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
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 vehiclehi 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 Construction
Development of World
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
History Construction
Development of 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
History Construction
Development of World
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)
History Construction

Early car evolved from

carriage , electric powered
Bersley 1897

Sports car with streamlined

composite body , Lotus

Pictures taken from Smith (2002)

History Construction
Development of World
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
‘système Panhard’
„ Windscreen was inventeed in 1920s with increasing
speed of vehicle
History Construction
Development of World
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
History Construction

Stream
mlining
„ IIn 1890s,
1890 A Amédée
édé B
Bollé
lléée
é 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)
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 70’s 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 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
History Construction

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.
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
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.
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 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
History Construction

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.
History Construction

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
History Construction
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.
History Construction
Transmissiion System
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
History Construction

Lanchester Gear box

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

Pre selecto
Pre-selecto
or gearbox

Wilson’s 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 Construction
Transmissiion System
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)
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 http://www.indiacar.com/infobank/tlt_const.htm
than others vehicles can be
controlled longer
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 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.
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 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.
History Construction

?? Too much Innovation ??

„ I
Innovation
i not always
l a key
k to fi
financial
i l sucess
„ Alec Issigonis’s 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)).
))
„ Jörnsen 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_V-
twin_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.novak-
adapt.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)