THIRDYEAR MECHANICALENGINEERING

Automobile Engineering
(22656)

A MICROPROJECT ON
“Power Steering System”

ACA D E M IC Y E A R 2023-24
 MAHARASHTRA STATE BOARD OF TECHNICAL
EDUCATION, MUMBAI

Certificate
This is to certify that the students, had carried out the micro project work for the
course Automobile Engineering on topic entitled "Power steering System" The
micro project work is here by accepted for the partial fulfilment towards
completion of Diploma in Mechanical Engineering, for the academic year 2023-24
from Government Polytechnic Ahmednagar ( MSBTE Institute code 0130)
.

Project Guide Head of the Department Principal

Prof. Gurav sir R.M. Mane B.M. Kardile

Seal of
Institute
 Index…

Sr. No Title Page No

1 Micro Project Proposal

2 Rationale

3 Aims/Benefits of the Micro Project

4 Conclusion / Learning Outcomes

5 Literature Review

Actual Methodology Followed

6

Actual Resources Used

7

Output of the Micro Projects

8

Skill Developed / Learning outcome of

9
the Micro Project
Applications of the Micro Project
10
 Micro Project Report
To study and prepare report on the constructional details, working principles and
operations of Power steering system, e.g. Rack and Pinion power steering system

1.0 Rationale:
Automobile sector has been helping the world for the overall development and it has been creating wage and self-
employment opportunities both in public and private sectors. A Mechanical engineering technologist should have an
overall understanding of various aspects of Automobile System. This course provides a broad knowledge about the
different vehicle layouts, transmissions and controls, electrical and electronics system, vehicle safety and security,
features of Motor Vehicle Acts along with automobile maintenance systems. This knowledge will be helpful to the
students in co-relating various automobile systems with each other and provide good practical input with theoretical
knowledge for technological advancement of the industry/society.

2.0 Aims/Benefits of the Micro Project:

a) Learned about different types of Power Steering system.
b) Understood purpose of Power Steering system

3.0 Course Outcomes Achieved:

C22656c: Select suitable braking and steering systems for different applications.

4.0 Literature Review:

4.1 Wikipedia- Hydropower Plant

5.0 Actual Resource Required:

Sr. No. Name of Resource/Material Specification Qty. Remark

1. Laptop H.P. 1
2. Printer - 1
3. Books Tech-knowledge 1
textbook
4. Websites Websites based on 3
Power steering
system
6.0 Outputs of the Micro project:

 Purpose of Steering System

The steering system allows the driver to guide the vehicle along the road and turn left or right as desired.
The system includes the steering wheel, which controls the steering gear. It changes the rotary motion of
the wheel into straight line motion. Manual systems were popular but now power steering has become
popular. It is now installed on about 90% of the vehicles being manufactured.

 What is Rack and Pinion steering?

While there are several types of steering systems used on the market, the two main ones
are recirculating ball steering, which is mostly used for heavy vehicles, trucks and larger SUVs, and rack
and pinion steering, which is commonly found on cars, small trucks and SUVs.

Pinion

Adjuster
mechanism

Rack

Tie-rod

Tie-rod end

Fig.1 An example of a manual rack and pinion unit. Rack and pinion systems use only inner and outer tierods, eliminating the center
link, Pitman, and idler arms.
 How does rack and pinion steering work?

Rack and pinion steering uses a gear-set to convert the circular motion of the steering wheel into the
linear motion required to turn the wheels. It also provides a gear reduction, so turning the wheels is easier.
It works by enclosing the rack and pinion gear-set in a metal tube, with each end of the rack sticking out
from the tube and connected to an axial rod. The pinion gear is attached to the steering shaft so that when
the steering wheel is turned, the gear spins, moving the rack. The axial rod at each end of the rack connects
to the tie rod end, which is attached to the spindle. When the steering wheel is turned, the piniongear
moves the rack gear side-to-side. Inner tie rods areconnected to the rack gear, either at the ends of the rack
or bolted to the center of the unit, and transfer the side- to-side motion to outer tie rods and the steering
arms orstrut assembly. When the inner tie rods are attached to the ends of the rack gear, it is called an end-
takeoff rack.When the inner tie rods are bolted at the center of the rack, it is called a center-takeoff rack.
Power-assisted rack and pinion gearboxes use a spoolvalve that is integrated into the pinion gear, shown
in Figure 2. Like the recirculating ball gearbox, a torsion bar is used. The lower end of the torsion bar is
connected to the end of the pinion gear, which meshes with the rack gear. As the driver turns the steering
wheel, thetop of the pinion gear begins to turn, but the lower end atthe rack gear does not. This is because
the weight on thefront suspension makes the rack gear resist moving. Thisdifference in torque between the
top and bottom of the pinion causes the torsion bar inside to twist. As the torsion bar twists, ports align in
the spool valve that allowfluid to pass through the valve and to one side of the piston attached to the rack
gear, as shown in Figure 8-26. When the driver turns the wheel back, the process repeatsand allows fluid to
travel to the other side of the rack piston. When the wheels are straight ahead, the ports arenot aligned, and
the fluid returns to the power steering pump reservoir.

 Rack and pinion steering ratios

Most cars need three to four complete turns of the steering wheel to go from lock to lock (from far right
to far left). The steering ratio shows you how far to turn the steering wheel for the wheels to turn a
certain amount. A higher ratio means you need to turn the steering wheel more to turn the wheels a
certain amount and lower ratios give the steering a quicker response.

Some cars use variable ratio steering. This rack and pinion steering system uses a different number of
teeth per cm (tooth pitch) in the center than at the ends. The result is the steering is more sensitive when
it is turned towards lock than when it is close to its central position, making the car more maneuverable.

There are two main types of rack and pinion steering systems:

 End take off – the tie rods are attached to the end of the steering rack via the inner axial rods.
 Centre take off – bolts attach the tie rods to the center of the steering rack.
  How does rack and pinion steering work with power steering?

When a rack and pinion system is connected to a power steering system, the design changes slightly. A cylinder
with a piston in the middle is placed in the rack. There is fluid on both sides of the piston. When pressure is
placed on the fluid on one side of the piston, it forces the piston to move, which turns the rack and assists with
steering.
  Common rack and pinion steering problems

As steering is essential for controlling your car, it’s important to diagnose and repair any steering issues
as quickly as possible. Typical steering problems include:

 Very tight steering wheel

if it is becoming more difficult to turn your steering wheel, it’s a sign that there’s probably a problem
either with your steering rack or a lack of pressure from the power steering unit. The solution could be as
simple as adding more power steering fluid, but it’s best to get it checked.

 Leaking power steering fluid

Power steering fluid levels only decrease and result in tight steering if there is a leak. This isn’t a big problem,
however the consequences for leaving it too long include causing the steering gearbox and steering rack to
overheat or gears to break. It is recommended to get this fixed when it is a simple (and cheap) task. Click here
for more information about the causes of these leaks
 Grinding noise when steering
a grinding noise from your steering gearbox comes from metal-on-metal contact, suggesting a lack of
lubrication. You’ll be able to hear it clearly when you turn either left or right. Ask your mechanic to take a look
at the problem, as your steering gearbox could need replacing.
 Burning oil smell
Power steering fluid smells like burning oil, so if you smell it when driving it’s a sign that the steering gearbox is
too hot. It’s best to stop your car as soon as possible and get the problem looked at it. Driving with an
overheated steering gearbox can result in fire.
7.0 Skill developed / Learning outcome of the Micro-Project:
a. Searching and collecting the information
b. Arranging the information in proper sequence
c. Preparing Presentation effectively.
d. Working in Group
e. Presenting information effectively

8.0 Applications of the Micro-Project:

The applications of this project are
 To know the different types of power steering systems.
 To study the Power steering system (Rack and Pinion type)

Prof. Gurav sir