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Rules regardind power-train and braking

Prefabricated Subassemblies

Extensive use of ready-made 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.
Required Engine

Briggs and Stratton Engine: 10 hp OHV Intake

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.
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.

Replacement Parts
Only original equipment Briggs & Stratton replacement parts may be used.


Piston Rings
Only standard size original Briggs & Stratton piston rings may be used.

Intake Ports
No cleaning or removing of aluminum flashing from intake or exhaust ports may be done.
Valves Clearance & Lapping
Any valve clearance setting between tappet and valve stem intake and exhaust may be set.
Valves may be lapped to ensure proper sealing. Intake angle must remain at 45 degrees;
exhaust angle must remain at 45 degrees.

Shafts and Rods
Camshaft, crankshaft, connecting rod and flywheel must not be altered or modified.

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.
Armature
Any armature air gap setting is allowed. No slotting or elongating of armature mounting holes to
increase or retard ignition timing.

Flywheel Rotation
No flywheel rotation to advance or retard timing is permissible.

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.
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.


Exhaust System

A. Muffler & Exhaust system
Since B&S Engine is supplied with pre mounted exhaust system, there is no need to change the
mounting. Regarding GO GREEN Award, concept model & system need to be separately
worked out for presentation during the event. Details for GO GREEN Award will be separately
put on the official BAJA SAEINDIA 2014 website.

B.Exhaust System Durability Required
The exhaust pipe and muffler must be completely intact and operational throughout the event,
and shall be grounds for penalty or disqualification if not intact at the end of any event, including
endurance event. The decision of the representatives of the engine manufacturer and/or the
Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to
all.

C. Exhaust system complete
The complete exhaust system exhaust system shall be located such 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 in this regard will be final and binding to all. This is in the
interest of safety.

D. Exhaust system painting
This is recommended but not compulsory.



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.

Alternator
The engine is not configured for fitment with an external alternator to generate electrical energy.
Hence it is not permitted.


Engine Governor
Each engine is equipped with a governor. Each governor will be set at the competition to a 3800
rpm or maximum speed. Random inspection of the governor may be conducted at any time. Any
attempt to defeat the engine governor so as to increase the engine speed grounds for
immediate disqualification.

GOVERNOR SETTING: NOT TO EXCEED 3800 RPM.
The governor operation must remain free of obstructions at all times. Governor area must be
shielded from debris. The stock configuration of fuel tank mounted to the engine is acceptable
for debris management. However, if the fuel tank is to be remote mounted, a debris shield
covering the exposed governor area is required. Briggs & Stratton part number 697326 Control
Cover may be used or some other part with equivalent features.

NOTE: The governor spring must be placed in hole # 6.

The top 10 vehicles in the Endurance Event will be checked for the same.

Hybrid Electric Power Systems
Hybrid electric power systems are specifically prohibited.


Energy Storage Devices Used for Propulsion
Hydraulic accumulators are the only type of stored energy device that may be incorporated into
the vehicle for propulsion purposes. If employed, hydraulic accumulators must be at zero energy
at the start of each event. Hydraulic power systems must be properly shielded and
documentation
of the shielding made available for review.

Engine Use Restriction
Briggs & Stratton generously provides engines to the teams for the exclusive purpose of use on
their BAJA SAEINDIA vehicle. If, for any reason, a team receives an engine and at a later date
decides not to participate, it must, at its own expense, return the engine to SAE or Briggs &
Stratton.

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

Electronic Controls
Electronic control of suspension and transmission systems is allowed. The power can be from
the approved battery.

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.

Engine Use Restriction
The B&S staff on-site is empowered to make final decisions regarding the condition and set-up
of all engines.
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.


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.


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.


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.


Foot Brake
The vehicle must have at least two (2) independent hydraulic braking systems that act on all
wheels and is operated by a single foot. The pedal must directly actuate the master cylinder (no
cables are allowed). Each hydraulic system shall have its own fluid reserve either through
separate reservoirs or by the use of a dammed, OEM-style reservoir. The brake system must be
capable of locking ALL FOUR wheels in a static condition and dynamically on pavement AND
an unpaved surface. Both the independent brake-systems may be actuated by a tandem master
cylinder and safely stop the vehicle at max speed of 45kmph or above.
All rigid brake pipes must be mounted securely along the roll cage / other members as required.
Loosely hanging / pipes located by using ties / tapes etc shall not be permitted. Wheel ends
should be connected with flexible pipe only. The bleed point location must lie on top of the
caliper cylinders, without exception. Vehicles not meeting this requirement will not clear
technical Inspection. This is in the interest of safety of vehicle & team. The brake(s) on the
driven
axle must operate through the final drive. Inboard braking through universal joints is permitted.
Braking on a jackshaft or through an intermediate reduction stage is prohibited.
NOTE: Plastic brake lines are not allowed. Use of OEM Brake lines is recommended.

Brake Light
The vehicle must be equipped with a red brake light whose lens must be marked with an SAE
S or U rating (i.e.: SAE IPRSTM) or if it is not rated as per SAE J759, it must be equal to or
exceed these standards (e.g.: OEM brake light assemblies)/ AIS and ISI rated brake lights are
also permitted. The determination of whether or not a brake light meets the required standards.
The brake light must be mounted at a minimum of 1 meter (40 in.) above the ground.
Light must be mounted such that it shines parallel to the ground, not at an angle, till a
distance of 10 meters.

FUEL SYSTEM

System Location
The entire fuel system must be located within the roll cage envelope such that it is protected
from impact. The tank mountings are done along with B&S engine and need not to be changed.
Fuel Tank
A single fuel tank (maximum capacity = 4.5 liter) is permitted on the vehicle which is supplied &
mounted along with B&S Engine. Quality, cleanliness of fuel tanks is important from both safety
& engine working point of view.
Spill Prevention: Drip Pan / Splash Shield
A drip pan, that is at least 203.2 mm (8 in) in diameter or equivalent area and have sides of at
least 38 mm (1.5 in) high above the top edge of the tank, is required so that if the fuel spills it
must not come in contact with the driver or the engine or catch fire. Fuel must not get
accumulated anywhere in the pan & it must drain through a drain line composed of pipe or
tubing that carries the fuel to the bottom of the car and releases it under the car (to ground).
At no point in the drain system (the drain lines and any associated fittings) will the
inner diameter be constricted to less than 9.53 mm (0.375 in) this includes bolts with a
hole drilled in the center used as a fitting. A shake resistant Drip Pan below the fuel tank is
must.
Drip Pan is invariably also called as Splash Shield for its added functionality of preventing fuel
being accidently spilled directly on engine or exhaust while re-fuelling or during the driving on
tilt.
Spill Prevention Drain Material
The drains must be either fuel line material, other pipe or tubing suitable for transferring fuel.
Tubing that is weakened or dissolved by fuel are unsafe and will not be permitted. If tubing is
used, it is highly recommended that a threaded and barbed fitting be used at the point where the
drain line connects to the drip pan.
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.
Compliance is mandatory.

Filler Cap
A standard Briggs and Stratton gas cap with a built in check valve (Part # 792647) is required.
The retail price must be included in the cost report
The standard filler caps provided with rated fuel tanks may not prevent fuel from leaking
in the event of a rollover. Teams must ensure that the filler cap gasket does not breakdown in
fuel, does not have any holes and prevents fuel from spilling. The cap must not come loose
during dynamic events or allow fuel to spill out even vehicle is tilted over banking.
In case of such spill over observed all spill over fuel must get drain off through drip pan & drain
pipe to ground. Compliance shall be checked and any vehicle failing to comply shall not be
allowed to start any dynamic event.
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 .


Power train Guards
All rotating parts must be shielded to prevent injury to the driver or bystanders should
the component fly apart due to centrifugal force. They must be mounted with sound
engineering practice, in order to resist vibration. They must be either (a) made of AISI 1010
steel at least 1.524 mm (0.06 inch) thick or (b) a material having equivalent energy absorption
at rupture per unit width of shield. Equivalency calculations for the alternative material
must meet the following requirements: All calculations must be shown in SI units.
Calculations must use the following material properties for the AISI 1010 steel: Yield Strength
= 305 MPa, Ultimate Strength = 365 MPa, Elongation at Break = 20.0%, Modulus of Elasticity =
205 GPa. Documentation from the material manufacturer showing the Ultimate Strength,
Elongation at Break, and Modulus of Elasticity of the alternative material must be provided. If a
stress-strain curve for the alternative material is not provided then it must be assumed that the
stress strain curve is linear to the yield point and linear from the yield point to the ultimate
strength, where strain = elongation at break.
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
xThickness)

Engine and Drive-train Inspection
The Technical Inspectors reserve the right to impound and inspect any vehicle during/ after the
dynamic or endurance events. Any vehicle found to have: (1) a drive-train configuration not
matching the Drive-train Certification Form submitted during technical inspection or (2) an
engine in violation of rules Sections 2.2 through 2.2, 1.2, 2.3, 2.4 shall receive zero points (0)
for
all dynamic competition events completed during the day on which the inspection was
performed.
Engine Recall Option
The organizers and SAE India may, at their sole option, recall the engine from any vehicle in the
competition in exchange for a new B&S engine. Recalled engines will not be returned and will
be inspected at B&Ss facilities to confirm compliance 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
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.

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.

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