two wheeler milage testing machine

8/14/2019 Two wheeler milage testing machine

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Two Wheeler Mileage Testing Machine

ABSTRACT

There have been major developments in the field of two wheelers with

respect to every aspect of the vehicle.

One of the major aspect of the vehicle that is responsible for making vehicle

more famous and popular is the mileage of vehicle.

This project was undertaken with an objective to test the average of vehicle

in showrooms and service centers.

The machine was fabricated and assembled according to design, with

flexible features. By standing the vehicle on main stand and within 10-15 min. we can find

the mileage of the vehicle with high accuracy.

The machine was tested and found to work as expected.

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At present, the service station persons, use the mileage testing machine for

which the vehicle is made to run on the roads. Whereas in this project the machines

calculates the mileage, making the vehicle on the service table itself.

The cost of machine is so low that even a small service station owner can

affect to use it.

For good mileage the running of the vehicle should be perfect for the setting

of running the service run has to rely on the customer information. So accordingly he

carries the running adjustment. On vehicle by using trial and error method. The results, he

obtained are probabilistic in nature. To convert probabilistic measures to actual,

implement the same practically. This is an attempt for service station to be aware of

mileage testing, there after running of vehicle to improve fuel economy.

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Market survey/ research for materials

& equipment.

The concept of market survey has a great importance in the field of

conceived product, as it facilities or aids of to judge the market for our product and its

future existence. It determines who and where the customer is what are his needs and

wants, what will lay for it. Market research also uncovers the future of existing product and

the products yet to be introduced into the market.

For the part 5 decades, market research has got immense popularity and has

resulted in gaining higher market shares.

The procedure of market survey must include the following steps :

1. Defining the objective of the product clearly.

2. Developing a clear set of research objectives.

3. Data collection from existing and future consumers about their needs /

requirements.

4. Extracting meaning - full data from collected information

5. Using the findings of survey in developing the product.

So, in the view of aforesaid important points, it is quite evident that for

launching /marketing a new concept in the market, survey research is very essential.

As far our project titled "Two wheeler Automobile mileage testing

machine is concern, we conducted a through survey in Akola and the adjoining areas.

From this survey we concluded that our product (i.e. M.T.M/c) has got immense scope in

market as it has got distinctive features for its promotions. The main advantage with our

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product lies within that, it can efficiently test the average or mileage of any two wheeler

(Automobile) when erected on its main stand that too with just 25-50 ml of fuel and takes a

few minutes to do the job. In our market survey, we went to various show rooms of two

wheelers like Bajaj (Krishna Motors), Hero Honda (Baheti Sales & Service) TVS (Prakash

Enterprises) and a few service station. Except the Bajaj Show room, none of them had this

facility for mileage testing. Their managers /owners should a great interest in our project

and they were all convinced with our new design features and various modifications mode

in the existing machine available in market. The main disadvantages with the equipment

or machine available in market lies in its big size difficult in operation, high noise and low

transmission ratio. We in our project have tried to minimize all these draw backs by

redesigning the whole structure, making suitable adjustment to reduced noise and increase

transmission ratio.

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"BASIC PRINCIPLE"

The basic principle of two-wheeler mileage testing machine is that the rear

wheel of the vehicle is placed in touch with the first idler. This idler will rotate due to

friction between the idler and tyre. This first idler revolution is transferred. On second

idler via belt and pulley arrangement. The r.p.m. of the rear wheel of the vehicle. The

loading conditions are created by encovering the second idler with belt and spring weight

arrangement on it. The r.p.m. of the second idler is calculated with the help of

speedometer assembly mounted on shaft of second idler. So that we can take the readings

of the distance traveled and also the fuel consumption is known to us. So average output

of vehicle per litre of fuel can be calculated by.

Distance traveled

Average =

Fuel consumed

The care of rolling resistance, air drag resistance and gradient resistance are

taken using belt and a weight arrangement (loading arrangement).

The quantity fuel supplied can be measured using a measuring bottle of 100

ml. Hence if all variables are known to us. Average output of vehicle under loading

conditions can be calculated.

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RESISTANCE TO THE MOTION OF THE VEHICLE

A tractive effect of force is provided by engine of a vehicle at the driving

road wheels. Varying at different engine speed and gear position it is mainly required to

overcome the force opposing motion of vehicle. The resistance to the motion of the

vehicle is called as tradre resistance. It is the sum of the three resistance that obstruct the

movement of the vehicle. The resistances are

i) Rolling and frictional resistances.

ii)Gradient resistances.

iii)Wind and air resistances.

1)Rolling Resistances :-

It is the force necessary to maintain the constant speed on a leveled load

surface the load on each tyre inflation pressure and type of tyre treated.

2)Frictional Resistances :-

Frictional resistances to the motion of the vehicle reduce the speed and also

induced transmission losses.

These frictional resistances are calculated as,

f = 66.6 + 0.012 W

t = Frictional resistance in Kg.

W = Total weight of vehicle in Kg.

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These transmission losses are generally 10% in direct gear 15.20% in low

gear. For calculating performances tractive force should be emitted at efficiency at 90%

for top gear and 80-85% for low gear. This also includes temp losses and the losses

occurring in oil churning in the closely desired gear box and contended rear axle. For

private car's it is 89-95%. The friction losses in the tyre in about two third of total losses in

the chasis.

3)Air and Wind Resistances :-

The air and wind resistances for two wheelers are negligible. Generally it

depends on speed of vehicle, wind velocity, size and shape of the body of the vehicle.

It is calculated from formula

Pn 2 sin (For the head on the direction of the wind)

Pn =1 + sin2

Pn = KV2A (For the same following direction of wind)

where

K = Coefficient of air resistance

A = Projected area in m2

V = Velocity of the vehicle in Km/h

= Angle between direction of vehicle and direction of wind

Pn & Ph = Air resistance.

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DESIGN

DESIGN OF SHAFT :-

The heaviest two wheeler vehicle in Indian Market "Enfield Bullet" 500cc

Gross weight : 165 kg.

Max. weight of single rider 90 kg.

Load of idler = 165 kg + 90 kg

= 255 kg.

Considering Factor of Safety : 2

Load on idler = 255 x 2

= 510 kg.

There are two idler

Load on each idler = 510/2

= 255 kg.

Idler is supported two Bearing ends

Load on each Bearing = 255/2

= 127.5 kg

Max. B.H.P. of Bullet = 18 B H P at 5625 r.p.m.

Taking factors of safety = 2

B.H.P. = 18 x 2 = 36 H P

Power transmission = 36 x 746

= 26856 W

P = 26.85 k w

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load on Each Bearing = 127.5 kg.

= 127.5 9.81

= 1250.77 N

The power is deliver at 5625 r.p.m. i.e. 6000 r.p.m.

We know that Power transmission

60

NT2P

=

60

T60002108526

3 =.

T = 42.74 N.m

The max. B.M. will be

B.M. (max) = 1250.8 0.137

= 171.3 Nm

M = 171.3 Nm

Now ,

22

eTMT +=

= 22 )74.42()3.171( +

Te = 177.21 Nm

Diameter of the shaft

Taking fs = 56 N/mm2

3

se df16

T

=

s

e3

f

16d

=

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=56

1021.17716 3

d = 25.25 mm

Say 30 mm

Design of Idler

1) We select outer diameter of Idler D=137 mm std.

2) Width of pulley rim

B = 1.1b + (15) mm

= 1.1 137 + 15

= 166 mm

3) Thickness of the rim (s)

S = 0.005 137 + 3 mm

=3.68 mm say 5 mm

4) Diameter of Hub d1 = 2 d

= 2 30

= 60 mm

5) Length of Hub L = 2 d

= 2 30

L = 60 mm

6) Thickness of Hub = 10 mm std.

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FOR MOTOR CYCLE :-

Design of pulleys :-

Function :- The power from first idler to second is transmitted with the help of pulleys and

belt.

For Motor - cycle

The diameter of rear wheel of motorcycle d1 = 630 mm.

The diameter of first idler = d2 = 137 mm

The r.p.m. of rear wheel = N1 = 420 rpm

RPM of idler will be

N1 d1N2 =

d2

420 630

=137

N2 = 193 1.38

N2 = 1931.38 = 4.59

N1 420

Velocity ratio of pulleys should = 4.59

Taking pulley A on first idler of diameter d1 =65 mm

R.P.M. of pulley B on second idler = N4 + 420 r.p.m.

Diameter of pulley B = d4 = N 2 d3

N4

= 1931.38 65

420

= 282.38mm

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For Scooter :-

The diameter of rear wheel of scooter D1 = 480 m

The diameter of first idler D2 = 137 mm

R.P.M. of rear wheel = 580 rpm

RPM of Idler will be2

11

2

D

nNN

=

137

480580 =

= 2032 rpm

The V.R. of rear wheel of scooter and idler will be

580

2032

N

N

1

=

= 3.5

Pulley A on first idler diameter D1 = 65 mm

RPM of pulley 'C' on second idler N4' = 580 rpm

RPM of pulley A on first idler N3' = 2032 rpm

4

33

4

N

DND

=

580

652032

D 4

=

D4 = 227.7 mm say 230mm

Belt suitable for this power transmission is B -56

Design of Key

We know

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Fs = 40 N/mm2

Fc = 80 N/mm2

T = 42.74 Nm

= 42740 N mm

l= 80 mm

W = 8 mm

D = diameter of shaft

= 25 mm

1. Considering shear failure of key

T = l W Fs d/2

42740 = 80 8 Fs 25/2

Fs = 25880

242740

Fs = 5.34

Since Fs = 5.34 40 N/mm2

Design is safe.

(ii) Consider Crushing Failure of key

We know Fc = 90 N/mm2

t = 6 mm

T =2

dstressd

4

2

=2

df

2

tL 2C

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for =2d

2tL

T

=dtL

T4

=25680

427404

= 14.24 N/mm2

Since for = 14.24 N/mm2

80 N/mm2

Design is safe.

(iii) Resisting Area =dFs

2T

d1 = Bolt diameter

= 2

1d4 dFs

2T

dfs

4T2d

2

1

=

=2540

4427402

mm83.108d2

1=

d1 = 10.43 mm 12 mm (say)

Design is safe

Considering crushing failure of bolt.

T = Resisting area x fcr x d/2

2

dfcd

4r

2

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dareasistingRe

2Tfc r

=

2512

4

242740

2

=

fcr = 30 N/mm2

Since fcr = 30 N/mm2 2mm/N80

Design is safe

fabrication & assembly

Materials Required

Sr. Particulars Quantity Size (mm) Length (mm)

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No.

1. Angle

Angle

Angle

2

2

1

50 50 5

50 50 5

50 50 5

860

200

350

2. Square pipe

Square pipe

Square pipe

2

2

4

22 25 2

25 25 2

35 35 3

460

515

90

3. Round pipe

Round pipe

1

1

25

25

355

305

4. Pedestal bearing 4 6206 _

5. Idler I

Idler II

1

1

137

137

130

160

6. Pulleys 1

1

1

280

230

65

7. V-belt 1 B-56

8. Flat belt 1 2" 1800 mm

9. Spring 1 0 -100 Kg.

10. Petrol pipe 1 - 2 ft.

11. Measuring bottle 1 100 ml.

12. Plywood 1

2

3

355 300 6mm

355 150 6mm

460 355 4 mm13. Speedometer assembly 1 Luna

14. Nuts & bolts for Pedestals 8 M-12 60 mm.

15. Nuts & bolts for plywood 6 M-6 25 mm

16. Screws for plywood 4 _ _

17. Red oxide 1 200 ml. _

18. Colours 2 500 ml

19. Grease 1 250 gm

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Fabrication

FRAME STRUCTURE :-

Two 860 mm angles are welded with four rectangular pipes of size 35 35

3 mm and length 90 mm at the four corners of the angles at bottom for preparing base

stand. The slots of size 102 mm 38 mm are made in the angles at required places before

welding base. A piece of angle of size 50 50 5 mm and length 355 mm is to be weld

from the back side of the frame which has a provision of hole for tightening of bolt.

A piece of angle of same size and length 350 mm. Is welded at a distance of

204 mm from one end of base as shown in fig

Two pieces of same size angles and length 185 mm are then welded with

the phase of both back side rectangular stands.

Rectangular pipe 25 mm 25 mm 2 mm

Two pieces of rectangular pipes of size 25 25 2 mm and have length

515 mm are welded vertically on the angles which are on ground as shown fig.

After that the two pieces of same pipes of same size and of length 460 mm

are welded with the vertical pipes in inclined manner and the other end is welded with the

angles of size 50 50 5 mm.

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Round pipe :- Outer diameter - 25 mm.

Internal dia. - 20 mm.

The pipe of 25 mm. and length 355 mm are then welded with the topmost

corner of the angles.

After than one more pipe of same diameter is welded in between the two

vertical angles of length 305 mm for attaching the spring hook.

FIRST IDLER ARRANGEMENT

A mild steel round bar of 35 mm and length 510 mm is mounted on

chuck of lathe. One end is drilled to depth of 5 mm. After applying grease over the hole,

tailstock is held tightly with the hole, to eliminate the vibrations in shaft at the time of

revolving. The chuck is made to run at 430 rpm and after adjusting centre, the shaft is turn

to 30 mm diagram. Then the shaft is cut down to a length of 490 mm. A slot for key is

made in the shaft from one side. A tapped hole of 10 mm is drilled on the shaft for

fixing of drum at a distance of 170 mm from one end of shaft.

After that the idler and pulley is assembled with the shaft.

SECOND IDLER ARRANGEMENT

A mild steel round bar of 35 mm and length 510 mm is mounted on

chuck of lathe. One end is drilled from one side of 5 mm depth. After applying grease

over the hole, tailstock is held tightly with the hole, to eliminate the vibrations in shaft at

the time of revolving. The chuck is made to run at 430 rpm and after adjusting centre, the

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shaft is turn to 30 mm dia. Then shaft is cut down to a length of 490 mm. A slot for key is

made in the shaft from one side. A tapped hole of 10 mm is drilled in shaft for fixing of

drum at a distance of 170 mm from one end of shaft.

Assembly

Complete fig. of machine

The prepared angle frame is placed on ground. After that firstly all the 4

pedestal bearings are fitted on the angles in their decided places, the upper cover of the

bearings is removed. After that the first idler, pulley of 65 which is already fitted on

shaft is placed on the first two bearings which is then tightened by upper cover, by

greasing them fully from inside.

Then the second shaft on which 2 pulleys of 280 mm, 230, one idler

drum of 237 of length 130 and the speedometer worm wheel is already fixed is placed

on the second 2 bearings, in required position. After that upper cover of bearing is

tightened by greasing them fully from inside.

The V-belt is then fixed on the pulleys of 65 and 280 with required

tension in belt. After that one end of the flat belt which is attached by a bolt is tighten by

the nut by inserting into the bottom hale. By taking the another end of the belt over the

second idler and forwarded over the upper bar of frame and then it is inserted from the

upper hook of spring weight and tightened by nuts and bolts. The lower hook of the spring

weight is attached to the bottom pipe of the frame.

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After that the plywood of size 460 355 4 mm on which speedometer is

to be fixed, is fitted to frame by screws. The remaining two plywood pieces are then fixed

to angles in their required position.

Then the total frame is coloured using primer (red oxide) over it. Hence the

assembly of "two wheeler mileage testing machine" is ready for testing.

Material and Process

Sr.No. Component Material Process1 Shaft 35 mm M.S. 1. Turning upto 30 mm of length 360

mm and 25mm of length 130 step.

2. Keyway of size 80x8x3 mm on shaping

machine.

2 Idlers C.I. 137 and length 160 mm Knurling on lathe m/c

3 Frame Structures :-

Angles

Plywood

M.S.

_

Cutting and Welding

Cutting according to size

4 Pulleys C.I. Bore 25 mm on lathe m/c.

Keyway on lathe machine.

5 Pedestal Bearings C.I. Mounting on frame

6 Spring Spring steel Readymade

7 V- Belt B- 56 Readymade

8 Flat belt Cotton fabric and

Rubber

Drilling holes at required place

9 Screw, Nuts and bolts M.S. Readymade

10 Pipe M.S. Cutting and welding

11 Bearings Standard No.

6206

Mounting on a shaft

12 Speedometer _ Readymade

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Performance

Test no - 1

Model :-

Reg. No :-

Fuel taken :-

Load applied :-

Initial reading :-

Later reading :-

Mileage :-

Test No. 2

Model :-

Reg. No :-

Fuel taken :-

Load applied :-

Initial reading :-

Later reading :-

Mileage :-

Test No - 3

Model :-

Reg. No :-

Fuel taken :-

Load applied :-

Initial reading :-

Later reading :-

Mileage :-

Test No 4

Model :-

Reg. No :-

Fuel taken :-

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Load applied :-

Initial reading :-Later reading :-

Mileage :-

Advantages

1) On stand Mileage testing

2) Mileage can be tested within 25 to 50 ml of fuel

3) Ideal transmission of power.

4) Low vibrations.

5) Low cast.

6) Easy Maintenance and operation.

7) Compact in shape

8) Low weight.

9) It can be used in small service stations

10) Less skilled operator required.

11) Consuming 5 to 10 minutes.

Disadvantages

1) Slippage may occur due to misalignment.

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2) Friction between rotating parts is comparatively more.

Applications

1) Service stations of automobiles.

2) Show room of automobiles

Estimation

Sr.No Particulars Cost

1. Fabrication cost 500.00

2. Machining Charges 300.00

3 Pulleys 410.00

4 Speedometer assembly 190.00

5 Pedestals 320.00

6 Plywood 100.00

7 Bearing 520.00

8 Petrol pipe 20.00

9 V-belt 225.00

10 Flat belt 105.00

11 Fastening 50.00

12 Colours 200.00

13 Drums 250.00

14 Shafts 350.00

15 Other expenses 300.00

3840

DRIVING SKILLS & MAINTENANCE

Maintenance plays an important role for proper functioning of any machine.

Following care should be taken

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1) Drive steadily at the optimum speed i.e. at 40-50 Kmph you will surprise to find that

your frames time does not increase significantly, sudden start and stop and go driving

waste fuel.

2) Use brake Springly. A good drive anticipates stop. When your slime on the brake.

You waste a lot of useful energy.

3) Let go off your clutch unnecessary use of the clutch leads to loss power.

4) Clean air filter regularly. Dust leads to rapid wear of engine components and increase

fuel. Consumption choked exhaust parts and silence make you engine struggle to

breath causing poor combustion.

5) When your tyre pressure under inflated tyre increase rolling resistance and petrol

consumption. Test show that under inflation of tyre by 25% cause a 5% increase in

fuel consumption and 25% decrease in tyre life.

6) Stop fuel leaks, check your fuel task, carburettor and fuel lines daily for leaking fuel.

Loss of one drop of fuel per second amounts to nearly 2000 litre per day.

7) Key off the engine if you want to stop more than 2 minutes for example at railway

crossing.

8) Keep your engine in good condition. Test on a large number of vehicle show that you

can save over 6% of fuel. If your engine emits smoke, check it immediately at a

reputed garage.

9) Use superior 27 oil for lubrication. Mix superior 27 oil consuming to intentional

API/TC Specification.

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10) The Speedometer cable is to be oiled and all the bearings are to be Greased

periodically.

FUTURE SCOPE

We can develop the project in various ways with respect to loading

arrangement for accurate measuring of loads.

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By attaching various electronic circuits, we can calculate mileage of the

vehicle in the digital form to high accuracy.

We can also attach exhaust gas analyser for analysing the exhaust gases, in

this way we can also control pollution. Hence, mileage as well as (PUC) can be made

known simultaneously.

BIBLIOGRAPHY

1. Machine design

Prof. R.S. Khurmi

2. Automobile Engg.

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Prof. R.B. Gupta

3. Design data book

DPV printers, Coimbatore

4. Auto India

. Nov.2001

two wheeler milage testing machine

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