Sprocket

A sprocket or sprocket-wheel is a profiled wheel with teeth, or

cogs, that mesh with a chain, track or other perforated or indented
material. The name ‘Sprocket’ applies generally to any wheel
upon which radial projections engage a chain passing over it.

It is distinguished from a gear in that sprockets are never meshed

togather directly, and differs from a pulley in that sprockets have
teeth and pulleys are smooth.

Sprockets are used in bicycles, motorcycles, cars, tracked

vehicles, and other machinery either to transmit rotary motion
between two shaft where gears are unsuitable or to impart linear
motion to a track, tape etc.

Types of Sprockets:

There are four types of sprocket -->

 Type A: Plain Plate sprockets

 Type B: Hub on one side
 Type C: Hub on both side
 Type D: Detachable hub
Application
Sprocket should be accurately aligned in a common vertical
plane, with their axes parallel. Chain should be kept clean and
well lubricated with a thin, light-bodied oil that will penetrate the
small clearance between pins and bushings.

Center distance should not be less than 1.5 times the diameter of
the larger sprocket , nor less than 30 times the chain pitch, and
should not exceed 60 times the chain pitch. Center distance
should be adjustable- one chain pitch is sufficient- and failing this
an idler sprocket should be used to adjust tension. A little slack is
desirable, preferably on the bottom side of the drive.

The chain should wrap at least 120 degree around the drive
sprocket, which requires a ratio of no more than 4 to 1; for grater
ratios, an idler sprocket may be required to increase wrap angle.

Chain
Chains have a surprising number of parts. Roller chains are
assembled using link plates, pins and rollers and connecting them
in an endless chain using a connecting link. The roller turns freely
on the bushing, which is attached on each end to the inner plate.
A pin passes through the bushing, and is attached at each end to
the outer plate.

F= T/r

A standard 520 has a max chain force of 27000N. By choosing

this chain, the chain will be the weakest link in the drive train. This
is relatively cheap to the other drive train parts and easy to repair.
Also 520 chain and sprockets are widely available.

To have the chain under the right tension prevents the chain from
excessive wear and from the possibility to hop of the sprocket
during driving. The chain tensioner disk is made out of aluminum
6082-T6. The maximum stress stays below the yield stress of the
material.

Differential
The differential is the connection between the rear sprocket of the
final drive and the drive shaft. A differential has also the function
of allowing the drive shafts to rotate with different speeds. This is
important while cornering.

For the differential, weight is an important issue. In Formula

student car, salisbury type differential is used. Salisbury type
differential custom made by a company in germany called
Drexler.

Advantage

 very wide adaption in torque bias.

 weight 2.6kg including housing
 different characteristic for accelerating and braking
 oil sealed

Disadvantage

 expensive
 High running cost
 very long delivery time

Because all disadvantage of salisbury differential can be

overcome this differential is chosen. This salisbury type
differential works like a normal differential with addition friction
plates.
Engine

In our formula student car, we are using “Bajaj 220F” bike engine.

It is a four stroke single cylinder with Digital Twin Spark-ignited

(DTS-i) engine. The engine can deliver 20.64 brake horsepower
at 8500 rpm and maximum torque of 18.55 Newton-meter at 7000
rpm.

Calculations:
Here,

we are using,

Driving sprocket teeth= 14

Driven sprocket teeth= 47

Drive ratio= 47/14=3.36 (higher ratio)

[ We know that the higher the drive ratio, the higher the
acceleration. In Formula Student car, Faster acceleration is
needed instead of higher speed. So we can use it.]
Angle

sina= difference between pitch diameter, d / distance between

center line, C

Chain length, L= 2[Ccosa+ (N+n)/4 + a/360 (N-n)]

a= angle

C= distace between center line

N= Driven sprocket teeth

n= Driving sprocket teeth

Center distance from a known chain length,

C= [L- {n(90-a)/180} – {N (90+a)/180}] / 2cosa