The project entitled

“DESIGN AND SIMULATION OF HYDRAULIC CIRCUIT FOR AUTOMOBILES”

BY

Akshata Ekbote , Tazeen Shaikh , Pranali Patil , Gauri Salunkhe

Department of Mechanical Engineering, Vishwakarma Institute of Technology, Pune.

UNDER THE GUIDANCE OF

PROF. S.P.Komble

PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE – 411037.

NOVEMBER 2018

o Department of Mechanical Engineering, Production Technology Course Project Report, 2018-19 1

 DESIGN AND SIMULATION OF HYDRAULIC CIRCUIT FOR AUTOMOBILES

Abstract: - Demands for including more functions such as haptic guiding in power steering systems in road
vehicles have increased with requirements on new active safety and comfort systems. Active safety systems, which
have been proven to have a positive eff ect on overall vehicle safety, refer to systems that give the driver assistance in
more and less critical situations to avoid accidents. Active safety features are going to play an increasingly important
roll in future safety strategies; therefore, it is essential that sub systems in road vehicles, such as power steering
systems, are adjusted to meet new demands. The traditional Hydraulic Power Assisted Steering, HPAS, system,
cannot meet these new demands, due to the control unit’s pure hydro-mechanical solution. The Active Pinion
concept presented in this thesis is a novel concept for controlling the steering wheel torque in future active safety and
comfort applications. The concept, which can be seen as a modular add-on added to a traditional HPAS system,
introduces an additional degree of freedom to the control unit. Diff erent control modes used to meet the demands of
new functionality applications are presented and tested in a hardware-in-the-loop test rig.
The design of an effective braking system plays a major role in high performance formula cars since the stopping
distance and speed control during cornering are the important part of any race. Everyone wants their car to go fast,
but the braking system should be capable to stop immediately and safely. Any car with highly effective braking
system fills confidence in the driver. It also increases driving pleasure.

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 .
Literature:-
In automobiles, power steering is a device that helps
drivers steer by augmenting steering effort of
the steering wheel.
Hydraulic or electric actuators add controlled energy to
the steering mechanism, so the driver can provide less
effort to turn the steered wheels when driving at typical
speeds, and reduce considerably the physical effort
necessary to turn the wheels when a vehicle is stopped
or moving slowly. Power steering can also be
engineered to provide some artificial feedback of forces
acting on the steered wheels.
Hydraulic power steering systems for cars augment
steering effort via an actuator, a hydraulic cylinder that
is part of a servo system. These systems have a direct
mechanical connection between the steering wheel and
the linkage that steers the wheels. This means that
power-steering system failure (to augment effort) still
permits the vehicle to be steered using manual effort
alone.
Electric power steering systems use electric motors to
provide the assistance instead of hydraulic systems. As
with hydraulic types, power to the actuator (motor, in
this case) is controlled by the rest of the power-steering
system.
Other power steering systems (such as those in the
largest off-road construction vehicles) have no direct
mechanical connection to the steering linkage; they
require electrical power. Systems of this kind, with no liquids are based on mineral oil.
mechanical connection, are sometimes called "drive by
wire" or "steer by wire", by analogy with aviation's "fly-
by-wire". In this context, "wire" refers to electrical
cables that carry power and data, not thin wire
rope mechanical control cables.
o Department of Mechanical Engineering, Production Technology Course Project Report, 2018-19
One design for measuring the torque applied to the steering
wheel has a torque sensor – a torsion bar at the lower end of the
steering column. As the steering wheel rotates, so does the
steering column, as well as the upper end of the torsion bar.
Since the torsion bar is relatively thin and flexible, and the
bottom end usually resists being rotated, the bar will twist by an
amount proportional to the applied torque. The difference in
position between the opposite ends of the torsion bar controls a
valve. The valve allows fluid to flow to the cylinder which
provides steering assistance; the greater the "twist" of the
torsion bar, the greater the force.
Since the hydraulic pumps are positive-displacement type, the
flow rate they deliver is directly proportional to the speed of the
engine. This means that at high engine speeds the steering
would naturally operate faster than at low engine speeds.
Because this would be undesirable, a restricting orifice and
flow-control valve direct some of the pump's output back to the
hydraulic reservoir at high engine speeds. A pressure relief
valve prevents a dangerous build-up of pressure when the
hydraulic cylinder's piston reaches the end of its stroke.
The steering booster is arranged so that should the booster fail,
the steering will continue to work (although the wheel will feel
heavier). Loss of power steering can significantly affect the
handling of a vehicle. Each vehicle owner's manual gives
instructions for inspection of fluid levels and regular
maintenance of the power steering system.
The working liquid, also called "hydraulic fluid" or "oil", is the
medium by which pressure is transmitted. Common working
Some modern systems also include an electronic control valve
to reduce the hydraulic supply pressure as the vehicle's speed
increases; this is variable-assist power steering.
3
 Introduction:- Need of Hydraulics:-

In automobiles, power steering (also power-assisted The main contribution of this thesis is the concept for
steering (PAS) or steering assist system) helps drivers enhancing functionality in traditional hydraulic power
steer by augmenting steering effort of the steering assisted steering systems. This project is a novel approach to
wheel. Hydraulic or electric actuators add controlled enhance the functionality of HPAS systems to meet the
energy to the steering mechanism, so the driver can demands of future active safety systems. The development of
provide less effort to turn the steered wheels when the enhanced power steering unit includes simulation and
driving at typical speeds, and reduce considerably the testing of diff erent control strategies that can be used in both
physical effort necessary to turn the wheels when a active safety systems and comfort systems. This project has
vehicle is stopped or moving slowly. Power steering resulted in a new concept called Active Pinion, which is can
can also be engineered to provide some artificial be seen as a modular add-on to a traditional hydraulic power
feedback of forces acting on the steered wheels. steering system. The focus of the active pinion concept is to
Hydraulic power steering systems for cars augment enable a haptic communication with the driver, which can be
steering effort via an actuator, a hydraulic cylinder used for guiding and easing the driver when performing
that is part of a servo system. These systems have a diff erent driving tasks. In addition to the concept, diff erent
direct mechanical connection between the steering controller designs are developed to meet future demands for
wheel and the linkage that steers the wheels. This active safety and comfort systems such as LKA systems and
means that power steering system failure (to augment automatic parking systems. Apart from concept validation
effort) still permits the vehicle to be steered using and controller design of the active pinion, the models have
manual effort alone. been proven eff ective to explain dynamic phenomena related
to HPAS systems, such as the chattering phenomena and
Braking system is the device which brings the
hydraulic lag.
moving vehicle into rest by converting kinetic energy
of the vehicle to frictional energy intern’s heat energy Hydraulic or electric actuators add controlled energy to the
which is dissipated to atmosphere. Brakes helps to steering mechanism, so the driver can provide less effort to
slow down or stop the vehicle in the shortest possible turn the steered wheels when driving at typical speeds, and
time as per the driver requisite and also at the time of reduce considerably the physical effort necessary to turn the
driving down the hill and to obtain a better traction wheels when a vehicle is stopped or moving slowly. Power
control in different terrains. steering can also be engineered to provide some artificial
There are various types of braking systems available feedback of forces acting on the steered wheel.
such as drum brakes and disc brakes based on the
components involved and also hydraulic and wire
actuated brakes and these brake actuation systems
converts drivers force into frictional force at the
rubbing surface

General Design of Hydraulic Power Steering

System Applications of hydraulics in automobile

There are basically two diff erent types of power 1. Hydraulic-powered and controlled sky tram
steering units on the market today, hydraulic power
assisted steering, HPAS, systems and electric power 2. Bendix hydro boost brake system
assisted power steering, EPAS, systems. EPAS
systems have been on the market for a few years and 3. Power steering
are installed in small and medium sized cars, due to
its limitation to cope with higher steering forces. 4. Welding
However, the functionality of these systems is greater
5. Bridge maintenance.
than a traditional power steering unit. HPAS system
layout is basically the same from car to car, This 6. Shock absorbers
figure shows the power steering unit in a more
o detailed
Department
view.of Mechanical Engineering, Production Technology Course
7. Lifts Project Report, 2018-19
and cleaners. 4
o Department of Mechanical Engineering, Production Technology Course Project Report, 2018-19 5
 Hydraulic circuit for power steering :-
Since the valve is the controlling element in the
HPAS system, the shaping and design will aff ect the
characteristic of the system deeply. Most of the
power steering systems used in cars today utilize an
open center valve solution instead of a closed center
solution. The reason for this is that the open center
valve is an inherit pressure control valve together
with a constant flow. A specific valve displacement
will result in a specific load pressure when
neglecting the motion of the controlled cylinder,
pumping motion, where a closed center valve is
more suitable for velocity control. A specific valve
displacement will result in a specific cylinder
velocity, when neglecting the variation in load.
Based on this knowledge, it is natural that most
power steering units utilize an open-center valve
over a closed-center valve. However, some
researchers and car manufactures are considering
closed-center valves, due to the fact that a valve
based on closed-center technology will have the
possibility to reduce energy consumptionthrough
sketch of a HPAS system including pump, valve
assembly, rack and the hydraulic cylinder is shown.
The photo of a separated valve unit, showing the
pinion, torsion bar, spool and valve body is shown.
The function of the torsion bar is to activate the
valve and at the same time transfer the applied
manual force down to the pinion. The top part of the Construction and Working:-
torsion bar is attached to the spool and the lower part
is attached to the pinion. Since the valve body is also Components:-
solidly attached to the pinion, a displacement of the
torsion bar will create an angular displacement 1. Tank
between the spool and the valve body. When torque 2. Filter
is applied to the steering wheel, the torque will be 3. Unidirectional pump
transferred down to the valve via the steering 4. Pressure relief valve (PRV)
column. When torque is applied to the torsion bar it 5. 4/3 double solenoid operated, double spring
will twist. The twisting of the torsion bar is linear to
returned, closed centered directional control
the applied torque. This means that the valve
displacement is proportional to the applied torque. valves (DCV)
When the valve is activated or displaced, the valve 6. Variable non return throttle valve
will modulate the pressure within the chambers of 7. Double acting, double rod cylinder
the hydraulic cylinder in order to assist the driver.

o Department of Mechanical Engineering, Production Technology Course Project Report, 2018-19 6

Working:
The working fluid used in this circuit is oil. This
oil is filtered before being passed through any of
the device in the circuit. When the pump is
started, this filtered oil is carried through the
conducting lines to the entire circuit.
When the DCV is shifted to the left envelope
mode of operation, the oil passes through a
variable non return throttle valve. The check
valve being in closed position, the entire flow
will pass through the flow control valve. The
amount of oil going to the cylinder depends
upon the opening of the flow control valve. This
controlled fluid enters the left side of the
cylinder. This causes the piston to move to the
right side. The oil on the right of the cylinder
returns to the tank through the check valve.
Thus, the car takes a right turn.
Similarly, when the DCV is shifted to the right
envelope mode of operation, the oil passes
through a variable non return throttle valve.
The check valve being in closed position, the
entire flow will pass through the flow control Components:-
valve. The amount of oil going to the cylinder 1. Tank
depends upon the opening of the flow control
valve. This controlled fluid enters the right side 2. Filter
of the cylinder. This causes the piston to move 3. Unidirectional pump
to the left side. The oil on the left cylinder 4. Single acting, spring returned cylinders
returns to the tank through the check valve. 5. 2/2 solenoid operated, spring returned
Thus, the car takes a left turn.
directional control valve (DCV).
When the pressure in the system exceeds the
setting pressure of the PRV, the PRV is actuated
and the flow of oil is directed to the tank.
Working:-
The working fluid used in this circuit is oil. This
Hydraulic circuit for brakes:- oil is filtered before being passed through any of
the device in the circuit. When the pump is
started, this filtered oil is carried through the
conducting lines to the entire circuit.
When DCV 1 is shifted to the right envelope
mode of operation, the oil from the tank will
pass through both, DCV 1 as well as the check
valve. At the same time, DCV 2 is also actuated,
thus DCV 2 will shift to its left envelope mode of
operation. The oil cannot flow through the DCV
2 in this position. So, the oil will flow to the
brake cylinder and hence the brake will be
applied.
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 When DCV 1 is shifted to left envelope mode of
operation, DCV 1 being in closed position, the
oil will flow through the check valve. DCV 2 will
be in its right envelope mode of operation and
hence the oil will flow through DCV 2 and the
oil will return to the tank. Thus no brakes are
applied during this operation.

Different valve used :-

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Calculations of Brakes :-
Speed of the Vehicle = 105kmph = 29.1666/sec
Weight of the vehicle including Driver = 300 kg
Vehicle momentum:
Brake torque:
Tbrake = Fbrake*effective radius of rotor
Tbrake = 6940.548*0.1m
Tbrake = 694.054 N-m
If we give 66.1386 lbs. (nearly equal to 30kg) of
force on to brake pedal with pedal ratio 6:1

Kinetic energy of the vehicle is calculated by Piston force on the cylinder=pedal ratio*applied load
in kg
KE=1/2𝑚𝑣2
Fpiston = 6 * 30 = 180 kg = 1765.1970 N
KE = 1/2(300 * 29.16662) = 127598.3334 N
=127.5983 KN
To find the diameter of disc:
KE = 127598.3334 𝑘𝑔𝑚2/𝑠𝑒𝑐2
T brake=2 * 𝜇* Fpiston * R

Stopping distance: R=694.054/2 * 0.45*6940.548

Stopping distance is calculated by dividing whole R=0.11m=110 mm

equation by force acting on the wheel by gravity
(Coefficient of friction between tire and road μ =
0.6)
F = μmg =0.6*300*9.81=1765.8N
Diameter of the disc d=110*2=220mm
Pulsar bike’s brake discs with diameter of 200mm
are used.

Stopping distance d = 𝑣2/2𝜇𝑔 Pedal travel:

d = 29.16662/ (2*0.6*9.81) = 72.26m (theoretical) The master cylinder used here is Bajaj bike’s
Or BYBRE calliper of bore diameter =19.02mm and
piston travel=25.4mm with pedal ratio 6:1.
Stopping distance d=KE/μmg
d=127598.3334 / (0.6*300*9.81) Pedal Travel = piston travel * pedal ratio
Pedal Travel = 25.54 * 6 = 153.24mm
d=72.26 m
Deceleration:
V2 =u2+2as Master cylinder pressure:

02=29.16662 + 2 a*72.26 Piston Area of the master cylinder = (𝜋/4) *d2

a=-29.16662 / (2*72.26) =-5.88 m/sec2 (negative Parea = (𝜋/4) *19.022 = 284 mm2
sign indicates the deceleration) Parea = 2.84*10-4 m2
Stopping time: Piston Pressure of the master cylinder = F/A
V=u + at =1765.19/2.84*10-4
0 =29.1666+ (-5.886) * t Piston pressure = 6.21*106 Pa =6.21 MPa
t = (-29.1666)/ (-5.886) = 4.9 sec For BYBRE calliper disk width = 4 mm Area of the
Braking force: calliper piston =5.07*10-4m2

Fbrake= m*a=300*38.5586*0.6=6940.548 N
Force acting on each piston of the calliper:
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F=Pressure *area
F=6.21*106*5.07*10-4
F=3.14 KN
Mean braking radius:
Mean braking diameter = (disc diameter– (pad plate
height/2))/2
R= (200-(25.4/2))/2
R=93.6 mm
Conclusion :-
Hydraulic power steering systems have been a
proven technology for decades, there are still
problems to be solved, most concerning quality
issues. In this thesis, two predominant problems
have been studied, hydraulic lag and the chattering
phenomena. As discussed above the braking system
is designed and fabricated, the system will be able to
slow down and stop the car from 105kmph to 0kmph
with the practical stopping distance of 4.8m by
performing linear braking within the shortest braking
time of 2.3 seconds without skidding the vehicle.
Even in the case of vehicle launch in the races,
during the starting the brakes are partially engaged
and released to get a good launch or acceleration.
And in traction control the sequential or pulsating
engagement of particular wheels is achieved with
traction controller module which also make use of
anti-lock braking system. As the rules of the
competition doesn’t permit the use of boosted brakes
neither electronically nor hydraulically, which makes
the normal disc brake, the exact option of use for the
open wheel race cars.
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References :-
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[5] van Zanten A.,“Bosch esp systems: 5 years of
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