Team Introduction

ISIE/HVC16/63 (MACTRON)
Faculty Advisor Faculty Advisor
(Mechanical) (Electrical)
Dr. Ravindra Rana Dr. Amit Ojha
Team Vice
Team
Captain
Captain
Dilip Chauhan
Vivek Kumar
Design
Dept.
MACTRO Electrical Dept.
Shubham Dwivedi
Vishal N
Shivam
Sharma Shrivastava
Brakes
Rahul Dept.
Uikey Steering Dept.
Suspension
R. Advait Rohan Mittal
Dept. Transmission
Akshay Warkade Dept. Raghavendra
Premabhishek
Rahul Dewangan Mahato Management Rishabh Katrolia Patel
Chandrashekhar Anubhav Shiva Rajkumar Das Sameer Khare
Sahu Noor Alam Shreyansh Pandey
Sumit Choubey
 Team Management
TEAM
LEADER

DESIGN & ANALYSIS MANUFACTURING

TEAM TEAM FINANCE

Roll cage
Parts Procurement SPONSORSHIP
Suspension Steering
Marketing and PR
Jigs & Fixtures
Brakes

Transmission Budgeting & Cost

Fabrication Estimations
Engine & Electricals
Market Survey

Modeling & Simulation

Ergonomics & Aesthetics

PROJECT PLAN
 ISOMETRIC
VIEW

FRONT BACK
VIEW VIEW

SIDE TOP VIEW

VIEW
 ERGONOMICS
Points that were
kept in mind
Optimization of
length to height
ratio
Compact design
Area of reach
Compatible driver A Ply prototype was
controls made to validate
Inspection
the design.

COKPIT Vision of Driver

MATE UTS Yield Elonga Wt. of Strength FRONT REAR
(MPa Strengt tion 1m tube : Weight
RIAL ) h IMPACT IMPACT
AISI 560 460 25.5% 1.468kg 381.5
4130 MPa MPa
Steel
CRITERIA FOR
MATERIAL
SELCTION
High Strength: Weight SIDE IMPACT BENDING TORSIONAL
Ratio STIFFNESS RIGIDITY
High yield strength
CALCULATION
METHOD
IMPACT =G FORCE
G FORCE=WEIGHT
xg

Weight = 270kg
TEST FRONT IMPACT REAR IMPACT SIDE IMPACT BENDING STIFFNES TORSIONAL RIGIDITY
FORCES 7G 5G 5G 1.4G 2G
MAX. STRESSES 191MPa 115MPa 310MPa 31MPa 48.63MPa
MAX. 2mm 1.4mm 2.6mm 1.9mm 1.6mm
DEFORMATION
FACTOR OF SAFETY 2.4 4 1.5 14 9.5
POWERTRAIN
SPECS ENGINE MOTOR
Name Briggs & Stratton Brushless D.C
950series 208ccc
Power 6.5 hp 2hp

Torque 12.88Nm 4.2Nm

Max. rpm 3300 3000

Primary 2.0:1 3.09:1

reduction
Final reduction 3.4:1 3.4:1

Max. 3.8m/s^2 2.22m/s^2

acceleration
Max. velocity 63km/hr 39km/hr

SPROCKET NO. OF TEETHS FOR

DRIVER SPROCKET 12 MOTOR

DRIVEN SPROCKET 36 MOTOR SHAFTS

DRIVER SPROCKET 12 ENGINE HALF
Max stress 212.521mpa
DRIVEN SPROCKET 24 ENGINE
FOS 2.21

diameter 1.25inch
DRIVER SPROCKET 14 DIFFERENTIAL

DRIVEN SPROCKET 48 DIFFERENTIAL length 16.9,18

 Suspension- Double
wishbone Adams
Simulation

Part Materia Yield FO images

name l strength S

Lower
control AISI S.N Parameters Front Rear
370 MPa 2.4 o
arm 1018
Front 1. Static camber -1.75 -1.5
2. Roll center 1.6 inch 2.6 inch
height
Lower
Control AISI 3. Motion ratio 0.58 0.6
370 Mpa 2.2
Arm 1018
5 4. Ride rate 18.43N/m 29.75
Rear
m N/mm
Camber vs wheel 5. Ride Frequency 2.33 Hz 2.57 Hz
travel Front
Oil 6. Spring rate 19.76 33.36
Front N/mm N/mm
tempere 1200 Mpa 1.5
spring
d 7. Number of turns 9 8
8. Free Length 170mm 170mm
9. Spring 43.76 mm 16.45 mm
Oil deflection in
Rear
tempere 1200MPa 1.5
spring maximum
d
Camber vs wheel braking
travel rear
10. Spring 23.25 mm 10.2 mm
 STEERING

PARAMETERS CALCULATED VALUES

FRONT TRACK WIDTH 51INCH Steering Dimensions Materials used
REAR TRACK WIDTH 53 INCH system
WHEEL BASE 66INCH parts
tie rods 12inch,10mm Aluminium
INSIDE WHEEL LOCK 300 diameter
OUTSIDE WHEEL LOCK 21.760 pinion 20mm O.D Cast iron
MINIMUM TURNING RADIUS 3.61m Steering 6inch radius Aluminium
KING PIN INCLINATION 12.50
wheel
Female Heim 10mm I.D Steel
CASTER 50 joint
STEERING RATIO 5:1 Female Ball 10mm I.D Steel
STEERING EFFORT 135.78N joint
Knuckle Shown in fig. Mild steel
UNIVERSAL JOINT BEND 300
ANGLE Steering 21.2 inch Steel
column
 BRAKES SYSTEM
Specification
Master Pedal Caliper Rotor Rotor B/w road B/w pad Pedal force on
cylinder ratio cup size diamet thickness & tire & rotor size pedal
bore size er
1 4.73:1 0.9 (both) 190mm 3mm 0.74 0.5 7.50 400N
Calculation Result
PEDAL FOS Weight distribution Rf : Rr = 44.46:55.54
at rest
(force=1892N) = 1.52 Weight dist. while Rf : Rr = 57.65:42.35
PERFORMANCE braking
Force on front wheel 1766.99 N
Stopping 8.5 m
Distance rotor
Force on rear wheel 1298.04 N
Pedal 400 N rotor
Force Braking torque on 145.77 Nm
Pedal 1.67 front rotor
Travel Braking torque on 107.08 Nm
All Wheels Lock rear rotor
simultaneously. Retardation 7.25 m/s2
Stopping distance at 8.5 m
ROTOR 40 km/h
FOS = 4.57 Stopping time at 40 1.53 s
km/h
Press. generated in 1867901.83 N/m2
 Fabrication and Hybrid
System Facilities for
fabrication

LATHE, MILLER, SHAPER AND POWER HACKSAW

PLANER
HYBRID SYSTEM

CNC LATHE DRILL GRINDING PIPE BENDING WELDING

 DESIGN VALIDATION
PLAN
S.NO DESCRIPTION ACCEPTENCE CRITERIA ASSIGENED TO TEST RESOURCES
DIMENSIONAL SHOULD BE MATCHING WITH MANUFACTURING HEAD TEMPLATES
STABILITY TECHNICAL SPECIFICATION SHEET
1
PREPARED,CHECK FOR OVERALL
WIDTH(CRITICAL)
CLEARENCE OVER SHOULD BE MATCHING WITH VALIDATION HEAD MEASURING TAPE AND
2 TRANSMISSION TECHNICAL SPECIFICATION SHEET TEMPLATE PREPARED
ASSEMBLY PREPARED
RULEBOOK CLAUSE SHOULD NOT EXCEED THE VALIDATION HEAD RULEBOOK
3
ADHERENCE PRESCRIBED LIMIT
TRANSMISSION NO LEAKAGES, TRANSMISSION OIL TRANSMISSION HEAD FILTER PAPER
4
SYSTEM CONDITION
SUSPENSION SYSTEM SPRING RATE SHOULD BE SUSPENSION HEAD UTM
5 ACCORDING TO THE DESIGN
PARAMETERS
ENGINE SYSTEM PROPER MOUNTING OF ENGINE- MANUFACTURING HEAD, VALIDATION VISUAL INSPECTION
6 TRANSMISSION ASSEMBLY.ALL TEAM
MOVING PARTS TO BE COVERED
KNUCKLE SHOULD NOT FAIL/DEFORM STEERING AND SUSPENSION HEAD UTM
7 UNDER STRESS DURING
CORNERING
8 ELECTRICALS NO LOOSE CONNECTIONS ELECTRICAL TEAM TEST CIRCUITS
ELECTRICALS PROPER WORKING OF KILL ELECTRICAL TEAM MULTIMETERS AND TEST
9
SWITCHES CIRCUITS
10 BRAKES NO LEAKAGES VALIDATION TEAM VISUAL INSPECTION
FASTENERS ALL FASTENERS CORRECTLY MANUFACTURING HEAD TORQUE WRENCH
11
TIGHTENED
 DESIGN FAILURE MODE AND
SUB SYSTEM ITEM NAME FAILURE EFFECT ANALYSIS SAFETY EFFECTS SR
OPERATIONS DR OR RPN SAFEGUARDS ACTIONS
CAUSES EFFECT
TO MUCH LOAD OR THE FRAME BENDS OR HIGH FOS TO ENSURE REPEATED TESTING FOR
CHASSIS FRAME INJURY TO THE DRIVER 10 5 3 150
SHOCK BREAKS STRUCTURAL INTEGRITY WORST CASE SCENARIOS
MECHANICAL AND STRUCTURAL HIGH FOS TO ENSURE REPEATED TESTING FOR
BRACKETS EXCESS LOAD OR VIBRATION INJURY TO THE DRIVER 8 3 3 72
COMPONENTS ARE NOT USABLE STRUCTURAL INTEGRITY WORST CASE SCENARIOS
STRUCTURAL DAMAGE LEADING SERIOUS DAMAGE TO THE HIGH FOS TO ENSURE REPEATED TESTING FOR
SUPPORTS TO MUCH LOAD OR SHOCK 8 3 3 72
TO INABILITY OF USE DRIVER STRUCTURAL INTEGRITY WORST CASE SCENARIOS
BEARING YIELD DUE TO DILIGENT TESTING TO ENSURE STRICT ADHERENCE TO
DRIVE SEAT DRIVERS SAFETY COMPROMISED DISCOMFORT TO THE DRIVER 5 2 1 10
EXCESS LOAD FUNCTIONALITY SPECIFIED WEIGHT RANGE
LACK OF AIR AND FUEL TO POSSIBILITY OF EXPLOSION, WORST CASE SCENARIO, ENGINE AND DRIVER SEPERATED USE OF GOOD QUALITY
DRIVETRAIN ENGINE 10 7 2 140
MAINTAIN OPERATION INABILITY TO OPERATE SERIOUS INJURY BY FIREWALL AIR AND FUEL FILTERS
LACK OF STRUCTURAL
SUDDEN FAILURE LEADING TO HIGH FOS ENSURING
GEARBOX INTEGRITY UNDER CYCLIC INABILITY TO OPERATE 10 4 2 80 EXTENSIVE TESTING
ACCIDENT MECHANICAL INTEGRITY
LOADING
LACK IN MOTION DUE TO
HIGH FOS ENSURING
GEAR SHIFTER LINK FAILURE AND WEAK INABILITY TO OPERATE N/A 6 2 5 60 DILIGENT TESTING
MECHANICAL INTEGRITY
LUBRICATION
VERIFICATION OF DESIGNED
LACK OF STRUCTURAL
TRANSMISSION INABILITY TO OPERATE N/A 9 5 3 135 SPECIFICATION OF THE EXTENSIVE TESTING
INTEGRITY
COMPONENT
USE OF GOOD QUALITY
POSSIBILITY OF BURNING, CAR WILL STOP, WORST CASE KILL SWITCH & REGENERATIVE
MOTOR BACK EMF DURING BRAKING 5 4 2 40 MOTOR WITH PROPER
INABILITY TO OPERATE SCENARIO-FIRE BRAKING
WINDING
SHORT CIRCUIT, IMPROPER VEHICLE STOPS DUE TO PROPER AND EFFICIENT
BATTERY POWER WASTAGE 5 3 2 30 EXTENSIVE TESTING
WIRING, CRACKING UNAVAILABILITY OF POWER ELECTRIC SYSTEM
SERIOUS DISCOMFORT TO THE HIGH FOS ENSURING REPEATED TESTING FOR
SUSPENSION A-ARMS TO MUCH LOAD OR SHOCK COMPROMISED SUSPENSION 9 3 2 54
DRIVER MECHANICAL INTEGRITY WORST CASE SCENARIOS
WRONG SPRING CHOSEN SERIOUS DISCOMFORT TO THE DILIGENT TESTING TO ENSURE
SPRINGS COMPROMISED SUSPENSION 6 4 3 72 EXTENSIVE TESTING
FOR APPLICATION DRIVER FUNCTIONALITY
VERIFICATION OF DESIRED
DEBRIS DAMAGING SERIOUS DISCOMFORT TO THE REPEATED TESTING FOR
SHOCK ABSORBERS COMPROMISED SUSPENSION 6 4 4 96 SPECIFICATION OF THE
COMPONENTS DRIVER WORST CASE SCENARIOS
COMPONENT
RUPTURE DUE TO REPEATED INJURY TO THE DRIVER AND MATERIAL SELECTION AND REPEATED TESTING FOR
KNUCKLE ASSEMBLY VEHICLE FUNCTIONING STOPS 10 1 3 30
LOADING SERIOUS ACCIDENT STRESS ANALYSIS WORST CASE SCENARIOS
THE VEHICLE CANNOT FOLLOW VERIFICATION OF DESIRED
OBSTRUCTION IN TRAVEL OF REPEATED TESTING FOR
STEERING RACK AND PINION INABILITY TO STEER THE COURSE AND MAY HAVE AN 6 1 2 12 SPECIFICATION OF THE
SYSTEM WORST CASE SCENARIOS
ACCIDENT COMPONENT
DEBRIS DAMAGING RELATIVELY HIGH FOS ENSURING
STEERING COLUMN INABILITY TO STEER CAN CAUSE SERIOUS INJURY 6 1 1 6 DILIGENT TESTING
COMPONENTS MECHANICAL INTEGRITY
VERIFICATION OF DESIRED
EXCESS LOAD APPLIED BY FAILURE CAN CAUSE SERIOUS
STEERING WHEELS INABILITY TO STEER 9 1 2 18 SPECIFICATION OF THE DILIGENT TESTING
DRIVER TO COMPONENT ACCIDENTS
COMPONENT
VERIFICATION OF DESIRED
RUPTURE DUE TO EXCESS FAILURE CAN CAUSE SERIOUS
TIE RODS INABILITY TO OPERATE 10 1 3 30 SPECIFICATION OF THE DILIGENT TESTING
LOADING OR IMPACT ACCIDENTS
COMPONENT
EXTENSIVE DAMAGE TO THE
INABILITY TO PROVIDE DILIGENT TESTING TO ENSURE REPEATED TESTING FOR
BRAKING BRAKE SYSTEMS VEHICLE IN UNDESIRED CAN LEAD TO SERIOUS INJURY 8 1 3 24
SUFFICIENT BRAKING FORCE FUNCTIONALITY WORST CASE SCENARIOS
SCENARIO
EXCESS LOAD APPLIED BY HIGH FOS ENSURING HIGH FOS AND DILIGENT
PEDALS INABILITY TO OPERATE CAN LEAD TO SERIOUS INJURY 8 1 2 16
DRIVER TO COMPONENT MECHANICAL INTEGRITY TESTING
 COST REPORT
Sr. Name of the Total Sales
No. Department Expenditure
1. Design Department 11,700/- Design
2. Transmission 79,450/- Transmission
Department
Steering and
3. Steering and Tyres 25,900/- Safety Tyres
Equipment; 1%
Fairings;
Electrical; 1% 1% Fasteners; 1% Innovation;
Design;2%
7%
Department Suspension
Brakes; 9%
4. Suspension 35,200/- Brakes
Department Suspension; 20%
79450 Electrical
5. Brakes Department 15,190/-
Steering and Tyres; 15% Fairings
6. Electrical Department 2,050/-
Fasteners
7. Fairings 2,500/-
Innovation
8. Fasteners 1,950/-
Safety
9. Innovation 2,740/- Equipment
10. Safety Equipment 1,640/-
Total 1,78,320/-