This document presents the final design project of a group for an INME 4012 class. It includes: - A list of group members and diagrams of the drivetrain arrangement with shafts and sprockets. - Details of preliminary calculations for forces, torques, and gear ratios needed. - Specifications and analyses of the sprockets, shafts, bearings, and brakes designed to meet the requirements. - Charts showing inertia, acceleration, and analysis results like weight and speed capabilities. - A parts list and cost analysis of the designed drivetrain system.

1. INME
4012,
Group
6
Final
Presentation
Fall
2014
Members:
Jeromi
Lopez
Miguel
Mora
Bryan
Ramirez
Fabio
Rodriguez

2. Drivetrain
Arrangement
Legend:
1= CVT Shaft
2= Intermediate Shaft
3= Dead Axle
A= C – between the CVT and the Dead
Axel=16.12”
B = C – Between the CVT and the
intermediate Shaft=8.06”
Red Circle = 17 teeth ANSI No. 40-2
sprocket
Blue Circle = 52 teeth ANSI No. 40-2
sprocket
Yellow Circle = 17 teeth ANSI No. 50-2
sprocket
Green Circle = 54 teeth ANSI No. 50-2
sprocket
Figure
1:
Shafts
and
Sprockets
Arrangement
Figure
2:
3D
Representation
of
the
arrangement
2

3. Preliminary
Work
Ø Forces
acting
on
the
vehicle:
ü
Rolling
Resistance
=
14.7
lbf
ü
Weight
component
in
the
plane
direction
=
346.48
lbf
ü
Drag
Force
=
17.76
lbf
Ø Torque
needed
at
the
Dead
Axle
=
555.77
lbf-­‐ft.
Ø Motor
Torque
=
20
lbf-­‐ft.
Ø Ratio
needed
from
the
motor
to
the
Dead
Axle
=
27.79:1
Ø CVT
Ratio
=
3:1
Ø Ratio
needed
after
CVT
=
9.26:1
3
Figure
3:
Vehicle
free
body
diagram

4. Sprockets
and
Roller
Chains
Ø Chains
pitch
and
length
ü
From
CVT
Shaft
to
Middle
Shaft:
0.5
in.
(ANSI
No.
40-­‐2)
–
2.86
feet
ü
From
Middle
Shaft
to
Dead
Axle:
0.625
in.
(ANSI
No.
50-­‐2)
–
3.33
feet
Ø Driver
Sprockets
fixed
at
17
teeth
Ø Sprockets
Ratios
ü
From
CVT
Shaft
to
Middle
Shaft:
3.059:1
ü
From
Middle
Shaft
to
Dead
Axle:
3.176:1
Ø
Driven
Sprockets
teeth
ü
Middle
Shaft:
52
ü
Dead
Axle:
54
4

5. Shafts
Ø Static
Analysis
ü This
will
give
the
Minimum
Static
Shafts
Diameters
as:
ü CVT
Shaft
=
1in
ü Middle
Shaft
=
1.25
in
ü Dead
Axle
Shaft
=
1.25in.
5

6. Shafts
Dynamic
Stress
Calculations
6
6
Table
1:
Values
for
the
modified
Goodman
theory
calculation
Table
2:
Values
of
the
minimum
diameter,
chosen
diameter
and
safety
factor
of
each
shaft

7. Bearings
7
Table
3:
Design
life
&
Basic
load
rating
results
Table
4:
Chosen
Bearings

8. Brakes
Ê The
normal
force
exerted
by
the
vehicle
(rear
shaft):
Ê The
required
braking
force:
Ê The
required
braking
torque:
8

9. Brakes
Ê The
force
provided
by
the
brakes:
Ê The
torque
provided
by
the
brakes:
9

10. Brakes
Ê These
values
were
determined
with
a
30-­‐70
weight
ratio.
Ê Normal
force
exerted
in
the
rear
part:
343
lbf
Ê Required
force
for
braking:
240.1
lbf
Ê Required
torque
for
braking:
320.13
lbf-­‐ft
Ê Force
provided
by
the
brakes:
268.875
lbf
Ê Torque
provided
by
the
brakes:
358.5
lbf-­‐ft
Ê The
percentage
of
difference
was
approximately
12%.
10

11. Acceleration
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
CVT
Middle
Dead
Inertia
(lb-­‐ft^2)
Shaft
0
1
2
3
4
5
6
7
8
9
10
CVT
Middle
Dead
Linear
Acceleration
(ft/s^2)
Shaft
0.00
20.00
40.00
60.00
80.00
100.00
120.00
CVT
Middle
Dead
Angular
Acceleration
(rad/s^2)
Shaft
Figure
4:
Inertia
of
the
shafts
Figure
5:
Angular
acceleration
of
the
shafts
Figure
6:
Linear
acceleration
of
the
shafts
11

12. Analysis
Results
12
Ê Weight
of
Drivetrain:
206.55
lbs
Ê Maximum
Linear
Acceleration
at
Dead
Axle:
9.34
ft/s^2
Ê Acceleration
time
for
100
ft.
(assuming
constant
acceleration)
:4.63
seconds
Ê Theoretical
top
speed:
29.5
mph
Ê Highest
grade
that
the
can
climb
is
45°

13. 13
Item
# Description Supplier Manufacturer Part
Number Units
Quantity Cost Final
Price Weight
per
unit[lb] Total
weight[lb]
1 CVT CVTech-­‐IBC CVTech-­‐IBC each 1 $175.55 $175.55 22 22
2 Chain-­‐
ANSI
No.
40-­‐2 Motion
Industries Martin's 151461 ft 3 $20.95 $62.85 0.86 2.58
3 Chain-­‐
ANSI
No.
50-­‐2 Motion
Industries Martin's 151798 ft 4 $26.12 $104.48 1.38 5.52
4 Sprocket
17
teeth
-­‐
ANSI
No.
40-­‐2 Motion
Industries Martin's 2168361 each 1 $104.10 $104.10 1.9 1.9
5 Sprocket
17
teeth
-­‐ANSI
No.
50-­‐2 Motion
Industries Martin's 2168393 each 1 $134.61 $134.61 3.4 3.4
6 Sprocket
52
teeth
-­‐
ANSI
No.
40-­‐2 Motion
Industries Martin's 2168381 each 1 $240.45 $240.45 16.1 16.1
7 Sprocket
54
teeth
-­‐
ANSI
No.
50-­‐2 Motion
Industries Martin's 2167526 each 1 $392.55 $392.55 26.8 26.8
8 1-­‐1/2"
4130
Rod Online
Metals Online
Metals ft 1.5 $16.43 $24.65 5.99 8.985
9 2"
4130
Rod Online
Metals Online
Metals ft 3 $29.34 $88.02 10.66 31.98
10 CVT-­‐Bearings McMASTER-­‐CARR McMASTER-­‐CARR 2722T36 each 2 $163.88 $327.76 3.5 7
11 MiddleAxle-­‐Bearings McMASTER-­‐CARR McMASTER-­‐CARR 2773T4 each 2 $95.06 $190.12 3.53 7.06
12 DeadAxle-­‐Bearings McMASTER-­‐CARR McMASTER-­‐CARR 2433K32 each 2 $246.13 $492.26 7 14
13 Grade
8
Bolts Bolt
Depot Not
Available
632 each 12 $0.57 $6.84 0.994 11.928
14 Grade
8
Nuts Bolt
Depot Not
Available
2678 each 12 $0.14 $1.68 0.033
15 Lock
Washers Bolt
Depot Not
Available
3040 each 12 $0.09 $1.08 0.225 2.7
16 Flat
Washers Bolt
Depot Not
Available
3050 each 12 $0.20 $2.40 0.158 1.896
17 Roller
Chain
Lube Ebay Schaeffer's
227
each 1 $12.99 $12.99 0 0
18 Asm.
Caliper,
LH
(1.188"
Bore) Polaris Polaris 1911150 each 1 $83.00 $83.00 5.6 5.6
19 Asm.
Caliper,
RH
(1.188"
Bore) Polaris Polaris 1911151 each 1 $83.00 $83.00 5.6 5.6
20 Asm.
Caliper,
Brake,
Rear
(1.5"
Bore) Polaris Polaris 1911063 each 1 $83.00 $83.00 6.5 6.5
21 Brake
Rotor
-­‐
Front
and
Rear
(9.56"
OD) Polaris Polaris 5250205 each 1 $22.00 $22.00 20 20
22Rear
Master
Cylinder
Assembly
(3/4"
Bore)Polaris Polaris 2203283 each 1 $54.00 $54.00 4 4
23 Brake
Pad
Kit Polaris Polaris 2202412 each 1 $25.00 $25.00 1 1
2712.385 Total 206.549
BOM
Table
5
:
Bill
of
Materials
13

14. Conclusion
14
Ê Torque
at
the
wheel
is
582.92
blf-­‐ft
Ê Acceleration
of
the
system
is
9.34
ft/s^2
Ê Sprockets
and
Chain
with
ANSI
No.
40-­‐2
and
50-­‐2
Ê Total
price:
$2712.39
Ê Total
weight:
206.55
lbs
Ê The
drivetrain
weights
57.38%
of
the
whole
car
weight

15. Assembly
15

16. Sprockets
16

17. Shafts
17

18. CVT
Shaft
Middle
Shaft
Dead
Axle
18

19. Shaft
Assemblies
19

20. Full
Assembly
20