BANGALORE INSTITUTE OF TECHNOLOGY

VIRTUAL BAJA PRESENTATION

STRATOS

INTRODUCTION
BAJA SAE INDIA OBJECTIVE: Baja SAE INDIA is an inter collegiate engineering design competition for engineering students. Each team is competing to have its design accepted for manufacture by a fictitious firm. The students must function as a team to design, build, test ,promote and compete with a vehicle within the limits of the rules. The primary objective of "STRATOS" is to pass the acceleration, hill climbing, maneuverability, endurance and various other test as demanded by the event effectively. RULES: Student Created:- use of professional assistance prohibited. Vehicle Configuration:- vehicle must have 4 wheels capable of carrying 1 person (63'') weighing (113.4kg max.)

TEAM ORGANISATION
Power Train
Divya Prakash Shreyas S Rohit Udit mittal Ashutosh Kumar Jeetender Joshi

Inventory
Kartik V. Akshat A.

Vehicle Dynamics
Vivek Dikshit Jeetender Joshi Amogh N Amogh Ashish Anand Nadish Roy

TEAM CAPTAIN
Ayan Roy
Marketing Fabrication
Madhushdhan Pravin kumar V
Sankalp Sahay Avishek Agarwal Arya Roy Varsha Kaushik

Design and Analysis

Aditya Chaudhury Ruchika Jain

DESIGN METHODOLOGY
Thorough study of the Rule book Establishing the key parameters and subsystem details. Getting the base chassis dimensions ready on the work floor Group Discussions to generate design ideas

Detailed design

Establishment of Vehicle Dynamics and Kinematics

Prototyping

Testing

Fabrication Re-Testing

CAR SUMMARY

TECHNICAL SPECIFICATIONS
1. a. b. c. d. e. 2. a. b. c. 3. 4. 5. VEHICLE DIMENSIONS (cm) MAXIMUM LENGTH MAXIMUM HEIGHT TRACK WIDTH WHEEL BASE GROUND CLEARANCE COCKPIT DIMENSIONS (cm) LENGTH WIDTH HEIGHT WEIGHT (KGS) MAXIMUM SPEED (Km/hr) ACCELERATION (m/s2) 165 118 152 146 15 120 75 118 350 60 1.57

* Design is 100% completely ready.

ROLL CAGE
Our roll cage is designed keeping vehicle dynamics; suspension design and human ergonomics in mind but using space efficiently to get superb handling and better acceleration. Material Specification : AISI 1018 steel will be used for roll cage and chassis having an ultimate Stress of 386 Mpa The diameter of the bar will be 26.9 mm having wall thickness of 3.5mm. Chromoly 4140 will be used for making wishbone and upright Young's Modulus is 210 GPa.

ROLL CAGE COMPLIANCE WITH RULE BOOK Rule Book Specs 162.65 cm 274.32 cm
Maximum thickness - 9.5 mm (0.375 in.) Hole diameter Minimum - 25.4 mm (1.0 in.) Radial clearance Maximum from hole 25.4 mm (1.0in) Hole to tube Minimum clearance 19.0 mm (.75 in)

Characteristic Width or track length Vehicle Length

Model Specs 151.488cm 235.36 cm

Thickness - 9.5 mm Hole diameter 25.4 mm Radial clearance 25.4 mm Hole to tube - 19.0 mm

Hitch plate

Front Bracing Members

Angle should be less than 45 degrees

30 degrees

FEA OF ROLLCAGE
Rollover Test : In rollover test , a force equivalent to the gross weight of the vehicle (3000N) was applied to one of the top corners of the frame while constraining the base. For a stress of 37.277 MPa the FOS obtained was 9.39 Frontal Impact Test : A frontal impact force of 4000N was applied at 4 points on the frame. the back of the frame was completely constrained. The deformation and stresses are shown below. for a stress of 127 MPa, the FOS obtained was 2.74.

TORSION TEST : For torsion test , a force equivalent to the gross weight of the vehicle (3000N) was applied at one of the 4 corners of the frame while constraining the other 3.
Deformation and stresses were as follows. for a stress of 81 MPa, the FOS obtained was 4.32.

HUMAN ERGONOMICS
Ergonomics is the application of scientific information concerning humans to the design of objects, systems and environment for human use.

The driver's line of sight The goal is to ensure enough of the race track in front is visible, and enough of the action to left and right is visible, through peripheral vision. The outer rear view mirror with power washer should act as an extension of the visible field. The steering wheel - The steering wheel is a tool of leverage thus we will be using a tilt adjustable steering wheel.

The Pedals - The pedals, like the steering wheel are a leverage item. We have ensured that the calf portion of the leg should probably not be at less than 120 degrees angle in relation to the thigh when the pedals are disengaged to ensure drivers legs safety in case of a crash. Other Controls - Positioning of controls such as the gear shift, kill switch, and adjustment knobs should be carefully considered. It does no good if shifting is hampered by the steering wheel, or if the kill switch is buried away from rescue crew access.

BRAKING SYSTEM
Assumed data The vehicle is travelling at 30km/hr. The mass of the vehicle is 350kg. The brake pedal is pressed with a force of 30kg i.e. 249.3 N The force amplified by the pedal is F(pedal)=249.3x(25/6)=1226.25N The tandem master cylinder has a brake bias of 60:40, the pressure is transmitted to rear and front brake caliper respectively in two different brake linings Brake pressure at rear P(r)=F(pedal)x(0.5)/area =1226.25x0.5/1.89e-4=3244047.619 N/m^2 At the calipers, F(caliper)=pressure x (net caliper area)=3244047.619x9.4287e-4 = 3058.7168N

Configuration: All four wheels with disk brakes with effective diameter of 0.8m Stopping distance in metres
35 30 25 20 15 10 5 0 0 5 10 15

Since the 2 brake pads are acting on the brake rotor, the net clamping force F(clamp)=F(caliper)x2=3058.7168 x 2 =6117.433N, the net brake force at the rear is F(clamp)x co-eff of fiction= 6117.433x0.4 =2446.97N this is the net brake force at rear wheels. Brake pressure at front Since the brake rotor is fixed to the P(f)=F(pedal)x(0.5)/area =1226.25x0.5/2.835e-4=2162698.41N/m^2 wheel hub they have the same torque, At the calipers, F(caliper) )=pressure x (net hence force on the tire is F(t)=torque/radius of the wheel caliper area)=2162698.41x9.428e-4 = =367.045/0.32=1147.01N 2038.99N Retardation = F(t)x(friction co-eff b/w Since the 2 brake pads are acting on the tire and road)/weight of vehicle brake rotor, the net clamping force and =1147.01x0.9/350=2.949m/s^2 considering the frictional losses Stopping distance = velocity F(clamp)=F(caliper)x2x(co-eff of friction)=2038.99x2x0.4=1631.192N this is squared/2xRetardation =8.33^2/2x2.949=7.79 meters the net brake force at front wheels. At static conditions The combine brake force is Front axle vertical load (Vf)= 122.68 kg 1631.192+2446.97=4078.162N Rear axle vertical load (Vr)= 227.32 kg Torque on the brake rotor=Brake force x % wt in front and rear are 36% and 64% effective radius of the respectively rotor=4078.162x0.09=367.034Nm

SUSPENSION
SUSPENSION AND WHEEL ALIGNMENT PARAMETERS: Front and rear : Double Wishbone with gas filled damper and adjustable coil spring. Camber angle : -1 0 to +1 0 Toe angle: -0.2 0 to +0.2 0 Castor angle: -2 0 to +2 0 Scrub radius : 6 mm Stiffness of spring (front): 240.58 lbf/inch Stiffness of spring (rear): 407.98 lbf/inch

SUSPENSION GRAPHS

WEIGHT TRANSFER
Weight transfer(WT)= (Retardation/acc due to gravity) x(vertical height of CG/wheel base) x weight of the vehicle =(2.949/9.81)x(241.3/1465.172)=17.32 kg During retardation due to the weight transfer the front axle vertical load changes to (Vf+WT)=140kg and the rear axle vertical load changes to (Vr-WT) 210kg Under dynamic conditions for the proper balancing of the brakes Front brake force/140= Rear brake force/210 1631.192/140=2446.92/210 11.65=11.65 and hence the brakes are balanced

STEERING
Applying the condition for correct steering, we have: cotx- coty = w/l = 60/146 = 0.41 Since, the above value is between 0.4 and 0.5, using the Ackermann steering gear mechanism, instantaneous centre lies on a line parallel to the rear axis at an approximate distance of 0.3l above it. Taking the maximum turning angle y = 45 deg, Cot x- Cot45 = 0.41 x = 35.34 deg. Let D be the turning circle Therefore, (D/2)(sin35.34) = l 0.3l = 102.2 D = 353.37 cm Or, Turning Circle = 3.5 m

ENGINE SPECIFICATIONS
Cylinders Displacement Bore Stroke Compression ratio RPM Rating N Cm3 Mm Mm 1 338 82 64 8.5:1 3000 3600 4000 7.4/10.0 8.1/11.0 8.3/11.3 6.6/9.0 7.4/10.0 23.7/2.42 342 6.0 1.2 30 35

Max Torque Min. Specific Fuel Consumption Fuel tank capacity Oil Sump capacity Max. Allowable Tilt For: Short Time Operations(max. time 30 minutes) Peak Values (max time 1 minute) Capacity Of Air Required For Correct Combustion At 3600 RPM Capacity Of Air Required For Correct cooling At 3600 RPM Dry Weight

N(80/1269/CEE) ISO 1585 kW/CV NA(ISO 3046/1 ICXN) kW/CV Nm/kgm g/kWh L L

l/min

550

l/min Kg

6000 31

Transmission : Mahindra Alfa transmission ( 4 forward and 1 reverse) will be used. It will be directly coupled to the wheels. Gear ratios will not be modified. 1) 2) 3) 4) 5)

Gear Ratio for different gears : 1 : 31.48 : 1 2 : 18.70 : 1 3 : 11.40 : 1 4 : 7.35 : 1 R : 55.08 : 1
Engine is directly coupled to gear box with splined shaft where the engine is behind the wheel to keep the engine and the gearbox in desired forward direction. Tyres: We are using BAJATRAX tyres for perfect Traction and torque required by an ATV with 13 rim

Drive Shaft length: 600 mm Drive shaft angle: 15 deg : Configuration

BODY WORK
We will be using FRP(Fibre Reinforced Plastic) to cover the roll cage and protect the subsystems.

INNOVATIONS
1. Box Upright It is an unique design of wheel uprights where the uprights are made hollow reducing the unsprung mass of the car but maintaining the same strength as of in a solid upright. We have planned to use chromoly steel to make the upright. We have done FEA of the upright and got FOS = 2.8.

Mechanical Shifting

2. E-Gear Shifter Introducing a revolutionary idea that delivers exceptionally smooth and swift gear shifting mechanism in an automobile. As the name suggests this gear shifter is an electronic based device, which gives a new dimension to accuracy and response time with minimum effort from the driver.

Infra Red LED Sensing

Microcontroller

Microcontroller controlled switch with timer programmed

Calibrated motor to shift CAM

Gear change

DESIGN FAILURE MODE EFFECT ANALYSIS (DFMEA)

Occurrenc e Detection 2 7 4 5 3 3 Severity Risk Priority No. (RPN) 126 100 72 S No. Subsystem (function) Potential Failure Mode Effects Ranking

1.1

1.2.

Transmission Multiply And distribute torque and speed between input and output shaft

Excessive torque and speed multiplication between input and output shaft Inadequate torq ue and speed multiplication between input and output shaft No torque and speed multiplication between input and output shaft

Unintended transmission function , noise factor

Low output from transmission (poor performance/ degraded performance) Transmission does not operate, Vehicle inoperable

1.3.

1.4.

Transmission

Intermittent torque and speed multiplication between input and output shaft( fluctuation is supply of torque) Differential does not work at all (both wheels rotate at the same speed)

Sluggish performance, intermittent performance of the machine

5 5

175

1.5.

Vehicle will drift or skid while making turns at higher speeds

3 4

108

Risk Priority No. (RPN)

S Subsystem No.

Occurrence

Detection

Potential Failure Mode

Effects

Ranking Severity

S No.

Potential failure Mode

Actions Taken Responsibility

1.1.

1.2.

Excessive torque and speed multiplication between input and output shaft inadequate torque and speed multiplication between input and output shaft No torque and speed multiplication between input and output shaft Intermittent torque and speed multiplication between input and output shaft Differential does not work at all(both wheels rotate at the same speed)

Ensure proper mating component for engine and transmission, Ensure internal gear ratios are suitable Internal part DFMEA, Transmission and engine compatibility should be maintained Replace Drive Shaft or Axle

Transmission Team

1.3.

1.4.

Check lubrication system

1.5.

Check for damages and rectify any

DESIGN FAILURE MODE EFFECT ANALYSIS (DFMEA)

Occurrenc e Detection 4 8 Severity Risk Priority No. (RPN) 320

S No.

Subsystem

Potential Failure Mode

Effects

Ranking

2.1.

Suspension

Rod end Breaking Rod end /rod end plate clearance Rod End Crushing Rod End Plate Breaking Tube breaking

Loss of wheel steer capability Loss correct suspension point kinematics High Steering Torque

10

2.2

378

2.3

270

2.4

Wheel Loss Wheel loss

10 10

3 3

9 9

270 270

2.5

S No.

Potential failure Mode

Actions Taken

Responsibility

2.1
2.2

2.3
2.4

Rod end Breaking Rod end /rod end plat clearance Rod End Crushing Rod End Plate Breaking

Avoid rod end clearance New caulking check procedure

Suspension Fabrication

New Caulking check procedure

Fabrication/design
Suspension

2.5

Tube breaking

Crush FEA Simulation Suspension

SAFETY FEATURES
Vertical clearance : A vertical clearance of 20 cm is provided from the helmet top of the team's driver to the bottom of the roll cage top members. Side Clearance : Ample space of 17.5 cm on either side of the driver's seat is provided. This facilitates easy movement of arms while shifting gears and steering the vehicle. Kill Switch ; Two easily accessible kill switches are provided for turning off the ignition and the entire electrical system of the car. Cockpit switch : It is located in the right side of the front of the cockpit placed at a distance of 40 cm from the distance of the seat which is within the easy reach of the driver.

External switch : It will be mounted on driver's right side of the vehicle on the panel perpendicular to the firewall between RRH and rear bracing behind the panel of the main roll hoop as mentioned in the rule book.
Seat Belt : We will be using 5 piece seat belt for complete driver safety.

TESTING AND VALIDATION : Extensive Physical and Virtual testing will be carried out for vehicle dynamics, that is Bump Steering. Cornering. Acceleration. Maneuverability, etc and will be tuned accordingly. Virtual test for collision through Lotus suspension and Suspension 3D program. Vehicle will be rigorously tested for distance of 100+ kilometers in dirt tracks and challenging terrains ( At Dirt Maniac, 20th mile Kanakpura, Bangalore ) VEHICLE COMPLETION DATE: 2011 TECHNICAL INSPECTION: After October 2011