Design of Battery Mount, Transponder mount and Instrument Panel

ABSTRACT
Designing purpose of this ATV is to manufacture an off road vehicle that could
help in transportation in hilly areas, farming field and as a reliable experience. In
order to accomplish this task, different design aspects of an ATV vehicle were
analysed, and certain elements of the ATV were chosen for specific focus. The
points of the car we decided to specifically focus on were the Battery mounting,
Instrument panel and Transponder mounting. The most time and effort went into
designing and implementing these components. It involves the planning and
manufacturing tasks found when introducing a new product to the consumer
industrial market.

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CHAPTER 1

INTRODUCTION

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1.1 INTRODUCTION:
An all-terrain vehicle (ATV), also known as a quad, three-wheeler, four-
Standards Institute (ANSI) is a vehicle that travels on low-pressure tires, with a
seat that is straddled by the operator, along with handlebars for steering control.
As the name track, four-wheeler, or quadricycle, as defined by the American
National implies, it is designed to handle a wider variety of terrain than most other
vehicles. Although it is a street-legal vehicle in some countries, it is not street-
legal within most states and provinces of Australia, the United States, or Canada.
The parts of ATV which are concerned here are seat, instrument panel,
transponder mount, battery mount.
Instrument panel is a control panel usually located directly ahead of a
vehicle's driver, displaying instrumentation and controls for the vehicle's
operation. It is used to show speed, fuel level and oil pressure, the modern
instrument panel may accommodate a broad array of gauges, and controls as well
as information, climate control and entertainment systems. In telecommunication,
a transponder is a device that, upon receiving a signal, emits a different signal in
response. In optical fiber communications, a transponder is the element that sends
and receives the optical signal from a fiber. A transponder is typically
characterized by its data rate and the maximum distance the signal can travel.
Vehicles must carry a functional, properly mounted and fully charged transponder
of the specified type. So a suitable mount of standard dimensions should be used
in order to fix the transponder. All vehicle transponders shall be mounted in the
proper location, correctly oriented, and using sufficient fastening methods.
Batteries play the major role of power resource. All batteries shall be mounted
with sound engineering practices and not come loose during normal operation, a
collision or rollover. Battery terminals shall be insulated and protected against an
electrical short. A seat shall work in concert with the driver harness to secure the
driver within the envelope of the roll cage. Seats shall be of conventional design.
Seats shall be designed to have at least two generally planar surfaces when the
driver is seated in the vehicle. All seats shall have no less than six total mounting
points to the vehicle frame. Seats shall have no less than four mounting points
from the seat bottom plane and no less than two mounting points from the seat
back plane.

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1.2 STATEMENT OF THE PROBLEM.

1.2.1 BATTERY MOUNT: To design a casing for the battery to be held rigidly
without any deformation under the vibrations of the engine.
1.2.2 TRANSPONDER MOUNT: To give stability to the transponder to give
effective information through sensors and signals.
1.2.3 INSTRUMENT PANEL: To get broad view of the RPM, Fuel consumption,
speed and distance travelled. To reduce weight of the vehicle and also give handy
features to the driver.

1.3 OBJECTIVES OF PROJECT:

1. Designing a battery mount to withstand vibrations in the engine.
2. Designing a transponder mount to sustain impacts while in motion.
3. Designing a the instrument panel to provide useful information for the
driver

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CHAPTER 2

LITRATURE SURVEY

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2.1: REVIEW OF LITRATURE:

ATV’s (ALL TERRIAN VECHILE) is a single sitter high performance off
road vehicle that well takes the ruggedness of rough roads with maximum safety
and driver comfort. These vehicles are specially modified for the racing unit on
rough roads and these vehicles gives more safety to the drivers by its framework.
These vehicles are too costly and not so economical and these vehicles are only
most used in off road application like hills etc.

2.2.1 INTRODUCTION TO BATTERY:

A battery is a device consisting of one or more electrochemical cells with
external connections provided to power electrical devices such as flashlights,
mobile phones, and electric cars. When a battery is supplying electric power, its
positive terminal is the cathode and its negative terminal is the anode. The
terminal marked negative is the source of electrons that will flow through an
external electric circuit to the positive terminal. When a battery is connected to
an external electric load, a redox reaction converts high-energy reactants to
lower-energy products, and the free-energy difference is delivered to the external
circuit as electrical energy. Historically the term "battery" specifically referred to
a device composed of multiple cells, however the usage has evolved to include
devices composed of a single cell.

2.2.2 BATTERY MOUNTING DESIGN:

Primary batteries readily available to consumers range from tiny button
cells used for electric watches, to the No. 6 cell used for signal circuits or other
long duration applications. Secondary cells are made in very large sizes; very
large batteries can power a submarine or stabilize an electrical grid and help level
out peak loads.
Design of the battery holder requires knowledge of how and where the
larger product will be used. Human factors to be considered include ease of
battery exchange, age range and physical condition of the intended user. These
elements must be taken into account for a design to be successful and are part of
the design process. A designer must select between a battery holder molded into
the product case or made as a separate part. For designing products regulations
and product safety standards affect the battery holder selection according to SAE
BAJA RULEBOOK 2020.

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Table 2.1 Recommended Batteries:

Particulars Capacity Price ($)

EXPERT POWER EXP1270 12V 7Ah 20

Yuasa YUAM620BH 12V 18Ah 80

Yuasa YTX14-BS 12V 10.5Ah 200

Odyssey PC680 12V 16Ah 130

USA-Made Big Crank ELX 12 V 20Ah 100

18L
Scorpion YTZ5S 12V 4Ah 40

2.2.3 INTRODUCTION TO TRANSPONDER:

A transponder is a wireless communications, monitoring, or control device
that picks up and automatically responds to an incoming signal. The term is a
contraction of the words transmitter and responder. Transponders can be either
passive or active. MYLAPS FLEX transponder is the official transponder of the
AMA ATV Motocross National Championship Series. The transponder shall be
mounted on the right side of the vehicle, forward of the seat, and preferably within
the lower horizontal plane of the front suspension. The transponder shall be no
more than 61cm (24 in) above ground level. The transponder shall have an open,
unobstructed path between the antenna on the bottom of transponder and the
ground.

2.2.4 DESIGN REQUIREMENTS TRANSPONDER MOUNTING:

Required transponders are All vehicles must be equipped with at least one
MYLAPS rechargeable transponder. The only
acceptable transponder types are:
 MX CLASSIC
 MX FLEX
 X2 MX RECHARGABLE
 X2 MX DIRECT POWER

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TABLE 2.2 (Allowed transponders)

Source: Baja rule book

2.2.5 INSTRUMENTAL PANEL SPECIFICATIONS

This is the important part in the vehicle and by this instrumental panel we can
get notified by many things such as the speedometer, fuel indication, light etc.
This instrumental panel does not contain much dimensions as such because
instrumental panel will be one size different from another company as well so
this instrumental panel will be depending on the cost, features etc.,

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SPECIFICATIONS:

1: INSTRUMENTAL PANEL (HIGH ECONOMY)

 NAME: KASO
 SPEED RANGE: 0-360 KM/HR
 TRIP METER DISPLAY RANGE :0-99999KM
 FUEL LEVEL DISPLAY :10 LEVELS
 TIRE CIRCUMFERENCE SETTING RANGE :300-2500M
 FUEL LEVEL DISPLAY UNIT :1 LEVEL=10% FUEL

2: INSTRUMENTAL PANEL (LESS COST)

 NAME :UNIVERSALMOTORMETER GAUGE INSTRUMENTAL

PANEL
 COLOUR : SILVER+WHITE
 MATERIAL :METAL+ABS
 METER SIZE : 2 INCHES(52mm)
 WORKING VOLTAGE :DC 10-15V
 MEASURING RANGE :200-1200
 PRODUCT SIZE :85*57*57mm

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Design of Battery Mount, Transponder mount and Instrument Panel

CHAPTER 3

DESIGN DETAILS

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3.1 DESIGNING OF TRANSPONDER MOUNTING:

For manufacturing transponder mount, after arriving to the final concept
design the 3D assembly design along with the individual part drawing with
dimensioning are generated using Solid Works 2016 software. While designing
the following considerations are made:

 The width, length and height of the attachment are fixed to (70 x 60 x 2)
mm as the attachment is to be compact and of less weight.
 Wherever it is possible standard elements are used in the design in order
to reduce the cost and to make the assembly as simple.
 The holes (6) of diameter 5mm are made to account for the bolt and
screws.
 Mostly fasteners (bolts, nuts, screws) are used for assembly wherever
possible for easy dismantling, maintenance and carry out correction works.

Figure 3.1(Transponder mount)

3.2 DESIGNING OF BATTERY MOUNTING:

Designing a battery mounting depends on the type of battery we are using

and the size of the battery and the model used. In designing here, we used model
USA-MADE Big Crank ELX 18L model.

 The width, length and height of the attachment are fixed to (6 x 3.55 x 2.5)
in as the attachment is to be compact and of less weight.

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Design of Battery Mount, Transponder mount and Instrument Panel

 Sheet metal option is used for modelling in solidworks.

 Handle bar is constructed separately using arc’s and extruded accordingly.
 The two are assembled in Solidworks assembly.

Figure 3.2 (Battery mount base)

Figure-3.3 (Battery mount handle)

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Figure 3.4

BATTERY MOUNTING ASSEMBLY

3.3 DESIGN INSTRUMENT PANEL

The cockpit must be protected with body panels that completely cover the area
between the LFS and the SIM. No gaps can exist that are larger than 6.35 mm
(0.25 in) and will be checked with a 6.35 mm (0.25 in dowel rod). These panels
must be made of puncture resistant material, including: plastic, fiberglass,
metal, or similar material.

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Figure-3.5 (instrument panel Design)

Figure-3.6 (Instrument panel Model)

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CHAPTER 4

TESTING AND PERFORMANCE

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Figure-4.1 (Total Deformation at frequency 0Hz)

Figure-4.2 (Total Deformation at frequency 3.82Hz)

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Figure-4.3 (Frequency vs Mode)

Table-4.1 (Results table)

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CHAPTER 5

5.1 ENVIRONMENTAL IMPACT

ATV impacts include noise disturbance, damage to vegetation, increased

runoff, soil erosion, and degradation of water quality. Wildlife also suffer from
all of these impacts. Unfortunately, when ATVs leave trails…and there is
extensive evidence that this occurs…these impacts to wildlife are even worse. As
ATVs move across the land, their heavy weight (anywhere from 400 to over 1,000
pounds) compacts soil. Soil compaction changes the properties of the soil, by
squeezing the tiny air spaces out of what would normally be healthy soils. When
this happens, water cannot be absorbed into the ground, likely causing runoff.
When runoff occurs, surface soils are washed downhill into water, where
sediments have negative impacts on aquatic habitats for fish, amphibians and
other wildlife. Soil compaction also limits root growth for plants, including those
that wildlife feed on.

5.2 HUMAN SAFETY ASPECTS

The following guidelines will help reduce the risk of injury to

employee operators of ATVs:

 Provide instruction and hands-on training on safe handling and

operation of ATVs. Ensure that employees are competent in
operating their specific ATV under the variety of conditions in which
they will be driving.
 The major ATV manufacturers and distributors provide free hands-
on training to purchasers of new ATVs and can provide additional
training at a reasonable fee. The ATV Safety Institute
(www.svia.org) also offers ATV classes that may be of assistance.
 Ensure that all likely ATV drivers have reviewed and understand the
operator’s manual.
 Ensure that all manufacturer’s warnings are followed and that
drivers review and understand them.
 Do not permit ATV drivers to carry passengers.

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CHAPTER 6

CONCLUSION
The design is first conceptualized based on personal experiences and intuition.
Engineering principles and design processes are then used to verify and create all
the parts, The design process included using Solid Works, and ANSYS software
packages to model, simulate, and assist in the analysis of the completed vehicle.
After initial testing it will be seen that our design should improve the design and
durability of all the systems on the car and make any necessary changes up until
the leaves for the competition.

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CHAPTER 7
REFERENCE
1. John C. Dixon; Suspension analysis and computation geometry; ISBN:
978- 0-470-51021-6; October 2009.
2. Thomas D. Gillespie; Fundamental of Vehicle Dynamics; ISBN: 978-1-
56091-199-9; February 1992.
3. Practical experience - R.P.M Bhopal (M.P) RPM, near Ratibad Town,
Bhadbhada Road, Bhopal, Madhya Pradesh – 462023 Polaris Indore
(M.P).
4. MyCar Polaris, Pipliya Kumar Mangal Compound Near Mttal Toll Kanta
Indore, India – 452010
5. Design of machine elements B BHANDARI,TATA MCGRAW HILL
publishing company ltd,delhi,2nd edition 2007
6. Design of machine element ,V B BHANDARI,4th edition ,tata McGraw
hill,2016
7. Design data hand book ,Mahadevan and balaveera reddy,CBS publication.

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