SRI MUTHUKUMARAN INSTITUTE OF TECHNOLOGY CHENNAI

Rollcage Design

Material : 1018 steel tube (ASTM A106 Grade B)

O.D: 1 inch Wall Thickness:

Primary: 0.12 inch (3mm) Secondary: .078inch (2mm)

Dimensions:

Max Length: 2159mm Max Width: 1089mm Max Height: 1301mm

Design Approach:

REQUIRED CLEARANCE

Bottom-up approach

Software: Pro Engineer 5.0/ Catia/ ANSYS 14 Rulebook Compliance: 100 % compliance

REQUIRED MEMBERS

Design Methodology

Ground sketch

Initial design (PRO/E)

Space frame (Bamboo)

Max length: 2159mm Max width: 1089mm Max height: 1301mm Rollcage Weight: 46kg No. of Welds: 74 Total Weld length: 1245mm

ANALYSIS

Final design (PRO/E)

Rollcage Design
Max length: 2159mm Max width: 1089mm Max height: 1301mm

Top View

Side View

Good impact stress distribution

Front View High aesthetic value Design for manufacture and assembly

Ergonomic design to reduce driver fatigue

Rigid and safe

Analysis

Type: Static Structural

Mesh size: 10mm

Software: ANSYS

Analysis Type Results

Front Impact Constraints Boundary condition
Rear ends of the rollcage fixed

Roll over
Base of the vehicle fixed

Front Bump

Torsional Rigidity

Loads

All wheel mntgs Rear part of the fixed except bump rollcage is fixed wheel. 10 G load applied to 2.5 G load applied to 2x40% of total Roll cage weight is the front ends front and front top weight acted on acted in both sides of edges the mntgs of bump the front end opposite wheel. in direction

Max stress induced (Von Mises) Max Deformation Factor of safety achieved

268 MPa 2mm 1.5

175 MPa 1mm 2.2

177 MPa 1mm 2.1

270 MPa 2.5mm 1.5

Front Impact

Roll over

Front Bump

Torsional Rigidity

Suspension System

Configuration:

Front: Double wishbone Independent Rear: Trailing arm

Specification:

A-arm: Front A-arm length:7.6 & 10 , Rear Trailing arm: 20 Shocks: Air Shocks or Coiled springs Travel: Front: 8.5 , Rear: 6.75 Knuckle: Self Designed Knuckle

A-arm: Max. Stress: 117 MPa Max. Deformation: 0.06mm F.O.S: 3 Knuckle: Max. Stress: 92mm Max. Deformation: 1mm F.O.S: 3

Pro/E Model and Analysis of Wishbone

Pro/E model and Analysis of Knuckle

Layout of Front and Rear Suspension

Steering System

Configuration: Rack and Pinion OEM Rack and Pinion gear box Specification:

Geometry: Ackermann

Rack Length: 14
Tie Rod: Equal Length Turning Radius: 2.2m Ratio: 17.5 : 1

Steering arm length: 127mm

Steering arm Inclination: 250 Camber: 1o (+ ve) Castor: 1o (+ve)
Turning radius Schematic

Scrub radius: 11mm

Power Train

Engine : Briggs and Stratton 10 HP OHV Transmission: Piaggio Ape Xtra

Specification

GRADEABILITY
ENGINE RPM 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 1st Gear (%) 58.6 59.0 59.3 59.5 59.6 59.7 59.6 59.3 59.0 58.6 58.1 2nd Gear (%) 32.9 33.1 33.2 33.4 33.5 33.5 33.5 33.2 33.1 32.9 32.6 3rd Gear (%) 18.1 18.3 18.4 18.5 18.5 18.5 18.5 18.4 18.3 18.1 18.0 4th Gear (%) 10.5 10.6 10.7 10.7 10.8 10.8 10.8 10.7 10.6 10.5 10.4

Max Speed: 59.60 Kmph Final drive ratio: 2.9 Rolling Resistance: 143.34 N Drag force: 9.19 N Power at wheels: 6.3 KW Max. Gradability (1st gear) : 59.7 % or 30.83o

Coupling: Self designed coupling and oil seal Casing Vibration Damping: 10 mm rubber sheet

Tyres & Rims: Big buster ATV tyres (25x8 R12), Alloy rims

Coupling with oil seal casing

Drive Line Layout

Brake System

Configuration: Independent differential hydraulic brakes Master Cylinder: Dual master cylinder with variable brake proportion OEM Discs and Calipers Specification: Braking Distance: 0.74 m, Pedal Force: 360 N, Brake ratio: Variable, Avg. Deceleration: 19.132 m/s2

Ergonomics

Wide and Spacious cockpit (Egress time: 4 sec) All controls within reach envelope of drivers hand Adjustable seat and steering Clear vision in all directions

Dual master cylinder With variable brake proportion

Reach Envelope

Driver View

Target Specifications - Comparison

2014 Vehicle

2013 Vehicle
DIMENSIONS
Wheel Base: 1802 mm Wheel Track Front: 1549.4 mm Rear: 1524 mm Height: 1640mm Weight : 420 Kg Clearance: 355.4mm

DIMENSIONS

Wheel Base: 1423mm (22 % decrease) Wheel Track: 1290mm (17% decrease) Height: 1301mm (21 % increase) Weight (Approx): 300kg (29% decrease)

PEFRORMANCE

Max speed: 59.60 kmph (22% increase) Stopping distance: 0.74 m (80% decrease) Deceleration: 19.132m/s2 Max Gradeability: 59.7 % (70% increase) Turning radius:2211.31mm (42% decrease) Ground clearance: 355.4mm (14)

PEFRORMANCE
Max speed: 45 kmph Stopping distance: 4.026 m Deceleration: 3.518m/s2 Grade ability: 35% Turning circle radius: 3820.73 mm

Smaller and compact design Simple design for high performance Light weight design with high rigidity

Manufacturing processes
Processes and Tools
Welding ( MiG/Arc/Gas) Grinding Drilling/ Boring Lathe

Availability in College
P P P P

Remarks
4 welding machines available Bench/ centreless available Radial/Bench available More than 10 nos.

Milling/Shaping/Slotting Hand Grinder/Chop off Machine

Bending Wrench set & other tools

P P
O P

Available All power tools available

Template will be Prepared and rented facilities will be used ( as approved by BAJA) All kind of forming tools available

TOTAL COST ESTIMATES:1.8 2 LAKHS TARGET WEIGHT OF FINAL VEHICLE: 280 300 Kg

Complete Model

EXPLODED VIEW

WHEEL BASE: 1423mm

WHEEL TRACK: 1290mm OVERALL WIDTH: 1376mm (1089mm)

OVERALL LENGTH: 2257mm (2159mm)

S.NO 1

Validation Plan
SYSTEM TEST NAME Rollcage Analysis Destructive Testing (Drop Test) Suspension Analysis Travel /Bump/ Clearance test 3 Engine Top Speed Test Acceleration Test/Engine Kill

TEST METHOD Theoretical (ANSYS) Physical

INSPECTION Software Results Visual

ACCEPTANCE CRITERIA FOS > 2 No Visible Bends and Cracks FOS > 2 Travel > 6, No damage, Clearance > 10 Not more than 60 kmph Nil

RESULT Passed To be Performed Passed To be Performed To be Performed To be Performed

Theoretical(ANSY Software Results S) Practical Visual Practical (Test track) Practical (Test track) Visual Visual

Steering

Turing Radius Test

Maneuverability Test/ Turing effort Braking Distance Test

Practical (Test track)

Practical (Test track)

Visual
Visual

Max turn without skidding

Easy turning without hitting cones/ Less fatigue Braking Distance not more than 2m

To be Performed
To be Performed

Brakes

Practical (Test track)

Visual

To be Performed

DESIGN FAILURE MODE AND EFFECT ANALYSIS

SYSTEM ROLL CAGE FAILURE MODE Mechanical Failure EFFECT Unstable Vehicle, Drivers safety at risk SEVERITY 10 10 SUSPENSION Mechanical Failure Spring failure Bracket failure Bearing Failure STEERING Rack and Pinion failure Tie rod failure Joint failure Column Failure BRAKES Brake oil leakage Mechanical Failure Insufficient oil Pedal Failure TRANSMISSION Clutch Failure Gear Failure Shifter failure ELECTRICALS Kill switch failure Light failure MISCELLANEOUS Seat failure Battery failure Belt harness failure Tire Puncture Inefficient braking, Drivers safety at risk Total Brake failure Inefficient braking No Braking No power transmission No Drive Possible No gear change possible Engine not shutdown Light doesnt work, May cause crash Driver safety at high risk Electricals shutdown Driver safety at risk Unstable Vehicle Unstable and wrecked vehicle System does not respond Wrecked Suspension, May lead to crash Wrecked Suspension Steering does not work 8 5 9 8 10 9 9 10 9 10 9 10 9 10 10 10 3 10 5 9 4 CAUSE Improper fabrication methods Crash during event Improper fabrication methods, Crash during event Wrong selection of spring parameters Improper fabrication Improper selection of bearing material, Bearing not secured properly Improper handling, crash during event Improperly secured tie-rod Joints not secured properly Harsh handling of steering and poor fabrication methods Improper sealing of Brake lines, Manufacturing defect Improper placement, Manufacturing defect Brake oil not upto recommended level Improperly placed pedal, Manufacturing defect Harsh driving, Manufacturing defect Manufacturing defect, Improper handling Harsh usage of gear lever Improper connection or break in circuit Improper connection or worn out bulbs Improper placement,Improper fabrication,Design failure Old battery, Poorly charged, Manufacturing defect Improper placement of seat belts Due to foreign objects in the path OCCURANCE 3 3 3 4 3 5 1 2 2 2 5 2 4 2 5 1 4 1 4 1 2 2 3 CONTROLS Improved fabrication methods, Recheck all fabrication twice Skilled Driver, use of rear view mirror and tail lights Improved fabrication methods, Recheck all fabrication twice Selection of springs based on requirements, Check all calculations and rectify Proper and safe fabrication, All weldings to be checked regularly Selection of suitable bearing, Improved design to remove unwanted stress at the bearing Careful Handling of steering Tie-rod to be secured properly and rechecked before every ride Joints to be secured properly and rechecked before every ride Improved fabrication and Careful handling Proper sealant to be used,All connections to be checked before every ride New parts to be used, Proper and secure placement of brakes Brake oil to be filled upto required level and checked before every ride Proper placement of pedal, New pedals to be used No harsh driving and proper oil should be used Proper and smooth Handling of Gears Careful and smooth usage of levers Check connections before everyride, Proper connection in circuit Proper connection and regular checks to be performed Sound under seat member design and fabrication New and fully charged battery to be used Properly secured belt mount points Use tubeless tire and drive cautiously DETECTION 6 8 6 4 4 5 3 3 3 3 4 4 4 3 4 4 6 5 3 6 3 5 8 RPN 180 240 144 80 108 200 30 54 54 60 180 80 144 60 180 40 240 50 36 60 30 90 96

PROJECT PLAN
Captain Nisar Ahamed Vice Captain Dhivakar

Resource Procurement Team

Gopinath

Fabrication and Assembly Team

Anand Inigo

Inspection And Quality Control Team

Siva Sankar

Finance And Documentation Team

Siva Subramanian

Marketing And Sponsorship Team

Kabilan

Jai ganesh

Raghupathy

Aravind

Vijayashankar

Saravanan

Rakesh

Dhivakar

Anand

Arunagiri

Hariharasudhan

Nandhan

Arputharaj

Santhosh

Nazeem

Sharath

Govind AP

Avinash

Nisar

Paul raja

Ragavan

Organisation Chart

Plan Schedule

THANK YOU