Module-2 21ME54

,Module-2 Transmission & Suspension System

Syllabus: Clutches; Plate Clutches, Cone Clutch, Centrifugal Clutch, Fluid Flywheel Gear Box; Gear Shifting
mechanism, synchromesh Gear box, Torque converter, Automatic Manual Transmission(AMT), Automatic
Transmission (AT), intelligent manual Transmission (IMT), Continuously Variable Transmission
(CVT),Infinitely Variable Transmission (IVT)- Working of Differential, Rear Axle types & construction.
Suspension – layout & working of Hydraulic& Air suspension, Independent suspension, Functions& advantages
of Leaf Spring, Coil Spring, Telescopic Shock Absorber, Torsion Bar.

 Transmission System
In a car, a transmission, or a gearbox, acts as the medium that transmits power generated
by the engine to the wheels via a mechanical system of gears and gear trains. A
transmission allows a person to apply power to a vehicle in a controlled manner, without
which, the car would not efficiently move.

 Suspension System

Suspension is the system of tires, tire air, springs, shock absorbers and linkages that
connects a vehicle to its wheels and allows relative motion between the two. Suspension
systems must support both road holding/handling and ride quality, which are at odds with
each other.

Clutches:
A clutch is a mechanical device that allows the output shaft to be disconnected from the
rotating input shaft. The clutch's input shaft is typically attached to a motor, while the
clutch's output shaft is connected to the mechanism that does the work.
In mechanical engineering terms, a clutch is one of the most vital devices of any
automobile. The mechanism connects and disconnects the power transmission from a
driving shaft to a driven shaft.
Clutches help to restrict the speed or the amount of power transmission between two
shafts. They are applied in many industries to power up rotary assemblies, equipment, and
systems. The kind and nature of the clutch applied to the vehicle vary on the basis of the
requirements and restrictions of the application.It contain various parts, including a
friction surface, coil spring, hub, diaphragm spring, etc. Applications of clutches are also
found in other industries. Furthermore, in automobiles, it enables the engine to work in an
immobile position. In order words, clutches connect and disconnect two rotating shafts.
Application of Clutch:

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Following are some key pointers on application of a clutch or function of a clutch:

 It enables transmitting the torque from the engine to its drivetrain.
 It forms a linkage between the engine flywheel and gearbox so that it can
transfer power from the engine to the drive shaft.
 Helps in lessening drive-related vibration.
 Avoids high heat generation to prevent engine malfunctioning, breakdown, etc.
 It prevents the vehicle from jerking, thereby stopping it from causing unnecessary
strain on rest of the car besides the passengers as well.
 In some cases, the clutch disengages when the torque exceeds the safety limit,
thereby acting as a safety device.
To conclude, the clutch plays a vital role in a car. It helps in efficient power transfer to the
vehicle’s wheels and helps you in efficient gear shifting. Thus, when you are maneuvering
your vehicle, you can rest assured of a safe and comfortable driving experience.
Single Plate Clutch
o The single plate clutch employs a friction plate connected to the splines of the driving
shaft, while the flywheel is attached to the engine's crankshaft and turns in tandem
with it. It harnesses the force of friction to initiate motion on the driven shaft,
smoothly accelerating it from rest to the desired speed while minimising excessive
slippage between the friction surfaces.
o Efficient power transmission relies on the careful engagement of the friction surfaces,
as the friction clutch assumes a pivotal role in establishing the connection between
the engine and the driven shaft. This process necessitates a gradual and controlled
engagement to achieve the desired speed of the driven shaft.
o To ensure effective load transfer, precise alignment of the bearing is crucial, and it
should be positioned as closely to the clutch as possible to minimise the risk of
fatigue failure over time.

Single Plate Clutch Main Parts

Single Plate clutch consists of the following Main Parts:
o Engine Shaft o Clutch Plate
o Flywheel o Pressure Plate
o Friction Lining o Clutch Pedal and
o Clutch Spring o Bearings.

Engine Shaft
The engine shaft is a rotating component that converts one form of motion into another.
This shaft is directly linked to the engine's mechanisms and acts as the focal point where
clutch operations take effect. It consists of two parts: the driving shaft connected to the
engine and the driven shaft, which operates concurrently with the driving shaft via a
gearbox.
Flywheel:
Flywheels are energy storage devices utilising a rotating wheel, with stored energy
increasing quadratically with angular velocity and linearly with the moment of inertia.
While they can reach high angular velocities, there is a risk of material disintegration due

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to the resulting forces. During clutch engagement and disengagement, the flywheel serves
as an energy source whenever needed.

Friction Lining:
The friction lining, a friction disc, plays a crucial role in initiating and terminating energy
transfer between a driven shaft and a drive shaft. Designed with a low coefficient of friction,
friction linings facilitate quiet, stable, and smooth clutch operations. Materials used for
friction linings typically include asbestos, fibreglass, and silicon dioxide.

Thrust Spring:
Helical-coil thrust springs are positioned between the pressure plate and the clutch cover.
In a compressed state, these springs provide the necessary torque to load the pressure
plate against the driven plate when the clutch is engaged. They are constructed from high
tensile steel and nickel-chrome steel.

Clutch Plate:
In a single plate clutch, a clutch plate is employed as a primary component. This clutch
plate is a thin, disc-shaped metallic piece featuring friction linings on both sides. The
frictional surfaces are responsible for transmitting the requisite torque.

Pressure Plate:
The pressure plate exerts force on the clutch plates, ensuring proper contact between
the flywheel and clutch plate surfaces through attached springs. Typically made from cast
iron, the pressure plate is a key element of clutch functionality.

Clutch Pedal:
The clutch pedal is the driver-operated control for the clutch. It is used when shifting gears,
and it involves a set of mechanical linkages that facilitate clutch engagement and
disengagement.

Release Bearings:
Also known as throw-out bearings, release bearings are positioned around the input shaft
at the rear of the pressure plate. Their role is to reduce friction between the release fork
and the clutch pressure plate lever, minimizing wear and tear on the pressure plate. Proper
lubrication is essential, and there are both mechanical and hydraulic
release bearings available.
Single Plate Clutch Working

o The pressure plate is affixed to the flywheel by means of clutch springs, utilising
splines on the shaft for this connection. It has the freedom to move along the clutch
shaft when the clutch pedal is operated.
o A single plate friction clutch comprises two flanges, with one flange securely attached
to the driving shaft and the other free to move along the driven shaft due to a splined
connection.

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o Working on the principle of a single plate clutch, the action force is generated by a
spring, which compels the driven flange to approach the driving flange. The surface of
the drive flange is lined with friction materials like cork, leather, and asbestos.
o The pressure plate is supported by release levers, acting against compression
springs, to keep the friction linings on the clutch plates separated from the flywheel
and pressure plate.
o Upon releasing the pressure plate, the compression springs allow the pressure plate
to move leftwards, bringing it into contact with the clutch.
o As the pressure plate shifts to the left, it slides along the splined cut on the hub
along the driven shaft until the friction lining makes contact with the flywheel's cone.
o The compression springs then cause the linings to be gripped between the pressure
plate and the flywheel. The resulting friction between the linings, flywheel, and
pressure plate initiates the rotation of the clutch plate around the driven shaft.
o Single plate clutches have relatively lower torque transmission capacity, reduced heat
generation, and exhibit a high coefficient of friction.

Single Plate Clutch Advantages

o Simple and cost-effective design
o Smooth engagement and disengagement of power
o Efficient transmission of power
o Lightweight and compact
o Minimal maintenance requirements

Single Plate clutch Disadvantages

 Limited torque handling capacity
 Prone to slipping under heavy loads
 Potential for clutch plate wear and replacement
 Heat generation during prolonged use
 Not suitable for high-performance or heavy-duty applications.

Cone Clutch:
The cone clutch transfers a higher torque than plate or disk clutches of the same size due
to the wedging action and increased surface area. Cone clutches are generally now only
used in low peripheral speed applications, although they were once common in automobiles
and other internal combustion engine transmissions.

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Schematic drawing of a cone clutch:

1. Cones: female cone (green), male cone (blue)
2. Shaft: male cone is sliding on the splines
3. Friction material: usually on female cone, here on male cone
4. Spring: brings the male cone back after using the clutch control
5. Clutch control: separating both cones by pressing
6. Rotating direction: both direction of the axis are possible.

Applications of Cone clutch:

 Cone Clutch used in various manual transmissions as synchronizers.
 They are used in various heavy machines as they can transmit high torque.
 These clutches are generally used in low peripheral speed applications.
 Cone clutches are commonly used in power racing boats.
 Cone clutches are used in racing and rallying vehicles.
 Cone clutches are used in some automobiles and other combustion engine
transmissions.
Centrifugal Clutch:
A centrifugal clutch is an automatic clutch that uses centrifugal force to operate. The
output shaft is disengaged at lower rotational speed and engages as the output increases to
a certain speed. It is often used in mopeds, underbones, lawn mowers, go-
karts, chainsaws, mini bikes, and some paramotors and boats to keep the engine from
stalling when the output shaft is slowed or stopped abruptly, and to remove load when
starting and idling. It has been superseded for automobile applications by the fluid
coupling, torque converter and automated manual transmissions.

Principle:
This works on the principle of centrifugal force, which means when engine speed reaches a
specific rpm (Revolutions per minute) it generates enough centrifugal force inside the clutch
which results in clutch engagement, and it transmits the engine power. At lower speeds, it
disconnects itself to stop power transmission
Operation:
The input of the clutch is connected to the engine crankshaft while the output may drive a
shaft, chain, or belt. As engine revolutions per minute increase, weighted arms in the
clutch swing outward and force the clutch to engage. The most common types have friction
pads or shoes radially mounted that engage the inside of the rim of a housing. On the
center shaft, there is an assorted number of extension springs, which connect to a clutch
shoe. When the central shaft spins fast enough, the springs extend, causing the clutch
shoes to engage the friction face. It can be compared to a drum brake in reverse. This type
can be found on most home-built karts, lawn and garden equipment, fuel-powered model
cars, and low power chainsaws.
Another type used in racing karts has friction and clutch disks stacked together like a
motorcycle clutch. The weighted arms force these disks together and engage the clutch.
When the engine reaches a certain speed, the clutch activates, working somewhat like
a continuously variable transmission. As the load increases, the speed drops, disengaging
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the clutch, letting the speed rise again, and reengaging the clutch. If tuned properly, the
clutch will tend to keep the speed at or near the torque peak of the engine. This results in a
fair bit of waste heat, but over a broad range of speeds, it is much more useful than a direct
drive in many applications.

Advantages of Centrifugal Clutch

 Automatic Disengagement. A centrifugal clutch automatically engages and
disengages, so there's no need for a control mechanism.
 Low Cost.
 Low Maintenance & Servicing.
 Safer.
 Speed Control.
 Longer Lifespan and Excess Energy.

Disadvantage
1. Loss of power due to friction and slipping.
2. This type of clutch not appropriate for the high amount of torque, the shoes will slip at
the heavy loaded condition.
3. They engage at full or near-full power, shoes get heated very quickly may cause
overheating.
Application of centrifugal clutch
Centrifugal clutch found application in the chain saw, lawn mower. The centrifugal clutch
engages after a particular speed limit, so they used to disengage the engine when starting
and idling.
Fluid Flywheel Gear Box:
A type of coupling for transmitting power from the engine of a motor vehicle to the
transmission using a torque converter. Also called: fluid coupling, fluid clutch, fluid
flywheel.The flywheel comprises a sealed chamber filled with hydraulic fluid containing an
impeller(the pump) driven by the engine and a turbine connected to an output shaft.
Fluid coupling also known as hydraulic coupling is a hydrodynamic device which is used to
transfer rotational power from one shaft to another by the use of transmission fluid. It is
used in automotive transmission system, marine propulsion system and in industries for

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power transmission. The flywheel is the interface between the clutch mechanism and the
transmission. It is a large metal disc, with a series of teeth around its outer edge; it
resembles a large gear. The purpose of the teeth is to allow the starter to engage it and
thus, turn the engine over. Flywheels used in car engines are made of cast or nodular iron,
steel or aluminum. Flywheels made from high-strength steel or composites have been
proposed for use in vehicle energy storage and braking systems.
Characteristics of a Fluid Flywheel:
 Stall speed The stall speed is defined as the highest speed at which the pump can turn
when the output turbine is locked and the maximum input power is applied. Under stall
conditions all of the engine’s power would be dissipated in the fluid coupling as heat,
possibly leading to damage.
 Slip The runner speed is almost equal to that of the impeller only when the efficiency of
liquid coupling is highest. But usually the runner speed is less than that of the impeller.
The (speed) lag of the runner behind the impeller is known as slip. This (speed) slip varies
with many factors such as engine speed, vehicle speed, and engine and vehicle load.
 Slip is given as (N1-N2)/N1 where N1, N2 are speed of driving and driven.

Advantages of Fluid Flywheel:

1. It gives smoother power take-up than the centrifugal type when the engine IS
accelerated.
2. The fluid in the coupling behaves as a cushioning agent between engine and gearbox in
order to absorb shocks during braking or coasting down on incline.
3. No need of separate pedal or lever to operate.
4. The driving member acts as a flywheel on the crankshaft. Thus. it is smoothened out the
torque variation.
5. There is no wear on moving parts.
6. No need of adjustment is required.
7. No maintenance is necessary. except maintaining the required oil level.
3. It is simple in design.
9. There is no jerk on transmission when the gear engages. It damps all shocks and strains.

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10. No skill is required for operating.

11. Car can be stopped in gear and moved off just by pressing the accelerator pedal itself.

Disadvantages of Fluid Flywheel:

1. There is a drag on the gear box-shaft even the slip is 100%.
2. It has the gear changing difficult with the ordinary crash type gearbox. so the fluid
flywheel is generally used with an epicyclic gearbox which avoids this difficulty.

Gear Shifting mechanism,

 A gear shift mechanism for a manual transmission includes a shaft axially movable
for selecting shift planes and rotatable for engaging the gears defining the shift
planes. The shaft is held in a reference shift plane by two helical springs.
 Gears are mechanisms that mesh together via teeth and are used to transmit rotary
motion from one shaft to another. Gears are defined by two important items: radius
and number of teeth. They are typically mounted, or connected to other parts, via a
shaft or base.
Types of gear:
 Spur Gear. Spur gears transmit  Bevel Gear.
power through shafts that are parallel.  Worm Gear.
 Helical Gear.  Hypoid Gear
 Double Helical Gear.
 Herringbone Gear.
Gears have various functions as precision component parts on a machine, such as:
 Gears for Setting the Rotate Speed. The gears can adjust the rotating speed of power.
...
 Gears for Transmitting Power. ...
 Gears for Changing Torque. ...
 Gears for Changing the Power Direction.

FIG: gear shifting mechanism

Synchromesh Gear Box:

 A synchromesh gearbox is a sophisticated and widely used manual transmission
system in modern vehicles that allows for seamless and efficient gear shifting. This

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ingenious engineering marvel enhances the driving experience by synchronising the

rotational speeds of the gear wheels before engagement, reducing gear clash and wear
on the transmission components. As a result, drivers can smoothly transition
between gears, ensuring optimal power delivery to the wheels and contributing to
improved fuel efficiency and overall vehicle performance.
 The synchromesh gearbox is a remarkable advancement in manual transmission
systems, specifically designed to facilitate seamless gear changes between gears
rotating at the same speed. Unlike its predecessors, such as the dog clutch and
constant mesh gearbox, this innovative transmission utilises synchronising
technology to eliminate clattering or grinding noises during gear shifts caused by
speed disparities between the input and output shafts.
 Thanks to the incorporation of specialized shifting devices called synchronizer rings,
the synchromesh gearbox allows for smooth engagement without requiring the driver
to declutch. These synchronizer rings ensure effortless gear shifts by bringing the
engaging components into frictional contact to equalize speeds. Typically configured
with 5 or 6 forward gears and 1 reverse gear, the synchromesh gearbox has become a
popular choice in regular vehicles and racing cars, owing to its quick and smooth
responsiveness.
 Earl Thompson. Earl A. Thompson, who as a youth in Portland invented the
synchromesh transmission and later led development of the Hydra-Matic
transmission will be honored in Detroit Wednesday by receipt of the Elmer A. Sperry
Award.
 The synchromesh serves to reduce the round elements will be partnered by utilizing
the friction in some cone. The working mechanism of a manual transmission without
using the clutch is the main aim is to utilize synchromesh and setting the motor
torque as a replacement clutch.
 The gears on the layshaft are fixed to it while those on the main shaft are free to
rotate on the same. Its working is also similar to the constant mesh type, but in the
former, there is one definite improvement over the latter. This is the provision of a
synchromesh device which avoids the necessity of double-declutching.

Working of Synchromesh Gearbox

Fig 2: Working of Synchromesh Gearbox

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o A synchronizer is positioned between specific gear pairs in the synchromesh gearbox,

commonly for first-second, third-fourth, and fifth-reverse gears, although the reverse
gear's location may vary among manufacturers.
o The gears on the clutch shaft, layshaft, and main shaft rotate together as long as the
engine powers the clutch shaft.
o When engaging the first gear, the clutch is disengaged, halting the rotating parts. The
gear shifter is then moved to the first gear position, initiating the movement of the
shift rod and synchronizer towards the first gear.
o The blocker ring interacts with the dog's teeth or straight cut teeth, locking onto the
gear and synchronizing their speeds.
o Re-engaging the clutch causes the synchronizer sleeve to rotate, matching the speeds
of the rotating parts.
o Once the speeds are synchronised, the synchronizer sleeve moves the gear,
interlocking it with the output shaft.
o For subsequent gears (second, third, fourth), similar principles apply, but different
shift forks and shift rods are used to engage each pair of gears.
o The fifth gear is engaged by moving the shifter from fourth to fifth gear, with the
synchronizer moving from fourth to fifth gear, synchronizing speeds and interlocking
the fifth gear.
o Engaging reverse gear involves bringing the vehicle to a complete stop, disengaging
the clutch, and shifting to reverse, causing the idler spur gear to slide between the
first gear and counter gear.
o Re-engaging the clutch in reverse results in the reversal of the output shaft's
direction, enabling backward movement of the vehicle.

Advantages of Synchromesh Gearbox

o De-clutching Not Required: Unlike constant mesh gearboxes, the synchromesh
gearbox eliminates the need for de-clutching during gear changes, simplifying the
driving experience.
o Reduced Noise: The use of helical gears with teeth cut at a specific angle contributes
to quieter gear operation, minimising noise compared to other gear types.
o Smooth Gear Transitions: The presence of a synchronizer device enables smooth and
seamless gear shifts in the synchromesh gearbox, ensuring a quiet transition
between gears.
o No Loss of Torque: The presence of synchronizers ensures that there is no loss of
torque during transmission, resulting in improved power transmission efficiency.
o Enhanced Power Transmission: With minimal torque loss, the synchromesh gearbox
can deliver more effective power transmission, enhancing the overall vehicle
performance.
o Reduced Vibration: The design and operation of the synchromesh gearbox result in
lower gearbox vibration levels, leading to a smoother and more comfortable driving
experience.
o Overcoming Clattering and Grinding: The synchromesh gearbox successfully
overcomes the clattering and grinding issues often encountered in constant mesh
gearboxes, further enhancing gear engagement smoothness.

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Disadvantages of Synchromesh Gearbox

o Higher Manufacturing Cost: The Synchromesh gearbox tends to be more expensive
due to the intricate and delicate nature of its components.
o Complexity and Bulky Design: The system's increased complexity and bulkiness can
make servicing and maintenance more challenging compared to simpler transmission
systems.
o Space Requirement: Synchromesh gearboxes demand a larger amount of space,
which can be a constraint in certain vehicle designs.
o Potential for Damage: Improper engagement of gears in the synchromesh gearbox can
lead to gear damage, affecting the overall performance and longevity of the
transmission.
o Limited Load Handling: The synchromesh gearbox may not be suitable for handling
very high loads, as higher loads can cause the teeth in contact to break.
o Selective Synchronization: Some vehicles employ synchronizer systems only on
higher gears, utilising constant mesh gears for lower and reverse gears to reduce
manufacturing costs.

Applications of Synchromesh Gearbox

o Sports Cars: Synchromesh gearboxes are commonly used in sports cars to provide
smooth and quick gear shifts, enhancing the overall driving experience.
o Local Delivery Trucks: The Synchromesh gearbox is favoured in local delivery trucks
for its ease of use and efficiency, allowing drivers to shift gears seamlessly while
navigating city traffic and making frequent stops.
TORQUE CONVERTER:
o A torque converter is a device, usually implemented as a type of fluid coupling, that
transfers rotating power from a prime mover, like an internal combustion engine, to a
rotating driven load. In a vehicle with an automatic transmission, the torque
converter connects the prime mover to the automatic gear train, which then drives
the load. It is thus usually located between the engine's flex plate and the
transmission. The equivalent device in a manual transmission is the
mechanical clutch.
o A torque converter serves to increase transmitted torque when the output rotational
speed is low. In the fluid coupling embodiment, it uses a fluid, driven by the vanes of
an input impeller, and directed through the vanes of a fixed stator, to drive an output
turbine in such a manner that torque on the output is increased when the output
shaft is rotating more slowly than the input shaft, thus providing the equivalent of an
adaptive reduction gear. This is a feature beyond what a simple fluid coupling
provides which can match rotational speed but does not multiply torque. Fluid-
coupling–based torque converters also typically include a lock-up function to rigidly
couple input and output and avoid the losses associated with transmitting torque by
fluid flow when operating conditions permit.
o Torque converters are fluid couplings that transfer rotational power from a prime
mover, such as an internal combustion engine, to a rotating load. In simple terms, it
transfers power between the engine and the gears. In vehicles with automatic
transmissions, the torque converter serves as the connection between the power
source and the load. It is a doughnut-shaped internal engine component located

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between the engine and the transmission. Inside the torque converter, there are two
series of curved blades, each facing the opposite direction. It is typically positioned
between the flex plate of the engine and the transmission, analogous to the
mechanical clutch in a manual transmission.

Operational phases

 Stall. The prime mover is applying power to the impeller but the turbine cannot rotate.
For example, in an automobile, this stage of operation would occur when the driver has
placed the transmission in gear but is preventing the vehicle from moving by continuing
to apply the brakes. At stall, the torque converter can produce maximum torque
multiplication if sufficient input power is applied (the resulting multiplication is called
the stall ratio). The stall phase actually lasts for a brief period when the load (e.g.,
vehicle) initially starts to move, as there will be a very large difference between pump
and turbine speed.
 Acceleration. The load is accelerating but there still is a relatively large difference
between impeller and turbine speed. Under this condition, the converter will produce
torque multiplication that is less than what could be achieved under stall conditions.
The amount of multiplication will depend upon the actual difference between pump and
turbine speed, as well as various other design factors.
 Coupling. The turbine has reached approximately 90 percent of the speed of the
impeller. Torque multiplication has essentially ceased and the torque converter is
behaving in a manner similar to a simple fluid coupling. In
modern automotive applications, it is usually at this stage of operation where the lock-
up clutch is applied, a procedure that tends to improve fuel efficiency.
Automated Manual Transmission (AMT)

 Automated Manual Transmission or AMT, is also known as Semi-Automatic

Transmission (SAT) or Clutchless Manual Transmission (CMT). As the name
suggests, an AMT’s prime function is to automate manual transmissions, which
means the job of pressing the clutch and shifting gears via a stick no longer rests
with the driver. There are two types of AMT – single-clutch and dual-clutch. While the
dual-clutch has proven better performance in terms of smooth gearshifts and swift
throttle response, the single-clutch option is more economical. It helps Original
Equipment Manufacturers (OEMs) keep prices in control.
 The automated manual transmission (AMT) is a type of transmission for motor
vehicles. It is essentially a conventional manual transmission equipped with
automatic actuation to operate the clutch and/or shift gears.
 Many early versions of these transmissions that are semi-automatic in operation,
such as Autostick, which automatically control only the clutch – often using various
forms of clutch actuation, such as electro-mechanical, hydraulic, pneumatic,
or vacuum actuation but still require the driver's manual input and full control to
initiate gear changes by hand. These systems that require manual shifting are also
referred to as clutchless manual systems. Modern versions of these systems that
are fully automatic in operation, such as Selespeed and Easytronic, can control both

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the clutch operation and the gear shifts automatically, by means of an ECU, therefore
requiring no manual intervention or driver input for gear changes.
 The usage of modern computer-controlled AMTs in passenger cars increased during
the mid-1990s, as a more sporting alternative to the traditional hydraulic automatic
transmission. During the 2010s, AMTs were largely replaced by the increasingly
widespread dual-clutch transmission, but remained popular for smaller cars
in Europe and some developing markets, particularly India, where it is notably
favored over conventional automatic and CVT transmissions due to its lower cost.
Advantages
1. Tackles Traffic Conveniently
This transmission type automates manual transmission, which removes the necessity to
manually shift gears and clutch unless the driver opts for a manual gear shift. It is ideal for
car drivers who regularly commute through traffic. Besides, the in-built 'Creep' allows a
driver to release the brake pedal without using the accelerator to drive at lower speeds.
2. Fuel-Efficient
It offers optimum fuel efficiency, unlike other ATs, and is another attribute to select a car
with automatic transmission. Individuals can find an automated manual transmission in
hatchbacks, and manufacturers add optimum pre-programmed shift patterns to provide
adequate mileage returns.
3. Flexible
If an individual wishes to switch from automatic to a manual transmission, he or she can
do the same with cars equipped with that feature. Besides, manual transmission in AMT-
equipped cars has a bidirectional shift path, and no complications of the clutch make it
easier.
4. Affordable
It is affordable compared to other automatic gearboxes, as it is nearly half of the latter's
price. At the same time, AMT gearboxes cost almost one-fourth of the price of DCT ones.
Disadvantages
1. Inconsistent Shifting of Gears
Individuals driving AMT-equipped cars may face inconsistency in shifting gears, and unlike
other automatic transmissions, AMT offers an inferior gear shifting experience.
2. Limited Manoeuvrability
Automated Manual Transmission operates on the preset RPM range, leading to unplanned
upshifts while overtaking. This can jeopardise one's on-road safety.
3. Unsuitable for Hilly Terrains
Driving a car with AMT on hilly terrain is inconvenient as a driver needs to shift to manual
mode with frequent utilization of brakes.Thus, assess the working mechanism, advantages
and disadvantages of an AMT in a car as mentioned above to make an informed decision
before buying one.
Automatic Transmission (AT),
 An automatic transmission (sometimes abbreviated AT) is a multi-
speed transmission used in motor vehicles that does not require any input from the

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driver to change forward gears under normal driving conditions. Vehicles

with internal combustion engines, unlike electric vehicles, require the engine to
operate in a narrow range of rates of rotation, requiring a gearbox, operated manually
or automatically, to drive the wheels over a wide range of speeds.

 The most common type of automatic transmission is the hydraulic automatic, which
uses a planetary gearset, hydraulic controls, and a torque converter. Other types of
automatic transmissions include continuously variable
transmissions (CVT), automated manual transmissions (AMT), and dual-clutch
transmissions (DCT).

 The 1904 Sturtevant "horseless carriage gearbox" is often considered to be the first
true automatic transmission.[1][2] The first mass-produced automatic transmission
is the General Motors Hydramatic four-speed hydraulic automatic, which was
introduced in 1939.

Advantages.
1. Ease of Use
Cars with automatic transmissions are much easier to use than stick-shift, or
manual, vehicles. The most common type of automatic transmission found in modern
cars is the hydraulic planetary automatic transmission.
2. Safety
Automatic vehicles are a bit safer to operate than manual cars. When driving a
vehicle with a manual transmission, the driver must use their right hand and left leg
to shift gears. Since automatic transmissions shift gears on their own, the driver is
free to keep both hands on the wheel.
3. Cost
Automatic vehicles have a higher initial cost than manual cars due to the complexity
of the transmission. Manual vehicles are often associated with b fuel-efficiency than
automatic transmissions because automatic transmissions rely on the torque
converter to switch gears.
4. Fun
While there are many benefits to driving an automatic car, driving a car with a
manual transmission can be far more enjoyable than driving an automatic.
Disadvantages:
1. Unusual Noises
If the vehicle is making strange buzzing, grinding, or brushing noises, the torque
converter may need repair or maintenance. While the problem may not seem like a
big deal at the time, unresolved issues with the torque converter or the needle
bearings can result in extensive damage to the transmission.
2. Leaks
If the vehicle is leaking transmission fluid or has low fluid levels, the car may shift
slowly or slip gears more often. Over time, this can cause significant problems for the

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vehicle. It’s best to immediately change or flush the transmission fluid once any leaks or
contamination are suspected.
3. Burning Smell
A significant symptom of transmission issues is a burning smell. Many car owners
describe the smell of overheated transmission fluid as a “burnt toast” scent. If a
driver smells burning during or after operating a motor vehicle, he or she should take
their car in for diagnosis by a trained professional as soon as possible. Many factors
could contribute to the overheating of transmission fluid.
4. The Sooner, the Better.

INTELLIGENT MANUAL TRANSMISSION (IMT)

IMT stands for Intelligent Manual Transmission. This system simply removes the clutch
pedal thus reducing a major point of interaction a driver has with the car. All these
components work together with a conventional manual gearbox mated to the engine. Now,
to drive a car with iMT, the 'intention sensor' on the gear lever senses when you are about
to shift gears. These intention sensors then send a signal to the transmission control unit
or TCU as to when the gears are changed.

IMT Transmission Advantages

IMT transmission is an exciting new technology that is transforming the driving experience.
With an intelligent manual transmission, you get the best of both worlds—the control and
performance of a manual transmission with the convenience of an automatic.
 Enhanced Driving Experience: iMT gives you more control and connection to the
road. You choose when to shift gears for an engaging drive. The transmission
automatically handles the clutch for seamless gear changes so you can focus on
accelerating and braking. This leads to a more dynamic, responsive feel behind the
wheel that performance enthusiasts will love.
 Improved Fuel Efficiency: Choosing when to shift into higher or lower gears means
you can optimize the engine’s power range for the driving conditions. Stay in lower
gears for maximum power or upshift early for efficiency on the highway. iMT has
been shown to improve fuel economy by up to 15% compared to a traditional
automatic transmission. That means more money in your pocket and less impact on
the environment.
 Cost Savings: iMT is a simpler, more compact system than a traditional automatic
transmission with fewer moving parts. This reduced complexity lowers manufacturing
costs which are passed onto consumers through lower vehicle prices. iMT can save
thousands of dollars per vehicle compared to a standard automatic.
 Enhanced Safety: With an iMT, there is no delay shifting between gears like in an
automatic transmission. The instantaneous gear changes and constant connection
between the engine and wheels provide improved acceleration and control. This gives
the driver more confidence in emergency situations where rapid acceleration or

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deceleration is needed. Studies show vehicles with iMT have up to 15% shorter
stopping distances.

IMT Transmission Disadvantages

A few preferred capacity risks that may be associated with certain forms of transmissions,
such as computerized guide transmissions or hybrid guide transmissions, which would
possibly have similarities to IMT transmissions:
 Complex and Expensive Repairs: Some superior transmission systems, mainly
those that integrate manual and automated factors, can be complicated and require
specialised information and gadget for upkeep. This might also bring about higher
restore prices as compared to standard manual or automatic transmissions.
 Learning Curve: If an IMT transmission calls for manual transferring, drivers who’re
accustomed to conventional computerized transmissions may want some time to
regulate to the guide shifting system. This could bring about a learning curve before
drivers experience comfortable and assured with the transmission.
 Potential for Clutch Wear: In transmissions that comprise a guide take hold of,
improper transferring techniques or immoderate take hold of slippage can cause
untimely put on of the grasp components. This should result in the need for extra
common grasp replacements or upkeep.
 Less Smooth or Refined Shifts: Automated manual transmissions, together with
IMT transmissions in the event that they function further, may have less smooth and
subtle shifts as compared to standard automatic transmissions. This can bring about
a distinct driving enjoy, with potentially greater important equipment modifications
or jerky shifts.
Continuously Variable Transmission (CVT),
A CVT doesn't use any gears at all. Instead, they rely on two cone-shaped pulleys to
transfer power from the engine, through the transmission, and to the drive wheels. These
pulleys are able to vary their width depending on power inputs, hence the name
Continuously Variable Transmission.

Fig: Continuously variable transmission (CVT) technology.

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ADVANTAGES OF CVT

 MAXIMUM POWER BAND

A CVT transmission always keeps your car in the right gear, without you having to
manage it. Contrary to other types like the traditional manual or automatic units, a
CVT transmission is designed to maintain the engine’s speed square at its best
powerband. This increases the performance of a car, especially when you are passing
by a car on the road.
 ECONOMIC BENEFITS
A CVT transmission offers more benefits as compared to its counterparts, especially
when it comes to fuel efficiency, where it maintains the right speed at the right time.
It is observed that when drivers drive at a steady speed, their tachometer reading is
very low, which indicates efficiency.
 SIMPLE STRUCTURE
In a CVT Transmission, the number of mechanical parts is less compared to a
traditional planetary gear transmission. Since there is no real gear involved, a CVT
box comes with adjustable pulleys that are connected via a belt. These pulleys move
away or towards each other according to the speed of a car while the belt moves in
between these pulleys. A simple mechanical structure ensures less wear and tear.
 LIGHT WEIGHT
Compared to a traditional automatic transmission, CVTs are lighter in weight and
compact in size. This has given these cars a competitive advantage over others like a
reduced weight has increased the fuel efficiency many times.
 SMOOTH DRIVE
In a manual transmission, you are always worried about changing gears and
stepping on the clutch pedal. When you change gears in a rush, it can be very rough
and you may have to struggle a little bit. This is not the case in CVT transmissions
where your car can go from 0 to the maximum allowed speed in no time without any
hassle.
DISADVANTAGES OF CVT
DRIVING EXPERIENCE
For many, the sensation of the slipping clutches while the vehicle is moving through the
shift points is exasperating. While it offers unlimited gear ratios, the transmission is
extremely slow to respond to throttle input. Also, drivers can not even regularly check the
fluid level.
NOISY OPERATION many drivers have complained about a CVT transmission engine
revving when accelerated. This trait is present in almost all the CVTs, including the ones
where a stepped gear is available. Many drivers do not like any extra noises in a car except
for the rumble of a powerful engine.

LACK OF SPORTINESS

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The CVT transmission may be efficient with a smooth drive but it is not sport and fun to
drive. A CVT transmission is incapable of handling high-torque applications which makes it
hard to achieve that sporty feel. Also, the lack of up shifting and downshifting, and fixed
gears makes the ride less engaging.
EXPENSIVE MAINTENANCE
The running cost of a CVT transmission is low. However, once it breaks down, its
maintenance can be very expensive. The mechanical parts like the drive belt wear or stretch
relatively fast and are available at a very high price. The electronic equipment also tends to
fail more often, which can be an additional expense.

INFINITELY VARIABLE TRANSMISSION (IVT)

Infinitely variable transmissions (IVT) are one type of continuously variable
transmission which ensure an infinite ratio range coverage by providing even zero
transmission ratio with an unmoving output shaft and an input shaft without zero velocity.
An infinitely variable transmission (IVT) is a continuously variable transmission with an
infinite ratio range, which means that the transmission ratio may be zero. IVTs are
generally made up of three elements: a continuously variable transmission (CVT), a
planetary gear train and a fixed ratio mechanism. Automatically regulated CVTs offer the
advantage of automatically changing the transmission ratio without requiring sophisticated
control systems.
In this work the possibility of realizing an automatically regulated IVT is appraised, i.e.
with automatic regulation of the transmission ratio, in relation to operational conditions.
The use of the automatically regulated V-belt CVT, endowed with simple devices of axial
force, is hypothesized. For the different types of devices the characteristic curves of
operation, the power flows and the efficiency of the automatically regulated IVT are
determined.
Working Of Differential, Rear Axle Types &Construction.
A differential is a system that transmits an engine's torque to the wheels. The
differential takes the power from the engine and splits it, allowing the wheels to spin at
different speeds.
The principle of differential operation
The basic principle of a differential relay is the comparison of two or more currents
entering and leaving a particular section of a power system. This is achieved by connecting
current transformers (CTs) on both sides of the protected equipment.
A differential gearbox, a critical component in many automotive vehicles, plays a
pivotal role in enabling smooth and efficient cornering. The differential gearbox is designed
to distribute rotational power to the wheels while allowing them to rotate at different
speeds. It allows a vehicle's wheels to maintain traction and stability, especially during
turns. By compensating for the varying distances travelled by the inner and outer wheels in
a turn, the differential gearbox ensures that the wheels receive the necessary power and
torque for optimal performance.
The differential gearbox is a crucial component in automotive mechanics, facilitating the
transmission of engine power to multiple driving wheels while ensuring an even distribution
of force among them. This arrangement allows the wheels to travel different paths,
accommodating turns and uneven terrains seamlessly.
Components of Differential Gearbox

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o A pinion gear is mounted on the propeller shaft, rotating the large ring gear.
o The ring gear supports a Carrier unit consisting of two bevel pinions (planet pinions)
and two bevel gears (sun gears).
o The sun bevel gears are connected to the half shaft of the rear axle.
o A differential housing covers the entire assembly, while the axle housing protects the
half shaft.

Working Principle of Differential Gearbox

o The working principle of a Differential Gearbox can be bifurcated into subheadings:

o When Running Straight
o In a straight-line movement, power is transmitted from the propeller shaft to the
bevel pinion, which drives the crown wheel. This power then flows into the differential
cage, housing planet pinions and sun gears. As the vehicle moves forward, the crown
wheel, differential cage, planet pinions, and sun gears rotate together as a single
unit, resulting in no relative motion between the sun gear and planet pinions. Since
the planet pinions do not rotate about their axis, and the resistance offered by the
road wheels, half shafts, and sun gears is uniform, the differential gearing does not
engage, causing both road wheels to turn at the same speed.
o When Taking a Turn
o During a turn, the inner wheel faces resistance, prompting it to rotate in the opposite
direction. Consequently, the planet pinions start rotating about their own axis while
revolving around the sun gear. This leads to increased rotary motion being
transmitted to the outer-side sun gear, causing it to rotate faster than the inner sun
gear. As a result, the outer road wheel runs at a higher speed than the inner road
wheel, allowing it to cover a greater distance while turning. This differential action
ensures smooth cornering and stability while navigating bends or curves.

Different Types of Differentials

There are three types of differentials:

o Conventional Type:
o The conventional type differential ensures equal torque delivery to each rear wheel.
However, if any wheel slips for any reason, that wheel stops rotating, causing the
vehicle to come to a halt.
o Non-slip or Self-locking Type:
o The non-slip or self-locking type differential overcomes this limitation. It features a
construction similar to the conventional type but includes two sets of clutch plates
additionally. The ends of the planet shafts are left loose in notches provided on the
differential cage, allowing better traction and preventing wheel slippage.
o Double Reduction Type:
o The double reduction type differential provides further speed reduction through an
additional gear. This differential is commonly used in heavy-duty automobiles that
require larger gear reduction between the engine and wheels, enhancing torque
delivery and improving performance.

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Functions of Differential Gearbox

o When a four-wheeler takes a turn, the outer wheel rotates at a higher speed than the
inner wheel, resulting in relative movement between them. As power is transmitted
from the engine to the drive wheels, it becomes apparent that during turning, the two
drive wheels do not require the same amount of power. For instance, while executing
a right turn, the outer wheel demands more power compared to the inner wheel.
Besides enabling the drive wheels to operate at different RPMs, the differential
gearbox also serves the purpose of speed reduction while effectively transmitting
torque. This functionality ensures smooth cornering and optimal power distribution
during turning manoeuvres.

Purpose of Differential Gearbox

When a vehicle turns on a curved road, the outer wheels need to cover a greater distance
than the inner wheels. If a vehicle has a solid rear axle without any specialised
mechanism, there is a higher risk of wheel skidding. To prevent this, it is crucial to
install a mechanism that reduces the speed of the inner wheel and increases the speed
of the outer wheel, ensuring that both wheels match their speed, just like when the
vehicle moves straight ahead. This mechanism is known as a differential gear, and it
effectively aids both wheels in turning smoothly and maintaining traction on the road.

o Advantages of Differential Gearbox

o The advantages of a differential gearbox are:
o Crosstalk Limitation: The differential gearbox helps in minimising electronic
crosstalk, ensuring better signal integrity and reduced interference between signals.
o Uniform Wheel Rotation: It allows both driving wheels to turn in the same direction
at the same speed, promoting smooth and coordinated movement.
o Differential Speed Capability: The differential gearbox enables both driving wheels to
rotate in the same direction at different speeds, facilitating easy turning and
manoeuvring.
o Opposite Direction Movement: It permits both driving wheels to turn in the opposite
direction at the same speed, ensuring effective handling in various driving conditions.
o Different Speeds in Opposite Directions: The differential gearbox enables both driving
wheels to turn in opposite directions at different speeds, enhancing stability and
control during complex manoeuvres.

Disadvantages of Differential Gearbox

o Some of the major disadvantages of Differential Gearbox include:
o Wheel Slip: In certain situations, such as icy or slippery road conditions, the
differential gearbox may cause wheel slip, leading to reduced traction and
compromised control.
o Uneven Torque Distribution: The differential gearbox may distribute torque unevenly
to the wheels, potentially causing one wheel to receive more power than the other,
affecting vehicle performance.
o Limited Off-Road Capability: In off-road or rough terrain conditions, the differential
gearbox may not provide sufficient traction, hindering the vehicle's ability to traverse
challenging landscapes.

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o Increased Maintenance: Differential gearboxes require regular maintenance to ensure

proper functioning, adding to the overall upkeep cost of the vehicle.
o Complexity: Differential gearboxes are relatively complex mechanisms, which can
result in higher manufacturing costs and more intricate repair processes.

Suspension – Layout & Working Of Hydraulic& Air Suspension,

Suspension is the system of tires, tire air, springs, shock absorbers and linkages that
connects a vehicle to its wheels and allows relative motion between the two. Suspension
systems must support both road holding/handling and ride quality, which are at odds with
each other.
The different types of suspension system in automobiles are as follows:
 Leaf Spring Suspension.  Double-Wishbone Suspension.
 Trailing Arm Suspension.  MacPherson Strut Suspension.
 Non-Independent Suspension. ...  Air Suspension.
 Independent Suspension.  Multi-Link Suspension.

Fig: Suspension System.

HYDRAULIC OF SUSPENSION SYSTEM:

Hydraulic suspension systems are a type of suspension system that uses work by using
pressurized fluid to power an engine and control the movement of the vehicle's suspension.
They are commonly found in heavy-duty trucks, luxury cars, buses and other large vehicles
that require a smooth ride and excellent handling.

COMPONENTS OF HYDRAULIC SUSPENSION SYSTEM:

The hydraulic suspension system consists of several components that work together to
provide a comfortable and safe ride. The main components of a hydraulic suspension
system include:
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 Hydraulic Pump: The hydraulic pump pressurises the hydraulic fluid and sends it
through the network of hoses and valves to the hydraulic cylinders.
 Hydraulic Fluid: The primary function of hydraulic fluid in the hydraulic suspension
system is to facilitate power transmission and regulate the vehicle’s suspension
movement.
 Valves: The valves are responsible for regulating the flow of hydraulic fluid to every
cylinder, thereby modifying the suspension’s stiffness and damping.
 Struts: Struts are integral components that provide structural support to the vehicle and
link the hydraulic cylinders to either the vehicle’s axle or frame, helping to bear its
weight. To comprehend the difference between struts vs shocks, it is crucial to know that
in the majority of contemporary cars, struts are utilised in the front, while shocks are
used in the rear.
 Sensors: Sensors are used to monitor the position and movement of the vehicle and
provide feedback to the hydraulic system to adjust the suspension’s stiffness and
damping.
 Hydraulic Cylinders: Inside the hydraulic cylinders, there is a piston and rod that move
out and in, respectively, depending on the pressure of the hydraulic fluid.

ADVANTAGES OF HYDRAULIC SUSPENSION SYSTEM

 Comfort: Hydraulic suspension systems provide a smooth and comfortable ride with the
help of shock absorbers caused on uneven terrains.
 Stability: Hydraulic suspension systems provide stability by keeping the vehicle level
even during hard braking, acceleration and cornering.
 Durability: Hydraulic suspension systems are highly durable and require minimal
maintenance due to their simple design and construction.
 Enhanced aerodynamics: These systems can also enhance automotive aerodynamics by
lowering the ride height at higher speeds.
 Improved Handling: They provide greater control over vehicle height and can be easily
adjusted to improve handling and stability.

DISADVANTAGES OF HYDRAULIC SUSPENSION SYSTEM

 Cost: Hydraulic suspension systems can be expensive to install and maintain.
 Weight: They can be heavier than other suspension systems, which can impact fuel
efficiency and acceleration.
 Complexity: The complexity of these systems can lead to more significant repair costs
and require specialized technicians.
AIR SUSPENSION SYSTEM
An air suspension system is an advanced technology used in modern vehicles to
enhance ride comfort, handling, and overall performance. Unlike conventional coil or leaf
spring suspensions, air suspension relies on compressed air to support the vehicle's weight
and adjust its ride height. Air suspension provides a smoother and more comfortable ride
by utilising air springs and sophisticated control systems, allowing drivers to adjust the
vehicle's height to suit various road conditions or loading requirements.
Air suspension is a vehicle suspension system powered by either an electric or engine-
driven air pump or compressor. This system operates by pumping air into flexible bellows
typically made of textile-reinforced rubber. Unlike hydro pneumatic suspension systems
that use pressurized liquid, air suspension relies on compressed air. The air pressure
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inflates the bellows, lifting the chassis away from the axle, providing numerous benefits
such as improved ride comfort and handling.
Components of Air Suspension System

o Vulcanised Rubber Air Springs: Each wheel is equipped with a vulcanised rubber air
spring that contributes to the suspension's flexibility and load-carrying capacity.
o Air Compressor: Typically located in the trunk or under the car's hood, the air
compressor pressurizes air for the suspension system's operation.
o Compressed Air Storage Tank: A storage tank capable of holding air at 150 psi (1000
kPa) allows for quick "kneeling" adjustments in the suspension. (1 psi = 6.89 kPa)
o Valve Block: The valve block contains solenoids, valves, and o-rings, which are
responsible for directing air from the storage tank to the four air springs.
o ECAS Computer: This computer communicates with the car's main computer, the
BeCM, and determines the distribution of air pressure within the system.
o 6 mm Air Pipes: An extensive network of 6 mm air pipes distributes air throughout
the entire system, connecting the storage tank to the air springs via the valve block.
o Desiccant-Filled Air Drier Canister: An air drier canister filled with desiccant helps to
remove moisture from the compressed air before it reaches the system.
o Height Sensors: Height sensors located on all four corners of the vehicle, preferably
using resistive contact sensing, provide accurate height references for each corner of
the suspension system.

Advantages of Air Suspension System

o Optimal Wheel Deflection: Automatic control devices enable the air suspension to
utilize variable space effectively, enhancing wheel deflection and providing a
smoother ride experience.
o Consistent Vehicle Altitude: Maintaining a constant vehicle altitude helps avoid
changes in headlamp alignment caused by varying loads, ensuring consistent
illumination and improved visibility.
o Reduced Spring Rate Variation: The air suspension exhibits minimal variation in
spring rate between laden and unladen conditions compared to conventional steel
springs, leading to reduced dynamic loading and improved stability.
o Enhanced Ride Comfort and Noise Reduction: Air springs contribute to an
improved standard of ride comfort, effectively reducing noise levels and resulting in
reduced driver and passenger fatigue during journeys.

Disadvantages of Air Suspension System

o Higher Initial Cost: Air suspension systems typically come with a higher initial cost
compared to conventional suspension setups, making them a premium option.
o Increased Space Requirements: Air suspension components may occupy more
space within the vehicle's chassis, potentially affecting available storage and design
considerations.
o Higher Maintenance Costs: Maintaining an air suspension system can incur higher
costs due to the complexity of its components and specialised maintenance
requirements.
o Damping Necessity: Air suspension lacks inherent friction damping, necessitating
the use of additional damping mechanisms to counteract road shocks effectively.
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Application of Air Suspension System

o Luxury Vehicles
o Commercial Trucks
o High-End SUVs
o Passenger Buses
o Recreational Vehicles (RVs)
o Emergency and Rescue Vehicles
o Motor homes
o Commercial Trailer

Independent suspension:
Independent suspension is any automobile suspension system that allows each wheel on
the same axle to move vertically (i.e. reacting to a bump on the road) independently of the
others. This is contrasted with a beam axle or deDion axle system in which the wheels are
linked. "Independent" refers to the motion or path of movement of the wheels or
suspension. It is common for the left and right sides of the suspension to be connected
with anti-roll bars or other such mechanisms. The anti-roll bar ties the left and right
suspension spring rates together but does not tie their motion together.

Advantages of Independent Suspension System

1. Better Handling – Independent suspension systems allow each wheel to move
independently, which can result in better handling and improved stability on the
road. This can be particularly important for sports cars and other vehicles that need
to handle sharp turns and sudden changes in direction.
2. Improved Comfort – Independent suspension systems can also provide a smoother
ride, as they are able to absorb bumps and other road imperfections more effectively.
This can lead to less jarring and a more comfortable driving experience, especially on
rough or uneven terrain.
3. Increased Traction – Independent suspension systems can also improve traction, as
each wheel is able to maintain contact with the road surface even when encountering
bumps or obstacles. This can be particularly important for off-road vehicles and other
vehicles that need to navigate challenging terrain.
4. Better Braking – Independent suspension systems can also improve braking
performance, as each wheel is able to brake independently. This can result in shorter
stopping distances and more controlled braking, which can be important for safety.
5. Enhanced Customization – Independent suspension systems can also be customized
to suit the needs of different types of vehicles and driving styles. This can result in
improved performance and a more tailored driving experience, which can be
particularly important for racing and other high-performance application

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Disadvantages of Independent Suspension System

1. Higher Cost – One potential disadvantage of independent suspension systems is
that they can be more expensive to design, manufacture, and maintain than other
types of suspension systems. This can make them less accessible to some drivers
and limit their use in certain vehicles.
2. Increased Complexity – Independent suspension systems are also more complex
than other types of suspension systems, with more parts and components that
can wear out or break over time. This can make them more difficult and costly to
repair or replace when something goes wrong.
3. Reduced Load Capacity – While independent suspension systems can provide
better handling and comfort, they may also have reduced load capacity compared
to other types of suspension systems. This means that they may not be ideal for
heavy-duty vehicles or those carrying a lot of weight.
4. Less Durability – Due to their increased complexity and moving parts,
independent suspension systems may also be less durable over time compared to
other types of suspension systems. This means that they may need to be replaced
or repaired more frequently, which can be a hassle and expensive.
5. Potentially Lower Fuel Efficiency – Finally, independent suspension systems may
have lower fuel efficiency compared to other types of suspension systems, as they
can add more weight to the vehicle and require more energy to operate. This can
be a concern for drivers who want to save money on gas or reduce their
environmental impact.

LEAF SPRING:
A leaf spring is a simple form of spring commonly used
for suspension in wheeled vehicles. Originally called a laminated or carriage spring, and
sometimes referred to as a semi-elliptical spring, elliptical spring, or cart spring, it is one
of the oldest forms of vehicle suspension. A leaf spring is one or more narrow, arc-
shaped, thin plates that are attached to the axle and chassis in a way that allows the
leaf spring to flex vertically in response to irregularities in the road surface.

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Leaf Spring Advantages

1. The way the suspension is constructed is really simple and strong, acting as a
linkage that holds the axle in position without the need for separate linkage.
2. Extra weight and costs are reduced because of the rear axle location. This
eliminates the need for trailing arms and a panhard rod (AKA track bar).
3. Leaf springs support the weight of the chassis, making them ideal for commercial
vehicles.
4. They also control axle damping.
5. The chassis roll can be controlled more efficiently due to the high rear moment
centre and wide spring base. If the springs are mounted wider apart, the roll
tendencies will be less.

Disadvantages
1. They aren’t always the easiest to install – but there is a clear process to follow that
makes life much easier.
2. The ride comfort isn’t as great because of the inter-leaf friction between each leaf.
3. Over time, the springs tend to lose shape and can sag. When the sag is uneven, it
can alter the cross weight of the vehicle which can affect the handling slightly.
This can also change the axle-to-mount angle.
4. Wind-up and vibration can be caused by acceleration and braking torque. The
wind-up can also cause nose-diving and rear-end squat.

COIL SPRING:
A coil spring is a helical-shaped mechanical device that is close-wound or open-wound.
Coil springs store mechanical potential energy. They can be made of elastic materials or
metal such as hardened steel. You can find coiled springs in many ordinary items—from
farm equipment to toys, trampolines and much more.
Coil springs in trucks allow them to ride smoothly when unloaded, and once loaded the
spring compresses and becomes stiff. This allows the vehicle to bounce less when
loaded. Coil spring suspension is also used in high performance cars so that the car can
absorb bumps and have low body roll.
As the force is removed, the coil spring expands and releases its stored mechanical
energy. The three main types of coil springs are compression, extension, and torsion,
each of which performs a different function.
Advantages of Coil Spring Suspension
 The Basics of Coil Spring Suspension
 Improved Ride Comfort
 Enhanced Handling and Stability
 Durable and Long-Lasting
 Adjustable Suspension
 Easy Maintenance

Disadvantages of Coil Spring Suspension

 Less Off-Road Capability
 Higher Cost
 Potential Coil Spring Sag

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Fig: Coil Spring

Telescopic Shock Absorber
A telescopic shock absorber is a type of suspension component that is used to dampen
the oscillations of a vehicle's suspension system. It is commonly used in automobiles,
motorcycles, and other types of vehicles to improve ride comfort and stability.
Shock absorbers are basically oil pumps. A piston is attached to the end of a piston rod
and works against hydraulic fluid in the pressure tube. As the suspension travels up
and down, the hydraulic fluid is forced through orifices (tiny holes) inside the piston.

Function of shock absorber:

The shock absorber is a part of suspension system used as springing device to
compromise between flexibility and stiffness. It absorbs the energy of shock converted
into the vertical movement of the axle by providing damping and dissipating the same
into heat.

CHANDRAKEERTHY MS, ASST PROF, ME DEPT.DR SMCE, BENGALURU. Page 27

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Construction of Shock Absorber:

The upper eye of the telescopic shock absorber is attached to the axle and the lower eye
is attached to the chassis frame as shown in Figure 4.55. A two-way valve V1 is
connected to a rod. Another one two-way valve V2 is connected to the lower end of the
cylinder. The fluid occupies in the space between above and below the valve VI and also
the annular space between the cylinder and tube. A gland is provided on the head. Fluid
scrapped out by the rod is brought down into the annular space through the inclined
passage.

Working of Shock Absorber:

When the vehicle comes across a bump, the lower eye will move up. So, the fluid follows
from the lower side of the valve V1 to the upper side. Due to less volume of the space
above valve V1 than the volume of the rod, the pressure is exerted on valve V2 Thus, the
damping force is produced by this pressure of the fluid. The fluid will flow from the
upper side of the valve V1 to the lower side when the lower eye moves down and from the
lower side of the valve V2 to its upper side.
When a car absorbs shocks from the road surface, the suspension springs will compress
and expand because the spring has the characteristic of continuing to oscillate for a long
time of oscillation to stop. So, a riding comfort will be poor even the damp oscillation is
supplied. Shock absorbers provide better road-holding characteristics and improved
steering stability to tires. The stronger is the damping force, the more will be the
oscillations of the body. But, the shock from the damping effect becomes greater than
the strength of the stronger damping force. The damping force varies with the speed of
the piston.

The following are the advantages and disadvantages of Telescopic Suspension:

Advantages Disadvantages

Better stability during rides Less stable at high speeds

Absorbs shock effectively Poor cornering ability

Enhances the bike’s handling Hard to maintain

Easy to maintain and repair More expensive to repair

Prolongs the bike’s lifespan Not suitable for heavy loads

Torsion Bar
A torsion bar suspension, also known as a torsion spring suspension, is any vehicle
suspension that uses a torsion bar as its main weight-bearing spring.
In automobiles a torsion bar is a long spring-steel element with one end held rigidly to
the frame and the other end twisted by a lever connected to the axle. It thus provides a
spring action for the vehicle.

CHANDRAKEERTHY MS, ASST PROF, ME DEPT.DR SMCE, BENGALURU. Page 28

Module-2 21ME54

Torsion bar, rod or bar that resists twisting and has a strong tendency to return to its
original position when twisted. In automobiles a torsion bar is a long spring-steel
element with one end held rigidly to the frame and the other end twisted by a lever
connected to the axle. It thus provides a spring action for the vehicle.
A torsion bar suspension, also known as a torsion spring suspension, is any
vehicle suspension that uses a torsion bar as its main weight-bearing spring. One end of
a long metal bar is attached firmly to the vehicle chassis; the opposite end terminates in
a lever, the torsion key, mounted perpendicular to the bar that is attached to a
suspension arm, a spindle, or the axle. Vertical motion of the wheel causes the bar to
twist around its axis and is resisted by the bar's torsion resistance. The effective spring
rate of the bar is determined by its length, cross section, shape, material, and
manufacturing process.

Fig: Torsion Bar

Advantages
 Smoothness: In contrary to the expectations of other people, the smoothness that the
torsion suspension applications provide is generally much better. They provide a very
good application for smooth systems.
 Space: In general, the torsion bar suspension applications take much less space than
the other conventional suspension applications.
 Maintenance: In terms of maintenance, it is much easier to deal with these
applications. Because of this, the maintenance costs are much lower than the usual
applications.
 Vehicle height: It is very easy to adjust the vehicle height with this suspension
application.
Disadvantages
Stiffness adjustment: It is impossible to adjust the stiffness and smoothness of the
suspension system of your car. As we stated at the parameters that affect the stiffness,
you cannot change these parameters instantly. You need to change the torsion bar
directly if you want to change the stiffness of the application.
With the proper consideration of these applications, they used these systems in different
vehicles throughout history.

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CHANDRAKEERTHY MS, ASST PROF, ME DEPT.DR SMCE, BENGALURU. Page 29