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UNIT 1
VEHICLE STRUCTURE AND
ENGINES
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Introduction to Automobile
Systems
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1A. Electrical Systems
Ignition
Charging
Accessories Lighting
Starting
Computer
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1BFuel System
Mixes air and gasoline for to explode inside
engine.
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1C - Cooling System
Keeps engine at correct operating
temperature
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1DLubrication System
Reduces friction between moving parts.
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2. Drivetrain
Converts engine movement to vehicle
movement
Variety of types:
Front Wheel Drive
Rear Wheel Drive
Four Wheel Drive
All Wheel Drive
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Vehicle Layout
Rear engine / rear wheel drive
Mid engine / four wheel drive
Front engine / front wheel drive Front engine / rear wheel drive
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2A - Transmission/Transaxle
Uses different gear ratios to increase torque(pulling power) or speed.
Uses gears for Reverse.
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2B - Differential Allow rotational torque to turn 90 degrees
Allow wheels to turn at different speeds.
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2CTransfer Case
Sends engine torque to both rear and front
differentials in four wheel drive vehicles.
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2D - Driveshaft
Transmits rotational torque to Differential/s
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2E - Half Shaft
Transmits Torque Directly to Wheels
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3. Brakes
Stop vehicle movement and keep it stationary.
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4. Steering
Changes vehicle direction.
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5. Suspension
A suspension system provides a flexible
connection between the wheels and the rest
of an automobile, allowing the car to ride
smoothly and comfortably over bumps in theroad while still permitting safe handling of the
vehicle while accelerating, braking and
cornering;
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5A - Springs
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5BShock Absorber
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6. Tires
Connect vehicle to road
Affect vehicle handling, traction, braking
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3 D VIEW OF VEHICLE CONSTRUCTION
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Topics :
Types of automobiles
Vehicle construction and different layouts
Chassis
Frame and body
Resistance to vehicle motion and need for a gear box
Components of engine-their function
Function and materials
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Vehicle Body Construction
Motor vehicles are a combination of many different systems all made up of
separate items. All these systems have to be brought together and mounted on
some form of frame or body shell to form a chassis. The chassis comprises the
following.
Frame or body shellforms the skeleton of the vehicle
Engineacts as the power unit
Transmissionconveys the drive to the road wheels
Suspension
absorbs the road shocks
Steeringcontrols the direction of movement
Brakesslows down the vehicle
Electrical equipmentprovides lighting, engine starting and other driver needs.
ll hi l d f d h h h i
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All vehicles are made up of separate systems and components, they have their
own purpose and operation, however, all of these systems are brought together
to give us the modern motor vehicle.
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TYPES OF AUTOMOBILES
i. Number of wheels and no. of axels
ii. Types of power plants
iii. Load carrying capacity and their weight
iv. Purpose served
v. Fuel used
vi. Drive system used
vii. Capacity of the engine
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NUMBER OF WHEELS AND NO. OF AXLES
i. 2-wheelers ( mopeds, scooties, scooters and
motorcycles)
ii. 3-wheelers (tempos, road rollers, tractors)
iii. 4-wheelers (car, jeep, trucks, buses)
iv. 5-wheelers (road rollers)
v. 6-wheelers (truck-tankers, foods carriage vehicle)
vi. 8 or more-wheelers (car transporting vehicles)
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TYPES OF POWER PLANT USED
i. Steam engine drive auto vehicles.
ii. I.C engine driven vehicles
a) petrol vehicles
b)diesel vehicles
c)gas vehicles
iii. Gas turbine driven automobiles.
iv. Winkle engine driven auto vehicles.
v. Electric power driven auto vehicles.
vi. Battery (chemical power)driven auto vehicles.
vii. Solar energy driven auto vehicles.
viii. Hybrid power auto vehicles.
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LOAD CARRYING CAPACITY
I . Heavy transport vehicle(H.T.V) ;(eg: trucks and lorries)
II .light transport vehicle (L.T.V)
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CAR BODY STYLE
I .closed cars:
saloon
hatchback(saloon with a door at the back)
coupe(only one row of seat for 2 person, 2 doors are provided)
limousine(driver compartment is separated from rear comp)
Ii .open car :
sports,
convertible(roof in this is soft folding type, with this provision the car may be either
open or closed)
III .special styles
estate cars (saloon car with passenger roof )
station wagon(
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ON THE BASIS OF THE PURPOSE SERVED
On the road vehicle
scooters
cars
trucks
Off the road vehicles
tractors
construction equipments
On and off the road vehicles
military tanks
gun carriage
bulldozers
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ON THE BASIS OF THE FUEL USED
Petrol vehicle
maruthi omni
matiz
felicia
santro
Diesel vehicle
mercedes-benzeambassador
fiat UNO diesel
Dual fuel
fargo
dodge
bedford trucksGas vehicles
CNG valvo
Hydrogen vehicle
Musashi III
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ON THE BASIS OF TYPE OF TH WHEEL
DRIVE SYSTEM
Single wheel drive (1 Wd)
Two wheel drive (2 Wd)
Four wheel drive (4 Wd)
All wheel drive( 6 Wd)
Left and right hand drive vehicles
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Rear engine / rear wheel drive
Mid engine / four wheel drive
Front engine / front wheel drive Front engine / rear wheel drive
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ON THE BASIS OF ENGINE CAPACITY
ENGINE CAPACITY ( CC) VEHICLE
60 KINETIC SAFARI V2, BAJAJ SIGNETS
70 TVS sport
93 kinetic k-4
150 Bajaj , Lambretta
796 Maruti omni
1200 Premier padmini
1366 Premier diesel
1489 HM Trekker
2982 Toyota land cruiser
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VEHICLE CONSTRUCTION
Main components of automobile
Chassis
Body
Frame
Power unit engine system
Transmission system
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CHASSIS
INTRODUCTION
Chassis is a French turn and was initially used to denote the
frame or main structure of a vehicle.
It is now extensively used to denote the complete vehicleexcept the body for the heavy vehicle having a separate body.
The chassis contain all the major units necessary to propel the
vehicle, direct its motion, stop it, and allow it to run smoothly
over uneven surfaces.It is the main mounting for all the components including the body.
It is also known as carrying unit.
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The chassis include following components as shown in fig: 1.1
Frame,
Front suspension,
Steering mechanism,Radiator,
Engine, clutch, gearbox,
Propeller shaft,
Rear spring,
Road wheels,
Differential, half shaft, universal joints,
Brakes end braking system,
Storage battery,
Silencer,Shock absorbers, fuel tank, petrol and hydraulics pipe cables
and some means of mounting these components.
Ch
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Chassis components
f h i
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1.1 Importance of chassis Frame
The frame or under body is the main part of the chassis, on
which the remaining parts of chassis are mounted.
It is a rigid structure that forms a skeleton to hold all the
major part together. The engine is mounted in the forward end
of the frame end of the frame and is connected to the clutch
and transmission units to form a complete power assembly.
At the rear end of the frame, the rear axle housing isattached through the rear spring.
The wheels and tyre assemblies supports the frame. The
steering system has some parts bolted to the frame and some
to the body. The petrol tank is fastened to the rear of the frame.
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As the chassis frame forms the backbone of a
heavy vehicle,
its principal function is to safely carry themaximum load for all designed operating
conditions.
it must also absorb engine and driveline
torque, endure shock loading andaccommodate twisting on uneven road
surfaces.
To achieve a satisfactory performance, the
construction of a heavy vehicle chassis is the result of
careful design and rigorous testing
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CHASSIS FRAME OF COMMERCIAL VEHICLE
2 Chassis frame of commercial vehicle
Basically there are two types of chassis frame are
available namely as under:
1. LMV frame2 HMV frame
Chassis frame of the commercial may made up of
different types of cross section. It is tube, I-section,
square section or C-section. In figure2.1 shows the
chassis frame made up of tube cross section for LMV.
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Th diff t t f t bil h i i l d
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The different types of automobile chassis include:
Ladder Chassis: Ladder chassis is considered to be one of the oldest forms of
automotive chassis or automobile chassisthat is still used by most of the SUVs
till today. As its name connotes, ladder chassis resembles a shape of a ladderhaving two longitudinal rails inter linked by several lateral and cross braces.
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Backbone Chassis:Backbone chassis has a rectangular tube like backbone, usually made up of glass fibre
that is used for joining front and rear axle together. This type of automotive chassis or
automobile chassis is strong and powerful enough to provide support smaller sportscar. Backbone chassis is easy to make and cost effective.
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Monocoque Chassis:
Monocoque Chassis is a one-piece structure that prescribes the overall shape of
a vehicle. This type of automotive chassis is manufactured by
welding floor panand other pieces together. Since monocoque chassis is costeffective and suitable for robotised production, most of the vehicles today make
use of steel plated monocoque chassis
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AUTOMOTIVE FRAMES:
Automotive frames are basically
manufactured from steel. Aluminum isanother raw material that has increasingly
become popular for manufacturing these auto
frames. In an automobile, front frameis a setof metal parts that forms the framework
which also supports the front wheels. It
provides strength needed for supporting
vehicular components and payload placed
upon it.
Bonnet:
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Bonnet:
Bonnet, an important part of automotive frame can be defined as a
protective covering made up of a hinged metal part used for
covering an engine of a vehicle. Usually automobile bonnets are
made of steel, aluminum, fiberglass, and carbon fiber reinforcedplastic
Hood:
Hood refers to a cover placed
over the engine and passenger
compartment of an automobile.Hoods form an important type
of automotive frames. These
auto frame parts are usually
made of steel, aluminum,
fiberglass, carbon fibre or drycarbon. A typical hood
comprises of several different
parts such as hood ornament,
hood scope, power bulge, and
wiper jets.
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FUNCTIONS OF FRAME
Frame is provided with cross members to increase the rigidity
and to withstand the shocks, blows, twists, and vibrations
coming during operation. A frame is required to carry theweight of the vehicle and its passengers, to withstand the
engine torque, thrust stresses, accelerating and breaking
torque, to resist the effect of centrifugal forces when cornering
and to withstand bending and twisting stresses due to
fluctuations of front and rear axles.
REQUIREMENT FOR A GOOD FRAME
It should be strong and stiff enough to resist the severe
twisting and bending forces to which it is subjected particularlywhen vehicle is travelling at high speed over a rough road.
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BODY
Body is superstructure of the vehicle
Bolted to chassis
Complete vehicle is referred to the combination of chassis and body
Body is merely a cover to the chassis
The body ma be shaped according to the need and convenience
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Body of the motor vehicle must fulfill the following requirement
Sufficient space to accommodate passenger and luggage
Suitable shape to reduce air resistance
It should be light and strong enough to resist bending, torsion and impact stress
Load should be distributed evenly
Mounting of the boady should have minimum vibration
Should be cheap and simple in manufacturing
It should be made of sheet metal of sufficient thickness for adequate safety
during collision
Should provide clear vision and be of aesthetic in shape
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Types of bodiesCar
Truck half body
Tractor
Tanker
Delivery van
Pick up
Truck-punjab body
Track-platform type
Tractor
Dumper truck
Station wagon
jeep
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Direct Injection
Differences in Operation
Indirect Injection
Injector Injector
Pre CombustionChamber
/ d
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Feature Direct Injection Indirect Injection
Efficiency / Economy More Less
Power More Less
Emissions Less More
Direct V/S Indirect Injection