1、Automotive Engineering Technology1汽车构造讲义Automotive Engineering Technology冯茂林 FOREST FENGThis is one of the main courses offered by our vehicle engineering speciality. I appreciate you are interesting in my classroom for 45hours and hope you will be also satisfactory after 4 months. I have confidence
2、 to make you acquire professional knowledge of Automotive engineering and strong ability to understand in English. It would be the best thing for you to remember the following words.When the theory and practice do not agree, you should examine the facts to see what is wrong with the theory.Charles F
3、. Kettering, General Motors(1934)Born: August 29, 1876 Loudonville, Ohio Died: November 25, 1958 Dayton, OhioCharles F. Kettering, first as an independent inventor and later as head of research for General Motors Corporation, conducted research that established him as one of the most creative Americ
4、ans of his generation. 学时： 45 其中讲授： 36 考试：2 实物教学 7教材： Automotive Engineering English 机械工业出版社 主编 李俊玲参考教材：汽车构造 上下册 web: 010568-851220164 of 200 pages of the teach book, un-including electric and electronic part, Automotive Engineering Technology2have to be spoken in 18 classes. Average pages for each
5、speaking are 10 p. 测验：每章结束后安排一次测验，一共进行 6 次小测验，每次占 10 分，共 60 分。课程结束时，进行一次大测验，占 40 分。共计满分 100 分。以下文字说明是课程讲义的补充内容，和电子教案共同使用。由于发动机原理课程中已经介绍过发动机的基本结构，鉴于课程学时的限制，本课程中发动机部分内容将缩减为 8-10 学时。 电器和电子部分由于已有专门的课程，所以本课程中省去不讲。Automotive technical abbreviationsABS Anti-blockier system (German) - anti-lock braking syst
6、emABDC After bottom dead centre (engine timing)A/C Air conditioningACL Automatic chassis lubrication (commercial vehicles)ACT Air charge temperatureA/F Air/fuel ratioAIR Air injection reactor (emission control)ALB Anti-lock brakes (Honda)ARCS Active roll control system (Citroen)ASD Automatic slip-co
7、ntrol differentialASF Audi space frame (aluminium body construction)ASR Antriebs-schulpf-regelung (German) -anti-slip regulation or traction control systerATC Automatic temperature controlATDC After top dead centre (engine timing)ATF Automatic transmission fluidAWD All-wheel drive (also 4WD)AWS All-
8、wheel steering (also 4WS)BBDC Before bottom dead centre (engine timing)BDC Bottom dead centre (engine timing)BHP Brake horsepowerBMEP Brake mean effective pressureBOFT Bearing oil film thicknessBSFC Brake specific fuel consumptionBTDC Before top dead centre (engine timing)CAD Computer aided designCA
9、FE Corporate average fuel economy (American)CAG Computer aided gearshift (Scania)Automotive Engineering Technology3CB Contact breakerCBE Cab behind engine (commercial vehicles)Cd Coefficient of drag (vehicle aerodynamics)CD Capacity discharge (ignition system)CFC Chlorofluorocarbon (refrigerant)CI C
10、ompression ignition (diesel engines)CO Carbon monoxide (emission control)CO2 Carbon dioxide (global warming)COE Cab over engine (commercial vehicles)CP Centre of pressure (vehicle aerodynamics)CR Compression ratio (engine)CTX Continuously variable transaxle (Ford)CV Constant velocity (universal join
11、ts)CVT Continuously variable transmissionCw Coefficient of drag (German) - vehicle aerodynamicsCx Coefficient of drag (French) - vehicle aerodynamicsDERV Diesel engine road vehicles (fuel)DI Direct injectionDIS Direct ignition system (no distributor)DOHC Double overhead camshaftsEBS Electronic braki
12、ng system (air brakes)ECI Electronically controlled injectionECM Electronic control moduleECS Evaporative control system (fuel system) Electronically controlled suspensionECT Engine coolant temperatureECU Electronic control unitEDC Electronic diesel controlEFI Electronic fuel injectionEGR Exhaust ga
13、s recirculation (emission control)EMS Engine management systemEP Extreme pressure (lubricants)EPAS Electrical power-assisted steering (NSK-RHP)EPHS Electrically powered hydraulic steering (TRW Steering Systems)EPS Electric power steering (EPAS)EUI Electronic unit injector (Lucas Diesel)EVC Exhaust v
14、alve closed (engine timing)EVO Exhaust valve open (engine timing)FHP Friction horsepowerFWD Front-wheel driveGCW Gross combination weight (articulated vehicles)GRP Glass reinforced plasticsGTW Gross train weight (drawbar vehicles)GV Governor valve (automatic transmissions)GVW Gross vehicle weight (r
15、igid vehicles)Automotive Engineering Technology4GWP Greenhouse warming potential (refrigerants)HC Hydrocarbons (emission control)HFC Hydrofluorocarbon (refrigerant)HGV Heavy goods vehicleHUCR Highest useful compression ratioHVAC Heating, ventilation and air conditioningIFS Independent front suspensi
16、onIHP Indicated horsepowerINJ Injection (timing mark)IOE Inlet over exhaust (obsolete valve layout)IRS Independent rear suspensionIVC Inlet valve closed (valve timing)IVO Inlet valve open (valve timing)KPI King-pin inclination (steering)LGV Large goods vehicleLI Load index (tyres)LS Leading shoe (dr
17、um brakes)MAF Mass air flow (engines)MAP Manifold absolute pressureMOFT Minimum oil film thicknessMON Motor octane number (more demanding ON test)MPI Multi-point injectionMPV Multi-purpose vehicle (people carrier)NOx Nitrogen oxides (emission control)NVH Noise, vibration and harshness (vehicle refin
18、ement testing)OBD On-board diagnosisOD OverdriveODP Ozone depletion potential (refrigerants)OHC Overhead camshaftOHV Overhead valvesON Octane number (petrol anti-knock rating)PAS Power-assisted steeringPBD Polybutadiene (tyres)PCV Positive crankcase ventilation (emission control)PFI Port fuel inject
19、ion (petrol engines)PM Particulate matter (diesel emission control)PR Ply-rating (tyres)PSV Public service vehiclePTFE PolytetrafluoroethylenePTO Power take-off (commercial vehicles)PVC Polyvinyl chlorideRC Roll-centre (suspension geometry)RON Research octane number (less demanding ON test)RTV Room
20、temperature vulcanizing (sealant)Automotive Engineering Technology5RWD Rear wheel driveSAMT Semi-automated mechanical transmission (Eaton)SBR Styrene-butadiene (tyres)SCA Supplemental coolant additivesSCS Stop control system (Girling)SEFI Sequential electronically-controlled fuel injection (Ford)SFC
21、 Specific fuel consumptionSFI Sequential fuel injectionSG Spheroidal graphite (high-strength cast iron)SI Spark ignition (petrol engines)SLA Short and long arm (American) - suspension linkageSOHC Single overhead camshaftSPI Single point injection (petrol engines)SV Side valves (obsolete valve layout
22、)TAC Thermostatic air cleanerTBI Throttle body injection (SPI)TC Twin carburettorsTCI Transistorized coil ignitionTCM Transmission control moduleTCS Transmision controlled spark (engine intervention system)TDC Top dead centre (engine timing)TDI Turbocharged direct injection (diesel engines)TEL Tetra
23、 ethyl lead (petrol anti-knock additive)TML Tetra methyl lead (as above)TPS Throttle position sensorTS Trailing shoe (drum brakes)TV Throttle valve (engine and automatic transmissions)TVS Thermal vacuum switch (exhaust gas recirculation)TWC Three-way catalyst (emission control)TXV Thermostatic expan
24、sion valve (refrigeration)UJ Universal jointVCP Variable cam phasing (valve timing)VCU Viscous coupling unit (transmission)VDC Vehicle dynamics control (Bosch)VI Viscosity index (lubricants)VIVT Variable inlet valve timingWOT Wide-open throttleCHAPTER 1 AUTOMATIVE BASICWe will have two topics concer
25、ned in this class speaking. How many kinds of automobiles should we learn from your images? Automotive Engineering Technology6What are the main parts which you can understand from an automobile? 1 汽车分类 道路车辆 Highway Vehicle汽车 Automobile轿车 Salooncar, racing car, roadster, hatchback, convertible, SUV商用
26、汽车 Commercial vehicletruck, bus, coach, trailer, tractor汽车列车 Saloon/Commerial+trailer挂车 trailer半挂车 tractor+trailer非道路车辆 Off-highway Vehicle工程车辆 Engineering vehicleloader, forklift, scraper, 军用车辆 Military vehicletank, armored car, . 2. 汽车组成An average car contains more than 15000 separate, individual
27、parts that must work together. All the parts are grouped into four major categories: body, engine, chassis and electrical system.2.1 BODYConfiguration: Sheet metal with windows, doors, hood and trunk deckAutomotive Engineering Technology7Function: Protection cover for passengers, engine and cargo Go
28、od lookingattractive, colorful, modern appearanceStructure Design for different kind of automobile:Sedan Design: enclosed body, maximum 4 doors (2 for racing car), passenger compartment, cargo trunk, fixed roof or soft-top(for convertible) Utility or pick-up Design: Stranger chassis components and s
29、uspension for carrying goods than saloon.Van Design: based on sedan design, get maximum cargo space in available.Commercial Vehicle Design: different design for special purpose of good transportation, Tank, tipper (dump), flatbed, van.Bus design: buses and coaches are designed with rigid structure,
30、4 wheels/2 axles and more, articulated buses for more capacity, single / double-deck.双层2.2 ENGINEFunction: acts as the power unitHeat Engines: Internal combustion engineburning a liquid fuel inside the engine, External combustion enginesteam engine, turbine,Types of internal engines: Gasolinespark-i
31、gnition engine, Automotive Engineering Technology8Dieselcompression-ignition engineThe burning fuel generates heat-causes the gas inside the cylinder to increase its pressure-supply power to push piston move-rotate a crankshaft-output to power train.Engine configuration: IN-LINE ENGINECYLINDERS ARE
32、IN-LINE V ENGINECylinders are configured in V type.Engine location: Front locationlongitudinally mounted, drive front or rear wheelsRear locationlongitudinally or transverse, usually drive rear wheels2.3 CHASSISPOWER TRAIN system conveys the drive to the wheelsSTEERING system control the direction o
33、f movementSUSPENSION systemsuspension and wheels absorb the road shocksBRAKE systembrake slows down the vehiclePOWER TRAINAutomotive Engineering Technology9Function: transfer turning effort from the engine to the driving wheelsComponents: Clutchused for manual transmissionTorque converterused for au
34、tomatic transmissionTransmissionDrive shaftFinal driveDifferential gearsDriving axlesTransaxletransmission+final drive+differentialHow do those components work together? Clutchengage or disengage the engine from the power train, just in case of manual transmission.Engine torque is transmitted throug
35、h the clutch or converter to the transmission or transaxleGear ratios in the transmission or transaxle:Lower gearlower gear ratio has bigger numeral from dividing driven gear teeth by driving gear teeth. At lower gear ratio a higher torque is transmitted to the rest of the power train. The vehicle s
36、tarting from rest to reach a speed needs a lot of torque, this is from the principle of F= ma.Automotive Engineering Technology10Higher gearhigher gear ratio has smaller numeral, usually the highest ratio is less than 1. At a speed higher gear ratio makes engine speed lower than lower gear ratio. Dr
37、ive shaftpropeller shaft, used for the conventional vehicle with the engine at the front and driving wheels at the rear, to transmit torque from transmission to the final drive.Final drivefinal gear reduction to multiply the torque before applying to the driving axles.Front engine rear wheel drive v
38、ehiclesfinal drive change the direction of drive by 90 degreesInside the final driveA differential gear set divides the torque to axles; allows for the difference in speed of each wheel when cornering (turning).Two axle shafts transmit the torque to the driving wheels.For movementin rear-wheel drive
39、 vehicle the axles can be solid or contain joints to allow for movement of suspension;For movementin front-wheel drive vehicle, the drive shafts have universal joints to allow for suspension and steering movement.Automatic transmissiongear selection is controlled either hydraulically or electronical
40、ly; converter acts as a hydraulic coupling to transfer the drive.Automotive Engineering Technology11STEERING SYSTEMFunction: to control the direction motion.3 main parts:Steering boxsteering wheel 转向器Linkagewheel assembly ，tie-rods 转向拉杆Front partsto let the wheel assemblies pivot. 转向枢轴SUSPENTION SYS
41、TEMFunction: the complete suspension system has two purposes as: Isolate the vehicle body from road shocks and vibrations, which will otherwise be transferred to the passengers and load.Keep the tires in contact with road regardless of road surface.Inclusion: springs, axles, shock absorbers, arms, r
42、ods and ball jointsThe springthe flexible component of the suspensionBasic types are: Leaf springsCoil springsTorsion barsUsages: Modern passenger vehicles usually use light coil springsAutomotive Engineering Technology12Light commercial vehicles have coil springs at the front and leaf springs at th
43、e rearHeavy commercial vehicles usually use leaf springs and hydropneumatic strut.Wheels (Rims) designed and made for following purposes: Strong enough to support the vehicle and withstand the forces caused by normal operation;As light as possible to help keep unsprung weight to a minimumGood appear
44、ance Heat conductiondissipate heat from brakes and tires Materialpressed-steeling two sections; cast aluminium alloy which is better that steel onesTiresinstalled on rims act as two pueposes:Cushion between the vehicle and road to reduce the transmission of road shocks;Provide friction to allow the
45、vehicle to perform its normal operation Materialrubber is mainly syntheticTypes of constructioncross-plygoing to be replaced by radial on 4-wheel drive and heavy vehiclesRadial- most of passenger car useAutomotive Engineering Technology13Tube tiresrequire an inner tube to seal air inside the tireTub
46、eless tiresare eliminating the inner tube by making the complete wheel and tire assembly airtight.BRAKE SYSTEMTypes of designDrum brakeshave a drum attached to the wheel hub, brake shoes can expend against the inside of the drum, brake occurs by means of above action.Disc brakesa disc attached to th
47、e wheel hub is clenched between two brake pads (calipers).Operation of the brakeHydraulic ( powerless) operated brake system: . Brake pedal operates a master cylinder. Hydraulic lines or hoses connect the master cylinder to brake cylinder at the wheel (brake shoes or pads). Disc brakes require great
48、er force to operate them. A brake booster assists driver by increasing the force applied to the master cylinder when the brake is operated.Air operated brake system: used on heavy duty vehiclesAir compressor pumps air to storage tank at pressure of 7-8 bar. Driver controls valves ( brake pedal) to direct compressed air to different wheel units to Automotive Engineering Technology14operate the friction brakes.Wheel unitslarge diameter diaphragms provide the large force to the brake assemblyFriction brakesboth of above concern
