UNIT 1 VEHICLE STRUCTURE AND ENGINES

Introduction to Automobile Systems

 Converts energy from gasoline into torque to make the car move. Is made up of several systems which operate at the same time.

1. Engine

1A. Electrical Systems

Ignition Charging Accessories
Lighting Starting Computer

1B Fuel System
Mixes air and gasoline for to explode inside engine.

1C - Cooling System
Keeps engine at correct operating temperature

1D Lubrication System
Reduces friction between moving parts.

2. Drivetrain
Converts engine movement to vehicle movement Variety of types:
Front Wheel Drive Rear Wheel Drive Four Wheel Drive All Wheel Drive

Vehicle Layout

Rear engine / rear wheel drive

Mid engine / four wheel drive

Front engine / front wheel drive

Front engine / rear wheel drive

2A - Transmission/Transaxle
Uses different gear ratios to increase torque (pulling power) or speed. Uses gears for Reverse.

2B - Differential
Allow rotational torque to turn 90 degrees Allow wheels to turn at different speeds.

2C Transfer Case
Sends engine torque to both rear and front differentials in four wheel drive vehicles.

2D - Driveshaft
Transmits rotational torque to Differential/s

2E - Half Shaft
Transmits Torque Directly to Wheels

3. Brakes
Stop vehicle movement and keep it stationary.

4. Steering
Changes vehicle direction.

5. Suspension
A suspension system provides a flexible connection between the wheels and the rest of an automobile, allowing the car to ride smoothly and comfortably over bumps in the road while still permitting safe handling of the vehicle while accelerating, braking and cornering;

5A - Springs

5B Shock Absorber

6. Tires
Connect vehicle to road Affect vehicle handling, traction, braking

3 D VIEW OF VEHICLE CONSTRUCTION

Topics :
Types of automobiles

Vehicle construction and different layouts

Chassis

Frame and body

Resistance to vehicle motion and need for a gear box Components of engine-their function Function and materials

Vehicle Body Construction

Motor vehicles are a combination of many different systems all made up of
separate items. All these systems have to be brought together and mounted on some form of frame or body shell to form a chassis. The chassis comprises the following. Frame or body shell forms the skeleton of the vehicle Engine acts as the power unit Transmission conveys the drive to the road wheels Suspension absorbs the road shocks Steering controls the direction of movement Brakes slows down the vehicle Electrical equipment provides lighting, engine starting and other driver needs.

All vehicles are made up of separate systems and components, they have their own purpose and operation, however, all of these systems are brought together to give us the modern motor vehicle.

TYPES OF AUTOMOBILES
i. Number of wheels and no. of axels

ii. Types of power plants

iii. Load carrying capacity and their weight

iv. Purpose served

v. Fuel used vi. Drive system used vii. Capacity of the engine

NUMBER OF WHEELS AND NO. OF AXLES

i. 2-wheelers ( mopeds, scooties, scooters and motorcycles) ii. 3-wheelers (tempos, road rollers, tractors)

iii. 4-wheelers (car, jeep, trucks, buses)

iv. 5-wheelers (road rollers) v. 6-wheelers (truck-tankers, foods carriage vehicle) vi. 8 or more-wheelers (car transporting vehicles)

TYPES OF POWER PLANT USED

i. Steam engine drive auto vehicles. ii. I.C engine driven vehicles a) petrol vehicles b)diesel vehicles c)gas vehicles iii. Gas turbine driven automobiles. iv. Winkle engine driven auto vehicles. v. Electric power driven auto vehicles.

vi. Battery (chemical power)driven auto vehicles.

vii. Solar energy driven auto vehicles. viii. Hybrid power auto vehicles.

LOAD CARRYING CAPACITY

I . Heavy transport vehicle(H.T.V) ;(eg: trucks and lorries)

II .light transport vehicle (L.T.V)

CAR BODY STYLE

I .closed cars: saloon hatchback(saloon with a door at the back) coupe(only one row of seat for 2 person, 2 doors are provided) limousine(driver compartment is separated from rear comp)

Ii .open car : sports, convertible(roof in this is soft folding type, with this provision the car may be either open or closed)
III .special styles estate cars (saloon car with passenger roof ) station wagon(

ON THE BASIS OF THE PURPOSE SERVED

On the road vehicle
scooters cars trucks

Off the road vehicles

tractors construction equipments

On and off the road vehicles

military tanks gun carriage bulldozers

ON THE BASIS OF THE FUEL USED

Petrol vehicle maruthi omni matiz felicia santro Diesel vehicle mercedes-benze ambassador fiat UNO diesel Dual fuel fargo dodge bedford trucks Gas vehicles CNG valvo Hydrogen vehicle Musashi III

ON THE BASIS OF TYPE OF TH WHEEL DRIVE SYSTEM

Single wheel drive (1 Wd) Two wheel drive (2 Wd) Four wheel drive (4 Wd) All wheel drive( 6 Wd) Left and right hand drive vehicles

Rear engine / rear wheel drive

Mid engine / four wheel drive

Front engine / front wheel drive

Front engine / rear wheel drive

ON THE BASIS OF ENGINE CAPACITY

ENGINE CAPACITY ( CC) VEHICLE

60
70 93

KINETIC SAFARI V2, BAJAJ SIGNETS

TVS sport kinetic k-4

150
796 1200

Bajaj , Lambretta
Maruti omni Premier padmini

1366
1489 2982

Premier diesel
HM Trekker Toyota land cruiser

VEHICLE CONSTRUCTION
Main components of automobile
Chassis
Body

Frame
Power unit engine system Transmission system

CHASSIS
INTRODUCTION Chassis is a French turn and was initially used to denote the frame or main structure of a vehicle. It is now extensively used to denote the complete vehicle except the body for the heavy vehicle having a separate body. The chassis contain all the major units necessary to propel the vehicle, direct its motion, stop it, and allow it to run smoothly over uneven surfaces. It is the main mounting for all the components including the body. It is also known as carrying unit.

The chassis include following components as shown in fig: 1.1 Frame, Front suspension, Steering mechanism, Radiator, Engine, clutch, gearbox, Propeller shaft, Rear spring, Road wheels, Differential, half shaft, universal joints, Brakes end braking system, Storage battery, Silencer, Shock absorbers, fuel tank, petrol and hydraulics pipe cables and some means of mounting these components.

Chassis components

1.1 Importance of chassis Frame

The frame or under body is the main part of the chassis, on which the remaining parts of chassis are mounted. It is a rigid structure that forms a skeleton to hold all the major part together. The engine is mounted in the forward end of the frame end of the frame and is connected to the clutch and transmission units to form a complete power assembly. At the rear end of the frame, the rear axle housing is attached through the rear spring. The wheels and tyre assemblies supports the frame. The steering system has some parts bolted to the frame and some to the body. The petrol tank is fastened to the rear of the frame.

As the chassis frame forms the backbone of a heavy vehicle, its principal function is to safely carry the maximum load for all designed operating conditions. it must also absorb engine and driveline torque, endure shock loading and accommodate twisting on uneven road surfaces. To achieve a satisfactory performance, the construction of a heavy vehicle chassis is the result of careful design and rigorous testing

CHASSIS FRAME OF COMMERCIAL VEHICLE

2 Chassis frame of commercial vehicle Basically there are two types of chassis frame are available namely as under: 1. LMV frame 2 HMV frame Chassis frame of the commercial may made up of different types of cross section. It is tube, I-section, square section or C-section. In figure2.1 shows the chassis frame made up of tube cross section for LMV.

The different types of automobile chassis include:

Ladder Chassis: Ladder chassis is considered to be one of the oldest forms of automotive chassis or automobile chassis that is still used by most of the SUVs till today. As its name connotes, ladder chassis resembles a shape of a ladder having two longitudinal rails inter linked by several lateral and cross braces.

Backbone Chassis:
Backbone chassis has a rectangular tube like backbone, usually made up of glass fibre that is used for joining front and rear axle together. This type of automotive chassis or automobile chassis is strong and powerful enough to provide support smaller sports car. Backbone chassis is easy to make and cost effective.

Monocoque Chassis:
Monocoque Chassis is a one-piece structure that prescribes the overall shape of a vehicle. This type of automotive chassis is manufactured by welding floor pan and other pieces together. Since monocoque chassis is cost effective and suitable for robotised production, most of the vehicles today make use of steel plated monocoque chassis

AUTOMOTIVE FRAMES: Automotive frames are basically manufactured from steel. Aluminum is another raw material that has increasingly become popular for manufacturing these auto frames. In an automobile, front frame is a set of metal parts that forms the framework which also supports the front wheels. It provides strength needed for supporting vehicular components and payload placed upon it.

Bonnet: Bonnet, an important part of automotive frame can be defined as a protective covering made up of a hinged metal part used for covering an engine of a vehicle. Usually automobile bonnets are made of steel, aluminum, fiberglass, and carbon fiber reinforced plastic
Hood: Hood refers to a cover placed over the engine and passenger compartment of an automobile. Hoods form an important type of automotive frames. These auto frame parts are usually made of steel, aluminum, fiberglass, carbon fibre or dry carbon. A typical hood comprises of several different parts such as hood ornament, hood scope, power bulge, and wiper jets
.

FUNCTIONS OF FRAME Frame is provided with cross members to increase the rigidity and to withstand the shocks, blows, twists, and vibrations coming during operation. A frame is required to carry the weight of the vehicle and its passengers, to withstand the engine torque, thrust stresses, accelerating and breaking torque, to resist the effect of centrifugal forces when cornering and to withstand bending and twisting stresses due to fluctuations of front and rear axles. REQUIREMENT FOR A GOOD FRAME It should be strong and stiff enough to resist the severe twisting and bending forces to which it is subjected particularly when vehicle is travelling at high speed over a rough road.

BODY
Body is superstructure of the vehicle Bolted to chassis Complete vehicle is referred to the combination of chassis and body Body is merely a cover to the chassis The body ma be shaped according to the need and convenience

Body of the motor vehicle must fulfill the following requirement

Sufficient space to accommodate passenger and luggage Suitable shape to reduce air resistance

It should be light and strong enough to resist bending, torsion and impact stress
Load should be distributed evenly Mounting of the boady should have minimum vibration

Should be cheap and simple in manufacturing

It should be made of sheet metal of sufficient thickness for adequate safety during collision Should provide clear vision and be of aesthetic in shape

Car Truck half body Tractor Tanker

Types of bodies

Delivery van
Pick up Truck-punjab body

Track-platform type
Tractor Dumper truck Station wagon jeep

Differences in Operation
Direct Injection Indirect Injection

Injector

Injector

Pre Combustion Chamber

Direct V/S Indirect Injection

Feature Efficiency / Economy Power Emissions

Direct Injection More More Less

Indirect Injection Less Less More