A

Project Report
On
ELEVATING CAR

Submitted in partial fulfillment of award of

Diploma in
Mechanical (Automobile) Engineering

by
1. MOHD AMIR 2. SHAIKH KASHIF EHTESHAM
(1500101123) (1500102835)
3. MO SAHIL SHAIKH 4. MOHAMMAD ADIL
(1500100388) (1500102036)
5. MOHD FAHAD ANSARI
(1500102490)

Under the guidance of

Mohd Amanuddin
Lecturer

Department of Mechanical (Automobile) Engineering

University Polytechnic
Integral University, Lucknow (U.P.) India
2017-2018
 CERTIFICATE

This is to certify that project report entitled, “ELEVATING CAR”

submitted by in partial fulfillment for the requirements of the award of the
diploma engineering in mechanical (automobile) engineering at integral
university is an authentic work carried out by them under my supervision and
guidance. This work has completed by MOHD AMIR, SHAIKH KASHIF
EHTESHAM, MO SAHIL SHAIKH, MOHAMMAD ADIL, MOHD
FAHAD ANSARI.

Date- _____________ ( MOHD AMANUDDIN)

(Lecturer),
Mechanical (Automobile) Engineering,
University Polytechnic,
Integral University,
Lucknow – 226026 (India).

2|Page
 ACKNOWLEDGEMENT

We are immensely thankful and express our deep sense of gratitude to our
guide Er. Mohd Amanuddin, lecturer, Mechanical (Automobile)
Engineering Dept, University of Polytechnic, Integral University, Lucknow
for suggesting us a problem of vital interest without whom guidance and
concrete advise to this project we would not have completed this project. His
continuous monitoring and time management was an inspired force for us to
complete the work. We would like to acknowledge our guide for all his
support in project programmed. Among rest to mention who would like to
thanks all my colleagues and friend who supported and helped us in
completion of this work. Lastly, we would like to thank our Parents. No
words can express our heartfelt gratitude for them.

3|Page
 TABLE OF CONTENT

CONTENT PAGE NO.

Title Page................................................................................... 1

Certificate................................................................................... 2

Acknowledgement...................................................................... 3

Table of content.......................................................................... 4-5

List of figures............................................................................. 6-7

Abstract...................................................................................... 6

CHAPTER- 1............................................................................. 7

Introduction............................................................................... 8-13

CHAPTER- 2............................................................................. 14

Mechanism of Elevating Car..................................................... 15-24

CHAPTER- 3............................................................................. 25

COMPONENT USED IN THE PROJECT..............................

1. 12V Battery ........................................................................... 26-31

2. DC Motors.............................................................................. 32-43

CHAPTER- 4............................................................................. 44

1. Chassis................................................................................... 45-49

2. Steering.................................................................................. 50-51

4|Page
 LIST OF FIGURES
NAME PAGE
Frame 13
Expanding Mechanism of Front Wheels 14
Completed Elevating Car 15
Expanding and Elevating of The Car 17
Passing the Car Over the Other Traffic 18
Bottle Jack 22
Floor Jack 23
Line Diagram of Simple Screw Jack 24
Simple Screw Jack Used in The Project 26
12V Battery 29
Lantern Battery 30
A23 Battery 32
DC Motor 35
Electromagnetic Motor 38
Brushed Motors 40
Brushless Motors 41
Permanent Magnet Stators 43
Wound Stator 44
Chassis 49
Chassis of Elevating Car 49
Rack and Pinion Steering 53
Solid Works 54
(Rack and Pinion Gear Steering)

5|Page
 ABSTRACT:

Communication Company Verizon builds a sky-scraping JEEP ‘grand

Cherokee’ to promote its ‘cloud-connected’ car technology. the ‘hum rider’ is
an SUV fitted with custom hydraulics elevating it five feet in the air, offering
enough clearance for it to rise above cars and cut through traffic. with its slick
transformation at the push of a button, the ‘hum rider’ is the ‘optimum
prime’ of the automotive world.It’s an impressive sight to see a
large JEEP SUV carry itself over stationary vehicles like a superhero-
gadget. the ‘hum rider’ was realized with Scott Beverly, the man behind the
visual effects of sci-fi films including ‘interstellar‘, ‘inception‘, and ‘the dark
knight‘. most of the SUV’s system is powered by a gasoline Honda generator
mounted underneath, pumping fluid through 300 feet of hydraulic lines. the
‘hum rider’s’ structure was also heavily reinforced, and now weighs in at a
substantial 8500 pounds.

6|Page
CHAPTER - 1

7|Page
 1. INTRODUCTION

CommunicationCompanyVerizon builds a sky-scraping JEEP ‘grand

Cherokee’ to promote its ‘cloud-connected’ car technology. the ‘hum rider’ is
an SUV fitted with custom hydraulics elevating it five feet in the air, offering
enough clearance for it to rise above cars and cut through traffic. with its slick
transformation at the push of a button, the ‘hum rider’ is the ‘optimum
prime’ of the automotive world.

It’s an impressive sight to see a large JEEP SUV carry itself over
stationary vehicles like a superhero-gadget. the ‘hum rider’ was realized with
ScottBeverly, the man behind the visual effects of sci-fi films including
‘interstellar‘, ‘inception‘, and ‘the dark knight‘. most of the SUV’s system
is powered by a gasoline Honda generator mounted underneath, pumping
fluid through 300 feet of hydraulic lines. the ‘hum rider’s’ structure was
also heavily reinforced, and now weighs in at a substantial 8500 pounds.

The driver can raise vehicle’s body above traffic by pressing a switch
on the dashboard. four cameras located beneath the vehicle’s body allow the
driver to visualize what the vehicle is driving over, ensuring the clearances
are met and maintained. unfortunately, the ‘hum rider’ won’t be entering
mass-production any time soon, but this unique custom job could be the
ultimate vehicle for the driver who doesn’t have time to waste.

The SUV’s wheels scoot outward as its bright blue body rises up into
the air on telescoping legs. Then the whole car drives over a line
of cars before sinking back down ahead of the traffic to zip away. If that
sounds like something out of an Inspector Gadget movie, you’re not far off
8|Page
the viral marketing stunt was created by a designer who specializes in jury-
rigging wild apparatuses for Hollywood studios.

“Verizon was pushing for something that was innovative and

different,” Scott Beverly, the Hollywood mechanical effects expert who built
the car, tells _Inverse. “I’ve got about 35 years of designing the shots for
feature films that are impossible to do for real, so this is kind of normal for
me.”
Like the straddle bus, the elevating car itself isn’t going to be
something you can buy anytime soon. The traffic-jam ignoring SUV was built
as a viral marketing stunt for Verizon’s Hum car gadget. The gadget is made
to turn older-model vehicles into connected cars, along with tracking your
car’s trips and speed. “It is the first car in the world that can drive over
traffic,” Sam Pezzullo, a producer for Thinkmodo, the viral marketing
company that produced the ad for Verizon, told Inverse in an email.
Beverly engineered the extend-car rig before he even knew what vehicle he
would be lifting. The legs that lift the car and move the wheels were designed
to be easy to put together. He says, “I laid out the assembly so the parts
interlocked when they came off the laser cutter.”

The other trick was getting all the hydraulic movement coordinated with only
three valves: wheels out, body up, and drive forward. This makes it easy for
the driver, but it takes 12 hydraulic cylinders to get the car into its upright
position and the cylinders had to be linked so they could lift evenly. “Those
original constraints forced the size of the rig,” he says. “We shoehorned the
rigging into the vehicle to make it work.”
The mid-sized SUV is not the large vehicle that Beverly originally wanted to
use. “I have to admit that [Verizon’s] choice definitely paid off, it definitely

9|Page
looks much better,” he says. “My performance comes from people who have
creative ideas and I make those creative ideas work.”
The build for the commercial was very similar to the film technology work
that Beverly does on movies like Inception or Interstellar. “I specialize in
getting shots that are either cost-prohibitive or physically impossible to do,”
he says. An example is the shot in Inception with the castle collapsing on a
mountain. Beverly and his team built a “miniature” that was five stories tall
with hydraulics designed to get the exact timing for how the hotel collapses.
“Basically you design the rigs that are going to do the action and then you
build the set around the rig,” he says. If everyone had a car that lifted itself
over traffic, it wouldn’t be quite as useful, and the SUV drives over a line of
cars that is clearly aligned for the stunt to work. But before you start trying to
build one of these for yourself, Beverly points out that it doesn’t move very
quickly. He had to use a hydraulic motor to create the forward speed for the
car while it was lifted up. “But that’s just the nature of the beast,” he says.
“The producer, James, I think he wanted things to go a little bit faster, but
every director wants it to be bigger or faster.”

There are three levers where the center seat heaters and climate control
should be. One controls the actuators that move the wheels outward, away
from the center. Another extends the legs vertically, pushing the car up
onto stilts that make it tall enough to clear a Honda Accord. The third is
the throttle for creeping over standstill traffic.

This heavily modified Jeep Cherokee is PR disguised in a feat of

engineering. Called the Hum Rider and named after Verizon's in-car
diagnostic tool called Hum, this strange transformer has been cruising
around the web the last couple weeks. Never mind its viral fame—the
really interesting story is how it was built."We had eight weeks to proof
out the concept and make sure everything worked," says Scott Beverly,
10 | P a g e
one of the designers. This heavily modified Jeep Cherokee is PR disguised
in a feat of engineering. Called the Hum Rider and named after Verizon's
in-car diagnostic tool called Hum, this strange transformer has
been cruising around the web the last couple weeks. Never mind its viral
fame—the really interesting story is how it was built. “We had eight
weeks to proof out the concept and make sure everything worked," says
Scott Beverly, one of the designers. Beverly primarily works at A2ZFX, a
company that builds mechanical props such as the tumbler Batmobile
from The Dark Knight. The other head designer, Art Thompson, helped
build the B-2 bomber while at Northrop Corporation. Consider them both
overqualified for the job.Under the hood, where the Jeep's
engine should be, there's a small Honda V-twin gas-powered engine that
drives a hydraulic pump. This powers the valve system for the hydraulic
cylinders throughout the vehicle, allowing it to elevate. A big horizontal
cylinder runs through the middle of the car, and inside that pipe is about
55 gallons of hydraulic fluid, which feeds through about 300 feet of
organized tubing to the wheels and elevating.

Fig1.1 - Frame

11 | P a g e
First, the 45-degree steel outriggers push the wheels sideways, out from
the center of the car. Then, secondary pistons lift the whole thing up. To
actually move forwards and backward, thin motors are lodged in the
wheels. These cam lobe hydraulic motors—the type of thing you'd find on
heavy lifting equipment—move the car, very slowly. The Hum Rider's top
speed comes in about 15 mph. However, it all sounds much more
impressive considering this car north of 8,000 pounds—more than double
the wait of your average coupe.

To design this four-wheeled wonder and make sure all those parts work in
concert, Beverly and Thompson used CAD software called Solidworks to
invent the Hum Rider. They first created a virtual concept and checked the
design and hydraulics for fit and function.

"Ten, 15 years ago, I drafted out parts for people to cut by hand, to drill by
hand," Beverly says. "Now, with water jet cutting, laser cutting, plasma

Fig1.2 – Expanding mechanism of front wheels

12 | P a g e
cutting, we send the files straight from the CAD program to a machine. A
file with all the dimensions of a specific metal piece goes from the
computer to a five-axis laser-cutting rig. The machine reads the
dimensions and spins a hunk of metal, precisely cutting out pieces that
then fit together like Lego. This modern tech makes an 8-week deadline
achievable rather than a logistical impossibility.

If the specs and design didn't make it obvious, the Hum Rider is an
impractical, ridiculous attempt for internet fame and luckily a menace
you'll never see on the road. But that doesn't make the engineering any
less impressive.

Fig1.3 –Completed Elevating Car

13 | P a g e
CHAPTER - 2
(Mechanism of Elevating Car)

14 | P a g e
 1.1 Mechanism of Elevating Car

The elevating car is based on the hydraulic jack; pneumatic jack, scissors jack
or screw jack that means the elevating mechanism of the car is done by
hydraulic jack or screw jack, mechanism. The hydraulic elevating car
mechanism is similar to the arm mechanism of restored and hydraulic jack.
The hydraulic jack mechanism is used on all wheelshorizontally for
expanding and vertically for elevating. During expanding the breadth or
width is become large which is more than the normal and non-expanding
cars. And after the elevating of the car the height of the car is increase. Since
the height and width had been increased therefore it can pass easily over a car
in traffic. By using this mechanism, we can save the time.

fig2.1.1 -Expanded and Elevated of the car

15 | P a g e
 Fig1.2- Passing the Car Over the Other Traffic

“But in the project, we used the screw jack mechanism and sliding
mechanism for elevating and expanding and vice-versa, which is fully
automated which is driven by a motor (12V and 100 RPM). The project
(elevating Car) steering is based on the rack and pinion which is fully
automated driven by a single motor 12V and 10 RPM. It is two wheels drive
and two wheels steering also”.

16 | P a g e
Final project

17 | P a g e
 2. MECHANISM WHICH MAY BE USED FOR

THE ELEVATING CAR

1. HYDRAULIC JACK MECHANISM

2. PNEUMATIC JACK MECHANISM
3. SCREW JACK MECHANISM
4. SCISSOR JACK MECHANISM

2.1 Hydraulic Jack Mechanism

A jack is a device that

uses force to lift heavy
loads. The primary
mechanism with which
force is applied varies,
depending on the specific
type of jack, but is
typically a screw thread or
a hydraulic cylinder.
Jacks can be categorized
based on the type of force they employ: mechanical or hydraulic. Mechanical
jacks, such as car jacks and house jacks, lift heavy equipment and are rated
based on lifting capacity (for example, the number of tons they can lift).
Hydraulic jacks tend to be stronger and can lift heavier loads higher and
include bottle jacks and floor jacks.

18 | P a g e
 2.1.1 How Hydraulic Jacks Work

Hydraulic Jack depends on force generated by pressure. Essentially, if two

cylinders (a large and a small one) are connected and force is applied to
one-cylinder, equal pressure is generated in both cylinders. However,
because one cylinder has a larger area, the force the larger cylinder produces
will be higher, although the pressure in the two cylinders will remain the
same. Hydraulic jacks depend on this basic principle to lift heavy loads:
they use pump plungers to move oil through two cylinders. The plunger is
first drawn back, which opens the suction valve ball within and draws oil
into the pump chamber. As the plunger is pushed forward, the oil moves
through an external discharge check valve into the cylinder chamber, and
the suction valve closes, which results in pressure building within the
cylinder.

1.1.3 Types of Hydraulic Valves

Two common types of hydraulic jacks include bottle jacks and floor
jacks.

1.1.3.1 Bottle Jacks

Bottle jack became popular in the early 1900s when the automobile
industry began to take off. Also called hand jacks, bottle jacks provided
an easy way for an individual to lift up a vehicle for roadside
inspection or service. Their resemblance to milk bottles earned bottle jacks
their name—today, they range in size and weight to offer a lifting capability
ranging from one hundred to several tons. Bottle jacks feature a vertical shaft,

19 | P a g e
which supports a platform (called a bearing pad) that directly bears the
weight of the object as it is lifted.

Although they are most commonly used in the automobile industry (1.5 to 5-
ton jacks are frequently used to lift cars), bottle jacks have other uses as well.
In the medical industry they can be used in hydraulic stretchers and patient
lifts. In industrial applications, they can be found as pipe benders used in
plumbing, as cable slicers for electrical projects, and as material lifts within
warehouses. Their ability to lift heavy loads plays a big role in enabling the
repair of large agricultural machinery and in many construction operations.
Bottle jacks can be secured within a frame, mounted on a beam, or simply
used as they are for easier jack transportation.

Fig2.1.3. - Bottle Jack

20 | P a g e
 1.1.4 Floor Jacks

Unlike bottle jack shafts, the shaft in a floor jacks is horizontal the shaft
pushes on a crank that connects to a lifting pad, which is then lifted
horizontally. Floor jacks typically provide a greater range of vertical lift than
bottle jacks and are available in two sizes. The original jack is about four feet
long, a foot wide, and weights around 200 pounds they can lift 4-10 tons. A
more compact model was later made, which is about three feet in length, and
can lift 11/2 tons. Although “mini jacks” are also produced, they are not a
recognized standard type of floor jack. Typically, one of the first two sizes
should be used.

Fig2.1.4 – Floor Jack

21 | P a g e
1.2 Screw Jack Mechanism

Fig2.2.1- Line Diagram of Simple Screw Jack

22 | P a g e
A screw jack is a gearbox assembly (either worm gear or bevel gear) and a
transmission product (lead screw, ball screw or roller screw) which through
use of a motor is used to convert rotary into linear motion. They can be used
to push, pull, tension, lock, unlock, tilt, pivot, roll, slide and lift or lower
loads, anything from a few kilos to thousands of tons. Screw jacks are
essential components in automated machinery. Safety and legislative
concerns drive the automation of handling and lifting of heavy loads,
particularly in regions which have developed workplace and health and safety
legislation.

The trend to electromechanical actuation from hydraulic actuation.

Screw jacks usually operate in high-load applications. The competing

technology at high loads tends to be hydraulics; however, hydraulics are less
energy-efficient than electro-mechanical actuation provided by screw jacks.
Hydraulic systems waste energy as the fluid circulates at constant pressure,
regardless of the amount of work required to be carried out by hydraulic
positioning. A hydraulic jack or ram requires a constant pressure to maintain
its position when holding a load in place. By contrast, an electric motor used
to power a screw jack uses energy only when it drives the load to a required
position.

The advantages of electro-mechanical over hydraulic can be summarized by:

 Demand for increased safety, in the event of power loss, screw jacks
can be self-locking
 Demand for machinery that operates with better energy efficiency
 Demand for machinery that operates greater levels of precision
 Machinery that requires less maintenance
 Machinery that requires less manual intervention to set up processes
 Increased range of actuation in terms of variable positioning

23 | P a g e
 Accurate and smooth delivery of force
 Cleaner machinery

Fig2.2.2 - Simple Screw Jack Used in The Project

24 | P a g e
 CHAPTER – 3
(COMPONENT USED IN THE PROJECT)

25 | P a g e
 3.1 12V BATTERY

It may refer to:

 Automotive battery (most batteries for vehicles and UPS are 12

volts)
 Lantern battery
 A23 battery, a small battery (roughly 2/3 of an AAA battery in
length) made for RF transmitters

3.1.1 Automotive Battery:

An automotive battery is a rechargeable battery that supplies electrical
current to a motor vehicle. Its main purpose is to feed the starter, which
starts the engine. Once the engine is running, power for the car's electrical
systems is supplied by the alternator. Typically, starting discharges less than
three per cent of the battery capacity. SLI (Starting, Lighting and Ignition)
batteries are designed to release a high burst of current and then be quickly
recharged. They are not designed for deep discharge, and a full discharge
can reduce the battery's lifespan. As well as starting the engine an SLI
battery supplies the extra power necessary when the vehicle's electrical
requirements exceed the supply from the charging system. It is also a
stabilizer, evening out potentially damaging voltage spikes. While the engine
is running, most of the power is provided by the alternator, which includes
a voltage regulator to keep the output between 13.5 and 14.5 V. Modern SLI
batteries are lead-acid type, using six series-connected cells to provide a
nominal 12 volt system (in most passenger vehicles and light trucks), or
twelve cells for a 24 volt system in heavy trucks or earth-moving equipment,

26 | P a g e
 Fig 3.1.1– 12V Battery

Battery electric vehicles are powered by a high-voltage electric vehicle

battery, but they usually have an automotive battery as well, so that they can
use standard automotive accessories which are designed to run on 12 V.

27 | P a g e
 3.1.2 Lantern Battery

Fig 3.2Lantern Battery

A lantern battery is a rectangular battery, typically an alkaline or zinc-

carbon primary battery, used primarily in flashlights or lanterns. Lantern
batteries are physically larger and consequently offer higher capacity than the
more common torch batteries. Lantern batteries comprise multiple cells inside
housing.

The most common variant in the US is the 6 volt square-base battery with
spring terminals. In Europe the most common is the 4.5 volt flat-pack types

6 volts

The 6-volt variety typically has spring or screw terminals. Different types
have different internal construction; the same package size may be made up
with "D" size or "F" size cells, giving different capacity. A rechargeable
version, comprising a three-cell sealed lead-acid battery with a lower capacity
than primary versions, has also been marketed. They are also used in the
construction industry for powering flashing lights at roadworks.

28 | P a g e
4.5 volt

4.5-volt, D, C, AA, AAA, AAAA, A23, 9-volt, CR2032 and LR44 batteries

More common in Europe and Russian Federation, this is a smaller, flat-pack

battery mostly used in flashlights. It uses two metal strips as terminals. The
shorter strip is the + terminal.

7.5 volts

The 7.5-volt version has screw terminals and rectangular base. A carrying
handle is usually connected between the terminals.

12 volts

The 12-volt version has screw terminals and a rectangular base. Since it is 12-
volt, this type can be used to power car accessories outside of an automobile,
using extra wiring or an adapter.

29 | P a g e
 3.1.3 A23 Battery

It is also known as 23A, 23AE, GP23A, V23GA, 8LR932, LRV08,

8LR23, MN21, L1028 or ANSI-1181A) is a dry cell-type battery mainly
used in small electronic keychain radio devices, such as keyless vehicle entry
systems, home security systems, garage door openers, and Bluetooth
headsets. An A23 battery is cylindrical and slightly shorter than a AAA
battery, measuring 28.5 mm long and 10.3 mm in diameter, with a typical
weight of 8 grams. An A23 battery is an 8-cell device with a nominal voltage
of 12 V. The higher voltage is necessary for the radio
frequencytransmitting and receiving devices which A23 batteries often
power. It has a capacity of around 55 mAh. A23 batteries are constructed of
eight individual LR932 alkaline button cells enclosed in a wrapper. The A23
battery is close in size to the N battery, which has a voltage of 1.25 V to 1.5
V. It is also similar to the A27 battery, which has the same 12 V nominal
voltage and almost the same length as the A23, but is smaller in diameter by
about 20%.

30 | P a g e
 3.2 DC MOTORS
A DC motor is any of a class of rotary electrical machines that converts direct
current electrical energy into mechanical energy. The most common types
rely on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor.

DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's
speed can be controlled over a wide range, using either a variable supply
voltage or by changing the strength of current in its field windings. Small DC
motors are used in tools, toys, and appliances. The universal motor can
operate on direct current but is a lightweight motor used for portable power
tools and appliances. Larger DC motors are used in propulsion of electric
vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of
power electronics has made replacement of DC motors with AC
motors possible in many applications.

Contents

1. Electromagnetic Motors
2. Brushed Motors
3. Brushless Motors
4. Uncommuted Motors
5. Permanent magnet stators
6. Wound stators
a. 6.1Series connection
b. 6.2Shunt connection
c. 6.3Compound connection

31 | P a g e
fig 3.2 – DC Motor

32 | P a g e
 3.2.1 Electro Magnetic Motor

A coil of wire with a current running through it generates

an electromagnetic field aligned with the center of the coil. The direction and
magnitude of the magnetic field produced by the coil can be changed with the
direction and magnitude of the current flowing through it.

A simple DC motor has a stationary set of magnets in the stator and

an armature with one or more windings of insulated wire wrapped around a
soft iron core that concentrates the magnetic field. The windings usually have
multiple turns around the core, and in large motors there can be several
parallel current paths. The ends of the wire winding are connected to
a commutator. The commutator allows each armature coil to be energized in
turn and connects the rotating coils with the external power supply through
brushes. (Brushless DC motors have electronics that switch the DC current to
each coil on and off and have no brushes.)

The total amount of current sent to the coil, the coil's size and what it's
wrapped around dictate the strength of the electromagnetic field created.

The sequence of turning a particular coil on or off dictates what direction the
effective electromagnetic fields are pointed. By turning on and off coils in
sequence a rotating magnetic field can be created. These rotating magnetic
fields interact with the magnetic fields of the magnets (permanent
or electromagnets) in the stationary part of the motor (stator) to create a force
on the armature which causes it to rotate. In some DC motor designs the
stator fields use electromagnets to create their magnetic fields which allow
greater control over the motor.

At high power levels, DC motors are almost always cooled using forced air.

33 | P a g e
Different number of stator and armature fields as well as how they are
connected provide different inherent speed/torque regulation characteristics.
The speed of a DC motor can be controlled by changing the voltage applied
to the armature. The introduction of variable resistance in the armature circuit
or field circuit allowed speed control. Modern DC motors are often controlled
by power electronics systems which adjust the voltage by "chopping" the DC
current into on and off cycles which have an effective lower voltage.

Since the series-wound DC motor develops its highest torque at low speed, it
is often used in traction applications such as electric locomotives, and trams.
The DC motor was the mainstay of electric traction drives on both electric
and diesel-electric locomotives, street-cars/trams and diesel electric drilling
rigs for many years. The introduction of DC motors and an electrical
grid system to run machinery starting in the 1870s started a new second
Industrial Revolution. DC motors can operate directly from rechargeable
batteries, providing the motive power for the first electric vehicles and
today's hybrid cars and electric cars as well as driving a host of cordless tools.
Today DC motors are still found in applications as small as toys and disk
drives, or in large sizes to operate steel rolling mills and paper machines.
Large DC motors with separately excited fields were generally used with
winder drives for mine hoists, for high torque as well as smooth speed control
using thyristor drives. These are now replaced with large AC motors with
variable frequency drives.

If external mechanical power is applied to a DC motor it acts as a DC

generator, a dynamo. This feature is used to slow down and recharge batteries
on hybrid car and electric cars or to return electricity back to the electric grid
used on a street car or electric powered train line when they slow down. This
process is called regenerative braking on hybrid and electric cars. In diesel

34 | P a g e
electric locomotives they also use their DC motors as generators to slow
down but dissipate the energy in resistor stacks. Newer designs are adding
large battery packs to recapture some of this energy.

Fig3.2.1 – Electromagnetic Motor

3.2.2 Brushed Motors

A brushed DC electric motor generating torque from DC power supply by

using an internal mechanical commutation. Stationary permanent magnets
form the stator field. Torque is produced by the principle that any current-
carrying conductor placed within an external magnetic field experiences a
force, known as Lorentz force. In a motor, the magnitude of this Lorentz
force (a vector represented by the green arrow), and thus the output torque,is
a function for rotor angle, leading to a phenomenon known as torque ripple)
Since this is a two-pole motor, the commutator consists of a split ring, so that
the current reverses each half turn ( 180 degrees).

35 | P a g e
The brushed DC electric motor generates torque directly from DC power
supplied to the motor by using internal commutation, stationary magnets
(permanent or electromagnets), and rotating electromagnets.
Advantages of a brushed DC motor include low initial cost, high
reliability, and simple control of motor speed. Disadvantages are high
maintenance and low life-span for high intensity uses. Maintenance
involves regularly replacing the carbon brushes and springs which carry
the electric current, as well as cleaning or replacing the commutator.
These components are necessary for transferring electrical power from
outside the motor to the spinning wire windings of the rotor inside the
motor. Brushes are usually made of graphite or carbon, sometimes with
added dispersed copper to improve conductivity. In use, the soft brush
material wears to fit the diameter of the commutator and continues to
wear. A brush holder has a spring to maintain pressure on the brush as it
shortens. For brushes intended to carry more than an ampere or two, a
flying lead will be molded into the brush and connected to the motor
terminals. Very small brushes may rely on sliding contact with a metal
brush holder to carry current into the brush or may rely on a contact
spring pressing on the end of the brush. The brushes in very small, short-
lived motors, such as are used in toys, may be made of a folded strip of
metal that contacts the commutator.

36 | P a g e
 Fig3.2.2. - Brushed Motors

3.2.3 BrushlessMotors

Typical brushless DC motors use one or more permanent magnets in the rotor
and electromagnets on the motor housing for the stator. A motor controller
converts DC to AC. This design is mechanically simpler than that of brushed
motors because it eliminates the complication of transferring power from

37 | P a g e
outside the motor to the spinning rotor. The motor controller can sense the
rotor's position via Hall effect sensors or similar devices and can precisely
control the timing, phase, etc., of the current in the rotor coils to optimize
torque, conserve power, regulate speed, and even apply some braking.
Advantages of brushless motors include long life span, little or no
maintenance, and high efficiency. Disadvantages include high initial cost, and
more complicated motor speed controllers. Some such brushless motors are
sometimes referred to as "synchronous motors" although they have no
external power supply to be synchronized with, as would be the case with

normal AC synchronous motors.

Fig3.2.3 - BrushlessMotors

38 | P a g e
3.2.4 Uncommitted

Other types of DC motors require no commutation.

Homopolar motor – A homopolar motor has a magnetic field along the axis
of rotation and an electric current that at some point is not parallel to the
magnetic field. The name homopolar refers to the absence of polarity change.
Homopolar motors necessarily have a single-turn coil, which limits them to
very low voltages. This has restricted the practical application of this type of
motor.

 Ball bearing motor –

A ball bearing motor is an unusual electric motor that consists of two ball
bearing-type bearings, with the inner races mounted on a common conductive
shaft, and the outer races connected to a high current, low voltage power
supply. An alternative construction fits the outer races inside a metal tube,
while the inner races are mounted on a shaft with a non-conductive section
(e.g. two sleeves on an insulating rod). This method has the advantage that
the tube will act as a flywheel. The direction of rotation is determined by the
initial spin which is usually required to get it going.

3.2.5 Permanent magnet stators

A PM motor does not have a field winding on the stator frame, instead
relying on PMs to provide the magnetic field against which the rotor field
interacts to produce torque. Compensating windings in series with the
armature may be used on large motors to improve commutation under load.
Because this field is fixed, it cannot be adjusted for speed control. PM fields

39 | P a g e
(stators) are convenient in miniature motors to eliminate the power
consumption of the field winding. Most larger DC motors are of the
"dynamo" type, which have stator windings. Historically, PMs could not be
made to retain high flux if they were disassembled; field windings were more
practical to obtain the needed amount of flux. However, large PMs are costly,
as well as dangerous and difficult to assemble; this favors wound fields for
large machines.

To minimize overall weight and size, miniature PM motors may use high
energy magnets made with neodymium or other strategic elements; most such
are neodymium-iron-boron alloy. With their higher flux density, electric
machines with high-energy PMs are at least competitive with all optimally
designed singly fed synchronous and induction electric machines. Miniature
motors resemble the structure in the illustration, except that they have at least
three rotor poles (to ensure starting, regardless of rotor position) and their
outer housing is a steel tube that magnetically links the exteriors of the curved
field magnets.

Fig3.2.5 -Permanent Magnet Stators

40 | P a g e
3.2.6 Wound Stator

A field coil may be connected in shunt, in series, or in compound with the

armature of a DC machine (motor or generator)

There are three types of electrical connections between the stator and rotor
possible for DC electric motors: series, shunt/parallel and compound (various
blends of series and shunt/parallel) and each has unique speed/torque
characteristics appropriate for different loading torque profiles/signatures.

Fig3.2.6 -Wound Stator

41 | P a g e
  Series connection

A series DC motor connects the armature and field windings in series with
a common D.C. power source. The motor speed varies as a non-linear
function of load torque and armature current; current is common to both the
stator and rotor yielding current squared (I^2) behavior. A series motor has
very high starting torque and is commonly used for starting high inertia loads,
such as trains, elevators or hoists. This speed/torque characteristic is useful in
applications such as dragline excavators, where the digging tool moves
rapidly when unloaded but slowly when carrying a heavy load.

A series motor should never be started at no load. With no mechanical load

on the series motor, the current is low, the counter-Electro motive force
produced by the field winding is weak, and so the armature must turn faster to
produce sufficient counter-EMF to balance the supply voltage. The motor can
be damaged by overspeed. This is called a runaway condition.

Series motors called universal motors can be used on alternating current.

Since the armature voltage and the field direction reverse at the same time,
torque continues to be produced in the same direction. However they run at a
lower speed with lower torque on AC supply when compared to DC due
to reactance voltage drop in AC which is not present in DC. Since the speed
is not related to the line frequency, universal motors can develop higher-than-
synchronous speeds, making them lighter than induction motors of the same
rated mechanical output. This is a valuable characteristic for hand-held power
tools. Universal motors for commercial utility are usually of small capacity,
not more than about 1 kW output. However, much larger universal motors
were used for electric locomotives, fed by special low-frequency traction
power networks to avoid problems with commutation under heavy and
varying loads.

42 | P a g e
  Shunt connection

A shunt DC motor connects the armature and field windings in parallel or

shunt with a common D.C. power source. This type of motor has good speed
regulation even as the load varies but does not have the starting torque of a
series DC motor. It is typically used for industrial, adjustable speed
applications, such as machine tools, winding/unwinding machines and
tensioners.

 Compound connection

A compound DC motor connects the armature and fields windings in a shunt

and a series combination to give it characteristics of both a shunt and a series
DC motor. This motor is used when both a high starting torque and good
speed regulation is needed. The motor can be connected in two arrangements:
cumulatively or differentially. Cumulative compound motors connect the
series field to aid the shunt field, which provides higher starting torque but
less speed regulation. Differential compound DC motors have good speed
regulation and are typically operated at constant speed.

43 | P a g e
 CHAPTER – 4
1. CHASSIS
2. STEERING

44 | P a g e
 4.1 CHASSIS FRAME AND BODY

4.1.1- Introduction

of Chassis Frame Chassis frame is the basic frame work of the

automobile. It supports all the parts of the automobile attached to it.
It is made of drop forged steel. All the parts related to automobiles
are attached to it only. All the systems related to automobile like
powerplant, transmission, steering, suspension, braking system etc.
are attached to and supported by it only.

4.1.2 Layout of Chassis

and its main components “Chassis” a French term which means the
complete Automobiles without Body and it includes all the systems
like power plant, transmission, steering, suspension, wheels tires,
auto electric system etc. without body. If Body is also attached to it
them it is known as the particular vehicle as per the shape and
design of the bodyLayout of Chassis and its main components
“Chassis” a French term which means the complete Automobiles
without Body and it includes all the systems like power plant,
transmission, steering, suspension, wheels tires, auto electric system
etc. without body. If Body is also attached to it them it is known as
the particular vehicle as per the shape and design of the body

45 | P a g e
fig 4.1.1-Chassis

Fig 4.1.2 – Chassis of Elevating Car

46 | P a g e
4.1.3 The Functions of the Chassis frame

1. To carryall the stationary loads attached to it and loads of

passenger and cargo carried in it.
2. To withstand torsional vibration caused by the movement of the
vehicle
3. To withstand the centrifugal force caused by cornering of the
vehicle
4. To control the vibration caused by the running of the vehicle.
5. To withstand bending stresses due to rise and fall of the front
and rear axles.

4.1.4 Types of Chassis frame

There are different types of chassis frame sections

1. Channel section
2. Box section
3. Tubular section

The conventional frame is also known as Non-load carrying frame. In these

type of frame, the loads on the vehicle are transferred to the suspension by the
frame which is the main skeleton of the vehicle. The channel section is used
in long members and box section in short members. Tubular section is used
now-a-days is three wheelers, scooters,
matadors and pickup vans. The frames should be strong enough to bear load
while sudden brakes and accidents.

47 | P a g e
4.1.5 Various loads acting on the Chassis frame

The loads acting on the chassis frame are as follow

1. Stationary loads namely the loads of permanent attachment like all

the parts of the chassis, body etc.
2. Short duration loads while turning, braking etc.
3. Momentary loads while quick acceleration, sudden braking etc.
4. Loads applied while crossing roads of irregular and uneven surfaces
5. Loads caused by sudden accidents, head on collusions etc.
6. Loads caused by irregular and overloading of vehicle.

4.1.6 Different Bodies used in Automobiles

The automobiles bodies are designed according to the requirement ofthe

vehicle. According to design and requirement of the vehicle, there
aredifferent types of Automobiles bodies. Some of them are listed as below:
(i) Car
(ii) Straight truck or Punjab truck body
(iii) Truck with half body
(iv) Platform type truck
(v) Tractor
(vi) Tractor with articulated trailer
(vii) Tanker
(viii) Bus
(ix) Dumper truck
(x) Delivery van
(xi) Station wagon
48 | P a g e
 (xii) Pick-up van
(xiii) Jeep
(xiv) Long wheel-based truck etc.

4.1.7 Requirement of Bodies for various types of vehicle

According to requirement, automobile bodies are classified mainly

intodifferent types namely private vehicle, commercial vehicle, fleet transport
vehicle,passenger transport vehicle, Ambulances vehicle used for transport of
Armypersonal, Ammunition etc., different types of tanker vehicle etc. If it is a
privatevehicle, the vehicle is used for luxury personal travelling, private cargo
transport etc., namely car,minivan, Omni bus, matador etc.If it is commercial
vehicle the vehicle is used for transportation of goodssome other vehicles,
freezer boxes etc. If it is tanker, it is used to transport milk, water, edible oils,
petroleum products,gases, acids etc.

49 | P a g e
 4.2 STEERING

(Rack and Pinion Gear Mechanism)

A rack and pinion are commonly found in the steering mechanism of cars or
other wheeled, steered vehicles. Rack and pinion provides a less efficient
mechanical than other mechanisms such as recirculation, but less backlash
and greater feedback, or steering "feel". Arthur Ernest Bishop invented the
use of a variable rack (still using a normal pinion) in the 1970s, to improve
vehicle response and steering "feel," especially at high speeds. He also
created a low-cost press forging process to manufacture the racks, eliminating
the need to machine the gear teeth. Generally, a steering system in modern
vehicle either commercial or owned consists of a Rack and Pinion gear
combination. Where the pinion is connected to the steering wheel through
steering column and while rotation the steering the pinion is rotated which is
in mesh with the rack which converts the rotational motion into linear
motions which moves the wheels with various geometry and positioning of
the steering unit. In India the cars are mostly found to be front wheel drive
and with the arrangement with drive shafts it made the turning of the wheels
limited. Rack-and-pinion steering is quickly becoming the most common type
of steering on cars, small trucks and SUVs. It is actually a 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, Fig 4.2.1-

50 | P a g e
 Fig 4.2.2 – solid works

(Rack and Pinion Gear steering)

51 | P a g e