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This design report of the Eco kart vehicle – The Polar Crown, 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
The initial point of design process started 4 Frame Material Yield strength = 303
with the driver ergonomics and adding to it MPa
was safety and cost effectiveness. A ASTM A106 - Carbon = 0.3 %
Grade B Density=7700Kg/m3
tentative design was made tailoring to the
5 Weight 175 kg
initial target values. Then further changes
6 Steering Ackerman steering
were made to the design considering the Ratio = 1:1
driver sitting virtually inside an assumed 7 Brakes Disc Brakes Calipers
model and finally modified. The design was – Maruti Alto
done under newer constraints and real time Master Cylinder –
simulations were done to analyze the Maruti Omni
systems. TQM tools and Design tools were 8 Wheels 16*4*3.5 Inch
Honda Activa
used to validate the final output.
9 Ground 5.12 Inch
2. Vehicle Technical Specification Clearance
3.2 Steering System The design was made based on the driver
ergonomics. A material of less weight
The target criterion for the steering system is without compensating the strength was
100 % Ackerman steering with a 1:1 ratio. taken into consideration to make the vehicle
3.2.1 Turning radius lesser in weight and optimizing the overall
performance. The material was found to suit
The target turning radius of the vehicle was our consideration well as it had yield
calculated to be 2.3m. strength 303MPa and a density of 7700
Kg/m3.The simulation was done with
3.3 Drive and Transmission System
ANSYS with ASTMA106 Grade B and its
3.3.1 Maximum velocity physical properties were given as input
parameters. The dimensions we settled for
The maximum velocity to be obtained by the frame material was 1.18 inch diameter
our vehicle is targeted to be 16.16 m/s (30mm) and 5mm thickness. The thickness
taking all other constraints of the vehicle was made minimal to have possible weight
dynamic parameters. reduction and the section is tubular with
above mentioned dimensions.
3.3.2 Gradability
5.2Properties of Frame Materials
The Gradability of our vehicle is targeted to
be 25.8̊ Material –ASTM A106 Grade B
4. 3D Model of the vehicle Yield strength – 303MPa
The 3D model of the vehicle shown here is Carbon composition – 0.3% c
designed in the modeling software SOLID
WORKS. Frame material weight – 30Kg
The Frame design was made according to The strength is good and the weight is
the loops and it is assembled with various comparatively very less to other available
materials as per specifications. Moreover the
material we chose is easily available in local the load applied. The stress and
markets. Hence this becomes the ideal displacement values are within the
selection of material for frame. permissible values.
The main criteria in analysis were the factor The rear impact load is same as the front
of safety, even stress distribution and the impact considering a vehicle at 16.16 m/s
maximum stress induced. The energy rate is speed and is applied to the nodes with the
used as the load on the nodes. front completely constrained this time. The
stress and displacement values are well
5.3.1 Front Impact within the permissible levels.
The energy for the impact is calculated as
12160N, by means of the following formula,
1
𝐸𝑛𝑒𝑟𝑔𝑦 = × 𝑚 × 𝑢2
4
The mass is considered to be 175 Kg with a
desirable factor of safety and the velocity is
considered to be 16.16 m/s.
1
𝐸𝑛𝑒𝑟𝑔𝑦 = × 175 × 16.162 = 11500 𝑁
4
The energy calculated for one second is the 5.3.3 Side Impact
load to be applied for the above mentioned For the side impact, the calculated preset
test.The load for one second impact comes load is used for font impact and rear impact
to 11500 N. test. In this the load is applied along the side
face of the frame and the other side wheels
are constrained referring to the frame.The
stress and the displacement values are within
the permissible values.
Speed (Kmph) = Power shaft rpm * 6.4 Torque Exerted on the wheels
𝜋* Wheel Dia * 60 /1000
= 255.833*3.14*0.4128*60*10-3 The maximum motor torque = 12.8 Nm
= 19.9 Kmph Transmission efficiency = 70% = 0.7
4) Motor RPM : 2280 rpm Formula
Wheel diameter : 0.4128m (16 inch)
Primary Reduction = 0.76 Drive torque (Nm) = Motor Torque *
CVT input RPM=3000RPM combined gear ratio * transmission
CVT Ratio at 3000 RPM is 8.997 efficiency
Power shaft rpm = 3000/8.997 =
333.44RPM
Combined gear ratio = Primary reduction * 1) Ɵ = sin-1( 729.45 / (175 * 9.81))=
CVT Ratio 25.81
2) Ɵ = sin ( 278.92 / (175 * 9.81)) =
-1
Calculation
18.7
1) Drive Torque = 12.8*0.76*22.11*0.7 = 3) Ɵ = sin ( 232.46 / (175 * 9.81)) =
-1
6.6 Gradability
7.1.1 Tyre force in static condition
Drive force = mg sin Ɵ
Total weight of the vehicle under static
m = 175 kg condition = 175 kg
g = 9.81 m/s-2 Wheel Base (l) = 51.18”
Ɵ = sin-1 ( Drive force / mg ) Distance of CG from front axle= 32.18”
Distance of CG from rear axle= 19”
Calculation Force on front wheels (2FZ1) = m*g*a1/l =
1079.42 N
Force on rear wheels (2FZ2) = m*g*a2/l = 7.1.4 Calculation of stopping distance
637.32 N with the selected components
Using the values of 2FZ1 and 2FZ2 we have
calculated the weight distribution to be Maximum force a driver can apply is 22 kgf.
63/37 in favor of front.
Force on the Master cylinder piston (FMC)
7.1.2 Calculation of target performance of = 22*9.81*4 = 863.28 N
the braking system
Area of the MC Piston (AMC) =
Maximum deceleration = 1.32g π*0.019052/4 = 2.85*10-4m2
Total weight of the vehicle = 175 kg
Maximum velocity of the vehicle= 16.67m/s Pressure developed in the system (P) = force
Target braking force = deceleration * total / area = 863.28/(2.85*10-4)
mass = 12.98 * 175 = 2271.5 N = 3031179.775 N/m2
Target stopping distance = Max velocity 2 /
(2 * max.deceleration) = 10.94 m Since the pressure in the system is entirely
7.1.3 Design of brake system elements the same,
8 Electricals
𝛽 = 21°48′ 5.07′′
Where 10. Innovation
𝑅 = (𝑅𝐼 2 + 𝑇𝑊 2 )0.5
𝑅𝐼 = 2051.4385𝑚𝑚
𝑇𝑊 𝑊𝐵
𝑅𝐼 = ( )+( )
tan 𝛼2 2
1 1 𝑊𝐵
( )+( )=
tan 𝛼1 tan 𝛼2 𝑇𝑊