Optimal design and enhancement of drive shaft mechanism in automobiles PDF

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Optimal design and enhancement of drive shaft mechanism in automobiles R. Kishore, P. Gurusamy ⇑, S. Nagendharan, P. Subash Department of Mechanical Engineering, Chennai Institute of Technology, Chennai 600069, Tamilnadu, India

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Article history: Received 1 April 2020 Accepted 12 May 2020 Available online xxxx Keywords: Differential Mechanism Driveshaft Gear box Slip rings All Terrain Vehicles

a b s t r a c t This paper reports on concentrating and creating an alternate mechanism for the existing differential mechanism in All Terrain Vehicles. The differential is a component in automobiles and other wheeled vehicles which allows the outer wheels to drive in a faster speed than the inner wheel drive during turns. This differential is a very essential part to turn the vehicle smoothly. An increase in one-wheel speed will be balanced by decreasing the speed of the other wheel. The vehicles with two drive wheels will face the problem when it comes to corners, here the drive wheel must be rotating in different speeds to achieve traction. Without Differential both driving wheels are forced to drive in same speed which results in very unpredictable and hectic handling issues and damages tires as well as roads also leads to possible failure of drive train. The existing differential have complicated mechanism and it takes huge space to occupy in the constrained cabin to overcome this design has been adapted by disengaging the drive shaft from the gearbox whenever the turns are taken. This drive shaft with engaging and disengaging mechanism has been adapted the disengaging driveshaft is a normal driveshaft or output shaft from gearbox with an additional mechanism attached to it. This mechanism is used to engage or disengage the wheels from the gearbox. This differential is light-weight, fast, less space-consuming and an economical solution for improving the turning radius as compared with existing differential gear system. Ó 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Nanotechnology: Ideas, Innovation and Industries.

1. Introduction All vehicles, the driving force permits the external force wheel to rotate faster than the internal force wheel in the course of a turn [1,2]. It is essential that the external force wheel rotate faster than the internal force wheel and this is very much essential in turning of automobile. This would help the wheel to rotate effectively. The external and internal speed of two riding wheels equals the input pace of the power shaft. The increasing the speed of one wheel is well-adjusted by means of a decrease within the velocity of the other wheel. The differential mechanism is activated through the longitudinal propeller shaft to the pinion, which causes the transverse ring gear to rotate. This function would reduce the number of gears in the system. The driving shafts are usually connected with rear wheel drive for better performance. In front wheel drive the gear

⇑ Corresponding author. E-mail address: [email protected] (P. Gurusamy).

box have engine crankshaft and differential mechanism is in the same location [3]. A separate drive shafts are connected with each wheel. In the differential mechanism one main shaft is operated by two output shafts and these are individually connected with wheel [4]. The eternal and internal wheels rotation radius is defined the track width of the vehicle. Variation between the wheels have to be maintained in the two-wheel drive automobile which in turn evaluate the performance of the vehicle. In general, the vehicle is cornering, the external force wheel rotates longer distance as compared with internal force wheel, hence these two wheels have to maintained the speed. In this case the differential plays a vital role for all kind of vehicles. These external and internal wheels have to be rotate at different speeds which has been controlled by differential mechanism. A common axle driven mechanism is adopted in vehicles like karts and wheels are designed to rotate at same speed which leads to effective performance. In addition to these the role of gear box played a very important role in this system. In this work, the part contains a locking mechanism for engaging/disengaging the wheels from the gearbox which moves with a linear

https://doi.org/10.1016/j.matpr.2020.05.341 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Nanotechnology: Ideas, Innovation and Industries.

Please cite this article as: R. Kishore, P. Gurusamy, S. Nagendharan et al., Optimal design and enhancement of drive shaft mechanism in automobiles, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.05.341

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R. Kishore et al. / Materials Today: Proceedings xxx (xxxx) xxx

achieved in this stage the new modified design has to be created in such a way that the turns at different speeds and at the same time the weight of the overall setup should not exceed [5]. The existing traditional differential design which has many complicated parts in manufacturing and as well as designing. Fig. 1 shows that the comparison of existing model with new design of disengaging system. The new modification initiated will be a simple setup which consist of a coupling mechanism that separates the driveshaft from the transmission system and gives an efficient run to the engaging driveshaft and to achieve the turn without any slips or drift. Thus, the idea of disengaging driveshaft has been nurturing and the design considerations have been taken into act. Fig. 3 shows greater turning capabilities on par with the existing model and the ATV’s can easily take sharp turns than the existing model of traditional differential which is connected with the drive shaft. Fig. 1. Comparison of existing model with disengaging design.

3. Modelling actuator for moving powered by a simple 12 V battery supply through two sets of slip rings.

2. Disengaging design The modification of the design has been initiated form the base idea to reduce the weight added towards the All-Terrain Vehicle transmission system. The existing design modifications cannot be

The design has been separated into three parts and as per the requirements the design process has been started the combination of three different parts were designed using CAD software CATIA V5. The parts that are designed from CATIA V5 are then manufactured and assembled to make the innovation successfully assembled in the ATV vehicle the designed parts are the following 1. The connecting part from gearbox 2. The part that connects the drive shaft 3. The long screw which connects the setup. Fig. 2

Fig. 2. CAD model of parts which connects gear box and drive shaft.

Please cite this article as: R. Kishore, P. Gurusamy, S. Nagendharan et al., Optimal design and enhancement of drive shaft mechanism in automobiles, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.05.341

R. Kishore et al. / Materials Today: Proceedings xxx (xxxx) xxx

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Fig. 3. Assembled CAD model.

shows that the CAD model of part which connects gear box and drive shaft.

4. Disengaging mechanism In All Terrain Vehicles, there is a need for achieving better turns. The solution needs to be comparatively light, not take too much space in the vehicle and be economical [6]. The Disengaging driveshaft benefits by being lightweight compared to other possible solutions. By making the changes to the drive shaft itself, it takes up very little space and is an economical solution without reducing the drifting capabilities of the ATVs. Since the use of gear is reduced, the gear wear loss as seen in the differential system is removed which also reduced the maintenance. The driveshaft is a component that connects the wheels to the gearbox. In an ATV, the driveshaft is the output of the gearbox that is connected to the rear wheels. The front wheels are used for mainly steering. Depending only on the Front steering for the turning gives us very little turning capabilities. Usually, to improve this issue, a differential gear system is used, which does improve the turning capabilities of the vehicle in exchange for consuming more vehicle space, increasing the vehicle weight and being expensive. A possible solution to this is the innovation Disengaging driveshaft. The Disengaging driveshaft is a normal driveshaft or output shaft from gearbox with an additional mechanism attached to it. This mechanism is used to engage or disengage the wheels from the gearbox. The innovation contains a locking mechanism for engaging/disengaging the wheels from the gearbox which moves with a linear actuator for moving powered by a simple 12 V battery supply through two sets of slip rings. The locking mechanism is a set of two interlocking elements which are designed and machined in the Lathe and VMC. One of the elements of the mechanism is kept stationary and the other element is moved linearly with the help of Linear actuator. The Linear actuator contains a simple high torque 12 V DC motor, a hollow lead screw placed onto the motor shaft and a suitable nut of the same pitch size placed fixed tightly onto the moving locking element. The power supply to the motor is given from a 12 V battery supply through two sets of two slip rings which are made in-house. When the locking mechanism is carried out, and the elements are interlocked, the wheels and the gearbox are connected to each other and the ATV moves in the usual manner. When the two elements are made to move away from each other, the wheel is free from the movement from the gearbox. When the driveshaft is disengaged and the vehicle is accelerated,

Fig. 4. Final assembly with drive shaft connected to the new part.

with that wheel as pivot the ATV moves making it turn towards the direction of the disengaged driveshaft. This can be used to turn the vehicle in the direction it requires [7]. The driveshaft which needs to be engaged or disengaged is controlled by the driver itself using buttons. Fig. 3 shows the assemble part of the model. The designed alternate part has been manufactured and assembled in the existing vehicle without changing any design. One of the elements of the mechanism is kept stationary and the other element is moved linearly with the help of Linear actuator. The Linear actuator contains a simple high torque 12 V DC motor, a hollow lead screw placed onto the motor shaft and a suitable nut of the same pitch size placed fixed tightly onto the moving locking element. The power supply to the motor is given from a 12 V battery supply through two sets of two slip rings which are made in-house. Fig. 4 shows that the final assembly with drive shaft connected to the new part. Recently, aluminium or magnesium alloy based nonferrous materials are highly used in automobile and aircraft applications, because of light weight and superior strength compared to the conventional material [8–42]. The engaged part consist of slip ring will be connected with a 12v DC motor which actuates the setup to rotate and it then disengages from the gearbox the motor acts as abridge between the gearbox and the innovation setup where the drive shaft is connected with new setup using universal joints [43,44]. The UV joints are intruded because the drive shaft might have an angular connection with the wheels hubs so the UV joint will act as a greater support and transmits power without losses.

Please cite this article as: R. Kishore, P. Gurusamy, S. Nagendharan et al., Optimal design and enhancement of drive shaft mechanism in automobiles, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.05.341

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R. Kishore et al. / Materials Today: Proceedings xxx (xxxx) xxx

5. Conclusions The following observations have been made  The proposed innovation, the disengaging driveshaft is a very suitable light-weight, fast, less space-consuming and an economical solution for improving the turning radius of the ATVs eliminating the need for differential gear system.  Using the proposed solution in ATVs improves the turning capabilities without compromising the drifting capabilities of the vehicle which is equally important.  This is the base model and further design improvements can be achieved by incorporating various design factors.  In future the passenger vehicles this mechanism and the innovation can be integrated with a sensor for engaging or disengaging the driveshaft.

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Please cite this article as: R. Kishore, P. Gurusamy, S. Nagendharan et al., Optimal design and enhancement of drive shaft mechanism in automobiles, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.05.341...