Beruflich Dokumente
Kultur Dokumente
Kamal Garg, Rohan Garg, Mohit Garg, Harmanpreet S. Maan, Prince Malhotra
3rd year Mechanical
Rack 7 8 8 5 28
and
Pinion Fig 4: Graph between steering angle vs Turning angle
Cam and 6 6 7 6 25
Lever
Worm 5 5 5 6 21
and Ergonomics of the driver will be considered for both
Sector steering wheel position and its rotation for maximum
wheel angle. In the last year’s design there was a bend
Recircula 5 6 4 8 23 in the steering column and it created an obstruction in
ting Ball driver’s legs but this year to increase the leg space for
driver we have kept the steering column straight upto
Worm 7 5 6 7 25
pinion. This year the rack and pinion will be placed
and
below the cockpit base. A special mounting is provided
Roller
in chassis for the same to increase the free space in
cockpit.2: Angle between steering angle vs Turning
Rack and Pinion Steering System is chosen after angle
benchmarking. After the detailed analysis of previous
vehicle we found that in previous year’s steering design
the driver had to turn the steering wheel by 450° to bring
the wheels from center to lock. So the driver had to
remove his hand from steering wheel while turning from
center to lock. Our goal is t reduce this angle by
achieving 7:1 steering ratio by calculating Ackerman
length.
WHEEL ASSEMBLY
Small and light weight
with simple design &
The wheel assembly has a very important contribution easy to manufacture
towards vehicle’s weight. So to achieve our main with ample strength.
objective of reducing the overall weight of our vehicle
we have to reduce the weight of wheel assembly. We Thus we
have a detailed study of previous year’s wheel finally
assembly. In previous year’s vehicle the wheel Knuckle achieved
Lighter & easily
our
assembly was custom made. But this year we have available with low
objective
decided to use Maruti 800 standard axle because in machining cost , AISI
s of
1026 steel alloy has
previous year’s vehicle the axle was custom made. And the higher utility than
strength,
there was too much play in the splines due to spline Knuckle compact
AISI 1020 & AISI 1018.
and Hub ness,
wear out. To avoid this kind of situation we are using weight
Material
standard axle of Maruti 800. The knuckle will be custom reductio
designed and an iterative analysis will be done on n, easy
knuckle to remove the unnecessary material make it assembl
Wheel Hub is y and
lighter. In previous year’s vehicle AISI 1018 material designed to disasse
was used for wheel assembly but this year as our aim is accommodate brake mbly,
to reduce weight so a benchmarking was done between Hub assembly which with
gives efficient & minimize
available materials for our wheel assembly.
compact packaging d
without stresses
Param Hardn UTS TYS Machi Dens Utilit Wheel compromising hub’s
eters ess (w= (w= ning ity y Assembly strength.
(w=.21 .21) .21) (w= . (w= . (∑p*
) 21) 17) w)
Spherical Standard spherical rod
end can adjust camber
Materi (p*w) (p*w (p*w (p*w) (p*w) (p*w Rod end
angle and make shock
al ) ) ) loads ineffective to a
(steel greater extent.
alloy) Rim
1018 .5943 .571 .615 .932 1.36 4.07 &
Tyre 25” Polaris tire which
provides better grip on off
1020 .498 .456 .564 .576 1.36 3.45 road surfaces.
Brake System
Fig 6: Exploded view of wheel assembly In previous year’s design we used hydraulic disc brakes
with two different master cylinders for brake fluid, one
for front wheels and one rear wheels. The main depending on the RPM at which they spin and the
drawback of this design is that if any of the 2 cylinders amount of torque required.
stops working the respective brakes will fail. To
overcome this drawback we have decided to use dual
master cylinder. In dual master cylinder there are two
chambers but they have the common circuit of brake
fluid for all the four wheels. So if any one chamber fails
we can still apply the brakes to all the four wheels.
POWER TRAIN
Fig: 8
Design
As we are all provided with the same LOMBARDINI As the engine reaches its governed rpm limit 3600 rpm,
LGA 340 engine so a lot of emphasis has to be placed the gear reduction across the CVT have been
on the design of power train. This year our objective is determined to be 0.76:1 and thus serving as an
to harness the power of 10HP engine and efficiently "overdrive" for the car. At low engine speeds the CVT
deliver this power to the tires for peak performance. In produces a reduction of 3.83:1 providing necessary
design of the drive train the optimization of several torque. The
desired characteristics are being kept in mind including CVT is assisted by a two speed with reverse gear box.
towing capacity, acceleration, top speed, and durability. The two speed gear box enables the vehicle to achieve
As it is known internal combustion engine have a both high torque and high speed. With the cockpit
power band (range of speeds) at which the engine mounted shift lever in low gear the driver has a torque
produces the maximum torque. Below or above this available for towing heavy load, climbing steep gradients
power band the engine does not provide enough torque and driving through mud and sand. The high gear is
to overcome the resistance torque and accelerate the designed for top speed and acceleration. The
vehicle. Since with such a small amount of power we do final gear reduction for the drive train comes from
not have much room within our power band for the sprocket sizes on the gearbox output shaft and the
performance we need. Therefore we either have many driven sprocket located on axle. Several combinations of
gear speeds or we use a CVT (Continuously Variable drive and driven sprockets were analyzed. The analysis
Transmission). Continuously variable transmission (CVT) was performed with the goal of maximizing the
belt drive is a device that is much smoother than a relationship between vehicle top speed and torque
conventional transmission and also has the ability to output. A low friction O-ring 520 series motorcycle chain
harness peak engine power during operation. The CVT will be used to power the axle from the output shaft of
transmits power from the engine to drive train in place of the transmission. The yield strength of the chain is listed
a conventional clutch dependent multi-gear transmission from the manufacturer to be 8100lb. Estimated forces on
that requires constant shifting to change reduction the chain will not exceed forces greater than 3800lb,
ratios. It consists of two variable pitch pulleys, the drive providing a 2.1 factor of safety for the chain. Constant
and driven, that semi-dependently change their ratios Velocity (CV) joints will be considered for the half shafts
because of their ability to transmit torque through a
higher range of suspension articulation.
These features will create a vehicle that utilizes all of its
power in a smooth, quick transition from rest to top
speed, and insures minimal maintenance.
CONCLUSION
REFERENCES
ABBREVIATIONS