BAJ CMEVolume 1 - June 2017Page No. 1

1. Welcome note2. Registration Demographics3. Performance of Indian team at BAJA USA4. Expert speak5. Expert speak 6. Time management article7. eBAJA : The way forwad! 8. Insights of BAJA SAEINDIA 2017

HIGHLIGHTS

2018

Welcome Note - Dr. EKTA SINGLA, IIT ROPAR

Welcome Note - Mr. Mukesh Tiwari, Convener, Pithampur Event

When we look back BAJA SAEINDIA has grown up to 11th Edition, year 2017 was a Decade Year, where 413 registrations have boasted our commitment of providing off classroom learning opportunities to budding Automotive Engineers. We moved a leap ahead with a humbling beginning to era of participation an International Team in year of Decade. In this journey we have graduated our standards and have benchmarked them with Global Standards so that our Participating Teams can not only get exposure to Global Norms but provides them a platform to compete globally.

In view to enhance our presence, from this year BAJA SAEINDIA will have two events one at NATRAX facility of NATRiP, Pithampur and other at new location i.e. IIT Roopnagar (Roar). We welcome 388 Teams this year to compete for excellence. We are setting eyes on bully with e-BAJA to make our students future ready for e-mobility solutions.

The Vroom of a racing field and the silence of an automotive-engineering lecture – the two possess their own importance for an aspirant to learn, understand and build tomorrow, and nothing can be better than a balanced exposure of both!! Keeping this in view, IIT Ropar extends assistance and support to facilitate 2nd-BAJA during March 9-11, 2018.

Over the banks of Satluj, the new campus of Indian Institute of Technology Ropar, is situated at the place once home to the Indus Valley civilization. The institute is one of the new IITs set up by the Ministry of Human Resource Development (MHRD), Government of India, and constantly working towards its vision of transforming young minds into excellent scientists, technologists, thinkers and leaders - with a sense of social responsibility, human values and concern for environment. It is a matter of pride to host a National event while completing 10 years of building a strong niche of a premiere institute to witness a powerful tomorrow.

IIT Ropar salutes the team-spirit of BAJA teams and congratulates SAEINDIA for a decade long journey of passion, enthusiasm and tremendous hard-work. I, on behalf of IIT Ropar, welcome all the teams and the entire BAJA fraternity for the upcoming event in 2018. Let the Northern region watch the heights of passion, listens to the rhythm of racing sounds and bystand Innovation!

I wish all the best to the participating teams and congratulate the Alumni committee for their efforts to scale the event to new heights.

We are thankful our varied Sponsors from Auto OEMs to Technology Partners who have been in pivotal support to make BAJA SAEINDIA from mere an event to the Dream Event for Engineers pursuing Automotive Industry as their career destination

If we look back at the journey of these magnificent eleven years, lots of efforts have gone into it to become a globally acknowledged event today. At each stage, it was true learning and sharing of experiences where experienced Technical Judges, who are seasoned with facet of failure to success and have hands on experience, shared their knowledge with participants and faculty Advisors. Association of BAJA Alumni has significantly improved our communication with student community through BAJA SAEINDIA Forum, ACME, and Facebook. Committed management Team has relentlessly worked on making every event a better experience for participants. Various Government Agencies have continued their support to us in handling the multifold volume over the years.

This is our endeavor to continually improve & imbibe learning to make BAJA SAEINDIA an event with tremendous opportunity for Students to Learn, Practice and Excel with their Career Aspirations.

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2017

mBAJA & eBAJA teams registrations 2018 vs 2017

2018

43 48

345 366

mBAJA eBAJA

VIRTUAL BAJA 2017 CONVENER NOTE

It is the corroboration to your efforts and allegiance that made BAJA SAEINDIA 2017 an astounding success and I would like to personally thank each one of you who made this decade edition a distinctive one. This event has been built through shared passion and ardour among students all over the country, who had the zeal and the intent to venture further. Students undergo a leap's bound in terms of technical knowledge along with an experience, which leads to the addition of an astonishing dimension to the overall persona. These individuals are propelling the Indian Auto Industry to new heights.

With the beginning of the 2018 season, I am glad to announce that 388 teams are participating which includes 43 eBAJA teams. Hence, it gives me immense pleasure to announce that we are expanding our ground for glory by organizing 2 events from this season, the event sites being Pithampur, Indore (January 2018) and Ropar, Punjab (March 2018). The competition is going to be sterner and mettlesome.

I extend a warm welcome to all participants, faculties, volunteers, judges and sponsors for the Virtual round of BAJA SAEINDIA 2018, which would take place at Chitkara University, Chandigarh-Patiala National Highway (NH-64), Punjab on 14th and 15th July 2017,which consists of 100 points inclusive of your Virtual BAJA Presentation and Viva (Rule book knowledge and General Automotive knowledge). After two days of spirited assessment, the final list of selected teams will be published on the official website of BAJA SAEINDIA/Social Media/ Forum.

All the best to all the teams!

Shoaib SadiqConvener - Virtual BAJA SAEINDIA 2017

BAJA SAEINDIA 2018 - GROUND TO GLORY

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2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

Virtual BAJA

Main BAJA

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106

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198

250260

327 323

395414

388

5975 80

100120 125 130

179 185

REGISTRATION DEMOGRAPHICS

BAJ CME

PERFORMANCE OF INDIAN TEAMS AT BAJA USA 2017

Finishing BAJA SAEINDIA 2017 at a higher note, the Indian teams entered into the BAJA SAE US Collegiate Design Series with heads held high and the dream of conquering BAJA at foreign soil. Beginning with Baja California, the Indian teams portrayed their potential at the international platform.

Team Nemesis Racing being the only Indian team at BAJA Kansas, finished fourth at Design event and third at Acceleration event. The team finished at ninth position overall becoming the first Indian team to finish in top ten. Their performance was further raised at the final leg of collegiate design series at Baja Illinois where it was the first time when we saw four Indian teams namely Team Nemesis racing, Team Avishkar, Team Kraftwagen, Team Red Baron in top ten acceleration timings with Team Nemesis Racing bagging first rank in Acceleration and Hill Climb event.

Starting from Team Jabaaz, Team Predators, Team Jatayu at Baja California to Team Nemesis Racing, Team Avishkar, Team Kraftwagen at Baja Illinois, a total of 16 Indian teams participated in 2017 US design series making it the highest Indian participation at foreign events. Giving a tough competition to the foreign teams at their soil, the teams kept us on our toes during endurance race of all the three events and have made us proud.

So, with the year 2017 winding up with BAJA, Indian teams have set higher bars for the 2018 event taking BAJA SAEINDIA to new heights.

BAJA SAEINDIA 2018 - GROUND TO GLORY

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34

18 17

15

12

12

98

5ChennaiPuneHydrabadCoimbatoreBangloreMumbaiIndoreAurangabadAhmedabadJaipur

Team distribution across major cities of India

Maharashtra

Tamil Nadu

Karnataka

Gujrat

Madhya Pradesh

Telangana

Uttar Pradesh

Punjab

Kearala

Andhra Pradesh

Rajasthan

Odisha

Uttarakhand

Delhi

Haryana

Jharkhand

West Bengal

Chattisgarh

Chandigarh

Himachal Pradesh

Goa

Bihar

Tripura

Jammu Kashmir

0 20 40 60 80 100

2017

2018

104104

8076

2423

3732

3421

021

1816

1213

0813

4312

1212

0908

0407

0606

0905

0404

0104

0103

0102

0101

0101

0101

0101

001

Number of teams

Sta

tes

REGISTRATION DEMOGRAPHICS - TEAMS FROM DIFFERENTSTATES

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BAJ CME

EXPERT SPEAK - DR. K.C VORA 1. Can you stress on the importance of various processes such as DVP and DFMEA for a Baja Vehicle?

Be it a BAJA vehicle or any other component, DVP and DFMEA are equally important. DFMEA is a proactive tool by which we can identify and prevent the product errors before they occur and with the help of design validation we can ensure that the component or the system requirement has been properly specified so that it can meet all the requirements for which that product was designed.

of the designer in his field as well. So, all the new teams should start their design process first form learning about the vehicle design through literature survey and then start applying it. They can contact the teams willing to help them so as to get an idea of the event and how to approach the designing phase

Focusing onto the different events in BAJA, it is very important to analyze from a prospective point of view to see what could go wrong with a particular component before experiencing real time loading conditions.

BAJA SAEINDIA 2018 - GROUND TO GLORY

2. Any tips on the presentation of DVP and DFMEA during Virtuals, since only one slide is assigned for both.

As both space and time constraint is present for the presentation in virtual BAJA, teams should focus on presenting the important aspects of the document like in DVP; for a particular test that you have set for a component, it is important to project what is acceptance criteria and what are the results that you are getting and with DFMEA; the recommended actions you have taken for different potential causes of failure and with what level those actions are affecting the RPN or SOD.

3. How important it is to keep track of the failures of the components and it's root cause analysis for a robust DFMEA ?

It is important to note that, with each failure occurring in the component apart from those estimated potential causes of failure, design reviews should be done following the updating of the DFMEA by adding the causes of that failure and actions to control it. With each failure , the DFMEA gets revised with the cause, prevention, detection and actions against that failure.

4. What are the important validation plans used by the OEMs for their vehicles and how can the participating teams incorporate the same for their buggies?

OEM's have specific test procedures and setups to validate different performance parameters of a product that are not available to the students at college level. So for the students to perform design validation, they should follow the testing standards and perform all the possible product testing available at their end, do the industry study and by the means of calculation.

5. Older teams have their previous season car's flaws to overcome, where should new teams start their design from and make their approach to the design more organized?

6. Most of the new teams face problem in choosing between manual and automatic transmission. What according to you they should be considering while designing?

Both manual and automatic transmissions have their individual pros and cons. The teams should analyze these before choosing a transmission for their buggy. Considering the challenges to be faced during the main event, teams should identify whether manual or automatic transmission is good for their design. For example, an automatic transmission like CVT may save the time compared to manual transmission, but there might be more losses due to belt drive in CVT. It would be worth for a new team to start with a manual transmission in first year followed by CVT in subsequent years to learn & feel both the types. So, in this way teams need to optimize their design to get better results, whether with an automatic or a manual transmission.

7. What role does Data Acquisition Systems play in defining the nature of actual power train performance w.r.t. designed output?

Using a Data Acquisition System gives real time data on what is happening with your Driveline and Steering, Suspension & Brakes systems, depending on the loads acting on it. Although while designing, we can simulate for a real scenario, but here are always some conditions which arises during the practical testing only and recording those will give a better understanding of thesystems. One can use potentiometers in suspension, sensors for engine/transmission/wheel speeds, steering angle sensor, accelerometers, strain gauges and also GPS. One can also use thermocouples at various locations, especially in eBaja buggy to understand the thermal conditions. You also need someone in the team to continuously use the DAQ and analyse the data. Thesedata can then be used in improving the transmission design further, tune CVT or suspension and prove design changes.

8. While performing CAE, what parameters do the teams need on?

The aim of CAE is to ensure weight reduction without sacrificing the function, strength and durability of a component, whether it is a roll cage, pedal, differential or suspension parts. The first job it to do the modeling & meshing. Generally, 2D Meshing is recommended. We need to do static as well as dynamic analysis. We need to decide the inputs like material strength, quantity & location of forces applied, constraints and degree of freedom. Average force can vary from 2G to 10G and Factor of Safety can be in the range of 1.2 to 3.0. Anything above that may lead to over design of the roll cage. One can do front/side/rear impact analysis, torsional/bump analysis as well as roll over analysis for a roll cage. Deformation in terms of displacement has to be within the permissible limit. So that the driver should be safe in case of any impact.

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It is true that one part of designing a vehicle is linked to the knowledge gained from previous experiences. But it is also true that majority of the designing part is dependent on the knowledge

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EXPERT SPEAK - MR. RAJIV MODI

1. What should be the basic approach of the teams while beginning the design phase of a BAJA vehicle?

BAJA SAEINDIA 2018 - GROUND TO GLORY

BAJA ALUMNI COMMITTEE

The Baja Alumni Committee consists of a bunch of working professionals, who take out the time from their busy schedules, to help bridge the gap between the students participating in BAJA SAEINDIA and the organizing committee.

The alumni committee for this year's event were selected through an application followed by an interview. Once the members were on board, a Team Building activity was carried out at Christ Institute of Management (CIM), Lavasa, from 16th through 18th July 2017. This was to kick-off the various activities that are to be carried out as Alumni Committee, throughout the year.

At Lavasa, the entire team participated in a group of activities, including a Meyer's Briggs Type Indicator(MBTI), a psychological tool, to determine the personalities of the various members of the team. These tasks were organised by Ms. Jayashree Kirtane, from the Alchemy organization. The events helped the members to relate to their personality and were enlightened by the insight provided regarding different personalities. At the end of 3 days, the team which consisted of people from various backgrounds and various parts of the country, joined hands to make this year's event a huge success.

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Understanding the rule book is must to start with, which helps in clarifying boundary conditions and intend of the vehicle to be engineered and build. Start the design by applying basic physics and build on engineering principles. e.g. while designing suspension, solve geometry, kinematic & motion first and then apply vehicle dynamics, this will help in arriving at correct hard point definitions.

Personally, I suggest, to make manual calculations for finalizing the entire structure and geometry before using any ready made tool to analyse/optimize these. My earlier observations say that sometime team makes design without sufficient calculations and starts simulating it using advanced software's like ANSYS or ADAMS etc., which does not give them enough insight of outcomes and does not aid in real optimizations.

2. How to consider optimization of design as safe during the design phase?

Consideration and design with appropriate factor of safety is backbone of successful and deployable outcome. While there are general guidelines available from many sources, the team must apply their own collective knowledge and wisdom to decide and validate these references. Different components systems, subsystem and aggregate may need different considerations which is derived based on amount of assumption being carried for calculation, the reliability and durability level expected, achievable compliance and accuracy in manufacturing and level of impact a failure can cause.

3. How does Data Acquisition and Benchmarking play a role in designing of a BAJA vehicle?

Data acquisition or RLDA and revisiting design assumption/calculations shall help in optimization designs and fine tuning of safety factors. Many of times, this helps in strengthening weak areas and mostly importantly this helps is removing fat of over design. Benchmarking should be only a reference or an object to challenge/cross question and not as something to guide your designs. If benchmarking is looked in the right context, the possibility of doing a better product is higher as one can make out opportunities to excel. Challenge each attribute, system, sub system of benchmark in the context of product and its intention, to discover opportunities of optimizations.

4. What are the general mistake teams commit while testing their vehicle before the main event?

One of the important observation on failures during the event has been that vehicle has already been tested extensively before event and has undergone high stresses and fatigue. Avoid enduring the vehicle meant for participating into the event, as during the development tests and evaluation, components get fatigued and may eventually fail during the event. The vehicle must be tested for its capability and capacity, but repetitions of such tests can cause fatigue and convert in failure during event.

Run enough, system by system tests during virtual simulation and physical testing during development which can build enough confidence for performance during the event. Maintain a log of test outcomes and regularly revisit DFMEA/DVP document, which can help achieving perfection/outstanding performance. Finally, maintain a genuine intention of OUTPERFOMING yourself and not just the COMPETITION.

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BAJA SAEINDIA 2018 - GROUND TO GLORY

TIME MANAGEMENT ARTICLE

SOFTWARE LINKS

Therefore, proper planning and the execution of that planning coupled with good technical skills should be there for any team to emerge as a champion.

how their team is going to tackle the design phase for BAJA. Since Virtual Baja is not just the test of the designing ability of the team but also is also to test their ability on how good they are in validating their design using CAE software, making prototypes and at last where they stand in their presentation skills. At the end of the day, if you are not able to present your design properly then all your efforts put into designing shall not be used upto complete potential.

So, in the end it's up to the teams on how wisely are they utilizing the slightest amount of time they have for the design phase or for the fabrication phase so as to get the best out of what is available.

The main essence of whole article can be summa-rized by the quotes mentioned below,

“Procrastination is the thief of time.” So, rather than just making plans, one should be following it too.

Also, keep in mind that “A plan without action is not a plan. It's a speech.”

In this era of high competition, all the teams are focused on getting best design with accurate fabrication. Most of the teams approach this with all of their technical knowledge/fabrication expertise and come out with calculators and computers to start fighting for superior edge. But we often don't put enough effort into makingsure that the year flows smoothly, that we set our goals and are adhering to them for the feasibility of competition taking care of human and budget resources.

Having an asset in your artillery is one good thing but using it at its fullest is what is going to give you the desired results. Getting people of different sub-teams to work together is one real challenge and this is the place where proper leadership is essential. Proper integration between different sub-teams, regular discussion, plan adherence, teamwork and feedback are some of the things which seems easy but are difficult to implement if not given proper attention.

As far as preparations for Virtual Baja is concerned, right after getting registered for the event, the teams should come up with a proper action plan, on

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Reference Books

Gillespie, Thomas; "Fundamentals of Vehicle Dynamics"Jazar, Reza; “Vehicle Dynamics - theory & Application”Smith, Carroll; “Tune to win”Limpert, Rudolf; “Brake Design and Safety”B. Heissing, M. Ersoy; “Chassis Handbook”Reimpell, Stoll &Betzler; “The Automotive Chassis Engineering Principles”Richard Stone and Jeffrey K. Ball; “Automotive Engineering Fundamentals”Milliken & Milliken; “Race car vehicle dynamics”LechnerGisbert, Naunheimer Harald; “Automotive Transmissions”

BAJA SAEINDIA Series – #bajasaeindiaBAJA SAEINDIA Indore – #bajaIndoreBAJA SAEINDIA Ropar – #bajaRopar

Hyperworks - http://www.altairuniversity.com/free-hyperworks-2017-student-edition/http://www.ansys.com/products/academic/ansys-studentAnsys -

http://www.optimumg.com/software/optimumkinematics/students/Optimum K - https://www.solidworks.com/sw/education/student-edition.htmSolid-works -

https://academy.3ds.com/en/software/catia-v5-student-edition?tx_3dscampusshop_pi1%5Bproduct%5D=9 Catia -

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eBAJA : THE WAY FORWARD!

With the vision of liberalization of e-mobility in automobile industry, e-BAJA is focused on shaping the young minds towards the future of automotive industry which is majorly inclined towards the electric automobiles. With the inaugural edition of e-BAJA, the teams have shown improvement In the design and performance of the buggies. Going further with this it is highly expected from the teams that they will raise the bar of the competition year on year.

To obtain this, teams should start working hard from the very first step of the event. While preparing for E-Baja, teams should be fully aware of the functioning and application of the major electric components which will be installed in the vehicle. Since the weight of electric buggy is higher than the main BAJA buggy due to the electric drive components, teams should concentrate more on roll cage, suspension, body panels and transmission design to get better results

BAJA SAEINDIA 2018 - GROUND TO GLORY

E-mobility which is expected to be a $390billion global market in 2020 is a rapidly growing industry. With the focus of major automotive giants shifting from conventional fuels towards electric vehicles, is providing a thrust to this industry.

The growth to this industry is currently limited by the power. The battery hasn't advanced from decades but, we are on verge of a power revolution. Big technology companies are aware of limitations on lithium ion batteries and are working towards a big change in this. Much research and development is being done on battery technology to improve performance while ensuring that batteries are lightweight, compact, and affordable. Some of the latest innovations in battery technology include – solid state batteries, Aluminum-ion batteries, Lithium-sulfur batteries and metal-air batteries.

The success of e-mobility is based on two common denominators: innovative networking and strategic alliances. With the innovation in technology, proper investment and support, this sector will emerge as one of the biggest sector and will lead the world towards a new era of electric vehicles. Come let us contribute together for the future of the Automobile Industry!

E - MOBILITY : DRIVE FOR A BETTER FUTURE

The roll cage design should be optimized earlier on in the design phase itself. The roll cage members should provide enough support for mounting of the e-kit and its cooling system. Extra care should be given on protection of e-kit against crash.

Since, e-mobility is something which is seen as the future of automobiles, it is expected from the teams that they come up with more innovative design which will drive the future of automotive industry to glory.

The integration of the e-kit with the buggy is one of the most important task. For any tweaking or rework, the whole assembly has to be disassembled and assembled again which is a time consuming activity. Therefore position of e-kit should be decided by keeping in mind the factors like weight distribution, clearances with the roll cage, cooling system, driver safety and impact resistance.

BAJACME TEAM

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Charu Goyal

1 2 3

Jatin Garg

4 5 6

Akshay Kawale

Manu Kamboj Shreyas Sastry

Abheek Maiti

BAJ CME

BAJA SAEINDIA 2018 - GROUND TO GLORY

2018

INSIGHTS OF 2017 EVENT THROUGH PHOTOGRAPHS

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