SAE NIS EFFI-CYCLE

2015
DESIGN REPORTS
Team ID

15062

Team Name:

ATIVIRYA

College Name
: Indira Gandhi Delhi
Technical University For Women.

City
Report Author

Old Delhi, Delhi-110006

Zoya Farooque

Report Co-Author :

Padma Priya

ABSTRACT
The participating team from Indira Gandhi Delhi Technical University in the event SAE NIS EFFICYCLE, ATIVIRYA is a team of 10 members with the aim of designing and fabricating a vehicle for this
years Light Weight Season 2015. SAENIS EFFI-CYCLE is an intercollegiate design competition which
requires the students to design and fabricate an aerodynamic, highly engineered, energy efficient hybridhuman powered three wheeled electric vehicle.
The project was designed keeping in mind the experiences from last years event and this years vehicle
requirements in compliance with SAE NIS Efficyle 2015 Rulebook. After a series of discussions and
consultation, this design was chosen by narrowing down various concepts and aspects based on the
technical needs of the efficycle and the team. Selection of material was based on design factors including
weight, cost, and performance.
Various improvements and new concepts are incorporated in the design in order to increase the efficiency
of the vehicle. Focusing on maneuverability and Figure Of 8Test, the steering geometry was designed
according to trapezoidal mechanism with Ackermann geometry. To perform efficiently in dynamic tests,
use of worm and wheel is considered to increase torque and thus the load carrying capacity of motor and
gear ratios for both human and electric drive is also improved for this time. Also keeping in mind the
performance in utility test , we have decided to incorporate suspension in this years efficycle.

TECHINICAL SPECIFICATIONS
S.N
O

DIVISION

1.

VEHICLE

SUBDIVISION

SPECIFICATION
NAME

MAGNITUDE

Wheelbase

47

Trackwidth

50

Turning Radius

2.98m

Configuration

Tadpole

Weight

71kg (without driver)

Ground Clearance

13.5

2.

3.

ELECTRICAL

MOTOR

Power

0.5 HP

Type

PMDC Static type

Gear Reduction

1:5

GEAR

Worm and Worm

Wheel

1:10

BATTERY

Number

Type

Lead Acid Battery

Runtime

2.24 hours

Volts

24Volt (12 V each)

Braking Disatnce

HPV:2.81m

BRAKES

Electric:3.59m

4.

5.

TRANSMISSION

FRAME

PROJECT PLAN

MATERIAL

Type

Disc

Type

HPV-RWD Electric
Drive-RWD

Gear Reduction

HPV-4.4:1 Electric Drive1:5

Type

Al 6063

IMPLEMENTATION OF LIGHT WEIGHT TECHNOLOGY

To meet the challenge of this years Light Weight Season, we incorporated various changes and
improvisations in the vehicle after narrowing down various materials and attributes of their dimension
and usage.

The use of ALUMINIUM 6063(density=2.7g/cc) of OD - 1.25inch and 4mm thickness because

of its bending strength, bending stiffness, cost and market availability of this material in place of
AISI 1018(density=7.8g/cc).

The kerb weight target this year as calculated, is 71kg which is nearly more than half the kerb
weight of last years vehicle.

Using different cross sections at different places depending upon the stress developed which
would help reduce the weight by using smaller cross section at areas less prone to stress.

Use of light weight material such as ABS for steering wheel, seats and Pedals with the help of 3D technology.
Subsystem

Weight(in kgs )

Chassis

30

Motor and
Batteries

3+20=23

Steering

Suspension

Brakes and
Wheels

Powertrain(HPV
)

DESIGN, CALCULATIONS AND SELECTION:

A.) Frame Configuration
The frame of the trike was aimed to be strong which is able to with stand the forces during impact yet
light in weight with minimum joints.
The design was based on tadpole structure. Two wheels in front offer excellent overall braking and
overall excellent handling. Tadpole design with properly calculated COG makes further design easier
and provides excellent traction, turning and braking stability. It provides a larger tilting range.
CHASSIS
Tadpole configuration
Wheel Base = 47
13.5
Chassis weight= 30kg

Track width = 50
Ground clearance =
Material Al 6063

Design Procedure: Initially a rough sketch was prepared on the paper with the frame fulfilling the
basic requirements using 13 steps of designing recumbent trike. It was then improvised and improved
while drawing it on the computer using Solid Works. The frame was then checked for its stability
during various impacts using SOLIDWORKS Simulation. Additional members were added to make
the frame able to withstand max forces which may occur during collision. The process was repeated
till desired results were not obtained.
Material Selection: Considering the factors like high strength, low cost, market availability, and
Light Weight, we decided to choose AL 6063 as our material over AISI 1018. The following are its
specifications:

MODULUS OF ELASTICITY (Gpa) = 68.9

YIELD STRENGTH (Mpa) = 145
B STRENGTH (Mpa mm^3)= 312805.2161
BENDING STIFFNESS (Gpa mm^4) = 2359603.002

B.) Drive Train:

Human as well as Electric mode both are rear wheel drive.

SEASON 2014

SEASON 2015

Hpv gear ratio

3:1

4.4 : 1

Electric mode gear

ratio

1:2

1:5(use of worm and worm

wheel)

Torque (electric mode)

5.14 N-m

12.85 N-m

HUMAN POWERED MODE

No of teeth on bottom bracket sprocket:
44
Acceleration of vehicle:
0.577 m / s2
Number of teeth on gear on intermediate shaft: 20
Number of teeth on gear of rear wheel:
10
Gear ratio obtained :
4.4:1
Maximum velocity at rear wheel:
35 km/hr (assuming 60 rpm at bottom bracket)
ELECTRIC MODE
Voltage:
Power:
Gear Ratio:
Worm and wheel Ratio:
Battery type:
Number:
Voltage:
Current:
Battery Runtime:
At gradient:
Maximum velocity at rear wheel:

24V
375 Watt
1:5
1:10 (to increase torque)
Lead Acid Battery
2
12 V (each)
35A-hr
2.24 hours(plane)
54 minutes
40km/hr

C.) Steering, Suspensions, and Brakes

Steering:
Using Trapezoidal steering mechanism in place of Rack and pinion. Selection was done primarily
to reduce weight and reduce the wheelbase of the vehicle and therefore increasing the turning
radius i.e. maneuverability of the vehicle.
Specification:-

ATIVIRYA
2014

ATIVIRYA
2015

MODIFICATION

Wheel-base

62inches

47inches

Smaller wheel base hence

decreased turning radius

Track width

55inches

50 inches

Decreased.

Turning
radius

3.94m

2.98m

Smaller turning radius and

hence offers more
maneuverability

FACTORS OPTIMISED

Ackerman Angle = 28 deg

Turning Radius=2.98m

Tie rod length = 44.84

During cornering, Ackerman condition:

Maximum inner wheel angle =38deg

Average wheel angle= 30.5deg

Critical speed of shaft = 294 m/s

Suspension:
In order to overcome difficulties of wheel breakdown which we faced last year, we have included
iron strips to all the three wheels and front and rear suspension systems keeping in mind the
target of overall kerb weight of the vehicle.

Suspension used in Rear Wheel: Swing-arm

Suspension used in Front wheels : Bicycle Shockers

Property

Value

Static Deflection

15.24 cm

Spring Constant(Rear)

2465.34 N/m
(=0.2503kg/mm)

Damping coefficient

309.352Ns/m

Brakes:

The selection for the use of the brakes for the vehicle is Cable actuated Disc brakes, two in
front wheels and one in the rear wheel. These were chosen on the basis of:
Easy availability Simple construction Slip-free braking Unaffected by tire width Less
prone to fading Self-adjusting
DESIGN

Fn (Clamping
Force)

801N

Formulas used:

Fb (Braking Force)
1.) Braking Distance :
2.) Braking Force :
3.) Braking time
: v/a

240.3N

HPV MODE
Braking Distance:
Velocity:
Braking Time:

SPECIFICATIONS:

2.81m
35km/hr
0.5 seconds

v2/2(+G) g
m*a

ELECTRIC MODE
3.59m
40km/hr
0.6 seconds

Assumption:
Average Human Grip Force= 267N
b(between Braking pad and rotor = 0.4)
g(between ground and the wheel)= 0.75

D.) Wheels and Tyres

The use of tubular tyre is incorporated in the trike design instead of tubeless tyres which were
used last year.
The rim of front wheel is made of steel, making it light in weight and of iron for rear wheel,
giving the rims enough strength to handle weight till 350 kg.
The inner diameter of front wheel = 24 inches,
The outer diameter of front wheel = 28 inches
Number of spokes in the tyres: 36 spokes in front tyre
36spokes in rear tyres.
E.) Seating arrangement, Seat design and features
This year we have incorporated the idea of using 3-D Printed
Rib Cage recumbent seats, the advantage of which would be
that new shapes and structures can be easily given and made. The
material is of better quality with lesser weight helping us to

material

density

ABS(Acrylonitril 1.04g/cc
e
butadiene
styrene)
WOOD

1.4g/cc

achieve our goal towards lighter weight in this Light Weight Season and moreover, the production is
cheap and affordable and manufacturing is quick.
Material: ABS (Acrylonitrile butadiene styrene)
Density: 1.04g/cc

PARALLEL TYPE ARRANGEMENT

Backrest angle= 35deg from vertical

Backrest Length=635mm

Headrest height= 228mm

Saddle length=430mm

Seat Width=100mm

Lumbar support = 203mm

Seat height = 469.9mm

F.) Safety

ROLL OVER PROTECTION

Provided to protect the rider from neck and head injuries in impact conditions.

HARNESS PROVISION
Harness ensuring the safety of the driver in case of any unfortunate accident

METALLIC GRID FOR MOTOR

Provides motor protection in case of a high-speed incident

KILL SWITCH
Used to completely shut down all electrical equipment in case of an emergency. Push to Kill
Switch has been used.

Strong rear impact and side impact resistance through members.

ERGONOMICS

Incorporation of adjustable customized pedals increases the human effort at pedals and helps the
driver in pedaling. Inclusion of Recumbent ergonomically seats as they are comfortable and
supportive for riders back.
Calculations for the size and placement of all the parts were done before making the cad model
so that everything is easily accessible to the driver and she can drive the vehicle with comfort and
minimum effort. Following are some key dimensions taken in consideration. The reference
values used in obtaining the results were taken by measuring the dimensions of all the team
members and then taking its mean.

HUMAN POWERED MODE

STEERING

Crank length:

141mm

HB-BOS: 557mm

Knee angle:

90

HB height: 863.6mm

BB Height:

590mm

BB BOS:

832.2mm

RECUMBENT SEATS (In mm)

Seat Height:

469.9

Saddle length: 430

Backrest length: 635
Backrest Inclination: 35 from vertical

Headrest:

228

Seat width:

100

Lumbar Support:203
INNOVATIONS:
This years first innovation was chosen keeping in mind the light weight season which is, the use
of 3-D printed material made from ABS (Acrylonitrile butadiene styrene)
Weve incorporated customized pedal lock mechanism to aid in steering and seating.
The next innovation includes the use of piezoelectric effect. The piezoelectric crystals would be
placed within the wheel tubes would undergo mechanical stress which in turn would produce and
develop enough amount of electric charge and voltage to charge up the batteries of mobile phone.

ISOMETRIC AND OTHER COMPLETE VIEWS OF VEHICLE.

HAND MADE SKETCHES OF THE VEHICLE (ABOVE IMAGES)

PROTOTYPE MADE USING PVC PIPES

USED

DISC BRAKES AND SUSPENSION

DRIVETRAIN ARRANGEMENT (LEFT) AND MOTOR WITH WORM AND WORM WHEEL
(RIGHT) . (ABOVE IMAGES)
INNOVATION (PEDAL LOCK MECHANISM) (IMAGES BELOW)

SPONSERS