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UNIT 1

VEHICLE STRUCTURE AND

ENGINES


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Introduction to Automobile

Systems


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1A. Electrical Systems

Ignition

Charging

Accessories Lighting

Starting

Computer
http://www.film.queensu.ca/cj3b/Photos/Tech/ignition.gif


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1BFuel System

Mixes air and gasoline for to explode inside

engine.


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1C - Cooling System

Keeps engine at correct operating

temperature


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1DLubrication System

Reduces friction between moving parts.


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2. Drivetrain

Converts engine movement to vehicle

movement

Variety of types:

Front Wheel Drive

Rear Wheel Drive

Four Wheel Drive

All Wheel Drive


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Vehicle Layout

Rear engine / rear wheel drive

Mid engine / four wheel drive

Front engine / front wheel drive Front engine / rear wheel drive


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2A - Transmission/Transaxle

Uses different gear ratios to increase torque(pulling power) or speed.

Uses gears for Reverse.


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2B - Differential Allow rotational torque to turn 90 degrees

Allow wheels to turn at different speeds.


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2CTransfer Case

Sends engine torque to both rear and front

differentials in four wheel drive vehicles.


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2D - Driveshaft

Transmits rotational torque to Differential/s


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2E - Half Shaft

Transmits Torque Directly to Wheels


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3. Brakes

Stop vehicle movement and keep it stationary.


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4. Steering

Changes vehicle direction.


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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 theroad while still permitting safe handling of the

vehicle while accelerating, braking and

cornering;


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5A - Springs


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5BShock Absorber


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6. Tires

Connect vehicle to road

Affect vehicle handling, traction, braking
http://go2.wordpress.com/?id=725X1342&site=wholesaletireblog.wordpress.com&url=http://wholesaletireblog.files.wordpress.com/2009/11/bald-tires.jpg&sref=http://wholesaletireblog.wordpress.com/category/tire-care/


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3 D VIEW OF VEHICLE CONSTRUCTION


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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


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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 shellforms the skeleton of the vehicle

Engineacts as the power unit

Transmissionconveys the drive to the road wheels

Suspension

absorbs the road shocks

Steeringcontrols the direction of movement

Brakesslows down the vehicle

Electrical equipmentprovides lighting, engine starting and other driver needs.

ll hi l d f d h h h i


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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.


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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


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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)


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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.


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LOAD CARRYING CAPACITY

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

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


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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(


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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


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ON THE BASIS OF THE FUEL USED

Petrol vehicle

maruthi omni

matiz

felicia

santro

Diesel vehicle

mercedes-benzeambassador

fiat UNO diesel

Dual fuel

fargo

dodge

bedford trucksGas vehicles

CNG valvo

Hydrogen vehicle

Musashi III


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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


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Rear engine / rear wheel drive

Mid engine / four wheel drive

Front engine / front wheel drive Front engine / rear wheel drive


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ON THE BASIS OF ENGINE CAPACITY

ENGINE CAPACITY ( CC) VEHICLE

60 KINETIC SAFARI V2, BAJAJ SIGNETS

70 TVS sport

93 kinetic k-4

150 Bajaj , Lambretta

796 Maruti omni

1200 Premier padmini

1366 Premier diesel

1489 HM Trekker

2982 Toyota land cruiser


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VEHICLE CONSTRUCTION

Main components of automobile

Chassis

Body

Frame

Power unit engine system

Transmission system


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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 vehicleexcept 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.


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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.

Ch


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Chassis components

f h i


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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 isattached 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.


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As the chassis frame forms the backbone of a

heavy vehicle,

its principal function is to safely carry themaximum load for all designed operating

conditions.

it must also absorb engine and driveline

torque, endure shock loading andaccommodate 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


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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 frame2 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.


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Th diff t t f t bil h i i l d


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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 chassisthat is still used by most of the SUVs

till today. As its name connotes, ladder chassis resembles a shape of a ladderhaving two longitudinal rails inter linked by several lateral and cross braces.
http://www.automotive-online.com/chassis-frame/automobile-chassis.htmlhttp://www.automotive-online.com/chassis-frame/automobile-chassis.html


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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 sportscar. Backbone chassis is easy to make and cost effective.


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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 panand other pieces together. Since monocoque chassis is costeffective and suitable for robotised production, most of the vehicles today make

use of steel plated monocoque chassis
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AUTOMOTIVE FRAMES:

Automotive frames are basically

manufactured from steel. Aluminum isanother raw material that has increasingly

become popular for manufacturing these auto

frames. In an automobile, front frameis a setof 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:
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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 reinforcedplastic

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 drycarbon. A typical hood

comprises of several different

parts such as hood ornament,

hood scope, power bulge, and

wiper jets.
http://www.automotive-online.com/chassis-frame/bonnet.htmlhttp://www.automotive-online.com/chassis-frame/bonnet.html


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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 theweight 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 particularlywhen vehicle is travelling at high speed over a rough road.


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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


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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


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Types of bodiesCar

Truck half body

Tractor

Tanker

Delivery van

Pick up

Truck-punjab body

Track-platform type

Tractor

Dumper truck

Station wagon

jeep


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Direct Injection

Differences in Operation

Indirect Injection

Injector Injector

Pre CombustionChamber

/ d


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Feature Direct Injection Indirect Injection

Efficiency / Economy More Less

Power More Less

Emissions Less More

Direct V/S Indirect Injection

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