2. 2 : LESSONS LEARNT
ROLL CAGE & AGGREGATES
ASPECTS LESSONS LEARNT IMPROVEMENTS
Motor Controller
Overheating of motor
controller due to excess
current
Two cooling fans are
incorporated to
maintain the
permissible
temperature
H-arm
In the semi-trailing arm,
we canโt get anti-squat
geometry, and it also
provides negative
camber gain while
cornering.
Providing more grip to
the weight carrying tire
and provides more free
parameters and wheel
motion easily optimized.
Frame
(Roll cage)
Clearance issue
between motor and
damper.
Slightly decrease the
placement height of the
motor.
Battery Placement
Battery removal was
quite hefty and also the
CG height was high.
Battery is placed axially
on cradle plane (behind
the firewall). CG height
was decreased
Brake light
Due to high (excess)
voltage our light was
brust out
We are using DC-DC
converter instead of
battery for efficiency.
VEHICLE PERFORMANCE
MAIN
EVENTS
LESSONS
LEARNT
IMPROVEMEN
TS
Power-
train
Torque on wheels
was not sufficient
for the vehicle to
climb incline tracks.
The gear ratio
is changed to
8:1.
Harness
Previously it was
difficult to
distinguish wire.
Different color
codes
3. SPECIFICATIONS 2021 2023
Overall Size 83โร57โร65.6โ 62.5โร47โร56โ
Track Width F/R 50โ/48โ 47โ/45.5โ
Wheel Base 54โ 51.18โ
Ground Clearance 14โ 14โ
Transmission Gearbox Gearbox
Tires Radial, 23x7x10
(+40mm offset)
Radial, 23x7x10
(+40mm offset)
Suspension F/R Double A-Arm /
H-Arms
Double A-Arm /
H-Arms
Steering Rack and pinion Rack and pinion
Brakes Disc Brakes Disc Brakes
Maximum Speed 41.29 kmph 44.6 kmph
Maximum
Acceleration
5 m/s2 5.55m/s2
Gear Ratio 12:1 8:1
Gradeability % 80% 57.73%
Stopping Distance 8.99 m 8.99 m
Kerb Weight (Kg) 175 172
Ratio FAW To RAW 45:55 62:38
3 :GENERAL SPECIFICATION - COMPARISON
2023
2021
4. 4 : ROLL CAGE DESIGN PROCESS-ERGONOMICS
PARAMETER
RULEBOOK
SPECIFICATIONS
DESIGNED
(Driver)
DESIGNED
(Co Driver)
Length of LC Members Minimum 8" 13.77โ 13.96โ
ALC Member Minimum 18" 22โ 22โ
Inclination of RRH Maximum 20
deg.
5 deg. 5deg.
Width of RRH 27" above seat bottom Minimum 29" 31.13โ 31.53โ
Width of RRH 14" above seat bottom Minimum 32" 33.37โ 34.2โ
Top and Bottom intersection of LDB and
RRH Members
Maximum 5" 5โ 5โ
Angle of LDB with RRH Minimum 20
deg.
70.11 deg. 70.5 deg.
Distance of point C from the center of the
template
Minimum 12" 12โ 12โ
RHO Diagonal Bracing distance from point C Maximum 3" 2โ 2โ
SIM Member Height from seat bottom 18" to 14" 11.02โ 11.12โ
Angle between the FBMUP and the vertical
in order to prevent the use of Front FAB
Maximum
45degree
20.82 deg. 21deg
Triangulation angles of rear FAB with the
vertical
Minimum 20
deg.
21.14 deg. 21.53 deg.
Driver Helmet Clearance Minimum 6" 14.96โ 14.45โ
Clearance of driverโs shoulders, torso, hips,
thighs, knees, Lower legs, arms, and hands
minimum 3โ 4.3โ 3.1โ
โ
5. 5 : CAE
No
.
Type of
Analysis
Total Load Applied Maximum Equivalent
Stress (Von Mises)
1 Front Impact 14746.53 N 365 Mpa
2 Rear Impact 6945.833 N (dv=45kmph) 840.95 Mpa
3 Side Impact 6390 N (dt=0.30s) 2486 Mpa
4 Roll Over 7375 N (dv=45kmph) 4192 Mpa
WELDABILITY
Type of welding: Tungsten inert gas welding(TIG)
Filler to be used:ER70S-2
Force Calculations:
F = ยฝ*230*dv/dt; dv=60kmph; dt=0.13
Max. Deformation FOS
0.46mm 2.34
Max. Deformation FOS
0.3504mm 2.58
Max. Deformation FOS
1.648mm 2.58
Max. Deformation FOS
2.87mm 1.401
Max. Deformation FOS
0.15856mm 1.921
Max.
Deformation
FOS
0.082mm 2.712
Max.
Deformation
Knuckle
F: 0.64mm
R:0.2379 mm
FOS:
F: 1.62
R:2.079
6. 6 : SUSPENSION
SPECIFICATIONS
2022 2023
FRONT REAR FRONT REAR
Suspension
Double
A-arms
Semi-
trailing
Double
A-arms
H-arms
Mass Distribution 92.5 157.5 92 138
Sprung Mass 185 Kg 170 kg
Un-sprung Mass 65kg 60 kg
Camber -2ยฐ 0 0ยฐ 0
Caster 11.26ยฐ 0 8ยฐ 0
KPI 6.64ยฐ 0 5.54ยฐ 0
Motion Ratio 0.6 0.65 0.6 0.65
Roll Centre 6.95โ 7.24โ 8.85โ 6.73โ
Scrub Radius (mm) 41.17 - 10.4 -
Suspension Travel
Jounce = 6โ
Rebound = 3โ
Jounce = 6โ
Rebound = 3โ
Spring
Stiffness(N/mm)
22 30 21 27
Ride Rate (N/mm) 17.83 22.73 15.58 21.68
CG Height 25โ 23โ
Desired Natural
Frequency (Hz)
1.55 1.76 1.52 1.68
Damping Ratio 0.7 0.7 0.7 0.7
Damping Stroke (mm) 90 102 42 52
Damping
Value@0.3m/s
43.18 65.80 40.28 61.89
IMPROVEMENTS
1. Reduced CG height
2. Optimized the toe angle with respect to wheel travel
-0.05
-1E-16
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
-150 -100 -50 0 50 100 150 200
TOE
ANGLE
[Degrees]
WHEEL TRAVEL [mm]
TOE ANGLE VS WHEEL TRAVEL
7. SPECIFICATIONS 2022 2023
Pedal Force 400 N 400 N
Pedal Ratio 6:1 6:1
Master Cylinder
(Bore Size X Stroke)
19.05 x 25 mm 19.05 x 25 mm
Brake Caliper Cylinder
(Bore Size X Nos.)
40 x 1 mm 31.75 x 2 mm
Caliper Piston Area 1256.63 mm2 791.73 mm2
Caliper Pad Area 1321.56 mm2 1372.81 mm2
Brake Pad Friction Coeff. 0.45 0.45
Brake Fluid DOT 3 DOT 3
Effective Radius 0.075 m 0.075 m
Torque Front Required 217.914 Nm 202.286 Nm
Torque Rear Required 154.600 Nm 127.246 Nm
Torque Front Available 395.458 Nm 414.97 Nm
Torque Rear Available 280.560 Nm 261.03 Nm
Stopping Distance 8.99 m 8.99 m
Force Required By Calipers (Front) 746.026 N 692.435 N
Force Required By Calipers (Rear) 529.273 N 435.625 N
Dynamic Load Transfer 691.149 N 685.595 N
Static Roll Radius (Tyre) 11.5โโ 11.5โโ
Pedal Travel 150 mm 150 mm
7 : BRAKES
Front Rear Split Brake System
Thermal Analysis Stress Analysis
8. SPECIFICATION 2022 2023
Steering System Over steer Over steer
Steering Geometry Ackerman 81% Ackerman 82%
Inner/Outer Angle 25.9/ 14.84 (deg) 44.66/27.27 (deg)
Turning Radius 1.5 m 1.2m
Steering Gear Rack and pinion Rack and pinion
Drive Type CHD CHD
End To End Travel 80 mm 60 mm
Turns Lock To Lock 1.1 turns 1.5 turns
Steering Ratio 72.73 mm/rev 40 mm/rev
IBJ/OBJ Centre Distance 214.63/553 mm 175/529.05 mm
Tie Rod Length 14.84 in 15.30 in
Rack Length 18.770 in 13.77 in
Column Type Single Column Single Column
Power Assist - -
Steering Wheel Diameter 180 mm 250 mm
Steering Wheel Torque 0.5-1.2 Nm 6.0 - 7.0 Nm
8 :STEERING AND WHEEL GEOMETRY
9. 9 : POWERTRAIN
MOTOR SPECIFICATIONS TYRE SPECIFICATIONS
BLDC MOTOR (48 V) Outer Diameter 23โ
Max. Torque 19 Nm Inner Diameter 10โ
Max. Power 9 kW Thickness 7โ
INTEGRATION
MOTOR CONTROLLER TRANSMISSION
Voltage 48 V
Fixed Gear
Ratio
8:1
Speed Control PWM Weight 13 kg
Weight 2 kg Dimension 16" x 8" x 4"
BATTERY (Li-ion) NVH CONSIDERATIONS
Cell Voltage 3.7 V (nominal)
Capacity
110 Ah
(13x42 cells)
Dimension 17.7โx11.8โx6โ
PERFORMANCE
Max Acceleration 5.55 m/s2
Gradeability 57.73 %
โข For motor and gearbox we
will use rubber(neoprene)
sheets.
โข Nylon nuts(self locking nuts)
are used .
โข Polyurethane foam are used
in driver seat to get most
comfortable ride.
โข Steering wheel is covered
with leather along with foam
to damp vibration.
10. 9-B : Tractive System & Complete Circuit Diagram
MCU Specification
Peak / Cont.
Phase Current
92.38 A & 51.96 A
Rated/ max. DC
Current
90 A DC & 160 A DC
Throttle Input
Type
Foot Padel
Cooling Type Passive Natural Cooling
Approximate
Weight
4.5 kg
Dimensional Size 288*185*94.3
BMS Features
(protection)
Over Charge , Short &
Temperature Prptections
Current
Protection
Over current delay time = 9MS
Over current Protection ๏
discoonect the load
Short Fuse
Protection
150 A
Charged /
Discharged
Voltage
48 V DC & 25 V DC
Specifications
Charge Delay Time = 0.5S
Max Discharge Current=60A
Peak Discharge Current =180 A
Battery Specification
Nominal Voltage 48 V
Max Cut off Voltage 54.75 V
Min. Cut off Voltage 37.5 V
Nominal Ah Capacity 110 Ah
SOC 5 โ 95 %
DOD 90%
Approximate Weight 52 Kg
Dimensions
240*370*2
80* mm
Maximum Charging
Current
50 A
Maximum Discharging
Current
150 A
Operating temp. 25-60 C
11. 9-C : GLV System & Component Analysis
GLV Component SPECIFICATIONS
Fuse Location
Perpose
Current/Voltage
Rating
Motor Controller 150A / 60V
After AIR 200A / 60V
Type (Instant
blow/
Delay blow)
Instant blow
AIR
Normally open
type(200A)
Kill Switch <=15V DC
DC-DC / GLV
Accumulator
<=15V
Auxiliary
Sub
System
Break Light, Reverse
Light, Reverse Alarm,
Ignition Switch,
Cockpit Switch, Kill
Switch, Fuse, AIR
Safety Components
TSAL [Flash Rate = 4Hz],
RTDS [Sound intensity at 3m = 70 dB] ,
Fuse [Voltage/Current rating = 150A / 60V,
Time Delay <500 mS]
AIR (Accumulator Insulation Relay ),
Firewall [Insulating Layer Thickness = 0.50
mm]
Microcontroller
OR Sensor
ESP 32, Thermistor,Voltage sensor,Optical
rotary encoder,Accelerometer,pressure
sensor.
Wiring /
Connectors
Properly insulated harness with help of
insulating caps & enclosures
TSAL Sequence Flow Diagram
1
2
12V IN
1
2
48V
IN
1
2
15V
OUT
1
2
OUT2
EMS 1.0
DC TO DC STEP-DOWN
48V TO 15V
TSAL
BATTERY
48V
ESP - 32
12. 10 : PROJECT PLAN
2022
TASK WORKDAYS July August September October November December January February March
TEAM SELECTION 5 5
IDEAS SHARING SESSIONS 5
DEPARTMENTS HEADS MAKING 3
DOCUMENTATION 5
SPONSORSHIP 30
DESIGNING 30 78
MATERIAL ORDERING 15 93
ROLL CAGE 10 108
STEERING 15
SUSPENSION 14 137
BRAKES 12
POWERTRAIN 20
ELECTRICAL DESIGNING 10 195
ASSEMBLY 30 225
TESTING 30 255
2023
10
13
18
48
123
151
185
CRITICAL PATH IN THE PROJECT
Timely procurement of raw materials and subsequent manufacturing and machining to meet the deadlines.
13. COMPONENT FAILURE MODE FAILURE CAUSE FAILURE EFFECT S O D RPN PREVENTIVE FACTORS
Frame
Frame bending,
Breaking
Excess and impact load
Frame deforms/
breaks`
9 3 5 135
Effective design and
analysis
Suspension Mechanical failure
Inappropriate choice of
spring
driver may face
physical discomfort.
5 6 3 90
Selection of standard
suspension systems,
dynamic factors
Knuckle Bending failure
Impact load and excess
load.
Suspension system
damage
8 4 4 128
Effective design and
analysis
Motor
Over heating, hall
sensor fault
Moisture, insulation
breakdown
Over current, fire 9 3 2 54
Protective Circuit: MCB,
Fuse, AIR, Regular
check-ups
Battery
Cell failure/Cell
damage
Over current, high
voltage and
temperature
Fire, explosion,
tractive system
stops working
10 7 2 140
BMS, Protection Circuit:
MCB, Fuse, AIR, Charge-
Discharge Test
Pedals
Bending &
Breaking
Excess load by driver
Brake fails &
acceleration cannot
take place
8 3 5 120
Effective design,
analysis and mounting
Welding/
Soldering
Cavities inclusions
Crack in weld/
solder
Formation of cavities
and inclusions
Job weakens/ Circuit
loosens
8 1 7 56
Preheat, increase weld
area & bead contour
Brake fluid
leakage
Improper flaring Improper flaring Reduced pressure 7 7 3 147
Double flaring with
flaring kit and proper
Teflon
11 : DFMEA & PFMEA
14. DEPARTMENT DESCRIPTION TEST SOURCE TEST PROCEDURE ELIGIBILITY CRITERIA
RULEBOOK CLAUSE
ADHERENCE
Specifications as
per rulebook
Verification from
rulebook
Measurements manually
checked
Vehicle specifications must match
with rulebook
DESIGN AND
FABRICATION
Weight Weighing Bridge Weighing the ATV Target weight โ230kg
Dimensions Measurements
Digital Vernier caliper &
Clinometer
Specified according to rulebook
ATV Ergonomics
Testing ATV in
rough terrains
Check the driverโs
adaptability to the vehicle
Must fulfil all design requirements
SUSPENSION
Drop Test Observation ATV dropped from 6 ft. Assembly must be intact
Bump Test Observation Testing it on a rough terrain Spring should rebound completely
POWERTRAIN
Acceleration Vehicle
Record time taken to travel a
certain distance
Least time must be taken (best
performance)
Battery SC &
Overcharge Test
Various Loads
Connecting loads across the
battery
No physical damage, melting of
components or explosion
STEERING
Agility Test Tracks and Cones Drive the figure of โ8โ and โOโ Turns without touching the cones
Straight Line
Stability
Tracks with white
stripes
Driving parallel to white
stripes
Should move in a straight line when
steering is at neutral position
BRAKES
Wheel locking
Slow motion
cameras
Brakes applied at full throttle
All four wheels must lock (stop
spinning) at the same time
Pressure and
Leak Test
Manual
Vehicle to be tested in
various road conditions
Reduced pressure and leakage in
the brake circuit should be absent
ELECTRICAL Kill Switch Vehicle
Manually checked if working
properly
HV system turned off; Brake light
working
12 : DVP
15. TEAM
FACULTY
ADVISORS
Dr. Alok Jain Rahul Deharkar
DEPARTME
NT
HEAD MEMBER
Design Meet Lakhani Devam purohit
Analysis Meet Lakhani Abhishek
Brakes Dhrumit bhatt Krishna
Suspension Smit Patel Anand
Steering
Rushang
kulkarni
Rishit Panchal
Motor &
Powertrain
Bhawani singh
shekhawat
Sahaj,Paresh
Controller Harshil, Vrinda Om,Jinisha
BMS Vrinda Kamya,Jugal
Sponsorship Rishit Maulin
Inventory Bhawani Paresh
Costing Harshil Shreya
GLV Vishal Sameul
VEHICLE
AGGREGATE
MANUFACTURING FACILITIES
MANUFACTURING
PROCESS
FACILIITIES
Roll Cage
Welding, Grinding,
Bending, Cutting
TIG Welding,
Grinding, Drilling,
Lathe, Milling, CNC,
Rapid Prototyping
Machine, Hydraulic
Band saw
A-arms and trailing
arms
Welding, Grinding, Bending
Knuckle and Hub Milling machine
Paneling
Sheet Bending, Molding,
Drilling
ELECTRICAL
AGGREGATE
ELECTRICAL FACILITIES
TESTING PROCESS FACILIITIES
BMS Protective Circuit Test EDC Lab
Motor Load Test EMEC Lab
13 : TEAM COMPOSITION AND COLLEGE WORKSHOP FACILITIES
Hydraulic Band Saw
Motor Load Testing
Shaping
Machine
* Highlighted are old members
