TEAM

TEAM ID: 141512

KIIT

TECHNICAL SPECIFICATIONS

STEERING

TYPE STEERING KNUCKLE SYSTEM

TURNING RADIUS

2.57m

ACKERMANN ANGLE

250

PERFORMANCE

Top Speed 77 Kmph

Acceleration 3.24 m/s2

0-60 kmph 4.33 seconds

GENERAL SPECIFICATIONS

Body Type AISI 1239B Cold Drawn Steel

Kerb Weight ~88kg

Overall Length & width

70 inches & 46inches

Wheelbase 44 inches

Track Width Front Rear

34 inches40 inches

Ground Clearance 2.5 in.

BRAKING

TYPE HYDRAULIC DISC BRAKE

STOPPING DISTANCE

4.2m

PEDAL RATIO 5:1

DISC SIZE 200mm

BRAKE OIL : Dot 3 or Dot 5 Poly-glycol based

TRANSMISSION

Type Manual

Gearbox 5 Speed Gear Box1 down and 4 up

ClutchType

multi-plate wet type

RULE BOOK KNOWLEDGEDesign Objective: To Design, Analyze , Simulate & Manufacture small GO-Kart Vehicle in extremely low budget Material:-Minimum cross section must be 1 inch (25.4mm), for pipe it will be OD and for rectangular section or square section it will be its

minimum height. Minimum Weight of the kart should be 60 kg. Dimension:-4 Wheels must not be in straight line in longitudinal direction .Wheel base Min 42 inches and smaller track of vehicle must be no less

than 75% of wheelbase. Minimum 3 inches clearances(gap) between the driver and any component of the vehicle in static and dynamic condition. Ground Clearance must be at least 1 inches from static ground clearance. Wheel must be incorporated with axles with proper safety locking system. Steering:-Free play of steering system is limited to 7 and stops must be used.⁰ Braking:-The brake system installed must be capable of stopping the vehicle in a straight line without losing control during the brake test. There

should be no leakage from the tandem master cylinder (TMC) or reservoir. Engine:- 4 stroke single cylinder with total displacement of engine not exceeding 125cc per cycle . Jack Point- There must be 2 jack point (1 in front & 1 in the rear); Bumpers- Compulsory front & rear bumpers. Minimum OD 25.4mm and minimum wall thickness 1.65mm. Drivers seat -The seat mounting must be rigid enough to withstand the dynamic conditions while the driver is driving the vehicle on the track. The

driver seat should be at least 3 inches away from the firewall. Brake Light:- The vehicle must be installed with a brake light red in colour which is clearly visible from the rear. Safety –Driver’s suit, underclothing, balaclava, neck support, gloves, shoes, socks, helmet , fire extinguisher , seat belt is necessary.A Firewall must be incorporated to separate the fuel tank from the driver. There should be min 3 inches clearance between the firewall and the engine. Capacity of the fuel tank must not exceed 8L in volume.The tank shall in no way be shaped to act as an aerodynamic device. Kill Switch-Minimum of 1 kill switch should be there to cut the power supply. Lock Nuts -use of lock nuts is mandatory . The driver egress should be less than 5 seconds. Exhaust System:-Use of suitable catalytic converter and the mufflers is recommended. Bolts:- All bolts used in the system must meet metric grade M8.8. Path for Wires and Pipes:- No pipelines/wire connections must go under the chassis.

ROLL CAGE DESIGN AND ANALYSIS

Side Force in (N)

Max combine stress in (mpa)

FOS Max total Deformation in(mm)

front 4G 134 1.94 3mm

rear 4G 158 1.64 1.3mm

side 4G 96 2.6 2.5mm

torsional 2G 141 1.84 1.4mm

Fig 4:Torsion DeformationFig1:Front Deformation Fig1.1:Front Stress

Fig 2:Rear Deformation Fig 2.1:Rear Stress

Fig 3:Side Deformation Fig 3.1: Side Stress

Fig 4.1: Torsional Stress

Design Methodology:*All Axle Points Should be at nodes.*There should not be any long continuous member to prevent bending.*No Square bar is used because of their high moment of inertia* Easy egress.* Keeping a driver alive during a 4G front impact, 4G Rear, 4G Side, 2G Torsional

VEHICLE ERGONOMICSMETHODOLOGY: Designed as per Rule Book. Enough to accommodate 6 foot tall driver. Easy entrance and exit for the driver. Proper mountings for safety belt ,steering,

rear compartments for engine and transmission etc. The ideal position for sitting at work exists when there is a

slight curve in the lumbar region of the back Proper positioning of steering wheel, making 80˚ elbow. Proper positioning of seat and paddle assembly,

making knees bent at 120˚ ideal for seating in Go Kart.

EASE OF EGRESS:Driver should come out from vehicle within 5 seconds after pressing the kill switch.

VISION & CONTROL:A minimum of 180˚ driver vision must be ensured.

STEERING•Use of Ackermann geometry :This geometry stabilizes the vehicle while travelling around a curve with minimized scrubbing of the tires.

•Use of Steering Knuckle system:Most reliable, most robust and most controllable system for go karts.Simple Geometry and light weight.Easy to repair.Cheaper than other system of steering.

PARTICULARS VALUE

Inside wheel turning angle 360

Outside wheel turning angle 26.680

Ackermann angle 250

Turning radius 2.57 m

Castor angle 120

Kingpin Inclination Angle 100

Toe in angle 10 Fig: Different parts of steering system.

Methodology: Because of lack of differential, a kart’s

natural direction of travel, forward, is very difficult to change.

The inside wheel travels a shorter distance than the outside, therefore it needs to take fewer revolutions to go round the corner.

However, the two rear wheels are attached by a solid axle, and must therefore move together, so in order to turn, one of the wheels need to skid over the track surface.

This skidding action, or indeed the lack of it, is what make a stationary kart so difficult to turn round.

This is the reason for lifting the inside wheel and it effectively turns the kart into a tricycle during the cornering process.

The inside wheel can be lifted with proper selection of castor angle and kingpin inclination angle.

BRAKES

PARTICULARS VALUE

TYPE OF BRAKE AND POSITION DISC BRAKE AT REAR AXLE

DYNAMIC WEIGHT TRANSFER 51%-49%

FRONT AXLE DYNAMIC WEIGHT(BOTH TIRES)

860.37N

REAR AXLE DYNAMIC WEIGHT(BOTH TIRES)

807.323N

REAR ROTOR BRAKING TORQUE 94.104N-m

PEDAL RATIO 5:1

PEDAL EFFORT 355.857N

STOPPING DISTANCE(at 1.5g) 4.2m

BRAKE PEDAL MASTER CYLINDER BRAKE LININGS PISTON

CALIPPERSVENTED ROTORS

Methodology:• Disc plate must be mounted perfectly on the axle using circular

plates and it also must be concentric on the axle.• Caliper must be rigidly mounted to the stationary body or frame.• The whole unit(plate and disc) is placed in the chuck of the lathe to

check that the Disc is mounted concentrically.• MC is bleeded before installing & is placed before pedal.• Brake Linings are checked whether leak proof or not.

WHY DISC BRAKE:• Reduced Maintenance / ease of installation • Disc Brake calipers have only a few moving parts whereas drum

brakes have many .• Disc brakes has less joints and links as compared to Drum .• Less sensitive towards corrosive conditions.• Fast response, quick release, soft braking etc.• The disc brake is less bulky and weighs less compared to the drum.

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.60

5

10

15

20

25

30

Stopping distance vs deceleration

deceleration in (m/s2)st

op

pin

g d

ista

nce

in

(m

)

POWERTRAIN

Engine Specifications Values

Displacement 125cc

Engine Type 4-Stroke Single Cylinder

Max. Power 11Bhp@ 8000 RPM

Max. Torque 11Nm@ 6500 RPM

Cooling Type Air Cooling

Max Speed 80 Kmph

Compression Ratio 9.2:1

Maximum Acceleration 3.24 m/s2

Why Manual Transmission? Significant reduction in cost. Light weight. Less uncovered parts to be taken care off. Reliable-uniform torque transmission in

all respective gears

Gear Reduction Speed (kmph)

1st 12.46:1 26.0

2nd 7.88:1 41.2

3rd 5.97:1 54.3

4th 4.82:1 67.2

5th 4.21:1 77.1

Final drive 1.21:1

ENGINE 5 STAGE REDUCTION GEARBOX DRIVE SPROCKET CHAIN DRIVE REAR AXLE

SPROCKET WHEELS

Type of wheel: Belted deep radial groove tire with wider foot- print & air captive.

METHODOLOGY Odd number of teeth of sprocket in combination with

even number of chain links facilitates uniform wear. Accurate allignment of shafts and sprocket tooth faces

provide uniform distribution of load across chain. Incorrect mounting can cause problems from chain and

drive to not be aligned causing express wear. Use of mounting blocks with plates would be suitable.

MANUFACTURING TECHNOLOGYCollege Facilities

Manufacturing Lab

Machine tools:-

1.Lathe machine

2.Welding shop

3.Grinding Shop

4.Shaping machine

5.Paint Shop

6.Carpentry shop

7.Bench Drill

8.Foundry Shop

9.Prototype Machine

10.CNC

Hand tools:-

1.250 gm Hammer

2.Hand Files

3.Tong, Measuring Tools

4.Wire Brush

5.Cutting Tools

6.Drill Bits

7.Wrench sets

Material Testing Lab

1.Universal Testing Machine

2.Impact Testing Machine

3.Brinell Hardness Tester

4.Rockwell Hardness Tester

Software Lab

1.CAD/CAE

2.CATIA v5

3.SOLID WORKS

4.ANSYS

5.ADAMS

6.LOTUS

Automobile lab

1.Wheel alignment machine

2.Tyre changing machine

3.Air Compressor

4.Impact Wrench

Tools

5.Screw Jacks

6.Machine Dynamics Lab

7.Wheel Balancing

Outside Facilities

1.FRP Molding

2.Hydraulic Press Fit

3.Emission Test Equipment

OVERALL WEIGHT AND COST ESTIMATION

50%

17%6%

20%

7% WeightEngine & Trans-missionBrakes & WheelsSteering

27%

19%

5%6%

30%

13% Cost Engine & Trans-mission

Wheels & Brakes

Steering

Roll Cage

TEAM SIZE AND PROJECT PLANTeam Captain – Ajit Pandey

Vice Captain – Bishnu Pratap SinghDesign• Snehasis Pattanaik• Chandan KumarTransmission• Kishore Ratan Jojowar• Nischal Nishant Shanker• Manasi Deshpande

Steering• Nikhil Nirupam• Saurav Prakash• Satyam Singh

Fabrication• Nirmal Singh• All team members

Brakes• Ankit Kumar Gupta• Shubham Chowdhury• Rohan Maharana• Ashutosh

Safety & Electrical• Bishnu Pratap Singh

Material Procurement• Prateek Jha• Joy Banerjee

Documentation• Manasi

Deshpande

Wheels• Shivani choudhary• Aadrika Borah• Ghanshyam Singh• Sanidhya Kumar

Faculty Advisor – Prof. I. Panigrahi

DESIGN VERIFICATION/QUALITY PROCESSNo. Description Required Condition Responsibility Test Resource Start Date Finish Date

1. Weld test welding joints of frame & brackets Ajit Pandey Visual defects 14/12/14 16/12/14

2. Dimensional VerificationThe difference in diagonal measurement of frame must not exceed

3-4 mmChandan Kumar Plumb Line 17/12/14 17/12/14

3. Fuel Leak Test Should not leak fuel or brake fluid in linings or from hoses Manasi Deshpande Wooden Platform at 45 degree 18/12/14 18/12/14

4. Egression Test Driver should come out from vehicle within 5 seconds Prateek JhaPressing Kill switch and coming

out of vehicle18/12/14 18/12/14

5. Brake Test Vehicle must stop in a straight line. Ankit Kumar GuptaBrakes applied when vehicle at

running condition19/12/14 19/12/14

6. Straight Line ,Stability Test Should move in a straight line when steering is at neutral position. Nikhil Nirupam Straight Line Road 19/12/14 19/12/14

7.Lock to lock &Turning

RadiusShould be equal to the calculated value. Saurav Prakash Measuring Tape 22/12/14 22/12/14

8. Skid Pad Test Should form 8-shape with specified dimensions limit Nirmal Singh 8 -shape Layout 23/12/14 23/12/14

9.Top Speed Test & Acceleration test

Maximum Top Speed 77 Kmph Snehasis Tachometer. 23/12/14 23/12/14

10. Gradability test Vehicle must safely ascend grade of 100 Kishore RatanRamp Inclined at 10 deg from

the ground24/12/14 24/12/14 

11. Autocross Test Vehicle must be maneuverable and have good handling Satyam Singh Driving vehicle on curved roads 25/12/14 25/12/14

12. Endurance Test Vehicle must run for 2-3 hours under different conditions. Bishnu Pratap SinghDriving vehicle through

different roads and condition16/12/14 2/1/15

INNOVATION

Nut Loosening & Detection System• Simple mechanism of close and open circuit using battery

and led light.• During Endurance race it Can avoid serious injury to

driver caused due to failure of parts.

TYRE PUNCTURE DETECTION :

Principle: A small pressure gauge transducers are fitted on tires valves, when tires is at optimum psi the needle moves away from alarm switch, but when pressure decreases the needle comes in contact with alarm system and starts detecting.

* The alarm switch is placed inside the pressure gauge.

* The alarm switch is connected to the positive terminal of the battery & needle of transducer is connected to negative terminal of battery.

Battery