DEPT. OF MECHANICAL ENGG. DESIGN AND FABRICATION OF OVERLOAD DETECTION IN AUTOMOBILE REVIEW-1 SUPERVISOR:MR.N.DINESH KUMAR TEAM MEMBERS: ASST.PROFF M.MOHAMEDH BYSAL MECHANICAL DEPT. R.RAJ BHARATH U.MADHANKUMAR

 TO DETECT THE MAXIMUM LOAD THAT A AUTOMOBILE CAN WITHSTAND AND TO LOCK THE STEERING IF IT EXCEEDS MAXIMUM LOAD AUTOMOBILEMAXIMUM LOAD SHARE AUTOS[3WHEELERS ] 350kg BUSES[4WHEELERS ] 10 [tonnes] COMMERCIAL TRUCKS[4WHEELERS ] 22.5[tonnes ] GYPSY[4WHEELERS ] 400kg

 MANY ROAD ACCIDENTS HAPPEN DUE TO LOADING PASSENGERS MORE THAN A LIMIT GIVEN TO THE PARTICULAR VECHICLE  THUS BY LOADING MORE PASSENGERS WHILE TAKING A SHARP CURVE THE LOAD ACTS ON THE SINGLE SIDE AND THE AUTOMOBILE TUMBLES DOWN

REFERENCE WEB: REFERENCE BOOK:DYNAMICS OF MACHINERY,KINEMATICS OF MACHINERY[DR.JEYAKUMAR]

 MECHANICAL ARRANGEMENT: HERE THE ENTIRE LOAD ACTING ON A AUTOMOBILE IS DETECTED USING MECHANICAL SENSOR THE MECHANICAL SENSOR IS CONSTRUCTED USING GEARS,SPRINGS,RACK AND PINION ARRANGEMENT etc WE CONVERT THE “RECIPROCATING MOTION INTO ROTARY MOTION” USING GEAR AND RACKPINION ARRANGEMENT

 ELECTRICAL ARRANGEMENT AN “AUTOMATIC IGNITION OFF” IS USED TO ARREST THE MOMENT OF THE STEERING WHEN THE LIMIT IS REACHED A 6V BATTERY FROM WHICH TWO TERMINALS ARE TAKEN ONE(+) IS CONNECTED TO THE IRON PIECE AND OTHER TO THE SENSOR WHEN THE LOAD REACHES MAXIMUM CURRENT ALSO FLOWS THROUGH THE (-) TERMINAL THUS MAKING THE IRON PIECE A MAGNET AND ARRESTING THE STEERIN MOTION

CONNECTING ROD SPUR GEAR

RACKINION PINION

HOLDER CONNECTOR

GEAR TEETH CALCULATIONS:  GEAR RATIO : 1  NUMBER OF TEETH : 20  DIAMETERAL PITCH : 5  PITCH DIAMETER : 4  OUTSIDE DIAMETER : 4.4  ADDENDUM : 0.2  DEDENDUM :  TOOTH THICKNES :  WORKING DE : 0.4  WHOLE DEH : 0.43  BASE DIAMETER : 4.5  PRESSURE ANGLE :  [ALL DIMENSION ARE IN MM] FORMULA USED:  TO FIND INVOLUTE:X(T)=RCOS(T)+Y*TSIN(T) Y(T)=RSIN(T)-Y*TCOS(T) WHERE T, IS TOOTH THICKNESS.  PITCH DIAMETER(Pc)=3.14D/T  WHERE D.IS THE OUTSIDE DIAMETEER  MODULIUS(M)=D/T

 RATCHET  PINION  RACK  SPUR GEAR  CONNECTING ROD  COUPLER  SPRING  SYNTHETIC RUBBER

THE PROCESS OF CONTROLING THE MOTION OF THE AUTOMOBILE IS TO BE DESIGNED,BECAUSE THE LOAD VARIES ON THE CHASIS EVEN IF THERE IS A UPS AND DOWNS IN THE ROADS.SO ACCURATE DETECTION AND IGNITION OFF MUST BE DESIGNED

 EQUIPMENT PARTSCOST[RS] SPUR GEARS[3]3X150=450 SYNTHETC RUBBER1SQFEET=300 ELECTRICAL ARRANGEMENT 500 MAINTANANCE1000 OTHERS500 TOTAL COST2750[APPROX]