IDEA Design Round Presentation
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The document describes the design of a go-kart by team EK-IDEA2015. It includes specifications for the chassis, braking system, steering, drive train, and other components. Calculations and simulations were performed to validate components will meet rules and withstand stresses. The team developed the design over several months, with members responsible for different tasks like CAD work, fabrication, and documentation. A cost report estimates the total project cost at $66050.
IDEA Design Round Presentation
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- 2. Friday, August 12, 2016 EK-IDEA2015 2 Provide a better atheistically designed go-kart and our technocrats merely make them seek livelihood, but to take our country ahead in all fronts of Automobile Innovations. Promoting engineering temperament and competitive spirit among aspiring students through imparting knowledge of Automobile by designing, fabricating, optimizing & racing.
- 3. Friday, August 12, 2016 3 3D View of the Vehicle with Specification EK-IDEA2015
- 4. Friday, August 12, 2016 4 Rule Book Conformation EK-IDEA2015 Article Specification / Content Constraint Provided / Rule Implemented Values / Method Remark A1.1 – 6.4 Administrative Regulation Eligibility, Age, Driver License & Insurance License & Insurance available B 1.1 – 1.1.1 With Four wheels & Capability Driver Height 190cms & weight 113kgs Confine as per rule B1.1.2 – 1.1.4 Max vehicle Dimensions & Jack Pt Wi: 50”,Le:80”,Wheel base relation Wheel Base: 43”, Track width: R42.6”,F34.4” B 1.1.5 Steering System Positive Steering With Mechanical Links Positive Steering without locking Wheels B 1.2.1-1.2.2 On Road Capability Ground Clearance & Sharp Edge Clearance 2.5” & No sharp Edges B 1.3 Vehicle Ergonomics Capacity 95th %ile male & 5th %ile Female Confine as per rule & Avg ht of team is taken B 2.1- 2.1.16 Engine Requirement Restrictions while Assembly & Caution Confine and Abide to rules B.3.1 – 3.5 Electrical System Battery, Wiring, Lights & Kill Switch Solar Power and confine as per rule B 5.1 – 5.9 Cock Pit & Throttle Control Firewall, Belly pan & Throttle console Fire Extinguisher Fitted & Confine as per rule B 6.1 – 6.3.1 Driver Restraint Seat Fastener, Shoulder Harness & Location Single Buckle fastener & Confine as per rule B7.1 – 7.4 Braking system & Fuel Tanks Foot brake lines and Fuel tank lines Safely Installed & Confine as per rule B8.1- 10.1.1 Fastener, Guard and Driver Equip Preferred bolts, nuts & washer employed Guards, ISI Driver suit is used with Helmet
- 5. Friday, August 12, 2016 5 Chassis Design EK-IDEA2015 Design Methodology: As per rule book confine & Considering the bare Weight of Kart, Engine & Racer. Material Selection : AISI 4130 (2” x 0.19” tube) with best rigidity often employed in FSAE vehicles. Calculation Results : Wheel Base 43”, Track Width Rear 42.6” & Front 34.4” & Ground Clearance: 2.5” Material Property: E: 205KN/mm2, μ: 0.285, ρ: 7850kg/mm3, σt: 731N/mm2 σy:460N/mm2, κ:42.7w/m0K Stress Analysis Report: Max Stress σ: 370N/mm2 Factor of Safety: 1.26 Displacement: 2.61emm
- 6. Friday, August 12, 2016 6 Ergonomics consideration in vehicle EK-IDEA2015 As per rule book confine & Considering the Average height of the team members.
- 7. Friday, August 12, 2016 Drawing of Disc Brake Brakes EK-IDEA2015 Design Methodology: As per rule book confine & Considering weight of the go-kart with driver. Selection: Disc brake with Double pistons acting towards on single Caliper & Pad is employed. S. No Configuration Obtained Values Slip No -Slip 1. Brake Force FFT= 352N & FRT= 653N FRT=725N 2. Brake Torque TRC= 60.2085 N-m 3. Stopping Distance 20.27m 13.54m 4. Stopping Time 4.49 sec 2.99 sec 5. Pedal Force 98.1 N 6. Leverage Ratio 6 : 1 7. Pedal Efficiency 80% 8. Disc Dimensions 0.24m x 0.006m (9.45” x 0.24”) 9. Caliper Dimensions 0.025m x 0.075m
- 8. Friday, August 12, 2016 8 Steering EK-IDEA2015 Design Methodology :As per rule book Confine & Considering Positive Steering without locking. Selection : Mechanical Linkages is employed for steering its simple with less effort & weight. S No Configuration Obtained values 1. Wheel Base 1066.8mm (43”) 2. Track Width 860mm (34”) 3. Track Rod 482mm (19”) 4. Turning Radius 1855mm ( 72”) 5. Ackermann Angle 150 6. Ackermann Arm Length 238.1mm (9”) 7. Ackermann Percentage 147% 8. Steering Ratio 1:1 9. Steering Wheel 10” dia. wheel 10. Steering effort 87.7N S No Parameter Values 1. Kingpin inclination 100 2. Caster -120 3. Camber 10 4. Toe out 2mm
- 9. Friday, August 12, 2016 9 Drive Train EK-IDEA2015 Design Methodology : As per rule book confine & Considering provided engine specification data. Selection: Centrifugal Clutch is employed for better power transmission with low cost and weight. S. No Configuration Obtained values 1. Mass of Shoe 0.36 kg 2. Centrifugal force outwards 1000.7 N 3. Centrifugal force Inwards 562.93 N 4. Radial force of shoe 437.45 N 5. Friction force 109.46 N 6. Frictional Torque 12.32 N-m (4.5 HP) 8. Max Speed 18.055m/s (65kmph) 9. Transmission to Rear Axle 1.6 H.P Exploded View of Clutch
- 10. Gantt Chart Friday, August 12, 2016 10EK-IDEA2015
- 11. Design Validation Plan 11Friday, August 12, 2016 EK-IDEA2015 S.NO SYSTEM TEST METHOD INSPECTION ACCEPTANCE CRITERIA RESULT 1 CHASSIS THEORITICAL SOFTWARE RESULTS PASSED PHYSICAL Analysis NO BENDS OR CRACKS DEVELOPED PASSED PHYSICAL VISUAL NO BENDS OR CRACKS DEVELOPED TO BE PERFORMED 2 TYRES PHYSICAL VISUAL NO SKIDDING OF VEHICLE TO BE PERFORMED 3 ENGINE PRACTICAL TEST VISUAL NOT MORE THAN 70KMPH TO BE PERFORMED PRACTICAL TEST VISUAL NIL TO BE PERFORMED 4 STEERING TEST PRACTICAL TEST VISUAL MAXIMUM TEST WITHOUT SKIDDING TO BE PERFORMED PRACTICAL TEST VISUAL EASY TURNING WITHOUT HITTING CONES TO BE PERFORMED 5 BRAKES PRACTICAL TEST VISUAL BRAKING DISTANCE NOT MORE THAN 4m TO BE PERFORMED THEORITICAL TEST BY FORMULAE AVERAGE PEDAL FORCE A MAN CAN OCCUR 98.1N(5lbs) PASSED
- 12. Design Failure Mode and Effect Analysis Friday, August 12, 2016 12EK-IDEA2015 COMPONENT FUNCTION POTENTIAL FAILURE MODE POTENTIAL EFFECTS S POTENTIAL CAUSES O D R.P.N. ACTIONS TAKEN S O D R.P.N BRAKES Retards motion Leakage of fluid from brake line Vehicle will not stop on time 6 Sub-standard brake lines 5 4 120 Replace the brake lines 6 1 3 18 Cracks due to high pressure 5 4 160 Replace the brake lines 6 2 3 36 Cracks due to rough terrains 4 4 96 Provide covering 6 2 3 36 Failure of pushrod All wheels will not lock simultaneously 8 Restriction to motion of pushrod 3 6 144 Pushrod should have adequate D.O.F 8 2 4 64 KNUCKLE Stationery part which integrates brakes, steering, transmission and suspension Knuckle dislocate Severe effects on brakes and steering 7 Selection of improper material 4 4 112 Use of high grade material 7 2 2 28 Improper press fit and size of bearing 6 4 168 Soldering of Knuckle 7 2 2 28 7 Small cross-section area of stub axle 4 3 84 Maintain cross-sectional area 7 2 3 42 Crushing 7 Free length of stub axle 4 5 140 Maintain length 7 2 3 42 Shear EXHAUST Guides exhaust gases away Corrosion on inner surface Unpleasant or cracking sound 7 Inner surface at lower temperature than exhaust gases leading to condensation 6 6 252 Replace exhaust 7 2 6 84 Formation of acidic mixture PEDAL Lever which actuates A B C of the vehicle Movement of pedal constrained Pedal does not reciprocate back 8 Accumulation of mud near pedal 7 2 112 Clean with high pressure jet of water 8 4 2 64 Difficulty in braking and acceleration Provide a metal sheet covering 8 3 2 48 FUEL LINES Transportation of fuel Fuel line or component sealing failure Chance of fire if fuel comes in contact with engine 7 Improper maintenance 6 4 168 Proper sealing should be inspected 7 4 3 84 Crack in lines Fuel loss 6 Cracks due to vibration 6 5 180 Lines should be mounted rigidly 6 4 3 72 Excess tightening of line screw Improper flow of fuel 6 Poor judgement while installation 6 3 126 It should be adequately tightened 6 4 3 72 SPARK PLUG Ignites fuel by means of electric spark Wet spark plug No sufficient voltage to start the engine 7 Contact with water 7 4 196 Cap should be provided to protect from water 7 4 2 56 Low voltage 6 Excessive usage 5 4 120 Distance between the electrodes should be checked to be around 0.8mm 7 4 2 56 Carbon deposition 7 Incomplete combustion of fuel 4 5 140 Spark plug should be cleaned with air jets 7 5 2 70 BATTERY Supplies electric energy Short circuit Starter motor will not work 8 Contact with water 6 3 144 Metal sheet covering for battery should be provided 8 2 2 32 Discharge of battery All electrical connections may fail 5 Over usage 5 4 100 Engine should be kept running 5 1 2 10 Improper connections 5 Failure of battery 5 3 75 Fuse box should be provided 6 1 2 12
- 13. Innovation Friday, August 12, 2016 13EK-IDEA2015 Implementing Automatic lights Switching through LDRs (Daylight Sensor). Working out the best Aerodynamic design. Automatic turn lights actuated with the >70 Angle of front wheel. Solar panel is employed for the charging batteries.
- 14. College Facility Friday, August 12, 2016 14EK-IDEA2015 Production Lab Lathe Machine Shaping Machine Slotting Machine Milling Machine Grinding & Drilling Machine Workshop Carpentry Fitting Sheet Metal House Wiring Bending Manufacturing Foundry Black smithy ARC Welding Band Saw Engg Laboratory Electrical & Electronic Instrumentation & CAD/CAM Thermal & Heat Transfer Metrology & Material Science Strength of Material & Hydraulics Arc Welding Turning Drilling Slotting Band Saw Milling Shaping MIG & TIG Welding Not Available
- 15. Team Structure and Allotted Responsibilities Friday, August 12, 2016 15EK-IDEA2015 S.No Name of the Participants Privileges Design Task Fabrication Task 1 Anthony Johnson Yesudas (Cpt) Work allocation & Follow up CAD, Chassis & Documentation Optimization & Inspection 2 R. V. N. Anurag1 (α - Team) Alpha Team Captain Steering Calculation & DVP Steering Assembly 3 Y. Maruthi2 Asst & Manual Drawing Drawing with Exploded View Bumper & Pads Arrangements 4 R. Rajesh Reddy3 Assisting team Cross Checking Service & Maintenance 5 A. P. D. Salman Basha4 (Racer) Asst & Subject expert Material Selection & Validating Stub & Rear Axle Assembly 6 U. Jagadesh1 (γ - Team) Gamma Team Captain Brakes, Drive Train & Aerodynamic Disc Brake Assembly 7 R. Kusuma Reddy2 Asst & Project Planning Gantt Chart Belly pan & Pedals Assembly 8 N.Yeswanth Sharma3 Asst & Manual Drawing Drawing with Exploded View Electrical Mounting Arrangements 9 K. Nagasunkanna4 Asst & Subject expert Cross Checking & Validating Drive train Assembly & Welder 10 T. Subba Reddy1 (β-Team) Beta Team Captain Material Selection Criteria & DFMEA Tyre & Wheel Alignment 11 K. Ravi Kumar2 Asst & Subject expert College facility info Technician & Engine Assembly 12 B. Basha3 Assisting team Cross Checking & Validating Turner & Machinist 13 K. Venkat Subbaiah1 (Ω-Team) Omega Team Captain Cost Report & Ergonomics Material Procurement & Fitter 14 M. Varun Kumar2 Assisting team Specification sheet & Market Survey Safety measures Arrangements 15 R. Prudvi Raj3 Asst & Sponcership Vendors quote & Estimation Shipping & Transportation
- 16. Cost Report Friday, August 12, 2016 16EK-IDEA2015 S NO Part Name Material Cost in Rs/- 1 Chassis & Plate AISI 4130 3050 2 Wheels & Tyres Whole Set 19500 3 Axle & Hubs Whole Set 6000 4 Braking System Disc brake set 3000 5 Transmission Centrifugal Clutch & Chain Sprocket 2000 6 Electrical System Solar Panel, Battery, Switches and Lights 4000 7 Mounting & Bumper Dash Board 5000 8 Manufacturing & Labor Welding cost, Machine cost & Labor Allowances 4000 9 Material Shipping Transportations Cost 2000 10 Miscellaneous Belly pan, tie rod & fire extinguisher etc 2500 11 Engine Brigg Stanton Vanguards 6.5 HP 15000 Total Cost ($1066)-66050
- 17. For your cherished time… 17Friday, August 12, 2016 EK-IDEA2015
- 18. 18Friday, August 12, 2016 EK-IDEA2015
Editor's Notes
- #2: IDEA Performance – Technology Optimized
- #3: Aim: Vision: Mission of Team:
- #4: 3D View of Vehicle with specification
- #7: As per rule book confine & Considering the Average height of the team Members
- #8: Drawing of Disc Brake
- #9: D
- #10: Exploded View of Clutch
- #14: qr
- #18: Where do you see your team after two years?