International Journal of Modern Trends in Engineering

and Research
www.ijmter.com
e-ISSN No.:2349-9745, Date: 28-30 April, 2016

Design of Head Light Moving Mechanism With Steering

Mangesh A. Jadhav1 ,Tushar S.Borkar2, Nilam B. Narote3, Pratik D.More4, Rajendra S.
Chaudhari5
1
Department mechanical engineering, SNJBs KBJ COE Chandwad, mangeshjadhav987@gmail.com
2
Department mechanical engineering, SNJBs KBJ COE Chandwad, borkartushar27@gmail.com
3
Department mechanical engineering, SNJBs KBJ COE Chandwad, nilam.narote14@gmail.com
4
Department mechanical engineering, SNJBs KBJ COE Chandwad, pratikdmore23@gmail.com
5
Department mechanical engineering, SNJBs KBJ COE Chandwad, errajendrachaudhari@gmail.com

Abstract The most important of this paper is Front wheel of steering system with moveable
headlights with latest technology. The most conventional steering arrangement is to turn the front
wheels using a handoperated steering wheel which is positioned in front of the driver, via the
steering column, which may contain universal joints to allow it to deviate somewhat from a straight
line. This idea gives more advantages for automobile. It gives the advantages such as low level of
steering torque during static steering, increase fuel efficiency or economy, low weight of vehicle
because of using EPS system, flexibility in steering system and more space for driver and front
passenger.
Keywords-Design, Headlight Mechanism, Synthesis of Mechanism, Rack And pinion spur gear.

I. INTRODUCTION
The aim is to design and develop a Steering Controlled Headlight Mechanism which acts as
directional headlights. This is done by connecting headlights and steering. Present day automobiles
dont have effective lighting system. Due to this many accidents are taking place during night times
especially in hilly areas. The accidents can be avoided by incorporating Steering Control Headlight
Mechanism. The rack and pinion steering gear mechanism is used for this project. When the steering
wheel is rotated and rotary motion is converted to translatory motion through the rack and pinion
mechanism. When the front wheels are steered, the headlights follows the same path and the light is
focused on more divergent area. In the present project, it is planned to design Steering Controlled
Headlight Mechanism and a live model unit is fabricated.

II. PROBLEM DEFINATION

A four wheeler usually find difficulty to drive especially at sharp turn .The model helps them to
change the focus of headlight as the steering move on either direction. Adaptive headlights react to
the steering system of the car and automatically adjust to illuminate the road wheel. Turn the car left,
the headlights angles to the left. Instead of moving the headlights, reflectors are fitted on the inside
on either side of the headlamp casing. These reflectors are moved to direct a beam in the same
direction as the movement of the vehicle .The power required to move the reflectors is transmitted
using hydraulic linkages.

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 International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 3, Issue 4, [April 2016] Special Issue of ICRTET2016

Objectives:-The main aim to move the head light on sharp turning as possible as. The vehicle should
get illumination front view that could help to driver taking turn on hill areas, And also to make the
nation with an accident free.

III. SYNTHESIS OF MECHANISM

Steering System
The manual steering system incorporates:-
1) Steering wheel and column,
2) A manual gearbox and pitman arm or a rack and pinion assembly,
3) Linkages; steering knuckles and ball joints; and
4) The wheel spindle assemblies.

Rack And Pinion Steering

Rack-and-pinion steering is quickly becoming the most common type of steering on cars, small
trucks and SUVs. It is actually a pretty simple mechanism. A rack-and-pinion gear set is enclosed in
a metal tube, with each end of the rack protruding from the tube. A rod, called a tie rod, connects to
each end of the rack. The pinion gear is attached to the steering shaft. When you turn the steering
wheel, the gear spins, moving the rack. The tie rod at each end of the rack connects to the steering
arm on the spindle.

Figure 3.1 Rack And Pinion Mechanism system

The rack-and-pinion gear set does two things:-
1) It converts the rotational motion of the steering wheel into the linear motion needed to turn
the wheels.
2) It provides a gear reduction, making it easier to turn the wheels. On most cars, it takes three
to four complete revolutions of the steering wheel to make the wheels turn from lock to lock
(from far left to far right).

IV. METHODOLOGY
The paper here is all about Front wheel steering system with moveable headlights with latest
technology. The most conventional steering arrangement is to turn the front wheels using a hand
operated steering wheel which is positioned in front of the driver, via the steering column, which
may contain universal joints to allow it to deviate somewhat from a straight line. Rack and pinion
steering gear mechanism where the steering wheel turns the pinion. The pinion moves the rack,

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 International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 3, Issue 4, [April 2016] Special Issue of ICRTET2016

which is a linear gear that meshes with the pinion, converting circular motion into linear motion
along the transverse axis of the car (side to side motion)

V. DESIGN OF MECHANISMS
Working Principle
In our concept of mechanism lead-acid 12 Volt batteries is used. The lead-acid batteries output is
given to the limit switch. There are two Limit switches are used in this project. These switch outputs
are connected to the steering D.C mot or in Forward and reverse rotation of operation. The rack and
pinion arrangement is used to turn the wheel in left and right direction. The Rack is connected to the
wheel with the help of liver mechanism and the pinion is coupled to the permanent magnet D.C
motor shaft. The Motor is drawn supply from the battery through limit switch arrangement. When
the steering is turn in the left direction, it pushes the left side limit switches, so that the D.C motor
rotate in forward direction to move the wheel in left side. Similarly When the steering is turn in the
right direction, it pushes the right side limit switches, so that the D.C motor rotate in reverse
direction to move the wheel in right side.

Figure 4.1. Line Diagram of Head Light Moving Mechanism with Steering.

Mechanical Design
Mechanical design phase is very important from the view of designer as whole success of the project
depends on the correct design analysis of the problem. Designer should estimate these forces very
accurately by using design equations. If he does not have sufficient information to estimate them he
should make certain practical assumptions based on similar conditions. This will almost satisfy the
functional needs. Assumptions must always be on the safer side. 1) Design parts 2) Parts to
be purchased

Design of Frame
Input data,
Total weight = 10KG (assume)
No of links = 4
2 links of 3000 mm
1 link of 1500 mm

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 International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 3, Issue 4, [April 2016] Special Issue of ICRTET2016

1 link of 1500 mm
Force = 10 kg
= 10 x 9.81 = 98.1 N 100 N
No of links = 4
Hence,
Force on each link = 100 / 4 = 25 N
Considering the max value of FOS = 2
Buckling load on each link = 25 x 2 = 50 N
LET,
T1 = Thickness of link, B1 = Width of link
Area of link = T1 X B1
Assuming width of the link = 3 X T1
Hence,
B1 = 3 X T1
AREA = 3T12
MI of link
I = 1/12 X T1.B1 ...(i)
= 0.25 T1
Let,
K = Radius of Gyration
A = AREA
K=I/A
K = 0.28 T1
For link 1
L1 = 3000 mm
PR = 50N
RANKINE CONSTANT = a = 1 / 7500
Crushing Load (Fy) = 325 MPa for MS
Now, Buckling Load
PR = Fy. A / 1 + a ... (ii)
WHERE = L / K
PR = F. A / 1 + a (L / K) ... (iii)
325 10 .25 X^4
50 =
13
1 + 7500 0.28 X
T1 =1.42 mm 2 mm
Similarly,
Calculating the thickness for all links,
Hence we take thickness
T = 2mm to 20mm we consider.

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 International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 3, Issue 4, [April 2016] Special Issue of ICRTET2016

Design of Steering Gear Mechanism

In order to make the design of our rack-pinion for the steering box, we base our work on the choice
of the rack and the pinion which will produce a greater lateral Displacement of the wheels with the
same turn of the steering wheel. The other start point is that the rack and the pinion must be the same
modulus and the same material. A suitable material for these elements is SAE 1045 steel which is
easy to mechanize.
Design of Rack and pinion spur gear
Ultimate tensile strength (Sut) = 625 N/mm2.
Assumptions:-
Number of teeth on pinion = 12
Number of teeth on rack = 28
Pitch line velocity of pinion = 0.5 m/sec.
Tangential force on pinion = 600 N.
Results:-
Hence selecting standard module m = 2 mm
Hence dimension of spur pinion:
Dp= Zp*m = 12 * 2 = 24 mm
B = 15* m = 15* 2 = 30 mm
Pressure angle = 20 0
Addendum = 1 m = 2 mm
Deddendum = 1.25 *m = 2.5 mm
Pitch (p) = 6.0283 mm
We have a pinion with a diameter of 24 mm,
T = 105.948*12= 1.27136Nm
This is the torque in the pinion and it is transmitted through the steering column.

Steering movement ratio

Therefore the movement ratio is 12.47:1 we needed to know the movement ratio in order to
determine the output load transmitted to the tie rods for a given input load.
The output load will be:
F = 2 *MR *F = = 2* 20* 12.47 = 498.8 N
Therefore the load transmitted to the tie rods is 498.8 N.
Selection of Motor
Motor Selection
1) Phase Induction Motor ( 2 Pole )
2) Power Rating = 0.05 Hp
3) Speed = 600 rpm (DC MOTOR)
4) Frame size = 71
5) Current = 1.70 Amp
6) Torque = 2.56 Nm
7) TEFC Construction.

Design of Main Spindle

T Design = 1.15 Nm. = 1.15x 10^3 N.mm
Selection of main spindle material:-C30

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 International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 3, Issue 4, [April 2016] Special Issue of ICRTET2016

Table No 5.2.6.1- Design of Main Spindle

Designation Ultimate Tensile Yield strength N/mm2

Strength N/mm2
EN 24(40 N; 2 CR 1 Mo28) 720 600
After Calculations Selecting minimum diameter of spindle = 10 mm

Assembly Designs on CATIA

Figure. Assembly Design on CATIA

VI. RESULT AND CONCLUSION

The effective Headlight Moving mechanism with Steering was designed, based on Rack and pinion
mechanism, to move the steering arm that gives predefined motion to wheel and headlights. This is
very important system, which help to move the headlight as per turn, right or left. And it can be help
for making nation accidents free roads.

REFERENCES
[1] J.B. Jiang, C.F. Cheung, S.To, K.W. Cheng, H. Wang, and W.B. Lee Design and fabrication of freeform
reflector for automotive headlamp 2nd International Conference on Power Electronics Systems and
Applications: Hong Kong, 12-14 November 2006, p. 220-224.
[2] Manisha V Makwana1a, Akshay Shah2a Shankar Rahul3a and Ajay Patel4, Design and Manufacture of
Movable Headlight System in Automobile, International Journal of Innovative and Emerging Research in
engineering,2014,12-16.
[3] N.Laxmi, B.Anil Kumar, D.kiran varma, Design and Fabrication of A Steering Controlled Headlights in
Automobile, International Journal & Magazine of Engineering, Technology, Management and Research, July
2015,98-102.
[4] Fundamentals of motor vehicle technology by V.A.W.Hiller, 4th edition, Pub: 2009, pg.no.313-336.
[5] Automobile engineering by Dr.kirpal singh vol 1, pub; 2010, chapter: front axle steering systems
[6] Automobile engineering by K.K.jain and R.B.Asthana, pub.2006.

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