MODULE 1

Automobile Vehicles - Definition - History and development in Abroad and in India before & after
independence Different Indian and foreign Automobile manufacturing concerns of two-wheeler,
three-wheeler, LMV and HTV - their products and plants location. Classification of Automobile,
Major systems of an Automobile - their functions, Chassis - definition, chassis layout of two, three
&four-wheeler with major components - their functions, engine mounts - need - types, definition of:
wheel base - wheel track - overall length - front overhung - rear overhung height of CG point -
ground clearance - gross weight and kerb weight.

History and Development of Automobile Industry

Development of Automobiles Abroad

(a) Early History (Before 1900)

 1769 – Nicolas-Joseph Cugnot (France) built the first steam-powered vehicle.

 1885–86 – Karl Benz (Germany) invented the first petrol engine automobile (Benz Patent-
Motorwagen).
 1890s – Daimler, Benz, Ford, and Peugeot began commercial vehicle production.

(b) Growth Phase (1900–1945)

 Henry Ford (USA) introduced mass production and assembly line (Model T, 1908).
 Rapid growth in USA, Germany, UK, France, Italy, and Japan.
 Focus on petrol and diesel engines, standardization, and affordability.

(c) Post-World War II Development (After 1945)

 Japan (Toyota, Honda, Nissan) emerged as a global leader.

 Introduction of:
o Fuel-efficient engines
o Automatic transmission
o Safety and emission standards
 Recent trends: electric vehicles (EVs), hybrids, autonomous vehicles.

Development of Automobile Industry in India

(a) Before Independence (Before 1947)

 Automobile industry was very limited.

 Vehicles were imported or assembled from imported parts.
 Early manufacturers:
o Hindustan Motors (1942)
o Premier Automobiles (1944)
 Mainly catered to British administration and elite class.
 (b) After Independence (After 1947)

(i) 1947–1980 (Controlled Growth)

 Government policies protected domestic manufacturers.

 Limited models and slow technological progress.
 Dominant companies:
o Hindustan Motors (Ambassador)
o Premier Automobiles (Fiat)

(ii) 1980–1991 (Modernization Phase)

 Entry of MarutiUdyog Ltd (1983) in collaboration with Suzuki (Japan).

 Focus on fuel efficiency and affordability.

(iii) After Liberalization (Post-1991)

 Entry of global manufacturers.

 Rapid expansion, exports, and technology transfer.
 India became a global hub for:
o Small cars
o Two-wheelers
o Auto components

Two-Wheeler Manufacturers
Indian Manufacturers

Company Products Plant Locations

Hero MotoCorp Splendor, Passion, Xpulse Haryana, Rajasthan, Uttarakhand
Bajaj Auto Pulsar, Platina, Dominar Pune, Aurangabad
TVS Motor Apache, Jupiter, iQube Hosur, Mysuru
Royal Enfield Classic 350, Bullet Chennai, Oragadam

Foreign Manufacturers (Operating in India)

Company Country Products Plant Locations

Honda Japan Activa, Shine Rajasthan, Gujarat
Yamaha Japan R15, FZ Tamil Nadu
Suzuki Japan Access 125, Gixxer Haryana
Three-Wheeler Manufacturers
Indian Manufacturers

Company Products Plant Locations

Bajaj Auto RE Auto, Maxima Aurangabad
Piaggio Vehicles Ape Baramati (Maharashtra)
Mahindra Electric Treo (Electric) Bengaluru

Foreign Presence

 Piaggio (Italy) – Major foreign brand in India for three-wheelers.

Light Motor Vehicles (LMV – Cars, SUVs, Vans)

Indian Manufacturers

Company Products Plant Locations

Tata Motors Tiago, Nexon, Punch Pune, Sanand
Mahindra & Mahindra Bolero, Scorpio, XUV Nashik, Chennai
Hindustan Motors Ambassador (earlier) Uttarpara (WB)

Foreign Manufacturers in India

Company Country Products Plant Locations

Maruti Suzuki Japan Swift, Baleno, Alto Haryana, Gujarat
Hyundai South Korea i10, Creta, Verna Chennai
Toyota Japan Innova, Fortuner Bidadi (Karnataka)
Honda Cars Japan City, Amaze Rajasthan
Kia South Korea Seltos, Sonet Anantapur (AP)
Volkswagen Germany Virtus, Taigun Pune
Heavy Transport Vehicles (HTV – Trucks & Buses)
Indian Manufacturers

Company Products Plant Locations

Tata Motors Trucks, Buses Jamshedpur, Pune
Ashok Leyland Trucks, Buses Chennai, Hosur
Eicher Motors (VE Commercial) Trucks, Buses Pithampur

Foreign Manufacturers

Company Country Products Plant Locations

Volvo Sweden Luxury buses, Trucks Bengaluru
Daimler (BharatBenz) Germany Heavy Trucks Chennai
Scania Sweden Heavy trucks, buses Bengaluru

Classification of Automobiles

1. Based on Purpose / Use

 Passenger Vehicles – Cars, buses, two-wheelers
 Goods Vehicles – Trucks, lorries, trailers
 Special Purpose Vehicles – Ambulance, fire engine, crane, tractor

2. Based on Load Capacity

 LMV (Light Motor Vehicle) – Cars, jeeps, vans
 MMV (Medium Motor Vehicle) – Medium trucks, buses
 HMV / HTV (Heavy Motor Vehicle) – Heavy trucks, trailers

3. Based on Number of Wheels

 Two-wheelers – Motorcycle, scooter
 Three-wheelers – Auto-rickshaw
 Four-wheelers – Car, jeep
 Multi-wheelers – Trucks, buses

4. Based on Fuel Used

 Petrol vehicle
 Diesel vehicle
 CNG / LPG vehicle
 Electric vehicle (EV)& Hybrid vehicle
5. Based on Drive
 Front Wheel Drive (FWD)
 Rear Wheel Drive (RWD)
 All Wheel Drive (AWD)

Major Systems of an Automobile and Their Functions

1. Engine System
Function:

 Produces power by burning fuel

 Converts chemical energy into mechanical energy

2. Transmission System
Components:

 Clutch
 Gearbox
 Propeller shaft
 Differential
 Axle

Function:

 Transmits engine power to wheels

 Varies speed and torque

3. Fuel Supply System

Components:

 Fuel tank
 Fuel pump
 Carburetor / Fuel injector

Function:

 Supplies correct amount of fuel to engine

4. Cooling System
Components:

 Radiator
 Water pump
 Fan

Function:

 Prevents engine overheating

5. Lubrication System
Components:

 Oil pump
 Oil filter
 Oil sump

Function:

 Reduces friction and wear of moving parts

6. Electrical System
Components:

 Battery
 Alternator
 Starter motor
 Lights, horn

Function:

 Starting engine
 Lighting and accessories

7. Braking System
Types:

 Drum brake
 Disc brake

Function:

 Slows down or stops the vehicle safely

8. Steering System
Function:

 Changes direction of vehicle

 Maintains control during motion

9. Suspension System
Components:

 Springs
 Shock absorbers

Function:

 Absorbs road shocks

 Provides comfort and stability

Definition of Chassis
Chassis is the main supporting frame of an automobile on which the engine, transmission
system, body, wheels, and other components are mounted.

Main Components of a Chassis

  Frame
 Engine
 Transmission system
 Axles
 Wheels and tyres
 Suspension system
 Steering system
 Braking system

Two-Wheeler Chassis Layout

Major Components:

 Frame
 Engine
 Front fork (suspension)
 Rear suspension
 Chain drive
 Wheels
 Handle bar
Functions:

 Lightweight frame supports engine and rider

 Chain drive transmits power to rear wheel
 Suspension absorbs shocks

Three-Wheeler Chassis Layout

Major Components:

 Ladder type frame

 Engine
 Gearbox
 Differential
 Front steering wheel
 Rear driving wheels
 Suspension

Functions:

 Carries passenger or goods

 Differential allows smooth turning
 Strong frame supports higher load than two-wheeler

Four-Wheeler Chassis Layout

Major Components:

 Frame / Monocoque body

 Engine
 Clutch and gearbox
 Propeller shaft
 Differential
 Axles
 Suspension
 Steering system
 Braking system
Functions:

 Supports vehicle body and load

 Provides stability and safety
 Transmits power efficiently to wheels

Engine Mounts
Engine mounts are supporting components used to fix the engine to the vehicle chassis
or frame while absorbing vibrations and shocks produced during engine operation.

Need / Purpose of Engine Mounts

1. Support the engine weight securely on the chassis.
2. Reduce engine vibrations transmitted to the vehicle body.
3. Absorb shocks caused by road irregularities.
4. Reduce noise (NVH – Noise, Vibration, Harshness) inside the cabin.
5. Maintain proper alignment of engine with transmission system.
6. Prevent damage to engine and chassis due to continuous vibrations.
7. Improve driving comfort and smoothness.

Types of Engine Mounts

Engine mounts are classified based on construction and material:

1. Rigid (Solid) Engine Mounts

Construction:
 Made of metal (steel or cast iron)
Features:
 Strong and durable
 No vibration damping
Application:
 Used in heavy vehicles and old models

2. Rubber Engine Mounts

Construction:
 Rubber sandwiched between metal plates
Features:
 Absorbs vibrations effectively
 Simple and low cost
Application:
 Widely used in passenger cars and two-wheelers
3. Hydraulic Engine Mounts

Construction:
 Rubber mount filled with hydraulic fluid
Features:
 Excellent vibration and noise reduction
 Adapts to different engine speeds
Application:
 Modern cars and luxury vehicles

4. Active (Electronic) Engine Mounts

Construction:
 Controlled electronically using sensors and actuators
Features:
 Actively cancels engine vibrations
 Best NVH performance
Application:
 High-end and premium vehicles

Wheel Base

Wheel base is the distance between the centers of the front wheel and the rear wheel of a
vehicle.

 It affects vehicle stability and ride comfort.

 Longer wheelbase → better stability.

Wheel Track (Track Width)

Wheel track is the distance between the centers of two wheels on the same axle.

 Front wheel track → distance between front wheels

 Rear wheel track → distance between rear wheels
 It affects cornering stability.
Overall Length

Overall length is the total length of the vehicle measured from the front-most point to
the rear-most point.

 Includes bumpers.
 Important for parking and vehicle classification.

Front Overhang

A- Front overhang
B- Rear overhang
Front overhang is the distance between the front axle center and the front end of the
vehicle.

 Affects approach angle and maneuverability.

Rear Overhang
Rear overhang is the distance between the rear axle center and the rear end of the
vehicle.

 Influences turning radius and vehicle balance.

Height of Centre of Gravity (CG)

Height of CG is the vertical distance from the ground to the center of gravity of the
vehicle.

 Lower CG → better stability

 Higher CG → more chances of overturning
Ground Clearance

Ground clearance is the minimum vertical distance between the lowest part of the
vehicle and the ground.

 Prevents underbody damage.

 Important for rough roads.

Gross Weight (Gross Vehicle Weight – GVW)

Gross weight is the total weight of the fully loaded vehicle.
It includes:

 Vehicle weight
 Passengers
 Cargo
 Fuel and accessories

Kerb Weight
Kerb weight is the weight of the vehicle without passengers or cargo, but with fuel,
engine oil, and coolant.

 It represents the empty vehicle condition.