Chapter 1 – Introduction

V Year, Semester 1, Mechanical Engineering

Course Handout

Prepared by

Mr. S. Venkatesh Kumar, Lecturer,

Department of Mechanical Engineering,

Mettu University, Metu, Ethiopia.

Motor Vehicle Engineering Chapter 1 - Introduction

Chapter 1
Introduction
1.1 INTRODUCTION TO AN MOTOR VEHICLE

Motor Vehicle Engineering: It is a branch of engineering which deals with everything about automobiles and their
practices to propel them.

An automobile is a self-propelled vehicle driven by an internal combustion engine and is used for the transportation
of goods and passengers on the ground.

In general, the modern automobile is essentially a transportation equipment unit. It is made up of a frame supporting
the body and certain power developing and transmitting units. These are further supported by tyres and wheels
through springs and axles. An engine supplies the power, which is delivered by the transmission system to the
wheels through the clutch or fluid coupling.

1.2 HISTORY OF THE AUTOMOBILE

Nicolas Cugnot, a French artillery officer, designed and built the world’s first self-propelled road vehicle. In 1769,
Cugnot constructed a crude three-wheeled steam tractor for handling canon. It attained a speed of about two and
a half mph for 15 minutes only.

The saga of the modern-day car began as early as 1860. In that year Jean Etienne Lenoir, a Belgian inventor, built
the first practicable gas engine, and which subsequently became the model from which all other internal-combustion
engines developed. In that first engine, however, the mixture of coal gas and the air was not compressed before
ignition, and as such it was inefficient. The next milestone in the history of the automobile, was in 1876 when Count
Nikolas Otto, a German engineer, first successfully applied the four-stroke principle that had been proposed by
the Frenchman Beau da Rochas. The four-stroke cycle enabled the charge to be compressed, which gave a
significantly better performance. At about the same time, gasoline—a distillate of petroleum later to be known also
as petrol came into use instead of coal gas.

In 1880, German and French efforts resulted in an internal combustion engine vehicle that was used to carry fruits.
The present-day automobile developed from this vehicle. In 1883, Gottlieb Daimler and Carl Benz Daimler,
working with Wilhelm Maybach, produced his first engine and it created a sensation by running at more than four
times the speed of Otto’s engines. On the other hand, Benz started with the objective of making his self-propelled
vehicle, and in 1885 installed his first engine at the back of a tricycle. Within a year or so, Daimler and Benz were
building cars for sale. In 1895, Panhard and Daimler in France had the engine placed in the front of a chassis,
hooked up to a sliding gear transmission, and incorporated the brake pedal, clutch and accelerator.

The Locomotives Act 1865, framed in Britain for steam-driven traction engines, set an overall speed limit of 4 mph
in open country and 2 mph in towns and villages. Cars had to be preceded by a man carrying a red flag to warn the

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drivers of horse-drawn vehicles. Although the flag was abolished in 1876, the man was still required by law until
1896.

In 1908, Ford started his model with an initial run of 20,000 vehicles, an output unheard of at that time. This was
the period when the designers’ chief objective was to make his vehicle run in mass production, at the lowest possible
price. In 1920 there was a gradual change and refinement in automobile design. By that time the spark-ignition
gasoline engine was to be the power plant of the modern motor vehicle. Water-cooled engines were almost
universal. The sliding gear transmission had established itself predominantly. The poppet valve was used in almost
every engine design. Engines were all located in the front of the chassis.

Substantial progress has been made after the second world war in every car feature. The designers during this time
tried to produce a vehicle that not only functioned at all times under all conditions but was also comfortable to ride
and easy to operate. The increased life of tyres, brakes, independent front wheel suspension, heating and
ventilation, improved engine design.

Safety and exhaust emission were the additional features. However, this is not an end. Further research and
development efforts continue and are focused to produce better, cheaper, safer and in the future, computer-
controlled vehicles.

1.3. AUTOMOTIVE IN ETHIOPIA

The Ministry of Transport, in its latest report, revealed that the total number of vehicles registered by the authority,
at both federal and regional levels, has reached close to 1.2 million vehicles. Out of the total registered number;
motorbikes top the list for any type of vehicle registered by the Federal Transport Authority.

According to the report, a total of 1,200,110 vehicles have been registered nationwide until the last fiscal year
ending July 7, 2020.

The report shows that Addis Ababa has registered around 630,440 vehicles while Oromia (204,026), Amhara
(106,434) and SNNPR have registered 118,424 vehicles. The above four regions rank from 1st to 4th, accordingly.
The rest of the regions, according to the Ministry, rank from 5th to 11th with Tigray registering 60,800 vehicles, Dire
Dawa Administration (24,510), Somali (19,579), Harari (10,728), Benishangul Gumuz (10,655), Afar (8,277) and
Gambella registering 6,237 vehicles, respectively.

According to the latest data and figure obtained by The Reporter from the Federal Transport Authority, the stated
total number of registered vehicles [Of the 1.2 million registered vehicles], the highest portion goes to motorcycles
(243,435) or 20.3 percent.

Meanwhile, Automobiles and Dry Cargos account for 19.71 percent (236,588) and 18.33 percent (220,060) of the
total registered vehicles, respectively.

Surprisingly, the data also shows that Forklifts, Liquid Trailers, Combiners, Dozers and Graders respectively
account for 316 (0.026 percent), 185 (0.015 percent), 167 (0.013 percent), 27 (0.002 percent) and 16 (0.001
percent).

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Motor Vehicle Engineering Chapter 1 - Introduction

1.4 CLASSIFICATION OF MOTOR VEHICLES

Motor vehicles are classified based upon,

 Types of Road
 Running Gear
 Intended purpose
 Drive Layout
 Engine Layout
FHWA developed a standardized vehicle classification system in the mid-1980s. This system was the result of
compromises designed to meet the needs of many traffic data users. Pavement designers were an important
segment of those users but by no means the only intended audience. Another segment of key users comprised the
safety community, which was (and still is) highly interested in the amount of travel occurring in multi-unit vehicles
(that is, power units of various types pulling trailers of various configurations).

In addition to these needs was the requirement that the electronic equipment and sensors available at the time
(mostly simple road tubes) be able to differentiate passing vehicles into the desired classifications. Available
sensors were capable of measuring the presence of vehicles, detecting axles, and determining the distance
between consecutive axles based on the speed of each vehicle as it passed over the sensors.
1.4.1. Current FHWA 13-Category Rule Set
The result of that 1980-era work is the FHWA 13-category classification rule set currently used for most Federal
reporting requirements and that serves as the basis for most State vehicle classification counting efforts. The FHWA
classification system is shown in table 1.

CLASS 1: Motorcycles: All two or three-wheeled motorized vehicles. Typical vehicles

in this category have saddle-type seats and are steered by handlebars rather than
steering wheels. This category includes motorcycles, motor scooters, mopeds, motor-
powered bicycles, and three-wheel motorcycles.

CLASS 2: Passenger Cars: All sedans, coupes, and station wagons manufactured
primarily to carry passengers including those passenger cars pulling recreational or
other light trailers.

CLASS 3: Other Two-Axle, Four-Tire Single Unit Vehicles: All two-axle, four-tire
vehicles, other than passenger cars. Included in this classification are pickups, panels,
vans, and other vehicles such as campers, motor homes, ambulances, hearses
(funeral vehicles), carryalls, and minibuses. Other two-axle, four-tire single-unit
vehicles pulling recreational or other light trailers are included in this classification.

CLASS 4: Buses: All vehicles manufactured as traditional passenger-carrying buses

with two axles and six tires or three or more axles. This category includes only
traditional buses (including school buses) functioning as passenger-carrying vehicles.
Modified buses should be considered to be a truck and should be appropriately
classified.

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CLASS 5: Two-Axle, Six-Tire, Single-Unit Trucks: All vehicles on a single frame

including trucks, camping and recreational vehicles, motor homes, etc., with two axles
and dual rear wheels.

CLASS 6: Three-Axle Single-Unit Trucks: All vehicles on a single frame including

trucks, camping and recreational vehicles, motor homes, etc., with three axles.

CLASS 7: Four or More Axle Single-Unit Trucks: All trucks on a single frame with
four or more axles.

CLASS 8: Four or Fewer Axle Single-Trailer Trucks: All vehicles with four or fewer
axles consisting of two units, one of which is a tractor or straight truck power unit.

CLASS 9: Five-Axle Single-Trailer Trucks: All five-axle vehicles consist of two units,
one of which is a tractor or straight truck power unit.

CLASS 10: Six or More Axle Single-Trailer Trucks: All vehicles with six or more
axles consisting of two units, one of which is a tractor or straight truck power unit.

CLASS 11: Five or fewer Axle Multi-Trailer Trucks: All vehicles with five or fewer
axles consisting of three or more units, one of which is a tractor or straight truck power
unit.

CLASS 12: Six-Axle Multi-Trailer Trucks: All six-axle vehicles consist of three or
more units, one of which is a tractor or straight truck power unit.

CLASS 13: Seven or More Axle Multi-Trailer Trucks: All vehicles with seven or more
axles consisting of three or more units, one of which is a tractor or straight truck power
unit.

1.4.2 Based on Type of Roads

Guided and Non-guided vehicles Guided Motor vehicles move along a fixed guideway; that includes railway
vehicles. Non-guided motor vehicles move in any direction. Non-guided motor vehicles are the subject of this
course.

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Motor Vehicle Engineering Chapter 1 - Introduction

1.4.3 Classification according to Running gear:

Single Track motor vehicles and multi-Track motor vehicles
 Single Track motor vehicles are motor vehicles with two wheels with or without a sidecar.
Examples: Motorcycle – Any two-wheeled vehicle with or without a sidecar.
Moped - Motorcycle with pedals and a petrol engine of low power.
Scooter –This is a light, small wheels automotive.
 Multi-Track Motor Vehicles -Motor vehicles with three or more wheels.
o Saloon car (sedan) –This is a type of motor car in which the space for driver and passengers is cut off
from other areas.
o Hatchback car has a large sloping back.
o Pick-up (also pickup) – it is a small truck commonly used by operators.
o Van - covered vehicle, with no side windows, for transporting goods or people.
o Truck (UK Lorry) - a large strong motor vehicle for transporting goods, soldiers, etc., by road.
o Tractor fitted with an endless belt passing around the wheels of a tractor enabling it to travel over rough
ground.
o Car - Motor vehicle intended for carrying a maximum of 9 passengers with luggage.

Figure 1.1 Single Track Motor Vehicles.

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Motor Vehicle Engineering Chapter 1 - Introduction

Figure 1.3 Multi-track Cars.

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Motor Vehicle Engineering Chapter 1 - Introduction

Buses
Buses are used to transport people. The capacity of buses is more than 9 passengers and luggage. Buses fall into
one of the following categories, depending upon the intended use.
1. Microbus: The capacity of microbuses is approximately 25 passengers.
2. City Buses (Urban buses): are designed and equipped for driving regularly scheduled in-city and suburban
routes. Due to short intervals between stops in local traffic, facilitation of rapid passenger turnover using low steps,
wide doors and as low a vehicle floor as possible, is particularly important.
3. Tour Buses (Long-distance coach): are designed to provide a comfortable ride over long distances. Tour
buses have large luggage compartments from front to rear below the floor.

Figure 1.4.: (a) Micro Bus (b) Tour Bus (c) Articulated Bus (d) Double Decker Bus

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Transport Vehicles
Transport vehicles are further classified as follows:
According to the type of body:
 General-purpose cargo trucks: with an open drop-sided body used for carrying bulk and packaged goods.
 Special-purpose trucks: with bodies adapted for a certain kind of work, e.g., dump trucks with tiltable bodies
used to carry viscous and bulk materials, or with bodies specially adapted for transporting peat, cement, mixed
fodder, grain, cotton, cattle, gasoline, milk, etc.

According to the load capacity:

 Extra-light-duty trucks: up to 0.75 Ton, built on the chassis of passenger cars and used for deliveries of light
loads in the communication and communal services and trade.
 Light-duty vehicles: from 0.75 to 2.5 Ton, that work in trade, at industrial enterprises and in agriculture, hauling
light loads. They also serve as cargo taxis.
 Medium-duty trucks: from 2.5 to 5.0 Ton, mostly carrying loads for organizations and enterprises with
moderate cargo traffic.
 Heavy-duty trucks: from 5.0 t to 10.0 Ton, used on hard surface roads for carrying building materials, fuel,
and products manufactured by large industrial enterprises.
 Extra-heavy-duty vehicles: above 10.0 Ton, for work in ore and coal mines and at big construction projects
with a large amount of steady cargo traffic. As a rule, these vehicles are diverted from public highways.

1.4.4 Classifications by ISO

ISO3833 classifies ground vehicles into 7 groups:
1. Motorbikes
2. Cars for travellers
3. Pick-up Buses
4. Pickup Trucks
5. Agricultural machinery
6. Trailer cars
7. Semi-trailers

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Figure 1. 5: (a) Flat Bed Truck (b) Off-Road Deep Truck (c) Dump Truck (d) Tractor-Trailer [Rigid]

1.4.5. Classifications of Vehicles according to their Drives as:

1. 2-Wheel Drive (2WD)
2. Front Engine Rear-Wheel Drive (FERWD)
3. Front Engine Front-Wheel Drive (FEFWD)
4. Cross Mounted Engine
5. Engine Behind Transmission
6. Engine in Front of Transmission
7. Rear Engine Rear-Wheel Drive (RERWD)
8. 4-Wheel Drive (4WD)
9. 6 Wheel Drive (6WD)

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Figure 1.7 Front Engine FWD, RWD, & 4WD

1.5 Functions of Subunits

Mechanical energy is converted into Motion. Any Automobile consists of Power-train and non-Power-train
components. Power-Train components are parts involved in the process of generating power to convert it to motion.
Non-Power-Train components parts include Body, Frame and Steering.

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Parts of Automobile Systems

1. Power plant
2. Engine
3. Drive train
4. Clutch, gearbox, shaft and differential
5. Electrical system
6. Ignition, starting lighting and battery
7. Wheels and tires
8. Suspension system
9. Steering system
10. Braking system
1.5.1 Transmission System
The transmission helps to transmit power from the engine to the wheels. It consists of gears, shafts, and other
electrical connections. It is composed of systems shown in Figure 1.7

Figure 1.7 Arrangement of components.

Drive train indicates the power flow of motor vehicles from the engine to the driving wheels.
The main components of the drive train are:
Engine-Clutch-Transmission-Driveshaft-Differential-Wheels.
Requirements Of Transmission System
 Provide means of connection and disconnection of the engine with rest of power train without shock and
smoothly.
 Provide varied leverage between the engine and the drive wheels
 Provide means to transfer power in opposite direction.
 Enable power transmission at varied angles and varied lengths.
 Enable speed reduction between the engine and the drive wheels in the ratio of 5:1.
 Enable diversion of power flow at right angles.
 Provide means to drive the driving wheels at different speeds when required.
 Bear the effect of torque reaction, driving thrust and braking effort effectively.

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Clutch
This part is used to engage and disengage the engine from the drive. It allows the driver to control the power flow
between the engine and transmission or transaxle operating by the friction principle.

Figure 1.8 Principle of a clutch.

Need for Clutch
 Allows gradual engagement of two rotating plates
 Provides positive linkage capable of transmitting maximum engine torque
 Rapidly separates the engine from the drive train and reengages the engine to the drivetrain
 Provides force between pressure plate and flywheel to load clutch disk
Transmission of torque depends on:
 Size
 Engagement time
 Free pedal play
 Rate of Heat loss
 Easy in operation
 Balancing of mass
 Lightness
Power flow from one unit to another can be controlled with a drive disc and a driven disc.
Thus, the clutch can transmit twice as much torque

Propeller Shaft or Drive Shaft

Driveshafts must therefore be strong enough to bear the stress, whilst avoiding too much additional weight as that
would, in turn, increase their inertia.

Figure 1.9 Driveshafts.

Role of Propeller Shaft
The torque from the engine is to be transmitted to the rear wheels for propelling a vehicle. The drive shaft must
provide a smooth, uninterrupted flow of power to the axles.

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Functions of the Drive Shaft

 Torque transmission.
 Maintain speed over roll over bumps in the road.
 The length changes of the shaft using a slip joint.
Differential
In automobiles and other wheeled vehicles, the differential allows the outer drive wheel to rotate faster than
the inner drive wheel during a turn. This is necessary when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll farther and faster than the other. The average rotational
speed of the two driving wheels equals the input rotational speed of the drive shaft. An increase in the speed
of one wheel is balanced by a decrease in the speed of the other.

Figure 1.10: Differential Unit

1.6 Electrical Systems of Automobile
The system in a motor vehicle that furnishes the electrical energy to crank the engine for starting, recharge the
battery after cranking, create the high-voltage sparks to fire the compressed air-fuel charges, and power the
headlamps, light bulbs, and electrical accessories.

The vehicle electrical system includes the battery, wiring, starting motor and controls, generator and voltage
regulator, electronic ignition, and electronic fuel metering. Also included may be a computerized electronic engine
control system, an electronically displayed driver information system, various types of radios and sound systems,
and many other electrically operated and electronically controlled systems and devices

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Figure 1.11: Automotive Electrical Systems

1.7 Suspension System
The suspension system is a protective lattice of shock-absorbing components such as springs and dampers. A
vehicle’s suspension helps ensure that our drive is safe and smooth by absorbing the energy from various road
bumps and other kinetic impacts. Furthermore, it helps your tires stay in contact with the road by increasing tire
friction.

The main parts of a car’s suspension include:

Springs, which help to control the height and load of the suspension and cabin.
Shocks (also called dampers), which absorb and dampen various kinetic energy impulses that your tires transmit
when they contact the road.

Figure 1.12: Suspension System

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Advantages of Suspension System

 Suspension systems maximize the friction between tires and the road. By maximizing friction, the driver can
steer the vehicle with more stability and experience more comfortable handling. The more contact tires have
with the road, the safer and more securely we will be able to drive.
 The suspension system of a vehicle also provides added comfort. By limiting the kinetic energy transferred from
road imperfections like bumps to the cabin, the bounce up and down far less, and the passengers will also
enjoy a smoother ride.
 Furthermore, suspension systems can help to increase the lifespan and durability of a vehicle. The vehicle’s
components will be taxed much less over time by limiting how much energy is transferred from bumps and
potholes in the road. Therefore, the vehicle’s other components will last longer.

1.8 Steering System

The steering system of your car is everything from the steering wheel to the steering shaft, rack, and pinion (also
known as the gearbox), all the way to the linkage which connects to the wheels themselves.

It is also known as the steering system, in automobiles, the steering wheel, gears, linkages, and other components
are used to control the direction of a vehicle’s motion.

The components of a steering system are listed below. They are:

1. Steering wheel
2. Steering column or shaft.
3. Steering gear
4. Drop arm or pitman arm
5. Ball joints
6. Drag link
7. Steering arm
8. Stub axle
9. Left spindle and kingpin
10. Left tie rod arm

The function of a Steering System:

The function of a steering system is to convert the rotary movement of the steering wheel in the driver’s hand into
the angular turn of the front wheels on road.
Additionally, the steering system should provide a mechanical advantage over front-wheel steering knuckles,
offering the driver an easy turning of front wheels with minimum effort in any desired direction.
The steering system provides the directional change in the movement of an Automobile and maintains a position
as per the driver’s decision without much strain on him.

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Motor Vehicle Engineering Chapter 1 - Introduction

This system converts the rotary movement of the steering wheel into the angular movement of the front wheels. It
multiplies the driver’s effort by mechanical advantage, enabling him to turn the wheels easily.

1.9 Braking System

In an automobile vehicle, a braking system is an arrangement of various linkages and components (brake lines or
mechanical linkages, drum brakes or disc brakes, master cylinder or fulcrums, etc.) that are arranged in such a
fashion that it converts the vehicle’s kinetic energy into the heat energy which in turn stops or decelerate the vehicle.
Most brakes use friction on both sides of the wheel, the collective actuation of the wheel converts the kinetic energy
of the moving object into heat.

Definition of Brakes

A brake is a mechanical device that inhibits motion by absorbing energy from a moving system. It is used for slowing
or stopping a moving vehicle, wheel, axle, or to prevent its motion, most often accomplished using friction.

Parts Of Brake System

Brake Pedal Master Cylinder

Brake Pads ABS Control Module
Brake Booster Disc Brakes
Drum Brakes Emergency Brake
Brake Pedal Wheel Speed Sensors

1.14 Braking System

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