National Go-kart Championship (NGKC, ISNEE) 2014

National Go-kart Championship (NGKC, ISNEE) 2014

• 2.
  TECHNICAL SPECIFICATION Weight: 250kg(approx. with riders & load) Wheel base : 43.5 inch Track width: 36 inch (front), 46 inches (rear) Centre of gravity: 7 inch from ground & 27 inch from front wheel Ground clearance: 1-2 inch (adjustable) Weight and Dimensions Engine type :4 Stroke Petrol Maximum power: 12.4 hp Compression Ratio : 9.5: 1 Swept Volume :124.6 cc Maximum Speed :9000rpm Torque :10.8 Nm Cooling system :Forced Air Ignition System: Electrical Engine Type : 4 speed constant mesh Gear Configuration: 5 Gear Ratio Forward: 21.85/14.26/ 10.50 /8.81/7.86 Top speed : 65 Kmph Optimum Speed: 50 Kmph Transmission Rim Dimension Front:5 Rear:5 Tire Dimension Front: 10 x 4.5 x 5 Rear:11 x 7.1 x 5 Wheels and Tires Linkage mechanism Turning radius C.G. : 2.0971 m Maximum steer angle: 35 degree Length of Tie Rod: 32 inch Steering Brake type : Disc brake Disc Diameter: 200 mm Disc Thickness : 3 mm Caliper Piston Diameter : 35 mm Master Cylinder Piston Diameter : 16mm Braking effort: 35 kg Brakes Material for the chassis of the vehicle : AISI 4130 Material Specification 12 Volts, 5 Ah Battery
• 3.
  DESIGN AND ANALYSIS Rearvonmisse Torsional vonmisse Side vonmisse Front vonmisse
• 4.
  Frame characteristics : Useof seamless tube. AISI 4130 material. Outer diameter of frame = 1 in. Wall thickness = 2 mm = 0.0787 in. Total Length = --- in. Front track width = 914.4 mm = 36 in. Rear track width = 1168.4 mm = 46 in. Wheelbase = 1104.9 mm = 43.5 in. Height of Centre of Gravity = 7 in. Frame can bear 4G load impact. Comfortable sitting arrangement for the driver. FRAME AND CHASSIS
• 5.
  Gear 7000rpm 9000rpm First8.605174 7.6781146 Second 5.616310 5.0170051 Third 4.136220 3.6908914 Fourth 3.470753 3.0968522 Fifth 3.097862 2.7641326 Gear 7000rpm First 240.4285714 Second 156.9197143 Third 115.566 Fourth 96.97285714 Fifth 86.55428571 TORQUE ENGINE AND TRANSMISION ACCELERATION Bajaj discover 125 ST Cylindrical capacity:125 ST Max net power: 11ps@8000rpm Max net torque: 10.8Nm@5500rpm Gears: 5 manual Primary Reduction: 3.4 Gearbox Reduction: 3,1.95,1.44,1.21,1.08 Overall Reduction: 21.85,14.26, 10.50,8.81,7.86 CHAIN DRIVE Front sprocket: 14 Rear sprocket: 42 Max Tractive Force: 1721.034871 N Max speed: 65 Kmph Max Torque: 240 Nm TRANSMISSION MAX TORQUE MAX SPEED MAX TRACTIVE FORCE ENGINE SPECIFICATION
• 6.
  TARGET: To minimizeturning radius, minimize steering effort, maximize return ability and stability ANALYSIS: Linkage mechanism- Turning Radius: 2.0971 m Steer axis inclination(Ѱ) : 20 degree Caster angle(ν) : 5 degree Static camber(ϒ̻) : +0.75 degree Toe in of 3 mm Steer angle: Inner (θ) : 35 degree Outer (φ): 23.91 degree Tie rod length: 0.8128 m Scrub radius (d): +0.08128 m Ackerman geometry: sin(α+θ) + sin(α-φ) = 1.8959 2 sinα= 1.37930 Camber angle equation ϒ=ϒ̻+ Ѱ+𝑐𝑜𝑠−1[(sinѰ) x cos δ] + 𝑐𝑜𝑠−1[(sinν) x sin δ] -180˚ Returnability Mv = -(Fzl + Fzr) (d sin δ)sin Ѱ+ (Fzl -Fzr) (d cosδ) sinν = 1.323 Nm (when δis steered negative ) & = - 1.323 Nm (when δis steered positive ) STEERING
• 7.
  CALCULATION: Wc=250kgX9.81 Wc=2452.5N µ= 0.7 l =43.5 inch = 1.1049 m Ycg = 7inch = 0.1778 m Xcg = 26.1 inch= 0.66294 m Pedal force= 35 kg Dynamic load transfer : 276.25N Brakes Fictional braking Fn= pressure x area = 9.42 x10^6 x9.6211x 10^-4 Fb = 2 x μ x Fn Fn = 9063.102107 N Fb = 7250.4816 N Ft = Fb x r = 725.0481 Nm STOPING DISTANCE: Speed 50 km/h = 13.888 m/s Braking force at the periphery of the tire = Fb x Rdisc / Rtire Braking force at the periphery of the tire = 7250.48 x 0.1/0.1397 Ftire = 5190.036936 N Ftotal = 2 x 5190.036936 Ftotal = 10380.07387 N K.E.= ½ x m x v^2 K.E.= ½ x 250 x 13.888^2 K.E.= 24112.34568 Nm Stopping distance = K.E. / Ftotal = 24112.34568 / 10380.07387 Stopping distance = 2.32294 m BRAKES TARGETS: To acquire minimum stopping distance, pedal force and weight of brake assembly with maximum brake torque. BRAKES CONSIDERED: Disc brakes of TVS APACHERTR 180 with floating calipers FRONT REAR Front Brake torque f = Ff x μ x R Ff = Wc –Fr Ff = N Braking torque required Btf= 1248.05 x 0.7 x 0.127 = 110.951645 N Rear Btr= Fr x μ x R Fr = Wc Xcg /l -Wc μ Ycg/l Fr = 1204.45 N Braking torque required Btr= 1204.45 x 0.7 x 0.1397 = 117.7831655 Nm
• 8.
  COST STRUCTURE System Materialcost Process Fasteners Tooling Total Brake 3250 700 300 100 4250 Engine and transmission 30000 1500 500 200 32200 Frame and body 7000 1000 300 100 8400 Instrument 10000 600 200 50 10850 Miscellaneous fit finish 3000 1200 800 300 4950 Steering 3200 1000 300 400 4900 Tier and rim 11000 400 400 100 11900 Innovation Total 67450 6400 2800 1250 77550
• 9.
  Name of Component PotentialFailure Effect S Potential causes O D R P N = S x O x D Immediate Corrective Measure Action Results New Action taken S O D RPN Chassis Breakage of Chassis 8 Improper Welding, Corrosion on Material, Weak Joints 4 6 192 ---------- Proper wielding at joints, anti-corrosion coating 8 2 6 96 Brakes Vehicle may not stop or will not move forward 10 Breakage or corrosion on brake lines, jamming of disc due to over heating 3 2 60 Bleeding of brakes Spill free brakes lining 2 3 6 36 Steering Loss of maneuverability, probability of accidents 9 Tie rod breaks or bends, improper alignment, excessive load on tie rod 5 3 135 Aligning by adjusting the screws Replacing tie-rod 9 2 3 35 Engine No power will be generated, vehicle does not moves. 6 Chocking of float valve, Breaking of Crank 5 4 120 ----------- Making valves choke free 5 4 4 80 Transmission Dynamic failure, vehicle 8 Breakdown of half- shaft due to over- 4 5 160 Proper lubrication of Replacing the chain 8 2 5 80 DFMEA
• 10.
  DFMEA Process Step Potential failuremode Potential failure effect S Potential causes O Current process control D R.P.N Action recommended Actions taken New s o d R.P.N Chassis Breakage of Chassis 8 Improper Welding, Corrosion on Material, Weak Joints 4 6 192 Proper wielding at joints, anti- corrosion coating 8 2 6 96 Brakes Vehicle may not stop or will not move forward 10 Breakage or corrosion on brake lines, jamming of disc due to over heating 3 2 60 Spill free brakes lining 2 3 6 36 Steering Loss of maneuverability, probability of accidents 9 Tie rod breaks or bends, improper alignment, excessive load on tie rod 5 3 135 Replacing tie-rod 9 2 3 35 Engine No power will be generated, vehicle does not moves. 6 Chocking of float valve, Breaking of Crank 4 4 120 Making valves choke free 5 4 4 80
• 11.
  TEAM MEMBERS Shivam Mishra DevpalSingh Punit soni Prem Alok Lakhan Verma Brakes Sourabh Saini (vc) Rupesh Mahajan Ratnesh Swarankar Prakhar Mishra Transmission Ashish Singh (c) Rajat Singh Sisodiya Sanu M.S. Vaibhav Porwal Design and Analysis Prateek Rathore Suyash Garg Sajan Kumar Panjiyara Amit Verma Steering THANK YOU Lavesh Ranpise Jay Chaudhary Mohit Srivastava Mohd. Saud Khan Ashish Patel Ayush Jain Marketing Mr. Kamal Ojha Mr. Soham Munjal Faculty Adviser