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BAJA SAEINDIA® RULES
Revision 0/2014 10th April, 2014
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Section 1 General Information Section 2 Vehicle Requirements and Restrictions Section 3 Roll Cage, Systems and Driver’s Equipment Requirements Section 4 Competition Procedures and Regulations Section 5 Technical Inspection Section 6 BAJA SAEINDIA Events Section 7 Appendices Appendix 01- Roll Cage Specification Sheet Appendix 02- Local Technical Inspection Rules Appendix 03- Code of Conduct Appendix 04- Virtual BAJA SAEINDIA Appendix 05- Design Report Format Appendix 06- Cost Report Format Appendix 07- Index Sheet for Process Cost Reference Appendix 08- Static Event Participation Sheet Appendix 09- BAJA SAEINDIA 2014 Scoring Appendix 10- BAJA SAEINDIA 2014 Awards Appendix 11- BAJA SAEINDIA 2014 Penalty Structure Appendix 12- BAJA SAEINDIA 2014 Contacts 3 6 15 40 43 48 57 57 58 60 61 64 66 69 70 71 72 73 74
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Section 1 – General Information
1.1 1.1.1 INDIVIDUAL PARTICIPATION REQUIREMENTS Eligibility Limits
Eligibility is limited to undergraduate students to ensure this is an engineering competition rather than a race. Individual members of teams participating in this competition must satisfy the following requirements:
Team members must be enrolled as degree seeking undergraduate student in a college or university. Team members who have already graduated prior to the competition (Feb. 2014) are NOT eligible to participate.
Team members must be members of SAE (Society of Automotive Engineers) or an SAE affiliate society. Proof of membership, such as a membership card, is required at the event.
Team members must be 18 (eighteen) years of age at the time of the competition.
Team members who will drive a competition vehicle at any time during a competition must hold a valid, government issued driver’s license. This will be required onsite for proof.
Liability Waiver All on-site participants and faculty are required to sign a liability waiver upon registering on-site.
Individual medical and accident insurance coverage is required and is sole responsibility of the participant.
FACULTY ADVISOR Faculty Advisor Status
Each team is expected to have a Faculty Advisor appointed by the university. The faculty advisor is expected to accompany the team to the competition and will be considered by competition officials to be the official university representative.
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faculty or professionals in the off-road and racing . testing or operation of the vehicle. maintenance.2. 3. may be penalized up to 400 points or even disqualified from the competition.1. The College / Institute needs to have at least 1 year of SAE India Collegiate membership before official registration for BAJA SAEINDIA 2014 for becoming eligible to participate.bajasaeindia.2 Responsibilities Faculty Advisors are expected to advise their teams on general engineering and engineering project management theory.3.3 1. designed and fabricated by the team members without direct /indirect involvement from professional engineers. The registration fee would NOT be returned in such case. The team captain or other designated members of the team must do all the presenting although Faculty Advisors may silently observe.org 4 | Page . In brief – Faculty Advisors may not design.3 Limitations Faculty advisors may not design any part of the vehicle nor directly participate in the development of any documentation or presentation.3. The decision of the organizers committee in this regard will be final. Also teams need to submit a list of facilities / equipments in operating condition with the college facilities which will be used to fabricate & assemble the vehicle as per design presented in virtual BAJA event. build or repair any part of the vehicle. www. Faculty Advisors may neither fabricate nor assemble any components nor assist in the preparation. 2. Proof of manufacturing location will be essentially required to be furnished by the teams on-site upon being so asked for by the officials. the video clips that covers students working in college facility need to be furnished in CD-Format during the College Level Technical Inspection. whose management gives an undertaking to allow them to use the workshop facilities. which have been professionally fabricated. The vehicle and associated documentation must be conceived.2 Professional Fabrication Limits 1. 1. 1. Faculty Advisors are not allowed to participate during technical inspection. During the actual manufacturing and fabrication process. Only those teams. Vehicles. 1.2. cost audit or design presentations. Extensive use of readymade subassemblies may invoke penalties.1 ELIGIBILTY – VEHICLES Student Created Undergraduate Engineering Student in India can participate in SAE BAJA 2014 event. would be allowed to participate without exception.
4 Top 10 Teams – Design Comparison Requirement Teams with vehicles that finished in a top ten position in any of the previous year’s Baja SAE INDIA competitions are classified as having created a “successful design”. but not limited to: New frame and/or roll cage design. Steering column. spring. or both. Steering gear box. Wheel rims & Tires. www. List of pre-fabricated parts allowed are – Shock Absorber. Master cylinder. Extensive use of readymade subassemblies may invoke penalties. Steering wheel. Brake calipers and brake holding assembly. Tie rod ends. Brake drum. new suspension design. Brake disc. then a penalty of up to one hundred (100) points may be assessed against the design score. Engine. (B) not supported by a detailed analysis or (C) have not been sufficiently documented. judges will evaluate the comparison documentation of the top ten teams.3 Prefabricated Subassemblies These rules do not exclude the use of prefabricated or modified sub-assemblies. 1. Fuel tank & Exhaust system . The redesign/design document may be in the form of either. Such teams are required to provide a comparison of their current design with their previous year’s design even if the current design is entirely new.1. Modifications are defined as.bajasaeindia. new drive train design or arrangement (gear ratio changes are NOT considered as drive train modifications). (A) posters or (B) report. Seat frame.complete assembly supplied from B&S to be used. As part of the design event.3. driver ergonomics and controls. All other parts need to be fabricated in house & not allowed to outsource from professional manufactures/ designers.org 5 | Page . If the judges find that the design changes are (A) not significant.
3 Eligible Teams . Similarly if the college has participated in 2013 event but not in 2014 event.org. The teams may be asked to collect their engines from specified locations. 2. but does not compete in a BAJA SAEINDIA event in 2013. the teams are needed to arrange all the transit requirements as required by the Transportation & Insurance Authorities. Please contact Briggs &Stratton and SAE INDIA if any team has www.2 Engine Eligibility Colleges/Institutes will be eligible to receive and use a new Briggs & Stratton engine in their THIRD participation only.bajasaeindia. Also.2 Maximum Vehicle Dimensions Width : 162.Vehicle Requirements and Restrictions 2. Three (3) wheeled vehicles are prohibited from the competition.4 kg (250 lb). www. Example: A college/institute that receives a new Briggs & Stratton engine in year 2012 for competition season of 2013 can participate in a BAJA SAEINDIA event in 2013 & 2014 with the same engine.2. then it can use the same engine for 2015 event provided its team qualifies the criteria of selection and is registered. It means the same engine can be used for 2014 & 2015 provided its team qualifies the criteria of selection and is registered. is not eligible to receive an engine in 2015. Example: A college/institute that receives an engine in 2012.org 6 | Page . It becomes eligible to receive a new engine only for the 2015 competition season if registered & qualified.2. at their own.3 cm (6’3”) tall weighing 113. 2. Engines are allocated on the basis of one engine per vehicle per two seasons of participation.32 cm (108 in) end to end: Recommended Vehicles exceeding the width will not be allowed to run in any event.1 Vehicle Configuration The vehicle must have four (4) or more wheels not in a straight line. 2.Receiving New Engines Teams that are eligible to receive a new engine must order online upon completion of registering the team for a competition. 2.56 cm (64 in) at its widest point: Mandatory Length : 274. “GO-NO-GO” device is made available by the organizers at the Technical Inspection area during the On-Site Technical Inspection to check the width (Section 5).2. Team pays for subsidized price and the shipping & handling charges.2 2.1. All such notifications would be made available on the BAJA website.Section 2 .bajasaeindia. The vehicle must be capable of carrying one (1) person 190. the Briggs & Stratton Corporation USA has generously provided engines to the BAJA SAEINDIA teams with charges.1 Required Engine Briggs and Stratton Engine: 10 hp OHV Intake Since last year.
1 Replacement Parts Only original equipment Briggs & Stratton replacement parts may be used. www.5 Shafts and Rods Camshaft.3 Engine Requirement and Restrictions To provide a uniform basis for the performance events. 2.2 Piston Rings Only standard size original Briggs & Stratton piston rings may be used.3.3. 2. This will prevent burning of wiring harness and HT Coil. connecting rod and flywheel must not be altered or modified. Before carrying any welding activity.trouble placing the engine order. 2.6 Spark Plugs Only RC12YC spark plugs must be used.New Engine having 3800 as the maximum rpm. 2.org 7 | Page . 2. all vehicles must use the same engine: a stock of four cycles. Eligible teams will have to pay the cost of engine & shipping as per SAE approved rate. Neither Briggs & Stratton nor SAE assume any responsibility for the delivery of engines. The Briggs & Stratton engine bearing the following part no.3. There is no special discount or purchase price for additional engines. 2. Intake angle must remain at 45 degrees. exhaust angle must remain at 45 degrees.bajasaeindia. crankshaft.3.3. air cooled.2. NOTE: Blueprinting (reworking an engine to a manufacturer’s exact specifications) is considered to be modification. it is recommended that the spark plug cable is removed and battery terminal cables are disconnected. Valves may be lapped to ensure proper sealing.4 Purchasing of Additional Briggs & Stratton Engines Teams may purchase additional Briggs & Stratton engines directly through their local Briggs & Stratton dealer.3. Transit Insurance can be separately born by team. is the only engine allowed for the BAJA SAEINDIA 2014 competition: 20S332 0036 . Briggs & Stratton OHV Intake Model. 2. 2.4 Valves – Clearance & Lapping Any valve clearance setting between tappet and valve stem – intake and exhaust may be set.3 Intake Ports No cleaning or removing of aluminum flashing from intake or exhaust ports may be done.
www. Any damage on account of failure to comply with the instructions would have to be borne by the team.This is a fixed carburetor.3. Idle Speed – Any idle speed adjustment: NOT ALLOWED. but Briggs & Stratton parts must be used to relocate the air filter: remote kits. The complete air intake system shall be located so that its extremities lie at least 100 mm within the perimeter of the vehicle. concept model & system need to be separately worked out for presentation during the event.9 Carburetor Carburetor . Carburetor Float . there is no need to change the mounting.7 Armature Any armature air gap setting is allowed.3. The supplied air hose may be shortened to a minimum of 152 mm (6. These parts must be included on the cost report.Carburetor float is non-adjustable and may not be re-adjusted.11 Exhaust System A. A fresh air cleaner element & paper filter are required during On-site Technical Inspection-Engine at BAJA SAEINDIA 2014. NOTE: Relocation of the air cleaner may decrease engine performance. No slotting or elongating of armature mounting holes to increase or retard ignition timing. 2. No other type of hose will be allowed. Carburetor Venturi .bajasaeindia.2. The teams may be required to submit proof of purchase. The filter should be located as close as possible to the engine. Muffler & Exhaust system Since B&S Engine is supplied with pre mounted exhaust system.3. 2. Details for GO GREEN Award will be separately put on the official BAJA SAEINDIA 2014 website. B&S recommends 1750 ± 100 rpm. Regarding GO GREEN Award.3. 2. A team may also add additional pre-filters (part number: 491435S) to the top of the air intake.3. Any changes made to the air filter will have to pass Briggs & Stratton inspection. re-jetting of the carburetor is prohibited.Modification of carburetor venturi is prohibited.org 8 | Page .10 Air Cleaner The air intake system should use a Filter from Briggs and Stratton recommended source. The decision of the Head of the Technical Committee of BAJA SAEINDIA / Briggs and Stratton personnel in this regard will be final and binding to all. 695329 – choke shaft and 699960 – air cleaner base (metal).8 Flywheel Rotation No flywheel rotation to advance or retard timing is permissible. This is in the interest of safety. The air intake may be relocated. 2.0 in).
However.12 Starter The Recoil Starter Rope may be extended to accommodate the driver starting the engine while being seated. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.3. Random inspection of the governor may be conducted at any time. 2. Any attempt to defeat the engine governor so as to increase the engine speed grounds for immediate disqualification.bajasaeindia. including endurance event.B. Exhaust system painting This is recommended but not compulsory. Briggs & Stratton part number 697326 Control Cover may be used or some other part with equivalent features.3. 2.org 9 | Page . This is in the interest of safety. The decision of the representatives of the engine manufacturer and/or the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.13 Alternator The engine is not configured for fitment with an external alternator to generate electrical energy.3. NOTE: The governor spring must be placed in hole # 6. The top 10 vehicles in the Endurance Event will be checked for the same. Governor area must be shielded from debris. Each governor will be set at the competition to a 3800 rpm or maximum speed.3. D. Electric start is not acceptable in any case even if it is from B&S standard parts. 2. Hence it is not permitted. Exhaust system complete The complete exhaust system exhaust system shall be located such that its extremities lie at least 100 mm within the perimeter of the vehicle. 2.15 Hybrid Electric Power Systems Hybrid electric power systems are specifically prohibited. if the fuel tank is to be remote mounted. GOVERNOR SETTING: NOT TO EXCEED 3800 RPM. Exhaust System – Durability Required The exhaust pipe and muffler must be completely intact and operational throughout the event.14 Engine Governor Each engine is equipped with a governor. C. The governor operation must remain free of obstructions at all times. The stock configuration of fuel tank mounted to the engine is acceptable for debris management. www. a debris shield covering the exposed governor area is required. and shall be grounds for penalty or disqualification if not intact at the end of any event.
hydraulic accumulators must be at zero energy at the start of each event. Queries regarding the engine and related peripherals may be addressed to engine. NOTE from B&S: B&S will Provide support. Failing this.5. safety items and other instrumentation). it must. The battery must be safely placed & concealed. The mounting of battery must prevent the battery from coming loose during a roll over & must be enclosed from the exhaust and the fuel system. for any reason.7 Engine Use Restriction The B&S staff on-site is empowered to make final decisions regarding the condition and set-up of all engines. 2. It is expressly prohibited to operate the vehicle by using power from an on-board battery. There should not be any positive contact with the exhaust unit of the fuel system. Hydraulic power systems must be properly shielded and documentation of the shielding made available for review.1 Electronic Controls Electronic control of suspension and transmission systems is allowed.org 10 | Page .firstname.lastname@example.org Engine Use Restriction Briggs & Stratton generously provides engines to the teams for the exclusive purpose of use on their BAJA SAEINDIA vehicle. the teams may be charged for the repairs or for procuring a new engine in place of the damaged engine. the technical inspectors may debar the team from the dynamic events. Teams without the approval may be penalized as per the decision of the Head of Baja Technical Committee. No components/spares shall be installed without consulting B&S authorities or the organizer committee member.3. 2. any modifications must be approved by the Technical Inspectors prior to the vehicle returning to the competition.16 Energy Storage Devices Used for Propulsion Hydraulic accumulators are the only type of stored energy device that may be incorporated into the vehicle for propulsion purposes. www. If employed. data acquisitions. brake light. The power can be from the approved battery. 2. If.org. or as specified in the manual supplied by B&S. return the engine to SAE or Briggs & Stratton.2. 44 Ah 2.bajasaeindia. a team receives an engine and at a later date decides not to participate. if it is observed that the damages to the engine are caused due to team’s negligence in handling/ installing/ running the engine as per the specified directions given by B&S. reverse light & beeper.6 Component Failure In the event of a major component failure during the course of the event. 2. Recommended Battery: 12 V.5 Battery Requirements The battery/batteries can only provide power to accessories on the vehicle (horn. at its own expense. however.
11 TOWING HITCH POINT Each vehicle must have towing hitch points at the front and rear.1. into a position where it will not affect anything during a front-end collision. Reverse alarm is not mandatory however it is recommended to be installed for safety reason which shall operate when the reverse gear is engaged.11.Teams can plan to install reverse gear for reverse drive of vehicle. or (b) A hitch plate complying with the requirements of Section 2. visible at a minimum distance of 10 meters from vehicle). The adapter for Engine & Transmission is to be designed and installed by students as per the type of transmission used.2. 2.org 11 | Page . Engine drive / output shaft side details are available on BAJA SAEINDIA official website.1 Front Hitch Point The front hitch point may be either: (a) A tubular front bumper strong enough to lift the weight of the car with no permanent deformation and having a maximum outside diameter of 25.bajasaeindia. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.11.4 mm (1 in) to which a clevis can be centrally attached. lever and shifting mechanism are installed at such locations which will not be hindrance for driver and his safety.19.2. Continuously Variable Transmission (CVT) is also permitted with appropriate shielding as in Sec 3. Teams need to safely install gear shifting cables.8 Transmission Teams are free to use any transmission. Figure 1.10 Front Bumper A tubular front bumper is MANDATORY for the safety requirement of the vehicle. such that maximum speed of the vehicle on a plain terrain is recommended to be no more than 60 km/hr in top gear. 2. 2.EXAMPLES OF ACCEPTABLE FRONT HITCH POINT www.9 Reverse Light and Alarm It is mandatory that each vehicle should be equipped with a reverse light (Amber color. which is designed to fold or pivot. 2. along its longitudinal centerline.
4 mm (1 in) Radial clearance Maximum from hole .Hitch Plate Specs 2.54 cm (1 in) and must strongly contrast with the background vehicle color.12 Vehicle Identification Each team is responsible to display its vehicle’s number as either a silhouette or stencil form cutout at least 203 mm (8 in.54 cm (1 in. The numbers must be clearly visible from both the front and rear sides of the vehicle.4 mm (1 in) Hole to tube Minimum clearance – 19.) high & have a minimum line width of 2.9.).75 in) Figure 3 .11.org 12 | Page .2 Rear Hitch Plate Requirements – Towing plate Maximum thickness . damaged or obscured may not be scored and may be black flagged.0 mm (0.bajasaeindia.25.3 cm (4 in) high. If a vehicle’s numbers are illegible then it may not be scored. www. This must form a pyramid shaped structure situated at the top of the vehicle.25.5 mm (0. Only stickers are allowed.375 in) Hole diameter Minimum . Painted-on numbers or stencils/decals mounted flush to a body panel will not be allowed. missing. These numbers must be at least 20. cars with numbers that are hard to read.Figure 2 . The numbers must allow mud to shed during dynamic events.EXAMPLES OF UNACCEPTABLE FRONT HITCH POINT (CUT-OUTS / PIVOTS) 2. Vehicle Number – Body All vehicles must display their assigned number in block numerals on the front and both sides. Assigned numbers may be found on the Baja SAE India website in the “registered team list” after final registration. have a minimum line width of 2.
in roman characters.12.1 Number Location These numbers must be affixed to the upper sides of the frame between the rear support and the rear roll hoop. at the centre of the side panels. at the firewall (Figure 4).org 13 | Page . 2. The numbers must be in the vertical plane of the side of the car and also on the rear of the vehicle on the plane containing the upper FABs (Figure 4). on each side in characters at least 2. Teams may display advertising from their vehicle’s sponsors. These will be distributed during registration at the event site. These are required to be pasted on both sides of the vehicle.5 cm (1 in) high and 1 cm (0. 2.Figure 4 – Number and Logo Placement 2. SAEINDIA logos would be provided to the teams at the event site only. provided it is in good taste and does not conflict with the vehicle’s number. and above the head of the driver.4 in) wide.12.3 Event Sponsor Logos Sponsor’s logos must be displayed in a prominent space on each side of the vehicle (Figure 4). www.2 College Name All vehicles must display their college name or initials.bajasaeindia.12.
Figure 5 – Transponder Figure 6 – Transponder Mounted It is the team captain’s responsibility to design a secure and safe mounting for the transponder at given location and acceptable method (Fig.bajasaeindia. The bracket needs to be attached with M4 size Pan/ Flat head bolts with lock nuts or fixed by strong wire. (1) Orientation . 2.13 Transponders One transponder as shown (Figure 5) is provided to each team on last day during the endurance event at no cost for the event purpose.2. (3) Unobstructed –No obstruction between the antenna on the bottom of the transponder and the ground.org 14 | Page .2 Transponder Black Flag If. so that the purpose of counting laps is not defeated. Metal and carbon fiber may interrupt the transponder signal. 2.13. The plate needs to have 4 holes of 4mm diameter at 50mm pitch in x-direction and 20mm from top and bottom side equally spaced. It’s essential to ensure the signal transmitted by transponder is read by timing system. 6) and returning at the end of endurance run. for any reason. relocation or replacement.13. This is essential to use for endurance event for counting the laps during endurance run. www. The transponder must be mounted on the driver’s right side forward of the seat (2) Location –no more than 61 cm (24 in.1 Transponder Mounting Teams need to make a sheet metal plate of size 100mm x 60mm x 2mm to be attached as a mounting bracket from outside SIM at RH side of the vehicle. Team & driver need to be carefully observing such flags & must respond promptly. The transponder mounting requirements are: The provision for fitment of transponder is essential to fix it in right position so that it does not come out due to bumps or shaking of vehicle.) above the track. a car’s transponder signal is not being received by the timing system.The bracket must be mounted vertical to the frame. then the car will be black flagged for transponder repair. (4) Protection – Mount the transponder where it will be protected from obstacles.
2.3. The driver’s helmet to be 152 mm (6 in) clearance to the top of roll cage. Teams may be penalized with a minimum deduction of 50 to the maximum of 200 points subject to the modifications done on vehicle.bajasaeindia. DRIVER DEFINITION.2 Lateral Space The minimum space is based on clearance between the driver and straight edge applied to any two points on the roll cage.org 15 | Page .3 3. Systems & Driver’s Equipment Requirements 3.3.2 Unstable Vehicle Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical inspectors will not be permitted to participate in the dynamic events. it is defined by the outside edges of the roll cage members less the padding installed. 3.For the purposes of this section "driver" refers to the team's largest driver and the 95-percentile male properly suited and wearing a helmet. and hands. No modifications in the design would be allowed after the conclusion of static events. The driver’s shoulders. thighs. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. shall have a minimum of 76 mm (3 in) of clearance from the envelope created by the structure of the car. hips. arms elbows. knees. 1. This is in the interest of safety of all teams. The cage must be designed and fabricated to prevent any failure of the cage’s integrity. NOTE : When minimal dimensions are given that is to the centerline of the members. torso. www.1 Modifications at Last Minute Once the Technical Inspection check is approved and stickers are issued for the vehicle indicating cleared for Static & Dynamic event. In case of any teams found doing changes/ modification in system will be disqualified/ penalized for such last minute changes in vehicle.Section 3 . All installations and construction are required to be intact as in approved condition by technical inspector. 3. It should be large enough for accommodating hefty & tallest member participating in a team in driving position. 3. teams need to participate with the vehicle without any modifications/ improvements.1 ROLL CAGE Objective The purpose of the roll cage is to provide a minimal space surrounding the driver and to support all subsystems.Roll Cage. and when a clearance for the driver is given.
Also. www.1 Elements of Roll Cage Roll cage must be space frame of tubular steel. Secondary Members – NOTE: Secondary members must be steel tube having minimum wall thickness of 0.18%. and are not considered to make a member not-straight.035 in) and min outside diameter 25.bajasaeindia. No holes are allowed to be drilled on the roll cage tubing. NOTE: Required dimensions between roll cage members are defined by measurements between member centerlines.3.89 mm (0.] Rear Roll Hoop (RRH) Rear Hoop Overhead Members (RHO) Front Bracing Member (FBM) Lateral Cross Member (LC) Front Lateral Cross Member (FLC) B.3. no tube should show any cracks or deformation.org 16 | Page .6. Final judgment rests with the Head BAJA Technical Committee.3. Lateral Diagonal Bracing (LBD) Lower Frame side (LFS) Side Impact Member (SIM) Fore / Aft Bracing (FAB) Under seat Member (USM) All other required cross members.1. Roll cage members which are not straight must not extend longer than 711 mm (28 in) between supports. Primary members – NOTE: The primary members must conform to Section 3. The required members of roll cage are – A.4mm (1 in). except where noted. All Roll cage members having a bend radius > 15.3.120 in) and a carbon content of at least 0. Small bend radii (<152 mm/ 6 in) at a supported end of a member are expected.1cm (28 in) unsupported. Any tube used to mount safety belts.3 Roll Cage Structure 3.2 cm (6 in) may NOT be longer than 71. The minor angle between the two ends of a notstraight tube must not exceed 30°. [Circular steel tubing with an outside diameter of 25mm (1 in) and a wall thickness of 3 mm (0.
The driver’s seat may not intrude into the plane(s) of the RRH.7 cm (5 in) above point AR or AL respectively.3.6 cm (27 in) above the driver’s seat (H-point of driver). (Sec. 3. The top and bottom intersections of the LDB members and the RRH vertical members shall begin at a point along the vertical portion of the RRH within 12. The RRH must be a minimum of 73. The RRH is substantially vertical.2 Rear Roll Hoop (RRH) The RRH is a structural panel behind the driver’s back. Figure 7 NOTE: The RRH will have an additional member for seat belt mounting. Lateral bracing may consist of more than one member.3 Rear Roll Hoop Lateral Diagonal Bracing (LDB) The RRH must be diagonally braced.3.org 17 | Page .6 cm (29 in) wide at 68.3. This is for the purpose of ascertaining the thickness of the Roll Cage Tubing. but may incline by up to 20 deg from vertical from points A to points B towards rear side in parallel with seat backrest. no break vertical members This may be one continuous hoop/tube. The RRH is made up of a maximum of four sections: two LCs at highest and lowest points and two continuous. The driver and seat must be entirely forward of this panel.12. (Figure 8) The angle between LDB members and RRH vertical members must be greater than or equal to 20 deg. The diagonal brace(s) must extend from one RRH vertical member to the other.3.3.bajasaeindia.7 cm (5 in) vertically of point BR or BL and extend diagonally to a point no farther than 12. 3.3) An extended portion of primary tube of length 2. www.54 cm (1 in) is needed to be welded at a convenient area on RRH so that it must not interfere with any body part and must not foul with any vehicle component (preferably rearwards). and defines the back side of the roll cage.
5 Lower Frame Side members (LFS) Lower frame side members defines the lower right & left edges of roll cage & joins RRH LC and the points forward of the driver’s heel to a front lateral cross member (FLC). in the vehicle’s elevation view.Figure 8 3. This point on the seat is defined by the seat bottom intersection with a 10. Figure 9 Figure 10 3. defined by the intersection of the RHO member and a vertical line rising from the after end of the seat bottom. Points CR and CL must be at least 30.3.3.bajasaeindia. The top edge of the template is exactly horizontal with respect to gravity. (Figure 10) www.5 cm (12 in) forward of a point.1 cm (4 in) radius circle which touches the seat bottom and the seat back.4 Roll Hoop Overhead members (RHO) The forward ends of RHO members (intersection with the LC) define points CR and CL (Figure 10).3.org 18 | Page .3.
org 19 | Page . NOTE: Every driver’s feet must be behind the plane created by points AF RL and SF RL. The USM must pass directly below the driver where the template in RC3 intersects the seat bottom. The SIM must be between 20. with no break) must join RHO. (The intention of this is to protect the driver’s feet from a tire intrusion). 3. L is below the driver’s toes then an additional LC must run between the FBM members above the driver’s toes. If the LC between SF R.3.8 Front Bracing members (FBM) Front bracing members (continuous.bajasaeindia. The lower Front Bracing Members (FBM LOW) must join points AF to points SF.3 cm (8 in) and 35. The FBM must be continuous tubes.3. The USM must be positioned in such a way to prevent the driver from passing through the plane of the LFS in the event of seat failure.3.3. 3.6 cm (14 in) (as measured vertically) above the area of the seat in contact with the driver (Figure 9).3. These members are joined to the RRH at points S and extend horizontally to points SF forward of the driver’s toes (Figure 10). The upper Front Bracing Members (FBM UP) must join points C on the RHO to the SIM at or behind points SF. SIM and LFS (Figure 11).6 Side Impact members (SIM) The two Side Impact Members define a horizontal mid-plane within the roll cage. Figure 11 www.3.3. The angle between the FBMUP and the vertical must be less than or equal to 45 degrees.7 Under Seat Member (USM) The two LFS members must be joined by the Under Seat Members.
The hoop must be braced on both right and left sides.3.3. The angles of the triangulation must be minimum 20 degrees.1.restrain both points C from longitudinal and vertical displacement. but may be formed using multiple joined members. have length at least 3 times the tube diameter and have a minimum thickness of 3.bajasaeindia. include the RRH vertical side as a member. Front Bracing Front systems of FAB must connect the FBMUP members to the SIM members (on the same sides).3. and have one vertex near Point B and one vertex near either Point S or Point A. The intersection with the FBMUP members must be within 127 mm (5 in) of points C. Better design will result if both front and rear bracing are incorporated. on each side of the vehicle. is not part of the structural triangle. Attachment of rear system FAB must be within 127 mm (5 in) of Point B.6 cm (40 in) between attachment points. From a side view. in the elevation view. In the plan view. The intersection with the SIM members must be vertically supported by further members connecting the SIM members to the LFS members. Rear Bracing Rear systems of FAB must create a structural triangle. and this assembly of tubes. and is subject to 3.2 mm (0.3. A bent tube cannot exceed 81. Gussets shall be made of steel plate. The third (after) vertex of each rear bracing triangle must additionally be structurally connected to whichever point. Each triangle must be aft of the RRH.org 20 | Page . S or A.13 in) The gussets shall be welded to the sides of the tubes and not directly in the plane of the tubes making up each joint (Figure 12). This additional connection is considered part of the FAB system.3. 3. the rear bracing structural triangles must not be angled more than 20 degrees from the vehicle centerline. The after vertices (right/left) of the FAB structural triangles must be joined by an LC.directly restrain both points B from longitudinal displacement in the event of failure of the joints at points C. thus supporting points B through the RHO members. a gusset is required at point C. from endpoint to endpoint.4 RHO/FBM Gusseting If the RHO and FBM are not fabricated from a continuous tube.3. www. may encompass a bend of greater than 30 degrees. with the maximum length of 101.9 Roll Hoop Bracing (FAB) The RRH must be restrained from rotation and bending in the elevation plane by a system of triangulated bracing. the bracing must be triangulated. Bracing must be either: 1) Rear Bracing . be triangular from a side view. or 2) Front Bracing .3 cm (32 in) between attachment points. and must be within 51 mm (2 in) of points S and A.
e. Right . 3.1 (excluding the required no break members described in 3.5 Butt Joints All butt joints within any of the elements on the roll cage listed in section 3.3. NOTE: Only students are to perform welding on the as-built vehicle i. 3. external sleeves are not allowed).3.4 and 3. The sleeve must be designed to tightly fit on the inside on the joint being reinforced (i. Each team must submit two (2) samples for each roll cage welder. any person that performs welding of the roll cage welds of the as-built vehicle may be asked to demonstrate their welding skills during technical inspection at college level. www. must extend into each side of the sleeved joint.3.Figure 12 Left – Gusseting required at point C.bajasaeindia. should be subject to destructive testing causing the joint to fail to which indicates superior weld strength with respect to the base material. The sample should be sectioned along the length of tube to reveal adequate and uniform weld penetration (Figure 13c).3. (Figure13a) Sample 2 – Destructive Inspection: A structure made up of roll cage material that has two tubes attached at a 30 degree angle with a length of at least 15cm from the center of the weld joint (Figure 13b).3.Gusseting NOT required at point C.188.8.131.52 Weld Confirmation Checks Teams must conduct weld confirmation testing for each welder that welds their vehicle roll cage. a length of at least two times the diameter.3.3. the length of each tube to be determined by the team. 3. the vehicle presented at technical inspection and roll cage welders i.e.e.8) must be reinforced with a welded sleeve.org 21 | Page .3. both of which are constructed of roll cage material which have been welded with the same tools and processes as those of the as-built vehicle and which have also been subject to the following destructive testing and inspection: Sample 1 – Destructive Testing: A structure made up of roll cage tubing welded at a 90 deg.
then no need to include a separate one. This must be submitted during Technical Inspection at college level.(a) (b) Figure 13 (c) Final judgment of weld strength with respect to the base material as it described in Sample 1 and the adequacy and uniformity of weld penetration as described in Sample 2 shall rest with the national technical inspectors. as defined below.5 cm (1 in) away from the helmet in the uncompressed state.1 cm (41 in).5 Driver Head Clearance Minimum driver head clearance = 104. All the teams need to take 10 min video shoot while 1) fabricating frame & 2) assembly of complete vehicle with the college premise & covering other facilities of college & team student working on vehicle.org 22 | Page . The head restraint must meet the above requirements for all drivers. Minimum area = 232 sq. Welding samples constructed of material other than the roll cage material and / or welded with a process other than that of the roll cage welds of the as-built vehicle shall not be considered sufficient demonstration of welding skill and craftsmanship with the tools.4 Head Restraint A head restraint must be provided on the driver seat / fire wall to limit rearward motion of the head in case of an accident. Note: Frames that were constructed in a previous year will need to have samples welded by that welder or remove two sections of the current frame and perform the tests on these components. Minimum vertical www.Minimum thickness = 3. 3. located no more than 2.bajasaeindia. shall not be eligible to compete in any dynamic or endurance event.8 cm (1.5 in). Teams unable to submit welding samples of adequate quality. 3. NOTE: If the head restraint is already a part of the seat. cm (36 sq in). padded with a closed cell foam (density of 50 100 kg/m3). processes and roll cage material. above the seating surface to the bottom of the upper roll cage tubes measured vertically using the template in Figure 14. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.
1 Roll Cage & Bracing Materials The material used for the Primary Roll Cage Members must be: A.2 The bending stiffness and bending strength must be calculated about a neutral axis that gives the minimum values.57 mm (0.bajasaeindia.6. The wall thickness must be at least 1. 3. All calculations must be in SI units. Circular steel tubing with an outside diameter of 25 mm (1 in) and a wall thickness of 3 mm (0.6 3. A steel tube with bending stiffness and bending strength exceeding that of circular steel tubing with an outside diameter of 25 mm (1 in) and a wall thickness of 3 mm (0. OR B.062 in).clearance = 15.6.18%. Calculations must be presented at Technical Inspection which proves sufficient bending stiffness and bending strength.120 in) and a carbon content of at least 0.2 cm (6 in) must be provided from the helmet top of the team’s tallest driver to the bottom of the roll cage top tubes or members.120 in) and a carbon content of 0.org 23 | Page . Invoices or other evidence of the properties of the roll cage materials must be attached to the calculations. Bending stiffness is considered to be proportional to the product EI where: E I : : Modulus of elasticity (205 GPa for all steels) Second moment of area for the structural cross section Bending strength is given by: where: Sy : ௌ௬ூ Yield strength (365 MPa for AISI 1018 Steel*) www.18%. regardless of material or section size. Figure 14 3. Calculations must be performed using three significant figures to the nominal tube sizes as specified by the invoice.
7 Roll Cage Specification Sheet: Each team must present a completed BAJA SAEINDIA Roll Cage Specification Sheet (Sec 7. clamps. fastener ends. Appendix 1) at Technical Inspection. zip ties or other features accessible during servicing.38 Nm 3. (B) Flange mounts must be twice (2X) the diameter of the attached tubing. Side Impact Members and the seat must be maintained. Inspectors shall measure this dimension as per the Technical Inspection Sheet. The load shall not be transferred to the firewall or any other member except those supporting the seat clearance of 75 mm (3in) between the firewall.2 cm (0.10. crew. gussets.10 COCKPIT 3. parallel and on each side of the tubing to which they are welded. Any vehicle not meeting this requirement shall not be allowed to take part in any events. This includes brackets. Recliner Seats are not allowed. (C) Tab mounts must be dual. Tubing held by bolts must be reinforced such that the area through which the bolt passes cannot be compressed from tightening or impact. The use of commercially available rally seats is highly recommended.8 Roll Cage Padding Any portion of the roll cage.org 24 | Page . and with no gap between the faces greater than 0. officials and safety staff must be eliminated by shielding and/or padding.07 mm (0. cushioning or padding attached to the frame and/or firewall will not be accepted as a seat. Both copies must be presented during Tech Inspection at College level and Final Check at event site. www. must be covered by a resilient foam material such as Polyethylene® (pipe insulation) with a minimum thickness of 1.9 Bolted Roll Cages Bolted Roll cages are acceptable only if the following requirements are met: (A) Flanges or tabs must be twice (2X) the thickness of the tube structures.003 in). flush mated. having a welded length of at least twice (2X) the diameter of the adjoined.5 in). made of the same material type. 3. 3.C : Distance from neutral axis to extreme fiber *Bending Strength of AISI 1018 Steel (for tube dimension of Sec.1 Driver’s Seat The use of a driver seat is mandatory.6. 3. They must be properly welded to each tubing part to be joined. NOTE: Latest Material Specification Check Report is essential for used material. The seat shall be fastened to the frame and shall support the entire body of the driver (full torso and head). All sharp edges which might endanger the driver. which would be contacted by the driver. 3.bajasaeindia. While procuring tube one should get copy of tube specification and also ensure this is certified from local laboratory. judging or competition impact or roll over.1 A) = 387. sheet stock.
25 in). These panels must be made of plastic. then a firewall is not required to cover the area between the RRH lateral cross members.1 “Power train Guards”). (F) The exhaust must not exit towards the driver and must be shielded. at least 0.org 25 | Page . Shielding must meet guarding requirements. hands in driving position on the connected steering wheel.3 “Spill Prevention”) (C) Engine must be completely enclosed and protect the driver in the event of an engine failure. . Instead. This firewall must be metal. Front or Mid-engine Cars If the engine is not placed in the rear of the vehicle. (B) Splash shields/ Drip Pan must prevent fuel from being poured anywhere in the cockpit area during fuelling. Body Panels The cockpit must be fitted with body panels that cover the area between the lower frame side member and the side impact member.508 mm (0. NOTE: Engine enclosures must prevent fuel from spilling onto driver area during any vehicle upset. It must cover the area between the lower and upper lateral cross member. (G) There must be a place to mount the Technical Inspection sticker (30cm x 30cm or 12 in x 12 in) on the RRH. (See rule 3. No gaps can exist that are larger than 6.bajasaeindia. (E) Driver must be able to still egress from either side of the vehicle. but they need to have grommets or boots that prevent large amounts of fuel from getting into the cockpit.35 mm (0. Exit time will stop when the driver has both feet on the ground. the firewall must meet the following standards: (A) Fuel tank must be in a sealed container that prevents fuel from leaking in the event of fuel tank failure. They must be designed to prevent debris and foreign object intrusion into the driver compartment. www.10. Exit time begins with the driver in the fully seated position.Driver Exit Time All drivers must be able to exit on either side of the vehicle within five (5) seconds. Cutouts in the firewall are allowed. (D) All engine compartment venting must be directed away from driver area. metal or similar material. The firewall is recommended to be behind the RRH. fiberglass. It must be located on the driver’s right side above the shoulders in easy view of track workers. This shielding must be made of metal. (See rule 3. and wearing the required driver equipment.020 in) thick.2 Firewall A firewall between the cockpit and the engine and fuel tank compartment is mandatory.19.16. 3.
15 . Kill Switch – Type The kill switch must be one of the following types: a) 01-171 Ski-Doo kill switch available at http://www.com/index.The machined block www. Fig. Kill switch which operates by “Push-to-Off” is only allowed to use on Baja Vehicle.25 in). from coming in contact. 16 .3 Belly Pan and Leg/ Foot Shielding The cockpit should be fitted with a belly pan (minimum length being the cockpit). No gaps can exist that are larger than 6. Rotary switches or Pull-to-Off type switches are not allowed. or becoming entangled during operation or a failure. A.10. However Brake light.The panels must be mounted securely to the frame using sound engineering practices NOTE: Zip ties and Velcro are not acceptable.The welded metal tabs Fig.com/m/c/01-171.bajasaeindia. All steering or suspension links exposed in the cockpit must be shielded with metal.parkeryamaha.mfgsupply. Reverse light and Reverse Alarm should not be switched off by use of Kill switch. 3.10. 3.35 mm (0.org 26 | Page . The shielding must prevent the driver’s legs and feet (completely within the roll cage).html?id=UxSI4Vzn b) AfterMarketWPS#27-0152 or 27-0124 http://www.asp?PageAction=PRODSEARCH&txtSearch=270152&Page=1 c) A Stock Polaris # 4110106 Sample Mountings NOTE: The kill switches need to be mounted (bolted or riveted) using the outer cases. so the driver cannot contact the ground and is protected from debris while seated normally.4 Kill Switches Each vehicle must be equipped with two (2) easily accessible kill switches to push off the ignition and the entire electrical system of the car. If they are mounted using adhesive on the back cover the switch will fail constraining the switch.
Fire extinguishers must be labeled with College name and vehicle number. All fire extinguishers must be equipped with a 2013 manufacturer installed with dial pressure gauge. The final authority of suitability of any other kill switch is left to the discretion of the Technical inspectors. NOTE: In case of either/ both switches in close condition. One must be mounted in the cockpit below the driver’s head.6 Throttle Only foot operated throttle controls are allowed. with the top half above the side impact member on the right side of the firewall and be easily accessible by course workers.10.Fig. Kill Switch – Locations and Orientation (a) Cockpit Switch – In the front of the cockpit within easy reach of the driver when strapped into the seat. A wide-open throttle stop must be mounted at the pedal. The switch must be within easy reach of track workers.Schematic for Kill Switch Mounting The Kill switch is primarily safety device to stop engine in case of fire or any type of accident. 18 . 3.org 27 | Page . www. The switch may not be mounted on a removable steering wheel assembly.bajasaeindia.10. The team and track volunteer at event will be required to follow unique convention of stopping engine in such case only by following up “Push-To-Off”. (b) External Switch – The external switch must be mounted on the driver’s right side of the vehicle. Hence any deviation from the kill switch specification will not pass technical inspection & team will be disqualified. B.8 mm (7 in) vertically below point BR. and behind the plane of the main roll hoop (Figure 17 & 18). engine should not get start. on a panel perpendicular to the firewall between RRH and Rear Bracing within the red area. The gauge must be readable by the Technical Inspectors. 3.5 Fire Extinguisher – Size and Location Each vehicle must have two identical fire extinguishers (minimum capacity = 1 liter) with an ISI rating. The second must be brought to technical inspection with mounting accessories. Cars having hand operated throttle will not be allowed to start any event. 17 – Actual mounting Fig. The switch cannot be more than 177.
However.bajasaeindia. (Figure 19) www.g.2 Release Mechanism All belts must join with a single metal-to-metal quick release lever type buckle. It should run directly from mounting to driver’s shoulder without twist & redirection by any part of vehicle. The team should show the SFI rating during inspection. it is strongly recommended to use a 5 point restraint harness meeting the following specifications. preventing the lap belt from riding up along the driver’s torso. All driver restraint systems must meet either SFI Specification 16.11 DRIVER RESTRAINT 3.5/16. “Y”-type shoulder straps are not allowed). The belts must bear the appropriate dated labels. and on 1st Jan of the competition year be no more than three years old. No more than a finger width gap between the belts and the driver will be allowed when the belt is pulled.11.e.1 Vertical Location The shoulder belts must NOT be mounted above the shoulder level. The restraint system installation is subject to approval of the Technical Inspector. 3. The straps shall not pass through anything that will cause the center distance to be less than 178 mm (7 in) from center to center of the strap. along with a fifth (anti-submarine) belt must be worn between the legs. A five-point system consists of a 76 mm (3 in) wide lap belt and approximately 76 mm (3 in) wide shoulder harness straps.11. 3. if required along with the bill.12.org 28 | Page .3 Safety Harness Expiration The material of all straps must be Nylon or Dacron polyester and in new or perfect condition.12.Throttle Extensions Teams may not add any type of extension (e. The straps shall not pass over anything that causes them to be more than 229 mm (9 in) apart center to center.2 Lateral Spacing The shoulder harness mounting points must be between 178 mm (7 in) and 229 mm (9 in) apart (Figure 19).1 Minimum Four Strap System Required All drivers must use a minimum of a four (4) strap restraint harness.12 Shoulder Harness The shoulder harness must be the over-the-shoulder type. (Figure 20) 3. No cam-lock systems are allowed.11.1 or FIA specification 8853/98 or ISI marks. Only separate shoulder straps are permitted (i. 3. and must be no more than 102 mm (4 in) below the perpendicular from the spine to the seat back at the shoulder level. blocks of wood) to either the control surfaces or to the driver in order to operate the vehicle. 3. Shoulder belt must be entirely on cockpit side of fire wall and be protected by fire wall. 3.
as long as no open gaps result.3 Harness Attachment Points The shoulder belts must be looped around a horizontal tube welded within the RRH that meets the Roll Cage Secondary Member requirements of Rule 3.Vertical Location Fig. 20 . the shoulder belts must be laterally constrained when passed through the seat. The firewall must protect the entire shoulder belt.3. In any case.Lap belt specification Fig. Lateral motion of the belts along their mounting tube must be restrained (Figure 23).3.1.org 29 | Page . Figure 23 www. The firewall may be pocketed to facilitate this. 19 . 21 . 22 – Lap Belt Anchoring Method 3.Fig.Distance of shoulder point Fig.bajasaeindia.12.
The mount should not exhibit noticeable deformation when pulled on during technical inspection. but ultimately subject to the judgment of the Technical Inspectors. the driver’s arms must be kept within the limits of the cockpit. in a way that the driver’s hands do not come out of the cockpit. The lap belts should not be routed over the sides of the seat.3 mm thick (0. To fit drivers of differing statures correctly. In side view. 3. 3.25 in) of material in the radial direction from the edge of the mounting bolt hole to the closest outside edge of the mounting tab. the lap belt must be capable of pivoting freely about the axis of the mounting bolt such that the webbing and tab can align with the direction of the load.14 Arm Restraints In the event of a rollover. The final decision in this regard rests with the technical committee head. The arm restraints must independently connect to the safety belts. the vehicle will not be cleared for Technical Inspection. NOTE: If the belts do not have enough adjustment capacity or improperly fitted.3 are allowed.3.bajasaeindia. (See Figure 22) 2) The frame tabs that accept the lap belt tabs shall be no less than 2.5 in) of weld length where mounted to the frame 4) These tabs shall have no less than 6. in side view.1 Specified Lap & Anti-Submarine Belts Mounting The frame tabs which accept the lap belt mounting tabs must meet the following requirements: 1) The lap belt tabs must be mounted in double-shear.13. 5) Where the harness tab mounts to the frame tabs. The lap belts should come through the seat at the bottom of the sides of the seat to maximize the wrap of the pelvic surface and continue in a straight line to the anchorage point.13 Lap & Anti-Submarine Belts The lap belt must pass around the pelvic area below the Anterior Superior Iliac Spines (hip bones) (Fig. the lap belt must be at an angle of between 45 degrees and 65 degrees to the horizontal. the lap / anti-submarine belts must be capable of pivoting freely by using either a shouldered bolt or an eye bolt attachment (Figure 22).4 mm (0. This means that the centerline of the lap belt at the seat bottom should be approximately 76 mm (3 in) forward of the seat back to seat bottom junction (see Figure 21). Arm restraints must be securely fastened to the driver restraint system. Mounting lap belts by wrapping them around frame tubes is no longer acceptable unlike the case of Shoulder Harness. Only commercially available arm restraints meeting SFI 3. The height of the tab is free. Figure 24 www.org 30 | Page . Under no condition may the lap belt be worn over the area of the intestines or abdomen.90 in) 3) The tabs mounted to the frame to accept the lap belt tabs shall have no less than 38 mm (1. 21).
Inboard braking through universal joints is permitted.e. The tank mountings are done along with B&S engine and need not to be changed. This is in the interest of safety of vehicle & team. it must be equal to or exceed these standards (e.g. All rigid brake pipes must be mounted securely along the roll cage / other members as required.16. The brake system must be capable of locking ALL FOUR wheels in a static condition and dynamically on pavement AND an unpaved surface.2 Fuel Tank A single fuel tank (maximum capacity = 4. cleanliness of fuel tanks is important from both safety & engine working point of view. Loosely hanging / pipes located by using ties / tapes etc shall not be permitted. and on 1st Jan of the competition year be no more than three years old.org 31 | Page .16. OEM-style reservoir. Wheel ends should be connected with flexible pipe only.15. The brake(s) on the driven axle must operate through the final drive.1 Foot Brake The vehicle must have at least two (2) independent hydraulic braking systems that act on all wheels and is operated by a single foot. Vehicles not meeting this requirement will not clear technical Inspection.: SAE IPRSTM) or if it is not rated as per SAE J759. The determination of whether or not a brake light meets the required standards.16 FUEL SYSTEM 3.: OEM brake light assemblies)/ AIS and ISI rated brake lights are also permitted.) above the ground. Quality. Use of OEM Brake lines is recommended. Both the independent brake-systems may be actuated by a tandem master cylinder and safely stop the vehicle at max speed of 45kmph or above. without exception. www.3. Braking on a jackshaft or through an intermediate reduction stage is prohibited.14.2 Brake Light The vehicle must be equipped with a red brake light whose lens must be marked with an SAE “S” or “U” rating (i. not at an angle. 3. The pedal must directly actuate the master cylinder (no cables are allowed).1 System Location The entire fuel system must be located within the roll cage envelope such that it is protected from impact.15. 3. NOTE: Plastic brake lines are not allowed. 3. Each hydraulic system shall have its own fluid reserve either through separate reservoirs or by the use of a dammed.15 BRAKING SYSTEM 3. The brake light must be mounted at a minimum of 1 meter (40 in.bajasaeindia. The bleed point location must lie on top of the caliper cylinders. Light must be mounted such that it shines parallel to the ground. till a distance of 10 meters.5 liter) is permitted on the vehicle which is supplied & mounted along with B&S Engine. 3.1 Arm Restraint – Expiration The belts must bear the appropriate dated labels.
Tubing that is weakened or dissolved by fuel are unsafe and will not be permitted. is required so that if the fuel spills it must not come in contact with the driver or the engine or catch fire.53 mm (0.4 Spill Prevention Drain Material The drains must be either fuel line material. A shake resistant Drip Pan below the fuel tank is must. Figure 25: Approved illustrations for a spill/splash shield and working.5 in) high above the top edge of the tank. 3. At no point in the drain system (the drain lines and any associated fittings) will the inner diameter be constricted to less than 9.bajasaeindia. other pipe or tubing suitable for transferring fuel.org 32 | Page .3 Spill Prevention: Drip Pan / Splash Shield A drip pan. that is at least 203. Drip Pan is invariably also called as Splash Shield for its added functionality of preventing fuel being accidently spilled directly on engine or exhaust while re-fuelling or during the driving on tilt. www.375 in) – this includes bolts with a hole drilled in the center used as a fitting. If tubing is used. Any vehicle failing to comply this test shall not be allowed to start any dynamic event. it is highly recommended that a threaded and barbed fitting be used at the point where the drain line connects to the drip pan. Fuel must not get accumulated anywhere in the pan & it must drain through a drain line composed of pipe or tubing that carries the fuel to the bottom of the car and releases it under the car (to ground). Figure 26: The above spill/splash shield is NOT acceptable Fuel spill prevention shall be checked by a 45 degree tilt test at the technical inspection site or any point of time during the event with fuel tank filled completely with fuel.16.3.2 mm (8 in) in diameter or equivalent area and have sides of at least 38 mm (1.16.
17 STEERING & SUSPENSION SYSTEMS 3. Figure 27. Compliance shall be checked and any vehicle failing to comply shall not be allowed to start any dynamic event.bajasaeindia. metal deactivators.80 for unleaded gasoline when measured at 60 degrees Fahrenheit.Tilt Test Layout (45⁰) 3.6 Fuel The only fuel permitted is automotive gasoline consisting of hydrocarbon compounds. See Section 4. or additives designed to liberate oxygen is strictly prohibited.75 for leaded gasoline or 0. does not have any holes and prevents fuel from spilling. Teams must ensure that the filler cap gasket does not breakdown in fuel. In case of such spill over observed all spill over fuel must get drain off through drip pan & drain pipe to ground. Compliance shall be checked and any vehicle failing to comply shall not be allowed to start any dynamic event. No straps or cables are allowed.Compliance is mandatory.org 33 | Page .5 Filler Cap A standard Briggs and Stratton gas cap with a built in check valve (Part # 792647) is required. corrosion inhibitors.1 Wheel Stops All vehicles must be equipped with positive wheel lock-to-lock stops. Wheel stops must function at full jounce. The cap must not come loose during dynamic events or allow fuel to spill out even vehicle is tilted over banking.16. 3. The gasoline may contain anti-oxidants.2.2 “Competition Fuel Supply “. These stops must mounted external to the steering gear and must be located on the non-rotating parts like knuckle/ uprights.17. The retail price must be included in the cost report The standard filler caps provided with rated fuel tanks may not prevent fuel from leaking in the event of a rollover. Specific gravity should not exceed 0. full rebound and all points in between. www. The addition of nitrogen bearing additives. or lead alkyl compounds such as tetra-ethyl lead.16. 3.
3.17.2 Tie Rod Protection
The tie rods of all vehicles must be protected from frontal impact. A bumper may be required, at the technical inspector’s discretion, depending on the design and installation. Adjustable tie rod ends must be constrained with a jam nut to prevent loosening.
3.17.3 Handlebar steering
Handlebar operated steering system is specifically prohibited.
All fasteners used in the systems designated in Section 3.18 must be captive; defined as requiring NYLON locknuts, cotter nuts or safety wired bolts (in blind applications). Lock washers or thread sealant do not meet this requirement.
184.108.40.206 Lock Wire Procedure Detail
EXAMPLE: A team using a custom hub with an OEM rotor must meet the locking requirements, but a team using an OEM hub and OEM rotor would be exempt. The above figure illustrates the procedure for using lock wire: A. Above illustrations assume right hand threads. B. No more than three (3) bolts may be safe-tied together.
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C. Bolt heads may be safe-tied as shown only when the female thread receiver is captive, or the nuts meet previous lock nut requirements. D. Nuts (pre-drilled) may be safe-tied in similar fashion to the illustrations with the following conditions: 1. Nuts are heat-treated. 2. Nuts are “factory drilled” for use with lock wire. E. Lock wire MUST fill a minimum of 75% of the drilled hole provided for the use of lock wire. F. Lock wire must be aircraft quality stainless steel of 0.508 mm, 0.813mm, or 1.067mm diameter (0.020 in., 0.032 in., or 0.042 in. diameter). Diameter of lock wire is determined by the thread size of the fastener to be satisfied: 1. Thread sizes of ¼” and smaller use 0 020” wire 2. Thread sized of ¼” to ½” use 0 032” wire 3. Thread sizes > ½” use 0 042” wire 4. The larger wire may be used in smaller bolts in cases of convenience, but smaller wire must not be used in larger fastener sizes.
3.18.2 Fastener Grade Requirements
All bolts used in the systems designated in Section 3.18 must meet SAE grade 5, metric grade M8.8 or AN military specifications. See Figures below.
Acceptable SAE Bolt Grades:
Figure 29 (a)
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Acceptable Military Specification Bolt Grades:
Figure 29 (b)
3.18.3 Thread Exposure
All threaded fasteners used in the systems designated in Section 3.18 must have at least two (2) threads . Compliance shall be checked 100% and failing to comply shall not be qualifying for technical clearance.
3.18.4 Socket Head Cap Screws
Socket head cap screws, also known as “internal wrenching bolts” or “Allen head bolts” used, must meet one of the following requirements: 1) The bolt head is clearly marked with the letters “N S”, “12.9”, or “10.9” indicating a military /aircraft or high-strength metric fastener. No other markings will be accepted. 2) Proper documentation is supplied, which must include a purchase receipt, and manufacturer’s documentation indicating the bolt strength
3.18.5 Single Shear Connections
All tie rods in single shear must have a factory steel safety washer. Ball joints are the only exception. (Figure 32)
A. Tie Rods
All tie rods in single shear must have a factory steel safety washer.
Rod end threaded into threaded tube adapter.
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524 mm (0. Ball Joints Any commercially manufactured ball joints or rod ends with studs are allowed. Modulus of Elasticity = 205 GPa.B.06 inch) thick or (b) a material having equivalent energy absorption at rupture per unit width of shield. Calculations must use the following material properties for the AISI 1010 steel: Yield Strength = 305 MPa. Elongation at Break = 20. In order to show equivalency the calculation must show the following: (Area under curve for AISI 1010 Steel x Thickness) ≤ (Area under curve for alternative material x Thickness) www. 3. They must be mounted with sound engineering practice. in order to resist vibration. Additionally. Elongation at Break.org 37 | Page .0%. where strain = elongation at break (Figure 31). They must be either (a) made of AISI 1010 steel at least 1. Vehicle failing to comply shall not be allowed to start any dynamic event. Ultimate Strength = 365 MPa.19 GUARDS 3.bajasaeindia. Equivalency calculations for the alternative material must meet the following requirements: All calculations must be shown in SI units.19. the curve for the composite material must be specific to the matrix and manufacturing methods used. If a stress-strain curve for the alternative material is not provided then it must be assumed that the stress strain curve is linear to the yield point and linear from the yield point to the ultimate strength. and Modulus of Elasticity of the alternative material must be provided. Student manufactured ball joints or rod ends with studs are specifically prohibited. Figure 31 If a fiber reinforced composite material is used. Compliance shall be checked and any reinforced composite material must be 3. then a stress strain curve must be provided for worst-case tensile loading. Documentation from the material manufacturer showing the Ultimate Strength.1 Power train Guards All rotating parts must be shielded to prevent injury to the driver or bystanders should the component fly apart due to centrifugal force.175 mm (0.125 inch) thick.
Figure 32 . B. gloves.1 Helmet. including long pants (cotton/ Nomex).bajasaeindia. The upper garment must have a factory label showing it is SFI rated. Goggles must incorporate the use of tear-offs or roll-off systems.20 DRIVER EQUIPMENT REQUIREMENTS 3. 3. and a long sleeved SFI/ ISI rated upper garment.Side Shields A. A complete cover around the engine and drive-train will be acceptable. and on 1st Jan of competition year be no older than 3years. Clothing Drivers must wear appropriate clothing. SA 2005. Side Shields Side shields must prevent fingers from getting caught in any rotating part. FIA rated or fire resistant. All restraints must bear appropriate dated labels. socks.20. Neck Support/ Collar & Goggles All drivers must wear a well-fitting Motor-Cross style helmet with an integrated (one piece composite shell) chin/face guard and a Snell M2005.org 38 | Page . ISI marks. British Standards Institution BS 6658-85 types A or A/FR. MOTOCROSS STYLE Figure 33 No Street Bikes Style HELMETS Figure 34 www. shoes.
No compromise with Safety of driver. www. This rule has no exceptions and it will be strictly enforced. The neck support must be a full circle (360°) and SFI 3.org 39 | Page . Simpson. Any non-specification helmets will be confiscated until after the competition. This combination of helmet/collar system is prohibited. Helmets certified to other rating systems may not be worn. RCI.Permitted Figure 35 Not Permitted Figure 36 In addition to the helmet. and on 1st Jan of the competition year be no more than three years old. Deist or Leaf Racing Products supply neck collars that meet this requirement. WARNING: Some Motor-Cross helmets have extended chin guards that will not contact the required neck collars when the head is flexed forward. a neck support/collar must be worn.3 rated (Figure 35). GForce. Neck support must bear the appropriate dated labels. Horseshoe collars are not allowed (Figure 36).bajasaeindia.
Teams may not protest rule interpretations or actions that have not caused them any substantive damage.2. www.1 COMPETITION PROCEDURES AND REGULATION (GENERAL) Drivers Meetings All team members identified as drivers and their support personnel MUST attend all drivers meetings. Any violations of this rule will be subjected to severe penalties.2 4.2 Competition Fuel Supply Fuel at the competition will either (1) be provided by the organizers or (2) the organizers will specify acceptable fuel providers.1 Re-fuelling All refueling of the cars done in the pit area or on the course must be done with (1) the engine shut-off and (2) the driver out of the car.bajasaeindia.bajasaeindia.Section 4 .org .org 40 | Page .1 4. All protests must be filed in writing and presented to the organizer or SAE staff by the faculty advisor or team captain within one hour (60 minutes) of the end of the event to which the protest relates.1 RULES CLARIFICATION AND PROTESTS Technical Questions Questions about the rules requirements and restrictions must be submitted by e-mail to the Technical Inspectors of the Baja SAE India at: email@example.com.Competition Procedures and Regulations 4. A fire extinguisher must be in hand whenever a vehicle is being refueled.2 Protests Any objection/matter must be brought to the notice of the organizers or SAE INDIA staff’s attention for an informal preliminary review before a protest can be filed. Questions and answers will be posted on the Baja SAE India website at: www. 4. a team must post a twenty-five (25) point protest bond which will be forfeited if their protest is rejected.2.2. NOTE: Please keep in mind that final operating approval of a BAJA SAEINDIA vehicle can only be given at the competition venue by the National Technical Inspectors.com . 4. Failure to attend drivers meetings can result in disqualification of members or the entire team. 4. 4. The decision of the competition protest committee or National Technical Inspectors regarding any protest is final.1. In order to have a protest considered.2.
org 41 | Page . goggles.2.2. DRIVING OFF-SITE IS ABSOLUTELY PROHIBITED.2. it must move at walking speed with a team member walking along side at a normal walking pace. Owing to any unsportsmanlike conduct which can include arguments with officials. 4. at their sole option.1 Rules of Conduct Sportsmanship Good conduct and compliance with the rules are requirements for every team member. 4. 1.2 through 2. at the discretion of the Technical Inspectors. and may have their competition driver’s privileges revoked Practicing outside of the designated practice area will result in a minimum fifty (50) point penalty and/or the revocation of driving privileges depending on the extent of the infraction. 2.4. required clothing and a properly fastened restraint system at all times when the vehicle is running in any event or on the test track. Drivers not wearing the proper equipment will not be permitted to drive.2.2. helmets. the organizer is authorized to impose an appropriate penalty.6 Penalties Organizers have the right to modify the penalties listed in the various dynamic event descriptions to better reflect the design of their event courses. including impounding the vehicle for a specific period of time.3. 4.4 shall receive zero points (0) for all dynamic competition events completed during the day on which the inspection was performed. TEAMS FOUND TO HAVE DRIVEN THEIR VEHICLE AT AN OFF. The walking speed rule will be strictly enforced and point penalties will be assessed for violations.3. Drivers must wear all of the equipment specified such as seatbelts. 2.5 Driving Restrictions When a vehicle is driven anywhere except the practice area or competition events.3 4.SITE LOCATION MAY BE EXPELLED FROM THE COMPETITION. recall the engine from any vehicle in the competition in exchange for a new B&S engine.bajasaeindia. wrist restraints. the course lengths or any special conditions unique to the site. Any vehicle found to have: (1) a drive-train configuration not matching the Drive-train Certification Form submitted during technical inspection or (2) an engine in violation of rules Sections 2. disobedience of official instructions and the use of abusive or threatening language to any official or other participant. Under no circumstances may anyone other than the driver ride on a vehicle.3 Engine and Drive-train Inspection The Technical Inspectors reserve the right to impound and inspect any vehicle during/ after the dynamic or endurance events. Recalled engines will not be returned and will be inspected at B&S’s facilities to confirm compliance with the rules. www.4 Engine Recall Option The organizers and SAE India may. 4.2.
The course officials and organizers have the absolute right to restrict spectator access to any parts of the site and to eject anyone who violates safety rules or ignores the instructions of officials.3. 4.3. failing which they may have to face point penalties or even disqualification.3 Site Condition Please help the organizers keep the site clean. Competitors and spectators are encouraged to police their areas after meals.4 Safety – Team Responsibility Safety is the primary consideration in the design of BAJA SAEINDIA vehicles and the conduct of the competitions. Failure to clean the premises will result in an unsportsmanlike conduct penalty. Disruptive parties either on or off-site should be prevented by the faculty advisor. 4. Spectators must keep well back from the event and practice tracks and from any area where vehicles are operating under power. advisors and any individuals working with the team on-site.org 42 | Page . Note: All teams. Teams need to include safety considerations in all parts of their program. spectators and faculty members are responsible for the safety of their own.2 Alcohol and Illegal Material Alcoholic beverages. Spectators who fail to strictly control their children will be asked to leave the site.bajasaeindia. faculty and volunteers are expected to help inform the spectators of the safety rules and help restrict spectators to the spectator areas. The teams are required to maintain the code of conduct throughout the event. 4. firearms. not just the individual(s) involved. No claims regarding these shall be entertained by the organizers. At all performance events.4. their vehicles and belongings. This rule applies to team members. Spectators may not drink alcoholic beverages at any event location. weapons of any type and illegal materials are prohibited at the Baja SAE India site during the competition. it is the responsibility of the team to ensure both the vehicle and driver meet and follow all the requirements and restrictions of the rules. www. The penalty for violation of this rule is the immediate expulsion of the entire team.5 Spectator Rules The competitors.
vehicle validation procedures/ facilities etc. 3. (4) Validate the vehicle performance by conducting preliminary tests. The teams are required to demonstrate – weld check.bajasaeindia. The college level technical inspection is scheduled in Dec’13. 4. Teams should download the most current version of the Self-Certification Check Sheet and thoroughly inspect their vehicle in accordance with the sheet. the team need to report with SCCs duly signed by technical inspector at college level and on its confirmation following sequence of Safety Scrutiny follows 1) Fuel Filling 2) Stage 1. during the technical inspection. the teams will be allowed to participate in BAJA SAEINDIA 2014.Panic Brake test at 45 kmph (Brake OK Sticker Issue) www. Overall Safety Scrutiny d. Fig of 8 . The inspection will be carried out by the trained technical inspectors at respective colleges.3 On-site Safety Scrutiny The objectives of On-Site safety scrutiny are to (1) Ensure engine is in proper operating condition & does not over speed 3800 rpm. 64-Inch (GO-NO-GO) Gauge b. On the zeroth day at the BAJA site. 2. Only on the confirmation from the technical inspectors.Section 5 – Technical Inspection 5.Test for turning & maneuverability (30 .Safety Scrutiny & Figure of 8 (Safety Scrutiny & Fig 8 OK Sticker Issue) a.1 Self-Certification Participating teams are required to carry-out a self-certification check at their end by the due date of 30th Nov. workshop facilities. (3) Compliance of basic requirements mentioned in the rulebook. tilt test. figure of 8-test. The decision of technical inspector will be final and non-challengeable. The list of documents/ certificates/ video clips etc. 5. Teams are liable to be DISQUALIFIED from participation in BAJA SAEINDIA 2014 on NON-COMPLIANCE with the rulebook.org 43 | Page . 5. 45 Degree Tilt Test c.2 Technical Inspection at College level 1. The completed Self-Certification Check Sheet duly signed by the faculty advisor and team captain should be sent to BAJA Technical Committee. 2013 and complete the check sheet.40 kmph) 4) Stage 3. brake-test. and the check sheet completed in all respect with the actual measurement values are to be submitted to the technical inspectors.Engine Inspection (Engine OK Sticker Issue) 3) Stage 2. (2) Ensure compliance with the safety parameters for the vehicle & driver.
Vehicles that do not pass the technical inspection will be disqualified for all other events and can’t participate in Dynamic and Endurance Tests. it is mandatory to get certified with the same Technical Inspector who has examined the vehicle at the first attempt (every test of the sequence bears dedicated inspectors).3. 5.bajasaeindia. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.5. To expedite the process.college level perfection & the shortest possible time in clearing the technical inspection. The time will be logged for the complete Technical Inspection for each vehicle to evaluate the best. The Self-Certification is vital for the commitment towards ensuring the basic quality standards aimed at completing the Technical Inspection on the 1st day of the event.org 44 | Page . each team needs to arrive with side cover removed and loosened bolts of fuel tank www.4 Inspection Stickers Technical inspection comprises of three stages. The team captains or other designated members (maximum 5) of the team must be present during Inspection. will be debarred from further participation. The inspectors at site will give two attempts to all for each test and team need to comply for the same within the stipulated time. vehicle has to be in running condition. The inspection sticker must remain on the vehicle throughout the competition. During the safety scrutiny. teams need to take the best efforts at college level manufacturing and ensure the vehicles are complete in all aspects. The parameters . full tank fuel topped-up condition and should be capable of undergoing for all the test sequence mentioned above. Teams not carrying Self Certification Check Sheet verified and approved by technical inspectors. Technical inspectors and officials may remove any or all parts of the inspection sticker from any vehicle that has been damaged or which they reasonably believe may not comply with the rules. teams are liable to be rewarded with point-deduction. If vehicles are not ready on the day of technical inspection.3 – Engine OK/ Safety Scrutiny & Fig 8 OK/ Brake OK Stickers) will be issued in sections to the team as each of the three stages of technical inspection is completed. Hence. Stage 1 – Engine Inspection OK Briggs and Stratton staff is responsible for the Engine Inspection of each vehicle. To satisfy the requirements and restrictions of the BAJA SAEINDIA rules.1 Zero Tolerance Policy All BAJA SAEINDIA vehicles must pass Safety Scrutiny in two attempts only. A three-parts inspection sticker (see Section 5. Faculty advisors are not allowed to participate during technical inspection. No special request for 3rd test will be entertained.
bajasaeindia. Stage 1 must be passed before a team may apply for Stage 2 inspection. The inspection ensures(1) Setting of the governor at 3800 rpm & spring at 6th notch position.org 45 | Page . On successful completion of Stage 1. if they do not have the items at the time of inspection they will receive a 10 point deduction for each item missing or not completely filled: a) Self-Certification Check sheet: With self checks carried out by team and verified by Technical Inspector (Format is due to be posted on www. Engine inspection will consist of . (See Section 7 – Appendix 1) d) Safety equipment and driver’s kit The following tests will be carried out in the sequential manner during this stage(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) 64 inch GO-NO-GO gauge 45 deg tilt test for fuel spillage and drain Wheel lock stoppers Accelerator pedal return ability Free operation of gear shift and hand brake Reverse lamp functionality Specified hardware and nylon lock nuts Safety belt and restraints as per specification Egress test of all drivers Figure of 8 test and maneuverability On successful completion of Stage 2. b) Tube Specification Certificate: Obtained from supplier with latest testing certificate from local laboratory (Section 3. the Second sticker will be put on the firewall.org by 10th November 2012.7). This inspection will include an examination of the driver’s equipment including helmet and arm restraints and a test of driver exit time. www. the First sticker will be put on the firewall.mounting with spare air filter kit. after-installation of new air-filter element and working of kill switch. Team is needed to download and ensure the compliance).bajasaeindia. Each team must bring the following items to inspection. and (2) Engine compliance for normal performance.the engine rpm setting with governor position verification. Stage 2 – Safety Scrutiny & Figure of “8” Each vehicle will be inspected to determine its compliance with the rules and restrictions. c) Roll Cage Specification Sheet: Completed Roll Cage Specification Sheet. ALL THE REGISTERED DRIVERS ARE MANDATORILY REQUIRED DURING SAFETY SCRUTINY.
do not correspond to the actual condition of the car) (3) are found to have more than 3 items not in accordance with the rules.bajasaeindia. or (4) do not represent a serious effort at pre-inspection will be denied inspection at that time and sent back to the end of the inspection line with a 100 point deduction /other penalties which shall be prominently displayed at the site at least 60minutes before commencement of Technical Inspection of the first vehicle. the Third sticker will be put on the firewall. Acquiring the three stickers marks the completion of “Technical Inspection” and makes them eligible for Dynamic Evaluation. (2) inaccurate (i. If both switches pass the test then the vehicle will be dynamically brake tested. On successful completion of Stage 3. in case of failure the names of driver will be removed from the Final list of drivers and a 10 point penalty will be applied to the team. All drivers must be present at technical inspection. Each vehicle must demonstrate its ability to lock all four wheels and come to rest in an approximately straight line after acceleration run to reach at least 45 kmph or as specified by the inspectors. 3. Overall Vehicle Inspection Flow- 6 Figure 37 www.Stage 2 must be passed before a team may approach for Stage 3 inspection. The inspectors and officials have the right to re-inspect any vehicle at any time during the competition and require correction of any non-compliance. Stage 3 – Dynamic (Panic) Brake Testing Both the external and cockpit kill switches will be tested for functionality. Teams presenting Self Certification Sheets that are (1) incomplete. NOTE: 1. If a vehicle fails to pass any part of the inspection it must be corrected/ modified and brought into compliance with the rules before it is permitted to operate.e. 2.org 46 | Page .
REPRESENTED AND PASSES THE TECHNICAL INSPECTION.org 47 | Page . This is in the interest of safety. MAXIMUM NUMBER OF REINSPECTIONS PER VEHICLE (BESIDES THE NORMAL INSPECTION AT SITE) SHALL BE 2 (TWO) ONLY.bajasaeindia. integrity of vehicle structure. FOR THIS COMPLIANCE. The team shall provide documented proof of fabrication process of every component and the design analysis. 64-Inch (GO-NO-GO) Gauge 3. Minor adjustments permitted by the rules and normal vehicle maintenance and tuning are not considered modifications. 45 Degree Tilt Test 4. Approved vehicles must remain in “as-approved” condition throughout the competition Necessary repairs that do not significantly change the configuration of the vehicle are permitted. www. fabrication processes adopted. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. THIS REQUIREMENT SHALL BE ENSURED WITHOUT EXCEPTION. THE BAJA SAEINDIA TECHNICAL COMMITTEE RESERVES THE RIGHT TO DISALLOW ANY VEHICLE FAILING TO COMPLY WITH THE REQUIREMENT OF THESE RULES TO TAKE PART IN ANY DYNAMIC EVENT TILL THE VEHICLE IN QUESTION IS RECTIFIED.INDEX (Figure 37): 1. Engine Check 2. TO AVOID DISAPPOINTMENT. etc will be judged. THEREFORE. failing which they may have to face point penalties or disqualification. IT IS REQUIRED THAT TEAMS COME WITH THEIR VEHICLES WELL PREPARED FOR THE EVENT. Figure of 8 Test 6.5 “As-Approved” Conditions Once a vehicle has passed technical inspection its configuration may not be modified. Overall Safety Scrutiny 5. Panic Brake Test 5. NOTE: It is important for every team to get their vehicle approved by the technical scrutiny during which the safety.
Acceleration – Procedure Each team may make two (2) attempts. 6.1 Speed Events 6. Please note that the organizers have the right to modify the dynamic events to address local conditions. Design Report and Cost Report are mandatory during Design and Cost Evaluations respectively. The choice of course length is at the organizer’s discretion. weather or resources. STUDENTS CAN INDEPENDENTLY APPROACH TO STATIC EVALUATION EVEN IF FAILED IN TECHNICAL INSPECTION. During Marketing Evaluation business case needs to be explicitly presented dealing with manufacturing and marketing strategies/plans. In case of failure at the first attempt in Design Evaluation. 6.org 48 | Page . Important instructions for Static Event1. 3. Scoring will be based on the better of the two www.Section 6 – BAJA SAEINDIA Events 6.2.1 Acceleration A. 6.2. Teams are required to clear the Static Event at different panels assigned for specific evaluation.48 m) or 150 ft (45. There are 3-4 rows (with panel of judges) for each Static Event namely Design Evaluation.bajasaeindia. 4. Teams are required to choose any one of the available rows and clear the same before proceeding to next static event.72 m) flat course. 5. B. BAJA SAEINDIA 2014 participating vehicle MUST be available for Design and Cost Evaluation.1 Static Events The static events comprise of Design Evaluation. Cost Evaluation and Marketing Presentation. teams are allowed for ONLY 1 more attempt (2nd attempt) at the same judges’ panel. Cost Evaluation and Marketing Presentation.2 Dynamic Events The dynamic events are intended to determine how the BAJA SAEINDIA vehicles perform under a variety of conditions. Objective Acceleration determines the time it takes the vehicle to accelerate along 100 ft (30.1. 2.
2. “T yours” is the best time of your team. C. Objective Hill climb assesses each vehicle’s ability to ascend a steep grade from a standing start. 6.2. the traction event will be either the hill climb or a pulling event.attempts. “T Longest” is either a.1 Hill Climb A.2 Traction Event The traction events are designed to demonstrate the vehicle’s ability to use its traction to accomplish various tasks. At the organizer’s discretion. whichever is the shorter interval. The following equation will be used for the acceleration score: Acceleration score = 100 x [(T Longest–T yours)/ (T Longest–T Shortest)] Where: “T Shortest” is the fastest time by any team. Hill Climb – Procedure Each vehicle may make two (2) climbing attempts with the best distance or the fastest completion time counting for score. Teams attempting the event. Once the vehicle stops moving forward the attempt is over and the attempt www. 2 times the fastest time. Acceleration . B. Timing may be done using either electronic systems or stop watches.org 49 | Page . The slowest time by any team or b. but exceeding the time limit will be classified as “Excess Time”.2. Acceleration – Penalties The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses. False Start or Stall at Start : First False Start Second False Start Leaving Course : Disqualification Rerun at end Disqualification D.bajasaeindia.Scoring If the time taken for acceleration by a team is more than twice that of the fastest car. it will not receive a score for this event. 6.
the attempt is scored for distance at that point. Hill Climb Event – Penalties The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses.is scored for distance at that point. or if its wheels are spinning without moving the vehicle forward. “D yours” is the best climb of your team. Method B: No One Climbs the Hill If none of the vehicles succeeds in climbing the hill. “D Longest” is the longest distance climbed by any team.bajasaeindia. “T yours” is the best time of your team. C. First False Start Second False Start Rerun at end Disqualification D. If a vehicle stalls before reaching the top of the hill. Leaving Course False Start : : Score equals distance covered before course violation. Hill Climb – Scoring Method A: Everyone Climbs the Hill If all of the teams succeed in completing a full climb. Vehicles may not continue the attempt after they have stopped on the course.org 50 | Page . then the score will be based on the time of the climb and calculated by the following formula: Hill Climb Score = 100 x [(T Longest–T yours)/ (T Longest–T Shortest)] Where: “T Longest” is the longest time by any team. Method C: Some Teams Make the Climb www. then the score will be based on the distance each team climbs as determined by the following formula: Hill Climb Score = 100 x [(D yours –D Shortest)/ (D Longest–D Shortest)] Where: “D Shortest” is the shortest distance climbed by any team. “T Shortest” is the shortest time by any team.
Figure 38 6. sand.bajasaeindia. gullies logs. ruts and bumps. and inclines.org 51 | Page . Objective Maneuverability is designed to assess each vehicle’s suspension. Scoring will be by the following formulas: Group I: Teams that complete the climb Score = 100 x (T Fastest / T yours) Where: “T yours” is your team’s best time “T Fastest” is the fastest time by any team Group II: Teams that stop on the hill Score = (Lowest score from Group I) x (D yours / D Hill) Where: “D yours” is the distance traveled by your vehicle.2. The course may consist of a variety of suspension and handling challenges. then the vehicles making the climb (Group I) will be scored based on time and the vehicles that stop on the hill (Group II) will be scored based on distance traveled.2. possibly including tight turns. www.If at least one team makes the climb while other teams do not. pylon maneuvers.2 Maneuverability Event A. “D Hill” is the length of the hill from the starting point to the finish line. handling and steering. rocks. drop-offs. at the organizer’s option.
Rerun at end Disqualification www.5X) that of the fastest vehicle will receive a score. C.bajasaeindia.5 x “T Shortest” whichever is the shorter time “T Shortest” is the shortest time through the course by any team “T yours” is your team’s time through the course 6. Maneuverability – Time Limit Only vehicles that complete the maneuverability course within a time not exceeding two and half times (2. Maneuverability Score = 100 x [(T Longest–T yours)/ (T Longest–T Shortest)] Where: “T Longest” is either (a) The longest time through the course by any team or (b) 2. Obstacle/Pylon moved Missed gate* Deliberate course violation False Start : : : : 2 seconds 10 seconds Run disqualification First False Start Second False Start *Missed gate is when 2 or more wheels are outside the gate D. If a vehicle is on the course for a time that exceeds twice the fastest time recorded to that point then the Event Captain may declare the attempt over. Maneuverability Procedure Each vehicle may make two (2) runs with the best time. Maneuverability – Penalty Default Values The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses. Maneuverability – Scoring Maneuverability scoring is based on the vehicle’s time through the course including any penalties. counting for score.B. remove the car from the course and score the attempt as “Excess Time”.3 PRACTICE ROUND One hour time will be dedicated to practice on endurance track those who have successfully completed Technical Inspection and Dynamic Event. E. including penalties.org 52 | Page .
4.org 53 | Page . to be determined by the organizer.1 Endurance Event Endurance – Objective The endurance event assesses each vehicle’s ability to operate continuously and at speed over rough terrain containing obstacles in any weather conditions. The organizer will announce the structure of the event prior to the start. In competitions of a given distance. the checkered flag will be given to the next highest running car in the same manner.4. the checkered flag will be given first to the leading car as it crosses the finish line at or after the expiration of the specified duration. If the leading car is not running at the expiration of the time limit.bajasaeindia.4. Determining the winner of the endurance race: • • • The team.4.General Description Endurance run may be based upon either total time taken or total distance covered. All vehicles will be considered to have begun the race simultaneously at the time when the starter releases the first vehicle onto the course regardless of their actual position in the grid. then to the other finishers as they cross the finish line. then to the other finishers as they cross the finish line.Starting The starting grid for endurance will be based on each team’s performance in a previous dynamic competition.2 Endurance . the checkered flag will be given first to the leading car.4 Endurance – Command Flags Command flags are just those flags which must be immediately followed by participants without any dissent. which completes the distance of the competition first.6.4 6. 6. A predetermined and published distance. or the greatest distance in the time set for the competition will be declared the winner.3 In competitions of a timed length. Endurance events for distance continue until at least one car has gone the specified distance. or set of dynamic events. or Elimination heats followed by a final in which the total time of one elimination heat plus the final is 4 hours. Endurance events for time usually run for four (4) hours. 6. 6. Endurance . Endurance will be run as one of the following(A) (B) (C) A single four (4) hour race. www.
Pull to the side of the course as much as possible to keep the course open. exit the course at the first opportunity. A time penalty may be assessed for the incident.Green Flag – (1) At a starting line or when re-entering the course: Your run. Yellow Flag. 6. BE PREPARED TO STOP.4. If a vehicle is stopped by officials for a mechanical fault. enter the course under the direction of the starter. The driver may not exit the vehicle to execute a restart. unless directed by the course workers. Furled and Pointed – Warning. something has happened beyond the flag station.4. (2) Pull into the penalty box for a mechanical inspection of your car. something has happened beyond the flag station.6 Endurance – Repairs The organizer will announce the rules governing repairs that are permitted to be made during the endurance event.org 54 | Page . Red Flag – Come to an immediate safe and controlled stop on the course. Waved – Great danger. SLOW DOWN. It is t he dri ve r ’ s responsibility to assist and cooperate with the course marshals in removing the vehicle. Black Flag. Steady – Danger. or session. has been completed. Displayed – ( 1) Pull into the penalty box for a discussion with the Director of Operations or other official concerning an incident. NO PASSING. Checkered Flag – Your run. something has been observed that needs closer inspection. 6. Yellow Flag. volunteers or team members may assist drivers in restarting their vehicles. NO PASSING. be prepared to take evasive action. Course marshals. the fault must be corrected / repaired before it may reenter the event. evasive action is likely to be required. unless directed by the course workers. NO PASSING. proceed. has started. SLOW DOWN. If repairs along the course are permitted then vehicles under repair must be www.5 Endurance – Stalled or Disabled Vehicles Disabled or stalled vehicles must be immediately removed from the roadway. (NOTE: If you stall the vehicle then restart and wait for another green flag as the opening in traffic may have closed. the officials are watching your driving – obey the event rules. or session. Black Flag. if they believe it no longer complies with the requirements and restrictions of the rules. Cars may only be started with the driver seated with all belts properly fastened. Follow course worker directions.) (2) While running on the course: Course is clear. at any time.bajasaeindia. Officials and course marshals may stop any vehicle.
6. away from the outside of turns and away from any natural run-off areas. No work will be done on the car when fueling. and a fire extinguisher is ready.8 Endurance – Scoring A. Only full the laps count.4. partial laps do not count for score. 6. A vehicle must cross the counting/timing line under its own power for a lap to be counted. * whichever the official determines is the greater penalty. www.4. General: The endurance event score is determined by (a) the number of laps each team completes during the endurance final and (b) the finish order of teams at the end of the event.removed well off the course. the driver is out of the car.7 Endurance Event – Penalty Default Values The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of the course Failure to stop for Black Flag Passing under a Yellow Flag Deliberate Ramming 10 minutes or 1 lap per flag* 1 lap penalty First time = 10 minutes Disqualification 10 minutes 20 minutes Disqualification Second time = Deliberate Forcing another Vehicle off the course First time Second time Third time Leaving Course and Advancing Driving in an Unauthorized Area Failure to Yield to Traffic on Entering Track Speeding in Pit Area Fueling : : : : : = = = 5 minutes 10 minutes 5 minutes 5 minutes 30 minutes Fueling will not be allowed until the engine is turned off. “Scored laps” are the number of full laps actually completed during the endurance event final.bajasaeindia.org 55 | Page .
9 Tie-breakers There will be no tiebreakers for static events. Thus. For example. the four hundred (400) total points will be allocated as one hundred (100) points to each elimination heat plus three hundred (300) points to the final. B. “L Lowest” is the lowest number of laps completed by any team. If both scores for tied teams in the event are equal then the tie remains. Ties for overall winner will be broken by the following criteria: Endurance score Total dynamic events score Total static events score If a tie remains after all the above tiebreakers then the tie remains for the overall winner(s). 6. Endurance Heats plus a Final – Point Distribution: When endurance is run as heats plus a final.org 56 | Page . if endurance is run as one (1) hour eliminations plus a three (3) hour final. the points for the event will be distributed between the heats and the final in proportion to the time/distance of each stage. the second vehicle will receive one less bonus point etc. in part to differentiate teams finishing with the same number of scored laps. if the top four teams finish with the same number of laps. Thus. “Bonus points” are additional points awarded to the first ten (10) vehicles on the leading (winning) lap. Up to 10 bonus points will be awarded in the inverse order of finish. “L Yours” is the number of laps completed by your team.4. Tiebreakers for dynamic events will be the second best run time or score for the given tied event. Ties in the endurance race will be judged by the endurance event judge and may remain a tie.bajasaeindia. Finish order determines the ranking of teams completing the same number of laps. as separated by finish order as required. the first vehicle to cross the finish line in the highest lap group will receive bonus points equal to the number of cars on the lead lap (max of 10). www.“Finish order” is the sequence in which vehicles cross the finish line after the lap scoring period has ended. Endurance scoring is based on number of laps the vehicle completes in the allowed time: Endurance Score = [400 x (L Yours–L Lowest)/ (L Highest–L Lowest)] + bonus points Where: “L Highest” is the highest number of laps completed by any team. then they will be ranked 1st to 4th based on their finish order.
www. TECHNICAL INSPECTOR : _________________ (SIGNATURE) ____________ (DATE) NOTE: It is extremely important that such an inspection be made. TEAM CAPTAIN FACULTY ADVISOR Team Captain E-mail : _________________ (SIGNATURE) : _________________ (SIGNATURE) ____________ (DATE) ____________ (DATE) : ____________________________________________________________ Faculty Advisor E-mail : ____________________________________________________________ BRING A COMPLETED COPY OF THIS FORM WITH YOU TO TECHNICAL INSPECTION.e.org 57 | Page .bajasaeindia.: 4130): _____________ OD: _______________ Thickness: _______________ 3. Faculty advisor and team captain are requested to do destructive testing on sample joints that represent the integrity of similar welds on their frame (as per Rule 3. Equivalency calculations if needed (attach to this sheet). Primary Welder: ______________________________ Welding Method Used: ______________ Type of Filler Material: ___________________________ Shielding Gas Used: ________________ 4. and for those constructed of materials (i.6). Failure to do so will result in penalty. Academic year the cage was constructed? ___________________________________________ 2. All welds and/or other attachment methods must be checked for integrity.e. aluminum) which do not exhibit and endurance limit.Section 7 . WE HAVE EXAMINED THE ABOVE INFORMATION AND TO THE BEST OF OUR KNOWLEDGE DEEM IT TO BE ACCURATE. ALSO BRING THE MATERIAL SPECIFICATION CERTIFICATE AS PROVIDED ALONG WITH THE ROLL CAGE MATERIAL BY THE VENDOR. Material Type (i. 5. The purpose of this sheet is to facilitate verification of roll cage materials/construction and to provide a means of tracking the age of older vehicles 1.Appendices APPENDIX 1 BAJA SAEINDIA ROLL CAGE SPECIFICATION SHEET 2014 BAJA SAEINDIA COMPETITION COLLEGE NAME _______________________________ CAR NUMBER__________________ This sheet MUST be completed and submitted in accordance with the event rules.3.
• • • • • • • www. Last date of technical inspection at college level will be 31 Dec ’2013 and all the teams will adhere to the deadlines for inspection. The teams failing to above timelines automatically gets eliminated out of the BAJA 2014 event. Allotted teams will directly contact the Technical Inspectors for mutually fixing Technical Inspection dates for the local level Technical Inspection.bajasaeindia. At least an early intimation of 20 days should be made by the teams so as the technical inspector can make necessary arrangement for visiting college campus for local inspection. the vehicle will not be allowed at the main event. BAJA main Technical inspection will start one day prior to the Starting day of the Main event at the Pithampur site and no Technical inspection will be conducted on a later date. vehicle should conform to 100 percent Self Certification Check Sheet criteria. failing which teams may be disqualified from the main event also. Any team. This impound time shall be 180 minutes per incident. Only one re-inspection will be conducted during the main event.org 58 | Page .APPENDIX 2 Local Technical Inspection Rules / Violation Penalties for 2014 • • • • • • • • • Names & contact details of Technical inspectors and their allotted colleges will be mailed/ put on the official BAJA 2014 website in December 2013. Teams shall be penalized with a minimum deduction of 50 points subject to the any Design modifications done after the conclusion of Static event. it also includes a “Figure of 8” test and a panic brake test at the local level inspection. Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical inspectors will not be permitted to participate in the dynamic events. Teams must retain the Original Technical Sheet /all the Documents of proof along with them only Teams will then submit these documents at the Main technical Inspection site at Indore only. Failing the 100 % acceptance criteria at local level and confirmed by the Technical Inspector. Teams unable to submit welding samples of adequate quality shall not be eligible to complete in any dynamic or endurance event. Extensive use of readymade subassemblies may invoke penalties. At local level inspection. if found to have fabricated their vehicle using professional assistance or from a Standard kit would be liable for a penalty of 400 points or may be ineligible to compete. The Baja SAEINDIA Technical Committee reserve the right to impound any on-site registered vehicle at any time during a competition for failure to comply to the discipline of the event at all times. failing which the teams will be disqualified for the dynamic events.
The decision of the Head of the Technical Committee of Baja SAEINDIA in this regard will be final and binding to all. • www.• Team representatives must be present during the comparison to discuss the design changes. then a penalty of up to three hundred (300) points may be assessed against the design score Any vehicles found unsafe at any given time of the event will not be allowed to run .org 59 | Page . This is in the interest of safety.bajasaeindia. If the judges find that the design changes are (A) not significant. (B) not supported by a detailed analysis or (C) have not been sufficiently documented.
the complete team may be penalized as deemed fit by the organizers. No one else will be permitted other than team members to work on vehicle if found so. Any team performing any welding operation at site should do it in a defined area preferably with empty fuel tanks. the team is likely to attract penalty / rejection as deemed fit by the organizers. Team may file a protest against professionally made vehicles with supporting evidence. including that the organizers reserving the right to refuse re-inspection.APPENDIX 3 RECOMMENDATIONS OF CODE OF CONDUCT DURING BAJA SAEINDIA 2014 If a technical inspector at site finds the vehicle incomplete during his/her final technical level vehicle inspection. Event timings shall be strictly adhered to.org 60 | Page . Team members without authentic ID Cards will be liable for penalty as deemed fit by the organizers. www. which may include disqualification.bajasaeindia. Teams which do not pass inspection at the 1 inspection may be penalized as deemed fit by the organizers. The decision of the organizers in this regard will be final and binding on all parties.
type of suspension. etc. Pre-Processing (framing the parameters. To acquaint the teams completely with the objectives of the BAJA SAEINDIA event. etc.1. The objectives of the Virtual BAJA Event are as follows: 1.1 4. The teams would be judged on the following basis: 220.127.116.11. Chosen configuration (disc. loads etc. Specifications (stopping distance.3. www.3. The teams are required to acquaint themselves with the technical guidelines and limits for the design of BAJA vehicle.3 4.org 61 | Page . tie-rod length.3 Knowledge of rulebook Project Plan Design Extent of completion of vehicle design Design Methodology Roll Cage Design 4. Post-Processing (result analysis.3. constraints.2 4.) 2.) B. changes in design.3 Materials Used Compliance with rulebook Finite Element Analysis A.4 Suspension. 18.104.22.168 4. drum brakes. suspension travel.3. caster.) C. steering geometry. Objective The Virtual BAJA SAEINDIA is a pre-qualifier to participation in the BAJA SAEINDIA event.1 4. Steering & Brakes 1.APPENDIX 4 Virtual BAJA SAEINDIA A.3.2 4.1. To design the complete CAD Model of the BAJA Vehicle. turning radius. 3. 2. The design should be complete in all respects to the extent of being considered ready-for-manufacture.1 4.3.bajasaeindia. Human Ergonomics 4.
3. exhaust design. etc.) 2.camber. toe-in. Transmission (chosen configuration. mounting. fuel system. 3. etc. traction. Engine (engine specifications. ONLY ONE TEAM PER COLLEGE shall be allowed on the basis of comparative merit.5 Power train 1. Suspension Design (wishbone. The selection would be purely on the basis of merit. the teams would be selected for participation in the main event. Selection 1.9 Safety DFMEA Innovation 4. damper mounting. turning radius. kill switch. braking circuit. routing etc. emission control.3.11 Vehicle Completion Date & Technical Inspection Date B.org 62 | Page .) 3.3. Ergonomics 4. www. pedal force etc. joint with final drive. Wheel Size (wheel mounting. knuckle design. final drive to wheels. Brake Design (braking effort. intake. power assistance etc. wheel size. max speed. 2.7 4. Weight (target) 2.3. A-arm. transmission coupling etc.10 Design Validation Plan 4.3. fuel lines.) 5.3. shock absorber. etc. travel. Steering Design (geometry.bajasaeindia. brake mounting.3. battery placement. wheel hub. trailing arm design.) 4. acceleration. power.8 4. braking effort.6 Body & Electricals 1. Electrical System (safety. Aesthetics 4.) 4. etc) 4. engine coupling.) 3. toe-out.) 3. joints. Based on the performance in the Virtual BAJA.
no ranks or awards would be issued for the Virtual BAJA event.C. The design presented during the event shall be considered as final and the team shall be considered to proceed towards fabrication activity using the same design. Steering Brakes Power train Safety Design Validation Plan Total 50 50 50 50 25 25 25 25 50 50 400 The qualified teams would be required to submit the design report soon after the Virtual BAJA event. thus.bajasaeindia. the teams shall be penalized / disqualified if the fabricated vehicle does not exhibit correlation with the design report or if the teams fail to fabricate within the stipulated timeframe.org 63 | Page . Failing this. www. NOTE: The Virtual BAJA is a pre-qualifier. Scoring • • • • • • • • • • Knowledge of rulebook Project Plan Roll Cage Design Over all Vehicle Technical Specification & Target Suspension.
the expected performance. turning circle diameter. etc. bump steer calculations. any other features etc. design methodology & outcome. drawings and optional content are all inclusive). deceleration. weight transfer. steering geometry. Introduction The author should describe the introduction of the project. grade ability. criterions. Roll/ pitch suspension layout.Vehicle Performance Target and 3D Views (10 Marks) Engine Drive Suspension Wheels Brake Steering Dimensions Weights The expected target vehicle performance (speed. www. ID. Front & Rear Suspension Design (10 Marks) Design considerations. fuel consumption). turning angles/ diameter. 3D View of the Complete Vehicle The CAD view and the isometric view of actual vehicle Roll Cage Design & Driver Ergonomics (15 marks) Design Considerations Material Used Static & Dynamic FEA Results Weight Material Properties Selection Criteria Driver Ergonomics Ergonomic considerations for driver comfort Design for driver ergonomics. Steering Design (5 marks) Design selection criterions. Technical Specification. design data. innovation. acceleration. lay-out. travels and safety factor. the design iterations done to get the desired configuration. sprung and unsprung mass. lay-out.org 64 | Page . Generally Applicable: Methodology of design as to why the particular configuration has been selected over other options. picture. brake system details and calculations. emissions. stopping distance. Brake System Design (5 marks) Design considerations. target specifications.APPENDIX 5 Design Report Format (A) Format – Design reports must follow the format for SAE Technical Papers. ground clearance.camber / caster / toe in. spring design considerations.bajasaeindia. The design report file must be named as follows: Team reg. design selection. steering effort etc. (Please use bullets wherever possible & max 10 pages + 4 pages for illustration) (B) Electronic version – The design report must be submitted electronically in Adobe Acrobat Format (PDF) The document must be a single file (text. Institute abbreviated name (C) File Size – The maximum size for the file is 5 megabytes. calculations. pedal force versus deceleration.
Body Panels (10 marks) and Safety Equipment Weight considerations and the design of body panels.Powertrain Design (10 marks) Power unit mountings. NVH considerations if any. Engineering Bill of Materials (5 marks) Innovations – (Separate Evaluation) Any innovation if used in the vehicle References & Acknowledgment / General Presentation (5 marks) www. drive line lay out. output shaft angularities for the full suspension travel. fuel tank. The safety features used in the vehicle. total weight of drive line parts.org 65 | Page .bajasaeindia. inlet air filter/ exhaust system. over all transmission ratios and maximum speed/ grade ability in each gear.
It’s based on indentifying unique components required to build the vehicle assembly / sub-assemblies.000 1.g. of Operations 10 1 2 Cost of Operation 150 12 10 0 Total Cost 28. etc. The part number should be a 10 digit number with the first three digits indicating the block. the next five digits classify the part number and the next two digits represent the level of hierarchy. Block: If the vehicle is considered as an assembly of the following major aggregates: Engine. manufacturing cost. Level Name Engine PTEENGIN00 1 1 Chain PTTCHAIN00 1 1 Qty 1 2 10 5 1 Cost (Procurement) 28. The teams are required to classify all the parts used in building the vehicle into either of the blocks as mentioned in the Index Sheet. The codes for block are mentioned in the sheet.00 Manufacturing Operation L SW GW GR NA No.APPENDIX 6 BAJA SAEINDIA Cost Report Format ILLUSTRATION: BOM of a Cost Report Block PTE PTT Part Part No. Sheet 2: It is the Bill of Materials Sheet. the students are required to fill in the following details: i.000 15. the teams are required to judicially choose the part number and revision number. The BAJA SAEINDIA COST Sheet comprise of three sheets: Sheet 1: It indicates the overall cost of the vehicle. Electricals & Instrumentation (E&I). www. The parts may be classified as Parent (Level1) or Child (Level 2) depending on whether it’s being assembled to vehicle directly. iii. The part should be named in a manner that it reflects the level of usage in the vehicle (e. Suspension. If it is in the form of another unit or subassembly which is assembled on vehicle subsequently.bajasaeindia. procurement cost. each one is regarded as a building block of the BAJA Vehicle. Herein. total no. It gives a brief overview about the cost and Bill of Materials for the BAJA Vehicle.org 66 | Page . Part Name: Every unique part is to be identified with a unique name. Transmission. ii.: Gearbox Assembly – indicates the gearbox is an assembly part). Example: Gears in gearbox are Level 2 parts while gearbox is Level 1 part. Part Number: Every unique part is to be identified with a unique part number. of parts used.800 120 50 0 Guideline for Cost Report for Baja SAEINDIA 2014 The cost report is based on Bill of Materials. Roll Cage.
Procurement Cost: The teams are required to mention the procurement cost of the finished product/ raw material required to build the vehicle. the cost is to be determined for a single wheel with Quantity as ‘4’. vii.iv. Cost would be indicated automatically. Please note that the manufacturing cost includes the raw material required for the operation. The teams are ONLY required to fill the codes as specified in the index in the ‘Manufacturing Operation’ column. irrespective of whether the part is a fresh sale or resale based procurement or even if it is sponsored. For example: the cost of welding is based on a 10 mm weld length. for example: filler material for weld. The teams are required to fill the exact code as mentioned in the index sheet. www. divided by 10 (mm) would give the no. of operations required for completion.bajasaeindia.: if the team plans to use the same wheel at all four locations in the vehicle. In case the cost of the parent is determined completely by its child parts. In such a case. The MRP must be mentioned for all the parts and must be supported through Original bills / invoice/ quotes etc. The codes for each operation are mentioned in the index sheet. For ex. The teams DO NOT have to add the cost of filler material. The teams are required to fill the MRP (without taxes). Manufacturing Operation: The teams must mention the manufacturing operation for each part. roll cage is also to be considered as an assembly of various pipes (RRH. viii. Total Cost: It is the sum of procurement cost and manufacturing cost. of operations are to be considered for determining the cost of the roll cage. The teams are required to fill either 1 or 2. It is already taken into account in the standardized cost. For example: to weld the roll cage. which constitute the child parts of the roll cage). The students need to identify the no. v. vi. This would be the cost of a single joint.org 67 | Page . Wherever there is no manufacturing operation applicable. to be required to bring it to the final shape for assembly in the vehicle. Cost of Operation: The cost of operation is standardized as in the index sheet. The standard tables also define the specification of the operation. Quantity: The number of such parts to be used. SIM etc. ix. Level: Indicates whether the part is the parent part (Level 1) or whether it is a child part (used as an entity in a parent assembly) (Level 2). please mention ‘NA’. of such welds required for the completion of the job. For multiple operations it is required to fill the manufacturing details in subsequent rows (only manufacturing operation is to be filled with the number of operations). The total joints and total no. Thus the cost of child parts may be established for a better and clear estimation. the outer diameter of the roll cage pipes is to be considered. the costing fields of the parent may be left blank as the cost would be indicated by the child parts.
This would be multiplied by an adjustment factor (penalty point) and the final adjusted cost may come out to be higher than the incurred cost. THE COST ADJUSTMENT WOULD BE DONE AT THE JUDGE’S DISCRETION. operations. This sheet is to be referred for cost. there would be an adjustment cost added to the cost as indicated by the team. etc. The objective is to find out the cost of the vehicle if a fictitious firm manufactures the BAJA vehicle at a rate of 4000 vehicles per annum. It is not necessary that the vehicle with the LOWEST COST would be awarded the maximum score. www. It is thus suggested for the teams. to accurately determine the cost of the vehicle and not minimize the cost intentionally. IT IS ENTIRELY THE RESPONSIBILITY OF THE TEAM TO UNDERSTAND THE GUIDELINES AND FORMULATE THE COST OF THE VEHICLE AS PER THEIR UNDERSTANDING. Instead in such case.bajasaeindia.Sheet 3: It is the index sheet.org 68 | Page . ANY DISCREPANCY IN DATA / FOULING WITH THE FORMULAE WOULD LEAD TO DISQUALIFICATION / PENALTY IN THE COST EVENT. Please note that the BAJA SAEINDIA Cost Event is meant for the teams to determine the vehicle cost precisely and accurately and NOT to the minimum.
org 69 | Page . Steering & Brakes Electricals & Safety Standard Parts (Fasteners.APPENDIX 7 Index Sheet for Process Cost Reference Operation Lathe (1000 mm3 volume) CNC (1000 mm3 volume) TIG (10 mm length) SMAW Welding (10 mm length) Gas Welding/Gas Cutting (10 mm length) Drill (1000 mm3 volume) Reaming (10 mm depth. etc.Engine. Intake & Exhaust Powertrain – Transmission Roll Cage & Body Suspension. Joints.bajasaeindia. 10 mm diameter) Boring (10 mm depth) Grinding (100 mm2 area) Super finishing (100 mm2 area) Filing (100 mm2 area) Riveting (per rivet) Shaper (1000 mm3 volume) Milling (1000 mm3 volume) Shearing (10 mm cut) Cutting (10 mm cut) Gear Hobbing (10 mm width per teeth) Rack Cutting (10 mm width per teeth) Pneumatic Operations (Requiring Pneumatic Source) Special Manufacturing Operation (actual expense incurred) Other Block Codes Powertrain .) Code L C TW SW GW D R B GR SF F RV SH M SG CT GH RC PO SP O PTE PTT RCB SSB EEE STD Cost 10 5 8 15 12 5 10 10 5 15 5 5 10 15 5 5 20 20 15 www.
: _______________ REGISTREATION ID: _______________ The participating team must get the sheet signed by Judge Panel for various Static Events & submit the same at the end of the clearing Static Event to event coordinator.APPENDIX 8 STATIC EVENT PARTICIPATION SHEET TEAM No.org 70 | Page . EVENT Originality & Innovation Feasibility for Mass Production Driver Comfort & Ergonomics Serviceability Suspension Steering & Brake Power train Structural Design Craftsmanship Emission – Low idle rpm Emission – High idle rpm Cost Event Marketing Presentation Sign of Judge (Head of Panel) www.bajasaeindia. Failing to this the team would not be considered eligible for scoring in static events.
Innovation (vis-à-vis earlier Innovations) Craftsmanship Suspension Front Suspension Rear Steering Brakes Power Train Roll cage Body Feasibility for mass production Serviceability Operator Comfort / Ergonomics Cost Report Bill of Materials Cost Criterion Discussions with team / Cost reductions Prototype costs (by formula) Presentation flow Timelines Effectiveness and solidity of aids Clarity of Technologies and ideas USP coverage and Customer Satisfaction Answers: Confidence / concise / correct Marks Design report Off Site 75 Design Evaluation On Site 125 Cost Report & Costs Off Site On Site 20 30 Technical Presentation On Site 50 Dynamic Events Dynamic Events On Site 1 2 3 Acceleration (Speed Event) Hill Climb Maneuverabilty 100 100 100 Endurance Events Endurance Events On Site 1 Endurance Event (max duration = 4 hrs. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 1 2 1 2 3 4 5 Sub-group Technical Specs / 3 D view of vehicle Roll cage design Suspension design Steering & Brakes design Powertrain Design Body panel / Safety equipment Engineering Bill of materials General Presentation – References etc.bajasaeindia.) 400 Grand Total 1000 marks www.APPENDIX 9 BAJA SAEINDIA 2014 Scoring Static Events Category Location No.org 71 | Page .
Safe Vehicle Award Criteria: “ZERO TOLERANCE” is the theme for BAJA SAEINDIA 2014. chiefly. Hence.bajasaeindia.org 72 | Page . www. The number of attempts for the On-Site Safety Scrutiny is important and the time taken. to clear it. it is very important for a team to ensure 100% compliance for Self Certification as well as the high quality of build so that there is no re-work during the main event.APPENDIX 10 BAJA SAEINDIA 2014 Awards Details of Various Awards Given in Event will be hosted on BAJA SAEINDIA official website. considered on the basis of the total compliance of BAJA SAEINDIA vehicle with the official RULEBOOK during the college-level and the main event-level Technical Inspection and on clearing of the On-Site (main event) Safety Scrutiny (Section 5.3) in “First Attempt & Shortest Time”. This is. will be recorded for each team.
org 73 | Page .bajasaeindia. The penalties may change subject to case. Insp. at Local level ON SITE Technical Safety Scrutiny Inspection Sheet Design Modification after Static Events Kill Switch Vehicle Impound Design Changes Accident / Violent Driving / Driving off the track Full payment of fee before the deadline Full payment of fee and submission of documents as per the deadline Compliance as indicated in rulebook OR as per guidelines of technical committee Compliance as indicated in rulebook OR as per guidelines of technical committee in maximum of 2 evaluations by the committee Compliance as per the test Running the vehicle without Tech OK & Brake OK Unruly behavior / misconduct with organizing committee / volunteers / other participants / spectators Accident prone activity Presence after closure of pits Accident on account of driving the vehicle at the site (non-dynamic events) Vehicle to be pushed with engine off Subject to case Any professional assistance sought during vehicle design or build or validation Due date submission for Self certification submission on line Compliance. The event specific penalties are specified in the rulebook. www. 100% compliance Local level Technical Inspection Sheet with pre declared reports must be present during the on-site Tech Inspection Any modification done to the design Deviation from specification As per judgment of Technical Committee Deviation from design report Driving in pit areas / violent driving instruction / accident prone drive & damage to other teams or Volunteer on test ground * T he penalties described above are for overall conduct of the event and not particular to any of the specific static / dynamic events.APPENDIX 11: BAJA SAEINDIA 2014 Penalty Structure Particular Cost / Design Report Judgment Criteria Submission as per timeline Penalty No evaluation of reports Disqualification Disqualification 100 points / Disqualification 400 points Disqualification from Dynamic Events Disqualification from the event 200 points / Disqualification 200 points / Disqualification 300 points 200 points 1000 points 50 points per case Subject to case 400 points or Disqualification 25 points Disqualification Disqualification from Technical Inspection Minimum 50 points 200 points 180 minutes per incident Up to 300 points 1000 points / Disqualification for next three years Registration Document All required details provided Fee Engine Order Technical Inspection (off-site) Technical Inspection (on-site) Brake Test Fuel Code of Conduct Vehicle Repairs in Pit Event Timings Traffic Guidelines Vehicle Movement Others Professional Help in Vehicle Build On line Submission of “Self certification” Compliance for Tech.
General Communication 3.org puviarasu@ppepl. 6.bajasaeindia.APPENDIX 12 BAJA SAEINDIA 2014 CONTACTS Name & Company 1) 2) Sanjay Nibandhe.com Anshuman Vagesh Sagar Bendre/ Akhand Pratap Singh Akhand Pratap Singh S. 5. General Issues/ Query Engine Related Query Alumni/ Student Contact Administrative Issues Online submission / Web site bajatechfaq@gmail. Following mail id are provided for respective communications – 1. 4. Cummins Convener Joint Convener Position Direct Communication to any member of organizing committee shall not be entertained and shall not be considered as official. Technical Issues & Questions 2. Puviarasu Taru Singhal Sagar Bendre Akhand Pratap Singh www.com bajahelpline@gmail. 7.org 74 | Page .com saeindia_indore@saeindia. Mahindra & Mahindra Ltd. Lalitkumar Suryawanshi.
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