1. 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

2.  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

3.  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

4. REFERENCE WEB:WWW.AUTO360.COM WWW.MEKANIZMALAR.COM REFERENCE BOOK:DYNAMICS OF MACHINERY,KINEMATICS OF MACHINERY[DR.JEYAKUMAR]

6.  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

7.  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

8. CONNECTING ROD SPUR GEAR

9. RACKINION PINION

10. HOLDER CONNECTOR

11. GEAR TEETH CALCULATIONS:  GEAR RATIO : 1  NUMBER OF TEETH : 20  DIAMETERAL PITCH : 5  PITCH DIAMETER : 4  OUTSIDE DIAMETER : 4.4  ADDENDUM : 0.2  DEDENDUM : 0.231  TOOTH THICKNES : 0.314  WORKING DE : 0.4  WHOLE DEH : 0.43  BASE DIAMETER : 4.5  PRESSURE ANGLE : -2.30  [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

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

13. 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

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