Lessons Learnt

Roll Cage

1. Poor weight transfer due to highly stiff roll cage

2. Complex geometry for suspension arm mountings
3. Large clearance from driver’s head to the top
member
4. Better integration with engine assembly
5. Large errors in 3D bending of tubes
6. Better fixtures for manufacture of roll cage

Powertrain

1. Tuning of CVT must be done accurately as it affects

vehicle performance
2. Loss of traction due to high gear ratio
3. Non-compliance of CV axle at high articulation
angles
4. Mechanism is needed to reduce heating of cvt
5. Gearbox heating lead to high pressure built up
6. CV axle hindered with suspension arms
Suspension and Steering
1. Stiff and light arms and joints should be
preferred. Fig.(a)
2. Accuracy in manufacturing to avoid play
3. Avoid toggle position in steering mechanism
4. Proper clearance to avoid hindrance to
shockers
5. Proper clearance between rear suspension
arms and CV axle required
6. To compact the front wheel hub assembly, Stub

axle assembly is suggested. Fig.(b)

7. To avoid the tie rod failure, proper orientation
is needed with material of more fractural Fig.(a) Fig.(b)
rigidity.

Braking

1. To increase FOS in FEA analysis

2. To maintain proper height of brake pedal from
base
3. To maintain proper clearance between rims and
calipers. Fig.(c)
4. Manufacturability of master cylinder and its
affordability
Fig.(c)
 Comparative Analysis
   Parameter Old vehicle New vehicle Parameter Old Vehicle New Vehicle
Length​ 77’’ 77” Maximum 7.355 KW (10
7.355 KW (10 HP)
Width​ 58”  56'' Power HP)
56”​ Maximum
Height​ 55.8” Torque 19.66 N-m 19.66 N-m
Wheelbase​ 57” 55'' CVT (CVTech),
Track Width 52” ratio 0.43:1 to CVT (CVTech),
50''
(front)​ 3:1 ratio 0.43:1 to
Track Width (rear)​ 46” 48'' Transmission Custom 3.0:1

Performance specifications
Gearbox, Custom Gearbox,
Design ​ Ground Clearance​ 11”  12''
Reduction Reduction 8.89:1
Kerb Weight​ 161 kg 150 kg
11.6:1
Weight 46.0 : 54.0  (F:R)​  42.0 : 58.0 (F:R) Maximum
Acceleration 6.8 m/s 5.37 m/s2
2
Distribution​
17.01” (height) 17.87” (height) Top Speed 54.9 kmph 56 kmph
Technical Specifications

COG Coordinates​ 30.75”( front axle) 31.9”( front axle) Gradeability 64.90% 64.9%
26.25”(rear axle)​ 23.1”(rear axle)​ 
22”x8”-10” Front; 22”x8”-10” Front;
Tyre Size​ 22”x8”-10” Rear​​ 22”x8”-10” Rear​​ 
Independent,
Front Suspension​ Double Wishbone Independent,
Double Wishbone​
Power to
Suspension Rear Suspension​ Independent, Independent, Weight Ratio 32.42 W/kg 33.89 W/kg
& Steering ​ H – Frame Lower​ H – Frame Lower
Steering Type​ Rack & Pinion​ Rack & Pinion Comparison
Turning Radius​ 106.30” (2.7m) 94.49"(2.4 m)​
Front​ Disc Brakes ​ Disc Brakes ​
Braking​
Rear​ Disc Brakes​ Disc Brakes​

BAJA 2017 BAJA 2018

Power Train
Design
Design constraints|
constraints| Application
Application |Weight
|Weight |Manufacturability
|Manufacturability |Safety
|Safety |Aesthetics
|Aesthetics |Cost
|Cost

DESIGN PROCESS Vehicle Performance

Acceleration 5.37 m2/s
Literature study and Benchmarking
Grade-ability 64.9%
Deciding vehicle parameters
Top Speed 56 Kmph
CVT selection
Power to Weight 33.89 W/Kg
Calculation
Gearbox design
ENGINE
Validation
Max. Power 10 HP at 3600
Design Review
Max. Torque 19.66Nm at
2800rpm

• Flat assembly Transmission Type

• Use of DAQ system for tuning the CVT Constant Velocity CV-Tech CVT
• Use of fan based air cooling system Transmission (Gear ratio
• Improved gear ratio as compared to (CVT) 0.43:1 to
last year 3.0:1)
• Modified Half-shaft
• Neoprene cylindrical dampers Coupled with a Gear Ratio
• single gear 8.89:1
Custom gearbox reduction custom
• No differential used to overcome gearbox
shortcomings of open differential