DESIGN & FABRICATION OF FOUR WHEEL STEERED MULTI- UTILITY VEHICLE

DESIGN & FABRICATION OF FOUR WHEEL
STEERED MULTI- UTILITY VEHICLE
Project Guide:
ARUN RAJ.A
Asst. Prof.
Dept. of Mechanical
JECC
Submitted by:
JYAMEME042 COLIN VARGHESE
JYAMEME043 DAVID BABU
JYAMEME044 DELWIN KURIYAKOSE
JYAMEME057 HARIKRISHNAN A S
JYAMEME059 IRSHAD M 1

DEPARTMENT OF MECHANICAL
ENGINEERING
VISION
• To provide quality education of international standards in Mechanical Engineering
and promote professionalism with ethical values, to work in a team and to face
global challenges.
MISSION
• To provide an education that builds a solid foundation in Mechanical Engineering.
• To prepare graduates for employment, higher education and enable a lifelong
growth in their profession.
• To develop good communication, leadership and entrepreneurship skills to enable
good knowledge transfer .
• To inculcate world class research program in Mechanical Engineering. 2

ABSTRACT
This project provides design and fabrication of four mode four
wheel steered multi- utility vehicle. Four wheel steering is a system
that allows the rear wheels to turn for maneuvering, rather than just
follow the front wheels. It is a system employed by some vehicles to
decrease turning radius. This would be very useful in industrial areas
with less floor space.
In addition with four wheels steering the vehicle is a multi utility
vehicle, so it is used for scrap collecting, shifting etc. The
conventional floor cleaning machines were not fast, efficient and of
high cost. Hence it is a need to develop low cost, user friendly floor
cleaning machine. 3

INTRODUCTION
Four-wheel steering provides a means to actively steer the rear
wheels during turning maneuvers. It improves handling and helps the
vehicle to make tighter turns. If a car could automatically compensate
for an under steer /over steer problem, the driver would enjoy
nearly neutral steering under varying conditions.
When both the front and rear wheels steer toward the same
direction, they are said to be in phase and this produces a kind of
sideways movement of the car. When the front and rear wheels are
steered in opposite direction, this is called anti-phase, counter-phase or
opposite-phase and it produces a sharper, tighter turn.
4

OBJECTIVE
5
• This project aims at developing a 4 Wheel Steering System
which would cater to the needs to improve steering response,
increase vehicle stability while maneuvering at high speeds,
or to decrease turning radius at low speed.
• Under slippery conditions, the rear of the car may fishtail out
of control. In a four-wheel-steer car, this high-speed sway can
be damped or even eliminated through the use of same-side
steering.
• In addition with the 4WS system we include a scrap collecting
mechanism which uses neodymium magnets to attract the
metal scraps.

LITERATURE REVIEW
SL.
NO
YEAR AUTHOR MAJOR FINDINGS
1 2011 Bella et
al[1]
A collision warning system for rear end collision. Their
function is to allow the driver enough time to avoid crash
and yet avoid annoying the driver with alerts perceived as
accruing too early or unnecessary.
2 2012 Zhang et
al[2]
Design and control implementation of AC electric power
steering system. The paper introduced the bench
structure, working principle and main components
3 2012 Alam et
al[3]
Aerodynamic study of human powered vehicles. The
wind tunnel testing was used to identify key characters of
these HPVS, and by identifying different results obtained
it was possible to understand more about aerodynamic of
HPV.
4 2014 Schwab et
al[4]
Balance and control of a rear-wheel steering speed record
recumbent bicycle. This shows that one can design a rear-
wheel steered bicycle which shows a stable forward speed
range. It is shown that rider steer torque stays with in 6

5 2012 Saeed Abu[5] Automotive brake pipe characteristics and and their effect on
brake performance. This paper investigates the effect of fitting a
brake pipe with different inner diameters to each wheel at the
rear axle on brake performance.
6 2015 Bitar et al[6] Testing the performance of DC series motor used in electric
car. This desk include practically verification of performance
and behavior of complete electric drive system and to convert a
diesel or petrol powered vehicle to an electric car.
7 2012 Hanif Mat et
al[7]
Design and analysis of Eco car chassis. This involves
developing a light weight chassis that can satisfy withstand the
required loads and also be able to present driver inerrant of
crash.
8 2015 Buchert et al[8] Design and manufacturing of a sustainable pedal. This paper
focuses on development of a pedal electric cycle. The results of
project shows how different scientific approaches for
improvement can be applied together.
9 2012 Nor et al[9] Different steering control for an Autonomous mobile robot.
This involves study of both velocity of DC motors with and
without control the pulse width modulation for DC motors
which control velocities of wheels of mobile robot. 7

10 2011 Zhao et
al[10]
Dynamic analysis of steering system of articulated
vehicle in heeled status. This paper analyze the force of
the front and rear car body and establish the steering
dynamic mathematical model and simulation model.
11 2012 Li et al[11] A reverse logistics model for recovery options. A
mixed integer multi-objective linear programming
reverse logistics model was developed in this study
12 2012 Hassan et
al[12]
Optimal design of electric power assisted steering
system. The paper discuss the implementation of GA-
PID algorithm to realize the potential of energy
reduction as compared to conventional PID method
13 2015 Novellis et
al[13]
Driving modes for designing the cornering response of
fully electric vehicles with multiple motors. This article
presents a torque vectoring control structure based on
the combination of feed and feed back contribution for
control of vehicle yaw rate. 8

14 2011 Chu et al[14] Coordinated control of electronic stability program
and active front steering. This improves vehicle
handling and stability by coordinating control of
electric stability program and active front steering.
15 2011 Gao et al[15] Dynamic modeling and steering performance
analysis of active front steering system. The
controller performance and the average of variable
steering ratio faction.
16 2012 Santos et al[16] Finishing process analysis between honing and hard
honing in pinion gears applied to a steering system.
This process provides an excellent surface finish of
the sprockets having a direct impact on the return
vehicle steering system.
17 2015 Ossama
Mokhiamar
[17]
Stabilization of car-caravan combination using
independent steer and drive on brake force
distribution. The proposed control system is
evaluated under severe driving conditions and
compared with results of integrated control system
18 2011 Chen et al[18] Study on electric power steering system based on
ADAMS.A model for the EPS system has been
established including full vehicle mechanical 9

19 2011 Guirong et
al[19]
The driving control of pure electric vehicle. The
paper analyze the advantages and disadvantages
of traditional drive mode, motor-driving axle
combined drive mode, motor driving axle integrated
driving mode.
20 2012 Hsien-Yu et
al[20]
Study on power train of two axles four wheel drive
electric vehicle. The works include mechanism and
design for clutch less AMT,optimal transmission
gear shifting design and finally power split strategy
design in 4wd.
21 2013 Alam et al[21] On road and wind-tunnel aerodynamic study of
human powered vehicle. The study shows that
aerodynamic efficiency of vehicle largely depends
on external shape especially the extrusion, gaps and
bumps
22 2014 Deepak et
al[22]
Design and analysis of 3 wheeled duel steering
vehicle. The aim of this vehicle that has steering on
both sides which is powered by hub motors
10

23 2014 Bhishikar et
al[24]
Design and simulation of 4 wheel steering system.
This involves developing a 4 wheel steering
system to implant a mechanism that can serve
purpose of changing in-phase and counter phase
steering of rear wheels.
24 2013 Lohith et
al[25]
Development of 4 wheel steering system for a car.
The main aim of this project is to turn the rear
wheels out of phase to the front wheels.
25 2015 M Renjith
Kumar[26]
Design and analysis of manually operated floor
cleaning machine. It can be an alternate for
convectional floor cleaning machine .This involves
developing a low cost user friendly floor cleaning
machine.
26 2015 Pushkin
Gautham[23]
Selectable all wheel steering for an ATV.In this
the engagement and disengagement of 4 wheel
steering can be done as per driver requirement.
11

METHODOLOGY
• Identify the requirements
• Selection of steering mechanism
• Design calculation of various gears were made
• Designed the model in PRO-E with dimensions
• Given motion study in Solid works
• Fabricated the model with designed dimensions
• Analysis of the system is carried out
12

DESIGN CALCULATION
CHAIN DRIVE
Assumed breaking load = 6810kgf
Pitch, p = 15.875
Teeth number, z1 = 16 z2 =45
Transmission ratio, i = z2 /z1 =45/16 =2.8125
Weight of car = 80kg
Total estimated weight = 200kg
Breaking load = 200*9.81=1962kgf
Hence designed chain is safe. 13

BEVEL GEAR
Teeth number, z1 = 12 z2 = 12
Gear ratio, i = z2 /z1 =12/12 =1
Assumed material of pinion =40 Ni 2 Cr 1 Mo 28
Assumed material of wheel = 40 Ni 2 Cr 1 Mo 28
Tensile stress = 400 N/ mm2
Compressive stress assumed = 1100 N/ mm2
Compressive stress theoretical =1058.479 N/ mm2
Thus the design is safe
14

SPUR GEAR
Torque, T = 7.127Nm
Design stress, [ b] = 400N/mm2
Compressive stress, [c] = 1100N/mm2
Teeth number, Z1 = 30, Z2 =80
c =635.63N/mm2
b =106 N/mm2
Thus the design is safe
15

16
MECHANISM USED
ACKERMAN STEERING MECHANISM
• To avoid the tyres to slip sideways when following the path
around a curve.
• The geometrical solution to this is for all wheels to have
their axles arranged as radii of a circle with a common
center point.
• The principle is sound for low speed manoeuvres.

Condition for True Rolling
While tackling a turn, the condition of perfect rolling motion
will be satisfied if all the four wheel axes when projected at one
point called the instantaneous centre, and when the following
equation is satisfied.
Cot Ø- Cotθ = c/b
17Fig:1 :True rolling condition

SCRAP COLLECTING MECHANISM
18
•Neodymium magnets are used to
attract the metal scraps
•Collected scraps are repelled by
pressing the lever

4 MODES OF 4WS
• Front wheel turn
• Short radius turn
• Parallel parking
• 360 degree turn
19

FOUR MODES OF STEERING
MECHANISM
20
Figure.3.1.Working of Four Modes of Steering Mechanism

FRONT WHEEL STEERING
21
• The lock nut is removed
• Steering wheel is attached to shaft with pinion at its end, which in turn meshes
with the rack.
• When the steering wheel is rotated, the pinion attached is rotated in the same
direction, thus producing horizontal movement with rack; enabling the wheels
to turn in the direction of rotation.

SHORTER RADIUS TURNING
22
• The lock nut is inserted
• The gear arrangement is moved to other side, the spur gear disengages
and the bevel gear gets engaged. Due to bevel gear arrangement, the rear wheel
steers in opposite direction to the front wheel. This results in shorter radius
mode steering.

PARALLEL PARKING
23
• The lock nut is inserted
• The gear arrangement is pushed to one position, the spur gears get engaged and
the steering of rear wheel is ensured and is in same direction as that of the front
wheels.

ZERO DEGREE ROTATION
24
• The 360 degree rotation mode of 4WS is applied by chain movement which
helps in movement of wheels in the required position.
• The movement of wheels is in a way that the vehicle will move or turn in
360 degree.

WORKING PRINCIPLE
• When the lock nut is removed, the steering operation is carried out
in normal condition. That is only front wheels steer.
• When the lock nut is inserted, the other two modes can be used.
When the gear arrangement is pushed to one position, the spur gears
get engaged and the steering of rear wheel is ensured and is in same
direction as that of the front wheels.
• When the gear arrangement is moved to other side, the spur gear
disengages and the bevel gear gets engaged. Due to bevel gear
arrangement, the rear wheel steers in opposite direction to the front
wheel. This results in third mode steering.
25

DESIGN OF THE MODEL
26
Fig 1: Frame of 4WS

27
Fig 2: Modes in four wheel steering

APPLICATIONS
1. Parallel Parking Maneuver Simplified With 0º rotation
Mode
30
Fig : 9.1: Parallel Parking Maneuver Simplified
With 0 degree rotation Mode
• To successfully park the vehicle
without incurring any damage.
• Driver can virtually park the
vehicle without even touching
the steering wheel.

2. High speed lane changing
31
Fig :9.2 – Parallel parking
mode in Action
Under slippery conditions, the rear of
the car may fishtail out of control
which can be damped or even
eliminated through the use of same-
side steering.

ANALYSIS
The different modes of four wheel steering has different
turning radius. Depending upon the turning angles of front and
rear wheels the turning radius has considerable changes.
1. Front wheel steering mode
 Turning angle of front wheels = 23°
 Turning radius calculated = 3.503 m
32

2. Shorter radius turning mode
 Turning angle of rear wheels = -17°
 Turning radius calculated = 2.779m
3. Parallel parking mode
 Turning angle of rear wheels = 19°
 Turning radius calculated = infinity
33

34
4. Zero degree rotation mode
1. Turning angle of front wheels = 41°
2. Turning angle of rear wheels = 37°
3. Turning radius calculated = 0m
• From the above analysis it was found that the short radius
turning mode has less turning radius while not considering
zero degree rotation mode which can rotate in its current
position.
• Parallel parking mode would not make a full round path
way so its turning radius is considered to be infinity.

ADVANTAGES
 Simplify the lane changing procedure.
 To successfully park the vehicle without incurring any damage
 Mode change is easy
 Implementation is easy
 Improve the vehicle handling
 Driver fatigue can be reduced
 Military reconnaissance and combat vehicles can benefit to a
great extent from 360 mode
35

DISADVANTAGES
 Gear arrangement adds weight to the vehicle.
 Even severe imbalance of a rear wheel on a speed sensitive
4WS system can cause problems and make basic
troubleshooting a bit frustrating.
 More maintenance is needed.
 Mechanism is complex.
 More expensive.
 Construction is difficult
36

VISIBLE OUTPUT
• A paper was presented entitled “Four wheel steered multi-utility
vehicle- a review” in the national conference on IDEAS -16 held at
UKF College of Engineering & Technology, Paripally on 31 March
2016.
• A paper was submitted entitled “Four wheel steered multi-utility
vehicle- a review” on IJES.
• Paper selected entitled “Four wheel steered multi-utility vehicle- a
review” on IJES.
• Participated in the project expo competition held at RIT Kottayom.
• Participated in the project expo SRISHTI -16 organized by Jyothi
Engineering College Cheruthuruthy, held on 19 March 2016
37

CONCLUSION
 The four-wheel steering system has got cornering capability,
steering response, straight-line stability, lane changing and low-speed
maneuverability.
 Even though it is advantageous over the conventional two-wheel
steering system, 4WS is complex and expensive. Currently the cost of a
vehicle with four wheel steering is more than that for a vehicle with the
conventional two wheel steering.
 Four wheel steering is growing in popularity and it is likely to
come in more and more new vehicles. As the system has multi-utility it
will be very much useful in industrial areas. The system can replace
conventional scrap collecting systems. 38

There are some points to describe this project from
existing system-
1. Superior cornering stability.
2. Improved steering responsiveness and precision.
3. High speed straight line stability.
4. Notable improvement in rapid lane changing
manoeuvres.
5. Relative wheel angles and their control.
6. Smaller turning radius and tight space manoeuvrability
at low speed.
39

REFERENCE
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Vehicles (2012) Procedia Engineering 34 ( 2012 ) 9 – 14
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43

DESIGN & FABRICATION OF FOUR WHEEL STEERED MULTI- UTILITY VEHICLE

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