Please fill in the following details:-

Team UID (Registration Number): 201550013

Team Leader’s name: Upender Rawat
Contact Number: 8818987431
Email ID: teamexergygwalior0751@gmail.com
Team Name: TEAM EXERGY
Vehicle Name: EXƎ -1.0
College Name: Malwa Institute Of Technology & Management, Gwalior, MP, 475001

Fill in the information about your Kart in the respective sections as mentioned below:
 1. Describe the chassis layout of your Kart. Use proper diagrams/Images to explain it. Also
attach the picture of your empty chassis if already fabricated. Cost For this Segment. You can
also Show Load Analysis and testing results (Optional)
ABSTRACT:

The frame or chassis is designed in such a way that it provides a safe 3d space around
the driver, with fulfilling the requirements of competition. The main objective of the chassis
is to link all components of the kart including the driver efficiently and safely principle
aspect of the chassis focus on during the design and implementation including driver
safety, drive train integration structural weight and operator ergonomics.

DESIGN
the main component of the chassis is divided into three components, first for steering,
brake pedals etc. Second for driver cabin and the third one or the rear one is for battery
and motor compartment, the second and the third component are separated by firewall for
the safety of driver.

By implementing bends into the design of the frame, the number of cuts and welds were
decreased. Decreasing the number of cuts and welds lowers the production cost and
increases overall chassis strength. For example, by using more bends, a bending die can
perform the job of bending behalf of the welding and joining hence reducing man-hours
and production costs. All bends were designed to be made using a tube bender fitted with
primary die of 10 cm, secondary die of 15cm, and tertiary of 30 cm, diameter die, which
would eliminate costly tooling changes from the manufacturing process.

BODY PANELS-
The body panels are made out of .03 inch thick FRP (fiber reinforced plastic) .FRP is a
composite material made of a matrix reinforced with fibers the polymer is usually epoxy,
infester or polyester thermosetting plastic are used in FRP.It is very light material that has
desirable properties for a body panel.
The panels are designed such that they tends to reduce the aerodynamic moments like
pitching from front, yawing from side and also helps to create the downward force to which
tends to make the good traction of vehicle with the road & also provide the properties
necessary to protect the driver and vehicle components from rocks and other debris.
When the panels were integrated into the car, the panels were recessed into the chassis
to provide visibility to the chassis members, making the car aesthetically pleasing.

FEA Analysis:
All simulation of the space frame was done in the Ansys14 by considering a static
structural analysis of meshing type ‘beam mesh’ and stimulated load were applied on the
critical points of the roll cage. Before attempting to calculate the input loads, it was
necessary to determine what kind of obstacles would be encountered during vehicle
operation. This was done by reviewing test and competition videos of other SAE EcoKart
vehicles on the internet. This allowed the team to get a very broad sense of what terrain
the vehicle would be required to overcome.

Front Impact Analysis: Force estimation for

loading conditions
As, F = m.a
Where,
F= Force, m = mass of
vehicle,
a = acceleration
For Front impact
analysis (Assumed G factor =
3.6)
Ff =120kg x 3.6 x 9.81 m/s2
Rear Impact Test:
Ff = 4233.6 N
 For Rear impact analysis
(Assumed G factor
= 3.6)
F= 120kg x 3.6 x 9.81
m/s2
Fr= 4233.6 N
Hence force was taken to
be 4233.6 N

Side Impact Testing:

For Side impact analysis
(Assumed G factor = 3.2)
F= 120kg x 3.2 x 9.81
m/s2
Fs = 3767.04 N
Hence force was taken to
be 3767.04 N

Roll Over Test:

These are the FEA Analysis of the kart simulated on the ANSYS 14.

COST ESTIMATED FOR THE PORTION IS AS:

Sl. No. PARTICULARS COST Grand Total
1. Roll Cage Material Rs. 5500
2’ Welding Charges Rs. 400
3. Roll Cage Finishing Rs. 300 Rs. 6,200
 2. Describe the steering mechanism of your Kart. Explain it along with proper diagrams/Images.
Also attach the pictures of your steering system if fabricated. Support your Write up with
Calculations and also highlight Cost for this Segment.
ABSTRACT:
Steering is the mechanism that allows the driver to controls the vehicle direction.
Steering convert the rotator motion of the steering wheel in a linear motion. This is made
possible by the linkage that connects the steering wheel to the wheels and tires.

We have designed our steering system to withstand the stress safely maintaining the
vehicle in any type of turning conditions.
The main consideration of our steering mechanism is to design a simple mechanism with
low steering ratios which achieve 100% Ackermann condition with quick steering response
as per as drive desired & also with minimum driver effort.

So, we decided to use linkage type steering which is truly based on Ackermann
condition because it is light in weight. Simple mechanism, low cost and easy to assemble.
INNOVATON DESCRIBED:
In eco-kart 2015 we are introduced multi hole sensitive steering plate with the adjustable
tie rod system. Sensitive plate increase and decrease the sensitive of steering mechanism
due to multy hole pivot point which allows adjusting the tie rod position according to path
condition.

We have introduced a ball bearing type steering cotter to minimize the driver effort or
steering effort at the time of turning condition. In this we are using a bearing which is fixed
at the upper end lower and of steering cotter. This gives the smooth rotator motion to the
cotter also minimize the friction between the cotter and C lock.
SPINDLE ANALYSIS:
DEFORMATION=4.8mm(max) FOS=4.3(min) STRESS=58MPa

BASIC CALCULATIONS: COST ESTIMATE:

PARTICULARS VALUES
SL. PRATICULARS COST
Inner lock angle 40º NO.
Outer lock angle 26.5º 1. Spindle & cotter Rs. 500
Turning Radius 2.1 assembly
Max. Turning Radius 3 2. Tie Rod & Sensitive Rs. 400
Min. Turning Radius 1.5 plate
Steering Ratio 6:1 3. Hem Joint Rs. 600
Lock to Lock turn 1.6 4. Steering kit Rs. 1500
Accr. Angle 29.6º
Rs. 3,000
Castor Angle 6º
Kingpin Inclination 8º
Tie Rod Length 15in
Ackermann % 100.9%
3. Describe the suspension mechanism of your Kart if used. Explain it along with proper diagrams. Also
attach the pictures of your suspension system. Explain used explain the necessity of use. Cost For this
Segment.
As it is not necessary to use the suspension in the Ecokart competition, so we have
decided not to use the suspension system this year. As the track and the terrain is not so
rough and the arena is quite smooth for the action so we have dropped the suspension
system for our kart.

If the suspension system would be used the geometry and the alignment of parts would be
so different, such that the kart’s full design and geometry will be different.

Generally in these kinds of events we use the two kinds of suspension which are very
effective and useful, and not so complicated in geometry. The Pushrod kind of suspension
and the double wishbone independent suspension are used in the formula vehicles are the
main consideration of these two kinds of suspension.

As we have planned our kart’s weight & cost up to minimum so we have removed extra
unnecessary assemblies in the kart so team has finally decided not to use suspension
system in the kart.
4. Describe the brake mechanism of your car. Explain it along with proper diagrams/Images. Also attach
the pictures of your brake mechanism if you have already fabricated. Support your write up with
Calculations. Cost For this Segment.
ABSTRACT:
The purpose of the brakes is to stop the car safely and effectively. In order to achieve
maximum performance from the braking system, the brakes have been designed to lock
up the rear wheels, while minimizing the cost and weight.

The brake system design includes the single disc at the rear axle to stop the vehicle. It is
mounted in one of the third part position of the axle with opposing the position of drive train
sprocket hence also enables the good balancing requirement.

Master cylinder is used at the front near the brake pedal providing the occupant to easily
accessible space. A proper master cylinder bore size was found by doing brake
calculations based on the mass, centre o gravity, master cylinder volume sixe and various
dimensions of the vehicle. Though braking power increased with a decrease in bore size,
the volume of brake fluid that was able to be displaced decreased with decreasing bore
size.
BRAKE CALCULATIONS: We are using Hydraulic Hand
Sl. PARTICULAR VALUE Brake System.
1. Braking Force 1059.48 N Brake Calculations:
2. Deceleration .9 g Sl. PARTICULAR VALUE
3. Stopping time 1.73s 1. Brake Force 741.69
4. Stopping distance 13.22 m N
5. Brake torque 105.948 N-m 2.. Stopping time 2.47 s
6. Disc Diameter 200 mm 3. Stopping 18.88 m
7. Area of Piston 13.255 cm2 distance
8. Brake line Pressure 30.1886 4. deceleration 0.6 g
Mpa 5. Handle Ratio 6:1
9. Pedal Fore 100 N
10. Pedal Ratio 4:1 Apache RTR 180 Rear calliper for
11. Brake Efficiency 72% hand brake
12. Static Axle load
At Front 48 kg
At Rear 72 kg
13. Dynamic Axle load
At Front 45.459 kg
At Rear 74.540 kg
14. Weight Distribution at braking
At Front 59.215 kg
At Rear 60.784 kg
 HEAT FLUX
MARUTI 800 Master Cylinder MAX HEAT FLUX = 1.46
w/M2

TEMPERATURE DISTRIBUTION
MAX TEMP. = 108.62° C
Brake CIRCUIT:

BRAKE CIRCUIT: The working of brake circuit starts DC power supply which runs the
motor. A contactor and condenser are installed in the circuit. When the brake pedal is
pressed it is necessary for motor to stop therefore contactor is installed which brake or
opens the closed circuit which previously running the motor. Hence the circuit break and
Brakes are applied. to the motor.
COST ESTIMATION
BRAKING
1. Disc Rs. 300
2. Caliper Rs. 1600
3. Brake Pedal Rs. 60
4. Brake Fluid Rs. 80
5. Brake wires Rs. 100
6. Master Cylinder Rs. 950
Rs. 3,090
5. Give the specification of you all the parts that you have bought from the market. Write in the details of
your Motor, Battery, Lights, Wires, Tires/Rim used, Dashboard specification and its features, Safety
measure in the kart. Calculate all suitable data for transmission and power train. Cost For this Segment.

ABSTRACT:

During our designing phase we have faced problems in fabrication all the parts as per or
requirement due to unavailable facilities. The other one is cost. If we fabricate all the parts
as per our requirement we will exceed our target cost which we have to minimize up to
maximum. So we brought some parts from market.

After the market analysis we found such parts are suitable for our requirements the list of
the parts which we have purchased from the market are as follows:

Roll cage material = AISI 1020 DOM

Body penal: Reinforced fiber
Chain sprocket set = hero Passion Pro
Speed controller = 40A – 48V 1000W
Calliper = TVS Apache RTR 180 Front caliper
Master Cylinder = Maruti 800 form foot brake & TVS Apache RTR 180 Rear Master
Cylinder for Hand Brake.
Brake Lines = Maruti 800.
Fire Extinguisher = 1 kg Dry Nitrogen Powder, ISI Marked.
MOTOR:
In AC/ BLDC/PMDC motor we are using PMDC motor with 3600 RPM 48 V, 11Amp. And
42 Amh and 2400 Watt having 12.8 N-m torque at 2400 RPM. Because it is fulfilling our
requirements it also provides maximum torque at the beginning comparison to other
motors.

Battery:
We are using two 12V and 46 Amh dry battries. It is better than the lead acidic battery
because its weight in less than the wet batteries and it has the less cost, as well as it
requires the less maintenance.

WIRE:
We are using ISI marked copper wire having ODI of 0.75cm. for less resistance the more
thick wire is used as we know that.

𝑅 = 𝜌 𝑙⁄𝐴.

As the current use is too high so we have selected the thick wires to use.

LIGHTS:
We are using round yellow headlights of power 35 Watt and we are using Red LED Tail
lights and Indicators of 10Watt that Clearly Visible when Brake will be applied.

TIRES & RIMS:

We are using SLACK Radial Tires Having Dimensions of
At Front: 10×4.5×5.
At Rear: 11×7.10×5.
These tires give a high coefficient of friction for a smooth Driving
and it is easily available in the market.

DASHBORAD:
we are using Reinforce Fiber Material for dashboard because this material was very cheap
and light weight and also a good strength and this easily available.

SAFETY POINTS:
Driver safety is our First priority for our. We are using five point harness seat belt and all
SFI rated accessories of driver. In our Kart two kill switches are assembled near the driver
and a fire extinguisher was installed at left side of the driver.
 TRANSMISSION:

OBJECTIVE
The drive-train is a very important part of the racing cars, taking into consideration that all
of the car’s power is transferred through the drive-train system to the ground. The
challenge is to harness the Motor 4 horsepower and distribute it to the ground in the most
efficient way. The drive-train needs to be able to operate in the lowest and highest gear
ratios while performing in all of the different aspects of the competition.

DESIGN
The goal of the drive train is to transfer power from the Motor installed in the vehicle to the
wheels. The power transferred must be able to move the vehicle. Acceleration is also an
important characteristic controlled by the drive train. There are several different methods
of power transmission that have been used in cars. The transmission used in our vehicle is
a Non-Geared Simple Chain Drive. The Transmission contains a single Chain & Sprocket
to connect to motor with the drive shaft directly through the help of chain to provide a fix
transmission ratio. Setup has an advantage in that it does not need any driver interaction,
and that it is mechanically simple. And also works on infinite no. of gear ratios according to
the speed of Motor.
BASIC CALCULATIONS:
On the observed calculation & Market Analysis we have selected the chain of Hero Passion
Pro chain Drive set.
Sl. Particulars Values
1. No. of teeth in Drive Sprocket 14
2. No. of Teeth in Driven Sprocket 44
3. Transmission Ratio 3.14
4. Dia. Of Drive Sprocket 4.5 cm
5. Dia. Of Driven Sprocket 17 cm
6. Pitch of Chain 1.587
7. No. of Chain link 90
8. Length of chain 1.29 m
9. Acceleration of kart 0.43 g
10. Max. velocity 60 kmph
11. Torque 25.01 N-m
COST ESTIMATE:
Transmission And Component : Rs.16000/-
Electricals & Lights: Rs.5400/-
Battery : Rs.4800/-

Drivers Safety accessories: Rs. 4000/-

 6. Describe the Material used and Body Work segment.. Also attach the pictures of the Body work if you
have already fabricated. Cost For this Segment.

ABSTRACT:
The most important part of any roll cage is material selection. A good material is
important because the roll cage needs to absorb as much energy as possible to prevent
the chassis from fracturing at the time of impact.

We have selected our roll cage according to the constrained given in the rule book. We
have selected medium carbon steel (AISI 1020) formally known as DOM for the fabrication
of our roll cage. We are using a tube of 1in. outer diameter with a 2mm wall thickness.

There are several advantages of using DOM, one such provides seamless tubing, the
other one is it provides good weight to strength ratio. It has higher ultimate strength in
comparison to AISI 1018; it is easily available as well as easy to weld.
For body work we are using GI sheet of 2 mm thickness for the chassis while the
dashboard and the body panels are made of reinforce fiber.

MATERIAL PROPERTIES OF AISI 1020 (DOM)

AISI 1020 steel can be largely utilized in all industrial sectors in order to enhance
weldability or machinability properties. It is used in a variety of applications due to its cold
drawn or turned and polished finish property.
CHEMICAL & MECHANICAL PROPERTIES:
Element Content Mechanical Properties Metric Imperial
Carbon, C 0.20 - 0.25 % Tensile Strength, Ultimate 394.72 MPa 57249 psi
Iron, Fe 99.08 - 99.53 % Tensile Strength, Yield 294.74 MPa 42748 psi
Manganese, Mn 0.30 - 0.60 % Elongation at Break 36.5 % 36.5 %
Phosphorous, P ≤ 0.040 % Reduction of Area 66.0 % 66.0 %
Sulfur, S ≤ 0.050 % Modulus of Elasticity 200 GPa 29000 ksi
Bulk Modulus 140 GPa 20300 ksi
Poisson Ratio 0.290 0.290
SL. NO. PARTICULARS COST
COST FOR THE FOLLOWING 1. Body Fire wall Rs. 400
SECTION: 2 Body Penals Rs. 400
3 Bearings & Bushings Rs. 195
Grand Total Rs. 995
7. Describe the Innovations in your Kart support them with calculations and Images. Cost for this Segment.

ABSTRACT:
innovation is new idea, device or process . innovation can be viewed as the application of
batter solution. This is achieved through more effective products, processes, services,
technologies or idea that are readily available to markets, government and society.

Same our team is doing for this event. We are using following as our innovation.

1. USING TRANFORMER BETWEEN BETTERY & MOTOR TO MAKE 24V DC

INPUT TO 48V OUTPUT.
Transformation ratio of step-up transformer
𝑉1 𝑁 𝐼
= 1 = 2 = 1/2
𝑉2 𝑁2 𝐼1
Where, V1 and V2 are the input and output potential.
N1 and N2 are the number of turns in primary and
secondary coils.
I1 and I2 are input and output currents.
Therefore, the ratio of number of coils is 1:2.

Advantages: this will decrease the weight of our vehicle because of two batteries of 12V
are used in Series here.

2. ELECTRICITY GENERATION BY WIND TURBINE: motion of the vehicle male the

kinetic energy of wind to work which rotates the fan and generate the electricity of
12V following are the volts obtained at different speeds of vehicle.
Volts generated by Wind Turbine: ADVANTAGES:

Sl. Speed of Volts It will work as a

vehicle generated power backup
1. 15 km/h 3.8 V and increase
2. 25 km/h 6V life of our DC
3. 35km/h 7.7V source.
4. 45 km/h 8.9 V
5. 60 km/h 11.9 V
3. PIEZIOELECTRI CRYSTALS ARE USED IN THE BUMPER OF THE KART TO
BLOW HORN IN ACCIDENTAL CASE.

COST ESTIMATED GOR THE INNOVATION PART IS ESTIMATED Rs. 3400/-

8. Showcase of full Vehicle Design with all Bodywork (3D CAD Model)

ISOMETRIC VIEW:

BODYWORK EXPLODED VIEW:

9. Left and Right Side Views, Top View and Front View of the Kart

SIDE VIEW OF KART

TOP VEIW OF KART

FRONT VIEW OF KART

10. Combined Cost Analysis and Your Market Price for the Kart.

According to the design and analysis on the basis of market value and fabrication of kart,
we are getting a cost of Rs. 49,200. In the given figure we have included the figure of the
whole kart. The part contained in the cost analysis and market value of the kart is taken
from the entire department separately. The cost of Rs. 49,200 contains the following
segments.
COST ESTIMATION
PARTICULARS COST AS PARTICULARS COST AS PER
PER MARKET MARKET
CHASSIS STEERING
1. Roll cage material Rs. 5500 1. Spindle & cotter assembly Rs. 500
2. Welding charges Rs. 400 2. Tie Rod & Sensitive plate Rs. 400
3. Roll cage finishing Rs. 300 3. Hem Joint Rs. 600
Rs. 6,200 4. Steering kit Rs. 1500
TRANSMISSION Rs. 3,000
1. Motor Rs. 15000 INNOVATIONS
2. Chain & Sprockets Rs. 400 1. Routers Rs. 400
3. Solid axle bar Rs. 300 2. Wind energy Circuit Rs. 500
4. Speed controller Rs. 1000 3. Capacitors Rs. 200
5. Accelerator pedal Rs. 60 4. Transformer Rs. 800
Rs. 16,760 5. Piezoelectric circuit Rs. 500
BRAKING 6. Converter Rs. 1000
1. Disc Rs. 300 Rs. 3,400
2. Caliper Rs. 1600 MISCELLANEOUS & DRIVER’S SAFETY
3. Brake Pedal Rs. 60 1. Firewall Rs. 400
4. Brake Fluid Rs. 80 2. Body Panels Rs. 400
5. Brake wires Rs. 100 3. Tires & Rims Rs. 6000
6. Master Cylinder Rs. 950 4. Bearings & Bushings Rs. 175
Rs. 3,090 5. Seat Rs. 375
ELECTRICALS 6. Driver’s Safety acce. Rs. 4000
1. Lights Rs. 200 Rs. 11,350
2. Wires Rs. 200
3. Horns and buzzers Rs. 200
Rs. 5,400 GRAND TOTAL Rs. 49,200
As per the above given figure of Rs.49, 200/- the vehicle cost as per the market value will
be Rs. 55596/-. Including 13% VAT.
11. Design Validation Plan Segment wise

The Design Validation Plan Of Our Kart is Given Below. The different segments are joined
in here: