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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 fr rom Smith (2002)

Czech Tatra 1937 Lincoln continental 1960s Ford S Sierra 1980s Lotus Eclat

Aim ms
Introduce the wide range of skills required for I d h id f kill i df vehicle design and manu ufacture. Briefly set the historical scene and development of l vehicles and their design gn. Introduce the vast range of possibilities for vehicle e design. design Demonstrate the interactivity of processes within the d i th design and manufact d f t ture of vehicles f hi l

Steps in Autom mobile History


Innovations and Inventi I i dI tions Mass production p Development of World Motor Industry d Streamlining S li i Commercial vehicles

History

Construction

Inventions and Innovations


Steam power to I S Internal Combustion engine al C b i i
Steam engine used till late 1940s l Petroleum spirit use by Dr. OTTO in 1870s was ed a useless by-product o naptha used for lamps of Dr. Gottelib Daimler i improved OTTO engine using petroleum vapour and in parallel Karl Benz also d produced tri-wheel car rriage in 1885

History

Construction

Mass pro oduction


Cars C were d l d fr developed f from h horse carriages. i Henry Ford -> mass p y production of Model T,1909
Concept from rifle ma anufacture of civil war Model T first car with design for manufacture h Engine E i 2898 cc was b ilt by ford and various built b f d d i independent bodybuil lders from buses to elegent family cars Hand-built cars to inte erchangeable parts
Picture taken from Smith (2002)

History

Construction

Mass Pro oduction


Moving M i workers -> m i vehicle during k moving hi l d i maufacture , Highland park Detroit, 1913 d

Picture taken from Smith (2002)

History

Construction

Mass Pro oduction


In 1970 Volkswagen I 1970s, V lk Beetle B l was sold in large ld i l numbers though syle wa antiquated as it was as
Non rusting car Mechanically reliab y ble

Toyota's contribution:
Production P d ti was flexibl fl xible Quality paramount, getting right first time - LEAN Shorter production runs, wide variants

History

Development of World Motor In ndustry

Construction

1920s 1930 1920 -1930s : small coa h b ild co-exist with ll ach builders i ih large companies By end of second world war only few specialized d manufacturers remain Rolls Royce y Large conglomerates lik British Motor ke Corporation (BMC) , Br ritish Leyland (BL) faced problem of large stock Americans and J A i d Japanese moved parts of operations e d t f ti around the world
Because of export restric ctions and to use facilities all over the world

History

Development of World Motor In ndustry

Construction

Construction Developmen C i D l nt: Till 1930s wooden fram with fabric or wood skin me used to build coaches Late 1930s onwards pre onwards, essed steel plates for skin Multiple curvature adde more strength and body ed panels shared the load l h d th l d Recent cars have shell structure with aerodynamic y structures

History

Development of World Motor In ndustry

Construction

Wooden S l h i frame was done away and W d / Steel chassis f d d 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 less weight and corrosion ser free body started after WWII ( Lotus) r Wheels progressed from wooden spokes to metal m spokes t metal hub con t ti to metal spokes ( k to t l h b nstruction t t l 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

Development of World Motor In ndustry

Construction

Styling D l S li Development: Powered versions of hor carriages rse g Engine was placed below vehicle by Daimler w hard maintenence 1890s, Panhard-Levasso created the concept of or having h i engine in front with clutch and gear box i i f t with l t h d b systme Panhard Windscreen was invente in 1920s with increasing ed speed of vehicle

History

Development of World Motor In ndustry

Construction

By h 1930 B the 1930s, excessivel elongated engine covers i ely l d i had become de rigeur for powerful cars with sporting aspirations. ti i ti Luggage was strapped in rear of vehicle and it gg g pp n became integral in europ pean cars. It grew in '50s,'60s and '70s to larg volume ger Till '50s open top was preferred as inspired from s horse carriages

History

Construction

Stream mlining
In 1890 Amde Boll h I 1890s, A d B ll the younger produced e d d first torpedo shaped designs with raked windscreen Americans did not like t air-streamlined design the

Czech Tatra of 1937 V8


Pictures taken from Smith (2002)

Chevrolet Air-flow

History

Construction

Stream mlining
Aerodynamics was cons sidered impediment to styles due to angles Box type was more cheap and easier to p yp aper produce Became more popular on after the 70s when oil nly prices went up & fuel ec conomy was considered important
Ford Sierra 1980

Picture taken from Smith (2002)

History

Construction

Commercia Vehicles al
End f E d of 19th century, fi t l first lorry and trucks were d k steam powered challen nged by petrol vehicles Threats of world wars le to increase in roads, ed commerical vehicle sale and haulage in Europe es g p IC engine led to the dev velopment of motor bus. Autobahns i 1930 G rmany l d to development A t b h in 1930s Ger led t d l t of good road transport a along with railways. Buses replaced electric t trams, challeged railways in USA, Britain.

Construction Co onfiguration and Styl ling


Engine D l E i Development Transmission and Syst Layout y tem y Steering Suspension S i Brakes Interior Design Safety S f Too much Innovation

History

Construction

Engine Dev velopment


Diamler d B Di l and Benz inven d IC engine automobiles i nted i bil in 1895 Diamler developed Vee twin engines in 1898 Ettore Bugatti 1910 crea first engine with Bugatti,1910 ated Overhead Cam shaft in M Model13, capable of achieving 100 kmph spe with 1327 cc. eed cc Side valves were more p preferred till WWII Improvements in materi led to other ials developments.

History

Construction

Engine Dev velopment


Diesel Engine: Main competitor to petrol engine spontaneous combustion unlike petro ignition ol It eliminated two weak p points carburettor and spark plugs hence more reliab ble It had inferior power to weight ratio, hence p g , restricted to heavy engin nes With turbo-charging and refinement, performance turbo charging d refinement at par with petrol engine with cleaner emissions es and higher efficiency efficiency.

History

Construction

Engine Dev velopment


Super charging and T bocharging: S h i d Turbo h i When air is compressed at inlet, power to weight p d ,p g ratio of engine improved d Compressors combined to engine shaft Used from 1930s in raci cars ing Compression with powe from exhaust using er turbine is turbocharging g g Turbochargers improve torque characteristics and smoother engine running g

History

Construction

Engine Dev velopment


Two S k T Strokes and U d Unconve i l petrol engines: entional l i Two stroke (2S) has one firing stroke p ( ) e g per revolution, theoretically twice efficiency y 2S in unsupercharged al lways has fuel-charge loss during scavenging Intake I t k needs to be mixed with lubricating oil d t b i d ith l b i ti il resulting in smoky exha aust Applications restricted t motor-cycles and small to cars like three cylinder S SAAB car.

History

Construction

Engine Dev velopment


Two T stroke diesel i still preferred in large marine k di l is ill l f di l i and railway engines Wankel engine had a sem mi-rotary than a reciprocating type of engine p g yp g It had a problem with se of rotor and inherent eals two stroke two-stroke emissions Gas turbines had good e efficiency and thrust to weight ratio but not effici t in low speeds. i ht ti b t t fficient i l d

History

Construction

Engine Dev velopment


Electric d H b id El i and Hybrid propul i ulsion: 1899, Jenatzy's La Jam Contente was first , y mais vehicle to cross 100kmp ph Initial cars restricted to short distances but has in considerably increased i recent times Improvements in Lead-A id b tt I t i L d A battery technology Acid t h l allowed increased range and even buses to operate e in U b i Urban areas on electri power to reduce smog. l tric t d

History

Construction

Engine Dev velopment


Limitations in battery led to hybrid vehicles of Li i i i b led h b id hi l f present day
Ultracapacitors or fl lywheel used Smaller petrol engin is used p g ne Regenerative brakin ng

*Not same as petrol-elec petrol elec ctric vehicle in past with pure electric operation f step-less operation for

History

Transmissi ion System Develo opment


Non-availabilityof f power at the start full Noisy operation y p Non -instant stop r restart

Construction

Some of the d b k of petrol engines over S f h drawbacks f l i steam engines were

Clutches have evolved f from belts and settled pre predominantly with plate cl lutch. Gear box G b evolved from shifting gears to constant l df hif i mesh with moving dog c clutches crash gear box.

History

Transmissi ion System Develo opment

Construction

F.W. Lanchester and Bri i h Daimler created FW L h d British D i l d epicyclic gear box with bands and planetary rings Epicyclic gears used in f ford model T , used in buses for ease of operati p ion In 1940's, preselector gearbox was developed with fluid torque conver becoming a Constant rter Variable Transmission s system (automatic) Earlier t E li automatics had p ti h d poor efficiency ffi i

History

Construction

Lanchester Gear box

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

History

Construction

Pre-selecto Pre selecto gearbox or

Wilsons Gearb box

Pictures taken from S Steeds and Garrett (1983)

History

Construction

Model T g gear 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 Converter e

Pictures taken from St teeds and Garrett (1983)

History

Transmissi ion System Develo opment

Construction

Ferdinand F di d porsche had f h h d fi patent in 1908 f a first i for electric transmission sys stem (890299) first step towards CVT t d Semi-stepless was achie p eved using fluid-torque g q converters in 1940's DAF variomatic type CV were used in dutch VT DAF cars (1959-63)

History

Construction

Porsche transmission ansmission a

Picture taken from the patent document 890299

History

Construction

DAF var riomatic

Double pulleys

http://www.philseed.com/daf-600.html

History

Construction

Stee ering
Earlier E li cars borrowed axl similar to horse b d xles i il h carriages with unstable p pivoting axles as horse is not present to stabilize t vehicle t t t t bili th the hi l Ackerman's arrangemen of pivoting wheels about g nt p g individual axes allowed rotation at varied angles / speed during turn Tiller was replaced with steering and linkages and h major development cam after power steering. me Four wheel steering is n available but restricted now to a few models

History

Construction

Ackerman Linkage nn

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 from Smith (2002) ken

History

Construction

Suspe ension
Elliptic i Elli i springs adopted f d d from carts problems bl during braking and start ting -need to be restricted Springing developed by torsion bars and further by y p pneumatic variable heig suspensions ght g p Independent wheel susp pensions developed Simple il i Si l coil springs were used f f t suspension e d for front i alone and then used in rear also Active suspensions have vehicle lifted by power e jacks controlled electron nically

History

Construction

Elliptic S Springs

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

Torsion bar on o

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

Pict ture taken from Reimpell et al., (2001)

History

Construction

Suspe ension
Independently moving wheels improved road-grip I d d l i h l i d d i Independent suspensio became popular by 90s. p p ons p p y

Jaguar 3.4 was with independent suspension in '55

Pictures tak from Smith (2002) ken

History

Construction

Suspe ension
Wheels d Ti Wh l and Tires: Wooden spoked wheel w metal outer was p with unsuitable for higher spe eed 1895, 1895 Michelin brothers fitted Dunlop tires on s peugeot cars for racing a it started and Pneumatic tires had prob P ti ti h d blems of puncture bl b f t Large tires were good fo poth-rudded roads, with g g or p roads improving size is reached to standard size.

History

Construction

Suspe ension
Smaller i i S ll tires improved rid and suspension d ride d i dynamics Wider tires had better ro grip oad Tubeless tires were intro oduced after WWII Radial ply was introduced Low profile tires rat of outer to inner tio diameter increased

History

Construction

Tubeles tires ss
Introduced i 1947 by I d d in 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

Tires res r

Pictures taken from Steeds and Garrett (1983)

History

Construction

Radial Tires l
Since there is no cross ply, Si h i l lesser heat generated hence more life 4 to 6 bracing plies of metal /rayon provides better contact grip and stability against deformation in higher g g speeds g Stiffer in resisting lateral loading hence reduces under/over steer.
Pictures taken from Steeds and Garrett (1983)

History

Construction

Low prof Tires file


Wider tires for same diameter Wid i f 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
Horse carriages were essentially stopped by horses H i i ll db h Drum brakes with pair o internal shoes emerged as p of g dominant Until 1920s brakes only in rear wheels y With drum brake proble of fading due to em overheat, emerged disc b k i 1952. h t d di brakes in 1952 Disc brakes were used in front wheels and not in n rear brakes as they requi ired mounting of parking drum brakes

History

Construction

Brakes
Brakes B k operated b mech i l rods and cables d by chanical d d bl required skilled adjustm or cars would swing ment 1930s hydraulic power a assisted brakes introduced 1960s, 1960s Dual hydraulic c circuit introduced to overcome leaks Heavy vehicles required servo arrangement H hi l i d t Vacuum assist Anti Lock Braking intro oduced from aircrafts. British Jensen FF,1960 w first passenger car to was have it.

History

Construction

Dual hydrau braking ulic


Dual master cylinder D l 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 braking sist

Bendix Hydrovac

Pictures taken from Steeds and Garrett (1983)

History

Construction

Anti-Lock Anti Lock Braking k

Ford Escort and Orion Anti-lock Braking System


Pictures taken from Steeds and Garrett (1983)

History

Construction

Interior Design
Modern f il cars not superior to high M d family i hi h performance cars of 193 30s. Essential dynamic analy and design to improve ysis q quieteness
Direct belt between en ngine and cooling fan replaced by intermediate electr y rical Vibration isolation Mathematical analysis of the design s

Air conditioning, power windows, windows r demisting added. added

History

Construction

Safety Design
Invention of motor cars produced more deaths than I i f d d d h h any other invention.
No. of civilian deaths per month in USA during WWII greater than de eaths due to war

1930s unitary Chevrolet airflow body construction was more r resistant 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 h d steerin columns like spears to P had ing l lik the heart of drivers in ca of frontal impact ase Collapsible steering intr roduced by 1960s Seat belts appeared arou 1950s for front seat und occupants and slowly sp pread to rear Airbags came later Ai b l t Vehicle is now designed with energy absorbers in g d gy front, rear and sides.

History

Construction

?? Too much Innovation ??


Innovation not always a k to fi I i l key financial sucess i l
Alec Issigoniss revol lutionary Mini with rubber bush suspension was famou but not with advanced hydrous elastic systems Wankel engine

Important to choose win p nners at right time g


Disc brakes Power Steering

Further R Reading
Julian-Happian Smith (2002), An I t d ti t M d J li H i S ith (2002), A Introduction to Modern Vehicle Design,Butterworth-H Heinmann (ISBN 0-7506-5044-3) Newton, K., Steeds, W. d Garrett, T.K. (1983), Th M t N t K St d W and G tt T K (1983) The Motor Vehicle (10th edn). Butterwor (ISBN 0-408-01118-1 (hard rths cover) and 0-408-01157-2 (so cover)). ) ( oft )) Jrnsen Reimpell et al (2001) The Automotive chassis ), (Second edition), Butterworth Heinman (ISBN 0-7506-5054-0) h

History

Construction

Vee-T Vee T Twin


Blumfield V twin engine 1913 14 1913-14 with O Overhead 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

Pictures taken from S Steeds and Garrett (1983)

History

Construction

Side Valve Engines e

Pictures taken from S Steeds and Garrett (1983)

History

Construction

Side Valv Engine ve

Biefield Diesel engine of 1930s Biefield


http://shopswarf.orconh hosting.net.nz/svdiesel.html

History

Construction

Plate c clutch

http://gtmotorsports.com http://www.novakadapt.com/knowledge/clutches_etc.htm

History

Construction

Plate C Clutch

Pic ctures taken from The Motor Vehicle Newton Steeds

History

Construction

Gear box r

Sliding mesh -> moving gears > Dog clutch


Pictures taken from S Steeds and Garrett (1983)

History

Construction

Gear box Co onstant mesh

Pictures taken from Stee and Garrett (1983) eds

History

Construction

Gearbox - Sy ynchromesh
Synchromesh S h h have synchronizers synchronizers for smoother gear shifting

Pictures taken from S Steeds and Garrett (1983)

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