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Please fill in the following details:Team UID (Registration Number): 201550013

Team Leaders name: Upender Rawat


Contact Number: 8818987431
Email ID: teamexergygwalior0751@gmail.com
Team Name: TEAM EXERGY
Vehicle Name: EX -1.0
College Name: Malwa Institute Of Technology & Management, Gwalior, MP, 475001

Team Logo Goes Here

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 PANELSThe 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:

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

Rear Impact Test:


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
Side Impact Testing:
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

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
1.
Roll Cage Material
2
Welding Charges
3.
Roll Cage Finishing

Grand Total
Rs. 5500
Rs. 400
Rs. 300

Rs. 6,200

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)

BASIC CALCULATIONS:
PARTICULARS
VALUES
Inner lock angle
40
Outer lock angle
26.5
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
29.6
Castor Angle
6
Kingpin Inclination
8
Tie Rod Length
15in
Ackermann %
100.9%

FOS=4.3(min)

STRESS=58MPa

COST ESTIMATE:
SL. PRATICULARS
NO.
1.
Spindle & cotter
assembly
2.
Tie Rod & Sensitive
plate
3.
Hem Joint
4.

Steering kit

COST
Rs. 500
Rs. 400
Rs. 600
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 karts 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 karts 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
1.
Braking Force
2.BRAKE
Deceleration
CALCULATIONS:
3.
Stopping time
4.
Stopping distance
5.
Brake torque
6.
Disc Diameter
7.
Area of Piston
8.
Brake line Pressure
9.
10.
11.
12.
13.
14.

VALUE
1059.48 N
.9 g
1.73s
13.22 m
105.948 N-m
200 mm
13.255 cm2
30.1886
Mpa
100 N
4:1
72%

Pedal Fore
Pedal Ratio
Brake Efficiency
Static Axle load
At Front
48 kg
At Rear
72 kg
Dynamic Axle load
At Front
45.459 kg
At Rear
74.540 kg
Weight Distribution at braking
At Front
59.215 kg
At Rear
60.784 kg

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
18.88 m
distance
Apache
RTR 180 Rear calliper for
4. deceleration
0.6 g
hand brake
5. Handle Ratio
6:1

HEAT FLUX
MAX HEAT FLUX = 1.46
MARUTI 800 Master Cylinder
w/M2

TEMPERATURE DISTRIBUTION
MAX TEMP. = 108.62 C

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
BRAKING
motor. Hence the circuit break and Brakes are applied.
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

to the motor.

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=

l
A .

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: 104.55.
At Rear: 117.105.
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 cars 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
observed
Analysis we have selected the chain of Hero Passion
1. No.On
of the
teeth
in Drive calculation
Sprocket & Market
14
chain in
Drive
set.Sprocket 44
2. No.Pro
of Teeth
Driven
3. Transmission Ratio
3.14
4. Dia. Of Drive Sprocket
4.5 cm
5. Dia. Of Driven Sprocket
17 cm
COST
ESTIMATE:
6. Pitch of Chain
1.587
Transmission
And link
Component : Rs.16000/7.
No. of Chain
90
8.
Electricals
Length& of
Lights:
chainRs.5400/1.29 m
9.
Acceleration
0.43 g
Battery
: Rs.4800/-of kart
10. Max. velocity
60 kmph
Drivers
Safety
accessories:
Rs.
4000/11. Torque
25.01 N-m

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.
Element
Carbon, C
Iron, Fe
Manganese, Mn
Phosphorous, P
Sulfur, S

CHEMICAL & MECHANICAL PROPERTIES:


Content
Properties
Metric
Imperial
0.20Mechanical
- 0.25 %
Tensile
Strength,
Ultimate
MPa
57249 psi COST
SL. NO. 394.72
PARTICULARS
99.08
- 99.53
%
Body Fire
wall 42748 psi
Rs. 400
1.
Tensile
Yield
294.74
0.30
- 0.60Strength,
%
COST FOR
THE MPa
FOLLOWING
Body
Rs. 400
2
Elongation
36.5Penals
%
36.5 %
0.040 % at Break SECTION:
Bearings
&
Bushings
Rs. 195
3
Reduction
66.0 %
66.0 %
0.050 % of Area
Grand Total
Rs. 995
Modulus of Elasticity
200 GPa
29000 ksi
Bulk Modulus
140 GPa
20300 ksi
Poisson Ratio
0.290
0.290

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
V 1 N1 I2
= = =1/2
V 2 N2 I1
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.
Volts generated by Wind Turbine:

ADVANTAGES:

It will work as a
Speed
Volts
power backup
of
generate
and increase
vehicle
d
1.
15 km/h 3.8 V
life of our DC
2.
25 km/h 6 V
source.
3.
35km/h 7.7V
4.
45 km/h 8.9 V
3. PIEZIOELECTRI
CRYSTALS
5.
60 km/h
11.9 V ARE USED IN THE BUMPER OF THE KART TO
BLOW HORN IN ACCIDENTAL CASE.
Sl.

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
PARTICULARS
COST AS PER
PER MARKET
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 & DRIVERS 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. Drivers 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:

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