MIT

BELLATORES
FACULTY ADVISOR - Mr. AMIT KUMAR MARWAH TEAM CAPTIAN - RAHUL AWATE

2007

2009

2010

2011

2012

3D VIEWS

TECHNICAL SPECIFICATIONS
ENGINE

Type Displacement cc. Max. Torque Nm @rpm

Briggs & Stratton 1450 OHV 305 19.6@ 2800 10 @ 3250

X Y

Max Power , hp@ rpm

TRANSMISSION
Mahindra Alfa Gearbox 4 Forward- 1 reverse Constant Mesh

STEERING
Rack And Pinion

SUSPENSION
Front Rear SLA Double Wishbone SLA Double Wishbone

BRAKES
Hydraulic Disc Brakes

DIMENSIONS

61 Wheel Base 54 Wheel Track

Length (inches) Width (inches) Height (inches)

88
58 60

WEIGHT
Kerb Weight Gross Weight

250kg
310kg

WHEEL

51.2 KG LEFT 76.5KG

FRONT Weight Distribution (Total = 250kg) REAR

48.8KG RIGHT 73.5 KG

Front (OD x Width x Diameter) Rear (OD x Width x Diameter)

Polaris : 22x7x12 Polaris: 23x8x12

CENTER OF GRAVITY
CG wrt centre of base of firewall (mm)
X:2.5 Y:241.3 Z:152.4

ROLL CAGE AND ERGONOMICS

Ergonomic Conditions
Parameter Angle at elbows Angle at Knees Angle at Back Std. Value 125-140 120-150 8-15 Our Values 132 130 10 Parameter Steering Wheel Dia.( mm) Angle of Steering Wheel Std, Value 40-50 Our Values 12 in. 45

Salient Features
Adjustable Seat

Roll Cage Features

Reach Bubble

Parameter Total Number of welds Weld Length Tubing Length

Value 81 7m 30.25 m

Parameter Tube Outer Diameter mm Thickness of tube (mm) Weight of tubing (Kg)

Value 25.4 3 59.7

Rulebook Conformance
Parameter Maximum vehicle width (inches)

Allowable Value 64

Designed value 62

Maximum vehicle length (inches)

Minimum firewall width at 27 inches above seat Material used Vertical distance of S.I.M. from seat (inches) Firewall angle in degrees Firewall triangulation members -Upper Lower F.B.M. angle

108
29 Steel alloys 8 -14 Maximum 20 Less than 5 inches Angle- Greater than 20 deg Less than 45 deg

87
41 AISI 4130 9.8 10 4 inches 35 deg 23.191 deg

Binocular Vision

FINITE ELEMENT ANALYSIS

FRONTAL IMPACT
Weight of vehicle Maximum Force (kN) 300 kg Impact time(sec) Maximum Force (g) 0.2

SIDE IMPACT
Weight of vehicle Maximum Force (kN) 300 kg Impact time Maximum Force (g) 0.2

23.25

7.9

9.27

3.15

Maximum Equivalent Stress (MPa) Maximum Deformation (mm) Factor of Safety

217.1 2.3 2.2

Maximum Equivalent Stress (MPa) Maximum Deformation (mm)

124.7 4.31

Factor of Safety

3.69

REAR IMPACT
Weight of vehicle 300 kg Impact time(sec) 0.2

ROLL OVER
Weight of vehicle Maximum Force (kN) 300 kg Impact time Maximum Force (g) 0.2

Maximum Force (kN)

23.25

Maximum Force (g)

7.9

7.12

2.149

Maximum Equivalent Stress (MPa) Maximum Deformation (mm) Factor of Safety

137.4 5.34 3.35

Maximum Equivalent Stress (MPa) Maximum Deformation (mm) Factor of Safety

122.2 1.5 3.77

SUSPENSIONS
Vehicle Dynamics Front Suspensions

Parameter

Value

Parameter

Value

Toe in
Camber gain Caster gain Weight transfer Static camber set zero

2.0 deg
2.3 deg 7.3 deg 111.3kg zero

Height roll center

Rolling force Ground Clarence King pin angle Scrub radius

10.64 in
1.76g 33 cm 5deg 2.53 in.
Rear Suspensions

Suspension Specifications

Parameter
Length of Spring Total Length Max.travel spring

Front
300 mm 450 mm 192 mm

Rear
250 mm 450 mm 96.8 mm

Spring Stiffness
Types Roll Centre Height

40.23N/mm2
Square grounded 10.4 in.

31.54N/mm2
Square grounded 10 in.

Boundary conditions

Front - 3g bump

Rear - 4g bump

STEERING SPECIFICATIONS
Parameter Length of rack Ratio rack and pinion Axial pitch of rack bar Column inclined No. of tie rods Value 144 mm 12:1 6mm 45 deg 2 Parameter Pitch circle diameter Moment ratio No. of universal joints Teeth on rack Length of tie rod Value 26 mm 12:1 2 36 10.18 inch

STEERING WHEELS DYNAMICS

Parameter Angle outer Angle inner Value 41 33 Parameter Rack travel Turning radius Value 61.26 mm 3.19m

Wheel angle lock to lock

Steering ratio

475

Scrub radius

2.53 inch

9.73:1

Steering effort

6.23kgf

BRAKES CONFIGURATIONS
Parameter
Disc Disc outer Diameter(mm) Braking Torque(Nm) Caliper Suzuki GS 150 R 26

Type/value
Honda Dazzler 20 115.08 Pulsar 220

Parameter
Leverage Pedal force (N) Dynamic Weight Transfer Stopping Distance (m)

Value
4.75 160 61.92 kg 17.6

BRAKE CIRCUIT LAYOUT

Diameter of piston(mm)

25.6

Radius of gyration(m)

0.198 m

Tandem Master Cylinder

Maruti 800

Moment of inertia(kg.m2)

.390

Diameter of piston(mm)

20

Temperature rise(deg c)

37

POWER TRAIN
Input Parameters
Max Power = 10 HP@3250 rpm Max Torque = 19.66Nm@2800 rpm Tire Rolling Radius = 0.286 m Rolling Coefficient = 0.1 Drag Coefficient = 0.9 Max Gradient = 26.7

Speed vs rpm graph

Optimization
Tire Size
Gearbox Mahindra Alfa pickup Mahindra Alfa passenger Tata Ace zip Acceleration (m/s) 4.46 3.36 3.52

23
Top Speed (Time) 52.3(22) 67(32) 63(30)

Tire Size
Acceleration (m/s) 3.97 3.07 3.17

25
Top Speed (kmph) (s) 57.3(36) 72(42) 68(38)

Tractive effort /resistances vs speed

Gear Ratios (Alfa pickup)

Gear 1st (31.45) 2nd (18.7) 3rd (11.4) 4th (7.35) Rev (55.08) Speed (Kmph) 12.2 20.5 33.7 52.3 7 Max gradient 26.7 12.7 5.16 0.60

Coupling Dimensions Diameter of shaft Diameter of outer hub Length of hub No of bolts

Length(mm) 25.4 50.8 38.1 4

BODY SAFETY & ELECTRICALS

DRIVERS SAFETY
Parameter
Distance of R.H.O. above helmet (inches) Distance of S.I.M. from drivers body (inches) Position of Drivers feet Firewall thickness (inches) Safety harnesses, clothing and restraints

SAFETY SALIENT FEATURES

Designed Value 5-point safety harness with arm restraints. Fire Resistant Driver Suit, gloves, helmet, tear-off goggles and safety shoes. Cockpit designed to keep driver safe during impact and roll over. Vehicle designed to facilitate ease in driver exit. Polymer based side panels; do not project sharp edges post impact. Provision of drip pan and splash shield. Provision of fire extinguisher and kill switches. Independent disc hydraulic braking systems. Engine Overheating alarm. High crumple in the front zone. Proper asbestos insulated fuel tank. Pressure differential valve to assist breaking.

Allowable Value

Minimum 6 Minimum 3

8 8.7

Behind the plane of AF(RL) and RF(RL) Minimum 0.02 S.F.I. Specifications 0.2

Provisions made accordingly

Binocular Vision

ELECTRICALS

Reach Bubble

MANUFACTURING PROCESSES & TOOLS

Component/Operations Wishbones Hub Spacer Roll Cage Material Testing Flange Gearbox Pipe Bending, Cutting, etc. Machine ARC Welding/TIG CNC Lathe Purchase ARC Welding/TIG U.T.M. ; Brinell Hardness Tester Outsource PBM

Hacksaw Pipe cutting machine

TECHNICAL PARTS LIST. OVERALL WEIGHT COST ELEMENTS/ESTIMATE FINANCING

S.N .
a) b) c) d) 2.

FACILITIES AVAILABLE

System Description

Particulars

Cost

1. Raw Material & Fabrication Tubes (80Kg) Labour Cost Welding Cost Painting Cost Total (A) @ Rs 100/ Kg At Institute At Institute At Institute 8000/00 00 00

8000/By SAE- India To be purchased Couplings, etc 35000/36000/10000/-

Power Train
a) Engine b) Transmission System c) Miscellaneous Total (B)

Lathe

Drilling

CNC

81000/@ Rs 3500 / item @ Rs 1000/ item @ Rs 4000/ item To be purchased To be purchased 14000/4000/16000/10000/5000/-

3.

Suspension & Steering System

a) Shock Absorbers (4 Nos.) b) c) d) e) A- Arms (4 Nos.) Uprights (4 Nos.) Rack & Pinion Accessories Total (C)

Arc Welding

Hardness Tester Impact testing

UTM

49000/To be purchased @ Rs 10000/ tire 12000/75000/-

4.

Brakes & Tires

a) Brakes b) Tires (4 No's) Total (D)

Gas welding

87000/30,000/-

5.

Miscellaneous
Total (E)

30,000/-

TOTAL COST (A+B+C+D+E)

255000/-

Millling ,machine

TEAM ORGANISATION
Faculty Advisor : Mr. Amit Kumar Marwah

Team Captain : Rahul Awate

Vice Captain: Shreyansh Sharma

Roll cage design & Analysis

Transmission

Steering

Suspension

Brakes

Body Safety & Electrical

Akshay Poal

Shreyansh Sharma

Darshan Upasani

Akshat Sharma

Ashray Pawar

Rajeet Ojha

Siddharth Shrivastava

Rohan Saxena

Sachin Kumar Singh

Abdul Faizal khan

Shantanu Dwivedi

Palak Vyas

Sudheer kumar

Pratik Mishra

Harsh Khardekar

Asmit Jain

Vishwas Parmar

Shreya Dwivedi

Rahul Awate

Kumaril Bhatt

Ankit Kalore

Akshay Upadhyay

Sharat Reddy

Aditi Dange

Shrey Arodia

PROJECT PLAN
TASK Interviews Task submissions & HOD determination Prilimanary Meetings Workshops And Member Training No. Of Day(s) 5 2 7 Dates 2/3/2013 7/3/2013 9/3/2013 16/3/13 10/4/2013 20/4/13 28/4/2013 13/05/13 20/07/13 30/06/13 3/7/2013 6/7/2013 9/7/2013 13/07/13 20/07/13 24/07/13 15/08/13 20/08/13 30/08/13 9/9/2013 10/9/2013 20/09/13 30/09/13 5/10/2013 10/10/2013 13/10/13 17/10/13 20/10/13 1/11/2013 10/11/2013 20/11/13 30/11/13

Design & Analysis

Primary Design And Analysis Modification & Analysis Tech. Assessment & Calculation Semester Exams Design Modification after Analysis Verification & Proofing Of Final Calculation Innovation And USP Saftey Features Final Design Modifications Presentation Drafting Presentation Mock Practice Virtual Round Virtual results Design Report 10 8 15 30 10 4 3 3 4 7 3 4 15 5 10 1 10 10 5 5 3 4 3 6 10 10 4 1

Fabrication
Material Procurement & Sponsorships Prototype Modelling Fabrication Of Rollcage Sub Assembly Delivery & Installation Suspension & A arm Power Train Steering Engine And Tyre Mounting Elecrical System Final Assembly+ Accessories

Vehicle Completion Date : 30/Nov/2013 Technical inspection Date : 05/Jan/2014

TESTING
1st Build test and Modifications 2nd Build test and Modifications Final test Drive Technical Inspection

DESIGN FAILURE MODE EFFECT & ANALYSIS (DFMEA)

Occur Detec

No

Item

Potential mode of failure

Deformation in rollcage due to weld failure

Severity (S)
8

Causes of Failure

rence

tion

(O)
Heavy impact or improper welding 2

(D)
9

Risk Priority Number (RPN)= S*O*D

144

Recommended Actions

After Actions

O D

RP N
72

1.

Roll cage

Better material and efficient design

2.
3. 4.

Brake system
Suspension system Transmission System

Failure of brakes
Failure of ball joint Bending of drive shaft

7
7 6

Air pocket in brake lines

Impact Loading Hitting of drive shaft to frame at full rebound

5
4 3

7
8 8

245
224 144

Bleeding point kept below TMC

Efficient positioning and lubrication of ball joint Validating the angular movement of drive shaft at rebound condition

7
7 6

2
2 2

7
8 8

98
116 96

5.
6. 7.

Engine air intake

TMC Engine

Clogging of air filter

Failure of push rod Fouled Spark Plug

4
2 5

Excessive dust entering

Restriction to motion of pushrod Spark Plug is dirty or broken Excessive load on wheel caused by heavy rider or performing tricks

6
8 3

7
8 3

168
128 45

Rerouting of air intake from above the driver seat

Pushrod should have adequate D.O.F Approximate life of spark plug and later on clean it at regular intervals. Use a stronger material and add a warning for max. weight

4
2 5

3
5 2

6
8 3

72
80 30

8.

Wheel Axle

Bends in axle

84

56

DESIGN VERIFICATION PLAN & REPORT

Test Plan Test ID Test Segment Test Description
Stopping Distance: The vehicle is to be loaded on a jack and front wheels and spring are removed.Damper is mounted in the designated position and point of maximum designed travel is marked. Hub is moved upwards manually till the point of maximum travel. Difference between the initial and final position of hub is to be noted.
Travel of spring: The vehicle is to be loaded on a jack and front wheels and spring are removed.Damper is mounted in the designated position and point of maximum designed travel is marked. Hub is moved upwards manually till the point of maximum travel. Difference between the initial and final position of hub is to be noted. Maximum speed: Vehicle is to be loaded on a jack. Transmission is shifted to final gear and full throttle is given for 20 seconds.Tachometer is to be held at the wheels and maximum reading is noted. Speed is calculated by using 0.051*reading*radius of wheel. Turning radius: Vehicle is to be taken to a surface with loose soil and a circle with steering wheel locked at full travel is to be negotiated. The distance between the two diametrically opposite points is to be measured. Weld Test: The welded joint is to be taken and tested on a Universal Testing Machine. The failure is to be observed. Another method is to take the welded joint and impact with multiple hammer blows until failure. Failure of weld or material is noted. Centre of gravity: Vehicle is kept on balancing machine and load on front & rear axle is noted. For finding height vehicle is lifted from front axle and load transfer is noted . Internal & External Body dimension Ground Clearance, Approach Maximum Gradient : Two planks are to be kept at 15 degrees initially. Increase angle by 5 degrees till the vehicle does not take off on gear oneataround 2800-3200 engine rpm. The previous angle is to be noted.

Test Report Target Our Values Requirements

15-20m 17m

Test Responsibility
Akshat Sharma

Result

1.

Brake system

2.

Suspension

5 cm

5.4 cm

Darshan upasani

3.

Transmission

55 kmph

52 kmph

Shreyansh Sharma

4.

Steering

< 3.5m

3.19m

Akshat Sharma

5.

Roll Cage

<= 10mm

5.7mm

Akshay Poal Siddhartha Shrivastava

6. 7. 8. 9.

Vehicle Vehicle Vehicle Transmission

>15,<25 80,60,55 8-10 >20 88,62,60 10 26.7

Akshay Poal Darshan Upasani Shreyansh Sharma

10.

Vehicle

Vehicle weight

220 kg

250 kg

Rajeet Ojha

THANK YOU
QUESTIONS PLEASE..