Team Gravity

Team id:17060
 Technical specifications of vehicle
Overall dimensions:
Overall performance of vehicle:
Overall dimensions values
Overall performance Specifications
Overall width 1320.32mm(51.9)
Max. speed 53kmph
Overall length 2130mm(83.85)
Max. acceleration 2.8m/s2
Front track width 1300mm(51.18)
Gradeability 29.260(64.79%)
Rear track width 120mm(47.24)
Stopping distance 9420mm
Wheel base 1500mm(59.05)
Stopping time 1.12s
Ground clearance 300mm(11.81)

Wheels / Tyres : Weight:

Wheels/ tyres dimensions Weight values

Kerb weight 290
Front wheel 609.6mm(24)
Total weight 350
Rear wheel 660.4(26)
Sprung mass 294
Rim 304mm(12)

Wheel width 203.2mm(8) Un sprung mass 56

 Roll cage design-process Ergonomics

Design consideration DRIVER ERGONOMICS

Rigidity of the structure during impacts Improved vision window for the driver

Overall weight of the roll cage Relaxed driving positon

Overall cost reduction Increased vertical and horizontal

allowances
Improve Stability
Ease of driver to egress and regress in 5
Safety of the driver seconds

Top view
Isometric view Side view Front view

Side view
Isometric
Top view
CHOSEN ROLL CAGE MATERIAL AISI 4130
Tensile strength 560.5N/mm4 Conditio Load Max Deformation(in Factor of
n stress(Mpa) mm) safety
Yield strength 460N/mm2
Front 7G 186 1.39 2.47
% Elongation 28.2 impact

Chemical composition C(0.28-0.33),Cr(0.8- Rear 7G 228 0.98 2.01

1.1),Mn(0.7-0.9),Mo(0.15- impact
0.25),P(<0.035),Si(0.15- Side 3G 274 1.26 1.66
0.35),S(<0.04) impact
RESULTS OF EQUIVALENCE CALUCULATIONS FOR Torsion 2G 182 3.64 2.48
PRIMARY MEMBERS (based on article C5.3.12)
Rollover 3G 86 0.7 5.42
Diamete Thickne Strength Stiffness Weight
r(in ss(in (in N- (in N- per Rear 2G 211 4.78 2.18
mm) mm) mm) mm2) meter bump
(N/mm)
31.75 1.651 513821 3.6*109 0.012
THE DIAMETER AND THE THICKNESS OF THE SECO-
NDARY MEMBERS ARE SAME AS THAT OF THE
PRIMARY MEMBERS(owing to the article C5.3.1 and
weldability risks)

CALCULATIONS:-
F =m*(v-u)/t, Weight of vehicle =340kg, Weight of
driver =60Kg, Max Speed of Vehicle v = 12.5m/sec ,
u=0m/s, Consider t = 0.2s. F=400*(12.5- Front impact analysis reports(von mises stress, total deformation)
0)/0.2=25000N.
 sprung mass=296 kg(with driver) Design Front Rear
SUSPENSION: Parameters:
Un sprung mass =54kg
Ride rates 16.5N/mm 21.42N/mm
OBJECTIVE:
Spring stiffness 18N/mm 24N/mm
Suspension acts to provide cushioning action to the Natural Frequency 1.27hz 1.19Hz
driver by absorbing the shocks from the road and
also help the tyres to maintain good traction. Wheel travel 181.4mm jounce 176.3mmjounce
50.8mm rebound 40.1mm
FRONT : DOUBLE WISHBONE WITH UNEQUAL ARMS
REAR: DOUBLE WISHBONE WITH UNEQUAL ARMS Suspension travel 5 5
Type Fox evol air Fox evol air
Damper stroke at 0.3m/s = 4.58mm
suspension suspension
CG height 400mm Damper ratio 0.4 0.32
Material 6061-T6 Aluminium 6061-T6
Ground clearance 300mm
Aluminium
Roll centre height(F/R) 147.23mm(5.8/7)

Motion ratio(F/R) 0.7/0.72

suspension Front rear

Geometry
Rear upright Rear swing arm
Camber -4.86 0 Front swing arm
Front upright
Castor angle 3.68 0

King Pin 6.84 0

Inclination
Scrub radius 21.46 No scrub
Camber change with Upright exploded view
Toe in 0.52 - Bump and droop
 Braking
Design considerations: Brake calculations Values
To provide ease for bleeding Weight transfer from 40-0kmph 4390.4N
Front wheels will be locked first Static rolling radius 304.8mm
To provide two independent brake circuits Co-efficient of friction b/w tyre 0.6
and road
Performance values
Brake torque requirement per 450Nm front, 418.5Nm rear
Stopping distance 9.4m wheel
Pedal ratio 6: 1 Static weight distribution 45: 55

Pedal travel 8.62cm Dynamic weight distribution 56: 44

Pedal force 370N Force required by calipers 4328N front, 4089N rear

Braking circuit Proportionating valve is not

required as the braking forces
Diagonal split Braking at front and rear are same.
system If needed the
Part specifications proportionating ratio is 16:15
Brake master cylinder Maruti 800 Bosch, bore(19.05mm) Brake caliper and disc
Calipers Apache RTR 180
Suzuki(cj), bore(26mm)
Disc Apache RTR rear disc 200mm OD 120mm ID
Calipers per pad Mean braking radius(92mm), area(108.6mm2X2)
caliper area(1210mm2), co-eff of friction= 0.3
Brake fluid Dot3
 Steering
Design considerations Steering wheel
Steering column
Self centering ability Turns(Lock to lock,rev) 2.5 rev
Collapsible column -> Type
Centre steering rack and Steering ratio 5.08: 1
pinion
Inner ball joint centre distance 200mm Without power assist (Tata Nano)
Optimum steering effort

Minimum turning radius Outer ball joint centre distance 568.5mm

Max. lock angles Length of steering rod(tie rod) 388.6mm

Reasonable steering ratio Steering system Wheel base-1500mm

Track width-1300mm
Steering gear
Under steer geometry
Type Rack and pinion
Ackermann percentage 70%
RHD Right hand drive
Inner wheel lock angle 41.320
Rack 127mm
travel(end to Outer wheel lock angle 27.290
end)
Turning wheel radius 2214mm

Steering wheel
As revised maximum steering moment at
Steering wheel diameter 25cm wheel is 70312.5Nmm and max. force at
Steering wheel torque 11250Nmm steering knuckle is 700N.
 POWER TRAIN Vehicle Accelerati Gradea Tractive Wheel Motor Top
mass on bility force torque torque speed
Specifications of Motor : recquire required required
d
1.VOLTAGE - 48V
400kg 1.66m/s2 18.66o 1726N 527N-m 48N-m 28kmph
2.CURRENT - 350A
350kg 1.66m/s2 28.88o 1800N 558N 51N-m 25kmph
3.TORQUE
-54N-m (2033 rpm) Rolling resistance coefficient-0.2, friction coeffficient-0.6, C.G.-38.2
4.PEAK POW
- 11.5kw (5051 rpm) GRADEABILITY Formulae used:-FT->[(Wl1+mah+Whcos)/L+RRR]

5.MAX RPM-9000Rpm MAXIMUM GRADEABILITY

FT-maximum tractive force
=29.260(64.79%)
W-weight of vehicle,h-C.G. height
Transmission Unit: Discharge Rate: -coefficient of friction
RR-coefficient of rolling resistance
ELECTRICAL CONTROLLER POWER OUTPUT OF
ACCUMULATOR BATTERIES=11.5Kw Mounting and Installations :
CONTROLLER Electric motor and transmission will be mounted
V.I=11500 at the rear end of the vehicle with the help of
MOTOR
TRANSMISSION I=239.583A bolts and nuts to the roll cage members.
WHEELS - When the motor is coupled to half axles ensure
ACCORDING TO PEUKERTS LAW that there will be no vibrations
OUTPUT GEAR RATIO-
10.83(R) Discharge Time=0.316hrs
1.USE SIMPLE RUBBER MOTOR
TYRE SIZE-26*12*8(Inch) MOUNTINGS

2.USING 3Ms THINSULATE

NVH INSULATION(SIDE WALLS)
Acceleration : CONSIDERATION
S: 3.USING SEMI RIGID
a=net tractive force/Mass
POLYURETHANE
=2.8m/S2 FOAM(CHASIS PILLARS)
 Weights and BOM costing
Component Weight Cost (INR)
Roll cage 33kg 34,000 Cost of components
Steering 15kg 10,000 26,000 34,000 10,000
14,500
Knuckles, HubsX4 2.8kg 14,500 Roll cage
Brakes 18kg 26,420
Suspension 18kg 60,000 Steering
56,390
Electricals 148kg 3,60,000
Safety 8kg 56,400 Knuckles,Hu
Driver 60kg - 0 60,000 bsX4
Wheels/Rims 36kg 26,000 26,420
Miscellaneous 12kg 10,000
Pie chart of weights
12.00 15.00
Roll cage
Our sponsers 33.00 2.80
36.00 Steering
18.00
Knuckles,HubsX4
18.00
60.00 Brakes
Suspension
Electricals
8.00 148.00
Safety
Driver
PROJECT PLAN:- (GAANT CHART)
DESIGN AND PROCESS FAILURE MODE AND EFFECT ANALYSIS :
current
Process Failure Severit Potential Occurrence Detectio controls Actions
Potential Causes What are the RPN
Step Mode y Failure Effects s n Recommended
Existing controls
and Procedures
Selection of
Ball joints Inability to
STEERING 6 1 Excess loading 4 suitable ball 28 Replacement
shear failure steer
joints
SUSPENSI A-Arm and Proper material
Vehicle Excessive Impact
ONS Swing arm 6 5 5 selection and 150 Re-welding
breakdown Loading
Weld Failure weld inspection
Air in the
Improper
BRAKING brake 9 Spongy Brake 7 1 Proper bleeding 63 Replacement
Bleeding
circuits
Observation of
Proper material
Weld Breakage pre and post
WELDING 6 5 Impact 7 selection and 210
breakages heat treatment
weld inspection
processes
DESIGN VALIDATION PLAN:
TESTID SPECIFICATION TEST DESCRIPTION ACCEPTANCE CRITERIA TEST RESOURCES

1 Brake test To access the stopping distance Car should stop with in 10.46 m Speed measuring
of the vehicle under fully without skidding. equipment.
applied brakes

2 Destructive weld To analyze the feasibility of Weld should sustain all the loads. Mechanical work
test welding shop.
3 Steerability test To estimate the lock angles Assumed lock angles should be Mechanical work
achieved. shop.
 Team composition with Work allocation:
Work shop facilities in our college
CATEGORY HEAD MEMBER 1 MEMBER 2
MARKETING P.Veerendra M.Madhav varma T.Krishna Avinash
R&D V.Yuva sai P.Harshit K.Pani
DESIGN S.S.Rahul Lakum suchith T.Surya Avinash
ASSEMBLY G.Pavan sai kumar R.Ravi Teja Ch.Harish Kumar
PRODUCTION Ch.Megha Sai Veer G.Sai shashanka N.Mani kanta
Tig welding equipment
INSPECTION Ch.Varma A.Srinath P.Vakul kumar
MAINTANANCE M.Yogeshwar reddy N.Rohith B.Suraj

QUALITY CONTROL D.Nikhil sai N.Sri Sairam Ch.Sai Kishore

Team members : Responsibilities : CNC Milling machine

V.Yuva sai Captain
Lakum Suchith Vice-Captain
S.S.Rahul Roll cage head
V.Yuva sai Suspension head Engine lathe

Surya Avinash Power Transmission Universal testing machine

head
N.Sri Sairam Brakes head Faculty Advisor : K.Mahendra Babu (Asst. Prof.)
Ch.Sai Kishore Steering head