Automobile Engineering (ME- 467)

1. Describe the requirement of a good clutch in an automobile. [2nd Slide 2 Set]

Solution:
Clutch: It is a mechanism which enables the rotary motion of the one shaft to be transmitted when desired to a second shaft.
Good clutch requirements:
a) Torque Transmission
b) Gradual Engagement
c) Heat Dissipation
d) Dynamic Balancing
e) Vibration Damping
f) Size
g) Inertia
h) Ease of Operation
i) Free pedal clutch play

2. How does the synchromesh gearbox work?

Solution:
Synchromesh gearbox: It is similar to constant mesh
Type gearbox where Synchronizer unit is used instead
of dog clutch.
 Gears are in constant mesh
 Main shaft gears are free to rotate
 Lay shaft gears are fixed to it
 Instead of dog clutch synchronizer unit is used
 Each pair of gear has one synchronizer unit
 Avoids the necessity of double declutching
 Synchronizer works like a friction clutch
 it equalize the speed of gear and dog Figure: Synchromesh gearbox
 to ensure smooth meshing
Working principle:

 Main shaft is connected to the wheel

 So, it is always rotating
 Lay shaft is connected to the engine
 when clutch is disengaged
 It rotates freely
 now, gears are first brought into frictional contact with synchronizer
 Synchronizer equalizes the lay shaft speed
 Then, the engagement takes place smoothly.

# In a constant mesh gearbox to equalize speed, clutch has to press twice this is known as double declutching.
3. What is the purpose of transfer case?
Solution: Transfer case: It is a part of four-wheel drive and used to transmit power from the transmission to the front and rear
drive shafts.
Purpose of transfer case:

 It receives power from the transmission

 and sends this power to both the front and rear axles
 This can be done with gear on chain drive.

4. With neat Sketch discuss the working principle of differential.

Solution: Differential Gear: It is a gear train with three shafts which used to rotate wheels at different speed during turn.

 It consists of
1. pinion drive gear
2. Crown wheel (ring gear)
3. planet gear (spider gear)
4. Sun gear (side gear)

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 Automobile Engineering (ME- 467)

 pinion gear connected with input drive shaft

 crown wheel mashed with pinion gear and it
(i) change & power flow direction in 90°
(ii) reduce gear ratio to increase the torque
 planet gear connected with crown wheel and it
(i) transfer power from crown wheel to sun gear
(ii) has 2 kinds of rotation
a. rotation along with crown wheel
b. rotation on its own axis
 Sun gear connected with rear axles and it transfer power from planet gear to shaft.

Working principle:

# When vehicle moves straight:

 Nleft = Nright
 the planet gear rotates along with sun gear
 but does not rotate on its own axis

# When vehicle takes a turn:

 Nleft = Nright
 inner wheel rotates less then outer wheel
 planet gear has a combined rotation
 planet gear rotates along with the sun gear
 also it rotates on its own axis
 it makes differential speed between inner and outer wheel

5. Write short notes on

a. Propeller Shaft
b. Overdrive
c. Planetary gear
d. Fluid Coupling

Propeller shaft: It is a shaft that transmits power from gear box to the differential.
Function:

 transmits rotary motion of gear box to the differential

 helps to rotate rear wheels

Overdrive: It is device to step up the gear ratio which

allows the engine to operate at a Lower rpm for a
given road speed.
It consist of -
i. Input shaft
ii. Sun gear
iii. Carrier
iv. Free wheel clutch
v. Output Shaft
vi. Ring gear

Planetary gear: It is a gear train. This allows changing gear ratio without having engagement or disengagement of a clutch.
 It consists of

(i) Ring gear

(ii) Sun gear
(iii) planet gear

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 Automobile Engineering (ME- 467)
Fluid Coupling: It consists of an impeller on driving shaft and a runner on
driven shaft which transfers energy from one rotor to another by means of Fluid.

6. How anti-lock breaking system works (ABS)? [1ST PDF 2 SET]

Anti-lock breaking system (ABS): It is an anti-skid breaking system which operates by preventing the wheels from locking up
during breaking thereby maintaining tractive contact with the road surface and avoiding uncontrolled skidding.
Working principle:
 It consists of four main parts
i. Speed sensors
ii. valves
iii. a pump
iv. a ECU

i. Speed sensors: There are four sensors which are located at each wheel. It provides information when a wheel is
about to lock up
ii. Valves: There is a valve in the brake line of each brake. It is used to control fluid pressure.
iii. A pump: When ABS system operates, the pressure falls. The pump is used to represurise the system
iv. ECU: A central electronic control unit (ECU) monitors constantly the rotational speed of each wheel.

 When a wheel is about to lock up

 Speed sensor collect this information and Send to the ECU.
 Then ECU send signals to the actuator valve to reduce the fluid pressure.
 Thus, reducing the brake force on that wheel
 The wheel then turns faster.
 If ECU detects a wheel, turns fasten then other wheel
 Pump is used to increase breaking force.

That’s how an anti-lock breaking system works.

So, it is used to
 maintain tractive contact
 prevent lock-up of wheel
 avoid uncontrolled skidding
 Brakes safely.

7. A car of mass 800 kg is travelling at 36 kmph. Determine

I. The kinetic energy it possesses and
II. The braking efficiency of a vehicle if the brakes bring the vehicle to rest from 60 kmph in a distance of 15m.
Solution:
I. kinetic energy: Given Data,
We know, m = 800 kg
1 V= 36 kmph
𝐸 = 𝑚𝑣 36 × 1000
2 = 𝑚/𝑠
1 36000
= × 800 × 10
2 =10 m/s
= 4000 𝑁

II. Breaking efficiency:

We know, Here,
Breaking distance, 𝑑 = × V= 60 kmph
𝜼𝒃𝒓 60 × 1000
1 𝑣 = 𝑚/𝑠
⇒𝜂 = × 36000
2 𝑔𝜇𝑑 =16.67 m/s
= ×
. d= 15m
. × . × 𝜂 =?
=104.9% 𝜇 = 0.9

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 Automobile Engineering (ME- 467)
8. A Maruti car moving at 80 kmph takes 32m to stop when the brakes are applied on it under standard test conditions.
How much is its braking efficiency? Also determine the retardation.
Solution:
1. Breaking efficiency:
We Know,
Braking distance, 𝑑 = ×
𝜼𝒃𝒓
1 𝑣 Given Data,
⇒𝜂 = × Here,
2 𝑔𝜇𝑑
.
V= 80 kmph
= × 80 × 1000
. × . ×
= 𝑚/𝑠
=87.4% 36000
2. Retardation: =22.22 m/s
We know, d= 32m
𝑎 𝜂 =?
𝜂 = × 100%
𝑔 𝜇 = 0.9
⇒𝑎 =𝜂 ×𝑔
=0.874× 9.81
=8.57𝑚𝑠
9. What is power steering system? Explain in brief.
Power steering: It is a steering system which uses power from the engine so that it is easier for the driver to steer the vehicle
 there are two types of power steering
i. Hydraulic power steering (HPS)
ii. Electric power steering (EPS)

 In HPS hydraulic pressure is used to create steering effort.

 In EPS an electric motor is used instead of fluid.
 main components of power steering
i. Reservoir
ii. Steering gearbox
iii. Rotary valve
iv. pump

a) Reservoir: It is used to reserve oil. This oil acts as fluid medium of

hydraulic pressure.
b) Steering gear box: It contains gears that transmits drivers input to steering linkage
and it multiply the drivers steering change.
c) Rotary valve: The device that sense the force on the steering wheel.A torsion bar is connected to measure the
torque applied to the steering.
d) Pump: It is used to increase hydraulic pressure. In former it is driven by the engine but now independent motor is
used.
 When a driver starts a turn
 the rotary valve sense the force
 it allow the fluid flow to the cylinder
 fluid extent hydraulic pressure on the piston
 This pressure assists the rock effort.
 So, driver makes turn fairly easy.

10. Describe Mechanical breaking system.

Mechanical breaking system: It is a braking system working by generating frictional force between two surfaces.
 there are two types of mechanical brake
a. Drum brake
b. Disc brake
a. Drum type: Drum brakes have a drum attached to the.
wheel hub It has two types
a. Internal expanding
b. External expanding
 In Internal expanding drum brake:
 Brake shoes contained within rotating drum
 Brake shoes expands outwards
 And create friction with rotating drum
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 Automobile Engineering (ME- 467)

 In External expanding drum brake:

 Brake shoes contained outside rotating drum
 Brake shoes contract inwards.
 And create friction with rotating drum

b. Disc type: A disc is used between a Caliper and a piston to

create friction while braking occurs

 When driven press brake pedal

 hydraulic pressure increased
 this pressure to transferred to the piston
 Piston creates friction with disc
 this friction reduces rotating motion of disc
 the disc is attached to the wheel
 So car's wheel also slowed down
 it gives good braking even at high temperature
 Better braking force than drum type brake.
 it is used in modern bikes, cars
 Drum type brake used in trucks, buses.

11. Give a comparison between disc and drum type brake.

Disc brake Vs. Drum brake:

Disc Brake Drum Brake

It uses disc shaped rotors It uses cylindrical drum
It uses a clamp (caliper) to hold the friction pods against motor It uses expanding brake shoe to press the friction against
disc rotating drum
Good breaking even at high temperature Reduced performance at high temperature
Better heat dissipation Slower heat dissipation
Fast braking, better braking force Slow braking
Cost is high Cheaper then disc brake
Generally used in modern bikes, cars used for bus, trucks
total frictional area is less total frictions, area is more
Lower weight higher weight

12. Write the essential properties of brake fluid.

Properties of brake fluid:

 Does not thicken on then with changing heat

 Must not boil
 Must lubricate internal parts
 Must not evaporate easily
 Non-compressible
 very low frizzing point
 very high boiling point
 Non corrosive
 Hygroscopic (absorb water)
 Correct viscosity at all temperature
 Example: ether, castor oil, mineral oil.

13. Describe the CNG production with neat sketch. [Last slide 1 set]
Solution: CNG Production: CNG is made by compressing natural gas of atmospheric pressure into the required pressure in the
order of 3000 psi.

 It is done through four stager using single acting reciprocating compressor in each stage.
 From Supply pipeline, natural gas is supplied into an inlet pressure vessel to gauge and to bring it to exactly at
pressure of 10 psi.
 From there the gas goes into the first stage comparison
 Here it is compressed up to 60-70 psi.
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 Automobile Engineering (ME- 467)
 Then gets cooler and separated from dust particles are also to get compressed up to 470-500 psi in 2nd stage.

 In third stage compression pressure ready to 1400 psi

 And at the end of it fourth stage compression (3600 psi) from where it is taken to storage tank.
 To make the CNG for vehicles, it goes from storage tanks to dispenser which disperses gas into vehicles.
 the dispenser takes CNG sequentially of high, medium and low pressure/ tanks respectively to make optimum use
of the storage and delivers it at 2900 psi
 Gas dispensed is metered electrically

14. What is dual fuel system?

Solution: Dual fuel system: Dual fuel system is the diesel engine that can run on both gaseous fuel and diesel fuel at the same
time in a CI engine

 Injection of small amount of diesel fuel can be used ignition source.

 No spark plug required
 Natural gas mixes with intake air
 Diesel can be used on its own if the vehicle runs out of natural gas.

15. Why conversion of diesel engine into CNG is difficult?

Solution: Diesel engine to CNG conversion:

 In diesel engine,
 CNG can be used either as a dust fuel or mono fuel
 In dual fuel mode,
 diesel provides combustion initiation for CNG burning, so no spark plus required
 But, the gains in emission reduction of diesel with CNG is quite low.
 For limitation of emission reduction in a dust fuel system,
 CNG can be used as mono fuel by converting the diesel engine to a spark ignition engine.
 This conversion wants major changes in the engine
 Such as, cylinder head modification for inclusion of spark plug.
 Compression ratio requires to be lowered by fitting low compression piston.
 That's why conversion of diesel engine into CNG is difficult.

16. Write short notes on

1) TCU
2) ECU
Solution:
1) TCU: The TCU (Telemetic Control Unit) is a smaller computer which makes integrated use of telecommunications and
informatics in a modern automotive vehicle
 It is used to listen in on the communications of other ECU (Electronic Control Unit) in the car.
 TCU is the primary communication module which connects the automobile to the external worlds.

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 Automobile Engineering (ME- 467)
Functions of TCU:
 Crash Detection and reporting
 Roadside assistance
 Stolen vehicle tracking
 Remote door lock/unlock
 Software upgrade OTA
 Maintenance status report
 Remote diagnostics
 Hands free module support
 In vehicle Wi-Fi

2) ECU: The ECU (Electronic Control Unit) is a type of electronic control unit that determines the amount of fuel, ignition timing
and other parameters of an internal combustion engine needs to keep running.
 It does this by reading values from Sensor devices monitoring the engine
Function of ECU:
 Control of fuel injection
 Control of ignition timing
 Control of idle speed
Sensors used in ECU:
 Oxygen sensor
 Throttle position sensor
 Engine temperature sensor
 Mass air flow sensor
 Inlet air temperature sensor
 Crankshaft position sensor

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