SAE MINI BAJA® POWERTRAINSenior Design Team 3

Michelle Blunt

Thomas Brinson

Brian Coldwell

Ned English

3 April 2003

SENIOR DESIGN INTRODUCTION

• Two-semester course integrating 4-yr curriculum• Design and implementation of a customer product• Resemble real-world design conditions of industry• Demonstrate mastery of both traditional and non-

technical engineering skills

POWERTRAIN SCOPE

•Design and build the powertrain for an off-road vehicle that will survive the severe punishment of rough terrain and must propel itself through water

•Integrate system with other major systems of the vehicle, i.e. the chassis/suspension and braking

•Customers: FAMU-FSU SAE Club, President Pat Middleton Faculty Advisor Dr. Patrick Hollis SAE Mini Baja 2003 Competition Rules

•Presentable and acceptable final product

SPECIFICATIONS• Max vehicle dimensions: 60” x 96”

• Max rider size: 250 lbs, 6’ 3”

• Velocity and Acceleration: 45 mph within 100 ft

• Weight ratings: GVWR: 700 lbs; GCWR: 7000 lbs

• Briggs & Stratton 10Hp engine; Comet-OEM Differential kit

• Tire diameters: 22”

• Cover and protect all dynamic components (chains, belts, etc.)

• Vehicle manufacturing cost $3000/unit at a rate of 4000 units per year.

• Integrate with all other vehicle subsystems (suspension, chassis, etc.).

BACKGROUND INFORMATION

Open Differential Kit

10 Hp Briggs & Stratton Engine

High-Neutral-Reverse-Low Gearbox

CVT / Torque Converter

CONCEPT GENERATION

CONCEPT SELECTION

• Decision matrix to determine most ideal configuration

• Compromise performance and economics

• Iterative revisions: donated CVT and gearboxcalculation revisionscustomer requestsswing arm and frame modificationsprocket and chain adjustments

POWERTRAIN CONFIGURATION

POWERTRAIN COST ANALYSIS

$500Sprockets, etc.Miscellaneous

$50FabricatedSwing Arm

$910Club ExpenseTotal

$130Comet-OEMDifferential

$100RecycledCVT & Gearbox

$130Briggs & Stratton

10 Hp EngineEngine

REQUEST FOR SPONSORSHIP

• Spring Proposal

• Solicit material and financial donations

Kartworld.com

Gokartsupply.com

ORDERING

POWERTRAIN ASSEMBLY

VEHICLE DESIGN

• Suspension• Braking• Steering• Body• Frame• Safety• Flotation• Aesthetics

VEHICLE COST ANALYSIS

$500Safety

$200Steering &

Braking

$2560Total

$250Chassis & Suspension

$700Frame & Body

$910Powertrain

VEHICLE ASSEMBLY

TESTING

• MAX SPEED: 27-30 MPH• ACCELERATION: Max speed reached in 70 ft• TOWING: 6400 LBS at 8 MPH (1999 GMC Sierra 1500)• ENDURANCE: • FLOTATION: Water line at engine mount with 200 lb driver• HANDLING: Land: 4.5 ft turning radius

Water: Cutting brakes and tires operate

SPECS ANALYSIS

• Max Velocity: Sacrifice top speed for power and cost• Acceleration: Max speed within 70 ft (Meets spec)• Towing: 6800 lbs at 8 mph (Meets spec)• Weight: 477 lbs (Meets spec)• Dimensions: 56” x 96” (Meets spec)• Cost: $2560 (Meets spec)• SAE Rules: Confirm at competition

ACKNOWLEDGEMENT

SPONSORS:• B.A.R. Racing• Engelhard• FAMU-FSU COE• Lee’s Machine• Spencer Faurot• Ford• Recycled Cycles• Signs Unlimited

SPECIAL THANKS:• Valorie Brinson• Dean C.J. Chen• Tim Gamble• Ed Hill• Dr. Hollis• Justin Kramer• Dr. Luongo• Lee Middleton• Patrick Middleton• Ben Robertson

REFERENCES

INTERNET:• www.howstuffworks.com• www.kartworld.com• www.gokartsupply.com• www.eng.fsu.edu/ME_senior_design/2003/team3

TEXT:• Automotive Engineering (Thomas)• Machine Design (Hollis)

COMPETITION

• Heigh-ho, heigh-ho, it’s off to Orlando we go…