53718_teamurjaretrofitted

8/3/2019 53718_TEAMURJARETROFITTED

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3D VIEW OF OUR ATV



TECHNICAL SPECIFICATIONS

ROLL-CAGE MATERIAL SAE-1018 one inch dia.o.24 wall thickness

OVERALL DIMENSION (L×W×H) INCH 86.40×63×61

ENGINE LOMBARDINI LGA340CC-11HP

BRAKES DISC BRAKE IN ALL 4 WHEEL

SUSPENSION FRONT AND REAR BOTHDOUBLE WISHBONEINDEPENDENT CONTROL ARMS

TYRES ATV COMPATIBLE,RADIAL 12.5 INCH

TARGETED WEIGHT 320 KGS.(APPROXI)

FUEL TANK CAPACITY 6 LITERS



PROJECT PLAN



SIDE IMPACT STRESS FRONT IMPACT STRESS

REAR IMPACT STRESS ROLL OVER STRESSS

FEA ANALYSIS

TYPE OFIMPACT Equ.STRESS DEFORMATION FACTOROF SAFTY

SIDE 161 2.6mm 2.79

FORNT 209 MP 3.4mm 2.37

REAR 189.5MP 2.6mm 2.15

ROLLOVER 220.9MP 4.9mm 2



5 Aspects of ErgonomicsCHASSIS MOCK-UP

1. Safety –

2. Comfort –

3. Ease of use –

4. Productivity/performance –

5. Aesthetics –



STEERING KNUCKLE DESIGN ASSEMBLY

CNC machined Sailma 350 HI upright.

Loading : 3G Vertical

Factor of Safety: 2.25.

Upright Analysis:



Materials used

COMPONENTS MATERIAL

Roll cage SAE 1018

Control Arms SAE 4130 Chromoly

Side Impact Members Fibre Reinforced plastic

Firewall Aluminum checked sheets

Knuckle , Brackets SAILMA 350 HI

Welding For Roll Cage – MIGFor Control Arms- MIG with HeatTreatment

Spring Suspension Oil tempered Wire (Chromosilicon vanadium )



DFMEA

Critical ComponentsDesign Process Followed

Roll Cage Front , Side , Rear and Roll overimpact analysis done andmodification done accordingly

Knuckle Design And analysis done andmaterial changed accordingly

A-arm Material chosen of high strengthand design is done according todimensions

Brake Disc Brakes used according to theload

Suspension High strength material is chosenaccording to the load on designedspring.



========



SUSPENSION SYSTEM

Parameter Sym

bols

Front

Spring

Rear

Spring

SpringIndex

C 6.3 6.3

WireDiameter

D 1mm 10mm

Coil

Diameter

D 63mm 63

mm

No. OfTurns

N 8 6

Pitch P 23mm 30 Mm

L/D Ratio L/D 3.3(safe)

3.7(safe)

Suspension’s spring result:-

Parameter Load Deflection

Front 548 N 16mm

Rear 1020N 23 mm

Parameter Load Deflection

Front 3288 N 99 mm

Rear 5100 N 115 mm

Static Condition:- Dynamic condition:-

Parameter Ground Clearance

Static 203 mm

Dynamic 88.2mm

Stiffness Obtained:-Front :- 49.6 N/MmRear :- 66.2 N/Mm

Actual Damping Coefficient In Front Is0.039 Ns/Mm, & In Rear Side Is

0.073ns/Mm

Position Wheel Travel

Front 8.03 Inch

Rear 10.6 Inch

INDEPENDENT DOUBLE WISH BONE SUSPENSION ,WE CHOOSE IT AS PER OUR DESIGNREQUIREMENT AND BETTER HANDLING CONDITION .



Motion ratio;- shock travel ,

PAPARAMETER FRONT REAR

Motion ratio 0.485 0.423

Wheel travel

Wheel rate :- stiffness× (motion ratio)^2

Parameter Front Rear

wheel rate 11.66 N/mm 11.84 N/mm

MR = l / T~ d1/d2

d1=distance from chasisd2= distance from hub

l=shock travelT= wheel travel

SPRUNG & UNSPRUNG WEIGHTSUn sprung weight represents a significant portion of the total weight of the vehicle.In standard-size ATV, the weight of un sprung components is normally in the rangeof 13 to 18 percent of the vehicle sprung weight. In our case total weight is

320kg & un sprung weight is 44kg .The ratio of unsprung by sprung weight is15.5% thus it lies in the design limits for maximum driver

ergonomics.

The formula tell us that the closer the bottoms of the shocks are mounted tothe middle of the chassis, the softer the wheel rate will be if the lower shockmounting location is changed then both the shock angle and the motion ratiochangesamount of suspension travel also changes, which can also affect thecar's handling.



ADJUSTABLE CAMBER MECHANISMBUSHING MECHANISM

A – Arm

Specification

Parameters Front side Rear side

Length 195.58 mm 236.98 mm

Width 127mm 127 mm

Suspensionmounting

At lowerarms

At upper arms

Distance fromchassis

137.6mm 99.6mm

we have design upper arm is small as compared to lower armdue to which steering handling is comfortable & easily handle.Rear suspension are mounted at a distance of 99mm from thechassis and the front suspensions are at 137.6mm i from the

chassis end.



BRAKING SYSTEM• URJA RETROFITTED Virtual equipped with a hydraulic braking system that

acts on all four wheels by disc brake and is operated by a single foot.• At the time of braking almost 65% weight reaction is transfer to the front

side and 35% to the rear side.

Disk Brake Specification Disc Brake Result

Outer Diameter230mm

Brake Force2800N

Inside Diameter75mm

Brake Torque57.4N-m

Disc Thickness11mm

Brake Pressure0.15MPa

Weight transfer during brakingWeight of the vehicle 320kg

Height of the C.G 420mm

Coefficient of friction 0.7

θ, inclination Depends on road profile

Distance of C.G fromrear

430mm

Distance of C.G fromfront

810mm

Wheel base 1240mm

Speed(kmph)

BrakingDistance

BrakingTime (sec)

40 7.05m 1.2

45 8.92m 1.4

50 11m 1.58

At 50kph our vehicle stopped at 11m takes

1.58 seconds.This is equal to 19 kilowatts.

And Braking Efficiency will be 89%.



Gear Ratio Speed (kmph)

(@ 3600 RPM)

31.48:113.67

18.70:1 23.04

11.40:1 37.80

7.35:1 58.64

R- 55.08:1 7.8

TRANSMISSION

• TRANSMISSION : Mahindra & Mahindra ALFA

( Constant Mesh Type )

• CONFIGUATION : 4 Forward, 1 Reverse

• COUPLING : Flange Type

• MAX. SPEED : 58.64 kmph at 4th Gearand 3600 RPM

• WHEEL SIZE (in.) : 25 X 8 – 12

• JOINTS : Constant Velocity (C.V.) Type,U- Joint, Ball Joint

• ACCELERATION : 0- 60 kmph in 8.13 secs

• MAX. TORQUE : 525.23 Nm @ Ist Gear

• LENGTH OF HALF- : 762.3 mmSHAFT

IMPLEMENTATION PLAN FOR



IMPLEMENTATION PLAN FOR

B & S ENGINE WITH POWERTRAIN

Disc Thickness10 mm

6 Holes10 dia

8 Holes8 dia

• As per our plan we will couple the B & S

Engine and the M & M Alfa transmission by ashaft whose one end fits onto the 3” output

shaft of engine and the other end fits inside thetransmission.

• Next, we mount a plate in between the engine

and transmission of 10 mm thickness.(O.D. =140mm and I.D. = 70mm).Overall Length = 198.3 mm

• The plate is bolted to the engine by 8 bolts(Ø 8mm) and the transmission is bolted then

by 6 bolts (Ø 8mm) onto it.

Figure 1

Figure 2



STEERING DESIGN

• Length of rack is 5.4 inch• Rotation completed by pinion in 3.125 turns• Effort of 20 N is applied by each hand onsteering wheel

By the stability point of view rack and pinion gearsystem is more stable as compare to worm and roller,because it has involutes teeth profile therefore themeshing of teeth is better as compare worm and roller

type of steering gear system. Rack and Pinion systemhas been used as muscular energy system. It is used forits simplicity as there as few parts, low cost, lightweighted, occupies less space so more suitable forcompact vehicles and also because it is stiff and preciseas compared to the re-circulating ball nut integral gear.

Geometric consideration• Caster angle is 3.• kingpin inclination is 10.5

Steering Specification Dimensions

Rack of steering 5.4 inch

Tie rod right 9 inch

Tie rod left 15.74

Wheel base (b) 55 inch

Wheel track (a) 56 inchRadius of steering wheel 6.1 inch

Inner turning angle 35

Outer turning angle 23.26

Turning radius 4 m

Steering ratio 22:1

Load transmitted to tie

rod

880 N

RESULT :-



Magnetic fuel saver

• Decrease the intermolecular force ofattraction• proper mixing of fuel takes place• efficiency increases• reduction of waste gases

Three way catalytic converter•Convert toxic exhaust emission intonon toxic substance

Important reactionsReduction of nitrogen oxides to nitrogen and

oxygen 2NOx → xO2 + N2 Oxidation of carbon monoxide to carbon dioxide:2CO + O2 → 2CO2 Oxidation of unburnt hydrocarbons (HC) tocarbon dioxide and water: CxH2x+2 + [(3x+1)/2]O2 → xCO2 + (x+1)H2O

EXHAUST AND INNOVATION -1



Components Specification

Voltage ComparatorIC

CA3140

Timer IC NE555

Diode 1N4007

Resistance 10k,100k,470k

Capacitance 0.1µ,10µ,100µ,1000µ

Buzzer and LED’s

Voltage Supply 12V from Car Battery

This System Is Based On Measuring ThePressure Drop At The Break Switch Which AreUsed To Operate The Rear Break Lamps.

When There Is A Pressure Drop In The BreakSystem Due To Leakage There Is A WarningIndication To The Driver. Because Due ToPressure Drop The Circuit Not Get The 12v

Supply From Battery And A Red Led GlowsAnd A Buzzer Sound Is Activated ByMonostable Circuit Used In The System.

1.This System Monitors & Provides An IndicationEvery Time The Breaks Paddle Is Pressed.

2.This System Can Be Easily And EffectivelyIntegrated Into The Vehicles To Provide TheAdvantages.3.This Approach Will Not Only Maximize TheEffectiveness Of Vehicle But Also EnsuresFunctionality And Performance Of Vehicle Is FullyOptimized4.As This System Is Powered From Car Battery So

No Need Of External Power Source.

INNOVATION-2



THANK YOU!!

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