Automobile Engineering

Teacher

AMIT KUMAR SAHOO

Category

Diploma Courses

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Diploma Course : Automobile Engineering

(250 hours, Theory + Practice)

Course Objectives

1. To familiarize the students with different systems and subsystems of automobile.
2. To teach basic skill in maintenance of different types of automobiles.
3. To know the operation and maintenance of electric vehicle.

Learning Outcomes

1. Students will gain knowledge about the construction and working of different systems and subsystems of automobile.
2. They will be able to disassemble and assemble major aggregates of the automobile
3. Students will be able to do vehicle trouble shooting

Course Syllabus

Module 1: (40 hour)

Automobile Architecture: Definition and Classification of Automobiles, Major Units of the Automobile, Types of Automobile Layouts, Automobile Chassis Types and Components, Automobile Body Types and Components, Automobile Safety Parameters.

Engine: Classification of Engine, Engine Nomenclature, Components of Engine, Valve Timing Diagram of SI & CI Engines, Variable Valve Timing, Working Principles of Modern Engine Combustion Technologies (CRDI, GDI, HCCI, Dual Fuel Engine, Stratified Charge Engine.

Carburetion: Air-Fuel Ratio, Mixture Requirements for Different Load Conditions, Factors Affecting Carburetion, Principle of Carburetion, Limitations of Simple Carburettor, Additional Systems in Carburettor, Concept of Electronic Carburettor.

Practice: Model Study of a Solex Carburettor.

Fuel Injection: BS4 AND BS6 ENGINE SYSTEM, Classification of Injection Systems, Fuel Feed Pump, Injection Pump, Injection Pump Governor, Fuel Injector and Nozzle, Electronic Injection Systems, Multi-Point Fuel Injection (MPFI) System, Direct and Indirect Fuel Injection.

Practice: Study of Fuel Injection System of a Diesel Engine.

Transmission System: Layout of Power Flow from Engine to Wheels, Brief Construction and Working Principles of - Clutch, Transmissions, Propeller Shaft, Final Drive and Differential, Front and Rear Axles.

Practice:

  • Study of Transmission System of Automobile.
  • Model Study of Differential of Automobile.

Cooling and Lubrication System: Direct Air Cooled and Indirect Liquid Cooled Cooling Systems, Types and Components of Liquid Cooled Cooling System, Engine Coolant and Antifreeze Solution, Desired Properties of Lubricants, Classification, Construction, Working Principles and Components of Various Types of Lubricating Systems.

Practice:

  • Model Study of Air Cooling System.
  • Model Study of Liquid Cooling System.

Super Charging &Turbo Charging: Naturally Aspirated and Forced Induction Engine, Effect of Forced Induction, Method of Supercharging, Types of Super Chargers, Basic Principle and Method of Turbo Charging, Types of Turbo Charging, Concept of Variable Geometry Turbocharging.

Practice:

  • Study of Working Model of Supercharger.
  • Study of Working Model of Turbocharger.

 

Module 2: (60 hour)

 Engine Emissions: Sources of Air Pollution from Automobiles and Their Control, Crank Case Emission Control System, Evaporative Emission Control System, Exhaust Emission Control System: Air Injection, EGR, Catalytic Converters, Selective Catalytic Reduction (SCR) Technology, EURO/Bharat Stage Norms: I, II, III, IV, V And VI, Road Map for Implementation of Bharat Stage Norms In India.

Practice:

  • Identification of Different Sub-Systems of Automobile.
  • Studies of Exhaust Gas Recirculation System (EGR) in KNOW Vehicle.

Ignition System: Effect of Spark Timing on Emission and Ignition Timing Controls, Drawbacks of Conventional Ignition Systems, Electronic Ignition Systems (TCI and CDI), Engine Cylinder Numbering Scheme and Firing Order of Multi Cylinder Engines.

Practice:

  • Study of Battery Ignition and Magneto Ignition System.
  • Disassembly and Assembly of 6-Cylinder Diesel Engine.

Transmission SystemPower Transmission in Automobile (Front Wheel Drive, Rear Wheel Drive, Four-Wheel Drive, All-Wheel Drive), Clutch System: Key Design Considerations of Clutches, Types of Clutches, Construction and Working Principle of Single Plate Friction Clutch, Diaphragm Clutch, Cone Clutch, Centrifugal Clutch.

Gear Box: Purpose of Gear Box, Types of Automobile Gear Boxes, Construction and Working Principle of Sliding Mesh, Constant Mesh, Synchronizer Mechanism and Synchromesh Gear Boxes, Planetary Gear Mechanism.

Practice:

  • Study of Single Plate Friction Clutches (Coil Spring Type And Diaphragm Type).
  • Study of Synchronizer Mechanism And Synchromesh Gear Box, Continuously Variable Transmission (CVT).

Steering System: Purpose of Steering System, Components of Steering System, Steering Geometry (Castor, Camber, Toe-In, Toe-Out, King Pin Inclination), Types of Steering Gear Boxes and their Construction and Working Principles

Braking SystemRequirement and Key Design Parameters of Braking System, Classification and Types of Braking Systems, Mechanical Brake, Hydraulic Brake, Air Brake, Vacuum Brake, Disc Brake. Construction, Working Principle and Components of Anti-Lock Braking System (ABS).

Practice:

  • Study of Steering Gear Box And Hydraulic Power Assisted Steering System.
  • Identifying the Different Components and Working Of Drum Brake, Disc Brake, Hydraulic Brake, Air Brake System.
  • Study of Anti-Lock Braking System (ABS) In KNOW Vehicle.

 

Module 3: (100 hour)

Maintenance of Automobile (Practice)

  • Safety Precautions in Automobile Maintenance.
  • Identification and Functions of Various Tools and Equipment used in Automobile Workshop.
  • Disassembling and Assembling of Engine of a Four Wheeler.
  • Disassembling and Assembling of Engine of a Two Wheeler.
  • Engine Troubleshooting.
  • Nomenclature of a Spark Plug and Spark Plug Reading, Testing and Cleaning of Spark Plug.
  • Checking and Replenishing Lubricating Oil, Engine Coolant, Power Steering Hydraulic Oil and Wind Screen Wiper Water.
  • Overhauling and Servicing of Fuel System including Air Filter.
  • Disassembling and Assembling Of Clutch, Clutch Troubles and Remedies.
  • Repairing and Adjustment of Brake System.
  • Disassembling and Assembling of Propeller Shaft.
  • Inspection and Servicing of Gear Box.
  • Inspection and Servicing Of CVT.
  • Tire Change Operation, Wheel Balancing, Wheel Alignment, Tire Inspection (Tubeless & Tube) and Inflation.
  • Overhauling of Suspension System.
  • Disassembling and Assembling of Steering System and Adjustment of Drag Link.
  • Preparation of Electrical Circuits using Switches and Fuses.
  • Checking of Battery Terminal Voltage, Electrolyte Level and Specific Gravity.
  • Inspection of Different Electrical Circuits and ECU.
  • Checking of Ignition System Circuit & Components.

 

Module 4: (50 hour)

Electric Vehicles: Introduction to Electric Vehicles: Electric Vehicles Advantages and Disadvantages,  EV Market and Promotion, Main Components of Electric Vehicle and Its Functions (Electrical and Mechanical).

Electric Vehicle Drive Trains: EV Transmission Configurations, Basic Architecture of Electric Drive Trains, Single and Multi-Motor Drives, In Wheel Drives.

Energy Sources: Working Principle of Battery, Types of Batteries, Lead-Acid Battery, Nickel-Cadmium Battery, Nickel-Metal-Hydride (Nimh) Battery, Lithium Batteries, Battery Parameters, Fuel Cells.

Electric Motors: Classification of Electric Motors, DC Motor, Types of DC Motors, Brushless DC Motor, AC Motor, Types of AC Motors, Induction Motor, Synchronous Motor, Regenerative Braking.

Design Concept of Electric Vehicle: Power and Torque Calculation of Electric Vehicles, Sizing of Components, Initial Acceleration, Maximum Velocity, Maximum Grad ability.

Practice:

  • Study of Different Components of E-Rickshaw and Assembling Methods.
  • Working of Circuits in Controllers with respect to Current and Voltage Rating.
  • Maintenance of Lead Acid Batteries.
  • Wiring & Harnessing of Battery Circuit.
  • Study of Different Parts of D.C. Motor and Make Connection.
  • Performance Characteristics of a Shunt and Series DC Motor.
  • Load Test on Three Phase Induction Motor.
  • Speed Control of DC Shunt Motor by Armature and Field Control.
  • Maintenance of BLDC Motor.

 

Text Books

  1. Gupta R. B., Automobile Engineering, Satya Prakashan, New Delhi.
  2. Giri N. K., Automobile Technology, Khanna Publishers.
  3. Hussein Iqbal, Electric and Hybrid Vehicles: Design Fundamentals, CRC Press
  4. Chau K. T., Electric Vehicle Machines and Drives: Design, Analysis and Application,Wiley.

 

References

  1. Gupta H. N., Fundamentals of Internal Combustion Engines, PHI Learning.
  2. Crouse William H and Donald Anglin, Automotive Mechanics, Tata Mcgraw Hill Publications.
  3. Newton K., Steeds W, and Garrett T K, The Motor Vehicle, Butterworth Heinemann
  4. Training Manual Of Four Wheeler Maintenance (Ashok Leyland)
  5. Training Manual Of Two Wheeler Maintenance (Yamaha)
  6. Chan C.C. and Chau K.T., Modern Electric Vehicle Technology, London: Oxford University.

Session Plan

Session 1

Automobile Architecture: Definition and Classification of Automobiles, Major Units of the Automobile.

Session 2

Types of Automobile Layouts, Automobile Chassis Types and Components

Session 3

Automobile Body Types and Components, Automobile Safety Parameters.

Case Studies

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AMIT KUMAR SAHOO

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