presentation - atv

To design and fabricate an eco-friendly all-terrain vehicle

MAJOR PROJECT - MECHANICAL ENGINEERING

PREPARED BY –AMANDEEP SINGHPIYUSH PARMARPRAKHAR KIYAWATROHIT SONI

SAKET GUPTAVIKAS LODHI

GO GREENPROJECT GUIDE –Dr. KESHAVENDRA CHOUDHARY

OBJECTIVE The purpose is to design and build a prototype of a rugged, single seat, off road, ‐

eco-friendly recreational vehicle intended for sale. The vehicle is safe, easy to transport, easy to maintain and fun to drive. An ATV negotiates rough terrain in all types of weather without damage.

DEPARTMENTS INCHARGE

DESIGNING of ROLL CAGE Prakhar Kiyawat, Amandeep Singh, Rohit Soni

ANALYSIS of ROLL CAGE Prakhar Kiyawat, Vikas Lodhi

FABRICATION of ROLL CAGE Saket Gupta,Rohit Soni

ENGINE and TRANSMISSION Vikas Lodhi,Saket Gupta

STEERING and SUSPENSION Amandeep Singh,Saket Gupta Prakhar Kiyawat

WHEELS and TYRES Amandeep Singh, Vikas Lodhi

BRAKES and CONTROL SYSTEMS Rohit Soni, Vikas Lodhi

ECO-FRIENDLY SYSTEMS Piyush Parmar , Saket Gupta

AESTHETICS and GRAPHICS Prakhar Kiyawat, Piyush Parmar

COST REPORT and BOM Saket Gupta, Amandeep Singh

DESIGNING of ROLL CAGEDESIGNING SOFTWARE :PRO-E WILDFIRE 5.0

MATERIAL : Mild Steel IS 1239Carbon Content – 18%

TYPE : Tubular Pipe

SPECIFICATION MEASURE

OD of Tubular Pipe 25.40 mm

ID of Tubular Pipe 19.30 mm

Overall Length – ATV 2490 mm

Overall Width – ATV 1575 mm

Wheel Base 1651 mm

Wheel Track – Front 1295 mm

Wheel Track – Rear 1372 mm

Height of ATV 1448 mm

ANALYSIS of ROLL CAGEANALYSIS SOFTWARE –

ANSYS 11

FRONT IMPACT ANALYSISModel: Full model

(Coordinate Generated)Loading : 8000 N on frontMax. Stress : 214.82 MPaMax. Displacement: 0.965E-03 inFactor of safety : Incorporated FOS

Ultimate Stress/Max Stress= Syt / Smax = 450/214.82 = 2.09

F.O.S. > 2Design is safe.


ANSYS 11

REAR IMPACT ANALYSISModel: Full model


Ultimate Stress/Max Stress= Syt / Smax = 450/188.18 = 2.39



ANSYS 11

SIDE IMPACT ANALYSISModel: Full model


Ultimate Stress/Max Stress= Syt / Smax = 450/161.86= 2.78


ENGINELOMBORDINI LGA 340cc engine is used for the ATV.

WHY THIS ENGINE:

The specifications of this ENGINE fulfills the requirement of our ATV.

The size and shape of the engine is compatible with the design of our vehicle.

ENGINE - LGA 340 Lombardini Kohler

Type Single Cylinder, 4- Stroke, Spark Ignition Engine

Bore x Stroke 84 mm X 64 mm

Displacement 338 CC

Compression Ratio

8:1

Rated Power 8 KW @ 4400 RPM

Max Torque 19 NM @ 3000 RPM

Lubrication Forced Lubrication Vane Pump

Lube Oil 15W40 CF4 Multi Grade Oil

Lube Oil Capacity

1.7 litres

Starting System Electric Start with Auto - Decomp on camshaft

Electric System 12V, 18 Amps Flywheel Mounted Alternator

Recommended Battery

12 V, 44 Ah

Weight of Engine 30.5 Kg

TRANSMISSION Mahindra Alfa Champion transmission having constant mesh type gear

assembly is used. It is a transaxle unit. A transaxle is a major mechanical component that combines the functionality

of the transmission, the differential, and associated components of the driven axle into one integrated assembly.

It is having a 4+1 gear box assembly.

WHY THIS TRANSMISSION:

Desired gear ratios for the ATV are very similar to the gear ratios of this transmission.

Low weight due to transaxle unit.

Excellent performance on rough conditions.

Cheap and easy service.

STEERING SYSTEMRACK and PINION STEERING SYSTEM is used in the ATV.

WHY RACK and PINION ?

Greater Steering Ratio.

Simple Mechanism

Light in Weight and Occupies less Space

MODIFICATIONS DONE:

Turning Radius Reduced.

Steering Effort Reduced.

SPECIFICATIONS Measure

Rack Travel (end to end) 10 cms

Steering Ratio 19.44 : 1

Minimum Turning Radius 3.13 mts

SUSPENSIONSINDEPENDENT UNEQUAL DOUBLE A-ARM WISHBONE SUSPENSIONS are used in the ATV.

Why this Suspension ?Better Stability.

Larger Wheel Travel.

Adjustable Camber and Caster angles. Better control over parameters as camber angle, caster angle, toe pattern, roll center height, scrub radius, scuff.

SPECIFICATIONS

Front Suspension Angle 62.3 deg

Rear Suspension Angle 42 deg

Ground Clearance 20 cms

WHEELS - TYRESREAR WHEELS and TYRES:

•BAJA TRAX tubeless tyres used.•Tread pattern such so as to increase traction.•Tyre Rating – 25 x 8 x 12

FRONT WHEELS and TYRES:

•Tubeless front tyres used of smaller radii.•The turning effort is reduced.•Increased Stability.•Tyre Rating – 145/70 – R12

BRAKESAll 4 wheels are Calibrated with DISC BRAKES.•Disc brakes dissipate heat better (brakes work by converting motion energy to heat energy).•Disc brakes also perform better in wet weather, because centrifugal force tends to fling water off the brake disc and keep it dry.•Under severe usage, disc brakes take longer to lose effectiveness (a condition known as brake fade).

GO GREEN – ECO-FRIENDLY SYSTEMSFUEL TANK NECK ASSEMBLY (FTNA)©

FTNA is an assembly of 2 concentric cylinders fixed over the inlet of fuel tank which helps in reduction of evaporative losses due to refueling in motor vehicles.

Since there is no unburnt fuel emission in the atmosphere during vaporization, thereby increasing the safety of the vehicle and the personnel.

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0.5Hrs.

1 Hrs. 1.5Hrs.

2 Hrs. 2.5Hrs.

3 Hrs. 3.5Hrs.

4 Hrs. 4.5Hrs.

Cylinder w ith opening Dia. 2.5 cm

Cylinder w ith opening Dia. 1 cm

3D Model of FTNAGraph shows reduction in fuel quantity that evaporates over interval of 30 minutes.

CATALYTIC CONVERTER• A catalytic converter is a device used to reduce the toxicity of exhaust

emissions from an internal combustion engine.

• A catalytic converter provides an environment for a chemical reaction wherein toxic combustion by-products are converted to less-toxic substances.

• A two way bed catalytic converter is used in our ATV which reduces hydrocarbon and carbon monoxide emissions.

The catalytic converter consists of the following components:

• Core or Substrate – Ceramic/Stainless Steel Honeycomb structure .• Washcoat – used to make converters more efficient, often as a mixture of

silica and alumina.• Catalyst – Platinum, Palladium, Rhodium.

SAFETY – PRIME IMPORTANCESafety is the primary consideration in the design of the ATV and we have included safety considerations in all parts of the Vehicle and the Driver:

•All elements of Roll Cage Dimensions meeting conformance to SAE.•All Sub Systems incorporated are according to SAE Rules.•All Safety equipment are SFI 3.3 Rated.•Fasteners – SAE Grade 5, 6, 7 and 8.•Safer Fuel Tank Assembly.•Steering Lock.•Firewall.•Kill Switch.•Lock Nuts.•5 restraint harness system incorporated for the safety of the driver.•5 seconds evacuation off the vehicle.

CONCLUSION• We have managed to successfully design, fabricate and test

our All-Terrain Vehicle.• We gave foremost importance to the Safety measures.• EMA is an environment friendly vehicle and can withstand

high values of load.• EMA negotiates rough terrain of all types and passed all the

tests very efficiently including the– Engine Test– Emission test– Brake Test– Acceleration Test– Hill Climbing Test (Angle of hill - 45 degrees)– Maneuverability Test– Endurance Test

• Thank you for giving us your precious time and listening to us so patiently.

presentation - atv

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