Please fill in the following details:-

Team UID (Registration Number): 201550013

Team Leader’s name: Upender Rawat

Contact Number: 8818987431

Email ID: teamexergygwalior0751@gmail.com

Team Name: TEAM EXERGY

Vehicle Name: EXƎ -1.0

College Name: Malwa Institute Of Technology & Management, Gwalior, MP, 475001

Fill in the information about your Kart in the respective sections as mentioned below:

1. Describe the chassis layout of your Kart. Use proper diagrams/Images to explain it. Also attach the picture of your empty chassis if already fabricated. Cost For this Segment. You can also Show Load Analysis and testing results (Optional)

ABSTRACT:

The frame or chassis is designed in such a way that it provides a safe 3d space around

the driver, with fulfilling the requirements of competition. The main objective of the chassis

is to link all components of the kart including the driver efficiently and safely principle

aspect of the chassis focus on during the design and implementation including driver

safety, drive train integration structural weight and operator ergonomics.

DESIGN

the main component of the chassis is divided into three components, first for steering,

brake pedals etc. Second for driver cabin and the third one or the rear one is for battery

and motor compartment, the second and the third component are separated by firewall for

the safety of driver.

By implementing bends into the design of the frame, the number of cuts and welds were

decreased. Decreasing the number of cuts and welds lowers the production cost and

increases overall chassis strength. For example, by using more bends, a bending die can

perform the job of bending behalf of the welding and joining hence reducing man-hours

and production costs. All bends were designed to be made using a tube bender fitted with

primary die of 10 cm, secondary die of 15cm, and tertiary of 30 cm, diameter die, which

would eliminate costly tooling changes from the manufacturing process.

BODY PANELS-

The body panels are made out of .03 inch thick FRP (fiber reinforced plastic) .FRP is a composite material made of a matrix reinforced with fibers the polymer is usually epoxy,

infester or polyester thermosetting plastic are used in FRP.It is very light material that has desirable properties for a body panel.

The panels are designed such that they tends to reduce the aerodynamic moments like

pitching from front, yawing from side and also helps to create the downward force to which

tends to make the good traction of vehicle with the road & also provide the properties

necessary to protect the driver and vehicle components from rocks and other debris.

When the panels were integrated into the car, the panels were recessed into the chassis

to provide visibility to the chassis members, making the car aesthetically pleasing.

FEA Analysis:

All simulation of the space frame was done in the Ansys14 by considering a static

structural analysis of meshing type ‘beam mesh’ and stimulated load were applied on the

critical points of the roll cage. Before attempting to calculate the input loads, it was

necessary to determine what kind of obstacles would be encountered during vehicle

operation. This was done by reviewing test and competition videos of other SAE EcoKart

vehicles on the internet. This allowed the team to get a very broad sense of what terrain

the vehicle would be required to overcome.

Front Impact Analysis:

Rear Impact Test:

Force estimation for

loading conditions

As, F = m.a

Where,

F= Force, m = mass of

vehicle,

a = acceleration

For Front impact

analysis (Assumed G factor =

3.6)

Ff =120kg x 3.6 x 9.81 m/s2

Ff= 4233.6 N

Side Impact Testing:

Roll Over Test:

These are the FEA Analysis of the kart simulated on the ANSYS 14.

COST ESTIMATED FOR THE PORTION IS AS:

Sl. No. PARTICULARS COST Grand Total

1. Roll Cage Material Rs. 5500

2’ Welding Charges Rs. 400

3. Roll Cage Finishing Rs. 300 Rs. 6,200

For Rear impact analysis

(Assumed G factor

= 3.6)

F= 120kg x 3.6 x 9.81

m/s2

Fr= 4233.6 N

Hence force was taken to

be 4233.6 N

For Side impact analysis

(Assumed G factor = 3.2)

F= 120kg x 3.2 x 9.81

m/s2

Fs= 3767.04 N

Hence force was taken to

be 3767.04 N

2. Describe the steering mechanism of your Kart. Explain it along with proper diagrams/Images. Also attach the pictures of your steering system if fabricated. Support your Write up with Calculations and also highlight Cost for this Segment.

ABSTRACT:

Steering is the mechanism that allows the driver to controls the vehicle direction.

Steering convert the rotator motion of the steering wheel in a linear motion. This is made

possible by the linkage that connects the steering wheel to the wheels and tires.

We have designed our steering system to withstand the stress safely maintaining the

vehicle in any type of turning conditions.

The main consideration of our steering mechanism is to design a simple mechanism with

low steering ratios which achieve 100% Ackermann condition with quick steering response

as per as drive desired & also with minimum driver effort.

So, we decided to use linkage type steering which is truly based on Ackermann

condition because it is light in weight. Simple mechanism, low cost and easy to assemble.

INNOVATON DESCRIBED:

In eco-kart 2015 we are introduced multi hole sensitive steering plate with the adjustable

tie rod system. Sensitive plate increase and decrease the sensitive of steering mechanism

due to multy hole pivot point which allows adjusting the tie rod position according to path

condition.

We have introduced a ball bearing type steering cotter to minimize the driver effort or

steering effort at the time of turning condition. In this we are using a bearing which is fixed

at the upper end lower and of steering cotter. This gives the smooth rotator motion to the

cotter also minimize the friction between the cotter and C lock.

SPINDLE ANALYSIS:

DEFORMATION=4.8mm(max) FOS=4.3(min) STRESS=58MPa

BASIC CALCULATIONS: COST ESTIMATE:

PARTICULARS VALUES

Inner lock angle 40º

Outer lock angle 26.5º

Turning Radius 2.1

Max. Turning Radius 3

Min. Turning Radius 1.5

Steering Ratio 6:1

Lock to Lock turn 1.6

Accr. Angle 29.6º

Castor Angle 6º

Kingpin Inclination 8º

Tie Rod Length 15in

Ackermann % 100.9%

SL. NO.

PRATICULARS COST

1. Spindle & cotter

assembly

Rs. 500

2. Tie Rod & Sensitive

plate

Rs. 400

3. Hem Joint Rs. 600

4. Steering kit Rs. 1500

Rs. 3,000

3. Describe the suspension mechanism of your Kart if used. Explain it along with proper diagrams. Also attach the pictures of your suspension system. Explain used explain the necessity of use. Cost For this Segment.

As it is not necessary to use the suspension in the Ecokart competition, so we have

decided not to use the suspension system this year. As the track and the terrain is not so

rough and the arena is quite smooth for the action so we have dropped the suspension

system for our kart.

If the suspension system would be used the geometry and the alignment of parts would be

so different, such that the kart’s full design and geometry will be different.

Generally in these kinds of events we use the two kinds of suspension which are very

effective and useful, and not so complicated in geometry. The Pushrod kind of suspension

and the double wishbone independent suspension are used in the formula vehicles are the

main consideration of these two kinds of suspension.

As we have planned our kart’s weight & cost up to minimum so we have removed extra

unnecessary assemblies in the kart so team has finally decided not to use suspension

system in the kart.

4. Describe the brake mechanism of your car. Explain it along with proper diagrams/Images. Also attach the pictures of your brake mechanism if you have already fabricated. Support your write up with Calculations. Cost For this Segment.

ABSTRACT:

The purpose of the brakes is to stop the car safely and effectively. In order to achieve

maximum performance from the braking system, the brakes have been designed to lock

up the rear wheels, while minimizing the cost and weight.

The brake system design includes the single disc at the rear axle to stop the vehicle. It is

mounted in one of the third part position of the axle with opposing the position of drive train

sprocket hence also enables the good balancing requirement.

Master cylinder is used at the front near the brake pedal providing the occupant to easily

accessible space. A proper master cylinder bore size was found by doing brake

calculations based on the mass, centre o gravity, master cylinder volume sixe and various

dimensions of the vehicle. Though braking power increased with a decrease in bore size,

the volume of brake fluid that was able to be displaced decreased with decreasing bore

size.

Sl. PARTICULAR VALUE

1. Braking Force 1059.48 N 2. Deceleration .9 g 3. Stopping time 1.73s 4. Stopping distance 13.22 m 5. Brake torque 105.948 N-m 6. Disc Diameter 200 mm 7. Area of Piston 13.255 cm2 8. Brake line Pressure 30.1886

Mpa 9. Pedal Fore 100 N 10. Pedal Ratio 4:1 11. Brake Efficiency 72% 12. Static Axle load

At Front 48 kg

At Rear 72 kg 13. Dynamic Axle load

At Front 45.459 kg

At Rear 74.540 kg 14. Weight Distribution at braking

At Front 59.215 kg

At Rear 60.784 kg

BRAKE CALCULATIONS:

We are using Hydraulic Hand

Brake System.

Brake Calculations:

Sl. PARTICULAR VALUE

1. Brake Force 741.69 N

2.. Stopping time 2.47 s

3. Stopping

distance

18.88 m

4. deceleration 0.6 g

5. Handle Ratio 6:1

Apache RTR 180 Rear calliper for

hand brake

BRAKE CIRCUIT: The working of brake circuit starts DC power supply which runs the

motor. A contactor and condenser are installed in the circuit. When the brake pedal is

pressed it is necessary for motor to stop therefore contactor is installed which brake or

opens the closed circuit which previously running the motor. Hence the circuit break and

Brakes are applied. to the motor.

BRAKING

1. Disc Rs. 300 2. Caliper Rs. 1600

3. Brake Pedal Rs. 60

4. Brake Fluid Rs. 80 5. Brake wires Rs. 100

6. Master Cylinder Rs. 950

Rs. 3,090

MARUTI 800 Master Cylinder

TEMPERATURE DISTRIBUTION

MAX TEMP. = 108.62° C

HEAT FLUX

MAX HEAT FLUX = 1.46

w/M2

Brake CIRCUIT:

COST ESTIMATION

5. Give the specification of you all the parts that you have bought from the market. Write in the details of

your Motor, Battery, Lights, Wires, Tires/Rim used, Dashboard specification and its features, Safety

measure in the kart. Calculate all suitable data for transmission and power train. Cost For this Segment.

ABSTRACT:

During our designing phase we have faced problems in fabrication all the parts as per or

requirement due to unavailable facilities. The other one is cost. If we fabricate all the parts

as per our requirement we will exceed our target cost which we have to minimize up to

maximum. So we brought some parts from market.

After the market analysis we found such parts are suitable for our requirements the list of

the parts which we have purchased from the market are as follows:

Roll cage material = AISI 1020 DOM

Body penal: Reinforced fiber

Chain sprocket set = hero Passion Pro

Speed controller = 40A – 48V 1000W

Calliper = TVS Apache RTR 180 Front caliper

Master Cylinder = Maruti 800 form foot brake & TVS Apache RTR 180 Rear Master

Cylinder for Hand Brake.

Brake Lines = Maruti 800.

Fire Extinguisher = 1 kg Dry Nitrogen Powder, ISI Marked.

MOTOR:

In AC/ BLDC/PMDC motor we are using PMDC motor with 3600 RPM 48 V, 11Amp. And

42 Amh and 2400 Watt having 12.8 N-m torque at 2400 RPM. Because it is fulfilling our

requirements it also provides maximum torque at the beginning comparison to other

motors.

Battery:

We are using two 12V and 46 Amh dry battries. It is better than the lead acidic battery

because its weight in less than the wet batteries and it has the less cost, as well as it

requires the less maintenance.

WIRE:

We are using ISI marked copper wire having ODI of 0.75cm. for less resistance the more

thick wire is used as we know that.

𝑅 = 𝜌 𝑙𝐴⁄ .

As the current use is too high so we have selected the thick wires to use.

LIGHTS:

We are using round yellow headlights of power 35 Watt and we are using Red LED Tail

lights and Indicators of 10Watt that Clearly Visible when Brake will be applied.

TIRES & RIMS:

We are using SLACK Radial Tires Having Dimensions of

At Front: 10×4.5×5.

At Rear: 11×7.10×5.

These tires give a high coefficient of friction for a smooth Driving

and it is easily available in the market.

DASHBORAD:

we are using Reinforce Fiber Material for dashboard because this material was very cheap

and light weight and also a good strength and this easily available.

SAFETY POINTS:

Driver safety is our First priority for our. We are using five point harness seat belt and all

SFI rated accessories of driver. In our Kart two kill switches are assembled near the driver

and a fire extinguisher was installed at left side of the driver.

TRANSMISSION:

OBJECTIVE

The drive-train is a very important part of the racing cars, taking into consideration that all

of the car’s power is transferred through the drive-train system to the ground. The

challenge is to harness the Motor 4 horsepower and distribute it to the ground in the most

efficient way. The drive-train needs to be able to operate in the lowest and highest gear

ratios while performing in all of the different aspects of the competition.

DESIGN

The goal of the drive train is to transfer power from the Motor installed in the vehicle to the

wheels. The power transferred must be able to move the vehicle. Acceleration is also an

important characteristic controlled by the drive train. There are several different methods

of power transmission that have been used in cars. The transmission used in our vehicle is

a Non-Geared Simple Chain Drive. The Transmission contains a single Chain & Sprocket

to connect to motor with the drive shaft directly through the help of chain to provide a fix

transmission ratio. Setup has an advantage in that it does not need any driver interaction,

and that it is mechanically simple. And also works on infinite no. of gear ratios according to

the speed of Motor. BASIC CALCULATIONS:

Sl. Particulars Values

1. No. of teeth in Drive Sprocket 14 2. No. of Teeth in Driven Sprocket 44

3. Transmission Ratio 3.14

4. Dia. Of Drive Sprocket 4.5 cm 5. Dia. Of Driven Sprocket 17 cm

6. Pitch of Chain 1.587

7. No. of Chain link 90

8. Length of chain 1.29 m 9. Acceleration of kart 0.43 g

10. Max. velocity 60 kmph

11. Torque 25.01 N-m

On the observed calculation & Market Analysis we have selected the chain of Hero Passion

Pro chain Drive set.

COST ESTIMATE:

Transmission And Component : Rs.16000/-

Electricals & Lights: Rs.5400/-

Battery : Rs.4800/-

Drivers Safety accessories: Rs. 4000/-

6. Describe the Material used and Body Work segment.. Also attach the pictures of the Body work if you

have already fabricated. Cost For this Segment.

ABSTRACT:

The most important part of any roll cage is material selection. A good material is

important because the roll cage needs to absorb as much energy as possible to prevent

the chassis from fracturing at the time of impact.

We have selected our roll cage according to the constrained given in the rule book. We

have selected medium carbon steel (AISI 1020) formally known as DOM for the fabrication

of our roll cage. We are using a tube of 1in. outer diameter with a 2mm wall thickness.

There are several advantages of using DOM, one such provides seamless tubing, the

other one is it provides good weight to strength ratio. It has higher ultimate strength in

comparison to AISI 1018; it is easily available as well as easy to weld.

For body work we are using GI sheet of 2 mm thickness for the chassis while the

dashboard and the body panels are made of reinforce fiber.

MATERIAL PROPERTIES OF AISI 1020 (DOM)

AISI 1020 steel can be largely utilized in all industrial sectors in order to enhance

weldability or machinability properties. It is used in a variety of applications due to its cold

drawn or turned and polished finish property.

Mechanical Properties Metric Imperial

Tensile Strength, Ultimate 394.72 MPa 57249 psi

Tensile Strength, Yield 294.74 MPa 42748 psi

Elongation at Break 36.5 % 36.5 %

Reduction of Area 66.0 % 66.0 %

Modulus of Elasticity 200 GPa 29000 ksi

Bulk Modulus 140 GPa 20300 ksi

Poisson Ratio 0.290 0.290

Element Content

Carbon, C 0.20 - 0.25 %

Iron, Fe 99.08 - 99.53 %

Manganese, Mn 0.30 - 0.60 %

Phosphorous, P ≤ 0.040 %

Sulfur, S ≤ 0.050 %

SL. NO. PARTICULARS COST

1. Body Fire wall Rs. 400

2 Body Penals Rs. 400

3 Bearings & Bushings Rs. 195

Grand Total Rs. 995

COST FOR THE FOLLOWING

SECTION:

CHEMICAL & MECHANICAL PROPERTIES:

7. Describe the Innovations in your Kart support them with calculations and Images. Cost for this Segment.

ABSTRACT:

innovation is new idea, device or process . innovation can be viewed as the application of

batter solution. This is achieved through more effective products, processes, services,

technologies or idea that are readily available to markets, government and society.

Same our team is doing for this event. We are using following as our innovation.

1. USING TRANFORMER BETWEEN BETTERY & MOTOR TO MAKE 24V DC

INPUT TO 48V OUTPUT.

Transformation ratio of step-up transformer 𝑉1

𝑉2=

𝑁1

𝑁2=

𝐼2

𝐼1= 1/2

Where, V1 and V2 are the input and output potential.

N1 and N2 are the number of turns in primary and

secondary coils.

I1 and I2 are input and output currents.

Therefore, the ratio of number of coils is 1:2.

Advantages: this will decrease the weight of our vehicle because of two batteries of 12V

are used in Series here.

2. ELECTRICITY GENERATION BY WIND TURBINE: motion of the vehicle male the

kinetic energy of wind to work which rotates the fan and generate the electricity of

12V following are the volts obtained at different speeds of vehicle.

3. PIEZIOELECTRI CRYSTALS ARE USED IN THE BUMPER OF THE KART TO

BLOW HORN IN ACCIDENTAL CASE.

Volts generated by Wind Turbine:

Sl. Speed of

vehicle

Volts

generated

1. 15 km/h 3.8 V

2. 25 km/h 6 V

3. 35km/h 7.7V

4. 45 km/h 8.9 V

5. 60 km/h 11.9 V

ADVANTAGES:

It will work as a

power backup

and increase

life of our DC

source.

COST ESTIMATED GOR THE INNOVATION PART IS ESTIMATED Rs. 3400/-

8. Showcase of full Vehicle Design with all Bodywork (3D CAD Model)

ISOMETRIC VIEW:

BODYWORK EXPLODED VIEW:

9. Left and Right Side Views, Top View and Front View of the Kart

SIDE VIEW OF KART

TOP VEIW OF KART

FRONT VIEW OF KART

10. Combined Cost Analysis and Your Market Price for the Kart.

According to the design and analysis on the basis of market value and fabrication of kart,

we are getting a cost of Rs. 49,200. In the given figure we have included the figure of the

whole kart. The part contained in the cost analysis and market value of the kart is taken

from the entire department separately. The cost of Rs. 49,200 contains the following

segments.

COST ESTIMATION

PARTICULARS COST AS PER MARKET

PARTICULARS COST AS PER MARKET

CHASSIS STEERING

1. Roll cage material Rs. 5500 1. Spindle & cotter assembly Rs. 500

2. Welding charges Rs. 400 2. Tie Rod & Sensitive plate Rs. 400 3. Roll cage finishing Rs. 300 3. Hem Joint Rs. 600

Rs. 6,200 4. Steering kit Rs. 1500

TRANSMISSION Rs. 3,000

1. Motor Rs. 15000 INNOVATIONS

2. Chain & Sprockets Rs. 400 1. Routers Rs. 400

3. Solid axle bar Rs. 300 2. Wind energy Circuit Rs. 500

4. Speed controller Rs. 1000 3. Capacitors Rs. 200 5. Accelerator pedal Rs. 60 4. Transformer Rs. 800

Rs. 16,760 5. Piezoelectric circuit Rs. 500

BRAKING 6. Converter Rs. 1000

1. Disc Rs. 300 Rs. 3,400

2. Caliper Rs. 1600 MISCELLANEOUS & DRIVER’S SAFETY

3. Brake Pedal Rs. 60 1. Firewall Rs. 400

4. Brake Fluid Rs. 80 2. Body Panels Rs. 400

5. Brake wires Rs. 100 3. Tires & Rims Rs. 6000 6. Master Cylinder Rs. 950 4. Bearings & Bushings Rs. 175

Rs. 3,090 5. Seat Rs. 375

ELECTRICALS 6. Driver’s Safety acce. Rs. 4000

1. Lights Rs. 200 Rs. 11,350

2. Wires Rs. 200

3. Horns and buzzers Rs. 200

Rs. 5,400 GRAND TOTAL Rs. 49,200

As per the above given figure of Rs.49, 200/- the vehicle cost as per the market value will

be Rs. 55596/-. Including 13% VAT.

11. Design Validation Plan Segment wise

The Design Validation Plan Of Our Kart is Given Below. The different segments are joined

in here: