CME 380-Automobile Engg
CME 380-Automobile Engg
CME 380-Automobile Engg
3 00 3
OBJECTIVES:
□ To understand the construction and working principle of various parts of an automobile.
□ To have the practice for assembling and dismantling of engine parts and transmission
system
Types of automobiles, vehicle construction and different layouts, chassis, frame and body,
Vehicle aerodynamics (various resistances and moments involved), IC engines –
www.EasyEngineering.
components functions and materials, variable valve timing (VVT).
net
Electronically controlled gasoline injection system for SI engines, Electronically controlled
diesel injection system (Unit injector system, Rotary distributor type and common rail direct
injection system), Electronic ignition system (Transistorized coil ignition system, capacitive
discharge ignition system), Turbo chargers (WGT, VGT), Engine emission control by three
way catalytic converter system, Emission norms (Euro and BS).
Clutch-types and construction, gear boxes- manual and automatic, gear shift
mechanisms, Over drive, transfer box, fluid flywheel, torque converter, propeller shaft,
slip joints, universal joints,Differential and rear axle, Hotchkiss Drive and Torque Tube
Drive.
Steering geometry and types of steering gear box-Power Steering, Types of Front Axle,
Types of suspension Systems, Pneumatic and Hydraulic Braking Systems, Antilock
Braking System (ABS), electronic brake force distribution (EBD) and Traction Control.
Use of Natural Gas, Liquefied Petroleum Gas, Bio-diesel, Bio-ethanol, Gasohol and
Hydrogen in Automobiles- Engine modifications required –Performance, Combustion
and Emission Characteristics of SI and CI engines with these alternate fuels - Electric and
Hybrid Vehicles, Fuel Cell
TOTAL: 45 PERIODS
TEXT BOOKS:
1. Kirpal Singh, ―Automobile Engineering‖, Vol 1 & 2, Seventh Edition, Standard Publishers,
New Delhi,
1997.
2. Jain K.K. and Asthana .R.B, ―Automobile Engineering‖ Tata McGraw Hill Publishers, New
REFERENCES:
TABLE OF CONTENT
4 Unit - 1 - Part B 2
6 Unit - 2 - Part B 15
8 Unit - 3 - Part B 25
12 Unit - 5 - Part B 45
ME6602 AUTOMOBILE ENGINEERING 3 0 0 100
□ Planned to visit automobile industries .latest development based upon alternate fuel
www.EasyEngineering.
cell and electric vehicle.
□
□ net
Bus Depot
Automobile components manufacturing company
Department of Mechanical
Engineering Detailed Lesson
Plan
Name of the Subject& Code: CME380 AUTOMOBILE ENGINEERING
Name of the Faculty:
TEXT BOOKS
1. Kirpal Singh, ―Automobile Engineering‖, Vol 1 & 2, Seventh Edition,
Standard Publishers, New Delhi, 1997.(copies available in library)
2. Jain K.K. and Asthana .R.B, ―Automobile Engineering‖ Tata McGraw Hill
Publishers, New Delhi, 2002. (copies available in library)
REFERENCES
1. Newton ,Steeds and Garet, ―Motor Vehicles‖, Butterworth Publishers,1989.
(copies available in library)
2. Joseph Heitner, ―Automotive Mechanics,‖ Second Edition, East-West Press, 1999.
3. Martin W, Stockel and Martin T Stockle , ―Automotive Mechanics Fundamentals,‖
The Good
heart –Will Cox Company Inc, USA ,1978. 64(copies available in library)
4. Heinz Heisler, ―Advanced Engine Technology,‖ SAE International Publications USA,
1998.
5. Ganesan V. ―Internal Combustion Engines‖, Third Edition, Tata McGraw-Hill, 2007.
(copies available in library)
i
CUMULA
NO OF BOOKS
S.NO UNIT TOPICS COVERED HOURS TIVE REFERRED
HOUR
S
VEHICLE STRUCTURE AND ENGINES
Types of automobiles, vehicle
1 Construction 2 2 T1,T2,R3
www.EasyEngineering.
Electronically controlled gasoline
injection system for SI engines,
1 2 11 T1,R5
Electronically controlled diesel
injection system
www.EasyEngineering.
net
iii
UNIT-1
VEHICLE STRUCTURE AND
ENGINES PART A
2. What loads are coming to axle? (May ’06, 09, Dec 14)
Vertical bending load due to vehicle weight
□ Driving torque
□ Braking torque
□ Side thrust
www.EasyEngineering.
3. Name the different kind of resistances to vehicle motion. ( Jun’07,Dec’ 11)
□ Air resistance
□ Rolling resistance
net
□ Gradient resistance
5. What are the stresses to which the frame members are subjected to? ( Dec’13,
May’10)
□ Frame longitudinal members – bending stress
□ Frame side members – twisting stress
1
Downloaded From : www.EasyEngineering.net
9. What are the two types of cylinder liners? ( Dec’14, May’11, Dec 09)
□ Dry liners
□ Wet liners
10. What are the functions of piston rings? Types? ( Dec’14, May’12, Dec 08)
To provide a gas tight seal between the piston and cylinder liner to prevent
the escape of gases from top side of the piston to the underside.
□ Compression rings
□ Oil rings
PART – B
1. Explain briefly the various types of chassis construction with the help of suitable
www.EasyEngineering.
diagrams and the types of frame with neat sketch. ( Dec’14, May’10, Dec 07)
The main components of an automobile refer to the following
components
□ Frame,
net □ Chassis,
□ Body,
□ Power unit,
□ Transmission system
2
Downloaded From : www.EasyEngineering.net
An automobile is made up of mainly two units, these are Chassis
and Body.
―Frame‖ + ―Base components‖ = ―Chassis‖
―Chassis‖ + ―Body‖ = ―Vehicle‖
Frame
The frame is the skeleton of the vehicle. It serves as a main foundation and base for
alignment for the chassis.
Type
□ Conventional frame,
□ Semi integral frame;
www.EasyEngineering.
□ Integral or untidiest frame
Chassis
If the frame contains the base components its called as chassis. The components are
net
like Engine, radiator, clutch, gearbox, silencer, road wheels, fuel tank, wirings, differential
units, etc..,
Body:
Body is the superstructure of the vehicle and it is bolted to the chasis
Types
□ Car
□ Truck,
□ Tractor,
□ Delivery van,
□ Jeep,
□ Bus, etc..,
3
Downloaded From : www.EasyEngineering.net
2. Discuss the forms, functions and materials of various components of
an engine. ( Dec’14, May’08)
The major components of the engine and their functions are briefly described below.
Definition of ‘Engine’
An engine is a device, which transforms one form of energy into another form. Normally,
most of the
engines convert thermal energy into mechanical work and therefore they are called ‗heat
engines‗
Cylinder Block
□ The cylinder block is the main supporting structure for the various components.
□ The cylinder of a multicylinder engine is cast as a single unit, called cylinder block.
□ The cylinder head is mounted on the cylinder block.
□ The cylinder head and cylinder block are provided with water jackets in the case
of water cooling with cooling fins in the case of air-cooling.
□ Cylinder head gasket is incorporated between the cylinder block and cylinder head.
□ The cylinder head is held tight to the cylinder block by number of bolts or studs. The
bottom portion of the cylinder block is called crankcase.
□ A cover called crankcase, which becomes a sump for lubricating oil is fastened to
the bottom
of the crankcase.
□ The inner surface of the cylinder block, which is machined and finished
accurately to cylindrical shape, is called bore or face.
Cylinder
□ As the name implies it is a cylindrical vessel or space in which the piston
makes a reciprocating motion.
□ The varying volume created in the cylinder during the operation of the engine is
filled with the
working fluid and subjected to different thermodynamic processes.
□ The cylinder is supported in the cylinder block.
4
Downloaded From : www.EasyEngineering.net
Piston
It is a cylindrical component fitted into the cylinder forming the moving boundary of the
combustion system. It fits perfectly (snugly) into the cylinder providing a gas-tight space
with the piston rings and the lubricant. It forms the first link in transmitting the gas forces to
the output shaft.
Combustion Chamber
The space enclosed in the upper part of the cylinder, by the cylinder head and the piston
top during the combustion process, is called the combustion chamber. The combustion of
fuel and the consequent release of thermal energy results in the building up of pressure in
this part of the cylinder.
Inlet Manifold
The pipe which connects the intake system to the inlet valve of the engine and through
which air or air-fuel mixture is drawn into the cylinder is called the inlet manifold.
Gudgeon Pin
It forms the link between the small end of the connecting rod and the piston.
Exhaust Manifold
www.EasyEngineering.
The pipe that connects the exhaust system to the exhaust valve of the engine
and through which the products of combustion escape into the atmosphere is called the
exhaust manifold.
net
Inlet and Exhaust Valves
Valves are commonly mushroom shaped poppet type. They are provided
either on the cylinder head or on the side of the cylinder for regulating the charge coming
into the cylinder (inlet valve) and for discharging the products of combustion (exhaust valve)
from the cylinder.
Connecting Rod
□ It interconnects the piston and the crankshaft and transmits the gas forces from the
piston to the crankshaft.
□ The two ends of the connecting rod are called as small end and the big end. Small
end is connected to the piston by gudgeon pin and the big end is connected to the
crankshaft by crankpin.
Crankshaft
□ It converts the reciprocating motion of the piston into useful rotary motion of
the output shaft.
□ In the crankshaft of a single cylinder engine there is pair of crank arms and balance
weights.
□ The balance weights are provided for static and dynamic balancing of the rotating
system.
□ The crankshaft is enclosed in a crankcase.
Piston Rings
Piston rings, fitted into the slots around the piston, provide a tight seal between
the piston and the cylinder wall thus preventing leakage of combustion gases
Camshaft
□ The camshaft and its associated parts control the opening and closing of the two
valves.
□ The associated parts are push rods, rocker arms, valve springs and tappets.
□ This shaft also provides the drive to the ignition system.
□ The camshaft is driven by the crankshaft through timing gears.
5
Downloaded From : www.EasyEngineering.net
Cams
These are made as integral parts of the camshaft and are designed in
such a way to open the valves at the correct timing and to keep them open for the
necessary duration.
Fly Wheel
□ The net torque imparted to the crankshaft during one complete cycle of operation
of the engine fluctuates causing a change in the angular velocity of the shaft.
□ In order to achieve a uniform torque an inertia mass in the form of a wheel is
attached to the output shaft and this wheel is called the flywheel.
3. Explain the need of cooling system in automobiles. Mention its types ( Dec’11,
May’10)
Cooling system
The cooling system removes excess heat to keep the inside of the engine at an efficient
temperature.
www.EasyEngineering.
Air Cooling
□ Liquid Cooling
□ Water cooling Coolant.
net
Water Jackets:
□
□ Water Jackets Surrounds the cylinders with water passage.
□ Absorbs heat from the cylinder wall.
□ Pump move water to radiator where heat is exchanged to
the air. Coolant Flow:
□ Coolant flows through the water jackets where it absorbs heat.
□ It then flows through the radiator where heat is transferred to the air passing through.
□ The amount of flow is determined by the water pump.
□ The flow direction is controlled by the
thermostat. Warm Engine:
□ The thermostat opens when the engine warms up.
□ This allows coolant to circulate through the radiator and the water
jackets. Cold Engine:
When an engine is cold, the thermostat is cold. Coolant flow is through the bypass hose
and the water jackets. This allows the engine to warm up evenly.
Coolant :
□ Coolant Water (Boiling Point 100° C)
□ Glycerin (Boiling Point 290 ° C)
□ Ethylene glycol (Boiling Point 197 ° C)
□ Antifreeze (methyl alcohol, ethyl alcohol )
Cooling System:
6
Downloaded From : www.EasyEngineering.net
□ Water pump is driven by the crankshaft through Timing Belt ( Keeps Cam and
Crank shafts in time)
□ Drive/accessory Belt (Runs alternator, power-steering pump, AC, etc.) Serpentine
Belt VBelt
□ Electric fan is mounted on the radiator and is operated by battery power. It
is controlled by the thermostat switch
Need for cooling system
The cooling system has four primary functions. These functions are as follows:
1. Remove excess heat from the engine.
2. Maintain a constant engine operating temperature.
3. Increase the temperature of a cold engine as quickly as possible.
4. Provide a means for heater operation (warming the passenger compartment).
Types of cooling system:
www.EasyEngineering.
The different Types of cooling system are
1. Air cooling system
2. Liquid cooling system
net
3. Forced circulation system
4. Pressure cooling system
Air-Cooled System :
The simplest type of cooling is the air-cooled, or direct, method in which the heat is drawn
off by moving air in direct contact with the engine Several fundamental principles of cooling
are embodied in this type of engine cooling. The rate of the cooling is dependent upon the
following:
1. The area exposed to the cooling medium.
2. The heat conductivity of the metal used & the volume of the metal or its size in cross
section .
3. The amount of air flowing over the heated surfaces.
4. The difference in temperature between the exposed metal surfaces and the cooling air.
Liquid-cooled system;
Nearly all multi cylinder engines used in automotive, construction, and material handling
equipment use a liquid-cooled system. Any liquid used in this type of system is called a
COOLANT.
□ A simple liquid-cooled system consists of a radiator, coolant pump, piping, fan,
thermostat, and a system of water jackets and passages in the cylinder head and block
through which the coolant circulates.
□ Some vehicles are equipped with a coolant distribution tube inside the cooling
passages that
directs additional coolant to the points where temperatures are highest.
□ Cooling of the engine parts is accomplished by keeping the coolant circulating and in
contact with the metal surfaces to be cooled. The operation of a liquid- cooled system is as
follows:
□ The pump draws the coolant from the bottom of the radiator, forcing the coolant
through the water jackets and passages, and ejects it into the upper radiator tank.
7
Downloaded From : www.EasyEngineering.net
□ The coolant then passes through a set of tubes to the bottom of the radiator from
which the cooling cycle begins.
□ The radiator is situated in front of a fan that is driven either by the water pump or an
electric motor.
□ The fan ensures airflow through the radiator at times when there is no vehicle motion.
□ The heating in the engine and the cooling in the radiator therefore create a natural
circulation that aids the water pump.
4. With the help of neat sketch explain in details and the construction and
working of different engine components? (May 2012)
www.EasyEngineering.
processes. The components of an engine can be grouped under two categories.
net
2. Moving or Mechanism forming components
The stationary components constitute the structural parts and the moving components
synthesize the mechanism parts of an engine. Important components among these are
listed below.
□ Engine block.
□ Pistons.
□ Rings.
□ Connecting rods.
□ Crankshaft.
□ Cylinder heads.
8
Downloaded From : www.EasyEngineering.net
□ Valves and related components.
□ Balance shafts
Engine Block:
The engine block is the basic support and attaching point for all other engine
parts. Engine blocks are made by pouring molten cast iron, steel, or aluminum into
molds,. After the metal cools, the molding sand is washed out and the block is
machined to allow other parts to be installedor attached. The major parts installed
in or on the block are the pistons, crankshaft, camshaft, cylinder heads, and
manifolds
www.EasyEngineering.
net
Pistons transfer the force of expanding combustion gases to the connecting rods.
They are made of aluminum to reduce weight. Most automotive pistons have two
compression rings and one oil ring. Compression rings seal in the pressure created
during the compression and power strokes. If this pressure is allowed to leak out, the
engine will not start or will have severe power and driveability problems. The
compression rings are installed at the top o f the piston. A film of oil between the
compression ring and cylinder wall seals pressure in the cylinder.
9
Downloaded From : www.EasyEngineering.net
The connecting rods are forged steel rods that connect the piston to the crankshaft.
They transfer the force from the piston to the crankshaft. Each connecting rod is
connected to a piston by a piston pin. The rod is attached to the crank shaft by a
bearing cap and bearing inserts that surround the crankshaft journal. The piston pin and
crankshaft bearings allow the rod to move in relation to both the piston and crankshaft.
The crankshaft converts the straight -line force from the piston and connecting rod into
rotary force. It is attached to the engine block by bearing caps and bearings that
surround the crankshaft journal. This design allows the crankshaft to rotate inside of the
bearings with minimal friction.
Cylinder Heads:
The cylinder head contains the combustion chamber for each cylinder and forms the
www.EasyEngineering.
top of the cylinder. Cylinder heads contain the intake and exhaust valves and, in some
cases, the camshaft and lifters. They also contain oil galleries, coolant passages, and
openings to allow the flow of intake and exhaust gases
net
Valves and Related Components:
One or more intake valves are used to control the flow of the air into each cylinder.
One or more exhaust valves are used to control the flow of exhaust gases out of each
cylinder. Valves also seal the cylinder during the compression and power strokes.
They are occasionally called mushroom valves due to their resemblance to a
mushroom. Intake and exhaust valves are identical in shape, but intake valves are
usually larger. Opening and closing of the valves are controlled by the valve train. The
valve spring holds the valve against its seat, keeping it closed. Valve springs are always
slightly compressed when installed. This ensures that the valve closes tightly.
Push rods are used only on cam-in-block engines. They transmit the lifter motion to
the rocker arm. Many push rods are hollow. Oil from the lifter flows through them to
lubricate the rest of the valve train. Rocker arms are pivoting levers that convert the
upward movement of the push rod or lifter into downward movement of the valve
Balance Shafts:
□ During the four strokes, there are five events to be completed, viz, suction,
compression, combustion, expansion and exhaust.
www.EasyEngineering.
□ Each stroke consists of 180° of crankshaft rotation and hence a four-stroke cycle is
completed through 720° of crank rotation.
□ The cycle of operation for an ideal four-stroke SI engine consists of the following four
strokes:
11
Downloaded From : www.EasyEngineering.net
□ The pressure at the end of the combustion process is considerably increased due to
the heat
release from the fuel
iv. Exhaust Stroke:
□ At the end of the expansion stroke the exhaust valve opens and the inlet
valve remains closed.
□ The pressure falls to atmospheric level a part of the burnt gases escape.
□ The piston starts moving from the bottom dead centre to top dead centre and
sweeps the burnt gases out from the cylinder almost at atmospheric pressure.
□ The exhaust valve closes when the piston reaches T.D.C. at the end of the exhaust
stroke and some residual gases trapped in the clearance volume remain in the
cylinder.
□ Residual gases mix with the fresh charge coming in during the following cycle,
www.EasyEngineering.
forming its working fluid.
□ Each cylinder of a four stroke engine completes the above four operations in two
engine
net
Revolutions, one revolution of the crankshaft occurs during the suction and
compression strokes and the second revolution during the power and exhaust
strokes.
□ Thus for one complete cycle there‗s only one power stroke while the crankshaft
turns by two
revolutions.
1. Aerodynamic drag
2. Gradient resistance
3. Rolling resistance
All the above produce a restraining force working against the tractive force. The
tractive force must be greater than or equal to the resistive forces in order to maintain
a sustainable motion. We can balance them as
F = F req = FA + FG + FR + FI
Where FA= Force due to air resistance FG = Force due to gradient of a slope
FG = Force due to rolling resistance FI = Force due to moving or static inertia The last
one FI comes into the picture only when the vehicle accelerates or decelerates, while
the first three always offer a resistance even when the vehicle is moving at a constant
speed.
12
Downloaded From : www.EasyEngineering.net
Air resistance/ Aerodynamic drag:
When a body travels within a dense medium, the molecules of the medium
collide with the moving object and thereby absorb some of the energy. This is felt as a
resistance to the moving object. If the medium is denser, then the resistance is more.
Also when the object moves at a faster speed, the resistance increases
proportionately. Mathematically it can be expressed as:
FA = −½ × Cd × P × V²
Gradient resistance
www.EasyEngineering.
A truck moving uphill When the vehicle travels uphill, a component of its weight
works in a direction opposite to its motion. If some energy is not supplied to overcome
this backward force, then the vehicle would slow down, stall and roll backwards. If the
vehicle is trading uphill at a slope of θ, then the weight of the vehicle, W has two
net
components: one perpendicular to the road surface (with a value W·Cos θ) and the
other along the road surface (with a value W·Sin θ). The component along the road
surface is the one that tries to restrict the motion.
Rolling resistance
When a vehicle rolls, it rolls with its tires in contact with the road surface. The
relative motion of two hard surfaces produces a friction. Further, neither the road, nor the
tires are perfectly rigid. Hence, both flex under the load slightly. As there is a gradual
deformation at the contact between the road and the tire, greatest at the bottom most point
and least at the entry and exit points, the slip of the tire w.r.t. the road produces another
type of loss of energy which results in a resistance. Rolling resistance is composed of the
following components:
The tire rolling resistance FR,T is a result of the resistance due to flexure of the tire,
air resistance on the tire and friction of tire with the road.
13
Downloaded From : www.EasyEngineering.net
These three can be summed up and
FR.T.fr.
In a simplified manner the total rolling resistance can be related to the vertical load
on the wheels and can be written as:
www.EasyEngineering.
net
14
Downloaded From : www.EasyEngineering.net
UNIT-2
PART A
2. Define common rail direct injection system. ( Dec’13, May’07, Dec 09)
www.EasyEngineering.
A common rail which is maintaining high fuel pressure is
connected to individual fuel injectors of a multi cylinder engine.
net The ignition system, in which the mechanical contact points are
replaced by electronic triggering and switching devices, is known as electronic
ignition system.
4. What are the functions of Turbo chargers? (Dec’14, May’11, Dec 09)
To produce more power from the same size engine
To provide the altitude compensation
To improve more complete combustion & hence less emissions
5. What are the advantages of petrol injection? (May ’06, 09, Dec 14)
High power can be developed
It has quick starting characteristics
It has lowest specific fuel consumption
Less engine emissions than carbureted engines
15
Downloaded From : www.EasyEngineering.net
8. What are the advantages of electronic fuel injection system over
conventional injection?
□ Cold starting is easier
□ High fuel economy
□ Less engine emissions
Quick response to varying engine operating conditions
9. What are the functions of generator and starting motor? (Dec’13, May’10)
www.EasyEngineering.
battery. The starting motor is used to crank the engine during the starting
condition.
net
10. What is the function of an ignition system in I.C engine? (Dec’13, May’11, Dec 09)
The function of an ignition system is to ignite the air-fuel mixture at the
end of the compression stroke.
PbO2 – Positive
plate Pb – Negative
plate
Electrolyte – Diluted Sulphuric acid
PART – B
1. With a neat sketch explain the working of a multi point fuel injection system
in diesel engines.
(Dec’13, May’10)
Carburetion
□ Spark-ignition engines normally use volatile liquid fuels.
□ Preparation of fuel-air mixture is done outside the engine cylinder and
formation of a homogeneous mixture is normally not completed in the inlet
manifold.
□ The process of mixture preparation is extremely important for spark-ignition engines.
□ The purpose of carburetion is to provide a combustible mixture of fuel and air in the
required quantity and quality for efficient operation of the engine under all
conditions.
The Simple Carburetor
□ Carburetors are highly complex.
□ The simple carburetor mainly consists of a float chamber, fuel discharge nozzle and
a metering orifice, a venturi, a throttle valve and a choke.
16
Downloaded From : www.EasyEngineering.net
□ The float and a needle valve system maintain a constant level of gasoline in the float
17
Downloaded From : www.EasyEngineering.net
chamber.
□ If the amount of fuel in the float chamber falls below the designed level, the float
goes down, thereby opening the fuel supply valve and admitting fuel.
□ When the designed level has been reached, the float closes the fuel supply
valve thus stopping additional fuel flow from the supply system.
□ Float chamber is vented either to the atmosphere or to the‖ upstream side of the
venturi.
□ During suction stroke air is drawn through the venturi.
www.EasyEngineering.
net
□ The gasoline engine is quantity governed, which means that when power output is
to be varied at a particular speed, the amount of charge delivered to the cylinder is
varied.
□ This is achieved by means of a throttle valve usually of the butterfly type that is
situated after
the venturi tube.
□ As the throttle is closed less air flows through the venturi tube and less is the
quantity of air fuel mixture delivered to the cylinder and hence power output is
reduced.
□ As the throttle is opened, more air flows through the choke tube resulting in
increased quantity of mixture being delivered to the engine. This increases the
engine power output.
□ A simple carburetor of the type described above suffers from a fundamental
drawback in that it provides the required A/F ratio only at one throttle position.
□ At the other throttle positions the mixture is either leaner or richer depending on
whether the
throttle is opened less or more.
□ As the throttle opening is varied, the air flow varies and creates a certain pressure
differential between the float chamber and the venturi throat.
□ The same pressure differential regulates the flow of fuel through the nozzle.
□ Therefore, the velocity of flow of air II and fuel vary in a similar manner.
Working Principle
18
Downloaded From : www.EasyEngineering.net
□ The injection of fuel or the quantity of injected fuel has a decisive influence on engine
starting, idling, power and emissions.
□ The engine ECU is programmed with relevant data to where the fuel rack position
has an
equivalent signal for the amount of fuel being injected.
□ The driver requests the torque or engine speed requirements via accelerator
pedal potentiometer thereby sending a signal to the engine ECU
□ The driver can also input additional commands such as idle speed increase to
compensate e.g. for PTO operation which can be either variably set or has a preset speed
which can be recalled.
□ The road speed function can be used to evaluate vehicle speed and possibly
activate a speed limiter (Heavy Vehicles), or maintain or restore a set speed (cruise
control).
www.EasyEngineering.
□ Further functions can include exhaust brake operation which, when activated, will
result in the
fuel pump rack position being set to zero delivery or idle.
net
□ The engine ECU can also interface with various other vehicle systems e.g. traction
control and carries out self monitoring duties and self diagnostic functions to keep the
system working at an optimal level.
□ To ensure the safe operation in case of failure, the limp home mode functions are also
integrated into the system, for e.g. should the pump speed sensor fail the ECU can use an
alternator speed signal function for engine RPMs counter as a backup signal.
Fuel Injector
□ Fuel injection is a system for admitting fuel into an internal combustion engine.
□ A variety of injection systems have existed since the earliest usage of the internal
combustion engine.
□ The primary difference between carburetors and fuel injection is that fuel injection
atomizes the fuel by forcibly pumping it through a small nozzle under high pressure, while
19
Downloaded From : www.EasyEngineering.net
a carburetor relies on suction created by intake air accelerated through a Venturi tube to
draw the fuel into the airstream.
□ Modern fuel injection systems are designed specifically for the type of fuel being used.
□ Some systems are designed for multiple grades of fuel (using sensors to adapt the t
uning for the fuel currently used).
□ Most fuel injection systems are for gasoline or diesel applications
www.EasyEngineering.
net
2. With a neat sketch explain the working of a battery coil and magneto coil
ignition system
( Dec’11,
May’13)
□ This is called ‗compression ignition‗ and relies on the fact that when air compressed,
its temperature rises.
□ In diesel engines, compression ratio of between 16:1 and 25:1 are common, and at
the end of a compression the temperature of the trapped air is sufficiently high to ignite the
diesel fuel that is sprayed into the cylinder at the appropriate time.
The functions of ignition system
The functions of the coil ignition systems in general use on motor vehicle may be
divided into three areas. These are:
□ Production of the high voltage necessary to produce a spark at the plug gap.
□ Distribute the spark to all the cylinders at proper time based on the firing order.
□ Varying the timing of the spark depending on the various operating conditions of the
engine like cranking time, varying speed and load, so that the best performance is
obtained from the engine under all operating conditions.
www.EasyEngineering.
Mechanism of Ignition
□ The vehicle battery voltages are usually 12 volt or 24 volt and this value is too low to
net
produce a heavy spark at the plug gap in a cylinder under compression.
□ One of the major functions of the battery ignition system is to raise the battery voltage
to the required level and then apply it to spark plugs.
□ This process is correctly initiated in the primary circuit and completed in the
secondary winding
of the ignition coil.
□ Depending on the type of engine and the conditions existing in the cylinders, a
voltage of between 5,000 to 20,000 volts is required and this is called the ionizing voltage
or firing voltage.
□ This firing voltage forces the electrons to jump between the electrodes of the spark
plug in the gap to produce the required spark.
□ The electric spark has sufficient heat energy to ignite the air fuel mixture which later
continues to burn itself.
The conventional coil ignition system
Inductive ignition systems: that uses an ignition coil to perform the step up
transformer action and to increase the electrical voltage. The ignition coils of the inductive
ignition systems operate on the principle of electromagnetic induction (EMI) irrespective of
whether it is triggered by contact breakers or by electronic triggering units.
The factors affecting the operation of the Ignition system.
The factors that determine the value of the voltages induced into the ignition coil
windings during the ignition cycle are:
(a) The strength of the magnetic field. The stronger the magnetic field produced in the
coil primary winding, the greater the possibility of producing a high secondary voltage.
(b) The number of conductors on the secondary winding being cut by the magnetic
field. This Is important when considering the voltages produced in both coil windings
during the ignition cycle.
(c) The speed of relative movement between the magnetic field and the conductors. The
20
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
faster the magnetic field can be made to cut the conductors, the higher will be the value of
voltage induced into the coil windings.
www.EasyEngineering.
net
Construction of the Ignition
coil
The source of the high voltage pulses of current produced in the inductive ignition
system is in the ignition coil. The coil stores the energy in the magnetic field around the
primary winding and at the required instant of ignition, transforms it into a pulse of high
voltage current in the secondary winding. From here it is delivered to the correct spark plug
via the high tension (HT) cables. This ‗Inductive storage device‗ may vary in
design between certain manufacturers, but in general the most common construction.
This coil contains a rod shaped, laminated soft iron core at its centre, and the soft iron cover
surrounds both primary and secondary windings. Both of these soft iron components are
used to intensify and maximize the effect of the primary magnetic field and thus, the energy
stored. The iron core must be laminated to minimize the effects of eddy currents that are
produced during operation and so keep to a minimum the heat developed. The outer soft
iron cover is slotted to allow circulation of the oil filling which is used for cooling purposes.
3. With a neat sketch explain the working of a common rail direct injection
system in diesel engines. ( Dec’14, May’10, Dec 08)
CRDI - Common rail fuel injection
system
□ Common rail direct fuel injection is a modern variant of direct fuel injection system for
petrol and diesel engines.
□ On diesel engines, it features a high-pressure (100 MPa or 15,000 psi) fuel rail
feeding individual solenoid valves, as opposed to low-pressure fuel pump feeding unit
injectors (or pump nozzles).
21
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ Third-generation common rail diesels now feature piezoelectric injectors for increased
precision, with fuel pressures up to 3,000 bar (300 MPa; 44,000 psi).
Working
Principle
□ Solenoid or piezoelectric valves make possible fine electronic control over the fuel
injection time and quantity, and the higher pressure that the common rail technology makes
available provides better fuel atomization.
□ To lower engine noise, the engine's electronic control unit can inject a small amount
of diesel just before the main injection event, thus reducing its explosiveness and
vibration, as well as optimizing injection timing and quantity for variations in fuel quality,
cold starting and so on.
□ Some advanced common rail fuel systems perform as many as five injections per
st roke.
www.EasyEngineering.
□ Diesel engines have used various forms of fuel injection. Two common types include
the unit injection system and the distributor/inline pump systems.
□ While these older systems provided accurate fuel quantity and injection timing
control, they
factors:net
were limited by several
□ They were limited in the number and timing of injection events that could be
commanded during a single combustion event.
□ For the typical distributor/inline system, the start of injection occurred at a pre-
determined pressure and ended at a pre-determined pressure.
□ Once the pressure in the injector reached a pre-determined level, the plunger would
lift and injection would start.
compressor
which compresses the intake air.
□ Compressed intake air has more density and hence more fuel can be injected
increasing the power of the engine.
□ Turbo charging is an ideal way to increase the engine power without increasing
the engine size.
□ Turbochargers were originally known as turbo superchargers when all forced induction
devices were classified as superchargers.
□ The key difference between a turbocharger and a conventional supercharger is that
the latter is mechanically driven by the engine, often through a belt connected to the
crankshaft, whereas a turbocharger is powered by a turbine driven by the engine's exhaust
gas.
□ Compared to a mechanically driven supercharger, turbochargers tend to be more
www.EasyEngineering.
efficient, but less responsive.
□ They are most often used with Otto cycle and Diesel cycle internal combustion
engines.
net
23
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
net
□ This results in an extremely porous structure providing a large surface area to
simulate the combination of oxygen with HC and CO.
□ The oxidation process converyts most of these components to water vapour and
carbon dioxide. The schematic diagram of a catalytic package. Converters
hydrocarbons, CO and NOx are arranged. The catalysts used for these converters
are closely guarded secrets.
□ The catalyst for NOx is the first element in the gas flow path and does not cause
any heat release. The HC/CO catalyst is the next. Its heat release is so great that
there is a risk of over experiments with various types of converters have led to the
conclusion that the axial flow form is superior to the radial floe type.
24
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ Three- way monolith catalyst converter. The front bed or inlet, is treated with
platinum and rhodium and is termed a reducing catalyst. The rear bed is coated
with palladium and is reffered to as the oxidizing catalyst.
□ In exhaust gases first pass through the reducing catalyst. This causes the levels of
NOx to be reduced. Pressurised air from the air injection system is forced in to the
space between the catalyst beds. The extra air supplies additional oxygen and
causes greater oxidation of the gases.
□ As the treated exhaust gases from the first bed continue flowing, they eventually
pass through the conventional oxidation catalyst made of palladium and platinum.
Here hydrocarbons and carbon monoxide emissions are reduced
www.EasyEngineering.
net
25
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
UNIT-3
TRANSMISSION SYSTEMS
PART
A
The function of the clutch is to connect and disconnect the engine with road
wheels. The clutch has to be disengaged during gear shifting, idling etc.
www.EasyEngineering.
□ Cone clutch
□ Semi centrifugal clutch
□ Centrifugal clutch Fluid clutches
7. What is a universal joint? What are its types? (May’10, Dec 08)
Universal joint is a type of flexible joint between two shafts who axes
26
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
intersect
27
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
9. What is Hotchkiss drive and Torque Tube drive? ( Dec’13, May’08, Dec 08)
In Hotchkiss drive, the loads such as vehicle weight, driving torque,
www.EasyEngineering.
braking torque and side thrust all are taken by leaf springs. Two universal joints
and one slip joint are must needed.
In Torque tube drive, the driving torque and braking torque are taken by
net
torque tube while the vehicle weight and side thrust are taken care of by leaf
springs. One universal joint is just sufficient.
10. What is the function of differential unit? ( Dec’14, May’12, Dec 08)
The function of a differential unit is to permit the vehicle turns without
wheel skidding. It permits higher speed for outer wheels and reduced speed for
inner wheels during turning.
PART B
1. What are the features of good quality clutch? Explain the working of multi
plate clutch with a neat sketch. ( Dec’10,11,May’08)
Clutch:
□ Clutch is a device which is used in the transmission system of automobile to
engage and disengage the engine to the transmission or gear box.
□ It is located between the transmission and the engine.
□ When the clutch is engaged, the power flows from the engine to the rear wheels in
a rearwheel- drive transmission and the vehicle moves.
□ When the clutch is disengaged, the power is not transmitted from the engine to the
rear wheels and vehicle stops even if engine is running.
28
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
□ The friction depends upon the surface area contact.
□ The friction surfaces are so designed that the driven member initially slips on
driving member when initially pressure is applied.
net
□ As pressure increases the driven member is brought gradually to speed the driving
member.
The three main parts of clutch are:
□ Driving member
□ Driven member
□ Operating member
□ The driving member consists of a flywheel mounted on the engine crank shaft.
□ The flywheel is bolted to cover which carries a pressure plate or driving disc,
pressure springs and releasing levers.
□ Thus the entire assembly of flywheel and cover rotates all the times.
□ The clutch housing and the cover provided with openings dissipate the heat
generated by friction during the clutch operation.
□ The driving member consists of a disc or plate called clutch plate.
□ It is free to slide length wise on the splines of the clutch shaft.
□ It carries friction materials on both of its surfaces when it is gripped between the
flywheel and the pressure plate; it rotates the clutch shaft through splines.
□ The operating members consists of a foot pedal, linkage, release or throw-out
bearing, release levers and springs necessary to ensure the proper operation of the
clutch.
□ Now the driving member in an automobile is flywheel mounted on crank shaft, the
driven member is the pressure plate mounted on transmission or gear box input shaft.
Multi-plate Clutch:
□ Multi-plate clutch consists of a number of clutch plates instead of only one clutch
plate as in case of single plate clutch.
□ As The number of clutch plates are increased, the friction surfaces also increases.
□ The increased number of friction surfaces obliviously increases the capacity of the
clutch to transmit torque.
□ The plates are alternately fitted to engine and gear box shaft.
29
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ They are firmly pressed by strong coil springs and assembled in a drum.
□ Each of the alternate plate slides on the grooves on the flywheel and the other
slides on splines on the pressure plate.
□ Thus, each alternate plate has inner and outer splines.
□ The multi-plate clutch works in the same way as a single plate clutch by operating
the clutch pedal.
□ The multi-plate clutches are used in heavy commercial vehicles, racing cars and
motor cycles for transmitting high torque.
□ The multi-plate clutch may be dry or wet.
□ When the clutch is operated in an oil bath, it is called a wet clutch.
□ When the clutch is operated dry it is called dry clutch.
□ The wet clutch is used in conjunction with or part of the automatic transmission.
www.EasyEngineering.
net
30
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ Now the clutch is reengaged and acceleration pedal is pressed to adjust the
engine speed according to driver‗s judgment. The clutch is disengaged(i.e.
second declutching) again the appropriate gear is engaged and then the clutch is
reengaged
□ It is that gear box in which sliding synchronizing units are provided in place of
sliding dog clutches as in case of constant mesh gear box.
□ With the help of synchronizing unit, the speed of both the driving and driven
shafts is
synchronized before they are clutched together through train of gears.
□ The arrangement of power flow for the various gears remains the same as in constant
mesh gear box. The synchronizer is made of frictional materials.
□ When the collar tries to mesh with the gear, the synchronizer will touch the gear first
and use friction force to drive the gear to spin at the same speed as the collar. This will
ensure that the collar is meshed into the gear very smoothly without grinding.
□ Synchromesh gear devices work on the principle that two gears to be engaged are
www.EasyEngineering.
first bought into frictional contact which equalizes their speed after which they are engaged
readily and smoothly.
net
3. Explain and detail bout Differential Unit with neat sketch. ( Dec’15, May’14, Dec 10)
□ Differentials are a variety of gearbox, almost always used in one of two ways.
□ In automobile and other wheeled vehicles, the differential allows each of the driving
wheels to rotate at different speeds, while supplying equal torque to each of them.
□ Purpose
The differential gear box has following functions:
□ Avoid skidding of the rear wheels on a road turning.
□ Reduces the speed of inner wheels and increases the speed of outer wheels, while
drawing a curve.
□ Keeps equal speeds of all the wheels while moving on a straight road.
□ Eliminates a single rigid rear axle, and provides a coupling between two rear axles.
31
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
The following description of a differential applies to a front-wheel-drive car or truck:
□ Power is supplied from the engine, via the transmission or gearbox, to a drive shaft
net
termed as propeller shaft, which runs to the differential.
□ A spiral bevel pinion gear at the end of the propeller shaft is encased within the
differential itself, and it meshes with the large spiral bevel ring gear termed as crown wheel.
□ The ring gear is attached to a carrier, which holds what is sometimes called a spider, a
cluster of four bevel gears in a rectangle, so each bevel gear meshes with two neighbors
and rotates counter to the third that it faces and does not mesh with.
□ Two of these spider gears are aligned on the same axis as the ring gear and drive the
half shafts connected to the vehicle's driven wheels.
□ The other two spider gears are aligned on a perpendicular axis which changes
orientation with
the ring gear's rotation
32
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ These two gears are just called pinion gears, not to be confused with the main pinion
gear.
□ As the carrier rotates, the changing axis orientation of the pinion gears imparts the
motion of the ring gear to the motion of the side gears by pushing on them rather than
turning against them, but because the spider gears are not restricted from turning against
each other, within that motion the side gears can counter-rotate relative to the ring gear
and to each other under the same force (in which case the same teeth do not stay in
contact).
www.EasyEngineering.
universal joints at both ends of the driveshaft, which is not enclosed.
□ The use of two universal joints, properly phased and with parallel alignment of the
drive and driven shafts, allows the use of simple cross type universals. (In a torque-tube
net
arrangement only a single universal is used at the end of the transmission tail shaft, and
this universal should be a constant velocity joint.)
□ In the Hotchkiss drive, slip-splines or a plunge-type eliminate thrust transmitted back
up the driveshaft from the axle, allowing simple rear-axle positioning using parallel leaf
springs. (In the torque-tube type this thrust is taken by the torque tube to the
transmission and thence to the transmission and motor mounts to the frame.
□ While the torque-tube type requires additional locating elements, such as a Panhard
rod, this allows the use of coil springs.)
□ Some Hotchkiss drive shafts are made in two pieces with another universal joint in the
center for greater flexibility, typically in trucks and specialty vehicles built on truck frames.
Some installations use rubber mounts to isolate noise
and vibration.
□ The "torque" that is referred to in the name is not that of the driveshaft, along the
axis of the car, but that applied by the wheels. The design problem that the torque
tube solves is how to get the traction forces generated by the wheels to the car
frame.
□ The "torque tube" transmits this force by directly coupling the axle differential to the
transmission and therefore propels the car forward by pushing on the
engine/transmission and then through the engine mounts to the car frame
□ In contrast, the Hotchkiss drive has the traction forces transmitted to the car frame by
using
other suspension components such as leaf springs or trailing arms. A ball and
socket type of joint called a "torque ball" is used at one end of the torque tube to
allow relative motion between the axle and transmission due to suspension travel.
□ Since the torque tube does not constrain the axle in the lateral (side-to-side)
direction a pan hard rod is often used for this purpose.
www.EasyEngineering.
□ The combination of the pan hard rod and the torque tube allows the easy
implementation of soft coil springs in the rear to give good ride quality.
□ In addition to transmitting the traction forces, the torque tube is hollow and contains
net
the rotating driveshaft. Inside the hollow torque ball is the universal joint of the
driveshaft that allows relative motion between the two ends of the driveshaft. In most
applications the drive shaft uses a single universal joint which has the disadvantage
that it causes speed fluctuations in the driveshaft when the shaft is not straight.
□ The Hotchkiss drive uses two universal joints which has the effect of canceling
the speed fluctuations and gives a constant speed even when the shaft is no
longer straight
34
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
5. Discuss about the fluid flywheel with simple sketch .MAY/JUNE 2013
□ A fluid flywheel is a hydraulic device. In 1905 Dr.Hermannn Fottinger ,a chief
engineer of the Vulcan werke AG in germany invented the flywheel. The fluid fly
wheel is now a fundamental part of modern car design and is used in other
applications including diesel locomotives.
□ Fluid flywheel is a kind of fluid coupling in which the flywheel is the driving rotor.
Fluid flywheel is a fluid device utilizing recirculated fluid with in a sealed housing to
maintain speed or torque applied to a mechanical apparatus without relying on
inertia of weight.
□ A fluid flywheel consists of two concentric housings—a main circulation chamber
and an angular recirculation chamber and an angular recirculation chamber
surrounding the main circulation chamber. A shaft is mounted on the bearing of the
outer housing and the extension of the shaft has a series of blades mounted there
on.
www.EasyEngineering.
net
□ Upon rotation of the shaft, fluid is drawn by the blades into the inlet end of the main
circulation camber.
□ The fluid is propelled from one series of blades to the next until it is discharged from
the outlet end. The fluid is then redirected around the inner housing and re-
circulated through the recirculation chamber. The fluid, being constantly re-circulated
within the device will increase in speed or maintain the existing speed with relatively
minimum force being applied to rotate the extending shaft. Toroidal shaped flow
deflectors at opposing ends are useful for smooth transition of fluid from the main
circulation chamber to the recirculation chamber and vice versa
□ The driving unit is called impeller and the driven limit is called as runner. When the
efficiency of the liquid coupling is highest, the impeller and the runner almost run at
same speed. But usually the runner speed is less than the impeller. This speed lag
of runner is called slip. The slip is greatest when the vehicle is at rest that is when
the runner is stationary.
□ Fluid coupling is used with conventional clutch and transmission to enable the driver
to use clutch and gear with less skill and fatigue as compared to the mechanical
linkage.
35
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
U TA
N
1. Define wheel track anI d wheel base. ( Dec’14, May’12, Dec 08)
T
The distance betwee n the tyre centers, mounted on the same axle is known
-
as wheel track. The wheelbase is the distance between the centers of the front
and rear wheels 4
www.EasyEngineering.
4
fading
Non uniform pressure
B
Uniform pressure
net
4. Define steering gear.R( Dec’14, May’12, Dec 08)
The steering gearAis used to convert the rotational movement of the
steering wheel into linearKmovement of the steering linkage. Moreover it
provides mechanical advEantage.
S
5. What is the purpose of Toe-in and Toe-out? ( Dec’14, May’12, Dec 08)
The purpose of proviAding a toe in and toe out is straight line stability of
the
vehicle, after negotiatiNng a
D
turn.
6. What are the different types of tyres used in automobile? ( Dec’14, May’12,
Dec 08) S
U
□ Cross ply
S
□ Radial ply
P
tyres
□ EBelted bias
N
7. What are the differen types of springs used in suspension system? (
S
Dec’14, May’12, Dec tI
08) O
□ LNeaf springs (Rigid axle suspension)
□ Coil springs (Independent suspension)
□ TSorsion bar (Independent suspension)
Y
8. Define king pin inclinSation. ( Dec’14, May’12, Dec 08)
The tilt of the kinTg pin from the vertical reference line is known as King Pin
Inclination (KPI). It is alsoE called as Steering Axis Inclination (SAI)
M
S
P
A
R
9. Give the function of tyre? ( Dec’14, May’12, Dec 08)
36
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
i
c
l
e
net W
e
i
g
h
t
Rack and pinion, recirculating ball, worm and
sector
T
r
a
n
s
f
e
r
r
i
n
g
37
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ of an Ariel Atom sports car chassis. For most high volume production, this
is usually mounted on the other side of this panel
R Steering box of a motor vehicle, the traditional (non-assisted), you may a
notice that the system allows you to adjust the braking and steering c
systems, you can also see the attachment system to the frame.
k Many modern cars use rack and pinion steering mechanisms, where the
steering wheel turns
a the pinion gear; the pinion moves the rack, which is a linear gear that
n meshes with the pinion, converting circular motion into linear motion along
d the transverse axis of the car (side to side motion).
□ This motion applies steering torque to the swivel pin ball joints that
p replaced previously used kingpins of the stub axle of the steered wheels via
i tie rods and a short lever arm called the steering arm.
n The rack and pinion design has the advantages of a large degree of i
www.EasyEngineering.
feedback and direct steering "feel". A disadvantage is that it is not
o adjustable, so that when it does wear and develop lash, the only cure is
n replacement.
net
□ The recirculating ball design also has a perceptible lash, or "dead spot" on
u center, where a minute turn of the steering wheel in either direction does
n not move the steering apparatus.
i
t This is easily adjustable via a screw on the end of the steering box to
account for wear, but it cannot be entirely eliminated because it will
m create excessive internal forces at other positions and the mechanism
o will wear very rapidly. This design is still in use in trucks and other large
u vehicles, where rapidity of steering and direct feel are less important than
n robustness, maintainability, and mechanical advantage.
t
2.
eDescribe the Anti-lock braking system (ABS). ( Dec’15, May’11, Dec 09)
d Anti-lock braking system (ABS) is an automobile safety system that allows the
wheels on a motor vehicle to maintain tractive contact with the road
i surface according to driver inputs while braking, preventing the wheels
n from locking up (ceasing rotation) and avoiding uncontrolled skidding.
□ It is an automated system that uses the principles of threshold braking and
t cadence braking which were practiced by skillful drivers with previous
h generation braking systems. It does this at a much faster rate and with
e better control than a driver could manage.
□ ABS generally offers improved vehicle control and decreases stopping
c distances on dry and slippery surfaces for many drivers; however, on loose
o surfaces like gravel or snow-covered pavement, ABS can significantly
c increase braking distance, although still improving vehicle control.
k Since initial widespread use in production cars, anti-lock braking systems p
have evolved considerably. Recent versions not only prevent wheel lock i
under braking, but also electronically control the front-to-rear brake bias.
t This function, depending on its specific capabilities and implementation,
38
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
k
n
o
wOperation
n The anti-lock brake controller is also known as the CAB (Controller Anti-lock
Brake).
a Typically ABS includes a central electronic control unit (ECU), four wheel
s speed sensors, and at least two hydraulic valves within the brake
e hydraulics. The ECU constantly monitors the rotational speed of each
l wheel
e if it detects a wheel rotating significantly slower than the others, a
c condition indicative of
www.EasyEngineering.
t impending wheel lock, it actuates the valves to reduce hydraulic pressure
to r the brake at the affected wheel, thus reducing the braking force on that
o
wheel; the wheel then turns faster.
n Conversely, if the ECU detects a wheel turning significantly faster than the i
net others, brake hydraulic pressure to the wheel is increased so the braking
c force is reapplied, slowing down the wheel.
□ This process is repeated continuously and can be detected by the driver
b via brake pedal pulsation. Some anti-lock systems can apply or release
r braking pressure 15 times per second. Because of this, the wheels of cars
a equipped with ABS are practically impossible to lock even during panic
k braking in extreme conditions.
e
Modern ABS applies individual brake pressure to all four wheels through a
control system of hub-mounted sensors and a dedicated micro-controller.
f
ABS is offered or comes standard on most road vehicles produced today
o
and is the foundation for electronic stability control systems, which are
r rapidly increasing in popularity due to the vast reduction in price of vehicle
c electronics over the years.
e ABS equipment may also be used to implement a traction control system
(TCS) on acceleration of the vehicle.
d If, when accelerating, the tire loses traction, the ABS controller can detect
i the situation and
s take suitable action so that traction is regained. More sophisticated
t versions of this can also control throttle levels and brakes simultaneously.
Cromponents of ABS
i There are four main components of ABS:
b Speed sensors,
u Valves,
t Pump, and
i Controller.
o
n
39
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
the controller, the controller will then limit the brake force (EBD) and activate the
ABS modulator which actuates the braking valves on and off.
net
Use
□ The ABS controller knows that such a rapid deceleration is impossible, so it reduces
the pressure to that brake until it sees an acceleration, then it increases the pressure
until it sees the deceleration again. It can do this very quickly, before the tire can
actually significantly change speed.
□ The result is that the tire slows down at the same rate as the car, with the brakes
keeping the tires very near the point at which they will start to lock up. This gives the
system maximum braking power.
□ When the ABS is in operation the driver will feel a pulsing in the brake pedal; this
comes from the rapid opening and closing of the valves. This pulsing also tells the
driver that the ABS has been triggered. Some ABS systems can cycle up to 16 times
per second.
3.
Describe the Hydraulic braking system( Dec’11, May’08, Dec 07)
□ The disc brake or disk brake is a device for slowing or stopping the rotation of a
wheel while it is in motion. A brake disc (or rotor in U.S. English) is usually made of
cast iron, but may in some cases be made of composites such as reinforced carbon-
carbon or ceramic-matrix composites.
□ This is connected to the wheel and/or the axle. To stop the wheel, friction material in
the form of brake pads (mounted on a device called a brake caliper) is forced
mechanically, hydraulically, pneumatically or electromagnetically against both sides
of the disc. Friction causes
40
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ The disc and attached wheel to slow or stop. Brakes (both disc and drum) convert
motion to heat, but if the brakes get too hot, they will become less effective because
they cannot dissipate enough heat. This condition of failure is known as brake fade.
www.EasyEngineering.
chrome-plated steel pistons (called caliper pistons), a set of thermally conductive
brake pads and a rotor (also called a brake disc) or drum attached to an axle.The
system is usually filled with a glycol-ether based brake fluid (other fluids may also be
net
used).
□ At one time, passenger vehicles commonly employed drum brakes on all four
wheels. Later, disc brakes were used for the front and drum brakes for the rear.
□ However disc brakes have shown better heat dissipation and greater resistance to
'fading' and are therefore generally safer than drum brakes.
□ So four-wheel disc brakes have become increasingly popular, replacing drums on
all but the most basic vehicles.
□ Many two-wheel vehicle designs, however, continue to employ a drum brake for the
rear wheel. The following description uses the terminology for and configuration of a
simple
□ In a hydraulic brake system, when the brake pedal is pressed, a pushrod exerts
force on the piston(s) in the master cylinder, causing fluid from the brake fluid
reservoir to flow into a pressure chamber through a compensating port.
□ This results in an increase in the pressure of the entire hydraulic system, forcing
fluid through the hydraulic lines toward one or more calipers where it acts upon one
or two caliper pistons sealed by one or more seated O-rings (which prevent leakage
of the fluid).
□ The brake caliper pistons then apply force to the brake pads, pushing them against
the spinning rotor, and the friction between the pads and the rotor causes a braking
torque to be generated, slowing the vehicle.
□ Heat generated by this friction is either dissipated through vents and channels in the
rotor or is conducted through the pads.
□ Subsequent release of the brake pedal/lever allows the spring(s) in my master
cylinder assembly to return the master piston(s) back into position.
□ This action first relieves the hydraulic pressure on the caliper, then applies suction to
the brake piston in the caliper assembly, moving it back into its housing and allowing
the brake pads to release the rotor.
41
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ The hydraulic braking system is designed as a closed system: unless there is a leak in
the system, none of the brake fluid enters or leaves it, nor does the fluid get consumed
through use.
□ With a neat sketch explain the function of a master cylinder in hydraulic brakes. In
a hydraulic brake system,
□ when the brake pedal is pressed, a pushrod exerts force on the piston(s) in the
master cylinder, causing fluid from the brake fluid reservoir to flow into a pressure
chamber through a compensating port.
□ This results in an increase in the pressure of the entire hydraulic system, forcing fluid
through the hydraulic lines toward one or more calipers where it acts upon one or two
caliper pistons sealed by one or more seated O-rings (which prevent leakage of the
fluid).
□ The brake caliper pistons then apply force to the brake pads, pushing them against the
www.EasyEngineering.
spinning rotor, and the friction between the pads and the rotor causes a braking torque
to be generated, slowing the vehicle.
□ Heat generated by this friction is either dissipated through vents and channels in
net
the rotor or is
conducted through the pads, which are made of specialized heat-tolerant
materials such as kevlar orsintered glass.
□ Subsequent release of the brake pedal/lever allows the spring(s) in the master
cylinder assembly to return the master piston(s) back into position.
42
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
□ This action first relieves the hydraulic pressure on the caliper, then applies
net
suction to the brake piston in the caliper assembly, moving it back into its
housing and allowing the brake pads to release the rotor.
4.
Discuss the working of suspension system used in cars( Dec’11, May’10, Dec 07)
43
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
or a tiny speck. Thus, either the wheel experiences a vertical acceleration as it passes over
an imperfection. The suspension of a car is actually part of the chassis, which comprises
all of the important systems located beneath the car's
body.
These system include:
□ Frame
□ Suspension system
□ Steering system
□ Tires or Wheels
www.EasyEngineering.
net
44
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
net
Advantages
□ Comfort to passengers
□ Good handling
Shields the vehicle from damage
□ Increases life of vehicle
□ Keeps the tires pressed firmly to ground.
45
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
5.
Discuss about the power assisted steering (PAS) ( Dec’12, May’11,
Dec 09)
□ In automobiles, power steering (also known as power assisted steering (PAS) or
steering assist system) helps drivers steer by augmenting steering effort of the
steering wheel.
□ Hydraulic or electric actuators add controlled energy to the steering mechanism,
so the
driver needs to provide only modest effort regardless of conditions.
□ Power steering helps considerably when a vehicle is stopped or moving
slowly. Also, power steering provides some feedback of forces acting on the
front wheels to give an ongoing sense of how the wheels are interacting with
the road.
□ This is typically called "rοad feel". Representative power steering systems for
cars augment steering effort via an actuator, a hydraulic cylinder, which is part
www.EasyEngineering.
of a servo system. These systems have a direct mechanical connection
between the steering wheel and the linkage that steers the wheels.
□ This means that power-steering system failure (to augment effort) still permits the
vehicle to be steered using manual effort alone.
net
□ Other power steering systems (such as those in the largest off-road construction
vehicles) have no direct mechanical connection to the steering linkage; they
require power. Systems of this kind, with no mechanical connection, are
sometimes called "drive by wire" or "steer by wire", by analogy with aviation's "fly-
by-wire".
□ In this context, "wire" refers to electrical cables that carry power and
data, not thin-wire-rope mechanical control cables.
□ In other power steering systems, electric motors provide the assistance instead
of hydraulic
systems. As with hydraulic types, power to the actuator (motor, in this case) is
controlled by the rest of the power-steering system.
□ Some construction vehicles have a two-part frame with a rugged hinge in the
middle; this hinge allows the front and rear axles to become non-parallel to steer
the vehicle. Opposing hydraulic cylinders move the halves of the frame relative to
each other to steer.
□ Power steering helps the driver of a vehicle to steer by directing some of the
power to assist in swiveling the steered road wheels about their steering axes.
As vehicles have become heavier and switched to front wheel drive, particularly
using negative offset geometry, along with increases in tire width and diameter,
the effort needed to turn the wheels about their steering axis has increased, often
to the point where major physical exertion would be needed were it not for power
assistance.
□ To alleviate this auto makers have developed power steering systems: or more
correctly power-assisted steering—on road going vehicles there has to be a
mechanical linkage as a failsafe.
□ There are two types of power steering systems hydraulic and electric/electronic.
A
46
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
hydraulic electric hybrid system is also possible. A hydraulic power steering (HPS)
uses hydraulic pressure supplied by an engine-driven pump to assist the motion
of turning the steering wheel.
□ Electric power steering (EPS) is more efficient than the hydraulic power steering,
since the electric power steering motor only needs to provide assistance when
the steering wheel is turned, whereas the hydraulic pump must run constantly.
Speed Sensitive Steering
□ An outgrowth of power steering is speed sensitive steering, where the
steering is heavily assisted at low speed and lightly assisted at high speed.
□ The auto makers perceive that motorists might need to make large
steering inputs while maneuvering for parking, but not while traveling at high
speed.
□ The first vehicle with this feature was the Citroën SM with its Diravi
layout[citation needed], although rather than altering the amount of
assistance as in modern power steering systems, it altered the pressure on a
www.EasyEngineering.
centring cam which made the steering wheel try to "spring" back to the
straight-ahead position.
□ Modern speed-sensitive power steering systems reduce the mechanical or
net electrical assistance as the vehicle speed increases, giving a more direct feel.
This feature is gradually becoming more common.
47
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
UNIT- 5
PART A
www.EasyEngineering.
the vehicle. The term most commonly refers to hybrid electric vehicles (HEVs), which
combine an internal combustion engine and one or more electric motors.
net
3. What is a fuel cell? ( Dec’12, May’11)
A fuel cell is an electrochemical device that converts a source fuel into an
electrical current and water. It generates electricity inside a cell through
reactions between a fuel and an oxidant, triggered in the presence of an
electrolyte.
www.EasyEngineering.
A larger quantity of fuel is required to produce a specified power output. For
example, in an automobile, more fuel is required for each mile driven.
Low boiling points and high vapor pressures of methyl and ethyl alcohol indicate that
net
vapor
lock could be a serious problem, particularly at high altitudes on warm
summer days.
PART B
1. With simple sketch explain the construction and working principle of fuel
cell. ( Dec’14, May’10)
□ A Fuel Cell is an electrochemical device that combines hydrogen and
oxygen to produce
□ electricity, with water and heat as its by-product. Since conversion of the fuel
to energy takes place via an electrochemical process, not combustion.
□ It is a clean, quiet and highly efficient process- two to three times more
efficient than fuel
burning.
49
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ It operates similarly to a battery, but it does not run down nor does it require
recharging As long as fuel is supplied, a Fuel Cell will produce both energy
and heat A Fuel Cell consists of two catalyst coated electrodes surrounding an
electrolyte.
□ One electrode is an anode and the other is cathode The process begins when
Hydrogen molecules enter the anode The catalyst coating separates
hydrogen‗s negatively charged electrons from the positively charged
protons The electrolyte allows the protons to pass through to the cathode, but
not the electrons. Instead the electrons are directed through an external circuit
which creates electrical current.
□ While the electrons pass through the external circuit, oxygen molecules pass
through the cathode. There the oxygen and the protons combine with the
electrons after they have passed through the external circuit.
□ When the oxygen and the protons combine with the electrons it produces
www.EasyEngineering.
water and heat. Individual fuel cells can then be placed in a series to form a
fuel cell stack. The stack can be used in a system to power a vehicle or to
provide stationary power to a building
net
2. Discuss the concept of electric and hybrid vehicle with neat sketch. (
Dec’12, May’10,
Dec 07)
□ A hybrid electric vehicle (HEV) is a type of hybrid vehicle and electric vehicle
which combines a conventional internal combustion engine (ICE) propulsion
system with an electric propulsion system. The presence of the electric power
train is intended to achieve either better fuel economy than a conventional
vehicle or better performance.
□ There are a variety of HEV types, and the degree to which they function as
EVs varies as well. The most common form of HEV is the hybrid electric car,
although hybrid electric trucks (pickups and tractors) and buses also exist.
□ Modern HEVs make use of efficiency-improving technologies such as
regenerative braking, which converts the vehicle's kinetic energy into electric
energy to charge the battery, rather than wasting it as heat energy as
conventional brakes do. Some varieties of HEVs use their internal combustion
engine to generate electricity by spinning an electrical generator (this
combination is known as a motor-generator), to either recharge their batteries
or to directly power the electric drive motors.
□ Many HEVs reduce idle emissions by shutting down the ICE at idle and
restarting it when Needed this is known as a start-stop system.
50
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
www.EasyEngineering.
□ A hybrid-electric produces less emission from its ICE than a comparably
sized gasoline car, since an HEV's gasoline engine is usually smaller than a
comparably sized pure gasoline-burning vehicle (natural gas and propane
net
fuels produce lower emissions) and if not used to directly drive the car, can
be geared to run at maximum efficiency, further improving fuel economy.
51
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
□ LPG has a typical specific calorific value of 46.1 MJ/kg compared with 42.5
MJ/kg for fuel oil and 43.5 MJ/kg for premium grade petrol (gasoline).[6]
However, its energy density per volume unit of 26 MJ/L is lower than either
that of petrol or fuel oil, as its relative density is lower (about 0.5–0.58,
compared to 0.71–0.77 for gasoline).
□ As its boiling point is below room temperature, LPG will evaporate quickly at
normal temperatures and pressures and is usually supplied in pressurised
steel vessels. They are typically filled to 80–85% of their capacity to allow for
thermal expansion of the contained liquid.
□ The ratio between the volumes of the vaporized gas and the liquefied
gas varies depending on composition, pressure, and temperature, but is
typically around 250:1. The pressure at which LPG becomes liquid, called its
vapour pressure, likewise varies depending on composition and
temperature; for example, it is approximately 220 kilopascals (32 psi) for
www.EasyEngineering.
pure butane at 20 °C (68 °F), and approximately 2,200 kilopascals (320 psi)
for pure propane at 55 °C (131 °F). LPG is heavier than air, unlike natural gas,
and thus will flow along floors and tend to settle in low spots, such as
net
basements.
□ There are two main dangers from this. The first is a possible explosion if the
mixture of LPG and air is within the explosive limits and there is an ignition
source. The second is suffocation due to LPG displacing air, causing a
decrease in oxygen concentration. Large amounts of LPG can be stored in
bulk cylinders and can be buried underground.
www.EasyEngineering.
leaving cargo areas free.
□ As with other alternative fuels, other barriers for widespread use of NGVs are
natural
net
gas distribution to and at fueling stations as well as the low number of CNG
and LNG stations. CNG powered vehicles are considered to be safer than
gasoline-powered vehicles
www.EasyEngineering.
Transesterification: alcohol + ester → different alcohol + different ester
net
□ The alcohol reacts with the fatty acids to form the mono-alkyl ester
(biodiesel) and crude glycerol. The reaction between the biolipid (fat or
oil) and the alcohol is a reversible reaction so excess alcohol must be
added to ensure complete conversion.
www.EasyEngineering.
combination epoch. At standard temperature
hydrogen
and pressure,
is acolorless, odorless, tasteless, non-
toxic, nonmetallic, highly combustiblediatomic gas with the molecular
net
formula H2. Since hydrogen readily formscovalent compounds with most
non-metallic elements, most of the hydrogen on Earth exists in
molecular forms such as in the form of water or organic compounds.
□ Hydrogen plays a particularly important role in acid–base reactions as
many acid-base reactions involve the exchange of protons between
soluble molecules. In ionic compounds, hydrogen can take the form of a
negative charge (i.e., anion)
□ The hydrogen cation is written as though composed of a bare proton, but in
reality, hydrogen cations in ionic compounds are always more complex
species than that would suggest..
54
Downloaded From : www.EasyEngineering.net
Downloaded From : www.EasyEngineering.net
Sixth Semester
Mechanical Engineering
www.EasyEngineering.
1. Give any two advantages of frameless
framed construction.
conventional
construction over the
2.
3.
net
Name the sources of automobile pollutants.
List out any two drawbacks of carburetor in multi cylinder engine.
4. Write the two methods of lead acid battery charging.
5. Show the motion of the differential pinion gears when a car is
Moving along a curve?.
6. Name the possible causes for the propeller shaft to develop
noise while runmng.
7. Define 'king pin inclination'.
Or
(b) With a neat schematic diagram, explain the floor
mounted gear shift mechanism. In detail.
www.EasyEngineering.
14. (a)
steering.
Discuss in detail the functions of an integral type power
net
Or
(b) With a neat sketch, explain the function of a master cylinder
in hydraulic brakes.
15. (a) Write short note on the following: (i) Air bags. (8
(ii) Fuel cells.
(Or)
b) With a schematic layout, explain the working of
serres and parallel configuration type hybrid cars.
Sixth Semester
Mechanical Engineering
www.EasyEngineering.
1. List out the forces acting on a chassis frame.
20
2.
3.
net
Define 'turbo lag'.
PART B - (5 x 16 = 80
marks)
Or
(b)/ Describe the cooling and lubrication systems
in automotive engine.
12. (a) With a schematic layouts explain the multi point electronic
fuel injection system.
Or
,/(b) Describe the working principle of electronic ignition system.
13. (a) JVith a neat sketch, explain the working of simple floor
mounted gear
/shift mechanism.
Or
(b) Explain the working principle of a torque converter.
www.EasyEngineering.
cylinder in a
Or
net
(b) Explain the working principle of Air suspension system used in
buses.
Or
(b) Discuss the functions and benefits of airbags used in cars.
/
2
31045
PART A- (10 x 2 = 20
www.EasyEngineering.
1. What are the components of a chassis?
2. What is supercharging?
3.
4.
net
What is meant by diesel knock?
PART B - (5 x 16 = 80 marks)
11. (a) Explain briefly the construction of an automobile with a neat layout.
Or
'
. 12. (a) With the help of a neat sketch, explain single point and
multi point fuel injection system.
Or
Or
(b) With the help of a neat sketch, explain the construction and
a Hotchkiss drive.
www.EasyEngineering.
(b)'
Or
net
'absorber with a sketch.
. Or
2
11046
(Regulation 2008)
PART A - (10 x 2 = 20
www.EasyEngineering.
1.
2.
What are the types of engine valves?
What is the advantage of turbocharger?
3.
4. net
What is CRDI?
What are the components of battery?
5. State the function of clutch.
6. What is synchromesh device?
7. What is steering geometry?
8. What is the use of stub axle?
9. State the advantages of natural gas.
10. What is fuel cells?
PART B - (5 x 16 = 80
marks)
·-
"
Or
(b) What are the types of ignition system? With a neat sketch
explain the magneto coil type ignition system.
(16)
www.EasyEngineering.
(2) Slip Joint
Or
net
(b) (i) With neat sketch explain the working of (8)
Or
15. (a) Discuss the concept of Electric and Hybrid vehicle with neat
sketch. (16)
Or
3.
4.
www.EasyEngineering.
Enumerate the factors whiehaffeet battery life.
Draw a simplified wiring circuit for the lighting system ofa car.
5.
6.
net
Differentiate between a live and a dead axle.
PART B - (5 x 16 = 80 marks)
01"
(b) Explain the various sensors used in an electronic engine management'
system and their functio~ns. .
12. (a) Discuss the construction and working of starting motor for automobiles.
Or
(b) Describe the MPFI system with port injection along with a
Or
.
(b) . Explain the working of a torque converter with its neat sketch.
Or
(b) (i) What is the 'understeering' and 'oversteering'?
(ii) Explain briefly with a neat sketch the steering
linkage for a con~entional rigid axl~·suspension.
15.. (a) Explain the production of natural gas with aneat sketch in detail.
Or
www.EasyEngineering.
(b) With simple sketch explain the construction and working principle offuel
cen.
net
41045
www.EasyEngineering.
net
www.EasyEngineering.
net