LAYOUT OF AN AUTOMOBILE

enginechasis is shown
in the Figure 1.l given bclow:
Layout of an

Gear Lever
Steering Wheol
Car Body Diierenta!
Battery
Alr Cleanor
Engine Shock Absoter
Atemator

Suet Tas

Head Lamp Back Ught

Fan

Radiator
Rear Brake
Distibuor
Whee!
Carburetkor and
TiPi4
Universal Rear Axe Tyres
Tredk Rod Exhaust Joint
Clutch
Pipe Slencer Leaf Spring

Hand Brake
lever
Fig. 1.1 Layout of an Automobile

It contains the source of power, i.e. engine, the

frame, which supports the engine, wheels, body,
suspension system and
transmission, the braking system and the steering. It also gives support to
springs.
COMPONENTS OF THE AUTOMOBILE

The automobile can be considered to consist of five basic components :

(a) The Engine or Power Plant :It is source of power.
(b)The Frame and Chasis :lt supports the engine, wheels, body, braking system, steering, etc.
(c) The transmission which transmits power from the engine to the car wheels. It consists of
clutch, transmission, shaft, axles and differential.
d) The body.
)Accessories including light, air conditioner/hearer, stereo, wiper, etc.

Scanned by CamScanner
 AUTOMOBILE
EUNCTIONS QF MAJOR COMPONENTS OF AN
Chasis and Frame
members and cross members, Thc frame is
The chasis is formcd by the frame with the frame side
wclded or riveted together. In
uSvally made of box, tubular and channcl members that arc
the steering system and the
addition to this, it compriscs of the springswith the axles and whecls,
other accessorics. Along
brakes, the fuel tank, the exhaust system, the radiator, thc battery and
with this the frame supports the body.
Engine or Power Plant
engine with petrol
The engine is the power plant of the vehiclc. In general, internal combustion four
or diesel fuel is used to run a vehicle. An cngine may be either a two-stroke engine or a
stroke engine.
(or MPFI
An engine consists of a cylinder, piston, valves,valve operating mechanism, carburetor
in modern cars), fan, fuel feed pump and oil pump, etc. Besides this, an engine requires ignition
system for burning fuel in the engine cylinder.
Transmission System (Clutch and Gear Box)
The power developed by the engine is transferred to the wheels by transmission system.
Transnission system must do three jobs:

(a) It must provide varying gear ratios. Number of gear ratios are equal to number of gears in a
vehicle.

(b) It must provide a reverse gear for moving vehicle in reverse direction.
(c) It must provide a neutral or disconnecting arangement so that the engine can be uncoupled
from the wheels of the vehicle. In a conventional transmission system, there is a clutch, a
manually operated transmission (gear box), apropeller shaft and adifferential or final drive.
Clutch

The purpose of the clutch is to allow the driver to couple or decouple the engine and
transmission. When clutch is in engaged position, the engine power flows to the transmission
through it (clutch). When gears are to be changed while vehicle is running, the clutch permits
temporary decoupling of engine and wheels so that gears can be shifted. In a scooter, the clutch
isoperated by hand where as in acar the clutch is operated by foot. It is necessary to interrupt
the flow of power before gears are changed. Without a clutch, it will by very difficult.

Scanned by CamScanner
FinalDrive
reduces the speed of
the last stage in ransierring power from engine to wheels. It
Thnal drive is turns the drive of the propeller shaft by
propcller shaf (drive shaft) to that of wheels. It also meshes
the
to drive the whcels.The propeller shaft has asmall bevel pinion whích
90o of crown wheel
an angleof crown whecl gives rotary motion to rear axles. The size
with crown whccl. The wheel) in lower
bicgcr than that of bevcl pinion, therefore, the speed of rear axles (or crown
in
pinion. Final drive is oftwo types, i.e. chain type and gear type.
than thespccd of
Braking System
Hydraulic brakes are generally used in
Brakes arc used to slow down or stop the vehicle. in
where brakes are applicd by pressure on a fluid. Mechanical brakes are also used
automobiles,
leavers, linkages, pedals, cams, etc. Hand
some vehicles. These brakes are operated by means of
These are used for parking the vehicles on
brake or parking brake is usually a mechanical brake.
sloppy surfaces and also in case of emergency.
Gear Box
Gears are used to get more than
Gear box contain gearing arrangement to get different speeds.
both will rotate at same
one speed ratios. When both mating gears have same number of teeth,
with less number of teeth
number speed, But when one gear has less teeth than other, the gear
reverse
willrotate faster than larger gear. In a typical car, there may be six gears including one
gear. First gear gives low speed but high torque. Higher gears give progressively increasing
speeds. Gears are engaged and disengaged by a shift lever.
Steering System
In front wheels can be turned to left and right by steering system so that the vehicle can be
steered. The steering wheel is placed in front of driver. It is mechanically linked to the wheels to
provide the steering control. The primary function of the steering system is to provide angular
motion to front wheels so that vehicle can negotiate aturn. It also provides directional stabilityto
vehicle when the vehicle moves ahead in straight line.Now-a-days, many vehicles are equipped
with power steering which uses pressure of a fluid to reduce steering effort. When driver turns
the steering wheel, a hydraulic mechanism comes into play to provide most of the effort needed
to turn the wheel.

Front Axle

Front axles are mounted at the end of front axle. Apart of the weight of vehicle is transmitted to
the wheels through this axle. The front axle performs several functions.
It carries the weight of the front of the vehicle and also takes horizontal and vertical loads when
vehicle moves on bumnpy roads, When brakes are provided on front wheels, it endures bending

Scanned by CamScanner
 in
generally made from steel drop forging. It is robust
cresses and torsional stresses. It is
construction.

Suspension System
wheel and axle assembly of the automobile
Suspension system of an automobile separates the
is to isolate the body of the vehicle from
from its body. Main function of the suspension system surface of roads. Shock absorbers are
shocks and vibrations generated due to irregularities on the
damper. The suspension
provided in the vehicles for this purpose. It is in the form of spring and
system is provided both on front end and rear end of the vehicle.
Asuspension system also maintains the stability of the vehicle in pitching or rolling when
vehicle is in motion.

Scanned by CamScanner
 Exp.3

Typical Disk Brake

BRAKING SYSTEM
Typical Drum Brake
Master Cyinder

Front Brakes Brake Pedal

Rear Brakes

Brake Lines

Typicai Automotive Braking System

Braking system is necessary in an automobile for stopping the vehicle. Brakes are applied on the
wheels to stop or to slow down the vehiçle.

EUNCTIONS OF VEHICLE BRAKING

There are two main functions of brakes :
(a) To slow down or stop the vehicle in the shortest possible time at the time of need.
(b To control the speed of vehicle at turns and also at the time of driving down on a
hill slope.
NCPLE OFVEHICLE BRAKING
adng of avehicle depends upon the static function that acts between tyres and road surface.
work on the following principle to stop the vehicle:
dcccry.due tomotion of the vehicle is dissipated in the form of heat energy due to
woen moving parts (wheel or wheel drum) and stationary parts of vehicle (brake

y o generate4d due to application of brakes is dissipated into air.

most effoctively wben they arc applied in a manner so that whecls do not lock
Continpe to rollwithout slipping on the surface of roa.

Scanned by CamScanner
 CLASSIFICATION OF BRAKES
Onthe Basis of Method of Actuation

(a) Foottbrake (also called

service brake) opetatcd by foot pcdal.
(b) Hand brake- it is also called parking brakc
operated by hand.
On the Basis of Mode of Operation
(a) Mechanical brakes
(b) Hydraulic brakes
(c) Air brakes
(d) Vacuum brakes
(e) Electric brakes.
On the Basis ofAction on Front or Rear Wheels

(a) Frontwheel brakes

(b) Rear-wheel brakes.
On the Basis of Method of Application of Braking Contact
(a) Intermally - expanding brakes
(b) Externally -contracting brakes.

SHORT NOTES ON MISCELLANEOUS BRAKING SYSTEMS

Air Brakes
Air brakes are applied by the pressure of compressed air. Air pressure applies force on brakes
shoes through suitable linkages to operate brakes. An air compressor is used to compress air.
This compressor is run by enginc power.
Vacuum Brakes
Vacuum brakes are a piston or a diaphragm operating in a cylinder. For application of brakes one
side of piston is subjected to atmospheric pressure while the other is applied vacuum by
Cxhausting air from this side. A force acts on the piston due to difference of pressure. This force
iS used to operate brake through suitable linkages.

Scanned by CamScanner
Electric
Brakes

laclectricalbrakes an electromagnet 1s used to actuate a cam to expand the brake shoes. The
cleciromagnetis energized by the curent flowing from the battery. When flow of
current is
stoppedthecamand brake shoes return to their original position and brakes are disengaged.
brakes are not used in automobiles as service brakes.
Electric
HYDRAULICBRAKES

Brake Fluid Reservoir

Master SpV

Cylinder
Assembly

PusnSOd t ¡ Brake
Brake Caliper Mast Cylindsar
Pistons Piston
Caliper
Assembly

Rolor
(Brake Disk}

The brakes which are actuated by the hydraulic pressure (pressure of a fluid) are called hydraulic
brakes. Hydraulic brakes are commonly used in the automobiles.
Principle
Hydraulic brakes work on the principle of Pascal's law which states that "pressure at a point in a
Aluid is equal in all directions in space". According to this law when pressure is applied on a fluid
it travels equally in all directions so that uniform braking action is appliedon all four wheels.
Construction and Working of Hydraulic Brakes
When brake pedal in pressed, the force is transmited to the brake shoes through aliquid (link).
Ihe pedal force is multiplied and transmitted to all brake shoes by a force transmission system.
Figure 6.1 shows the system of hydraulic brake ofa four whecler automobilc. Itconsists of a
master cylinder, four wheel cvlinders andpipes carrying a brakefluid from master cylinder to
whecl cylinder.
mastercylinder is connected to allthe four-whcel cylinders by tubing or piping. AlI
cylinders and tubes are fitted with afluid which acts as alink to transmit pedal force from master
cylinder 1o wheel cylinders.

Scanned by CamScanner
Brake
Fluid

filledinthe hydraulic brake system is known as brake fluid. It is a mixture of glycerine

flluuid
The
alcohollorcaster l and some additives.
oil
and
Mastercylinder consists of a piston which is connected to peal through connecting rod. The
consists oftwo pistons between which fluid is filled.
wheelcylinder
Each wheel
brake consists offa cylinder brake drum. This drum is mounted on theinner side of
wheel. The drum revolves with the wheel. Two brake shoes which are mounted insíde the drum
Heat and wear resistant brake linings are fitted on the surface of the brake
remain stationary.
shoes.
ApplicationofBrakes
When brake pedal is pressed to apply the brakes, the piston in the master cylinder forces the
brake fluid. This increases the pressure of tluid. This pressure is transmitted in all the pipes and
unto all wheel cylinders according to Pascal's law. This increased pressure forces out the two
wictons in the wheel cylinders. These pistons are connected to brake shoes. So, the brake shoes
erpand out aginst brake drums. Due to friction between brake linings and drum, wheels slow
down and brakes are applied.two pipes carrying braked fluid are connected to front wheel
evlinders which may be same as rear wheel cylinders. The front wheels may also have same type
of brakes (drum brakes) as shown in the rear wheels. But, in modern cars, there are disc brakes in
the front wheels and drum brakes in the rear wheels.

Release of Brakes

When pedal is relcased, the piston of master cylinder returns to its original position due to
retractor spring provided in master cylinder. Thus, fluid pressure drops to originalvalue. The
retractor spring provided in the wheel cylinders pulls the brake shoes and contact between drum
and brake linings is broken. Therefore, brakes are released.
CONSTRUCTION AND WORKING OF MECHANICAL BRAKES
Iidenal expanding shoe brakes are most commonly used in automobiles. In an automobile, the
Wheel is fitted on awheel drum. The brake shoes come in contact with inner surface of this drum
to apply brakcs.

Ihe construction of intermal expanding mechanical brake is shown in Figure 6.2. The whole
Sembly consists of a pair of brake shoes along with brake linings, a retractor spring two anchor
Ps acam and a brakc drum. Brake linings are fitted on outer surfaceof each brake shoe. The
brake shocs arc hiinged at one cnd by anchor pins. Other end of brake shoe is operated by acam
o
Cxpand it out against brake drum. Aretracting spring brings back shoes in their original
position when brakes arc not applied. The brake drum closes inside it the whole mechanism to

Scanned by CamScanner
protect
ittrom dust and first, Aplate holds whole assembly and fits to car axle. It acts as a base
the
brake shoes and other operating mechanism.
fasten
to
Brakesare Applied
and Released
How
Whenbrakeepedalis pressed, the cam turns through brake linkages. Brake shoes expand towards
brakedrumdue to turning of cam. The brakelinings, rub against brake drum and therefore
motionofwheelsis stopped. The pedal force is transmitted tothe brake shoes through a
mechanicallinage. This meechanism also multiplies the force to applythe brakes effectively.
When force on brake pedal is removed, the retractor spring brings back shoes in original position
released
and brakesare
DISCBRAKES

Mdem motor cars are fitted with disc brakes instead of conventional drum tyne bralkes In
Sontro car and Maruti-800, iront wheels are provided with disc brakes whereas rear wheel are
provided with drum brakes. Adisc brake consists of a rotating disc and two friction pads which
are actuated by hydraulic braking system as described ealier. The friction pads remain free on
each side of disc when brakes are no applied. They' rub against disc when brakes are applied to
on the yehicle. These brakes are applied in the same manner as that of hydraulic brakes, But
mechanism of stopping vehicle is different than that of drum brakes.
Advantage of Disc Brakes
(a) Main adyantage of disc brakes is their resistance to wear as the discs rermain cooleven after
repeated brake applications.
(b) Brake pads are easily replaceable.
(c) The condition of brake pads can be checked without much dismantling of brake system
Diaadvantage of Disc Brakes
(2) More force is needed be avpliedas the brakes are not self
emerging.
(b) Pad wear is rmore.
iand brakes are not effective if disc brakes are used in rear whecls also. (Hand
brakes are
beter with mechanical
brakes).
PARKING BRAKE OR EMERGENCY BRAKE
Paking brakes or emergency brakes are cssentially mecharnical brakes operuted by hand. These
egod tO
Cars, these prevent thc generally
motion of vchicle when parked al aplace or when parked on slopes. In
brakes arc attached to rear wheels. In this type. a cuble connects the hand

Scanned by CamScanner
levertothebrake. Brakes are applied by pulling the lever and released by pushing abutton
the
on,lever) and pressing lever down.
(provided
BLEEDINGOFBRAKES

enters,intothei brake system and any brake line is disconnected, bleeding of brakes has
Whenair compressible so any presence of air inside brake lining does not allow to
to bedone. Since air is
transmitbrakeforce toapply brakes. Therefore, the system must be free from presence of air.
sofremoval of air from the. braking system.
Bleedingisthe process

Scanned by CamScanner
 Exp.4
SUSPENSION SYSTEM
fan automobile are mounted on
front and rcar axles through springs and
bodyof:
frameand mounted dircctly on axles, all socks
the and vibrations will be
The absorbers.Ifitis absorbers are
shock causing discomfort to the passengers. The springs and shock
transmittedto
body
shocksandIvibrations. The suspensions
system includes all those parts which
the
damp
usedto performthedamping action. Besides, springs
and shock absorbers, asuspension
areused
to mountings also. The suspension system ofa vehicle is divided into front
includes other
system suspension.
suspen1sionandrear
SUSPENSIONS WORK Basic Components
HOW CAR

Control
Arm S
Shock
Absorber

Frame

-3Steering
Linkage

FUNCTIONS OF SUSPENSION SYSTEM

(a) The main function of a suspension system is to prevent the socks to transmit to car or vehicle
body so that passengers may ride comfortably.
(0) 10 maintain the stability of vehicle during pitching and rolling actions while the vehicle is in
motion.
(e) Toprovide beter road holding at the time of driving, braking and cornerìng.
(a) To allow proper stoering geometry.
SRRNGS
Diferet types of spring are used in the suspemsion system of an automobile. Springs absorb the
Ssy Which is generated due to force which comes when vehicle moves over bumps and

Scanned by CamScanner
 Springsare required to absorb the cnergy of shocks very quickly and relcase it slowly
trenches. absorber is also used. Coil springs and lcaf springs arc used in the
slowly.Forthis a
and Besidesthis sone other devices are also used such as torsion bars and shock
automobiles.
absorbers.
Descriptionofthese devices is given in the following scctions.
LEAFSPRINGS

are made by placing several flat strips onc over the other. Thesc are made of stcel
Thesesprings aleaf Lowest lcafis of smallest length and the length of other
plates.Oneflat strip is called
placed above this keeps on increasing progressivcly. In this way, the length of top most
leaves
largest. Main leaf has eyes at the ends. All the lcaves are clamped together at
leaf(main leaf)
centreandIsides by
the centre bolt and side clamps respectivcly. The centre portion ofthe leaf
to the axle with the help of U-bolt. Spring eye is used to attach spring to the
springs is connected one eye. Other end of leaf spring is attached toa
shackle
body frame by passing a bolt through
is in turn attachedto chassis. The shackle is used to accommodate any
through its eye. Shackle contraction. The contraction and expansion
change in length of spring due to its expansion and irregularities. Semi-elliptical springs are
surface
takes place when the vehicle passes over road
In case, leaf springs were used in rear
generally used in all the vehicles particularly n trucks. springs are not used n cars also.
front. But, leaf
SuSpension and independent suspension in the
COIL SPRINGS

springs are in the form of helix. These are made from special steel. It is made from steel
Coil
energy when this spring is compressed while
wire in the form of a coil. The coilsprings absorb
mainly used in independent suspension.
vehicle moves over road bump. The coil springsare
axle suspension. Coil springs are
However, these can also be used in the conventional rigid
torsion and side thrust.
capable of resisting shear and bending stresses but not
arrangements are made to bear
When coil springs are used in the suspension system, other
torsion and side thrustL

Scanned by CamScanner
AdvantagesofCoiI
Springs
almost double encrgy per unit
than leaf springs as hey can absorb
better
are
springs
to
Coil Compared leafsprings.
(a)
as
Voume than leaf springs and can be used in very restricted
spaces.
require lessspace
also
They
6) lighterr in weight for the same load.
springsare
Coil
(c)
insize.
Compact
(d)
TORSIONBARS

stresses. Torsion bar acts as spring

steel rod which an take torsional and shear
Torsion bar is a shown in Figure 8.3. One
arm parallel. The torsion bar is
and keens the lower and upper control Other end is also
x-section which fits into lower control arm,
end of the rod is made of hexagonal on the
attached to an anchor, When any force acts
hexagonal x-section which fits into an arnchor
wheel axle is supported by lower control arm.
wheelassenbly, the torsion bar gets twisted. The lower am
arm. The torsion bar is used to keep the
The torsion bar is connected to lower control allowing
provides cushion to road shocks by
at agiven height. This suspension (torsional bar) occupies normal condition when the
the lower arm to twist the torsion bar. The torsion bar
up and down the torsion bar is twisted
wheels are not under any stress. When the wheels move
and it absorbs the vibrations so generated.

SHOCK ABSORBERS
lf only springs are used to absorb shocks, the oscillations of springs continue even after the
Vehicle has passed over a bump, The oscillations cause the wheels the jumps up and fall down till
ne oscilations dic out, Thus. dampers or shock absorbers are used to arrest the oscillation of
Springs after the vehicle passes over irregular road surface.
Shock absorbers are necessary used with coil springs. In case of leaf springs, the friction between
eaves provides some dampening effect. However, this is not sufficient sometimes, depending
Cpon netion between leaves, Hence. shock absorbers are necessarily used as additional damping
devices.

Scanned by CamScanner
 Shock
Absorbers
of
Runction
earlier,thefunction of the shock absorber is to dampen the vibrations of
coil and
vehicle passes
As
explained suspension system, These vibrations are generated when
usedinthe
leaspringsS
bump.
road
a
Over Shock Absorber
Telescopictype
gof
Working absorbers use apiston and a cylinder
hydraulicshock absorbers are used. These
modencars, suitable oil. The oil is used to dampen the oscillations of piston by
In filled with a
cylinderis
awhere
suitablearrangement.
tube.
absorber, mainly consists of a piston a cylinder tube and areservoir
The telescopicshock
provided with through orifices or opening so that fluid can pass
from top to
is
has been
Thepistonfrom top reservoir. Figure
8.4(a) shows the condition when absorber
bottom to shock
Under this condition the
bottomor
This happens when vehicle passes over abump.
compressed. down into cylindertube.
length. The piston rod forces the piston
short in forcefully
absorber becomes compressed to high pressure. The fluid passes
under the piston is the
Thenefore. fuid
into the moves ahead of bump or drops into a depression in
through small orifices (in piston) condition the piston moves up in the cylinder
tube.
expands. Under this
road. the shock absorber of cylinder tube to the lower part through
the
is forced from upper part
Because ofthis, fluid
orifices provided in the piston.
Because of
cases, i.e. expansion and compression, fluid is forced through orifices.
In both the
slowed down. This puts restriction over the spring action and
this the motion of the piston is depression
frame are arrested in shortest time. In this way, shocks (of bump and
vibrations of the wheel
absorbed by the shock absorber. It also prevents excessive oscillations of
of road) are
when it passes over a bump and depression on the road.
automobiles
are always provided along with springs in the suspension system of
Onoek absorbers
to prevent oscillations of springs.
TYRES
tube between rim and itsclf. Air is
Countcd on the rims of wheels. Thcy enclose a
inflated due to air pressure inside
ata pressure inside the tube. The tyre remains
designated some of the
tube. The tyre carries the vehicle load and provides cushioning effect. It absorbs vehicle's
surfaces. It also resists the
vibrations generated due to vehicle's movenent on uneven when vehicle
tendency to OVeT steer or turm which comering. Tyre must generate minimum noise
takes turn on the road. It should provide good grip with the road surface under all conditions.

Scanned by CamScanner
TYPES
OFTVRES

areused in
vehicles:
pesoftyres
Tho
and
(yres,
Tuihe
a Tubeless
)
(6) tyres,

are
called pneumatic tyres because air is filled in them.
thesetyres
Both

TubeTyres
a tube which is wrapped on the wheel rim. Air
is forced into tube whích
tyres.encloses
Tube
tube,and tyre. The outer side of tyre which comes in contact of road is made from
inflatesthe
iscalledItread. Tread provides resistance to slipping. It is very thick at the outer
rubber. It
made atthe inner bide by reinforcing it with steel wires. Beads are very
penphery.Beads are
which have good resistance to wearing against the wheel rim. Rayon cords are also
strong piles. Beads are cords provide good strength to tyres.
formeddinto anumber of

Tubeless Tyres
pressure is filled into the tyre itself. The
These tyres do not require any tube. The air at
the air, a non-return valve is filled in
construction of tyre is same as that of tube tyre. For filling
the tyre itself.
Advantages ofTubeless Tyres
(a) Tubeless tyres are lighter in weight.
(0) They remain cooler compared to tube tyres.
for long time even if these
(0) The main advantage of tubeless tyre is that they remain inflated
re punctured by a nailifthe nail remains inside the tyre.

Ay hole in the tyre, due to puncture, can be repaired by rubber plugging.

(e) Asimple puncture can be: repaired without removing tyre from wheel.

Scanned by CamScanner
 Exb. s
STEERING SYSTEM

DRVZ EAT
DRAGONX
BOX
BALJONT
DRAO-NK
DIOP AM

DRAO
NK

FORWARD
DrRCTON

KNO
SEAT

ACKOO
AaE TRACK-00
TRACK-ROD ND O0ST
AM

Steering is the term applied to the collection of components, linkages, etc. which will allow a
vehicle to follow the desired course.

An automobile is steered with the help of steering gears and linkages, which transfer the motion
of the hand operated steering wheel to the pivoted front wheel hubs via steering column. The
other parts that are used for steering a vehicle are steering wheel pads, steering shafts, steering
boxes, steering arms and steering stabilizers. These parts are made of durable materials like
stainless steel, iron, aluminun, copper, magnesium, titanium, platinum, rubber, and plastics.
FUNCTIONS OF STEERINGSYSTEMS
It helps in swinging the wheels to the left or right.
It converts the rotary movement of the steering wheel into an angular turm of the front wheels.
It multiplics the efforn of the driver by leverage in order to make it fairly easy toturn the wheels.
absorbs a major part of the road shocks thereby preventing them toget transmitted to the hands
of the driver
STEERINGGEOMETRY
known as "ront-cnd gcomctry") refers to thc angular
geomelry"(also front whccls, and the road surfacc. Bccause
"seering suspensionand stcoring parts,
Theterm betwecn stccring,the mcthodl of describing alignment
Relationship atnglesandaffects
with
alignmentdeals calledstcering gcomctry.
measurementsis
angles: Camber, Caster ,T'oc, Stcering
axis inclination, and
geometry
Thereare
fivesteering
Toe-outonturns.
ASTER
MBER

FRONT OF EHICLE

TOE-N

STEERING GEARS

wheel into straight

The steering gear is a device for converting the rotary motion of the steering
line motion of the linkage with a mechanical advantage.
If the steering wheel is connected directly to the steering linkage it would require a great efiort to
move the front wheels. Therefore, to assist the driver, areduction system is used having a
stering ratio (he ratio between the turn of the steering wheel in degrees or handlebars and the
turn ofthe wheels in degrees ) between 10:1to 24:1l the actual value depending upon the type
and weight of the vehicle.

The stecring gears are enclosed in a box, called the steering gear box. There arc many different
designs of steering gear box. They are as follows:
Worm and soctor steering gear
Worm and roller steering gear
Recirculating ball steering gear
" Rack and pinion
steering gear.

Scanned by CamScanner
 POWERSTEERING

hastwo types of
PowersteeringThe
device for steering effort one type issa hydraulic device utilizíng
other type utilizes an elcctric motor. For the former, the engine is used to
enginepower.
For the latter, an independent electric motor in the
drive a pump. front luggage compartment is
usedthe pump. Both develop fluid pressure, and this pressure acts on a piston within the power
cylinderSo that the pinion assists the rack effort. The amount of this assistance depends on the
estent of preureacting on the piston. Thercfore, if more steering force is requíred, the pressure
must be raised. The variation in the fluid pressure is accomplished by a control valve whích is
linked to the steering main shaft.

ELECTRIC POWER STEERING (EPS OR EPAS) is designed to use an electric motor to

reduce effort by providing steering assist to the driver of a vehicle. Sensors detect the motion and
torque of the steering column, and a computer module applies assistive torque via an eiectric
motor coupled directly to either the steering gear or steering column. This allows varying
amounts of assistance to be applied depending on driving conditions. The system allows
engineers to tailor steering-gear response to variable-rate and variable-damping suspension
systems achieving an ideal blend of ride, handling, and steering for each vehicle. In the evenat of
component failure, a mechanical linkage such as a rack and pinion serves as a back-up in a
manner similar to that of hydraulic systems.

(1) Driver inputs torgue

Mechnt eer
(3) Electronic torque
Steeg wheet sensor sends signat to
shat omputer

(8) Bett and b

transmit aatet toro ue
to rnck s o r

(2) Rack-and-plnion
(9) Rack soronNertS
converts driver torgve
to rack force San toroue to n

(4) Computer reads vehlcle

spoed from sensor

(5) On-demand electto pawer Is (6) Computer sends

drawn from ohen Jn system torquo command to
motor
OMotór creates asstorq

HYDRAULIC
effort on
POWER STEERING (HPS) is a hydraulic
vehicles by using system for reducing the steering
provide for easier driving hydraulic
direction
pressure to assist in turning
control of the car while
the wheels. It is intended to
unambiguity of the trajectory specified. The
booster fail, the steering steering booster
preserving "feedback"
is arranged so that stability and
will continue to work should the
(although the wheel will feel heavier).

Scanned by CamScanner
 Fluid
Reservoir

Retrn
Hose
Fitting

Vane

Rotor

Presure
Hose
Fitting

Relief
Valve

ELECTROHYDRAULIC SYSTEMS

ECU Nctor d

Lefi

Cylinder

Powe pck Power ack

St¢aring whocl

Pumg Pung

Torgue sansor

Scanned by C