DESIGN & FABRICATION OF FOUR WHEEL STEERED MULTI- UTILITY VEHICLE

Project Guide:ARUN RAJ.AAsst. Prof.Dept. of MechanicalJECC

Submitted by:JYAMEME042 COLIN VARGHESEJYAMEME043 DAVID BABUJYAMEME044 DELWIN KURIYAKOSEJYAMEME057 HARIKRISHNAN A SJYAMEME059 IRSHAD M 1

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DEPARTMENT OF MECHANICAL ENGINEERING

VISION

• To provide quality education of international standards in Mechanical Engineering

and promote professionalism with ethical values, to work in a team and to face

global challenges.

MISSION

• To provide an education that builds a solid foundation in Mechanical Engineering.

• To prepare graduates for employment, higher education and enable a lifelong

growth in their profession.

• To develop good communication, leadership and entrepreneurship skills to enable

good knowledge transfer .

• To inculcate world class research program in Mechanical Engineering.

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ABSTRACTThis project provides design and fabrication of four mode

four wheel steered multi- utility vehicle. Four wheel steering is a

system that allows the rear wheels to turn for maneuvering, rather

than just follow the front wheels. It is a system employed by some

vehicles to decrease turning radius. This would be very useful in

industrial areas with less floor space.

In addition with four wheels steering the vehicle is a multi

utility vehicle, so it is used for scrap collecting, shifting etc. The

conventional floor cleaning machines were not fast, efficient and of

high cost. Hence it is a need to develop low cost, user friendly floor

cleaning machine.

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INTRODUCTION

Four-wheel steering provides a means to actively steer the rear

wheels during turning maneuvers. It improves handling and helps the

vehicle to make tighter turns. If a car could automatically compensate

for an under steer /over steer problem, the driver would enjoy nearly

neutral steering under varying conditions.

When both the front and rear wheels steer toward the same

direction, they are said to be in phase and this produces a kind of

sideways movement of the car. When the front and rear wheels are

steered in opposite direction, this is called anti-phase, counter-phase or

opposite-phase and it produces a sharper, tighter turn.

.

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OBJECTIVE

• This project aims at developing a 4 Wheel Steering System

which would cater to the needs to improve steering response,

increase vehicle stability while maneuvering at high speeds,

or to decrease turning radius at low speed.

• Under slippery conditions, the rear of the car may fishtail out

of control. In a four-wheel-steer car, this high-speed sway can

be damped or even eliminated through the use of same-side

steering.

• In addition with the 4WS system we include a scrap

collecting mechanism which uses neodymium magnets to

attract the metal scraps.

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LITERATURE REVIEWSL.NO

YEAR AUTHOR MAJOR FINDINGS

1 2011 Bella et al[1]

A collision warning system for rear end collision. Their function is to allow the driver enough time to avoid crash and yet avoid annoying the driver with alerts perceived as accruing too early or unnecessary.

2 2012 Zhang et al[2]

Design and control implementation of AC electric power steering system. The paper introduced the bench structure, working principle and main components

3 2012 Alam et al[3]

Aerodynamic study of human powered vehicles. The wind tunnel testing was used to identify key characters of these HPVS, and by identifying different results obtained it was possible to understand more about aerodynamic of HPV.

4 2014 Schwab et al[4]

Balance and control of a rear-wheel steering speed record recumbent bicycle. This shows that one can design a rear-wheel steered bicycle which shows a stable forward speed range. It is shown that rider steer torque stays with in human bounds.

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5 2012 Saeed Abu[5] Automotive brake pipe characteristics and and their effect on brake performance. This paper investigates the effect of fitting a brake pipe with different inner diameters to each wheel at the rear axle on brake performance.

6 2015 Bitar et al[6] Testing the performance of DC series motor used in electric car. This desk include practically verification of performance and behavior of complete electric drive system and to convert a diesel or petrol powered vehicle to an electric car.

7 2012 Hanif Mat et al[7]

Design and analysis of Eco car chassis. This involves developing a light weight chassis that can satisfy withstand the required loads and also be able to present driver inerrant of crash.

8 2015 Buchert et al[8] Design and manufacturing of a sustainable pedal. This paper focuses on development of a pedal electric cycle. The results of project shows how different scientific approaches for improvement can be applied together.

9 2012 Nor et al[9] Different steering control for an Autonomous mobile robot. This involves study of both velocity of DC motors with and without control the pulse width modulation for DC motors which control velocities of wheels of mobile robot.

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10 2011 Zhao et al[10]

Dynamic analysis of steering system of articulated vehicle in heeled status. This paper analyze the force of the front and rear car body and establish the steering dynamic mathematical model and simulation model.

11 2012 Li et al[11] A reverse logistics model for recovery options. A mixed integer multi-objective linear programming reverse logistics model was developed in this study

12 2012 Hassan et al[12]

Optimal design of electric power assisted steering system. The paper discuss the implementation of GA-PID algorithm to realize the potential of energy reduction as compared to conventional PID method

13 2015 Novellis et al[13]

Driving modes for designing the cornering response of fully electric vehicles with multiple motors. This article presents a torque vectoring control structure based on the combination of feed and feed back contribution for control of vehicle yaw rate.

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14 2011 Chu et al[14] Coordinated control of electronic stability program and active front steering. This improves vehicle handling and stability by coordinating control of electric stability program and active front steering.

15 2011 Gao et al[15] Dynamic modeling and steering performance analysis of active front steering system. The controller performance and the average of variable steering ratio faction.

16 2012 Santos et al[16]

Finishing process analysis between honing and hard honing in pinion gears applied to a steering system. This process provides an excellent surface finish of the sprockets having a direct impact on the return vehicle steering system.

17 2015 Ossama Mokhiamar[17]

Stabilization of car-caravan combination using independent steer and drive on brake force distribution. The proposed control system is evaluated under severe driving conditions and compared with results of integrated control system

18 2011 Chen et al[18] Study on electric power steering system based on ADAMS.A model for the EPS system has been established including full vehicle mechanical system EPS mechanical system and EPS electric control system.

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19 2011 Guirong et al[19]

The driving control of pure electric vehicle. The paper analyze the advantages and disadvantages of traditional drive mode, motor-driving axle combined drive mode, motor driving axle integrated driving mode.

20 2012 Hsien-Yu et al[20]

Study on power train of two axles four wheel drive electric vehicle. The works include mechanism and design for clutch less AMT,optimal transmission gear shifting design and finally power split strategy design in 4wd.

21 2013 Alam et al[21] On road and wind-tunnel aerodynamic study of human powered vehicle. The study shows that aerodynamic efficiency of vehicle largely depends on external shape especially the extrusion, gaps and bumps

22 2014 Deepak et al[22]

Design and analysis of 3 wheeled duel steering vehicle. The aim of this vehicle that has steering on both sides which is powered by hub motors

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23 2014 Bhishikar et al[24]

Design and simulation of 4 wheel steering system. This involves developing a 4 wheel steering system to implant a mechanism that can serve purpose of changing in-phase and counter phase steering of rear wheels.

24 2013 Lohith et al[25]

Development of 4 wheel steering system for a car. The main aim of this project is to turn the rear wheels out of phase to the front wheels.

25 2015 M Renjith Kumar[26]

Design and analysis of manually operated floor cleaning machine. It can be an alternate for convectional floor cleaning machine .This involves developing a low cost user friendly floor cleaning machine.

26 2015 Pushkin Gautham[23]

Selectable all wheel steering for an ATV.In this the engagement and disengagement of 4 wheel steering can be done as per driver requirement.

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METHODOLOGY

• Identify the requirements

• Selection of steering mechanism

• Design calculation of various gears were made

• Designed the model in PRO-E with dimensions

• Given motion study in Solid works

• Fabricated the model with designed dimensions

• Analysis of the system is carried out

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DESIGN CALCULATION

CHAIN DRIVE

Assumed breaking load = 6810kgf

Pitch, p = 15.875

Teeth number, z1 = 16 z2 =45

Transmission ratio, i = z2 /z1 =45/16 =2.8125

Weight of car = 80kg

Total estimated weight = 200kg

Breaking load = 200*9.81=1962kgf

Hence designed chain is safe.

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BEVEL GEAR

Teeth number, z1 = 12 z2 = 12

Gear ratio, i = z2 /z1 =12/12 =1

Assumed material of pinion =40 Ni 2 Cr 1 Mo 28

Assumed material of wheel = 40 Ni 2 Cr 1 Mo 28

Tensile stress = 400 N/ mm2

Compressive stress assumed = 1100 N/ mm2

Compressive stress theoretical =1058.479 N/ mm2

Thus the design is safe

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SPUR GEAR

Torque, T = 7.127Nm

Design stress, [ b] = 400N/mm2

Compressive stress, [c] = 1100N/mm2

Teeth number, Z1 = 30, Z2 =80

c =635.63N/mm2

b =106 N/mm2

Thus the design is safe

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MECHANISM USED

ACKERMAN STEERING MECHANISM

• To avoid the tyres to slip sideways when following the path

around a curve.

• The geometrical solution to this is for all wheels to have

their axles arranged as radii of a circle with a common

center point.

• The principle is sound for low speed manoeuvres.

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Condition for True Rolling While tackling a turn, the condition of perfect rolling

motion will be satisfied if all the four wheel axes when projected at one point called the instantaneous centre, and when the following equation is satisfied.

Cot Ø- Cotθ = c/b

Fig:1 :True rolling condition

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SCRAP COLLECTING MECHANISM

•Neodymium magnets are used to

attract the metal scraps

•Collected scraps are repelled by

pressing the lever

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4 MODES OF 4WS

• Front wheel turn

• Short radius turn

• Parallel parking

• 360 degree turn

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FOUR MODES OF STEERING MECHANISM

Figure.3.1.Working of Four Modes of Steering Mechanism

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FRONT WHEEL STEERING

• The lock nut is removed

• Steering wheel is attached to shaft with pinion at its end, which in turn meshes

with the rack.

• When the steering wheel is rotated, the pinion attached is rotated in the same

direction, thus producing horizontal movement with rack; enabling the wheels

to turn in the direction of rotation.

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SHORTER RADIUS TURNING

•The lock nut is inserted

•The gear arrangement is moved to other side, the spur gear disengages

and the bevel gear gets engaged. Due to bevel gear arrangement, the rear wheel

steers in opposite direction to the front wheel. This results in shorter radius

mode steering.

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PARALLEL PARKING

•The lock nut is inserted

•The gear arrangement is pushed to one position, the spur gears get engaged and

the steering of rear wheel is ensured and is in same direction as that of the front

wheels.

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ZERO DEGREE ROTATION

•The 360 degree rotation mode of 4WS is applied by chain movement

which helps in movement of wheels in the required position.

•The movement of wheels is in a way that the vehicle will move or turn in

360 degree.

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WORKING PRINCIPLE

• When the lock nut is removed, the steering operation is carried out

in normal condition. That is only front wheels steer.

• When the lock nut is inserted, the other two modes can be used.

When the gear arrangement is pushed to one position, the spur gears

get engaged and the steering of rear wheel is ensured and is in same

direction as that of the front wheels.

• When the gear arrangement is moved to other side, the spur gear

disengages and the bevel gear gets engaged. Due to bevel gear

arrangement, the rear wheel steers in opposite direction to the front

wheel. This results in third mode steering.

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DESIGN OF THE MODEL

Fig 1: Frame of 4WS

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Fig 2: Modes in four wheel steering

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Fig 3:Gear system

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Fig 4:Rack and pinion

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APPLICATIONS1. Parallel Parking Maneuver Simplified With 0º rotation

Mode

Fig : 9.1: Parallel Parking Maneuver

Simplified

With 0 degree rotation Mode

• To successfully park the

vehicle without incurring any

damage.

• Driver can virtually park the

vehicle without even

touching the steering wheel.

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2. High speed lane changing

Fig :9.2 – Parallel parking mode in Action

Under slippery conditions, the rear of

the car may fishtail out of control

which can be damped or even

eliminated through the use of same-

side steering.

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ANALYSIS

The different modes of four wheel steering has different

turning radius. Depending upon the turning angles of front and

rear wheels the turning radius has considerable changes.

1. Front wheel steering mode

Turning angle of front wheels = 23°

Turning radius calculated = 3.503 m

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2. Shorter radius turning mode

Turning angle of front wheels = 22°

Turning angle of rear wheels = -17°

Turning radius calculated = 2.779m

3. Parallel parking mode

Turning angle of front wheels = 22°

Turning angle of rear wheels = 19°

Turning radius calculated = infinity

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4. Zero degree rotation mode

1. Turning angle of front wheels= 41°

2. Turning angle of rear wheels = 37°

3. Turning radius calculated = 0m

• From the above analysis it was found that the short

radius turning mode has less turning radius while not

considering zero degree rotation mode which can rotate in its

current position.

• Parallel parking mode would not make a full round

path way so its turning radius is considered to be infinity.

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ADVANTAGES

Simplify the lane changing procedure.

To successfully park the vehicle without incurring any damage

Mode change is easy

Implementation is easy

Improve the vehicle handling

Driver fatigue can be reduced

Military reconnaissance and combat vehicles can benefit to a

great extent from 360 mode

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DISADVANTAGES

Gear arrangement adds weight to the vehicle.

Even severe imbalance of a rear wheel on a speed sensitive

4WS system can cause problems and make basic

troubleshooting a bit frustrating.

More maintenance is needed.

Mechanism is complex.

More expensive.

Construction is difficult

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VISIBLE OUTPUT

• A paper was presented entitled “Four wheel steered multi-utility vehicle-

a review” in the national conference on IDEAS -16 held at UKF College

of Engineering & Technology, Paripally on 31 March 2016.

• A paper was submitted entitled “Four wheel steered multi-utility vehicle-

a review” on IJES.

• Paper selected entitled “Four wheel steered multi-utility vehicle- a

review” on IJES.

• Participated in the project expo competition held at RIT Kottayom.

• Participated in the project expo SRISHTI -16 organized by Jyothi

Engineering College Cheruthuruthy, held on 19 March 2016

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CONCLUSION The four-wheel steering system has got cornering capability,

steering response, straight-line stability, lane changing and low-speed

maneuverability.

Even though it is advantageous over the conventional two-wheel

steering system, 4WS is complex and expensive. Currently the cost of a

vehicle with four wheel steering is more than that for a vehicle with the

conventional two wheel steering.

Four wheel steering is growing in popularity and it is likely to

come in more and more new vehicles. As the system has multi-utility it

will be very much useful in industrial areas. The system can replace

conventional scrap collecting systems.

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There are some points to describe this project from existing system-

1. Superior cornering stability. 2. Improved steering responsiveness and precision. 3. High speed straight line stability. 4. Notable improvement in rapid lane changing manoeuvres. 5. Relative wheel angles and their control. 6. Smaller turning radius and tight space manoeuvrability at

low speed.

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