2. Parameter Value
vehicle length 70 inch
vehicle width 55 inch
Wheel base 45 inch
Wheel track 35 inch
Roll cage material AISI 1018
Tube dimensions 1 inch OD
3 mm thick
Roll cage mass 12 kg
Total mass 170 kg
Ground clearance 1 inch
Battery 12 V
Max speed 65 kmph
Brake Hydraulic disc
brake
Steering Pitman arm
Tyre 10*4.5*5 (front)
11*7.1*5 (rear)
VEHICLE SPECIFIATIONS
4. FINITE ELEMENT ANALYSIS
FRONT IMPACT REAR IMPACT
Total Deformation(max) = 0.67 mm
Load applied = 7.5 G
Total Deformation(max) = 0.13 mm
Load applied = 7.5 G
Equivalent Stress(max) = 285.6 Mpa
Load applied = 7.5 G
Equivalent Stress(max) = 138.9 Mpa
Load applied = 7.5 G
5. SIDE IMPACT TORSION
Case Total applied
Force (G)
Max Stress
(Mpa)
FOS Max
Deformation(mm)
Front impact 7.5 285.65 1.20 0.67
Rear impact 7.5 138.90 2.80 0.13
Side impact 5.0 662.72 1.07 1.30
Torsion 43 N-m 26.17 1.68 0.022
6. ERGONOMICS AND SAFETY
MAINTAINED
• SPACIOUS COCKPIT.
• INTEGRATION OF 95 PERCENTILE MALE IN COMFORTABLE POSITION.
• CLEAR LINE OF SIGHT.
• ALL THE PARTS ARE WITHIN REACH TO ACCESS.
• COMPLETE DRIVER’S KIT.
INNOVATION
1. THINKING TO HAVE A BRAKE FLUID SENSOR OVER MASTER
CYLINDER TO KNOW THE LEAKAGES.
2. ENERGY GENERATION USING EXHAUST GASES
7. STEERING
Parameters Values
Wheel track 35 inch
Wheel base 45 inch
Mechanism Ackerman steering
(pitman arm)
Tie rod length 13.7 inch
Inner turning radius 1.6 m
Outer turning
radius
2.67 m
Max. inner turning
angle
34.89o
Max. outer turning
angle
24.530
Max Deformation = 0.295mm
8. BRAKING SYSTEMOuter dia of disc 200 mm
Disc thickness 6 mm
Tyre radius 127 mm &139.7
mm
Pedal ratio 6 : 1
TMC piston dia 19 mm
Caliper piston dia 29 mm
Driver effort 100 N
Brake force on TMC 600 N
Pressure inside TMC 4.23 N/mm2
Caliper force 2795.56 N
Frictional force(disc
and pad)
1677.36 N
Braking torque 143.48 N-m
Deceleration 25.36 m/sec2
Velocity 40kmph 50kmph 60kmph 70kmph 80kmph
Stopping
distance(m)
2.43 3.80 5.47 7.45 9.73
Stopping
time(sec)
0.44 0.55 0.65 0.74 0.87
COG LOCATION
Height of COG 6 inch
wheel base 44 inch
Dynamic load
distribution
60 : 40
Brake fluid DOT 3
Fluid max temp. 205 0 c
Max deformation = 0.18mm
12. DESIGN VALIDATION PLAN (DVP)
S. No Description Acceptance Criteria Test Method Assignedto
1. Tensile Strength Of Pipe Application Based Tensile Strength Test on
UTM
Santhosh
2. Weld Strength Test Weld should not crack or
break
Rapid Hammering Yashwanth
3. Shear Strength of Brackets Application Based Test through Ansys khaja
4. Dimensional Stability Should match with technical
specifications sheet
prepared
Provided tolerance Ravi
5. Engine Mount Durability Not less than 75% energy
should be absorbed by
mounts
Vibration test using
accelerometer
Anil
6. Alignment of Pipes No variation of calibrated
spirit level
CombinationSet Gautham
7. Breakcircuit Noleakages Visual inspection Ashok
8. Kill switches Should workproperly Repeated testing Varun
9. Temperature of Firewall Should not exceed 40 C Using Resistance
Temperature Detector
Varun
