An Introduction to Automobiles

Benz tricycle 1896

Stanley Steam car 1905

London B type bus - 1910

Railton 1935

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 manu ufacture. 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 vehicle hi 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

Development of World Motor In ndustry

Construction

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 lik ke 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

C Construction i Developmen D l nt:

Till 1930s wooden fram me 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

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

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

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 Pictures taken from Smith (2002)

Chevrolet Air-flow

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 Europe p IC engine led to the dev velopment of motor bus. Autobahns A t b h in i 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 nted d 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 dU Unconveentional 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 needs d to t be b mixed i d with ith lubricating l b i ti oil il resulting in smoky exhaaust Applications restricted to t motor-cycles and small cars like three cylinder SAAB S car.

History

Construction


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 sem mi-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 Jam mais Contente” was first vehicle to cross 100kmp ph Initial cars restricted to short distances but has i recent times considerably increased in IImprovements t 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 to t reduce d smog.

History

Construction


Limitations Li i i in i battery b le led d 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

Transmissiion System Develo opment

Construction

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 predominantly 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

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

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 than others vehicles can be controlled longer

http://www.indiacar.com/infobank/tlt_const.htm

History

Construction

Tirres res


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 rods d 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


History

Construction

Vacuum Ass sist braking

Bendix Hydrovac


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 sp pread 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 hydroelastic 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 dG Garrett, 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_Vtwin_motorcycle_engine.jpg

Mercedes Benz V6, 199 96

History

Construction

Overhead Cam Shaft


History

Construction

Side Valve e Engines


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.novakadapt.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
