Team Raftaar, CCET

8/13/2019 Team Raftaar, CCET

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Team RAFTAAR

Presents


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Subsystem

Properties

PerformanceCost,

Ergonomics

Parameters

Optimization Parameters

Market

Availability of Resources

Selection of Resources

Design

Design Approach

Designing Analysis and Synthesis

Optimization

Optimized Design

Revaluation And

Fool-Proofing

Final Product


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S

No

RULES REMARK

1 Capability of carrying one person 190.3

cm (63) tall weighing 113.4 kg (250 lb).

Followed

2 Width: 162.56 cm (64 in) and Length:

108 inches end to end

Followed

3 At least 3 inches(76 mm) clearance from

the envelope created by the structure of

the car.

Followed

4 Head restraint must be provided on the

car to limit rearward motion of the head

in case of an accident.

Followed

5 Shake resistant Drip pan and Splash

shields on tank

Followed

6 Tie Rod Protection Followed

Design Parameter Constraints as per Rulebook


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Wheelbase 71.54Track Width: 56 (Front, Rear)Ground Clearance

15

Weight: 330kg


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SteelAISI 1018 for Roll Cage Members)Length :41m

Outer diameter :1

Thickness : 3mm

Sheet Metal ASTM A653 for Base Members)Thickness 0.8mm

Area 3 sq. meter

ABS Sheet for Body Panels)Thickness 3mm

Area 4 sq. meter

AISI 4130 AISI 1018Specifications 1.25 OD with 3 mm

thick

1 OD with 3 mm

thickWeight/Length

(kg/m)

1.45 1.64Length used (m) 41 41Total weight (kg) 59.45 67.24

Cost /kg( Rs.) 275

140

Padding Foam for Roll Cage members )Length 7m

AISI 1018 is finalized as the material to

be used for the chassis and the

Roll cage.

AISI 4130 dropped because there is

minor weight difference between

AISI 1018 and AISI 4130 but Cost of

AISI 4130 was approximately double.

AISI 4130 requires pre heating and post

quenching when welded.


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Double wishbone type Suspension mounted.

Formulas Used For Spring Selection

The Spring Values Derived from: Bullet Electra(Front & Rear Both)

Parameter Front Rear

Spring Const (N/mm) 28 28

IR (Installation Ratio) 0.6 0.36

MR (Motion Ratio) 0.657 0.38

Inclination (alpha) (deg) 25 20

The Steering system is derived from : TATA Nano

Rack and Pinion Properties:

Rack travel : 51.60 mm

Steering ratio : 15.1 : 1

Length Of tie-rods : 390mm

OBJ to OBJ distance : 1146mm

No. of turns( lock to lock) : 3.32

Turning Radius of the vehicle is2.32m

Reference Book: The Automotive Chassis

Reference Book: Fundamental Of Vehicle Dynamics

Positive Ackermann is followed with Ackermann Percentage : 96%


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The load is decided using theimpulse momentum theorem:

Pre-processing to define the model geometry

Initial Model According To Rulebook Final Result

Defining Element type

and Material properties

using E = 200 GPa , v= 0.29


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Front Impact Analysis

Rollover Impact Analysis

Rear Impact Analysis

Side Impact Analysis

2.95

2.73

3.03

2.86

Resultant FOS


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Performance:

Torque Required : 420.63Nm

Torque Developed : 520.65Nm

Clamping Force : 632.40 N

Stopping Distance : 4.37m

Brakes: Disc Brakes (Front And Rear)

Specifications:

Braking System: Maruti 800 Tandem

master cylinder and Disc Caliper

assembly

Braking Effort: 250 N

Battery Used : Dry Type (12 V- 44 Ah)

Complete Head and Rear Light ,Side

Indicator, Reversing Lights system

installed.

Independent Fuse for different

components.

Kill Switches routed for full vehicle

except lights.

Cross Braking System


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Engine Used Briggs & Stratton

Power 10 hp OHV Intake

Governor Settings 3800 rpm

Transmission Used : Mahindra Alpha

Transmission

Gear No.Gear Ratio Top Speed(km/hr)

1 31.48 13.25

2 18.7 22.31

3 11.4 36.60

4 7.35 56.88

Reverse 55.08 7.57

Tyre Specification :

Outer Diameter 23

Track Width 8

No. of plies 6

Rim Diameter 12

Aspect Ratio 1.45:1

Coupling Used :

Axles Used :

Axles of Alpha and Maruti 800 will befriction welded to form our custom

axles.

Maruti 800 parts are used because of

cheap and easily available standard

parts.


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SEVSeverity OCCOccurrence

DETDetection RPN - SEVxOCCxDET


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S No. Parameter Methodology of Testing

1 Wishbones Impact Failure & Stress Failure

Vehicle to be driven on various terrains like muddy,stony, slurry, gradiants

for stress testing

2 Steering-Tie Rod or RackVehicle to be driven on zigzag track having bumps like s-bend, 90degree

bend, U bend etc

3 Turning Circle Diameter Testing track to be prepared having a radius of 2 m

4 Engine FailureVehicle to be driven on various terrains like muddy, stony, slurry, gradients

for engine failure

5 Gear box FailureVehicle to be driven on various terrains like muddy, stony, slurry, gradients

for power train failure

6 Damper failureVehicle to be driven on bumpy track for 200mm bump and 100 mm

rebound

7 Brake Disc Loose Inspect disc mountings before driving the vehicle and tighten all nut bolts

8 Brake Pad Failure Check the pads after 1000km and replace if needed

9 Tyre Puncture By using Anti-Puncture Sealing fluid

10 Fuel Tank spill overVehicle to be run on a 45degree sideways incline and check for fuel spill

over

11 Emissions Pollution check of vehicle to be done


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Flexible PVC Piping protects all the electrical wires from short circuiting.

Front and Rear Bumpers are provided to safeguard in the event of rear and front collisions.

Five point racing Harnessis attached to the most rigid and structural roll cage members.

Low Centre of Gravityensures minimal chances of roll over of the vehicle

Driver Can See Road, Speedometer

Fuel Indicator and Rear View In

Mirror at Same Time.

Insulated Battery Cover is Provided to avoid short circuit and to secure its coordinates.

Parameter Ergonomic Range Design Values

Seat angles 95-100 for alert 99

Knee angle 110-120 for strength 104

Ankle angle 90-100 for comfort 96

Elbow angle 80 80-165 for comfort 108

Upper arm angle 0-35 for comfort 10All angles given above are in Degrees


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Gulshan Bansal & Co.

Plot No 377, Indl. Area,

Phase 1, Panchkula

T.G. Steels & Scaffolds

S.C.O-4, Wadhava Nagar,

Zirakpur, (Punjab).

Sr. No. Item Price(in Rs)

1. Steering And Suspension 20,000

2. Roll cage and Mountings 30,0003. Power Trains And Tire Assembly 60,000

4. Customized Seat 5,000

5. Miscellaneous 45,000

Total 1,60,000

Estimated Total Cost : Rs 1,60,000/-


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