Automotive Steering System Design Project

This solved assignment focuses on the design of an automotive steering system using a rack-and-pinion gear mechanism. It details the process from initial mechanical design through testing and defect identification. The document highlights challenges faced, such as calculation errors and team conflicts, and their solutions. The project aimed to improve lighting systems in automobiles by integrating a steering-controlled headlight mechanism to reduce accidents.

CAREER EPISODE 3
CE 3.1 Project Information
Name of the project: Development of Movable Headlights with Steering System
Location of the project: [please fill name of the place where the project was conducted]
Project Duration: From [please fill] to [please fill]
Organization: [please fill]
Role and Designation during the time: Project Team Leader
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
This project was undertaken by my team for designing and developing a steering
controlled mechanism for moving the headlights of automobiles. I executed this project by
connecting the steering with the headlights of a vehicle. The lighting system of automobiles is
not effective. The ineffective lighting system leads to several road accidents in the hilly regions
and during the nights. I along with my team members decided to improve the lighting system of
vehicles by incorporating steering control mechanism. The mechanism used in this project was
rack-and-pinion steering gear mechanism. Four wheelers usually face difficulty during sharp
turns. This project was conducted to change the direction of headlights based on the direction of
the steering. I had used adaptive headlights for this project. I assisted my team members to fit

reflectors on both the sides of headlamp casing. We used hydraulic linkages to transmit power
for moving the reflectors.
CE 3.2.2 Objectives developed for the project
The main objectives of this project were to:
 To develop a steering-controlled-headlight-mechanism
 To improve the lighting system of automobiles
 To enhance the movements of automobile headlights at sharp turning points
 To provide the vehicles with illumination front-view for helping the drivers to
take proper turns on hilly areas
 To reduce road accidents due to ineffective lighting and make an accident-free
nation
CE 3.2.3 My area of work
Being the team leader, my main area of work was to monitor the activities of the project
team members. I had to understand the scope and objectives of the project before initiating the
project activities. I had to study in details about the rack-and-pinion steering gear mechanism for
effectively carrying out this project. I had to explain the mechanism of steering system and
provide technical training to the project team members for ensuring success of the project. I had
to report to the project supervisor about any discrepancy between the project plan and actual
activity carried out. One of my main areas of work was to detect any inaccuracy or defect in the
design and develop effective solutions for rectifying the faults. I also had to prepare project
reports and PowerPoint presentation for this project.

CE 3.2.4 Project Group
Figure 1: People involved in the project
CE 3.2.5 My responsibilities throughout the project
The project supervisor had given me the responsibility to get an insight into the problem
statement and the main motive of the project. I had to research on steering mechanism and
various components of an automobile for connecting the headlights with the steering. I had to
understand the functions of rack-and-pinion gear and provide a presentation on it to the team
members for clarifying their doubts. I had to identify the most conventional arrangement of
steering. I was responsible for carrying out the mechanical design of the system. It was my
responsibility to identify the parts to be designed and the parts that need to be bought. I had to
ensure accurate problem design analysis. One of my main responsibilities was to carry out the
mathematical calculations for designing the frame, rack-and-pinion gear and main spindle. It was
my responsibility to select the motor. I was responsible for ensuring high quality of the final
ProjectSupervisorProjectTeamLeader(ME)Teammember2Teammember3

system developed by us. Being the team leader, I had to ensure completion of the project work
within a specified time.
CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the Theory of the project
The rack-and-pinion steering is a simple mechanism that is being used in various
vehicles. The rotational motion of steering wheel can be converted into linear motion by the
rack-and-pinion gear. The linear motion helps in turning the wheels. The rack-and-pinion gear
helps in providing gear reduction that makes it easier for turning the wheels. In our project, lead-
acid batteries of 12 volts were used. The output of the limit switches was connected to DC
motors. The concept of steering-controlled-headlight-mechanism gives certain benefits such as
increase of fuel-efficiency, low-level steering torque and flexible steering system.
Figure 2: Steering Mechanism System

CE 3.3.2 Engineering Knowledge and Skills applied in the project
I have utilized my knowledge of steering mechanism and steering system for
accomplishing this project work. My excellent understanding of the working mechanism of
steering components such as steering wheel, manual gearbox, steering knuckles and wheel
spindle has helped me to appropriately carry out the project activities. I have utilized my rack-
and-pinion gear knowledge for achieving the objectives of the project. My exemplary designing
skills have been utilized for carrying out the mechanical design. I have applied my technical and
engineering skills to carry out appropriate calculations and to determine appropriate technical
specifications. I have also used my technical skills for preparing the technical documents after
the completion of the project. I have also utilized my computer skills for carrying out the design
on CATIA software.
CE 3.3.3 Accomplishment and task performed
The accurate project schedule and plan that was developed by me helped to complete the
project without any delay. I was able to develop my engineering as well as leadership skills
while working on this project. The initial step taken by me was to start with the detailed study of
the steering mechanism. After the research study, I explained the project team members about
the components of the steering system along with the project objectives. I had used CATIA
software for creating a three-dimensional design. After the mechanical design phase, I tested the
system for identifying defects. I had properly monitored the project phases that helped in
completing the project within the given time.

Figure 3: Rack Steering Gear
CE 3.3.4 Identified issues and their solutions
CE 3.3.4.1 Issues
There were faults in the mechanical design. The project team members had made
calculation errors while designing the frame and rack-and-pinion gear. The choice of rack and
pinion was not correctly done. Moreover, there was conflict among the team members. They did
not want to cooperate with one another and this led to the delay of some of the intermediate
phases of the project.
CE 3.3.4.2 Solution
I had identified the defects in the design and proposed innovative solutions for rectifying
the errors by using the CATIA software. I had applied my numerical skills to quickly correct the
calculation mistakes that affected the design of the frame as well as the rack-and-pinion gear. I
had made a correct selection of the rack and pinion having the same material and modulus that
could produce maximum lateral displacement of wheels. Being the project team leader, I had
conducted group discussions and meetings for resolving the conflict. The group discussion
sessions played a significant role in enhancing the coordination among the team members. I had

revised the project plan and schedule for covering up the delay that occurred in the intermediate
project phases.
CE 3.3.5 Plan to produce creative and innovative work
My main focus was on the front wheel of the steering system. I had found the most
conventional arrangement of steering to be hand-operated. I had used my innovative concepts to
use the rack-and-pinion gear mechanism where the pinion is turned by the steering wheel. The
circular motion is converted into linear motion when the rack is moved by the pinion. I had used
lead-acid batteries and a couple of limit switches in this project. I had connected the outputs of
the switches to DC motor. I made use of the DC motor for moving the wheel in the correct
direction depending on the rotation of the DC motor.
CE 3.3.6 Collaborative work
Collaborative activities have led to the success of the project. Being the team leader, I
had motivated the team members to coordinate and cooperate with each other for getting
effective result. Before starting with the execution of the project activities, I had trained the team
members and enhanced their technical competencies. The project supervisor was supportive and
helped me to easily carry out the project activities.
CE 3.4 Project review
CE 3.4.1 Project overview
This project was about developing a steering-controlled-headlight-mechanism for
improving the lighting system of the automobiles. The primary objective of the project was to
reduce the accidents across the nation. My team was successful in achieving the objectives of the
project through collaborative activities and effective planning.

CE 3.4.2 My contribution to work
I delivered accurate project reports along with technical documents that helped the
project supervisor to get an insight into all the project activities at a quick glance. The
PowerPoint presentation prepared by me helped to clarify the doubts of the team members. I
ensured timely completion of all the project activities by motivating and guiding the team
members. The research work carried out by me helped in effectively identifying the needs and
technical specifications of the project. I made appropriate use of project management tools such
as MS project for preparing an effective project schedule. I was able to rectify the mechanical
faults in the design. The calculation errors were also rectified by me. I had played an active role
throughout the project and solved complex engineering problems for achieving project success. I
was able to maintain an ethical conduct throughout the project. My technical and professional
skills have been enhanced while working on this project.