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Virtual BAJA SAEINDIA 2014
Team Name Piranha Racing
Team ID 14127
Maharashtra Institute of Technology,
Pune
Wheel base 58”...
Roll Cage - Analysis
Front Impact
Stress:
216.6MPa
Side Impact
Pre Stress:
446.2MPa
Side Impact
Post Stress:
365.1MPa
Roll...
CVT- Polaris P85 Belt CVT
Reduction
Gear Drive:
Compound Planetary Differential
• Epicyclic gear train is
used as differen...
0.000
0.500
1.000
1.500
2.000
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
55.00
60.00
ACCELERATION v/s ROAD...
PARAMETER FRONT REAR
Suspension Type
Double
Wishbone
McPherson
Strut
Natural Frequency 2.23 Hz 2.29 Hz
Stiffness 11.8 N/mm...
FEA of Critical Components
Wheel
Assembly
Wheel
Assembly
exploded
view
Steering
Ackerman Steering Geometry
(Rack & Pinion System)
Wheel Base (L) 58”
Pivot to Pivot distance (t) 42”
Kingpin Incl...
Disc and
Caliper
assembly
Brakes
• Hydraulically actuated disc brakes on all wheels.
• Two different pedal designs (offeri...
Innovation
Event
Desired
Sensitivity
Pedal rotation
for Max Accn
(X)
Ra
(KΩ)
Ra=R1+Rp
Rb
(KΩ)
C
(μF)
R1 Rp 00 X0
Accelerat...
Ergonomics & Electrical
Hand Reach Envelope
Vision Cone
Reach
Limit &
Visibility
Infrared Emitter Infrared Sensor
Safety
ABC Grade
0.5 kg Fire
extinguisher
INFRARED
EMITTER
Component Potential Failure Mode
Potential
Causes/
Mechanism of
Failure
Potential Effects of
Failure
O S D RPN Recommended...
Project Plan & Team Distribution
TeamDistribution(25)
Steering 1BE, 2TE
Suspension 2TE
Transmission 2BE, 2TE
CAD/CAE 1BE
B...
Workshop Facilities & Technical
Components
Facilities Technical
Components
Quantity Unit Cost (INR) Total Cost (INR)
Engin...
Design Validation
Camber Angle Variation v/s Wheel Travel Roll Centre Height v/s Wheel Travel
Half Car Model
Thanks
Vehicle completion Date:
18 January 2014
Vehicle Inspection Date:
22 January 2014
Our Sponsor
M.I.T. Pune
CAE SUPPO...
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BAJA 2014 presentation

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BAJA 2014 presentation

  1. 1. Virtual BAJA SAEINDIA 2014 Team Name Piranha Racing Team ID 14127 Maharashtra Institute of Technology, Pune Wheel base 58” Wheel Track 50” Vehicle Height 1.58m Height of C.G. 22” Ground Clearance 13” Roll Cage Material O.D. Thickness AISI 4130 1.125” 0.095” Total Length of Pipe 39.23m Weld Length 3.45m
  2. 2. Roll Cage - Analysis Front Impact Stress: 216.6MPa Side Impact Pre Stress: 446.2MPa Side Impact Post Stress: 365.1MPa Roll Analysis Stress: 64.67MPa Torsional Stress: 156.6MPa Rear Impact Stress: 171.7MPa
  3. 3. CVT- Polaris P85 Belt CVT Reduction Gear Drive: Compound Planetary Differential • Epicyclic gear train is used as differential with no speed reduction. • Fixed – Ring gear • Input – Flange • Output 1 – Sun 1 • Output 2 – Sun 2 ω(out) = ω(in) x 7 Reverse Gear Train CVT Input Differential CVT ratio=R1/R2 0.78 3.84 Shaft • Self-designed • Material: 16Mn5Cr4 Dia=22 mm Transmission CVT Output R2=115 mm Engine Input R1=95 mm • Gear Ratio = 7 • Works as FNR Kings KT 102 Traction Dimension(mm): 22x8x10 Wheel
  4. 4. 0.000 0.500 1.000 1.500 2.000 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 55.00 60.00 ACCELERATION v/s ROAD SPEED Engine (rpm) Power (w) Gear Ratio Traction (N) Air Drag (N) Inertia (N) Velocity (m/s) Acceleration (m/s2 ) Gradability 2000 3730.00 25.08857 1600 1.650798193 1045.436 7.55325 1.485838009 31.85770558 2400 4699.80 23.89388 1600 2.620807212 986.9174 9.517095 1.572957555 31.83547437 2800 5445.80 24.05753 1600 3.518841429 994.765 11.027745 1.55964594 31.81489748 3200 6117.20 24.47666 1600 4.439986821 1015.107 12.38733 1.527484809 31.79379581 3600 6714.00 25.08857 1600 5.348586146 1045.436 13.59585 1.482300934 31.77298626 3800 6863.20 25.90668 1600 5.588942363 1087.156 13.89798 1.425196698 31.76748219 3800 6863.20 21.04918 1300 8.466090207 859.0678 17.105206 1.451030902 25.05948271 3800 6863.20 17.81084 1100 11.82453922 733.2261 20.215244 1.422720129 20.76034664 3800 6863.20 14.57251 900 17.66381784 628.3579 24.70752 1.332578354 16.53003386 3800 6863.20 9.715004 600 39.74359014 510.3813 37.06128 1.009551889 10.08323425 3800 6863.20 8.095837 500 57.2307698 481.5426 44.473536 0.826031286 7.767741583 3800 6863.20 6.667602 411.792 104.1666667 460.4569 60 0.57035811 5.119730408 0 200 400 600 800 1000 1200 1400 1600 1800 7.55325 13.89798 44.473536 AIR DRAG (N) TRACTION VS VELOCITY INERTIA ROLLING RESISTANCE FORCES v/s VELOCITY 0 1000 2000 3000 4000 7.55325 13.89798 44.473536 ENGINE RPM v/s VELOCITY ENGINE… Transmission Briggs & Stratton Model 20 Specifications: Displacement 305 cm3 Bore x stroke 79.25 mm x 61.93 mm Compression Ratio 8:1 Max. Power 7.5 kW @ 4000 rpm Max. Torque 25.18 Nm @ 2200 rpm
  5. 5. PARAMETER FRONT REAR Suspension Type Double Wishbone McPherson Strut Natural Frequency 2.23 Hz 2.29 Hz Stiffness 11.8 N/mm 32.38 N/mm Damping Ratio 0.35 0.35 Wishbone Material AISI 4130 AISI 4130 Max. Suspension Travel 127 mm 74 mm Transmissibility Ratio < 2.5 Spring Material SUP 7C Steel SUP 7C Steel Toppling Speed (at min. turning radius) 20.3 kmph Roll Gradient 5.19 deg/g Sprung Mass 300 Kg Un-sprung Mass 50 Kg Pitch Frequency 1.79 Hz Bounce Frequency 1.64 Hz Camber Angle Variation -2.80 – 30 Suspension CAMBER ANGLE VARIATION SUSPENSION GRAPHS
  6. 6. FEA of Critical Components Wheel Assembly Wheel Assembly exploded view
  7. 7. Steering Ackerman Steering Geometry (Rack & Pinion System) Wheel Base (L) 58” Pivot to Pivot distance (t) 42” Kingpin Inclination 7⁰ Caster Angle 3⁰ Camber Angle 0⁰ to 0.5⁰ (+ve) Toe Angle 0⁰ Scrub Radius 24 mm Steering Arm Length 120 mm Rack & Pinion Steering Ratio 8:1 Rack Travel (lock to lock) 4.25” Steering Wheel Diameter 14” Extreme Turning Angle Inside 35⁰ Outside 23.57⁰ Steer Angle Error (max) 2⁰ Minimum Turning Radius 2.77m Characteristic Speed 77kmph Parameter Value Length of Tie Rod 12.97” Assumed O.D. 15mm Calculated I.D. 12.82mm Material AISI 1026 0 10 20 30 40 0 20 40 60 80 Y a w G a i n Velocity (kmph) Yaw Gain v/s Velocity 0 5 10 15 20 25 30 35 0 20 40 60 80 S t e e r A n g l e Velocity (Kmph) Steer angle v/s Velocity 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 10 20 30 40 50 60 Lateral Acceleration Gain v/s Velocity
  8. 8. Disc and Caliper assembly Brakes • Hydraulically actuated disc brakes on all wheels. • Two different pedal designs (offering left/right foot flexibility). • 200mm petal discs (SS304) with floating caliper. Pedal and Master Cylinder assembly Part Specifications Master Cylinder M800 (Bosch) Bore 19.05 mm Hose STD 3/16” Caliper Apache 150 & Suzuki GS 2 POT Bore 26 mm Disc TVS Apache RTR 180 Rear Disk 200 mm OD 120 mm ID Performance Parameters Value Perception Distance 16.66 m Total Braking Force 1024 N Deceleration 8.812 m/s2 Stopping Distance (60kmph) 13.4 m Max. Dynamic wt. Front Axle 2200 N Min. Dynamic wt. Rear Axle 1233.61 N % Weight transfer 34 % Bias Ratio (Front : Rear) 16 : 9 Design Parameters Value Pedal Force 100 N Leverage (Pedal Ratio) 6:1 Piston Ratio 3.75 Braking Torque (per wheel) 71.9 Nm Proportioning valves TMC
  9. 9. Innovation Event Desired Sensitivity Pedal rotation for Max Accn (X) Ra (KΩ) Ra=R1+Rp Rb (KΩ) C (μF) R1 Rp 00 X0 Acceleration High 120 4.0 4.0 4.0 8.0 76 – 72 0.361 Endurance Medium 180 6.0 6.0 6.0 12.0 114 – 108 0.241 Maneuverability Low 240 8.0 8.0 8.0 16.0 152 – 144 0.180 Rack & Pinion Accelerator Pedal Electronic Throttle Control System Max. Pedal Travel= 300 300 IC 7806
  10. 10. Ergonomics & Electrical Hand Reach Envelope Vision Cone Reach Limit & Visibility
  11. 11. Infrared Emitter Infrared Sensor Safety ABC Grade 0.5 kg Fire extinguisher INFRARED EMITTER
  12. 12. Component Potential Failure Mode Potential Causes/ Mechanism of Failure Potential Effects of Failure O S D RPN Recommended Action • Gearbox Provides variable torque and speed to lower power train. • Enables effective conversion of engine power according to variable loads Surface Wear Abrasive Wear Foreign particles in lubricant Lapped finish; radial scratch marks; grooves on contacting surfaces 1 6 7 42 Oil filters; high viscosity oils; gear enclosure; regular replacement of oil; increase in surface hardness Corrosive Wear Chemical action of active ingredients in lubricant Fine uniform wear 1 6 7 42 Proper selection of lubricant; regular check-up and replacement of oil Initial Pitting Tooth profile errors; surface irregularity; misalignment Redistribution of loads due to progressive removal of high contact spots 1 7 4 28 Precise machining and alignment; Destructive Pitting Loads > surface endurance strength of material Complete destruction of tooth surface and premature breaking 3 8 3 72 Design gears for wear strength > (static + dynamic) loads; increase surface hardness Scoring Overheating due to excessive frictional heat Alternate welding and shearing 2 6 4 48 Adjusting surface parameters to reduce working temp.; proper air and lubricant circulation Breakage Fatigue Failure Root stress > endurance limit of material Fretting and breach marks; breakage of part or whole tooth 2 8 2 32 Design for reduced stresses; polishing and shot-peening of root fillet Overload Breakage Sudden overloads > tensile strength of material Stringy fibrous break (pulled or torn apart abruptly) 2 8 2 32 Design with greater factor of safety, and higher value of service factor. DFMEA
  13. 13. Project Plan & Team Distribution TeamDistribution(25) Steering 1BE, 2TE Suspension 2TE Transmission 2BE, 2TE CAD/CAE 1BE Brakes 1BE, 1TE Electrical 2SE Innovation 3SE Cat-Con 1BE, 1SE Marketing/Project Planning 2SE Aesthetics/ Ergonomics 2SE Safety 2SE
  14. 14. Workshop Facilities & Technical Components Facilities Technical Components Quantity Unit Cost (INR) Total Cost (INR) Engine 1 20000 20000 Gear Box 1 20000 20000 CVT 1 80000 80000 Steering Rack 1 7000 7000 Hub 4 5000 20000 Knuckle 4 6000 24000 Brake Calliper 4 2500 10000 Brake Disc 4 500 2000 Shafts 2 2700 5400 Shock Absorbers 4 4500 18000 Battery 1 3000 3000 Kill Switches 2 2000 4000 Steering Column 1 1800 1800 Servo Motor 1 2800 2800 Grand Total = 218000 • Weight of Vehicle with Driver: 350 Kgs • Finance Budget: INR 3.5 Lakh
  15. 15. Design Validation Camber Angle Variation v/s Wheel Travel Roll Centre Height v/s Wheel Travel Half Car Model
  16. 16. Thanks Vehicle completion Date: 18 January 2014 Vehicle Inspection Date: 22 January 2014 Our Sponsor M.I.T. Pune CAE SUPPORT

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