SRI RAMAKRISHNA ENGINEERING COLLEGE

PHOENIX

Width - 62 at widest point Length - 108 end to end Capable of carrying 1 person 190.3 cm weighing 113.4 kg Proposed to use Briggs & Stratton Engine Reverse light (white visible at min10m) and reverse alarm equipped Towing Hitch Points 2 (Front & Rear) Drivers helmet to be 6 inches away from a straightedge applied to any two points on the cockpit of the car. The drivers torso, knees, shoulders should be 3 inches from envelope of car. Minimum vertical clearance = 6 provided from top of the helmet and bottom of the roll cage top tube members Roll cage materials: Steel tubing OD - 1 ; Wall thickness - .120 ; carbon content - .18% Roll cage Foam material Polyethylene with minimum thickness - .5 A clearance of 3 between firewall, side impact members and seat is maintained Ingress & Egress -5 secs Emergency Kill Switches 2 5 point restraint harness with 3 wide lap belt and shoulder harness straps along with 5th anti submarine belt Positive wheel lock-to-lock stops located at wheel kingpins to be mounted Equivalent bending stiffness and bending strength in accordance with SAE 1018

VEHICLE SPECIFICATION
Overall height = 1180mm Overall width = 1403 mm Overall length = 1915 mm Wheel base = 1450 mm Track width = 1200 mm Weight (approx) = 290 kg (without driver) Ground Clearance = 10 Turning Radius = 3.820m Maximum Speed = 57.25 Kmph @ 3600 rpm Acceleration = 1.775 m/s^2 Maximum Gradability = 31.186 @ 3600 rpm at 1st gear

Target Design & Performance Specifications

Braking Front =215 mm ventilated discs Rear = 180 mm drum brakes Biasing = 70:30 Braking Distance (45-0 Kmph) = 10.49m Steering Type Variable Rack and pinion Turning Radius =3.820m Steering Ratio = 14:1 20:1 Lock to lock turns = 3

Suspension
Front : Unequal double wishbone with coil springs Rear : Unequal double wishbone with coil springs Material :ASTM A106B Section : Circular 33.4mm OD , 30.02mm ID , 3.38mm thickness

Front Spring Stiffness = 17 N/ mm Travel =150 mm Max Possible Force=2920N Mean Dia of Coil=90mm Wire Dia = 10mm Spring Length =260 mm No. of active coils = 8

Rear Spring Stiffness = 27 N/ mm Travel = 128 mm Max Possible Force=4468N Mean Dia of Coil=98mm Wire Dia =12mm Spring Length =260mm No. of Active Coils =8

WHEEL GEOMETRY
Rim Dia =14 Front Tires = 25 X 8 X 14 Rear Tires = 25 X 8 X 14 Tires to be used BAJATRAX TIRES

TRANSMISSION
Type Rear Wheel Drive Gearbox - 4 speed manual constant mesh gearbox with 1 reverse Model Piaggio Ape Ratio / Kmph per 2400 rpm 1st 35.298 / 8.134

2nd20.053 / 14.32
3rd 11.382 /25.23 4th 7.523 / 38.17

Roll Cage Design

Material: ASTM A106B Yield strength: 463.77 MPa
Ultimate strength: 552.43 MPa

E=205 Gpa Outside diameter: 33.4 mm Wall thickness: 3.38 mm Total no. of welds = 57 Weld Length = 5.98 m TIG Welding

FINITE ELEMENT ANALYSIS

FRONTAL IMPACT TEST FORCE APPLIED=64680 N REAR IMPACT TEST
FORCE APPLIED 47432 N

FRONT BUMP TEST

LOAD APPLIED=11760 N

REAR BUMP TEST

LOAD APPLIED=11760N

HEAVE TEST
LOAD APPLIED=600 N

SIDE IMPACT TEST

LOAD APPLIED=43120 N

ROLL OVER TEST

LOAD APPLIED=3775 N

3D-VIEW

Cost report
ITEM NAME Frame Hardware Brackets Supports Engine Manual transmission A-arms Front & Rear Spring Shock Absorbers Rack & Pinion CV joints Steering Column Brake system Kit Pedals Steering wheel Electrical Wires & Sensors Transponder Driver Seat Hub Tires Rims Neck Support Goggles Gloves Helmet Wrapping Foam Fire Extinguisher TOTAL USED IN Structural Structural Structural Structural Drivetrain Drivetrain Suspension Suspension Suspension Controls Controls Controls Controls Controls Controls Accessories MAKE BUY MATERIAL ASTM A106B STEEL STEEL STEEL N/A N/A ASTM A 106B N/A STEEL STEEL STEEL STEEL COMPOSITES ALUMINIUM ALUMINIUM ELECTRONICS QUANTITY 4 N/A N/A N/A 1 1 2 4 4 1 2 1 1 2 1 N /A ESTIMATED COST(IN RUPEES) 3750 4200 4000 5500 17000 9500 2000 6500 9500 4400 800 4500 8500 1400 1200 5750

Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories

N/A PLASTIC ALUMINIUM RUBBER ALUMINIUM PLASTIC PLASTIC FABRIC PLASTIC STYROFOAM N/A

1 1 4 4 4 3 3 3 3 1 2

N/A 4500 2400 11000 7000 3000 3300 3600 6000 1000 5500 135800

MS Project Plan

Independent Rear Wheel Braking System (IRBS)

When one wheel is stuck in swamp surface, IRBS is employed Auxiliary lever and additional braking line that locks one rear wheel at a time 3 positions of lever off/left/right Rotation of stuck wheel is prevented- Power is transmitted to the opposite wheel

AUTOMATIC ACTUATION OF KILL SWITCH DURING FIRE EMERGENCY USING TEMP SENSORS

To actuate the kill switch automatically in the event of fire accidents, using temperature sensors. Temperature difference during accidental fire breaks Sensor actuates the kill switch Binary sensor mounted at various points that provide signal to a micro controller

FAILURE ITEM NAME POTENTIAL FAILURE MODE EFFECT SEVERITY

CAUSE CAUSE
Too much load or shock applied leading to excess axial stress Too much load or shock applied leading to excess axial stress Excess load or vibration causing excess bearing and yielding stress Too much load or shock applied leading to excess axial stress Lack of clean air and fuel to maintain operation Too much load or shock applied leading to excess axial stress

DETECTION OCCURANCE DESIGN CONTROL DETECTION RPN

FRAME

STRUCTURAL/ SAFETY

The frame bends or breaks

10

Relatively high factor of safety to ensure structural integrity

80

HARDWARE

STRUCTURAL

Mechanical and structural components damaged leading to inability of use

Mechanical and structural components damaged leading to inability of use

10

Relatively high factor of safety to ensure structural integrity

80

DFMEA

BRACKETS

STRUCTURAL

10

Relatively high factor of safety to ensure structural integrity

80

SUPPORTS

STRUCTURAL

Structural damage leading to inability of use Possibility of explosion; inability to operate

10

Relatively high factor of safety to ensure structural integrity

80

ENGINE

MECHANICAL

10

Placement in area to minimize risk to driver

10

A-ARMS

MECHANICAL

Suspension compromised

Relatively high factor of safety to ensure mechanical integrity

72

DFMEA

ITEM NAME

POTENTIAL FAILURE MODE

MECHANICAL

EFFECT
Suspension compromised

SEVERITY

CAUSE
Wrong spring chosen for application Debris damaging component

OCCURANCE

DESIGN CONTROL
Diligent testing to ensure functionality Verification of desired specifications of component Verification of desired specifications of component Verification of desired specifications of component Relatively high factor of safety to ensure mechanical integrity Diligent testing to ensure functionality Relatively high factor of safety to ensure mechanical integrity Verification of desired specifications of component
Verification of desired specifications of component

DETECTION

RPN

SPRINGS

36

SHOCK ABSORBERS

MECHANICAL

Suspension compromised

81

RACK AND PINION

MECHANICAL

Inability to steer

Obstruction in travel of system

Excess torque applied

64

DFMEA

STEERING COLUMN

MECHANICAL

Inability to steer

Debris damaging component

N/A

18

BRAKE SYSTEM KIT

MECHANICAL

Extensive damage to THE VEHICLE in undesired scenario

10

Inability to provide sufficient braking force Excess load applied by driver to component Excess load applied by driver to component Lack of structural integrity under cyclic

20

PEDALS

MECHANICAL

Inability to operate

10

20

STEERING WHEEL

MECHANICAL

Inability to steer

N/A

16

TRANSMISSION

MECHANICAL

Inability to OPERATE

216

DFMEA

CV JOINTS

MECHANICAL

Inability to operate

72

ITEM NAME
DRIVER SEAT

POTENTIAL FAILURE MODE

SAFETY

EFFECT
Driver's safety compromised

SEVERITY
9

CAUSE
Excess load leading to bearing yield

OCCURANCE
2

DESIGN CONTROL
Diligent testing to ensure functionality
Verification of desired specifications of component Verification of desired specifications of component Verification of desired specifications of component Constant checking

DETECTION
1

RPN
18

DFMEA

DFMEA

TYRES

MECHANICAL

Inability to operate

Puncture by debris

48

RIMS

MECHANICAL

Inability to operate

Damaged by debris

24

HELMET

SAFETY

DRIVERS SAFETY COMPROMISED Can lead to excess fire damage VEHICLE WILL BE BLACK FLAGGED

10

Damaged by debris Lack of maintenance

20

FIRE EXTINGUSHER TRANSPONDER

SAFETY

N/A

27 21

ELECTRICAL

Water damage to component

Insulation to avoid shock driver

N/A

Electrical circuits

DESIGN VALIDATION
Steering-Rack and pinion -light weight -simple design -low cost - relatively small size Suspension -It gives more movement of the tires and hence the vehicle for the same movement of the spring -Independent suspension -Force is distributed at 5 points in the roll cage unlike at only one point in Mcpherson strut -Can be slightly adjusted for different parameters of suspension tuning like camber angle, ground clearance at the time of testing and then finally proper adjustments are made at the time of fabrication.

Brakes -Ventilated disc for higher heat dissipation rather than a single disc