Team ECB Racers Presentation BAJA

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    Team ECB Racers

    Engineering College Bikaner(AN AUTONOMUS INSTITUTE OF GOV. OF RAJASTHAN)

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    Our Goals

    To design a vehicle which is low cost, low weight, fun todrive , easy to maintain & ecofriendly in accordance with the

    BAJASAE rules.

    To design a vehicle which can negotiate through all terrains

    and able to withstand worst conditions.

    To design a vehicle to provide maximum comfort level to itsrider in vehicle handling during off road traversal.

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    Vehicle technical specifications

    Overall dimensions:overall length : 90 in. Overall height : 60 in.

    ground clearance : 8 in. Track width : 52 in.

    Braking system:

    dual hydraulic disc brakes at both front and rear wheels.Steering :

    type : central rack and roller pinion

    steering ratio : 10.58:1 turning radius : 9 ft.

    Tires and wheels: (in inches)front : 21x10x6

    rear : 22x10x8

    Suspensions:

    double wishbone at both front and rear.

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    Target design and performance specifications

    Speed:For better economy, the range of speed in each gear, for driving tires of O.D 22 inches operated

    in normal forward orientation is:

    braking performance:

    Time to come in the rest from position of maximum speed : 8 sec.

    Distance covered by the vehicle before coming to rest from maximum speed when

    the brakes are applied : 11 mtr.

    Gear Speed (km/hr)

    First 10-12

    Second 15-18

    Third 25-33

    Fourth 40-51

    Reverse 8-11

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    Roll Cage Design

    Objective:

    Roll cage Specifications: Roll Cage View:

    Safety of the

    Driver

    Ease offabrication &

    manufacture

    Stability of themounting

    components

    Driver

    Ergonomics

    Roll over

    Prevention

    Aerodynamicstability

    Cost & Quality Low WeightOverall

    Attractiveness

    Durability &Maintainability

    of the Frame

    LENGTH 90in

    WIDTH FRONT END 22in

    REAR END 25in

    MAX 37in

    HEIGHT 52in

    WEIGHT 43kg

    VOLUME 333095.40 in3

    SURFACE AREA 6958.53 in2

    CENTRE OF MASS x=2.95mm

    y=465.99mm

    z=381.54mm

    WELD JOINTS 52

    TOTAL WELD LENGTH

    261.48in

    ESTIMATED COST 8400 Rs

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    FEA ANALYSIS

    Impact Factors & load Applied:

    Front impact:

    Front impact Test-Displacement Front impact Test-F actor of Safety

    Max. Displacement:1.50mm Min. FOS: 2.01

    Impact Impact factors Load Applied Result

    Front Impact At 15 m/s 6000N Passed

    Side Impact At 11m/s 4000N Passed

    Rear Impact At 13 m/s 5000N Passed

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    Side Impact:

    Side Impact Test- Displacement Side Impact Test- FOS

    Max. Displacement-5.4 mm Min. FOS -3.21

    Rear Impact

    Rear Impact Test- Displacement Rear Impact Test- FOS

    Max. Displacement-7.463mm Min. FOS-1.91

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    Material selection

    Availability of Material as per Rulebook:

    1.AISI 1018 2.AISI 1020

    3.IS 1239 (part 1) 4.AISI 4130

    Comparison of materials:Cost of per meter length of 1018 is

    3.6 and 1.275 times cheaper than

    4130 and IS 1239 respectively. Also

    Its easily available in market.

    Conclusions:The material we are going to use is

    AISI 1018 steel.

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    MS Project plan

    Here is a brief description of the project plan team ECB racers going to follow:

    Name of the job period

    Roll cage prototype 25 Jul. - 5 Aug.

    Raw material collection 6 Aug. - 10 Aug.

    Rollcage fabrication 11 Aug-25 Aug

    Steering fabrication 26 Aug-18Sep

    Engine mounting 19Sep-25Sep

    Wheel assembling 26Sep-7Oct

    Riders accessories 8Oct-20Oct

    Vehicle Testing 20Oct-30Oct

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    Design validation plan

    ROLLCAGE ANALYSIS :

    *FRONT IMPACT : (AT 15m/s) as per FSAE Society Rules:

    => F=360*15=5400N&Thus Force applied is 6000N.

    *SIDE IMPACT: (AT 11m/s)=> F=360*11=3960N&Force applied is 4000N

    *REAR IMPACT: (AT 13m/s)=> F=360*13=4680&Force applied is 5000NFORCE ON AXELS(WHEN BREAK APPLIED)

    FRONT AXEL = 1800N

    REAR AXEL = 1200N

    ACCELERATION= 9.1M/S2

    Suspension:Mass falling over front wheels=76.5Kg

    Mass falling over rear wheels=138.5Kg

    Max. Compression at front suspensions = 20mm

    Max. compression at rear suspensions = 25mm (under static conditions).

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    Innovations

    A touch screen GPS system with quick satellite viewer

    enabling to have a view of vehicle position and a live picture

    of surface around the vehicle also with weather information

    plus information regarding other vehicles also.

    For cooling of the Engine, we are going to use funnel with

    tubes to focus air directly to the areas of engine where

    cooling is required.

    Using the iPhone to start/stop the vehicle engine via start

    smart hardware in the vehicle(range ).

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    Go green

    Mounting the Enamel coated plate at the exhaust of theengine to decompose and reduce the emission of carbon

    containing gases.

    75% material of vehicle parts are recyclable .

    HID headlights(Xenon) instead of mercury lights.

    Paints that we are going to use would be lead free.

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    Team detailsTeam member Task

    Prof. M.P.Poonia Faculty adviser

    Pushpendra Kumar Sharma Marketing, suspensionPrabhakar pal Brakes, co-captain

    Priyank shastri Transmission, marketing

    Jagrat Agar Roll cage design

    Adarsh Maurya Roll cage design

    Dinesh Chand gangawal Roll cage design

    Harshit sharma Suspension

    Himani jangid Braking system

    Tanushree pareek Vehicle accessories

    Dharmraj meena Ignition System

    Mukesh pathak Accessories

    Divya suman Tires & wheels

    Sanu pal Steering system

    Harish Fabrication & Mounting.

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    College facilities to be used

    We are going to use :

    CUTTER MACHINE

    DRILLING MACHINE

    GRINDER MACHINE

    MIG WELDING &

    LATHE MACHINE.

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