SAE NIS EFFI-CYCLE 2015 DESIGN REPORTS Team ID
:
15062
Team Name :
ATIVIRYA
College Nam amee : Indira Gandi Deli Te!ni!al "ni#er$i%& 'or (omen)
Ci%&
Re,or% A-%or
:
Old Deli* Deli+110006
:
.o&a 'aroo/-e
Re,or% Co+A-%or :
Padma Pri&a
ASTRACT
The participating team from Indira Gandhi Delhi Technical University in the event SAE NIS EFFICC!E" ATI#I$A is a team of %& mem'ers (ith the aim of designing and fa'ricating a vehicle for this year)s !ight *eight Season +&%, SAENIS EFFI-CC!E is an intercollegiate design competition (hich re./ires the st/dents to design and fa'ricate an aerodynamic" highly engineered" energy efficient hy'ridh/man po(ered three (heeled electric vehicle The pro0ect (as designed 1eeping in mind the e2periences from last year )s event and this year)s vehicle re./irements in compliance (ith SAE NIS Efficyle +&%, $/le'oo1 After a series of disc/ssions and cons/ltation" this design (as chosen 'y narro(ing do(n vario/s concepts and aspects 'ased on the technical needs of the efficycle and the team Selection of material (as 'ased on design factors incl/ding (eight" cost" and performance #ario/s improvements and ne( concepts are incorporated in the design in order to increase the efficiency of the vehicle Foc/sing on mane/vera'ility and Fig/re 3f 4Test" the steering geometry (as designed according to trape5oidal mechanism (ith Ac1ermann geometry To perform efficiently in dynamic tests" /se of (orm and (heel is considered to increase tor./e and th/s the load carr ying capacity of motor and gear ratios for 'oth h/man and electric drive is also improved for this time Also 1eeping in mind the performance in /tility test " (e have decided to incorporate s/spension in this year)s efficycle
TECINICA SPECI'ICATIONS S)N O
DIVISION
1)
VEICE
S"+ DIVISION
SPECI'ICATION NA3E
3AGNIT"DE
(eel4a$e
7
Tra!89id%
507
T-rning Radi-$
2);m
Con
Tad,ole
(eig%
18g =9i%o-% dri#er>
Gro-nd Clearan!e
1?)57
2)
?)
EECTRICA
3OTOR
Po9er
0)5 P
T&,e
P3DC S%a%i! %&,e
Gear Red-!%ion
1:5
GEAR
(orm and (orm (eel
1:10
ATTERY
N-m4er
2
T&,e
ead A!id a%%er&
R-n%ime
2)2 o-r$
Vol%$
2Vol% =12 V ea!>
ra8ing Di$a%n!e
PV:2);1m
RA@ES
Ele!%ri!:?)5m
)
5)
TRANS3ISSION
'RA3E
PROECT PAN
3ATERIA
T&,e
Di$!
T&,e
PV+R(D Ele!%ri! Dri#e+R(D
Gear Red-!%ion
PV+):1 Ele!%ri! Dri#e+ 1:5
T&,e
Al 606?
I3PE3ENTATION O' IGT (EIGT TECNOOGY
To meet the challenge of this year)s !ight *eight Season" (e incorporated vario/s changes and improvisations in the vehicle after narro(ing do(n vario/s materials and attri'/tes of their dimension and /sage •
The /se of A!U6INIU6 7&789density:+;gmm thic1ness 'eca/se of its 'ending strength" 'ending stiffness" cost and mar1et availa'ility of this material in place of AISI %&%49density:;4g
•
Using different cross sections at different places depending /pon the stress developed (hich (o/ld help red/ce the (eight 'y /sing smaller cross section at areas less prone to stress
•
Use of light (eight material s/ch as A?S for steering (heel" seats and @edals (ith the help of 8D technology S-4$&$%em
(eig%=in 8g$ >
Chassis
8&
6otor and ?atteries
8+&:+8
Steering
8
S/spension
8
?ra1es and *heels
,
@o(ertrain9B@# =
;
DESIGN* CAC"ATIONS AND SEECTION: A)> 'rame Con
The frame of the tri1e (as aimed to 'e strong (hich is a'le to (ith stand the forces d/ring impact yet light in (eight (ith minim/m 0oints The design (as 'ased on tadpole str/ct/re T(o (heels in front offer e2cellent overall 'ra1ing and overall e2cellent handling Tadpole design (ith properly calc/lated C3G ma1es f/rther design easier and provides e2cellent traction" t/rning and 'ra1ing sta'ility It provides a larger tilting range
CHASSIS • Tadpole confguraton • &#eel 'a(e $ )*% 1,5.. • C#a((( "eg#t$ ,0!g
•Trac! "dt# $ 50% • +round clearance $ • /ateral Al 0,
De$ign Pro!ed-re: Initially a ro/gh s1etch (as prepared on the paper (ith the frame f/lfilling the 'asic re./irements /sing %8 steps of designing rec/m'ent tri1e It (as then improvised and improved (hile dra(ing it on the comp/ter /sing Solid *or1s The frame (as then chec1ed for its sta'ility d/ring vario/s impacts /sing S3!ID*3$S Sim/lation Additional mem'ers (ere added to ma1e the frame a'le to (ithstand ma2 forces (hich may occ/r d/ring collision The process (as repeated till desired res/lts (ere not o'tained 3a%erial Sele!%ion: Considering the factors li1e high strength" lo( cost" mar1et availa'ility" and !ight *eight" (e decided to choose A! 7&78 as o/r material over AISI %&%4 The follo(ing are its specifications 3OD""S O' EASTICITY =G,a> B 6;) YIED STRENGT =3,a> B 15 STRENGT =3,a mm?>B ,1205211 ENDING STI''NESS =G,a mm> B 2,530,002
)> Dri#e Train:
B/man as (ell as Electric mode 'oth are rear (heel drive
SEASON 201
SEASON 2015
Bpv gear ratio
8%
>> %
Electric mode gear ratio
%+
%,9/se of (orm and (orm (heel=
Tor./e 9electric mode=
,%> N-m
%+4, N-m
"3AN PO(ERED 3ODE No of teeth on 'ottom 'rac1et sproc1et >> Acceleration of vehicle &,;; m < s + N/m'er of teeth on gear on intermediate shaft +& N/m'er of teeth on gear of rear (heel %& Gear ratio o'tained >>% 6a2im/m velocity at rear (heel 8, 1m
+># 8;, *att %, %%& 9to increase tor./e= !ead Acid ?attery + %+ # 9each= 8,A-hr ++> ho/rs9plane= ,> min/tes >&1m
C)> S%eering* S-$,en$ion$* and ra8e$ S%eering: Using Trape5oidal steering mechanism in place of $ac1 and pinion Selection (as done primarily to red/ce (eight and red/ce the (heel'ase of the vehicle and therefore increasing the t/rning radi/s ie mane/vera'ility of the vehicle
Specification-
ATIVIRYA 201
ATIVIRYA 2015
3ODI'ICATION
*heel-'ase
7+inches
>;inches
Smaller (heel 'ase hence decreased t/rning radi/s
Trac1 (idth
,,inches
,& inches
Decreased
T/rning radi/s
8>m
+4m
Smaller t/rning radi/s and hence offers more mane/vera'ility
'ACTORS OPTI3ISED •
Ac1erman Angle : +4 deg
•
T/rning $adi/s:+4m
•
Tie rod length : >>4>
D/ring cornering" Ac1erman condition •
6a2im/m inner (heel angle :84deg
•
Average (heel angle: 8&,deg Critical speed of shaft : +> m
S-$,en$ion
In order to overcome diffic/lties of (heel 'rea1do(n (hich (e faced last year" (e have incl/ded iron strips to all the three (heels and front and rear s/spension systems 1eeping in mind the target of overall 1er' (eight of the vehicle •
S/spension /sed in $ear *heel S(ing-arm
•
S/spension /sed in Front (heels ?icycle Shoc1ers
4ropert
6alue
Static Defection
15.24 cm
Spring Constant(Rear)
2465.34 N/m (=0.2503g/mm)
Damping coe!cient
30".352Ns/m
ra8e$:
The selection for the /se of the 'ra1es for the vehicle is Ca4le a!%-a%ed Di$! 4ra8e$* t(o in front (heels and one in the rear (heel These (ere chosen on the 'asis of Easy availa'ility Simple constr/ction Slip-free 'ra1ing Unaffected 'y tire (idth !ess prone to fading Self-ad0/sting DESIGN
%= ?ra1ing Distance 2.) ?ra1ing Force 8= ?ra1ing time &
Fn 9Clamping Force=
4&%N
F ' 9?ra1ing Force=
+>&8N
S@ECIFICATI3NS Form/las /sed v +<2(#$%) g mHa
'/a
PV 3ODE
?ra1ing Distance #elocity ?ra1ing Time
+4%m 8,1m
EECTRIC 3ODE
8,m >&1m
Ass/mption Average B/man Grip Force: +7;N '9'et(een ?ra1ing pad and rotor : &>= g9'et(een gro/nd and the (heel=: &;,
D)> (eel$ and T&re$
The /se of t/'/lar tyre is incorporated in the tri1e design instead of t/'eless tyres (hich (ere /sed last year The rim of front (heel is made of steel" ma1ing it light in (eight and of iron for rear (heel" giving the rims eno/gh strength to handle (eight till 8,& 1g The inner diameter of front (heel : +> inches" The o/ter diameter of front (heel : +4 inches N/m'er of spo1es in the tyres 87 spo1es in front tyre 87spo1es in rear tyres E)> Sea%ing arrangemen%* Sea% de$ign and
This year (e have incorporated the idea of /sing ?+D Prin%ed Ri4 Cage re!-m4en% seats" the advantage of (hich (o/ld 'e that ne( shapes and str/ct/res can 'e easily given and made The material is of 'etter ./ality (ith lesser (eight helping /s to
material
density
A?S9Acrylonitril e '/tadiene styrene=
%&>g
*33D
%>g
achieve o/r goal to(ards lighter (eight in this !ight *eight Season and moreover" the prod/ction is cheap and afforda'le and man/fact/ring is ./ic1 3a%erial: AS =A!r&loni%rile 4-%adiene $%&rene> Den$i%&: 1)0g!!
@A$A!!E! T@E A$$ANGE6ENT
•
?ac1rest angle: 8,deg from vertical
•
?ac1rest !ength:78,mm
•
Beadrest height: ++4mm
•
Saddle length:>8&mm
•
Seat *idth:%&&mm
•
!/m'ar s/pport : +&8mm
•
•
Seat height : >7mm
')> Sa
•
$3!! 3#E$ @$3TECTI3N @rovided to protect the rider from nec1 and head in0/ries in impact conditions
•
BA$NESS @$3#ISI3N Barness ens/ring the safety of the driver in case of any /nfort/nate accident
•
6ETA!!IC G$ID F3$ 63T3$
•
@rovides motor protection in case of a high-speed incident
•
I!! S*ITCB Used to completely sh/t do(n all electrical e./ipment in case of an emergency @/sh to ill S(itch has 'een /sed
•
Strong rear impact and side impact resistance thro/gh mem'ers
ERGONO3ICS
Incorporation of ad0/sta'le c/stomi5ed pedals increases the h/man effort at pedals and helps the driver in pedaling Incl/sion of $ec/m'ent ergonomically seats as they are comforta'le and s/pportive for rider)s 'ac1 Calc/lations for the si5e and placement of all the parts (ere done 'efore ma1ing the cad model so that everything is easily accessi'le to the driver and she can drive the vehicle (ith comfort and minim/m effort Follo(ing are some 1ey dimensions ta1en in consideration The reference val/es /sed in o'taining the res/lts (ere ta1en 'y meas/ring the dimensions of all the team mem'ers and then ta1ing its mean
"3AN PO(ERED 3ODE
STEERING
Cran1 length
%>%mm
B?-?3S ,,;mm
nee angle
&J
B? height 4787mm
?? Beight
,&mm
?? ?3S
48++mm
REC"3ENT SEATS =In mm>
Seat Beight
>7
Saddle length >8& ?ac1rest length 78, ?ac1rest Inclination 8,K from vertical
Beadrest
++4
Seat (idth
%&&
!/m'ar S/pport+&8 INNOVATIONS:
This year)s first innovation (as chosen 1eeping in mind the light (eight season (hich is" the /se of ?+D ,rin%ed ma%erial made from A?S 9Acrylonitrile '/tadiene styrene= *e)ve incorporated c/stomi5ed pedal loc1 mechanism to aid in steering and seating The ne2t innovation incl/des the /se of ,ieoele!%ri! e<
ISO3ETRIC AND OTER CO3PETE VIE(S O' VEICE)
AND 3ADE S@ETCES O' TE VEICE =AOVE I3AGES>
PROTOTYPE 3ADE "SING PVC PIPES "SED
DISC RA@ES AND S"SPENSION
DRIVETRAIN ARRANGE3ENT =E'T> AND 3OTOR (IT (OR3 AND (OR3 (EE =RIGT> ) =AOVE I3AGES> INNOVATION =PEDA OC@ 3ECANIS3> =I3AGES EO(>
SPONSERS
