Two Wheeler Milage Testing Machine

Two Wheeler Mileage Testing Machine

“ABSTRACT” There have been major developments in the field of two wheelers with respect to every aspect of the vehicle. One of the major aspect of the vehicle that is responsible for making vehicle more famous and popular is the mileage of vehicle. This project was undertaken with an objective to test the average of vehicle in showrooms and service centers. The machine was fabricated and assembled according to design, with flexible features. By standing the vehicle on main stand and within 10-15 min. we can find the mileage of the vehicle with high accuracy. The machine was tested and found to work as expected.

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Two Wheeler Mileage Testing Machine

“INTRODUCTION” We, the final year production engineering students have designed and fabricated a very useful project namely "Two wheeler mileage testing machine". Thus it is as excellent opportunity given to us, we also have utilized this with adequate interest, initiative, self-motivation and self confidence. The project "Two wheeler Mileage testing machine" is intended to be employed at two wheeler service stations, as well as manufacturers and Pre delivery inspection section (PDI). Mileage is as important term used with respect to any vehicle Mileage is the average distance traveled by a vehicle consuming one litre of fuel. As far as economy is concerned, the mileage of vehicle should be maximum. The need of mileage testing machines arises from following points. 1) The manufacturer must know the fuel efficiency of vehicle at standard conditions as well as at loading conditions. 2) In the service station, after the service of vehicle it is necessary to know the average of the vehicle .Instead of, leaving it to customer to run it until one litre of fuel is burnt after a heavy long run. This machine consumes just 50 ml fuel and within a period of 5 minutes at certain specified conditions i.e. creating on road load conditions, the mileage is known to us. The creation of loads includes the load of vehicle, driver, load due to air resistance, road friction etc.

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Two Wheeler Mileage Testing Machine

At present, the service station persons, use the mileage testing machine for which the vehicle is made to run on the roads. Whereas in this project the machines calculates the mileage, making the vehicle on the service table itself. The cost of machine is so low that even a small service station owner can affect to use it. For good mileage the running of the vehicle should be perfect for the setting of running the service run has to rely on the customer information. So accordingly he carries the running adjustment. On vehicle by using trial and error method. The results, he obtained are probabilistic in nature.

To convert probabilistic measures to actual,

implement the same practically. This is an attempt for service station to be aware of mileage testing, there after running of vehicle to improve fuel economy.

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Two Wheeler Mileage Testing Machine

“Market survey/ research for materials & equipment.” The concept of market survey has a great importance in the field of conceived product, as it facilities or aids of to judge the market for our product and its future existence. It determines who and where the customer is what are his needs and wants, what will lay for it. Market research also uncovers the future of existing product and the products yet to be introduced into the market. For the part 5 decades, market research has got immense popularity and has resulted in gaining higher market shares. The procedure of market survey must include the following steps : 1. Defining the objective of the product clearly. 2. Developing a clear set of research objectives. 3. Data collection from existing and future consumers about their needs / requirements. 4. Extracting meaning - full data from collected information 5. Using the findings of survey in developing the product. So, in the view of aforesaid important points, it is quite evident that for launching /marketing a new concept in the market, survey research is very essential. As far our project titled "Two wheeler Automobile mileage testing machine is concern, we conducted a through survey in Akola and the adjoining areas. From this survey we concluded that our product (i.e. M.T.M/c) has got immense scope in market as it has got distinctive features for its promotions. The main advantage with our product lies within that, it can efficiently test the average or mileage of any two wheeler

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Two Wheeler Mileage Testing Machine

(Automobile) when erected on its main stand that too with just 25-50 ml of fuel and takes a few minutes to do the job. In our market survey, we went to various show rooms of two wheelers like Bajaj (Krishna Motors), Hero Honda (Baheti Sales & Service) TVS (Prakash Enterprises) and a few service station. Except the Bajaj Show room, none of them had this facility for mileage testing. Their managers /owners should a great interest in our project and they were all convinced with our new design features and various modifications mode in the existing machine available in market. The main disadvantages with the equipment or machine available in market lies in its big size difficult in operation, high noise and low transmission ratio. We in our project have tried to minimize all these draw backs by redesigning the whole structure, making suitable adjustment to reduced noise and increase transmission ratio.

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Two Wheeler Mileage Testing Machine

"BASIC PRINCIPLE" The basic principle of two-wheeler mileage testing machine is that the rear wheel of the vehicle is placed in touch with the first idler. This idler will rotate due to friction between the idler and tyre. This first idler revolution is transferred. On second idler via belt and pulley arrangement. The r.p.m. of the rear wheel of the vehicle. The loading conditions are created by encovering the second idler with belt and spring weight arrangement on it.

The r.p.m. of the second idler is calculated with the help of

speedometer assembly mounted on shaft of second idler. So that we can take the readings of the distance traveled and also the fuel consumption is known to us. So average output of vehicle per litre of fuel can be calculated by. Distance traveled Average = Fuel consumed The care of rolling resistance, air drag resistance and gradient resistance are taken using belt and a weight arrangement (loading arrangement). The quantity fuel supplied can be measured using a measuring bottle of 100 ml. Hence if all variables are known to us. Average output of vehicle under loading conditions can be calculated.

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Two Wheeler Mileage Testing Machine

RESISTANCE TO THE MOTION OF THE VEHICLE A tractive effect of force is provided by engine of a vehicle at the driving road wheels. Varying at different engine speed and gear position it is mainly required to overcome the force opposing motion of vehicle. The resistance to the motion of the vehicle is called as tradre resistance. It is the sum of the three resistance that obstruct the movement of the vehicle. The resistances are i) Rolling and frictional resistances. ii)Gradient resistances. iii)Wind and air resistances.

1)Rolling Resistances :It is the force necessary to maintain the constant speed on a leveled load surface the load on each tyre inflation pressure and type of tyre treated.

2)Frictional Resistances :Frictional resistances to the motion of the vehicle reduce the speed and also induced transmission losses. These frictional resistances are calculated as, f = 66.6 + 0.012 W t = Frictional resistance in Kg. W = Total weight of vehicle in Kg.

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Two Wheeler Mileage Testing Machine

These transmission losses are generally 10% in direct gear 15.20% in low gear. For calculating performances tractive force should be emitted at efficiency at 90% for top gear and 80-85% for low gear. This also includes temp losses and the losses occurring in oil churning in the closely desired gear box and contended rear axle. For private car's it is 89-95%. The friction losses in the tyre in about two third of total losses in the chasis.

3)Air and Wind Resistances :The air and wind resistances for two wheelers are negligible. Generally it depends on speed of vehicle, wind velocity, size and shape of the body of the vehicle. It is calculated from formula Pn 2 sin φ Pn =

(For the head on the direction of the wind)

1 + sin2φ

Pn = KV2A

(For the same following direction of wind)

where K = Coefficient of air resistance A = Projected area in m2 V = Velocity of the vehicle in Km/h φ = Angle between direction of vehicle and direction of wind Pn & Ph = Air resistance.

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Two Wheeler Mileage Testing Machine

“DESIGN” DESIGN OF SHAFT :The heaviest two wheeler vehicle in Indian Market "Enfield Bullet" 500cc Gross weight : 165 kg. Max. weight of single rider 90 kg. Load of idler = 165 kg + 90 kg = 255 kg. Considering Factor of Safety : 2 Load on idler = 255 x 2 = 510 kg. There are two idler Load on each idler = 510/2 = 255 kg. Idler is supported two Bearing ends Load on each Bearing = 255/2 = 127.5 kg Max. B.H.P. of Bullet = 18 B H P at 5625 r.p.m. Taking factors of safety = 2 B.H.P. = 18 x 2 = 36 H P Power transmission = 36 x 746 = 26856 W ∴ P = 26.85 k w

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Two Wheeler Mileage Testing Machine

load on Each Bearing = 127.5 kg. = 127.5 × 9.81 = 1250.77 N The power is deliver at 5625 r.p.m. i.e. 6000 r.p.m. We know that Power transmission P= 26.85 × 10 3 =

2πNT 60 2 × π × 6000 × T 60

T = 42.74 N.m The max. B.M. will be B.M. (max)

= 1250.8 × 0.137 = 171.3 Nm

M

= 171.3 Nm

Now , Te = M 2 + T 2 =

(171.3) 2 + (42.74) 2

Te = 177.21 Nm Diameter of the shaft Taking fs = 56 N/mm2 Te =

π fsd3 16

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Two Wheeler Mileage Testing Machine

∴

d3 =

=

16 × τ e π × fs 16 × 177.21 × 10 3 π × 56

d = 25.25 mm Say 30 mm Design of Idler 1) We select outer diameter of Idler D=137 mm std. 2) Width of pulley rim B = 1.1b + (15) mm = 1.1 × 137 + 15 = 166 mm 3) Thickness of the rim (s) S = 0.005 × 137 + 3 mm =3.68 mm say 5 mm 4) Diameter of Hub d1 = 2 × d = 2 × 30 = 60 mm 5) Length of Hub

L=2×d = 2 × 30 L = 60 mm

6) Thickness of Hub

= 10 mm std.

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Two Wheeler Mileage Testing Machine

FOR MOTOR CYCLE :Design of pulleys :Function :- The power from first idler to second is transmitted with the help of pulleys and belt. For Motor - cycle The diameter of rear wheel of motorcycle d1 = 630 mm. The diameter of first idler = d2 = 137 mm The r.p.m. of rear wheel = N1 = 420 rpm RPM of idler will be N1 d1 N2 = d2 420 × 630 = 137 N2 = 193 1.38 N2 N1

= 1931.38 = 4.59 420

Velocity ratio of pulleys should = 4.59 Taking pulley A on first idler of diameter d1 =65 mm R.P.M. of pulley B on second idler = N4 + 420 r.p.m. ∴Diameter of pulley B = d4 = N 2 d3 N4 = 1931.38 × 65 420 = 282.38mm

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Two Wheeler Mileage Testing Machine

For Scooter :The diameter of rear wheel of scooter

D1 = 480 m

The diameter of first idler D2 = 137 mm R.P.M. of rear wheel = 580 rpm RPM of Idler will be N ′2 =

=

N1′ × n 1 D2 580 × 480 137

= 2032 rpm The V.R. of rear wheel of scooter and idler will be N ′ 2032 = N 1′ 580 = 3.5 Pulley A on first idler diameter D1 = 65 mm RPM of pulley 'C' on second idler N4' = 580 rpm RPM of pulley A on first idler N3' = 2032 rpm ∴

D4 =

N ′3 D 3 N ′4

∴

D4 =

2032 × 65 580

D4 = 227.7 mm say 230mm Belt suitable for this power transmission is B -56 Design of Key We know

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Two Wheeler Mileage Testing Machine

Fs = 40 N/mm2 Fc = 80 N/mm2 T = 42.74 Nm = 42740 N mm l = 80 mm W = 8 mm D = diameter of shaft = 25 mm 1. Considering shear failure of key T = l× W × Fs × d/2 42740 = 80 × 8 × Fs × 25/2 ∴ Fs =

42740 × 2 80 × 8 × 25

Fs = 5.34 Since Fs = 5.34 ≤ 40 N/mm2 ∴ Design is safe. (ii) Consider Crushing Failure of key We know

Fc = 90 N/mm2 t = 6 mm T=

π d × d 2 × stress × 4 2

t d = L × × f C2 × 2 2

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Two Wheeler Mileage Testing Machine

T t d ∴ for = L× × 2 2 =

4×T L× t×d

=

4 × 42740 80 × 6 × 25

= 14.24 N/mm2 Since for = 14.24 N/mm2 ≤ 80 N/mm2 ∴ Design is safe. (iii) Resisting Area =

T×2 Fs × d

d1 = Bolt diameter π T×2 2 × d1 = 4 Fs × d 2

d1 =

=

2×T× 4 π × fs × d 2 × 42740 × 4 π × 40 × 25

2

d 1 = 108.83mm d1 = 10.43 mm ≅ 12 mm (say) ∴

Design is safe

Considering crushing failure of bolt. T = Resisting area x fcr x d/2

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Two Wheeler Mileage Testing Machine

π d × d 2 × fc r × 4 2 fc r =

=

T×2 Re sisting area × d 42740 × 2 π × 12 2 × 25 4

fcr = 30 N/mm2 Since

fcr = 30 N/mm2 ≤ 80 N / mm 2

Design is safe

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Two Wheeler Mileage Testing Machine

“fabrication & assembly” Materials Required S r.N o. 1.

2.

3.

4. 5.

6.

Particulars

Quantity

Size (mm)

Length (mm)

Angle

2

50 × 50 × 5

860

Angle

2

50 × 50 × 5

200

Angle

1

Square pipe

2

50 × 50 × 5 22 × 25 × 2

Square pipe

2

25 × 25 × 2

Square pipe

4

Round pipe

1

Round pipe

1

Pedestal bearing Idler I

4 1

Idler II

1

Pulleys

V-belt Flat belt Spring Petrol pipe Measuring bottle Plywood

460 515 90 355

φ 25 6206 φ137

305

160

1

φ137 φ280

1

φ230

1 7. 8. 9. 10. 11. 12.

35 × 35 × 3 φ 25

350

1 1 1 1 1 1

φ65 B-56 2" 0 -100 Kg. 100 ml. 355 × 300 × 6mm

2

355 × 150 × 6mm

3

_ 130

1800 mm 2 ft.

460 × 355 × 4 mm

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Two Wheeler Mileage Testing Machine

13. 14. 15. 16. 17. 18. 19.

Speedometer assembly Nuts & bolts for Pedestals Nuts & bolts for plywood Screws for plywood Red oxide Colours Grease

1 8 6 4 1 2 1

Luna M-12 M-6 _ 200 ml. 500 ml 250 gm

60 mm. 25 mm _ _

Fabrication FRAME STRUCTURE :Two 860 mm angles are welded with four rectangular pipes of size 35 × 35 × 3 mm and length 90 mm at the four corners of the angles at bottom for preparing base stand. The slots of size 102 mm × 38 mm are made in the angles at required places before welding base. A piece of angle of size 50 × 50 × 5 mm and length 355 mm is to be weld from the back side of the frame which has a provision of hole for tightening of bolt. A piece of angle of same size and length 350 mm. Is welded at a distance of 204 mm from one end of base as shown in fig Two pieces of same size angles and length 185 mm are then welded with the phase of both back side rectangular stands. Rectangular pipe 25 mm × 25 mm × 2 mm

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Two Wheeler Mileage Testing Machine

Two pieces of rectangular pipes of size 25 × 25 × 2 mm and have length 515 mm are welded vertically on the angles which are on ground as shown fig. After that the two pieces of same pipes of same size and of length 460 mm are welded with the vertical pipes in inclined manner and the other end is welded with the angles of size 50 × 50 × 5 mm. Round pipe :- Outer diameter - φ 25 mm. Internal dia. - φ20 mm. The pipe of φ25 mm. and length 355 mm are then welded with the topmost corner of the angles. After than one more pipe of same diameter is welded in between the two vertical angles of length 305 mm for attaching the spring hook.

FIRST IDLER ARRANGEMENT A mild steel round bar of φ 35 mm and length 510 mm is mounted on chuck of lathe. One end is drilled to depth of 5 mm. After applying grease over the hole, tailstock is held tightly with the hole, to eliminate the vibrations in shaft at the time of revolving. The chuck is made to run at 430 rpm and after adjusting centre, the shaft is turn to 30 mm diagram. Then the shaft is cut down to a length of 490 mm. A slot for key is made in the shaft from one side. A tapped hole of φ10 mm is drilled on the shaft for fixing of drum at a distance of 170 mm from one end of shaft. After that the idler and pulley is assembled with the shaft.

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Two Wheeler Mileage Testing Machine

SECOND IDLER ARRANGEMENT A mild steel round bar of φ35 mm and length 510 mm is mounted on chuck of lathe. One end is drilled from one side of 5 mm depth. After applying grease over the hole, tailstock is held tightly with the hole, to eliminate the vibrations in shaft at the time of revolving.

The chuck is made to run at 430 rpm and after adjusting centre, the shaft is

turn to 30 mm dia. Then shaft is cut down to a length of 490 mm. A slot for key is made in the shaft from one side. A tapped hole of φ10 mm is drilled in shaft for fixing of drum at a distance of 170 mm from one end of shaft.

Assembly Complete fig. of machine The prepared angle frame is placed on ground. After that firstly all the 4 pedestal bearings are fitted on the angles in their decided places, the upper cover of the bearings is removed. After that the first idler, pulley of φ65 which is already fitted on shaft is placed on the first two bearings which is then tightened by upper cover, by greasing them fully from inside. Then the second shaft on which 2 pulleys of φ280 mm, φ230, one idler drum of φ237 of length 130 and the speedometer worm wheel is already fixed is placed on the second 2 bearings, in required position. After that upper cover of bearing is tightened by greasing them fully from inside.

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Two Wheeler Mileage Testing Machine

The V-belt is then fixed on the pulleys of φ65 and φ280 with required tension in belt. After that one end of the flat belt which is attached by a bolt is tighten by the nut by inserting into the bottom hale. By taking the another end of the belt over the second idler and forwarded over the upper bar of frame and then it is inserted from the upper hook of spring weight and tightened by nuts and bolts. The lower hook of the spring weight is attached to the bottom pipe of the frame. After that the plywood of size 460 × 355 × 4 mm on which speedometer is to be fixed, is fitted to frame by screws. The remaining two plywood pieces are then fixed to angles in their required position. Then the total frame is coloured using primer (red oxide) over it. Hence the assembly of "two wheeler mileage testing machine" is ready for testing.

Material and Process Sr.No. 1

Component Shaft

Material φ 35 mm M.S.

1.

Process Turning upto φ 30 mm of length 360 mm and φ25mm of length 130 step.

2.

Keyway of size 80x8x3 mm on shaping

Idlers Frame Structures :-

C.I.

machine. φ137 and length 160 mm Knurling on lathe m/c

Angles

M.S.

Cutting and Welding

4

Plywood Pulleys

_ C.I.

Cutting according to size 1. Bore φ 25 mm on lathe m/c.

5 6 7 8

Pedestal Bearings Spring V- Belt Flat belt

C.I. Spring steel B- 56 Cotton fabric and

2. Keyway on lathe machine. Mounting on frame Readymade Readymade Drilling holes at required place

2 3

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Two Wheeler Mileage Testing Machine

9 10 11

Screw, Nuts and bolts Pipe Bearings

12

Speedometer

Rubber M.S. M.S. Standard No.

Readymade Cutting and welding Mounting on a shaft

6206 _

Readymade

“OBSERVATION AND RESULTS” Test Procedure First of all, the vehicle is led on middle (main) stand. It's carburetor is made empty and dry. 50 ml petrol is poured in the bottle and it's pipe is connected to input of carburetor. After that according to calculations loads are applied on belt over second idler. Now the vehicle is started after touching it's rear wheel to first idler. The initial meter reading is noted and vehicle is made to run at speed between 40 to 50 km/h. During this time throttle for acceleration is kept constant. After the petrol in vehicle is finished it will experience jerks, switch off the vehicle at this time. Take the second meter reading. Calculate the distance traveled by vehicle. Distance traveled = Final reading - Initial reading Hence, Mileage of = Distance traveled × 20 Km/liter For Scooter The V - belt is shifted on pulley of φ 230 and belt is tightened. Same procedure is followed.

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Two Wheeler Mileage Testing Machine

Performance Test no - 1 Model Reg. No Fuel taken Load applied Initial reading Later reading Mileage

:::::::Test No. – 2

Model Reg. No Fuel taken Load applied Initial reading Later reading Mileage

:::::::-

Test No - 3 Model Reg. No Fuel taken Load applied Initial reading Later reading Mileage

:::::::Test No – 4

Model

:-

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Two Wheeler Mileage Testing Machine

Reg. No Fuel taken Load applied Initial reading Later reading Mileage

::::::-

Advantages 1) On stand Mileage testing 2) Mileage can be tested within 25 to 50 ml of fuel 3) Ideal transmission of power. 4) Low vibrations. 5) Low cast. 6) Easy Maintenance and operation. 7) Compact in shape 8) Low weight. 9) It can be used in small service stations 10) Less skilled operator required. 11) Consuming 5 to 10 minutes.

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Two Wheeler Mileage Testing Machine

Disadvantages 1) Slippage may occur due to misalignment. 2) Friction between rotating parts is comparatively more.

Applications 1) Service stations of automobiles. 2) Show room of automobiles

Estimation Sr.No 1. 2. 3 4 5 6 7 8 9 10 11 12 13 14 15

Particulars Fabrication cost Machining Charges Pulleys Speedometer assembly Pedestals Plywood Bearing Petrol pipe V-belt Flat – belt Fastening Colours Drums Shafts Other expenses

Cost 500.00 300.00 410.00 190.00 320.00 100.00 520.00 20.00 225.00 105.00 50.00 200.00 250.00 350.00 300.00 3840

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Two Wheeler Mileage Testing Machine

“DRIVING SKILLS & MAINTENANCE” Maintenance plays an important role for proper functioning of any machine. Following care should be taken 1) Drive steadily at the optimum speed i.e. at 40-50 Kmph you will surprise to find that your frames time does not increase significantly, sudden start and stop and go driving waste fuel. 2) Use brake Springly. A good drive anticipates stop. When your slime on the brake. You waste a lot of useful energy. 3) Let go off your clutch unnecessary use of the clutch leads to loss power. 4) Clean air filter regularly. Dust leads to rapid wear of engine components and increase fuel. Consumption choked exhaust parts and silence make you engine struggle to breath causing poor combustion. 5) When your tyre pressure under inflated tyre increase rolling resistance and petrol consumption. Test show that under inflation of tyre by 25% cause a 5% increase in fuel consumption and 25% decrease in tyre life. 6) Stop fuel leaks, check your fuel task, carburettor and fuel lines daily for leaking fuel. Loss of one drop of fuel per second amounts to nearly 2000 litre per day. 7) Key off the engine if you want to stop more than 2 minutes for example at railway crossing. 8) Keep your engine in good condition. Test on a large number of vehicle show that you can save over 6% of fuel. If your engine emits smoke, check it immediately at a reputed garage.

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Two Wheeler Mileage Testing Machine

9) Use superior 27 oil for lubrication. Mix superior 27 oil consuming to intentional API/TC Specification. 10) The Speedometer cable is to be oiled and all the bearings are to be Greased periodically.

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Two Wheeler Mileage Testing Machine

“FUTURE SCOPE” We can develop the project in various ways with respect to loading arrangement for accurate measuring of loads. By attaching various electronic circuits, we can calculate mileage of the vehicle in the digital form to high accuracy. We can also attach exhaust gas analyser for analysing the exhaust gases, in this way we can also control pollution. Hence, mileage as well as (PUC) can be made known simultaneously.

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Two Wheeler Mileage Testing Machine

“BIBLIOGRAPHY” 1.

Machine design Prof. R.S. Khurmi

2.

Automobile Engg. Prof. R.B. Gupta

3.

Design data book DPV printers, Coimbatore

4.

Auto India …. Nov.2001

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