TEAM ADROIT

TEAM REGISTRATION ID:-14251

PRESENTATION ON VIRTUL BAJA 2014 REPORT

ENGINE TYPE BRIGGS & STRATTON INTEK OHV 305 ENGINE 305 CC 8:1 10 hp @ 3250 rpm 19.66Nm @ 2800 rpm GASOLINE

CHASSIS/SUSPENSION
CHASSIS TYPE OVERALL LENGTH OVERALL WIDTH HEIGHT FRONT & REAR SUSPENSION BRAKES Steel AISI 4130, Tubular Frame 240 cm 157 cm 164.5cm DOUBLE WISHBONE, A-ARM WITH SAME LENGTH

DISPLACEMENT COMPRESSION RATIO POWER TORQUE FUEL DRIVE TRAIN TYPE MAX SPEED WHEELS & TIRES

FRONT & REAR

STEERING STEERING TYPE STEERING GEAR BOX CG LOCATION HORIZONTAL VERTICAL GRADEABILITY

DISC BRAKE WITH MASTER BOOSTER

4+1 synchronizing mesh gear box assembly 59 Kmph (In Top Gear)

MANUAL ASSISTED (CENTRALIZED) RACK & PINION (MANUALLY ASSITED)

FRONT & REAR

MEASURING RIM WHEEL LOAD CAPACITY IN KG

175/65R15
5J*15 487 with 2.5 bar tyre pressure

From Front 1.04 m From rear 0.7 m h=0.212m, angle=40* 28%

LOAD INDEX

83

THE PROTOTYPE WAS MADE BY PVC PIPES TO CARRY OUT THE DRIVER ERGONOMICS TEST & DIMENSIONAL STABILITY OF VEHICLE. AERODYNAMIC : FRONT ROLL STIFFNESS =67600N-m/rad REAR ROLL STIFFNESS=36100N-m/rad

DRIVER ERGONOMICS DETAILS: MINIMUM HEAD RESTRAINT=7inch DISTANCE FROM SIM=10inch max DRIVER SEAT IS ADJUSTABLE i.e it CAN MOVE FORWARD & BACKWARD.

 SAFETY & SERVICEABILITY.

SUFFICIENT STRENGTH. EXTENSIVE RESEARCH ON EACH COMPONENT OF VEHICLE.
OPTIMIZING EACH COMPONENT ALONG WITH CONSIDERING THE SIMULTANEOUS EFFECT ON OTHER COMPONENTS.

EASY ACCESS AND EFFECTIVE CONTROLS. MINIMUM COST & SIMPLE DESIGN. AESTHETIC VALUE.

STRESS ELONGATION GRAPH OF AISI 4130 ON COMPARING IT WITH AISI 1018 & 1048

TOTAL LENGTH = 220cm. TOTAL WIDTH = 110cm. SOFTWARE USED CATIA V5R20 & PRO-E ENGINEER WILDFIRE 4.0.

MATERIAL USED FOR ROLL CAGE DESIGN :- AISI 4130 alloy steel
1) 2) 3) 4) MODULUS OF ELASTICITY :-205GPa YIELD STRESS :-465MPa ELONGATION :-25% CARBON :-0.30%

1) FRONT IMPACT TEST: -18000N(FOS-2.27)

2) SIDE IMPACT TEST:-15000N(FOS-1.71)

2) REAR IMPACT TEST :-18000N(FOS-2.27)

3) FRONT ROLLOVERTEST :-10000N(2.10)

Taguchi Method is been used for improving the quality of ROLL CAGE with great success. It is also used for quality control , tolerance & robust engineering. Taguchi loss function L = k * ( y m )2 The loss due to performance variation to the square Of the deviation of the performance characteristic from its nominal value.

L = k * ( y m )2

k18000/ k40000 =2.27/1 L = k * ( y m )2 40000=k*(0-54) 2 k=13.71 This relation states that roll cage is much more safe when a 18000 N force is applied on it as compared to 40000 N force i.e 2.27 % much safer.

18000=k*(0-24) 2
k=31.25

DESIGN METHODOLOGY
1) To stop the vehicle quickly with in a shortest possible distance and time. 2) To slow down or stop the motion of a moving vehicle. 3) To control the speed of the vehicle. 4) To work equally good in all weather conditions. 5)It should have less weight and reliable.

TYPICAL AUTOMOBILE BRAKING SYSTEM

DISC BRAKES IN ALL 4 WHEELS WITH MASTER BOOSTER.

MASTER BOOSTER

THEORETICAL CALCULATIONS:1.) Braking circuit - Two independent system 2.) Brake pedal ratio - 6:1 3.) Force applied - 2689N 4.) Disc size - 200mm 5.) Deceleration - 2.56m/s^2 6.) Stopping Distance - 11.5m 7.) Stopping time - 3secs hydraulic

FRONT WHEEL SUSPENSION TYPE OF SUSPENSION ACTIVE LENGTH SOLID LENGTH WIRE DIAMETER Double Wishbone A-arm suspension 240mm 160mm 8mm

REAR WHEEL SUSPENSION Double Wishbone A-arm suspension 270mm 112mm 8mm

STEERING TYPE

Manual assisted (centralized) Rack & pinion(TATA NANO) For Front Wheel: -2 degree + 4 degree 2949mm 2864mm 380mm For Rear Wheel: -2 degree + 4 degree

STEERING GEAR BOX CAMBER ANGLE

MEAN COIL DIAMETER

SPRING INDEX ACTIVE COILS PITCH MAXIMUM DIFFLECTION

Inner dia:40mm Outer dia:48mm

5 19 12mm 39.56mm

Inner dia:40mm Outer dia:48mm

5 13 20mm 40.60mm

CASTER ANGLE TURNING RADIUS INSTANTANEOUS CENTER STEERING WHEEL DIAMETER

WAHL STRESS FACTOR :1.3105

GEAR RATIOS
GEAR RATIO SPEED (km/hr)

POWERTRAIN SPECIFICATIONS Engine speed Gear ratio (highest) 3800 6.2:1 RPM -

First

1:31.48

13.84

Tire diameter
RPM of tires Theoretical top speed

60.9
517 59.3

cm
RPM Km/hr

Second
Third Fourth Reverse

1:18.70
1:11.40 1:7.35 1:55.08

23.32
38.25 59.31 7.91

TRANSMISSION:- WE OPTED FOR SYNCHRONIZING GEAR BOX ASSEMBLY OF PIAGGIO APE(CARGO) TRANSMISSION. USE OF TWO WHEEL DRIVE MECHANISM HELPS TO INCREASE THE TURNING RADIUS OF VEHICLE. LONGITUDINAL ACCLERATION(G)=6.01 THE RADIAL TIRES WERE SELECTED AS IT MAINTAINS MORE RELIABLE AIR PRESSURE & LONGEVITY . LIGHTER IN WEIGHT & STRONG AS COMPARED TO THEIR BIAS PLY COMPETITORS.

PROCEDU RE NO. 1

DESCRIPTION DIMENSIONAL STABILITY

ACCEPTANCE CRITERIA

RESPONSIBILITY

TEST RESOURCE TESTED ON SOFTWARE & 1 THEN ON PROTOTYPE MADE IN WORKSHOP

SAMPLE QTY

ACCORDING TO RULEBOOK & TECHNICAL SHEET RAJ GOPAL GUPTA & INSPECTION OF OVERALL LENGTH & WIDTH OF THE VEHICLE

CLEARANCE AT TRANSMISSION ENGINE ASSEMBLY TUBING BEND SUPPORTS RULE BOOK CLOSE ADHERENCE STEERING SYSTEM SUSPENSION SYSTEM

MIN. 1" EACH SIDE TO THE TOTAL 15" HT FROM THE MOUNTING BASE.

AJAY PRATAP & RAJ GOPAL GUPTA

MEASURED FROM THE SOFT 2 WARE ASSEMBLY MADE IN THE DESIGN RULE BOOK RULE BOOK 1 1

3 4 5 6

SUPPORT MEMBERS SHOULD NOT EXCEED MORE RAJAT SHARMA THAN 711mm (28 ) inch SHOULD NOT EXCEED THE PRESCRIBED LIMIT THROUGH THEORETICAL CALCULATIONS NITIN V NAIR SHASHANK SINGH TANMAY MEHTA

ENGINE SYSTEM AND TRANMISSION SYSTEM

PROPER MOUNTING OF THE ENGINE TRANSMISSION ASSEMBLY,COVERS TO ALL MOVING PARTS AT PLACE VALVE TIMING,SPARK PLUG,LUBRICATION PUMP,LUBRICATION OIL CONDITION

AJAY PRATAP

VISUAL INSPECTION

AIR FILTER

NITIN V NAIR

AUTOMOBILE WORKSHOP

9 10

BRAKES FASTENERS

ALL FOUR WHEELS SHOULD BE LOCKED WHILE APPLYING BRAKES ALL FASTENERS CORRECTLY TIGHTENED WITH MIN .TWO THREADS OUT.

RAJAT SHARMA & NEERAJ RAO DINESH SINGH

VISUAL INSPECTION

TORQUE WRENCH & OTHER 1 TOOLS

11

TYRES

PROPER BALANCING & WHEEL ALIGNMENT,TIRES AT RECOMMENDED INFLATION PRESSURE. FRONT AND REAR BUMPERS PROPERLY INSTALLED, SAFETY KIT INSTALLED ON VEHICLE ETC

SHASHANK SINGH & NEEL KORI

ON TRACK

12

SAFETY

TEAM MEMBERS

VISUAL INSPECTION

1.) N2 FILLED TYRES

Nitrogen is lighter than air and has a diffusion coefficient less than that of normal air

2.) CHARCOAL CANISTER

Minimizes the evaporative losses from the fuel tank and hence save not only the fuel but also the environment from being polluted.
3) CATALYTIC

CONVERTER

To achieve minimum emission . To attenuate engine exhaust noise to human comfort level with out affecting other engine parameters.

 COST OF THE VEHICLE WHICH INCLUDES PURCHASING OF PARTS & FABRICATION OF VEHICLE= 154,500INR DRIVER EQUIPMENT COST= 70,000INR. MAIN EVENT REGISTRATION CHARGE= 36,500INR TRANSPORTATION CHARGE=40,000INR OVERALL EXPENDITURE OF THE PROJECT=30,1000INR. 30% SPONSORSHIP FROM COLLEGE NAI DUNIYA NEWS PAPER & TVS MOTOR COMPANY IS LIKELY TO SPONSOR US. 10% FUND FROM SAE IPS-CTM COLLEGIATE CLUB.