1-Automobile Intro-V5 1 PDF

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 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 manuufacture.
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
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)

Mass Pro
oduction
Moving
M i workers
k -> moving
m i vehiclehi l during
d i
maufacture , Highlandd park Detroit, 1913

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
Motor In
ndustry
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 likke 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
Motor In
ndustry
C
Construction
i Developmen
D l nt:
Till 1930s wooden framme 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
Motor In
ndustry
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)
Early car evolved from

carriage , electric powered
Bersley 1897
Sports car with streamlined

composite body , Lotus
Pictures taken from Smith (2002)

Motor In
ndustry
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
Motor In
ndustry
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
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 Chevrolet Air-flow

Pictures taken from Smith (2002)
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

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 Europep
IC engine led to the dev
velopment of motor bus.
Autobahns
A t b h ini 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
Engine Dev
velopment
Diamler
Di l and
d Benz
B inven
i ntedd 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.
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.
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
Engine Dev
velopment
T Strokes
Two S k and
dUUnconveentional
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 needsd to
t be
b mixed
i d withith lubricating
l b i ti oilil
resulting in smoky exhaaust
Applications restricted to
t motor-cycles and small
cars like three cylinder SAAB
S car.
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 semmi-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
Engine Dev
velopment
El i and
Electric d Hybrid
H b id propu
ulsion:
li
1899,, Jenatzy's
y La Jammais Contente was first
vehicle to cross 100kmp
ph
Initial cars restricted to short distances but has
considerably increased in i recent times
IImprovementst 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 tot reduce
d smog.
Engine Dev
velopment
Limitations
Li i i in
i battery
b le
ledd 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
Transmissiion System
Develo
opment
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
pre-
dominantly 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.
Develo
opment
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
Lanchester Gear box
http://commons.wikimedia.org/wiki/File:Lanchester_epicyclic_gearbox.jpg
Pre selecto
Pre-selecto
or gearbox
Wilsons Gearb
box
Pictures taken from Steeds

S and Garrett (1983)
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
Fluid Torque
e Converter
Pictures taken from Stteeds and Garrett (1983)

Develo
opment
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)
Porsche tra
ansmission
ansmission
Picture taken from the patent document 890299

DAF varriomatic
Double pulleys
http://www.philseed.com/daf-600.html
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
Ackerman
nn Linkage
Ackerman
linkages for
Independent
Suspension
Pictures taken from Ste

eeds and Garrett (1983)
Tille
ers
Benz tricycle 1896

Panhard Levassor 1890-95
Pictures tak
ken from Smith (2002)
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
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)

Torsio
on bar
on

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)

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)
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.
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
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 http://www.indiacar.com/infobank/tlt_const.htm
than others vehicles can be
controlled longer
Tirres
res

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.

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
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
Brakes
Brakes
B k operatedd bby mecchanical
h i l rodsd 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.
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

Vacuum Ass
sist braking
Bendix Hydrovac

Anti Lock
Anti-Lock
k Braking
Ford Escort and Orion Anti-lock Braking System

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
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
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 sppread to rear
Ai b
Airbags came later
l t
Vehicle is now designed
g d with energy
gy absorbers in
front, rear and sides.
?? 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 hydro-
elastic 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
dGGarrett,
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)
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_V-
twin_motorcycle_engine.jpg
Mercedes Benz V6, 199

96
Overhead Cam Shaft

Side Valve
e Engines

Side Valv
ve Engine
Biefield
Biefield Diesel engine of 1930s
http://shopswarf.orconh
hosting.net.nz/svdiesel.html
Plate clutch
c
http://gtmotorsports.com
http://www.novak-
adapt.com/knowledge/clutches_etc.htm
Plate Clutch
C
Pic
ctures taken from The Motor Vehicle Newton Steeds
Gearr box
Sliding mesh ->

> moving gears
Dog clutch

Gear box Co
onstant mesh
Pictures taken from Stee

eds and Garrett (1983)
Gearbox - Sy
ynchromesh
Synchromesh
S h h
have
synchronizers
synchronizers
for smoother
gear shifting


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Benz tricycle 1896 Stanley Steam car 1905 Railton 1935

London B type bus - 1910 Ford Model T 1913

Pictures taken frrom Smith (2002)

Czech Tatra 1937

Lincoln continental 1960s Ford Sierra

Inventions and Innovations

Picture taken from Smith (2002)

Picture taken from Smith (2002)

Early car evolved from

Sports car with streamlined

Pictures taken from Smith (2002)

Czech Tatra of 1937 V8 Chevrolet Air-flow

Ford Sierra 1980

Picture taken from Smith (2002)

Lanchester Gear box

Pictures taken from Steeds

Pictures taken from Stteeds and Garrett (1983)

Picture taken from the patent document 890299

Pictures taken from Ste

Benz tricycle 1896

Mounting to reduce Squat

Axle guidance interferes with stee

Pictures taken from Steeds and Garrett (1983)

Pictures taken from Steeds and Garrett (1983)

Flat, non-driven air-suspended semi-trailing-arm rear axle of the

Pictture taken from Reimpell et al., (2001)

Jaguar 3.4 was with

Pictures taken from Steeds and Garrett (1983)

Pictures taken from Steeds and Garrett (1983)

Low proffile Tires

Pictures taken from Steeds and Garrett (1983)

Pictures taken from Steeds and Garrett (1983)

Ford Escort and Orion Anti-lock Braking System

?? Too much Innovation ??

Mercedes Benz V6, 199

Overhead Cam Shaft

Pictures taken from Steeds

Pictures taken from Steeds

Sliding mesh ->

Pictures taken from Steeds

Pictures taken from Stee

Pictures taken from Steeds

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