Unit- VI

Automobile systems and its

Technical Specifications [05 Hrs]

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 VEHICLE SYSTEMS
• Automobile engineering is the one of the stream of mechanical
engineering. It deals with the various types of automobiles, their
mechanism of transmission systems and its applications. Automobiles are
the different types of vehicles used for transportation of passengers,
goods, etc.

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 COMPONENTS OF THE AUTOMOBILE
 The Engine or Power Plant : It is source of power.
 The Frame and Chassis : It supports the engine, wheels, body, braking system, steering,
etc
 Chassis: It is the part of car which provides the basic frame where all the car parts are
screwed and protected.
 Power Transmission System: The transmission which transmits power from the engine
to the car wheels. It consists of clutch, transmission, shaft, axles and differential.
 The body.
 Suspension System: Suspension increases the friction between the tyre and the road
which provides stability to steering and allows the car to run in comfort condition.
 Steering system:
• Braking System: It is made of different components including Disk & Drum Brakes,
Master Cylinder, Power Booster & Anti-lock Brakes. Their main function is to slow down
the speed of wheel in wanted situation.
• Cooling System
• Fuel Supply System

 Accessories including light, air conditioner/hearer, stereo, wiper

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Vehicle System picture

Engine
It is source of power.
The engine uses fuel and burns it
to produce mechanical power.

Frame and Chassis

Support, carrying the weight of
the vehicle and its passengers,
withstanding the engine and
transmission torque and thrust
stresses, as well as accelerating
and braking torque,

Transmission System
transferring engine power to the
driveshaft and rear wheels

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 Vehicle Systems
Vehicle System Picture
Braking System-To slow down or to .
completely stop a vehicle one needs braking
a system

Cooling System -it removes excess heat from .

the engine; it maintains
the engine operating temperature where it
works most efficiently; and it brings
the engine up to the right operating
temperature as quickly as possible
Fuel Supply System -to store and supply fuel
to the engine.

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Vehicle System picture

Suspension System
To absorb shocks, maximizing the contact
between the tires and the road surface,
providing steering stability and good
handling, ensuring the comfort of
passengers by absorbing and dampening
shock

Steering system
to allow the operating to control the
direction of the vehicle with the least
amount of effort.

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Chassis
Main Supporting

Structure of

vehicle consist of

almost all major

parts except

automobile body

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Chassis is a French term and was initially used to
denote the frame parts or Basic Structure of the
vehicle. It is the back bone of the vehicle.
A vehicle without body is called Chassis. The
components of the vehicle like Power plant,
Transmission System, Axles, Wheels and Tyres,
Suspension, Controlling Systems like Braking,
Steering etc., and also electrical system parts are
mounted on the Chassis frame.
It is the main mounting for all the components
including the body. So it is also called as Carrying
Unit.
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Key component of Chassis is Frame
Frame Have 3 different types
1. Conventional frame
2. Integral Frame
3. Semi Integral Frame

Functions of Frame
• To support chassis components & body
• Withstand the static & dynamic load of different components
of chassis
• To withstand load of the body
• To carry load
• To withstand stresses caused due to uneven road conditions.
• To withstand force caused due to turning of the vehicles &
sudden braking or acceleration.
FRONT
REAR
 Frame Cross Sections

Channel Section – Good Resistance to Bending

Box Section – Good Resistance to both bending
and torsion
Tubular Section – Good Resistance to torsion.
Types of Chassis
• According to layout
• Conventional
• Forward
• Semi forward
• According to mounting of engine and transmission
• Engine at front
• Engine fitted in front but crosswise
• Engine fitted at the center of the chassis
• Engine fitted at the back
According to mounting of
Component of Chassis

• Front Engine Rear Wheel Drive

• Front Engine Front Wheel Drive

• Rear Engine Rear Wheel Drive

• All Wheel Drive

Conventional Chassis

Affects visibility of driver

Engine is fitted in front of the driver cabin or driver seat such as in

cars.
Chassis portion can not be utilized for carrying passengers and goods

Heavy Engine can be fitted, which can used to give more power
 Semi Forward Chassis

• Half portion of the engine is in the driver cabin & and remaining
half is outside the cabin such as in Tata trucks / Tempos

• In this arrangement a part of the chassis is utilized for carrying

extra passengers
 Forward Chassis

• Complete engine is mounted inside the driver cabin, Driver seat

is just above the front wheel.

• More Boot Space Available as full utilization of chassis

 Engine at front
• Conventionally the engines
are fitted at front & drive is
given to the wheels from the
“rear”
• Advantages
• Enough space is available for
luggage behind the rear seat
• The weight of vehicles is well
balance
• Increased efficiency of
cooling system
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Front Engine Rear Wheel Drive

Engine

Transmission

Drive Shaft
Clutch
Final Drive
The following main components of the Chassis are
1. Frame: it is made up of long two members
called side members
riveted together with the help of number of cross
members.
2. Engine or Power plant: It provides the source of
power
3. Clutch: It connects and disconnects the power
from the engine fly
wheel to the transmission system.
4. Gear Box
5. U Joint
6. Propeller Shaft
7. Differential
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FUNCTIONS OF THE CHASSIS FRAME:
1. To carry load of the passengers or goods
carried in the body.
2. To support the load of the body, engine, gear
box etc.,
3. To withstand the forces caused due to the
sudden braking or acceleration
4. To withstand the stresses caused due to the
bad road condition.
5. To withstand centrifugal force while
cornering

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 TYPES OF CHASSIS FRAMES:
There are three types of frames
Conventional frame:
In this type of chassis the body is made as a separate unit and then
joined with ladder frame. It supports all the systems in a vehicle
such as the Engine, Transmission system, Steering system,
Suspension system.
Advantage -Higher load capacity and strength Disadvantage -The
body tends to vibrate easily and the overall vehicle handling and
refinement is lower.
Application: It is used in truck, bus and in SUV cars and bigger
vehicles.

Integral frame :Also called “chassis less”, unitary or

monocoque construction.This frame is used now a days
in most of the cars. There is no frame and all the
assembly units are attached to the body.  All the
functions of the frame carried out by the body itself. Due
to elimination of long frame it is cheaper and due to less
weight most economical also.  The disadvantage is
repairing.
Semi-integral frame: In some vehicles half frame is fixed in
the front end on which engine gear box and front
suspension is mounted. It has the advantage when the
vehicle is met with accident the front frame can be taken
easily to replace the damaged chassis frame. This type of
frame is used in some of the European and American
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 STEERING SYSTEM
This system provides the directional change in the movement of
an Automobile and maintain in a position as per the driver’s
decision without much strain on him.

REQUIREMENTS OF STEERING SYSTEM:

a. It must keep the wheel at all times in to
rolling motion with out rubbing on the road.
b. This system should associate to control the
speed.
c. It must light and stable.
d. It should also absorb the road shocks.
e. It must easily be operated with less
maintenance.
f. It should have self-centering action to some
extent.

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Functions of Steering
System:
1. It helps in swinging the wheels
to the left or right.
2. It helps in turning the vehicle at
the will of the driver.
3. It provides directional stability.
4. It is used to minimize the tyre
wear and tear.
5. It helps in achieving self-
centering efforts.
6. It absorbs major part of the
road shocks.

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 The following are the main
components of steering system
are
1. Steering Wheel
2. Steering column or shaft
3. Steering Gear
4. Drop Arm or Pitman Arm
5. Drag Link
6. Steering Arm
7. Track-Arms
8. Track Rod or Tie-Rod
9. Adjusting Screws

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Types of Steering Gear Boxes:
1. Worm and Wheel Steering Gear.
2. Worm and Roller Steering Gear.
3. Re-circulating Ball type Steering Gear.
4. Rack and Pinion type Steering Gear.
5. Cam and Roller Gear type Steering Gear.
6. Cam and Peg Steering Gear.
7. Cam and Double lever Steering Gear.
8. Worm and Sector Type Steering Gear

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 Steering Mechanism:
There are two types of steering gear mechanisms
1. Davis Steering gear 2. Ackermann Steering gear

Ackermann Steering System: To achieve true rolling for a four wheeled vehicle
moving on a curved track,
•It has only turning pair.
•It is not mathematically accurate except in three positions.
•The track arms are made inclined so that if the axles are extended they
will meet on the longitudinal axis of the car near rear axle. This system is
called ackermann steering.

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 SUSPENSION SYSTEM
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The suspension system of an automobile is one which separates
the wheel/axle Assembly from the body.
The primary function of the suspension system is to isolate the
vehicle structure from shocks and vibration due to irregularities of
the road surface.

Functions of suspension system:

1. It prevents the vehicle body and frame
from road shocks.
2. It gives stability of the vehicle.
3. It safeguards the passengers and goods
from road shocks.
4. It gives the good road holding while
driving, cornering and braking.
5. It gives cushioning effect.
6. It provides comfort.
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Requirements of suspension system:
1. There should be minimum deflection.
2. It should be of low initial cost.
3. It should be of minimum weight.
4. It should have low maintenance and low operating
cost.
5. It should have minimum tyre wear.
Components of Suspension system: Coil springs, Leaf springs,
shock
absorbers, Spring shackles, stabilizer

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Independent suspension system: The independent suspension
system means any arrangement that connects road wheels to the frame in
which raise or fall of the wheel has no direct effect on the other wheel. It
eliminates wheel wobbling.

Advantages:
1. It provides softer suspension.
2. It reduces wheel wobbling
3. It reduces the tendency of fitting of the wheel on
one side due
to road vibration
4. It provides more space for engine
accommodation.
5. It promotes under steer which results low un
sprung weight.
6. The movement of the spring on one wheel is not
transmitted to
the other wheel.

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Basic suspension movements:
1. Bouncing: The vertical movement of the complete body.
2. Pitching: The rotating movement of all the parts between the
spring and road and the portion of spring weight itself.
3. Rolling: The movement about longitudinal axis produced by the
centrifugal force during cornering

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 TYPES OF SUSPENSION SYSTEM
1.Rigid Suspension
2.Independent Suspension
1.Rigid Suspension: has both right and left wheel attached to the
same solid axle. When one wheel hits a bump in the road, its upward movement
causes a slight tilt of the other wheel.
2.Independent Suspension :allows one wheel to move up and down with minimal
effect to the other.

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 Modern car mostly have following types of
shock absorber:
1.Telescoping dampers
2.Rocking lever damper

Telescopic type shock absorber is of

direct acting type. It is mounted between the
axle and the frame. A simplified diagram of the
telescopic shock absorber is shown in Figure.
Its upper eye is attached to the axle and the
lower eye to the chassis frame. A two-way
valve A is attached to a rod G. Another two-
way valve B is connected to the lower end of
cylinder C.
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 Working OF TELESCOPIC SHOCK ABSORBERS

It consists of an inner cylinder fitted with head at the open mouth.

• The head is also screwed into the outer reservoir, which is fixed to the eye by means of
which the reservoir is secured to the axle.
• The piston slides inside the inner cylinder.
• The piston is secured to the piston rod, which is connected to the other eye and this
eye will be connected to the chassis frame.
• The outer portion of the piston rod and the reservoir are covered with a protecting
cover which is fixed with the eye and the rod.
• The gland provided at the head prevents the leakage of the fluid by scrapping around
the piston rod and then passing it the reservoir through the drain hole.
• The inner cylinder is provided with two valve systems. One foot valve is fixed at the
bottom and the other with the sliding piston.
• Both the piston valve as well as the foot valve assembly has outer ring of holes and
inner ring of holes covered by the disc valves

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•The inner cylinder is completely filled with the fluid and the reservoir is half
filled.
• When the axle eye is moved upward then the fluid is displaced from the bottom
side to the top side of the piston.
• Under this condition the fluid must pass through the disc valve by opening the
outer ring of holes.
• In this condition when the upper portion of the cylinder is fully filled or has less
space, then the fluid will also be displaced through the inner rings of holes of the
foot valve and the level of fluid will rise in the reservoir.
Similarly when the axle eye will move downwards, then the fluid will be displaced
from the top side to the bottom side of the piston.
• In this condition the fluid will pass through the disc valve by opening the inner
ring of holes.
• The vacuum left by the piston rod inside the inner cylinder during this
movement is filled by the fluid from the reservoir to the inner cylinder by opening
outer ring of holes of the foot valve.
• This process will be repeated until the vibrations are damped out.

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Suspension system
• Double wishbone system

• Macpherson
stud

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 BRAKING SYSTEM:
Braking is the mechanism in the motor vehicle which is
used to slowing down and stopping the vehicle to rest in
the shortest possible distance
Principle of Braking system: While operating the braking system
the KINETIC ENERGY of moving vehicle is converted in to HEAT
ENERGY.
Functions of Brakes: Brakes have the following functions.
1.It is used to stop the vehicle.
2.It is used to control the speed where and
when required.
3.It is used to control the vehicle while
descending along the slope.
4.To park the vehicle and held it in stationary
position without the presence of Drive
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 Classification of Brakes
• The following are the classifications of Brakes
1.By method of power
a) Mechanical brakes 3.By method of operation:
b) Hydraulic brakes a) Manual
c) Air brakes b) Servo
d) Vacuum brakes c) Power operation
e) Power assisted hydraulic brakes
f) Magnetic brakes
4. By method of Brakingcontact
g) Electrical brakes
a. Internal Expanding Brakes
b. b. External Contracting Brakes
2.By method ofapplication:
a) Service or foot brakes 5. By Method of ApplyingBrake force:
b)Parking or hand brakes a. Single Acting Brakes.
b. Double Acting Brakes.
 Types of MechanicalBrakes
1. Drum Brakes (Internal Expanding or External Contracting)
2. Disc Brakes
 Drum Brakes
• The main components of drum brakesare
1. Brakedrum
2. Backplate
3. Brakeshoes
4. BrakeLiners
5. Retaining Springs
6. Cam
7. BrakeLinkages
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Drum Brakes
Construction:

•In this system the wheel is attached todrum.

•There are brake shoes used to contact the rotating drum for braking
operation.

• The shoes provide lining on their outer surface.

•The cam is used to lift the brake shoes at one end, other end is
connected by some method so as to make as the brake sleeve come into
contact in the brakedrum.

•The retaining spring is provided for bringing the brake shoes back to its
original position, after releasing thebrake pedal.

•All these parts are fitted in the back plate and enclosed with brake
drum.
 Working:
• When the pedal is pressed the cam moves the
shoes outwards through linkages, there by coming
in frictional contact with the rotating drum.

• As soon as the brake pedal is released the retaining

springs help the brake shoes to brought back and
release the brakes.
Disc Brake

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 Components of disc brakes
Disc
Calipers
Friction Pads
• DISC: It is made of high-grade of gray cast iron having pearlitic structure to
give better wear resistance property.
• This disc, which rotates with the car wheel, is efficiently cooled as most of its
area lies exposed..
• Calipers: These are of V-shaped type and are in two halves. Each half has a
pad bonded to a steel plate, a steel piston and a brake cylindrical housing
bolted together.Both these halves are hydraulically linked so that equal
pressure may be applied on the pad through floating pistons.
• Hydraulic pressure is applied only on one side of the piston.
• FRICTION PADS: These are made of asbestos, fiber and metal oxide
fillers bonded with organic compounds.Each pad is fixed to a steel plate
that has to take torque during braking on to the caliper. The pads may
be of square, rectangular, oval or segmental in shape.The size of the
piston is made the same as that of pads to avoid noise during braking.
• Rubber sealing rings prevent dust and moisture to enter the piston housings.

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 COOLING SYSTEM
A system, which controls the engine temperature, is known as a
cooling system

NECESSITY OF COOLING SYSTEM The cooling system is provided in the IC

engine for the following reasons: • The temperature of the burning gases in
the engine cylinder reaches up to 1500 to 2000°C, which is above the melting
point of the material of the cylinder body and head of the engine. (Platinum, a
metal which has one of the highest melting points, melts at 1750 °C, iron at
1530°C and aluminium at 657°C.) Therefore, if the heat is not dissipated, it
would result in the failure of the cylinder material. • Due to very high
temperatures, the film of the lubricating oil will get oxidized, thus producing
carbon deposits on the surface. This will result in piston seizure. • Due to
overheating, large temperature differences may lead to a distortion of the
engine components due to the thermal stresses set up. This makes it
necessary for, the temperature variation to be kept to a minimum. • Higher
temperatures also lower the volumetric efficiency of the engine.

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 TYPES OF COOLING SYSTEM

• Air cooling system • Water-cooling system

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 Water Cooling System
In this method, cooling water jackets are
provided around the cylinder, cylinder head,
valve seats etc. The water when circulated
through the jackets, it absorbs heat of
combustion. This hot water will then be cooling
in the radiator partially by a fan and partially by
the flow developed by the forward motion of
the vehicle. The cooled water is again
recirculated through the water jackets.

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 Water cooling system mainly consists of : (a) Radiator, (b)
Thermostat valve, (c) Water pump, (d) Fan, (e) Water Jackets,
and (f) Antifreeze mixtures

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Basics of Automobile-VVA 52
Basics of Automobile-VVA 53
Advantages
(a) Uniform cooling of cylinder, cylinder head and valves.
(b) Specific fuel consumption of engine improves by using water cooling
system.
(c) If we employ water cooling system, then engine need not be provided at the
front end of moving vehicle.
(d) Engine is less noisy as compared with air cooled engines, as it has water for
damping noise.

Disadvantages
(a) It depends upon the supply of water.
(b) The water pump which circulates water absorbs considerable power.
(c) If the water cooling system fails then it will result in severe damage of
engine.
(d) The water cooling system is costlier as it has more number of parts. Also it
requires more maintenance and care for its parts

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Fuel injection system and fuel supply
system

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 FUEL SUPPLY SYSTEMS
• The fuel passes through a number of stages
before reaching the combustion chamber.
• It includes the filtration and atomization of fuel
into fine particles.
• It is necessary to atomize the fuel before entering
into the combustion chamber so that complete
combustion of fuel can take place.
• There are different fuel supply systems for spark
ignition (petrol) and compression ignition (diesel)
engine.
Fuel Supply and Injection system for
Diesel Engine

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Fuel Supply and Injection system for Petrol Engine

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Power Transmission System

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The mechanism that transmits the power developed by the engine of
automobile to the engine to the driving wheels is called the
TRANSMISSION SYSTEM (or POWER TRAIN).

• It is composed of –
• Clutch
• The gear box
• Propeller shaft
• Universal joints
• Rear axle
• Wheel
• Tyres

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 Clutch
• THE CLUTCHES ARE MOUNTED BETWEEN THE DRIVING SHAFT AND THE
DRIVEN SHAFT.
• THE FLOW OF MECHANICAL POWER FROM THE PRIME MOVER TO THE
DRIVEN MACHINE IS CONTROLLED BY MEANS OF CLUTCHES.
• IN AUTOMOBILES, IN ORDER TO CHANGE THE GEARS OR TO TEMPORARILY
STOP THE VEHICLE THE REQUIREMENT IS THAT THE DRIVEN SHAFT
SHOULD STOP BUT THE ENGINE SHOULD CONTINUE TO RUN.THIS IS
ACHIEVED BY MEANS OF CLUTCH, MOUNTED BETWEEN THE ENGINE AND
THE GEAR BOX, WHICH IS OPERATED BY LEVER.
 CLASSIFICATION OF CLUTCHES
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CLUTCHES

FRICTION POSITIVE
CLUTCHES CLUTCHES

PLATE OR DISK CONE

CLUTCHES CLUTCHES

SINGLE PLATE MULTI-PLATE

CLUTCHES CLUTCHES
 Single plate clutch

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TMA
 Gear Box
The gear box is necessary in the transmission system to maintain engine
speed at the most economical value under all conditions of vehicle
movement.
•An ideal gear box would provide an infinite range of gear ratios, so that
the engine speed should be kept at or near that the maximum power is
developed what ever the speed of the vehicle

Function Of A Gear Box

• Torque ratio between the engine and wheels to be varied for rapid
acceleration and for climbing gradients.
• It provides means of reversal of vehicle motion.
• Transmission can be disconnected from engine by neutral position of gear
box

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Machine Elements II - Rini D - TM FT UGM 65
Constant Mesh Gear box

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 Propeller Shaft –
1) Normally transmits power from the gearbox to the rear axle.
2) It is a mechanical component for transmitting torque and rotation,
usually used to connect other components of a drive train that cannot
be connected directly because of distance or the need to allow for
relative movement

Machine Elements II - Rini D - TM FT UGM 67

 Propeller Shaft
The power is transmitted from gear box to the differential gear
box through long shaft called Propeller Shaft.

Universal Joint: A universal joint is a joint or

coupling connecting rigid rods/shafts whose axes are
inclined to each other, and is commonly used in shafts that
transmit rotary motion.
Application: steering, automobile transmission system

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Differential Gear Box

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 Differential is the mechanism by means of which outer wheel runs faster
than the inner wheels while taking a turn or moving over upheaval road.
 D ifferentialis a part of the inner axle housingassembly, which
includes the differential, rear axles, wheels and bearings.
 The differential consists of a system of gears arranged in such a way that
connects 'the propeller shaft with the rear axles.
 The purpose of the differential is to provide the relative movement to
the two rear wheels, while the vehicle is taking a turn.
 The torque transmitted to each wheel is, however, always equal.
Differentials are used in rear drive axle of front-engine, rear-wheel drive
vehicles.
 Differentials are also used in the Trans axles on front-engine, front-wheel
drive wheels.
 Also, four-wheel drive vehicles have differential at both the front and rear
wheels. In
addition, some four-wheel-drive vehicles have a third differential in the
transfer case.
NUMERICAL BASED ON ONLY SIMPLE GEAR RATIO &
VELOCITY RATIO
Gear – Toothed wheel [Pinion and Gear]
Gear Ratio:
It is the ratio of number of teeth on driven gear and number of teeth
on driver gear.
G = np/nG=dG/dP=ZG/ZP
Torque required to Transmit Power for =P=(2πnpTp)/60 for Pinion

Torque required to Transmit Power = P(2πNG TG)/60 for Gear

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 Vehicle Safety System
1]ACTIVE SAFETY SYSTEM and
2] PASSIVE SAFETY SYSTEM
Automobile safety is the study and
p ra c t i c e of design, construction,
equipment and regulation to minimize the
o c c u r r e n c e a n d c o n s e q u e n c e s o f t ra f f i c
collisions. Ro a d t r a f f i c safety more
broadly includes roadway design.

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This is incorporated in our car to protect us and other
passengers from injury and death during a collision or crash.

Active Safety System-Active Safety includes set of

safety features which reduce the chances of an accident
or collision in the first place.

ABS antilock braking system

TCS traction control System
ESP Electronic stability program
Cruise Control - speed control

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 PASSIVE SAFETY SYSTEM- system that does not
do any work until it is called to action
• Seat Belt - device designed to secure the driver or a passenger of a
vehicle against harmful movement that may result during a collision or a
sudden stop.

• Air bags - Airbags help prevent head, chest and other severe injuries
during a car collision.

• Pretensioners - to tighten up any slack in the belt webbing in

the event of a crash.

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ABS:-ANTI LOCKBRAKING SYSTEM

 An anti-lock braking system or anti-skid braking

system (ABS) is an automobile safety system that
allows the wheels on a motor vehicle to maintain
tractive contact with the road surface according to
driver inputs while braking.
 This prevent the wheels from locking up (ceasing
rotation) and avoiding uncontrolled skidding.
7
5
 MAIN COMPONENTSOFABS
 Speed sensors
 Valves
 pump
 Controller

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77
Thank You

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