SAE SUPRA 2014

A REPORT BY

TEAM
GENSONIC

SAE SUPRA 2014

SAEINDIA organized, SUPRA SAEINDIA 2014 Event followed
by HR Meet on 2014 for the students of the Engineering
Institutes all over India. This event provides a real world
engineering challenge for the SAEINDIA Student members that
reflect the steps involved in the entire process from design and
engineering to production to marketing and endurance.
The SUPRA SAEINDIA 2014 is a competition which presents the
Under Graduate & Post Graduate Engineering Students the task
of designing, modeling and fabricating a formula type racing car.
The concept behind SUPRA SAEINDIA 2014 is that a fictional
manufacturing company has contacted a design team to develop
a small Formula style race car. The prototype is to be evaluated
for its potential as a racing car.
The target marketing group for the race car is the
nonprofessional weekend autocross racer. Each team designs
and produces a prototype based on well laid down rules &
regulations.
The project fuels the exuberance of the youth by providing
teams a platform to test their mettle, giving them a pragmatic
exposure to real world challenges as faced in the industry.
Students realize their talent through such an experience, making
them proven candidates for the future as technocrats,
entrepreneurs, designers, innovators and leaders.
This helps the objective of bringing out student talent to serve
the nation for the years to come, in fulfillment of the Automotive

Mission Plan (AMP2016) a dream to make India an International

Automotive Hub.

PHASES OF THE COMPETITION

The competition consisted of mainly two phases or
rounds i.e. The virtual round & The final round respectively. The
event eventually started with a virtual round which was a prequalifier round to participate in the main event. The VIRTUAL
SUPRA SAE INDIA round was held at KIIT Bhubaneswar in
September, 2013. 179 teams participated in the virtual round.
Out of which 100 teams qualified for the next round. In Virtual
SUPRA SAE INDIA 2014 competition, each team had to submit
a preliminary design report and had to give a PPT on the design
of their vehicle. Our college registered in the virtual round with
team name as GENSONIC. The college stood at 41st rank in the
VIRTUAL SUPRA SAE INDIA 2014 COMPETITION. Then the
team GENSONIC qualified for the next round and registered for
main event.
The main event started with the technical inspection of the
vehicle. The schedule of Technical inspection and each static
event (which includes design and innovation evaluation, cost

presentation and Business & marketing Presentation) was prefixed and each team was notified their slots for the various static
events. Out of 85 teams, only 12 teams could clear the technical
inspection round and were allowed to participate in dynamic
events. In the technical inspection round, judges from the
different well reputed automobile companies evaluated the
vehicle. Out of the 12 teams, only two teams were there from the
northern region.

THE VIRTUAL ROUND

The virtual round was scheduled on 20 th & 21st of September
2013 at the Kalinga Institute of Industrial Technology, KIIT UNIVERSITY,
BHUBANESWAR, ODISHA. A team of 5 members went for the virtual
round. The members were:
1.
2.
3.
4.
5.

Puneet Madhav (Captain)

Sahil Palta
Raghav Sharma
Arjun Ahluwalia
Arhant Rai

The Preliminary Design Reports (PDR) were sent in CDs to

SAEINDIA Office. There was a 20 min. presentation session followed

by a 5 min. questionnaire session. The team presented the following

things:
1) Preliminary technical specifications and 2D / 3D views of the proposed
design of the SUPRA Vehicle.
2) The teams are required to present following related to SUPRA vehicle.
Knowledge of rulebook
Design Methodology for Roll Cage
Proposed engineering process for Finite Element Analysis loads and
constraints, Factor of Safety &
Deformations.
Human Ergonomics knowledge related to vehicle cockpit layout
Suspension Design Methodology & considerations for springs,
Damper, Links arms design, Centre of
Gravity, Roll centre, methods to determine and its importance.
Steering -Design Methodology & considerations for steering selection,
turning circle, wheel Geometry
(Caster, camber, toe in, toe out) etc.
Brakes -Design Methodology & considerations for brakes selection (Disc
/ drum brakes), brake
Layout/actuation, braking efficiency, pedal force etc
Power train (Engine to wheel including tyres) & mounting considerations,
Vehicle
Performance specifications e.g. Vehicle speed, Acceleration etc.
Safety equipments ratings
Overall Performance Targets and validation procedure
List of static & dynamic tests.
3) Project Plan

4) Team -Organisation chart

5) College workshop facilities for manufacturing vehicle & overall cost
elements/ estimates and financing for the project

The team cleared the virtual round successfully, securing 41st rank

out of 179 teams all over India.

SPONSORSHIP PROCURING AND MARKETING

After clearing the virtual round the team started marketing &
procuring sponsorships for funding the project. The students procured
sponsorships from various organisations and industrial firms.

MANUFACTURING
The team started manufacturing the vehicle in the month of may
which lasted till the end of june. The manufacturing was done at a hired
industrial workshop by the students themselves.

The manufacturing was started by the making of a pvc pipe model of the
roll cage which was then converted into a mild steel pipe roll cage.

The

vehicle

was manufactured with the following specifications:

1. ENGINE: The engine was borrowed from a Honda VFR 400
motorcycle. This

engine best suited

the vehicles

requirements for

power and

torque. Moreover

the engine was

convenient to mount

as per the

design and the

design could

take up the weight of

the heavy

engine.

The engine had the following specifications:

ENGINE SPECIFICATIONS

HONDA VFR 400 NC24

Displacement

399 ccm

Type

V4

Power

59HP(43kw) @ 12800 rpm

Torque

39Nm @ 10000 rpm

Transmission type

Chain, sprocket differential

2. SUSPENSION: The suspension system employed was

a Push rod suspension system with shorter upper arm for
lesser camber gains. Non parallel arms were placed for
desirable

roll center

position

and an

Anti-Roll

bar used

to reduce

rolling

rate.

3. BRAKES: Diagonally split system is followed for the

vehicle with double reservoir system which will work even in

case of failure of front or rear disc braking systems.

The braking system was designed so as to meet the requirements of the

surface and the track. There were various events to test the braking of
the vehicle like the stopping distance test

4. STEERING: The steering employed was of the rack and pinion type

STEERING
Type

Rack and pinion type

Turning radius

3055 mm

COST ANALYSIS OF THE VEHICLE

COST ANALYSIS
Brake System

Brake
System;
7%
Engine & Drive
Train& Tries;
Frame
& Body
Electrical
Wheels
15%

Suspension System; 7%

Miscellaneous, Fit & Finish

Engine & Drive Train; 31%

Steering System; 4%

Miscellaneous, Fit & Finish; 18%

Steering System

Suspension System
Electrical; 3%

Wheels & Tries

Frame & Body; 17%

The team manufactured the car sourcing all the parts of which the cost
report is following. The parts sourced were a mix of new and second
hand

The detailed cost report about each and every part that was used in the
manufacturing of the car has been mentioned as follows. The sourcing of
tools and parts was done after thorough research through the market.

The parts purchased were the cheapest and of the utmost quality serving
the best purpose for the project.

Area of
Commod
itys
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Brake
System
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &

Component

Uni
t
QT
Cos Y
t

Materi Proc
als
ess
Cost
Cost

Faste
ner
Cost

Tooli
ngs
Cost

Total
Cost

Brake Fluid

70

280

280

Brake Master
Cylinder

750

1500

1500

Fasteners

50

100

100

200

Brake Lines

110
0

1100

1100

Brake Disc Rear

950

1900

1900

Brake Discs
Front

915

1830

1830

Balance Bar

Callipers RHS

110
0

2200

2200

Callipers LHS

575

1150

1150

Proportioning
Valve

10060

100

1016
0

Area Total
Air Filter

200

200

200

Axles

450

900

900

Chain

350

350

350

Coolant

Collant Lines

100

100

100

Differential

150
0

900

200

150

250

1500

325

450

200

650

400

300

100

400

Engine

360
00

35000

400

600

3600
0

Engine Mounts

400

600

200

800

Engine Oil

120

1200

1200

Differential
Bearings
Differential
Mounts

Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Engine &
Drivetrain
Frame &
Body
Frame &
Body
Frame &
Body
Frame &
Body
Frame &
Body
Frame &
Body
Frame &
Body
Frame &
Body
Frame &
Body
Frame &

0
Exhaust
Manifold

600

200

100

300

600

Fuel Filter

150

300

300

Fuel Injectors

Fuel Lines

80

80

80

Fuel Pressure
Regulator

Fuel Pump

Fuel Tank

140
0

800

100

500

1400

Fuel Vent

Hose Clamps

20

40

40

Intake Manifold

800

600

200

800

Muffler

Oil Cooler

Overflow
Bottles

Radiator

110
0

1050

50

1100

Radiator Fans

450

450

450

43520

400

1300

1650

4687
0

4000

2000

500

500

7000

800

400

1200

350

350

1910

2000

3910

7620

2000

9620

Area Total
Body Panel
Floor Pan
Clutch
Frame(25.4*2.5
mm)
Frame(25.4*2m
m)
Mounts
Intergral To
Frame

700
0
120
0
350
52
320

75f
t
30
m

110

16

1000

800

1800

Pedals

250

450

150

150

750

Shifter

800

600

200

800

200

200

200

16930

2150

500

6050

2563

Throttle
Controls
Area Total

Body
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Misc. , Fit
& Finish
Steering
System
Steering
System
Steering
System
Steering
System
Steering
System
Steering
System
Suspensio

0
Battery
Brake Light &
Bulbs
Dash Panel
ECM
Fuses
Indicator Lights
Kill Switches
Oil Pressure
Gauge
Relays
Solenoids
Starter Button
Tachometer
Wire Harness
Area Total
Driver's
Harness
Fire Wall

180
0

1800

1800

300

300

300

300
0
0
0
500

1
0
0
0
3

300
0
0
0
1500

0
0
0
0
0

0
0
0
0
0

0
0
0
0
0

300
0
0
0
1500

0
0
400
0
500

0
0
1
0
1

0
0
400
0
500
4800

0
0
0
0
0
0

0
0
0
0
0
0

0
0
0
0
0
0

0
0
400
0
500
4800

7000

200

7200

850

200

50

1100

720
0
110
0

Headrest

250

150

100

250

Paint - Body

230
0

1600

700

2300

Paint - Frame

700

500

200

700

750
0

7000

500

7500

720
0

7000

200

7200

100
0

650

350

1000

24750

500

600

1400

2725
0

Impact
Attenuator
(Testing)
Impact
Attenuator
(Actual)
Seats
Area Total
Steering Rack

305

305

305

Steering Shaft

450

450

450

1500

50

150

1700

2500

2500

420

20

440

5175

50

170

5395

600

200

800

Steering Wheel
Quick Release

170
0
250
0

Tie Rods

220

Steering Wheel

Area Total
Bell Cranks

100

n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Suspensio
n System
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires
Wheels,
Wheel
Bearings
& Tires

Front A

300

720

200

280

1200

Front Uprights

990

440

240

1100

200

1980

Pushrods

320

600

120

240

320

1280

Rear A

280

640

200

280

1120

Rear Uprights

625

460

120

550

120

1250

Rod Ends

275

450

100

550

Shocks Front

500

900

100

1000

Shocks Rear

500

900

100

1000

5710

480

2490

1500

1018
0

Area Total
Front Hubs

250

500

500

Rear Hubs

250

500

500

Tires

350
0

14000

1400
0

Wheel Bearings

175

1400

1400

Wheel Studs

30

16

480

480

Wheel Weights

Wheels

150
0

6000

6000

Area Total

22880

2288
0

Totals

133825

3530

4940

10870

1531
65

SOME GLIMPSES OF THE MANUFACTURING PHASE

The vehicle was successfully manufactured by the team before the

competition and was transported to the competition site that is the
MADRAS MOTOR RACE TRACK, Chennai. The vehicle was transported
through a private transport arranged by the students themselves. The
students also reached Chennai on 15th of July, a day before the main
event was to commence. A private accommodation was rented for the

few days stay for the competition.

THE MAIN EVENT

The Supra SAE 2014 competition was a 4 day event
which saw 80 colleges from various parts of the country
participating on various engineering levels to win the title of the
National Champions. Over 2500 students and faculty members
had come with their cars to participate and become the best
engineering team in the country. The competition was judged
and sponsored by various multinational companies like Maruti
Suzuki, Volkswagen, Ansys, Bosch, BPCL, Altair. The team had
a very good learning experience by interacting with like-minded
students and experienced judges.
On 16th July the vehicle was unloaded on MMRT race track
Chennai. The event consisted of four days and the sequence of
events was:

1.16th July: Registrations for the final round. A total of 80

teams registered for the main event.

2.17th July : The team presented the cost report, the design
report and the business logic case in front of the jury.
3. 18th July: The team did not have any event scheduled on
this day.
4. 19th July: The team had the technical inspection on this day.
The technical inspection was conducted by the event
officials and judges. The team failed to pass the technical
inspection due to some technical faults in the car and due to

the non-presence of the faculty advisor of the team, which

was mandatory, failing to which the team was not allowed to
pass through and go forward to the dynamic events.
5. 20-21st July: The scheduled HR meet was cancelled due to
unavoidable reasons by the management.
The team returned from the competition on 22nd of July 2013.

SUPRA SAE INDIA 2015

The team is planning to participate in SAE SUPRA 2015 for
which the registrations have already started and will last till 20th
of September. The team is quite motivated to participate in the
competition further.
The team has conducted an information seminar regarding the
upcoming competition. The seminar was conducted on 25 of
august 2014. The seminar received overwhelming response
from the students irrespective of their year or branch.

INTERVIEWS FOR SAE

SUPRA 2015
After a successful information seminar, the interviews for the
interested candidates were conducted by the team. Around 130
applications were received. On 27th august the first round of
interviews was conducted in the workshop seminar hall. The
team received an overwhelming response for the interviews. A
total of 30 candidates were selected to appear in the final round.
Some glimpses of the interviews are

The second round of

interviews was conducted on 2nd of august in the workshop seminar hall.
A total of 30 candidates appeared for the interviews for the various
departments of the team like design, manufacturing, presentations &
marketing. The list if the selected students are as follows:

3rd year students:

Harjot Singh
Rohit Roushan
Mohit Kumar Chawla
Prakaram Attry
Jaspreet Singh
Vishnu Kumar
Sonu Kumar
Gopal Sharma
Jagmeet Singh

2nd year students:

Tanshikha Mudhar
Amuldeep Singh
Mantej Singh
Gurjap Singh
Harshmeet Singh

1st year students:

Harsimranpreet Singh
Manpreet Kaur.

16 new members were recruited and 9 existing members of the team

form a team of 25 students to participate in SAE SUPRA 2015.

FUTURE ENDEAVOURS

In future the team wants to participate in SAE SUPRA 2015, of

which the registrations have already started. The team is quite
dedicated and motivated to participate in the event and come out
with flying colours. For this the team requires the cooperation of
the esteemed faculty.