AUTOMOTIVE SYSTEM DESIGN GROUP PROJECT Presentation

AUTOMOTIVE SYSTEM
DESIGN GROUP PROJECT

TUTOR: Mr. NEIL RAYNER
Group Members:
Venkatesh Peria Perumal (3521766)
Joel Fredrick Solomon (3444258)
Sanjai Jayakumar (3553790)
Madhan Mohan Soma Sundaram (3502514)
Riyaz Quraise Hyder Ali (3500554)
ABSTRACT
• To meet the growing demand for energy-efficient and environmentally
friendly vehicle needs
• Design of a commercially hybrid vehicle manufacturing in terms of
market knowledge, design and specification, advanced technology in
power train, management development tools.
• This paper also reports on the techniques of project planning and
development work packages, cost analysis and risk assessment for the
identification of the hybrid vehicle
INTRODUCTION
• Hybrid electric vehicle is the combination of internal combustion engine of
a conventional vehicle with the battery and electric motor.
• This combination offers the extended range and rapid refuelling that
consumers expect from a conventional vehicle, with a significant portion
of the energy and environmental benefits of an electric vehicle.
• The engine design, fuel consumption would be designed will be considered
as an important factor to increase due to the resulting fuel prices.
• The drive system powered by lithium - ion battery, the maximum voltage
of 200V 25kW of power production, if it is coupled with AC - synchronous
motor.
• The vehicle is also equipped to help with energy saving lamps and
recovery systems, which would results in the efficiency of the vehicle.
SERIES PARALLEL HYBRID
TECHNOLOGY
SPECIFICATION OF OUR HYBRID
VEHICLE
Engine type In line- 3 cylinder engine
Displacement 1200cc
Power 37 kw
Max torque 85 N-m at 4500 rpm
Fuel used Diesel
Battery Lithium –ion
Output 24 kw
Voltage 216V
Weight 52 kg
Motor Permanent Magnet AC Synchronous motor
Power output 55 kw
Voltage 450 V
Torque 190.@ 3000 rpm
VEHICLE DIMENSIONS
Wheel base 2820 mm
Length 4650 mm
Height 1675 mm
Width 1880 mm
Fuel tank capacity 45 litres
BATTERY
• Batteries have two functions energy storage and energy conservation.
• Lithium is mainly used because of its the lightest metal in addition to

having the highest electric potential of all metals.
• Energy density in the limits of 100-150.
• Power density is 300 (w/kg).
• After 10 years the battery is expected to have 70-80% of the original

storage capacity.
MOTOR
• Permanent Magnet AC Synchronous Motor.
• higher torque-to-volume ratio as compared with the induction motors.
• 4-poles 60KW (80hp) Permanent magnet AC synchronous motor which has three-
phase stator similar to that of an induction motor.
Motor characteristics
1. Motor speed:
Speed =
2. Torque:
Torque consists of force acting on distance.
Torque = Force × Distance
Force = Mass (Mv) × Acceleration (A)
A = change in velocity, V (speed) with respect to time
V= change in distance with respect to time
3. Power:
Power = V × I × P.F
AERODYNAMIC PERFORMANCE
• The main problem which reduces the performance of the car is

aerodynamic drag.
• Drag is nothing but a opposing force by the air.
Aerodynamic drag can be reduced by
following approaches for LCV:
• The front end of the LCV should have smooth and curve finish which
gives good improvement in performance.
• Low position of front-end is required to reduce Coefficient of drag which

also reduce the lift force at the front.
• LCV Roof should be smooth and curvature because it gives good looking
and good aerodynamic shape.
• Smooth finishing on the under body also plays important role to reduce the
frictional drag.
By the above discussion of the following consideration, the
following advantages can be obtained:
• Higher efficiency.
• Smoother design.
• Lower drag coefficient.
• Low wind noise while travelling in LCV.
• Quieter and smoother drive.
ENGINE
• The engine configuration would be an CI diesel engine 1.2 litre with 3

cylinder inline layout
• Engine power can be expressed as the product of brake torque Tb and the
engine speed N.
Engine output power, Pb =
•The mean effective pressure (MEP) measures the engine’s work done per
cycle per cylinder displaced volume.
•Indicated mean effective pressure (IMEP) is the total net work performed
by the working mixture in the cylinder of the engine over the compression
and expansion strokes.
SUSPENSION SYSTEM
MACPHERSON STRUT SUSPENSION
1. Macpherson strut suspension system was used in the large number of modern
vehicle in United Kingdom.
2. Based on a triangle design, typical Macpherson strut suspension assembly

includes
• A coil spring
• Upper suspension locator
• Shock absorber
MULTILINK SUSPENSION
• Upper and lower lateral arms attach between the knuckle and rear cross
member and are used to control lateral forces.
• The compression arm found on the front system is replaced with a toe
control system, which also connects between the cross member and
knuckle.
• A coil-over shock absorber attaches between the vehicle's body and the knuckle.
• The toe control arm limits toe-out on turns tendencies, and helps to control toe
angles during cornering.
• The configuration of the lower lateral arm and toe control arms also provide
passive rear steering.
REGENERATIVE BRAKING SYSTEM
• It is one of the major processes held in the EVs by which the electric motor
can be controlled and made to operate as a generator.
• It converts the kinetic or the potential energy produced by the vehicle into
electrical energy and finally stored in the battery and it is reused as power
for the vehicle.
• During the stopping the vehicle does not receive any energy from the
motor or the batteries.
• At that moment the axle rotates without any energy received from the
motor which acts as a generator for storing energy.
MANUFACTURING PROCESS
• The Laser-MIG hybrid welding which would the most feasible process for
joining of aluminium to steel for both structural and tailored blank
applications.
• The process is performed with the steel sheets coated with a thin layer of
zinc for the bonding process finished by laser beam.
• Aluminum edges acts as filler material with uniform depth and speed.
• advantage of this process would have the ability of gap to be bridged up to
1mm and compared to arc based processes a higher processing speed
which is exceeding 6m/min in thin sheet applications.
FASTENERS
• The flow drilling screws have been used in assemble of body panels and
chassis made of aluminium and thin mild steels.
• They can be performed with or without installing the punched or drilled
holes.
• They are often easier to install and more economical than the spot welding.
• The screw is screwed by automated robots which perform accurate
screwing with precise torque value.
COST ANALYSIS
Commercially available components:

• Tyres : 195/55/R15
• Bridgestone :£70 (each wheel)
• Nexen : £75
• Continental : £61.45
• Michelin : £ 74
• Pirelli : £ 81.43
• Dunlop SP : £ 69
• Internal Dashboard console : £ 1000 to £ 2200 (based on the variant of the car)
• Steering wheel : £100 to 300
• Light accessories (Interior) : £120 to 200 (http://www.phoenixautobulbs.co.uk)
• Light accessories (Exterior) : £ 250 to 300
• Seats and Leather upholstery :£ 150 to 300 (Caltrend -www.caltrend.com)
• Front Bumper (Fiber glass /ABS) : £ 200 (ABS moulders www. Asbmoulder.com/front
fenders)
• Rear Bumper (Fiber glass /ABS):£ 150 (ABS moulders www. Asbmoulder.com/rear fenders)
• Audio system: £ 200 to 300 (Kenwood)
SWOT ANALYSIS
Strengths:
• Better fuel efficiency than other similarly sized cars.
• Comfortable and quiet ride, smooth acceleration and braking without gear
changes.
• Spacious interior
• Low pollution
Weaknesses:
• Remains reliant on fossil fuel More expensive than other similarly sized
cars.
• Fuel economy can be highly dependent on season, climate, and driving
style.
Opportunities:
Developing a "plug-in hybrid" developed with higher capacity batteries
and a power train to be operated for long periods in pure electric mode.
• Distributed in other market segments (already happening at the upper end
with Lexus hybrid models)
• Raising awareness of environmental issues likely to keep demand high.
Threats:
• More competitors in the market.
• The vehicle has to get identity because its new to the market.
• Fluctuating government rules and regulations.
CRITICAL PATH ANALYSIS
RISKS
• Battery safety needs more concentration.

• Cost limitations
• Negative market feedback
• Country regulations
CONCLUSION
• This project demonstrates the growing need for sustainable transport and
the possible role of the Low Carbon Vehicle as a hybrid solution.
• A hybrid-efficiency and emissions depend on the particular combination of
subsystems, these subsystems into one system and the control strategy that
integrates the subsystems integrated.
• Hybrid fuel consumption reaches 10 to 15 percent higher than for
conventional vehicles
• The potential gains in fuel efficiency of hybrids depend on the type of
driving the vehicle will be used for higher profits in crowded city traffic
and highway driving

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AUTOMOTIVE SYSTEM

DESIGN GROUP PROJECT

• Lithium is mainly used because of its the lightest metal in addition to

• Energy density in the limits of 100-150.

• Power density is 300 (w/kg).

• After 10 years the battery is expected to have 70-80% of the original

• The main problem which reduces the performance of the car is

• Low position of front-end is required to reduce Coefficient of drag which

• The engine configuration would be an CI diesel engine 1.2 litre with 3

MACPHERSON STRUT SUSPENSION

2. Based on a triangle design, typical Macpherson strut suspension assembly

Commercially available components:

• Battery safety needs more concentration.

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