TEAM SCREWDRIVERS

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TEAM SCREWDRIVERS

INTRODUCTION: ABSTRACT:
After a lot of Team hard work , we have come up with a great design and its analysis. We kept our primary objective on more and more optimization of design based on Ergonomic, Aesthetic & performance value. This is our report which shows our total work breakdown and the methodology we used for our Go-Kart Design. During this session we learnt many things of the importance of the team. Our innovation team took lots of effort and conclude with Great innovation. Primarily based on safety and Security. This is insuring the driver safety cum security.

DESIGN OF VEHICLE:
Our competition approach was to for bring out this a

successful vehicle with some new innovations. The Preliminary Design Report is outcome of our approach towards this competition. Before

beginning the design .we must know the needs which, where required for the go kart, that is why we put ourselves in the shoes of the customers who are going to purchase this vehicle. The designing was started only after thorough study of the aforementioned GO KARTs, which was followed by system advantages and production costs. All the design issues were studied and an attempt has been made to solve them in the present design. In order to increase the ease and speed of manufacturing, great care was taken to ensure that every component of the vehicle was modeled using CATIA V 5 R20 software. Using an accurate master assembly of the digital car, we were able to quickly and easily verify design ideas and ensure inter

component compatibility. Also, most of the designed parts subject to loading conditions were modeled with Finite Element Analysis (FEA) used ANSYS
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TEAM SCREWDRIVERS
14.0 software modules. while designing any of the parts so that no major modifications are made while 3 4 5 6 7 8 9 10 Performance Serviceability High High 2 Ease of Design Essential

manufacturing and a technically sound all terrain vehicle is resulted in. Our main aim was to work under the guidelines of the rule book, and use the maximum limits. With this we had a view of our GO KART. This started our mission and we set up some parameters for our work, distributed ourselves in groups. SUB-TEAMS FOR DESIGN Chassis Transmission Brakes and Wheels Steering REQUIREMENTS OF A VEHICLE: Cost of the vehicle. Aesthetic. Endurance or Life. Parts easily available. Speed and Acceleration. Maneuverability. Mass and Overall dimensions must be less. Design Criteria of the Vehicle

Manufacturability High Health and Safety High Lightweight Economic/Low Cost Easy Operation Aesthetically Pleasing High Desired Desired Desired

3D VIEW OF VEHICLE:

SPECIFICATION:

Weight of vehicle(approx)= 160 Kg No. Criterion 1 Reliability Priority Essential Length of vehicle =75 inches Wheel base = 47.125 inches Track width = 44.38 inches
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TEAM SCREWDRIVERS
Height of vehicle: 14 inches Ground clearance=3.15 inches Cost of vehicle: 45000/- Rs It is the backbone of any vehicle. Designed to bear all types of Major Component Weight (Kg) LOAD WHEEL: Reaction force at wheels due to weight Distance from Load to centre of rear wheel LR =491.012mm Distance from load to centre of front wheel LF =705.96 mm Total Load = 1557.8 N DISTRIBUTION IN load whether long duration, short duration or impact load. It contains Seat(passenger) Engine Self Weight of Chassis Total vehicle mounting space and points for all the component of the vehicle DESIGN CONCEPT: In the previous year`s vehicle, chassis being designed by the students was thought of as a component vulnerable to failures, and hence due importance was given to ensure its RF= F+RR RF=639.02N Reaction force at both front wheels= 639.02 N strength. This year more importance has been put on optimizing the chassis without compromising on safety. Also the vision of driver was an issue, as the driver`s seat was laid quiet low. We have first finalized the position of major sub-systems and then built up our chassis around these equipments. This approach gave us a lot of flexibility. Now since the mounting points can be adjusted, we can easily manipulate our chassis design While
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CHASIS DESIGN:

70 Kg 25 Kg 26.8 Kg

Weight

of 159.3 Kg

[F x LF] + [RR x (LR + LF)] = 0 RR= -(F x LF )/ (LR+LF) Newton RR=918.77 N Reaction Force at both rear wheels = 918.77 N

according to our requirement.

TEAM SCREWDRIVERS
designing the chassis, component rules. Since the frame is being used in a racing vehicle rather than a recreation vehicle, weight is a very large factor in the shape and size of the frame. The proper balance of strength and weight is crucial for the team overall success. The rules define the roll cage must be made out of a material with properties at least as equivalent to the following specifications: (A) Circular steel tube with an outside diameter of 2.5 cm (1 inch) and a wall thickness of 3.05 mm (.120 inch) and a carbon content of at least OR (B) Steel members with at least equal bending stiffness and bending strength to 1018 steel having a circular crosssection with a 2.54 cm (1 inch) outer diameter and a wall thickness of 3.05 mm (.120 inch)

spacing, driver`s comfort and high torsion rigidity were given special considerations apart from closely

monitoring the damper mounting points for better positioning /Road Response and additional strength. Minimal

vehicle dimensions in accordance with rulebook were chosen in order to make vehicle light as well as cost effective. A round pipe has high polar moment of inertia (J) and moment of inertia (I). These are the property relative to the area of the material by virtue of which it is able to resists torsional and bending moment respectively. Round hollow pipes are light in weight. The team designed a vehicle frame with primary emphasis given to factors of safety, and durability,

performance, while

manufacturability by requirements

abiding

established by GO KART rulebook.

Some of the goal design points are 1. Factor of safety =3 2. Overall chassis weight = 25 kg 3. Least additional members for

Load Distribution calculations:

strength and support

The materials used in the cage must meet certain requirements of geometry and minimum strength

Taking moment at A -0.66 x 900 300 x 0.71 100 x 0.99 + Rb x 1.17

requirements found in SAE competition

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TEAM SCREWDRIVERS
Rb = 774.35 N Now, Fy=0 Ra 900 300 100 + Rb = 0 Ra = 525.65 Shear Force Diagram (SFD): MA = 0 Bending Moment Diagram:

Taking Max Moment, SF at A= 525.65N SF at C= -374.35N SF at D= -674.35N By selecting Material MS-1018 SF at E= -774.35N SF at B= 0 Calculate moment at each point, MB = 0 ME = 774.35 x 0.18 = 139.383 N-m MD = -100 x 0.28 + 774.35 x 0.46 = 328.01 N-m MC = -300 x 0.05 100 x 0.33 + 774.35 x 0.51 = 346.92 N-m Mpa Now, (t) = (b) (b) = 32 M / d3 211.33 = 32 x 346.92 x 1000 / d3
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M = 346.92 N-m M = 346.92 x 103

Ultimate Tensile Strength (Sut) = 634 MPa Factor of Safety (Nf) = 3 Tensile Stress (t) = Sut / Nf (t) = 634 / 3 = 211.33

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TEAM SCREWDRIVERS
D=25.4 mm (chassis diameter)

DESIGN ANALYSIS:
MODEL ANALYZED:

C-Clamp Calculation:

Assume Thickness = 7 mm safety Yield Stregth (Sut )= 386 MPa Tensile Stress (t) = 128.66 MPa Eccentricity (e)= 36 mm Centroid in x direction Y= 10.5 mm

The design was validated for and deflections based on

permissible stresses of the material used. Further analysis on the chassis was done on ANSYS 14.0. Chassis was analyzed with the following tests: 1. Front impact 2. Side impact

Ixx = (1/12) x t d

3. Rear impact Area = A = 3 t2 = 147 mm2 (t) = (P /A) +( P.e.Y / Ixx) (t) =128.66 = (P/147)+ (P x 36.5 x 10.5 / 600. 25) P=200 N
Load Carried by C-Clamp= 200N =20.38 Kg

4. Self weight impact

1. Front Impact In this analysis the tire

mounting point/rear and front axle were fixed and an impulse was applied on the nodes of front bulk head.

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TEAM SCREWDRIVERS
Analysis type Gravit Force Numbe r of fixed and force was applied on the side nodes. Analysis type 1275 structural Off Gravity Force status in Number of

y status in Newto n

Nodes

Structura l

Off

405 N

Newton Nodes 95 N 300

RESULT:

RESULT:

2. Side impact In this analysis the tire

Max. Deflection 0.134477 inches

Max. stresses 8.94346 MPa

mounting point/rear and front axle were

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TEAM SCREWDRIVERS
Max. Deflection 0.054101 mm Max. stresses 2.69596 MPa Max. Deflection 0.215738 mm Max. stresses 6.99718 MPa

4. Self weight impact In 3. Rear impact In this analysis the front cross member and rear axle were fixed and force was applied on the rear side nodes. Analysis type Gravity Force status in Number of Structura l On Analysis type Gravit Force Numbe r of y status in Newto n 900 N 2150 & 300N vertical downward direction. RESULT: The this analysis the tire

mounting point/rear and front axle were fixed and force was applied in the

Nodes

Newton Nodes structural Off 103 N 911

acceleration due to gravity (9.81 m/s) applied in vertical direction. RESULT:

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TEAM SCREWDRIVERS

MATERIAL:
CHASI MATERIAL (AISI 1018): American Iron and Steel

Institute (AISI) 1018 cold-drawn steel is a mild carbon steel used in a wide range of applications because of its simple chemical makeup and ease of production. It is one of the most
Max. Deflection 0.50559 mm Max. stresses 45.021 MPa FOS 8

common forms of steel used in many products requiring strength and

malleability without

the need for

extreme properties found in much more expensive tool steels. Known for its good mix of strength, ductility and hardness, 1018 steel is a mild, lowcarbon steel. This alloy of steel has a small percentage of manganese to help achieve these properties. While other steels can exceed its mechanical

properties, 1018 steel is more easily manufactured and machined, reducing its cost. The properties of 1018 make it ideal for a wide array of components such as pins, rods, shafts, spindles and sprockets. AISI 1018 mild/low carbon steel has excellent weld ability and produces a uniform and harder case and it is considered as the best steel for

carburized parts. AISI 1018 mild/low carbon steel offers a good balance of toughness,
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strength

and

ductility.
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TEAM SCREWDRIVERS
Provided with higher mechanical Physical Properties: Mechanical Properties Mechanical Properties Met ric Hardness, Brinell Hardness, (Converted hardness) Hardness, (Converted hardness) Hardness, (Converted Chemical Composition hardness) Tensile Strength, Ultimate Element Carbon, C Iron, Fe Content 0.14 - 0.20 % 98.81 - 99.26 % (as remainder) Manganese, Mn Phosphorous, P Sulfur, S 0.050 % Modulus of 0.040 % 0.60 - 0.90 % Tensile Strength, Yield 634 MP a 386 MP a Elongation at Break (In 50 15.0 15.0 % mm) Reduction of Area % 40.0 40.0 % % Elasticity 210 GPa 20300 ksi 29700 ksi 53700 psi 63800 psi from Vickers 131 Brinell 131 Rockwell from B 71 71 from 126 Knoop 145 Brinell 126 145 Imperial

properties, AISI 1018 hot rolled steel also includes improved machining

characteristics and Brinell hardness. Specific manufacturing controls are used for surface preparation, rolling and

chemical

composition,

heating processes. All these processes develop a supreme quality product that are suited to fabrication processes such as welding, forging, drilling,

Brinell

machining, cold drawing and heat treating

(Typical for steel)

Bulk Modulus (Typical for 140 steel) Physical Properties Density 7.87 g/cc
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GPa

Metric Imperial 0.284 lb/in3

Poissons Ratio (Typical For 0.29 0.290 Steel) Machinability (Based 0 70 70 %

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TEAM SCREWDRIVERS
on AISI 1212 steel. as 100% machinability) % contains trace elements such as

chromium, tungsten and silicon, which tool steels added corrosion

give Shear Modulus (Typical for 80.0 11600 ksi steel) GPa

resistance and toughness. Thermal Properties:

Electrical Properties Electrical Properties Metric

This steel is heat treated at specific temperatures. Annealing, which makes English Comm the steel soft and easily machined, ents 0.00001 anneale occurs from 1575 to 1700 C.

@100 C/ 212 F

@ 200 C/392 F

59 -cm d Normalization, which eliminates conditio n microscopic stress within the steel, 0.00002 anneale occurs from 1625 to 1700 C. Because it 19 -cm d has such a low carbon content, 1018 conditio n cannot be hardened, but it can be case 0.00002 anneale 93 -cm d hardened through backing it in a highconditio carbon mixture for an extended period n

of time.

Weldability: Chemical Properties: AISI 1018 mild/low carbon steel can AISI 1018 cold-drawn steel is a simple steel, a family of steel classified by its simple chemical makeup. This steel is primarily composed of iron and carbon with trace amounts of be instantly welded welding by all the

conventional

processes.

Welding is not recommended for AISI 1018 mild/low carbon steel when it is carbonitrided and carburized. Low carbon welding electrodes are to be used in the welding procedure, and post-heating and pre-heating are not necessary. Pre-heating can be

phosphorous and sulfur. While the carbon content is quite low, at only 0.15 to 0.2 percent, the phosphorous content of 0.04 percent maximum and sulfur content of 0.05 percent maximum are low enough that they have little impact on the material's physical properties. Like other, more complex steels, 1018
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performed for sections over 50 mm. Post-weld stress relieving also has its

TEAM SCREWDRIVERS
own beneficial aspects like the preheating process. Heat Treatment Annealing: The heat treatment for AISI 1018 mild/low carbon steel consists of the following processes: Normalizing: Stress Relieving:

mild/low carbon steel is tempered at the above mentioned

temperature.

The AISI 1018 mild/low carbon steel is heated at 870C 910C and allowed to cool in a furnace

AISI 1018 mild/low carbon steel should be heated at 890C 940C and then cooled in still air.

500C 700C is required to relieve stress in AISI 1018

mild/low carbon steel that is later Forging:

cooled down in still air. process requires heating Case Hardening:

This

between 1150C 1280C and AISI 1018 mild/low carbon steel is held until the temperature becomes constant.

This process requires heating to be carried out between 780C 820C. AISI 1018 mild/low carbon steel is then quenched in water.

900C is the minimum temperature required for the forging process.

The steel is then cooled in air after this process.

Core Refining:

This is an optional process that requires heating at 880C 920C.

Tempering:

AISI 1018 mild/low carbon steel after being heated is moistened in oil or water.

AISI 1018 mild/low carbon steel is tempered at between 150C 200C for improvement of case toughness. This process has little or no effect on hardness.

Carburizing:

Carburizing takes place at 880C 920C.

The occurrence of grinding cracks is reduced when AISI 1018

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TEAM SCREWDRIVERS
Other Properties The simple structure of AISI 1018 cold-drawn steel makes it an excellent machining steel once it is fully annealed. The lack of carbon makes the steel incredibly soft in its annealed state, saving machining

worms,

dogs,

pins,

liners,

machinery parts, special bolts, ratchets, chain pins, oil tool slips, tie rods, anchor pins, studs etc. It is used to improve drilling, machining, threading and punching processes. It is used to prevent cracking in severe bends

surfaces from the wear that tougher steels would induce. The lack of a moderate chromium content and simple chemistry, however, makes 1018 prone to oxidation, necessitating an air-tight coating to protect the steel from rusting too quickly. Applications of AISI 1018 Mild/Low Carbon Steel:

AXEL MATERIAL (EN 8): The function of rear axle is to transmit power and motion from engine to rear axle and tyres. The selected axle material is of grade En8. The Diameter of the axle is 1.25 inches and length is

It is used in bending, crimping and swaging processes.

54 inches. It is a medium strength steel having good tensile strength. It is easily

Carburized

parts

that

include

available, cheap and keys can be created in it without any difficulty.

worms, gears, pins, dowels, noncritical components of tool and die sets, tool holders, pinions, machine parts, ratchets, dowels and chain pins use AISI 1018 mild/low carbon steel.

Properties of En8: Property Ultimate Tensile Strength Yield Strength Elongation Density Poissons Ratio Youngs Ratio Value 850MPa 465MPa 16% Min 7.8 Kg/m3 0.3 2.05e5

It is widely used for fixtures, mounting plates and spacers.

It is suitably used in applications that do not need high strength of alloy steels and high carbon.

It provides high surface hardness and a soft core to parts that include

Chemical Composition:

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TEAM SCREWDRIVERS
Chemical Carbon Phosphorous Manganese Sulphur Silicon Content 0.40% 0.06% 0.80% 0.015% 0.25% When you are getting the engine from market you must know about every condition it is designed to demand from us to give its peak performance, so Engine mounting point is one among that factor. Our engine has got three Mounting Points two at side and one on rear. We will use high strength nut-bolt and washer for

FABRICATION:
The entire chasis of this years car will be manufactured within the teams shop, made from scratch. Each piece of tubing will be cut to the specific measurements based on the detailed drawing of the chasis. The fabrication process chart is given below:

mounting the engine. Selecting a Right Power source to do your respective job is very important and it needs full knowledge about it. Engine and transmission selection of our go kart has been done by keeping in mind of some consideration: Rule Book Market Research Go-kart track Test (Dynamics as well as static) Calculation Ergonomics

Market Result:
WELDING All welds on the go kart vehicle will be made using electric arc welding process. It is easily available, economic and easy to operate. Engin e Engine type Selection reason

Honda Activa

4 cvt

stroke

Transmissi on Problem hence not

Engine:
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selected
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TEAM SCREWDRIVERS
Honda Shine 4 and manual transmissi on Hero Honda Glamour 4 and manual transmissi on stroke Max.power , Torque,

stroke

Availabilit y Problem hence selected

Compression Ratio 9.1 : 1 Starting Electric start / Kick start

not

Ignition DC - Digital CDI with TCIS Oil Capacity 1 litre Oil Grade SAE 10W 30 SJ Grade

Availabilit y, Transmissi on

Drive train:
The goal of the drive train is to

ENGINE SPECIFICATION

transfer power from the engine of the vehicle to the wheels. The power transferred must be able to move the vehicle up steep grades and propel it at high speeds on level terrain.

Type Air cooled, 4-stroke single cylinder OHC

Displacement 124.7 cc

Acceleration is also an important characteristic controlled by the drive train. It was also decided that the vehicle should be able to achieve a velocity of approximately 50 kilometers per hour on level terrain. The next most important design goal was to minimize weight of the assembly in order to improve acceleration and decrease

Max. Power 6.72 KW (9BHP) @ 7000 RPM

Max. Torque 10.35 N-m @ 4000 RPM

Max. Speed 80 Km/hr

Acceleration --

Bore x Stroke 52.4 x 57.8 mm

rolling resistance.

Reasons for Selecting Chain Drive: Carburetor 1.) Maximum speed will be around 40 which is appreciable.
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TEAM SCREWDRIVERS
2.) If not used the thrust can overturn the vehicle. = 165.1 x sin(180/43) P = 12.05 mm Gear Ratio G.R. = T2/T1 = 43/13 = 3.30 Output speed T2/T1 = N1/N2 N2 = 7000/3.30 = 2121.21 rpm N2 = 2122 rpm Speed) Design Power Design Power = Rated power x Service Chain Sprocket Calculation: Power P=6.5 KW Input speed: N2= 7000 rpm. Large sprocket T1= 43 N Small sprocket T2= 13 N pitch for Sprocket P = D sin(180/T) ratio Ks = 1.875 = 6.5 x 1.875 KW From Table, N= 7000 rpm Design Power= 12.187 KW Roller Diameter = 8.51 mm Width between inner plate W=7.75mm Breaking Load = 106 p2 =106 x (12.05)2 =15.39 x 103 N ... (Sprocket (pitch for Sprocket)

Drive selection calculation:

Power required to drive Go-Kart P= (W x V x T)/270 Where, P= Power required To drive W= Weight V=Speed T= Rolling Resistance = 0.05 for asphalt P = 160 x 13.88 x 0.05 /270 P= 5.486 HP Power required to drive=5.486 HP

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TEAM SCREWDRIVERS
Pitch circle diameter of sprocket d1 = P cosec (180/T1) = 50.35mm d1 = 50mm= 0.05 m Pitch circle diameter of large sprocket d2 = P cosec (180/T2) = 165.01mm d2 = 165mm=0.165m Pitch line velocity of small sprocket, V1= ( d1 N1)/60 =( x 0.05 x 7000)/60 V1=18.323 m/s Load on Chain w= Rated Power/Pitch line velocity = 6.75/18.32 = 0.354 KN Factor Of Safety = wb /w =(15.39 x 103)/(0.354 x 103) = 43.47 = 43 According Standard = Centre distance = 3O x P = 30 x 12.05 Centre distance = 361.5mm In Order to accommodate initial sag in chain Correct the Centre distance X = 361.5 4 =357.5 X=357 mm No of Chain links, K= (T1+T2)/2 + 2X / P + [(T2-T1)/2 ]2 P/X = (43+13)/2 + (2 x 357) / 12.05 + [(43-13)/ 2 ]2 x = 28+59.25+0.76 = 88.01 K=88 links Length of the chain L=K x P=88 x 12.05 =1060.4mm L=1060.4mm ...(Length of the chain) Angle of wrap chain 1 = 180 2sin-1[(d2 d1)/2c] 1 = 161.860 2 = 360 - 1
=198.1350

(12.05)/357

Tractive Force: F= .t.w =.t.m. g Where, F=Traction effort t = adhesion coefficient w =weight of the wheel t = 0.4 0.7 for asphalt w= 4 Kg F= 0.5 x 4

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F= 2N Rolling Resistance Rolling Resistance = a x w x s2 Where, s = Speed m/s w= Weight of vehicle kg a= Coeff. Of rolling resistance = 0.05 dirt road R.R. = 0.05 x 160 x 13.882 R.R.= 1541.23 N Summary: 1) Pitch of chain: P= 12.05 mm 2) Length: L= 88 pitch = 1060.4 mm 3) Centre distance: 357 mm (max) P= 2 N T / 60 Sprocket=Single Stand, Small = 14 teeth = 50mm Large = 43 teeth= 165mm Torque T= 9.2609 N-m = 9.2609 x 103 N-mm The combination of engine, clutch, tyres, and axle sprocket yields a drive ratio of 3.3 to1 and a top speed of 50Km/Hr. I it is expected that the vehicle will be used to climb Te= 50.35 x 103 N-mm Shear Stress T = 55 MPa T = 16 Te / d3
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Design of Axel = The axel is a solid(live) and sprocket driven.the material used for axel is EN 8 (AISi 1040). The diameter of axel shaft is 1.25 inches and 54 inches length. Calculation: Material: EN-8 Moment M= RR x 2.5 M= 49.171 x 103 N-mm Power P= 9.1 BHP = 6788.6 W

6788.6 = 2x 7000 T / 60

Equivalent toque Te= [M2+T2]1/2

exceptionally steep hills regularly, the clutch should be replaced by a torque converter and the engine position shifted to match.

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d= 21 mm Axel Diameter = 21 mm (solid ) during a turn , thus avoiding the wear of tires. For that reason, the team decided to use the direct system. it is not necessary

Steering:
Design concept: The objective of the steering system is to control lateral motion while the vehicle is in longitudinal motion. The objective of the steering geometry was to provide Ackerman geometry. This the first important decision that the steering design team had to make was whether a rack and pinion system or direct system should be used. Some objectives established for the steering system were to use a simple design, easily controlled Ackerman, and limit steering wheel rotation from lock to lock. Two different steering designs were considered for this vehicle. The first design that was

to have a lot of power in the steering system. Since the only moving

components in the system are the direct system, it is very simple and more importantly, very durable. This concept contained less parts, a less chance of failure, and could be repaired much more easily.

Steering Design Considerations Consideration Simple Design Priority Reason

Essential Easy to repair during competition

Light Weight

Essential Minimize weight to maximize power to weight ratio of car

Low Ratio

Steering Essential Quick response Conserve momentum

steering

considered was a rack and pinion. However this steering configuration would restrict and complicate the primary design considerations. It was

Billed time of High fabrication

forward

throughout suspension travel

determined that using a direct system would allow all design considerations to be achieved for a fairly low cost with ease of maintenance. also Ackermann steering avoids the slip of front wheels Wheelbase= 47.125 inches Track width= 43.94 inches Castor= +7
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Calculations/Dimensions:

TEAM SCREWDRIVERS
Camber= +3 Free play= 1o the pavement. Considerations for the brakes can be found in Table Through Steering angle Inside wheel angle, d1= 30 deg. Outside wheel angle, d0= 21 deg. research and

applications from previous years, disc brakes have been selected as the optimal choice for the braking system. The vehicle is equipped with a

Turning radius Outer Turning radius = (43.94/2 + 47.125/sin30) = 116.22 inches or 2.95 m Inner Turning radius = outer turning radius - Track width = 116.22 43.94 = 72.28 inches or 1.84 m

hydraulic braking system. All major components have also been installed. For the braking system, the brake is from 150 Pulsar. To ensure proper fit of the pedal assembly into the frame, the brake pedal leverage has been shortened. Although shortening the lever arm requires an increase in foot force, the vehicle is still capable of decelerating safely and efficiently. The disk

assembly consist of calipers, disk and

BRAKING SYSTEM:
Design concept: The criterion for designing the brakes stated as per the rule book is that all the four wheels should lock

friction

pads.

Two

independent

diagonal lines are used, in order to provide braking in case of failure of one line. Braking Design Considerations Considerations Simplicity Priority High Reason Overall vehicle goal of

simultaneously as the brake pedal is pressed. The objective of the braking system is to provide a reliable and prompt deceleration for the vehicle. Moreover, the driver must have

Performance

High

Capable

of

complete control of the vehicle while the brakes are activated. More Light weight High

decelerating a 160 kg vehicle Prevent air bubble within the brake lines
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importantly, the brakes must be capable of locking up all four wheels while on

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Reliability Velocity Essential Lightweight parts to of vehicle= 50 Km/Hr minimize weight Ergonomics Essential Optimal Location of center of gravity is 28.66 pedal total V=13.88 m/s

inches assembly fitment to from rear wheel and 19.33 suit every driverinches from wheel axle line and height from ground is 11.81 inches. Components:Tandem master, cylinder, oil tank, proportioning valve, oil lines, disk valves. Where mv = the mass (commonly thought of as weight) of the vehicle in motion vv = the velocity (commonly known as speed) of the vehicle in motion K.E .= 160 x (13.88)2 K.E.= 15.432 KJ Brake Layout Diagram: Brake Pedal Force: Fbp=Fd x (L2/L1) Fbp = 70 N where Fbp = the force output of the brake pedal assembly Calculation/dimensions: Approximate total weight (Including driver) = 160kg W = 1569.6 N
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Breaking System: 1) Kinetic Energy: K.E. = mv.vv2

Actuation System:The system is hydraulically actuated, via a brake pedal which in turn generates a pressure in the master cylinder, which about 50 KPa, this pressure transmitted via the oil carrying line to the brakes.

Fd = the force applied to the pedal pad by the driver

TEAM SCREWDRIVERS
L1 = the distance from the brake pedal arm pivot to the output rod clevis attachment L2 = the distance from the brake pedal arm pivot to the brake pedal pad Fclamp = 741.999 x 2 = 1483.99 where Pmc = Fbp / Amc Pmc= 70 / 0.015 = 4666.6667 Pmc= 4666.6667 N/m2 Where, Pmc = the hydraulic pressure generated by the master cylinder Amc = the effective area of the master cylinder hydraulic piston Fclamp = the clamp force Acal = the effective area of the caliper hydraulic piston(s) found on one half of the caliper body Fclamp = Fcal x 2

generated by the calliper Ffriction = Fclamp x bp Ffriction = 1483.99 x 0.3 = 445.199 N Ffriction = 445.199 N Where, Ffriction = the frictional force generated by the brake pads opposing the rotation of the rotor bp = the coefficient of friction between the brake pad and the rotor Tr = Ffriction x Reff Tr = 445.199 x 0.12 = 53.423 N-m Where, Tr = the torque generated by the rotor Reff = the effective radius of the rotor Tt = Tw = Tr Tt = 445.199 x 0.12 = 53.423 N-m where Tt = the torque found in the tire Tw = the torque found in the wheel

Pcal = Pmc Pcal = 4666.6667 N/m2 where Pcal = the hydraulic pressure transmitted to the calliper Fcal = Pcal x Acal Fcal = 4666.6667 x 0.159 = 741.999 N Fcal = 741.999 N where Fcal = the one-sided linear mechanical force generated by the caliper

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Ftire = Tt / Rt Ftire = 53.423 / 0.2 = 267.11 N Where Ftire = the force reacted between the tire and the ground (assuming friction exists to support the force) Rt = the effective rolling radius Rear axle dynamic load =

w1+(a/g)*W*(H/L)

Front axle dynamic load = w2(a/g)*W*(H/L). Where, w1=weight on the front axle in the static condition. w2=weight on the rear axle in the static condition. g=acceleration due to gravity.

(moment arm) of the loaded tire Ftotal = Ftire x 4 Ftotal= 267.11 x 4= 1068.47 N Deceleration av = Ftotal / mv av = 1068.47 / 160 = 6.678 m/s2 where av = the deceleration of the vehicle Stopping distance: SDv =Vv2 / (2 x av) SDv= 13.882/ (2 x 6.678) stopping distance = 14.42m where SDv = the stopping distance of the vehicle

W=total weight of the vehicle. H=height of the centre of gravity. L=length of the wheel base. a=deceleration of the vehicle.

rear axle dynamic load =(525.65 N*(.299/1.219) = 787.73 N front axle dynamic load =774.35 (6.678/9.81)*1569.6 N)+(6.678/9.81)*1569.6

N*(.299/1.219) =512.27 N Summary:

For designing the braking system, we will have to calculate the dynamic weight using the formulae as given below:

Pedal Force=70 N Deceleration=6.678 m/s Stopping Distance=14.42 m

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Front: 3.00-10 4PR

TYRES
In an All-terrain vehicle, traction is one of the most important aspects of both steering and getting the power to the ground. Tire configuration treads depth, weight, and rotational of inertia are critical factors when choosing proper tires. The ideal tire has low weight and low internal forces. In addition, it must have strong traction on various surfaces and be capable of providing power while in puddles. Keeping in mind all the above

Rear: 3.50-10 4PR

ERGONOMICS AESTHETIC:

and

Ergonomics is the science of equipment design intended to maximize productivity by reducing driver fatigue and discomfort.
Ergonomics include the belly pan structure running over the entire length of the cockpit, foam padding of the roll cage, gear shifting indicators and such other things.

mentioned aspects we studied about the various types of tires available in market. After enough market research and guidance from our faculty advisor we have decided to use 4-ply rating, After going through the engine,

transmission and some basic torque and angular velocity calculations we have finalized the diameter of tires to 15 inches which would help us to transmit maximum power. The Rims shall be made up of Aluminium to minimize unsprung weight. By reducing the width of the rim the inertia will be directly decreased and subsequently this will also reduce the overall weight. Tyre specification:
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Our design is completely based on ergonomics

TEAM SCREWDRIVERS
8 correct and analyzed seat tilt angle for comfort sitting = 70 9. Seat belt arrangement according to type of seat = 4 point Harness belt

Kill switch:
Approach Keeping in mind the This reduced current flow through the relay branch and is enough to cause the relay to shut off, which then disconnects power to the regulated and 1 Proper top roll height for Ease of Egress = 368 mm = 14.5 inches 2.Correct sight line for complete view of dashboard = 60 0 3 Good vision during driving 4 Proper leg angle and Ankle angle for Ease in reaching pedals = 120 0 5 Proper clearance between leg and unregulated buses, but still leaves the safety lights bus connected to the battery independent of the relay. following parameters Approx values from our Design

Anything connected to the unregulated bus is either not sensitive to electronic noise and voltage spikes in the power supply, or contains protection circuitry. This electrical system provides a

reliable and efficient way to manage all the electronic components on the GO KART.

pitman arm

Battery placement:
= 115 mm = 4.5 inches 6. Ease in reach of gear shifter lever. 7,Correct distance between chest and steering wheel to avoid injury during collusion= 280mm=10 inches The 12V battery boxes are integrated into the chassis on left side of the drivers compartment, adding to the overall stiffness of the chassis, but they have larger potential to add further stiffness to the structure. The shape of these boxes can be altered in many
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TEAM SCREWDRIVERS
ways as the cells are very small, about the size of a domestic C sized battery, if designed efficiently the integrating of the battery boxes into a carbon fiber monologue would have huge potential. A fire extinguisher, flame extinguisher, or simply an extinguisher, increasingly being designed to mitigate injury to pedestrians struck by cars.

Extinguisher:

SAFETY:
As per the rules, we have securely layered all tubing members in the cockpit with a shock absorbing foam to protect the driver during an event. 4POINT SAFETY BELTS sponsored by Autolive India and SAE rated brake lights have been installed to maintain highest safety standards. The remaining standard safety equipment, including fire extinguisher, bumper and kill

is an active fire protection device used to extinguish or control small fires, often in emergency situations. It is not intended for use on an out-of-control fire. Depending on the agent used, different propellants are used. With dry chemical typically extinguishers, nitrogen is used; water and foam

extinguishers typically use air. Stored pressure fire extinguishers are the most common type. They have the advantage of simple and prompt recharge,

switches were all placed for easy access and use, as well as maximum

allowing an operator to discharge the extinguisher, recharge it, and return to the fire in a reasonable amount of time.

optimization of their functions during an emergency. Apart from this arm restrains, neck collar, Moto-cross type helmet and fire extinguishers have also been procured.

4 point Seat belt:

Bumper:
In automobiles, a bumper is the frontmost or rear-most part, ostensibly designed to allow the car to sustain an impact without damage to the vehicle's safety systems. They are not capable of reducing injury to vehicle occupants in high-speed impacts, but are

improvement in technology the safety of the passenger Four-point

harnesses are typically found in child safety seats and in racing cars. A 4point harness is similar to five points, but without the strap between the legs.

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oxides to nitrogen and oxygen: 2NOx = xO2 + N2 Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 = 2CO2 Oxidation of unburnt hydrocarbons (HC) to carbon dioxide and water: CxH2x+2 + [(3x+1)/2]O2 = xCO2 + (x+1)H2O. Exhaust Shielding : We are using Glass wool for exhaust shielding. Calculation

EXHAUST & MUFFLER:

Shielding

thickness

for

exhaust=

Thermal conductivity of material / convective coefficient surrounding = 0.035 / 8 . (thermal conductivity of glass wool ) / (convective H.T coeffn of air) = 4.75 mm Shielding thickness for exhaust = 5mm (approx) heat between transfer exhaust and

chemical reactions. Platinum is the most active catalyst and is widely used, but is not suitable for all applications because of unwanted additional

reactions and high cost. Palladium and rhodium are two other precious metals used. Rhodium is used as a reduction catalyst, palladium is used as an oxidation catalyst, and platinum is used both for reduction and oxidation. Cerium, iron, manganese and nickel are also used, although each has its own limitations. Reduction of nitrogen

PAINTING:
The corrosive nature of a metal used in a motor body construction,

necessitate the application of an anti corrosion coating. For this reason the painting should be done. It reduces the
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corrosion and protects the vehicle body, cleanliness and esthetic appearance. It is used to reduce the friction due to the aerodynamic drag and allow the vehicle in stream lining. For this event we used spray painting.

DVP REPORT:

COST REPORT:

INNOVATION
Electronic Component Interfacing Program statement: 1. Obstacle Detection and CruiseControl 2. Anti Theft Security System

GANTT CHART:

3. Anti Alcohol Drive 4. Seatbelt Automation

Block diagram:

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U SB D M A Microcontroller LPC 2148 is based on a 32-bit ARM7 having only two General Block Diagram of Electronic Interfacing ports-Port1 and Port2. CPU operating voltage range of 3.0 V to 3.6 V (3.3 V 10 %) with 5 V tolerant I/O pads. 1. Microcontroller (ARM-7) LPC 2148 Specification Chart:Type R O R A A D C C D Temp A eratur e Rang e Cl oc k In pu t LPC21 48FBD 64 5 1 2 32 2 1 ( 1 0 b -140 to +85 125 M H z 5V 100 mA

Input voltage

Input Current

M M

Kb (14 + cha nnel

K 8 b

Kb s) sh

(10b it )

are it) d wi th

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PIN Diagram of IC- LPC 2148

Block Diagram of Microcontroller Working: It will operate all electronic system which we are designing automatically as we program

2. Ultrasonic Ranging Module HC SR04 Specification:

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Electric Parameter: Working voltage Working Current Working Product Features: Ultrasonic ranging module HC - SR04 provides 2cm - 400cm non-contact Measurement function, the ranging accuracy can reach to 3mm. The modules Includes ultrasonic transmitters, receiver and control circuit. Dimension Basic Principle: Working: It will transfer and receive 1. Using IO trigger for at least 10s high level signal 2. The Module automatically sends eight 40 kHz and detect whether there is a pulse signal back. 3. If the signal is back through high level time of high output IO duration is the time from sending ultrasonic to returning. the ultrasonic waves and measure the distance between obstacle and vehicle and display it on 16X2 displays As well as in fog conditions we can see the obstacle is present or not on the path if present then it will displays it on display by which driver can take corresponding decisions. Frequency Max Range Min Range Measuring Angle Triggering Input Signal Echo Output Signal Input ITL lever signal and range in proportion 45 x 26 x 15 mm 4m 2cm 150 10uS IIL pulse DC 5 V 15mA 40Hz

Test distance = high level time velocity of sound (340M/S) / 2

3. MQ-303A Alcohol Detection Sensor:

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Specification: High sensitivity Fast response and resume Long life and low cost Miniature Size Application: Working

Configuration

The

MQ-303A

is

tin

dioxide

semiconductor gas sensor which has a high sensitivity to alcohol with quick response speed. This model is suitable for alcohol detection such as portable breath alcohol checker or ignition locking system in automobiles.

Technical Data:

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The change of the sensor resistance (RS) is obtained as the change of the output voltage across the fixed or variable resistor (RL). In order to obtain the best performance and specified characteristics, the values of the heater voltage (VH) circuit voltage (VC) and Sensitivity Characteristics load resistance (RL) must be within the range of values given in the standard Sensitivity characteristics of the gas sensors are expressed between the by the sensor operating conditions shown in the Specification table on the next page. Generally the sensor enters into normal working conditions after several

relationship

resistance and gas concentration. The sensor resistance decreases with an increase of gas concentration based on a logarithmic function.

minutes of pre-heating, If the sensor is connected to heater with a high voltage 2.2 0.20V for 5-10 sec before normal testing, the sensor shall stabilize and enter into normal working conditions quickly.

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4. Keypad Hex key pad is essentially a collection of 16 keys arranged in the form of a 44 matrix. Hex key pad usually have keys representing numeric 0 to 9 and characters A to F. The simplified diagram of a typical hex key pad is shown in the figure below. In this method a particular row is kept low (other rows are kept high) and the columns are checked for low. If a particular column is found low then that means that the key connected between that column and the corresponding row (the row that is kept low) is been pressed. Each person (max 5 persons) will given a PIN (which is also fed in the microcontroller). On entering the PIN the microcontroller will cross check and accordingly will let the person access the vehicle or deny the access if the PIN is incorrect. On entering the PIN wrong consecutively for three times a warning will be given either by LED indication or a buzzer alarm. 4. Display: Specification: LCD Display 16X2 When a particular key is pressed the corresponding row and column to
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which the terminals of the key are connected gets shorted. . The program identifies which key is pressed by a method known as column scanning.

TEAM SCREWDRIVERS
Working: Is will displays the pin which is entered by user on keypad to cross check As well as it will display the obstacle in fog conditions to user Seatbelts are used for safety of the driver as well as for passengers travelling in automotives. With

improvement in technology the safety of the passenger has also been kept into consideration due to which many new

5. Basic Electronic and Electrical components: Resisters Capacitors Inductors Wires Push Buttons X-OR gate ICS Bread Boards IC Case Power Supply Power Supply Plug OR gate IC LED Speaker Diodes Transistors Heat sink ETC

inventions have been made( from a normal seatbelt to four point harness or five point harness).With new

technology the seatbelt can also act as a switch (a mandatory section helping in the vehicle to start).The circuit

completion helps in the starting of the vehicle making it mandatory for the driver to wear the seatbelt while driving.

WORKING OF INNOVATION:

1. OBSTACLE DETECTION AND CRUISE-CONTROL (SAFETY)

This Seatbelt Automation Based

Innovation

Is

Completely

On Safety Of A Vehicle

Travelling In A Hilly Region Or In A Foggy Weather. In Such Situations Is Is Very Magnetic Seat Belt Difficult To Sense The

approachig Vehicle And This Results In Severe Loss Of Life And Property. To
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Tackle Such Condition We Innovated The Concept Of Obstacle Detection And Cruise Control. This System Consist Of A Ultrasonic Transmitter And Receiver. It Will Transfer And Receive The Ultrasonic Waves And Measure The Distance Between It Controls The Ignition Of Vehicle If The Driver Is Drunked. It Provides A Great Saftey Drive And Awareness For The Drivers Which Are Drunked. The MQ-303A Is A Tin 3. ANTI ALCOHOL DRIVE ( SAFETY ) A Buzzer System Is Used To Alert

The Surrounding . .

Obstacle And Vehicle And Display It On 16X2 Displays , As Well As In Fog Conditions We Can See The Obstacle Is Present Or Not On The Path If Present Then It Will Displays It On Display By Which Driver Can Take Corresponding Decisions.

Dioxide Semiconductor Gas Sensor Which Has A High Sensitivity To Alcohol With Quick Response Speed.

2. Anti Theft Security System (SECURITY)

This Model Is Suitable For Alcohol Detection Such As Portable Breath Alcohol Checker Or Ignition Locking

Now That If Vehicle

Another Important Point Is Your Vehicle Is Multi User I.E Many People Use The

System In Automobiles. The Range Of Sensor Is 20-1000ppm.

Vehicle , Then There Might Be Chance That Vehicle May Be Stolen Due To Some Or Another Reason Or

4. SEATBELT AUTOMATION ( SAFETY )

Unathorised Person Wants To Drive The Vehicle Then , Ther Might Be

The Most Important Thing While Driving Is Safety , And The Most Important Safety Gear Is Seat Belt . In India And Rest Of The World Drivers Genrally Dont Use The Seat Belt , Because Of Such Unaware Behaviour Accidents Takes Place Which

Chance Of Vehicle Breakdown. Thus Keeping This Innovated Point In Mind We

A Concept Of Anti Theft

Security System In Vehicle . A Hex Keypad Is Used To Check The Owner Or Authorised Driver . The Codes Are Pre Entered In The Micro Controller . If A Person Enters A Wrong Code Then

Ultimately Lead To Death .Thus Seat Belt Is Most Important . Keeing This In Mind We Have Innovated A Concept
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Of Seat Belt As An Ignition Switch . Unless And Until To Put On Your Seat Belt Your Vhicle Will Not Start . This Things Compels Drivers To Use Seat Belt While Driving .

CONCLUSION
When undertaking any design project there are several factors to be considered that are common to all engineering projects. A project must have a proper scope with clearly defined goal. Our team is participating for the first time in this event, so a comparative study of various

automotive systems is taken as our approach. With such an approach, engineers can come up with the best possible product for the society. We are also planning to conduct a customer needs survey to improve the vehicle further more. Anything being done for the first time, few difficulties are sure to come. Further improvements and a detail design of all other systems of the vehicle will lead to competitive vehicle. We hope to come with the best possible final product so that we will be one of the noticeable competitors in this years competition.

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