3D VIEW OF OUR ATV

TECHNICAL SPECIFICATIONS
ROLL-CAGE MATERIAL OVERALL DIMENSION (LWH) INCH ENGINE BRAKES SUSPENSION SAE-1018 one inch dia. o.24 wall thickness 86.406361 LOMBARDINI LGA340CC-11HP DISC BRAKE IN ALL 4 WHEEL FRONT AND REAR BOTH DOUBLE WISHBONE INDEPENDENT CONTROL ARMS ATV COMPATIBLE,RADIAL 12.5 INCH 320 KGS.(APPROXI) 6 LITERS

TYRES TARGETED WEIGHT FUEL TANK CAPACITY

PROJECT PLAN

FEA ANALYSIS
SIDE IMPACT STRESS FRONT IMPACT STRESS
TYPE OF IMPACT Equ. STRESS DEFORMA TION FACTOR OF SAFTY

SIDE FORNT REAR ROLL OVER

161 209 MP 189.5MP 220.9MP

2.6mm 3.4mm 2.6mm 4.9mm

2.79 2.37 2.15 2

REAR IMPACT STRESS

ROLL OVER STRESSS

5 Aspects of Ergonomics
CHASSIS MOCK-UP
1. Safety

2. Comfort

3. Ease of use

4. Productivity/performance

5. Aesthetics

STEERING KNUCKLE DESIGN ASSEMBLY

CNC machined Sailma 350 HI upright.

Upright Analysis:
Loading : 3G Vertical Factor of Safety: 2.25.

Materials used
COMPONENTS
Roll cage Control Arms Side Impact Members Firewall Knuckle , Brackets Welding SAE 1018 SAE 4130 Chromoly Fibre Reinforced plastic Aluminum checked sheets SAILMA 350 HI For Roll Cage MIG For Control Arms- MIG with Heat Treatment Oil tempered Wire (Chromo silicon vanadium )

MATERIAL

Spring Suspension

DFMEA
Critical Components
Roll Cage Design Process Followed Front , Side , Rear and Roll over impact analysis done and modification done accordingly Design And analysis done and material changed accordingly Material chosen of high strength and design is done according to dimensions

Knuckle A-arm

Brake
Suspension

Disc Brakes used according to the load

High strength material is chosen according to the load on designed spring.

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SUSPENSION SYSTEM
INDEPENDENT DOUBLE WISH BONE SUSPENSION ,WE CHOOSE IT AS PER OUR DESIGN REQUIREMENT AND BETTER HANDLING CONDITION . Dynamic condition:Static Condition:Parameter Front Rear Load 548 N 1020 N Deflection 16mm 23 mm Parameter Front Rear Load 3288 N 5100 N Deflection 99 mm 115 mm

Suspensions spring result:-

Position
Front

Wheel Travel
8.03 Inch 10.6 Inch

Parameter

Sym bols
C D D N P L/D

Front Sprin g
6.3 1mm 63mm 8 23mm 3.3(sa fe)

Rear Spring
6.3

Rear

Spring Index Wire Diameter Coil Diameter No. Of Turns Pitch L/D Ratio

Parameter 10 mm 63 mm 6 30 Mm 3.7(safe) Static Dynamic

Ground Clearance 203 mm 88.2mm

Stiffness Obtained:Front :- 49.6 N/Mm Rear :- 66.2 N/Mm

Actual Damping Coefficient In Front Is 0.039 Ns/Mm, & In Rear Side Is 0.073ns/Mm

Motion ratio;- shock travel , MR = l /

Wheel travel
PAPARAMETER Motion ratio FRONT 0.485 REAR 0.423

T~ d1/d2

Wheel rate :Parameter

wheel rate

stiffness (motion ratio)^2

Front
11.66 N/mm

Rear
11.84 N/mm

d1=distance from chasis d2= distance from hub l=shock travel T= wheel travel

The formula tell us that the closer the bottoms of the shocks are mounted to the middle of the chassis, the softer the wheel rate will be if the lower shock mounting location is changed then both the shock angle and the motion ratio changesamount of suspension travel also changes, which can also affect the car's handling. SPRUNG & UNSPRUNG WEIGHTS Un sprung weight represents a significant portion of the total weight of the vehicle. In standard-size ATV, the weight of un sprung components is normally in the range of 13 to 18 percent of the vehicle sprung weight. In our case total weight is 320kg & un sprung weight is 44kg .The ratio of unsprung by sprung weight is 15.5% thus it lies in the design limits for maximum driver ergonomics.

A Arm

we have design upper arm is small as compared to lower arm due to which steering handling is comfortable & easily handle. Rear suspension are mounted at a distance of 99mm from the chassis and the front suspensions are at 137.6mm i from the chassis end.

Specification
Parameters Length Width Suspension mounting Front side 195.58 mm 127mm At lower arms Rear side 236.98 mm 127 mm At upper arms

Distance from chassis

137.6mm

99.6mm

BUSHING MECHANISM

ADJUSTABLE CAMBER MECHANISM

BRAKING SYSTEM
URJA RETROFITTED Virtual equipped with a hydraulic braking system that acts on all four wheels by disc brake and is operated by a single foot. At the time of braking almost 65% weight reaction is transfer to the front side and 35% to the rear side.
Disk Brake Specification Outer Diameter 230mm Inside Diameter 75mm Disc Thickness 11mm Disc Brake Result Brake Force 2800N Brake Torque 57.4N-m Brake Pressure 0.15MPa

Weight transfer during braking

Weight of the vehicle Height of the C.G Coefficient of friction , inclination Distance of C.G from rear Distance of C.G from front Wheel base 320kg 420mm 0.7 Depends on road profile 430mm 810mm 1240mm

Speed (kmph) 40 45 50

Braking Distance 7.05m 8.92m 11m

Braking Time (sec) 1.2 1.4 1.58

At 50kph our vehicle stopped at 11m takes 1.58 seconds. This is equal to 19 kilowatts. And Braking Efficiency will be 89%.

TRANSMISSION
TRANSMISSION CONFIGUATION COUPLING MAX. SPEED : Mahindra & Mahindra ALFA ( Constant Mesh Type ) : 4 Forward, 1 Reverse : Flange Type
Gear Ratio Speed (kmph) (@ 3600 RPM) 31.48:1 18.70:1 11.40:1 7.35:1 13.67 23.04 37.80 58.64 7.8

: 58.64 kmph at 4th Gear and 3600 RPM WHEEL SIZE (in.) : 25 X 8 12 JOINTS ACCELERATION MAX. TORQUE : Constant Velocity (C.V.) Type, U- Joint, Ball Joint : 0- 60 kmph in 8.13 secs : 525.23 Nm @ Ist Gear

R- 55.08:1

LENGTH OF HALF- : 762.3 mm SHAFT

IMPLEMENTATION PLAN FOR B & S ENGINE WITH POWERTRAIN

As per our plan we will couple the B & S Engine and the M & M Alfa transmission by a shaft whose one end fits onto the 3 output shaft of engine and the other end fits inside the transmission. Next, we mount a plate in between the engine and transmission of 10 mm thickness.(O.D. = 140mm and I.D. = 70mm). Overall Length = 198.3 mm The plate is bolted to the engine by 8 bolts ( 8mm) and the transmission is bolted then by 6 bolts ( 8mm) onto it.

Figure 1
Disc Thickness 6 8 Holes Holes 10 mm 10 dia 8 dia

Figure 2

STEERING DESIGN
By the stability point of view rack and pinion gear system is more stable as compare to worm and roller, because it has involutes teeth profile therefore the meshing of teeth is better as compare worm and roller type of steering gear system. Rack and Pinion system has been used as muscular energy system. It is used for its simplicity as there as few parts, low cost, light weighted, occupies less space so more suitable for compact vehicles and also because it is stiff and precise as compared to the re-circulating ball nut integral gear.

Geometric consideration
Caster angle is 3. kingpin inclination is 10.5 Length of rack is 5.4 inch Rotation completed by pinion in 3.125 turns Effort of 20 N is applied by each hand on steering wheel
Steering Specification Rack of steering Tie rod right Tie rod left Wheel base (b) Wheel track (a) Radius of steering wheel Dimensions 5.4 inch 9 inch 15.74 55 inch 56 inch 6.1 inch

RESULT :Inner turning angle 35

Outer turning angle

Turning radius Steering ratio Load transmitted to tie rod

23.26
4m 22:1 880 N

EXHAUST AND INNOVATION -1

Magnetic fuel saver
Decrease the intermolecular force of attraction proper mixing of fuel takes place efficiency increases reduction of waste gases

Three way catalytic converter

Convert toxic exhaust emission into non toxic substance

Important reactions
Reduction of nitrogen oxides to nitrogen and oxygen 2NOx xO2 + N2 Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 2CO2 Oxidation of unburnt hydrocarbons (HC) to carbon dioxide and water: CxH2x+2 + [(3x+1)/2]O2 xCO2 + (x+1)H2O

INNOVATION-2
This System Is Based On Measuring The Pressure Drop At The Break Switch Which Are Used To Operate The Rear Break Lamps. When There Is A Pressure Drop In The Break System Due To Leakage There Is A Warning Indication To The Driver. Because Due To Pressure Drop The Circuit Not Get The 12v Supply From Battery And A Red Led Glows And A Buzzer Sound Is Activated By Monostable Circuit Used In The System.

Components
Voltage Comparator IC Timer IC Diode Resistance Capacitance Buzzer and LEDs Voltage Supply

Specification
CA3140 NE555 1N4007 10k,100k,470k 0.1,10,100,1000 1.This System Monitors & Provides An Indication Every Time The Breaks Paddle Is Pressed. 2.This System Can Be Easily And Effectively Integrated Into The Vehicles To Provide The Advantages. 3.This Approach Will Not Only Maximize The Effectiveness Of Vehicle But Also Ensures Functionality And Performance Of Vehicle Is Fully Optimized 4.As This System Is Powered From Car Battery So No Need Of External Power Source.

12V from Car Battery

Queries ?

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