PPT VIRTUAL.pptx

PPT VIRTUAL.pptx

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  VIRTUAL PRESENTATION TEAM ID: 23153 EBAJA 2023 TEAM SOVEREIGN
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  2 : LESSONSLEARNT ROLL CAGE & AGGREGATES ASPECTS LESSONS LEARNT IMPROVEMENTS Motor Controller Overheating of motor controller due to excess current Two cooling fans are incorporated to maintain the permissible temperature H-arm In the semi-trailing arm, we can’t get anti-squat geometry, and it also provides negative camber gain while cornering. Providing more grip to the weight carrying tire and provides more free parameters and wheel motion easily optimized. Frame (Roll cage) Clearance issue between motor and damper. Slightly decrease the placement height of the motor. Battery Placement Battery removal was quite hefty and also the CG height was high. Battery is placed axially on cradle plane (behind the firewall). CG height was decreased Brake light Due to high (excess) voltage our light was brust out We are using DC-DC converter instead of battery for efficiency. VEHICLE PERFORMANCE MAIN EVENTS LESSONS LEARNT IMPROVEMEN TS Power- train Torque on wheels was not sufficient for the vehicle to climb incline tracks. The gear ratio is changed to 8:1. Harness Previously it was difficult to distinguish wire. Different color codes
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  SPECIFICATIONS 2021 2023 OverallSize 83”×57”×65.6” 62.5”×47”×56” Track Width F/R 50”/48” 47”/45.5” Wheel Base 54” 51.18” Ground Clearance 14” 14” Transmission Gearbox Gearbox Tires Radial, 23x7x10 (+40mm offset) Radial, 23x7x10 (+40mm offset) Suspension F/R Double A-Arm / H-Arms Double A-Arm / H-Arms Steering Rack and pinion Rack and pinion Brakes Disc Brakes Disc Brakes Maximum Speed 41.29 kmph 44.6 kmph Maximum Acceleration 5 m/s2 5.55m/s2 Gear Ratio 12:1 8:1 Gradeability % 80% 57.73% Stopping Distance 8.99 m 8.99 m Kerb Weight (Kg) 175 172 Ratio FAW To RAW 45:55 62:38 3 :GENERAL SPECIFICATION - COMPARISON 2023 2021
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  4 : ROLLCAGE DESIGN PROCESS-ERGONOMICS PARAMETER RULEBOOK SPECIFICATIONS DESIGNED (Driver) DESIGNED (Co Driver) Length of LC Members Minimum 8" 13.77” 13.96” ALC Member Minimum 18" 22” 22” Inclination of RRH Maximum 20 deg. 5 deg. 5deg. Width of RRH 27" above seat bottom Minimum 29" 31.13” 31.53” Width of RRH 14" above seat bottom Minimum 32" 33.37” 34.2” Top and Bottom intersection of LDB and RRH Members Maximum 5" 5” 5” Angle of LDB with RRH Minimum 20 deg. 70.11 deg. 70.5 deg. Distance of point C from the center of the template Minimum 12" 12” 12” RHO Diagonal Bracing distance from point C Maximum 3" 2” 2” SIM Member Height from seat bottom 18" to 14" 11.02” 11.12” Angle between the FBMUP and the vertical in order to prevent the use of Front FAB Maximum 45degree 20.82 deg. 21deg Triangulation angles of rear FAB with the vertical Minimum 20 deg. 21.14 deg. 21.53 deg. Driver Helmet Clearance Minimum 6" 14.96” 14.45” Clearance of driver’s shoulders, torso, hips, thighs, knees, Lower legs, arms, and hands minimum 3” 4.3” 3.1” “
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  5 : CAE No . Typeof Analysis Total Load Applied Maximum Equivalent Stress (Von Mises) 1 Front Impact 14746.53 N 365 Mpa 2 Rear Impact 6945.833 N (dv=45kmph) 840.95 Mpa 3 Side Impact 6390 N (dt=0.30s) 2486 Mpa 4 Roll Over 7375 N (dv=45kmph) 4192 Mpa WELDABILITY Type of welding: Tungsten inert gas welding(TIG) Filler to be used:ER70S-2 Force Calculations: F = ½*230*dv/dt; dv=60kmph; dt=0.13 Max. Deformation FOS 0.46mm 2.34 Max. Deformation FOS 0.3504mm 2.58 Max. Deformation FOS 1.648mm 2.58 Max. Deformation FOS 2.87mm 1.401 Max. Deformation FOS 0.15856mm 1.921 Max. Deformation FOS 0.082mm 2.712 Max. Deformation Knuckle F: 0.64mm R:0.2379 mm FOS: F: 1.62 R:2.079
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  6 : SUSPENSION SPECIFICATIONS 20222023 FRONT REAR FRONT REAR Suspension Double A-arms Semi- trailing Double A-arms H-arms Mass Distribution 92.5 157.5 92 138 Sprung Mass 185 Kg 170 kg Un-sprung Mass 65kg 60 kg Camber -2° 0 0° 0 Caster 11.26° 0 8° 0 KPI 6.64° 0 5.54° 0 Motion Ratio 0.6 0.65 0.6 0.65 Roll Centre 6.95” 7.24” 8.85” 6.73” Scrub Radius (mm) 41.17 - 10.4 - Suspension Travel Jounce = 6” Rebound = 3” Jounce = 6” Rebound = 3” Spring Stiffness(N/mm) 22 30 21 27 Ride Rate (N/mm) 17.83 22.73 15.58 21.68 CG Height 25” 23” Desired Natural Frequency (Hz) 1.55 1.76 1.52 1.68 Damping Ratio 0.7 0.7 0.7 0.7 Damping Stroke (mm) 90 102 42 52 Damping [email protected]/s 43.18 65.80 40.28 61.89 IMPROVEMENTS 1. Reduced CG height 2. Optimized the toe angle with respect to wheel travel -0.05 -1E-16 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 -150 -100 -50 0 50 100 150 200 TOE ANGLE [Degrees] WHEEL TRAVEL [mm] TOE ANGLE VS WHEEL TRAVEL
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  SPECIFICATIONS 2022 2023 PedalForce 400 N 400 N Pedal Ratio 6:1 6:1 Master Cylinder (Bore Size X Stroke) 19.05 x 25 mm 19.05 x 25 mm Brake Caliper Cylinder (Bore Size X Nos.) 40 x 1 mm 31.75 x 2 mm Caliper Piston Area 1256.63 mm2 791.73 mm2 Caliper Pad Area 1321.56 mm2 1372.81 mm2 Brake Pad Friction Coeff. 0.45 0.45 Brake Fluid DOT 3 DOT 3 Effective Radius 0.075 m 0.075 m Torque Front Required 217.914 Nm 202.286 Nm Torque Rear Required 154.600 Nm 127.246 Nm Torque Front Available 395.458 Nm 414.97 Nm Torque Rear Available 280.560 Nm 261.03 Nm Stopping Distance 8.99 m 8.99 m Force Required By Calipers (Front) 746.026 N 692.435 N Force Required By Calipers (Rear) 529.273 N 435.625 N Dynamic Load Transfer 691.149 N 685.595 N Static Roll Radius (Tyre) 11.5’’ 11.5’’ Pedal Travel 150 mm 150 mm 7 : BRAKES Front Rear Split Brake System Thermal Analysis Stress Analysis
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  SPECIFICATION 2022 2023 SteeringSystem Over steer Over steer Steering Geometry Ackerman 81% Ackerman 82% Inner/Outer Angle 25.9/ 14.84 (deg) 44.66/27.27 (deg) Turning Radius 1.5 m 1.2m Steering Gear Rack and pinion Rack and pinion Drive Type CHD CHD End To End Travel 80 mm 60 mm Turns Lock To Lock 1.1 turns 1.5 turns Steering Ratio 72.73 mm/rev 40 mm/rev IBJ/OBJ Centre Distance 214.63/553 mm 175/529.05 mm Tie Rod Length 14.84 in 15.30 in Rack Length 18.770 in 13.77 in Column Type Single Column Single Column Power Assist - - Steering Wheel Diameter 180 mm 250 mm Steering Wheel Torque 0.5-1.2 Nm 6.0 - 7.0 Nm 8 :STEERING AND WHEEL GEOMETRY
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  9 : POWERTRAIN MOTORSPECIFICATIONS TYRE SPECIFICATIONS BLDC MOTOR (48 V) Outer Diameter 23” Max. Torque 19 Nm Inner Diameter 10” Max. Power 9 kW Thickness 7” INTEGRATION MOTOR CONTROLLER TRANSMISSION Voltage 48 V Fixed Gear Ratio 8:1 Speed Control PWM Weight 13 kg Weight 2 kg Dimension 16" x 8" x 4" BATTERY (Li-ion) NVH CONSIDERATIONS Cell Voltage 3.7 V (nominal) Capacity 110 Ah (13x42 cells) Dimension 17.7”x11.8”x6” PERFORMANCE Max Acceleration 5.55 m/s2 Gradeability 57.73 % • For motor and gearbox we will use rubber(neoprene) sheets. • Nylon nuts(self locking nuts) are used . • Polyurethane foam are used in driver seat to get most comfortable ride. • Steering wheel is covered with leather along with foam to damp vibration.
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  9-B : TractiveSystem & Complete Circuit Diagram MCU Specification Peak / Cont. Phase Current 92.38 A & 51.96 A Rated/ max. DC Current 90 A DC & 160 A DC Throttle Input Type Foot Padel Cooling Type Passive Natural Cooling Approximate Weight 4.5 kg Dimensional Size 288*185*94.3 BMS Features (protection) Over Charge , Short & Temperature Prptections Current Protection Over current delay time = 9MS Over current Protection  discoonect the load Short Fuse Protection 150 A Charged / Discharged Voltage 48 V DC & 25 V DC Specifications Charge Delay Time = 0.5S Max Discharge Current=60A Peak Discharge Current =180 A Battery Specification Nominal Voltage 48 V Max Cut off Voltage 54.75 V Min. Cut off Voltage 37.5 V Nominal Ah Capacity 110 Ah SOC 5 – 95 % DOD 90% Approximate Weight 52 Kg Dimensions 240*370*2 80* mm Maximum Charging Current 50 A Maximum Discharging Current 150 A Operating temp. 25-60 C
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  9-C : GLVSystem & Component Analysis GLV Component SPECIFICATIONS Fuse Location Perpose Current/Voltage Rating Motor Controller 150A / 60V After AIR 200A / 60V Type (Instant blow/ Delay blow) Instant blow AIR Normally open type(200A) Kill Switch <=15V DC DC-DC / GLV Accumulator <=15V Auxiliary Sub System Break Light, Reverse Light, Reverse Alarm, Ignition Switch, Cockpit Switch, Kill Switch, Fuse, AIR Safety Components TSAL [Flash Rate = 4Hz], RTDS [Sound intensity at 3m = 70 dB] , Fuse [Voltage/Current rating = 150A / 60V, Time Delay <500 mS] AIR (Accumulator Insulation Relay ), Firewall [Insulating Layer Thickness = 0.50 mm] Microcontroller OR Sensor ESP 32, Thermistor,Voltage sensor,Optical rotary encoder,Accelerometer,pressure sensor. Wiring / Connectors Properly insulated harness with help of insulating caps & enclosures TSAL Sequence Flow Diagram 1 2 12V IN 1 2 48V IN 1 2 15V OUT 1 2 OUT2 EMS 1.0 DC TO DC STEP-DOWN 48V TO 15V TSAL BATTERY 48V ESP - 32
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  10 : PROJECTPLAN 2022 TASK WORKDAYS July August September October November December January February March TEAM SELECTION 5 5 IDEAS SHARING SESSIONS 5 DEPARTMENTS HEADS MAKING 3 DOCUMENTATION 5 SPONSORSHIP 30 DESIGNING 30 78 MATERIAL ORDERING 15 93 ROLL CAGE 10 108 STEERING 15 SUSPENSION 14 137 BRAKES 12 POWERTRAIN 20 ELECTRICAL DESIGNING 10 195 ASSEMBLY 30 225 TESTING 30 255 2023 10 13 18 48 123 151 185 CRITICAL PATH IN THE PROJECT Timely procurement of raw materials and subsequent manufacturing and machining to meet the deadlines.
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  COMPONENT FAILURE MODEFAILURE CAUSE FAILURE EFFECT S O D RPN PREVENTIVE FACTORS Frame Frame bending, Breaking Excess and impact load Frame deforms/ breaks` 9 3 5 135 Effective design and analysis Suspension Mechanical failure Inappropriate choice of spring driver may face physical discomfort. 5 6 3 90 Selection of standard suspension systems, dynamic factors Knuckle Bending failure Impact load and excess load. Suspension system damage 8 4 4 128 Effective design and analysis Motor Over heating, hall sensor fault Moisture, insulation breakdown Over current, fire 9 3 2 54 Protective Circuit: MCB, Fuse, AIR, Regular check-ups Battery Cell failure/Cell damage Over current, high voltage and temperature Fire, explosion, tractive system stops working 10 7 2 140 BMS, Protection Circuit: MCB, Fuse, AIR, Charge- Discharge Test Pedals Bending & Breaking Excess load by driver Brake fails & acceleration cannot take place 8 3 5 120 Effective design, analysis and mounting Welding/ Soldering Cavities inclusions Crack in weld/ solder Formation of cavities and inclusions Job weakens/ Circuit loosens 8 1 7 56 Preheat, increase weld area & bead contour Brake fluid leakage Improper flaring Improper flaring Reduced pressure 7 7 3 147 Double flaring with flaring kit and proper Teflon 11 : DFMEA & PFMEA
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  DEPARTMENT DESCRIPTION TESTSOURCE TEST PROCEDURE ELIGIBILITY CRITERIA RULEBOOK CLAUSE ADHERENCE Specifications as per rulebook Verification from rulebook Measurements manually checked Vehicle specifications must match with rulebook DESIGN AND FABRICATION Weight Weighing Bridge Weighing the ATV Target weight –230kg Dimensions Measurements Digital Vernier caliper & Clinometer Specified according to rulebook ATV Ergonomics Testing ATV in rough terrains Check the driver’s adaptability to the vehicle Must fulfil all design requirements SUSPENSION Drop Test Observation ATV dropped from 6 ft. Assembly must be intact Bump Test Observation Testing it on a rough terrain Spring should rebound completely POWERTRAIN Acceleration Vehicle Record time taken to travel a certain distance Least time must be taken (best performance) Battery SC & Overcharge Test Various Loads Connecting loads across the battery No physical damage, melting of components or explosion STEERING Agility Test Tracks and Cones Drive the figure of ‘8’ and ‘O’ Turns without touching the cones Straight Line Stability Tracks with white stripes Driving parallel to white stripes Should move in a straight line when steering is at neutral position BRAKES Wheel locking Slow motion cameras Brakes applied at full throttle All four wheels must lock (stop spinning) at the same time Pressure and Leak Test Manual Vehicle to be tested in various road conditions Reduced pressure and leakage in the brake circuit should be absent ELECTRICAL Kill Switch Vehicle Manually checked if working properly HV system turned off; Brake light working 12 : DVP
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  TEAM FACULTY ADVISORS Dr. Alok JainRahul Deharkar DEPARTME NT HEAD MEMBER Design Meet Lakhani Devam purohit Analysis Meet Lakhani Abhishek Brakes Dhrumit bhatt Krishna Suspension Smit Patel Anand Steering Rushang kulkarni Rishit Panchal Motor & Powertrain Bhawani singh shekhawat Sahaj,Paresh Controller Harshil, Vrinda Om,Jinisha BMS Vrinda Kamya,Jugal Sponsorship Rishit Maulin Inventory Bhawani Paresh Costing Harshil Shreya GLV Vishal Sameul VEHICLE AGGREGATE MANUFACTURING FACILITIES MANUFACTURING PROCESS FACILIITIES Roll Cage Welding, Grinding, Bending, Cutting TIG Welding, Grinding, Drilling, Lathe, Milling, CNC, Rapid Prototyping Machine, Hydraulic Band saw A-arms and trailing arms Welding, Grinding, Bending Knuckle and Hub Milling machine Paneling Sheet Bending, Molding, Drilling ELECTRICAL AGGREGATE ELECTRICAL FACILITIES TESTING PROCESS FACILIITIES BMS Protective Circuit Test EDC Lab Motor Load Test EMEC Lab 13 : TEAM COMPOSITION AND COLLEGE WORKSHOP FACILITIES Hydraulic Band Saw Motor Load Testing Shaping Machine * Highlighted are old members