SAE NIS EFFI-CYCLE 2014

VIRTUAL ROUND

Team Name: INFINITY

Team ID: 14200
Indian Institute of Technology, Kanpur
Kanpur, Uttar Pradesh
North Zone
DESIGN METHODOLOGY
Tadpole
Fairing
Fairing Design Adjacent
Adjacent
Riders
Riders

Chassis
Chassis Recumbent
Recumbent
Material
Material Seating
Seating
Selection
Selection

Front
Front
Chassis
Chassis Underseat
Underseat
Development
Development Steering
Steering

Rear
Rear Wheel
Wheel
Braking
Braking Drive
Drive

Suspension
Suspension
and
and Wheel
Wheel
Assembly
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Fairing
Fairing
Adjacent
Riders

Chassis
Chassis
Material
Material
Selection
Selection Recumbent
Seating

Front
Front
Chassis
Chassis Underseat
Underseat
Development
Development Steering
Steering

Rear
Rear Wheel
Wheel
Braking
Braking Drive
Drive

Suspension
Suspension
and
and Wheel
Wheel
Assembly
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Adjacent
Adjacent
Fairing
Fairing Riders
Riders

Chassis
Chassis Recumbent
Recumbent
Material
Material Seating
Seating
Selection
Selection

Front
Chassis
Chassis
Development
Development Underseat
Steering

Rear
Rear Wheel
Wheel
Braking
Braking Drive
Drive

Suspension
Suspension
and
and Wheel
Wheel
Assembly
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Adjacent
Adjacent
Fairing
Fairing Riders
Riders

Chassis
Chassis Recumbent
Recumbent
Material
Material Seating
Seating
Selection
Selection

Our
Vehicl
e
Front
Front
Chassis
Chassis Underseat
Underseat
Development
Development Steering
Steering

Rear
Braking
Braking Wheel
Suspension
Suspension
Drive
and
and Wheel
Wheel
Assembly
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Adjacent
Adjacent
Fairing
Fairing Riders
Riders

Chassis
Chassis Recumbent
Recumbent
Material
Material Seating
Seating
Selection
Selection

Front
Front
Chassis
Chassis Underseat
Underseat
Development
Development Steering
Steering

Rear
Rear Wheel
Wheel
Braking
Braking
Suspension Drive
Drive

and Wheel
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Adjacent
Adjacent
Fairing
Fairing Riders
Riders

Chassis
Chassis Recumbent
Recumbent
Material
Material Seating
Seating
Selection
Selection

Front
Front
Chassis
Chassis Underseat
Underseat
Development
Development Steering
Steering

Rear
Rear Wheel
Braking Wheel
Drive
Drive

Suspension
Suspension
and
and Wheel
Wheel
Assembly
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Adjacent
Adjacent
Fairing
Fairing Riders
Riders

Chassis
Recumbent
Material Recumbent
Seating
Seating
Selection

Chassis Front
Front
Underseat
Underseat
Design Steering
Steering

Rear
Rear Wheel
Wheel
Braking
Braking Drive
Drive

Suspension
Suspension
and
and Wheel
Wheel
Assembly
Assembly
DESIGN METHODOLOGY
Tadpole
Tadpole
Design
Design

Adjacent
Fairing Adjacent
Riders
Riders

Chassis
Chassis Recumbent
Recumbent
Material
Material Seating
Seating
Selection
Selection

Our
Vehicl
e
Front
Front
Chassis
Chassis Underseat
Underseat
Development
Development Steering
Steering

Rear
Rear Wheel
Wheel
Braking
Braking Drive
Drive

Suspension
Suspension
and
and Wheel
Wheel
Assembly
Assembly
 Its
 Tough
 Fast
 Comfortable
OVERVIEW OF THE VEHICLE
Aerodynamic

You’ll love it!

 TECHNICAL SPECIFICATION
Dimensions 90”X51”X48”

Weight 75 kg

Weight distribution 58 (front) :42 (rear)

Motor Specifications 400 W, 1500 RPM, 48 V

Battery Specifications Li-ion Battery 48 V

35A-hr (48V 15 Ah +
48V 20 Ah) Side View of our Vehicle
 PROJECTED PERFORMANCE
Minimum torque required to start 5 Nm

Battery charge Time 8 hrs

Battery run Time 3.5 hrs

Minimum turning radius 3.5 m

Stopping distance (max. speed) 4.7 m

 Vehicle performance:

QUANTITY MOTOR HUMAN+MOTOR

Max. Speed 32 kph 49 kph
Initial Torque 28 N-m 38 N-m
Speed in 0-10 sec 15 kph 23 kph
 FRAME MATERIAL SELECTION
Parameter IS 3074 1018 1020 4130
Basis of material selection
 Strength Weight 4 2 4 4
Cost 3 4 3 1
 Availability
Manufacturability 4 4 4 2
 Cost Strength 4 1 3 4
 Manufacturing operations Total 15 11 14 11

Selected Material :
IS 3074
Yield strength : 430 MPa

 Cost is much lower than AISI 4130.

 More durable and corrosion resistant.
 Nearest International Equivalent Specification : ASTM A-513
 Recommended Welding Process : MIG
 CHASSIS DESIGN
 Low weight and firmly rigid.
 Very low center of gravity to give more stability.
 Roll hoop and side structures with paddings on both sides to give topple
protection and side impact protection.

Wheelbase 50”

Track-width 52.24”

Ground Clearance 8.5”

Seating Height- 13”

Isometric View of the Chassis

 STRUCTURE RIGIDITY ANALYSIS
Static Analysis Roll-Over Analysis Side Impact Analysis Front Impact Analysis

Maximum Stress 105 155 152 145

(MPa)
Maximum 3.8 34 15 10
Displacement
(mm)
Minimum FOS 4.3 2.9 3.0 3.1

*Impact force 100kgf, Weight of riders 120 kg, Payload = 20 kg

 FRAME SELECTION

Tubes (circular cross- section) for the frame as-

 Tube is better than Beams under torsion.
 Tube has better performance in unpredictable
loads case.
 Tubes with OD 1.25”, thickness 2.5 mm for
highly stressed structural members .
 Tubes with OD 1”, thickness 1.5 mm for
relatively less stressed structural members to
reduce the weight of the chassis.

Isometric View of Chassis

 DRIVE TRAIN

HUMAN MOTOR
BLDC MOTOR 400 W 1500 RPM
Ratchet mechanism between 48V
pedals and front shaft
Gear box 3.61:1
Pedal to Rear wheel gear ratio Motor to Rear wheel gear ratio
from 1.1 to 3.9 from 0.3 to 1
Li-ion Batteries 48V 35 A-hr
Front and rear derailleur Ratchet mechanism
between rear wheel and main
shaft Controller and throttle!

Maximum power
Optimized gear
INDEPENDENT during
ratios to save
COASTING simultaneous
energy!
run
 Drive analysis
Steady state speed, mass 250 kg
0 degree 32 kph
1 degree 22 kph
2 degree 14.7 kph
5 degree 5.3 kph

Critical mass on 5 340 Kg

Electric drive, Speed vs time degree
Critical slope on 300 5.7 deg
kg

18

5 degree, distance vs time

 SEATING
 Aim of seating: Driver can maintain a comfortable position well over a hundred miles.
 Recumbent seats reduce the force per square inch on the stays. Torso support is reclinable
relative to thigh support. Less need of suspension.
 Adjustable angle of recumbent seats increases comfort manifold.
 Material to be used for frame: Wood
 Seating Height: 13”
 Inclination variable from 120° to 150°
 Distance of handle from H point
in neutral position = 9”
Distance of H point from pedal axle:
Vertical = 1.6” Horizontal = 27”
 STEERING ASSEMBLY
Handle Bar  Challenge:
Unsymmetrical steering
with single tie rod and a drag link
 Front Wheel -Under Seat-Indirect-
Drag link Steering System.
 Handle – Aluminium grade 6061
Tie Rod
 Tie rod and drag link - HDG Steel
Steering Assembly

Minimum turning radius 3.5 m

Critical speed 18.9 kph

Handle span -20° to 20°

Drag link 39”

Tie rod 31”

STEERING ANIMATION
 STEERING SYSTEM ANALYSIS
ACKERMAN GEOMETRY
Geometric representation 60
50
d 40

Right wheel turn

30
Practical
 20
10 theoretical

`
0
0 5 10 15 20 25 30
Left wheel turn(in degrees)

For fixed ‘d’ and track width, we optimized ‘’ to minimize

deviations from Ackerman by iterative algorithm.

Steering angle () =

37.5°
 BRAKING SYSTEM

 Non-hydraulic mechanical braking mechanism.

 Disc brakes in all three wheels.
 Mechanical cable actuation.
 Rotor : 16cm diameter.
 Force on rotor=2.1kN.
ROTOR

BRAKING DISTANCE 4.7

m at max speed

CALIPER

Disk Brake
 WHEELS
Front Wheel dia: 24”X2.1”
Rear Wheel dia: 26”X2”

 Bigger wheels generally roll faster, roll over road obstacles better, and are generally more
comfortable.
 They also provide more gyroscopic feel, like an upright bicycle.

TUBELESS
TIRES!

Wider
wheels for
off road
Wheels connected to chassis
toughness
 SUSPENSION

Suspension connected to chassis and wheel

Force constant 385 kgf/in

Suspension connected to wheel
Force per front wheel 72 kgf
Front:
Stationary compression 4.7 mm
Spring Suspension
Free length 6”
 KINGPIN AND UPRIGHT
 Pivot through headset to chassis
 Upright material : Stainless Steel sheet of thickness 6 mm.

Caster angle Kingpin angle Scrub radius

10° 17.5° 8 mm

Disc brake calipers mount

Front wheel
axle

Drag Tie rod

link

Upright design
 FAIRING
Light weight

High
Temperature
Resistant

Polycarbonate Weather
sheet Resistant

High Impact
Resistance

U.V. Stabilized

Windshield to reduce drag

 SAFETY FEATURES

BUMPER IN FRONT WINDSHIELD

SIDE PROTECTION ROLL OVER HOOP

 Enclosures to motor and battery, Insulating wool behind the seats.

 Seat belts to both drivers, front and tail lights.
 Chain cover, sprocket covers, mudguard.
 Factor of safety of chassis : 2.9.
 No sharp edges, only rounded corners.
 Every moving part is atleast 3” far from riders.
 UTILITY AND PURPOSES

 Payload box dimension: 16”X12”X8”, thickness- 10mm

1. Restaurants and food chains providing home delivery services
2. Courier and post services

 Can be used conveniently for day to day travel over short and
long distances in cities .

 Fun-rides at zoos, wildlife sanctuaries and amusement parks.

 Can be used in petrol/diesel vehicles prohibited areas such as area

surrounding the Taj Mahal at Agra where it can provide an alternate for CNG vehicles.

 People having issues with back or some lazy ones who want to stay fit but avoid gym can use
it as means to exercise by cycling and switch on to electric drive only whenever feel tired up.
 OBJECTIVES OF OUR VEHICLE
• USP: Wide range of customers: Students, teachers, workers,
environmentally aware people, people with neck and back issues, assisted
Commercially viable handicapped patients etc.
• No balance issues and can ride with your partner.

• No petroleum based fuel and zero emission vehicle.

Sustainable and green • Best when travelling short distances.

Ergonomically • Safety measures and structures.

designed • Comfortable seating, supporting thigh, torso and head of the driver.

Aerodynamically • Full frontal fairing.

engineered • Less frontal area exposed.

• Easily operational and quickly adaptable steering.

Consumer friendly • Support handle to the left driver.
• Seat belts, bottle holder, front and tail lights have been installed.
 INNOVATIONS

 Recumbent seat with changing recline

Comfortable for long journeys.

 Unsymmetrical under-seat indirect steering

Comfortable with recumbent seats.

 Independent coasting
For those little breaks in between.
 WORKS SO FAR

PVC Structure of the chassis

 Market visits
 Sample inspection
 Quotations of motor
and batteries
 PROJECT PLAN
31/3/14 20/4/14 10/5/14 30/5/14 19/6/14 9/7/14 29/7/14 18/8/14 7/9/14 27/9/14 17/10/14

BRAINSTORMING
Completed
SOFTWARE TUTORIALS
In progress
DESIGNING SUB SYSTEMS To be started

DESIGNING ASSEMBLY

MARKET VISITS & COST ANALYSIS

P.V.C STRUCTURE

DOCUMENTATION AND PRESENTATION

MANUFACTURING

VIRTUAL ROUND

TESTING PHASE

REPAIR AND MODIFICATION

 TEAM STRUCTURE
Faculty Advisor
Prof. Avinash Agarawal

Team Captain
Rajkamal Kumar
Y11 CE

Suspension and
Power Wheel Assembly
Chassis Design Braking System Steering System
Transmission

Hitesh Jangid Aman Rusia Rohit Kumawat Sourya Basu Aman Trigunait
Y12 ME Y12 ME Y13 ME Y13 EE Y13 ME

Jaiprakash
Himanshu Chaurasia Mrinal Mahajan Aditya Jain
Kumawat
Y12 ME Y13 ME Y13 ME
Y13 ME

Shubham Thakur Vaibhaw Kumar

Y13 CHE Y13 EE
 Acknowledgements

 Solidworks premium 2014

 Matlab R2013a
 Electric Machinery - Fitzgerald Kingsley Uman
 Engineering Mechanics Dynamics – Meriam and Kraige
 Sheldonbrown.com
Do you have any questions?