
direction to the CUstomer šervices
ensuring that all company policies are folowed. Providing leadership and
Service and
maintained.
of is provided and
Supervisors and their teams to ensure that an excellent standard service
customers and facilitate in growa.
customer service experience, create engaged
lmproving
problems through to resolution.
2. Taking ownership of castomers issues and following
towards that mision.
3. Settinga clear mission and deploying strategies focused

Responsibilities
grown:
and facilitate organic
customer service experience, create engaged customers timescales.
Lmprove confirmations within agreed
quotations, orders and order
lo ensure the accurate processing of customer
focused towards that mission.
3. Set a clear mission and deploy strategies
standards.
4. Develop service procedures, policies and
discussions.
customer service.actions and
3. Keep accurate records and document
reports.
6. Analyse statistics and compile accurate
can excel through
service agents and, nurture an environment where they
mentor and develop customer
.Recruit,
encouragement and empowerment.
efficient service to internal
Services function is adequately staffed and trained to deliver an
8. To ensure that the Customer
and external customers.
active member of the Senior
Management Team.
9. Torepresent the Customer Services function as an
the process of continuous improvement
in Customer Service standards within Caf
10. To actively promote and manage
Enquiries and Order Processing
spirit.
a
11. Create and sustain positive team
evironment displaying high levels of motivation and excellent team

12. Keep ahead of industry's developments and apply

best practices to areas of improvement

13. Control resources and utilise assets to achieve qualitative and quantitative targets.

14. Adhere to and manage the approved budget

15. Maintain an orderly workflow according to priorities

Review Questions

Q.1 Enlist the titles of various chapters of motor vehicle acts 1988.

Q2 Describe salient feature of motor vehicle act 1988.

Q.3 Descrbe salient feature of central motor Act rule 1989.

Q4 State the vehicle safety standard and regulation in india.

Q5 State the factors consider for site selection of service station.

Q6 Describe the role and responsibility of senvice

manager.

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