DESIGN PRESENTATION

Virtual BAJA SAEINDIA 2012

TEAM THE KRIEGER

TEAM ID

Velammal Engineering College,

CHENNAI

DESIGN METHODOLOGY

THE KRIEGER

ROLL CAGE

Material: All the members of the roll cage are made SAE 1541 Grade B steel with a
OD of 25.4mm and a wall thickness of 3 mm. These members have circular cross
section.
Properties of the roll cage material:
Material
SAE 1541
Yield Strength
N/mm2
Ultimate Strength
800N/mm2
Carbon composition
0.425% C (>0.18% C)
The total weight of the roll cage is estimated to be 57kg
The driver ergonomics for the roll cage are
Elbows to Side Impact Members = 3.5
Drivers Seat to Firewall (RRH)=3
Drivers head to Front Bracing member=15
Drivers helmet to top of the vehicle= 7
Overall Length = 2400mm
Wheel Base = 1574.8mm
Overall Width = ?
Track Width =?
Overall Height = ?
Ground Clearance =?
THE KRIEGER

ROLL CAGE (Analysis)

TEST

MAX
STRESS
(N/mm2 )

LOAD
APPLIED
/NODE
(N)

MAX
DEFLX
(mm)

FOS

FRONT
IMPACT 368.032
TEST

5125*
4

4.199 2.173

REAR
IMPACT 385.071
TEST

5125*
4

5.143 2.077

STRESS ANALYSIS DIAGRAM

SIDE
IMPACT 378.297 3416.6 13.88 2.077
TEST
*6

THE KRIEGER

DISPLACEMENT DIAGRAM

ROLL CAGE (Analysis)

TEST

MAX
STRESS
(N/mm2 )

LOAD
APPLIED
(N)

MAX
DEFLX
(mm)

FOS

ROLL
OVER

292.471

10250*2

4.644

2.735

212.051

1900

10.5

3.772

288.343

2310

17.8

2.774

FRONT
BUMP

REAR
BUMP

STRESS ANALYSIS DIAGRAM

THE KRIEGER

DISPLACEMENT DIAGRAM

BRAKES
Braking Effort (Driver on pedal) = 27kgf
Target Stopping Distance = 10m
Braking force = 4962.26N
Comparison of OEMs
PARAMETERS

ALTO

OMNI

Pedal Ratio

4:1

4:1

Diameter of master cylinder

19.05mm

22.25mm

Caliper piston effective

diameter
Rotor effective diameter

43mm

43mm

91mm

91mm

Braking force

4757.04N

3487.145N

Stopping Distance

10.432m

14.24m

OEM Selected : Maruthi Omni braking system

Weight transfer=1373.2N
Dynamic load acting on the front during braking =3179.2 N
Dynamic load acting on the rear during braking= 1020.8 N
THE KRIEGER

Adjustable braking system

THE KRIEGER

STEERING

100% Ackermanns steering

Proposed track width = 65.98
Proposed wheel base = 54

Parameter

Krieger

Indica

35

30.37

24

20.56

Steering
Ratio

16:1

19.37:1

Turning
Radius

3.07m

3.41m

Max angular travel

of steering wheel=540
Toe out = 2 (for Altos knuckle)
Tie rod length = 9.87 inch
Kingpin inclination= 8.740
Camber = 0 (for Altos knuckle)
Included angles =80 (constant value)
THE KRIEGER

SUSPENSION
Parameters
Type

Wire diameter
Mean Coil Diameter
Number of coils
Total Length
Suspension travel
Spring Rate
Best suited shock absorber
Lower wishbone length
Upper wishbone length
Angle of upper wishbone with respect to ground
Angle of lower wishbone with respect to ground
Height of roll center
Scrub Radius

THE KRIEGER

Front Suspension

Rear Suspension

Unequal, parallel,
Double wishbone

Unequal ,parallel
,Double wishbone

9mm
63mm
17
348mm
200mm
15.69N/mm
Apache bike
11.23inch
8.53inch
20
200
Ground level
0

12mm
120mm
18
433mm
200 mm
6.78N/mm
Alto suspension
8.31inch
Nil
200
20
Ground level
16mm

SUSPENSION ANALYSIS

FRONT

REAR

THE KRIEGER

TRANSMISSION

Engine power output = 8.1kW at 3600rpm, Maximum torque obtained = 24.4 Nm at 3000rpm
Corresponding power performance function P = (21.496+ 0.05705 -0.0001514)
Corresponding output torque T = (21.496+ 0.05705 -0.0001514) Nm
Wheel Radius = 0.3175m, Engine Range 2200rpmN3600rpm

Assuming efficiency as 85%

Gear Ratio Comparison

Gradability

Gear

Krieger

Alpha

Gear

Krieger (m/s)

Alpha (m/s)

3.304

4.6

5.293

3.587

2.2

2.73

7.349

6.0401

1.45

1.667

10.204

9.891

0.8918

1.074

16.67

15.353

20

Alpha

3
2

1
0

Gear

Speed (m/s)

Krieger

4
Gear Ratio

Speed Comparison

Krieger

Alpha

Maximum traction
force

(1734.6)N

(2417)N

Gradability

24.39

36.14

Krieger
40

15

Alpha

Maximum
traction
force(*10^2N)

30

10

20

Gradability

10

Parameter

Gear

THE KRIEGER

Krieger

Alpha

INNOVATION-Generation of Thermo EMF from exhaust

The innovation involves conversion of exhaust temperature of an IC engine to generate a thermo
emf which can be used to generate reserve power supply using the concept of seebeck effect.
The average temperature of the exhaust for an IC engine is around 250C and the temperature of
the atmosphere is about 25C. this difference in temperature can be used by a thermocouple to
constitute an electric current.
The material for the hot junction at this temperature can be taken as constantan (an alloy of 60%
copper and 40% nickel) and the cold junction as lead. The two layers are separated by a ceramic
membrane for insulation.
For one thermocouple we can generate a voltage of (9.410-3) volts. To generate 12V we need
1275 thermocouples which costs Rs390

THE KRIEGER

SAFETY, BODY AND ELECTRICAL

Centre of Gravity (COG)

Starting Circuit - Check

Supply from
the Battery

Is seat belt
fastened ?

Is remote kill
switch ON ?

Ready to Start
the Vehicle

Reference point

Component
Engine/ Transmission
Steering rack
Steering column
Pedal
Seat + Driver
Front left Hub+ wheel
A-arm (FL) upper
A-arm (FL) lower
Front right Hub+ wheel
A-arm (FR) upper
A-arm (FR) lower
Rear left Hub+ wheel
A-arm (RL) lower
Rear right Hub+ wheel
A-arm (RR) lower
Front left shock
Front right shock
Rear left strut
Rear right strut
Roll cage
Muffler
Fuel tank
Battery
THE KRIEGER

The centre of gravity of

the entire vehicle is
located at
(46.86, 10, -6.596)
which is below the seat.
X(inch)

Y(inch)

Z(inch)

Weight (kg)

6
17.5
21
22
54
11.5
11.5
11.5
11.5
11.5

35.15
29.5
29.5
29.5
29.5
54
46
46
5
13

22.5
13.14
22
20
13.93
12.5
24
10
12.5
24

80
4
2.5
7
90
22
1.8
2.1
22
1.8

11.5
77.68
77.68
77.68
77.68
11.5
11.5
77.68
77.68
51.15
91.07
77.74
72

13
54
47
5
12
46
13
47
12
29.5
20
29.5
20

10
12.5
10
12.5
10
19
19
26.5
26.5
25.5
21.81
38
13

2.1
22
1.8
22
1.8
2.5
2.5
6
6
82
7
7
10

DFMEA

THE KRIEGER

DFMEA
TOP TEN OCCURANCES

TOP TEN DETECTION

THE KRIEGER

DFMEA

COST ESTIMATION (Fabrication)

FMEA TOP TEN RPN

FMEA CHANGED TOP TEN RPN

THE KRIEGER

DESIGN VALIDATION PLAN

DESIGN ASPECT

ACCEPTANCE CRITERIA

PLAN AND ANALYSIS METHODOLOGY

RESULT

Roll cage

SAE BAJA RULE BOOK

-SECTION 3

FEA

Suspension

To provide good damping without

failure

1 A suspension analyzer software (ADAMS) shall be used to

determine the performance of the suspension system.
2 Load will be applied on the vehicle in dynamic and static
conditions to test the performance of the suspension.

Achieved
No yield stress
No yield stress
No yield stress
No yield stress
Awaited

Steering

The vehicle has to move in straight

path when steering wheel is in centre
position and used to turn the vehicle
with turning radius 2.8m.

The system that gives the required turning radius and the least Awaited
steering effort will be selected.

Brakes

All the four wheel has to lock when

the brake is applied. The stopping
distance must be limited to 10m.

The system that gives stopping distance closest to 10m and the Awaited
best suitable one will be selected.

Front impact test

Side impact test
Rear impact test
Roll over

THE KRIEGER

3-D VIEW

THE KRIEGER

TEAM RESPONSIBILITY
S.no

Team Members

1
2
3
4
5

G Chandra Mouli
M.N.Karthik
J.Syed Naushad
K.Rajesh

6
7
8

J.Ananthanarasimhan
B.Baranidharan
P.Karthikeyan

9
10
11
12

T.Shriram
R.Banukanthan
Sarath Vishnu
E.Meethun Kumar

13
14
15
16

L.Shrivatsa
M.Pradeep Kumar
N.A.Thushal
L.Gnanasekaran

17
18
19

M.Siddarth
B.Ilankadhir
K.Vivek Kumar

20
21
22
23

M.Gautam
A.S.praveen
S.Sharath Viswanath
Abhishek Kuravi

Team Grouping
Roll Cage and overall Management
A
A
A
A
A
Suspension System
B
B
B
Brake and Brake bias innovation
C
C
C
C
Steering System
D
D
D
D
Engine and Transmission
E
E
E
Electricals and other Innovations
F
F
F
F
THE KRIEGER

Responsibility
Captain, Fabrication Head
Vice-captain, Design head
Driver, Testing
Accounts
Fabrication
Design Engineer
Co Driver2, Fabrication
Purchase
Design Engineer
Fabrication
Purchase
Innovation
Design Engineer
Co Driver 1, Testing
Fabrication
Fabrication
Design Engineer
Fabrication
Fabrication
Innovation
Purchase
Marketing head
Marketing

PROJECT PLAN

THE KRIEGER

COST ESTIMATION (Fabrication)

S.No

COMPONENTS

ESTIMATED COST

Materials ( Sheet Metal, Bolt Nuts, 10,000/Roll Cage Material )

Engine (B&S)
17,000 (plus shipping)

Transmission (for B&S)

25,000

4.

Brake with brake bias

8,000/-

5.

Steering

1,500/-

6.

Suspension

5,000/-

7.
8.

Fire extinguisher, neck brace, fire 8,000/suit

Seat
7,000/-

9.

Tyres

16,000/-

10.

Miscellaneous

10,000/-

11.

Total

1,07,500/-

1.

THE KRIEGER