Team Terasvin Supra Virtuals Ppt1

8/12/2019 Team Terasvin Supra Virtuals Ppt1

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SUPRA SAEINDIA 2013 VIRTUAL PRESENTATION

TEAM TERASVIN

SONA COLLEGE OF TECHNOLOGY, SALEM


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KNOWLEDGE OF RULE BOOKFor the STUDENT FORMULA competition, teams are to assume that they

work for a design firm that is designing, fabricating, testing and demonstrating aprototype vehicle for the non-professional, weekend, competition market.

Cockpit Opening &Cockpit Internal Cross Section must be as per the template . Firewall &Floor Close-out must be of suitable material as per the rules. Any portion of frame which might be in contact with driver helmet must be padded .

The car must have a wheelbase of at least 1525 mm (60 inches). The smaller track of the vehicle must be no less than 75% of the larger track. The suspension system with shock absorbers must have minimum travel of 2 inches . The wheels of the car must be 8.0 inches or more in diameter. The steering wheel must be mechanically connected to the wheels. The braking system must act on all four wheels and be operated by a single control. Engine displacement Limitation is set to below 610cc . The throttle must be actuated mechanically , i.e. via a cable or a rod system. Intake System Restrictor of 20mm must be used. The maximum permitted sound level from the vehicle is 110 dBA . The vehicle must be equipped with two (2) master switches which

form part of the shutdown system.


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TEAM ORGANIZATION CHART

SUSPENSION/FRAMES SUB LEADER:ANANDH

AJAY KUMAR

STEEERINGSUB LEADER: ROSHAN

THILAK RAJ

BRAKES

SUB LEADER: ARIEF MKASHIF AHMED

ENGINE/DRIVETRAINSUB LEADER: RAGAVAN

KIRAN RAJ

RAMPRASATHMOHAMED ARIF

ELECTRONICSSUB LEADER: RAJESH

PRADEEPRAGHU

MARKETINGSUB LEADER: ARIEF M

PRADEEP

TEAM LEADER: ANANDH


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Technical specsDimensions : 2832x1397x1058 mmWheelbase : 1572mmSuspension : Push rod actuated unequal

double A-armBrake : Parallel hydraulic actuation

ventilated petal discsFrame : 4130 chromoly steelSteering : Rack and pinionTires : 20.5x7.0-13 (Hoosier)


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Steel Space Frame Suspension mounts are mostly nodded. Comply with all rule templates. Machine around the man concept. Material Used SAE 4130 steel tubes. Low cost, manufactured with conventional tools. Easy to repair and modify. Inclined the drivers seat angle to get low CG.

SPECIAL FEATURES High torsional rigidity of 4022Nm/deg. Weight of the chassis is less than 230kg . Factor of safety is greater than 2

for impact tests.

DESIGN METHODOLOGY OF ROLL CAGE


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Side impact FOS:2.2

FEA

Front impact FOS: 2.7 Rear impact FOS :2.4

Roll over FOS:3.5

Load applied: 20,600 N Load applied: 8830 N

Load applied : 14,720 N Load applied : 4420 N


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ERGONOMICS

Good visibility for the driver. Frame tracing the shape of human body. Large cock pit opening for quick exit. Comfortable seating position. Quick release steering wheel.

95th percentile male template


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SUSPENSION

METHODOLOGY

Push Rod Suspension Load transfer during braking, acceleration and cornering were considered. FVSA and SVSA geometry were used to finalise roll centre, instantaneous centre

and finally mounting points were determined. Anti dive and Anti squat were considered during the design.

Mounting points were mostly nodded.SPRINGS AND DAMPERS Based on requirements and availabilityLINKARM DESIGN To obtain good camber curve

Roll centre FR: 17.78mmRR: 25.4mm

Stiffness FR: 25.05 N/mmRR: 56.64 N/mm

Camber -2.

Roll angle 0.124.


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SUSPENSION

Optimum K analysis

Input :Static valuesOutput : Dynamic conditions obtained

Front lower control arm

FOS : 5.8

Rear lower control arm

FOS : 6.4


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20.5x7.0-13

FOS:2

REAR UPRIGHTFRONT UPRIGHT

FOS:3

UPRIGHT ANALYSIS

WHEEL GEOMETRY

Tyre specs

Slick tyres


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FRONT HUB

Material : Aluminium 6061 T-6

HUB ANALYSIS

STRESS

FATIGUE

FOS:5.5

REAR HUB

Material: 4340 steel

STRESS

FATIGUE

FOS: 2.9


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Disc brakes on all four wheels Hydraulically operated braking system Independent front and rear brake circuit Parallel brake lining systemMASTER CYLINDER Front bore : 15.8 mm Rear bore : 20.02 mm

DISC SPECIFICATION 200 mm ventilated petal disc

Stopping distance: 3.9 m(40 km/hr)Pedal force : 1423.4 NPedal ratio : 4:1Brake efficiency : 85%

BRAKES

BRAKE LINING


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STEERING

Rack and Pinion Steering :

Team Design and Manufacturing Steering ratio : 3:1 Maximum Turning

Radius : 4.71m Steering Angle : 35 degrees Material : Mild steel caster : 7 degree


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ENGINE (HONDA CBR 600 RR)

599 cc Inline 4 cylinder Compression ratio 12:1 Electrically controlled Fuel injection DOHC 4 valve per cylinder 32 mm throttle body chosen 6 speed sequential transmissionENGINE STOCK PERFORMANE FIGURES Power : 105.6 hp @ 13,250 rpm Torque : 60.7 Nm @10,500 rpmDRIVE TRAIN Chain drive (520) Final drive ratio 4:1 Torsen limited slip differential DOJ type CV joint

POWER TRAIN

Mounting points


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INTAKE SYSTEM

Top Feed Intake system plenum volume set two times the engine

displacement Runner length calculated to optimize power. Flow analysis done for even distribution of mixture Runner length : 256 mm Runner diameter : 38 mm

EXHAUST SYSTEM 4-2-1 configuration Reduced Back pressure Free flow muffler Lowered sound level

POWER TRAIN


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ELECTRONICS

ELECTRONIC CONTROL

UNITRD 0901

GEAR SHIFTER

ADDITIONAL ELECTRONIC KITS

Speed meter RPM meter Malfunction indicator Gear indicator Gear shifting indicator

Shift timing :30 ms Ignition interruption

GEAR SHIFTER FEATURES


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SAFETY EQUIPMENT RATING

EQUIPMENT EQUIPMENT RATINGPADDING SFI spec 45.1 or FIA 8857-2001

HELMET Snell K2000,SFI 31.2A or FIA 8860-2010

DRIVER SUITSFI 3-2A/5, FIA Standard 1986 FIA Standard 8856-2000

SHOES SFI 3.3, FIA 8856-2000

ARM RESTRAINT SFI Standard 3.3

FIREEXTINGUISHERS

Powder extinguishanthomologated by the FIA

DRIVERRESTRAINTSYSTEM

SFI Specification 16.5, or FIAspecification 8853/98


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OVERALL PERFORMANCE TARGETSAND VALIDATION PROCEDURES

PERFORMANCE TARGETS

Engine power : 75 HP Engine torque : 55 N-M Estimated top speed : 140 KPH Acceleration : 4.2 sec for 0-75 meters Stopping distance : 3.9 m

VALIDATION PROCEDURE & TESTS TO BE PERFORMED

Engine : Dynamometer for power and torque figures of the vehicle.Braking : Chassis Dynamometer.Chassis : Real time prototyping will be done to test the key points for strength. Vehicle leakage test Torsional rigidity test Noise level testing


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COLLEGE WORKSHOP FACILITIES

CNC LATHE (INDUSTRIAL MODEL LT16) WIRE CUTTING MACHINE (EDM) CONVENTIONAL LATHE (TURN MASTER 35 KRILOSKAR) CAPSTAN TURRET LATHE MILLING MACHINE HORIZONTAL AND VERTICAL SHAPING MACHINE MEDIUM AND HEAVY DUTY

RADIAL DRILLING MACHINE UNIVERSAL TESTING MACHINE TORSION TESTING MACHINE FATIGUE TESTING MACHINE COMPUTIRISED I.C ENGINE LAB & DATA ACQUISITION SYSTEM


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COST ELEMENTS AND SPONSORSHIP

AREATOTAL

(RS)

BR Brake system 13040.00

EN Engine&drivetrain 227380.00

FR Frame & Body 99455.00EL Electricals 133320.00

MSMiscellaneous Fit &Finish

84400.00

ST Steering system 3520.00SU Suspension, shocks 57780.00

WT Wheels & Tires 74600.00

Total 693495.00

BR ENFR ELMSSTSU

WTOUR SPONSORS TILL DATE

SONA COLLEGE OF TECHNOLOGYTHE PROFESSIONAL COURIERSJK CEMENTS

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Team Terasvin Supra Virtuals Ppt1