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- BY ANADI
This design report of the go kart vehicle Anadi, deals with the engineering and designing
processes that we followed in the development of each and every working system of the vehicle.
The system designs were made through detailed analysis of the user and vehicle requirements.
With this as the base of the designing criteria for the systems are drawn using SOLID WORKS.
They are virtually simulated under real time simulations by ANSYS and SOLIDWORKS taking
possible number of parameters as constraints. Design validation, DFMEA and Project Planning
were done using Microsoft office and Smart Sheets.
1. Introduction
2. The initial point of design process
started with the driver ergonomics
and adding to it was safety and cost
effectiveness. A tentative design was
made tailoring to the initial target
values. Then further changes were
made to the design considering the
driver sitting virtually inside an
assumed model and finally modified.
The design was done under newer
constraints and real time simulations
were done to analyze the systems.
TQM tools and Design tools were
used to validate the final output.
13.
11. Overall
height
14.
16.
3
17. Drive
Train
18. Continuously
variable
transmission
CVT Chain
sprocket
ratio 0.76
SCOOTY
PEP
21. Frame
Material
22. Yield
strength =
303 MPa
Carbon =
0.3 %
Density=770
0Kg/m3
25. 175 kg
19.
20.
4
7.
1
5. Technica
l
descripti
on
6. Specification
8. Dimensi
ons
9. Overall
length
10. Overall
width
12.
1.7294m
0.48982m
1.118m
15.
23.
5
26.
6
29.
7
ASTM
A106
-Grade
B
24. Weight
27. Steering
30. Brakes
28. Ackerman
steering
Ratio = 1:1
31. Disc Brakes
Calipers
Maruti Alto
32.
8
33. Wheels
35.
9
36. Ground
Clearan
ce
Master
Cylinder
Maruti Omni
34. 16*4*3.5
Inch Honda
Activa
37. 5.12 Inch
38.
39. 3. Target Performance Value
40. The target performance of various
systems are calculated through
various methods which are explained
in detail in the later section. The
following are the target constraints
of our ECOKART vehicle we were
indented to meet the during the
design process.
41.
42. 3.1 Braking System
43. 3.1.1 Braking force
44. Target braking for our vehicle was
calculated as 2271.5 N. The
calculations are explained in the later
section of braking system.
45. 3.1.2 Stopping Distance
46. Target stopping distance optimal for
our vehicle was calculated to be
10.94m.
1
2
Energy= mu
4
N.
78. For the front impact test the front
nodes are applied with the load
calculated. The rear is completely
constrained and the allowing
1
Energy= mu
2
86.
1
Energy= 175 16.16=1458.65 N
2
Performance
ANSYS
and
1)
102.
rpm
RPM
8.997
103.
Speed (Kmph) =
Power shaft rpm *
* Wheel Dia * 60 /1000
=
132.28*3.14*0.4128*60*10-3
=10.29 Kmph
104.
rpm
3)
4)
107.
Speed (Kmph) =
Power shaft rpm *
* Wheel Dia * 60 /1000
=
333.44*3.14*0.4128*60*10-3
= 25.93 Kmph
108.
rpm
5)
Speed (Kmph) =
* Wheel
Power shaft rpm *
Dia * 60 /1000
=
503.61*3.14*0.4128*60*10-3
= 39.17 Kmph
110.
rpm
6)
=12.8*0.76*10.80*0.7 =
6.33
73.54
Speed (Kmph) =
* Wheel
Power shaft rpm *
Dia * 60 /1000
=
748.31*3.14*0.4128*60*10-3 =
58.2 Kmph
112.
6.4 Torque Exerted on the
wheels
113.
The maximum motor torque
= 12.8 Nm
114.
Transmission efficiency =
70% = 0.7
115.
Formula
116.
Drive torque (Nm) = Motor
Torque * combined gear ratio *
transmission efficiency
117.
Combined gear ratio =
Primary reduction * CVT Ratio
118.
Calculation
119.
1) Drive Torque =
12.8*0.76*22.11*0.7 =
N-m
4) Drive Torque
=12.8*0.76*8.997*0.7 =
61.26
N-m
5) Drive Torque
=12.8*0.76*6.584*0.7 =
44.83
N-m
6) Drive Torque
=12.8*0.76*6.33*0.7 =
43.104
N-m
120.
6.5 Vehicle Tractive Effort
(or) Drive Torque
121.
122.
Drive Force = Drive torque /
Wheel Radius
123.
N-m
2) Drive Torque =
12.8*0.76*16.71*0.7 =
126.
6.6 Gradability
Drive force = mg sin
127.
m = 175 kg
g = 9.81 m/s-2
= sin-1 ( Drive force / mg )
128.
Calculation
113.78
N-m
3) Drive Torque
Calculation
124.
1) 150.56/0.2064 =
729.45 N
2) 113.78/0.2064 = 551.26 N
3) 73.54/0.2064 = 356.29 N
4) 61.26/0.2064 = 296.80 N
5) 44.83/0.2064 = 217.20 N
6) 43.104/0.2064 = 208.84 N
125.
150.56
Formula
32.18
Distance of CG from rear axle= 19
Force on front wheels (2FZ1) =
m*g*a1/l
=
1079.
42
N
Force on rear wheels (2FZ2) =
m*g*a2/l
=
637.3
2
N
Using the values of 2FZ1 and 2FZ2
we have calculated the weight
distribution to be 63/37 in favor of
front.
129.
7. Braking System
135.
7.1.2 Calculation of target
performance of the braking system
130.
136.
Maximum deceleration =
1.32g
Total weight of the vehicle = 175 kg
Maximum velocity of the vehicle=
16.67m/s
Target braking force = deceleration *
total mass = 12.98 * 175 = 2271.5 N
Target stopping distance = Max
velocity 2 / (2 * max. deceleration) =
10.94 m
131.
138.
132.
133.
7.1.1 Tyre force in static
condition
134.
Total
under
=
Wheel Base
Distance of
137.
7.1.3 Design of brake
system elements
Brake pedal
139.
Passenger cars generally use
a pedal ratio of 4 to 6. We select a
pedal ratio of 4, i.e., when the driver
applies 1N force it gets multiplied by
4 times to produce a 4 N force.
140.
Master cylinder
141.
Analyzing the available ones,
we chose the master cylinder
MARUTI OMNI. The piston
diameter of the MC is 19.05 mm.
142.
143.
144.
We compared the rotor
caliper assemblies of two OE namely
Hyundai Santro and Maruti Alto.
Finally we zeroed in on Maruti
ALTO which had the following
dimensions
145.
rotor
Dimensions of the
=
230
mm
Caliper piston Diameter = 42
mm
146.
7.1.4 Calculation of
stopping distance with the selected
components
147.
Maximum force a driver can
apply is 22 kgf.
Force on the Master cylinder piston
(FMC) = 22*9.81*4 = 863.28 N
Area of the MC Piston (AMC) =
*0.019052/4 = 2.85*10-4 m2
Pressure developed in the system (P)
= force / area = 863.28/(2.85*10-4)
= 3031179.775 N/m2
Since the pressure in the system is
entirely the same,
Therefore, the force on the brake
149.
7.1.5 Calculating dynamic
weight Transfer and Brake
Distribution
159.
motors positive terminal and the
negative is grounded.
150.
Weight transfer = Weight of
the vehicle * max deceleration*
height of COG/Wheel base= 98.77 N
160.
151.
Dynamic load on the front
wheels during braking = Static front
load + weight transfer
= 1178.19 N
152.
Dynamic load on the rear
wheels during braking = static rear
load weight transfer = 538.55 N
161.
161.
161.
161.
8.1 Pulse Width Modulation (PWM)
153.
Torque required to stop front
wheel = dynamic load / 2 * Radius/2
* 1.32 = 79 Nm
154.
Torque required to stop rear
wheel = dynamic
load/2*Radius/2*1.32 = 36.11 Nm
162.
155.
156.
8 Electricals
157.
The electrical circuit of the
design comprises of 4 Batteries (12V,
20 Ah) connected in series as shown
in the figure. The series connection
of batteries is in turn connected to a
Pulse Width Modulation circuit that
is used to control the speed of the
motor by means of varying voltage
supply to it.
The Pulse Width
Modulation is connected to the
158.
163.
164.
Pulse-width
modulation
(PWM),
or
pulse-duration
modulation (PDM), is a modulation
technique that conforms the width of
the pulse, formally the pulse
duration, based on modulator signal
information.
Although
this
170.
171.
9. Steering
172.
The steering system used in
our vehicle has its tie rod directly
connected to the steering rod in the
ratio of 1:1. The Ackermann angle of
this type of steering is calculated as
follows:
173.
mm
174.
mm
184.
( Track2Wid th )
175.
=tan
176.
177.
178.
Wheel Base
RI =
185.
186.
187.
Where
= Ackermann angle
179.
Ackermann arm=519.8143 mm
181.
The value of turning radius is
assumed to be 2.3m. Also the values
of TW and WB are 1040mm and
1300mm. Substituting these values,
the value of Ackermann arm is found
to be 519.8143mm. Now, the values
of inner and outer angles are:
2
2 0.5
188.
189.
182.
R=( RI +TW )
190.
183.
RI =2051.4385mm
191.
10.1 Continuously Variable
Transmission
192.
10. Innovation