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Automotive Engineering
Note from the Publisher
This book has been compiled using extracts from the
following books within the range of Automotive
Engineering books in the Elsevier collection:
Blundell, M and Harty, D. (2004) The Multibody Systems
Approach to Vehicle Dynamics, 9780750651127
Brown, J., Robertson, A.J. and Serpento, S. (2001) Motor
Vehicle Structures, 9780750651349
Davies, G. (2003) ,Materials for Automobile Bodies
9780750656924
Fenton, J. and Hodkinson, R. (2001) Lightweight Electric/
Hybrid Vehicle Design, 9780750650922
Garrett, T.K., Newton, K. and Steels, W. (2000) The
Motor Vehicle 13e, 9780750644495
Happian-Smith, J (2001) Introduction to Modern Vehicle
Design, 9780750661294
Heisler, H. (1998) Vehicle and Engine Technology,
9780340691861
Martyr, A.J. and Plint, M.A. (2007) Engine Testing 3e,
9780750684392
Pacejka, H. (2005) Tyre and Vehicle Dynamics,
9780750669184
Reimpell, J., Stoll, H. and Betzler, J. (2001) Automotive
Chassis: Engineering Principles, 9780750650540
Ribbens, W. (2003) Understanding Automotive Electron-
ics, 9780750675994
Vlacic, L. and Parent, M. (2001) Intelligent Vehicle Tech-
nologies, 9780750650939
The extracts have been taken directly from the above
source books, with some small editorial changes. These
changes have entailed the re-numbering of Sections and
Figures. In view of the breadth of content and style of the
source books, there is some overlap and repetition of
material between chapters and significant differences in
style, but these features have been left in order to retain
the flavour and readability of the individual chapters.
Units of measure
Units are provided in either SI or IP units. A conversion
table for these units is provided at the front of the
book.
Upgrade to an Electronic Version
An electronic version of Automotive Engineering, the
Automotive Engineering e-Mega Reference, 9781856175784
A fully searchable Mega Reference eBook, providing all
the essential material needed by Automotive Engineers
on a day-to-day basis.
Fundamentals, key techniques, engineering best
practice and rules-of-thumb at one quick click of
a button
Over 1,500 pages of reference material, including over
1,000 pages not included in the print edition
Go to http://www.elsevierdirect.com/9781856175777
and click on Ebook Available
Automotive
Engineering
Powertrain,ChassisSystemand VehicleBody
EditedbyDavidA.Crolla
Amsterdam$ Boston$ Heidelberg$ London$ NewYork $ Oxford
Paris$ SanDiego$ SanFrancisco$ Sydney$ Tokyo
Butterworth-HeinemannisanimprintofElsevier
Butterworth-Heinemann is an imprint of Elsevier
Linacre House, Jordan Hill, Oxford OX2 8DP, UK
30 Corporate Drive, Suite 400, Burlington, MA 01803, USA
First edition 2009
Copyright 2009 Elsevier Inc. All rights reserved
No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means electronic, mechanical, photocopying, recording or otherwise
without the prior written permission of the publisher
Permissions may be sought directly from Elsevier’s Science & Technology Rights
Department in Oxford, UK: phone (+44) (0) 1865 843830; fax (+44) (0) 1865 853333;
email: permissions@elsevier.com. Alternatively visit the Science and Technology website at
www.elsevierdirect.com/rights for further information
Notice
No responsibility is assumed by the publisher for any injury and/or damage to persons or
property as a matter of products liability, negligence or otherwise, or from any use or
operation of any methods, products, instructions or ideas contained in the material herein.
Because of rapid advances in the medical sciences, in particular, independent verification of
diagnoses and drug dosages should be made
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing-in-Publication Data
A catalog record for this book is available from the Library of Congress
ISBN: 978-1-85617-577-7
For information on all Butterworth-Heinemann publications
visit our web site at elsevierdirect.com
Printed and bound in the United States of America
09 10 11 11 10 9 8 7 6 5 4 3 2 1
Contents
Section1 INTRODUCTIONTOENGINEDESIGN .......... ..................... ............ ..... 1
1.1 Piston-enginescyclesofoperation .... ...... ......... ......... ........ ......... 3
Section2 ENGINETESTING .... . .... . .. . ... ... .... . . .. ... . .. .. .... . ... ... ... . .. . . .. . .. . .. 19
2.1 Measurement oftorque,power,speedandfuel consumption;acceptance
andtypetests,accuracyofthemeasurements . ..... ........ ................ . .... 21
Section3 ENGINEEMISSIONS .... . ... .. .. . ... ... .... .. .. ... ... . .... .... . . .. ... ... .... ... . 51
3.1 Emissionscontrol ................ ......... ........ ......... ............ .... 53
Section4 DIGITALENGINECONTROL .... .. .... ... . .. . . . .. .... .. ... .. .... . . .. ... ... ... .. . .. 75
4.1 Digitalenginecontrolsystems ........ ...... .............. .......... ........ .. 77
Section5 TRANSMISSIONS .. ... .. ... .. . ... ... .... . . .. ... . .. .. .. ... ... ... ... . .. . . .. . .. .. 105
5.1 Transmissionsanddriveline . ............ ... .............. .......... ....... .. 107
Section6 ELECTRIC VEHICLES .. .. ... .. . ... ... . . .. . . .. . . .. .... .. ... ... ... ... . .. .. . . .. . .. 141
6.1 Battery/fuel-cellEVdesign packages ..... ............ . ........ ........ ....... 143
Section7 HYBRIDVEHICLES .............................. ............................. . 173
7.1 Hybridvehicledesign ............. . ........ ........ ............... ...... ... 175
Section8 SUSPENSIONS .. .. .. . ... .. . ... ... .. ... . .. . . .. . .. . .. ... ... ... . . .. .... .. ... ... . 203
8.1 Typesofsuspensionand drive . ...... ...... .............. .......... ........ . 205
Section9 STEERING ... ..... ... .... ... .... ..... ..... ... .... ..... .... .... ... ..... ... ... 255
9.1 Steering .. ....................... ............... ...... ......... ........ . 257
Section10 TYRES .. .. .... .. ... .. .... ... . ... ... . .. . . ... ... . .. .. ... .... .... ... ... ... . .. . 283
10.1 Tyresandwheels ............. ....... ......... ....... ................. . ... 285
Section11 HANDLING ... .. .. ... ... ... ... . ... ... . .. . . . .. .. . . .. .. .... ... .... .... .. ... .. . . 323
11.1 Tyre characteristicsandvehiclehandlingandstability . ....... ..... ........... .... 325
Section12 BRAKES .................... ............ ......................... ........... 359
12.1 Brakingsystems ..... ........... ............. .... ............ ......... ... 361
v
Section13 VEHICLECONTROLSYSTEMS .... . .. ... ... ... . .. . . .. .. . .. . .. .... ... . .. . ... ... .. . 391
13.1 Vehiclemotioncontrol . .. ........... .... ............... ....... ............ . 393
Section14 INTELLIGENTTRANSPORTSYSTEMS ............................. ......... ....... 417
14.1 Globalpositioningtechnology ......... ........... ....... ........ ............ 419
14.2 Decisionalarchitecture... ....... ........ ........ ......... .............. .... 437
Section15 VEHICLEMODELLING ....... ... . .. .. ... . ... . ... ... ... . .. .. .... ... . ... ... . .. .. . 473
15.1 Modellingandassemblyofthefullvehicle .... ............. .. .............. .... 475
Section16 STRUCTURALDESIGN .... .. . .... .... . . .. .... ... ... . . .. .... . . .. .... .. . .... .... . 525
16.1 Terminologyandoverviewofvehiclestructuretypes .. . ...... ........ ............ 527
16.2 Standardsedan(saloon) –baselineloadpaths . ....... ........ ...... ............ 542
Section17 VEHICLESAFETY ........................... ........................... ....... 567
17.1 Vehiclesafety ........ ......... ......... ........... ...... ........... ...... 569
Section18 MATERIALS .... ... . .. .. . . .. . .... .. ... .. . ... ... . . .. . . .. .. ... ... ... .... .... ... 591
18.1 Designandmaterialutilization .... ........ ............... .. .............. .... 593
18.2 Materialsforconsiderationanduseinautomotivebodystructures .............. .... 632
Section19 AERODYNAMICS ............. .......... ............................... ...... . 661
19.1 Body design:aerodynamics. . ............ . ....... ......... .............. .... 663
Section20 REFINEMENT . ............ ......................... ... ....................... 673
20.1 Vehiclerefinement:purposeandtargets ............ ..... ......... ............. 675
Section21 INTERIORNOISE ................................... ... ....................... 685
21.1 Interiornoise:assessmentandcontrol ...... ........... ...... ............. .... 687
Section22 EXTERIORNOISE ................................... .......................... 737
22.1 Exteriornoise:assessmentandcontrol ..... ....... ........... ...... ........... 739
Section23 INSTRUMENTATIONANDTELEMATICS ................................... ........ . 783
23.1 Automotiveinstrumentationandtelematics .. ........ ......... ...... ........... . 785
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
CONTENTS
vi
SectionOne
Introduction toenginedesign
SectionOne Section SectionOne One SectionOne SectionOne
1
Thispageisleftintentionallyleftblank
1.1
Chapter1.1
Piston-enginecycles
ofoperation
HeinzHeisler
1.1.1 Theinternal-combustion
engine
Thepistonengineisknownasan internal-combustion
heat-engine.Theconceptofthepistonengineisthat
asupplyofair-and-fuelmixtureisfed totheinsideofthe
cylinderwhereitiscompressedand thenburnt.This
internalcombustionreleasesheatenergy which isthen
convertedintousefulmechanicalworkasthehighgas
pressuresgenerated forcethepistonto movealongits
strokeinthecylinder. Itcanbesaid,therefore,that
aheat-engineis merelyanenergytransformer.
To enablethepistonmovementtobeharnessed,the
drivingthrustonthepistonistransmittedbymeansof
aconnecting-rod toacrankshaft whosefunctionisto
convertthelinear piston motioninthe cylinderto
arotarycrankshaftmovement( ).ThepistonFig.1.1-1
canthusbemadetorepeatitsmovementtoandfro,due
totheconstraintsofthecrankshaft crankpin’scircular
pathandtheguidingcylinder.
The backward-and-forward displacement of the
piston isgenerallyreferredtoasthereciprocatingmotion
ofthepiston,sothesepower unitsarealsoknownas
reciprocatingengines.
1.1.1.1 Engine components and terms
Themainprobleminunderstandingtheconstructionof
thereciprocatingpistonengineisbeingabletoidentify
andnamethe variouspartsmakingupthepowerunit. To
this end, the following briefly describes the major
componentsand thenamesgivento them(Figs.1.1-1
and1.1-2).
Cylinderblock Thisis acaststructurewithcylin-
dricalholesboredtoguide andsupportthepistonsandto
harnesstheworkinggases.Italsoprovidesajacketto
containaliquidcoolant.
Cylinderhead Thiscastingencloses the combus-
tionendofthe cylinderblockandhousesboththeinlet
andexhaustpoppet-valvesandtheirportstoadmitair–
fuelmixtureandtoexhaustthecombustionproducts.
Crankcase Thisis acastrigid structurewhichsup-
portsandhousesthe crankshaftand bearings.Itisusually
castasamono-constructionwith thecylinderblock.
Sump This isapressed-steelorcast-aluminium-
alloy containerwhichenclosesthebottomofthecrank-
caseandprovidesareservoirfortheengine’s lubricant.
Fig.1.1-1 Pictorialviewofthebasicengine.
VehicleandEngineTechnology,ISBN:9780340691861
Copyright 1998HeinzHeisler.All rightsof reproduction,inanyform,reserved.
| 1/80

Preview text:

Automotive Engineering Note from the Publisher
This book has been compiled using extracts from the
The extracts have been taken directly from the above
following books within the range of Automotive
source books, with some small editorial changes. These
Engineering books in the Elsevier collection:
changes have entailed the re-numbering of Sections and
Figures. In view of the breadth of content and style of the
Blundell, M and Harty, D. (2004) The Multibody Systems
source books, there is some overlap and repetition of
Approach to Vehicle Dynamics, 9780750651127
material between chapters and significant differences in
Brown, J., Robertson, A.J. and Serpento, S. (2001) Motor
style, but these features have been left in order to retain
Vehicle Structures, 9780750651349
the flavour and readability of the individual chapters.
Davies, G. (2003) Materials for Automobile Bodies, 9780750656924 Units of measure
Fenton, J. and Hodkinson, R. (2001) Lightweight Electric/
Units are provided in either SI or IP units. A conversion
Hybrid Vehicle Design, 9780750650922
table for these units is provided at the front of the
Garrett, T.K., Newton, K. and Steels, W. (2000) The book.
Motor Vehicle 13e, 9780750644495
Happian-Smith, J (2001) Introduction to Modern Vehicle
Upgrade to an Electronic Version Design, 9780750661294
An electronic version of Automotive Engineering, the
Heisler, H. (1998) Vehicle and Engine Technology,
Automotive Engineering e-Mega Reference, 9781856175784 9780340691861
 A fully searchable Mega Reference eBook, providing all
Martyr, A.J. and Plint, M.A. (2007) Engine Testing 3e,
the essential material needed by Automotive Engineers 9780750684392 on a day-to-day basis. Pacejka, H. (2005) Tyre and Vehicle Dynamics, 9780750669184
 Fundamentals, key techniques, engineering best
Reimpell, J., Stoll, H. and Betzler, J. (2001) Automotive
practice and rules-of-thumb at one quick click of
Chassis: Engineering Principles, 9780750650540 a button
Ribbens, W. (2003) Understanding Automotive Electron-
 Over 1,500 pages of reference material, including over ics, 9780750675994
1,000 pages not included in the print edition
Vlacic, L. and Parent, M. (2001) Intelligent Vehicle Tech-
Go to http://www.elsevierdirect.com/9781856175777 nologies, 9780750650939 and click on Ebook Available Automotive Engineering
Powertrain,ChassisSystemand VehicleBody EditedbyDavidA.Crolla
Amsterdam$ Boston$ Heidelberg$ London$ NewYork $ Oxford
Paris$ SanDiego$ SanFrancisco$ Sydney$ Tokyo
Butterworth-HeinemannisanimprintofElsevier
Butterworth-Heinemann is an imprint of Elsevier
Linacre House, Jordan Hill, Oxford OX2 8DP, UK
30 Corporate Drive, Suite 400, Burlington, MA 01803, USA First edition 2009 Copyright
2009 Elsevier Inc. All rights reserved
No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means electronic, mechanical, photocopying, recording or otherwise
without the prior written permission of the publisher
Permissions may be sought directly from Elsevier’s Science & Technology Rights
Department in Oxford, UK: phone (+44) (0) 1865 843830; fax (+44) (0) 1865 853333;
email: permissions@elsevier.com. Alternatively visit the Science and Technology website at
www.elsevierdirect.com/rights for further information Notice
No responsibility is assumed by the publisher for any injury and/or damage to persons or
property as a matter of products liability, negligence or otherwise, or from any use or
operation of any methods, products, instructions or ideas contained in the material herein.
Because of rapid advances in the medical sciences, in particular, independent verification of
diagnoses and drug dosages should be made
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing-in-Publication Data
A catalog record for this book is available from the Library of Congress ISBN: 978-1-85617-577-7
For information on all Butterworth-Heinemann publications
visit our web site at elsevierdirect.com
Printed and bound in the United States of America
09 10 11 11 10 9 8 7 6 5 4 3 2 1 Contents
Section1 INTRODUCTIONTOENGINEDESIGN .......... ..................... ............ ..... 1
1.1 Piston-enginescyclesofoperation .... ...... ......... ......... ........ ......... 3
Section2 ENGINETESTING .... . .... . .. . ... ... .... . . .. ... . .. .. .... . ... ... ... . .. . . .. . .. . .. 19
2.1 Measurement oftorque,power,speedandfuel consumption;acceptance
andtypetests,accuracyofthemeasurements . ..... ........ ................ . .... 21
Section3 ENGINEEMISSIONS .... . ... .. .. . ... ... .... .. .. ... ... . .... .... . . .. ... ... .... ... . 51
3.1 Emissionscontrol ................ ......... ........ ......... ............ .... 53
Section4 DIGITALENGINECONTROL .... .. .... ... . .. . . . .. .... .. ... .. .... . . .. ... ... ... .. . .. 75
4.1 Digitalenginecontrolsystems ........ ...... .............. .......... ........ .. 77
Section5 TRANSMISSIONS .. ... .. ... .. . ... ... .... . . .. ... . .. .. .. ... ... ... ... . .. . . .. . .. .. 105
5.1 Transmissionsanddriveline . ............ ... .............. .......... ....... .. 107
Section6 ELECTRIC VEHICLES .. .. ... .. . ... ... . . .. . . .. . . .. .... .. ... ... ... ... . .. .. . . .. . .. 141
6.1 Battery/fuel-cellEVdesign packages ..... ............ . ........ ........ ....... 143
Section7 HYBRIDVEHICLES .............................. ............................. . 173
7.1 Hybridvehicledesign ............. . ........ ........ ............... ...... ... 175
Section8 SUSPENSIONS .. .. .. . ... .. . ... ... .. ... . .. . . .. . .. . .. ... ... ... . . .. .... .. ... ... . 203
8.1 Typesofsuspensionand drive . ...... ...... .............. .......... ........ . 205
Section9 STEERING ... ..... ... .... ... .... ..... ..... ... .... ..... .... .... ... ..... ... ... 255
9.1 Steering .. ....................... ............... ...... ......... ........ . 257
Section10 TYRES .. .. .... .. ... .. .... ... . ... ... . .. . . ... ... . .. .. ... .... .... ... ... ... . .. . 283
10.1 Tyresandwheels ............. ....... ......... ....... ................. . ... 285
Section11 HANDLING ... .. .. ... ... ... ... . ... ... . .. . . . .. .. . . .. .. .... ... .... .... .. ... .. . . 323
11.1 Tyre characteristicsandvehiclehandlingandstability . ....... ..... ........... .... 325
Section12 BRAKES .................... ............ ......................... ........... 359
12.1 Brakingsystems ..... ........... ............. .... ............ ......... ... 361 v CONTENTS
Section13 VEHICLECONTROLSYSTEMS .... . .. ... ... ... . .. . . .. .. . .. . .. .... ... . .. . ... ... .. . 391
13.1 Vehiclemotioncontrol . .. ........... .... ............... ....... ............ . 393
Section14 INTELLIGENTTRANSPORTSYSTEMS ............................. ......... ....... 417
14.1 Globalpositioningtechnology ......... ........... ....... ........ ............ 419
14.2 Decisionalarchitecture... ....... ........ ........ ......... .............. .... 437
Section15 VEHICLEMODELLING ....... ... . .. .. ... . ... . ... ... ... . .. .. .... ... . ... ... . .. .. . 473
15.1 Modellingandassemblyofthefullvehicle .... ............. .. .............. .... 475
Section16 STRUCTURALDESIGN .... .. . .... .... . . .. .... ... ... . . .. .... . . .. .... .. . .... .... . 525
16.1 Terminologyandoverviewofvehiclestructuretypes .. . ...... ........ ............ 527
16.2 Standardsedan(saloon) –baselineloadpaths . ....... ........ ...... ............ 542
Section17 VEHICLESAFETY ........................... ........................... ....... 567
17.1 Vehiclesafety ........ ......... ......... ........... ...... ........... ...... 569
Section18 MATERIALS .... ... . .. .. . . .. . .... .. ... .. . ... ... . . .. . . .. .. ... ... ... .... .... ... 591
18.1 Designandmaterialutilization .... ........ ............... .. .............. .... 593
18.2 Materialsforconsiderationanduseinautomotivebodystructures .............. .... 632
Section19 AERODYNAMICS ............. .......... ............................... ...... . 661
19.1 Body design:aerodynamics. . ............ . ....... ......... .............. .... 663
Section20 REFINEMENT . ............ ......................... ... ....................... 673
20.1 Vehiclerefinement:purposeandtargets ............ ..... ......... ............. 675
Section21 INTERIORNOISE ................................... ... ....................... 685
21.1 Interiornoise:assessmentandcontrol ...... ........... ...... ............. .... 687
Section22 EXTERIORNOISE ................................... .......................... 737
22.1 Exteriornoise:assessmentandcontrol ..... ....... ........... ...... ........... 739
Section23 INSTRUMENTATIONANDTELEMATICS ................................... ........ . 783
23.1 Automotiveinstrumentationandtelematics .. ........ ......... ...... ........... . 785
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809 vi
SectionOne SectionOne SectionOne SectionOne SectionOne SectionOne Introduction toenginedesign 1
Thispageisleftintentionallyleftblank Chapter1.1 1.1 Piston-enginecycles ofoperation HeinzHeisler 1.1.1 Theinternal-combustion engine
Thepistonengineisknownasan internal-combustion
heat-engine.Theconceptofthepistonengineisthat
asupplyofair-and-fuelmixtureisfed totheinsideofthe
cylinderwhereitiscompressedand thenburnt.This
internalcombustionreleasesheatenergy which isthen
convertedintousefulmechanicalworkasthehighgas
pressuresgenerated forcethepistonto movealongits
strokeinthecylinder. Itcanbesaid,therefore,that
aheat-engineis merelyanenergytransformer.
To enablethepistonmovementtobeharnessed,the
drivingthrustonthepistonistransmittedbymeansof
aconnecting-rod toacrankshaft whosefunctionisto
convertthelinearpistonmotioninthecylinderto
arotarycrankshaftmovement(Fig.1.1-1).Thepiston
canthusbemadetorepeatitsmovementtoandfro,due
totheconstraintsofthecrankshaft crankpin’scircular pathandtheguidingcylinder.
The backward-and-forward displacement of the
Fig.1.1-1 Pictorialviewofthebasicengine.
piston isgenerallyreferredtoasthereciprocatingmotion
ofthepiston,sothesepower unitsarealsoknownas reciprocatingengines.
harnesstheworkinggases.Italsoprovidesajacketto containaliquidcoolant.
1.1.1.1 Engine components and terms Cylinderhead
Thiscastingencloses the combus-
tionendofthe cylinderblockandhousesboththeinlet
Themainprobleminunderstandingtheconstructionof
andexhaustpoppet-valvesandtheirportstoadmitair–
thereciprocatingpistonengineisbeingabletoidentify
fuelmixtureandtoexhaustthecombustionproducts.
andnamethe variouspartsmakingupthepowerunit. To
Crankcase Thisis acastrigid structurewhichsup-
this end, the following briefly describes the major
portsandhousesthe crankshaftand bearings.Itisusually
componentsand thenamesgivento them(Figs.1.1-1
castasamono-constructionwith thecylinderblock. and1.1-2). Sump
This isapressed-steelorcast-aluminium- Cylinderblock
Thisis acaststructurewithcylin-
alloy containerwhichenclosesthebottomofthecrank-
dricalholesboredtoguide andsupportthepistonsandto
caseandprovidesareservoirfortheengine’s lubricant.
VehicleandEngineTechnology,ISBN:9780340691861 Copyright
1998HeinzHeisler.All rightsof reproduction,inanyform,reserved.