MINI PROJECT-III

On

“DESIGN AND DEVELOPMENT OF 4WS SYSTEM.”

Submitted to
MIT Art, Design & Technology University
in partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
Group Code: ME2425MPIII-04
SAMEEP RAUT MITU22BTML0056
ADITYA UPADHYE MITU22BTML0009
MOHAMMAD KAIF MOMIN MITU22BTML0039
GOURAV MALI MITU22BTML0028

Under the Guidance of

PROF. ABHIJEET CHAVAN

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING AND SCIENCES, MIT ADT UNIVERSITY
RAJBAUG, LONI KALBHOR, PUNE – 4122012
3rd DECEMBER 2024
 DEPARTMENT OF MECHANICAL ENGINEERING
SCHOOL OF ENGINEERING AND SCIENCES,
RAJBAUG, LONI KALBHOR,
PUNE – 412201

CERTIFICATE

This is to certify that the Mini Project-II report entitled

“DESIGN AND DEVELOPMENT OF 4 WHEEL STEERING SYSTEM.”

Submitted by

Sameep Raut (MITU22BTML0056)

Aditya Upadhye (MITU22BTML0009)
Mohammad Kaif Momin (MITU22BTML0039)
Gourav Mali (MITU22BTML0028)

is a Bonafide work carried out by them, under the supervision of Prof. Abhijeet
Chavan and it is submitted towards the partial fulfilment of the requirement of MIT
Art, Design and Technological University, Pune for the award of the Bachelor of
Technology in Mechanical Engineering.

Prof. Abhijeet Chavan Prof. Dr. Savita Shinde

Guide Mini-Project Co-ordinator

Prof. Dr. Sachin Pawar Prof. Dr. Virendra Shete

Professor & Head Mechanical Director SOES

Chairperson / Examiner

Place: Pune Date: 3rd December 2024

 DECLARATION

We hereby declare that the Mini project II entitled “Design and development of 4
wheel steering systems.” submitted towards the partial fulfilment of the requirement
of MIT-ADT University, Pune for the award of the Bachelor of Technology in
Mechanical Engineering is a record of bonafide work carried out by us under the
supervision of Prof. Abhijeet Chavan, Asso. Professor, Department of Mechanical
Engineering, School of Engineering and Sciences.

Place: Pune Student Names and Sign

Date: 3rd December 2024

Sameep Raut

Aditya Upadhye

Mohammad Kaif Momin

Gourav Mali
 Design and Development of 4 Wheel Steering System.

ACKNOWLEDGEMENT

We express our profound thanks to Guide Prof. Abhijeet Chavan,

Department of Mechanical Engineering MIT School of Engineering, MIT-ADT
University, Pune for his expert guidance, encouragement and inspiration during this
Mini project work.
We are very thankful Prof. Dr. Savita Shinde, Mini-Project Co-ordinator,
Mechanical Engineering Department for her guidance and all kinds of help to
complete our work.

We also express thanks to Prof. Dr. Sachin Pawar, Head, Department of

Mechanical Engineering, being constant source of inspiration throughout the
execution.
We are grateful to Prof. Dr. Virendra Shete, Director, School of Engineering and
Sciences, MIT-ADT University, Pune, for providing us the facilities to carry out this
work. We also thank all the faculty members in the department for their support and
advice. We are very much grateful to our parents for their immense love, affection,
help, cooperation and encouragement to complete this course.

Finally, a special thanks to all our classmates and friends who helped and encouraged
us to complete successfully our Mini projectwork.

Sameep Raut
(MITU22BTML0056)

Aditya Upadhye
(MITU22BTML0009)

Mohammad Kaif Momin

(MITU22BTML0039)

Gourav Mali
(MITU22BTML0028)

Department of Mechanical Engineering, MITSOES Pune

 Design and Development of 4 Wheel Steering System.

ABSTRACT

This final report presents the process of designing and prototyping a 4-wheel steering
system for a car. The increasing demand for efficiency, speed, precision and safety in
modern day vehicles has driven the adoption of various technologies in car
manufacturing. This project aims to provide a thorough understanding of the key
components, technologies, and challenges associated with designing a 4-wheel
steering. This project had begun with understanding the steering system
fundamentally, then introducing the concept of AWS/4WS. The Applications of 4WS
are more diverse than just cars these are used in vehicles relating to Construction,
warehousing, and logistics, highlighting the potential benefits of increased steering
efficiency, enhanced safety and easier autonomous adaptability have been explored,
but for the purpose of the prototype a car model was finalised for the 4WS system.

An analysis regarding components to be used for the projectwork is conducted and

presented, it includes general specification of items such as battery, motor, rack,
pinion, chassis(acryllic) etc. This report delves into the actual making of a steering
system right from the design decisions to the final working prototype. Further
progressing the prototype was tested for efficiency and the steering data output is
compared to 2WS. In conclusion, this study provides valuable insights regarding the
functioning of 4WS, fundamentally, and just scratches the surface in a world full of
technolgies yet to be adapted in mass produced automobiles.

Department of Mechanical Engineering, MITSOES Pune

 Design and Development of 4 Wheel Steering System.

TABLE OF CONTENTS

Contents
ABSTRACT iv
TABLE OF CONTENTS v
TABLE OF FIGURES vi
LIST OF TABLES vii
CHAPTER 1 1
1.1 Introduction 1
1.2 Organization of the Report 2
1.3 Closure 2
CHAPTER 2 3
2.1 Introduction 3
2.2. Literature Review 3
2.3 Identification of Gaps/Scope of Work 3
2.4 Problem Statement 4
2.5 Objectives 4
2.6 Closure 4
CHAPTER 3 5
3.1 Introduction 5
3.2 Methodology Details 5
3.3 Closure 8
CHAPTER 4 9
4.1 Introduction 9
4.2 Calculations 9
4.3 Closure 16
CHAPTER 5 17
5.1 Introduction 17
5.2 Car Chassis 17
5.3 Steering Mechanism 18
5.4 Wheels 19
5.5 ESP-WROOM-32 19
5.6 Motor 20
5.7 Battery 21

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 Design and Development of 4 Wheel Steering System.

5.8 Miscellaneous 21
5.9 Closure 21
CHAPTER 6 22
6.1 Introduction 22
6.2 Design Phase 22
6.3 Closure 23
CHAPTER 7 24
7.1 Introduction 24
7.2 Results 24
7.3 Closure 27
CHAPTER 8 28
8.1 Introduction 28
8.2 Conclusion 28
8.3 Closure 28
REFERENCES 29
APPENDIX I 30

TABLE OF FIGURES

Fig 1:Final Concept of 4 Wheel Steering System 1

Fig 2 :Phases in 4 wheel Steering steering 2
Fig 3:Methodology used for the project work 5
Fig 4: Terminology image for reference 10
Fig 5: Ackermann Geometry 11
Fig 6: Dimensions For Calculation of Ackermann 13
Fig 7: Acrylic sheet 17
Fig 8: Rack and pinion 18
Fig 9: Shaft for transmission 18
Fig 10: Primary wheels of the setup 19
Fig 11: ESP-WROOM-32 microcontroller 19
Fig 12: SG90 Servo motor 20
Fig 13: 6F22 9V battery 21
Fig 14: Complete Assembly 22
Fig 15:Front view 23
Fig 16: Side view 23
Fig 17: Arrangement of pins & their functions 25
Fig 18: Circuit diagram for Steering input 26
Fig 19: Interface of Blynk IOT app Fig 20: Interface of MIT app Inventor 27

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 Design and Development of 4 Wheel Steering System.

LIST OF TABLES
Table 1: Assumptions 11
Table 2:Outputs 11
Table 3: Dimensions 13
Table 4: Estimated Cost Sheet 30
Table 5: Project Based Outcomes 31

CHAPTER 1
INTRODUCTION

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 Design and Development of 4 Wheel Steering System.

1.1 Introduction

The design and development of a 4-wheel steering system represents an innovative

approach to enhancing vehicle manoeuvrability and stability. Unlike traditional 2-
wheel steering systems, a 4-wheel steering system allows all four wheels to steer,
offering increased precision and agility, particularly in tight spaces and high-speed
conditions. Key components of this system include the Rack & Pinion, steering
linkage, hub, wheel, all of which must be precisely designed and integrated to ensure
smooth and reliable operation.

Fig 1:Final Concept of 4 Wheel Steering System

Types of mechanical steering:

Passive: In a passive 4WS system, the rear wheels are mechanically linked to the front
wheels. At low speeds, the rear wheels turn opposite to the front for better
maneuverability, while at higher speeds, they turn in the same direction for improved
stability. This system operates without electronic control, relying on fixed mechanical
connections between the front and rear wheels.

Active: In active 4WS, the rear wheels are independently controlled by electronic
systems, adjusting their steering angle based on vehicle speed, steering input, and
other factors. At low speeds, the rear wheels turn opposite to the front for better
maneuverability, while at high speeds, they turn in the same direction as the front
wheels for enhanced stability.

This mini project focuses on creating a fully mechanical 4-wheel steering system with
the ability to switch between in-phase and counter-phase steering modes. In-phase
mode synchronizes the rotation of the front and rear wheels in the same direction for

Department of Mechanical Engineering, MITSOES Pune

 Design and Development of 4 Wheel Steering System.

improved stability at higher speeds, while counter-phase mode steers the rear wheels
in the opposite direction of the front wheels, facilitating sharper turns at low speeds.

Fig 1 :Phases in 4 wheel Steering

This project aims to
showcase the mechanical
innovation behind such systems, emphasizing practical design solutions for enhanced
vehicle control.

1.2 Organization of the Report

● Chapter 1: Introduction to the project work.
● Chapter 2: Literature review.
● Chapter 3: Methodology of the project work.
Counter-Phase In-Phase
● Chapter 4: Design considerations.
● Chapter 5: Calculation used for the Steering system.
● Chapter 6: Selection of standard components.
● Chapter 7: Results and discussions.
● Chapter 8: Conclusion.
1.3 Closure
An introduction was provided to the project work in this chapter. Now literature
reviewed by the team members to initially understand 4WS will be discussed.

CHAPTER 2
LITERATURE REVIEW
Department of Mechanical Engineering, MITSOES Pune
 Design and Development of 4 Wheel Steering System.

2.1 Introduction
This chapter elucidates the complete review of the literature pertinent to the present
study. For easy understanding, the literature review has the following subsections

2.2. Literature Review

Shreyansh Chaugule, Jotiba Avatade [1] IRJET,Vol-10, Issue-04, 2023 "Design and
development of Ackerman Steering System for formula Student Vehicle". This
literature review paper provided with insights for calculations required for making an
FSAE Steering System. Jakub Jan Farynski, Dariusz Piotr Zardecki, Andrzej
Debowski, [2] The Archives if Automotive Engineering Archiwum Motoryzacji, Vol-
94, Issue-04, 2021 "Study of the problem of operation of Four-Wheel-Steering Cars”.
This literature review paper provided with general manufacturing comparisions of
Ackermans of 2WS and 4WS, Control Algorithms for Active 4WS. Ahsan Salauddin
and Pratik Padmesh, [3] IRJET, Vol-09, Issue-03, 2022 "Mathematical Modeling and
Design of a Rack and Pinion Steering Mechanism". Condition for Geometrically
Correct Steering, List of Cars Using 4WS. V. Arvind [4] IJSER, Vol-4, Issue-12,
2013, "Optimizing the turning radius of a vehicle using symmetric four wheel steering
system,". Calculation of reduction in Turning radius. Rahul G. Shete, Maneetkumar
R. Dhanvijay, Sudhir Madhav Patil, [5] IEOM Society international, Vol-03,2022
"Modeling and Simulation of Four-Wheel Steering System for Shorter Wheelbase
Vehicle," Matlab Simulink models, Design for 4WS at college level.

2.3 Identification of Gaps/Scope of Work

● The complexity of the 4WS systems, especially active systems, can lead to
issues with long-term durability and reliability.
● Active 4WS systems are still expensive due to complex components and
electronic controls.
● 4WS systems are often not fully integrated with autonomous driving
technologies.
● Many current 4WS systems offer limited customization options for drivers

2.4 Problem Statement

Design and Development of 4 Wheel Steering System

2.5 Objectives
● To be familiarized with fundamental knowledge of steering system.

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 Design and Development of 4 Wheel Steering System.

● To conceptualize a miniature version of 4WS.

● To make a design of the car ladder containing this 4 wheel steering system.
2.6 Closure
These were the various Literature (research papers, review papers, blogs, etc.) that
have been referenced for project work.

CHAPTER 3
METHODOLOGY
3.1 Introduction
The path taken by the team to complete the study, analysis, design and prototyping of
4 wheel steering has been put down in this chapter.

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 Design and Development of 4 Wheel Steering System.

3.2 Methodology Details

Fig 3:Methodology used for the project work

The above flowchart in Fig. 3.1 explains the methodology for developing the
prototype of the 4WS involved several systematic phases, each critical to ensuring the
project's success. The process was structured as follows:

1. Research and Study Phase

● Desk Research

The initial phase involved extensive desk research to gather existing knowledge and
insights about 4WS. This included reviewing existing technologies, identifying
potential challenges and solutions and feasibility of the solution to us.

● Literature Review
A comprehensive literature review was conducted to study previous research papers,
articles, and technical documents. This helped in understanding the theoretical
foundations and advancements in the field of Automobiles, Vehicle dynamics and
Steering systems.

● Researching similar existing steering mechanisms

In the development of 4-Wheel Steering (4WS) systems, it is crucial to explore and

understand similar existing steering mechanisms, as these provide valuable insights
into the effectiveness, limitations, and potential improvements for 4WS technologies.
By reviewing these mechanisms, we can assess how they influence vehicle handling,

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 Design and Development of 4 Wheel Steering System.

stability, and maneuverability, and identify best practices for integrating such systems
into modern vehicles.

2. Conceptualization

● Rough Concepts

This involves brainstorming and sketching basic ideas for the miniature 4WS system.
The focus is on determining the key components, such as the steering mechanism
(e.g., mechanical linkage or actuators), wheel turns (how the front and rear wheels
will move), and the overall structure. Basic concepts will consider space constraints,
functionality, and movement of both front and rear wheels to ensure the system works
at both low and high speeds..

● Calculations

Perform essential calculations related to the steering angles, the ratio of movement
between front and rear wheels, and material failure forces. These calculations help
define the required rack and pinion measurements for the steering system and the
potential turning radius of the vehicle. Consideration of the mechanical linkages or
servos required to achieve the desired steering effect is also critical. These
calculations ensure the steering performance is functional and stable

● Results

This section contains the inferences from all the calculations performed. The results
could be segregated in a few categories, calculation for concept, calculation for design
and calculation for material selection. The titles are pretty self explanatory

[Link]

● CAD Designs

The CAD model includes dimensions of components such as the steering mechanism,
chassis, and wheels. CAD helps in refining the design, checking for potential
interferences, and ensuring the system’s feasibility before physical prototyping.

● Research presentation

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 Design and Development of 4 Wheel Steering System.

Whatever inferences were obtained from the study procedures completed up until
now, are to be concluded and presented in the mini project presentation.

● Project Report

The submission of this project report file.

4. Fabrication

● Material Selection/Procurement

Choose materials based on the size, weight, and functionality requirements of the
prototype. For a miniature 4WS system, lightweight, durable materials such as plastic
(e.g., ABS or PLA for 3D printing) are selected. Components like gears, linkages, and
steering rods may also require specific materials for strength and precision. Materials
are sourced from suppliers based on these criteria.

● 3D Printing

Utilize 3D printing to create intricate parts of the prototype, such as wheel assemblies,
linkages, and steering components.

● Assembly

Once all components are fabricated, the assembly process involves fitting together the
3D-printed parts, motors, servos, linkages, and wheels according to the CAD design.
This stage ensures that the steering system functions as intended, with proper
alignment and movement of the front and rear wheels. Wiring and testing for the
control mechanisms (e.g., motor controls or servos) are also carried out during the
assembly phase to ensure smooth operation of the 4WS system.

5. Testing

● Motor integration

The motors responsible for steering the wheels are integrated into the prototype, and
interfacing with a control system is done using platforms like MIT App Inventor or
Blynk IoT. These platforms allow for wireless control of the motors via smartphone
or other devices, enabling real-time adjustments to the steering mechanism. The

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 Design and Development of 4 Wheel Steering System.

motor control setup is tested to ensure that the input from the user interface correctly
drives the front and rear wheels based on the desired steering angle and system
response.

● Steering angle validation

The steering angles of both the front and rear wheels are validated by comparing them
against a standard 2-Wheel Steering (2WS) system. The steering angles of the 4WS
system are measured and compared at various speeds and steering inputs to ensure
they align with the intended functionality, such as turning opposite at low speeds (for
better maneuverability) and in the same direction at higher speeds (for stability). The
angles are validated using a protractor or digital angle sensor, ensuring that the system
operates as expected for both the front and rear wheel

3.3 Closure
This Section Focused on the overall methodology used into materializing this project,
here the first three phases will take into effect in this semester while the fabrication
and testing phase is going to happen in the next instalment. The further section delves
more deeper into the design of the robot.

CHAPTER 4
CALCULATIONS

4.1 Introduction
The calculation of the 4-Wheel Steering (4WS) system in this project focuses on key
parameters such as the steering angles of the front and rear wheels, turning radii, and
the coordination between the front and rear systems. This includes determining the
rear-wheel steering angle based on the front wheel input to maintain vehicle stability

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 Design and Development of 4 Wheel Steering System.

and manoeuvrability. Also, the geometry of the steering linkages and their effect on
the overall turning radius and stability at different speeds are considered. These
calculations ensure the system’s efficiency and form the foundation for its design and
potential application.

4.2 Calculations

Required calculations
i. Turning Radius
ii. Ackermann geometry
iii. Rack calculations
iv. Pinion Calculations

Ackerman Geometry Calculations for 4 wheel steering mechanism

Step 1:

● Ackerman Geometry calculations

● Turning Radius
● Outer wheel turning angle
Step 2:

● Ackerman arm calculations

● Ackerman angle
● Length of Ackerman arm

Step 3:

● Rack and pinion calculations

● Tie Rod calculations
● Rack and pinion calculations
Step 4:

● Steering effort calculations

Calculations terminology:

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 Design and Development of 4 Wheel Steering System.

1. Wheelbase: Distance Between Front wheel centre and Rear wheel Centre
viewed from Side plane.
2. Track Width: Distance between Front wheel centre viewed from Front Plane.
3. Turning Radius: The turning radius of a vehicle refers to the smallest
circular turn that the vehicle can make. It is typically measured by the distance
from the center of the turning circle to the outer edge of the vehicle's path.

Fig 4: Terminology image for reference

4. Steering Wheel Angle: It is the angle steered by the driver via steering wheel.
5. Wheel Steer Angle: It is the angle steered by the wheels on road.
6. Inner Wheel Steering angle: This is the angle at which the wheel on the inside
of the turn (closer to the centre of the turn) is steered.
7. Outer Wheel Steering Angle: This is the angle at which the wheel on the
outside of the turn (farther from the centre of the turn) is steered.
8. Pitch Centre Diameter: PCD is the basic parameter from which all the gear
terminology are derived.
9. Face width: Face width is the width if the tooth viewed from front plane.
10. Pressure Angle: Angle between the line of action (the direction of the force
transmitted between two meshing gear teeth) and the line tangent to the pitch
circle (the theoretical circle where two gears effectively mesh).
11. Rotational Speed Of pinion: Speed at which the pinion rotates.
12. Pinion Radius: Radius of pinion gear.

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 Design and Development of 4 Wheel Steering System.

13. Rack Travel: Rack travel refers to the total distance that the steering rack (a
component in a rack-and-pinion steering system) can move from one end to
the other when turning the steering wheel.
14. Steering Ratio: It is ratio of Steering wheel angle to wheel steered angle.
15. Rack Length: Rack length refers to the total length of the steering rack in a
rack-and-pinion steering system. The rack length is the full measurement of
the rack from end to end, including the portions that extend beyond the
toothed area where the tie rods connect to the wheels.
16. Module: Ratio of PCD to Number of teeth
17. Linear travel per rotation: it describes how far the steering rack moves (side
to side) for each full rotation of the steering wheel.

Calculations:

Note: Ackerman geometry deals with inside wheel turning more angle than outside
wheel.

For further calculations we need to assume some factors

Inner Wheel angle (θ) 40 Degrees

Rack length (l) 100 mm

Steering Ratio 01:04 -

Rack and pinion module 1.5 -

(m)

Wheel Base (WB) 300 mm

Track width (TW) 200 Mm

Table 1: Assumptions

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 Design and Development of 4 Wheel Steering System.

Fig 5: Ackermann Geometry

Inside turning Ri 466.72 mm

Radius

Outside Ro 633.12 mm
turning Radius

Outside wheel Φ 28.28° -

turning angle

Extra Length e 357.53 mm

Table 2:Outputs

Calculation of extra length (e):

WB
θ=
e

300
40=
e

300
¿> e= =357.52mm
tan tan 40

Therefore, the extra length is 357.52 mm

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 Design and Development of 4 Wheel Steering System.

Calculation of Inside and outside turning radius

● Inside turning radius

Ri=√ ❑

Ri=√ ❑

Ri=466.71 mm …………………………………………..(1)

● Outside turning radius

Ro=√ ❑
Ro= √❑

Ro=633.11 mm…………………………………………..(2)

Outside Turning Angle (Φ)

WB 300
sin sin ∅ = = =0.4738
Ro 633.11

∅ =0.4738=28.28 °

Therefore, the Outside turning angle is 28.28°.

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 Design and Development of 4 Wheel Steering System.

Fig 6: Dimensions For Calculation of Ackermann

Length of Tie rod Y 41.21 mm

Length of Rack Z 100 mm

Distance between rack centre and d 15 mm

front axle

Table 3: Dimensions

To calculate Ackerman angle β:

0.5 ×TW 0.5 ×200

tan tan β= = =0.3333
WB 300

β=0.3333=18.43 °

Rounding off Ackerman angle to 18°.

If we round it up that tends to below 100% Ackerman that tends to understeer so we

don’t want to understeer than we round it down for above 100% Ackerman.

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 Design and Development of 4 Wheel Steering System.

Rack Travel (δ):

( TW −z )
δ=x sin sin ( θ+ β )− + √❑
2

( 200−100 )
δ=41.21sin sin ( 40+18 )− + √❑
2

Therefore δ= 24.64 mm

So total displacement of Rack is having when the wheel is Rotating at 40°

Pinion calculations:

Imagine pinion to be a circle open the circle into straight line representing the distance
travelled by rack when the pinion completes one rotation, which is the circumference
of our pinion imaginary circle(πd) From using the logic we can calculate diameter of
pinion. Therefore, we can say that rack travel; for 1° of wheel turn wheel be (δ 1),

δ 24.64
Now δ 1= = =0.6162mm
θ 40

Since our steering ration is 1:4 for (δ 1) travel in rack we need 4° rotation of (δ 1)

Arc length is S= r x w

In our case s will be (δ 1)

4π
δ 1=r ×
180

4π
0.6162=r ×
180

r=8.825 mm

PCD of pinion=2r=2x8.825=17.65mm

Rounding off to r= 18mm

Therefore, PCD of pinion is 18mm

Now Module available is m=1.5

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 Design and Development of 4 Wheel Steering System.

Therefore, no of teeth will be

PCD 18
N= = =12
m 1.5

Rounding it off to 12 teeth.

So total no of teeth on pinion will be 16.

Circular pitch= πx m = π x 1.5 =4.7123

Rack Calculations:

Rack travel for one side is already calculated it in δ.

So therefore, Rack Travel for both sides will be = 2xδ =2x 31.32 =62.64 mm

For perfect meshing of rack with pinion module for both will be same.

m=1.5

2 ×δ 2 ×24.64
Minimum teeth required= = =10.45
π ×m π ×1.5

Rounding it off to 11 teeth for manufacturing.

Therefore, minimum no of teeth required are 13 Teeth for the Rack

Minimum length of the rack required = No of teeth x π x m

=11xπx1.5=49.29 mm

Available and selected length =100 mm

Note: For both side rear and front same rack and pinion will be used for the same
geometry.

Pinion calculations

Addendum is substandard value

Addendum= 1m=1x 1.5= 1.5 mm

Dedendum= 1.2 m= 1.2-1.5 = 5.5 mm

Working depth = 2m = 2x1.5 =3 mm

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 Design and Development of 4 Wheel Steering System.

Clearance = Total depth – Working depth =5.5 -5 =0.5 mm (clearance between rack
and pinion)

sin 90
Thickness of teeth=PCD ×
Tp

sin 90
Thickness of teeth=30 × =1.5 mm
12

Circular pitch = 3.142xm= 3.142x 1.5= 7.8539 mm

4.3 Closure
In conclusion, the calculations for the 4-Wheel Steering (4WS) system have provided
essential insights into its design and functionality. By determining the steering angles,
turning radii, and the coordination between the front and rear wheels, the project has
laid the groundwork for the steering system. The careful consideration of steering
geometry and stability factors ensures the system's effectiveness in practical
applications. These calculations not only support the conceptual design but also
potentially highlight the benefits of 4WS in enhancing vehicle performance, setting
the stage for future development and implementation.

CHAPTER 5
COMPONENTS SELECTION

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 Design and Development of 4 Wheel Steering System.

5.1 Introduction
This chapter will discuss the various hardware components that are used in the
project. It will give the team some insights on the respective technologies and variants
of the same present in the market according to the research carried out.

5.2 Car Chassis

Acrylic sheets

Fig 7: Acrylic sheet

Specifications:-

● Dimensions :180 X 200 (mm)

● Type : Glossy black hard acrylic sheet
● Quantity : 1

Function And Placement

The acrylic sheet serves as the structural base of this robot. This was the most obvious
choice because the car had to house various vital components, which would be more
complex if we could

3D-Printed parts

5.3 Steering Mechanism

Rack and pinion

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 Design and Development of 4 Wheel Steering System.

Fig 8: Rack and pinion

● Quantity for each : 2

Function And Placement:-

The full assembly of the 4WS system contains two sets of rack and [Link] motor
is connected to one primary pinion and this drives the network of gears.

Shaft

Fig 9: Shaft for transmission

Specifications: unknown

Function and placement

It is the only point of contact between the front pinion gear and rear. It’s placed
centrally in the middle of the car, connected the front pinion to transmit rotation.

5.4 Wheels
Primary Wheels

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 Design and Development of 4 Wheel Steering System.

Fig 10: Primary wheels of the setup

Specifications :-

● Diameter : 65 mm X 26 mm
● Type : Standard Diy project level wheels
● Quantity : 4

Function and Placement

The four 65 mm diameter wheels serve as the main driving wheels of the car platform.
They are positioned in pairs on either sides of the car and are not powered by any
motor.

5.5 ESP-WROOM-32

Fig 11: ESP-WROOM-32 microcontroller

Specifications:-

● Max dimensions : 28 X 50 X 14mm

● Type : ESP-WROOM-32
● Quantity : 1

Function and placement

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 Design and Development of 4 Wheel Steering System.

This microcomputer establishes a connection b/w phone and motor using Wi-fi and
the phone has an app installed which provides an interface for interacting with the
motor. This is placed centrally on the floor of the car.

5.6 Motor

Fig 2: SG90 Servo motor

Primary function

For the function of giving steering input to the steering system.

Specification:-

● Torque: 2.5kg/cm
● Type : 180 degree operation
● Quantity : 1

The SG90 can rotate approximately 180 degrees. The SG90 Servo Motor is a flexible
and widely used component in robotics and electronics. It offers precise control over
rotational motion, making it an ideal choice for various applications. Additionally,
this compact motor rotates accurately within a specified range using pulse width
modulation (PWM) signals.

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 Design and Development of 4 Wheel Steering System.

5.7 Battery

Fig 13: 6F22 9V battery

Specifications:-
● Capacity : 400-600 mAh
● Voltage : 9 V
● Quantity : 1
Function and placement
This battery powers each and every electronic component and is placed in the rear
centre of the Chassis and secured to the floor of the chassis using double sided
sticking tape.

5.8 Miscellaneous

Jumper wires : These are connected to the raspberry pi and are the primary source of
connection between the different components and The GPIO input and output ports.
Double sided tape : This regular double-sided tape was used to mount a few
components like battery and motors.
Screws : These are used wherever required to pin and lock items onto a specific
place.

5.9 Closure
An overview of all components used in this bot were given in this chapter. The
following chapter will describe the results obtained in the project work.

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 Design and Development of 4 Wheel Steering System.

CHAPTER 6
DESIGN

6.1 Introduction

The design phase lays the groundwork for subsequent manufacturing and assembly
phases, ensuring that the prototype not only meets all functional requirements but also
adheres to high standards of performance and reliability. Through this structured and
meticulous design process, the foundation is set for developing a sophisticated and
fully operational.

6.2 Design Phase

Fig 14: Complete Assembly

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 Design and Development of 4 Wheel Steering System.

Fig 15:Front view

Fig 16: Side view

6.3 Closure
The design phase of the 4WS concluded with the successful creation of a detailed and
comprehensive blueprint that guided the subsequent stages of development. This
phase was marked by rigorous research, careful selection of components, and drafting
of schematics, ensuring that every aspect of the steering system was thoughtfully
planned and optimized. The integration of mechanical, electrical, and software
elements was achieved with precision, establishing a robust framework for the
steering’s functionality. The completion of this phase not only provided a clear and
actionable roadmap for manufacturing and assembly but also set high standards for
performance and reliability.

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 Design and Development of 4 Wheel Steering System.

CHAPTER 7
RESULTS & DISCUSSIONS

7.1 Introduction
The results section of this report presents the outcomes of the design and calculations
for the prototype model of the 4-wheel steering mechanism. This section provides a
detailed analysis of the various design parameters, including the mechanical structure,
steering geometry, and control system integration. In the following subsections, the
results of key calculations, such as steering angles, stability and control factors, are
presented and discussed, followed by a summary of the entire project work.

7.2 Results

1] Calculations:

Rack length= 100mm

Rack Travel=24.64 mm

PCD of pinion =18 mm

Inner steering angle= 40°

Outer steering angle = 28°

Inner turning radius = 466.71 mm

Outer turning radius =633.11 mm

2] Control

i) GPIO Pins Setup in the ESP-WROOM-32 30 Pin Variant

The ESP-WROOM-32 microcontroller used in this project has a 30-pin configuration,
with multiple GPIO pins that allow for flexible control of the system.

Additional GPIO Pins:

● Other GPIO pins are available for connecting additional components such as
sensors, buttons, or other control mechanisms if required for future expansion
or advanced features.

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 Design and Development of 4 Wheel Steering System.

Fig 17: Arrangement of pins & their functions

The versatility of the ESP-WROOM-32’s GPIO configuration enables efficient motor

control while providing the flexibility for future updates or additions to the system.

ii) Connections of the Circuit

The circuit for the 4-wheel steering system integrates the following components:

● SG90 Servo Motor: This motor controls the steering mechanism by adjusting
the angle of the front and rear tyres.
● 6F22 9V Battery: Powers the servo motor and ESP-WROOM-32
microcontroller.

● ESP-WROOM-32 Microcontroller: This microcontroller serves as the brain of

the system, controlling the motor based on commands received from the
smartphone app.

● Breadboard: All components are connected to a breadboard, which allows for

easy connections and testing.

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 Design and Development of 4 Wheel Steering System.

Wiring:

● The 9V battery is connected to the breadboard’s power rail, providing power

to both the servo motor and microcontroller.

● The servo motor's control pin is connected to one of the GPIO pins on the
ESP-WROOM-32.

● The ESP-WROOM-32 is powered through its 3.3V pin, ensuring it

communicates properly with the servo motor.

Fig 18: Circuit diagram for Steering input

For further clarification, these connections can be referenced in the circuit diagram
provided above.

ii) Motor Control Using Blynk IoT App or MIT App Inventor

Control Interface:

● The motor control is made interactive through a smartphone interface

developed using either the Blynk IoT app or MIT App Inventor. Both
platforms allow users to control the servo motor remotely, adjusting the
steering angles of the front and rear tyres.

Blynk IoT App:

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 Design and Development of 4 Wheel Steering System.

● Widgets such as sliders or buttons can be used to control the rotation of the
SG90 servo motor.

● The app communicates with the ESP-WROOM-32 over Wi-Fi, sending

control signals to adjust the motor's angle.

● DAQ Data Acquisition features in Blynk provide real-time feedback on the

motor's angle, allowing users to monitor position of both the front and rear
tyres.

Fig 19: Interface of Blynk IOT app Fig 20: Interface of MIT app Inventor

MIT App Inventor:

● Users can create a custom interface with components like sliders to send
control signals to the ESP-WROOM-32.

● It also supports the DAQ feature, where the app can display real-time data on
the motor's angle, ensuring accurate monitoring of the steering system.

7.3 Closure
In conclusion, the design and calculations for the 4-wheel steering prototype have
been successfully completed, confirming the system's feasibility. The results show

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 Design and Development of 4 Wheel Steering System.

that the design meets the required performance, stability, and maneuverability
specifications. The calculations support the system's efficient operation, with steering
angles requirements within expected parameters. The prototype demonstrates the
potential for improved vehicle handling, with further testing recommended for real-
world optimization.

CHAPTER 8
CONCLUSION

8.1 Introduction
The design process focused on developing a 4-Wheel Steering (4WS) system to
enhance vehicle manoeuvrability and stability in a compact, scaled-down model. This
project involved conceptualizing the system's functionality, performing the necessary
calculations for its operation, and designing the components to optimize performance
without the need for physical prototyping.

8.2 Conclusion
In conclusion, this mini project successfully involved the calculations, design, and
conceptualization of a miniature 4-Wheel Steering (4WS) system. Through careful
analysis and design, the project demonstrated the potential benefits of 4WS in
enhancing vehicle manoeuvrability and stability, particularly in compact, scaled-down
models. The system's functionality was thoroughly conceptualized, and the necessary
calculations were made to ensure optimal performance. Although no physical
prototype was developed, the results of this design phase provide a strong foundation
for future work in 4WS systems, offering valuable insights into its feasibility and
potential applications.

8.3 Closure
In conclusion, the project provided insights into the design, fabrication, and testing of
a 4WS system, offering a foundation for further exploration and refinement. Future
improvements could focus on enhancing the scalability of the system, reducing costs,

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 Design and Development of 4 Wheel Steering System.

and exploring more advanced control methods, contributing to the broader potential
applications of 4WS technology in full-scale vehicles.

REFERENCES

[1] Shreyansh Chaugule, Jotiba Avatade IRJET,Vol-10, Issue-04, 2023 "Design and
development of Ackerman Steering System for formula Student Vehicle". This
literature review paper provided with insights for calculations required for making an
FSAE Steering System.

[2] Jakub Jan Farynski, Dariusz Piotr Zardecki, Andrzej Debowski, The Archives if
Automotive Engineering Archiwum Motoryzacji, Vol-94, Issue-04, 2021 "Study of
the problem of operation of Four-Wheel-Steering Cars”. This literature review paper
provided with general manufacturing comparisions of Ackermans of 2WS and 4WS,
Control Algorithms for Active 4WS.

[3] Ahsan Salauddin and Pratik Padmesh, IRJET, Vol-09, Issue-03, 2022
"Mathematical Modeling and Design of a Rack and Pinion Steering Mechanism".
Condition for Geometrically Correct Steering, List of Cars Using 4WS.

[4] V. Arvind IJSER, Vol-4, Issue-12, 2013, "Optimizing the turning radius of a
vehicle using symmetric four wheel steering system,". Calculation of reduction in
Turning radius.

[5] Rahul G. Shete, Maneetkumar R. Dhanvijay, Sudhir Madhav Patil, IEOM Society
international, Vol-03,2022 "Modeling and Simulation of Four-Wheel Steering System
for Shorter Wheelbase Vehicle," Matlab Simulink models, Design for 4WS at college
level.

Weblinks:

[Link]

[Link]

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 Design and Development of 4 Wheel Steering System.

[Link]

[Link]

APPENDIX I

COST SHEET (Est.)

S. N. Date Particular Amount (Rs.)

1 N/A Acrylic Sheets 200

2 N/A 3D-Printed Parts 500

3 N/A Rack & Pinions 1000

4 N/A Gears 600

5 N/A Shaft 200

6 N/A Wheels 250

7 N/A ESP-WROOM-32 330

8 N/A SG90 Servo Motor 150

9 N/A 9V battery 100

10 N/A Jumper wires 70

11 N/A Breadboard 100

Total 3500

Table 4: Estimated Cost Sheet

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 Design and Development of 4 Wheel Steering System.

PROJECT BASED OUTCOMES

The student needs to fill the below table for the outcomes they have gained during the
work. These outcomes will vary based on project-based learnings.

Outcomes Agree Moderately Highly

Agree (3)
(1) (2)

1. Engineering knowledge: Apply the knowledge of mathematics science

engineering fundamentals and a mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex
engineering problems engineering problems.

2. Problem analysis: Identify, formulate, review research literature, and

analyze complex engineering problems reaching substantiated conclusions
using first principles of mathematics, natural sciences, and engineering
sciences.

3. Design/development of solutions: Design solutions for complex

engineering problems and design system components or processes that meet
the specified needs with appropriate consideration for the public health and
safety, and the cultural, societal, and environmental considerations

4. Conduct investigations of complex problems: Use research-based

knowledge and research methods including design of experiments, analysis
and interpretation of data, and synthesis of the information to provide valid
conclusions

5. Modern tool usage: Create, , select, and apply appropriate techniques,

resources, and modern engineering and IT tools including and modeling to
complex engineering activities with an understanding of the limitations

6. The engineer and society: Apply reasoning informed by Apply reasoning

informed by the contextual knowledge to assess societal, health, safety, legal
and cultural issues and the consequent responsibilities legal and cultural
issues and the consequent responsibilities relevant to the professional
engineering practice

7. Environment and sustainability: Understand the impact of the

professional engineering solutions in societal and environmental contexts,
and demonstrate the knowledge of, and need for sustainable development
and need for sustainable development.

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 Design and Development of 4 Wheel Steering System.

8. Ethics: Apply ethical principles and commit to professional ethics and

responsibilities and norms of the engineering practice

9. Individual and team work: Function effectively as an individual and as a

member or leader in diverse teams and individual, and as a member or leader
in diverse teams, and in multidisciplinary settings

10. Communication: Communicate effectively on complex engineering

activities with the engineering community and with society at large, such as,
being able to comprehend and write effective reports and design
documentation, and write effective reports and design documentation, make
effective presentations, and give and receive clear instructions

11. Project management and finance: Demonstrate knowledge and

understanding of the engineering and knowledge and understanding of the
engineering and management principles and apply these to one’s own work,
as a member and leader in a team, to manage projects and in
multidisciplinary environments.

12. Life-long learning: Recognize the need for and have the Recognize the
need for, and have the preparation and ability to engage in independent and
lifelong learning in the broadest context of technological change

Table 5: Project Based Outcomes

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