Monday, 10 August 2009

Valve Mechanism














A valve mechanism is a group of components that
opens and closes the intake and exhaust valves in
the cylinder head at the appropriate timing.
Crankshaft
Timing sprocket
Timing chain
Intake camshaft
Intake valve
Exhaust camshaft
Exhaust valve
* The diagram shows a VVT-i system valve
mechanism.

Intake stroke



The exhaust valve closes and the intake valve
opens. The downward stroke of the piston causes
the air-fuel mixture to be drawn into the cylinder
from the open intake valve

Exhaust stroke



The exhaust valve opens as the piston is about to
complete its downward stroke. Then, the exhaust
gases that result from the combustion are
discharged outside of the cylinder

Combustion stroke



When the piston is about to complete its upward
stroke, current flows to the spark plug, thus
creating a spark. This is then followed by the
combustion of the compressed air-fuel mixture and
an explosion. This explosion pushes the piston
downward, causing the crankshaft to rotate

Compression stroke



The piston completes its downward stroke and the
intake valve closes. The air-fuel mixture that is
drawn into the cylinder becomes highly
compressed with the upward stroke of the piston

Fuel cell hybrid vehicle (FCHV)



This electric vehicle uses the electric energy that is
created when the hydrogen fuel reacts with the
oxygen in the air to form water. Because it emits
only water, this is considered to be the ultimate
form of low- pollution vehicle, and is anticipated to
become the motive power for the next generation.
• The diagram indicates Toyota fuel cell hybrid
system.
Power control unit
Electric motor
Fuel cell stack
Hydrogen storage system
Secondary battery

Electric vehicle (EV)



This vehicle uses the power of the batteries to
operate the electric motor. Instead of using fuel, the
batteries require recharging. It offers many
advantages, including zero emissions and low
noise during operation. System of wheel drive uses
290V, on the other hand, other electric 12V.
• The diagram indicates Toyota EV system.
Power control unit
Electric motor
Battery

Diesel engine vehicle



This type of vehicle runs on an engine that uses
diesel fuel. Because diesel engines produce large
torque and offer good fuel economy, they are
widely used in trucks and SUVs.
SUV: Sports Utility Vehicle
Engine
Fuel tank (diesel fuel)

Classification by Drive Method



Vehicles can be classified by the position of the
engine and drive wheels, and the number of drive
wheels.
FF (Front-engine, Front-drive)
Because a FF vehicle does not have a propeller
shaft, a spacious interior can be realized, thus
achieving excellent comfort.
FR (Front-engine, Rear-drive)
Because a FR vehicle has a good weight
balance, it excels in controllability and stability.
MR (Midship-engine, Rear-drive)
Because a MR vehicle has a good weight
balance on the front and rear axles, it excels in
controllability.
4WD (4-Wheels Drive)
Because a 4WD vehicle drives with four
wheels, it can operate under poor conditions in
a stable manner. Its weight is greater than that
of other types of vehicles.

Tuesday, 4 August 2009

The Master Cylinder Brake system


The master cylinder displaces hydraulic brake fluid under pressure to the rest of the brake system. When the brake pedal is depressed, the push rod moves the primary piston forward in the cylinder. The hydraulic pressure created and the force of the primary piston spring moves the secondary piston forward. When the forward movement of the pistons causes their primary cups to cover the bypass holes, hydraulic pressure builds up and is transmitted to the wheel cylinders. When the pedal retracts, the pistons allow fluid from the reservoir to fill the chamber if needed. Special sensors within the master cylinder are used to monitor the level of the fluid in the reservoir, and to alert the driver if a pressure imbalance develops. The standard dual master cylinder gives the front and rear brakes separate hydraulic systems. If a brake fluid leak occurs in one system, the other system will still operate, making it possible to stop the car.

Some Details of Car Engine


The basic components of an internal-combustion engine are the engine block, cylinder head, cylinders, pistons, valves, crankshaft, and camshaft. The lower part of the engine, called the engine block, houses the cylinders, pistons, and crankshaft. The components of other engine systems bolt or attach to the engine block. The block is manufactured with internal passageways for lubricants and coolant. Engine blocks are made of cast iron or aluminum alloy and formed with a set of round cylinders.

The upper part of the engine is the cylinder head. Bolted to the top of the block, it seals the tops of the cylinders. Pistons compress air and fuel against the cylinder head prior to ignition. The top of the piston forms the floor of the combustion chamber. A rod connects the bottom of the piston to the crankshaft. Lubricated bearings enable both ends of the connecting rod to pivot, transferring the piston’s vertical motion into the crankshaft’s rotational force, or torque. The pistons’ motion rotates the crankshaft at speeds ranging from about 600 to thousands of revolutions per minute (rpm), depending on how much fuel is delivered to the cylinders.

Fuel vapor enters and exhaust gases leave the combustion chamber through openings in the cylinder head controlled by valves. The typical engine valve is a metal shaft with a disk at one end fitted to block the opening. The other end of the shaft is mechanically linked to a camshaft, a round rod with odd-shaped lobes located inside the engine block or in the cylinder head. Inlet valves open to allow fuel to enter the combustion chambers. Outlet valves open to let exhaust gases out.

A gear wheel, belt, or chain links the camshaft to the crankshaft. When the crankshaft forces the camshaft to turn, lobes on the camshaft cause valves to open and close at precise moments in the engine’s cycle. When fuel vapor ignites, the intake and outlet valves close tightly to direct the force of the explosion downward on the piston.

Brake Bands and Piston infomation


A brake band is made of steel, and has a friction lining. One end of the band is attached a servo actuating rod. A servo actuating rod is a hydraulic piston (a cylinder with a piston inside it) that is open at one end to allow oil to flow in. The piston is normally in the released position because it's kept that way by a spring. However, when pressurized oil is sent to the cylinder, the oil forces the piston forward. This causes the brake band to tighten, and this locks the brake.

Bleeder Valves


Since the brake system is filled with fluid, it must be occasionally "bled" or the old fluid released in order to install new fluid. It is also occasionally necessary to remove air bubbles that get into the system if any of the parts are changed. Disc brakes, drum brakes and all hydraulic brakes have bleeder valves next to the slave pistons. These are opened when the system is being bled and brake fluid flows out as well as air bubbles. When the brake fluid is coming out without any air bubbles, the mechanic seals the bleeder valve and tops off the brake fluid reservoir. Bleeder valves can also be found on the side of the reservoir. These are used for the same purpose; getting air bubbles out of the master cylinder assembly. If you have air bubbles in your fluid, your pedal will feel softer than normal, and braking power will be reduced, so it is a good idea to have your brakes bled and the fluid changed according to your owner's manual.

All about brakes system



Brakes enable the driver to slow or stop the moving vehicle. The first automobile brakes were much like those on horse-drawn wagons. By pulling a lever, the driver pressed a block of wood, leather, or metal, known as the shoe, against the wheel rims. With sufficient pressure, friction between the wheel and the brake shoe caused the vehicle to slow down or stop. Another method was to use a lever to clamp a strap or brake shoes tightly around the driveshaft.

A brake system with shoes that pressed against the inside of a drum fitted to the wheel, called drum brakes, appeared in 1903. Since the drum and wheel rotate together, friction applied by the shoes inside the drum slowed or stopped the wheel. Cotton and leather shoe coverings, or linings, were replaced by asbestos after 1908, greatly extending the life of the brake mechanism. Hydraulically assisted braking was introduced in the 1920s. Disk brakes, in which friction pads clamp down on both sides of a disk attached to the axle, were in use by the 1950s.

An antilock braking system (ABS) uses a computer, sensors, and a hydraulic pump to stop the automobile’s forward motion without locking the wheels and putting the vehicle into a skid. Introduced in the 1980s, ABS helps the driver maintain better control over the car during emergency stops and while braking on slippery surfaces.

Automobiles are also equipped with a hand-operated brake used for emergencies and to securely park the car, especially on uneven terrain. Pulling on a lever or pushing down on a foot pedal sets the brake.

Disc and Drum Brakes Disc and drum brakes create friction to slow the wheels of a motor vehicle. When a driver presses on the brake pedal of a vehicle, brake lines filled with fluid transmit the force to the brakes. In a disc brake, the fluid pushes the brake pads in the caliper against the rotor, slowing the wheel. In a drum brake, the fluid pushes small pistons in the brake cylinder against the hinged brake shoes. The shoes pivot outward and press against a drum attached to the wheel to slow the wheel.

Air Compressor information


Air Compressor, also air pump, machine that decreases the volume and increases the pressure of a quantity of air by mechanical means. Air thus compressed possesses great potential energy, because when the external pressure is removed, the air expands rapidly. The controlled expansive force of compressed air is used in many ways and provides the motive force for air motors and tools, including pneumatic hammers, air drills, sandblasting machines, and paint sprayers. See Compressed Air.
Air compressors are of two general types: reciprocating and rotating. In a reciprocating, or displacement, compressor which is used to produce high pressures, the air is compressed by the action of a piston in a cylinder. When the piston moves to the right, air flows into the cylinder through the intake valve; when the piston moves to the left, the air is compressed and forced through an output-control valve into a reservoir or storage tank.
A rotating air compressor used for low and medium pressures, usually consists of a bladed wheel or impeller that spins inside a closed circular housing. Air is drawn in at the center of the wheel and accelerated by the centrifugal force of the spinning blades. The energy of the moving air is then converted into pressure in the diffuser, and the compressed air is forced out through a narrow passage to the storage tank.





As air is compressed it is also heated. Air molecules tend to collide more often with each other in a smaller space, and the energy produced by these collisions is evident as heat. This heat is undesirable in the compression process, so the air may be cooled on the way to the reservoir by circulating air or water. For high-pressure compressed air, several stages of compression may be employed, with the air being further compressed in each cylinder and cooled before each stage.

also Heating, Ventilating, and Air Conditioning; Heat Transfer; Pump.

Two Stroke Engine



By suitable design it is possible to operate an Otto-cycle or diesel as a two-stroke or two-cycle engine with a power stroke every other stroke of the piston instead of once every four strokes. The power of a two-stroke engine is usually double that of a four-stroke engine of comparable size.

The general principle of the two-stroke engine is to shorten the periods in which fuel is introduced to the combustion chamber and in which the spent gases are exhausted to a small fraction of the duration of a stroke instead of allowing each of these operations to occupy a full stroke. In the simplest type of two-stroke engine, the poppet valves are replaced by sleeve valves or ports (openings in the cylinder wall that are uncovered by the piston at the end of its outward travel). In the two-stroke cycle, the fuel mixture or air is introduced through the intake port when the piston is fully withdrawn from the cylinder. The compression stroke follows, and the charge is ignited when the piston reaches the end of this stroke. The piston then moves outward on the power stroke, uncovering the exhaust port and permitting the gases to escape from the combustion chamber.

Monday, 3 August 2009

How to work Turbo Charger


The turbocharger is bolted to the exhaust manifold of the engine. The exhaust from the cylinders spins the turbine, which works like a gas turbine engine. The turbine is connected by a shaft to the compressor, which is located between the air filter and the intake manifold. The compressor pressurizes the air going into the pistons.
The exhaust from the cylinders passes through the turbine blades, causing the turbine to spin. The more exhaust that goes through the blades, the faster they spin.
On the other end of the shaft that the turbine is attached to, the compressor pumps air into the cylinders. The compressor is a type of centrifugal pump -- it draws air in at the center of its blades and flings it outward as it spins.
In order to handle speeds of up to 150,000 rpm, the turbine shaft has to be supported very carefully. Most bearings would explode at speeds like this, so most turbochargers use a fluid bearing. This type of bearing supports the shaft on a thin layer of oil that is constantly pumped around the shaft. This serves two purposes: It cools the shaft and some of the other turbocharger parts, and it allows the shaft to spin without much friction.
There are many tradeoffs involved in designing a turbocharger for an engine. In the next section, we'll look at some of these compromises and see how they affect performance.

Shocking Developments

The first electric-powered road vehicle is believed to have been built in Scotland about 1839 by Robert Anderson, but it, along with others within the next several years, were generally unsuccessful. The steamer had to wait for a boiler to build up pressure and was very noisy besides. The concept of an electrical engine that could start immediately and run quietly was very attractive at that time. There were disadvantages, however. Electric batteries were heavy, bulky, unreliable, and needed recharging after a short run. In 1880, there was a general improvement in the development of longer-lasting batteries. There still existed, however, excessive weight and bulk of the batteries and a need for frequent rechargings, although electric cabs appeared on the streets of London in the late 1800s. Steamers and electric vehicles gained only restricted acceptance on the continent as well. In France, the electric had a shining, brief hour of public acclaim when Camille Jenatzy, driving a Jeantaud electric, pushed the cigar-shaped vehicle to a record of sixty miles per hour on April 29, 1899. The high-speed run, however, burned out the specially fabricated batteries and the interest in electrics died almost as soon as the cheers of the attending public. It was in America that steamers and electric cars gained their most sustained measure of success. Eventually twenty different U.S. car companies would produce electrics; and in the peak of popularity, 1912, nearly 35,000 were operating on American roads. But even America could not shake the limitations of the bulky batteries and the short ranges between recharging. Steamers were actually more popular. More than 100 American plants were making steamers, the most famous of which were the Stanley brothers factory in Newton, Massachusetts. The "Stanley Steamer" had the affectionate nickname, "The Flying Teapot," and with good reason. In 1906, a Stanley Steamer was clocked at 127.6 miles per hour on the sands of Ormond Beach, Florida. In spite of this, the steamers, along with the electrics, were only living on borrowed time. Experiments were being made on an automobile powered by a gasoline-fueled, internal-combustion engine, and the steamers and electrics would not survive the impact of the coming collision. Internal-combustion automobiles did not just burst forth on the scene all of a sudden to crowd the electrics and steamers off the road. The theories of internal-combustion engines had been on the way ever since 1860, when Etienne Lenoir applied to the authorities in Paris for a patent on his invention, an internal-combustion engine powered by coal gas. Two years later, Lenoir hooked his engine to a carriage, and, although it was crude, it worked. It worked so poorly and so slowly (about one mile an hour), however, that he became discouraged and abandoned his efforts. In 1864, a resourceful Austrian in Vienna, Siegfried Marcus, built a one-cylinder engine that incorporated a crude carburetor and a magneto arrangement to create successive small explosions that applied alternating pressure against the piston within the cylinder. Bolting his engine to a cart, Siegfried geared the piston to the rear wheels, and while a strong assistant lifted the rear of the cart off the ground, Siegfried started the engine. The wheels began to turn and continued to turn with each successive "pop." Marcus signaled the assistant to lower the cart and watched it burp along for about 500 feet before it ran out of fuel. Ten years later, he built the new, improved version of his motorcar, and then, mysteriously washed his hands of the entire thing, saying it was a waste of time. (The second model, which is preserved in an Austrian museum, was refurbished and taken for a test run in Vienna in 1950. It reached a top speed of ten miles per hour on level ground.) Although Lenoir and Marcus did not have the grit and determination to pursue their enterprises, they made some valuable contributions to the theory of internal-combustion engines. It would be overstating the case to credit them with the creation of the internal-combustion automobile, however.

About Valve Seals

The valve seal is a unit that goes over the end of the valve stem. It keeps excess oil from getting between the valve guide and the valve stem.

Semiconductors and Diodes

Semiconductors are made from material somewhere between the ranges of conductors and nonconductors. Semiconductors, basically, are designed to do one of three things: (1) stop the flow of electrons, (2) start the flow of electrons, or (3) control the amount of electron flow. A semiconductor diode is a two-element solid state electronic device. It contains what is termed a "P" type material connected to a piece of "N" material. The union of the "P" and "N" materials forms a PN junction with two connections. The "anode" is connected to the P material; the "cathode" is connected to the N material. A diode is, in effect, a one-way valve. It will conduct current in one direction and remain non conductive in the reverse direction. When current flows through the diode, it is said to be "forward biased." When current flow is blocked by the diode, it is "reverse biased." When a diode is reverse biased, there is an extremely small current flow; actually, the current flow is said to be "negligible." When the P and N are fused together to form a diode, it can be placed in a circuit. The P material is connected to the positive side of the battery and the N material is connected to the negative side of the battery. Connected in this manner, current will flow. If connected in the reverse manner, current will not flow.

Worm Gear

A "worm gear" is a shaft with very coarse thread, which is designed to operate or drive another gear or a portion of a gear. The special shape of the gear allows the rotation direction to be turned when the gears engage with minimal friction. An example is found inside the steering box, where the steering shaft turns a worm gear that is screwed into a large nut. The nut moves back and forth on friction-reducing ball bearings, which are continuously recirculated by dropping into the nut's bored channels and emerging at the opposite side. Power to move the nut comes from pressurized fluid entering from a pump through rotary valves that open in response to the steering wheel. The worm gear engages the cross shaft through a roller or by a tapered pin.

Worm and Tapered Peg Steering

The manual worm and tapered peg steering gear has a three-turn worm gear at the lower end of the steering shaft supported by ball bearing assemblies. The pitman shaft has a lever end with a tapered peg that rides in the worm grooves. When the movement of the steering wheel revolves the worm gear, it causes the tapered peg to follow the worm gear grooves. Movement of the peg moves the lever on the pitman shaft which in turn moves the pitman arm and the steering linkage.

Wires and Cables


Wires and cables are conductors of electricity. Usually, they are made of annealed copper and are used to carry electricity to the various electrical devices and equipment on passenger cars and trucks. Wires and cables must be the right size for the application and must have proper insulation. If the wire or cable is too small in cross section or too long for its size, its resistance will be too great and valuable voltage will be lost. This will then result in poor operation of the electrical device in the connecting circuit. Wire size and length determines the resistance of the wire. Wire and cable sizes are expressed by a gauge number, which indicates the cross-sectional area of the conductor. The cross-sectional area of the wires is given in metric size or circular mils. The diameter is given in decimals of an inch. A circular mil is a unit of area equal to the area of a circle one mil in diameter. A mil is a length unit equal to .001 inches. The larger the diameter of the wire or cable, the smaller the gauge size number. Cables are made of several strands of wire. The cross-sectional area is equal to the circular mil area of a single strand times the number of strands. Special gauges are available for measuring the gauge size of wires and cables. Many multi-purpose electrician's pliers feature wire size holes for stripping, cutting, and crimping operations. When comparing cables, consider that the external diameter of insulated wire or cable has nothing to do with its current-carrying capacity. Thick insulation will make a small gauge wire look much larger. It is important that only the size of the metal conductors are compared.

Windshield Wipers


There are three types of motors that can be used for windshield wipers. The permanent "magnet" motor has two ceramic magnets that are cemented to the field frame and does not use field windings. It needs less energy than the other types of motor design, but the switch must be wired in series, creating many areas of resistance. The "shunt wound" motor provides a very consistent speed, but doesn't provide much torque upon starting. The "compound" motor wiper has a strong starting torque and provides consistent speed, but it is the most expensive. Most cars have an intermittent wiper system, which permits the driver to select a delayed wipe that operates only every few seconds. A representative wiper/washer unit is the wiper assembly, which incorporates a depressed park system that places the wiper blades below the hood line in the parked position. The relay control uses a relay coil, relay armature, and switch assembly. It controls starting and stopping of the wiper through a latching mechanism. An electric washer pump is mounted on the gear box section of the wiper. It is driven by the wiper unit gear assembly.

Window Winding Mechanisms



There are two types of window winding mechanisms; hand cranked and power. Hand cranks work two ways. With "window winders," the crank turns a "sector gear" that pivots a pair of arms. The arms raise the "window carrier" and the glass. Some cars have fixed glazing
oors so that the window cannot go up or down. The other type of window crank is a tape mechanism. It winds up a ladder-like tape made of plastic links. The plastic links are wound on to or off a spool to raise or lower the glass. The tape mechanism was introduced in 1980 GM cars. It saves weight and space. Its parts will not corrode when rainwater gets into the door, and it needs no lubrication. First introduced in 1946, power windows use a small electric motor inside the door. The motor turns the crank that raises the window. Door and vent windows are made of laminated "safety" plate glass, which is a sandwich of glass and clear plastic. The plastic acts as a soft, protective barrier, keeping the glass in place, if it is struck during a collision. The glass sticks to the plastic even when shattered.

About Windshield


Up until 1935 many cars had hinged windshields that could be folded on the hood of the car or opened up. Today, most windshields are stationary. They are fixed in place with a weather-strip made of rubber. The strip has a groove on the inside and a groove on the outside. The inside groove holds the glass; the outside groove holds the metal rim of the windshield opening in place. The glass "floats" in a plastic sealant that is spread out between the edge of the glass and the frame of the windshield. Windshields are made of laminated safety plate glass, which is a sandwich of glass and clear plastic. The plastic acts as a soft, protective barrier, keeping the glass in place, if it is struck during a collision. The glass sticks to the plastic to eliminate glass from flying around the interior and injuring someone. Safety glass for windscreens was one of the first passive safety devices introduced into cars in the 1930s, but its use remains a controversial question. North America and Scandinavia favor a laminated glass, which consists of two sheets of annealed glass, separated by a layer of transparent plastic. The rest of Europe and Japan favor toughened glass because it is cheaper. This type is a single sheet of glass which is heat strengthened, and which on impact fractures into small cubic fragments without very sharp edges. In recent years, laminated glass has been improved by changes in the properties of the plastic interlayer. Research has demonstrated that this new laminated glass is about 4 times safer than toughened glass, but because it is more expensive, controversy continues as to whether or not toughened glass windscreens should be banned by legislative action and replaced by laminated glass. Recent developments have combined the benefits of both laminated and toughened material in that a laminated construction is used, but the sheet next to the inside of the car is made of toughened glass.

Where Did The Idea Come From?

No one person can be credited for the invention of the automobile that you are driving today. It has developed bit by bit from the ideas, imagination, fantasy, and tinkering of hundreds of individuals through hundreds of years. In the 13th-century, the English philosopher-scientist, Roger Bacon, said that "cars can be made so that without animals they will move with unbelievable rapidity." Oh, Roger, if you only knew! Bacon was positive that these vehicles had existed in ancient times, but he didn't know what propelled them. The Greeks apparently had their own Olympic assembly line. In the "Iliad," Haephestus (the Roman "Vulcan"), was the god of fire and invention. When he had time off from making thunder bolts and beautiful jewelry for the vain goddesses, he built three-wheeled vehicles, which moved from place to place under their own power. Homer says they were "self-moved, obedient to the gods," and would Homer lie? The really remarkable thing about this is that even as far back as the Homeric era (8th-9th (?) century B.C.), man had already imagined automobiles. The motorized vehicle is, indeed, a prime example of creeping development; i.e., invention through slow accumulation of bits and pieces over a time so long that it is hard to pin down its origin. Thomas Russell Ybarra, in this century, wrote rhyming doggerel which pointed to the automobile as a Roman invention. Those who care to can point to two 15th-century Italians: Francesco di Giorgio Martini (whose concept has been presented in another section) and Leonardi Da Vinci. Da Vinci conceived an armor-plated war vehicle, the propulsion system of which is much like that of Martini's. This particular concept of Da Vinci did not contribute anything of value, not even a name, as did Martini's. The important thing to remember is the automobile is not some recent idea that popped up in the 19th-century, or the 18th, or even the 14th. It is a creation that has charmed imagination and inventiveness before man was able to conceive how to make it go. Perhaps that is why Homer placed it in the hands of the gods.

Wheel Lugs

Wheel lugs are the large bolts that go through the wheel rim and secure it to the wheel hub. They are pressed into the hub from the inboard side so they cannot pull out when tightened. The Lug nuts thread onto the wheel lugs, clamping the wheel rim between the hub and lug nuts. It is extremely important that the wheel lug nuts are securely tightened! If they are not -- your wheel will come off! Over- tightening is also a bad idea; it can prevent you from being able to change a flat tire.

Wheel Well




The wheel well is either plastic or metal. Metal wheel wells are usually part of the body shell. Metal wheel wells strengthen the structure of the car because of their shape, and because they are strongly welded to the body shell. Most rear-wheel wells are made of metal. Wheel wells are coated with a rock-proof, rubberized coating underneath, in order to prevent the rocks kicked up by the wheels from damaging the metal and making a lot of noise when they hit. Often the front wheel wells are made of plastic. This is because it is harder to mount the engine with the front wheel wells in place. Plastic wheel wells can be removed, and make it easier to mount the engine during the manufacturing of the car.