TEAM ACRO STREAK

Team ID : NKRC15-065
ACROPOLIS INSTITUTE OF TECHNOLOGY
AND RESEARCH

Technical & Performance

Specification
SPECIFICATIONS

Weight

Overall Width

1110

Kerb Weight

72kg

Overall Length

1530

Ratio FAW to RAW laden

0.67

Overall Weight

132kg

Overall Height

927

Front Track Width

988.06

Rear Track Width

1060

Wheel Base

1099.8

Ground Clearance

50.8

Tube Dimension

25.4

Roll cage Mass

13

Front view

Overall Performance
Maximum Speed
Stopping
Distance(40kmph)

Side view

80
4.91

Wheels & Tyres

Front
Rear

10*4.5*5in
ch

Top view

Isometric view

S.N
O

PARAMETERS

OUR DESIGN

RULEBOOK

1.

Tube outer diameter

25.4 mm

25.4mm

2.

Wheelbase

1099.82 mm

1066.8-1422.4
mm

3.

Ground clearance

50.8 mm

Min .25.4 mm

4.

Track width

988.06

Min .75%

5.

Distance of seat from firewall.

76.2 mm

Min .76.2 mm

6.

Kill switch

3 nos.

Min. 2 nos.

7.

Kerb weight

72kg

Min.60kg

8.

Max. capacity of engine

125cc

125cc

9.

Distance of firewall from

engine

76.2mm

Min 76.2mm

10.

Max.speed of vehicle

80 KMPH

80 KMPH

11.

Drivers suit

SFI Rated

SFI Rated / FIA

standard

12.

Drivers helmet

Snells Rated

Snell/SFU/FIA
Rated

13.

Drivers shoes

SFI Rated

SFI/FIA Rated

Roll Cage Design & Processergonomics

Design methodology
Design started considering
rulebook and by drawing
conceptual sketches
An iterative optimization
processes used for attaining
design objectives
Rear impact analysis

Technique used
triangulation method is
employed

Front impact analysis

Modeling software :- CREO

parametric chromoly
2.0
Material:-

4130
Cas Total

Max.
Stress
(MPa)

FOS

Max.
Deform
ation
(mm)

Applie
d
Force(
N)

Fro
nt

1294
9.2

356.
62

1.2
2

4.3

Sid
e

1294
9.2

353.
25

1.2
3

.98

Rea 1294

378.

1.1

Mes
hing
Size

10

Side impact analysis

ERGONOMICS AND SAFETY

ERGONOMICS
Spacious Cockpit
Sufficient Legroom
Integration of 95 Percentile male
in comfortable position
Unhindered Line of vision
Sufficient Reach Envelope

SAFETY
Fire Extinguisher within reach
Complete Drivers Kit
Kill switch
Foam Padding on bumpers
SFI rated drivers suit
Drivers seat belt

Steering and Wheel

Geometry
Specifications

Dimensio
ns

Steering Ratio

1:1

Length of Track Rod

440mm

Track Width

988.06

Wheel Base

1099.82mm

Steering wheel dia.

260mm

Steering wheel
torque

2.6Nm

Steering Inclination

THE STEERING MECHANISM WHCH WE

ARE USING IS FOUR BAR MECHANISM.

50

Inner
turning
angle()

Outer
turning
angle()

Ackermann %

30

22.69

35

Turning radius
Inner (mm)

Outer(mm)

88.74%

2066.29

2984.5

25.59

87.4%

1784.13

2679.65

40

28.37

86.2%

1577.67

2447.9

44

30.53

85.54%

1449.9

2298.39

BRAKE
SYSYTEM
OUTER
DIA. OF
DISC

DIMENSIO
NS

TYRE
RADIUS

0.254 m

TMC
PISTON
DIA.

19.05 mm

CALIPER
PISTON
DIA.

20 mm

LEVERAGE

6:1

DRIVER
EFFORT

225 N

CALIPER
FORCE

2976.03 N

FRICTIONA
L FORCE
(disc and
pad)

4166.45 N

BRAKING
TORQUE
DECELARATI
ON

CONSIDERATION
Short Stopping
Distance
Effective Braking in
light Vehicles
Good Performance in
Wet Conditions
HEIGHT OF CENTRE OF
GRAVITY

Dimensio
ns

WHEEL BASE

1099.82
mm

DYNAMIC LOAD ON FRONT

WHEELS

870.26 N

DYNAMIC LOAD ON REAR

WHEELS

424.20 N

velocity

40
KM/H

50
KM/H

60
KM/H

70
KM/H

80
KM/H

749.96 Nm

Stopping
Distance
(m)

4.91

7.67

11.07

15.04

19.64

11.40
m/s^2

Stopping

1.61

2.20

2.42

2.83

3.23

Power train
Engine Specifications
Model
:Bajaj DTSS-i
Power
: 10 Hp
Volume : 125CC
Strokes : 4
Torque
: 10.85 Nm @
5000 rpm
Compression Ratio : 9.5 :
1

Gear

Overal
l Gear
Ratio

Maximu
m Speed

3.000
1.684
1.208
0.875

23.336
41.665
58.331
80.088

(Max. Speed)

Specifications
Vehicle Weight
Tyre size

Dimensions/Value
s
132 Kg
RAD 13.97cm

Rolling Radius

13.4112 cm

Frontal area for

drag
(Firewall Area)

2.78x10mm

Transmission Line

1 down 3 up

Maximum Velocity

80.088

COMPONENT

Chassis

Rear axle

Wheel hub

Disc hub

Sprocket hub

Mounting bracket

Steering linkage

PREOCESS AND
MACHINES
INVOLVED
Cutting, cutter, Pipe
bender,Bending,
Welding,

Lathe machine
,turning., threading
Lathe machine ,
drilling, step turning,
reaming.
Lathe machine,
Turning
Lathe machine,
Turning
Cutting, grinding

Lathe machine,
Turning

College Workshop Facilities

Milling Machine

Surface Grinder

Shaper

Lathe

MIG Welding

Electric Arc
Welding
Pipe Bending
machine
Universal Testing
Machine

TEAM STRUCTURE
Faculty
Advisor
Mr. Aatish
Rajore

VICE
CAPTAIN

CAPTAIN
Suyash Gupta

Ashwini
Motiwale

DESIGN

STEERING

BRAKING

ENGINE
AND
TRANSMISSI
ON

Suyash

Shashwa
t

Ashwini

Yash

Abhishek
M
Abhishek
Y

Nitin

Nishchay

Tanmay

Sarthak

Shubha
mD

Shubha
mJ

Shreyas

Pratyaks
h

Tushar11

ERGONOMIC
S AND
SAFETY

Suryansh
Nihar
Prateek
Sagar
Amit

Validation
Plan
DVP
Text ID

Scope

Vt 01

Prototyping

Test
PVC Pipe Structure for
manufacturability
1. Dimension Inspection
(Multistage)

Vt 02

Vt 03

Inspection

Weight
Distribution

Validation Method Team Allocation

Check interference

Manufacturing
team

1. Tapes, Flex

2. Quality of welded joints

2. Visual Inspection Inspection team

3. Overall Dimension

3. Go - No Go
gauges

Test for front and rear weight

distribution

Weighting machine

Design Team

Rough prototype
testing for shorter
ranges

Electrical team

Vt 04

Electricals

Possibility of planned innovation

Vt 05

Leakages

Elimination of any leakages in the

Testing on incline
system before finals

Inspection team

Vt 06

Fasteners

Validating tight connection

Torque wrench

Inspection team

Vt 07

Stability

Straight line stability test

Test rig and turn

tables

Design Team

DFMEA
Sr.
Potential
Potential effect of Seve Potential cause/ Occurr
Item
No.
Failure mode
failure
rty
Mechanism
ence
Improper
turning of
Steerin front and
1
Difficult handling
g
rear wheels,
bending of
track rod

2 Brakes

Less
efficient
braking

Difficulty in
stopping

Vehicle
Transm
speed
3
ission exceeding
80 Kmph

Exceeding rule
book limits

Improper
4 Engine
performance

Low eficiency,
reduced torque

Electri
Short circuit
cals

Fuel

Leakage

Fire in vehicle

Fire in vehicle

Accident
possibility ,nil
manoeuvrability

Leakage in break
fluid line

Vehicle weight
lighter than
design load

Improper
maintenance

Uncovered wire
harness

Banking of
vehicle

Current
design
control

Proper
Bearing
support is
provided

Four
independen
t brake lines
are
provided

Designed to
get speed
under 60
Kmph

Use of
insulated
wirings

Spill
prevention

Respo
Dete
Recommond
RAN
nsibilit
ction
ed action
y

Replacement
/ machining

Assem
bly
team

126

Remedies in
leakages and Assem
128 performing
bly
bleeding
team
again

80

Reduce
Power
engine max
train
speed by
team
governor

168

Power
Send engine
train
to repair
team

70

Providing
Electri
insulations,
cal
pressing kill
team
switches

210

Blocking
leakage
immediately
press kill
switch

Driver
/Powe
r train
team

Thank - You