Académique Documents
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CONTENTS
Section 1 General Information Section 2 Vehicle Requirements and Restrictions Section 3 Roll Cage, Systems and Drivers Equipment Requirements Section 4 Competition Procedures and Regulations Section 5 Technical Inspection Section 6 BAJA SAEINDIA Events Section 7 Appendices Appendix 01- Roll Cage Specification Sheet Appendix 02- Local Technical Inspection Rules Appendix 03- Code of Conduct Appendix 04- Virtual BAJA SAEINDIA Appendix 05- Design Report Format Appendix 06- Cost Report Format Appendix 07- Index Sheet for Process Cost Reference Appendix 08- Static Event Participation Sheet Appendix 09- BAJA SAEINDIA 2014 Scoring Appendix 10- BAJA SAEINDIA 2014 Awards Appendix 11- BAJA SAEINDIA 2014 Penalty Structure Appendix 12- BAJA SAEINDIA 2014 Contacts 3 6 15 40 43 48 57 57 58 60 61 64 66 69 70 71 72 73 74
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1.1.2
Student Status
Team members must be enrolled as degree seeking undergraduate student in a college or university. Team members who have already graduated prior to the competition (Feb. 2014) are NOT eligible to participate.
1.1.3
Society Membership
Team members must be members of SAE (Society of Automotive Engineers) or an SAE affiliate society. Proof of membership, such as a membership card, is required at the event.
1.1.4
Age
Team members must be 18 (eighteen) years of age at the time of the competition.
1.1.5
Drivers License
Team members who will drive a competition vehicle at any time during a competition must hold a valid, government issued drivers license. This will be required onsite for proof.
1.1.6
Liability Waiver All on-site participants and faculty are required to sign a liability waiver upon registering on-site.
1.1.7
Insurance
Individual medical and accident insurance coverage is required and is sole responsibility of the participant.
1.2 1.2.1
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1.2.2
Responsibilities
Faculty Advisors are expected to advise their teams on general engineering and engineering project management theory.
1.2.3
Limitations
Faculty advisors may not design any part of the vehicle nor directly participate in the development of any documentation or presentation. Faculty Advisors may neither fabricate nor assemble any components nor assist in the preparation, maintenance, testing or operation of the vehicle. Faculty Advisors are not allowed to participate during technical inspection, cost audit or design presentations. The team captain or other designated members of the team must do all the presenting although Faculty Advisors may silently observe. In brief Faculty Advisors may not design, build or repair any part of the vehicle.
1.3 1.3.1
1.3.2
1. Only those teams, whose management gives an undertaking to allow them to use the workshop facilities, would be allowed to participate without exception. Also teams need to submit a list of facilities / equipments in operating condition with the college facilities which will be used to fabricate & assemble the vehicle as per design presented in virtual BAJA event. 2. During the actual manufacturing and fabrication process, the video clips that covers students working in college facility need to be furnished in CD-Format during the College Level Technical Inspection. 3. Extensive use of readymade subassemblies may invoke penalties. Vehicles, which have been professionally fabricated, may be penalized up to 400 points or even disqualified from the competition. The decision of the organizers committee in this regard will be final. The registration fee would NOT be returned in such case.
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1.3.3
Prefabricated Subassemblies
These rules do not exclude the use of prefabricated or modified sub-assemblies. Extensive use of readymade subassemblies may invoke penalties. List of pre-fabricated parts allowed are Shock Absorber, spring, Brake drum, Brake disc, Brake calipers and brake holding assembly, Master cylinder, Steering gear box, Steering column, Steering wheel, Wheel rims & Tires, Seat frame, Tie rod ends. Engine, Fuel tank & Exhaust system - complete assembly supplied from B&S to be used. All other parts need to be fabricated in house & not allowed to outsource from professional manufactures/ designers.
1.4
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2.1.2
2.2 2.2.1
2.2.2
Engine Eligibility
Colleges/Institutes will be eligible to receive and use a new Briggs & Stratton engine in their THIRD participation only. Engines are allocated on the basis of one engine per vehicle per two seasons of participation. Example: A college/institute that receives a new Briggs & Stratton engine in year 2012 for competition season of 2013 can participate in a BAJA SAEINDIA event in 2013 & 2014 with the same engine. It becomes eligible to receive a new engine only for the 2015 competition season if registered & qualified. Example: A college/institute that receives an engine in 2012, but does not compete in a BAJA SAEINDIA event in 2013, is not eligible to receive an engine in 2015. It means the same engine can be used for 2014 & 2015 provided its team qualifies the criteria of selection and is registered. Similarly if the college has participated in 2013 event but not in 2014 event; then it can use the same engine for 2015 event provided its team qualifies the criteria of selection and is registered.
2.2.3
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trouble placing the engine order. Eligible teams will have to pay the cost of engine & shipping as per SAE approved rate. Neither Briggs & Stratton nor SAE assume any responsibility for the delivery of engines. Transit Insurance can be separately born by team.
2.2.4
Purchasing of Additional Briggs & Stratton Engines Teams may purchase additional Briggs & Stratton engines directly through their local Briggs & Stratton dealer. There is no special discount or purchase price for additional engines.
2.3
Engine Requirement and Restrictions To provide a uniform basis for the performance events, all vehicles must use the same engine: a stock of four cycles, air cooled, Briggs & Stratton OHV Intake Model. The Briggs & Stratton engine bearing the following part no. is the only engine allowed for the BAJA SAEINDIA 2014 competition:
20S332 0036 - New Engine having 3800 as the maximum rpm. NOTE: Blueprinting (reworking an engine to a manufacturers exact specifications) is considered to be modification. 2.3.1 Replacement Parts
Only original equipment Briggs & Stratton replacement parts may be used.
2.3.2
Piston Rings
Only standard size original Briggs & Stratton piston rings may be used.
2.3.3
Intake Ports
No cleaning or removing of aluminum flashing from intake or exhaust ports may be done.
2.3.4
2.3.5
2.3.6
Spark Plugs
Only RC12YC spark plugs must be used. Before carrying any welding activity, it is recommended that the spark plug cable is removed and battery terminal cables are disconnected. This will prevent burning of wiring harness and HT Coil.
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2.3.7
Armature
Any armature air gap setting is allowed. No slotting or elongating of armature mounting holes to increase or retard ignition timing.
2.3.8
Flywheel Rotation
No flywheel rotation to advance or retard timing is permissible.
2.3.9
Carburetor
Carburetor - This is a fixed carburetor, re-jetting of the carburetor is prohibited.
Idle Speed Any idle speed adjustment: NOT ALLOWED. B&S recommends 1750 100 rpm. Carburetor Float - Carburetor float is non-adjustable and may not be re-adjusted. Carburetor Venturi - Modification of carburetor venturi is prohibited. 2.3.10 Air Cleaner
The air intake system should use a Filter from Briggs and Stratton recommended source. The teams may be required to submit proof of purchase. The filter should be located as close as possible to the engine. The air intake may be relocated, but Briggs & Stratton parts must be used to relocate the air filter: remote kits, 695329 choke shaft and 699960 air cleaner base (metal). The supplied air hose may be shortened to a minimum of 152 mm (6.0 in). No other type of hose will be allowed. A team may also add additional pre-filters (part number: 491435S) to the top of the air intake. These parts must be included on the cost report. Any changes made to the air filter will have to pass Briggs & Stratton inspection. NOTE: Relocation of the air cleaner may decrease engine performance. Any damage on account of failure to comply with the instructions would have to be borne by the team. The complete air intake system shall be located so that its extremities lie at least 100 mm within the perimeter of the vehicle. The decision of the Head of the Technical Committee of BAJA SAEINDIA / Briggs and Stratton personnel in this regard will be final and binding to all. This is in the interest of safety. A fresh air cleaner element & paper filter are required during On-site Technical Inspection-Engine at BAJA SAEINDIA 2014.
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2.3.12 Starter
The Recoil Starter Rope may be extended to accommodate the driver starting the engine while being seated. Electric start is not acceptable in any case even if it is from B&S standard parts.
2.3.13 Alternator
The engine is not configured for fitment with an external alternator to generate electrical energy. Hence it is not permitted.
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2.4
2.5
Battery Requirements
The battery/batteries can only provide power to accessories on the vehicle (horn, brake light, reverse light & beeper, data acquisitions, safety items and other instrumentation). It is expressly prohibited to operate the vehicle by using power from an on-board battery. The mounting of battery must prevent the battery from coming loose during a roll over & must be enclosed from the exhaust and the fuel system. There should not be any positive contact with the exhaust unit of the fuel system. The battery must be safely placed & concealed. Failing this, the technical inspectors may debar the team from the dynamic events. Recommended Battery: 12 V, 44 Ah
2.5.1
Electronic Controls
Electronic control of suspension and transmission systems is allowed. The power can be from the approved battery.
2.6
Component Failure
In the event of a major component failure during the course of the event, any modifications must be approved by the Technical Inspectors prior to the vehicle returning to the competition. Teams without the approval may be penalized as per the decision of the Head of Baja Technical Committee.
2.7
NOTE from B&S: B&S will Provide support, however, if it is observed that the damages to
the engine are caused due to teams negligence in handling/ installing/ running the engine as per the specified directions given by B&S. or as specified in the manual supplied by B&S, the teams may be charged for the repairs or for procuring a new engine in place of the damaged engine. No components/spares shall be installed without consulting B&S authorities or the organizer committee member. Queries regarding the engine and related peripherals may be addressed to engine.baja@bajasaeindia.org.
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2.8
Transmission
Teams are free to use any transmission, such that maximum speed of the vehicle on a plain terrain is recommended to be no more than 60 km/hr in top gear. Continuously Variable Transmission (CVT) is also permitted with appropriate shielding as in Sec 3.19.1.Teams can plan to install reverse gear for reverse drive of vehicle. Teams need to safely install gear shifting cables; lever and shifting mechanism are installed at such locations which will not be hindrance for driver and his safety. The adapter for Engine & Transmission is to be designed and installed by students as per the type of transmission used. Engine drive / output shaft side details are available on BAJA SAEINDIA official website. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.
2.9
2.10
Front Bumper A tubular front bumper is MANDATORY for the safety requirement of the vehicle.
2.11
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2.13
Transponders
One transponder as shown (Figure 5) is provided to each team on last day during the endurance event at no cost for the event purpose. This is essential to use for endurance event for counting the laps during endurance run.
Figure 5 Transponder
It is the team captains responsibility to design a secure and safe mounting for the transponder at given location and acceptable method (Fig. 6) and returning at the end of endurance run.
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3.2
Unstable Vehicle
Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical inspectors will not be permitted to participate in the dynamic events. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. This is in the interest of safety of all teams.
3.3 3.3.1
3.3.2
Lateral Space
The minimum space is based on clearance between the driver and straight edge applied to any two points on the roll cage. 1. The drivers helmet to be 152 mm (6 in) clearance to the top of roll cage. 2. The drivers shoulders, torso, hips, thighs, knees, arms elbows, and hands, shall have a minimum of 76 mm (3 in) of clearance from the envelope created by the structure of the car. NOTE : When minimal dimensions are given that is to the centerline of the members, and when a clearance for the driver is given, it is defined by the outside edges of the roll cage members less the padding installed. DRIVER DEFINITION- For the purposes of this section "driver" refers to the team's largest driver and the 95-percentile male properly suited and wearing a helmet.
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3.3.3
A. Primary members NOTE: The primary members must conform to Section 3.6.1. [Circular steel tubing with
an outside diameter of 25mm (1 in) and a wall thickness of 3 mm (0.120 in) and a carbon content of at least 0.18%.] Rear Roll Hoop (RRH) Rear Hoop Overhead Members (RHO) Front Bracing Member (FBM) Lateral Cross Member (LC) Front Lateral Cross Member (FLC)
B. Secondary Members NOTE: Secondary members must be steel tube having minimum wall thickness of 0.89 mm
(0.035 in) and min outside diameter 25.4mm (1 in). Lateral Diagonal Bracing (LBD) Lower Frame side (LFS) Side Impact Member (SIM) Fore / Aft Bracing (FAB) Under seat Member (USM) All other required cross members. Any tube used to mount safety belts. Roll cage members which are not straight must not extend longer than 711 mm (28 in) between supports. Small bend radii (<152 mm/ 6 in) at a supported end of a member are expected, and are not considered to make a member not-straight. The minor angle between the two ends of a notstraight tube must not exceed 30. NOTE: Required dimensions between roll cage members are defined by measurements between member centerlines, except where noted. All Roll cage members having a bend radius > 15.2 cm (6 in) may NOT be longer than 71.1cm (28 in) unsupported. No holes are allowed to be drilled on the roll cage tubing. Also, no tube should show any cracks or deformation. Final judgment rests with the Head BAJA Technical Committee.
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Figure 7 NOTE: The RRH will have an additional member for seat belt mounting. (Sec. 3.12.3)
An extended portion of primary tube of length 2.54 cm (1 in) is needed to be welded at a convenient area on RRH so that it must not interfere with any body part and must not foul with any vehicle component (preferably rearwards). This is for the purpose of ascertaining the thickness of the Roll Cage Tubing.
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Figure 9
Figure 10
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Figure 11
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Front Bracing
Front systems of FAB must connect the FBMUP members to the SIM members (on the same sides). The intersection with the FBMUP members must be within 127 mm (5 in) of points C. The intersection with the SIM members must be vertically supported by further members connecting the SIM members to the LFS members.
Rear Bracing
Rear systems of FAB must create a structural triangle, in the elevation view, on each side of the vehicle. Each triangle must be aft of the RRH, include the RRH vertical side as a member, and have one vertex near Point B and one vertex near either Point S or Point A. The third (after) vertex of each rear bracing triangle must additionally be structurally connected to whichever point, S or A, is not part of the structural triangle. This additional connection is considered part of the FAB system, and is subject to 3.3.3.1, but may be formed using multiple joined members, and this assembly of tubes, from endpoint to endpoint, may encompass a bend of greater than 30 degrees. Attachment of rear system FAB must be within 127 mm (5 in) of Point B, and must be within 51 mm (2 in) of points S and A. In the plan view, the rear bracing structural triangles must not be angled more than 20 degrees from the vehicle centerline. The after vertices (right/left) of the FAB structural triangles must be joined by an LC.
3.3.4
RHO/FBM Gusseting
If the RHO and FBM are not fabricated from a continuous tube, a gusset is required at point C. Gussets shall be made of steel plate, be triangular from a side view, have length at least 3 times the tube diameter and have a minimum thickness of 3.2 mm (0.13 in) The gussets shall be welded to the sides of the tubes and not directly in the plane of the tubes making up each joint (Figure 12).
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Figure 12 Left Gusseting required at point C; Right - Gusseting NOT required at point C.
3.3.5
Butt Joints
All butt joints within any of the elements on the roll cage listed in section 3.3.3.1 (excluding the required no break members described in 3.3.3.2, 3.3.3.4 and 3.3.3.8) must be reinforced with a welded sleeve. The sleeve must be designed to tightly fit on the inside on the joint being reinforced (i.e. external sleeves are not allowed), must extend into each side of the sleeved joint, a length of at least two times the diameter.
3.3.6
Each team must submit two (2) samples for each roll cage welder, both of which are constructed of roll cage material which have been welded with the same tools and processes as those of the as-built vehicle and which have also been subject to the following destructive testing and inspection:
Sample 1 Destructive Testing: A structure made up of roll cage tubing welded at a 90 deg, the length of each tube to be determined by the team, should be subject to destructive testing causing the joint to fail to which indicates superior weld strength with respect to the base material. (Figure13a) Sample 2 Destructive Inspection: A structure made up of roll cage material that has two tubes attached at a 30 degree angle with a length of at least 15cm from the center of the weld joint (Figure 13b). The sample should be sectioned along the length of tube to reveal adequate and uniform weld penetration (Figure 13c).
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(a)
(b) Figure 13
(c)
Final judgment of weld strength with respect to the base material as it described in Sample 1 and the adequacy and uniformity of weld penetration as described in Sample 2 shall rest with the national technical inspectors. Teams unable to submit welding samples of adequate quality, as defined below, shall not be eligible to compete in any dynamic or endurance event. Welding samples constructed of material other than the roll cage material and / or welded with a process other than that of the roll cage welds of the as-built vehicle shall not be considered sufficient demonstration of welding skill and craftsmanship with the tools, processes and roll cage material. Note: Frames that were constructed in a previous year will need to have samples welded by that welder or remove two sections of the current frame and perform the tests on these components. All the teams need to take 10 min video shoot while 1) fabricating frame & 2) assembly of complete vehicle with the college premise & covering other facilities of college & team student working on vehicle. This must be submitted during Technical Inspection at college level. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.
3.4
Head Restraint
A head restraint must be provided on the driver seat / fire wall to limit rearward motion of the head in case of an accident. Minimum area = 232 sq. cm (36 sq in), padded with a closed cell foam (density of 50 100 kg/m3).Minimum thickness = 3.8 cm (1.5 in), located no more than 2.5 cm (1 in) away from the helmet in the uncompressed state. The head restraint must meet the above requirements for all drivers. NOTE: If the head restraint is already a part of the seat, then no need to include a separate one.
3.5
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clearance = 15.2 cm (6 in) must be provided from the helmet top of the teams tallest driver to the bottom of the roll cage top tubes or members.
Figure 14
3.6
3.6.1
3.6.2
The bending stiffness and bending strength must be calculated about a neutral axis that gives the minimum values. Bending stiffness is considered to be proportional to the product EI where: E I : : Modulus of elasticity (205 GPa for all steels) Second moment of area for the structural cross section
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*Bending Strength of AISI 1018 Steel (for tube dimension of Sec. 3.6.1 A) = 387.38 Nm 3.7 Roll Cage Specification Sheet: Each team must present a completed BAJA SAEINDIA Roll Cage Specification Sheet (Sec 7, Appendix 1) at Technical Inspection. While procuring tube one should get copy of tube specification and also ensure this is certified from local laboratory. Both copies must be presented during Tech Inspection at College level and Final Check at event site. NOTE: Latest Material Specification Check Report is essential for used material.
3.8
3.9
3.10
COCKPIT
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3.10.2 Firewall
A firewall between the cockpit and the engine and fuel tank compartment is mandatory. The firewall is recommended to be behind the RRH. It must cover the area between the lower and upper lateral cross member. This firewall must be metal, at least 0.508 mm (0.020 in) thick. Cutouts in the firewall are allowed, but they need to have grommets or boots that prevent large amounts of fuel from getting into the cockpit. Front or Mid-engine Cars If the engine is not placed in the rear of the vehicle, then a firewall is not required to cover the area between the RRH lateral cross members. Instead, the firewall must meet the following standards: (A) Fuel tank must be in a sealed container that prevents fuel from leaking in the event of fuel tank failure. (B) Splash shields/ Drip Pan must prevent fuel from being poured anywhere in the cockpit area during fuelling. (See rule 3.16.3 Spill Prevention) (C) Engine must be completely enclosed and protect the driver in the event of an engine failure. Shielding must meet guarding requirements. This shielding must be made of metal. . (See rule 3.19.1 Power train Guards). (D) All engine compartment venting must be directed away from driver area. (E) Driver must be able to still egress from either side of the vehicle. (F) The exhaust must not exit towards the driver and must be shielded. (G) There must be a place to mount the Technical Inspection sticker (30cm x 30cm or 12 in x 12 in) on the RRH. It must be located on the drivers right side above the shoulders in easy view of track workers. NOTE: Engine enclosures must prevent fuel from spilling onto driver area during any vehicle upset. Body Panels The cockpit must be fitted with body panels that cover the area between the lower frame side member and the side impact member. No gaps can exist that are larger than 6.35 mm (0.25 in). These panels must be made of plastic, fiberglass, metal or similar material. They must be designed to prevent debris and foreign object intrusion into the driver compartment.
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The panels must be mounted securely to the frame using sound engineering practices NOTE: Zip ties and Velcro are not acceptable.
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The Kill switch is primarily safety device to stop engine in case of fire or any type of accident. The team and track volunteer at event will be required to follow unique convention of stopping engine in such case only by following up Push-To-Off. Hence any deviation from the kill switch specification will not pass technical inspection & team will be disqualified.
3.10.6 Throttle
Only foot operated throttle controls are allowed. Cars having hand operated throttle will not be allowed to start any event. A wide-open throttle stop must be mounted at the pedal.
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Throttle Extensions
Teams may not add any type of extension (e.g. blocks of wood) to either the control surfaces or to the driver in order to operate the vehicle.
3.11
DRIVER RESTRAINT
3.12
Shoulder Harness
The shoulder harness must be the over-the-shoulder type. Only separate shoulder straps are permitted (i.e. Y-type shoulder straps are not allowed).
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Figure 23
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3.13
NOTE: If the belts do not have enough adjustment capacity or improperly fitted, the vehicle will not be cleared for Technical Inspection. The final decision in this regard rests with the technical committee head. 3.14 Arm Restraints
In the event of a rollover, the drivers arms must be kept within the limits of the cockpit. Arm restraints must be securely fastened to the driver restraint system, in a way that the drivers hands do not come out of the cockpit. Only commercially available arm restraints meeting SFI 3.3 are allowed. The arm restraints must independently connect to the safety belts.
Figure 24
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3.14.1 Arm Restraint Expiration The belts must bear the appropriate dated labels, and on 1st Jan of the competition year be no more than three years old. 3.15 BRAKING SYSTEM
3.16
FUEL SYSTEM
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Figure 26: The above spill/splash shield is NOT acceptable Fuel spill prevention shall be checked by a 45 degree tilt test at the technical inspection site or any point of time during the event with fuel tank filled completely with fuel. Any vehicle failing to comply this test shall not be allowed to start any dynamic event.
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Compliance is mandatory.
3.16.6 Fuel
The only fuel permitted is automotive gasoline consisting of hydrocarbon compounds. The gasoline may contain anti-oxidants, metal deactivators, corrosion inhibitors, or lead alkyl compounds such as tetra-ethyl lead. The addition of nitrogen bearing additives, or additives designed to liberate oxygen is strictly prohibited. Specific gravity should not exceed 0.75 for leaded gasoline or 0.80 for unleaded gasoline when measured at 60 degrees Fahrenheit, See Section 4.2.2 Competition Fuel Supply .
3.17
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3.18
FASTENERS
3.18.1 Fasteners
All fasteners used in the systems designated in Section 3.18 must be captive; defined as requiring NYLON locknuts, cotter nuts or safety wired bolts (in blind applications). Lock washers or thread sealant do not meet this requirement.
Figure 28
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C. Bolt heads may be safe-tied as shown only when the female thread receiver is captive, or the nuts meet previous lock nut requirements. D. Nuts (pre-drilled) may be safe-tied in similar fashion to the illustrations with the following conditions: 1. Nuts are heat-treated. 2. Nuts are factory drilled for use with lock wire. E. Lock wire MUST fill a minimum of 75% of the drilled hole provided for the use of lock wire. F. Lock wire must be aircraft quality stainless steel of 0.508 mm, 0.813mm, or 1.067mm diameter (0.020 in., 0.032 in., or 0.042 in. diameter). Diameter of lock wire is determined by the thread size of the fastener to be satisfied: 1. Thread sizes of and smaller use 0 020 wire 2. Thread sized of to use 0 032 wire 3. Thread sizes > use 0 042 wire 4. The larger wire may be used in smaller bolts in cases of convenience, but smaller wire must not be used in larger fastener sizes.
Figure 29 (a)
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Figure 29 (b)
A. Tie Rods
All tie rods in single shear must have a factory steel safety washer.
Rod end threaded into threaded tube adapter.
Safety Washer
Figure 30
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B. Ball Joints
Any commercially manufactured ball joints or rod ends with studs are allowed. Student manufactured ball joints or rod ends with studs are specifically prohibited.
3.19
GUARDS
Figure 31 If a fiber reinforced composite material is used, then a stress strain curve must be provided for worst-case tensile loading. Additionally, the curve for the composite material must be specific to the matrix and manufacturing methods used. Compliance shall be checked and any reinforced composite material must be 3.175 mm (0.125 inch) thick. Vehicle failing to comply shall not be allowed to start any dynamic event. In order to show equivalency the calculation must show the following: (Area under curve for AISI 1010 Steel x Thickness) (Area under curve for alternative material x Thickness)
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A.
Side Shields
Side shields must prevent fingers from getting caught in any rotating part. A complete cover around the engine and drive-train will be acceptable.
B.
Clothing
Drivers must wear appropriate clothing, including long pants (cotton/ Nomex), socks, shoes, gloves, and a long sleeved SFI/ ISI rated upper garment. The upper garment must have a factory label showing it is SFI rated, FIA rated or fire resistant. All restraints must bear appropriate dated labels, and on 1st Jan of competition year be no older than 3years.
3.20
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Permitted Figure 35
In addition to the helmet, a neck support/collar must be worn. The neck support must be a full circle (360) and SFI 3.3 rated (Figure 35). Horseshoe collars are not allowed (Figure 36). Simpson, RCI, GForce, Deist or Leaf Racing Products supply neck collars that meet this requirement. Neck support must bear the appropriate dated labels, and on 1st Jan of the competition year be no more than three years old. WARNING: Some Motor-Cross helmets have extended chin guards that will not contact the required neck collars when the head is flexed forward. This combination of helmet/collar system is prohibited. Any non-specification helmets will be confiscated until after the competition. This rule has no exceptions and it will be strictly enforced. Helmets certified to other rating systems may not be worn.
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4.1.2
Protests
Any objection/matter must be brought to the notice of the organizers or SAE INDIA staffs attention for an informal preliminary review before a protest can be filed. Teams may not protest rule interpretations or actions that have not caused them any substantive damage. All protests must be filed in writing and presented to the organizer or SAE staff by the faculty advisor or team captain within one hour (60 minutes) of the end of the event to which the protest relates. In order to have a protest considered, a team must post a twenty-five (25) point protest bond which will be forfeited if their protest is rejected. The decision of the competition protest committee or National Technical Inspectors regarding any protest is final.
4.2 4.2.1
4.2.2
4.2.2.1 Re-fuelling
All refueling of the cars done in the pit area or on the course must be done with (1) the engine shut-off and (2) the driver out of the car. Any violations of this rule will be subjected to severe penalties. A fire extinguisher must be in hand whenever a vehicle is being refueled.
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4.2.3
4.2.4
4.2.5
Driving Restrictions
When a vehicle is driven anywhere except the practice area or competition events, it must move at walking speed with a team member walking along side at a normal walking pace. The walking speed rule will be strictly enforced and point penalties will be assessed for violations, including impounding the vehicle for a specific period of time, at the discretion of the Technical Inspectors. Under no circumstances may anyone other than the driver ride on a vehicle. Drivers must wear all of the equipment specified such as seatbelts, helmets, goggles, wrist restraints, required clothing and a properly fastened restraint system at all times when the vehicle is running in any event or on the test track. Drivers not wearing the proper equipment will not be permitted to drive, and may have their competition drivers privileges revoked Practicing outside of the designated practice area will result in a minimum fifty (50) point penalty and/or the revocation of driving privileges depending on the extent of the infraction. DRIVING OFF-SITE IS ABSOLUTELY PROHIBITED. TEAMS FOUND TO HAVE DRIVEN THEIR VEHICLE AT AN OFF- SITE LOCATION MAY BE EXPELLED FROM THE COMPETITION.
4.2.6
Penalties
Organizers have the right to modify the penalties listed in the various dynamic event descriptions to better reflect the design of their event courses, the course lengths or any special conditions unique to the site.
4.3 4.3.1
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4.3.2
4.3.3
Site Condition
Please help the organizers keep the site clean. Failure to clean the premises will result in an unsportsmanlike conduct penalty. Competitors and spectators are encouraged to police their areas after meals.
4.4
4.5
Spectator Rules
The competitors, faculty and volunteers are expected to help inform the spectators of the safety rules and help restrict spectators to the spectator areas. Spectators may not drink alcoholic beverages at any event location. Spectators must keep well back from the event and practice tracks and from any area where vehicles are operating under power. Spectators who fail to strictly control their children will be asked to leave the site. The course officials and organizers have the absolute right to restrict spectator access to any parts of the site and to eject anyone who violates safety rules or ignores the instructions of officials. Note: All teams, spectators and faculty members are responsible for the safety of their own, their vehicles and belongings. No claims regarding these shall be entertained by the organizers.
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5.3
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5.3.1
5.4
Inspection Stickers
Technical inspection comprises of three stages. A three-parts inspection sticker (see Section 5.3 Engine OK/ Safety Scrutiny & Fig 8 OK/ Brake OK Stickers) will be issued in sections to the team as each of the three stages of technical inspection is completed. The inspection sticker must remain on the vehicle throughout the competition. Technical inspectors and officials may remove any or all parts of the inspection sticker from any vehicle that has been damaged or which they reasonably believe may not comply with the rules. Stage 1 Engine Inspection OK Briggs and Stratton staff is responsible for the Engine Inspection of each vehicle. To expedite the process, each team needs to arrive with side cover removed and loosened bolts of fuel tank
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mounting with spare air filter kit. Engine inspection will consist of - the engine rpm setting with governor position verification, after-installation of new air-filter element and working of kill switch. The inspection ensures(1) Setting of the governor at 3800 rpm & spring at 6th notch position, and (2) Engine compliance for normal performance. On successful completion of Stage 1, the First sticker will be put on the firewall. Stage 1 must be passed before a team may apply for Stage 2 inspection. Stage 2 Safety Scrutiny & Figure of 8 Each vehicle will be inspected to determine its compliance with the rules and restrictions. This inspection will include an examination of the drivers equipment including helmet and arm restraints and a test of driver exit time. ALL THE REGISTERED DRIVERS ARE MANDATORILY REQUIRED DURING SAFETY SCRUTINY. Each team must bring the following items to inspection; if they do not have the items at the time of inspection they will receive a 10 point deduction for each item missing or not completely filled: a) Self-Certification Check sheet: With self checks carried out by team and verified by Technical Inspector (Format is due to be posted on www.bajasaeindia.org by 10th November 2012. Team is needed to download and ensure the compliance). b) Tube Specification Certificate: Obtained from supplier with latest testing certificate from local laboratory (Section 3.7). c) Roll Cage Specification Sheet: Completed Roll Cage Specification Sheet. (See Section 7 Appendix 1) d) Safety equipment and drivers kit The following tests will be carried out in the sequential manner during this stage(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) 64 inch GO-NO-GO gauge 45 deg tilt test for fuel spillage and drain Wheel lock stoppers Accelerator pedal return ability Free operation of gear shift and hand brake Reverse lamp functionality Specified hardware and nylon lock nuts Safety belt and restraints as per specification Egress test of all drivers Figure of 8 test and maneuverability
On successful completion of Stage 2, the Second sticker will be put on the firewall.
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Stage 2 must be passed before a team may approach for Stage 3 inspection. Stage 3 Dynamic (Panic) Brake Testing Both the external and cockpit kill switches will be tested for functionality. If both switches pass the test then the vehicle will be dynamically brake tested. Each vehicle must demonstrate its ability to lock all four wheels and come to rest in an approximately straight line after acceleration run to reach at least 45 kmph or as specified by the inspectors. If a vehicle fails to pass any part of the inspection it must be corrected/ modified and brought into compliance with the rules before it is permitted to operate. The inspectors and officials have the right to re-inspect any vehicle at any time during the competition and require correction of any non-compliance. On successful completion of Stage 3, the Third sticker will be put on the firewall. Acquiring the three stickers marks the completion of Technical Inspection and makes them eligible for Dynamic Evaluation. NOTE: 1. All drivers must be present at technical inspection, in case of failure the names of driver will be removed from the Final list of drivers and a 10 point penalty will be applied to the team. 2. Teams presenting Self Certification Sheets that are (1) incomplete, (2) inaccurate (i.e. do not correspond to the actual condition of the car) (3) are found to have more than 3 items not in accordance with the rules, or (4) do not represent a serious effort at pre-inspection will be denied inspection at that time and sent back to the end of the inspection line with a 100 point deduction /other penalties which shall be prominently displayed at the site at least 60minutes before commencement of Technical Inspection of the first vehicle. 3. Overall Vehicle Inspection Flow-
6
Figure 37
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INDEX (Figure 37): 1. Engine Check 2. 64-Inch (GO-NO-GO) Gauge 3. 45 Degree Tilt Test 4. Overall Safety Scrutiny 5. Figure of 8 Test 6. Panic Brake Test
5.5
As-Approved Conditions
Once a vehicle has passed technical inspection its configuration may not be modified. Approved vehicles must remain in as-approved condition throughout the competition Necessary repairs that do not significantly change the configuration of the vehicle are permitted. Minor adjustments permitted by the rules and normal vehicle maintenance and tuning are not considered modifications. NOTE: It is important for every team to get their vehicle approved by the technical scrutiny during which the safety, integrity of vehicle structure, fabrication processes adopted, etc will be judged. The team shall provide documented proof of fabrication process of every component and the design analysis, failing which they may have to face point penalties or disqualification. THE BAJA SAEINDIA TECHNICAL COMMITTEE RESERVES THE RIGHT TO DISALLOW ANY VEHICLE FAILING TO COMPLY WITH THE REQUIREMENT OF THESE RULES TO TAKE PART IN ANY DYNAMIC EVENT TILL THE VEHICLE IN QUESTION IS RECTIFIED, REPRESENTED AND PASSES THE TECHNICAL INSPECTION. FOR THIS COMPLIANCE, MAXIMUM NUMBER OF REINSPECTIONS PER VEHICLE (BESIDES THE NORMAL INSPECTION AT SITE) SHALL BE 2 (TWO) ONLY. THIS REQUIREMENT SHALL BE ENSURED WITHOUT EXCEPTION. THEREFORE, IT IS REQUIRED THAT TEAMS COME WITH THEIR VEHICLES WELL PREPARED FOR THE EVENT, TO AVOID DISAPPOINTMENT. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. This is in the interest of safety.
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6.2
Dynamic Events
The dynamic events are intended to determine how the BAJA SAEINDIA vehicles perform under a variety of conditions. Please note that the organizers have the right to modify the dynamic events to address local conditions, weather or resources.
6.2.1
Speed Events
6.2.1.1 Acceleration A. Objective Acceleration determines the time it takes the vehicle to accelerate along 100 ft (30.48 m) or 150 ft (45.72 m) flat course. The choice of course length is at the organizers discretion. B. Acceleration Procedure Each team may make two (2) attempts. Scoring will be based on the better of the two
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attempts. Timing may be done using either electronic systems or stop watches. C. Acceleration Penalties The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses.
False Start or Stall at Start : First False Start Second False Start Leaving Course : Disqualification Rerun at end Disqualification
D. Acceleration - Scoring If the time taken for acceleration by a team is more than twice that of the fastest car, it will not receive a score for this event. Teams attempting the event, but exceeding the time limit will be classified as Excess Time. The following equation will be used for the acceleration score: Acceleration score = 100 x [(T LongestT yours)/ (T LongestT Shortest)] Where: T Shortest is the fastest time by any team. T Longest is either a. The slowest time by any team or b. 2 times the fastest time, whichever is the shorter interval. T yours is the best time of your team. 6.2.2 Traction Event
The traction events are designed to demonstrate the vehicles ability to use its traction to accomplish various tasks. At the organizers discretion, the traction event will be either the hill climb or a pulling event.
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is scored for distance at that point. Vehicles may not continue the attempt after they have stopped on the course. If a vehicle stalls before reaching the top of the hill, or if its wheels are spinning without moving the vehicle forward, the attempt is scored for distance at that point.
If all of the teams succeed in completing a full climb, then the score will be based on the time of the climb and calculated by the following formula: Hill Climb Score = 100 x [(T LongestT yours)/ (T LongestT Shortest)] Where: T Longest is the longest time by any team. T Shortest is the shortest time by any team. T yours is the best time of your team. Method B: No One Climbs the Hill
If none of the vehicles succeeds in climbing the hill, then the score will be based on the distance each team climbs as determined by the following formula: Hill Climb Score = 100 x [(D yours D Shortest)/ (D LongestD Shortest)] Where: D Shortest is the shortest distance climbed by any team. D Longest is the longest distance climbed by any team. D yours is the best climb of your team. Method C: Some Teams Make the Climb
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If at least one team makes the climb while other teams do not, then the vehicles making the climb (Group I) will be scored based on time and the vehicles that stop on the hill (Group II) will be scored based on distance traveled. Scoring will be by the following formulas: Group I: Teams that complete the climb
Score = 100 x (T Fastest / T yours) Where: T yours is your teams best time T Fastest is the fastest time by any team Group II: Teams that stop on the hill
Score = (Lowest score from Group I) x (D yours / D Hill) Where: D yours is the distance traveled by your vehicle. D Hill is the length of the hill from the starting point to the finish line.
Figure 38 6.2.2.2 Maneuverability Event A. Objective Maneuverability is designed to assess each vehicles suspension, handling and steering. The course may consist of a variety of suspension and handling challenges, at the organizers option, possibly including tight turns, pylon maneuvers, ruts and bumps, drop-offs, sand, rocks, gullies logs, and inclines.
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B. Maneuverability Procedure Each vehicle may make two (2) runs with the best time, including penalties, counting for score. C. Maneuverability Penalty Default Values The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses. Obstacle/Pylon moved Missed gate* Deliberate course violation False Start : : : : 2 seconds 10 seconds Run disqualification First False Start Second False Start *Missed gate is when 2 or more wheels are outside the gate D. Maneuverability Time Limit Only vehicles that complete the maneuverability course within a time not exceeding two and half times (2.5X) that of the fastest vehicle will receive a score. If a vehicle is on the course for a time that exceeds twice the fastest time recorded to that point then the Event Captain may declare the attempt over, remove the car from the course and score the attempt as Excess Time. E. Maneuverability Scoring Maneuverability scoring is based on the vehicles time through the course including any penalties. Maneuverability Score = 100 x [(T LongestT yours)/ (T LongestT Shortest)] Where: T Longest is either (a) The longest time through the course by any team or (b) 2.5 x T Shortest whichever is the shorter time T Shortest is the shortest time through the course by any team T yours is your teams time through the course 6.3 PRACTICE ROUND One hour time will be dedicated to practice on endurance track those who have successfully completed Technical Inspection and Dynamic Event. Rerun at end Disqualification
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6.4 6.4.1
Endurance Event Endurance Objective The endurance event assesses each vehicles ability to operate continuously and at speed over rough terrain containing obstacles in any weather conditions.
6.4.2
Endurance - General Description Endurance run may be based upon either total time taken or total distance covered. Endurance events for time usually run for four (4) hours. Endurance events for distance continue until at least one car has gone the specified distance. Endurance will be run as one of the following(A) (B) (C) A single four (4) hour race, A predetermined and published distance, or Elimination heats followed by a final in which the total time of one elimination heat plus the final is 4 hours.
The organizer will announce the structure of the event prior to the start. Determining the winner of the endurance race: The team, which completes the distance of the competition first, or the greatest distance in the time set for the competition will be declared the winner. In competitions of a given distance, the checkered flag will be given first to the leading car, then to the other finishers as they cross the finish line.
6.4.3
In competitions of a timed length, the checkered flag will be given first to the leading car as it crosses the finish line at or after the expiration of the specified duration, then to the other finishers as they cross the finish line. If the leading car is not running at the expiration of the time limit, the checkered flag will be given to the next highest running car in the same manner. Endurance - Starting The starting grid for endurance will be based on each teams performance in a previous dynamic competition, or set of dynamic events, to be determined by the organizer. All vehicles will be considered to have begun the race simultaneously at the time when the starter releases the first vehicle onto the course regardless of their actual position in the grid.
6.4.4
Endurance Command Flags Command flags are just those flags which must be immediately followed by participants without any dissent.
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Green Flag (1) At a starting line or when re-entering the course: Your run, or session, has started; enter the course under the direction of the starter. (NOTE: If you stall the vehicle then restart and wait for another green flag as the opening in traffic may have closed.) (2) While running on the course: Course is clear, proceed. Yellow Flag, Steady Danger, SLOW DOWN, be prepared to take evasive action, something has happened beyond the flag station. NO PASSING, unless directed by the course workers. Yellow Flag, Waved Great danger, SLOW DOWN, evasive action is likely to be required, BE PREPARED TO STOP, something has happened beyond the flag station. NO PASSING, unless directed by the course workers. Red Flag Come to an immediate safe and controlled stop on the course. Pull to the side of the course as much as possible to keep the course open. Follow course worker directions. NO PASSING. Black Flag, Furled and Pointed Warning, the officials are watching your driving obey the event rules. Black Flag, Displayed ( 1) Pull into the penalty box for a discussion with the Director of Operations or other official concerning an incident. A time penalty may be assessed for the incident. (2) Pull into the penalty box for a mechanical inspection of your car; something has been observed that needs closer inspection. Checkered Flag Your run, or session, has been completed, exit the course at the first opportunity. 6.4.5 Endurance Stalled or Disabled Vehicles Disabled or stalled vehicles must be immediately removed from the roadway. It is t he dri ve r s responsibility to assist and cooperate with the course marshals in removing the vehicle. Cars may only be started with the driver seated with all belts properly fastened. The driver may not exit the vehicle to execute a restart. Course marshals, volunteers or team members may assist drivers in restarting their vehicles. Officials and course marshals may stop any vehicle, at any time, if they believe it no longer complies with the requirements and restrictions of the rules. If a vehicle is stopped by officials for a mechanical fault, the fault must be corrected / repaired before it may reenter the event. 6.4.6 Endurance Repairs The organizer will announce the rules governing repairs that are permitted to be made during the endurance event. If repairs along the course are permitted then vehicles under repair must be
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removed well off the course, away from the outside of turns and away from any natural run-off areas. 6.4.7 Endurance Event Penalty Default Values The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of the course Failure to stop for Black Flag Passing under a Yellow Flag Deliberate Ramming 10 minutes or 1 lap per flag* 1 lap penalty First time = 10 minutes Disqualification 10 minutes 20 minutes Disqualification
Second time = Deliberate Forcing another Vehicle off the course First time Second time Third time Leaving Course and Advancing Driving in an Unauthorized Area Failure to Yield to Traffic on Entering Track Speeding in Pit Area Fueling : : : : : = = =
Fueling will not be allowed until the engine is turned off, the driver is out of the car, and a fire extinguisher is ready. No work will be done on the car when fueling. * whichever the official determines is the greater penalty. 6.4.8 Endurance Scoring A. General: The endurance event score is determined by (a) the number of laps each team completes during the endurance final and (b) the finish order of teams at the end of the event. Scored laps are the number of full laps actually completed during the endurance event final. Only full the laps count, partial laps do not count for score. A vehicle must cross the counting/timing line under its own power for a lap to be counted.
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Finish order is the sequence in which vehicles cross the finish line after the lap scoring period has ended. Finish order determines the ranking of teams completing the same number of laps. For example, if the top four teams finish with the same number of laps, then they will be ranked 1st to 4th based on their finish order. Bonus points are additional points awarded to the first ten (10) vehicles on the leading (winning) lap, as separated by finish order as required, in part to differentiate teams finishing with the same number of scored laps. Up to 10 bonus points will be awarded in the inverse order of finish. Thus, the first vehicle to cross the finish line in the highest lap group will receive bonus points equal to the number of cars on the lead lap (max of 10); the second vehicle will receive one less bonus point etc. Endurance scoring is based on number of laps the vehicle completes in the allowed time: Endurance Score = [400 x (L YoursL Lowest)/ (L HighestL Lowest)] + bonus points Where: L Highest is the highest number of laps completed by any team. L Lowest is the lowest number of laps completed by any team. L Yours is the number of laps completed by your team. B. Endurance Heats plus a Final Point Distribution: When endurance is run as heats plus a final, the points for the event will be distributed between the heats and the final in proportion to the time/distance of each stage. Thus, if endurance is run as one (1) hour eliminations plus a three (3) hour final, the four hundred (400) total points will be allocated as one hundred (100) points to each elimination heat plus three hundred (300) points to the final. 6.4.9 Tie-breakers There will be no tiebreakers for static events. Tiebreakers for dynamic events will be the second best run time or score for the given tied event. If both scores for tied teams in the event are equal then the tie remains. Ties in the endurance race will be judged by the endurance event judge and may remain a tie. Ties for overall winner will be broken by the following criteria: Endurance score Total dynamic events score Total static events score If a tie remains after all the above tiebreakers then the tie remains for the overall winner(s).
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Section 7 - Appendices
APPENDIX 1 BAJA SAEINDIA ROLL CAGE SPECIFICATION SHEET 2014 BAJA SAEINDIA COMPETITION
COLLEGE NAME _______________________________ CAR NUMBER__________________
This sheet MUST be completed and submitted in accordance with the event rules. Failure to do so will result in penalty. The purpose of this sheet is to facilitate verification of roll cage materials/construction and to provide a means of tracking the age of older vehicles 1. Academic year the cage was constructed? ___________________________________________ 2. Material Type (i.e.: 4130): _____________ OD: _______________ Thickness: _______________ 3. Primary Welder: ______________________________ Welding Method Used: ______________ Type of Filler Material: ___________________________ Shielding Gas Used: ________________ 4. Equivalency calculations if needed (attach to this sheet). 5. All welds and/or other attachment methods must be checked for integrity. Faculty advisor and team captain are requested to do destructive testing on sample joints that represent the integrity of similar welds on their frame (as per Rule 3.3.6). TECHNICAL INSPECTOR : _________________ (SIGNATURE) ____________ (DATE)
NOTE: It is extremely important that such an inspection be made, and for those constructed of materials (i.e. aluminum) which do not exhibit and endurance limit. WE HAVE EXAMINED THE ABOVE INFORMATION AND TO THE BEST OF OUR KNOWLEDGE DEEM IT TO BE ACCURATE. TEAM CAPTAIN FACULTY ADVISOR Team Captain E-mail : _________________ (SIGNATURE) : _________________ (SIGNATURE) ____________ (DATE) ____________ (DATE)
: ____________________________________________________________
Faculty Advisor E-mail : ____________________________________________________________ BRING A COMPLETED COPY OF THIS FORM WITH YOU TO TECHNICAL INSPECTION. ALSO BRING THE MATERIAL SPECIFICATION CERTIFICATE AS PROVIDED ALONG WITH THE ROLL CAGE MATERIAL BY THE VENDOR.
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APPENDIX 2
Local Technical Inspection Rules / Violation Penalties for 2014 Names & contact details of Technical inspectors and their allotted colleges will be mailed/ put on the official BAJA 2014 website in December 2013. Allotted teams will directly contact the Technical Inspectors for mutually fixing Technical Inspection dates for the local level Technical Inspection. At least an early intimation of 20 days should be made by the teams so as the technical inspector can make necessary arrangement for visiting college campus for local inspection. At local level inspection, vehicle should conform to 100 percent Self Certification Check Sheet criteria; it also includes a Figure of 8 test and a panic brake test at the local level inspection. Any team, if found to have fabricated their vehicle using professional assistance or from a Standard kit would be liable for a penalty of 400 points or may be ineligible to compete. Failing the 100 % acceptance criteria at local level and confirmed by the Technical Inspector, the vehicle will not be allowed at the main event. Last date of technical inspection at college level will be 31 Dec 2013 and all the teams will adhere to the deadlines for inspection. The teams failing to above timelines automatically gets eliminated out of the BAJA 2014 event. Teams must retain the Original Technical Sheet /all the Documents of proof along with them only Teams will then submit these documents at the Main technical Inspection site at Indore only, failing which teams may be disqualified from the main event also. Only one re-inspection will be conducted during the main event, failing which the teams will be disqualified for the dynamic events. BAJA main Technical inspection will start one day prior to the Starting day of the Main event at the Pithampur site and no Technical inspection will be conducted on a later date. Teams shall be penalized with a minimum deduction of 50 points subject to the any Design modifications done after the conclusion of Static event. Teams unable to submit welding samples of adequate quality shall not be eligible to complete in any dynamic or endurance event. Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical inspectors will not be permitted to participate in the dynamic events. The Baja SAEINDIA Technical Committee reserve the right to impound any on-site registered vehicle at any time during a competition for failure to comply to the discipline of the event at all times. This impound time shall be 180 minutes per incident. Extensive use of readymade subassemblies may invoke penalties.
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Team representatives must be present during the comparison to discuss the design changes. If the judges find that the design changes are (A) not significant, (B) not supported by a detailed analysis or (C) have not been sufficiently documented, then a penalty of up to three hundred (300) points may be assessed against the design score Any vehicles found unsafe at any given time of the event will not be allowed to run .The decision of the Head of the Technical Committee of Baja SAEINDIA in this regard will be final and binding to all. This is in the interest of safety.
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APPENDIX 4
1. Chosen configuration (disc, drum brakes, type of suspension, steering geometry, etc.) 2. Specifications (stopping distance, suspension travel, tie-rod length, turning radius, caster,
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camber, toe-in, toe-out, braking effort, pedal force etc.) 3. Suspension Design (wishbone, A-arm, trailing arm design, wheel hub, knuckle design, shock absorber, damper mounting, travel, etc.) 4. Brake Design (braking effort, braking circuit, brake mounting, etc.) 5. Steering Design (geometry, turning radius, power assistance etc.) 4.3.5 Power train
1. Engine (engine specifications, mounting, emission control, intake, exhaust design, fuel system, fuel lines, transmission coupling etc.) 2. Transmission (chosen configuration, engine coupling, max speed, traction, power, acceleration, final drive to wheels, wheel size, joints, etc.) 3. Wheel Size (wheel mounting, joint with final drive, etc) 4.3.6 Body & Electricals
1. Weight (target) 2. Electrical System (safety, battery placement, kill switch, routing etc.) 3. Ergonomics 4. Aesthetics 4.3.7 4.3.8 4.3.9 Safety DFMEA Innovation
4.3.10 Design Validation Plan 4.3.11 Vehicle Completion Date & Technical Inspection Date
B. Selection 1. Based on the performance in the Virtual BAJA, the teams would be selected for participation in the main event. 2. The selection would be purely on the basis of merit. 3. ONLY ONE TEAM PER COLLEGE shall be allowed on the basis of comparative merit.
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C. Scoring Knowledge of rulebook Project Plan Roll Cage Design Over all Vehicle Technical Specification & Target Suspension, Steering Brakes Power train Safety Design Validation Plan Total 50 50 50 50 25 25 25 25 50 50 400
The qualified teams would be required to submit the design report soon after the Virtual BAJA event. The design presented during the event shall be considered as final and the team shall be considered to proceed towards fabrication activity using the same design. Failing this, the teams shall be penalized / disqualified if the fabricated vehicle does not exhibit correlation with the design report or if the teams fail to fabricate within the stipulated timeframe. NOTE: The Virtual BAJA is a pre-qualifier, thus, no ranks or awards would be issued for the Virtual BAJA event.
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APPENDIX 5
Design Report Format
(A) Format Design reports must follow the format for SAE Technical Papers. (Please use bullets wherever possible & max 10 pages + 4 pages for illustration) (B) Electronic version The design report must be submitted electronically in Adobe Acrobat Format (PDF) The document must be a single file (text, drawings and optional content are all inclusive). The design report file must be named as follows: Team reg. ID, Institute abbreviated name (C) File Size The maximum size for the file is 5 megabytes. Introduction The author should describe the introduction of the project, the expected performance, design methodology & outcome. Generally Applicable: Methodology of design as to why the particular configuration has been selected over other options, the design iterations done to get the desired configuration, etc. Technical Specification- Vehicle Performance Target and 3D Views (10 Marks) Engine Drive Suspension Wheels Brake Steering Dimensions Weights The expected target vehicle performance (speed, acceleration, stopping distance, deceleration, grade ability, turning circle diameter, ground clearance, emissions, fuel consumption).
3D View of the Complete Vehicle The CAD view and the isometric view of actual vehicle Roll Cage Design & Driver Ergonomics (15 marks) Design Considerations Material Used Static & Dynamic FEA Results Weight Material Properties Selection Criteria Driver Ergonomics Ergonomic considerations for driver comfort Design for driver ergonomics. Front & Rear Suspension Design (10 Marks) Design considerations, target specifications, calculations, innovation, picture, design selection, criterions, design data, sprung and unsprung mass, spring design considerations, travels and safety factor. Roll/ pitch suspension layout- camber / caster / toe in, bump steer calculations, any other features etc. Steering Design (5 marks) Design selection criterions, lay-out, steering geometry, turning angles/ diameter, steering effort etc. Brake System Design (5 marks) Design considerations, weight transfer, brake system details and calculations, lay-out, pedal force versus deceleration.
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Powertrain Design (10 marks) Power unit mountings, NVH considerations if any, over all transmission ratios and maximum speed/ grade ability in each gear, inlet air filter/ exhaust system, fuel tank, drive line lay out, output shaft angularities for the full suspension travel, total weight of drive line parts. Body Panels (10 marks) and Safety Equipment
Weight considerations and the design of body panels. The safety features used in the vehicle. Engineering Bill of Materials (5 marks) Innovations (Separate Evaluation) Any innovation if used in the vehicle References & Acknowledgment / General Presentation (5 marks)
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APPENDIX 6
1,800
120 50 0
Guideline for Cost Report for Baja SAEINDIA 2014 The cost report is based on Bill of Materials. Its based on indentifying unique components required to build the vehicle assembly / sub-assemblies. The parts may be classified as Parent (Level1) or Child (Level 2) depending on whether its being assembled to vehicle directly. If it is in the form of another unit or subassembly which is assembled on vehicle subsequently. Example: Gears in gearbox are Level 2 parts while gearbox is Level 1 part. The BAJA SAEINDIA COST Sheet comprise of three sheets: Sheet 1: It indicates the overall cost of the vehicle, manufacturing cost, procurement cost, total no. of parts used, etc. It gives a brief overview about the cost and Bill of Materials for the BAJA Vehicle. Sheet 2: It is the Bill of Materials Sheet. Herein, the students are required to fill in the following details: i. Block: If the vehicle is considered as an assembly of the following major aggregates: Engine, Suspension, Transmission, Roll Cage, Electricals & Instrumentation (E&I), each one is regarded as a building block of the BAJA Vehicle. The teams are required to classify all the parts used in building the vehicle into either of the blocks as mentioned in the Index Sheet. Part Name: Every unique part is to be identified with a unique name. The part should be named in a manner that it reflects the level of usage in the vehicle (e.g.: Gearbox Assembly indicates the gearbox is an assembly part). Part Number: Every unique part is to be identified with a unique part number. The part number should be a 10 digit number with the first three digits indicating the block, the next five digits classify the part number and the next two digits represent the level of hierarchy. The codes for block are mentioned in the sheet, the teams are required to judicially choose the part number and revision number.
ii.
iii.
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iv.
Level: Indicates whether the part is the parent part (Level 1) or whether it is a child part (used as an entity in a parent assembly) (Level 2). The teams are required to fill either 1 or 2. Quantity: The number of such parts to be used. For ex.: if the team plans to use the same wheel at all four locations in the vehicle, the cost is to be determined for a single wheel with Quantity as 4. Procurement Cost: The teams are required to mention the procurement cost of the finished product/ raw material required to build the vehicle. The teams are required to fill the MRP (without taxes), irrespective of whether the part is a fresh sale or resale based procurement or even if it is sponsored. The MRP must be mentioned for all the parts and must be supported through Original bills / invoice/ quotes etc.
v.
vi.
vii. Manufacturing Operation: The teams must mention the manufacturing operation for each part, to be required to bring it to the final shape for assembly in the vehicle. The codes for each operation are mentioned in the index sheet. The teams are required to fill the exact code as mentioned in the index sheet. For multiple operations it is required to fill the manufacturing details in subsequent rows (only manufacturing operation is to be filled with the number of operations). Please note that the manufacturing cost includes the raw material required for the operation, for example: filler material for weld. The teams DO NOT have to add the cost of filler material. It is already taken into account in the standardized cost. The standard tables also define the specification of the operation. For example: the cost of welding is based on a 10 mm weld length. The students need to identify the no. of such welds required for the completion of the job. For example: to weld the roll cage, the outer diameter of the roll cage pipes is to be considered, divided by 10 (mm) would give the no. of operations required for completion. This would be the cost of a single joint. The total joints and total no. of operations are to be considered for determining the cost of the roll cage. In such a case, roll cage is also to be considered as an assembly of various pipes (RRH, SIM etc. which constitute the child parts of the roll cage). Thus the cost of child parts may be established for a better and clear estimation. In case the cost of the parent is determined completely by its child parts, the costing fields of the parent may be left blank as the cost would be indicated by the child parts. Wherever there is no manufacturing operation applicable, please mention NA. viii. Cost of Operation: The cost of operation is standardized as in the index sheet. The teams are ONLY required to fill the codes as specified in the index in the Manufacturing Operation column. Cost would be indicated automatically. ix. Total Cost: It is the sum of procurement cost and manufacturing cost.
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Sheet 3: It is the index sheet. This sheet is to be referred for cost, operations, etc. Please note that the BAJA SAEINDIA Cost Event is meant for the teams to determine the vehicle cost precisely and accurately and NOT to the minimum. It is not necessary that the vehicle with the LOWEST COST would be awarded the maximum score. Instead in such case, there would be an adjustment cost added to the cost as indicated by the team. This would be multiplied by an adjustment factor (penalty point) and the final adjusted cost may come out to be higher than the incurred cost. It is thus suggested for the teams, to accurately determine the cost of the vehicle and not minimize the cost intentionally. The objective is to find out the cost of the vehicle if a fictitious firm manufactures the BAJA vehicle at a rate of 4000 vehicles per annum. IT IS ENTIRELY THE RESPONSIBILITY OF THE TEAM TO UNDERSTAND THE GUIDELINES AND FORMULATE THE COST OF THE VEHICLE AS PER THEIR UNDERSTANDING. THE COST ADJUSTMENT WOULD BE DONE AT THE JUDGES DISCRETION. ANY DISCREPANCY IN DATA / FOULING WITH THE FORMULAE WOULD LEAD TO DISQUALIFICATION / PENALTY IN THE COST EVENT.
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APPENDIX 7
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APPENDIX 8
The participating team must get the sheet signed by Judge Panel for various Static Events & submit the same at the end of the clearing Static Event to event coordinator. Failing to this the team would not be considered eligible for scoring in static events. EVENT Originality & Innovation Feasibility for Mass Production Driver Comfort & Ergonomics Serviceability Suspension Steering & Brake Power train Structural Design Craftsmanship Emission Low idle rpm Emission High idle rpm Cost Event Marketing Presentation Sign of Judge (Head of Panel)
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APPENDIX 9
Design report
Off Site
75
Design Evaluation
On Site
125
20 30
Technical Presentation
On Site
50
Dynamic Events
Dynamic Events On Site 1 2 3 Acceleration (Speed Event) Hill Climb Maneuverabilty 100 100 100
Endurance Events
Endurance Events On Site 1 Endurance Event (max duration = 4 hrs.) 400
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APPENDIX 10
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Registration Document All required details provided Fee Engine Order Technical Inspection (off-site) Technical Inspection (on-site) Brake Test Fuel Code of Conduct Vehicle Repairs in Pit Event Timings Traffic Guidelines Vehicle Movement Others Professional Help in Vehicle Build On line Submission of Self certification Compliance for Tech. Insp. at Local level ON SITE Technical Safety Scrutiny Inspection Sheet Design Modification after Static Events Kill Switch Vehicle Impound Design Changes Accident / Violent Driving / Driving off the track Full payment of fee before the deadline Full payment of fee and submission of documents as per the deadline Compliance as indicated in rulebook OR as per guidelines of technical committee Compliance as indicated in rulebook OR as per guidelines of technical committee in maximum of 2 evaluations by the committee Compliance as per the test Running the vehicle without Tech OK & Brake OK Unruly behavior / misconduct with organizing committee / volunteers / other participants / spectators Accident prone activity Presence after closure of pits Accident on account of driving the vehicle at the site (non-dynamic events) Vehicle to be pushed with engine off Subject to case Any professional assistance sought during vehicle design or build or validation Due date submission for Self certification submission on line Compliance. 100% compliance Local level Technical Inspection Sheet with pre declared reports must be present during the on-site Tech Inspection Any modification done to the design Deviation from specification As per judgment of Technical Committee Deviation from design report Driving in pit areas / violent driving instruction / accident prone drive & damage to other teams or Volunteer on test ground
* T he penalties described above are for overall conduct of the event and not particular to any of the specific static / dynamic events. The event specific penalties are specified in the rulebook. The penalties may change subject to case.
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APPENDIX 12
Direct Communication to any member of organizing committee shall not be entertained and shall not be considered as official. Following mail id are provided for respective communications 1. Technical Issues & Questions 2. General Communication 3. 4. 5. 6. 7. General Issues/ Query Engine Related Query Alumni/ Student Contact Administrative Issues Online submission / Web site bajatechfaq@gmail.com bajahelpline@gmail.com saeindia_indore@saeindia.org puviarasu@ppepl.com Anshuman Vagesh Sagar Bendre/ Akhand Pratap Singh Akhand Pratap Singh S. Puviarasu Taru Singhal Sagar Bendre Akhand Pratap Singh
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