Benz tricycle 1896

Stanley Steam car 1905

London B type bus - 1910

Railton 1935

Ford Model T 1913

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

Czech Tatra 1937

Lincoln continental 1960s

Ford Sierra
S
1980s

Lotus Eclat

Aim
ms

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

Steps in Autom
mobile History

I
Innovations
i
andd 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 IInternaall Combustion
C b i engine
i

Steam engine used tilll late 1940s

Petroleum spirit useed 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 andd in parallel Karl Benz also
produced tri-wheel carrriage in 1885

History

Construction

Mass pro
oduction

C were ddeveloped
Cars
l d from
ffr
hhorse carriages.
i
Henry
y Ford -> mass p
production of Model
T,1909

Concept from rifle maanufacture of civil war

Model T first car withh design for manufacture

Engine
E
i 2898 cc was built
b ilt by
b ford
f d andd various
i
independent bodybuillders from buses to elegent
family cars
Hand-built cars to inteerchangeable 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 , Highlandd park Detroit, 1913

Picture taken from Smith (2002)

History

Construction

Mass Pro
oduction

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

Non rusting car

Mechanicallyy reliabble

Toyota's contribution:

P d ti was flex
Production
fl xible
ibl

Quality paramount, getting right first time - LEAN

Shorter production runs, wide variants

History

Development of World
Motor In
ndustry

Construction

1920s -1930s
1920
1930 : small
ll coaach
h bbuilders
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) , Brritish Leyland (BL) faced
problem of large stock
Americans
A
i
and
d JJapanesee moved
d parts
t off operations
ti
around the world

Because of export restricctions 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, preessed steel plates for skin
Multiple curvature addeed 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 andd
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 lessser weight and corrosion
free body started afterr WWII ( Lotus)
Wheels progressed from
m wooden spokes to metal
spokes
k tto 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 horrse 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 andd gear box
b
systme Panhard
Windscreen was inventeed 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 wass preferred as inspired from
horse carriages

History

Construction

Stream
mlining

IIn 1890s,
1890 A
Amde
d B
Boll
lle
the
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 conssidered impediment to

styles due to angles
Box type
yp was more cheaaper
p and easier to pproduce
Became more popular on
nly after the 70s when oil
prices went up & fuel ecconomy was considered
important
Ford Sierra 1980

Picture taken from Smith (2002)

History

Construction

Commercia
al Vehicles

Endd off 19th century, first

E
fi t lorry
l
andd trucks
k were
steam powered challen
nged by petrol vehicles
Threats of world wars leed to increase in roads,
commerical vehicle salees 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
Stylling

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 creaated first engine with
Overhead Cam shaft in Model13,
M
capable of
achieving 100 kmph speeed with 1327 cc.
cc
Side valves were more preferred
p
till WWII
Improvements in materiials led to other
developments.

History

Construction

Engine Dev
velopment
Diesel Engine:

Main competitor to petrol engine spontaneous

combustion unlike petrool 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 enginees 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 raciing cars

Compression with poweer 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
Unconveentional
i l petroll engines:
i

Two stroke ((2S)) has onee firing

g stroke pper
revolution, theoretically
y twice efficiency
2S in unsupercharged allways has fuel-charge loss
during scavenging
IIntake
t k needs
d to
t be
b mixed
i d with
ith lubricating
l b i ti oil
il
resulting in smoky exhaaust
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 iis still
illl 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 seeals 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 nott 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
IImprovements
t in
i Lead-A
L d Acid
A id bbattery
tt
technology
t h l
allowed increased rangee 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 off
present day

Ultracapacitors or fllywheel used

Smaller ppetrol engin

g ne is used

Regenerative brakinng

*Not same as petrol-elec

petrol elecctric vehicle in past with
pure electric operation for
f step-less operation

History

Transmissiion System
Develo
opment

Construction

Some off the

S
h ddrawbacks
b k off petroll engines
i
over
steam engines were

Non-availabilityof full
f power at the start

Noisyy operation
p

Non -instant stop restart

r

Clutches have evolved ffrom belts and settled pre

predominantly with plate cllutch.
Gear bbox evolved
G
l d from
f
shifting
hif i gears to constant
mesh with moving dog clutches
c
crash gear box.

History

Transmissiion System
Develo
opment

Construction

F.W.
F
W Lanchester
L h
and
d Br
British
i i h Daimler
D i l createdd
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 converrter 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 Stteeds and Garrett (1983)

History

Transmissiion System
Develo
opment

Construction

Ferdinand
F
di d porsche
h had
h d first
f
fi
patent in
i 1908 ffor a
electric transmission sysstem (890299) first step
t
towards
d CVT
Semi-stepless
p
was achieeved usingg 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 varriomatic

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
nott presentt to
t stabilize
t bili the
t vehicle
th
hi l
Ackerman's arrangemen
g
nt of p
pivotingg 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 startting -need to be restricted
Springing developed by
y torsion bars and further by
ppneumatic variable heig
ght suspensions
g
p
Independent wheel susp
pensions developed
Simple
Si
l coil
il springs
i
weree used
d ffor ffrontt suspension
i
alone and then used in rear also
Active suspensions havee 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

Pictture 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
byy 90s.

Jaguar 3.4 was with

independent suspension
in '55

Pictures tak
ken from Smith (2002)

History

Construction

Suspe
ension
Wh l andd Tires:
Wheels
Ti

Wooden spoked
p
wheel with
w metal outer was
unsuitable for higher speeed
1895, Michelin brotherss fitted Dunlop tires on
1895
peugeot cars for racing and
a it started
P
Pneumatic
ti tires
ti had
h d prob
bl
blems
b
off 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 andd suspension
i
dynamics

Wider tires had better ro

oad grip

Tubeless tires were introoduced after WWII

Radial ply was introduced

Low profile tires rattio of outer to inner

diameter increased

History

Construction

Tubeles
ss tires
Introduced
I
d d iin 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

Tirres
res

Pictures taken from Steeds and Garrett (1983)

History

Construction

Radiall 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
Stiffer in resistingg lateral
loading hence reduces
under/over steer.
Pictures taken from Steeds and Garrett (1983)

History

Construction

Low proffile 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 stoppedd by
b horses
h
Drum brakes with p
pair of
o internal shoes emerged
g as
dominant
Until 1920s brakes onlyy in rear wheels
With drum brake probleem of fading due to
overheat,
h t emergedd disc
di brakes
b k iin 1952.
1952
Disc brakes were used in
n front wheels and not in
rear brakes as they requiired mounting of parking
drum brakes

History

Construction

Brakes

Brakes
B
k operatedd bby mecchanical
h i l rods
d andd 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 arrangementt Vacuum 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
ffamily
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 enngine and cooling fan replaced

by
y intermediate electrrical

Vibration isolation

Mathematical analysiss of the design

Air conditioning, powerr windows, windows

demisting added.
added

History

Construction

Safety Design

IInvention
i off 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 deeaths 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 caase of frontal impact
Collapsible steering intrroduced 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 revollutionary Mini with rubber bush

suspension was famouus but not with advanced hydroelastic systems
Wankel engine

Important
p
to choose win
nners at right
g time

Disc brakes

Power Steering

Further Reading
R

JJulian-Happian
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). Butterworrths (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

Gearr 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)