2. Friday, August 12, 2016 EK-IDEA2015 2
Provide a better atheistically designed go-kart and our technocrats
merely make them seek livelihood, but to take our country ahead in all
fronts of Automobile Innovations.
Promoting engineering temperament and competitive spirit among
aspiring students through imparting knowledge of Automobile by designing,
fabricating, optimizing & racing.
3. Friday, August 12, 2016 3
3D View of the Vehicle with Specification
EK-IDEA2015
4. Friday, August 12, 2016 4
Rule Book Conformation
EK-IDEA2015
Article Specification / Content Constraint Provided / Rule Implemented Values / Method Remark
A1.1 – 6.4 Administrative Regulation Eligibility, Age, Driver License & Insurance License & Insurance available
B 1.1 – 1.1.1 With Four wheels & Capability Driver Height 190cms & weight 113kgs Confine as per rule
B1.1.2 – 1.1.4 Max vehicle Dimensions & Jack Pt Wi: 50”,Le:80”,Wheel base relation Wheel Base: 43”, Track width: R42.6”,F34.4”
B 1.1.5 Steering System Positive Steering With Mechanical Links Positive Steering without locking Wheels
B 1.2.1-1.2.2 On Road Capability Ground Clearance & Sharp Edge Clearance 2.5” & No sharp Edges
B 1.3 Vehicle Ergonomics Capacity 95th %ile male & 5th %ile Female Confine as per rule & Avg ht of team is taken
B 2.1- 2.1.16 Engine Requirement Restrictions while Assembly & Caution Confine and Abide to rules
B.3.1 – 3.5 Electrical System Battery, Wiring, Lights & Kill Switch Solar Power and confine as per rule
B 5.1 – 5.9 Cock Pit & Throttle Control Firewall, Belly pan & Throttle console Fire Extinguisher Fitted & Confine as per rule
B 6.1 – 6.3.1 Driver Restraint Seat Fastener, Shoulder Harness & Location Single Buckle fastener & Confine as per rule
B7.1 – 7.4 Braking system & Fuel Tanks Foot brake lines and Fuel tank lines Safely Installed & Confine as per rule
B8.1- 10.1.1 Fastener, Guard and Driver Equip Preferred bolts, nuts & washer employed Guards, ISI Driver suit is used with Helmet
5. Friday, August 12, 2016 5
Chassis Design
EK-IDEA2015
Design Methodology: As per rule book confine & Considering the bare Weight of Kart, Engine & Racer.
Material Selection : AISI 4130 (2” x 0.19” tube) with best rigidity often employed in FSAE vehicles.
Calculation Results : Wheel Base 43”, Track Width Rear 42.6” & Front 34.4” & Ground Clearance: 2.5”
Material Property:
E: 205KN/mm2, μ: 0.285,
ρ: 7850kg/mm3, σt: 731N/mm2
σy:460N/mm2, κ:42.7w/m0K
Stress Analysis Report:
Max Stress σ: 370N/mm2
Factor of Safety: 1.26
Displacement: 2.61emm
6. Friday, August 12, 2016 6
Ergonomics consideration in vehicle
EK-IDEA2015
As per rule book confine & Considering the Average height of the team members.
7. Friday, August 12, 2016
Drawing of Disc Brake
Brakes
EK-IDEA2015
Design Methodology: As per rule book confine & Considering weight of the go-kart with driver.
Selection: Disc brake with Double pistons acting towards on single Caliper & Pad is employed.
S. No Configuration
Obtained Values
Slip No -Slip
1. Brake Force FFT= 352N & FRT= 653N FRT=725N
2. Brake Torque TRC= 60.2085 N-m
3. Stopping Distance 20.27m 13.54m
4. Stopping Time 4.49 sec 2.99 sec
5. Pedal Force 98.1 N
6. Leverage Ratio 6 : 1
7. Pedal Efficiency 80%
8. Disc Dimensions 0.24m x 0.006m (9.45” x 0.24”)
9. Caliper Dimensions 0.025m x 0.075m
8. Friday, August 12, 2016 8
Steering
EK-IDEA2015
Design Methodology :As per rule book Confine & Considering Positive Steering without locking.
Selection : Mechanical Linkages is employed for steering its simple with less effort & weight.
S No Configuration Obtained values
1. Wheel Base 1066.8mm (43”)
2. Track Width 860mm (34”)
3. Track Rod 482mm (19”)
4. Turning Radius 1855mm ( 72”)
5. Ackermann Angle 150
6. Ackermann Arm Length 238.1mm (9”)
7. Ackermann Percentage 147%
8. Steering Ratio 1:1
9. Steering Wheel 10” dia. wheel
10. Steering effort 87.7N
S No Parameter Values
1. Kingpin inclination 100
2. Caster -120
3. Camber 10
4. Toe out 2mm
9. Friday, August 12, 2016 9
Drive Train
EK-IDEA2015
Design Methodology : As per rule book confine & Considering provided engine specification data.
Selection: Centrifugal Clutch is employed for better power transmission with low cost and weight.
S. No Configuration Obtained values
1. Mass of Shoe 0.36 kg
2. Centrifugal force outwards 1000.7 N
3. Centrifugal force Inwards 562.93 N
4. Radial force of shoe 437.45 N
5. Friction force 109.46 N
6. Frictional Torque 12.32 N-m (4.5 HP)
8. Max Speed 18.055m/s (65kmph)
9. Transmission to Rear Axle 1.6 H.P Exploded View of Clutch
11. Design Validation Plan
11Friday, August 12, 2016 EK-IDEA2015
S.NO SYSTEM TEST METHOD INSPECTION ACCEPTANCE CRITERIA RESULT
1 CHASSIS
THEORITICAL SOFTWARE RESULTS PASSED
PHYSICAL Analysis
NO BENDS OR CRACKS
DEVELOPED
PASSED
PHYSICAL VISUAL
NO BENDS OR CRACKS
DEVELOPED
TO BE PERFORMED
2 TYRES PHYSICAL VISUAL NO SKIDDING OF VEHICLE TO BE PERFORMED
3 ENGINE
PRACTICAL TEST VISUAL NOT MORE THAN 70KMPH TO BE PERFORMED
PRACTICAL TEST VISUAL NIL TO BE PERFORMED
4 STEERING TEST
PRACTICAL TEST VISUAL
MAXIMUM TEST WITHOUT
SKIDDING
TO BE PERFORMED
PRACTICAL TEST VISUAL
EASY TURNING WITHOUT
HITTING CONES
TO BE PERFORMED
5 BRAKES
PRACTICAL TEST VISUAL
BRAKING DISTANCE NOT
MORE THAN 4m
TO BE PERFORMED
THEORITICAL TEST BY FORMULAE
AVERAGE PEDAL FORCE A
MAN CAN OCCUR 98.1N(5lbs)
PASSED
12. Design Failure Mode and Effect Analysis
Friday, August 12, 2016 12EK-IDEA2015
COMPONENT FUNCTION POTENTIAL FAILURE MODE POTENTIAL EFFECTS S POTENTIAL CAUSES O D R.P.N. ACTIONS TAKEN S O D R.P.N
BRAKES Retards motion
Leakage of fluid from brake line Vehicle will not stop on time 6
Sub-standard brake lines 5 4 120 Replace the brake lines 6 1 3 18
Cracks due to high pressure 5 4 160 Replace the brake lines 6 2 3 36
Cracks due to rough terrains 4 4 96 Provide covering 6 2 3 36
Failure of pushrod
All wheels will not lock
simultaneously
8 Restriction to motion of pushrod 3 6 144 Pushrod should have adequate D.O.F 8 2 4 64
KNUCKLE
Stationery part
which integrates
brakes, steering,
transmission and
suspension
Knuckle dislocate
Severe effects on brakes and
steering
7
Selection of improper material 4 4 112 Use of high grade material 7 2 2 28
Improper press fit and size of bearing 6 4 168 Soldering of Knuckle 7 2 2 28
7 Small cross-section area of stub axle 4 3 84 Maintain cross-sectional area 7 2 3 42
Crushing
7 Free length of stub axle 4 5 140 Maintain length 7 2 3 42
Shear
EXHAUST
Guides exhaust
gases away
Corrosion on inner surface
Unpleasant or cracking sound
7
Inner surface at lower temperature than
exhaust gases leading to condensation
6 6 252 Replace exhaust 7 2 6 84
Formation of acidic mixture
PEDAL
Lever which
actuates A B C of
the vehicle
Movement of pedal constrained
Pedal does not reciprocate back
8 Accumulation of mud near pedal 7 2 112
Clean with high pressure jet of water 8 4 2 64
Difficulty in braking and
acceleration
Provide a metal sheet covering 8 3 2 48
FUEL LINES
Transportation of
fuel
Fuel line or component sealing
failure
Chance of fire if fuel comes in
contact with engine
7 Improper maintenance 6 4 168 Proper sealing should be inspected 7 4 3 84
Crack in lines Fuel loss 6 Cracks due to vibration 6 5 180 Lines should be mounted rigidly 6 4 3 72
Excess tightening of line screw Improper flow of fuel 6 Poor judgement while installation 6 3 126 It should be adequately tightened 6 4 3 72
SPARK PLUG
Ignites fuel by
means of electric
spark
Wet spark plug No sufficient voltage to start
the engine
7 Contact with water 7 4 196 Cap should be provided to protect from
water
7 4 2 56
Low voltage 6 Excessive usage 5 4 120 Distance between the electrodes should be
checked to be around 0.8mm
7 4 2 56
Carbon deposition 7 Incomplete combustion of fuel 4 5 140 Spark plug should be cleaned with air jets 7 5 2 70
BATTERY
Supplies electric
energy
Short circuit Starter motor will not work 8 Contact with water 6 3 144 Metal sheet covering for battery should be
provided
8 2 2 32
Discharge of battery All electrical connections may
fail
5 Over usage 5 4 100 Engine should be kept running 5 1 2 10
Improper connections 5 Failure of battery 5 3 75 Fuse box should be provided 6 1 2 12
13. Innovation
Friday, August 12, 2016 13EK-IDEA2015
Implementing Automatic lights Switching through LDRs
(Daylight Sensor).
Working out the best Aerodynamic design.
Automatic turn lights actuated with the >70 Angle of front wheel.
Solar panel is employed for the charging batteries.
14. College Facility
Friday, August 12, 2016 14EK-IDEA2015
Production Lab Lathe Machine Shaping Machine Slotting Machine Milling Machine Grinding & Drilling Machine
Workshop Carpentry Fitting Sheet Metal House Wiring Bending
Manufacturing Foundry Black smithy ARC Welding Band Saw
Engg Laboratory Electrical &
Electronic
Instrumentation &
CAD/CAM
Thermal & Heat Transfer Metrology & Material
Science
Strength of Material &
Hydraulics
Arc Welding Turning Drilling Slotting
Band Saw Milling Shaping
MIG & TIG Welding
Not Available
15. Team Structure and Allotted Responsibilities
Friday, August 12, 2016 15EK-IDEA2015
S.No Name of the Participants Privileges Design Task Fabrication Task
1 Anthony Johnson Yesudas (Cpt) Work allocation & Follow up CAD, Chassis & Documentation Optimization & Inspection
2 R. V. N. Anurag1 (α - Team) Alpha Team Captain Steering Calculation & DVP Steering Assembly
3 Y. Maruthi2 Asst & Manual Drawing Drawing with Exploded View Bumper & Pads Arrangements
4 R. Rajesh Reddy3 Assisting team Cross Checking Service & Maintenance
5 A. P. D. Salman Basha4 (Racer) Asst & Subject expert Material Selection & Validating Stub & Rear Axle Assembly
6 U. Jagadesh1 (γ - Team) Gamma Team Captain Brakes, Drive Train & Aerodynamic Disc Brake Assembly
7 R. Kusuma Reddy2 Asst & Project Planning Gantt Chart Belly pan & Pedals Assembly
8 N.Yeswanth Sharma3 Asst & Manual Drawing Drawing with Exploded View Electrical Mounting Arrangements
9 K. Nagasunkanna4 Asst & Subject expert Cross Checking & Validating Drive train Assembly & Welder
10 T. Subba Reddy1 (β-Team) Beta Team Captain Material Selection Criteria & DFMEA Tyre & Wheel Alignment
11 K. Ravi Kumar2 Asst & Subject expert College facility info Technician & Engine Assembly
12 B. Basha3 Assisting team Cross Checking & Validating Turner & Machinist
13 K. Venkat Subbaiah1 (Ω-Team) Omega Team Captain Cost Report & Ergonomics Material Procurement & Fitter
14 M. Varun Kumar2 Assisting team Specification sheet & Market Survey Safety measures Arrangements
15 R. Prudvi Raj3 Asst & Sponcership Vendors quote & Estimation Shipping & Transportation
16. Cost Report
Friday, August 12, 2016 16EK-IDEA2015
S NO Part Name Material Cost in Rs/-
1 Chassis & Plate AISI 4130 3050
2 Wheels & Tyres Whole Set 19500
3 Axle & Hubs Whole Set 6000
4 Braking System Disc brake set 3000
5 Transmission Centrifugal Clutch & Chain Sprocket 2000
6 Electrical System Solar Panel, Battery, Switches and Lights 4000
7 Mounting & Bumper Dash Board 5000
8 Manufacturing & Labor Welding cost, Machine cost & Labor Allowances 4000
9 Material Shipping Transportations Cost 2000
10 Miscellaneous Belly pan, tie rod & fire extinguisher etc 2500
11 Engine Brigg Stanton Vanguards 6.5 HP 15000
Total Cost ($1066)-66050
