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Transcript of 57991 Phoenix
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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
4 Relatively high factorof safety to ensurestructural integrity 2 80
BRACKETS STRUCTURALMechanical
and structural
components
damaged
leading to
inability of use10
Excess load
or vibrationcausing
excess
bearing and
yielding
stress
4 Relatively high factorof safety to ensurestructural integrity 2 80
SUPPORTS STRUCTURALStructural
damage
leading to
inability of use10
Too much
load or
shock
applied
leading toexcess axial
stress
4 Relatively high factorof safety to ensurestructural integrity 2 80
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
leading toexcess axial
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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