International Journal of Modern Trends in Engineering and Research www.ijmter.com e-issn No.:2349-9745, Date: 28-30 April, 2016 Design of Head Light Moving Mechanism With Steering Mangesh A. Jadhav1,Tushar S.Borkar2, Nilam B. Narote3, Pratik D.More4, Rajendra S. Chaudhari5 1 Department mechanical engineering, SNJB s KBJ COE Chandwad, mangeshjadhav987@gmail.com 2 Department mechanical engineering, SNJB s KBJ COE Chandwad, borkartushar27@gmail.com 3 Department mechanical engineering, SNJB s KBJ COE Chandwad, nilam.narote14@gmail.com 4 5 Department mechanical engineering, SNJB s KBJ COE Chandwad, pratikdmore23@gmail.com Department mechanical engineering, SNJB s KBJ COE Chandwad, errajendrachaudhari@gmail.com Abstract The most important of this paper is Front wheel of steering system with moveable headlights with latest technology. The most conventional steering arrangement is to turn the front wheels using a hand operated steering wheel which is positioned in front of the driver, via the steering column, which may contain universal joints to allow it to deviate somewhat from a straight line. This idea gives more advantages for automobile. It gives the advantages such as low level of steering torque during static steering, increase fuel efficiency or economy, low weight of vehicle because of using EPS system, flexibility in steering system and more space for driver and front passenger. Keywords-Design, Headlight Mechanism, Synthesis of Mechanism, Rack And pinion spur gear. I. INTRODUCTION The aim is to design and develop a Steering Controlled Headlight Mechanism which acts as directional headlights. This is done by connecting headlights and steering. Present day automobiles don t have effective lighting system. Due to this many accidents are taking place during night times especially in hilly areas. The accidents can be avoided by incorporating Steering Control Headlight Mechanism. The rack and pinion steering gear mechanism is used for this project. When the steering wheel is rotated and rotary motion is converted to translatory motion through the rack and pinion mechanism. When the front wheels are steered, the headlights follows the same path and the light is focused on more divergent area. In the present project, it is planned to design Steering Controlled Headlight Mechanism and a live model unit is fabricated. II. PROBLEM DEFINATION A four wheeler usually find difficulty to drive especially at sharp turn.the model helps them to change the focus of headlight as the steering move on either direction. Adaptive headlights react to the steering system of the car and automatically adjust to illuminate the road wheel. Turn the car left, the headlights angles to the left. Instead of moving the headlights, reflectors are fitted on the inside on either side of the headlamp casing. These reflectors are moved to direct a beam in the same direction as the movement of the vehicle.the power required to move the reflectors is transmitted using hydraulic linkages. 905
Objectives:-The main aim to move the head light on sharp turning as possible as. The vehicle should get illumination front view that could help to driver taking turn on hill areas, And also to make the nation with an accident free. III. SYNTHESIS OF MECHANISM Steering System The manual steering system incorporates:1) Steering wheel and column, 2) A manual gearbox and pitman arm or a rack and pinion assembly, 3) Linkages; steering knuckles and ball joints; and 4) The wheel spindle assemblies. Rack And Pinion Steering Rack-and-pinion steering is quickly becoming the most common type of steering on cars, small trucks and SUVs. It is actually a pretty simple mechanism. A rack-and-pinion gear set is enclosed in a metal tube, with each end of the rack protruding from the tube. A rod, called a tie rod, connects to each end of the rack. The pinion gear is attached to the steering shaft. When you turn the steering wheel, the gear spins, moving the rack. The tie rod at each end of the rack connects to the steering arm on the spindle. Figure 3.1 Rack And Pinion Mechanism system The rack-and-pinion gear set does two things:1) It converts the rotational motion of the steering wheel into the linear motion needed to turn the wheels. 2) It provides a gear reduction, making it easier to turn the wheels. On most cars, it takes three to four complete revolutions of the steering wheel to make the wheels turn from lock to lock (from far left to far right). IV. METHODOLOGY The paper here is all about Front wheel steering system with moveable headlights with latest technology. The most conventional steering arrangement is to turn the front wheels using a hand operated steering wheel which is positioned in front of the driver, via the steering column, which may contain universal joints to allow it to deviate somewhat from a straight line. Rack and pinion steering gear mechanism where the steering wheel turns the pinion. The pinion moves the rack, 906
which is a linear gear that meshes with the pinion, converting circular motion into linear motion along the transverse axis of the car (side to side motion) V. DESIGN OF MECHANISMS Working Principle In our concept of mechanism lead-acid 12 Volt batteries is used. The lead-acid batteries output is given to the limit switch. There are two Limit switches are used in this project. These switch outputs are connected to the steering D.C mot or in Forward and reverse rotation of operation. The rack and pinion arrangement is used to turn the wheel in left and right direction. The Rack is connected to the wheel with the help of liver mechanism and the pinion is coupled to the permanent magnet D.C motor shaft. The Motor is drawn supply from the battery through limit switch arrangement. When the steering is turn in the left direction, it pushes the left side limit switches, so that the D.C motor rotate in forward direction to move the wheel in left side. Similarly When the steering is turn in the right direction, it pushes the right side limit switches, so that the D.C motor rotate in reverse direction to move the wheel in right side. Figure 4.1. Line Diagram of Head Light Moving Mechanism with Steering. Mechanical Design Mechanical design phase is very important from the view of designer as whole success of the project depends on the correct design analysis of the problem. Designer should estimate these forces very accurately by using design equations. If he does not have sufficient information to estimate them he should make certain practical assumptions based on similar conditions. This will almost satisfy the functional needs. Assumptions must always be on the safer side. 1) Design parts 2) Parts to be purchased Design of Frame Input data, Total weight = 10KG No of links = 4 2 links of 3000 mm 1 link of 1500 mm (assume) 907
1 link of 1500 mm Force = 10 kg = 10 x 9.81 = 98.1 N 100 N No of links = 4 Hence, Force on each link = 100 / 4 = 25 N Considering the max value of FOS = 2 Buckling load on each link = 25 x 2 = 50 N LET, T1 = Thickness of link, B1 = Width of link Area of link = T1 X B1 Assuming width of the link = 3 X T1 Hence, B1 = 3 X T1 AREA = 3T12 MI of link I = 1/12 X T1.B1 = 0.25 T1 Let, K = Radius of Gyration A = AREA K= I/A K = 0.28 T1 For link 1 L1 = 3000 mm PR = 50N RANKINE CONSTANT = a = 1 / 7500 Crushing Load (Fy) = 325 MPa for MS Now, Buckling Load PR = Fy. A / 1 + a λ WHERE λ = L / K PR = F. A / 1 + a (L / K) 325 10.25 X^4 50 = 1 3 1 + 7500 0.28 X...(i)... (ii)... (iii) T1 =1.42 mm 2 mm Similarly, Calculating the thickness for all links, Hence we take thickness T = 2mm to 20mm we consider. 908
Design of Steering Gear Mechanism In order to make the design of our rack-pinion for the steering box, we base our work on the choice of the rack and the pinion which will produce a greater lateral Displacement of the wheels with the same turn of the steering wheel. The other start point is that the rack and the pinion must be the same modulus and the same material. A suitable material for these elements is SAE 1045 steel which is easy to mechanize. Design of Rack and pinion spur gear Ultimate tensile strength (Sut) = 625 N/mm2. Assumptions:Number of teeth on pinion = 12 Number of teeth on rack = 28 Pitch line velocity of pinion = 0.5 m/sec. Tangential force on pinion = 600 N. Results:Hence selecting standard module m = 2 mm Hence dimension of spur pinion: Dp= Zp*m = 12 * 2 = 24 mm B = 15* m = 15* 2 = 30 mm Pressure angle = 20 0 Addendum = 1 m = 2 mm Deddendum = 1.25 *m = 2.5 mm Pitch (p) = 6.0283 mm We have a pinion with a diameter of 24 mm, T = 105.948*12= 1.27136Nm This is the torque in the pinion and it is transmitted through the steering column. Steering movement ratio Therefore the movement ratio is 12.47:1 we needed to know the movement ratio in order to determine the output load transmitted to the tie rods for a given input load. The output load will be: F = 2 *MR *F = = 2* 20* 12.47 = 498.8 N Therefore the load transmitted to the tie rods is 498.8 N. Selection of Motor Motor Selection 1) Phase Induction Motor ( 2 Pole ) 2) Power Rating = 0.05 Hp 3) Speed = 600 rpm (DC MOTOR) 4) Frame size = 71 5) Current = 1.70 Amp 6) Torque = 2.56 Nm 7) TEFC Construction. Design of Main Spindle T Design = 1.15 Nm. = 1.15x 10^3 N.mm Selection of main spindle material:-c30 909
Table No 5.2.6.1- Design of Main Spindle Designation EN 24(40 N; 2 CR 1 Mo28) Ultimate Tensile Strength N/mm2 720 Yield strength N/mm2 600 After Calculations Selecting minimum diameter of spindle = 10 mm Assembly Designs on CATIA Figure. Assembly Design on CATIA VI. RESULT AND CONCLUSION The effective Headlight Moving mechanism with Steering was designed, based on Rack and pinion mechanism, to move the steering arm that gives predefined motion to wheel and headlights. This is very important system, which help to move the headlight as per turn, right or left. And it can be help for making nation accidents free roads. REFERENCES [1] J.B. Jiang, C.F. Cheung, S.To, K.W. Cheng, H. Wang, and W.B. Lee Design and fabrication of freeform reflector for automotive headlamp 2nd International Conference on Power Electronics Systems and Applications: Hong Kong, 12-14 November 2006, p. 220-224. [2] Manisha V Makwana1a, Akshay Shah2a Shankar Rahul3a and Ajay Patel4, Design and Manufacture of Movable Headlight System in Automobile, International Journal of Innovative and Emerging Research in engineering,2014,12-16. [3] N.Laxmi, B.Anil Kumar, D.kiran varma, Design and Fabrication of A Steering Controlled Headlights in Automobile, International Journal & Magazine of Engineering, Technology, Management and Research, July 2015,98-102. [4] Fundamentals of motor vehicle technology by V.A.W.Hiller, 4th edition, Pub: 2009, pg.no.313-336. [5] Automobile engineering by Dr.kirpal singh vol 1, pub; 2010, chapter: front axle steering systems [6] Automobile engineering by K.K.jain and R.B.Asthana, pub.2006. 910