SAE SUPRA 2014

A REPORT BYTEAM GENSONIC

SAE SUPRA 2014

SAEINDIA organized, SUPRA SAEINDIA 2014 Event followed by HR Meet on 2014 for the students of the Engineering Institutes all over India. This event provides a real world engineering challenge for the SAEINDIA Student members that reflect the steps involved in the entire process from design and engineering to production to marketing and endurance.The SUPRA SAEINDIA 2014 is a competition which presents the Under Graduate & Post Graduate Engineering Students the task of designing, modeling and fabricating a formula type racing car.The concept behind SUPRA SAEINDIA 2014 is that a fictional manufacturing company has contacted a design team to develop a small Formula style race car. The prototype is to be evaluated for its potential as a racing car.The target marketing group for the race car is the nonprofessional weekend autocross racer. Each team designs and produces a prototype based on well laid down rules & regulations.The project fuels the exuberance of the youth by providing teams a platform to test their mettle, giving them a pragmatic exposure to real world challenges as faced in the industry. Students realize their talent through such an experience, making them proven candidates for the future as technocrats, entrepreneurs, designers, innovators and leaders.This helps the objective of bringing out student talent to serve the nation for the years to come, in fulfillment of the Automotive Mission Plan (AMP2016) a dream to make India an International Automotive Hub.

PHASES OF THE COMPETITION

The competition consisted of mainly two phases or rounds i.e. The virtual round & The final round respectively. The event eventually started with a virtual round which was a pre-qualifier round to participate in the main event. The VIRTUAL SUPRA SAE INDIA round was held at KIIT Bhubaneswar in September, 2013. 179 teams participated in the virtual round. Out of which 100 teams qualified for the next round. In Virtual SUPRA SAE INDIA 2014 competition, each team had to submit a preliminary design report and had to give a PPT on the design of their vehicle. Our college registered in the virtual round with team name as GENSONIC. The college stood at 41st rank in the VIRTUAL SUPRA SAE INDIA 2014 COMPETITION. Then the team GENSONIC qualified for the next round and registered for main event.The main event started with the technical inspection of the vehicle. The schedule of Technical inspection and each static event (which includes design and innovation evaluation, cost presentation and Business & marketing Presentation) was pre-fixed and each team was notified their slots for the various static events. Out of 85 teams, only 12 teams could clear the technical inspection round and were allowed to participate in dynamic events. In the technical inspection round, judges from the different well reputed automobile companies evaluated the vehicle. Out of the 12 teams, only two teams were there from the northern region.

THE VIRTUAL ROUND

The virtual round was scheduled on 20th & 21st of September 2013 at the Kalinga Institute of Industrial Technology, KIIT UNIVERSITY, BHUBANESWAR, ODISHA. A team of 5 members went for the virtual round. The members were:1. Puneet Madhav (Captain)2. Sahil Palta3. Raghav Sharma4. Arjun Ahluwalia5. Arhant Rai

The Preliminary Design Reports (PDR) were sent in CDs to SAEINDIA Office. There was a 20 min. presentation session followed by a 5 min. questionnaire session. The team presented the following things:

1) Preliminary technical specifications and 2D / 3D views of the proposed design of the SUPRA Vehicle.

2) The teams are required to present following related to SUPRA vehicle.Knowledge of rulebookDesign Methodology for Roll CageProposed engineering process for Finite Element Analysis loads and constraints, Factor of Safety &Deformations.Human Ergonomics knowledge related to vehicle cockpit layout Suspension Design Methodology & considerations for springs, Damper, Links arms design, Centre ofGravity, Roll centre, methods to determine and its importance.Steering -Design Methodology & considerations for steering selection, turning circle, wheel Geometry(Caster, camber, toe in, toe out) etc.Brakes -Design Methodology & considerations for brakes selection (Disc / drum brakes), brakeLayout/actuation, braking efficiency, pedal force etcPower train (Engine to wheel including tyres) & mounting considerations, VehiclePerformance specifications e.g. Vehicle speed, Acceleration etc.Safety equipments ratingsOverall Performance Targets and validation procedureList of static & dynamic tests.

3) Project Plan

4) Team -Organisation chart

5) College workshop facilities for manufacturing vehicle & overall cost elements/ estimates and financing for the project The team cleared the virtual round successfully, securing 41st rank out of 179 teams all over India.

SPONSORSHIP PROCURING AND MARKETING

After clearing the virtual round the team started marketing & procuring sponsorships for funding the project. The students procured sponsorships from various organisations and industrial firms.

MANUFACTURING

The team started manufacturing the vehicle in the month of may which lasted till the end of june. The manufacturing was done at a hired industrial workshop by the students themselves.

The manufacturing was started by the making of a pvc pipe model of the roll cage which was then converted into a mild steel pipe roll cage.

The vehicle was manufactured with the following specifications:

1. ENGINE: The engine was borrowed from a Honda VFR 400 motorcycle. This engine best suited the vehicles requirements for power and torque. Moreover the engine was convenient to mount as per the design and the design could take up the weight of the heavy engine.

The engine had the following specifications: ENGINE SPECIFICATIONSHONDA VFR 400 NC24

Displacement399 ccm

TypeV4

Power59HP(43kw) @ 12800 rpm

Torque39Nm @ 10000 rpm

Transmission typeChain, sprocket differential

2. SUSPENSION: The suspension system employed was a Push rod suspension system with shorter upper arm for lesser camber gains. Non parallel arms were placed for desirable roll center position and an Anti-Roll bar used to reduce rolling rate.

3. BRAKES: Diagonally split system is followed for the vehicle with double reservoir system which will work even in case of failure of front or rear disc braking systems.

The braking system was designed so as to meet the requirements of the surface and the track. There were various events to test the braking of the vehicle like the stopping distance test

4. STEERING: The steering employed was of the rack and pinion type

STEERING

Type Rack and pinion type

Turning radius 3055 mm

COST ANALYSIS OF THE VEHICLE

The team manufactured the car sourcing all the parts of which the cost report is following. The parts sourced were a mix of new and second hand

The detailed cost report about each and every part that was used in the manufacturing of the car has been mentioned as follows. The sourcing of tools and parts was done after thorough research through the market. The parts purchased were the cheapest and of the utmost quality serving the best purpose for the project.

Area of CommoditysComponent Unit CostQTYMaterials Cost Process Cost FastenerCost Toolings CostTotal Cost

Brake System Brake Fluid704280000280

Brake System Brake Master Cylinder750215000001500

Brake System Fasteners50410000100200

Brake SystemBrake Lines1100111000001100

Brake SystemBrake Disc Rear950219000001900

Brake System Brake Discs Front915218300001830

Brake System Balance Bar0000000

Brake System Callipers RHS1100222000002200

Brake SystemCallipers LHS575211500001150

Brake SystemProportioning Valve0000000

Brake SystemArea Total100600010010160

Engine & Drivetrain Air Filter2001200000200

Engine & Drivetrain Axles4502900000900

Engine & Drivetrain Chain3501350000350

Engine & Drivetrain Coolant0000000

Engine & Drivetrain Collant Lines1001100000100

Engine & Drivetrain Differential150019002001502501500

Engine & Drivetrain Differential Bearings325245002000650

Engine & Drivetrain Differential Mounts400130001000400

Engine & Drivetrain Engine36000135000040060036000

Engine & Drivetrain Engine Mounts400260002000800

Engine & Drivetrain Engine Oil1200112000001200

Engine & Drivetrain Exhaust Manifold60012000100300600

Engine & Drivetrain Fuel Filter1502300000300

Engine & Drivetrain Fuel Injectors0000000

Engine & Drivetrain Fuel Lines8018000080

Engine & Drivetrain Fuel Pressure Regulator0000000

Engine & Drivetrain Fuel Pump0000000

Engine & Drivetrain Fuel Tank1400180001005001400

Engine & Drivetrain Fuel Vent0000000

Engine & Drivetrain Hose Clamps2024000040

Engine & Drivetrain Intake Manifold800160020000800

Engine & Drivetrain Muffler0000000

Engine & Drivetrain Oil Cooler0000000

Engine & Drivetrain Overflow Bottles0000000

Engine & Drivetrain Radiator11001105005001100

Engine & Drivetrain Radiator Fans4501450000450

Engine & Drivetrain Area Total435204001300165046870

Frame & Body Body Panel70001400020005005007000

Frame & Body Floor Pan12001800004001200

Frame & Body Clutch3501350000350

Frame & Body Frame(25.4*2.5mm)5275ft19100020003910

Frame & Body Frame(25.4*2mm)32030m76200020009620

Frame & Body Mounts Intergral To Frame110161000008001800

Frame & Body Pedals25034501500150750

Frame & Body Shifter80016000200800

Frame & Body Throttle Controls2001200000200

Frame & Body Area Total169302150500605025630

Electrical Battery1800118000001800

Electrical Brake Light & Bulbs3001300000300

Electrical Dash Panel3001300000300

Electrical ECM0000000

Electrical Fuses0000000

Electrical Indicator Lights0000000

Electrical Kill Switches500315000001500

Electrical Oil Pressure Gauge0000000

Electrical Relays0000000

Electrical Solenoids0000000

Electrical Starter Button4001400000400

Electrical Tachometer0000000

Electrical Wire Harness5001500000500

Electrical Area Total48000004800

Misc. , Fit & FinishDriver's Harness720017000020007200

Misc. , Fit & FinishFire Wall110018500200501100

Misc. , Fit & FinishHeadrest250115000100250

Misc. , Fit & FinishPaint - Body230011600007002300

Misc. , Fit & FinishPaint - Frame700150000200700

Misc. , Fit & FinishImpact Attenuator (Testing)750017000500007500

Misc. , Fit & FinishImpact Attenuator (Actual)720017000020007200

Misc. , Fit & FinishSeats10001650003501000

Misc. , Fit & FinishArea Total24750500600140027250

Steering SystemSteering Rack3051305000305

Steering SystemSteering Shaft4501450000450

Steering SystemSteering Wheel1700115000501501700

Steering SystemSteering Wheel Quick Release2500125000002500

Steering SystemTie Rods22024200020440

Steering SystemArea Total51750501705395

Suspension SystemBell Cranks100860000200800

Suspension SystemFront A300472002002801200

Suspension SystemFront Uprights990244024011002001980

Suspension SystemPushrods32046001202403201280

Suspension SystemRear A280464002002801120

Suspension SystemRear Uprights62524601205501201250

Suspension SystemRod Ends275245000100550

Suspension SystemShocks Front5002900010001000

Suspension SystemShocks Rear5002900010001000

Suspension SystemArea Total57104802490150010180

Wheels, Wheel Bearings & Tires Front Hubs2502500000500

Wheels, Wheel Bearings & Tires Rear Hubs2502500000500

Wheels, Wheel Bearings & Tires Tires350041400000014000

Wheels, Wheel Bearings & Tires Wheel Bearings175814000001400

Wheels, Wheel Bearings & Tires Wheel Studs3016480000480

Wheels, Wheel Bearings & Tires Wheel Weights0000000

Wheels, Wheel Bearings & Tires Wheels1500460000006000

Wheels, Wheel Bearings & Tires Area Total2288000022880

Totals1338253530494010870153165

SOME GLIMPSES OF THE MANUFACTURING PHASE

The vehicle was successfully manufactured by the team before the competition and was transported to the competition site that is the MADRAS MOTOR RACE TRACK, Chennai. The vehicle was transported through a private transport arranged by the students themselves. The students also reached Chennai on 15th of July, a day before the main event was to commence. A private accommodation was rented for the few days stay for the competition.

THE MAIN EVENT

The Supra SAE 2014 competition was a 4 day event which saw 80 colleges from various parts of the country participating on various engineering levels to win the title of the National Champions. Over 2500 students and faculty members had come with their cars to participate and become the best engineering team in the country. The competition was judged and sponsored by various multinational companies like Maruti Suzuki, Volkswagen, Ansys, Bosch, BPCL, Altair. The team had a very good learning experience by interacting with like-minded students and experienced judges.On 16th July the vehicle was unloaded on MMRT race track Chennai. The event consisted of four days and the sequence of events was:

1. 16th July: Registrations for the final round. A total of 80 teams registered for the main event.

2. 17th July : The team presented the cost report, the design report and the business logic case in front of the jury.

3. 18th July: The team did not have any event scheduled on this day.

4. 19th July: The team had the technical inspection on this day. The technical inspection was conducted by the event officials and judges. The team failed to pass the technical inspection due to some technical faults in the car and due to the non-presence of the faculty advisor of the team, which was mandatory, failing to which the team was not allowed to pass through and go forward to the dynamic events.

5. 20-21st July: The scheduled HR meet was cancelled due to unavoidable reasons by the management.The team returned from the competition on 22nd of July 2013.

SUPRA SAE INDIA 2015The team is planning to participate in SAE SUPRA 2015 for which the registrations have already started and will last till 20th of September. The team is quite motivated to participate in the competition further. The team has conducted an information seminar regarding the upcoming competition. The seminar was conducted on 25 of august 2014. The seminar received overwhelming response from the students irrespective of their year or branch.

INTERVIEWS FOR SAE SUPRA 2015

After a successful information seminar, the interviews for the interested candidates were conducted by the team. Around 130 applications were received. On 27th august the first round of interviews was conducted in the workshop seminar hall. The team received an overwhelming response for the interviews. A total of 30 candidates were selected to appear in the final round. Some glimpses of the interviews are

The second round of interviews was conducted on 2nd of august in the workshop seminar hall. A total of 30 candidates appeared for the interviews for the various departments of the team like design, manufacturing, presentations & marketing. The list if the selected students are as follows:

3rd year students:

Harjot SinghRohit RoushanMohit Kumar ChawlaPrakaram AttryJaspreet SinghVishnu KumarSonu KumarGopal SharmaJagmeet Singh

2nd year students:

Tanshikha MudharAmuldeep SinghMantej SinghGurjap SinghHarshmeet Singh

1st year students:

Harsimranpreet SinghManpreet Kaur.

16 new members were recruited and 9 existing members of the team form a team of 25 students to participate in SAE SUPRA 2015.

FUTURE ENDEAVOURS

In future the team wants to participate in SAE SUPRA 2015, of which the registrations have already started. The team is quite dedicated and motivated to participate in the event and come out with flying colours. For this the team requires the cooperation of the esteemed faculty.