Automotive Engineering

Basics
Dr.Eng. Ahmed Sameh
Training Director at FEMU
Assistant Professor in Mechatronics and Robotics Engineering
Faculty of Engineering
Mansoura University
[email protected]
[email protected]
[email protected]
2024

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 What is Mechatronics?
For many practicing engineers on the front line of engineering
design, mechatronics is nothing new. Many engineering products
of the last 25 years integrated mechanical, electrical, and computer
systems, yet were designed by engineers that were never formally
trained in mechatronics. It appears that modern concurrent
engineering design practices, now formally viewed as part of the
mechatronics specialty, are natural design processes.

The ongoing information technology revolution, advances in

wireless communication, smart sensors design (enabled by MEMS
technology), and embedded systems engineering ensures that the
engineering design paradigm will continue to evolve in the early
twenty-first century.

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 Key Elements of Mechatronics

1. Physical Systems Modeling.

2. Sensors and Actuators.
3. Signals and Systems.
4. Computers and Logic Systems.
5. Software and Data Acquisition (Digitizing real measurements).

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The Development of the Automobile as a Mechatronic System

Until the 1960s, the radio was the only significant electronics in an automobile. All other functions were entirely mechanical or
electrical, such as the starter motor and the battery charging systems. There were no “intelligent safety systems,”

Seat belts, introduced in the early 1960s, were aimed

at improving occupant safety and were completely
mechanically actuated.

All engine systems were controlled by the driver

and/or other mechanical control systems. For
instance, before the introduction of sensors and
microcontrollers, a mechanical distributor was used
to select the specific spark plug to fire when the fuel–
air mixture was compressed. The timing of the
ignition was the control variable. The mechanically
controlled combustion process was not optimal in
terms of fuel efficiency.

The electronic ignition system was one of the first

mechatronic systems to be introduced in the
automobile in the late 1970s.

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The Antilock Brake System (ABS) was also
introduced in the late 1970s in automobiles.
The ABS works by sensing lockup of any of
the wheels and then modulating the hydraulic
pressure as needed to minimize or eliminate
sliding.

Traction control is an electronic system that uses the

same sensors as the anti-lock braking system (ABS) to
reduce or prevent wheelspin.

The Traction Control System (TCS) was introduced in

automobiles in the mid-1990s. The TCS works by sensing
slippage during acceleration and then modulating the
power to the slipping wheel. This process ensures that the
vehicle is accelerating at the maximum possible rate under
given road and vehicle conditions.

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The Development of the Automobile as a Mechatronic System

Millimeter wave radar technology has recently found applications in

automobiles. The millimeter wave radar detects the location of objects
(other vehicles) in the scenery and the distance to the obstacle and the
velocity in real-time.
This technology provides the capability to control the distance between the
vehicle and an obstacle (or another vehicle) by integrating the sensor with
the cruise control and ABS systems. The driver is able to set the speed and
the desired distance between the cars ahead of him. The ABS system and the
cruise control system are coupled together to safely achieve this remarkable
capability.

In automobiles today, typically, 8, 16, or 32-bit CPUs are used for

implementation of the various control systems.
Using a radar to measure distance and velocity to
The 32-bit processor is used for engine management, transmission autonomously maintain desired distance between vehicles.
control, and airbags; the 16-bit processor is used for the ABS, TCS,
instrument cluster, and air conditioning systems; the 8-bit processor is
used for seat, mirror control, and window lift systems. Today, there are
about 30–60 microcontrollers in a car.

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Types of Links
 MOBILITY
The degree of freedom is the number of independent inputs required to precisely position all links of the mechanism with
respect to the ground. It can also be defined as the number of actuators needed to operate the mechanism. A mechanism
actuator could be manually moving one link to another position, connecting a motor to the shaft of one link, or pushing a
piston of a hydraulic cylinder.
Skeleton Diagrams

A skeleton diagram is a simplified drawing of a mechanism or machine that shows only the dimensions that effect its
kinematics.

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Examples on Mobility
Examples of Mechanisms and Machines

An automobile hood mechanism

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 A door damper mechanism

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 Machine Design

The subject Machine Design is the creation of new and better machines and improving the existing ones. A new or better
machine is one which is more economical in the overall cost of production and operation.
In designing a machine component, it is necessary to have a good
knowledge of many subjects such as Mathematics, Engineering Mechanics,
Strength of Materials, Theory of Machines, Workshop Processes and
Engineering Drawing.

Classifications of Machine Design

1. Adaptive design. 2.Development design. 3.New design.
General Considerations in Machine Design
1. Type of load and stresses caused by the load. 6. Convenient and economical features.
2. Motion of the parts or kinematics of the machine. 7. Use of standard parts.
3. Selection of materials. 8. Safety of operation.
4. Form and size of the parts. 9. Workshop facilities.
5. Frictional resistance and lubrication. 10. Number of machines to be manufactured.

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 General Procedure in Machine Design

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 Classification of Engineering Materials

1. Metals and their alloys, such as iron, steel, 2. Non-metals, such as glass, rubber, plastic, etc.
copper, aluminum, etc.

The metals may be further classified as :

(a) Ferrous metals, and (b) Non-ferrous metals.
The *ferrous metals are those which have the The non-ferrous metals are those which have
iron as their main constituent, such as cast iron, a metal other than iron as their main constituent,
wrought iron and steel. such as copper, aluminum, brass, tin, zinc, etc.

Selection of Materials for Engineering Purposes

1. Availability of the materials,

2. Suitability of the materials for the working conditions in
service, and
3. The cost of the materials.

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 The History of Car Technology

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 Carl Benz, the inventor of the
Steam machine of Verbiest, in 1678 first modern car, built in 1885 modern car 1807

Ransom E. Olds founded Olds

Motor Vehicle Company
Cugnot's 1771 fardier à vapeur, Paris (Oldsmobile) in 1897.

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 Ford Motor Company automobile
assembly line in the 1920s

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In the case of heavy vehicles,
vehicle without body is
called as chassis; it consists
of the following systems:

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Adaptive suspension system is electronically
controlled with a continuously adaptive
damping system. It consists of various types
of sensors and switches to provide the
information to the ECU (electronic control
unit), according to which the system
works.
In this system, instead of springs and
dampers computer controlled hydraulic
actuators are used to take the suspension
loads. So when the vehicle is subjected to
bumper due to any road irregularity, then the
hydraulic actuators come in action and
raise or lower the wheels to restrain any
movement of the vehicle body, in
accordance with signals received by the
computer from strategically positioned
sensors.

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The chassis frame is the main part of
the vehicle; it holds the important
parts of the chassis. It is made up of
two long side members riveted
together with the help of a number of
cross members. It is also called an
under body.

• To support the chassis components and

body.
• To withstand static and dynamic loads
due to deflection and distortion.

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• No propeller shaft, so height so low. Floor
profile can be used.
• The centre of gravity of the vehicle is lower, so
overall height can be reduced.
• Engine and transmission shaft linkages are
simplified.
• Better steering response during high wind speed,
as more weight is concentrated in the front part of
the vehicle.

• There is heavier steering as weight is concentrated in the front side of the vehicle.
• While climbing a hill, traction of the front wheel may reduce due to shifting of the centre of gravity to the rear side of the
vehicle.
• Heat, noise, fumes may transfer to the passenger compartment

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The engine mounted in the front part of the vehicle and drive is transmitted to the rear wheels through proper arrangement This
type of drive arrangement has the following advantages and disadvantages.

• Front-mounted engine provides better safety

during crash.
• Radiator can be mounted in front of the
vehicle, enabling effective cooling.
• A front-mounted engine is easy to maintain.
• Engine and transmission linkages are simple
in construction.
• The slope of the propeller shaft is very small
so simple hook joint can be used.
• During hill climbing, the centre of gravity
shifts towards the back side, which provides a
grip on the rear wheels.
• Provides good traction to the vehicle.

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• Extended sections are required to
accommodate the propeller shaft
• In case of muddy road this vehicle tend to
plough more into the ground.
• Additional universal joints and drive shafts
are required because of independent rear
suspension system.

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The engine is mounted in the rear side of the vehicle and drive is trans-mitted to the rear wheels through proper arrangement.
Engine can be mounted transversally or longitudinally. This type of drive arrangement has the following advantages and
disadvantages.

• Due to rear mounting of the engine, passengers do not

experiences noise, heat, fumes, etc.
• Steering is smoother due to absence of the heavy weight
in the front side.
• With a compact exhaust system, span of exhaust travel is
less.

• Linkages of the clutch and gear box are required to transmit

the power at the driver’s location.
• Lighter weight in the front side allows for a more sensitive steering.
• Lighter front end subjected to car more sensitive to steer at high wind speed.
• Accommodation for the cooling system is difficult to acquire effective cooling.
• Most convenient location for the petrol engine, for such type of layout is location of the petrol tank is at front, which
is dangerous at the time of collision.

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• What is Automotive Design?
The automotive design process is a
creative process that defines the
physical appearance of a vehicle,
including trucks, cars, motorcycles, etc.
The design takes into consideration the
exterior and interior design of the
automotive. It also considers the
materials like the type of metal, plastic,
and fabric to use on different car parts of
the vehicle, as well as paint patterns,
bumpers, etc.
Automotive designers tackle the
challenge of combining different aspects
of a vehicle, like aesthetics, ergonomics,
and aerodynamics, while meeting safety
regulations.

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• Plan Shape
The plan shape of a car and most automobiles are curved. The reason for this curvature is to improve aerodynamics. Aside
from aerodynamics, this curvature also hides the rear and front overhangs. The top half of a vehicle houses the windows,
which shape is the main area for curvature.
Additionally, the plan shape considers the windscreen angle, ensuring it is never less than 30 degrees from the horizontal. It
is also important to note that plan shape curvature varies between vehicles and depends on their size.

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Packaging Considerations
The car designs submitted by
designers are changed as
manufacturers implement packaging
considerations. The considerations
here range from engine availability to
safety requirements and drive-train
layouts.
At this stage of the design process, the
idea meets reality and when the
designer and manufacturer reach a
compromise. It is important to note
that while the car is on paper, it would
still need various modifications and
probably re-drawings to meet
engineering needs.

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3D Computer Modeling
This is a digital model of the vehicle’s design. The aim is to put the car’s ergonomics, functionality, and aesthetics on full
display to judge its manufacturability. It begins with a computer rendering which helps designers and engineers visualize and
measure the car’s physical dimensions. Also, designers continue modifying the 3D model and testing it to ensure the design is
optimal at this level.

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 Clay Model
• After modeling the car on a computer, designers and engineers create a clay model. This model provides designers with a
realistic view of the car they are making. The proportion is usually 1:1 and involves applying 55-600C heated clay on a metal
chassis.
• It is important to note that while clay remains the industry standard, alternatives are made using polymer and other materials.
Polymer models are often lighter, cheaper, and easier to transport than clay ones.

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• Interior Modeling
• The original designer must have sketched the vehicle’s interior, but before modeling takes place, a team would have to
examine the sketch. The aim is to ensure the car’s interior dimension and appearance matches the car’s overall design. After
sketch approval, the 3D computer renderings and models begin.
• You should note that the process required when producing models for a car’s interior and exterior are similar. The only
difference is that modeling for the interior often requires prototype components and 3D printing.

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Automotive Lighting
• With the interior and exterior design and model complete, engineers attach lighting and glass items to the car. These
items find application both in the car’s interior and exterior. Designers use automotive lighting under the bonnet’s edge
to improve the model’s aesthetics.

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Testing and Material Refinement
To confirm a material, it has to withstand the use of tests and time. This ensures that the chosen material’s color does not fade
quickly. Tests include environmental tests to examine how the chosen material reacts under heat, cold, and direct sunlight
exposure.
Other tests include using robotic arms to thump and rub the material incessantly to see if it fails. If it fails, the designer changes
the material.

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Final Modeling on
Interior and Exterior
Combined
It is important to note that
up until this point, the
interior and exterior of the
vehicle have been apart.
In other words, they’ve
not been in one piece.
This final modeling called
the concept phase, allows
designers to view the
model in its full physical
form and use it for
marketing. It is also the
phase with the most
engineering
considerations, as it is the
final phase for design
finalization.

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Model Approval
Not every model gets approved. The model approval phase is the stage of the car manufacturing process where management
decides whether to approve the model. If a model is not approved, there is zero chance of building the vehicle. On the other
hand, if approval is given, the car manufacturer begins using the planned materials. Approved models are also often used for
marketing, some will be sleds (not drivable since no drive train is present), while others will be fully mobile.

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Production Begins After Engineering And Concept Completion
In this phase, engineers and car production companies like Autoprotoway that specialize in building vehicles will analyze the
vehicle’s design to make production cost-effective and faster. The details taken into consideration include how to couple
individual parts as well as sourcing materials used. The production engineers would also lay out the plan and schedule for
completing different stages, from the bare frame to the finished car.
It is important to note that most vehicle designs take about 3 to 5 years to move from the initial concept to the finished car.
Some even eclipse the 6 years mark.

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