Effi Cycle Presentation

TEAM ROADRUNNERNational Institute of Technology Rourkela

When given some intelligence, a cycle can be more efficient and safe.

EXTRACTS FROM RULE BOOK

Design and fabricate an energy efficient Hybrid human powered three‐wheeled electric vehicle. The vehicle must be aerodynamic, highly engineered and ergonomically designed. The design should be commercially viable as a product and should be attractive to the consumers because of its visual appearance, performance, reliability and ease of operation.

The vehicle must have three wheels that should not be in a straight line. The vehicle must be capable of carrying two riders, of at least of 190.3 cm (6’3”) height and weighing 115 kg.

Vehicles participating in the completion can have a maximum dimension of 90 inch x 48 inch (L x B). To check the dimension, teams may be asked to drive the vehicle through a gate of defined width.

Vehicles must be driven by human power and electric powered (Use of PMDC Motor ‐ Permanent Magnet DC motor is must and max power of motor should not be more than 400 watts). Teams can use a battery source of d12V‐48V and up to 35Am‐hr.

Teams are allowed to use only mechanical KERS systems in their vehicles. KERS is allowed to be used only during the race and teams are not allowed to keep the system in a charged state during start.

All vehicles are required to have brakes on all wheels. Teams can use both hydraulic and non hydraulic brakes that satisfy the minimum defined criteria of locking of brakes in a static condition.

Each vehicle must be equipped with rollover protection system to keep riders safe in case of accidents irrespective of whether the vehicle is open or having a roof. No vehicle may discard any part after the vehicle is in motion.

Vehicles participating in the main event should be capable of carrying a load of 50 kg. Vehicles need to have a proper mounting system with a clamp to carry a sand bag of dimension 20 inches x 12 inches with thickness of 6 inches. The load should be properly clamped during running condition and hung load would not be allowed.

The Overall cost of the vehicle shall not exceed by INR 20,000. Penalty in the form of points will be imposed if the amount of the vehicle increases by INR 20,000.

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Efficycle Events

Presentation

SprintManeuverability

Circuit

Kerb weight: : 64 kg (approx without riders & load)Total weight: 64+70+70+50 = 254kgBounding box volume: 208.6 cm x 100 cm x 102.4 cmWheel base : 144.6 cm,Track width: : 98 cm

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TECHNICAL SPECIFICATIONSDimensions and weight Suspension

Power train

Material specificationMaterial for the frame of the vehicle : Aluminum 6061

T6 tempered Material used for axle :structural steel 45 grade

Front suspensionDouble super shox suspensionLength :42cm

Rear suspensionClosed coil helical torsion beam springSpring travel: 2 inchesSpring Rate : 64.8 N/mmLength:18.5cm

GEAR NUMBER(REAR)

DIAMETER(CM)

NO.OF TEETH

1st 10.5 28

2nd 9.5 24

3rd 8.5 21

4th 7.5 18

5th 6.5 15

6th 5.5 12

Braking

CHAIN SPECIFICATION 1st person 2nd person

CENTER DISTANCE 85.5cm 33.5cm

NO.OF LINKS=(K=(T1+T2)/(2)+(2*x)/(p)+(T2-T1)2/(2*3.14)*(p)/x)

172 87

LENGTH OF CHAIN 213.33cm 110.5cm

WEIGHT OF CHAIN 1.3671kg 0.69kg

Steering Fork length:45cmOffset:4cmHead angle:70 degreeMechanical trail:6.45cmWheel static chamber: 2 degree(negative on both rear wheels)Handle to seat distance:74cm

Fly wheel Mass:4.175kgThickness: 3.4cm

Rear axle Mass:1.5kgDiameter: 1.5 inches

Wheel diameter:28”Wheel width:1.5”

Fixed caliper disc brakesRotor diameter:160mmForce by caliper:150N(approx)

Wheels and tyres

TARGET PERFORMANCE SPECTe

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53 kmph – 0 braking : 18.2 m

52.7 kmph = 14.64 m/sAccording to equations of motion Braking Distance :

v2 = u2 + 2as s = v2 / 2awhere v = 14.64 m/s

u = 0 = 18.19 ma = μg = 0.6 * 9.81 m/s2

= 5.89 m/s2

Gear No. Speed (m/s) Speed (kmph)

1st gear 6.27 m/s 22.57 km/hr

2nd gear 7.32 m/s 26.35 km/hr

3rd gear 8.36 m/s 30.09 km/hr

4th gear 9.76 m/s 35.14 km/hr



Top Speed : 52.7 = 53 kmph

Average speed supposed to be attained throughout : 35 kmph

DESIGN OF VEHICLE (FULL DESIGN)Te

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ELECTRONIC CIRCUIT FLOWCHARTTe

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DESCRIPTION OF DRIVE TRAIN ALONG WITH PICT.Te

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UNIQUE SELLING PROPOSITION (USP)Te

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Most of the people across the world spend a lot of money in travelling from their homes to their workplace. They do this by scooters, motorcycles, and cars(mostly in foreign countries). Not only does this result in a lot of wastage of money but also results in air pollution and today it is in fact the major cause of air pollution due to automobiles. This also results in tremendous dependence on petroleum-based resources and hence is the reason for non-preventable rise in the prices of both petrol and diesel.

When people drive cars to drive to their workplaces, they are surely wasting a lot of energy in driving those huge-sized vehicles to carry them to their destination. This vehicle can solve this problem to a great extent. First of all, it is a light weight vehicle weighing only XXXX kg. This is because it is made of aluminum alloy which is very light. Again, it can be driven mechanically, or if you are tired, then it can be driven electrically as well, without disturbing you with any noise or polluting the environment.

No need to waste money in buying cycles and a vehicle. This vehicle itself acts as both a two-seated tri-cycle(more stable than bicycle) and as a two-seated vehicle. So, you can now not only save energy consumption but also your money.

For students, this vehicle is great since this vehicle has a proper speed control and cannot be driven faster that XXXX km/hr which enhances their safety. They will be able to carry their bags simply by keeping it in the rear carrier. This vehicle can also act as an inspiration to them to make efficient and environment-friendly vehicles in future.

“Get your money back in 3 years and start earning afterwards !!” *

*Assuming that you spend Rs. 417 per month in nearby travelling, and the vehicle costs Rs. 15,000.

ROUND PIPE PROCURED AND CUTTING

PRESSING OF ROUND PIPES INTO OVAL PIPES

WEILDING ON FIXTURES(MAIN FRAME)

ASSEMBLY OF MAIN AND REAR FRAME WITH SUSPENSION

FRONT FORK ASSEMBLY WITH SUSPENSION

GEAR AND SPROCKET ASSEMBLY ON MAIN FRAME

CHAIN AND PEDAL FITTING

REAR AXEL FITTING WITH KERS,GEARS , AND CLUTCH SYSTEM

CONNECTING ELECTRONICS

BRAKE FITTING ALONG WITH FITTING OF BRAKE CABLES WITH BRAKE

LEVERS

MUD GUARD, CHAIN FITTING,AND COVERING OF OTHER MACHINE PARTS

WEILDING OF REAR FRAME

ERGONOMICS CHECKING

WHEEL ,SEAT ,BRAKE,BRAKE CABLE ,GEAR ALLIGNMENT

WHEEL ASSEMBLY

CARRIER ASSEMBLY ACCORDING TO THE REQUIREMENT

HANDLE AND SEAT ASSEMBLY

COMPLETE PRODUCT.

DRIVE TEST, BRAKE TEST,AND ELECTRONIC TEST

PAINT, OILING,GREASING AND FINAL TOUCH UP

PROJECT PLAN & PROCESS FLOW DIAGRAM

Pro

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Week

Activity

1 Got news about event Efficycle. Download of Rulebook and other materials provided by the event organizers. Consulting with the SAE Collegiate Club Faculty Advisor. Permission. Team selection and division. Registration for the Efficycle event. Net search on various existing 3-wheeled vehicles to get a rough idea. Referring Theory and search for various Automobile books.

2 Planning the general design. Detail hand drawing of the design. Finalization of frame design. Decision on various parts and equipments to be attached to the vehicle. List out all necessary devices and hardware materials to be used. Planning, how well the electrical and electronic parts can be integrated with the vehicle and in which way their use will make the vehicle better.

3 Collection of details regarding the use of finalized materials. Assigning measurements of various parts of the cycle according to human ergonomic point of view. Enquiry of availability of materials in the local market and in the Internet. Estimation of total cost of fabrication. Designing the parts to make the vehicle simple and have increased load bearing capacity. Performing analysis of each part separately. (Using 3DS CATIA)

4 Assembly of all parts to form the entire vehicle. Detail ANSYS analysis of the entire frame under various loaded conditions, both static and dynamic. Finalizing on the design of drive train. Design of drive train. Planning for motor fitting and all electrical switches and controls. Planning and designing the electronic circuit design and determining the parts that are cheap and can be used. Validation of entire vehicle design.

5 Design Report preparation. Cost Report preparation. Presentation preparation. Consulting Faculty Advisor and data collection regarding the various workshop facilities available for the vehicle fabrication if selected. Final Report submission with all details, and analysis.

VALIDATION PLAN Te

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TEST METHOD

TEST COMPONENTS

TEST REQUIREMENT ACCEPTANCE CRITERIA

ASSIGNED TO

Strength, stiffness and deflection analysis

FEA via ANSYS

Space frame with rear swing arm and rear suspension

Confirms stress bearing capacity & ensures tolerance of straightness & orientation

Elastic moduli should not show much variation.

Chitta Ranjan Meher

Drive train analysis

Fair calculation using machine design formulas

Total chain drive and derailleur’s gear system

Confirm maximum power transmission from the pedals of both the drivers

Minimum energy loss during transmission and minimum slacking of chain.

Satya Prakash Pradhan & Chitta Ranjan Meher

Rear axle analysis


Rear axle with gear arrangement

Confirm the ability of the axle to bear the total weight of the vehicle, torque and moment created by the chain drive.

Torsional rigidity, bending moment should not show much variation

Satya Prakash Pradhan & Chitta Ranjan Meher

Fly wheel design analysis


Fly wheel Confirm the ability of the flywheel to store kinetic energy &to minimize fluctuation is energy

Capability of storing the kinetic energy & delivering it when required

Satya Prakash Pradhan

Electronic Circuit design analysis

Approximation and calculation using device characteristics

High power MOSFETs, 555 Timer, H-bridge motor controllers & Atmega32 ADC output

Confirm usability of electronic circuit with 36V high voltage and 400W high power motor

Each device has a sufficient voltage and current margin in working condition from breakdown.

Subhajit Sahu

INNOVATIONS PROPOSED

AUTO-MOTOR MODE WHEN DRIVING THE VEHICLE IN ELECTRICAL MODE

The new feature of this vehicle is its Auto-Mode operation of motor. In this mode of operation the microcontroller (Atmega32) automatically switches the motor between motor mode and generator mode automatically as per the requirement. This is achieved with the help of difference de-amplifier, a comparator, a microcontroller, and high power MOSFETs. What the circuit essentially does is measure the back-emf generated by motor to determine at what speed the vehicle is running. It then compares this speed with the speed required as set by the accelerator. If, the speed is more than needed (or set), then the microcontroller automatically switches form motor mode to generator mode by the help of high power MOSFETs. In this generator mode the battery charge is replenished. Thus, energy is restored during down hills, slopes, slowing down the vehicle or braking.

PARALLEL DERAILLEURS DESCRIPTION

Two rear axle derailleur were connected in the same shaft. Front rider drives one derailleur via a flip flop and the back rider drives the another derailleur. But both the derailleur were controlled by the front rider through a parallel connection of the derailleur’s cable. due to common, parallel control and single control of both the derailleur there is no probability of mismatch in power transmission.

INDIVIDUAL PEDALLING

Special ball bearing and flip flop arrangement in the rear pedal, gives the freedom of individual pedaling to the passenger. Individual pedaling means ,if the passenger don’t want to pedal he or she can rest without rotating the pedal along with the driver which is a common problem in most of the two seated cycles, which makes it very uncomfortable and tiring for the passenger. So such an arrangement is proposed so that passenger and driver both gets total comfort while driving.

It also includes multiple gears and gearbox to increase the load carrying capacity of the vehicle even when driven by a small boy. It also includes an electrical accelerator to control the speed of vehicle when the motor is switched on. There are many other switches for various purposes and this also includes mechanical disc brakes and electrical brakes for safety. Other features include shock absorbers, topple protection bar and comfortable seats.

Hence, these features increase the efficiency of the vehicle and thus can be called an “EFFI-CYCLE”.

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WHY “GO GREEN” WITH ROADRUNNER This is a mechanically and electrically driven vehicle. It does not pollute the environment since it

does not use any petroleum-based motor, but uses a simple DC motor. This vehicle also has higher efficiency when compared with other electrical bikes available in the

market. This is because of its new auto-motor mode which also enhances battery life of the battery being used.

In every day life, people normally travel short distances between their home and their workplace. For this purpose, they use scooters, motorcycles, and cars. This results in a lot wastage of energy, particularly is they use cars. Instead, if they start to travel with this vehicle, the pollution level in the country can greatly reduce for sure. (In fact about 80% of pollution caused by automobiles is due to people using their vehicles for short distance travel)

The vehicle can also be set in generator mode in which one or two persons can ride the vehicle and then energy is produced by the motor as it now acts as a generator. The energy produced is stored in the battery. Hence the battery can be recharged without having to plug it into a socket and thus it allows the people to be more environmentally friendly.

The frame of the vehicle is made of aluminum alloy which can be recycled. Fly wheel or KERS, used helps in restoring energy fluctuation and in storing energy which when

used properly can make the vehicle more efficient. The rear rack/ carrier enhances utility and are perfect for heavier loads. As it is above the rear

axle, it proves to be excellent an carrier.

This vehicle is expected to be used by students, teachers, workers, auto-rickshaw drivers, people who don’t earn much money, environmentally-aware people, or those who only need to travel small distances (i.e., from their home to their workplace). This cycle is itself an efficient cycle because it requires lesser energy for a ride and also for luggage and good transport because of the gear arrangements .

This vehicle has a sufficiently large rear rack where people can carry some luggage in it. Hence this vehicle is also expected to be used by local business men to transport their goods at a cheaper rate and earn greater profit. Industrial workers can use it for their transportation purposes. This vehicle can also be a part of campaigning , in public awareness programs and also in the zoos by the care takers.

In general, anywhere there is a need of short distance travel, this vehicle can be the easiest and the most environmentally friendly way of doing it.

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POTENTIAL MARKETS AND CUSTOMERS

TEAM DETAILSNo. Name Designation Branch Responsibility Role

1 Name – Faculty Advisor Associate Professor Mechanical Engineering Guidance and Help

Faculty Advisor

2 Satya Prakash Pradhan B.Tech. 3rd Year Mechanical Engineering Design and Analysis

Captain & Driver

3 Chitta Ranjan Meher B.Tech. 3rd Year Mechanical Engineering Marketing Captain & Driver

4 Subhajit Sahu B.Tech. 1st Year Electronics & Communication

Engineering

Design and Analysis

Team Member

5 D Jaswant Kumar B.Tech. 1st Year Mechanical Engineering Fabrication Team Member

6 Protsahan Pradhan B.Tech. 1st Year Mechanical Engineering Marketing Team Member

7 Rajat Kumar Nayak B.Tech. 1st Year Mechanical Engineering Electrical and Electronics

Team Member

8 Shaikh Tarik Mobin B.Tech. 1st Year Mechanical Engineering Fabrication Driver

9 Saurav Kumar Kachriya B.Tech. 1st Year Mining Engineering Aerodynamics Team Member

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Effi Cycle Presentation

Documents

Transcript of Effi Cycle Presentation