5.

4 ENTRY FORMS

Driving Innovation Bosch Power Tools Asia Cordless Race 2011

Application Form

We would like to participate in the Driving Innovation - Bosch Power Tools Asia Cordless Race 2011 in Malaysia by giving our personal data.

Name of Institute ...............................................................................................

UNIVERSITI TEKNOLOGI MALAYSIA

Address of Institute

FACULTY OF MECHANICAL ENGINEERING ..............................................................................................

..............................................................................................

UNIVERSITY TEKNOLOGI MALAYSIA SKUDAI

Name of the Team

THE U TEAM ..............................................................................................

Team Members: Leader of the Team Name

............................................................................................. Address

DR AFANDI BIN DZAKARIA

............................................................................................. E-mail

FACULTY OF MECHANICAL ENGINEERING ,UTM SKUDAI

dafandi@fkm.utm.my

............................................................................................. Phone Number .............................................................................................

0137505161

Page 30 of 36

Team Member 1 Name ............................................................................................. E-mail ............................................................................................. Phone Number .............................................................................................

MOHD FIRDAUS BIN MAT GHANI dev_knowz87@yahoo.com 0137032053

Team Member 2 Name

............................................................................................. E-mail ............................................................................................. Phone Number .............................................................................................

MOHAMAD FADZYA UZIRRUDIN BIN YAHYA xhardcrewx@gmail.com 0134767579

Team Member 3 Name ............................................................................................. E-mail

KHAIRUL ADLI BIN MUSA ardlie89@yahoo.com

............................................................................................. Phone Number .............................................................................................

0176737139

Team Member 4 Name

............................................................................................. E-mail ............................................................................................. Phone Number

MOHD FIRDAUS BIN ZAINAL

.............................................................................................

0137625572

Page 31 of 36

Bosch Power Tools Asia Cordless Race 2011

1. Introduction

In conjunction to Bosch Power Tools Asia Cordless Race 2011, we take the challenge to design a kart to show the capabilities the BOSCH GSB 18V-Li Professional cordless impact drills beyond their normal application. Design to Win concept without compromising the safety aspect is developed. Light weight kart with maximum gripping capabilities concept will maximize the power transmission from the cordless drill. In general, the kart is powered by four cordless drills. All features, dual speed and various torque setting have been taken into consideration in the development of the design. The cordless drill can be ergonomically attached to the kart without any modification. .

2.

Design Brief

The kart is built according to the general guidelines for kart design and competition. The detail specification is in the Appendix B 2.1 Design dimension (Refer to drawing no UTM 01, 02, and 03) The front track width is 1.14m. The rear track width is 1.08m. The overall length of kart is 1.51m. The distance between the drivers foot and vehicles front is 3.00m. Roll bars are installed, which shall rise above the drivers crash-helmet by the proper side

support of the driver is provided at the drivers seat at 0.28m. The kart has four wheels. The kart has a ground clearance of 0.14m with driver on board.

2.2 Safety (Refer to drawing no UTM 01, 02, and 03) Complies to regulation A two-point safety belt is installed to seat. The kart has side brace that protects the drivers from injuries in case of possible collisions. The leg space of the vehicle is covered with floor board in order to avoid foot injuries. The kart is constructed in such way that the height of the seats seating surface is not exceeding 50% of the kart width. The kart is equipped with two independent brakes, capable, in case of a moving kart, to provide for efficient reduction of speed and to stop the kart. Brake is installed for stationary and moving Emergency button with additional quick-release mechanism to ensure the driver safety Free-wheel is installed.

Additional safety Roll cage is installed Back board is installed to separate the driver with the prime mover mechanism

2.3 Prime Mover (Refer to drawing no UTM 04 and 05) Dual powered drill will drive on each side of wheel separately.

3.

Closing Remark
Design to Win concept guides the development of a kart that focuses on the light weight

design to maximize the power from the Bosch cordless power drill. The design itself is not just the number and figures (as in design spec) and it is the blending of theoretical engineering knowledge and engineering intuition. We hope that the concept is eligible to further develop and fabricated.

12

13

14

15

4
B

11 16
B

5 10

6 18 7 8 19 17

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

ROLL BAR ROLL CAGE SIDE BRACE QUICK RELEASE UNIT (REFER FIGURE 2.0) FRONT TIRE PLATE FRONT FLOORBOARD FLOORBOARD REAR TIRE BACK BOARD SEAT SEAT BELT (SAFETY FEATURES) BRAKE PEDAL THROTTLE PEDAL STEERING BOSCH CORDLESS DRILL TRIGGERING SYSTEM(REFER FIGURE 1.0) GEAR TRAIN BRAKE
1 2 3 4

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR:

FINISH:

VARIES
DATE

DEBUR AND BREAK SHARP EDGES

DO NOT SCALE DRAWING

REVISION

DRAWN CHK'D APPV'D MFG Q.A

FIRDAUS

NAME

SIGNATURE

TITLE:

DR.AFANDI

OVERALL VIEW OF UTM POWER KART

MATERIAL:

VARIES
WEIGHT:

DWG NO.

UTM01
SHEET 1 OF 5

A3

SCALE:1:20

1.51

0.28

1.02

0.14 1 SIDE VIEW 0.50 SAFETY DISTANCE FOR DRIVER FOOT FRONT VIEW REAR VIEW

1.14
E

1.08

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR: NAME DRAWN CHK'D
FIRDAUS DR. AFANDI

FINISH:

VARIES
DATE

DEBUR AND BREAK SHARP EDGES

DO NOT SCALE DRAWING

REVISION

SIGNATURE

TITLE:

DIMENSION OF UTM POWER KART

PLAN VIEW

APPV'D MFG Q.A MATERIAL: DWG NO.

VARIES
1 2 3 4
WEIGHT:

UTM02
SHEET 2 OF 5

A3

SCALE:1:20

1 2

3
C

5 4
C

1. 2. 3. 4. 5.
D

ROLL BAR (15 MM DIAMETER TUBE ) SIDE BRACE (20 MM DIAMETER TUBE) CASTOR ANGLE 20 DEGREE BOTTOM PART (20 MM DIAMETER TUBE) PRIME MOVER LOCATION
D

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR: NAME DRAWN CHK'D APPV'D
FIRDAUS DR AFANDI

FINISH:

DEBUR AND BREAK SHARP EDGES

DO NOT SCALE DRAWING

REVISION

SIGNATURE

DATE

TITLE:

CHASSIS

MFG Q.A MATERIAL:

ALUMINUM ALLOY
1 2 3 4
WEIGHT:

DWG NO.

UTM03
SHEET 3 OF 5

A3

SCALE:1:20

0.34
B B

0.56

1. 2. 3. 4. 5. 6. 7. 8. 9.

REAR DRIVING SHAFT BRAKES UNIT POWER TRAIN TRIGGERING SYSTEM (REFER TO FIGURE 1.0) DRILL HOLDER REAR WHEEL SUPPORTING BRACKET BOSCH CORDLESS DRILL PLATFORM

3 4

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR: NAME DRAWN CHK'D APPV'D
FIRDAUS DR AFANDI

FINISH:

VARIES
DATE

DEBUR AND BREAK SHARP EDGES

DO NOT SCALE DRAWING

REVISION

SIGNATURE

TITLE:

REAR DRIVE SYSTEM

MFG Q.A MATERIAL: DWG NO.

VARIES
1 2 3 4
WEIGHT:

UTM04
SHEET 4 OF 5

A3

SCALE:1:10

8 7 1

6 9

3 5 4

10

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
1

BOSCH CORDLESS POWERDRILL DRILL HOLDER (WELDED TO BASE ) BASE L-BRACKET BEARING FOR REAR DRIVEN SHAFT BEARING FOR REAR DRIVING SHAFT DRIVE CHAIN CAGE DRIVING SPROCKET DRIVEN SPROCKET CHAIN
2 3 4

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: ANGULAR: NAME DRAWN CHK'D APPV'D MFG Q.A
FIRDAUS DR AFANDI

FINISH:

MILLING
DATE

DEBUR AND BREAK SHARP EDGES

DO NOT SCALE DRAWING

REVISION

SIGNATURE

TITLE:

LEFT SIDE PRIME MOVER UNIT

MATERIAL: DWG NO.

ALUMINUM
WEIGHT:

UTM05
SHEET 5 OF 5

A3

SCALE:1:5

FIGURE 1.0
THE BRACKET WELDED TO THE MAIN CHASIS 1

WHEN THE DRIVER PUSHES THE PEDAL, THE CABLE WILL BRING THE TRIGGER FINGER CLOSE AND SWITCH ON THE CORDLESS DRILLS.AS THE DRIVER RELEASE THE PEDAL, THE SPRING RETURN THE FINGER TO INITIAL POSITION

5 2 1. 2. 3. 4. 5. BRACKET SPRING WITH SLOT PULLEY CABLE SLOT TRIGGERING PAD

FIGURE 2.0

QUICK RELEASE UNIT

1 2

1. BASE (ATTACH TO SEAT) 2. TRIGGER 3. SCREW 4. CABLE SLOT

QUICK RELEASE UNIT IF UNEXPECTED ACCIDENT HAPPEN, THE DRIVEN CAN PULLUP THE TRIGGER .THIS WILL LOOSE THE CONNECTION BETWEEN PEDAL AND THROTTLE CABLE

DETAIL WORKING OF QUICK RELEASE UNIT ARE NOT PROVIDED AT THIS STAGE