7. ANALYSIS
SIMULATIONS
Type of loading Front Impact Test
Load 3G
Maximum Stress 219MPa
Maximum Displacement 3.459mm
Factor of Safety 1.68
Type of loading Side Impact Test
Load 1.5G
Maximum Stress 199.6MPa
Maximum Displacement 2.232mm
Factor of Safety 1.85
8. ANALYSIS
SIMULATION
Type of loading Rear Impact Test
Load 3G
Maximum Stress 198.2 MPa
Maximum Displacement 1.473 mm
Factor of Safety 1.86
Type of loading Torsion Test
Load 1000N
Maximum Stress 204 MPa
Maximum Displacement 17.353 mm
Factor of Safety 1.81
9. ERGONOMICS AND
SAFETY
FEATURE DESCRIPTION
Seating Comfort •Backrest reclined at 5° to 15° degree from
vertical.
•Seat Belts to hold the driver in place.
Steering location •Steering wheel18 to 24 inches in front at chest
level.
•Proper angle of steering wheel, ensures
sufficient elbow room
Egress/Ingress •Apt distance between Dashboard and
cockpit’s floor.
•Interference and bumping of knees is
reduced.
Driver’s view point •The driver has clear view of all the sides.
•Ensures a safe drive.
Better controls for
driver
•Steering wheel ,pedal etc well within the
reach.
•Reduces unnecessary pressure on body .
Kill switch position • Kill switch easily accessible to the driver.
Fire extinguisher •Installed in complete reach of the driver
•Deters excessive vehicle damage during
hazards.
EROGONOMICS OF DESIGN
10. HUB MOTOR
• It is a permanent magnet BLDC motor
• that is incorporated into the hub of a
• wheel which drives it directly.
Advantages:-
No drive train loses
High torque by weight
ratio.
Noiseless operation.
RATED VOLTAGE 48 VOLTS
Rated Current 25A
Peak Power 1500 Watt
Output Power 800 Watt
Torque 16.9N.m.
Running R.P.M. 456.89r.p.m
MOTOR
CONTROLLER
• Controls motor speed by varying
voltage.
• Inculcates the reversing mechanism.
11. ELECTRIC AND SOLAR SYSTEMS
BATTERY
TYPE Li-Ion
Nominal voltage 48V
Nominal
capacity
50 Ah
Weight 10Kg
Dimension 11 X 9 X 5
(inch)
SOLAR PANELS
TYPE MONOCRYSTALLINE
Output power 150W + 80W X2
Output voltage 18V each
Open circuit
voltage
22V each
Dimension 1480X680X34 (mm)
785X670X34 (mm)
CHARGE
CONTROLLER
1. Prevents our battery from
overcharging and discharging.
2. Two types:
• Follow MPPT Algorithm
• Follow PWM Algorithm
Output power Characteristics of a 24V
solar panel at different irradiance and
temperature
3 stage charge cycle
Discharge Characteristic of 48V,
50Ah battery
12. STEERING
Rack and Pinion( Maruti 800 ):
• better feedback and more responsive
• Low cost and low weight in comparison to
others
• Good Market availability and compatible
steering ratio
Ackerman Geometry :
• Excellent for low speed manoeuvres
• Prevents tire wear and increases controllability
Type Geometry Rack
Length
Tie
Rod
Length
Rack
Travel
Steerin
g Ratio
Max.
Inner
Turnin
g
Angle
Max
Outer
Turning
Angle
Minimum
Turning
Radius
Steering
Wheel
Revolution
Scrub
Radius
Castor K.P.I Mecha
nical
Trail
Rack
and
Pinio
n
Ackerman 18” 9” 4.7” 17.5:1 35 24.62° 3.03mm 3.25 1.28” 5° 9.65° 1.39”
13. SUSPENSION
DOUBLE WISHBONE
SUSPENSION
FRONT SUSPENSION REAR SUSPENSION
DOUBLE COILOVER SHOCKS
AND SINGLE AXLE
DESIGN CONSIDERATION -
• A-arms provide good strength.
• Provides negative camber gain which gives good camber control.
• It provides compact design and good suspension performance.
14. SUSPENSION SPECIFICATION
PARAMETERS FRONT REAR
Type Double Wishbone Double Coilover Spring & Single
Arm
Upper arm length 7.06 inches N/A
Lower arm length 8.5 inches 13.34 inches
Roll center height 5.2076 inches N/A
Motion ratio 0.68 0.70
Wheel travel 4 inches 4 inches
Shock travel 2.72 inches 2.80 inches
Spring stiffness 34.89 N/mm 26.66 N/mm
Knuckle Coustom N/A
PARAMETERS FRONT REAR
Camber +2 degree N/A
Caster +5 degree N/A
Toe 2 degree Toe in N/A
Kingpin Inclination 9.65 degree N/A
Scrub Radius 1.28 inches N/A
WHEEL GEOMETRY
16. BRAKES AND TIRES
BRAKE TYPE HYDRAULIC DISC BRAKE
Maximum speed 35km/h
Disc diameter 140mm
Pedal force 392.4N
Pedal ratio 5:1
Brake force 5466.168N
Deceleration 26.16ms-2
Stopping distance 1.80m
Caliper Hero electric 1.4inch piston diameter
Disc Hero electric non ventilated
Master cylinder Bosch Tandem master cylinder
19.05 mm diameter
(compatible with these calipers )
Tires diameter 16 inch (Front)
16 inch (Rear)
Advantages of disc brakes
1. High stopping power
2. Quick heat dissipation
3. Easy maintenance
4. Adaptability to technology
5. Cheap spares
17. BRAKE CIRCUIT
• Disc brake are use in all the three tires.
• One line will attach to the front tires
and the second one will be attached to
the rear tire disc brake.
• This will provide a safe mechanism as
if one line is damaged the other will
still work.
18. INNOVATION
ULTRA SONIC PARKING SENSOR
DRIVER SEAT BELT ALARM USING IR PAIRS
TEMPERATURE MEASUREMENT OF
BATTERY AND SOLAR PANEL
19. PARAMETER VALUE
Weight (unladen) 180 kg
Wheel Base 64 in
Track width 49 in
Overall Length 80 in
Overall Width 54 in
Overall height 39 in
Top Speed 35 km/h
Ground clearance 5 in
Centre of gravity 18 in
Braking Deceleration 26.16 ms-2
Turning Radius 3.03 m
Percentage Ackermann
Geometry
100
Pedal Ratio 5:1
MATERIAL USED MILD STEEL
AISI 1018
Outer Diameter 25.4mm
Thickness 3mm
Tensile strength 370MPa
TECHNICAL
SPECIFICATION
20. TASK DURATION START FINISH
TEAM FORMATION 4 days 14/10/16 19/10/16
GETTING ACQUAINTED WITH RULEBOOK 5 days 19/10/16 25/10/16
VARIOUS DEPARTMENT FORMATION 3 days 20/10/16 24/10/16
ALLOCATING TASKS TO EACH DEPARTMENT 3 days 25/10/16 27/10/16
REVIEW MEET 1 day 27/10/16 28/10/16
MARKET SURVEY 7 days 29/10/16 5/11/16
MODELLING OF CHASSIS 5 days 3/11/16 9/11/16
MODELLING OF SUB SYSTEMS 5 days 11/11/16 17/11/16
ASSEMBLY OF DIFFERENT COMPONENTS 3 days 17/11/16 21/11/16
DESIGN REVIEW 2 days 21/11/16 22/11/16
COST REPORT 3 days 22/11/16 24/11/16
ANALYSIS AND SIMULATION PHASE 13 days 23/11/16 9/12/16
STEERING REPORT 5 days 22/11/16 29/11/16
BRAKING REPORT 6 days 24/11/16 1/12/16
INNOVATION REPORT 7 days 25/11/16 5/12/16
DESIGN VALIDATION PLAN 3 days 1/12/16 4/12/16
DFMEA REPORT 3 days 3/12/16 6/12/16
PRELIMINARY DESIGN REPORT 4 days 5/12/16 9/12/16
FINAL DESIGN REPORT 5 days 11/12/16 16/12/16
PROJECT PLAN
21. DESCRIPTION ACCEPTANCE CRITERIA RESPONSIBILITY METHODS USED
Solar Panel Current and voltage should be such so
as to provide sufficient power and
torque to motor
Electrical Dept., Multimeter
Ergonomics Design should be validating driver’s
safety and comfort
Safety Dept. Measure tape and protractors
Battery Sufficient discharge time (Approx. 2.5
Hours)
Electrical Dept.,
Design team
Measuring discharge time of fully
charged battery.
Impact test Safety factor should be greater than 1 Design team Altair Hyperworks
Welding Strength Joint should not fail under rigorous
conditions
Safety team,
Design team
Dye Penetrant Test, Universal
Testing machine
Brakes test Braking Distance Brakes Dept. Speedometer, Measuring tape
Turning radius Minimum turning radius Steering Dept. Practically measured using a
circular path of minimum radius.
Hub Motor Sufficient Laden Torque Electrical Dept. With the help of the graphs Torque
vs RPM and Torque vs Current
Inner Wheel Lock
Angle
35 ± 2 Degrees Steering Dept. Max. angle of inner wheel with
the vertical reference line
measured practically
DESIGN VALIDATION
PLAN
22. COMPONENT FUNCTION POTENTIAL
FAILURE
MODE
POTENTIAL EFFECTS POTENTIAL CAUSES S O D R.P.N ACTIONS
TAKEN
SOLAR
PANELS
Converts solar
energy to
electrical
energy
Broken solar
panels or
degradation of
solar panels
Batteries are not charged Sudden shock , improper
mounting of panels,
unknowing use of more
boosters
6 3 3 54 Replace the solar
panels
CHARGE
CONTROLLE
R
Controls the
amount of
energy entering
in battery from
solar panels
Circuit failure Batteries would be over charged
or over discharge as flow of
back current is not hindered
now
Over current in circuit 6 2 3 36 To include a circuit
breaker or fuse in
the circuit.
Replacing of parts.
ACCELERATI
ON SYSTEM
Controls the
amount of
electrical
energy
transmitted to
the motor
Failure in
mechanism or
circuit
No variation in the speed of
motor OR no power is
transmitted to the motor
Break down of recoil spring
or malfunction in circuit
6 4 2 48 Replace / repair
recoil spring
mechanism
HUB MOTOR
ASSEMBLY
Propels the
vehicle
forward, elec.
Energy to
mech. energy
Unresponsive to
the driver
Uncontrolled motion of Vehicle Over current , over heating ,
dirt , moisture
9 2 1 18 Replace / repair the
hub motor assembly
BATTERY Supplies
electric
energy and get
charged by
solar panel
system
Over discharge
of current in
circuit ,
explosion of
battery
Vehicle won’t be propelled , no
electric system will work
Contact with water ,
frequent and continuous
overcharging of battery
9 2 5 90 Metal sheet
covering for battery
should be provided,
and a charge
controller to be
used.
DESIGN FALIURE MODE AND EFFEC
23. RACK &
PINION
Transmits
circular motion
into linear
Pinion failure:
Crack
development,
Overload
Breakage
Improper steering Fatigue, Corrosion,
Application of excessive
sudden torque
6 2 3 36 Replacing of parts
and Greasing
STEERING
COLUMN
Connect
Steering Wheel
with Rack and
Pinion
Restrictions in
proper motion
of joints and
links
Vibration in the steering,
abnormal noise from inside
the column
Sudden shocks to the tires 5 2 3 30 Lubrication of
joints, or replace
joints
FRAME Providing rigid
structure
Fracture, bend Vibration in the vehicle, may
cause the entire frame to fail.
Load beyond endurance
limit, sudden shock.
7 2 3 42 Welding test,
Buckling Tests,
Impact Test
TIRES To provide
rolling friction
Hole, crack, or
bursting
Reduce in stability Debris or over inflation 5 5 2 50 Tire pressure
monitoring system
BRAKE
SHOES
To Produce
friction to
retard the
vehicle
Worn brake
shoes
Increment in braking effort Wear due to friction 7 2 3 42 Replace the brake
shoes
BRAKE
LINES
Delivery of
brake fluid from
master cylinder
to pistons
Pressure loss in
the brake lines
Brakes won't be applied Cuts due to debris 7 2 3 42 Replace the brake
lines
KNUCKLE Stationary part
which integrates
brakes, steering,
transmission
and suspension
Bending Severe effects on brakes and
steering
Selection of improper
material , Sudden loads
8 3 2 48 Use of high grade
material
DESIGN FALIURE MODE AND EFFEC
24. Sl. No. Component Parts Specification Unit Price(INR) Dealer/Supplier
1 Chassis & Body Works Roll cage Pipes AISI 1018 Pipes 65ft 2200 Local Market, Jaipur
Body & Floor Sheet Mild Steel Sheet 1000 Local Market, Jaipur
2 Brakes Master Cylinder Tandem Master Cylinder 1 650 Local Market, Jaipur
Caliper & Discs Hero Electric 140 mm discs 2 4000 Local Market, Jaipur
Brake Lines, Pipe & Fluid Castrol Dot-3 Fluid 1 Lt 350 Local Market, Jaipur
3 Wheels & Tires Front Tire Hero Electric(16") 2 4800 Hero, Jaipur
Rear Wheel Hero Electric Hub Motor Wheel (18’’)with motor
controller
1 16000 Hero, Jaipur
4 Steering Assembly Steering Wheel Universal Steering Wheel(12") 1 250 Local Market, Jaipur
Steering Column UV Joints & Columns 2 4000 Local Market, Jaipur
Steering Gear & Tie rod Rack & Pinion (Maruti 800), Tie rod 1 1800 Local Market, Jaipur
Ball Joints 4 1000 Local Market, Jaipur
Knuckle Customized 1 5000 Local Market, Jaipur
5 Suspension Strut Spring Stiffness 35N/mm and 30N/mm 2 each 7000 Local Market, Jaipur
Ball Joints 4 1000 Local Market, Jaipur
Rubber Bushing 10 500 Local Market, Jaipur
6 Electrical Equipment Battery 48V, 50Ah Lithium Ion Battery 1 60000 Delhi
Solar Panel 150 W + 80X2 W 2 13500 Local Market, Jaipur
Head & Tail Light 2 520 Local Market, Jaipur
MCB and Kill Switch 2 each 3900 Local Market, Jaipur
Indicators 2 260 Local Market, Jaipur
Speedo Meter and Horn 1 each 1400 Local Market, Jaipur
Sensors Ultrasonic Sensor and IR sensors 1 740 Local Market, Jaipur
Temperature measurement
equipment
LM 35, Arduino, LCD Screen 1 700 Local Market, Jaipur
7 Safety Driver Suit and Helmet 1 10250
Seat Belt Customized 1 1000 Local Market, Jaipur
Driver Seat 400 Local Market, Jaipur
Fire Extinguisher ISI Rated 1 1450 Local Market, Jaipur
8 Miscellaneous Nut, Bolt, cable, wire etc. 2500 Local Market, Jaipur
Paint 250 Local Market, Jaipur
T O T A L C O S T = 1, 46, 410
COST REPORT
