TABLE OF CONTENTS

• OBJECTIVE 3

• DESIGN PLAN 3
o Initial study
o Initial design
o Stability
o Braking
o Steering
o Seat
o Suspension
o Pedals
o Wheel

• TESTING & ANALYSIS PLAN 4

• DESIGN & FABRICATION 5

• INSTITUTIONAL & FINANCIAL SUPPORT 5

• PRIOR EXPERIENCE WITH HPVC 5

• APPENDICES 6
o HPVC 2019 Timeline

• DESIGN OF VEHICLE 8

• 2D SKETCH OF HPVC 9

• INSTITUTIONAL APPROVAL 10

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CONCEPT SELECTION AND DEVELOPMENT METHODS

Objective
● To design and fabricate a hum an pow ered vehicle in com pliance w ith the 2020 ASM E
HPVC rules and regulations.
● To have a lightweight single seater HPV with increased aerodynamic and on road
performance.
● To give a stable and safe mode of transport ensuring rider’s comfort and safety.

1. Design plan

Initial study
● Perform ed extensive studies on the existing designs of hum an pow ered vehicles and
tried to point out the defects in them.
● Tricycle design w as ineffective since it increases the area of contact betw een the road
and the tires and increases the turning radius which affects the endurance and
performance of the vehicle. They are difficult to handle because of larger width.
● All these reasons lead to investigate the design of a bicycle which has far more
advantages over the tricycle.

Initial design
Since the benefits of a bicycle clearly outweigh the tricycle design, a two-wheel design is
adopted.

Stability
● The vehicle would be equipped with a strong, lightweight frame.
● The front wheel drive has been selected for the vehicle as it has a compact drivetrain.
The drivetrain does not pass below the seat or above the shoulder. Also, it improves
the streamline of the HPV.
● Roll cage made of aluminum 6063 T-6 AISI 1020 steel.

Braking
● The braking system decided to use is v-brake at the front wheel and disk brake at the
rear wheel for effective braking.

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Steering
● The steering was designed to achieve two main goals which are reliability and ease of
manufacturing. From our perspective the design which suited our requirements was
the modified upright bicycle steering system (ref fig2 & fig1).

Seat
● Low seating arrangement is used.
● Hard seat is used to avoid energy loss and better stability for the rider (ref fig2).

Suspension
● We don’t intend to use any kind of suspension system in our HPV as no such difficult
terrain is encountered. A suspension would simply add extra weight and
unwanted complexity to the design.

Pedals
● Loops or pedal straps attached to the pedals will help the rider in providing
continuous output throughout, i.e. no idling of pedal in between.

Wheels
● Front wheel and back wheel are chosen to be of same diameter.
● Thin wheel width is used to reduce friction and obtain lighter tyres.

2. TESTING AND ANALYSIS PLAN

The material will be tested in the institution’s Material testing lab that has

● Universal Testing Machine for vertical and inclined load testing.

● Izod test to check if the material has desired strength.
● Rockwell test to check the material hardness.
● The CAD/CAM lab has Catia V6 and Ansys software which are the key software’s
required in analysing our HPV.
● The vehicle will be tested upon completion by different riders.

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3. DESIGN AND FABRICATION

The fabrication stage is crucial, as it involves turning concepts to reality. Fabrication of H PV

would be done at our institution, as it has most of the machine tools required for the
fabrication and testing. Which includes the following:

● Angle cutters-for cutting the pipes

● Radial drilling machine
● Lathe
● Milling machine for creating gears that suit our requirements
● CNC lathe-for turning small parts
● TIG-welding, MIG-welding & Gas cutter.

Provision of a Fab-Lab within the institution that has 3D printers, engraving machine
and vinyl cutters. 3D printing would be useful in fabricating the parts(metallic) which
could be replaced by a suitable 3D printed one. A 3D printed material can reduce the
weight of the vehicle and the functionality remains same.The intricate parts that pose
a challenge can be fabricated at HMT (Hindustan Machine Tools Ltd.). Our institution
has an MoU with HMT which facilitates the support required to fabricate parts in their
industry.

4. INSTITUTIONAL AND FINANCIAL SUPPORT

The institution’s administration was highly supportive to the enthusiasm showcased to

enter this competition. Institution has also promised us with all the required facilities to
fabricate the HPV. The Mechanical department has offered us complete support in
proceedings on HPVC.

5. PRIOR EXPERIENCE WITH HPVC

This is our second attempt to design and fabricate HPVC, we were fortunate to have
participated in this year’s ASME E-fest (19 October 2019) held at our very own
campus at Rajagiri School of Engineering & Technology and learn from our own
previous design and its lim itations from the different participants. The H PVC talk
conducted in R SET by M r. Sunder R am an M ohan, (G M Siem ens Indian & H PVC Judge)
enlightened us w ith the do’s and don'ts in the process. Mr. Sunder pointed out the
following changes needed :
• Harder seating to avoid damping losses
• More efficient and less bulky RPS to be designed
• Usage of FWD to lower ride height
We have taken into consideration these requirements and hope to fabricate and
obtain a better and promising result.

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APPENDICES
ASME HPVC 2019 TIMELINE

TASK NAM E STAR T D ATE EN D D ATE D U R A T IO N (D A Y S )

F O R M A T IO N O F T E A M 1 4 -S e p 1 7 -S e p 3

AN ALYSIN G PR EVIO U S 1 8 -S e p 25-Sep 8

D ESIG N
D ATA C O LLEC TIO N 26-Sep 01-Oct 6

PR IM AR Y AU TO C AD D ESIG N 03-Oct 09-Oct 7

RPS ANALYSIS 10-Oct 11-Oct 2

STRUCTURAL ANALYSIS 13-Oct 16-Oct 4

D R IVE TR AIN 17-Oct 22-Oct 6

CONFIGURATION

M ATER IAL SELEC TIO N 23-Oct 26-Oct 4

AERODYNAMIC ANALYSIS 27-Oct 31-Oct 5

PRODUCT CYCLE 02-Nov 05-Nov 4

ENERGY ANALYSIS

QUALIFICATION REPORT 07-Nov 08-Nov 2

SUBMISSION

COST ANALYSIS 10-Nov 13-Nov 4

PROTOTYPING FRAME 17-Nov 24-Nov 8

AND RIDER POSITION

QUALIFICATION RESULT 26-Nov 26-Nov 1

O P T IM IS A T IO N 27-Nov 29-Dec 5

VEHICLE REGISTRATION 02-Dec 03-Dec 2

FABR IC ATIO N 30-Nov 13-Dec 14

RPS TESTING 16-Dec 18-Dec 3

PER FO R M AN C E TESTIN G 19-Dec 21-Dec 3

R O AD TESTIN G 22-Dec 24-Dec 3

R EPO R T SU BM ISSIO N 06-Jan 08-Jan 3

RIDING PRACTICE 10-Jan 24-Jan 14

EVEN T 28-Feb 01-Mar 3

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GANTT CHART

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DESIGN OF THE VEHICLE

Fig 1(front view)

Fig 2(top view)

Fig 3(side view)

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2D SKETCH OF HPVC

Side view

Top view Front view

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INSTITUTIONAL APPROVAL

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