Virtual presentation

TECHNICAL SPECIFICATION& KART VIEWS

PARAMETER VALUE
Overall length 69.01inch
Wheel base 45 inch
Track width 40 inch
Total weight 120kg
Weight distribution Front -42%
Rear -58%
Ground clearance 2 inch
Engine type CVT
Front track width 40 inch
Rear track width 40inch
Steering system Ackerman’s 4 bar
mechanism
Chassis type Ladder type
Engine mounting Centrally mounted FRONT SIDE
Material Mild Steel 1018 VIEW VIEW

Primary Member Outside dia.=25.4

Inside dia.=22.1
Secondary Member Outside dia.=25.4mm
Inside dia.=20.4mm

TOP VIEW
 CONFORMANCE TO RULEBOOK

Dimension of go cart Our kart According to rule

Wheel base must be 40 inch 55 inch

The vehicle must have 2 inch 2 inch

adequate ground clearance
Difference between front 40 inch 40 inch
track and rear track width
No. of accessible kill 2 kill switches 2 kill switches
switches
Clearance between side 3 inch 3 inch
bumper & driver seat
Clearance between driver 3 inch 3 inch
seat ,firewall & engine
DESIGN METHODOLOGY & MATERIAL SELECTION

 literature rule book  MATERIAL PROPERTIES

 internet – market survey
 safety- reliability
 managements
 sketch design
 design in software
 finalization & test
• Material = AISI1018
• Density = 7.9 g/cm3 (490 lb./ft3)
• Elastic = 210GPa (30 x 106 psi)
• Poisson's Ratio = 0.29
• Specific Heat Capacity = 450 J/kg-K
• Strength to Weight –Ratio= 54 to 59 kN-m/kg
• Thermal Expansion=12 µm/m-K

 MATERIAL SELECTION PROCEDURE

material of less weight without compensating the strength was taken in
consideration. Two thickness were taken as per frame design requirement
having the outer diameter of 25.4 mm.
 FRONT IMPACT ANALYSIS

 SIDE IMPACT ANALYSIS

 REAR IMPACT ANALYSIS

 STEERING SYSTEM
• Advantages of Ackerman 4 bar mechanism
PARAMETE CALCULAT STANDARD
 Simple in construction.
R ED VALUES VALUES
 Cost is less.
 Light in weight . Steering ratio 12:1 12:1
 Moderated efficiency Camber angle 0 degree 0 degree
Caster angle 0 degree 0 degree
Steering wheel 12 inch 12 inch
diameter

Inner turning 38.21 degree -

angle
Outer turning 26.71degree -
angle
Turning radius 1.838m 1-3m

Turns lock to 60 degree up to 65

lock degree
 POWER TRAIN
PARAMETER VALUE/ DISCRIPTION

Transmission type Continuous variable transmission

Manufacturer Honda

Capacity 124.9cc

Max. power 8.6bhp @ 6500rpm

Max. torque 10.12Nm @5000rpm

Top speed 85kmph

Engine model Honda activa 124.9cc

 BRAKE SYSTEM
METHODOLOGY-
1.List Out Design Requirements.
2.Calculate Tire Forces.
3.Assign Maximum Deceleration Of The Vehicle .
4. Calculate Target Braking Torque
5.Calculate Minimum Stopping Distance

PARAMETER VALUE /DISCRIPTION

Torque generated is
Brake Type Disc Brake On Rear Axle always more than
Tandem Master Cylinder 13 torque required.
Diameter
Caliper Piston Diameter 25.4
Pedal Force 245.25N
Leverage Ratio 4:1
Brake Force 558.67N
Disc Diameter 190mm
Deceleration 9.31m/s^2
Stopping Distance 6.62m
 COST REPORT
Sr. No. Systems Materials Processes Fasteners Tooling Total
Brake
1 System 4000 200 200 100 4500
Engine and
2 Transmission 25000 1000 200 300 26500

3 Frame 8900 500 300 200 9900

4 Body 2200 150 50 50 2450

Instruments
5 & Wiring 2900 50 50 50 3050
Steering
6 System 1500 100 200 100 1900
Wheels &
7 Tires 18000 50 400 50 18500
Miscellaneou
s, Fit &
8 Finish 3500 200 100 50 3850
Total
70650
GANTT CHART
 COLLEGE FACILITIES
Machines :
Wind Tunnel
Milling Machine
Grinding Machine
Radial Drilling Machine
Plastic Molding m/c
Lathe Machine
CNC Lathe
Cutting Machine
Bench Vice
UTM
Bending Machine
Portable Welding m/c
Instruments :
Vernier Calipers
Micrometer Screw Gauge
Vernier Height Gauge
Thread Gauges
Slip Gauge
 TEAM
ORGNIZATION

DESIGN & BRAKE

ANALYSIS SYSTEM

Kudale sujit
Kharde shubham
Kumbhojkar
Parulekar anuj
TEAM shubham
Jadhav Rahul
TRITANS Attar sufiyan

STEERING ENGINE &

SYSTEM TRANSMISSION

Sadanshiv shubham
Zadge devendra Chavan chetan
Kalbhor lalit Saurabh shendge
Kale akshay
 DESIGN VALIDATION PLAN
No. Component Description Acceptance Responsible Test Resource Remarks
Criteria Person
Stress should Chavan Ansys Design is
FEM Analysis of be below
1 chetan safe.
ANALYSIS chassis 445mpa

Steering Sadanshiv Manual Works

should able shubham properly
To check
to sustain
2 STEERING Function of cornering
Steering load under
steer
Vehicle Kudale Manual Works
To check should stop Sujit properly
3 BRAKING stopping in desired
distance distance

To check Minimum Kudale Manual Ok

4 TYRE wheel are Tyre Wear Sujit
balance
Electrical Kharde Manual Works
To verify
system shubham properly
ELECTRICAL working of
5 should
SYSTEM electrical
works
system
properly
 DFMEA
POTENTIAL CURRENT
POTENTIAL POTENTIAL
PROCESS STEP FAILURE SEV OCC PROCESS DET RPN
FAILURE MODE CAUSES
EFFECTS CONTROLS
too much load or use of bends
the frame bends 8 shock applied 3 instead of welded
FEA structural failure 3 72
or brake leading to exes joints as far as
axial stress possible.
lack of clean air
possibility of
mechanical 5 and fuel to 4 use of clean fuel
engine explosion, 3 60
failure maintain operation and lubricant.
inability to operate
.
3 puncture by 2 use good condition
tyre mechanical inability to operate 2 18
debris& explode tyre and handle it.

fluid leakage failure of breaking breakage of fluid to find oil leakage

break failure & air trap , system or very less 6 line and wear due 3 body to check oil 2 36
bleeding failure breaking. to overhauling. level.
check it
impact, shear and failure of steering 7 frontal impact and 4 regularly. 2 56
steering
bending failure system excessive

Leakages & loss of fuel & loose repair the

carburettor dirt in fuel damage engine 6 connections 4 leakages 2 48
component

short circuit & damage of improper

electrical high voltage electrical 6 connections 2 proper wiring and 2 24
components system inspection.

damage improper
bending 6 handling 6 proper inspection 2 72
body panel &impact & rigid mounting
 ERGONOMICS AND INNOVATION
• maximum vision of the road.
• Cushion tilted so that front edge is in lowest
• positional Avoid pressure behind the knee
• Driver Visibility : 300 degree
• Fire Extinguisher : B Class
• 2 Master Kill Switch
• Fully safe driver suite & shoes pf FIA standard
• 1 Brake Over Travel Switch
• H Type Harness Seatbelt (76 mm Lap Belt) :
SFI 16.1
 EXTERNALLY ENGINE COOLING
This innovation inspired from F1
racing car. This is first time used in
go-kart in which air duct are used for
cooling the engine. On hot summer
days temperature of engine reaches
critical temperature, to cool engine
and to achieve maximum efficiency
as well as we can drive our go kart at
more speed and for more time than
other go karts .
Assumption:
THANK YOU !