For semesters % a AutomobilejEngineering jApram Singh Quantum Publications® (A Unit of Quantum Page Pvt. Ltd.) Plot No. 59/2/7, Site - 4, Industrial Area, Sahibabad, Ghaziabad-201 010 Phone : 0120-4160479 Email: pagequantum@gmail.com Website: www.quantumpage.cain Delhi Office : 1/6590, East Rohtas ‘Nagar, Shahdara, Delhi-110032 © Att Ricis Reserve No part of this publication may be reproduced or transmitted, in any form or by any means, without permission, Information contained in this work is derived from sources believed to be reliable. Every efforthas been made to ensure accuracy, however neither the publisher nor the authors {guarantee the accuracy or completeness of any information published herein, and neither the publisher nor the authors shall be responsible for any errors, omissions, or damages arising out of use of this information, Automobile Engineering (ME : Sem-7) 1* Edition : 2011-12 2” Edition : 2012-13 3" Edition : 2013-14 4 Edition : 2014-15 5% Edition : 2015-16 6 Edition : 2016-17 ‘7 Edition : 2017-18 of an automobile, Power and Torque ¢ and gradient resistance. Tractive determination. UNIT-II : TRANSMISSION SYSTEM Requirements. Clutches. Toque converters. sal joint. Differential Automatic transmission, nd wheel camber & Toe-in, Toe-out ete. transfer, Braking ratio, Mechanical brakes, | Vacuum and air brakes, Thermal aspects. Chasis and Suspension System: Loads o type, Parallel arm type, Dead axle “ suspension system, Air suspension & shock abso UNIT-IV: ELECTRICAL & FUEL SUPPLY SYSTEM Electrical System : Types of starting motors, generator & 1 lighting system, Ignition system, Hor, Fuel Supply System: Diesel & Petrol UNIT-V : EMISSION STANDARDS Emission standards and pollution control: automotive vehicles-Bharat I and Il, Euro-1 fuel quality standards, ‘maintenance and over hauling, VERY SHORT ANSWER TYPE |transportation of passengers. ‘Main Components of an. Frame, ‘Suspension system, Axles, Wheels, Steering system, and n of Main Components Characteristics A. Concept Outline : Part-1 __B.Long and Medium Answer Type Questions - 23B 23B An automobile is a self-propelled transportation of passengers and goods ae AE) B ‘4. Stoam carriages— Steam road rollers 5. Gasvehicles — CNG vehicles, Namber of Wheels: __ 1. Twowhecler — Mopeds, scooters, motorcycles, ee, ' ete Four whecler—Cars,jeops, buses, tractors, ete. & Drive of the Vehicles ; 1. Single whee! drive vehicle, 2 Two wheel drive vehicle, 3. Fourwheel drive vehicle, and 4. Sixwheel drive vehicle, BRBRAY exptain what are tho major components of an automobile? 1 Engine : It produces power to move the vehicle. hog Power Train : It is used to transmit the power from the engine to the drive wheels, ‘Suspension System the shock on the tyres caused by Siac ‘Steering System : To control the direction of vehicle. ‘Braking System : To slow and stop the vehicle. ‘System : For powering the light, charging of battery and jequipments. In front wheel drive, there is 5 % to the front and 25% braking force distribution2)A. Valve Timing Diagram for a Four Stroke Diesel Engine : 1. Inlet valve opens 10° to 25° in advance of the top dead centre, and closes 25° to 50” after the bottom dead centre as shown in Fig. 1.6.1 Compression A Pree e eee QUueTA] List out the main parts of an continues upto 15° to 25° after ‘upon the speed of the engine. Valve Timing Diagram for 2-8 8 lain with neat sketches any two ‘The Main Parts of An, Cylinder block and Crank case, Cylinder head, ‘Sump or oil span, Manifolds, Gasket, Cylinder, Pistons, Piston rings,11. Crankshan, ‘Main bearings, Valves and valve actuating mechanism, and evlindrical in shape and forms the movable portion of the combustion chamber. ‘The gas pressure acts on the head of the piston which is also called crown, ‘The force duc to this pressure is transmitted to the connecting rod via the piston. ‘The connecting rod helps to change the reciprocating motion of piston into a revolving motion at the crank shaft Following are the functions of piston : 4. Totransmit the force of explosion to the erank shat. b. To form a seal, so that the high pressure gases in the combustion chamber do not escape into the crank case. ¢. It serves as a heat transfer medium to the cylinder walls. d_ It acts as.a guide to the small end of the connecting rod. Head of piston or crown ook Ee: Supporti ouarsin isp sate ea Lamp ae l ee Fig 17a. Piston Ring: ‘The construction of piston ring and nomenclature ofits various parts is shown in Fig. 1.7.2. a ng is generally casted individually and machined carefully so the see exer union pressure agit the linder wall Following are the funetions of piston 8, To form a seal for the high pressure gase chamber against leak into the crank ease. b, Toprovide easy passage for heat flow: cylinder walls . Tomaintain sufficient lubricating oilon ey the entire length of the piston travel. ‘Guat | Describe diterent penal piston differ from 4-stroke piston of a vehicle? ‘The pistons are sometimes tured taper, the smaller in diameter than the skirt end. As higher temperatures oceur| ‘more than the skirt, due to which ‘uniform under running conditions. ‘The pistons are eam ground : instead of the usual circular one.‘Special Alloys Pistons : 1. Special alloys having low coefficient of ex; l : expansion coefisint of expansion is nearly equal to that fo cet been used in the manufacture of pistons, without elite shaped skirts and giving no piston slap. Pit OF specially Wire Wound Pistons : 1. Aband of steel wire under initial te \ . sion i Pin and the oil control ring, thus restricting ieee Which is of split type or eam ground type.” P&PSiOn of kit Autothermie Pistons : 1. These pistons contain | i c low expansion steel inserted a the piston gin 2, These inserts are so mol These inserts are so molded that their ends are anchored inthe 3. Athigher temperatures during 2 i 8 running the bimetallic actio inserts causes them to bend outward: thes manne erton atte expand lng th pater ae ras ung in eee is corresponding contraction of the piston due to Bi-metal Pistons : 1. These pistons are made from both steel and aluminium. 2, ‘The skirt is formed by steel and the aluminium alloy cast insideit forms piston head and piston pin bosses. 8. As the evefficient of thermal expansion for steel is quite small, the piston will not expand much and hence smaller cold clearances can. be maintained. Some other types of pistons are : Pistons with Inserted Ring Carrier: Lo avoid the corrosive action on the piston rings the special ring inserts made from austenitic form of cast iron have been used, ‘which resist the corrosive action of the acids product. 2. As the co-efficient of thermal expansion of austenitic iron sof aluminium alloy are nearly the same, the ring insert does not wor loose. Cast Steel Pistons :The pistons cast from alloy stool containing silicon and copper wil plating have been found tobe highly wetr and heat resis Pistons: | i pnedized: es of pistons. The anodizing ‘and resulting coating is darkdrilled passages. |: Refer Q. 1.8, Page 13B, Unit-1. ‘What are the main components of an internal engine ? Give their material of construction and their A. Cylinder Blocks. 1. The basic framework of the engine is formed by the cylinder block. 2 ‘It houses the engine cylinders, which serve the pistons reciprocating in them. 8. Cylinder block also carries lubrication oilto various components through ‘Materials: Alloy cast iron, aluminium alloy. functions of a piston : Refer Q. 1.7, Page 118, UPTU 2012-13, Marics 05] Cylinder Block position Introduction, | bearings and guides for ‘The cylinder head gasket is used Ithas a heat proof material to co Materials : Copper fillings or asbestosis fi two thin copper or steel sheets, ‘The part of the cylinder block which houses crankshaft and the camshaft is termed as: Materials: Cast iron, aluminium. Engine Sump: It is used to store lubricating oil and vehicle is in motion, 1t aio collects grit and dit atthe lowest poe # Materials : Pressed sheet steel.‘The connecting rod acts as a link between the piston and the Tt converts the reciprocating motion of the piston into a rot Materials : High grade alloy steel and drop-forged steel. crank yi, be kot now whe desing an ‘Wat considerations are Bea ry 1 Safety of an automobts eae gaan i Firstly, the design should be such Fig. 1.10.6 Connecting rod. happening eresnaaiaay ji, Secondary, ifthe accident does: H. Engine Valves: should be minimum. 1 Bvery eylinder of a four-stroke engine has two valves: the intake and Hence, the exhaust. 2. Materials: Inlet valve ~Nickel chromium alloy steel Smallend Big end bearing _ bearing a. Preventive design. b. Designing for minimum injury in Exhanst valve — Silicon chromium alloy steel. Preventive Design: ‘There should be largest possible caused by body pillars. This will parking and whei driving in heavy traf i ‘The instrument panel should be d Stem able to read all meters and see al ‘The controls should be located Spring retainer lock groove that he feels minimum fatigue, By providing air circulation the minimised. | ‘camshaft changes the rotary motion of the crankshaft into ‘motion at the valve. ike lubricating gear pump, distribut p and compressor. iron, alloy steel.of spilled fuel and consequent fire in case of «should be suitably located. accidents it is very important that the doors stay py ithe car comes to rest, because if the door opens the: ‘thrown out and being killed are increased. hanes yr of the cars should be suitably upholstered with ad ‘to protect the occupants from impact injuries. — Various switches, controls, ete. should be shaped that they are ny ares excessively s0 as to cause injury to the occupants at te oe Explain power and torque characteristics. 1. Performance of an engine can be described in terms of torque, power (P) orhorse power (hp), efficiency, pick-up (acceleration), gradeabilty and power to weight (P/W) ratio etc. ‘Torque (T) and Horse power (P) Power and jue characteristics can be ase frec carve between power and engine speed, and torque and "engine speed. Power developed in the engine varies with change in engine: ‘speed as “shown in Fig. 1.12.1. " Torque developed by an engine changes with a change in engine speed: ie greater torque is applied. speed, maximum torque is produced. Engine performance presentation of an engine ‘They are constructed the engine and are ‘one engine with that of another. 0: BMEP. 60: 50 40 30 20 10 Brake horse power Fig. 1418.1. Performance curve, Jn comparison to petra engine, the speeds of 0 engines are slower due to heavy m valve gear, connecting rod and piston combustion process._Inease of Cl engine, peak of brake horse power is not reacheg lative speed is limited on account of their heavier rest” | _asosyiilein case of petrol engine; the brake horsepower ere 5, Incomparison to petrol engine, the torque for the diesel e is more flexible over a wider speed 1: etl Praia sroctiod i RSEHIE] way meximum power and maximum ore gy produced at the same r.p.m. in an engine ? [TPR noT ag ‘There is a certain speed, within the speed range of a particular engine, ‘st which the charge inducted per cylinder per cycle will be maximam 2. Atthis point, the maximum force is exerted on the piston. $8. The torque, or engine capacity to do work, will also be maximum at this point, 4. Thus, thereis a particular engine speed at which the charge per cylinder Per yele is maximum and approximately at this speed, the torque ofthe ‘engine will be maximum. i ee i | i : ‘ A i Engine speed (r.p.m.) Fig. 1141. 5. Asthe speed of the engine is increased, above this speed, the quantity of the indicated charge will decrease. ‘6 However, the power output of the engine increases with speed because ‘more number of cycles are executed per unit time. be noted that the air consumption will continue to increase ‘engine speed until some point is reached where the ‘cylinder per stroke decreases very rapidly than the number _ ‘unit time is increasing. i that the maximum air consumption point is not ‘operating speed of the engine, In fact the indicated power pre proportional to the Rolling Restetance Tt ocsus dunia {yre and dissipation of energy trough impact Frictional Resistance It inelodes amie Tractive Effort : The sum of the resistances, ie.,: sradient resistance, fictional resistance, aad Known asthe tractive reset Gear Ratio : It is the ratio of speed of driven ‘WESTIE ] Discuss al types of autovehicle during its operation depend.: A. Factors on which rolling resistance depend : : 1, Material ofthe road surface (Cemented, asphalted ete, 2 Quality of the road surface (Wet, dry or rough ete,), 8. Design and material of the tyres, and 4, Inflation in tyre. B. Factors on which gradient resistance depend : 1. Slope of the road, and | 2. Mass of the vehicle. | Answer ‘Que 1.17. | Name various types of moving vehicle. How can these Factors on which air resistance depend : A. Types of Resistance: Refer Q.1.15, Page 23 Rea vchiAeepeed, Wich the ale Road gradient resistance depends: ofthe vehicle. 1. Need of constant speed, ‘ [Air resistance depends upon the speed: 2 Rate of acceleration, the vehicle, speed of air and direction of 3. Driving habits, and of the vehicle's motion. 4. Frictional resistance. Air resistance canbe minimised by designing — ‘ound shape. This generally involves smoath ‘Que 1.16. | What types of resistance are offered by a vehicle? Explain veo / Que 18] Name different resistances with diagram. UPTO GOTS 1G MAPEEIG] 15h, plain any two of ¢ OR ‘Answer Briefly explain the variation of resistance ‘Types of Resistance Offered : Refer Q.1.15, Page 23B, Unit-L the various speeds and total resistance to’ Nex Motion ‘Answer Different Types of Resistances : 4. Rolling Resistance 1, It occurs due to the iz Fan wae N, sat ‘ Fig. 1.16. W = Weight of vehicle (force), IN, = Reaction (force), Py, = Rolling resistance (force), Fu, = Aerodynamic dra (force),Frictional Resistance : wee Itis given by, R= 132.5 +50.5m Road Gradient Resistance : Due to slope of the road and weight of the vehicle, resistance is higher. R, vo mg sin® Mass of the vehicle, and = Slope of the road Air Resistance: Air resistance varies as the square of the speed. It is given as wee Rix Av ‘efficient of air resistance, v= Specd Ga an) TRRTABT ow wittyou nd the tract avehicle ? OR Write short notes on the following : a. Tractive effort, b. Gradeability of a car, and © Taxable horse power of a vehicle. a. ‘Tractive Effort : Frictional resistance includes resistance due to transmission losses, Toad gradient effort required for moving A = Projected frontal area of the vehicle (in m*), and | 1. The sum of the resistances (i-., air resistance, road gradient resistance, frictional resistance and rolling resistance) is known as the tractive resistance or tractive effort and is denoted by R,- 2. Thisis considered at the axle of the vehicle. 3 Ry =R,+R,+R, +R, +R where, EE = Rolling resistance, R R,__= Acceleration resistance. 4. Work required to be done at the axle is, WeR,xV N-kmhr. ‘ R,xVx1000 = WattA. Tractive Effort : Refer Q. 1.19, Page 268, Unit-1 B. Traction : 1. _Ikisthe ability of the rear wheels to transmit the tractive effort without ne 2. P,=KAv" (For the same flowing direction of the wind) where K = The coefficient depending upon the amount of streamlining effect on the car's exterior, A= The projected area in square metres, and v= The speed of the vehicle in km/hr. 3. The tractive resistance is expressed as Gradient resistance + Rolling resistance + Air resistance. C. Effects on the performance of an automobil 1 Thehorse power available at the engine flywheel is about 85 % due to loss of power in piston bearings and gears of the engine due to friction, 2 Thereis a further loss of 10 to 15 % due to transmission lines, i-e., ty=34.3~34 teeth tg = 0.72 x 34 = 24.48 ~25 teeth FRETS] wat do you know shout an epieytic gearbox? Hay the overdrive can be obtained in an epicyclic gear box ? Explain wrth eat sketch A. Epieyclic Gear Box: | ieyelie consists of two or more epicyclic gear se {pbtomobile ? Explain the working of synchronizer Seed. 1. Anepicyelic gear box consists of t epicysticgearset,, eum a ‘They have generally planetary arrangement in overdrives and automate | ~~ pj } transmission of automobiles. _ i AnoulusA 5 Describe the working of a synchromesh gear box with the! | sketch. What are its merits and demerits ? V on Zh wow “Describe the working of a synchromesh gear box with the Driving ele Vee A. Necessity of a Synchromesh Gear Box: (Figi1S1-1. Bpicyelic gear box. 1. _Inconstant mesh gear box there is a phenomenon of B. Construction : involved which creates jerk until the speed of lay haf ‘A simple planetary gear box has a sun gear S, a planet gear Pan) not maich. : internal gear A and an arm. 2, To remove this problem of matching of speed, we 2, The internal gear is called annulus gear and arm is known as link: synchromesh which is used in synchromesh gear box. 8. A yoke houses the planet gears in which sun gear is placed cata 'B. Working of Synchronizer : driving shaft while the annulus gear on driven shaft, sun gear 1, Asynchronizer consists of mainly three parts: driving gear and annulus gears are driven gears. a kee rae ‘To Obtain Overdrive i internal % aoe taen cis ia achieved by holding the sun gear and driving Me b, Male (M) and female (F) synchromesh carrier which causes the pinion gears to move around tp ‘Twothed dogs A and B. zed than the input i = Stationary sun gear and ring gear at a faster spetInternal teeth, ‘on ring ia ‘free on shaft Input shaft Output shat Entiro in Lay JA rotates with shah output shaft ‘Toothed dogs @ rg — Selector Ball Splines ® ©) Fig. 1.82.1. Working of synchronizing assembly : (a) Disengaged cones + dogs, (b) Engaged cones but disengaged dogs, and (c) Engaged cones ee dogs, on moving a selector. 2. Ring rotates with the output shaft and can also be slided along the splines cut on this shaft. 3. Thering is maintained normally by spring loaded balls. 4, Fig 1.32.l(a) shows a disengaged position as there is no meshing! ‘the male (M) and female (F) synchromesh cone and no meshing beh the toothed dogs A and B. 5. The input shaft, lay shaft and gears are running free. § 6. _Ifselector moves in a particular direction as shown in Fig. 132.10) ‘male (M) and female (F) synchromesh cones meshes with each Y ‘and the friction between them either speeds-up or slows-down the E, with respect to output shaft. 7. Now f'selector moves forward in this direction tl Boverrides by overcoming spring-loaded balls, and tht locked to the output shaft. 8, This situation is called gear engagement. ‘They are very sensitive to amount of ch Que 139. | Make comparison synchromesh gear box. ‘The operation of constant, mesh gear box is based on double declutching phenomenon. ‘This is an improvement over sliding mesh gear box. ‘There will be clashing and damaging of dog clutches during their operation. ‘These gear boxes produce more noise as compared to synchromesh gear box. Constant mesh gear box is cheap.©The compound gear train is preferred over the sim, jin manual gear box because : ple 1, Simple gear train has non-compact arrangement, 2 Dueto use of many gears in a compound gear box we ¢ _ range of speed by meshing different sets of gear, / 4. Higher gear ratio can be achieved easily in compound gear tr f ©©© A. Concept Outline : Parted mm B. Long and Medium Answer Type A, Concept Outline : Part-2 ~ B. Long and Medium Answer TypePART-1 Transmission System Requirements, Clutches, Torque Converters, Over Drive, Universal Joint, Differential Gear Mechanism of Rear Axle. CONCEPT OUTLINE: PART-1 ‘Transmission System : Iti the system by means of which power developed by th engines transnlted tote road wel to roel ie Clutch :1t isa mechaniam by means of which engine is connected or disconnected from the restof transmission ‘a Torque Converter : It is a kind of hydraulic transmission which increases torque while reducing speed Universal Joint : I is the joint which enables the drive shat to transmit power at varied angles Differential Gear Mechanism : Its the mechanism by means of which outer wheels run faster than the inner wheels taking tuon Questions-Answers ad Long Answer Type and Medium Answer Type Questions | Que 21, | Define a transmi system classified ? Answer] 1, Transmission system is the system by means of which power develope by the engine is transmitted to the road wheels to propel the vehicle 2. Typeoftransmission systems a. Blectrical and electromagnetic transmission system. b. Hydraulictransmission system, © Mechanical transmission system, 3, Electric transmissions have been used for motor vehicles but nowada they have become obsolete, 4, Hydraulic transmissions are now becoming common in the shape fluid coupling, torque converter, automatic transmission etc ‘Mechanical transmissions can be divided into the following classes: a, Cluteh, gearbox and live axle transmission, ion system. How is transmission ‘The Transmission Should Fulfil th 18 must provide a means ofeonnection and dis the rest of powertrain without I must provide a varied leverage wheels, 4 must provide a means to transfer power in It must enable the power to he transmitted at: lengths must enable speed reduction between: the ratio af about §to 1 Il must enable the power low tobe diverted: [i must provide a means to drive the driving when needed It must bear the effects of torque reaction, effort effectively. The Requirements are Fulfilled by the the Transmission System : Clutch : It provides a smooth means ofd between the engine and the remainder of Gear Box : It provides varied leverage tothe d ‘Transfer Case : It helps in diverting direction Propeller Shaft and Universal Joints: Propeller shaft enables the drive wheels t due toflexing of road springs:& Torque Tube : In torque tube drive, all the driving thrust, ‘effort and torque reactions are taken by the torque tube. hh. Road Wheels : The road wheels provide last leverage to the Power to act as tractive effort at them. More the diameter of ‘wheel, more the leverage it would provide. PERBRRE ni need ota tech in an ontomosite? is orktng at esutisgal cies, te What is the need of a clutch in the transmi sion system ? W, eee on What are the basic requirements of an automatic clutch ? = these fulfilled in a diaphragm clutch ? Answer ] A. Need of a Clutch in Transmission System (or in Automobile); 1. Clutch is @ mechanism, located between the engine flywheel and ge box. This mechanism couples and uncouples the manta transmis and the engine 2, When driver presses the clutch pedal, no engine power ean flow throug ‘the transmission, when driver releases the clutch pedal, the clu ‘engages, and power flows through the transmission. 8. The clutch has following four functions : a. It can be disengaged to permit the engine to run freely withed delivering power to the transmission. b, During the disengaged position, driver is free to select a propel gear for the operating condition . During the engagement, the clutch slips momentarily and provid O) socth cogagementand minimum shockon gears andother dd train parts @ After the engagement, clutch transmits power from the engine the transmission. Basic Requirements of a Good Clutch (or an Automatic Clutehl! During reengaged position, clutch should take on the power ‘smoothly without undesired jerks. This increases feof the clutch nm (Clutch disengagement should be easy to avoid erratic running. ‘Size of clutch should be optimum for an engine. ‘The clutch should have low inertia moving parts to avoid hard shifting which may result in damage of gear, Adlutch should be able to transmit 100% torque produced at the erank shaft to the gear box ie., the clutch should not: slip ‘engagement. oe 2 BEE generally four-wheelers, In centrifugal cluteb, t used between the pressure 3. These clutch automatically 600 r-p.m. Cluteh plates5, During acceleration the weight tends to move outwards, the inereasy ns i , the inereas centrifugal force on the pivoted levers bring the pressure and ffir Plates together by overcoming the stiff spring pressure 6. Daring lower speeds (speed below 1000 r.p.m) there is some slip but Yanishes at higher speeds due to centrifugal effect, ie, fall engial torques transmitted without any slip, D. Working of Diaphragm Spring Type Clutch : 1. Diaphragm spring type clutch is similar to helical spring type cluteh its working. The only difference between them is the helical springs Release levers in helical spring type clutch are replaced by a singly diaphragm spring. 2 The pressure plate E can move axially, butt is fixed radially wth resp to the cover. 3. The diaphragm spring is supported through a fulcrum, 4. The drive from the engine flywheel is transmitted through the cov Pressure plate, and the friction plate to the gear box input shaft, 5. On pressing the clutch pedal, (ie., disengaging the clutch) the pr actuates by means of a release ring. | 6. It pivots the spring about its fulcrum, relieving the spring load on tht outside diameter thereby disconnecting the drive. A, Cover B. Diaphragm C. Clutch plate D. Retaining ring E, Pressure plate F. Release ring ‘The quality of the facings and the determine the smoothness or otherwise inturn-vehicle operation, It is important that individual If the pressure springs do not have au ‘matched, then only a portion of the p the driven plate, which will result in ‘may cause clutch shudder. Hence, itis important that pressure springs: ‘complete set, never individually. : ‘The total pressure requirement ofthe fr the engine torque tobe transmitted. It that, when changing pressure springs, specifications, 1t is important that the release levers: ‘minimum ran out in order lever movement by censure that there isLoe ‘Trans 3 The fir evenly. 4. Most ofthe engines are designed to avoid firing two cylinders, one ater che other, at the same end of the crank shaft. Firing Orders for Different Engines For In-line Four Cylinder Engine : The firing order is 1-3-4-2and1-2~4-3. For Inline Six Cylinder Engine: The firing order is : 1-5-3-6-2-4 For a Chrysler V—6 and two General Motors V —6 engines (GM 90° V6 and GM 60° V—6) the firing order is 1-2-3-4-5-6 3, ForFord V~6 engines, the firing order is 1-4-2-5-3-6and1-4~2-3-5-6 © For Inline Eight Cylinder Engines : 1. The firing order for Chrysler and General Motors V~8engine is 1-8-4-3-6-5-7-2 2. The firing order for Ford V8 engine is ion System order distributes the power strokes along the crank shaq ee wp 1-5-4-2-6-3-7-8and1-3-7-2-6-5-4-8 Bring i Lett i in multiplate elu friction om Bank Pine hak of pat ees ea splines on the pressure plate hub: 5 1 plines on the p ~ LO hy Alternate plates belong to each set. a: Ca- + 3h 3. To keep the clutch in engaged position, some: ri 6 (oho rs) the circumference to provide axial foree. ‘The friction plate is mounted on a hub whi a? Cy 7 3] | free to slide over the gear box shaft. ri}: : Fig. 25.1. Que 2.6. | What type of clutch is used in case of motorcycles?Pree Horaue converter is a type torque while reducing speed. of hydraulic transmission which increases Higrovides a continuous variation of gear ratio from the lowest to highest, _ A torque converter consists ‘of the & Driving element or impeller b. Driven element or rotor, and © Fixed element or reaction member, ‘lowing three principal components, Turbine shat WTS Driving Element or Impeller : : It's also known as driving torus and connected to engine's flywheel. Tt acts asa pump. Driven Element or Rotor ; It is a sort of turbine which is connected to propeller shaft,Driven member (Runner) Baththe members have pockets in their facings and ha cach other. wae Both members are fixed on their respective shafts and having a elearance between them, ‘The members are kept in an oil tight housing which keeps i certain level. 7 filler plug Driver Runner Engine shat ae Bearing = Gear box shaft Bearing Casing a v Fig. 2.8.1. Fluid fywheel Drain plug : : The driving member or impeller begins to move inside the housing | containing oil, as engine starts. ! The pockets of the moving driving member are filled with oil and the | centrifugal force causes the ol tobe forced outward radially. ‘The design of the pocket is made such that the splashed oil strikes the vanes of the driven member and it is forced to move along in the same direction. AAs the engine speed increases, the thrown out oil from the pockets of the driving member strikes the pockets of the driven member or runnet ‘with greater force and tends the driven member to rotate at the | ‘speed, becoming one unit by means of ol film which combines both ‘members. ‘As the engine speed slows down, the ol film between the members its driving and driven members) is broken away and the members disengaged60 (ME-7) B ‘Transmission 8 Tho vehicle is thus put into the overdrive B. Coming Out of the Overdrive : 1 Bypresoing the accelerator pedal beyond the wide open ‘a kick-down switch below the accelerator pedal, which de. Solenoid and also cuts off the engine ignition momentarily. Due to cut off the ignition, engine slows down, taking the load off the pawl and deenergisation causes the paw! to retreat freeing the fun gear. ‘The retreat of the pawl, however, causes the ignition circuit tog the vehicleis thus put into direct drive. ‘This cutting off the ignition is momentarily, hence does not smooth running of the engine. a Que 212, | With the help of suitable sketches, describe the. UPTU 2012-13, 2 x 4. of universal joint. oR What is the function of universal joint ? “Answer Universal Joint : It isthe joint used to transmit power at varied angles from: al ‘The propeller shaft is never in-line with the engine crank shaft.So drive shaft is subject to transmit power at an angle. | 3, This angle is never uniform as it varies when the road wheels mave® ‘and down due to road irregularities and the frame moves up and in relation to wheels, depending on the amount of weight in body. ‘The universal joint provides the ability to the shaft to work vivid angles. List its usage in vehicle ‘UPTU 2014-15, Ma A it 2, ‘Que 2.13. | Explain the also explain its necessity in. b, At the joint the propeller shaft Describe the differential gear: ‘Answer A. Need of Differential Assembly : 1. Differential assembly is located in b axles. : 2. Ibis necessary in an autovehiele sit It avoids skidding of rear wheds Ona curved path, it reduces thep the speed of outer wheels 1. On a straight road it maintains uniform wheels Iteliminates a single rigid rear axle, between two rear axles. ‘The necessity of differential Fig. 213.1Ry>R AB > CD ‘Hence ‘This arises following two problems : . Theouter wheel wll exhibit tendency ofg fh The inner wheel will be pressing hard on they, i ji ties there is a qo avoid these difficulties need of di place of single rigid axle ifere B, Construction : Ny fz Power from propeller shaft ‘This resultsin speedot aT by the same proportion asthe S [-—« Cage o carrier For outer wheels, Torque: ‘ Bush = Cross pin Connected to Connected eft wheel hub wheel hab Splines pet z 9. Here 3.5 Slip angles of rear wheels Oversteer: ‘Slip angles of front wheels < Ship angles of rear wheelsTre Sytem ‘The drive to the ring gear ofthe second gear train is then taken the planet carrier ofthe ist train ao that the two actin sorieg 10. ‘This arrangement provides three forward and one reverse speeds - Direct Gear : By engaging clutch A, we obtain direct gear, . Second Gear: By engaging catch B, and api F ae engaging clut and applying brake BS, we obtain Cc First Gear : By applying both brakes BS and BF, we obtain first or low : pa ! D Reverse Gear : By applying brake BR only, we obtain reverse gear, NN ee eer ee ee tystem (Wilec's goar box) A. Wilson Gear Box : 2, — = _= 1. The gear box consists of a number of simple epicyclic gear sets compounded together. 2 Inthe Fig. 2.17.1 the notations areas follows 4 denotes an input shaft connected directly tthe engine crank b. Reenotes the output shaft coupled with the propeller shaft through € Cisthemultiplate clutch. 4 1,2,Sand4are four epicyelic goar trains which are interconnected 8, The mechanism of Wilson gear box is given as follows : 3 B. Direct Gear: By locking, toby applying the clutch C, we get aslid drive and direct gears obtained, x ‘The sun gear S, is already fixed to the ALA babies in ed Firat Gear : Apply the brake By to obtain fist gear, Reverse Gear : Apply the brake 8, which holds ther and obtain the reverse gemel roverso automatic geared transmission witha ‘The hydramatic transmission is termed as the ‘transmission y In this transmission, there is no clutch pedal.3. {At the ends there will be torsional loads hence circular action is used at the seca oat” 8 Wheels Kine via Spring. C. Stub Axle: 1 Stub axle isan intermediate shaft between the road and the front axle. é. Gor end of stub axl is connected to the axle beam by means of aking Pin ora bal joint while on other end, the front wheel ie mountod & The stub axles are available indifferent shapes and their comnectionsto the axle beam are in different styles. ‘4 Mis stub axles can be one ofthe following types, depending upon the ‘shapes and styles of connection ; ‘% Eliot type and reversed Elliot type, b Lamoine type and reversed Lamoine type, and © Ball Joint Connection type.a Jr camber goes negative when the tyr hits a bump and moves up, ‘4 Itgoes positive when the tyre drops into ahole in the road ‘This is due ‘unequal-length control arms of the suspension system, 5. Camber is a tyre wear angle. 6 Any camber either positive o negative can cause uneven and rapid: wear. 7 Tilting the wheel puts more load and wear on one side of the thread 8. Incorrect camber at both wheels can cause hard and unstable steering. and wander. © Caster: 1. Caster is the tilt of the steering axis towards the front or rear of the vehicle 2. Ifthe tilt is towards the front, the wheel has negative caster. 3. Arearward tilt provides positive caster. 4. Caster is measured in degrees, 5. Caster is used for following three reasons i Tomaintain directional stability and control, ii, Toincrease steering returnability, and iii, To reduce steering effort. 6. Positive castor tends to make the front wheels Toe-in and negative caster tends to make the wheels Toe-out. Tire center line Camber angle Steering-axisDirectional stability isthe tendency toturninto the wind, Most, but not all ears are directionally unstable, ie. when pi the wind they wil end to turn more tans # when Printed ou This phenomenon bee: ymes at his 3] is rutin hha Sees MEM ere dma ge ieee as aici eee c. Caster,and | it Factor Explanation : Refer Q. 2.23, Page 72B, Unit-2. BBE] state principle and derive equation for correct steering a vehicle. Draw Ackermanns steering mechanism and eepag wheel lock and steering lock angles. _ [UPTU 019-13, Marka oR / Explain the Ackermann steering mechanism with a neat sketch, _ [GPrU anise waa] Pa | A. Principle of Ackermann Steering: Outer wheel sca Was 1 ‘Ackermann steering med whose link AC is kept fixed. ‘The joints A, C, E and F are the equal lengths but links AC and BP ‘The links AP and CE have equal: axis ofthe vehicle. Consider a vehicle having : a = Tength of wheel base, w = track width, For right turn of wheels, 0> 9 Prominent ote equation (226.1) is satisfied at least ‘Vehicle while moving straight, Vehicle while turning right at a corresponding to the equation (2.26.0), ‘Vehicle while turning point @).turn nf: 2.26.2 shows a right front wheel in strai Positions by locations S, Land R rempectivet rome ight 3. From the Fig. 2.26.2, we see that it turns by an angle, when steered to ight side but during the left side steering tia only So wheel lock angle = 0 +4 4. For Ackermann steering, wheel lock angle = 23° + 20° = 49° C. Steering Lock Angle: 1. Steering lock angle is defined by the maximum turning of the front left and front right wheels with respect tothe straight position of the vehicle. . Steering lock angle easy 2 During leftward steering the left wheel can turn to a maximum of @ angle, and same for the right wheel during rightward steering. 3. Thus, two front wheels will be locked when they turn by 0 + 0 angles. 4, Thus, the steering lock angle = 0 + 0 = 20 5. For Ackermann steering, steering lock angle = 2 x 23° = 46°, TRGBRT] Write « short note on cornering force, understeer and ‘The ‘through which the wheel [sald he sipenglend tee pac aa to the plane of the wheel) which counters | cornering fore.For rear wheel drive, account of sharing of drive ‘Tyre type and pressure, oversteer and understeer, Active Factors : Entering the corner too fast In powerful engine, if pedal is pre ‘motion of the drag link. tassists in multiplying are eo reIdler arm Frame Steering shaft }+ Steering wheel Pig. 2861; Recireilating ball stecring system. 1. This steering gear is used in trucks and large cars, 2 Its construction is shown in the Fig, 2.28.1 8. Tthas a sector gear on the inner end of output shaft. 4. This output shaft is known as sector shaft or pitman 5. The tecth on the sector gear mesh with the tecth ofa ball nut. 6 It rides on the worm or worm gear that connects to the end of the steering shaft. Balls roll in grooves inside the ball nut and in the worm ii, Working: 1. When the steering shaft rotates, the worm forces the balls to rollin the grooves. 2 The rolling balls force the ball nut to move up or down the worm. 8, Movement of ball nut forces the pitman arm shaft to turn, ‘4. This swings the pitman arm which forces the steering linkage to pivot the wheels for steering. PRERBRBT] Weite a short note om steering ratio, 1. Steering ratio is a mechanical advantage of the steering gears. 2 Ttequals to ratio of output force to the input force applied to a steering gear system, 3. nother words, steering ratio is the number of degrees that the steering ‘wheel must turn to pivot the front wheels one degree. 4. Higher the steering ratio, the easier itis to steer. 5. Ifthe steering ratio is 24: 1, it means, the driver must turn the steering wheel 24 degrees to pivot the front wheels 1 degree. 1inkages both 3. ‘The value of OSR is about 20% more than the SGR, ‘SGR is defined as “angle turned OSR is defined as “angle turned by the steering wheel to the corresponding angle turned by the front road wheele™ ‘QueBSi. | Describe about the power steering and its types, also ive its construction, A. Power Steering: 1. Power steering uses hydraulic power forits working operation © 2. ‘This hydraulic system in power steering operates by oil under pressure, 3. Generally the ol of viscosity ratings SAE 5 W to 15 Wat 1 MPa pressure intensityis used. 4. Following are different types of power steering: A) Integral type used on cars: i Reaction control valve type, and ‘i, Rotary spoolvalve type. . Semi integral type used for trucks and heavy vehicles, Linkage booster type used onar, and d.__ Speed responding type used on car. B. 1 Construction : ‘The construction of linkage booster type power Fig. 2311. 2. As the steering wheel turns, worm I tums sector ‘and arm 5, which turns the wheels by drag link 6 3. Ir the resistance offered to the turn of the wheels cil (or compressed ar) into booster 4. ‘The piston will move in eylinder rack 4, a toothed sector, arm:When the steering wheel is turned in other direction, turned appropriately in the same sense, r Fig. 2.31.1. Steering ‘gear booster in a typical power qh power stering is used i ight, medium and heavy vhlceaty the following advantages b. a e. Lesser steering effort, Reduced driver fatigue, Effiion shock absorption, Better directional stability, and Higher performance and safety. Que 2.32. | Discuss the working of power steering with neat a OR With the help of a suitable sketch describe the working of any om type of steering systein used in a modern passenger car, | Working of Power Steering : 1. Power steering utilizes engine power as steering effort. Control valve position all he Md wil em ps en Fel port and ack othe pons At this time, no pressure is created and the pressure piston is equal on both sides ce, the piston will, . When turning : ‘As the steering main shaft is turned in. ‘The other passage then opens wider, causing: and at the same time pressure is ereated.General Requirements Road-Tyre Adhesion, and Weight Transfer Braking Ratio, and Types of Brakes Thermal Aspects A. Concept Outline : Part] cu. B. Long and Medium Answer Type Questions... Part-2 Loads on the Frame Strength and Stiffness Types of Suspension System A. Concept Outline : Part-2 ...... ee | B.Long and Medium Answer Type Questions... 3 86 (ME-7) B CONCEPT OUTLINE : PART-1. Brakes : These are the mechanieal friction to stop the vehicle. The a. Mechanical baking system, Hydraulic braking system, «, Pheumaticbraking system, and 4. Blectreal braking system. ‘Thermal Aspects : Braking of the vehicle generates enormous amount of heat due to friction,(ME-7) B Braking System, Chassis and Suspension S 2 This heat is heat is generated by the friction between the brake lining. 3 re The heat generated is dissipated into the surrounding air. 3. Brakes must have i 7 have fod ante characteristic, Cosig ofthe braken be eaupped witheffiientcolingspnane, neon nem Classity different types of brakes. . UPTU 2013-13, Marks A. Classification of Brakes : 1. On the Basis of Purpose : Primary or Servi: the moreeraerrice Operational Brakes Used tosto or sow down b. Parking Brakes : In emergency; to hold the vehicle on the slope. 2 On the Basis of Location : & Wheel Brakes: Brakes are located within the whee-yr assembly, b. Transmission Brakes : Brakes are located in is Tranemision he transmission system & On the Basis of Driver’s Ergonomics : 8. Foot Brakes : These brakes are operated by the foot of driver, 1b, Hand Brakes : These are hand controlled brakes, 4 On the Basis of Actuating Method : & Mechanical Brakes : Brakes are actuated by means of fj consisting of rods, levers and/or wire cables. a b. Hydraulic Brakes : Brakes are actuated by means of pressurized brake oil. Fs Pneumatic Brakes : The braking medium Wed in thse bape, ‘compressed air. é Electric Brakes : The braking is done by the use of battery curreny 1, "operate an electromagnet. : © On the Basis of Construction : + Drum brakes have mis Se cheno mil ee Band Brakes : Band br (On the Basis of Applicat ‘Manual Brakes : They driver without any other Servo and Power Brakes : Servo | combination of vacuum and hy ‘On the Basis of Action of Brake Shoes : Internal expanding brakes, and External contracting brakes. adhesion ? 1. Adhesion stands for maintaining the contact ‘surfaces, here itis for contact between road and tyre. 2. The frictional resistance F, experienced between | the road surface is proportional to the - 5 FazweR ne vt the road surface 3. And, re We Wei west 4. Since jis leas on 8 wot su stopping distance is more in 5. The valuecfy depends uponthef 2 6 b, Tyretread pattern, c. Inflation pressure, and Material ofroad surface. 6, ‘The maximum value of te1. The braking force is equal and opposite to the linear inertia the vehicle. a 4 3 : : the force required to stop a vehicle is dependent on the weight, Weight of vehicle Rate of deceleration ‘1 ms? 4. Ifthe sum of retarding forces at all the wheels is equal to vehicle, the deceleration is equal tog. na ‘The limiting value of braking force depends upon the grip of friction or 7. Rate ofdeceleration, GaeSs. | What do you understand by the terms reaction| stopping distance ? Aaewer | ‘Time : Reaction time is the duration elapsed between! A. Reaction ‘accident and the driver’s reaction to act. the cause of probable. B. Stopping Distance : 1L Stopping distance is the distance travelled by the vehicle after the is applied and it comes to rest. 2 ‘Tobring the vehicle to rest, some work has to be done on wheels 3, This braking work is the product of average frictional resistanet! the road-wheel junction and the distance d moved by the vehicle ‘stopping. ‘Stopping distance is also known as braking distance, the road surface. 6 The ratio of grip to the weight of vehicle is known as | ‘efficiency is defined ‘the rate at which the | vcortain road speed. ‘vehicle to rest from a certain brings a ‘The maximum value of it ean be 100) heels is equal to the vehicle's weight. y is taken as 70°% t0.85 %Braking System, Chassis and Suspension, This is called as we on the front and re Mechanism of Weight Transfer : Fig. 3.7.1 shows the free bod, wing ly diagram of a vehicle showing the and moments acting on it at the time of braking, 4 Fig. 8.7.1. Forees and momenta to vehicle during weight teat! Inertia force acting on the C.G. of vehicle is ee z Braking foree Facts on the road surface in the direction opposite toy The line of action of , and F are separated by a distance h, which isthe height of C.G. of the vehicle from the ground. However, ea As brakes are applied, the forces /,-and F, form an anticlockwise ‘wheel, the wheel will C'whose tendency is to cause overturning effect on the vehicle, ‘vehicle's kinetic ‘The magnitude of this overturning couple is given by ond these ees: nia é ‘The vehicle is not going to overturn due to a righting couple onthe establishment of forces @ between the wheel and the ground. The direction of @ on front and rear wheels are such as to form clod ‘moment of righting couple with magnitude : 1 ¢, where, ! = wheel base, wheels and the ground by an amount equal to Q and to dec ‘between the rear wheels and the ground by the same amount. 10. Initially the weight of the vehicle is shared equally by each wheel. 4-wheeler, it is W/4 which now becomes, 4Let us consider a vehicle Potting the vale of Ry fom, of weight W moving downs rod incline, fansleO with horizontal. YW ®Vingdownaroad inlined tan woah + Wein © From equilibrium offorees and moments; ; Ry+Ry= Weos W-Ry= Wein 9+ A mM,=0 Wah +Wein@-h+Rp:b-Wi @ = Normal reaction at the front wheel Fix = Normal reaction at the rear whee! base = Retardation due to braking = Coefficient of friction between wheels andthe | road surfacein in i iantiaetsti AW cos 8= Wsino+ a e = He08 0~sing W(x+h)cos0 6 By = Wib-x-wh)eos0 @ 3 Rp } GC: Weight Transfer Reduction : Refer Q. 3.7, Page 91B, Unit.g, What are different types of brake system used ? Explain the working of one of them wi = ; if of one of them with the “Answer 1. Following are diferent types hraking system er & Mechanical braking system, ‘into peg >. Hydraulic braking system, Electric braking system, and Pneumatic braking system A Hydraulic Braking System : Working Principle : {ine Principle of hydraulic braking system depends upon the law. me 2 Pascal's law states that “the ‘equally in all directions.” 3. Hydraulic brake system consists. ‘of the following Master cylinder, operated by foot pedal, ‘b. Wheel cylinder, and F © _ Brake oil (or fluid) in pipelines. Working: 1 Asthe pedal is depressed by the driver, the effort. ‘is transmitted | od 3 to piston 2 of master cylinder 7. 2 The riston moves inthe cylinder and compresses return spring, Gut fuid from the cylinder into brake lin 6 through a bypass cylinder 5 is acted upon by the fluid and press: bringing their linings tightly against the working st Confined liquid transmits pressure in 1g main components: is released, the return spring pushes piston 2 back.2. Drum brake consists of the following main component : Brake drum Back plate or torque plate Brake shoe Brake lining | ‘Expander Anchor Retracting spring | Adjuster Brake drum. Leading brake. FR pao ep Brake lining Heel of trailing shoe Adjuster Anchor Fig. 8.11.1, Assembly of a drum type brake in braked condition? pe 3. Drum brak tal brake dr encloses the brake sfeeatt ad Drm brake has a metal brake drum that encloses the brake sent serag retracing Srp <— Poowaed 4. The brake assembly is attached to steering knuckle, axle housing. eating aig ro eae . % nse 5. There are two curved brake shoes which expand outward to slow owt) -S==S7E] what are the factors that affect the rs or stop the vehicle. . 6, These curved brake shoes rotate with the wheel. con 7. Brake shoesare made of metal and they are faced with a friction materi, “Answer Factors Affecting the Braking Effect: B. Working of Leading. Trailing Drum Brake: ize of Brake Drum and Wheel? 1. The return or retracting springs hold both shoes against the whedl Let R, is the radius of brake drum and yi ‘evlinder at the top, and against fixed anchor pins at the bottom. Rick 2 Depressing the brake pedal causes the wheel cylinder piston to matt the top of the shoes outward against the drums. 8, The friction between the leading shoe and the drum causes the leading ‘shoe to try to rotate with the drum. 4, This self energizing action of the leading shoe forces the bottom of tt, shoe against the anchor pin, | 5 Due to this, the leading shoe does most of the braking. 1 ‘When the trailing shoe contracts the drum, drum rotation tries ‘the shoe away from the drum, called brake lining. A 1As the force F is normal to Fy ie, Fy pF Re ie. Fy= igs pe G3 where, tip = Coefficient of friction between brake lining and drum. 7. The above expression concludes that a. The brake system having a larger brake drum helps in an i braking force on the ground.10. The pressure of pads, stops rotation of the dise and hence, the, 11. During the release of brake, the compression springs force Pistons to release pressure from the fiction pads. BR a cnr periece trove ram brake ond da Answer S.No. ‘Drum Brake 2 Master evlinder 1. | ‘The friction material can be | The friction material can be side) and to the wheel eytnde used upto 15000 km run. | upto 25000km run. 2 | Itsheat dissipation ability is | Itsheat dissipation ability is 3, Te transfers the effort of not good. ‘As the disc is exposed to air, with aleverage advantage, 3. | Friction material cannot be | Friction material can be D. Construction and Working; easily replaced asit is time | very easily # taking 4. | Itiscomparatively heavier. | Its weight is approximatelt less than drum brakes, 5. | It has no self cleaning | Itisselfcleaning. property as water and dirt accumulates 6. | Ithasselfenengizing action. | It doesn’t have self-energia action. 7. | Comparatively lesser foree | More force is required as these is required toapply brake. | not self energizing 8 | There is non-uniform wear. | Wear is uniform 9. | Due to temperature rise, | There is no effect of temperatan drum expands, tends to separate out from linings. QueSasi] whatis the function of master cylinder ? Explain working of master cylinder and wheel cylinder in automobile: hen UPTU 2011-12, Marl b, ‘The compression chamber in BZ Coe oR ‘The reservoir supplies fluid to the| at are the requirements of good braking system ? BE: ‘One larger port is known as filler oF i a : sod i ‘the hollow portion of the piston | m jaster eylinder used in it with P hydraulic brake system and master cylindes it ta ein suaere®. 4. Other smaller port is oR ‘which connects: Explain the function of master cylinder with a neat sketch.Braking System, Chassis and Suspension 8 The boot covers the pushrod and the end of the cyl yushrod a cylinde from foreign matter” ae 7. As the brake pedal is depressed, the liquid under pressure is the master cylinder piston. & The relief port is sealed out of the system. 9. This liquid pressure forces the wheel eylinder piston outwards, 10. The piston forces the brake shoes out against the brake drums, Ul, As the brake pedal is released, the return spring fang . 1 1 quick! master eylinder piston back against the piston stop. 12. The liquid may flow from the reservoir through the relief i relief port taster cylinder, supply ines and wheel elnders to make up fe luid that lost or to compensate for shrinkage on Fr ce eon Se vias oe 13. By this, a complete column of liquid is always . of liquid is always present betw ‘master cylinder piston and wheel cylinder piston. “7 E. Wheel Cylinder: : @ Bas, ‘Spring| ) Dust cover Rub! | cup | ‘Fig. 3.15.2. Wheel cylinder. 1. Wheel eylinder consists of two pistons which can move in o directions by the fluid pressure. 2 Ithasthree important parts : one piston return spring and two ‘each piston is connected to the left and right brake shoes and cylinder body enclosing the piston and the spring. 3. Whenthe brakes are applied, the brake fluid enters the cylinder! brake line connection inlet between the two pistons. ‘Due to this, the two pistons are forced out in opposite directions. is transmitted to the brake shoes directly or through’ ‘against the brake drum, thus the brake is applied. are generally connected directly to alineTobrake S linkage BAN A az herie F Pressure) — Breathersystem vehicles ? ‘answer ] He Fa xV 4 for four wheeler, 240 320)] What is brake effectiveness ? Why is hydraulie b Preferred over 4200 Kealmin ‘when all the wheels are braked, mechanical braking system in he A. Brake Effectiveness: 1. Effectiveness of brake determines that a las effort, sven by the dri Produce a quick and safe braking eta; on the autovehicle 2 Brake effectiveness de, ends upon the follo wing factorsFrame: 1. To support the chassis components and the body. 2 To withstand static and dynamic loads withove distortion, = C. Loads on the Frame: ‘® Flexural (or Bending) Load : 1. This load is produced in a vertical & Dead weight of the vehicle, b. Weight of the passengers, Engine torque, and @ Braking torque. 2 Flexural load also develops in lateral plane of the side membera Road camber, b. Comering force, and ©. Side wind. b. Torsional Load (Twisting Moment) : | 1. Torsional load is caused due to vertical load when the vehicle ‘across a road bump. 2. The design of frame is done as to resist torsion by providing: Torque resisting members, b. Cross members., © Aradiusrod, and 4 Benzo-frame type torque members. © Impact Load: 1. Impact load is due to the obstacles present on the road. 2 Toreduce the impact load bumpers and over-riders are used, they ‘safety and longer life to the frame, Discuss the types of frames and its stiffness and. plane of the side members, err paeeenV assis and §, ery Gatch Geeta Prepele Fig. 8.28.1. Layout of chassis ofa four wheeler Fon. What are the loads coming on a chassis frame?) various types of Ae Objectives of aS Pie ee / chassis frame. ‘Suspension system is used to minimize | hoc comfort riding La {tis used to reduce stresses ands Answer A. Various Loads Coming on a Chassis Frame : Refer @ Page 1098, Unit-3, B. Types of Chassis Frame Sections : 1. Various cross-sections are used for the side ‘members or cross-men of the chassis frame. These are : Channel section Itimproves the life ofSuspension System : Refer Q. 3.25, Working of Shock Absorber: “pp For this reason, the friction between and additional d; lam or shock-absorbers, What are the functions of a ahock absorber? Describe the shock absorber with a sketch, ee rae pireatce, caper lstatrlthe wring aco, sowing fe toma ahr tn ig | B. Telescopic Shock Absorber: x In the Fig. 3.27.1, a twin-tube type shock absorber is shown, valve, while another simier two. rapa Biba ete vr ent inde Saw Beans ts as oats beite Eee ii dining, 3. pee epace through the load Peaeas skews te ‘ down into the annularBraking System, Chassis and Suspension sown B. Different Types of Suspension System: Automobile eneees a 1, Aleafspring co Jength but of 1 L oe f | Ii | Ee ae Wishbone type Bush Fern Vertical guide type Te Fig. 8.28.1. Classification of suspension system. €. tdescopihec berber er, Poe 8 Un ; ‘Que 329. ] What are the various types of suspension springs in an automobile ? Discuss the semi-elliptic type leaf spring. 3 ‘Answer ‘ A. Types of Suspension Springs : < 1. Depending Upon Shape and Construction : a a. Leaf Spring : Used in trucks, buses ete . b. Helical Spring : Used in cars and low commercial vehicles 1 al for independent front suspension cither front or rear or & Asthe vehicle: © Torsion Bar; Used in cars and other LCVs both on front and rear: of the vehicle. due to which Aha) 2 Depending Upon the Spring Material: 9. Thechangein ising which provides al b, Rubber spring Que 3.30. ] Explain} h © Plastic spring discuss the 4. Composite material spring. ta m 8 Depending Upon The Fluid Used : Answer a Airspring A. Two Basic b. Hydraulic spring. &. Soring : Refer‘ 4 Depending Upon The Load-Deflection Behaviour: Shock. Soft and hard springs, B. Bouncing, b. High and low frequency springs. 1 Whena: © Constant rateand variable rate springs, 2 Duettothis dis4 The tendency of, b ‘motion along width is termed as rolling ‘The tendency of motion along height is termed te bon ci ‘The tendency of motion along length is termed as pitchin Leaf springs are made of long, fat strips of spring steel, 2 Several strips are placed one. centre bolt and clamps, Each strip is called aleaf. ‘on the other and held together by means, ‘There is one leaf which extends the full length of spring and contains eyes at both ends for making connections with the heme 5. The other leaves in the spring are assembled with the main leaf ‘means of centre bolt and clamps. 6 Each succeeding leaf is shorter than the preceding one The springs which are suspended with the frame through zu Bee atatetes end pi dozer ‘contain loops or the ofthe main leaf. ‘Que 532. | Differentiate between the leaf spring suspension of front wheels used for an a coll spring sytem of front wheal: ard fr an automobile2 While the arrangement of independe: i pendent suspension system fash front wheel is hinged separately, and both the wheels aoe ‘move up and down independently, he bump or pit on one wheel does not affect the vehicle move the vehicle does not tilt and remains vertical. ‘4. That's why, independent suspension system is widely used on the fy wheels of the modern cars. 5. "It is achieved in both front and rear wheel suspension, B. Independent Front Suspension System : Independent front suspensior m system achieved in wishbone type suspension is as follows : a. Wishbone Type Front Suspension : Change in She chamber Tt King pin Upper wishbone Frame \ cross-member Connecting Lower arm, wishbone (883.1. Arrangement of a wishbone type independent front 1. The figure shows an arrangement of wishbone type front suspension system. It consists of the following main parts a Smaller upper wishbone and longer lower wishbone. b. Connecting arm to connect upper and lower wishbones with the eons ¢. Coiled spring enclosing a shock absorber. Frame cross-member on which the upper and lower wishbones ar pivoted.1. In thia type of suspension, shown in Fig. 3.34.1, acoil to tho trailing link which itecif ic atechot oon wheel hub. When the whee! moves uy A torsion bar has also spring. i and down, it winds and unwinds th been used in certain designs in place of Frame side member ‘Arm for brake torque Hole for king pin ‘Trailing link Multiplate shock absorber. Pig. 8.94.1. Trailing link suspension, 7 4. This system does maintain the camber and the wheel track const 5. However, the distance between the front and the rear wheelsdo 6. Difficulty to rectify this defect is the main reason for its very limit in actual practice. ‘Que3.35.| Write shorts note on parallel arm type si system. oR Classify dead axle independent suspension system. Discuss: of them. Front Wheel (Dead Axle) Independent Suspension Independent suspension has become almost universal in the ¢ front axle, due to the simplicity of construction of such a s system. Five types of independent suspension are in use for front axleiniversal Joint : Sliding Joins Fig. 3.36.1. Rear ‘wheel independent suspension, Universal couplings A and B keep the whee! vertical, while the arent Cis required to maintain the wheel track constant, avoiding scrubbing ofthe tyres, Another method of rear wheel independent suspensi is tr link Fig. 3.36.2, i a 4’s and B's are the universal joints to keep the wheel track and th camber constant with the up and down movement of the wheels, ‘S's are the coil springs with shock absorbers mounted concet es ‘The trailing links hold the wheels firmly and also sustain acce ‘and braking forces.126 (ME-7) B Braking System, Chassis and Su ‘The other cirenits have a supply of air at 20 ke/em*, correct additional loading of the ear. 13, This eireuit maintains the ear level, irrespective of whether sor not passe ‘The air at 20 kylem pressure is admitted into the levelling the solenoid valve, ‘The air is fed into the lower air bag which has been comp weight by the levelling valve, thus bringing it in evel with the ‘The air is quickly released by the levelling valve, when the} decreased from the air bag to lower it tothe proper level. ©o9 A, Concept O B. Long and10. 1. Series wound motor, Series shunt wound motor, 2pole motor, pole motor, and. &-pole motor. Characteristics of D.C. Motors : There are four types of D.C. motors, vz, shunt wo qrnPound wound and with permanent magnet excit TigsPeed torque charactristies of each ofthese will be with an objec to determi A shunt wound motor is sh ‘sconnected in parallel wit Popes the suitability ofeach as a starter own in Fig. 4.2214), In this the fea ith the armature. Series wound ‘Compound wound ‘Shunt wound “Folothrw’ bendix eve, Compression spring Rubber spring type Dyer drive. Inaseries motor Fig S270 te feldand amature are in series, on means the armature and field current are an oe high inal current iw resins ado back ENE, iotor pede ery strug mage nde torque as shown in Fig. 4.2.1. That in why serie wound motor are ensierd mst stale motors. al In a compound wound motor Fig. 42200, the eta wins exciraxiocio¢ onto ae eat ac Large starter ton Leela Fig. 4.2.20, the feta the permanent magnet pes eit constant under al operating condition, Asa et lare quite similar tothe shunt wound motors,b. Series wound motor, Series shunt wound motor, 4 2pole motor, . Spole motor, and £ &-pole motor. B. Characteristics of D.C. Motors : 1. ‘There are four types of D.C. motors, viz., shunt wound, series ‘compound wound and with permanent magnet excitation type en ceinrcmerac cad Fetaets octcoaccae oe a 3. Ashunt wound motor is shown in Fig. 4.2.2(a). In this the field wy fee cern “ Series wound ‘Compound wound ‘Shunt wound Permanent magnet Torque Fle 42:1: Totes sped carcino varios peso i 4. As the eld excitation in this remains constant, the speed ractically constant, ie, independent of torque, i ae 5. Thusthe staring torque in thiscasislow, de ea due to which it is not suitable 6 Inaseries motor Fig. 42.6 the feld and armature are means the armature and fel currents ace en 8 78 Mish 8, Due thigh initial current, ow resistance andre bac . 0 back ‘motor producesa very strong magnetic asa ect eM ths toed torque as shown in Fig. 42.1 ery high ini 9. That iswhy series wound motors are considered motors. most suitable as stare 10, Ina compound wound motor Fig. 4.2.20), the fea w:- x combination of series and shunt types. Large stan windings aes often compound wound. starter mators are quit 11. Inthe permanent magnet types Fig. 42.21) the Feld ex constant under all operating conditions. ‘As such thei sation remains are quite similar to the shunt wound motors, racteristicé (0) Series wound 0 ae 2. However due to fallin battery voltage under armature windings, their characteristics are ¢ > \ ‘esky ae motors. set Qae4S. | What are the different types of starting motor drives ? Explain any one. ae € Answer Over-running clutch or the preengaged type drive: Bendix Drive: Standard bendix drive, ‘Folo-thru' bendix drive, Compression spring type bendix dive, and Rubber spring type bendix drive, Dyer drive. Over-running Clutch Drive: () Shunt wound ‘note pare re eeElectrical and Fuel Supply 12. 008-0B J theantchos arene concent but are smaller inthe on, eae lis turned by the armature shaft, the seein dutch abel a turned by the armature sha th a 4 Wace the notches vo force the collar trun withthe she’ Since the collar drives the pinion gear, this action enables tho, 5% Grotate the pinion, cranking the engine. a. Working 1. When the driver presses the starting lever, the shift lever posh twitch of starting motor. Iealsomoves the over running clutchaeg ‘There is threaded sleeve pinion against the spring pressure. the or turn freely over the shaft. 2 Thiscauses the shaft to rotate with motor, while the rial ‘The shat in keyed tothe fxed well as to engage with the ring gear on the flywheel. Now the saat to the sleeve through a col ote ee ‘nagement) and the siding dog ie (On the sleeve, thereis pinion te oe ‘To starter pedal the purpose of the weight i to prevent jattory cable : sleeve aaa terminal ox Shit lever Field ple Pivot Spring Armature Brush Front Over ranaing ill ees Pinion gear Rear bearing Flywheel gear ArwNture Drivesheath housing hub Fig. 43.2, Over-running clutch drive 3. _Asthe engine picks up speed, the pinion rotates at much faster sped . Construaa 4. Now, over-running clutch play its role by disconnecting the pinion fom When the maison the motor. rotate and because the pinion it moves axially towards the) Further movement of the pia stops the sleeve and because ofthis Qaeda] What is the function of a starting drive ? Describethe _* —_s-ow itigin mesh with and the engine starts, construction and working of any one type Bendix drive. When tu ren the engine starts it is [UPrU 2012-13, nara) Decause oft gp = than the armature (which! Taower | the self-starter switch) asa ‘A. Function of Starting Driv. the firwnal ; An important p 1. Starting drive transfers motion from starter motor shaft to the crankshaft rage of the engine. ; i 5. Once the engine has started, the driver lifts his feot-ff the pedal, herp causing shift lever to come back to its original position and the mala neee pe ‘These are the field magnets used to 1 4. Spread-out the magnetic lux in the air-gaps, ii Support the exciting coils, ‘They are generally 2to 4 in numbers. Field Coils Field coilsare used to electrom: them, Field coils are made of copper wire, Armature Winding : Armature winding is the assembly: cut within the armature core. Each conductor is insulated from each other. ‘There are two types of winding made i Wave winding ii Lap winding Tn wave winding, the armature conductors are divided into two part Paths between the positive and negative brushes, {nlap winding, the armature conductors sre divided into parallel pl qual to the number of poles in the generator. Commutator and Brushes : Gemmutator is made up ofhighly conductive copper rings andisusd facilitate the current collection from the armature. Commutator consists of a large number of ‘segments insulated fra ‘each other by thin mica sheets, : Escheegment ‘seonnected to the armature conductors through \ jagnetize the ples bypassing th cay, ‘of conductors placed inside the, ‘The magnetic field lin ceil of wire As armature through the load. If pole strength is 6 We of armature N'r-pam 4c. generator is given by