Automobile Basics

Automotive Systems
Broadly an automobile can be divided in to following main systems. Body & Chassis Engine and related Systems Transmission Braking System Steering System Suspension System Heating and Air Conditioning System Safety Systems

Chassis & Body

Body Construction
There exists 2 main ways of automobile construction
The Chassis and Body method & The Monocoque method.

The Chassis and Body method

Body is separate unit joined with ladder type chassis. All other parts like steering, suspension etc. are attached to the chassis. The benefits are higher load capacity and strength. Disadvantages are vibrations less refined handling Used mostly for MUVs, SUVs and bigger vehicles.

Body Construction
The Monocoque method.
No ladder frame Suspension, steering etc. are all bolted directly to the body, the body is thus made sturdier. Makes vehicle solid Less rattles and squeaks Handling is better lesser load carrying capacity Highly suitable for passenger cars

Body Shapes
No hard & fast rules for classification as new segments and sub segments keep emerging Broad classifications of the vehicles. SUV MUV/MPV Pik Up Hatchback Sedan/Notchback Station Wagon/Estate 3 Wheeler

Sport Utility Vehicle (SUV)

The engine area is separate and the passenger and boot area are enclosed together. Equipped with 4 wheel drive or has as an option of 4 wheel drive. Highly performance oriented. (Powerful Engine) Designed for off road usage. Are generally equipped with technologically advanced & luxury features. Examples in India: Scorpio, Tucson, Pajero, Safari, CR-V

MPV / MUV

Two versions
1. Engine, passenger area and boot area enclosed together. 2. Passenger and boot area enclosed with separate engine area

Can also have third row of seating.

Taller and generally more spacious as they are people carriers. Not feature rich hence cost is usually on the lower side. Examples in India: Tavera, Innova, Sumo

Pick Up

They have a separate engine area, a passenger area and a large loading area. Large tyres High load carrying capacity Good ground clearance. Examples in India: Bolero Pik-Up, Bolero Camper Maxx Maxi Truck, 207 DI,

Hatchback

Separate engine area, and passenger area

Luggage area merged the passenger area behind the rear seats. The luggage area is generally smaller than notchback. 5 doors (4 passenger doors + hatchback) or 3 doors (2 passenger doors + hatchback) Examples in India: Santro, Getz, Palio, Indica etc.

Sedan / Notchback

Separate engine area, passenger area, and boot area, 4 doors.

Examples in India :Logan, Elantra, Sonata, Corolla, Camry etc.

Estate / Station Wagon

Much like hatchback Large luggage area extended till the roof Examples in India: Indigo Marina, Adventure

3 Wheelers

Generally employed as rickshaws or goods carriers Separate area for driver with a comparatively larger area for passengers or goods Examples in India: Alfa, Champion & Ape

Basic Terminologies
Lets look at some common automotive terms:

Ground Clearance

Distance between the ground and lowest portion of the bottom of a vehicle
Can also be measured at other points on the vehicle. Avoids scraping the bottom of the vehicle body on rough roads and terrain.

Tread

Front Tread

Rear Tread

Distance between the front or rear wheels measured from the tyres center point. A wider tread generally gives more stability.

Wheel Base

Wheel Base

Distance between the center of the front wheels and the center of the rear wheels.

A longer wheel base generally leads to more passenger space, and results in enhanced vehicle stability at high speeds

Turning Radius

Turning Radius

Smallest Radius in which car can turn. Lower turning radius improves the maneuverability of the car Definite advantage in city driving. It is usually measured from the center point of the outer most wheel (kerb to kerb)

Engine & Engine Systems

Petrol Engine Operation

Stroke 1 (Intake) air & fuel mixture enters cylinder Stroke 2 (Compression) air & fuel mixture is compressed Stroke 3 (Power) spark plug fires, ignites fuel. Stroke 4 (Exhaust) burnt gases are expelled from the engine Power is generated only during the power stroke Process of 4 strokes is repeated to keep engine running.

Diesel Engine Operation

Stroke 1 (intake) only air enters cylinder. Stroke 2 (compression) air is compressed to high extent, raising its temperature. Stroke 3 (power) diesel is injected, high air temperature ignites diesel. Stroke 4 (exhaust) burnt gases are expelled from the engine.

Differences in Operations
Petrol Stroke 1 (intake) air & fuel mixture enters cylinder Stroke 2 (compression) air & fuel mixture is compressed Stroke 3 (power) spark plug fires, ignites fuel. Stroke 4 (exhaust) burnt gases are expelled from the engine Diesel Stroke 1 (intake) only air enters cylinder. Stroke 2 (compression) air is compressed to high extent, raising temperature. Stroke 3 (power) diesel is injected, high air temperature ignites diesel. Stroke 4 (exhaust) burnt gases are expelled from the engine.

Engine And Engine Basics

COMPRESSION RATIO:
Compression Ratio compares the volume of air in Cylinder before Compression with volume of air after compression . Vs + Vc = COMPRESSION RATIO Vc Vs = Volume between T.D.C TO B.D.C position. Vc = Volume above the piston when it is in the T.D.C position Compression Ratio for petrol Engine : 8 ~ 10 for Diesel Engine : 15 ~ 24
TDC Swept Volume (Vs)

BDC

Cylinder Block

TDC

Clearance volume (Vc)

Cylinder Bl ock

Engine And Engine Basics

Dia of cylinder

SIZE OF ENGINE (CC)=

Dia. of Cylinder x length of stroke X Number of Cylinders

TDC

Length Of Stroke (mm)

BDC

Measurement taken in cubic centimeters (cc),

1000cc = 1 liter (litre) e.g. 1800cc engine = 1.8 Liter Higher cc of engine, results in higher amount of power generation.

Cylinder Block

Cylinder Block

No. of Cylinders = 4

Cylinder Block

Cylinder Block

Cylinder Block

Cylinder Block

No. of Valves

Valves are provided in the engine to breathe (to take in air & fuel and to let out exhaust gases). We know that at least 2 valves are required in each cylinder of engine. One for intake and other one for exhaust.

No. of Valves

However it is possible to have more than 2 valves in each cylinder such as 3 or 4 In 3 valves cylinder 2 valves are for intake and 1 for exhaust. In 4 valves cylinder 2 valves are for intake and 2 for exhaust

Why More No. of Valves

Try to breathe through one nostril and then through both. Did you notice the difference. Yes it was hard to breathe through only one nostril. Similarly more number of valves helps engine to breathe easily

Camshaft Arrangements
Camshaft:

The part of engine which opens and closes the valves is called Camshaft. The layout of camshaft and valves in the engine is called camshaft arrangement. There are different types of Valve and Camshaft arrangement in engines depending on shape, size and use of engine.

Single Over Head Camshaft (SOHC)

Here, all inlet and exhaust valves are operated by one camshaft directly that is located above the cylinder block. This type of arrangements is superior to the older arrangement operating the valve through push rods.

Dual Over Head Camshafts (DOHC)

These engines have two camshafts over the engine head. One to operate the intake valves and the other to operate the exhaust valves. This generally makes the operation move precise and thus it is easier for the car to give better performance & efficiency

Dual Over Head Camshafts (DOHC)

DOHC features & benefits

Two camshafts placed on cylinder head

Faster valve response (better control on valve timing) Engine operates efficiently at high speed too Efficient combustion More powerful engine

Engine Performance

Engine performance is presented by various manufacturers using the following terms: Power - BHP/ PS Torque

Engine Power (BHP)

Power Work done per unit time. P = work time

BHP (Brake Horse Power) is unit of measuring engine power. Depends on its torque and engine speed (RPM). Engine Power = Torque X RPM The higher the BHP, the more powerful an engine is. Conversion BHP to Kw : - Multiply By 0.7457 Conversion Kw to BHP : - Multiply By 1.341

Engine Power (PS)

PS (Pferdestrke = Horse Strength) is a German term for Horse Power 1 PS = 0.9863 bhp In Indian Market all the manufacturers use unit of PS or Brake Horsepower to indicate engine power.

Torque
Torque Exerted on Bolt

A twisting force is defined as torque.

Torque = Force X Radial Distance Measured in Kilogram-meter (Kg-m) or Newton-meter (N-m).

Conversion Kg-m to Nm : - Multiply By 9.80665

Conversion Nm to Kg-m : - Multiply By 0.1019716

High Torque at Low RPM

Advantages & Benefits Faster pick up Lesser gear shifts Enhanced fuel economy Longer engine life Lesser maintenance costs

Power To Weight Ratio

Power-to-weight ratio = __________________ power generated

Weight Of The Vehicle

A higher figure indicates more power for a given weight. More power for a given weight leads to better pick up & better fuel economy (Keeping all other variables
constant**)

Diesel Engines

Differences in Operation

Based on the injection there are two main types of diesel engines today a) Direct Injection b) Indirect Injection

Direct Injection
In a direct injection diesel engine, fuel is injected directly into the cylinder.

Injector

Indirect Injection
Pre Combustion Chamber
Injector

Here diesel engine fuel is injected into a small pre-chamber which is connected to the cylinder by a narrow opening. The initial combustion takes place in this prechamber slowing the rate of combustion.

Difference

Direct

In Direct

Direct V/S Indirect Injection

Feature Sound & Vibration Efficiency / Economy Power Emissions

Direct Injection More More More Less

Indirect Injection Less Less Less More

Regular Direct Injection

In this system a fuel pump, pumps fuel and also distributes it to each injector. This system is mechanically controlled or can be computer controlled.

Injectors

ENGINE
FUEL PUMP

Common Rail Direct Injection

Fuel pump pumps fuel into a rail at very high pressure. Injection is computer controlled as the pump is not metering fuel. As the injectors are controlled by computer the injection can be done in small steps to reduce the noise drastically. This CRDe technology helps to reduce the noise level in diesel engine while keeping all the benefits of direct injection.

Common Rail Direct Injection

Rail Rail Pressure Sensor

High Pressure Pump ECU (Electronic Control Unit)

Accelerometer

Electronically Controlled Injectors Fuel Filter

Diesel engines are infamous for unwanted noise, black emissions, and low performance & responsiveness CRDe takes care of all these issues.

Common Rail Direct Injection

Engine Type Conventional Diesel Engine (IDI) Indirect Injection

Operation # Fuel Injection Pump mechanically meters the fuel quantity to be injected in the cylinder # Timing of fuel injection (& hence the quantity) is controlled mechanically by the FIP as per the engine RPM # The ECU (like a MPFI Petrol engine) operates the solenoid valve injector # Fuel quantity and injection timing is controlled electronically, as such is independent of engine RPM # The CRDI operates with electronically controlled injection timing and quantity and at high pressure throughout the injection process (the high pressure common rail helps maintain the high pressure)

Diesel Engine with Electronic Fuel Injection Control Unit / Module

Common Rail Direct Injection.

Advantage CRDe
Higher Fuel Economy Low Emissions Low Engine Noise High Power High Torque

Petrol Engines

Petrol Engines
Carburetors:
A carburetor is a device that blends air and fuel before it is supplied to the intake manifold. It is a mechanical device which used to depend on the speed and pressure of the air passing through it. This device had its limitations which led to fuel injection becoming the preferred method of automotive fuel delivery.

Petrol Engines
Limitations of Carburetors:

In a carburetor the ratio of air & fuel in the injected mixture has to be preset. So the mixture is either fixed as lean or rich.

This causes the cars to be either under powered or overcharged.

So it was primarily due to the stricter emission norms and the ever increasing quest for engine power a better solution for this problem was required.

Engine Management System

To ensure that a correct proportion of air and fuel is supplied to the engine in all conditions. Earlier, performed by the carburettor Now computerized system calculates the required air-fuel ratios. Resulted in improved performance, fuel efficiency & lower emissions. Controlled by a computer called Engine Control Module (ECM)

Petrol Engines
The new device that replaced the carburetors was the fuel injection system that primarily comprised of : An Electronic Control Module (ECM) A fuel injector A fuel pump This kind of a fuel injection setup is called Single Point Fuel Injection (SPFI) OR Throttle Body Injection (TBI)
Video

Petrol Engines
Disadvantages of SPFI: Since the injection setup was feeding fuel to all the cylinders on every cycle hence they were not economical and caused a lot of pollution.

So, with the increasing need for refined engines and even stricter emission norms coming in, the injection technology moved a step up. Latest in the injection technology is the: Multi Point Fuel Injection (MPFI)

Petrol Engines

Multi Point Fuel Injection

In MPFi (Multi Port Fuel Injection) system, there is an electronic fuel injector for each cylinder.
These injectors spray fuel into the cylinders.

Petrol Engines
With the advanced microprocessor technology coming in, the ECMs became more powerful and a more precise fuel injection timing was attained. There are different injection timings that are used in different driving conditions: Simultaneous Group Sequential Sequential Injection Injection Injection

Video

Video

Multi-Port Fuel Injection

Advantage: Efficient distribution and combustion of fuel. Benefit: Cleaner Emissions Better Fuel Economy

Transmission System

Transmission (Gearbox)
Transmission:
To vary the engine torque as per the driving needs and transfer it to wheels.

Lower gear (1st, 2nd etc) for more torque (turning force) & less speed. For example at starting, climbing etc
Higher gears for more speed but less torque like highway driving Two types of transmissions are used in cars. Manual Transmissions

Automatic Transmissions

Gear Ratios
The gear ratio can be determined by counting the teeth on both gears.

Gear Ratios
Example : - If driving gear = 20 teeth and driven gear = 40 teeth, the gear ratio is 2 to 1. The driven gear makes one revolution for every two revolutions of the drive gear. In an overdrive gear (Usually 5th) the ratio is such that the output shaft rotates faster then the input shaft.
Example : Gear 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse Ratio 2.97:1 2.07:1 1.43:1 1.00:1 0.84:1 3.28:1

Manual Transmissions
Manual Transmissions Advantages: Cheaper to manufacture than A/T Economical on fuel Easy to maintain Lighter than A/T units Benefits: Lower vehicle cost

Fuel efficient
Lower maintenance cost

Manual Transmissions

Automatic Transmissions

In automatic transmission, the gearbox changes gear ratios automatically as the vehicle moves, thus freeing the driver from having to shift gears manually.

Automatic Transmissions

Operation Modes : D Drive P Park N Neutral R Reverse 2 Lock in 2nd Gear L Lock in 1st Gear

Automatic Transmissions Trip-tronic

It has an H-gate for the gearshift. In normal operation, the gearbox is just like an automatic, putting it in 'D' for Drive and just letting it go about its business. It has a H-gate with a + & sign which allows the driver to manually shift gears.

Automatic Transmissions

Advantages:
No Clutch Pedal Automatic shifting of gears Smooth power transmission Benefits: Smoother drive

Suitable for congested city driving conditions

Less tiring to the driver

Tips for Fuel Efficiency & Use of Gear Box

Tips to get best fuel efficiency using the gearbox Shift to higher gears as quickly as permitted by traffic and road conditions in city driving. Use the D Range as much as possible.

Note: For more tips on fuel efficiency please refer to fuel efficiency tips given to customer at the time delivery in booklet.

Drive Train Types

Front Wheel Drive Here the drive train channels the power of the engine to the Front Wheels.

Rear Wheel Drive Here the drive train channels the power of the engine to the Rear Wheels.

Drive Train Types

Four Wheel Drive Here the drive train channels the power of the engine to both the front & rear differential and Wheels.

Part Time Four Wheel Drive (eg. Scorpio)

Here the driver has the option to drive the vehicle in 2 wheel or 4 wheel drive mode.

Drive Train Types

Part Time Four Wheel Drive Operation Modes

2H - Regular two-wheel drive high ratio. 4H - Regular 4-wheel drive high ratio for minor slippery surfaces such as sand / slush where speed is needed. 4L - Multiplies the torque by 2.72 times, giving it ability to

climb steep inclines / tow a huge load.

Drive Train Types

Full Time Four Wheel Drive Here the drive train channels the power to both

the front & rear differential and wheels all the the
time. Or in other words driver has no option to drive the vehicle in 2 Wheel Drive Mode.

Differential
Transmits power to the wheels while allowing them to rotate at different speeds. When turning a cars inside wheels travel a shorter distance than the outside wheels. The differential is a device that splits the engine torque two ways, allowing each wheel to spin at a different speed.
Front Wheel Drive Rear Wheel Drive All Wheel Drive

Differential - Working
To Right Wheel To Left Wheel

Input torque is applied to the If the left side gear encounters ring gear resistance, the planet gear rotates about the left side gear, Which turns the entire carrier, in turn applying extra rotation to providing torque to both side the right side gear. gears , which in turn may drive the left and right wheels. Blue Ring Gear & Carrier If the resistance at both wheels is Red (Right) Side Gear equal, the planet gear does not Yellow (Left) Side Gear rotate, and both wheels turn at Green Planet gear the same rate.

Limited Slip Differential

Consider a situation where the right tire looses traction. It will start spinning and because of the design of the ordinary differential the left wheel will be at a stand still. LSD is a modified type of differential gear arrangement that allows for some difference in rotational velocity of the output shafts, but does not allow the difference in speed to increase beyond a preset amount. Torque sensitive (geared or clutch-based) and speed sensitive (viscous/pump and clutch pack) are commonly used on passenger cars.

Braking System

Types of Braking System

There are two types of braking system Drum type Disc Type

The frictional materials are fixed to either brake pads or brake shoes, depending on the type of system.

Drums Brakes & Disc Brakes

Drum Brakes: This type of brakes have a round shape of revolving drum attached to the wheels and two brake shoes that expand within the round drum when you apply the brakes. The friction between shoes and the drum causes the vehicle to slow or stop. Brake Drums are usually used in rear wheels.

Drums Brakes & Disc Brakes

Disc Brakes: Revolving disc attached to the wheels Pads which touch the disc to stop it More effective than drum brakes Generally used on the front wheels. The front wheels require better braking, as most of the vehicle load shift towards the front of the vehicle during braking.

CALIPER PAD

DISC

Booster Assisted Brakes

The brake booster assists the driver in pressing the brake pedal using vacuum from the engine. The engine creates a partial vacuum inside the vacuum booster on both sides of the diaphragm. When you hit the brake pedal, the rod opens a valve, allowing air to enter the booster on one side of the diaphragm while sealing off the vacuum. This increases pressure on that side of the diaphragm so that it helps to push the rod

Steering System

Steering Systems

The steering system enables the driver to effect directional control of the vehicle. Rack & Pinion steering system. Most passenger cars use rack and pinion system.

Rack and Pinion Steering Rack

The system uses a pinion attached to the steering wheel and a long component called rack connecting the two front wheels. When the steering wheel is moved the pinion moves the rack. As the wheels are connected to the rack they change the direction of car. It is simple in construction,

Has less number of parts

It provides good judgment of wheels position to the driver and provides good control of car.

Power Steering Hydraulic

Power Steering helps to reduce the effort of the driver to turn the steering wheel In Rack & Pinion power steering, rack movement is assisted by pressurised oil.

The power steering system is powered from the engine via a drive belt and a pump. Therefore, it is important to remember the Power assistance is available to steering, only when the engine is running.

Power Steering Electronic

Here the rack movement is assisted by a motor powered by electric current. The Power assistance is available to steering, only when the ignition is ON.

Electronic vs Hydraulic Steering

Lighter steering feel. Environmentally friendly as no use of hydraulic oil. Marginal improvement in fuel efficiency as the engine power required to run the hydraulic pump is saved. Application limited to smaller passenger vehicles

Gives a continuos feedback from the road unlike EPS Does not need to be cut off at high speeds (Unlike EPS) as the speed of the motor depends on engine RPM.

Suspension System

Components of Suspension System

Springs:
The car body is supported by the spring on each wheel.
Function of Springs: Absorbs the major part of shocks generated by irregular road surface thus providing a smooth ride. These springs compress when car hits a bump and expand when the wheel goes over potholes on the road. Other parts like tyres, springs & foam used in the seats also help in absorbing these shocks to improve ride quality.

Coil Spring

Coil springs are the most commonly used springs. As the name suggests the spring is made of a spring steel rod by giving it a shape of a coil.

Shock absorber/Damper & its Function

Spring has the tendency to compress and lengthen (oscillate) for a time. This behaviour can produce a very bouncy and uncomfortable ride. This also makes the car difficult to control. Therefore shock absorber is used to control the oscillation of springs. In shock absorber a piston moves inside pushing the oil to escape through small openings. This slows movement of piston and thus dampens the spring action. In some cases the dampers use gas which gives a better ride & does not leak easily, & also lasts longer.

MacPherson Struts

The strut will usually carry both the coil spring on which the body is suspended and the shock absorber, which is usually in the form of a cartridge mounted within the strut.
Advantages It allows for more width in the engine bay, which is useful for smaller cars.

Simple assembly & low manufacturing cost.

Types of Suspension System

Suspensions can be classified mainly into three broad categories

Independent Non Independent (Rigid Link Axle) Semi Independent

Type of Suspension systems

Non-Independent Suspension (Rigid Link Axle):

Left and right wheels are connected together with the help of a solid link
Movement of one wheel also affects the other wheel

Hence the ride and handling of the vehicle is not very good.
Has a higher load capability Preferred on heavier and utility vehicles.

Non Independent Suspension

Types of Suspension System

Independent Suspension: Left and right wheels are not connected together by a solid link Each wheel can move up and down independently of the other. Advantageous Better ride and handling. Most cars have independent systems on the front and some cars have all four-wheel independent suspension.

Independent Suspension

Type of Suspension systems

Semi-Independent Suspension: Left and right wheels are connected together with the help of a flexible link Movement of one wheel does not affect the other wheel entirely. Has the benefits of both, non independent and fully independent systems.

Semi Independent Suspension

Other Related Terms in Suspension

Anti Roll (Stabilizer) Bar

Compression of the springs causes the body to roll during cornering.
Anti roll bar reduces this roll and improves the vehicle handling The resistance to twist the bar during cornering controls the roll Attached to the both left & right side of suspension. Can be fitted on the front and rear or only one place

Multi-Link Suspension
Multi link suspension has 3 or more links (control arms, rods etc) to connect each wheel with the vehicle body.

Due to a higher number of linkages the suspension behaves better and thus gives a better ride and handling.
Scorpio is equipped with multi link rear suspension.

Tyre Size

1 7 5 /7 0 R 1 3
Tyres size is usually identified by a code that looks like the number alongside. The significance of these numbers is as below: 1. Tyre width in mm 2. Aspect Ratio (Height/Width) 3. R for radial tyre 4. Rim Diameter in Inches.

Aspect Ratio
1
2

Application Of Lateral Forces

Example 1 : Tire height => (.75 X 235 = 176.25 mm) Example 2 : Tire height => (.45 X 295 = 132.75 mm)

The smaller the aspect ratio, the wider the tire in relation to its height.
When a car goes around a turn lateral forces are generated and the tire must resist these forces.

Tires with a lower profile have shorter, stiffer sidewalls so they resist cornering forces better.

Tubeless Tyre

Tubeless Tyre

Tube Type Tyre

Q. What are the benefits of tubeless tyres? Tubeless tyres are tyres wherein there is no tube, the air is held between the tyre and the rim. The advantages of this are:Incase of a puncture, the air does not rapidly escape through the valve hole as the valve is fitted to the rim, the air if at all only escapes slowly. The chances of a blow out are also minimal.

Tubeless Tyre

Tubeless Tyre

Tube Type Tyre

Q. What are the benefits of tubeless tyres? (Cont) The ride & handling is also marginally better. The mileage too increases slightly. And the only care one has to take is when changing a tyre or repairing, is the work should be done on a machine not a local hammer and awl job.

Heating & AirConditioning System

Air Conditioning System

To cool the vehicle interior To reduce humidity Windows can remain closed which maintains the vehicles aerodynamics. This results in improved fuel economy and reduction of traffic noise and fumes. Avoids misting of glasses. Reduces driver fatigue.

The Air Filtering Process

The A/C system also acts as a filter for outside air. As air passes over the damp surface of the evaporator, large quantities of irritating particles are removed. Some systems also use a separate filter, these filters can some times filter out even the smallest pollen grains & dust.

Heating Systems

For cool climates cars also have a heating system. The heating system passes air over a heat exchanger heated by engine heat. To quickly dehumidify the interior of the car in cold and rainy weather the AC can be used along with the heater for smaller duration.

Tips for better AC operation Efficiency

Use fresh air mode in AC switch on condition to clear FR windshield fogging from inside. Use defogger switch to clear RR windshield (if installed). Blower without AC should only be used with fresh air mode to avoid any fogging. Operate at first blower speed after initial cooling at high speed. Do not turn the air louvers towards window side.

FATC (Fully Automatic Temperature Control)

FATC maintains cabin temperature at the selected level irrespective of outside weather conditions.
It does so by continuously monitoring inside & outside temperature and automatically making adjustments to the system components like the compressor, blower, vent selection etc.

Safety System

Vehicle Safety Features

Safety features in automobiles can be grouped in to: Active Safety Systems, Passive Safety Systems

Active Safety Systems These systems avoid accidents and hence they function at all times during use of the vehicle. E.g. Vacuum Assisted (power) Brakes. Anti-Lock Brake (ABS) System. Electronic Brake Distribution (EBD) System. Spoiler, Child Lock and Rear Window Demister etc. Passive Safety Systems These systems reduce the level of injury to the occupant and increase their safety in case of accident. E.g. Laminated Windshield Glass, Seat Belts, Side Impact Beams, Crumple Zones, Collapsible Steering Column, Head Restraints, Anti Submarine seats, Air Bags, Monocoque Body Structure etc.

Crumple Zones

Crumple Zones are deformable structures, provided in the car.

Advantage: These are intentionally designed to deform during an accident and absorb the impact of the collision. Benefits: This increases the safety of passengers.
Logan Crash Test Video

Side Impact Bars

The side impact bars are provided in the doors to reduce injuries during collisions into the side of the car.

Seat Belts
Seat belts protect the passengers from injury in the event of an accident. The Emergency Locking Retractor (ELR) mechanism in the seat belt locks the belt during a sudden stop or impact. At the Same time ELR mechanism allows the freedom of movement under normal conditions.

Safety
Pretensionor:
The idea of a pretensionor is to tighten up any slack in the belt webbing in the event of a crash. This force helps move the passenger into the optimum crash position in his or her seat.

Seatbelt pretensionors and force limiters work together to reduce the impact forces transferred to an occupant in a crash.

Safety
Generally, pretensionors are wired to the same central control processor that activates the car's air bags. The processor monitors mechanical or electronic motion sensors that respond to the sudden deceleration of an impact. When an impact is detected, the processor activates the pretensionor and then the air bag.

Safety
Air Bags: Airbags are credited with reducing numerous injuries and saving many lives during vehicle accidents.

Airbag Video

Safety
Single - DAB ACU

AIRBAG*
FIS

- Flexible membrane or envelope - Provides cushioning in case of automobile collision

Components of Dual airbag

Single - PAB

Seat Belt Pre-tensioner

ACU (Airbag Control Unit): Located in the area below the parking brake lever. G Force Sensor : Senses sudden deceleration and the G Forces acting on the vehicle. Ensures the airbags are opened only when required (G forces are above or equal to a threshold value).

DAB (Driver Airbag) module housed in the center of the steering wheel
PAB (Passenger Airbag) module is located in the passenger side crash pad. FIS (Front Impact Sensors) : Sends the signals to airbag to inflate in case of collision

SPT (Seatbelt Pre-tensioner)

It helps to reduce the severity of injury to the front occupant

ABS
Effective at even low speeds Anti Locking Brake System sensors mounted on the wheels continuous monitor wheel speed and the system modulates braking pressure to prevent wheel lock up.
With ABS
Without ABS

With wheel lock up prevented the car can come to a perfect controlled stop on all surface conditions with the driver always having steering control.

Video

LSPV :

* Load Sensitive Proportioning Valve Controls the amount of brake oil going to the rear wheels depending on the load on the vehicle.

* To prevent the rear wheels from locking, there by reducing the braking distance.

By Pass Valve :* Ensure supply of full amount of brake oil to the rear wheels irrespective of vehicle load, in the unlikely event of front brake circuit failure.

Head Restraints
Head restraints installed on top of the seat reduce the risk of neck injuries (whiplash injuries) in the case of a rear collision.

With Proper Restraint

Without Proper Restraint

Collapsible Steering Column

Made of telescopic tube

Designed to collapse
During a collision, one tube slide one into the other. Reduces the potential for injury to the drivers chest

Anti-Submarine Seats
Compared to a standard seat the anti-submarine seat has a raised lip at the front end. In a frontal collision, the lip restricts the person sliding underneath the seat belt.

This reduces the potential of injury to the occupants.

The raised lip is of little use on its own; the seat belt must be worn.