ANURAG GROUP OF INSTITUTIONS

2016 ASME India Human Powered Vehicle Challenge

Team

FALCON

Team Advisers

P. Saritha
Prof. T.G. Rajaswamy

Team Members

M.P.S.Sai Prakash (Team Captain) J.S. Puneeth Kumar

S. Vishal Reddy O. Rishiraj
M. Shanthan Reddy P. Mahesh
B. Bharath D. Vikram Reddy
B. Ravi Yadav B. Shravya
P.V.L. Bhargavi S. Praveen Kumar
ABSTRACT

We Team Falcon are participating in ASME HPVC India 2016 representing Anurag
Group of Institutions. This is the first time our team is participating in HPVC. During our
research we have learnt that Human powered vehicles (HPVs), such as bicycles, tricycles are one
of the purest forms of sustainable energy. Bikes, Trikes are common throughout the world and
have gone through many improvements over the centuries to make them lighter, faster, more
economically and environmentally friendly.
We are making a Delta Recumbent i.e (two wheels rear and one wheel front) breaking the
myth of using a tadpole. This provides more stability than two wheel bike and also meets the
requirements of travelling for 30 meters in a straight line at a speed of 5-8 km/h.
This design report consists of documents the design, analysis, safety and construction
efforts undertaken by the team. The goal of the project is to build a fast trike that can win the
Drag and Endurance competitions, as well as train riders to be comfortable and fast on such a
trike and to sustain all terrain roads and conditions.
As part of this challenge, we need to be able to develop a vehicle capable of coping with the
everyday tasks that any other fossil-fuel-powered vehicle would encounter. We have to design a
vehicle that is capable of:
 Coming to a complete stop while maintaining complete stability of the vehicle.
 Accommodating small parcels.
 Clearing road debris/obstacles such as a speed bump, rocks, or branches.
 Turning within a 25 foot radius and completing a pre-determined obstacle course.
 Completing all tasks listed above while maintaining driver safety and vehicle control.

Disc brakes are used for the rear two tyres to reach the required braking within 6 meters
at 24km/h. Suspension is used at the rear for the vehicle to be as firm as it can be in remote
conditions.
The trike is a rear left wheel drive. The seat is positioned in the trike so that it takes
minimum effort for the driver to pedal. A utility box is arranged behind the seat for the
transportation of goods. Fabrication material and parts are outsourced while the assembly is done
with the help of equipment available at the college campus.
While we are a new team, and started development comparatively late, we hope that a
trike can be built in time and with the required reliability to challenge the more established teams
at the 2016 ASME HPVC.
DESIGN

NEW DESIGN:

As this is the first time we are competing in HPVC our hpv is an entirely new design as far as we
are concerned.

Objectives:

 Produce a human powered vehicle within compliance with the 2016 ASME HPVC
rules.
 Place within the top 2 overall of all competing teams.
 Win endurance event.
 No mechanical failures at competition.
 Produce a vehicle weight of 40 kg or less.
 Produce a vehicle that costs no more than 45,000 rupees.
 Build a safer, faster comfortable trike.

Background Research
Initially we thought of designing a bicycle. But, we preferred a trike because of its
higher load carrying capacity and increased stability. We went through several other previously
designed HPVs and found that most of them are Tadpole rather than Delta. But we preferred
Delta because of many reasons mentioned later in the report.
We found that most of the Delta trikes use rear left wheel drive because of several
advantages so we used the same. We went through several articles about HPVs in internet and
gained some knowledge about gearing and braking systems in regular trikes.
As the clearance decreases, stability increases. This is a well-known fact. So we made our
trike with ultra-low clearance. We preferred under steering over oversteering because it is more
comfortable for the hands to operate. We also went through several articles over how to build
Roll over protection. We also studied about different materials that can be used to build frame
and singled out mild steel because of its less cost and more load bearing capacity.

Prior Work

We went through several international HPV designs on different websites, took them as
inspiration and modified many components to suit our requirements. As this is the first time we
are participating in HPVC we have no idea if our design bears resemblance to any of the
previously designed HPV for the competition.

Description

The Falcon racing trike is a low and laid back recumbent trike. It will perform equally well on
the road and the trail. The low centre of gravity allows Falcon to race into corners at full speed,
 hugging the road like a performance race car while you keep on pedaling. Under seat steering
offers complete control over the handling at any speed and places arms in a comfortable and
relaxed position. For the rugged terrain, the Falcon is equipped with rear suspension and a low
climbing gear range that will smooth out the ride. It is not a tadpole type. It has ultra low seating
position which gives more stability. We chose Delta Trike over Tadpole as this type of trike
offers stable handling using standard bicycle components in the steering system and a great deal
of cargo carrying ability.

ORGANIZATIONAL TIMELINE:

The following is our timeline chart that enabled us to have fully operational HPV prior to the
competition.

Formation of Team
Study and Understanding of Rule Book 2016
Preplanning for Qualifier
Material Investigation & Availabilty Research
Idea of basic design for Qualifier
Acquiring Financial Support and Permissions
Preparation of Report for Qualification Round
Verification of Report for Qualification Round
Submission of Reoprt for Qualifier
Design of Frame
Design of Air Drag Reduction System
Design of Power Transmission
Design of Suspension & Steady Steering Mechanism
Design of Wheel, Tyres & Braking System
Design of Ergonomics and Safety
Analysis of Roller Protection System
Analysis of Frame
Analysis of Air Drag Reduction System
Analysis of Power Transmission
Analysis of Suspension & Steady Steering Mechanism
Analysis of Wheels, Tyres & Braking System
Procurement of Material
Manufacture of Components
Assembly of Vehicle
RPS Testing for Vehicle
Stability and Steering Test for Vehicle
Braking Test for Vehicle
Performance Tests for Vehicle
Preperation for Final Event
DESIGN ELEMENTS:

Rear Frame
Most of the frame is made using 38 mm thick mild steel square tube with 1.7 mm thick wall. We
used square tube instead of round tube as square tube is easy to cut, weld and helps in using the
adjustable bottom bracket with variable length pedaling system by guiding the motion of the
bracket in a fixed plane. This frame can bear even a heavy rider of 125 kg. The following
picture explains the design of the rear frame.

Wheels

We used a normal bicycle front tyres for this project. All the three tyres are chosen same with 36
spokes each. Our trike does not use a normal bicycle hub. Instead we made our own hub which
perfectly matches with a regular bicycle hub and directly welded it to the axle rods, as this
simplifies and strengthens the final design.

Braking:

Hydraulic disc brake system was chosen due to its ability to meet the ASME braking
requirement as well as having the ability to adjust braking power on the fly. There are two major
requirements that the brake system must satisfy. First of those requirements is set by ASME and
it requires that the HPV come to a stop from 24km/h in a distance of 6 meters or less. In order to
meet the first requirement, it was decided to use disk brakes. While the ASME requirement is
simple to satisfy, a shorter stopping distance is desired for the sake of safety. The other
requirement is that the vehicle comes to a stop within 100 meters of the sprint competition end
line. The vehicle will be doing approximately 40-50 km per hour at the end of the sprint;
however 100 meters (~330 feet) is a large stopping distance, making this requirement not as
difficult to achieve as the initial ASME requirement.
In order to calculate the amount of force required to stop the HPV in accordance with the ASME
requirement, the amount of kinetic energy lost while the vehicle comes to a stop must be found.
The equation for finding the kinetic energy can be found in the Braking Forces Calculation
Sheet. The mass, velocity and distance are required in order to find the force.
DISC BRAKE ANALOGY

The brake system is the fundamental item to safety of vehicles. The break must provide a
capacity of decelerate over and over that its capacity of acceleration. A brake is a device used to
bring a moving system to rest, to slow its peed or to control it to a certain value under varying
conditions. Because of that we can choose the disc brakes for more effective running
The purpose of friction brakes is to decelerate a vehicle by transforming the kinetic energy of the
vehicle to heat, via friction, and dissipating that heat to the surroundings. Brake materials have
additional requirements, like resistance to corrosion, light weight, long life, low noise, stable
friction, low wear rate, and acceptable cost versus performance.

CLASSIFICATION OF BRAKES:
There are two common types of friction brakes:
1) Drum/shoe brakes and
2) Disk/pad brakes.
The design of the brakes affects heat flow, reliability, noise characteristics, and ease of
maintenance.

On the road, drilled

DISC/PAD or slotted discs still have a positive effect in wet conditions because the holes
BRAKES:
or slots prevent a film of water building up between the disc and the pads. Cross-drilled discs
may
Theeventually crack
brake disc is at
thethecomponent
holes due toofmetal fatigue.
a disc brakeCross-drilled brakesthe
against which thatbrake
are pads are
manufactured poorly or subjected to high stresses will crack much sooner and more severely.
applied. The material is typically grey iron a form of cast iron. The design of the
disc varies somewhat. Some are simply solid, but others are hollowed out with fins
or vanes joining together the disc's two contact surfaces (usually included as part
of amain
The casting process).
components of The
a discweight and power of the vehicle determines the need for
brake are:
The
ventilated discs. The "ventilated" disc to
brake pads, caliper, rotor that is mounted the hub.
design helps to dissipate the generated heat
The
and is commonly used on the more-heavily-loadedbrakes
disc brake is a lot like the brakes on a bicycle. Bicycle fronthave a caliper, which squeezes
discs.
the brake pads against the wheel. In a disc brake, the brake pads squeeze the rotor instead of the
Many higher-performance brakes have holes drilled through them. This is known
wheel, and the force is transmitted either hydraulically or mechanically instead of through a
as cross-drilling
cable. Friction between andthewaspadsoriginally
and the disc done
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vehicle has a heat
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of kinetic energy, is stillhave
and the brakes used on some
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the kineticunder
cracks energysevere
to heatconditions.
generated by the friction between the pads and the disc. Most vehicle
disc brakes
Discs may arealso
vented.
be slotted, where shallow channels are machined into the disc to
Advantages of Disk brake over Drum brake: Disk brake requires less effort (brake torque) to
aid in removing dust and gas. Slotting is the preferred method in most racing
stop the vehicle. It generates less heat compare to normal brake for the same brake torque. Ease
ofenvironments
maintenance as to remove
disk brake isgas and the
outside water and
wheel to Itdeglaze
rim. brake
is less likely to pads. Some discs
skid compare to otherare
both in
brakes drilled and slotted.
wet condition. Slotted
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othergenerally not used
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standardItvehicles
has brake
because
pad they quickly
wear indicator, which is wear downin brake
not there pads; however, this removal of material is
drum brake.
beneficial to race vehicles since it keeps the pads soft.
WHY DO DISK BRAKES HAVE A BETTER BRAKING BEHAVIOR? Driver friendly
braking behavior. Sensitive braking in all situations. Uniform braking from small fluctuations in
brake forces. Retardation values retained even under heavy stresses. Minimal “pulling to one
side” due to uneven brake forces. Disk brake axial arrangement permits a simple and compact
design. Linear characteristics lead to an even progression of brake force. Basic design principle
makes for higher efficiency.
So, we have confirmed disk brakes are more efficient than other brakes

BREAKING EQUIPMENT:
Disk diameter = 160mm

SUSPENSION
Falcon trike uses rear suspensions in the same way as the suspension on a typical mountain bike-
a pivot and a suspension spring to help take up shocks from bumps on the road. All the
suspension parts are salvaged from an old bicycle frame which we own. They include parts like
suspension spring, pivot bearings, mounting hardware which are made of steel.

Main frame
It is part of the trike which carries the rider. It is designed in such a way that even with long legs
can easily pedal the trike without any kind of discomfort. Even this is made of mild steel-square
tube with tube dimensions similar to that of rear frame. The dimensions are show in the below
figure.

Suspension swing arm:

A rear suspension swing arm acts as the connection between the rear and main frames. The
below figure shows the connection link.
Steering system

An under steer mechanism is used in this trike because it provides better comfort than over steer
mechanism. We provided a connecting rod from this steer rod to the front fork

Analysis:

We analysed our hpv model using ANSYS 14. We devided the analysis into two categories:

(1) Rollover Protection System (RPS) strength and deflection

(2) General structural analysis using strength of materials and machine design principles.

Rollover Protection System (RPS) ANALYSIS:

The purpose of the RPS is to protect the rider in a rollover event. To that effect, the RPS needs
to withstand large forces while deforming minimally. We are using mild steel as our rollover
protection system material inorder to minimize cost. The RPS extends both over the helmeted
head of 6’ rider and outside of rider’s shoulders.

The displacement and stress results of our roll over protection system up on application of
loads are found out in analysis phase and the results are exemplary. We applied top load of
2700 N and side load of 1500N to test the strength of our roll over protection system in the
worst cases possible.

The analytical results for maximum displacement and maximum stresses developed upon
application of loads on our rollover protection system are as follows:
1.max displacement on application of top load:

2.MAX DISPLACEMENT ON APPLICATION OF SIDE LOAD:

3.MAX STRESS ON APPLICATION OF TOP LOAD:

4.max stresses on application of side load:

STRUCTURAL ANALYSIS:

General structural analysis is done using strength of materials and machine design principles.
We assumed a maximum load of 2000N applied on the top and a maximum load of 1500N
applied to the side of structure and analysed our structure. The displacements as well as
stresses developed upon the application of loads and their results are as follows:

1. Displacement upon top loading:

We can see that maximum displacement upon application of load of 2000N on top of the
structure is 0.12144 meters.

2. Stress developed on top loading:

We can observe that the maximum stress developed during the application of load on
top side of the structure is 2.01e9 Pa
 3. Displacement upon side loading:
The maximum displacement of the structure upon application of 1500N side loading is
0.169 meters.

4 . Stress developed on side loading:

The maximum stress developed in the structure on side loading of 1500N is 2.5e9 Pa
Testing:

According to our gantt chart given above, our testing process is underway. So we cannot attach
our testing results with this report. We will report the testing results at the time of competition

Safety

Rollover protecting system

The rollover rod is simple design with partly rectangle and partly elliptical. We design it in
such a way that the wideness is measured when the rider folds his hands at elbow and keeps it
at right angle to the neck of the rider, and the height is sufficient enough for installing any
overhanging equipment from the rod( decoration purpose). It is well installed by using the
mounting clamps on both sides of the main frame.

Consistent with RPS rule

It clearly follows the RPS HPV rules and is within the limits of it. As we have also performed the
test and analysis on it, the rollover perfectly bears the values within the range.

Prevents bodily contact with ground

The RPS is well framed and built that it can easily prevent the body of the rider from touching
the ground in case of rolling of the vehicle.

Seat belt

There is also a seat belt provided similar to that of car. The belt comes starts from shoulder
level and ends at the waist level with a buckle locking system.

Steering system

There is no excessive play of the steering rod, it is perfectly stable. Exactly installed to the
comfort of the rider as the under steer mechanism. It holds the front fork with a connected rod
and provides easy transmission.

There are no sharp edges, or any protruding parts from the vehicle. And no other
obvious hazards.

The rider has view mirrors and gets more than 1800 view.

Safety accessories
 We are equipping the vehicle with horn, headlight, taillight, side and rear view mirrors in
order to provide increased riders safety.

Materials of construction

Most of the parts used for the vehicle are made of mild steel, which may be little heavy
that normal steels but provides great load bearing capacity and because of soft corner edges its
harmless.

Manufacturing process

The rollover rod is made with mild steel square frame and is manufactured by welding to gain
the elliptical shape, the frame is cut with power cutting wheel.

Aesthetics :

Overall impression of vehicle

The trike is well-built and is easy to ride on roads of any trail. We are also painting the trike in
order to prevent corrosion of material. And even dome will be made of light material. Rider
comfort is very good, the vehicle may even go above to 52kmph

Quality of craftsmanship
The welds which are made on the trike are perfect and looks great. The frame cuts are made
with power cutting wheel which are exact to our dimensions. The paint job is done pretty well.
The seat feels really comfortable as we made them with soft cushion and switched it leather
covering.

Quality of custom parts

We customized our own hubs, axles, steering rod, connecting rods, adjustable bottom bracket
which are perfect to the dimensions, well welded, machined perfectly on lathes, since these are
also made of mild steel they look good and are of better quality

Quality of frame

The overall look and finish of the trike is perfect. The finish is made by using hand grinding
machine. The frame is well machined with perfect cuts and there are no protruding parts so its
very safe. Trike looks neat, attractive, and very eye-catching. It reflects the work of a
professional mechanical engineer.