SAE NIS EFFI-CYCLE 2014VIRTUAL ROUND

14031- PETROLHEADS WALCHAND INSTITUTE

OF TECHNOLOGY SOLAPUR, MAHARASHTRA SOUTH ZONE

College or Team Logo

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• Project Objectives• Design • Transmission• Steering • Brakes• Suspension• Queries

Outline

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Project Objectives

• To build a human & electric powered three wheeled Vehicle.• An attempt to replace vehicles running on fuel.• To experience the problems faced while working in real time projects.• Widen the perspective of typical approach adopted in common

towards given problem statement.

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Performance targetsVEHICLE CONFIGURATION TYPE

Configuration Tadpole (2F1R)

Type of drive Front wheel manual drive Rear wheel motor drive

Wheelbase 62 inches

Track width 33 inches

Motor BLDC 400W , 24v ,6 N-m

Steering Ackermann

Brakes Disc and V brakes

Suspension Hydraulic Shock Absorber

Passenger Capacity 2

Weight 3139.2N ( 320kg)

Weight without driver 882.9 N (90kg)

Top speed 25 kmph

Braking distance 4 m 4

Methodologies adopted• Safety of driver• Inside out approach• Simple design• Long lasting• Lightweight• Ergonomics and aesthetic consideration• Economical• DFMEA

Design

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• Ergonomic considerations as per ILO norms & SAE standards.• Safe design for front, side & roll over impact for a force value of 3G

(375N).• CAD, analysis, selection of appropriate material & prototype.

Design requirements

Material selection

AISI 1018

AISI 1020

AISI 1025

AISI 1040

AISI 1215

AISI 304

AISI 4130

0

50000

100000

150000

200000

250000

300000

Strength/weight ratio

Strength/weight ratio

Material

Stre

ngth

/wei

ght

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Richness Volume

120°

110°

110°

Straight vision

Eye level

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Parts Dimensions

Seat length 900 mm

Seat width 430 mm

Seat base angle with horizontal

7°

Back rest height 500 mm

Inclination of back rest with horizontal

110°

Head rest width 220 mm

Head rest height 150 mm

Thickness 70 mm

SeatType of seat: Bench seat

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Front impact in ANSYS

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F = 3G DMX = 0.31E-03SMX = 126.4MPa

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Max. axial and bending stress = 228.82 MPa

Front impact in SOLID WORKS

Side impact in ANSYS

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F = 3GDMX = 0.374E-03 SMX = 1265.82

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Side impact in SOLID WORKS

Maximum axial and bending stress = 38.561 MPa

Roll over in ANSYS

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F = 3GDMX = 0.508E-04 SMX = 0.508E-04

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Roll over in SOLID WORKS

Maximum axial and bending stress = 906.911 MPa

Frame after modification

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Material = AISI 1018Yield strength = 365 MPa

Final cad of vehicle

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Power train Human Drive Calculations

• Total resistance:

• Centre distance:

Where,

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Gear ratio & CV-Joints• Geometric gear steps• Progressive gear steps• Availability in the market• Type of CV joint employed and its advantages.

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Motor Transmission :Motor Specification: BLDC Motor (400 watt -1500rpm-24v dc)

Battery: 24 volt ,18Ahr

Pedal Transmission: 5 Speeds.

Gear shifting: Derailleur

Performance parameters : Maximum speed: 21 km/ph

Gradeability: 30%

Braking: 21 km/h to 0 km/h in 2 seconds(stopping distance=12m)

Turning radius: 3.28 m 19

Motor

Advantages of BLDC motor:• High speed • High efficiency• Minimum temperature rise• Smooth operation• Robust• Customization available• Electronic communication

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Battery• Purpose:

Source of Energy.Power storage.

• Classification:Non rechargeable batteries.Rechargeable batteries.Batteries by application.

• Lead Acid Battery:Inexpensive.Reliable.Simple to manufacture.Low maintenances.Capable of high discharge rate.

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• Specification:Voltage: 24 VCapacity:18AhSize: 7-1/8" long x 3" wide x 6-5/8"Type: Sealed Lead-Acid / SLAConnectors: Nut and bolt post connectors / T4 Weight: 13.1 poundsItem # BAT-12V18A

• Calculation: (Ah) = Device's Wattage (W) x Time to run (Hours) /

Battery Voltage (V) Run time=1.08hr per Battery The total run time for two batteries in series is 2.16hr

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Tire Selection• Selection parameters:

1) Type of tire 2) Contact patch3) Aspect ratio

• Front wheels:1) Type of tire employed2) Specifications: (24 inch*(1/2)inch)

• Rear wheels:1) Type of tire employed2) Specifications: (28 inch*(1/2)inch)

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Steering system

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Objective & Calculations• Objective:

1) Effective handling2) Simplicity3) Reduced space & cost4) Reduces turning radius

• Calculation: Turning radius =[(-b/sin )^2+c^2+(2bc/tan )]^1/2+(a-c)/2Ѳ Ѳ

= 3.037 m

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Steering Angle v/s Turning Radius

0 5 10 15 20 25 30 35 40 45 500

2

4

6

8

10

12

14

16

18

20

Turning Radius(m)

Turning Radius(m)

Steering Angle (Ѳ)

Turning Radius(m)

5 17.9

10 8.93

15 6.54

20 5.02

25 4.26

30 3.69

35 3.28

39 3.03

40 2.98

45 2.7426

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Front brakes: Disc brakesRear brakes: V- brakes

• Advantages of disc brakes:•Greater braking power•Reduces braking distance•Less prone to brake fade

•Advantages of V- brakes:•Lighter & cheaper•Easy to install

Brakes used on front and rear wheel

Brakes

0 2 4 6 8 10 12 140

2

4

6

8

10

12

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Velocity v/s Stopping Distance

velocity

Vel.(m/s)

Stopping Distance (m)28

Graph

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0 2 4 6 8 10 12 140

1000

2000

3000

4000

5000

6000

7000

8000

Stopping Distance(m)stopping time(sec)Braking Power(KW)Brake Force(N)Brake Torque(Nm)deceleration(m/s^2)

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Suspension

• Type of suspension used: HYDRAULIC SHOCK ABSORBER

Wheel Force

Front wheel 820 N

Rear wheel 1350

Force acting on front and rear wheel

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Part Dimensions

Wire diameter 6 mm

Mean coil diameter 30 mm

No. of active coils 16

Total no. of coils 18

Free length 145 mm

Spring rate 32 N/mm

Suspension used only on rear wheel

Safety Features:• Types:1. Active Safety2. Passive Safety

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• Driver’s safety:Element of safety

1. Helmet 2. Eye Protection 3. Seat belts4. Elbow and knee pads5. Mud-guards for every wheel, Chain covers6. Head lights, Horn, Mirror

• Electric Safety:1. Insulation to electric wires2. Kill switch

3333

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Innovation• The charging mechanism of the battery is the innovation.• The charging is done by pedalling. The diode is connected to

motor and battery by terminal block; this is connected to the second rear axel through which the charging phenomenon occurs.

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Team structure

NAME BRANCH YEAR OF DEGREE ROLE IN PROJECT

HIMANSHU U GORE

MECHANICAL THIRD YEAR DESIGN

AJIT S DIGHE MECHANICAL THIRD YEAR POWER TRAIN-HUMAN DRIVE

ABHIJIT G ALMELKAR

MECHANICAL THIRD YEAR ERGONOMICS/SUSPENSION

NOOSRAT S SHAIKH

MECHANICAL THIRD YEAR POWER TRAIN -ELECTRIC DRIVE

CHAYYA DHERE MECHANICAL THIRD YEAR STEERING

RAJSHREE HUNGUND

MECHANICAL THIRD YEAR BRAKES