Please fill in the following details:-

Team UID (Registration Number): 201750020

Team Leader’s name: Yash Phatak
Contact Number: 7089126120
Email ID: yash.phatak97@gmail.com
Team Name: GNOSIS 2.0
Vehicle Name: Nimbus
College Name: Gyan Ganga Institute of Technology and Sciences

Fill in the information about your Kart in the respective sections as mentioned below:
1. Describe the chassis layout of your Kart. Use proper diagrams/Images to
explain it. Also attach the picture of your empty chassis if already
fabricated. Cost for this Segment. You can also Show Load Analysis and
testing results (Optional)
● The chassis contains 23 rods with 3 bending rods included made up of 4130
Carbon Molybdenum alloy having following characteristics:-

560 MPa Ultimate Tensile Strength

460 MPa Yield Tensile Strength
190 GPa – 210 GPa Modulus of Elasticity
140 GPa Bulk Modulus (Typical for
Steel)
80 GPa Shear Modulus (Typical for
Steel)
0.27 – 0.30 Poisson’s Ratio
21.50 % Elongation at Break (in 50
mm)

● The length of the chassis is 55.9 inches while the breadth is 38 inches. The material
used is AISI 4130 Steel normalized at 870 degree Celsius. The frame used is
Tubular Framed with inner diameter is 26 mm and outer diameter is 30 mm.

● The rods are 26.9*3.2 with inner diameter 0.81 in and outer diameter 1.06 in and
21.3*2.3 with inner diameter 0.66 in and outer diameter 0.81 in.

● The chassis is uni-body type having a tubular frame. It helps in uniform distribution
of all vertical loads into horizontal sections.
Cost for this segment will be Rs. 10,145.6.
2. Describe the steering mechanism of your Kart. Explain it along with
proper diagrams/Images. Also attach the pictures of your steering
system if fabricated. Support your Write up with Calculations and also
highlight. Cost for this Segment.
The steering mechanism used is Ackermann steering having 4 bar linkage. The
Ackermann steering mechanism is used because the turning radius of one wheel is
smaller than the turning radius of other one which ultimately reduces the slip
occurring due to incorrect synchronization of the adjacent wheels.
The axle and steering column have been connected through universal joint. This
allows free movement without any frictional hindrances due to constrictions.
The Ackermann angles provide optimum turning angles for the turning which reduces
turning problems.
Cot θ – cot Φ = w / e

Wheel Base = 101.6 cm

Front Wheel Track = 96.52 cm
Steering Ratio = 6.5:1
Inner Angle (Ө) = (Steering wheel rotation / Steering ratio) * 360
= (0.64 / 6.5) *360
(Ө) = 35.46°
Ackermann angle (β) = tan β = {track width / 2} / wheel base

β = 25.2°

Turning Radius (r) = √ (R₁^2 + TѠ^2)

= 1.25 m
Cost for this segment is Rs.3000.
3. Describe the suspension mechanism of your Kart if used. Explain it
along with proper diagrams. Also attach the pictures of your suspension
system. Explain used explain the necessity of use. Cost for this
Segment.

The suspensions in the car have been omitted assuming the terrain to be smooth,
devoid of any high crests or troughs.
The wheels used in the car will allow low to medium amount of shock appearing due
to irregularities of road to be cancelled out.

4. Describe the brake mechanism of your car. Explain it along with proper
diagrams/Images. Also attach the pictures of your brake mechanism if
you have already fabricated. Support your write up with Calculations.
Cost for this Segment.
Rear Brakes:-

The brakes used are disc brakes placed beside the hubs of the rear tyres of the vehicle.
The rear braking allows uniform distribution of brake force throughout the driving shaft thus
allowing efficient braking while reducing unnecessary torsion force on the driving shaft.
The braking system we used was single disc hydraulic operated disc brake system which
is localized on the rear tyre assembly. The rear braking allows uniform distribution of brake
force throughout the driving shaft thus allowing efficient braking while reducing
unnecessary torsion force on the driving shaft.
Maximum Speed of vehicle: 60 kmph
Total Mass Of kart: 135 kg
Brake Force = µ*N
µ = 0.6
Brake Force = 1059.58 N
Deceleration = 7.8 m/s^2
U = 60kmph = 16.66m/s
Stopping time = 1.02 seconds
Stopping Distance = 6.42 meters
Cost for this segment would be Rs. 4000.

Single Disc Hydraulic Disc Brake

5. Give the specification of you all the parts that you have bought from the market.
Write in the details of
your Motor, Battery, Lights, Wires, Tires/Rim used, Dashboard specification and its
features, Safety measure in the kart. Calculate all suitable data for transmission and
power train. Cost for this Segment
The following given list is the detail of parts and their cost analysis:-
S.No. Cost Analysis Name of the Parts
1. Rs. 2200 Mortise headlight
2. Rs. 800 Basic Wiring (Yamaha RX 100)
3. Rs. 1700 Wagnor Bumper (Black)
4. Rs. 1600 Bumper (Maruti)
5. Rs. 3300 Steering Complete
6. Rs. 1300 Disc Brake (Discover)
7. Rs. 1150 Lighting Set Full
8. Rs. 3000 each Amaron Battery ( 48V,35A)
9. Rs. 4281 each Exide Battery ( 48V,35A)
10. Rs. 4000 Seat Panel
11. Rs. 2900 Rear Axel
12. Rs. 1500 Hub
6. Describe the Material used and Body Work segment. Also attach the pictures of
the Body work if you have already fabricated. Cost for this Segment
The material used is AISI 4130 Carbon Molybdenum alloy.
Its physical properties are as follows:-

Imperial Metric Physical

Properties

0.284 lb/in³ 7.85 g/cm² Density

2610°F 1432°C Melting Point

It’s Chemical composition are as follows:-

Content (%) Element
97.03 – 98.22 Iron (Fe)
 0.8 – 1.10 Chromium
0.40 – 0.60 Maganese
0.280 – 0.330 Carbon

0.15 – 0.25 Silicon

0.040 Sulphur
0.035` Phosphorous

It’s mechanical properties are as follows :-

560 MPa Tensile strength, ultimate
460 MPa Tensile strength, yield
190-210 Modulus of elasticity
GPa
140 GPa Bulk modulus (Typical for steel)
80 GPa Shear modulus (Typical for steel)
0.27-0.30 Poisson’s ratio
21.50% Elongation at break (in 50 mm)
59.6 Reduction of area
217 Hardness, Brinell
240 Hardness, Knoop (Converted from Brinell hardness)
95 Hardness, Rockwell B (Converted from Brinell hardness)
17 Hardness, Rockwell C (Converted from Brinell hardness, value below normal
HRC range, for comparison purposes only.)
228 Hardness, Vickers (Converted from Brinell hardness)
70 Machine ability (Annealed and cold drawn. Based on 100% machine ability for
AISI 1212 steel.)

The flooring is made up of Polyvinyl Chloride. This helps in cost effective flooring along
with durability

7. Describe the Innovations in your Kart support them with calculations and Images.
Cost for this Segment
Following Innovations have been implemented on the vehicle:
 1st Innovation : Raspberry Pi 3
Specifications:-
SoC: Broadcom BCM2837
CPU: 4× ARM Cortex-A53, 1.2GHz
GPU: Broadcom Video Core IV
RAM: 1GB LPDDR2 (900 MHz)
Networking: 10/100 Ethernet, 2.4GHz 802.11n wireless
Bluetooth: Bluetooth 4.1 Classic, Bluetooth Low Energy
Storage: microSD
GPIO: 40-pin header, populated
Ports: HDMI, 3.5mm analogue audio-video jack, 4× USB 2.0, Ethernet, Camera Serial
Interface (CSI), Display Serial Interface (DSI)

List of Components required:-

1. Raspberry pi 3
2. Sensors
3. Small LCD display

LCD Display

 2nd Innovation : Regenerative Braking

In this a V-belt and pulley will be mounted on the shaft connected to electric motor
having chain and sprocket mounted on it too. This V-belt and pulley will be further
connected to eccentric bearing which will be connected to generating device and that
output will be used for auxiliary battery charging.

 3rd Innovation : Smart Helmet

 The innovation is safety cum security system. It obliterates the need for keys and
replaces it with more user customized apparel and safety gears. The seat belt,
helmet and fireproof suit chosen will have switches such that when driver wears the
above all the safety equipments then only the cart will start. This will remove the
use of key to start the motor as such the motor runs only when all the switches are
on. The overall working is based on ELECTRONIC COMPONENTS.
The main feature of the helmet will be that it will have an inbuilt breathalyzer in it.
After the driver wears the helmet, the breathalyser will be continuously taking the
inputs of the alcohol value and only if the driver is sober the kart will start.

 4th Innovation : MSS/Mutable Steering System

This System provides three modes of Steering ratios, for more personalisation for
the driver. Its consist of a Reverted Gear System, consisting of a Compound
gear(made up of 4 gears), 3 different Driver gears, one Driven gear. Just with small
change in position(vertical) of the compound gear, 3 different combination can be
achieved. This is how the System allows the Driver to choice from 3 available mode
options: Normal steer mode, Understeer mode, Oversteer mode.
  5th Innovation : APF/Alterable Pedal Force
This system provides an access to vary to the Pedal ratio, which allows the driver to
have different modes of sensitivity of the brake. If the pedal ratio is x:y , then this
system allows the driver to change the value of ratio by changing the value of x,
which consequently results in different pedal force for same amount brake force.

Cost for overall innovation segment would be 10,000.

8. Showcase of full Vehicle Design with all Bodywork (3D CAD Model)
9. Left and Right Side Views, Top View and Front View of the Kart

LEFT SIDE VIEW

 RIGHT SIDE VIEW

FRONT VIEW
 TOP VIEW

10. Combined Cost Analysis and Your Market Price for the Kart.
The Material used in chassis has a market value of Rs. 180 /ft^2.
Calculating according to 55 inch length and 38.2 inch width of the chassis the overall price
for this segment will be Rs. 6145.6.
Cost Layout:-
Frame Rs. 10,145.6
Steering Assembly Rs. 3000.0
Motor Rs. 6000.0
Rear Axle Assembly Rs. 3000.0
Rear Hub Rs. 1500.0
Disc Brakes Rs. 2400.0
Pedals and Hand Brakes Rs. 2000.0
Tyre Rs. 6500.0
Electrical Instrument Rs. 5000.0
Battery(x4) Rs. 4400.0
CVT Rs. 7500.0
Raspberry Pi3 Rs. 3500.0
LCD Screen Rs. 3000.0
Total Cost Rs. 57,945.6
Proposed Market Price Rs. 85,000.0
11. Design Validation Plan Segment wise
The design of the chassis is so formed that it will support all the important loads. The
numbers of links are increased for the case where the load density is high as in the
position where driver seat is placed and the heavy batteries are placed. Two beams are
placed below the seat to manage the weight of driver and special segments are introduced
to support batteries and the motors.

The design of steering is precisely done keeping in mind the available parts. The
maximum turning angles were 33 degree and 45 degrees respectively. According to these
values the turning radii of the cart was calculated and is somehow close to reality.

The brake used is a disk brake assembly and is mounted on the rear axle and hence will
provide a better braking power as compared to one placed at the centre of the rear axle as
used traditionally. The braking ability is tested at 50 kmph which is the optimum speed of a
vehicle and the braking friction is taken for a general value which is close to reality.