Benz tricycle 1896

Stanley Steam car 1905

Railton 1935

London B type bus - 1910

Ford Model T 1913

An Introduction to Automobiles
Jaguar 1955
Pictures taken fr rom Smith (2002)

Czech Tatra 1937 Lincoln continental 1960s Ford Sierra S 1980s Lotus Eclat

Aim ms

Introduce I d the h wide id range of f skills kill required i d for f vehicle design and manu ufacture. Briefly set the historical l scene and development of vehicles and their design gn. Introduce the vast range e of possibilities for vehicle design. design Demonstrate the interactivity of processes within th design the d i and d manufact f ture t of f vehicles hi l

Steps in Autom mobile History

I Innovations i and d Invent I tions i Mass production p Development of World d Motor Industry S Streamlining li i Commercial vehicles

History

Construction

Inventions and Innovations

S Steam power to I Interna al l Combustion C b i engine i

Steam engine used till l late 1940s Petroleum spirit use ed by Dr. OTTO in 1870s was a useless by-product of o naptha used for lamps Dr. Gottelib Daimler improved i OTTO engine using petroleum vapour and d in parallel Karl Benz also produced tri-wheel car rriage in 1885

History

Construction

Mass pro oduction

C were d Cars developed l d from fr f h horse carriages. i Henry y Ford -> mass p production of Model T,1909

Concept from rifle ma anufacture of civil war Model T first car with h design for manufacture Engine E i 2898 cc was built b ilt by b ford f d and d various i independent bodybuil lders from buses to elegent family cars Hand-built cars to inte erchangeable parts
Picture taken from Smith (2002)

History

Construction

Mass Pro oduction

Moving M i workers k -> moving m i vehicle hi l during d i maufacture , Highland d park Detroit, 1913

Picture taken from Smith (2002)

History

Construction

Mass Pro oduction

In 1970s, I 1970 V Volkswagen lk B l was sold Beetle ld in i large l numbers though syle wa as antiquated as it was

Non rusting car Mechanically y reliab ble P d ti was flex Production fl xible ibl Quality paramount, getting right first time - LEAN Shorter production runs, wide variants

Toyota's contribution:

History

Development of World Motor In ndustry

Construction

1920s -1930s 1920 1930 : small ll coa ach hb builders ild co-exist i with ih large companies By end of second world d war only few specialized manufacturers remain Rolls Royce y Large conglomerates lik ke British Motor Corporation (BMC) , Br ritish Leyland (BL) faced problem of large stock Americans A i and dJ Japanese e moved d parts t of f operations ti around the world

Because of export restric ctions and to use facilities all over the world

History

Development of World Motor In ndustry

Construction

C Construction i Developmen D l nt:

Till 1930s wooden fram me with fabric or wood skin used to build coaches Late 1930s onwards onwards, pre essed steel plates for skin Multiple curvature adde ed more strength and body panels l shared h d the th load l d Recent cars have shell structure with aerodynamic y structures

History

Development of World Motor In ndustry

Construction

Wooden W d / Steel S l chassis h i frame f was done d away and d replaced by stiff floor pan by spot welding By 1950s, unitary con nstruction was universally followed for mass produ p uced cars Composite body for less ser weight and corrosion free body started after r WWII ( Lotus) Wheels progressed from m wooden spokes to metal spokes k t to metal t l hub h b con nstruction t ti to t metal t l spokes k ( Alloy)

History

Construction Early car evolved from carriage , electric powered Bersley 1897

Sports car with streamlined composite body , Lotus

Pictures taken from Smith (2002)

History

Development of World Motor In ndustry

Construction

S li Development: Styling D l

Powered versions of hor rse carriages g Engine was placed below w vehicle by Daimler hard maintenence 1890s, Panhard-Levasso or created the concept of h i engine having i in i front f t with with clutch l t h and d gear box b systme Panhard Windscreen was invente ed in 1920s with increasing speed of vehicle

History

Development of World Motor In ndustry

Construction

By the B h 1930s, 1930 excessive i ely l elongated l d engine i covers had become de rigeur for powerful cars with sporting ti aspirations. i ti Luggage gg g was strapped pp in n rear of vehicle and it became integral in europ pean cars. It grew in '50s,'60s and '70s to larg ger volume Till '50s open top was s preferred as inspired from horse carriages

History

Construction

Stream mlining

In 1890s, I 1890 A Amde d B Boll ll the e h younger produced d d first torpedo shaped designs with raked windscreen Americans did not like the t air-streamlined design

Czech Tatra of 1937 V8

Pictures taken from Smith (2002)

Chevrolet Air-flow

History

Construction

Stream mlining

Aerodynamics was cons sidered impediment to styles due to angles Box type yp was more chea aper p and easier to p produce Became more popular on nly after the 70s when oil prices went up & fuel ec conomy was considered important
Ford Sierra 1980

Picture taken from Smith (2002)

History

Construction

Commercia al Vehicles

End E d of f 19th century, first fi t lorry l and d trucks k were steam powered challen nged by petrol vehicles Threats of world wars le ed to increase in roads, commerical vehicle sale es and haulage g in Europe p IC engine led to the dev velopment of motor bus. Autobahns A t b h in i 1930s 1930 Ger G rmany led l d to t development d l t of good road transport along a with railways. Buses replaced electric trams, t challeged railways in USA, Britain.

Construction Co onfiguration and Styl ling

E i Development Engine D l Transmission and Syst y tem Layout y Steering S Suspension i Brakes Interior Design S f Safety Too much Innovation

History

Construction

Engine Dev velopment

Diamler Di l and d Benz B inven i nted d IC engine i automobiles bil in 1895 Diamler developed Vee twin engines in 1898 Ettore Bugatti,1910 Bugatti 1910 crea ated first engine with Overhead Cam shaft in Model M 13, capable of achieving 100 kmph spe eed with 1327 cc. cc Side valves were more preferred p till WWII Improvements in materi ials led to other developments.

History

Construction

Engine Dev velopment

Diesel Engine:

Main competitor to petrol engine spontaneous combustion unlike petro ol ignition It eliminated two weak points p carburettor and spark plugs hence more reliab ble It had inferior p power to weight g ratio, , hence restricted to heavy engin nes With turbo-charging turbo charging and d refinement, refinement performance at par with petrol engine es with cleaner emissions and higher efficiency efficiency.

History

Construction

Engine Dev velopment

S Super charging h i and dT Turbo bocharging: h i

When air is compressed p d at inlet, , power p to weight g ratio of engine improved d Compressors combined to engine shaft Used from 1930s in raci ing cars Compression with powe er from exhaust using turbine is turbocharging g g Turbochargers improve torque characteristics and smoother engine running g

History

Construction

Engine Dev velopment

T Strokes Two S k and dU Unconve entional i l petrol l engines: i

Two stroke ( (2S) ) has one e firing g stroke p per revolution, theoretically y twice efficiency 2S in unsupercharged al lways has fuel-charge loss during scavenging Intake I t k needs d to t be b mixed i d with ith lubricating l b i ti oil il resulting in smoky exha aust Applications restricted to t motor-cycles and small cars like three cylinder SAAB S car.

History

Construction

Engine Dev velopment

Two stroke T k diesel di l i is still ill l preferred f d in i large l marine i and railway engines Wankel engine had a sem mi-rotary than a reciprocating p g type yp of engine g It had a problem with se eals of rotor and inherent two-stroke two stroke emissions Gas turbines had good efficiency e and thrust to weight i ht ratio ti but b t not t effic fficient i t in i low l speeds. d

History

Construction

Engine Dev velopment

El i and Electric d Hybrid H b id propu ulsion: li

1899, , Jenatzy's y La Jam mais Contente was first vehicle to cross 100kmp ph Initial cars restricted to short distances but has i recent times considerably increased in Improvements I t in i Lead-A L d Acid A id b battery tt technology t h l allowed increased range e and even buses to operate i Urban in U b areas on electr l tric i power to t reduce d smog.

History

Construction

Engine Dev velopment

Limitations Li i i in i battery b le led d to hybrid h b id vehicles hi l of f present day

Ultracapacitors or fl lywheel used Smaller p petrol engin g ne is used Regenerative brakin ng

*Not same as petrol-elec petrol elec ctric vehicle in past with pure electric operation for f step-less operation

History

Transmissi ion System Develo opment

Non-availabilityof full f power at the start Noisy y operation p Non -instant stop restart r

Construction

Some of S f the h d drawbacks b k of f petrol l engines i over steam engines were

Clutches have evolved f from belts and settled pre predominantly with plate cl lutch. Gear b G box evolved l d from f shifting hif i gears to constant mesh with moving dog clutches c crash gear box.

History

Transmissi ion System Develo opment

Construction

F.W. F W Lanchester L h and d Br British i i h Daimler D i l created d epicyclic gear box with bands and planetary rings Epicyclic gears used in ford f model T , used in buses for ease of operati p ion In 1940's, preselector gearbox was developed with fluid torque conver rter becoming a Constant Variable Transmission system s (automatic) E li automatics Earlier t ti had h d poor p efficiency ffi i

History

Construction

Lanchester Gear box

http://commons.wikimedia.org/wiki/File:Lanchester_epicyclic_gearbox.jpg

History

Construction

Pre selecto Pre-selecto or gearbox

Wilsons Gearb box

Pictures taken from Steeds S and Garrett (1983)

History

Construction

Model T gear g box

http://commons.wikimedia.org g/wiki/File:Model_T_Ford_epicyclic_gearbox_%28Montagu,_C ars_and_Motor-Cycles,_1928 8%29.jpg

History

Construction

Fluid Torque e Converter

Pictures taken from St teeds and Garrett (1983)

History

Transmissi ion System Develo opment

Construction

Ferdinand F di d porsche h had h d first f fi patent in i 1908 f for a electric transmission sys stem (890299) first step t towards d CVT Semi-stepless p was achie eved using g fluid-torque q converters in 1940's DAF variomatic type CV VT were used in dutch DAF cars (1959-63)

History

Construction

Porsche tra ansmission ansmission

Picture taken from the patent document 890299

History

Construction

DAF var riomatic

Double pulleys

http://www.philseed.com/daf-600.html

History

Construction

Stee ering

Earlier E li cars borrowed b d ax xles l similar i il to horse h carriages with unstable pivoting p axles as horse is not t present t to t stabilize t bili the t vehicle th hi l Ackerman's arrangemen g nt of p pivoting g wheels about individual axes allowed rotation at varied angles / speed during turn Tiller was replaced with h steering and linkages and major development cam me after power steering. Four wheel steering is now n available but restricted to a few models

History

Construction

Ackerman nn Linkage

Ackerman linkages for Independent Suspension

Pictures taken from Ste eeds and Garrett (1983)

History

Construction

Tille ers

Benz tricycle 1896 Panhard Levassor 1890-95

Pictures tak ken from Smith (2002)

History

Construction

Suspe ension

Elliptic Elli i springs i adopted d d from f carts problems bl during braking and start ting -need to be restricted Springing developed by y torsion bars and further by pneumatic variable heig p ght suspensions g p Independent wheel susp pensions developed Simple Si l coil il springs i were e used df for f front t suspension i alone and then used in rear also Active suspensions have e vehicle lifted by power jacks controlled electron nically

History

Construction

Elliptic Springs S

Mounting to reduce Squat

Mounting to function as anti-roll bar Axle guidance interferes with stee ering
Pictures taken from Steeds and Garrett (1983)

History

Construction

Torsio on bar on

Pictures taken from Steeds and Garrett (1983)

History

Construction

Pneumatic S Suspension

Flat, non-driven air-suspended semi-trailing-arm rear axle of the Mercedes-B Benz V class

Pict ture taken from Reimpell et al., (2001)

History

Construction

Suspe ension

I d Independently d l moving i wheels h l improved i d road-grip d i Independent p suspensio p ons became p popular p by y 90s.

Jaguar 3.4 was with independent suspension in '55

Pictures tak ken from Smith (2002)

History

Construction

Suspe ension
Wh l and Wheels d Tires: Ti

Wooden spoked p wheel with w metal outer was unsuitable for higher spe eed 1895, Michelin brothers 1895 s fitted Dunlop tires on peugeot cars for racing and a it started P Pneumatic ti tires ti had h d prob bl blems b of f puncture t Large g tires were good g fo or p poth-rudded roads, with roads improving size is reached to standard size.

History

Construction

Suspe ension

Smaller S ll tires i improved i d ride rid and d suspension i dynamics Wider tires had better ro oad grip Tubeless tires were intro oduced after WWII Radial ply was introduced Low profile tires rat tio of outer to inner diameter increased

History

Construction

Tubeles ss tires
Introduced I d di in 1947 by b Goodridge An air-tight layer to inner layer of carcass Soft inner layer of highly viscous material to fill in punctures Retain air-pressure longer than others vehicles can be controlled longer
http://www.indiacar.com/infobank/tlt_const.htm

History

Construction

Tir res res

Pictures taken from Steeds and Garrett (1983)

History

Construction

Radial l Tires
Since Si there h is i no cross ply, l lesser heat generated hence more life 4 to 6 bracing plies of metal /rayon provides better contact grip and stability against g deformation in higher g speeds g lateral Stiffer in resisting loading hence reduces under/over steer.
Pictures taken from Steeds and Garrett (1983)

History

Construction

Low prof file Tires

Wider Wid tires i for f same diameter di Improvement of radial tires Larger chamber allows operation in lower pressure hence smooth ride or increase in comfort Increased traction as more area in contact

Pictu ures taken from 65 series off road tire manual of Goodyear

History

Construction

Brakes

H Horse carriages i were essentially i ll stopped d by b horses h Drum brakes with p pair of o internal shoes emerged g as dominant Until 1920s brakes only y in rear wheels With drum brake proble em of fading due to overheat, h t emerged d disc di brakes b k i in 1952. 1952 Disc brakes were used in n front wheels and not in rear brakes as they requi ired mounting of parking drum brakes

History

Construction

Brakes

Brakes B k operated db by mec chanical h i l rods d and d cables bl required skilled adjustm ment or cars would swing 1930s hydraulic power assisted a brakes introduced 1960s, Dual hydraulic circuit 1960s c introduced to overcome leaks Heavy vehicles H hi l required i d servo arrangement tVacuum assist Anti Lock Braking intro oduced from aircrafts. British Jensen FF,1960 was w first passenger car to have it.

History

Construction

Dual hydrau ulic braking

Dual D l master cylinder li d Both actuating different circuits Failure of one is not affecting another At least one circuit operational

Pictures taken from Steeds and Garrett (1983)

History

Construction

Vacuum Ass sist braking

Bendix Hydrovac

Pictures taken from Steeds and Garrett (1983)

History

Construction

Anti Lock Anti-Lock k Braking

Ford Escort and Orion Anti-lock Braking System

Pictures taken from Steeds and Garrett (1983)

History

Construction

Interior Design

Modern M d f family il cars not superior i to high hi h performance cars of 193 30s. Essential dynamic analy ysis and design to improve q quieteness

Direct belt between en ngine and cooling fan replaced by y intermediate electr rical Vibration isolation Mathematical analysis s of the design

Air conditioning, power r windows, windows demisting added. added

History

Construction

Safety Design

Invention I i of f motor cars produced d d more deaths d h than h any other invention.

No. of civilian deaths per month in USA during WWII greater than de eaths due to war

1930s unitary Chevrolet airflow body construction was more resistant r to impact with another car. No significant work till 1950s and 60s as it was not a selling point

History

Construction

Safety Design

Pre-war cars had P h d steerin ing columns l like lik spears to the heart of drivers in ca ase of frontal impact Collapsible steering intr roduced by 1960s Seat belts appeared arou und 1950s for front seat occupants and slowly sp pread to rear Ai b Airbags came later l t Vehicle is now designed g d with energy gy absorbers in front, rear and sides.

History

Construction

?? Too much Innovation ??

I Innovation i not always l a key k to fi financial i l sucess

Alec Issigoniss revol lutionary Mini with rubber bush suspension was famou us but not with advanced hydroelastic systems Wankel engine Disc brakes Power Steering

Important p to choose win nners at right g time

Further Reading R

Julian-Happian J li H i Smith S ith (2002), (2002), An A Introduction I t d ti to t Modern M d Vehicle Design,Butterworth-H Heinmann (ISBN 0-7506-5044-3) Newton, N t K K., St Steeds, d W W. and dG Garrett, tt T.K. T K (1983), (1983) Th The M Motor t Vehicle (10th edn). Butterwor rths (ISBN 0-408-01118-1 (hard cover) ) and 0-408-01157-2 ( (so oft cover)). )) Jrnsen Reimpell et al (2001) ), The Automotive chassis (Second edition), Butterworth h Heinman (ISBN 0-7506-5054-0)

History

Construction

Vee Twin Vee-T T

Blumfield V twin engine 1913 1913-14 14 with Overhead O Cam Shaft

http://en.wikipedia.org/wiki/File:Mercedes_V6_D TM_Rennmotor_1996.jpg

http://en.wikipedia.org/wiki/File:Blumfield_Vtwin_motorcycle_engine.jpg

Mercedes Benz V6, 199 96

History

Construction

Overhead Cam Shaft

Pictures taken from Steeds S and Garrett (1983)

History

Construction

Side Valve e Engines

Pictures taken from Steeds S and Garrett (1983)

History

Construction

Side Valv ve Engine

Biefield Biefield Diesel engine of 1930s

http://shopswarf.orconh hosting.net.nz/svdiesel.html

History

Construction

Plate clutch c

http://gtmotorsports.com http://www.novakadapt.com/knowledge/clutches_etc.htm

History

Construction

Plate Clutch C

Pic ctures taken from The Motor Vehicle Newton Steeds

History

Construction

Gear r box

Sliding mesh -> > moving gears Dog clutch

Pictures taken from Steeds S and Garrett (1983)

History

Construction

Gear box Co onstant mesh

Pictures taken from Stee eds and Garrett (1983)

History

Construction

Gearbox - Sy ynchromesh
Synchromesh S h h have synchronizers synchronizers for smoother gear shifting

Pictures taken from Steeds S and Garrett (1983)