Electric solar vehicle

championship-2014

MOLTRES

Team. I.D.-ESVC030
SUMIT MITTAL (c)

RAHUL KUMAR

AMAN DAGAR

DEVAN BHARDWAJ

Project Management

Team Management
Sr. No.

Student name

Designation

Department

Work Assigned

Sumit Mittal

Captain

Transmission

Selection of components, Calculation, Innovation

Farrukh Ahmed

Team Member

Transmission

Market survey, Calculation

Devan Bhardwaj

Team Member

Transmission

Innovation

Deepak Raina

Vice Captain

Designing

Analysis using Ansys and Solid works

Prasanjit Biswas

Team Member

Designing

Market survey, Designing of Component

Naresh Kumar

Team Member

Designing

Designing of components

Shubham Sood

Team Member

Braking

Selection and study of components

Akshansh Dwivedi

Team Member

Braking

Calculations

Aman Dagar

Team Member

Suspension, Steering

Selection of mechanism and component

10

Satish Kumar

Team Member

Suspension

Market survey, Calculation

11

Atif Amim

Team Member

Suspension

Calculations

12

Amit Kishore

Team Member

Steering

Market survey, Calculation

13

Praveen Kumar

Team Member

Steering

Calculations

14

Indrajit Biswas

Team Member

Solar

Selection of Solar panel and Battery

15

Manoj Kumar Rana

Team Member

Solar

Market Survey

16

Chirag Banga

Team Member

Solar

Selection of charger and Mppt

17

Gautam Kumar

Team Member

Electrical

Selection of Motor and controller

18

Rahul Kumar

Team Member

Electrical

Market survey, Calculation

19

Akshay Dogra

Team Member

Electronics

Market survey

20

Akshay Mittal

Team Member

Electronics

Selection of Battery charger

CADD MODEL
Objective

Method

To produce lightweight, reliable and

stable Solar powered vehicle that can
be used safely for everyday .

Designing vehicle by considering

suspension, transmission and Focused
on keeping Center of Gravity as near
as possible to the ground.

Roll cage

Side view

Result
Vehicle with track width 5ft and
Wheel base 6.5 ft having tadpole
configuration with RWD is
accomplishing all the objectives.

Roll cage with assembly

Complete assembly with bodyworks

Front View

Simulation
Objective

Method

Result

To design a safe roll and comfortable roll

cage for driver

Designing of roll cage with proper dimensions

using material with good strength and low weight

Design of an efficient roll cage with factor of

safety 3.8 in front impact test at 15kN load of
material AISI1020 DOM weighing 44kg.

Front Impact Test(5G)

FOS -:3.8
URES -:1.5mm

Rear Impact Test(4G)

FOS -:1.3
URES -:1.6mm

Side Impact Test(2G)

FOS -:1.8
URES -:1.464mm

Static Impact Test(1G)

FOS -:3.7
Torsion Impact Test
FOS -:4.5

Safety & Ergonomics

Safe Roll cage design.
Evacuation-Easy entry & quick exit possible.
Driver gears-helmet, goggles, suit, neck collar, restraints.
Tube Padding-The minimum required thickness is .inch.
Kill Switches- 2 required, cockpit & external.
Safety Harness- 4 strap system, 3lap belt, quick release connection
Wires properly insulated.

Ergonomics
Sitting without back pain.
Check your seating position in mirror
Seat back angle 110-120
Seating too far from the tire
Visibility angle more then 210

SOLAR SYSTEM
Objective

Methods

VALUE

MAX. POWER (Pm)

140W

MAX. VOLTAGE (Vm)

19V

MAX. CURRENT (Im)

7.2A

OPEN CIRCUIT VOL. (Voc)

25.5V

SHORT CIRCUIT CUR. (Isc)

8.3A

MODULE EFFICIENCY (%)

13.5

CELL TYPE

POLYCRYSTALLINE

CELL DIMENSION(MM)

156X156

DIMENSIONS(MM )

1465X650X35

WEIGHT(Kg)

Max. Power output from panel is 560 watts

150

power

SPECIFICATION PER PANEL

10
8
6
4
2
0

power

SOLAR PANEL

Use of four panels with polycrystalline

cells

current

Use of max. efficiency solar array.

To charge battery as soon as possible with panel.

Results

100
50
0

20

40

voltage
V-I CURVE

AC TO DC CHARGER

INPUT AC VOLTAGE

220V, 50Hz

OUTPUT DC VOLTAGE

12V

OUTPUT CURRENT

7A

10

current

20

voltage

I P CURVE

V-P CURVE

PARELLEL CONNECTION OF SOLAR PANEL CIRCUIT CONNECTION

BATTERY

CHARGE CONTOLLER
CHARGER TYPE

150
100
50
0

CIRCUIT FOR CHARGER

BATTERY TYPE

LEAD-ACID

RATED VOLTAGE

12V

CAPACITY

20AH

CHARGING CURRENT

7A

DISCHARGING CURRENT

30A

40

Power Train
Method
Mounting of motor very near to wheel
with less rotating parts

PARAMETERS
MOTOR

D.C MOTOR (12V-60A)

TYPE

BRUSHLESS MOTOR

MOTOR POWER

0.75 hp

MAX TORQUE

10 N-m

MAX. RPM

2500

TRANSMISSION

Use of A. R. CVT

Motor
RPM

Efficient use of Power and effective

transmission

Result

A.R. CVT
Axel
Tire

3000
2500
2000
1500
1000
500
0
0

20
40
Current

60

20

60

2500
2000
1500
1000
500
0

RPM

Objective

40
Speed

Axial Radial CVT

MOTOR CONTROLLER
SPECIFICATION

Gear Ratio

5.4 to 4.2

Tire

16*3.5

Controller type

PWM

Max. Speed

42kmph

Rated voltage

12V

Max. Traction

239.2 N

Rated current

60A

Rated power

720W

Max. Torque

48.9 N-m

BRAKES
Objective

Methods

To stop vehicle at minimum distance

as per the criteria of competition.
STANDARD PARTS & DETAILS

Results

Use of disc brakes both in front and

rear wheels.
QUANTITY

Honda Aviator

Brake
Calipers

Honda Aviator

Tandem
Master
Cylinder

Maruti 800

Velocity Vs Stopping dis.

Stopping distance

Disc

At velocity 30 km/hr vehicle comes to

rest in 4.4 m

6
4
2
0
0

10

15

20

25

velocity

SPECIFICATIONS BRAKING
Leverage Ratio

1:7

Master Cylinder
Diameter

19 mm

Tire Outer Diameter

Front

Rear

406.4mm(16)

406.4mm

Velocity (km/hr)

Stopping distance (m)

20

2.1

30

4.4

40

6.8

Exploded view of wheel assembly

Weight distribution is 60:40, ; if the vehicle stops within 4.4m, then weight transfer of 20 kg from rear
to front will take place. Now, the weight distribution is of 70:30.

30

STEERING
Objective
Turn effectively with reduced
human effort for maneuvering.

Method
Use of Positive Ackerman
Geometry

Result
Minimum turning radius is 11.12
feet

Parameters
Steering Type
Steering Ratio

Centered Rack &

Pinion
11:1

Max Steering Angle

40

Minimum Turning Radius

11.12 feet

Steering Column Height

1.03 feet

Steering Column Length

2.57 feet

Length Of Rack

0.694 feet

Length Of Tie Rod

1.215 feet

Steering Arm Length

0.42 feet

Ackerman Angle

22.75

Table : Steering Geometry Summary

Figure: Steering System Design

Figure: Steering Geometry Drawing

Suspension
Objective

Methods

Results

To obtain safe, reliable and comfort ride, having

easy manufacturability

Front-SLA Suspension

Negative camber gain in front.

Rear- Trailing arm

Graph 1: camber vs. roll angle

FEA (KNUCKLE) ,FOS- 19

URES- 3.23mm ,LOAD- 2000 N

Graph 2: toe angle vs. bump

FEA (LOWER WISHBONE), FOS- 13

URES-1.94 mm, LOAD- 2000 N

Camber, Caster and Toe are optimized in Lotus Suspension Analysis.

Suspension geometry

Angle (deg)

caster

camber

KPI

10

upright

The lower control

arm mounts level to
the axle and the upper
control arm mounts
at point roughly level
to the top of the
wheel.

Anti-squat

76.1%

Anti-dive

48%

Innovation
Objective

Method

Result

Easy and effective transmission

Use of Axial Radial CVT

Gear ratio is continuous and can

be controlled manually.

gear wheel1
Variable dia
pulley

gear wheel2
Constant dia
pulley

Advantages
Need no clutch to change gears
Smooth and continuous gear changing
Compact
Light in weight
Low maintenance
Easy to operate

Design validation plan

Test of

Test name

Test method

Acceptance criteria

Location

Remark

Assigned to

Brakes

Bleeding
test
Panic brake
test

Continuously press the peddle

and check for leakages.

If no leakage then it is
under safe condition.
If all wheels are locked,
braking is efficient.

Workshop

Add more fluid ,tighten

hose & connector.

Shubham

University
ground

If all the wheels do not

lock then do bleeding .

Shubham

Stopping
distance
test

Run vehicle at max speed, apply

brake & check stopping distance.

Braking Efficiency
accepted at 80 % under
working.

University
ground

Akshansh

Suspen
sion

Impact on
suspension

Run vehicle at 45kmph and drive

it over bump & observe its
condition on landing .

Damping time should

be less on impact .

A bumpy
road

If <80 then increase

leverage ratio & check
for peddle force .
If condition unsatisfied
change damper & adjust
spring .

Roll
cage

Material
selection

Using material having C content

of 0.18% conduct different tests.

It should satisfy the par

-ameters for main event

Material
testing lab

In any problem consider

high carbon content .

Prasanjit

Weld
strength

After fabrication check for any

bend & crack in welded area .

There should not be

any bend or crack at
welded

A high
podium

In failure welding is
done again for strength.

Deepak

Steering

Maneuvera
bility test

Drive the vehicle on zigzag path

& travelling at much corner
without crossing the boundary.

The vehicle should

move within the path &
be smooth & easy.

Bumpy
track

Adjust the component

in any failure .

Amit

Transmi
ssion

Tuning Test

Drive vehicle on a smooth track

and note readings of Tachometer
and Speedometer and compare
the readings with ideals.

Results should be as
close as possible to
ideal curve .

Smooth
Track

In case of deviation
from ideal curve make
adjustments with
controllers for tuning.

Sumit and
Rahul

Electric
al

Efficiency
test

calculating voltage current and

power by multimeter
&wattmeter to draw graphs.

Efficiency should be
near about the given
efficiency of the panel.

workshop

Proper inclination of
panel and proper
insulation .

Indrajit &
Akshay

Load test at
no load

To check maximum rpm and

minimum current.

Rated rpm should be

obtained at no load.

Electric
lab

Armature control

Rahul

Load test at
full load

To check maximum torque and

maximum current.

Rated current should be

obtained for maxtorque

Electric
lab

By field control

Gautam

At 42 km/h apply brakes & check

for locking of all wheel.

Aman Dagar

DFMEA
Item

Potential Potential
Failure
Effect of
Mode
Failure

SE Potential
V Failure Cause

Roll Cage

Roll Cage
Welding
Bends/
Breakage
Breaks

failure of Decrease
Solar System solar
in Power
system
output

O Current
C Process
R Controls

Excessive load
6 TIG Welding
applied

Action Results

D
E RPN
T

Recommended Responsi
Action(s)
bility
Action Taken

7 294

High Factor of
Safety

Prasanjit
Biswas

Re-weld
properly

7 280

Proper
installation of
solar panel
&appropriate
selection

Indrajit
Biswas

Solar panels are

properly
4 4 3 48
mounted

S OD
E C E RPN
V R T
7 4 3 84

Harsh driving
appropriate
&inappropriat 5
Solar system
e selection

Standard Rack
8 and pinion
7 336
system

Verification of Deepak
steering linkage Raina

Replace
5 4 3 60
Steering linkage

6 252

Verification of
Aman
Clevis Rod ends
Dagar
and ball joints

Replace A-arms 7 5 3 105

6 432

Testing to check
Shubham Use standard
proper
6 4 3 72
Sood
hoses/ cylinder
functionality

Steering
System

Braking
of
steering
links

Improper
joints of
steering links

Suspension

Breakage Uncomfort
6
of A-arm able drive

Taking large
bumps with
high velocity

Double
7 Wishbone
Suspension

Braking
System

Leakage
in
Cylinder

Excessive
pressure in
hoses

Standard Disc
8
Brakes

Improper
alignment of
pulley

Standard pulley
with
7
8 448
appropriate
belt

Proper
alignment of
pulley

Sumit
Mittal

Properly aligned
pulley and belt 2 3 6 36
drive

Loose
connection

Using good
7
quality wires

Proper
insulation and
connections

Akshay
Dogra

Proper wiring &

7 3 3 63
insulation

Unable to
steer

Inability to
stop
9
vehicle

Transmission Breakage
of belt
Power Loss 8
System
Drive
Electrical
System

ShortCircuit

Power-Cut
for
8
equipment

7 392

Business Plan
Cost Report

Mission & Vision: To develop eco-friendly vehicle

To utilize renewable source of energy
To reduce CO2 emissions
To overcome shortage of conventional
fuels
Business Strategy & Management:Analysis
Idea
Innovate
Refresh

Develop
Plan
Process
Organize

Execute
Training
Materials
Roll Out

Category

Vehicle Cost+
Labor Cost

Presented
Vehicle
(INR)
69600

Production
Run ( 100
Vehicles Per
Month)(INR)
6960000

Sale Tax (13%)

9048

904800

Advertisement
Cost (4%)

2784

278400

PIPE FOR CHASSIS

COST

1020 DOM(10.058)

1900

1020 DOM(10.083)

4200

1020 DOM (10.118)

2300

SUSPENSION SYSTEM

COST

SPRING + DAMPER

2400

BALL JOINTS

280

UPRIGHT

1600

MISCELLANEOUS

COST

NUT & BOLT + WASHER

PAINT + PRIMER

COST

OPERATIONAL
APPARATUS

3000

STEERING& BRAKING
RACK AND PINION
STEERING COLUMN +WHEEL

2300

SEAT

1000

KILL SWITCH

400

BRAKING SYSTEM
(CALLIPER + DISC+BREAK
LININGS)

3900
SEAT BELT

500

TANDEM MASTER CYLINDER

500

FABRICATION AND
BODYWORKS

BRAKE STOP LIGHT

200

GLASS FIBRE

ELECTRICAL SYSTEM

COST

PLYWOOD

SOLAR PANEL

24200

MS SHEET

BATTERY

5400

M.S. PLATES

CHARGER

1000

MOTOR CONTROLLER

2000

MOTOR

1750

TRANSMISSION

COST

WHEEL AND TIRE

5400

COST

3200
APPROX.

OTHER MATERIALS
TOTAL COST FOR THE
VEHICLE

COST

PIPES FOR CHASSIS

8400

TRANSMISSION AND

Other (12%)
(Transport,
Machinery etc.)

8352

835200

Total
Production Cost

89784

8978400

Profit

13467.6

1346760

MRP

103251.6

10325160

BEARING+CLAMP

500

7570
INNOVATION
STEERING & BRAKING

6900

INNOVATION A.R. CVT

400

FABRICATION AND BODY

WORKS

3200

VARIABLE DIA PULLEY

FIXED DIA PULLEY

100

MISCELLANEOUS

4900

GEARS

120

ELECTRICAL SYSTEM

34350

LEVER

50

SUSPENSION SYSTEM

4280

MOUNTINGS

1000

TOTAL COST

69600

Achievements
BAJA SAE INDIA 2013
overall 31st position out of 236 teams

HPVC 2014
Organised by ASME

AERO- 2012