ABSTRACT
Now a day, machines are widely controlled by
embedded system. To meet the need of exploding population economic and
effective control of machines is necessary. In our project we bought all the
parts and assembled it in our laboratory so we gained knowledge on the
transmission system and we as mechanical engineer gained hands on experience in
assembling the three wheeler auto rickshaw. A differential is a gear train with
three shafts that has the property that the angular velocity of one shaft is
the average of the angular velocities of the others, or a fixed multiple of
that average. Power at the rear wheels move the vehicle forward overcoming
external forces. Differential rod is located between the engine and wheel. It
is also known as yoke rod.Its is used to convert axle of rotation. In
Three-wheeler,two yoke rod is used. When the yoke or CV joint is in the
disengaged position, the power transfer is interrupted. Such power interruption
will enable shifting of gears smoothly without damaging gear teeth. Gearbox
provides different torque at the rear wheel according to the requirements by
engaging different gear combination.
SAFETY PRECAUTIONS
We should
wear proper uniform and shoes.
We should handle all tools and parts carefully.
Keep a fire extinguisher near your work space.
Donot
allow children near the auto while working on it.
Never trust a jack rather buy
some sturdy stands and use them whenever you need to cravel underneath your auto
.
Never leave tools on the battery, where they might
shorhe terminals the and create spark.
To avoid
damaged tools on workplaces.
Keep
loose clothing and long hair from moving parts.
Always wear eye protection while
operating any machine. Do not run the engine for long in an enclosed space.
Machines should be cleaned after use Do not keep
the petrol tank open.
INTRODUCTION
A differential
is a device, usually but not necessarily employing gears, capable of
transmitting torque and rotation through three shafts, almost always used in one of two
ways: in one way, it receives one input and provides two outputs--this is found
in most automobiles--and in the other way, it combines two inputs to create an
output that is the sum, difference, or average, of the inputs.Inautomobilesand
other wheeled vehicles, the differential allows each of the driving roadwheelsto rotate at different speeds, while for most vehicles supplying equal
torque to each of themThe mention of three wheelers in India bring forth such
similar images. the rickshaw look that has been greatly embedded on our
minds.The very mention of the project as a three wheeler design made people
think that I am doing something on the auto rickshaw platform.Very soon I
realized that I will have to have a form that will have to destroy such
image.Automobile engineering is the one of the stream of mechanical
engineering. It deals with the various types of automobiles, their mechanism of
transmission systems and its applications. Automobiles are the different types
of vehicles used for transportation of passengers, goods, etc. Basically all
the types of vehicles works on the principle of internal combustion processes
or some times the engines are called as internal combustion engines. Different
types of fuels are burnt inside the cylinder at higher temperature to get the
transmission motion in the vehicles. Most of the automobiles are internal combustion
engines vehicles only. Therefore, every mechanical and automobile engineer
should have the knowledge of automobile engineering its mechanism and its
various applications.
LITERATURE REVIEW
There are many
claims to the invention of the differential gear but it is likely that it was
known, at least in some places, in ancient times. Some historical milestones of
the differential include:
Ø 1050 BC–771 BC:
The Book of Song(which itself was written
between 502 and 557 A.D.) makes the assertion that the South Pointing Chariot, which uses a differential
gear, was invented during the Western Zhou Dynasty in China.
Ø 227 – 239 AD – Despite
doubts from fellow ministers at court, Ma Jun from
the Kingdom of Wei in China invents
the first historically verifiable South Pointing Chariot, which provided
cardinaldirection as a non-magnetic, mechanized compass.
Ø 658, 666 AD – two Chinese
Buddhist monks and engineers create South Pointing Chariots for Emperor Tenjiof Japan.
Ø 1027, 1107 AD – Documented
Chinese reproductions of the South Pointing Chariot by Yan Su and then Wu
Deren, which described in detail the mechanical functions and gear ratios of
the device much more so than earlier Chinese records.
Ø 1720 – Joseph Williamson
uses a differential gear in a clock.
Ø 1810 – Rudolph Ackermann of Germany invents a four-wheel steering system
for carriages, which some later writers mistakenly report as a differential.
Ø 1827 – modern automotive
differential patented by watchmaker OnésiphorePecqueur(1792–1852) of the Conservatoire
des Arts et MétiersinFrance for use
on a steam cart. (Sources: Britannica Online and [1])
Ø 1832 – Richard Roberts of England patents 'gear of compensation', a
differential for road locomotives.
Ø 1876 – James Starleyof Coventry invents chain-drive differential for use on
bicycles; invention later used on automobiles by Karl Benz.
Ø 1926 – Packard introduces
the hypoid differential, which enables the propeller shaft
and its hump in the interior of the car to be lowered.
2
Ø 1958 – Vernon Gleasmanpatents the Torsendual-drive differential, a type of limited slip differential that relies solely on the action of gearing
instead of a combination of clutches and gears.
DIFFERENTIAL WORKS:
3.1Ring Gear:
Transfers
power to the differential case assembly.
3.1.1Side/spider gears:
Help both
wheels to turn independently when turning.
3.1.2Differential case assembly:
Holds the ring gear and other
components that drive the rear axle.
3.2Gear box
Ø A gear is a toothed wheel designed to transmit the force to another gear
or toothed component. The teeth of a gear is known as cogs. They are shaped to
minimize wear, vibration and noise and at the same time maximize the efficiency
of power transmission.
Ø Gears of different size, the larger one is called a wheel and the
smaller one is called a pinion, are used in pairs so that the force of the
driving gear can produce a larger force in the driven gear, that also at a
lower speed or it can be for the purpose of producing a smaller force at a
higher speed.
DESIGN AND FABRICATION
4.1 INTRODUCTION
A differential is a gear train with three shafts that has the property
that the angular velocity of one shaft is the average of the angular velocities
of the others, or a fixed multiple of that average., it helps to havethe
knowledge of differentcomponentsand its working.
4.2 SELECTION OF AUTO RICKSHAW
In India the Ape is
most commonly found in the form of an auto rickshaw. A relatively small number
of Apes is still made in Italy. On October 16, 2013, Piaggio announced that the
production of Ape would be completely shut down in Italy and entirely moved to
India.
5
SL
|
COMPONENTS
|
QUANTITY
|
1
|
4 stroke engine
|
1
|
2
|
Transmission shaft
|
1
|
3
|
Yoke rod & coupling
|
2
|
4
|
Clutch plate
|
1
|
5
|
Petrol tank
|
1
|
6
|
Gear box setup
|
1
|
7
|
Brake wires
|
2
|
8
|
Clutch wires
|
2
|
9
|
Bolts & Nuts
|
1 box
|
10
|
Starting lever
|
1
|
Table 4.1MATERIAL REQUIRED FOR THREE WHEELER AUTO
4.5Technical specification of Auto Rickshaw
Bajaj
Auto Rickshaw
This type of auto rickshaw is in great use for commercial
transportation. Specially designed for better performance the vehicle is
entitled with durability, good looks and fuel efficiency.
4.5.1Technical specifications:
Engine
Type 2 Stroke
Cooling Type Forced Air Cooled
Displacement 145.45 cc
Max Power 7 bhp(
5.15 kW) @ 5000 rpm
Max Torque 12.1 Nm @
3500 rpm
Ignition Type CDI
Transmission Type 4 forward and one reverse
Clutch Type Wet
multidisc type
Electrical System
System 12V AC +
DC
Head Light 35/35W
Horn 12 V AC
8
Chassis
Chassis Type Monocoque
Maximum Payload 333 kg
Suspension
Front Helical spring and hydraulic shockabsorber with antidive
Suspension link
Rear Independent
suspension with spring and hydraulic shock
Suspension Absorber
Tyres
Front
Tyre Size 4.00-8,
4PR
Rear Tyre
Size 4.00-8,
4PR 2 Nos.
Brakes
Front Brakes Drum
Hydraulic
Rear Brakes Drum
Hydraulic
9
FUNCTIONAL DISCRIPTION
The following description of a differential applies
to a "traditional" rear-wheel-drive car or truck with an
"open" or limited slip differential.Torqueis supplied from the
engine, via the transmission, to a driveshaft (British term: 'propeller shaft', commonly and
informally abbreviated to 'prop-shaft'), which runs to the final drive
unit and contains the differential. A spiral bevel
pinion gear takes its drive from the end
of the propeller shaft, and is encased within the housing of the final drive
unit. This meshes with the large spiral bevel ring gear, known as the crown wheel.
5.1Loss of traction
– the rotational force which propels the vehicle.
The amount of torque required to propel the vehicle at any given moment depends
on the load at that instant – how heavy the vehicle is, how much drag and
friction there is, the gradient of the road, the vehicle's momentum, and so on.
For the purpose of this article, we will refer to this amount of torque as the
"threshold torque"
5.2Epicyclic differential
An epicyclic differential uses epicyclic
gearing to split and apportion torque asymmetrically between the front and rear axles. An epicyclic
differential is at the heart of the Toyota Prius automotive drive train, where it interconnects the engine,
motor-generators, and the drive wheels (which have a second differential for
splitting torque as usual). It has the advantage of being relatively compact
along the length of its axis (that is, the sun gear shaft)
10
This is another type of differential that was used
in some early automobiles, more recently the Oldsmobile
Toronado, as well as other non-automotive
applications. It consists of spur gears only.A spur-gear differential has two equal-sized spur gears, one for
each half-shaft, with a space between them. Instead of the Bevel gear, also known as a miter gear, assembly (the "spider") at the
centre of the differential, there is a rotating carrier on the same axis as the
two shafts. Torque from a prime mover or transmission, such as the drive shaft of a car, rotates this carrier.Mounted in this
carrier are one or more pairs of identical pinions, generally longer than their
diameters, and typically smaller than the spur gears on the individual
half-shafts. Each pinion pair rotates freely on pins supported by the carrier.
Furthermore, the pinions pairs are displaced axially, such that they mesh only
for the part of their length between the two spur gears, and rotate in opposite
directions.
5.4Non-automotive applications
A differential gear train can
also be used to allow a difference between two input axles. Mills often used
such gears to apply torque in the required axis. It's also used in fine
mechanical watches with a hand to show the amount of reserve power in the
mainspring.The oldest known example of a differential was once thought to be in
the Antikythera
mechanism. It was supposed to have used such
a train to produce the difference between two inputs, one input related to the
position of the sun on the zodiac, and the other input related to the position of the moon on the zodiac; the output of the differential gave a quantity related to
the moon's phase. It has now been proven that the assumption of the existence of a
differential gearing arrangement was incorrect.
Differentials, usually flat but also spherical, are
used in wristwatches to allow the power reserve to be indicated. Power from the
mainspring is split via the differential to the time indications and the power
reserve indicator. Differentials are also used in watchmaking to link two separate
regulating systems with the aim of averaging out errors. GreubelForseyuse
a spherical differential to link two double
tourbillon systems in their Quadruple Differential Tourbillon.
A relatively new technology is
the electronically-controlled 'active differential'. An electronic
control unit (ECU) uses inputs from multiple
sensors, including yaw rate, steering input angle, and lateral acceleration – and adjusts the
distribution of torque to compensate for undesirable handling behaviours like understeer. Active differentials used to play a large role in the World Rally
Championship, but in the 2006 season the FIA has limited the use of active differentials only to those drivers who
have not competed in the World Rally
Championship in the last five years.
Fully integrated active
differentials are used on the Ferrari F430,
Mitsubishi Lancer Evolution, and on
the rear wheels in the Acura RL. A version manufactured by ZF is also being offered on the latest Audi S4 and Audi A4.
The second constraint of the
differential is passive – it is actuated by the friction kinematics chain
through the ground. The difference in torque on the roadwheels and tires
(caused by turns or bumpy ground) drives the second degree of
freedom, (overcoming the torque of inner
friction) to equalise the driving torque on the tires. The sensitivity of the
differential depends on the inner friction through the second degree of
freedom. All of the differentials (so called “active” and “passive”) use
clutches and brakes for restricting the second degree of freedom, so all suffer
from the same disadvantage – decreased sensitivity to a dynamically changing
environment. The sensitivity of the ECU controlled differential is also limited
by the time delay caused by sensors and the response time of the actuators.
Ø
Aron's
electricity meter, an early electricity
meter, relying on the use of a
mechanical differential.12
DESIGN OF THREE WHEELER
6.1Frame:
The frame serves as a skeleton upon which parts
like gearbox and engine are mounted. It can be made of steel, aluminum or an
alloy. It keeps the wheels in line to maintain the handling of the
three-wheeler.
6.2Suspension:
It is a collection of springs and shock absorbers.
It can be of two types: front suspension and rear suspension. It insulates both
the rider and the bulk of the machine from road shocks and also keeps the
wheels in the closest possible contact with the ground and gives control of the
vehicle to the rider. The front suspension helps to guide the front wheel, to
steer, to spring, to dampen, and to provide support under braking.
6.3Wheels:
A wheel is a circular object which with an axle,
allows low friction in motion by rolling. A wheel is made up of the rim and
spokes or disc plate. Wheels should be aligned properly because it directly
influences driving. Two-wheeler wheels are generally of aluminum or steel rims
with spokes.
13
Generally, there are two independent brakes on a
two-wheeler: one set on the front wheel and one on the rear, however, there are
many models which have 'linked brakes' and apply both at the same time. The
front brake is generally much more powerful than the rear brake. Brakes can
either be drum or disc based. When the rider operates one of the brakes, a
fluid element known as hydraulics is pressurized to provide the required forces
to squeeze the brake pad material onto the rotor and slow down or stop the
vehicle.
CHAPTER 7
AUTOMOTIVE DIFFERENTIAL WITH REDUCTION RATIO
We shall now design a differential using a worm gear reduction around
the miter gear set. This is inspired from the“Napier Worm Gear Drive” invented by the British “Napier& Sons” before the
First World War. The company waslater consumed by “English Electric” however their concept of a worm drive seems very
promising.
7.1Input Parameters
Input
power:
|
5.8913
kW
|
Input
Speed:
|
4100
rpm
|
Input
Torque:
|
13.7231 Nm
|
Reduction
Ratio Reqd.:
|
7:1
|
7.2Design Objective
To design a differential offering a reduction ratio
of 7 (7:1). It reduces output speed 7 times and multiplies output torque 7
times.
7.3DESIGN OF INNER BEVEL SET
7.3.1Constraints for Inner Bevel Set
Miter Gears:
Pitch geometry (D) = 80 mm
= 45°
15
Back
cone Angle (β)
|
= 45°
|
Pressure
Angle (ψ)
|
= 20°
|
Module
(m) = 4 mm
Velocity Ratio (G) = 1 (1:1)
Height of Dedendum (hf):
hf= 1.25*m
• 1.25*4
• 5 mm
Mean Radius (Rmean):
Rmean =2−2sin( )
=802−192sin 45
=33.28 mm
Minimum Number of Teeth on Pinion (Zmin):
2hacos (
)
Zmin= ∅2
2∗4cos (45)
Zmin=4 20 2
Zmin =
12.08 teeth ≈13 teeth
16
D= m*Z80
= 4 * Z
Z= 20
teeth
Since Zact>Zmin PERMISSIBLE
Force Analysis of Inner Bevel Set
Torque acting on Bevel Set (T) =
96.0617Nm =96061.7Nmm
Speed of rotation of Bevel
Set = 585.7143 rpm
Tangential Force (FT)=
(FT)=
2886.021811 N
Radial Force on Pinion (FR):
FR = FTtan(ψ)cos(φ)
FR = FTtan(20)cos(45)
FR =
742.649 N
7.4Temperature Rise:
The temperature must not show a rise greater than
380C ( ), and temperature of lubrication oil should be maintained at less
than or around 600C, so that the viscosity index is
maintained, (considering a mineral oil).
Also if the oil gets too hot, viscosity will drop,
but also due to higher temperature seals may get damaged. Since the system
normally only produces a temperature rise of up to 34.190C and max. permissible rise is normally to be kept under 380C we can allow overloading conditions, so long as temperature rise is
below 380C
GEAR RATIO CALCULATION
8.1Gear Box :
Gear box contain gearing arrangement to get
different speeds. Gears are used to get more than one speed ratios. When both
mating gears have same number of teeth, both will rotate at same number speed.
But when one gear has less teeth than other, the gear with less number of teeth
will rotate faster than larger gear. In a typical car, there may be six gears
including one reverse gear. First gear gives low speed but high torque. Higher
gears give progressively increasing speeds.Gears are engaged and disengaged by
a shift lever.
Figure 8.1
18
Finding
gear ratio:
1st gear =
PR *(T8/T9)
2nd gear=
PR*(T6/T5)
3rd gear=
PR*(T4/T3)
4th gear=
1:1
Permanent
reduction (PR) = (T2/T1)
T4, T6, T8 No. of teeth on driven
T3, T5, T7 No. of teeth on driver
8.3EXPERIMENTAL CALCULATION
Calculation of gear ratios
Driver
|
Driven
|
||||||
Sl
|
Gears
|
Shaft
|
Teeth
|
No of
|
Shaft
|
Teeth
|
No of teeth
|
no
|
teeth
|
||||||
1
|
First
|
Main
|
T8
|
57
|
Lay
|
T7
|
12
|
Shaft
|
Shaft
|
||||||
2
|
Second
|
T6
|
53
|
T5
|
17
|
||
3
|
Third
|
T4
|
47
|
T3
|
22
|
||
4
|
Fourth
|
T2
|
41
|
T1
|
29
|
||
Table 8.1CALCULATION OF GEAR RATIO
19
Permanent reduction (PR) =T2/T1
=41/29
=1.45≈1
First gear ratio
=PR*(T8/T7)
=1*(57/12)
=4.75 First gear ratio=1:4.75
Second gear ratio =PR*(T6/T5) =1*53/17 =3.117
Second gear ratio=1:3.117
Third gear ratio
=1*47/22
=2.3416 Third gear ratio=1:2.3416
Fourth gear ratio =1
Fourth gear ratio=1:1
20
DIFFERENTIAL PARTS
Figure 9.1
9.1Power flow
Ø Drive
shaft spins the Pinion gear.
Ø
Pinion gear turns the larger ring
gear to producegear reduction.
Ø Ring gear attached to differential case, hence itrotates with the ring
gear.
Ø Differential case spins the sun gears which are attached to the axles.
9.2Function
Ø Transfers
power from driveshaft to the wheels.
Ø
Provides final gear reduction.
Ø
Splits amount of torque going to
each wheel.
Ø
Allow the wheels to rotate at
different speeds in turns.
9.3Differential carriers
Removable carrier:
can be serviced at a workbench.
Integral or unitized carrier
formed as a part of axle housing.
9.4Breather tube
Ø Breather tube vents pressure or vacuum in or out of the rear axle
astemperature changes.
Ø If blocked lubricant could blow out the axle seals or pinion drive gear
seals.
9.5Differential lubrication
Ø Uses
80W-90 hypoid oil (distinct smell).
Ø Remove fill plug (mostly with 3/8” ratchet) insert finger;if you are able
to touch oil, level is good.
9.6Removing rear axle
Ø Integral carrier: remove the center pin, use a magnet and remove the c-clipsholding the
axle on to the sun gears, and remove
the axle.
Ø Removable carrier type:Remove the bolts holding the axle flange to thedrum/disc backing plate and pull the axle.
Ring and pinion gear backlash refers to
theamount of space between the meshing teeth of the gears.
Ø Hydrate ferric oxide (yellow oxide of iron) is used to check the contact
patternbetween pinion and ring gear.
Ø Too little back lash will cause the gears to jam and too much backlash
willcause gear noise (whirring, roaring, or clunking).
Ø pinion gear. To decrease movethe ring gear toward the pinion gear
(controlled by case bearing nuts or shims).
9.8Transaxle Axle Shaft
Figure 9.2
A short
shaftsplined to the side differential gear and connected to the inner universal
joint.
9.8.2Outer Stub Shaft
A short shaftconnected to the outer universal joint
and the front wheel hub.
9.9Interconnecting Shaft
The
centershaft that fits between the two universal joints.
9.10Universal Joints
Ø Universal
Joints in the front drive vehicles allow the front wheels to turn and spin.
Ø
Are normally called CV Joints
(Constant Velocity Joints)
Ø
Rzeppa (ball-and-cage) is normally
the outer joint and is a fixed (non sliding)joint.
Ø
Outer CV Joint transfers power
from the axle shaft to the hub assembly.
Ø
Locking nut is used on the hub
side
Ø
Plunging (sliding) tripod Jointis
commonly used on the inner joint.
Ø
Acts as a slip joint in a drive
shaft forrear wheel drive vehicles.
Ø As the front wheel moves up and downover the humps, the axle shaft must
change total length.
Ø The plunging action of the inner CVJoint allows for a change in distance
between the transaxle and the hub.
Ø Boots are
used to keep road dirt out of theCV-joints (made of rubber).
Ø
Prevent loss of grease.
Ø
Flex with movement of the joint.
Ø
Once damaged, will make a
clicking soundwhile accelerating and turning.
Figure9.3
TRANSMISSION SYSTEM
The mechanism that transmits the power developed by
the engine of automobile to the engine to the driving wheels is called the
TRANSMISSION SYSTEM (or POWER TRAIN).It is composed of –
Ø Clutch
Ø
The gear box
Ø
Propeller shaft
Ø
Universal joints
Ø
Rear axle
Ø
Wheel
Ø
Tyres
10.1How fluid coupling can be act as a mechanical clutch ?
In automotive applications, the pump typically is
connected to the flywheel of the engine The turbine is connected to the input
shaft of the transmission. While the transmission is in gear, as engine
speedincreases torque is transferred from the engine to the input shaft by the
motion of the fluid, propelling the vehicle . So, the behavior of the fluid
coupling strongly resembles that of a mechanical clutch driving a manual
transmission.
10.2Hydraulic transmission system
Fluid coupling -:A fluid coupling isa
hydrodynamic device used to transmit rotating
mechanical power.It has been used in automobile transmissions as an
alternative to a mechanical clutch.
10.3Construction Of a Fluid Coupling
It consists of a pump-generally known as impeller
and a turbine generally known as rotor, both enclosed suitably in a casing .
They face each other with an air gap. The impeller is suitably connected to the
prime mover while the rotor has a shaft bolted to it.
10.4Torque converter
Torque converter is a hydraulic transmission which
the torque of the vehicle reducing its speed . It provides a continuous
variation of ratio from low to high. The key characteristic of a torque
converter is its ability to multiply torque when there is a substantial
difference between input and output rotational speed, thus providing the
equivalent of a reduction gear. cars withan automatic transmission have no
clutch that disconnects the transmission from the engine. So, they use an
amazing device called a torque converter.
10.5Intersting facts about stator
Something a little bit tricky
happens when the car gets moving. There is a point, around 40 mph (64 kph), at
which both the pump and the turbine are spinning at almost the same speed (the
pump always spins slightly faster). At this point, the fluid returns from the
turbine, entering the pump already moving in the same direction as the pump, so
the stator is not needed.
Even though the turbine changes the direction of
the fluid and flings it out the back, the fluid still ends up moving in the
direction that the turbine is spinning because the turbine is spinning faster
in one direction than the fluid is being pumped in the other direction.
CHAPTER 11
STAGES OF AUTOMATIC TRANSMISSION
11.1Park(P)
Selecting
the park mode will lock the transmission, thus restricting vehicle from moving
11.2Reverse( R)
Selecting the reverse mode puts the car into reverse gear, allowing the
vehicle to move backward.
11.3Neutral (N)
Selecting
neutral mode disconnects the transmission from the wheel.
11.3.1Low (L)
Selecting
the low mode will allow you to lower the speed to move on hilly andmiddy areas.
11.3.2Drive (D)
Selecting
drive mode allows the vehicle to move and accelerate through a range of gears.
11.4CLUTCH
A clutch is a mechanism which enables the rotary motion of one shaft to
be transmitted at will to second shaft ,whose axis is coincident with that of
first.
28
Clutch is located between engine and gear box. When
the clutch is flows from the engine to the rear wheels through the transmission
system and the vehicle moves . when the clutch is disengaged ,the power is not
transmitted to the rear wheels and the vehicle stops, while the engine is still
running.
Clutch is disengaged when-
a)
Starting the engine,
b)
Shifting the gears,
c)
Idling the engine
clutch is engaged only when the
vehicle is to move and is kept engaged when the vehicle is moving.
Figure11.1
29
Electrical :Operating
of all tell tale lights, switches, horn etc. Brakes: Effectiveness, lever play, dragging of the brakes.
Steering / Suspension :Smoothness, any play or
looseness.
Controls : Free play, smooth operation, positive return to the
close position.
11.5Fuel Saving Tips
Ø Ride
smoothly and steadily at an optimum speed of 30 40 kmph
Ø
Change the gear judiciously
according to the speed requirement.
Ø
Avoid following
Ø
Sudden acceleration and frequent
/ sudden braking.
Ø
Driving with foot on brake pedal.
Ø
Driving with partial disengaging
of clutch (half clutch).
Ø
Overloading & Driving at high
speeds.
Ø
Over / under inflated tyres.
Ø
Keeping the engine running at
traffic signals if the idling time is more.
Running - In
Ø During
first 2000 km running-in period do not exceed following speed limits.
Ø
Always keep within the specified
running in speeds.
Ø
Do not race the engine
excessively.
Ø Do not start moving or race the engine immediately after starting. Run
the engine for a minute at idle speed to give the oil a chance to work up into
the engine.
11.6Starting the Engine
Ø Turn
ignition switch key ON
Ø
Ensure that vehicle is in Neutral
gear, by confirming the neutral lamp in tell tale indicator is lit.
Ø
Check Tell tale lights for
Battery charging indicator in tell tale indicator is lit.
Ø
Use ignition switch key to start
the vehicle.
Ø
Wait for about a minute for
engine to warm up before engaging gears and moving on.
30
Ø Close the
throttle while pressing the clutch.
Ø
Shift into the next higher or
lower gear.
Ø
Open the throttle partially,
while releasing the clutch.
11.6.2Reverse Gear
For engaging reverse gear –
Ø Change to
neutral, stop the vehicle with engine in idling condition.
Ø
Pull the reverse gear lever.
Ø
Press clutch .
Ø
Engage transmission into first
gear.
Ø
Release the clutch pedal lever
and open throttle to set the vehicle in motion.
11.7On Petrol mode
Ø Put
Selector switch in Petrol mode.
Ø
Wait for some time for filling of
the Carburettor bowl.
Ø
Crank the engine.
11.7.1Engine Oil replacement
Replace oil as per Lubrication
Chart.
For Replacing Engine Oil :
Ø Run the
engine for about 10 minutes to warm up the oil
Ø
Place the vehicle on a level
ground so that the oil settles down
Ø
Remove oil drain plug. Let the
oil drain completely
Ø
Tighten the drain plug
Ø Remove oil filling plug and pour the correct quantity of recommended
oil. • Ensure oil level at top ‘C’ level of dipstick
Ø Fit back oil filling plug. Ensure that there is no oil leakage.
31
Ø Place the
vehicle on a level ground.
Ø
Let the oil settle for a few
minutes.
Ø
Remove differential oil level
bolt.
Ø
The oil level is correct, if oil
just starts flowing out when bolt is removed.
Ø If oil is not flowing out i.e. Less oil level top up with specified oil till
the oil starts flowing out. Fit back oil level bolt.
11.8Propeller Shaft
Greasing Do the Propeller shaft
greasing at every 5000 kms.
Use only following recommended
grease for greasing the propeller shaft. Hindustan petroleum - AP3
Castro/ volvotine - NLGI-3
Indian Oil - Servo RR3
Bellows of propeller shaft should be kept in good
condition and replaced immediately if torn. Torn bellows will allow dust and
water entry into the propeller shaft flanges which will cause damage to
flanges, slider blocks and pins and reduce its life.
11.9Brake Oil container
Brake oil container is located on Master Cylinder
near brake pedal. Check the brake fluid level by looking at the reservoir.
Check that the fluid level is between the “Max” and “Min” lines. If the brake
fluid level is near the “ Min” line, fill it up to the “MAX” line with
recommended brake fluid.
32
COST OF THE PRODUCT
SL
|
COMPONENTS
|
QUANTITY
|
COST(RS)
|
1
|
4 stroke engine
|
1
|
6000
|
2
|
Transmission shaft
|
1
|
1500
|
3
|
Yoke rod & coupling
|
2
|
1000
|
4
|
Clutch plate
|
1
|
500
|
5
|
Petrol tank
|
1
|
350
|
6
|
Gear box setup
|
1
|
2000
|
7
|
Brake wires
|
2
|
150
|
8
|
Clutch wires
|
2
|
100
|
9
|
Bolts & Nuts
|
1 box
|
100
|
10
|
Starting lever
|
1
|
300
|
TOTAL
|
12000
|
||
Table 12.1
33
ADVANTAGES & DISADVANTAGES
13.1Advantages
Ø Reduction
ratio of even 20:1 is possible by this method.
Ø Worm shaft is placed higher in this arrangement near the underbelly of
the chassis thus less prone to damage.
Ø Entire structure is centralized in terms of mass & since C.G. is in
the center the positioning is easier.
Ø The entire differential offers rotational flexibility about the drive
axle axis thus the worm shaft can be tilted at any angle without any trouble or
complications. This will not affect the design calculations nor increase design
complexity.
Ø The entire enclosure floats around the mechanism. Once disconnected from
its mounting, both the shells can come apart offering maintenance worker
complete access to the mechanism from any angle.
Ø Design is
very simple and has good serviceability.
34
Ø Limited
efficiency at best up to 95%.
Ø Due to poorer efficiency, temperature rise must be within permissible
limits or else seals may get damaged. Also excessive temperature could lead to
tooth failure due to seizure.
Ø The entire system is made of two metals. The worm wheel normally has to
be made of a more conformable metal (such as Phosphor Bronze). This may
increase costs.
Ø If the gearing size requirement is larger (for increased torque
transmitting capacity), height increases
Ø Since the worm wheel is made out of phosphor bronze, whose wear strength
is not as high as that of alloy steels, the frequency of replacement of worn
out parts may be greater.
13.3APPLICATIONS AND SCOPE
Ø Encourages public transport use as one can easily get to one’s
destination from the end point if in a hurry, or it is raining, etc.
Ø Encourages non-ownership of private vehicles as point-to-point
transportation is easily available for special occasions.
Ø TSR/taxi drivers do not cheat when supply is abundant and fare structure
is reasonable, and so passengers are not scared of hassles and arguments.
35
CONCLUSION
Overall, the worm gear differential seams viable
for heavy, load-carrying vehicles used for construction and material
transportation as well as public transport such as buses. However for small
reduction ratios the system can be made even more compact as mentioned above,
hence permitting use in consumer vehicles.
In this
project we gained the knowledge about the fabrication of differential system
and how
the
differential system
|
in three
wheeler auto works. All the required
materials and parts are
|
purchased
and assembled
|
in our college laboratory .In our project we
gained hands on experience on
|
assembling the three wheeler auto. It meet over the ordinary existing
auto .Our project three wheeler auto rickshaw is built comparatively in small
budget. Enough knowledge on the functioning of the differential system and also
about the assembling of the auto are gained
36
REFERENCE
Ø Provatidis, Christopher, G. (2003). "A critical presentation of
Tsiriggakis’ gearless differential". Mobility
& Vehicles Mechanics
Ø Wright, M T. (2005). "The Antikythera Mechanism and the early
history of the Moon Phase Display". Antiquarian
Horology29 (3 (March 2006)): 319–329.
Ø H. Johannsen, L. Lasek, S. Sohr, P. Krams: "Safety Concept for
Narrow Track Urban Vehicles;"; InnovativerKfz-Insassen- and Partnerschutz
- Fahrzeugsicherheit 2010, VDI-Konferenz Berlin, 20./21.11.2003
Ø Osendorfer,
H; Rauscher, S.: “The development of a new class of two-wheeler vehicles”; 17th
Int. ESV-conference Amsterdam, June 4-7, 2001;
Proceedings
Ø Internal Investigation of TAKATA-PETRI by using the actual Database of
the GIDAS – German In Depth Accident Study
Ø Internal Investigation of TAKATA-PETRI by using the actual Database of
the NASS – National Automotive Sampling System –look at:
http://www-nrd.nhtsa.dot.gov/departments/nrd-30/ncsa/NASS.html
Ø Monitoring of ACEA’s Commitment on CO2 Emission Reduction from Passenger
Cars; Final Report, Commission of the European Communities, 2002
Ø Bri1999] Van den Brink, C.Realisation of high performance man wide
vehicles with an automatic active tilting mechanism, EAEC conference, Barcelona
1999
Ø [Con2005]Conrads, Axel:
KonstruktioneinesDreiradfahrzeugsmitKurvenneigetechnik, Diploma thesis, IKA,
RWTH Aachen, 2005
Ø [DC1997] DaimlerChrysler AG, Presseveröffentlichungzum F300 Lifejet,
Stuttgart 1997
Ø [Hib1993] Hibbard, R.: The Dynamic of Ground Vehicles with Active
Tilting Suspensions, Ph.D.thesis, Departement of Mechanical Engineering,
University of California Davis, 1993
Ø [Hen1996] Henker, E.: FahrwerktechnikGrundlagen, Bauelemente, Auslegung.
Vieweg-Verlag, 1996
Ø [Kah2004] Kahlert, Jörg: Simulation technischerSysteme,
ViewegPraxiswissen, ISBN 3-528-03964-7, 2004
Ø [Kar1992] Karnopp, Dean: A Simple Model of Steering-Controlled Banking
Vehicles, DSC-Vol 44, Transportations Systems , ASME 1992
37
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