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PHOENIX

SRI RAMAKRISHNA ENGINEERING

COLLEGE

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Width - 62 at widest point

Length - 108 end to end

Capable of carrying 1 person 190.3 cm weighing 113.4 kg

Proposed to use Briggs & Stratton Engine

Reverse light (white visible at min10m) and reverse alarm equipped

Towing Hitch Points 2 (Front & Rear)

Drivers helmet to be 6 inches away from a straightedge applied to any two points on the

cockpit of the car. The drivers torso, knees, shoulders should be 3 inches from envelope of car.

Minimum vertical clearance = 6 provided from top of the helmet and bottom of the rollcage top tube members

Roll cage materials: Steel tubing OD - 1 ; Wall thickness - .120 ; carbon content - .18%

Roll cage Foam material Polyethylene with minimum thickness - .5

A clearance of 3 between firewall, side impact members and seat is maintained

Ingress & Egress -5 secs

Emergency Kill Switches 2

5 point restraint harness with 3 wide lap belt and shoulder harness straps along with 5thanti submarine belt

Positive wheel lock-to-lock stops located at wheel kingpins to be mounted

Equivalent bending stiffness and bending strength in accordance with SAE 1018

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Overall height = 1180mm Overall width = 1403 mm

Overall length = 1915 mm

Wheel base = 1450 mm

Track width = 1200 mm

Weight (approx) = 290 kg (without driver)

Ground Clearance = 10

Turning Radius = 3.820m Maximum Speed = 57.25 Kmph @ 3600 rpm

Acceleration = 1.775 m/s^2

Maximum Gradability = 31.186 @ 3600 rpm at 1st gear

VEHICLE SPECIFICATION

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Braking

Front =215 mm ventilated discs

Rear = 180 mm drum brakes

Biasing = 70:30

Braking Distance (45-0 Kmph) = 10.49m

Steering

Type Variable Rack and pinion

Turning Radius =3.820m

Steering Ratio = 14:1 20:1

Lock to lock turns = 3

Target Design & Performance Specifications

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Front Spring

Stiffness = 17 N/ mm Travel =150 mm

Max Possible Force=2920N

Mean Dia of Coil=90mm

Wire Dia = 10mm Spring Length =260 mm

No. of active coils = 8

Rear Spring

Stiffness = 27 N/ mm

Travel = 128 mm

Max Possible Force=4468N

Mean Dia of Coil=98mm

Wire Dia =12mm

Spring Length =260mm

No. of Active Coils =8

SuspensionFront : Unequal double wishbone with coil springs

Rear : Unequal double wishbone with coil springsMaterial :ASTM A106B

Section : Circular 33.4mm OD , 30.02mm ID , 3.38mm

thickness

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WHEEL GEOMETRY

Rim Dia =14

Front Tires = 25 X 8 X 14

Rear Tires = 25 X 8 X 14Tires to be used

BAJATRAX TIRES

TRANSMISSION

Type Rear Wheel Drive

Gearbox - 4 speed manual constantmesh gearbox with 1 reverse

Model Piaggio Ape

Ratio / Kmph per 2400 rpm1st 35.298 / 8.134

2nd20.053 / 14.32

3rd 11.382 /25.23

4th 7.523 / 38.17

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Material: ASTM A106B

Yield strength: 463.77 MPaUltimate strength: 552.43 MPa

E=205 Gpa

Outside diameter: 33.4 mm

Wall thickness: 3.38 mm

Total no. of welds = 57

Weld Length = 5.98 mTIG Welding

Roll Cage Design

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FRONTAL IMPACT TEST

FORCE APPLIED=64680 N

FINITE ELEMENT ANALYSISREAR IMPACT TEST

FORCE APPLIED 47432 N

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FRONT BUMP TEST

REAR BUMP TESTLOAD APPLIED=11760 N

LOAD APPLIED=11760N

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HEAVE TEST SIDE IMPACT TEST

LOAD APPLIED=600 N LOAD APPLIED=43120 N

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ROLL OVER TEST

LOAD APPLIED=3775 N

3D-VIEW

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Cost reportITEM NAME USED IN MAKE BUY MATERIAL QUANTITY

ESTIMATED COST(IN

RUPEES)

Frame Structural ASTM A106B 4 3750

Hardware Structural STEEL N/A 4200

Brackets Structural STEEL N/A 4000

Supports Structural STEEL N/A 5500

Engine Drivetrain N/A 1 17000

Manual transmission Drivetrain N/A 1 9500

A-arms Front & Rear Suspension ASTM A 106B 2 2000

Spring Suspension N/A 4 6500

Shock Absorbers Suspension STEEL 4 9500

Rack & Pinion Controls STEEL 1 4400

CV joints Controls STEEL 2 800

Steering Column Controls STEEL 1 4500

Brake system Kit Controls COMPOSITES 1 8500

Pedals Controls ALUMINIUM 2 1400

Steering wheel Controls ALUMINIUM 1 1200

Electrical Wires &

SensorsAccessories ELECTRONICS N /A 5750

Transponder Accessories N/A 1 N/A

Driver Seat Accessories PLASTIC 1 4500

Hub Accessories ALUMINIUM 4 2400Tires Accessories RUBBER 4 11000

Rims Accessories ALUMINIUM 4 7000

Neck Support Accessories PLASTIC 3 3000

Goggles Accessories PLASTIC 3 3300

Gloves Accessories FABRIC 3 3600

Helmet Accessories PLASTIC 3 6000

Wrapping Foam Accessories STYROFOAM 1 1000

Fire Extinguisher Accessories N/A 2 5500TOTAL 135800

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MS Project Plan

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When one wheel is stuck in

swamp surface, IRBS is

employed

Auxiliary lever and additional

braking line that locks one

rear wheel at a time

3 positions of lever

off/left/right

Rotation of stuck wheel is

prevented- Power istransmitted to the opposite

wheel

Independent Rear Wheel BrakingSystem (IRBS)

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To actuate the kill switch

automatically in the event of fire

accidents, using temperature

sensors.

Temperature difference during

accidental fire breaks

Sensor actuates the kill switch

Binary sensor mounted atvarious points that provide signal

to a micro controller

AUTOMATIC ACTUATION OF KILLSWITCH DURING FIRE EMERGENCY USING TEMP SENSORS

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FAILURE CAUSE DETECTIONITEM NAME POTENTIALFAILURE

MODE EFFECT SEVERITY CAUSE OCCURANCE DESIGNCONTROL DETECTION RPN

FRAME STRUCTURAL/SAFETY

The frame

bends or

breaks10

Too much

load or

shock

applied

leading toexcess axial

stress

4 Relatively high factorof safety to ensurestructural integrity 2 80

HARDWARE STRUCTURALMechanical

and structural

components

damaged

leading to

inability of use10

Too much

load or

shock

applied

leading to

excess axial

stress


BRACKETS STRUCTURALMechanical

and structural

components

damaged

leading to

inability of use10

Excess load

or vibrationcausing

excess

bearing and

yielding

stress


SUPPORTS STRUCTURALStructural

damage

leading to

inability of use10

Too much

load or

shock

applied


stress


ENGINE MECHANICALPossibility of

explosion;

inability to

operate10

Lack of clean

air and fuel

to maintain

operation1 Placement in area tominimize risk to

driver 1 10

A-ARMS MECHANICAL Suspensioncompromised

9

Too much

load or

shock

applied


stress

4Relatively high

factor

of safety to

ensuremechanical

integrity2 72

DFMEA

DFMEA

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ITEM NAME POTENTIALFAILUREMODE EFFECT SEVERITY CAUSE OCCURANCE DESIGNCONTROL DETECTION RPN

SPRINGS MECHANICAL Suspensioncompromised 9

Wrong

spring

chosen for

application4

Diligent testing

to

ensure

functionality1 36

SHOCK

ABSORBERS MECHANICALSuspension

compromised 9Debris

damagingcomponent 3Verification of

desired

specifications ofcomponent 3

81

RACK AND

PINION MECHANICAL Inability tosteer 8Obstruction

in travel of

system 2Verification of

desired

specifications of

component4 64

CV JOINTS MECHANICAL Inability tooperate 8

Excess

torque

applied 3Verification of

desired

specifications of

component3 72

STEERING

COLUMN MECHANICAL Inability tosteer 9Debris

damaging

component 2Relatively highfactor

of safety to

ensure

mechanical

integrityN/A 18

BRAKE SYSTEM

KIT MECHANICALExtensive

damage to

THE VEHICLE in

undesired

scenario10

Inability to

provide

sufficient

braking force2 Diligent testingto ensure

functionality 1 20

PEDALS MECHANICAL Inability tooperate 10

Excess load

applied by

driver to

component2

Relatively highfactor

of safety to

ensure

mechanical

integrity1 20

STEERING

WHEEL MECHANICAL Inability tosteer 8Excess load

applied by

driver to

component2

Verification of

desired

specifications of

componentN/A 16

TRANSMISSION MECHANICAL Inability toOPERATE 9

Lack of structural

integrity

under cyclic4 Verification ofdesired

specifications of

component6 216

DFMEA

DFMEA

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ITEM NAME POTENTIALFAILUREMODE EFFECT SEVERITY CAUSE OCCURANCE DESIGNCONTROL DETECTION RPN

DRIVER SEAT SAFETY Driver's safetycompromised 9

Excess load

leading to

bearing yield 2Diligent testing

to ensure

functionality 1 18

TYRES

MECHANICAL Inability to

operate 8Puncture by

debris 6Verification of

desired

specifications ofcomponent 1

48

RIMS MECHANICAL Inability tooperate 8 Damaged bydebris 3

Verification of

desired

specifications of

component1 24

HELMET SAFETY DRIVERS SAFETYCOMPROMISED 10 Damaged bydebris 2

Verification of

desired

specifications of

component1 20

FIREEXTINGUSHER SAFETY Can lead toexcess fire

damage 9Lack of

maintenance 3 Constantchecking N/A 27TRANSPONDER ELECTRICAL VEHICLE WILL BE

BLACK FLAGGED 7Water

damage to

component 3Insulation to

avoid shock

driver N/A 21

D

FMEA

D

FMEA

Electrical circuits

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Steering-Rack and pinion

-light weight

-simple design

-low cost

- relatively small size

Suspension

-It gives more movement of the tires and hence the vehicle for the same movement of the spring

-Independent suspension

-Force is distributed at 5 points in the roll cage unlike at only one point in Mcpherson strut-Can be slightly adjusted for different parameters of suspension tuning like camber angle,

ground clearance at the time of testing and then finally proper adjustments are made at the

time of fabrication.

Brakes

-Ventilated disc for higher heat dissipation rather than a single disc

DESIGN VALIDATION

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Documents

57991 Phoenix