THE DREAM COMPETITION

BAJA SAE ASIA 2010 BY

ATV (ALL TERRAIN VEHICLE)

CONSIDERATIONS IN AN

A.T.V

TARGET-2010
Our team consists of 25 members with a different talent,united toward one mind set i.e. to deliever the quality performance at BAJA SAE ASIA 2010 The following is the structure where we keep a proper contact between us and the experienced faculty advisors. They are a really a blessing to work with keeping in mind the limitations as per the rule book.

Being An Automotive Design Engineer

We were lucky enough to get the knowledge the working of an automobile right from the day we were admitted to our university. Automotive Design teaches us to tackle the problems in designing any vehicle. The above said was very useful for us to prepare for the competiton and really makes us stand out of the lot.

METHODOLOGY
DESIGN CONSIDERATIONS: ATV, Restraints like length, width, speed etc. TASK ASSIGNMENT: Tasks divided among members. CAD MODELLING: 3-D model made using softwares like CATIA etc. ANALYSIS OF CAD MODEL: Stress analysis of the model using CATIA & SOLIDWORKS. PROTOTYPE: A PVC prototype would be made. ERROR ANALYSIS: Errors and high stress concentration areas would be identified. REVISION OF CAD MODEL AFTER ERROR ANALYSIS. DESIGN FAILURE MODE & EFFECT ANALYSIS: RISK ANALYSIS

METHODOLOGY (Continued)
CHASSIS FABRICATION: Using AISI 1018 mild Steel. SUSPENSION FABRICATION: Using custom made coil springs and shockers etc. STEERING & BRAKING SYSTEMS INTEGRATION. ENGINE & TRANSMISSION MOUNTING. FINAL INTEGRATION TESTING & OPTIMIZATION: Testing at the Bidholi grounds.

TIMELINE
JUNEJULY Design Phase Market Research Manufacturin g Prototype Chassis Suspension System Assembly Steering System Drive Train Testing & AUG SEPT OCT NOV DEC

PROGRESS TILL DATE

Design Consideration Task Assignment CAD Modeling Analysis of CAD modeling PVC Prototype Error Analysis Revision of CAD Model after analysis DFMEA(Design Failure Mode & Effect Analysis) Chassis Fabrication Suspension System Integration Steering & Braking Systems Integration Engine & Transmission Mounting Final Integration Testing & Optimization.

The Work Behind

Being a team of 25 members we divided ourselves and started working according to the department allotted to us. Our Engineering team started working about different aspects of the fabrication of our vehicle, accompanied by our marketing team doing some real hard work for the convenience of our Engineering team. This all process is always guided as per hierarchy, which ensures proper action plan.

INITIAL DESIGN

ANALYSIS OF DESIGN

Preliminary Design Report attached here with

DESIGN CONSIDERATIONS
Self Weight of Roll cage = 35Kg (Approx) Other weights on the roll cage: Engine = 30.4 Kg Transmission system = 25Kg Driver = 115Kg Other weights = 50Kg (Max) Total Weight = 255.4 Kg Design weight = 400 Kg

FINAL DESIGN

S I D E

V I E W

T O P

V I E W

I S O M E T R I C

V I E W

THE SOURCES
Designed using solid works ,PRO-E and CATIA. Mannequin used. Weight < 35kg Material : AISI 4130/AISI 1018(under consideration), tubes to be used. Max width of roll cage : 850mm Max length of the roll cage : 1800mm Height of the roll cage: 1350mm

SAFETY CONSIDERATIONS
Safety being the highest priority in any vehicle, our whole team is dedicated to produce a vehicle that is safe enough and a fun to ride The vehicle has been designed keeping in mind the safety of the driver. The vehicle has been analyzed under following conditions:
FRONT IMPACT SIDE IMPACT VEHICLE ROLLOVER FACTOR OF SAFETY: 1.5 FORCE OF 4000N.

Other safety parameters included are:

FIRE EXTINGUISHER, 4 HOSE SEAT BELT, SFI RATED HELMETS, KILL SWITCHES, NECK & ARM RESTRAINTS.

ENGINE &TRANSMISSION

si nsmis tra on

Engi Engine ne

AISI 4130

AISI 1018

SUSPENSION
Equal arm double wishbone Mc pherson strut Brake reaction support angle Progressive suspension with all three spring parameter non constant. Front strut brace attached between the

BRAKING
Four wheeled integrated hydraulic disc brakes Brake biasing. Weight shift adjusted. Pneumatic system used for brake boosting. Independent

STEERING SYSTEM
Rack & Pinion of Maruti 800 Gear Ratio- 16:1 Housing- Right Hand Worm- Right Hand 90 travel of drop arm 4.3 turn of steering wheel. Availability Cost Effectiveness Small installation space.

SAFETY
Crumble zone created between the G.I sheets. Neck and arms restraints . Helmet and safety goggles. Safety Jacket and hand gloves. Two fire extinguishers. Two Kill switches. Seat belts.

COMPARISON WITH LAST YEAR VEHICLE

Small changes are also done like: Hand steering angle is changed to add more comfort. Seat angle is also attuned. Engine mounting is perverted. More stronger rear compartment. Brake boosting is installed. Strut braces are employed in front suspension. Buttocks distance increased to easily get out of the vehicle in case of emergency.

ITEMS Roll cage Tubing(AISI 1018) Suspension System i)Springs ii)Shocks absorbers Steering System Engine Transmission Axles, Couplings, etc. Hub Seat Tires + Rim(alloy) Brakes i) Piston Cylinder assembly ii)Brake Hose Fire Extinguisher Fire Wall Pedals Battery Wiring Harness Lights Paint and Coating Miscellaneous (extra parts, prototype cost, testing fuel, repairs etc.) TOTAL COST OF THE PROJECT

PRICE(Rupees) 350(p.mt. approx)

COST ESTIMATE

Qty 50 Meters

ITEM TOTAL(Rupees)

17,500 12,000

2,000 NIL 8,000

1,000 2,000 7,000 4,500 900 250 800 1,000 400 5,000 5,00 5,00 6,000 30,000 x4 x4 x1 x4 x2 x4 x2 x1 x3 x1 x1 x4

4,000 8,000 7,000 18,000 1,800 1,000 1,600 1,000 1,200 5,000 500 2,000 6,000 30,000

1,26,600

UPES OFF-ROADIES THE BEST

SPONSERSHIP:
All of us are currently going under training from major automotive companies of India e.g.: Ashok Leyland, Bajaj, Maruti Suzuki, Tata, Swaraj Mazda, Volkswagen, Skoda, General Motors, Fiat, Mahindra and Mahindra, INCAT etc. We already collected a total sum of 1.5 lakh with equal contribution from each team member. We are even trying for sponsorship through our seniors who are already placed in companies as they know the benefits of Baja as they themselves were part of the event. We have already given proposal to some companies and have received a positive response even during the recession period.

The Refreshing Changes We are surely working in a direction where we can

omit the mistakes of last year but also have taken a lot of positives out of that as a learning experience. This time we are well planned to present our vehicle with features that will make our vehicle stand out of the lot. We have ensured that our vehicle is not only a mere ATV but also a vehicle which is comfortable to ride and fun to drive. The following arrow diagram on the next slide shows our action plan for the changes that we will encorporate in our vehicle.

AISI 1018 USED FO R MORE STRENGTH

IC ALYT R CAT O VERT CON ED ADD

LENGTH & WEIGHT REDUCTION CRUMBLE ZONE

PROGRSSIVE SPRING EQUAL LENGTH DOUBLE WISHBONE

EQUAL LENGTH AARMS

The Market Viability of our vehicle

Right from the day we started we were all aligned to fabricate a vehicle which would undergo some harsh test conditions. The introduction of features like catalytic converter, pneumatic breaking etc. helps us to improve on the aspects other than endurance. As already mentioned we have also kept in mind the safety of the people inside and outside the vehicle , the latter being most important for any

Ensuring the best ahead

Design being a dynamic proess,we will always try to ensure the best market viablity accompanied by a better performance.For this we will always keep ourselves in knowledge of the latest improvements in automative sector keeping in mind the cost factor. We will equip our vehicle with the technologies that are essential and some of those that will make it a real nice one to ride upon

FACE OF MODERNISING COMMUNITY, SO WHAT IS THIS COULD VERY

THIS...

Special thanks to: Kunal dutt Without his data card it