virtual baja 2012 ppt (1)

Automobiles are not ferocious....but we make them....

SRI VENKATESHWARA COLLEGE OF ENGINEERING, BANGALORE

Team

Welcome one and all for the “ Virtual BAJA event 2012” - 19-08-2011

TEAM REG. ID - 45209

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EKALAVYAS

ROLL CAGE DESIGN

3D MODELLING

-CHETAN-AVINASH-ANISH

FEA-HARSHA-SHIVARAJU-MAYUR

SUB SYSTEMS POWER TRAIN BODY &ELECTRICALS

SAFETY QUALITY

SUSPENSION-PONNAPPA-SUYASH-SANDESH

STEERING-CHETAN-BHARATH-JIBY

BRAKES-HARSHA-PROMOD

ENGINE-AVINASH-SURYA-KARTHIK

TRANSMISSION-MRINAL-AVINASH

WHEELS-PRAJWAL-SUMALYA

BODY PANELS

-JEEVAN-P. JOSHI

ELECRTICAL SYSTEM

-SEEMA-SURYA

-MAYUR

-NILADRI DAS

-ROHIT

-HARSHA

PROJECT PLAN

Team Work Breakdown flow chart -

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….2The whole project was planned and scheduled in MS Project Planner for that we made use of GANTT chart procedure the below chart shows activity against time.

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The purple line indicates the planned time & the yellow line indicates the actual time taken for each task.

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Automobiles are not ferocious....but we make them....ROLL CAGE DESIGN

IS 4923 Grade Hot rolled Structural tubes with 0.20% C content with Yield strength 310 Mpa &Ultimate strength 410 Mpa.

MATERIAL USED -

Design Methodology-

The distance from seat bottom to RHO is 1193.8mm & the point 27” from the seat bottom has 740mm width in compliance to the rule.

The Design is Done according to Bottom Up method taking driver comfort accordingly the whole Roll cage is developed & designed as per the rules.

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Automobiles are not ferocious....but we make them....….4The Final completed Roll Cage & General Assembly of the vehicle views which is ready for Fabrication.

SPECIFICATIONS - Overall Length -Overall Width -

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….5Automobiles are not ferocious....but we make them....

FEA -To check for the safety design we used FEA approach and made necessary changes in the design to obtain the desired stress values.Linear Static Analysis is carried out.

Material Properties - Elasticity Modulus - 210 MpaDensity - 7780 Kg/mm3Co efficient of Friction - 0.3

Element used -3D Elastic Beam with 6 Degrees of Freedom.

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Automobiles are not ferocious....but we make them....FRONT IMPACT TEST -....6

REAR IMPACT TEST -The Maximum deflection of 21mm is found ahead of driver’s toe i.e. near front nose.

The Maximum stress of 175.825Mpa is found on rear members of Engine compartment.

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Automobiles are not ferocious....but we make them....Roll over test -

The Maximum stress of 130Mpa is found on the members of FBM & RHO.

The type of weld used to weld roll cage is MIG welding with 60 weld joints and 85” of total weld length.

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Suspension

Front – Double Wishbone type with Unequal Arm.

REAR – Trailing Arm.

SPRING RATE

CAMBER CASTER WHEELTRAVEL

GROUNDCLEARENCE

90N/mm +VE -2 Degree

+VE-4Degree

152.4mm 228.6mm

SPECIFICATION -

KINEMATIC SUSPENSION PERFORMANCEPARAMETERS -

WHEEL TRAVEL - Length of Arm = 10” Up = 4” Down = 4”

TOE – Minimized during travel via Tie rod.

CAMBER – Camber adjustment via Heim joint.

Compression- Max –ve Drop - Min +ve


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Brakes -Front - •Specifications – 270 mm Dia Hydraulic Disc Brake.•Brake torque obtained = 550N-m•Mounting- The Rotor is mounted on Front Hub

spaced from wheel. A steel plate will be fabricated to mount Calipers.

Rear -

• Specifications – 240 mm Dia Hydraulic Disc Brake.• Brake torque obtained = 482 N-m• Mounting- The Rotor is mounted on Rear Hub.

A steel plate will be fabricated to mount Calipers which will be welded to Trailing Arm.

Pedal Force – 100N

Circuit – Diagonal type

Front Right and Rear Left Front Left and Rear Right.


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Steering

TYPE OF STEERING

GEOMETRY WHEEL BASE

TURNING RADIUS

TIE ROD LENGTH

STEERINGRATIO

STEERING WHEEL DIA

Rack And Pinion Ackerman 1.67m 3.05m 228.6mm 12:1 360mm

SPECIFICATION -

Knuckle

• It is designed so as to Interchange wheel with 4 Bolt & 2.25” radius.• Outer dia of Hub corresponds to a clearance fit with inner dia of wheel at 2.75”.• Inner dia corresponds to Press fit with Outer face of the Taper roller Bearing

• The front A-arm configuration connects upper & Lower control arm.• The tie rod is attached to Knuckle by a steering arm that controls the knuckle rotation and vehicle.

Hub


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Power train

Engine - Lombardini LGA 340 with Single cylinder , 338cc , 11 H.P, 19 N-m.

Engine Mounting - Rear engine compartment with rubber damper.

Exhaust - Standard Lombardini make having <450mm back pressure.

Fuel Tank – 6 liters capacity Honda make.

Fuel lines - SAE 30 R14 with barricade and having capacity of working pressure 50Psi.

Exhaust design


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Transmission - Mahindra Alfa Champion (Sequential Gear Box).

Gears First Second Third Fourth Reverse

Gear Ratios (G) 31.48:1 18.07:1 11.40:1 07.35:1 55.08:1

Speed@3000rpm (kmph) D=22 inches 15.80 20.02 32.20 53.95 7.70

CONFIGURATION -

COUPLING - Is done using Stock assembly.

Maximum Speed – 54 Km/hr.

ACCELERATION – Capable of accelerating through 150ft in 4 sec.

WHEEL SIZE – FRONT/REAR 22 in*8in*10in Kings Tyre is used.

FINAL DRIVE - Drive shaft of Piaggio & Maruthi 800 will be modified and used.

JOINT – A slider couple joint is used.


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AESTHETICS -

BODY & ELECTRICALS

ERGONOMICS -

ELECTRICAL SYSTEM -

WEIGHT - The approximate Unladen weight of Vehicle is 280 Kg.

• Aesthetics of the vehicle has been considered in the design stage which is aesthetically appealing.• Spot Welding in assistance with Back bar for welding of body panel to give attractive looks.• Painting & stickering the vehicle according to the theme color of our team.• Painting the individual assemblies, sub assemblies, and roll cage.

• A sliding type of seat for driver adjustment.• A 3D closed envelop for driver safety & comfort.• Vehicle is equipped with Rear view mirror.• Engine start through Starter Motor.

• Battery used – 12V 10Ah Rechargeable.• Battery is placed in Front Nose area.• Battery is mounted on OEM battery mounting plate.• Two Kill switch of Push-Pull type is used.


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Safety -

• Securely layered all tubing member in the cockpit and welded rigidly for driver safety.

• Seat belt with 5 point system.

• SAE rated brake light, Reverse Alarm ,Fuel lines are installed.

• Spill way is provided.

• Other Equipment used –

• Vehicle is Equipped with positive Wheel- Lock.

Fire extinguisher Kill switches Neck Collar, Helmet, Goggles.


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Automobiles are not ferocious....but we make them....INNOVATIONCONCEPT - Use of solar panel of [500*400]mm in Nose Area.

SOLARPANEL

USAGE – The power developed through solar energy is used to recharge the battery.

CALCULATIONS – Battery used 12V 10Ah Power developed in panel = 30 W/hr.Maximum power harnessed in a day by panel =3hrTotal power developed = 90W/day.

COST

COMPLIANCE TO RULE – The power developed is only used to recharge Battery which in turn is used for starter motor, Tail Lamp, Reverse alarm.

ADVANTAGE - Better power for propulsion as engine power is not used for recharging of battery as in conventionalVehicles.

• Panel = Rs 2800• Charge controller = Rs 700• Wiring = Rs 200 CIRCUIT

PANEL

BATTERY

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In the same manner it is done for Maneuverability, Acceleration, Fuel Consumption,Vehicle Weight, Driver exit time.

DESIGN VALIDATION PLAN

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DFMEA Automobiles are not ferocious....but we make them....

virtual baja 2012 ppt (1)

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