Crimson Thrusters

7/26/2019 Crimson Thrusters

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CRIMSON THRUSTERS

Team ID: 14042

Anand Institute of Higher Technology

Presentation by :• Gowri Shanker.K• Hariharan.B• Rahul Dharmarajan• Srinivasan E.R



SI.NO RULEBOOKSPECIFICATIONS

MAX VALUES CRIMSONTHRUSTERS

1. Length, Width 108”, 64” 80”,62”

2. 3D space around driver ≥6 7”

3. SIM placement 8” to 14” from the seat. 10”

4. Driver’s head clearance fromseat base

≥41” 45”

5. Bend radius of the roll cage

member

6” to 28” 10.5”

6. Fasteners Bolts: Metric or Military Metric 8.8

7. Minimum pipe thickness Primary: 0.120” Secondary: 0.035”

0.12”

8. Minimum outside diameter ofpipe

Primary: 1” Secondary: 1”

1”

9. Clearance between RRH and

seat

≥3” 4”

10. Weight(with driver) (kg) - 420kg

11. Wheel base - 58”

12. Maximum speed 60kmph 54.5kmph

13. Ground Clearance - 12.5”

14 Tyre dimensions - 25”x8”x12”

Design Methodology & SpecificationsMarket Survey

Data Assumption

DesignCalculation

OEM Comprison& Selection

Virtual Design

Analysis & Design

Validation

FEA

Completion



All the members of the roll cage are made of SAE 4130 steel with OD 1” and wall thickness of .118”

(3mm).

PROPERTIES OF MATERIAL:Material :SAE 4130

Yield strength :600 N/mm2

Carbon composition :0.3%C(>0.18%C)

The total weight of the roll cage is estimated to be 62kg.

Total number of weld joints is 56Maximum number of welds at a point is 2

•The driver ergonomics for roll cage

Elbow’s to side impact member= 3.5”

Driver’s seat to fire wall(RRH)= 3”

Driver’s head to front bracing member= 15”

Driver’s helmet to top of the vehicle= 7”

•Overall roll cage length = 80”

•Wheel base = 59”

•Overall roll cage width = 42’’

•Overall roll cage height = 54 ”

•Overall width = 58”

Roll Cage



Roll CageTEST DETAILS RESULTS STRESS ANALYSIS DISPLACEMENT

FRONTIMPACT

TEST

Max Stress(N/mm2) 224.332

Load Applied(N) 20,000

Max Deflection(mm) 1.50883

FOS 2.7

REARIMPACT

TEST

Max Stress(N/mm2) 296.421



FOS 2.1

SIDEIMPACT

TEST

Max Stress(N/mm2

) 284.399Load Applied(N) 13,000


FOS 2.2



TEST DETAILS RESULTS STRESS ANALYSIS DISPLACEMENT

ROLLTEST

MaxStress(N/mm2)

328.304


MaxDeflection(mm) 15.2842

FOS 2

BUMPTEST

MaxStress(N/mm2)

313.525


MaxDeflection(mm)

12.2493

FOS 2

Roll Cage



Parameter Crimson

Thrusters

Maruti 800

Θi 37o 37o

Θo 26o 32o

Steering ratio 15 : 1 17 :1

Turning radius 3.133 m 4.4 m

• 100 % Ackermann’s steering

• Proposed track width = 54”

• Proposed wheel base = 58”

Steering set up – Adams car

• Type of steering :Rack and pinion

• Maximum Angular travelof steering wheel : 540o

• Tie rod length = 9.889”• Steering effort = 20 N

Scrub radius Vs Steering angle



Brake System

Parameters Target Santro Omni

Type of Brake Disc Brake Disc Brake Disc Brake

Pedal Ratio 4:1 4 : 1 4 : 1

Diameter of MasterCylinder

19.05 22.25mm 19.05mm

Caliper Piston EffectiveDiameter

42mm 43mm 42mm

Rotor Effective Diameter 230mm 230mm 230mm

Braking Force 3296.16 N 3257.399 N 4239.38 N

Stopping Distance 14.33m 14.5 m 11.145 m

Deceleration 0.8g 0.925g 1.028g

OEM Selected: Maruthi OMNI’s Braking System Weight Transferred: 208.43N

Dynamic load acting on front during braking: 2848.45 N

Dynamic load acting on rear during braking: 1271.74 N

Brakes and Steering

Steering Geometry

Caster 7o

Camber 1o

Steering angle inner wheel 37o

Steering angle outer wheel 26o

Turning Radius 3.133m



Parameters Front suspension Rear suspension

Type Unequal , parallel double wishbone

Mac Pherson Strut

Wire diameter 9mm 9mm 12 mm

Mean coil diameter 57 mm 97 mm

Number of coils 11 5 4

Total length 322.63mm 540 mm

Lower wishbone or control armlength 231.71mm 58.55mm

Upper wishbone length 208.8396mm -

Inclination of wishbone wrtground

13.281o 1.413o

Caster angle 7o 0o

Camber +1o +1o

Scrub radius 5mm 5 mm

Spring stiffness 9 N/mm 9.8 N/mm

Motion ratio 2.4 2.61

Spring travel 62.5 mm 57.4 mm



Camber Vs wheel travel

Scrub radius Vs wheel travelToe angle Vs wheel travel



Drive TrainThe power is transmitted using the Mahindra Alfa Gear Box from engine to the wheels in the following way

Gear Final

GearRatio

Max

VehicleSpeed

(Kmph)

Max

TractiveEffort

(N)

Final

GearRatio

Max

VehicleSpeed

(Kmph)

Max

TractiveEffort

(N)

First Gear 31.48 12.7 2119.32 55.08 7.27 3708.14

Second

Gear

18.70 21.4 1258.94 32.72 12.23 2202.80

Third Gear 11.40 35.11 767.48 19.95 20.06 1343.09

Fourth Gear 7.35 54.45 494.82 13.40 29.87 902.13

Reverse

Gear

55.08 7.27 3708.14 31.48 12.71 2119.32

Engine

Gearbox

Drive shaft

Stub axle

Wheels

Engine working range ( ωM ) = 1750rpm-

3800rpm

Recommended maximum power (PM) = 6.7

KW at 3800rpm

To calculate power performance function

Pe = P1 ωe + P2 ωe2- P3 ωe3

P1 = PM/ ωM P1 = 16.8455 ω/s

P2 = PM/ ωM2 P2 = .04235 ω/s

P3 = PM/ ωM3 P3 = 1.064 E -4 ω/s

Therefor power performance function is

Pe = 1608455 ωe + 0.04235 ωe2 – 1.064 E-4

ωe3



Electrical Circuit



Ergonomics and ValidationERGONOMICPARAMETER

VALUES

Visibility 67’

Front visibility distance 61.59”

Seat rest angle 20’

Cock pit length 79.48”

Cock pit height 53”

Design Aspect Criteria Plan and Analysis Methodology Result

Roll Cage SAE BAJA Rule Book Section 3 FEA :

Front Impact Test

Side Impact Test

Rear Impact Test

Roll over

Achieved

Below yield stress

Below yield stress

Below yield stress

Below yield stress

Suspension To provide good cushioning against shocks, without

failure.

1. ADAMS shall be used to determine the performance

of the suspension.

2. Load will be applied on the vehicle in dynamic and

static conditions to test the performance of the

suspension.

Achieved

Steering To design a steering mechanism which satisfies

Ackermann’s mechanism and also provide self centering

effect and avoids nervousness.

The system that gives the required turning radius and

the least steering effect will be selected.

Achieved

Brakes To design a braking system which provides comfortable

stop at a distance of 14.3m

The system that gives stopping distance closest to 11.14

m and best suitable will be selected.

Achieved

Transmission To increase the torque and speed of the vehicle to meet

the demands of the hill climbing test.

To select the required gear ratio, which gives torque and

speed.

Achieved

Electricals To provide fool proof lighting and sound circuits To design the kill switch and the various circuitry Achieved



Component (X,Y,Z Coordinates) Weight (kg)

Engine (339,316,-1230) 30

Gearbox (247,307,-851) 15

Seat (671,566,-1050) 2

Driver (973,529,-1100) 80

Steering (1550,502,-1050) 6

Back Right Brake (314.6,163,-162) 1.265

Back Left Brake (311,163,-1950) 1.265

Front Right Brake (1780,165,-296) 1.265

Front Left Brake (1780,165,-181) 1.265

Back Right Tyre (314.6,158,-112) 20.246

Back Left Tyre (315,158,-1960) 20.246

Front Right Tyre (1780,158,-286) 20.246

Front Left tyre (1780,158,-1820) 20.246

Front Right Suspension (306,367,-430) 1.2985

Front Left Suspension (306,367,-1600) 1.2985

Back Right Suspension (1790,337,-585) .5234

Back Left Suspension (1790,337,-1520) .5234

Brake Pedal (1730,132,-1090) .586

Clutch Pedal (1730,132,-981) .586

Acceleration Pedal (173,132,-878) .586

The centre of gravity for the entire vehicle is located at

(995,189,-1050) which is below the seat

Co-Ordinates and Innovations

INNOVATIONS:

• Fly ash incorporation in brakes• Piezo Electric power generation• Roll cage diameter optimization



Team Faculty Advisor : Dhanasekhar

Team Captain : Mohammed ZaidS.No Name Role in Team

1 Aravindh Machinist / Brake

2 Adithyan Design / Administration

3 Harish Inspection / Machinist

4 Harikrishnan Co-Driver / machinist

5 Arun Electrician

6 Benraja Design

7 Madumitha Machinist / Steering

8 Sahithya Sabari Gireesh Design / Welding

9 Pawan Kumar Inspection / Machinist

10 Sai Vishnu Machinist / Administration

11 Gowri Shanker Design / Welding

12 Dhivaker Machinist / Driver

13 Mohammed Zaid Stocker / Machinist

14 Manikandan Inspection / machinist

15 Mahendran Machinist

16 Mohammed Mudassir Machinist / Stocker

17 Hariharan Machinist / Stocker

18 Manoj Somoosay Machinist / Steering

19 Varun Inspection / Stocker

20 Vaisikan Electrician

21 Rahul Dharmarajan Design / suspension

22 Vaishnavi Machinist / Suspension

23 Srinivasan Machinist / Steering

24 Soorya Machinist / Brakes

25 Deepak Welding

Crimson Thrusters

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