POWER TRAIN DEPARTMENT

POWER TRAIN DEPARTMENTEMD5M7A

Prepared By:

Muhamad Shafiq Bin Sudarman 2014680068Ahmad Syukrillah Bin Sidi Ahmad 2014424642Wan Kamarul Ariff Bin Wan Kamaruddin 2014421604Muhd Asyraf Bin Kamarudin 2014864946Muhammad Afiq Bin Mat Akhir 2014493572

Organization ChartIntroductionThe 4-strokes engine (Internal Combustion Engine) is commonly used in front body of the chassis

our parts is to design linkage transmission for the vehicle that use rear engine

This project must solve the joining and linkage from the rear engine so that it can get through the acceleration pedal and brake

Scope of ProjectThe requirements for this project include:

Vehicle will only use internal combustion engine (gasoline).All engines must be 4-strokes & single cylinder below than 200 cc.The use of differential is a mandatory.The installation of the chain/belt guard is mandatory and made of metal or composite material rigid enough to withstand a break. It must be made of a minimum width equal to three times the width of the chain/belt.Use the engine type of HONDA GX160 (Uitm provided).Any transmission and drive train may be used. The use of differential is also permissible.Each car must be equipped with an on board starter/ignition switch and be able to start without any outside assistance at any time.The firewall must be attach together on the chassis separated the driver cockpit and engine compartment.The firewall must be a non-permeable surface made from a fire resistance material.The emergency shutdown must be attached outside the vehicle body and also on the instrument panel and must disable. All electrical circuits, including the light ignition and electrical controls.All necessary analysis and calculation (e.g power and torque output, drive train ratio, differential ratio. Firewalls heat transfer analysis component strength analysis material use analysis, joint method analysis (bolt/welding/other joint method) and etc.

Honda GX 160Engine SpecificationType of engine : HONDA GX 160Performance: power output:3.6kW net torque: 10.3 N.m revolution: 3600rpmWeight : 15.1kg

Relialibility: high quality materia

Safety: installation of chain and gear guard

Ergonomics : realible and easy to starting : easy starting and quiet running : easy to use and maintain : fuel efficient operation : low vibration when running

FUNCTIONAL DECOMPOSITION

Pugh Concept

Sample CalculationWeighted Decision MatrixSelection criteriaWeightage (%)Concept 1Chain sprocketConcept 2BeltingConcept 3GearingRankingWeighted ScoreRankingWeighted ScoreRankingWeighted ScoreCost (RM)0.220.410.230.6Easy to assemble0.2541.020.520.5Weight (kg)0.1530.4510.1520.3Total score rank3.451.252.2Details selection of MaterialNo Part MaterialAnalysis 1Engine Honda GX 160Manufacture From Honda-Net power Output:3.6kW @ 3600rpm-Connect the power output by using drive train2Solid circular shaftSteel ASTM- 36-Tall= 145 MPa-Choosing a suitable diameter of shaft-Calculating angle of twist of the shaft3Gear sprocketHardened steel-Long life span of drive train.-Easy to maintenance and service.

No Part MaterialAnalysis 4ChainHardened steelLong life span of drive train.-Easy to maintenance and service.5Heavy duty ball bearingStainless steel-Smooth the rotation of shaft.-Withstand high load and pressure6Emergency switch buttonElectric component-To stop the engine during emergency happen

12Failure Mode Effect Analysis FMEAFunction or Process StepFailure TypePotential ImpactSEVPotential CausesOCCDetection ModeDETRPNBriefly outline function, step or item being analyzedDescribe what has gone wrongWhat is the impact on the key output variables or internal requirements?How severe is the effect to the customer?What causes the key input to go wrong?How frequently is this likely to occur?What are the existing controls that either prevent the failure from occuring or detect it should it occur?How easy is it to detect?Risk priority numberShaft :To transmit the rotation or powerFracture,brake and high angle twistThe tyre rotation is not working8The diameter and selection of material is not meet requirement 1Coice the diameter or material that meeet requirement972SprocketThe teeth of sprocket will wear and tearReduce the performance and speed 3The sprocket or chain is rusty2The speed is reduce and chain noisy.212ChainBrake or rustReduce the performance and speed3The chain is rusty2Change the chain by period and make a maintenance212BearingsThe rotation not smooth, too compact.Reduce the speed and make a noise2Small size. Too big will increase the force required.3The control system box may require a new design.318Concept EvaluationRobustness is the property of systems that enables them to survive unforeseen or unusual circumstances. In our design there are several parameter that we cannot controlled which is called as uncontrollable parameter, this parameter if it is totally out of control it will causes our design to be failure, therefore we should ensure our controllable parameter to be balanced enough to reduced the effects of this uncontrollable parameter.

Powertrain Parts And Component

Engine GX 160Centrifugal Clutch

Engine Base

Back BearingFront BearingJack Shaft

Sprocket T 40Sprocket T 15Sprocket T 35Chain System With ShaftDifferential Gear With Drive ShaftSprocket T 7Parts AnalysisThis is the shaft below the engine that connected with sprocket.The green arrow where their force from sprocket is exerted on the shaftFrom the pic, clearly the shaft is a little bit bend. This is due to higher force apply on the shaft.The shaft still can be used without any problem after the analysis because the shaft is not twist too much

1) ShaftThis is engine base. This is where the base to support the weight of the engineThe base is a little bit bend because we take the maximum possible weight of engine.The green, red, and blue indicator shows where is the stress and force occur on the base engine.Since our system use vertical engine placement, so we need to consider the best design of the base engine and make analysis about it.

2) Engine baseThis is sprocket with 35 tooth on it. It connects with chain that connected with driver sprocket.There are red, green, and blue indicator on the sprocket that show the value of stress that produce in the sprocketThe red indicator means that there is there place where the higher stress occurs. This is because, it is the place where the sprocket is connected with the shaft and force from shaft give stress in the sprocket

3) SprocketThis part name as jack shaft where it supports differential gear that connected with drive shaftThe green indicator means that the jack shaft can support the weight of differential gear and drive shaft that can be consider quite heavy.There also blue and red indicator on the jack shaft analysis and it means that the crucial point of the load that can support.

4) Jack Shaft

Costing EstimationBill Of Materials

Full Assembly

Full assembly of the power train and engine without chasis

Full assembly of engine and power train with chasisConclusionFor the conclusion for power train and drive train department, we are manage to achieved the objective in designing and drawing the power train and drive train for a Single Seated Vehicle (SSV) after we have go through a lot of research, survey and designs. The main material of our component is alloy steel since this material is easy to find and it have higher Modulus of Elasticity (high strength) which is good enough to support higher load. Furthermore, it is quite difficult to make this power train and drive train as light as possible which is due to the engine compartment but we manage to reduce it by choosing the most suitable engine which is lighter and have more horsepower. The weight of the component can be estimate by using the CATIA software