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IIT JODHPUR Team VAAYU 2.0 2 & Steering Braking Suspension Design Specifications Length Width Height Wheelbase Track Width (front) Track Width (rear) Ground Clearance Kerb Weight Weight Distribution COG Coordinates Tyre Size Front Suspension Rear Suspension Steering Type Turning Radius Front Rear 84” 59” 59” 60” 52” 46” 11.3” 237 kg 46.4 : 53.6 (F:R) 19.3” (height) 32.18”(from front axle) 27.82” (from rear axle) 23”x7”-10” Front 25”x8”-12” Rear Independent, Double Wishbone Independent, H – Frame Lower Rack & Pinion 111.73” (2.83m) Disc Brakes Disc Brakes PERFORMANCE SPECIFICATIONS Engine & Transmission TECHNICAL SPECIFICATIONS Max. Power 10hp Max. Torque 19.66Nm Transmission Top Speed CVT (.43:1 to 3:1) 54.8km/h Max Acceleration 4.12m/s^2 Gradability 46.6% Power to Weight Ratio 21.9W/kg Benchmarking,Design Constraints PVC Model 3 Rough Design sketches Adding Suspension, Steering & Transmission constraints Detailing the Manufacturing and marketing/aesthetic aspects Analysis and Simulations in Ansys Integrating and selecting the design 3 Roll Cage Design Process - Ergonomics Need Statement & Constraints Idea Rack • Benchmarking. • Rulebook Constraints. • Multiple rough sketches. • PVC Pipe Model. Parallel Development Testing • Suspension, Steering & Transmission inputs. • Suspension, Steering & Transmission inputs. • Design Inputs from Analysis team. • Converging to common design features after design verification. • CAD Model. • Detailing from manufacturing POV. • Design Release. • Design iterations. Design Review 0 Product Detailing Design Review 1 • CAD Model (Common). • Design Release. Design Review 2 Selecting an Idea • CAD Model with multiple tube • Seat – Hammock Style (Made thickness. of Cordura Classic fabric stitched together to give a • Analysis and simulations on tight & comfortable fit) multiple thickness CAD attached using kevlar straps. designs. • Design inputs from Analysis team. • Steering Wheel is placed at a comfortable position. • CAD Model of final assembly. • A virtual dummy of the driver was used to ensure leg space and comfort. • Design Release. Design Review 3 DR0 DR1 DR2 Modification Final Product DR3 • Placement of Driver Controls. Ergonomics 4 CAE Basic Processes and Applications ITERATIONS Mesh independent method Literature Roll-cage :Primary : AISI 4130 (460MPa,560MPa, 21.8%) Secondary : AISI 1018 (340MPa,470MPa, 15%) Body panel : -Aluminium 5052 sheet metal Metal 4130+4130 4130+1018 Filler Material ER10S-2 E7018-A1 or E7018-A1 or ER70S-6 ER70S-6 Welding type TIG TIG Thickness Bending stiff. Bending Strength Weight / meter AISI 1018 1” 3mm 27642331Nm^2 3928 N-m 1.66 kg/m AISI 4130 AISI 4130 1” 1.25” 3mm 1.6mm 27642331Nm^2 35415370Nm^2 4035 N-m 5005 N-m 1.65 kg/m 1.19 kg/m AISI 1018 1” 1mm 11718900Nm^2 1665 N-m 0.60 kg/m 7.5g DR 69.17 MPa, .24 mm, 3.47 TIG/MIG OD 264 MPa, 4.2mm, 1.742 Design modifications 103.8 MPa, .08mm, 2.31 1018+1018 MATERIAL 150 MPa, .8mm, 1.63 Analysis 78.3 MPa, .63mm, 3.06 7.8g 321 MPa, 2.9mm, 1.433 7.5g 7.5g 291 MPa, 3.2mm, 1.580 Suspension design front/rear ITERATIONS F Double wishbone R O Wheel travel N T Roll center height Literature Damper to lower wishbone 7inch Jounce; 5inch rebound 46mm 5 Trackwidth & Wheelbase • • • • Camber Adjustment & Toe control on LOTUS Roll Stiffness &Gradient & Natural Frequency Front: Double Wishbone Rear: H – Frame Lower Roll Gradient: 4.39 deg/g Damper Coefficient: 0.3 Spring stiffness & Damper Calculations Shocker Selection & Verification H-frame lower DR Single upper link R Wheel travel 7inch Jounce; 5inch rebound Roll center height 46mm Toe change during bump 0.14° Camber Change during 1.25° bump Roll stiffness 9490.72 N-m/rad Toe change during bump 0.28° Natural ride frequency Spring Stiffness Wheel rate 2.45Hz 14.73 N/mm 10.89 N/mm Initial camber Damping coefficient Motion ratio Roll Camber 0° 935.3 N-s/m 0.86 1deg/deg ° Camber Change during bump 0.53° Roll stiffness 11388.87 N-m/rad Natural ride frequency 2.34Hz Spring Stiffness 27.89 N/mm Wheel rate 16.71 N/mm Initial camber 0° Damping coefficient 1505.1 N-s/m Motion ratio 0.774 Roll Camber 1deg/deg E A R 6 Brakes ITERATIONS Literature Weight Transfer Pedal Ratio & Master cylinder 4 Disc Brakes F/R split configuration Dual Master Cylinder Self Designed Disc: 4 Mounting pts Spiral drilled pattern 200mm OD Grey Cast Iron brake disc Properties Values Density 7100 kg/m3 Young’s Modulus of elasticity 125 Gpa Poisson’s Ratio 0.25 Specific Heat 586 J/Kg.K Thermal conductivity 54 W/mK Brake Disc Dia & Stopping distance Specifications Design & Analysis in Solidworks, Ansys Value Specifications DR Value F/R split or X-split F/R split Weight Transfer Disc or drum brake Disc brake Static Rolling Radius of Tyre Brake calliper cylinders- bore size* nos. 30 mm bore dia*4 Brake Torque (front/rear) 24.56 Nm /12.07 Nm 89.2mm Force Required by Calliper Cylinders 837.1 N 30 mm piston dia Balance between two braking Circuits 67:33 Stopping Distance 8.99 m Pedal force 150 N Pedal Travel 2.195 cm Mean braking radius Brake calliper dimensions Brake pad friction 0.45 coefficient Brake Fluid DOT-4 78.49 kg 11.04”(Front) 12.0” (Rear) Friction Coefficient of Road 0.7 7 Steering and Wheel Geometry ITERATIONS Front Literature Trackwidth & Wheelbase Front: Front:-Motorcross ATV tire Features: 1)Extended surface and tread pattern provides better contact surface for improved acceleration and braking. 2)Ideal for all terrain types 3)Specialized tread compound improves traction and tread life. Rear: Mud ATV tires Features: 1)Angled knobs dig into the terrain for maximum traction. 2)Use under a wide array of conditions. Turning Radius & Steering Radius Steering arm & Tie Rod length Cornering Stiffness & Understeer Gradient Analysis in LOTUS & ADAMS Specifications : Scrub Radius Rack Travel Turning Radius Steering Angles Rear Wheel Geometry Front tire Rear tire Tubeless tires 23*7-10 (8 psi) 25*8-12 (7 psi) DR Rack and Pinion Drive 43.65mm 4.25 inch Steer Ratio 2.834m Inner- 33.03° Outer – 24.63° 9:1 Understeer gradient Steering Torque Ackerman percentage -0.000276 375.56 Nm 73.37 % Steering wheel 1.5 turns lock to lock 12 inch collapsible Steering wheel 4.09 ° 3.12 ° Caster Kingpin Inclination 8 Power Train ITERATIONS Literature Performance Values Power Train Integration: For reverse clutch, gearbox and differential, H-12 FNR is used Through cable, FNR lever is controlled from the driver cabin Power and Torque will be transferred from Engine to CVT to FNR gearbox to tyres(rear hub) via CV Shafts. Power Train Mounting Subframe is custom designed. It has been designed to hold the drive components at one place and ensure minimum dislocation of the assembly. NVH Consideration: The mounting points have been lined with Poly-urethane(Rubber) to damp the vibrations. For the joints Silicon Based adhesives will be used to further dampen the vibration. Transmission Selection Differential Selection Axle Selection and Verification DR Engine Max Power 10 hp at 3800 rpm Max rpm 3800 rpm set by governor Max Torque Cooling system 19.66 Nm at 2800 rpm Custom designed air cooling system Transmission Constant Velocity Transmission (CVT) Centrifugal Clutch Differential Gear Box CV Shafts Gear Ratios 0.43:1 to 3.0:1 Spring Type 13.58:1 Forward Gear Ratio 14.36:1 Reverse Gear Ratio AISI 4340 0.5” ID 1.0” OD Cost and Weight Analysis- pie chart SR NO 1 2 3 4 5 6 7 8 9 10 11 PARTICULARS ENGINE (BRIGGS AND STRATTON) ENGINE 20S232-F1 TRANSMISSION CV SHAFTS DIFFERENTIAL CVT ROLLCAGE AISI 4130 AISI 1018 STEERING RACK AND PINION ASSEMBLY STEERING COLUMN STEERING WHEEL STEERING BALL JOINTS TIE ROD AND ENDS,STABILIZER LINK CUSHIONS CASTLE NUTS WHEELS AND TYRES TYRES &RIMS WHEEL STUDS WHEEL HUBS WHEEL BEARINGS FRONT WHEEL BEARINGS REAR SUSPENSION WISHBONES[SS SQUARE TUBE (1INCH DIA)] LOWER BALL JOINTS KNUCKLE UPPER BALL JOINTS SHOCK ABSORBERS REAR MOUNTS(MS PLATES) CLAMPS MADE OF MILD STEEL BRAKES BRAKE DISC CALIPER ASSEMBLY SINGLE MASTER CYLINDER BRAKE PEDAL BRAKE OIL BOTTLE BRAKE PIPES(IN FEETS) SAFETY HELMET + GLOVES RACING SUIT + NECK COLLAR ELECTRONICS AND INSTRUMENTATION HORN AND ALARM BRAKE LIGHT AND REVERSE LIGHT KILL SWITCH HYDRAULIC SWITCH BATTERY SEAT MISCELLANEOUS NO. OF QUANTITIES COST PER PIECE(IN RS) 9 TOTAL COST (IN RS) 1 33750 33750 1 PAIR 1 1 13000 60000 12000 13000 60000 12000 25 20 2000 400 42000 8000 1 1 1 2 5000 400 1500 650 5000 400 1500 1300 2 2 2800 500 5600 1000 4 16 16 2 2 6000 200 20 300 400 24000 3200 320 600 800 6 2 4 6 4 200 400 5000 135 15520 16 100 1200 800 20000 800 62080 1500 1600 4 4 2 1 2 7 1000 700 4000 500 200 400 4000 2800 8000 500 400 400 1 1 2200 8800 2200 8800 1 1 2 1 2 1 800 800 1200 800 1500 5000 800 800 2400 800 3000 5000 12000 TOTAL COST 350370 STEERING 4% BRAKES 5% Miscellaneous Electronics and Seat Instrumentation 1% 4% 2% SAFETY 4% Total Cost (in Rs) SUSPENSION 26% WHEELS AND TYRES 9% TRANSMISSION 22% ROLL CAGE 14% ENGINE (Briggs and Stratton) 9% Total cost= Rs 3,50,370 Electrical 3% STEERING 2% Fire Extinguisher 2% BRAKES 3% hub+knuckle 6% SUSPENSION 9% Sheets 1% Weight (in Kg) SEAT 0% Driver 32% Chassis 11% TRANSMISSION 14% Total weight = 350 Kg WHEELS AND TYRES 17% Project Plan 10 VALIDATION STEERING SUSPENSION TRANSMISSION BRAKING Components 11 Potential Failure Mode Potential Causes of failure Recommended Actions Validation • Uneven force by caliper or Loose mounting • Poor manufacture/heat dissipation • Loose joints or jerks • Jerk or collision • Replace • Replace • Repairing • Fixing Pressure measure on implementing brakes • Misalignment in bearing • Poor construction of drive train • Heavy bump • Alignment of drive system-top priority • Alignment check • F.N.R cable • Breaking of F.N.R cable • Replace the cable • Pre run tests • C.V axle • Engine • Tone up boot • Changing the mode without attaining zero rpm • Wear and tear of shaft • Replacement of boot • C.V axle stress analysis • Hydro-Lock • Piston Seizure • Water gets into the cylinder • Engine oil runs out • Replace • Regular checking of engine oil level. • Protect intake manifold from mud. • Suspension Arm • Bend • Breakage • Tire wear • Total Control Loss • Replace the concerned arm • Immediate replacement • Stress analysis • Bounce test • Shocker mounting joints • Bend • Break • Suspension gets displaced • Repair • Subject to Dynamic uneven stresses • Replacement • Joint play test • Joint Load Test • Shock absorber • Tie Rod • Leakage or Crack/Bend • Uneven Dynamic loading • Pressure check or replacement • Regular pressure check • Bending and breaking leading to permanent toe • Extensive loading • Proper material for tie rod, ready to mount extra tie rod. • Bump Steer Test • Offset in steering wheel • Tie rod end play test Tyres • Low/High pressure • Wear out • Irregular pressure check. • Handling grade reduction • Braking /slip conditions. • Tire pressure check • Replacement • Manufacturer authorized pressure limit • Toe in/out, camber adjustment Safety Material • Threat to driver and/or to passion for podium • Cheap/Improper assembly • Accidents • Immediate replacement • Inspection of safety material FABRICATION AND ASSEMBLY • Vehicle Breakdown • Improper welding practice • Poor material selection • Extreme fracture conditions • Repair • Replacement • Stress and Strain hardening • Manuf. strong joints and assembly • Recommended Material property test before manufacturing • Brake Disc • Breakage • Deformation • Brake Line • Leakage • Bent • Drive shaft Brake dynamic test Team composition with work allocation, College Manufacturing facilities 12 Faculty Advisor Captain Vice-Captain Treasurer Design & Analysis Suspension & Steering Braking Power Train Material & Manufacturing • Overlook the overall functioning of the team • Final Approval for design • Team Management • Sub-Team Work co-ordination • Recruiting Project leads • Design Sub-Team • Paper Work • SAE Membership overlook • Project plan • Manufacturing Sub-Team • Overlook the financial issues of the team. • Analysis SubTeam • Roll Cage, Knuckle, Hub, Suspension arms, Brake Disc Design. • Analyzing the designs and modifications. • Final CAD Assembly • Suspension Geometry design • Shocker selection. • Steering Geometry design. • Front wheel selection • Master Cylinder selection. • Braking Configuration. • Brake Pedal Design • Brake Disc Design • Transmission selection. • Designing power train layout. • Power Train subframe. • Engine cooling system. • Driving performance. • Material selection for various components. • Checking for manufacturing feasibility and complexity. • Exploring new manufacturing techniques. Dr. Kaushal K. Desai Dr. Rahul Chhibber Ayush Raina Manish Jadhav Akhil Mehta Hardik Jain Manoj Malviya Shubham Shinde Vedant Bhuyar Mohit Agarwal Shubham Shaurya Dheeraj K Sisodiya Himanshu Sharma Pradyuman Meena Aditya Saxena Gourav Singh Mohit Vijay Rajendra Manda Viraat Srivastava Dron Airon Mayank Gupta Lakshaya Bhatt Rohit Singh Kartik R. Madhvendra Tiwari Pruthvi Boghara Anandhu S. Nandhu