Automobile Engineering

Aero Dynamics
Ergonomics
Comfort System
Air Conditioning
AERODYNAMICS IN CARS
INTRODUCTION
When objects move through air, forces are generated by the relative
motion between air and surfaces of the body, study of these forces
generated by the motion of air is called aerodynamics.

CLASSIFICATION:-

on basis of flow environment

1.External Aerodynamics 2. Internal Aerodynamics

on basis of flow behavior

1.Subsonic 2.sonic 3.Supersonic
FIELD OF APPLICATION:-

1.Aerospace Engineering
2.Design Of Automobile
3.Prediction of forces & moments in ships and sails
4.In design of bridges and buildings for calculating wind loads
 Aerodynamic Forces on Aerofoil
Considered a aerofoil move through air, forces which are considered
for aerodynamic analysis over aerofoil are,

1.Lift (causes body to rise)

2.Drag (Fluid resistance)

3.Weight

4.Thrust

Aerofoil
1.Lift :-
It is the sum of all fluid dynamic forces on a body normal to
the direction of external flow around the body. it is caused by
Bernoulli’s effect . It results body to rise by creating pressure
difference .
2.Drag:-
It is the sum of all external forces in the direction of fluid flow,
so it acts opposite to the direction of the object. it is the force
which opposes forward motion of the body through fluid.
3.Weight:-
It is actually just the weight of the object that is in motion. i.e.
the mass of the object multiplied by the magnitude of
gravitational field.
4.Thrust:-
When a body is in motion a drag force is created which
opposes the forward motion of the object so thrust can be the
force produce in opposite direction to drag. it must be higher
than that of drag so that the body can move through the fluid.
 ADVANTAGES OF AERODYNAMICS IN
CARS
It is essential that aerodynamics be taken into account during the
design of cars as an improved aerodynamics in car would attain

1.More fuel efficiency

2.Higher speeds
3.Good Aesthetic and stylish appearance of car.
4.More stability of car at higher speed
5.Reduces noise level
 History & Evolution of Aerodynamic
Car design in 1920:-
In Cars
In the earlier times aerodynamics was not a factor as the cars
where traveling at very slow speeds, but with increase of speeds it is
necessarily for cars to become more streamlined, which resulted in
smooth design and almost all corners of car are rounded off . during
this period majority of the work was done on reducing air drag .
Car design in 1950:-
up to 1950 the aerodynamic drag had been cut by about 45%
of the early cars. However, after this the level of drag found on cars
began to slowly increase. This is due to cars were becoming more
family friendly. This changes the streamed lined shape of car into
rectangular shape which is more purposeful to give comfort for the
family rather than reducing drag.
Car design 1970:-
During the 1970’s there was a fuel crisis and so the demand
for more economical cars became greater, which lead to changes in
car aerodynamics for achieving more economical cars.
If a car has poor aerodynamics then the engine has to do
more work to go the same distance as a car with better
aerodynamics. Hence, there is increase in demand for improved
aerodynamic cars in order to be more economical for family

Present design:-
Now a days almost all cars are manufactured aerodynamically
for having good looking, stylish and fuel efficient car.
 STUDY OF AERODYNAMICS IN CARS
In order to improve the aerodynamics of cars, we must know
how the flow of air past a car. the major forces which affecting the
motion of car in fluid flow are,
1.Drag Force 2.Lift or Down force.

1.Drag Force:-
some energy are lost to move the car through the air & this
energy is used to overcome a Drag force.
In vehicle aerodynamics drag is due to Frontal pressure and
Rear vacuum.
For calculating drag force following formula is use
F = ½ CDAV²
Where, F - Aerodynamic drag force A - Frontal area
C - Coefficient of drag V - Velocity of object
D - Density of air
Coefficient of drag:-
The drag coefficient is a common measure of aerodynamic
efficiency in a automotive design. The drag coefficient is a unit less
value that denotes how much an object resists movement through a
fluid such as water or air.

Hence the coefficient of drag

must have low value which
leads to low drag force and
ultimately increases aerodyn-
amic efficiency of car.

Different Values of drag

coefficient for various shapes
body is given as,
FRONT END OF CAR
Drag Force due to Frontal pressure:-
This Drag force is caused by the air attempting to flow
around the front of the car. When Air molecules approaches
the front of the car they begin to compress and raise the air
pressure in front of car.
Frontal pressure is reduced by minimizing exposed
frontal surface area and making front end smooth, continuous
curve originating from the line of front bumper allowing the air
molecules to pass smoothly.
REAR END OF CAR
Drag Force due to Rear Vacuum:-
Rear vacuum is caused by the Flow Detachment in the air flow
as the car passes through it. Flow Detachment is inability of air
molecules to fill the empty zones which are created at the rear end of
vehicle.
Which results in continuous vacuum zone in the opposite
direction of Vehicle motion in the rear area.
Drag forces are increases due to turbulence in the rear end
which is caused due to flow detachment
To decrease drag force, it is
necessary to decrease Flow
detachment .
It is achieved by allowing
the air molecule to follow
continuously the contours of a car's
body.
this can be ideally achieved
by a long , smooth surface and
gradual slope at rear end.
Hence, shape of car is
streamlined so that air molecule
flow smoothly towards the end of
car to avoid flow detachment .
2.LIFT OR DOWN FORCE:-
Every object traveling through air creates either a lifting or
down force situation. Down force is the same as the lift experienced
by airplane wings, only the difference is, it acts to press down,
instead of lifting up .
It is calculated as
F=(1/2)CLdV2A
For a given volume of air, the higher the speed of air molecules, the
lower is the pressure and vice-versa

This creates low pressure over hood, roof

and trunk which increases the chances of
rise of vehicle.
The underside of the car is also responsible for creating lift or down
force.
If a car's front end is lower than the rear end, then the
widening gap between the underside and the road generates vacuum
or low pressure area, and therefore suction is created that equates to
down force.

Overall to increase the performance of car aerodynamically.

It is necessary to Generate right amount of Down Force
While keeping Drag Force to a minimum level
 AERODYNAMICS DEVICES IN CARS

1.WINGS

2.SPOILER

3.SCOOPS
1.WINGS:-
Probably the most popular form of aerodynamic device is
the wing. Wings perform very efficiently and generating lots of
down force in the car.
The wings works by differentiating pressure on the top and
bottom surface.

Air molecules approaching the leading edge of the wings

are forced to travel different distances over and below the wings.
which results in lower pressure area under the wing and
allows the higher pressure area above the wing to "push" down
on the wing, and hence the car is stable during high speed.
2.Spoiler:-

They act like barriers to

air flow, in order to build up
higher air pressure in front of
the trunk of car.
It is mostly used in race
cars which are lighter in rear
end because low pressure
created above the trunk which
lifts the rear end of car.
Hence spoilers are use
to create high pressure that
pushes down the car and also it
gives stability at corners.
3.Scoops:-

Scoops, or positive pressure

intakes consist of the air box which
has an opening that permits an
adequate volume of air to directly
enter .
Its main function is to
provide high pressure, denser and
adequate volume of outside air
directly into the the engine
compartment.
 Aerodynamics in F1 car
Aerodynamics is the single most important aspects of F1 car design,
it defined the entire shape of the car
 METHODS FOR EVALUATING
AERODYNAMCIS OF CARS
1.Wind tunnel:-
A wind tunnel is a research tool
developed to study the effects of air moving
over or around solid objects.
Air is blown or sucked through a duct
equipped with a viewing port and instruments.
where models or geometrical shapes are
mounted for study.
wind tunnel testing is a trial and error
process
2.SOFTWARES:-
Number of software’s are developed for the analysis and
optimization of aerodynamics in automobiles.
For the design and analyzing aerodynamics the most
commonly used software’s are CATIA , HYPERMESH, ICEMCFD, FLUENT
and other CFD software.
software programs makes possible to test small size parts
which are costly in the wind tunnel.
Ergonomics
 5 Aspects of Ergonomics
✔ There are five aspects of ergonomics:

✔ Safety –

✔ Comfort –

✔ Ease of use –

✔ Productivity/performance –

✔ Aesthetics -
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Aspects of Designing Car
✔ Occupant Packaging
✔ Computer-Aided Ergonomics Design Of car
✔ Visual Aspects in vehicle Design
✔ Automotive Seat Design for sitting comfort
✔ Physical Aspect of Car Design
✔ Design of symbols for automobile Control and
Displays
✔ Informational aspect of vehicle Design
Ergonomic Aspects in automobile
Design
✔ Visual aspect
✔ Air Bag warnings
✔ Comfort, usability seat belts
✔ Collision avoidance system
✔ Traction control system
✔ Brake assist system
✔ Navigation system
✔ Vehicle interior, controls, pedals etc
✔ Reach to advanced recreational systems.
Occupant Packaging
✔ Workspace Anthropometry :
– Conventional Static Measurements
anthropologist
(are taken on the human body in rigid , standarized position)
– Functional Task Oriented Measurements
Engineer Designer
(are taken with the human body at work , in motion or in
workspace attitude and typically are expressed as 3
dimensions.)
Occupant Packaging

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Occupant Packaging

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Occupant Packaging

10
Computer Aided Ergonomic
Design of automobile
Engineers will simulate
driver behavior and
measure key criteria such
as reach, visibility,
comfort, posture,
biomechanics, strength
and anthropometrics.
This analysis will enable
the team to make driver-
oriented decisions about
cockpit design, while
respecting the overall
aerodynamics of the
racecar body.
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Simulation with computer

✔ To optimize cockpit ergonomics, engineers will first

create a digital model of each driver using a combination
of laser scanning and manual anthropometrical
techniques. The resulting virtual models will be used to
analyze and improve specific accommodation issues such
as driver comfort and security, and accessibility and
serviceability of components inside the cockpit during pit
stops— without the need to involve the actual drivers.
The SAMMIE system
✔ SAMMIE CAD Limited is an Ergonomics
Design Consultancy dedicated to improving
product, workplace, and service design for the
benefit of the user and ultimately the producer.
✔ SAMMIE CAD Limited was started in 1986 by the
SAMMIE system originators to continue
the consultancy work of the SAMMIE
Research Group, U.K.
✔ Has its reach in other 91 countries
✔ Approved by SAE
The SAMMIE System
✔ The SAMMIE system is a computer
based Human Modeling tool. Its
capabilities make it an invaluable tool
to designers and design teams working
on products that are used by people.
The system offers the following
advantages:

✔ 3D analysis of fit, reach, vision and

posture.
✔ reduced timescale.
✔ early input of ergonomics expertise.
✔ rapid interactive design.
✔ improved communication.
✔ cost effective ergonomics
Application areas
✔ These include the design and layout of
equipment and furniture in public areas, offices
and homes; cockpit, cabin and interior
evaluations for all types of vehicles; design of
control panels; field of view, reflection and
mirror evaluations; safety and maintenance
evaluations etc.
Advantages of SAMMIE
✔ Product concepts can be built within SAMMIE or imported from an
external CAD system and rapidly assessed.
✔ A complete range of human mannikins can be created to simulate
any age, gender, nationality, and body shape.
✔ Ergonomics input is provided right from the concept stage of design
reducing the likelihood of expensive or unfeasible modifications
being necessary at downstream stages.
✔ The system promotes the exploration of a wide range of design
solutions.
✔ The systems supports the 3D analysis of complex tasks.
✔ The combination of product concepts populated with human
mannikins provides an excellent forum for all members of the design
team.
✔ The ergonomics issues can be investigated throughout the design
process thereby promoting the 'right first time' philosophy.
Automotive Seat Design For
Sitting Comfort

kind of motor vehicles:

1. Family and personal business sedan
2. Minivan and off-road vehicle
3. Sport cars
Three different occupants in the vehicle:
1)Driver
2) Front seat passenger
3) Rear set passengers
 Automotive Seat Design For
Sitting Comfort
Criteria for a driver s seat :
1: the set should position the driver with
unobstructed vision and within reach of all
vehicle control

2: the seat must accommodate the driver

s size and shape

3: the seat should be comfortable for

extended period

4: the seat should provide a safe zone

for the driver in a crash
Why should respect
Ergonomics In Design?

Safety
Safety in a race car is the art of protecting the
human occupant, at whatever cost to the car.
Designing the car to be damaged minimally while
hindering driver safety is definitely the
wrong approach.
So how do we protect the driver? Well first we need
to consider the basic physiological weak
points of the human body.
 Safety
✔ The diagram above shows that pretty much any part
of the body exposed to the chassis of the race car is
at risk. Injuries occur because the body sustains
impacts beyond the G (gravities) level that it can
sustain.
✔ The brain is particularly succeptible to injury,
because it is really just a soft tissue mass stored
inside a very solid bone container, the skull. The key
to avoiding injury in the brain is to avoid
instantaneous decelleration of the skull. That is,
when the skull strikes something hard, it decellerates
instantaneously. The brain inside unfortunately keeps
on moving, causing head trauma.
✔ Neck and spinal injuries also present a serious threat
to life and career. These "Connector" type elements
in our body are flexible and stretchable, to a point,
and can sustain tremendous G loads before breaking.
However, depending on angle of impact, they can
break rather easily.
✔ Other bone injuries (breakages) are not as life-
threatening or career ending, but still are to be
prevented. The bones in our arms, legs and spine are
designed to be stressed in tension and compression
along their length. In the case of impacts they are
often stressed in shear or bending, and therefore snap
relatively easily
 Safety/Ergonomics
Design Tips
✔ Use energy absorbing materials in the collapsable crash
structure - In lower cost racing cars, most of the car is usually built from
mild steel. Using that same mild steel in areas such as wishbones means that
impacts will bend the material long before it breaks the material, meaning
energy absorption takes place over a longer period.

✔ For light weight, use a stressed skin over a lightweight

core material - crushable zones such as the nose cone on a formula car
can be made from balsa, honeycomb or high density styrofoam covered with a
stressed skin of composites.

✔ Triangulate the driver "safety cell" to prevent collapse -

The safety cell can be designed in such a way that a catastrophic impact which
collapses the safety cell, will make the safety cell expand away from the driver,
instead of collapsing it onto the driver. In the case of a frontal impact, this
would mean the sides of the cockpit would expand outward, upward and
downward, instead of inward.
 Safety/Ergonomics
Design Tips
✔ Use a clear windscreen or bodywork to increase vision - using lexan
or other non-shattering clear material can help increase visibility without
compromising the function of the bodywork. In some cases, the driver can be
lowered for better CG (center of gravity), and the normally opaque bodywork
replaced with clear lexan, to aid in re-establishing the vision field.

✔ Keep the fuel cell and battery away from the driver and danger.
Keeping dangerous items away from the driver is sometimes very difficult. In
order to reduce the weight balance change over a race, designers will frequently
put the fuel cell at the CG, so that no matter how empty or full it is, it does not
cause a front/rear or side-to-side weight bias. However, most drivers don't like
to sit next to fuel. Use secured, sealed firewalls between the fuel cell and driver
compartment, and further, use the safety cell to protect the fuel cell from
outside intrusions.

✔ Don't scrimp on safety. Use only top quality certified suppliers of safety
equipment. The cost is perhaps high, but consider how much you value your
life. Fuel
body cells only!),
certified (Sanctioning bodysafety
and driver certified),
wear seat belts (5
(Nomex, ormore
2 or 6 point sanctioning
layers
minimum! -- anything less is like wearing nothing).
Control and Displays
Design Of Symbols For
Automobile Control and Displays
✔ 1) Digital meters
Discreet digital meters maximize
forward visibility and help create a sense
of uncluttered spaciousness.
✔ 2) Triangle-motif steering wheel
The triangle-motif steering wheel helps
harmonize exterior and interior design,
for a feeling of unity throughout.
✔ 3) Centrally positioned audio panel
A 2DIN opening for audio components
is centrally positioned at the top of the
instrument panel for easy access and
visibility.
✔ 4) Textured dashboard and console
The dashboard centre, floor console, and
front pillars are trimmed with a new
textured material with a refined look and
feel.
✔ 5) Sporty two-tone fascia
The sporty two-tone fascia adds a touch
of pizzazz to the Liana's interior.
Displays

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Displays

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Displays

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Case Study
✔ Glastonbury Police Department - The Police
Car of the Future
PROBLEM
✔ The benefits of new technology have transformed
patrol cars across the country; a vehicle mounted
computing device with wireless capability means
officers have realtime access to information, database
files and GPS mapping systems. However, this
capability does not come without drawbacks.
✔ Two of the most frequently cited complaints are space
issues in the cab as more and more hardware is
installed and the need to look down to type and access
the computer system.
✔ Furthermore, departments are constrained by cost,
space limits, power and existing infrastructure. The
overall objectives for the department are officer safety
and to improve environment and efficiency while
watching the cost.
Problems Cont…
✔ Officer Robin Timmer of the Glastonbury Police Department
describes the older system installed in the patrol cars. “You
couldn’t move around the car, keys flew off the keyboard,
when an officer turned in his seat he would knock a USB
loose. Once an officer accidentally spilled milk on the laptop
and fried the system! We had to explain that our computers
are lactose intolerant.”
✔ The current system simply was not built for in-vehicle usage
and posed a threat to officer safety.
✔ When considering a new mobile solution the Glastonbury PD
placed a high importance on human factors and ergonomics.
“There’s more stuff, more radios, more hardware, and a lot of
it is mounted directly in front of the airbag,”
✔ Timmer explains. “Over the past several years, we’ve seen
violent offenses against police decline, but what we’ve seen is
a 30 – 35% increase in the amount of injuries to an officer in 34
a
police cruiser.
Solutions
✔ The GPD performed their due diligence in
researching a mobile computing solution.
They wanted a system that would meet their
exacting needs for ruggedness, interior
ergonomics and officer safety as well as
offer best in class computing technology
REFERENCES
✔ Aesthetics and Engineering Design
– http://design.stanford.edu/PD/kbase/Aesthetics_and_Engineering_Design.pdf

✔ Introduction of design
– http://deed.ryerson.ca/DesignScience/1.html

✔ design basics in IT
– http://www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/6

✔ user engineering in IT
– http://www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/1996

✔ Automotive Ergonomics
Brayan Peacock & Waldemar Karowski
✔ Sitting posture

E. Granjin 40
Air Conditioning
WHY AC SYSTEM?
Stopped in traffic on a may afternoon?
Sweat drips all over your body?
Hands feel like they are about to slip away from the
steering wheel due to sweat?
Need a luxurious and a comfortable ride?
Why don’t you attach an automotive air conditioning
system to your ride, which 99% of all new cars produced
since 2010 are equipped with?
HOW DOES IT WORK?
Main function- to cool and remove humidity from air
inside the car.
Parts of a typical car AC system are:
(i)Compressor (ii)Condenser (iii)Receiver or Dryer
(iv)Expansion valve (v)Evaporator
COMPRESSOR

It is a pump driven by a belt attached to the engine’s

crankshaft.
Puts the refrigerant gas under pressure and forces it to the
condenser.
It cant compress liquids, only gases.
By increasing the pressure the refrigerant gas leaving the
compressor becomes hot.
Also called as heart of the air conditioning system.
Earlier freons(R-12) were used as refrigerants. Nowadays
they are replaced by environment friendly HFC(R-134a).
CONDENSER
Identified as second radiator of the car that shares air f low
with main radiator.
Has its own cooling fans that become active when AC is
on.
Takes up the heat from the high pressure refrigerant gas
and cools it.
Condensing of the refrigerant gas causes it to loose heat
and form into a liquid.
Heat is expelled into the atmosphere by the air flowing
from the cooling fans.
RECEIVER OR DRYER
Small reservoir installed in the line of the condenser.
Main function is to remove moisture and other
contaminants from the cool refrigerant liquid.
Contains small granules called desiccants that attract
water.
If water is not removed, it can form ice crystals, thereby
damaging the whole system.
EXPANSION VALVE
Here the pressure of refrigerant is reduced causing
expansion of the liquid, resulting in further cooling.
Slowly the liquid reverts back into a gaseous form.
Also the valve reduces pressure on the refrigerant so it can
easily move into the evaporator.
The valve senses pressure and
regulates the f low of refrigerant,
which allows the system to
operate steadily.
EVAPORATOR
Radiator like device buried deep under the dashboard.
Refrigerant gas enters the evaporator coils and absorbs the
heat inside the car’s cabin and moves out of the coils.
A fan blowing over the outside of the evaporator coil
blows cool air into the passenger compartment.
Thus the evaporator takes humidity out of the air in the
car, which helps you feel cool.
SCHEMATIC DIAGRAM FOR EASY
UNDERSTANDING
CONCLUSION
An AC system not only cools the cabin, it removes dust
and dirt, leaving only with fresh air.
One has to remember to use only environment friendly
refrigerants and avoid CFCs as much as possible.
The AC system can be recharged by adding fresh
refrigerant and removing the remaining one.
Care must be taken in the disposal of refrigerants as they
may affect the soil, rivers, etc.,
Its also necessary to check the AC system for leaks as it
may lead to the loss of refrigerant as well as
environmental hazards.