SAE NIS EFFI-CYCLE
2015
DESIGN REPORTS
Team ID
15062
Team Name:
ATIVIRYA
College Name
: Indira Gandhi Delhi
Technical University For Women.
City
Report Author
Old Delhi, Delhi-110006
Zoya Farooque
Report Co-Author :
Padma Priya
ABSTRACT
The participating team from Indira Gandhi Delhi Technical University in the event SAE NIS EFFICYCLE, ATIVIRYA is a team of 10 members with the aim of designing and fabricating a vehicle for this
years Light Weight Season 2015. SAENIS EFFI-CYCLE is an intercollegiate design competition which
requires the students to design and fabricate an aerodynamic, highly engineered, energy efficient hybridhuman powered three wheeled electric vehicle.
The project was designed keeping in mind the experiences from last years event and this years vehicle
requirements in compliance with SAE NIS Efficyle 2015 Rulebook. After a series of discussions and
consultation, this design was chosen by narrowing down various concepts and aspects based on the
technical needs of the efficycle and the team. Selection of material was based on design factors including
weight, cost, and performance.
Various improvements and new concepts are incorporated in the design in order to increase the efficiency
of the vehicle. Focusing on maneuverability and Figure Of 8Test, the steering geometry was designed
according to trapezoidal mechanism with Ackermann geometry. To perform efficiently in dynamic tests,
use of worm and wheel is considered to increase torque and thus the load carrying capacity of motor and
gear ratios for both human and electric drive is also improved for this time. Also keeping in mind the
performance in utility test , we have decided to incorporate suspension in this years efficycle.
TECHINICAL SPECIFICATIONS
S.N
O
DIVISION
1.
VEHICLE
SUBDIVISION
SPECIFICATION
NAME
MAGNITUDE
Wheelbase
47
Trackwidth
50
Turning Radius
2.98m
Configuration
Tadpole
Weight
71kg (without driver)
Ground Clearance
13.5
2.
3.
ELECTRICAL
MOTOR
Power
0.5 HP
Type
PMDC Static type
Gear Reduction
1:5
GEAR
Worm and Worm
Wheel
1:10
BATTERY
Number
Type
Lead Acid Battery
Runtime
2.24 hours
Volts
24Volt (12 V each)
Braking Disatnce
HPV:2.81m
BRAKES
Electric:3.59m
4.
5.
TRANSMISSION
FRAME
PROJECT PLAN
MATERIAL
Type
Disc
Type
HPV-RWD Electric
Drive-RWD
Gear Reduction
HPV-4.4:1 Electric Drive1:5
Type
Al 6063
IMPLEMENTATION OF LIGHT WEIGHT TECHNOLOGY
To meet the challenge of this years Light Weight Season, we incorporated various changes and
improvisations in the vehicle after narrowing down various materials and attributes of their dimension
and usage.
The use of ALUMINIUM 6063(density=2.7g/cc) of OD - 1.25inch and 4mm thickness because
of its bending strength, bending stiffness, cost and market availability of this material in place of
AISI 1018(density=7.8g/cc).
The kerb weight target this year as calculated, is 71kg which is nearly more than half the kerb
weight of last years vehicle.
Using different cross sections at different places depending upon the stress developed which
would help reduce the weight by using smaller cross section at areas less prone to stress.
Use of light weight material such as ABS for steering wheel, seats and Pedals with the help of 3D technology.
Subsystem
Weight(in kgs )
Chassis
30
Motor and
Batteries
3+20=23
Steering
Suspension
Brakes and
Wheels
Powertrain(HPV
)
DESIGN, CALCULATIONS AND SELECTION:
A.) Frame Configuration
The frame of the trike was aimed to be strong which is able to with stand the forces during impact yet
light in weight with minimum joints.
The design was based on tadpole structure. Two wheels in front offer excellent overall braking and
overall excellent handling. Tadpole design with properly calculated COG makes further design easier
and provides excellent traction, turning and braking stability. It provides a larger tilting range.
CHASSIS
Tadpole configuration
Wheel Base = 47
13.5
Chassis weight= 30kg
Track width = 50
Ground clearance =
Material Al 6063
Design Procedure: Initially a rough sketch was prepared on the paper with the frame fulfilling the
basic requirements using 13 steps of designing recumbent trike. It was then improvised and improved
while drawing it on the computer using Solid Works. The frame was then checked for its stability
during various impacts using SOLIDWORKS Simulation. Additional members were added to make
the frame able to withstand max forces which may occur during collision. The process was repeated
till desired results were not obtained.
Material Selection: Considering the factors like high strength, low cost, market availability, and
Light Weight, we decided to choose AL 6063 as our material over AISI 1018. The following are its
specifications:
MODULUS OF ELASTICITY (Gpa) = 68.9
YIELD STRENGTH (Mpa) = 145
B STRENGTH (Mpa mm^3)= 312805.2161
BENDING STIFFNESS (Gpa mm^4) = 2359603.002
B.) Drive Train:
Human as well as Electric mode both are rear wheel drive.
SEASON 2014
SEASON 2015
Hpv gear ratio
3:1
4.4 : 1
Electric mode gear
ratio
1:2
1:5(use of worm and worm
wheel)
Torque (electric mode)
5.14 N-m
12.85 N-m
HUMAN POWERED MODE
No of teeth on bottom bracket sprocket:
44
Acceleration of vehicle:
0.577 m / s2
Number of teeth on gear on intermediate shaft: 20
Number of teeth on gear of rear wheel:
10
Gear ratio obtained :
4.4:1
Maximum velocity at rear wheel:
35 km/hr (assuming 60 rpm at bottom bracket)
ELECTRIC MODE
Voltage:
Power:
Gear Ratio:
Worm and wheel Ratio:
Battery type:
Number:
Voltage:
Current:
Battery Runtime:
At gradient:
Maximum velocity at rear wheel:
24V
375 Watt
1:5
1:10 (to increase torque)
Lead Acid Battery
2
12 V (each)
35A-hr
2.24 hours(plane)
54 minutes
40km/hr
C.) Steering, Suspensions, and Brakes
Steering:
Using Trapezoidal steering mechanism in place of Rack and pinion. Selection was done primarily
to reduce weight and reduce the wheelbase of the vehicle and therefore increasing the turning
radius i.e. maneuverability of the vehicle.
Specification:-
ATIVIRYA
2014
ATIVIRYA
2015
MODIFICATION
Wheel-base
62inches
47inches
Smaller wheel base hence
decreased turning radius
Track width
55inches
50 inches
Decreased.
Turning
radius
3.94m
2.98m
Smaller turning radius and
hence offers more
maneuverability
FACTORS OPTIMISED
Ackerman Angle = 28 deg
Turning Radius=2.98m
Tie rod length = 44.84
During cornering, Ackerman condition:
Maximum inner wheel angle =38deg
Average wheel angle= 30.5deg
Critical speed of shaft = 294 m/s
Suspension:
In order to overcome difficulties of wheel breakdown which we faced last year, we have included
iron strips to all the three wheels and front and rear suspension systems keeping in mind the
target of overall kerb weight of the vehicle.
Suspension used in Rear Wheel: Swing-arm
Suspension used in Front wheels : Bicycle Shockers
Property
Value
Static Deflection
15.24 cm
Spring Constant(Rear)
2465.34 N/m
(=0.2503kg/mm)
Damping coefficient
309.352Ns/m
Brakes:
The selection for the use of the brakes for the vehicle is Cable actuated Disc brakes, two in
front wheels and one in the rear wheel. These were chosen on the basis of:
Easy availability Simple construction Slip-free braking Unaffected by tire width Less
prone to fading Self-adjusting
DESIGN
Fn (Clamping
Force)
801N
Formulas used:
Fb (Braking Force)
1.) Braking Distance :
2.) Braking Force :
3.) Braking time
: v/a
240.3N
HPV MODE
Braking Distance:
Velocity:
Braking Time:
SPECIFICATIONS:
2.81m
35km/hr
0.5 seconds
v2/2(+G) g
m*a
ELECTRIC MODE
3.59m
40km/hr
0.6 seconds
Assumption:
Average Human Grip Force= 267N
b(between Braking pad and rotor = 0.4)
g(between ground and the wheel)= 0.75
D.) Wheels and Tyres
The use of tubular tyre is incorporated in the trike design instead of tubeless tyres which were
used last year.
The rim of front wheel is made of steel, making it light in weight and of iron for rear wheel,
giving the rims enough strength to handle weight till 350 kg.
The inner diameter of front wheel = 24 inches,
The outer diameter of front wheel = 28 inches
Number of spokes in the tyres: 36 spokes in front tyre
36spokes in rear tyres.
E.) Seating arrangement, Seat design and features
This year we have incorporated the idea of using 3-D Printed
Rib Cage recumbent seats, the advantage of which would be
that new shapes and structures can be easily given and made. The
material is of better quality with lesser weight helping us to
material
density
ABS(Acrylonitril 1.04g/cc
e
butadiene
styrene)
WOOD
1.4g/cc
achieve our goal towards lighter weight in this Light Weight Season and moreover, the production is
cheap and affordable and manufacturing is quick.
Material: ABS (Acrylonitrile butadiene styrene)
Density: 1.04g/cc
PARALLEL TYPE ARRANGEMENT
Backrest angle= 35deg from vertical
Backrest Length=635mm
Headrest height= 228mm
Saddle length=430mm
Seat Width=100mm
Lumbar support = 203mm
Seat height = 469.9mm
F.) Safety
ROLL OVER PROTECTION
Provided to protect the rider from neck and head injuries in impact conditions.
HARNESS PROVISION
Harness ensuring the safety of the driver in case of any unfortunate accident
METALLIC GRID FOR MOTOR
Provides motor protection in case of a high-speed incident
KILL SWITCH
Used to completely shut down all electrical equipment in case of an emergency. Push to Kill
Switch has been used.
Strong rear impact and side impact resistance through members.
ERGONOMICS
Incorporation of adjustable customized pedals increases the human effort at pedals and helps the
driver in pedaling. Inclusion of Recumbent ergonomically seats as they are comfortable and
supportive for riders back.
Calculations for the size and placement of all the parts were done before making the cad model
so that everything is easily accessible to the driver and she can drive the vehicle with comfort and
minimum effort. Following are some key dimensions taken in consideration. The reference
values used in obtaining the results were taken by measuring the dimensions of all the team
members and then taking its mean.
HUMAN POWERED MODE
STEERING
Crank length:
141mm
HB-BOS: 557mm
Knee angle:
90
HB height: 863.6mm
BB Height:
590mm
BB BOS:
832.2mm
RECUMBENT SEATS (In mm)
Seat Height:
469.9
Saddle length: 430
Backrest length: 635
Backrest Inclination: 35 from vertical
Headrest:
228
Seat width:
100
Lumbar Support:203
INNOVATIONS:
This years first innovation was chosen keeping in mind the light weight season which is, the use
of 3-D printed material made from ABS (Acrylonitrile butadiene styrene)
Weve incorporated customized pedal lock mechanism to aid in steering and seating.
The next innovation includes the use of piezoelectric effect. The piezoelectric crystals would be
placed within the wheel tubes would undergo mechanical stress which in turn would produce and
develop enough amount of electric charge and voltage to charge up the batteries of mobile phone.
ISOMETRIC AND OTHER COMPLETE VIEWS OF VEHICLE.
HAND MADE SKETCHES OF THE VEHICLE (ABOVE IMAGES)
PROTOTYPE MADE USING PVC PIPES
USED
DISC BRAKES AND SUSPENSION
DRIVETRAIN ARRANGEMENT (LEFT) AND MOTOR WITH WORM AND WORM WHEEL
(RIGHT) . (ABOVE IMAGES)
INNOVATION (PEDAL LOCK MECHANISM) (IMAGES BELOW)
SPONSERS
