Automotive Systems: Principles and Practice

✍ Scribed by G.K. Awari; V.S. Kumbhar; R.B. Tirpude

• Publisher: CRC Press
• Year: 2021
• Tongue: English
• Leaves: 303
• Category: Library

✦ Synopsis

This book introduces the principles and practices in automotive systems, including modern automotive systems that incorporate the latest trends in the automobile industry. The fifteen chapters present new and innovative methods to master the complexities of the vehicle of the future. Topics like vehicle classification, structure and layouts, engines, transmissions, braking, suspension and steering are illustrated with modern concepts, such as battery-electric, hybrid electric and fuel cell vehicles and vehicle maintenance practices. Each chapter is supported with examples, illustrative figures, multiple-choice questions and review questions. Aimed at senior undergraduate and graduate students in automotive/automobile engineering, mechanical engineering, electronics engineering, this book covers the following: Construction and working details of all modern as well as fundamental automotive systems Complexities of operation and assembly of various parts of automotive systems in a simplified manner Handling of automotive systems and integration of various components for smooth functioning of the vehicle Modern topics such as battery-electric, hybrid electric and fuel cell vehicles Illustrative examples, figures, multiple-choice questions and review questions at the end of each chapter

✦ Table of Contents

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Acknowledgements
Abbreviations
Authors
Chapter 1 Automobile Evaluation and Market Review
1.1 Introduction
1.2 History and Evolution of Vehicles
1.3 Indian Automotive Market
1.4 Global Automotive Market
1.5 Automotive Research Perspectives
1.6 Indian and Global OEMs
1.7 Indian and Global Auto Components Manufacturers
1.7.1 Industry Scenario
1.7.2 Global Automotive Components Manufacturers
Summary
Multiple Choice Questions
Review Questions
Chapter 2 Vehicle Classification, Structure and Layouts
2.1 Introduction
2.2 Classification of Vehicles
2.3 Constructional Details of Vehicle Chassis and Body
2.4 Basic Terminology and Legislative Requirements of a Vehicle as per CMVR and MVA
2.4.1 Lead Dimensions of a Vehicle
2.5 Various Systems of the Vehicle and Their Functions
2.6 Various Types of Chassis Frames: Their Construction and Material
2.7 Various Loads Acting on the Vehicle Chassis Frame, and Its Deformation
2.8 Types of Chassis and Vehicle Layouts, Advantages and Disadvantages
Summary
Multiple-Choice Questions
Review Questions
Chapter 3 Vehicular Engines
3.1 Introduction
3.2 Working Principle and Terminology of the Engine
3.3 Components of the IC Engine and Their Constructional Details
3.3.1 Piston and Rings
3.3.2 Connecting Rod and Bearings
3.3.3 Crankshaft Assembly and Bearings
3.3.4 Cylinder Head and Gasket
3.3.5 Cylinder Block, Crankcase and Head
3.3.6 Crankshaft Assembly and Main Bearings
3.3.7 Crankshaft Torsional Vibration Dampers
3.3.8 Valve Train
3.4 Classification of IC Engines
3.5 Two-Stroke and Four-Stroke Engines
3.6 Comparison of Engines
3.7 Selection of Engine as Per Functional Requirement
3.8 Fuel Supply System for SI Engines: General Layout and Components
3.9 Principles of Carburetion and Fuel Injection in SI Engines
3.10 Types of Carburettors and Their Constructional Details
3.10.1 Multiple and Compound Carburettors
3.10.2 Electronically Controlled Carburettors
3.10.3 Fuel Injection System
3.11 Continuous and Timed Injection System
3.12 Single-Point TBI and MPFI Systems
3.13 Fuel Supply System for CI Engine: General Layout and Components
3.14 TDI and CRDI System
3.15 Types of Fuel Injection Pumps and Their Constructional Details and Testing of Fuel Pumps
3.15.1 Distributor Fuel Injection Pump
3.15.2 Testing of Fuel Injection Pump
3.16 Fuel Injectors and Nozzles
3.17 Electronically Controlled Unit Fuel Injection System
3.18 Injection Timing and Its Importance
3.19 Spray Characteristics
3.20 Principles of Lubrication Systems
3.21 Friction and Wear Mechanics
3.22 Lubricants: Their Composition and Properties
3.23 Wet Sump Lubrication Device
3.24 Dry Sump Lubrication System
3.25 Mist Lubrication System
3.26 Principles of Cooling System
3.27 Liquid Cooling System
3.27.1 Pressurised Water Cooling System
3.27.2 Components of a Water Cooling system
3.28 Air Cooling System
3.29 Current Advancements in Cooling Systems
3.30 Principles of Air Intake and Exhaust
3.31 Air Cleaners and Silencers
3.32 Intake and Exhaust Manifolds
3.32.1 Intake Manifolds
3.32.2 Exhaust Manifolds
3.33 Tailpipe Emissions from Vehicular Engines
3.34 HC, CO, NO , PM Formation Process
3.34.1 Formation of Nitrogen Oxides
3.34.2 HC Emission
3.35 Methodologies Adopted to Reduce Emission
3.36 Current Advancements in Emission Control and Reduction
3.37 Principles of Turbocharging and Supercharging
3.37.1 Naturally Aspirated Engines
3.37.2 Forced Induction
3.38 Types of Superchargers and Their Constructional Details
3.39 Types of Turbochargers and Their Constructional Details
3.40 Engine Electronics and Management System
Summary
Multiple-Choice Questions
Review Questions
Chapter 4 Automotive Clutches
4.1 Introduction
4.2 Necessity and Functions of the Clutch
4.3 Working Principle of the Clutch
4.4 Classification of Clutches
4.5 Requirements of the Clutch
4.6 Torque Transmission Capacity of the Clutch
Number of Friction Surfaces
Surface Area/Size of the Friction Plate (Which Depends on the Mean Radius of the Friction Plate)
Pressure over the Disc
Coefficient of Friction of the Material Used
Elements of the Clutch and Their Construction
4.7 Construction and Working of the Single Plate Clutch
Construction
Diaphragm Clutch
4.8 Construction and Working of the Multi-Plate Clutch
4.9 Construction and Working of the Centrifugal Clutch
Centrifugally Operated Clutches
4.10 Construction and Working of Electromagnetic Clutch
4.11 Operating Mechanism of the Clutch
Mechanically Operated Clutch Linkage
Cable-Operated Clutch
4.12 Operating Mechanism of the Clutch: Hydraulic
4.13 Design Aspects of the Automotive Clutch
Summary
Multiple-Choice Questions
Review Questions
Chapter 5 Manual Transmission and Transaxles
5.1 Introduction
5.2 Various Types of Resistances
5.3 Motive Power, Traction and Tractive Efforts
5.4 Necessity of the Gear Box
5.5 Calculation of Gear Ratios
5.6 Construction and Working of the Constant Mesh Gear Box
5.7 Construction and Working of the Sliding Mesh Gear Box
5.8 Construction and Working of the Synchromesh Gear Box
5.9 Overdrive
5.10 Transfer Box Construction and Working
5.11 Heavy Vehicle Gear Boxes
5.11.1 Splitter Drive Gear Boxes
5.11.2 Range Change Gear Boxes
5.12 Gear Shifting Mechanisms
5.13 Gear Box Lubrication and Sealing
5.14 Transaxle Construction and Working
Summary
Multiple-Choice Questions
Review Questions
Chapter 6 Semiautomatic and Automatic Transmission
6.1 Introduction
6.2 Fluid Flywheel
6.2.1 Limitations
6.3 Torque Convertor
6.4 Planetary Gear Box
6.5 Continuous Variable Transmission System
6.6 Automatic Transmission System for Passenger Cars
6.7 Automatic Transaxles
6.8 Automatic Transmission System for Heavy Vehicles
6.9 Hydraulic Control System
6.10 Electrohydraulic Control System
6.11 Automated Manual Transmission System
Summary
Multiple-Choice Questions
Review Questions
Chapter 7 Propeller Shaft, Differential and Rear Axles
7.1 Introduction
7.2 Driveline Arrangements
7.2.1 Hotchkiss Drive
7.2.2 Torque Tube Drive
7.3 Propeller Shaft
7.4 Universal Joint
7.5 Slip Joint
7.6 Constant Velocity Joints
7.7 Final Drive Gears and Bearings
7.7.1 Bearings
7.8 Differential
7.8.1 Limited Slip Differential
7.9 Rear Axle Construction
7.10 Types of Rear Axles
7.11 Various Types of Loads Acting on the Rear Axles
7.12 Tandem Axle Drive for Heavy Vehicles
Summary
Multiple-Choice Questions
Review Questions
Chapter 8 Suspension System
8.1 Introduction
8.2 Basic Ride Considerations of the Vehicle
8.3 Functions of the Suspension System
8.4 Classification of the Suspension System
8.5 Independent Suspension System
8.6 Dependent Suspension Systems
8.6.1 Advantages of Axle Beam Suspension
8.6.2 Disadvantages of Axle Beam Suspension
8.7 Air Suspension
8.8 Rubber Suspensions
8.9 Types of Springs Used in the Suspension System
8.9.1 Leaf Springs
8.9.1.1 Benefits of Leaf Springs
8.9.2 Coil Springs
8.10 Dampers
8.11 Adaptive Suspension System
8.11.1 Soft Mode
8.11.2 Firm Mode
Summary
Multiple-Choice Questions
Review Questions
Chapter 9 Braking Systems
9.1 Introduction
9.2 Classification of Brakes
9.3 Drum Brakes and Disc Brakes
9.3.1 Leading and Trailing
9.3.2 Twin Leading Shoes
9.3.3 Duel Servo
9.3.4 Advantages of Drum Brakes
9.3.5 Disadvantage of Drum Brakes
9.3.6 Disc Brakes
9.4 Hydraulic Braking System Construction and Working
9.5 Air Brakes
9.5.1 System Actuation
9.6 Antilock Braking Systems
9.6.1 Wheel Speed Sensors
9.6.2 Operation
9.6.2.1 Normal Braking Condition
9.6.2.2 Pressure Holding
9.6.2.3 Pressure Reducing
9.6.2.4 Pressure Increasing
9.7 Parking Brakes
Summary
Multiple-Choice Questions
Review Questions
Chapter 10 Vehicle Body Engineering
10.1 Introduction
10.2 Functions of the Vehicle Body
10.3 Requirements of the Vehicle Body
10.4 Classification of Vehicle Body
10.5 Car Body Construction
10.5.1 Passenger Vehicles
10.5.2 Under Body Section
10.5.3 Body Side Assemblies
10.5.4 Shroud and Dash Panel Assembly
10.5.5 Roof
10.5.6 Back Window Aperture Panel
10.5.7 Rear End Assembly
10.5.8 Frontend Assembly
10.5.9 Front Wings
10.5.10 Front Door Panel Assembly
10.5.11 Bonnet Panel Assembly
10.6 Bus Body Construction
10.7 Body Mounting
10.7.1 U Bolts
10.7.2 Balata Packing
10.8 Body Materials
10.9 Various Loads Acting on the Vehicle Body and Their Analysis
10.9.1 Symmetric Vertical Load
10.9.2 Asymmetric Vertical Load
10.9.3 Longitudinal Loads
10.9.4 Side Loads
10.10 Anthropometric and Ergonomic Considerations
10.11 Upcoming Trends in Vehicle Body Manufacturing
Summary
Multiple-Choice Questions
Review Questions
Chapter 11 Front Axle and Steering Systems
11.1 Introduction
11.2 Functions of the Front Axle
11.3 Constructional Details of the Front Axle
11.4 Requirements of Steering
11.5 Principle of Correct Steering
11.6 Ackerman’s Steering Gear Mechanism
11.7 Steering Linkage Arrangements
11.8 Axle Beam Suspension Steering System Layout
11.9 Independent Suspension Steering System Layout
11.10 Steering Gear Boxes
11.11 Power-Assisted Steering
11.11.1 Introduction
11.11.2 The Need for Power-Assisted Steering
11.11.3 Hydraulic Power-Assisted Steering
11.11.4 Features of the Power-Assisted Steering System
11.11.5 Hydraulic Power-Assisted Steering Components
11.11.6 Speed-Sensitive Hydraulic Power-Assisted Steering
11.11.7 Electrohydraulic Power-Assisted Steering
11.11.8 Electrical Power-Assisted Steering
11.11.9 Electrical Power-Assisted Steering Components
11.11.9.1 Electrical Motor
11.11.9.2 Actuating System
11.11.9.3 Steering Input Sensors
11.11.9.4 Electronic Control Unit
11.11.9.5 Types of Electrical Power-Assisted Steering
Summary
Multiple-Choice Questions
Review Questions
Chapter 12 Wheels and Tyres
12.1 Introduction
12.2 Requirements of the Wheel
12.3 Classification of Wheels
12.4 Construction of Wired and Pressed Disc Wheels
12.5 Types of Rims and Their Constructional Details
12.5.1 Rim Designs
12.5.2 Well-Base Rims
12.5.3 5° Seat-Angle Well-Base Rim
12.5.4 Drop-Centre 15° Taper Rim
12.5.5 Detachable-Rim Wheels
12.5.6 Semi-Drop-Centre Two-Piece Rim
12.5.7 Wide-Base Two-Piece Rim
12.5.8 Wide-Base Three-Piece Rim
12.5.9 Divided Flat-Base Rim
12.6 Wheel Alignment and Balancing
12.6.1 Wheel Alignment
12.6.2 Wheel Balancing
12.7 Tyre Characteristics
12.7.1 Tyre
12.7.2 Tyre Properties
12.7.2.1 Non-Skidding
12.7.2.2 Uniform Wear
12.7.2.3 Load-Carrying Capacity
12.7.2.4 Cushioning
12.7.2.5 Tyre Noise
12.7.2.6 Balance
12.8 Cornering Properties of the Tyre
12.8.1 Static Load and Standard Wheel Height
12.8.2 Contact Patch
12.8.3 Cornering Force
12.8.4 Slip Angle
12.8.5 Pneumatic Trail and Self-Aligning Torque
12.8.6 Camber Thrust
12.9 Requirements of Tyres
12.10 Classification of Tyres
12.10.1 Tubed Tyres
12.10.2 Tubeless Tyre
12.10.3 Cross Ply Type
12.10.4 Radial Ply Type
12.10.5 Belted Bias Type
12.11 Tyre Construction
12.12 Tyre Treads
12.12.1 Symmetrical Tread Pattern
12.12.2 Asymmetrical Tread Pattern
12.12.3 Directional (Unidirectional) Tread Pattern
12.12.4 Asymmetrical and Vertical Tread Patterns
12.12.5 Non-directional Tread Patterns
12.13 Tyre Size and Designations
12.14 Factors Affecting Tyre Life
12.14.1 Selection of Correct Tyre and Its Installation
12.14.2 Tyre Pressure
12.14.3 Loading Capacity
12.14.4 Wheel Alignment
12.14.5 Car Speed
12.14.6 Tyre Temperature
12.14.7 Chassis Status
12.14.8 Road Conditions
12.14.9 Seasonal Factors
12.14.10 Driving Habits
12.14.11 Vehicle and Tyre Maintenance
12.15 Tyre Material
12.16 Tyre Re-treading
Summary
Multiple-Choice Questions
Review Questions
Chapter 13 Vehicle Aerodynamics
13.1 Introduction
13.2 Air Flow Fundamentals
13.3 Drag Forces
13.4 Lift Forces
13.5 Aerodynamic Stability
13.6 Car Body Drag Reduction
13.7 Aerodynamic Lift Control
13.8 Wind Tunnel
13.8.1 Open Loop
13.8.2 Closed Loop
13.9 Aerodynamics of Commercial Vehicles
13.10 Aerodynamics in Two-Wheelers
Summary
Multiple-Choice Questions
Review Questions
Chapter 14 Battery Electric, Hybrid Electric, and Fuel Cell Vehicles
14.1 Introduction
14.2 General Layout of a Battery Electric Vehicle
14.3 Basic Systems of Battery Electric Vehicles
14.4 General Layout of Hybrid Electric Vehicles
14.5 Basic Systems of HEVs
14.6 Operation and Types of Fuel Cell Vehicles
14.6.1 Polymer Electrolyte Membrane Fuel Cells (PEMFCS)
14.6.2 Direct Methanol Fuel Cells (DMFCs)
14.6.3 Alkaline Fuel Cells (AFCs)
14.6.4 Phosphoric Acid Fuel Cells (PAFCs)
14.6.5 Molten Carbonate Fuel Cells (MCFCs)
14.6.6 Solid Oxide Fuel Cells (SOFCs)
14.7 General Layout of Fuel Cell Vehicles
14.8 Characteristics of BEVs, HEVs and FCVs
14.9 Current Advancements in BEV, HEV and FCV Technology
Summary
Multiple-Choice Questions
Review Questions
Chapter 15 Vehicle Maintenance Practices
15.1 Introduction
15.2 Necessity of Maintenance
15.3 Types of Maintenance
15.3.1 Preventive Maintenance
15.3.1.1 Scheduled Preventive Maintenance
15.3.1.2 Condition-Based Preventive Maintenance
15.3.1.3 Predictive Maintenance
15.3.1.4 Proactive Maintenance
15.3.2 Breakdown Maintenance
15.4 Procedure and Methodologies Adopted
15.5 Maintenance Documentation
15.6 Advanced Techniques and Tools Used
15.6.1 Modern Tools Used
15.6.1.1 On-Board Diagnostics
15.6.1.2 Handheld
15.6.1.3 PC/Laptop with Scan Tool
15.6.1.4 Mobile Device (Phone or Tablet) Application
15.7 Recent Trends in Routine Maintenance
Summary
Multiple-Choice Questions
Review Questions
Bibliography
Index