POWER TRAIN DEPARTMENT

EMD5M7A
Prepared By:
Muhamad Shafiq Bin Sudarman
Ahmad Syukrillah Bin Sidi Ahmad
Wan Kamarul Ariff Bin Wan Kamaruddin
Muhd Asyraf Bin Kamarudin
Muhammad Afiq Bin Mat Akhir

2014680068
2014424642
2014421604
2014864946
2014493572

Organization Chart
Muhammad Shafiq
Bin Sudarman
(Head of
Department)

Muhd Ashraf Bin

Kamaruddin
(Research of
Delevelopement)

Ahmad Syukrillah
Bin Sidi Ahmad
(Design and
Modelling)

Wan Kamarul Ariff

Bin Wan
Kamaruddin
(Design and
Analysis

Muhammad Afiq Bin

Mat Akhir
(Secreatary of
Department)

Introduction

The 4-strokes engine (Internal Combustion Engine) is

commonly used in front body of the chassis

our parts is to design linkage transmission for the

vehicle that use rear engine

This project must solve the joining and linkage from

the rear engine so that it can get through the
acceleration pedal and brake

Scope of Project
The requirements for this project include:

Vehicle will only use internal combustion engine (gasoline).

All engines must be 4-strokes & single cylinder below than 200 cc.
The use of differential is a mandatory.
The installation of the chain/belt guard is mandatory and made of metal or
composite material rigid enough to withstand a break. It must be made of a
minimum width equal to three times the width of the chain/belt.
Use the engine type of HONDA GX160 (Uitm provided).
Any transmission and drive train may be used. The use of differential is also
permissible.
Each car must be equipped with an on board starter/ignition switch and be able
to start without any outside assistance at any time.
The firewall must be attach together on the chassis separated the driver cockpit
and engine compartment.
The firewall must be a non-permeable surface made from a fire resistance
material.
The emergency shutdown must be attached outside the vehicle body and also
on the instrument panel and must disable. All electrical circuits, including the
light ignition and electrical controls.
All necessary analysis and calculation (e.g power and torque output, drive train
ratio, differential ratio. Firewalls heat transfer analysis component strength
analysis material use analysis, joint method analysis (bolt/welding/other joint
method) and etc.

Honda GX 160

Engine Specification

Type of engine : HONDA GX 160

Performance: power output: 3.6kW
net torque: 10.3 N.m
revolution: 3600rpm
Weight : 15.1kg

Relialibility: high quality materia

Safety: installation of chain and gear guard

Ergonomics : realible and easy to starting

: easy starting and quiet running
: easy to use and maintain
: fuel efficient operation
: low vibration when running

FUNCTIONAL DECOMPOSITION

Pugh Concept

Sample Calculation

Weighted Decision Matrix

Concept 1

Concept 2

Concept 3

Selecti

Weight

on

age

Chain sprocket
Rankin Weight

Belting
Rankin Weight

Gearing
Rankin Weight

criteria

(%)

ed

ed

Score

ed

Score

Score

Cost

(RM)
Easy to

0.2

0.4

0.2

0.6

assem

0.25

1.0

0.5

0.5

ble
Weight

(kg)
Total

0.15

0.45

0.15

score
rank

0.3

3.45

1.25

2.2

Details selection of
Material
No
1

Part
Engine Honda GX 160

Material

Manufacture From Honda

Analysis

-Net power Output:

3.6kW @ 3600rpm
-Connect the power output by using
drive train

Solid circular shaft

Steel ASTM- 36

Gear sprocket

Hardened steel

-Tall= 145 MPa

-Choosing a suitable diameter of
shaft
-Calculating angle of twist of the
shaft

-Long life span of drive train.

-Easy to maintenance and service.

No

Part

Material

Analysis

Chain

Hardened steel

Long life span of drive train.

-Easy to maintenance and
service.

Heavy duty ball bearing

Stainless steel

-Smooth the rotation of shaft.

-Withstand
high
load
and
pressure

Emergency switch button

Electric component

-To stop the engine

emergency happen

during

Failure Mode Effect Analysis FMEA

Function or
Process Step

Failure Type

Potential
Impact

SEV

Potential
Causes

OCC

Detection
Mode

DET

RPN

What are the

Briefly outline
function, step or
item being
analyzed

existing

What is the
Describe
what has
gone wrong

impact on the key How severe is

What causes How frequently

output variables the effect to the the key input is this likely to
or internal

customer?

to go wrong?

occur?

requirements?

controls that
either prevent How easy is
the failure from it to detect?
occuring or

Risk
priority
number

detect it should
it occur?

Shaft :

Fracture,brak

To transmit the

e and high

rotation or power

angle twist

Sprocket

The teeth of
sprocket will
wear and tear

The tyre rotation

is not working

Reduce the
performance and

speed

Brake or rust performance and

The rotation

Bearings

not smooth,
too compact.

diameter or

of material is

meeet

requirement

requirement

The sprocket

The speed is

or chain is

Reduce the speed

and make a noise

reduce and

72

12

12

18

chain noisy.

The chain is
rusty

chain by period
and make a
maintenance

material that

not meet

Change the

speed

Coice the

and selection

rusty

Reduce the
Chain

The diameter

Small size. Too

big will
increase the
force required.

The control
system box
may require a
new design.

Concept Evaluation
Robustness is the property of systems that enables them to survive
unforeseen or unusual circumstances. In our design there are several
parameter that we cannot controlled which is called as uncontrollable
parameter, this parameter if it is totally out of control it will causes
our design to be failure, therefore we should ensure our controllable
parameter to be balanced enough to reduced the effects of this
uncontrollable parameter.

Engine Efficiency
Use gasoline with suitable viscosity

Chain And Sprocket

made from high melting point material to sustain high
temperature because of high friction.
lubricant to dissipate heat friction

Powertrain Parts And Component

Engine
GX 160

Back
Bearing

Centrifugal
Clutch

Front
Bearing

Engine
Base

Jack Shaft

Sprocket
T 40

Sprocket
T 15

Chain
System
With Shaft

Differentia
l Gear
With Drive
Shaft

Sprocket
T 35

Sprocket
T7

Parts Analysis
1) Shaft

This is the shaft below the engine

that connected with sprocket.

The green arrow where their force

from sprocket is exerted on the
shaft

From the pic, clearly the shaft is a

little bit bend. This is due to higher
force apply on the shaft.

The shaft still can be used without

any problem after the analysis
because the shaft is not twist too
much

2) Engine base

This is engine base. This is where the

base to support the weight of the
engine

The base is a little bit bend because

we take the maximum possible weight
of engine.

The green, red, and blue indicator

shows where is the stress and force
occur on the base engine.

Since our system use vertical engine

placement, so we need to consider the
best design of the base engine and
make analysis about it.

3)
Sprocket

This is sprocket with 35 tooth

on it. It connects with chain
that connected with driver
sprocket.

There are red, green, and blue

indicator on the sprocket that
show the value of stress that
produce in the sprocket

The red indicator means that

there is there place where the
higher stress occurs.

This is because, it is the place

where the sprocket is connected
with the shaft and force from
shaft give stress in the sprocket

4) Jack Shaft

This part name as jack shaft

where it supports differential
gear that connected with drive
shaft

The green indicator means that

the jack shaft can support the
weight of differential gear and
drive shaft that can be consider
quite heavy.

There also blue and red

indicator on the jack shaft
analysis and it means that the
crucial point of the load that
can support.

Costing Estimation

Bill Of Materials

Full Assembly
Full assembly of the power train and
engine without chasis

Full assembly of engine and power train with chasis

Conclusion

For the conclusion for power train and drive train department, we
are manage to achieved the objective in designing and drawing the
power train and drive train for a Single Seated Vehicle (SSV) after
we have go through a lot of research, survey and designs. The main
material of our component is alloy steel since this material is easy to
find and it have higher Modulus of Elasticity (high strength) which
is good enough to support higher load. Furthermore, it is quite
difficult to make this power train and drive train as light as possible
which is due to the engine compartment but we manage to reduce it
by choosing the most suitable engine which is lighter and have more
horsepower. The weight of the component can be estimate by using
the CATIA software