Electric solar vehicle championship-2014

MOLTRESTeam. I.D.-ESVC030

SUMIT MITTAL (c) RAHUL KUMAR AMAN DAGAR DEVAN BHARDWAJ

Project Management

Sr. No. Student name Designation Department Work Assigned

1 Sumit Mittal Captain Transmission Selection of components, Calculation, Innovation

2 Farrukh Ahmed Team Member Transmission Market survey, Calculation

3 Devan Bhardwaj Team Member Transmission Innovation

4 Deepak Raina Vice Captain Designing Analysis using Ansys and Solid works

5 Prasanjit Biswas Team Member Designing Market survey, Designing of Component

6 Naresh Kumar Team Member Designing Designing of components

7 Shubham Sood Team Member Braking Selection and study of components

8 Akshansh Dwivedi Team Member Braking Calculations

9 Aman Dagar Team Member Suspension, Steering Selection of mechanism and component

10 Satish Kumar Team Member Suspension Market survey, Calculation

11 Atif Amim Team Member Suspension Calculations

12 Amit Kishore Team Member Steering Market survey, Calculation

13 Praveen Kumar Team Member Steering Calculations

14 Indrajit Biswas Team Member Solar Selection of Solar panel and Battery

15 Manoj Kumar Rana Team Member Solar Market Survey

16 Chirag Banga Team Member Solar Selection of charger and Mppt

17 Gautam Kumar Team Member Electrical Selection of Motor and controller

18 Rahul Kumar Team Member Electrical Market survey, Calculation

19 Akshay Dogra Team Member Electronics Market survey

20 Akshay Mittal Team Member Electronics Selection of Battery charger

Team Management

Objective Method Result

To produce lightweight, reliable and stable Solar powered vehicle that can be used safely for everyday .

Designing vehicle by considering suspension, transmission and Focused on keeping Center of Gravity as near as possible to the ground.

Vehicle with track width 5ft and Wheel base 6.5 ft having tadpole configuration with RWD is accomplishing all the objectives.

CADD MODEL

Roll cage Roll cage with assembly

Side view Front ViewComplete assembly with bodyworks

Simulation

Front Impact Test(5G)FOS -:3.8URES -:1.5mm

Rear Impact Test(4G)FOS -:1.3URES -:1.6mm

Side Impact Test(2G)FOS -:1.8URES -:1.464mm

Static Impact Test(1G)FOS -:3.7

Torsion Impact TestFOS -:4.5

Objective Method ResultTo design a safe roll and comfortable roll cage for driver

Designing of roll cage with proper dimensions using material with good strength and low weight

Design of an efficient roll cage with factor of safety 3.8 in front impact test at 15kN load of material AISI1020 DOM weighing 44kg.

Safety & Ergonomics

Safe Roll cage design.

Evacuation-Easy entry & quick exit possible.

Driver gears-helmet, goggles, suit, neck collar, restraints.

Tube Padding-The minimum required thickness is .inch.

Kill Switches- 2 required, cockpit & external.

Safety Harness- 4 strap system, 3lap belt, quick release connection

Wires properly insulated.

Ergonomics

Sitting without back pain.

Check your seating position in mirror

Seat back angle 110-120

Seating too far from the tire

Visibility angle more then 210

02468

10

0 20 40

curr

ent

voltage

SOLAR PANEL

V-I CURVE

0

50

100

150

0 5 10

pow

er

current

I P CURVE

CHARGE CONTOLLER

050

100150

0 20 40

pow

er

voltage

V-P CURVE

CHARGER TYPE AC TO DC CHARGER

INPUT AC VOLTAGE 220V, 50Hz

OUTPUT DC VOLTAGE 12V

OUTPUT CURRENT 7ACIRCUIT FOR CHARGER

SOLAR SYSTEM

PARELLEL CONNECTION OF SOLAR PANEL

Objective Methods Results

Use of max. efficiency solar array.To charge battery as soon as possible with panel.

Use of four panels with polycrystalline cells

Max. Power output from panel is 560 watts

SPECIFICATION PER PANEL VALUE

MAX. POWER (Pm) 140W

MAX. VOLTAGE (Vm) 19V

MAX. CURRENT (Im) 7.2A

OPEN CIRCUIT VOL. (Voc) 25.5V

SHORT CIRCUIT CUR. (Isc) 8.3A

MODULE EFFICIENCY (%) 13.5

CELL TYPE POLYCRYSTALLINE

CELL DIMENSION(MM) 156X156

DIMENSIONS(MM ) 1465X650X35

WEIGHT(Kg) 6 CIRCUIT CONNECTION

BATTERYBATTERY TYPE LEAD-ACID

RATED VOLTAGE 12V

CAPACITY 20AH

CHARGING CURRENT 7A

DISCHARGING CURRENT 30A

Power Train

PARAMETERS

MOTOR D.C MOTOR (12V-60A)

TYPE BRUSHLESS MOTOR

MOTOR POWER 0.75 hp

MAX TORQUE 10 N-m

MAX. RPM 2500

TRANSMISSION Axial Radial CVT

Gear Ratio 5.4 to 4.2

Tire 16*3.5

Max. Speed 42kmph

Max. Traction 239.2 N

Max. Torque 48.9 N-m

0500

10001500200025003000

0 20 40 60

RPM

Current

Objective Method Result

Efficient use of Power and effective transmission

Mounting of motor very near to wheel with less rotating parts

Use of A. R. CVT

Motor

A.R. CVT

Axel

Tire

MOTOR CONTROLLERSPECIFICATION

Controller type PWM

Rated voltage 12V

Rated current 60A

Rated power 720W

0500

1000150020002500

0 20 40 60

RPM

Speed

BRAKES

STANDARD PARTS & DETAILS QUANTITY

Disc Honda Aviator 3

Brake Calipers

Honda Aviator 3

Tandem Master

Cylinder

Maruti 800 1

SPECIFICATIONS BRAKING

Leverage Ratio 1:7

Master Cylinder Diameter

19 mm

Tire Outer Diameter Front Rear

406.4mm(16) 406.4mm

Weight distribution is 60:40, ; if the vehicle stops within 4.4m, then weight transfer of 20 kg from rear to front will take place. Now, the weight distribution is of 70:30.

Objective Methods ResultsTo stop vehicle at minimum distance as per the criteria of competition.

Use of disc brakes both in front and rear wheels.

At velocity 30 km/hr vehicle comes to rest in 4.4 m

Velocity (km/hr) Stopping distance (m)20 2.1

30 4.4

40 6.8 Exploded view of wheel assembly

0

2

4

6

0 5 10 15 20 25 30Stop

ping

dis

tanc

e

velocity

Velocity Vs Stopping dis.

STEERING

Table : Steering Geometry Summary Figure: Steering Geometry Drawing

Figure: Steering System Design

Parameters

Steering Type Centered Rack & Pinion

Steering Ratio 11:1

Max Steering Angle 40

Minimum Turning Radius 11.12 feet

Steering Column Height 1.03 feet

Steering Column Length 2.57 feet

Length Of Rack 0.694 feet

Length Of Tie Rod 1.215 feet

Steering Arm Length 0.42 feet

Ackerman Angle 22.75

Objective Method Result

Turn effectively with reduced human effort for maneuvering.

Use of Positive AckermanGeometry

Minimum turning radius is 11.12 feet

Suspension geometry Angle (deg)

caster 7

camber 0

KPI 10

upright The lower control arm mounts level to the axle and the upper control arm mounts at point roughly level to the top of the wheel.

Anti-squat 76.1%

Anti-dive 48%

Graph 1: camber vs. roll angle Camber, Caster and Toe are optimized in Lotus Suspension Analysis.Graph 2: toe angle vs. bump

SuspensionObjective Methods ResultsTo obtain safe, reliable and comfort ride, having easy manufacturability

Front-SLA Suspension

Rear- Trailing arm

Negative camber gain in front.

FEA (KNUCKLE) ,FOS- 19URES- 3.23mm ,LOAD- 2000 N

FEA (LOWER WISHBONE), FOS- 13URES-1.94 mm, LOAD- 2000 N

Innovation

AdvantagesNeed no clutch to change gearsSmooth and continuous gear changingCompactLight in weightLow maintenanceEasy to operate

Objective Method Result

Easy and effective transmission Use of Axial Radial CVT Gear ratio is continuous and can be controlled manually.

Variable diapulley

Constant diapulley

gear wheel2gear wheel1

Test of Test name Test method Acceptance criteria Location Remark Assigned to

Brakes Bleeding test

Continuously press the peddle and check for leakages.

If no leakage then it is under safe condition.

Workshop Add more fluid ,tightenhose & connector.

Shubham

Panic brake test

At 42 km/h apply brakes & check for locking of all wheel.

If all wheels are locked, braking is efficient.

University ground

If all the wheels do not lock then do bleeding .

Shubham

Stoppingdistancetest

Run vehicle at max speed, apply brake & check stopping distance.

Braking Efficiency accepted at 80 % under working.

University ground

If

ItemPotential Failure Mode

Potential Effect of Failure

SEV

Potential Failure Cause

OCR

Current Process Controls

DET

RPNRecommended Action(s)

Responsibility

Action Results

Action TakenSEV

OCR

DET

RPN

Roll CageWelding Breakage

Roll Cage Bends/ Breaks

7Excessive load applied

6 TIG Welding 7 294High Factor of Safety

Prasanjit Biswas

Re-weld properly

7 4 3 84

Solar Systemfailure of solar system

Decrease in Power output

8Harsh driving &inappropriate selection

5appropriate Solar system

7 280

Proper installation of solar panel &appropriate selection

Indrajit Biswas

Solar panels are properly mounted

4 4 3 48

Steering System

Braking of steering links

Unable to steer

6Improper joints of steering links

8Standard Rack and pinion system

7 336Verification of steering linkage

Deepak Raina

Replace Steering linkage

5 4 3 60

SuspensionBreakage of A-arm

Uncomfortable drive

6Taking large bumps with high velocity

7Double Wishbone Suspension

6 252Verification of Clevis Rod ends and ball joints

AmanDagar

Replace A-arms 7 5 3 105

Braking System

Leakage in Cylinder

Inability to stop vehicle

9Excessive pressure in hoses

8Standard Disc Brakes

6 432Testing to check proper functionality

Shubham Sood

Use standard hoses/ cylinder

6 4 3 72

TransmissionSystem

Breakage of belt Drive

Power Loss 8Improper alignment of pulley

7

Standard pulley with appropriate belt

8 448Proper alignment of pulley

Sumit Mittal

Properly aligned pulley and belt drive

2 3 6 36

Electrical System

Short-Circuit

Power-Cut for equipment

8Loose connection

7Using good quality wires

7 392Proper insulation and connections

Akshay Dogra

Proper wiring & insulation

7 3 3 63

DFMEA

PIPE FOR CHASSIS COST

1020 DOM(10.058) 1900

1020 DOM(10.083) 4200

1020 DOM (10.118) 2300

TRANSMISSION COST

WHEEL AND TIRE 5400

BEARING+CLAMP 500

INNOVATION A.R. CVT

VARIABLE DIA PULLEY 400

FIXED DIA PULLEY 100

GEARS 120

LEVER 50

MOUNTINGS 1000

STEERING& BRAKING COST

RACK AND PINION STEERING COLUMN +WHEEL

2300

BRAKING SYSTEM (CALLIPER + DISC+BREAK LININGS)

3900

TANDEM MASTER CYLINDER 500

BRAKE STOP LIGHT 200

FABRICATION AND BODYWORKS

COST

GLASS FIBRE

3200APPROX.

PLYWOOD

MS SHEET

M.S. PLATES

OTHER MATERIALS

MISCELLANEOUS COST

NUT & BOLT + WASHER

3000PAINT + PRIMER

OPERATIONALAPPARATUS

SEAT 1000

KILL SWITCH 400

SEAT BELT 500

SUSPENSION SYSTEM COST

SPRING + DAMPER 2400

BALL JOINTS 280

UPRIGHT 1600

ELECTRICAL SYSTEM COST

SOLAR PANEL 24200

BATTERY 5400

CHARGER 1000

MOTOR CONTROLLER 2000

MOTOR 1750

TOTAL COST FOR THE VEHICLE

COST

PIPES FOR CHASSIS 8400

TRANSMISSION AND7570

INNOVATION

STEERING & BRAKING 6900

FABRICATION AND BODY WORKS

3200

MISCELLANEOUS 4900

ELECTRICAL SYSTEM 34350

SUSPENSION SYSTEM 4280

TOTAL COST 69600

Cost Report

Develop

Analysis

Execute

PlanProcessOrganize

IdeaInnovateRefresh

TrainingMaterialsRoll Out

Mission & Vision:-

To develop eco-friendly vehicle

To utilize renewable source of energy

To reduce CO2 emissions

To overcome shortage of conventionalfuels

Business Plan

Business Strategy & Management:-Category Presented

Vehicle(INR)

ProductionRun ( 100

Vehicles PerMonth)(INR)

Vehicle Cost+Labor Cost

69600 6960000

Sale Tax (13%) 9048 904800

Advertisement Cost (4%)

2784 278400

Other (12%)(Transport,

Machinery etc.)

8352 835200

TotalProduction Cost

89784 8978400

Profit 13467.6 1346760

MRP 103251.6 10325160

AchievementsBAJA SAE INDIA 2013overall 31st position out of 236 teams

HPVC 2014Organised by ASME

AERO- 2012