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Design Report
PHOENIX
Rajiv Gandhi Institute
of Technology,
Kottayam
KERALA
South-2 Zone
PHOENIX
E-COZI
Team structure
STEERING
BRAKE
SYSTEM
Jithu KS
Jeeva Mathew
Jithu KS
Kiran Kumar C
Anuvind Surendran
FACUTY ADVISOR
Mr. Antony JK
TEAM CAPTAIN
POWER TRAIN
DESIGNING AND
TESTING TEAM
VICE CAPTAIN
Kevin Sebastian
Thoompunkal
SUSPENSION
Mareena Antony
Kevin Sebastian Thoompunkal
Vinu Krishna
ELECTRICAL
Arun Mohan
Mareena Antony
Introduction
PHOENIX E-COZI is a recumbent tadpole trike with side-by-side
seating which incorporates modern technology so as to make it
passenger friendly . The complete designing process was based on
the theme of Safety and Comfort. Tadpole design is preferred to
delta design since tadpole has advantages of better driver safety,
dimensional stability, aerodynamics and ergonomics. An innovative
Kinetic Energy Recovery System (KERS) has also been incorporated
for better performance and easiness. With strong chassis designed
to withstand impacts and covering to protect the rider from debris,
wind current and rain, PHOENIX E-COZI makes sure that no
where it compromises safety and comfort.
Design Methodology
The vehicular design and the subsystem designs are performed after
profound research into the particular field.
The subsystems are separately designed, validated and accepted after
rigorous comparisons and market analysis.
The components to be procured such as the differential, electric motor
drive system, electronic components like sensors and switches are selected
based on the market availability. The companies have been contacted to
know the feasibility of availing us with the components, the following are
the companies which had provided us with the specifications regarding the
components:
1.) Samagaga Industries, Taiwan (DIFFERENTIAL)
2.) Falbrook Technologies, USA (NUVINCI HUB)
3.) Tachometric Controls, India (BLDC MOTOR,DRIVE SYSTEM and
EPICYCLIC GEARS)
4.) Keltron Ltd.
(ELECTRONIC COMPONENTS)
Project Plan
The Gantt chart was prepared to aid us in arriving at our
final vehicle design and specifications.
The duration for the event was speculated from 11th
February to 8th June, allocating considerations for the
academics and activities
Our design methodology of designing the chassis with
reference to the requirements of the subsystems like
steering , suspension etc. was adhered while preparing the
plan
Technical Specifications
Chassis
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The Chassis design imparts the following specification for the vehicle:
Wheelbase: 1650 mm
Track: 1200 mm
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The strengthening members are fabricated from NPS 1 Schedule 5,with the
following specs: O.D = 26.67 mm , thickness = 1.65 mm
The utility box of the prescribed dimensions is position in the front of the vehicle to
balance the load distribution
A metal sheet will be provided on the underbelly of the vehicle for the safety and
comfort of the passengers, which helps in developing a neat floor space
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Material Selection
Owing to the benefits such as high corrosion resistance, fire and heat resistance,
strength, toughness, better hygienic quality, aesthetic appearance, ease of fabrication
and 100% recyclability stainless steel was selected.
We have various grades of stainless steels : Austenitic (200 & 300 series), Ferritic and
Martensitic (400 series and above). Owing to wide availability, good general corrosion
resistance, good cryogenic toughness and excellent weldability properties AUSTENITIC
grade stainless steel was opted.
COMPARISON BETWEEN STAINLESS STEEL 200 AND 300 SERIES GRADES
Properties
200 series
300 series
Chemical Composition
Strength
Corrosion resistance
Excellent
Weldability
Aesthetic appearance
Cost
Excellent
Excellent
High, precisely around thrice
(from latest Ni market values)
Availability of the stainless steel pipes of required size in the Indian market is the sole reason
for SS grade 202 being selected in the 200 series.
Properties of Stainless Steel:
Density= 7.8 kg/3
Nominal Yield Strength= 310 MPa
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The stress value is within the limits of the tensile strength of SS 202.
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Power Transmission
For better ease in motoring, an all-wheel drive system is implemented in the vehicle
The drive-train layout is as illustrated below:
For the ease of interpretation, the drive-train layout has categorized into two:
1.) Pedal Drive-train
2.) Motor Drive-train
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Pedal Drive-train
Both the passengers are provided with 160 mm pedal cranks which transmit power
to the rear wheels via an intermediate shaft as shown in the illustration
Center-to-center Distances:
Sprocket 1- Sprocket 2= 472.367 mm
Central Sprocket- NuVinci Hub= 989.586 mm
Chain 2(Central-NuVinci)
pitch= 989.586/50
= 19.7 mm
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The calculated pitches of the chains are compared with ISO 2403-1991 standards of
chains.
Chain 1- 06 B (pitch=9.525 mm)
Chain 2- 12 B (pitch=19.05 mm)
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= 82.04 mm
= 163.815 mm
Considering the market availability of these sprocket the following specifications are
fixed
= 80 mm and =160 mm
3.1482.014150/60 = 0.64 m/s
((1 +2 /2) + (
1 +2
2
8((2 1 )/2)2 )]
Solving the above equation for the value of K , as the values of x, p , 1 and 2 are known.
Chain 1K= 139.804~ 140
Length of Chain 1 = 1.33m
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Chain 2-
K=124.9 ~ 125
Length of Chain 2 = 2.37 m
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- System offers seamless and continuous transition to any ratio within its range
- It is referred to as a tractive drive When this fluid undergoes high contact pressures under
rolling contact between the two very hard elements, the spheres and the disks, the fluid
undergoes a near-instantaneous phase transition to an elastic solid. Within this patch
of traction the molecules of the fluid stack up and link to form a solid, through which shear
force and thus torque can be transferred. Note that the rolling elements are actually not in
physical contact
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Electric-motor drive
A 400W BLDC motor is used to power the front wheels via a differential unit.
The BLDC and PMDC motors were compared
BLDC MOTOR
Higher speed range
Power loss at brushes can be avoided
High Output Power and Efficiency
Maintain or increase torque at various speeds
Longer life
Compact size and low noise operation
Low rotor inertia
Improves dynamic response
Less or sometimes no maintenance required
(due to absence of brushes)
Higher cost of construction
(Total cost becomes comparable)
PMDC MOTOR
Low speed range
(due to limitations imposed by the brushes)
Power loss at brushes
Moderate values
As speed increases torque decreases
(due to increased brush friction)
Shorter
Electromagnetic Interference (EMI) is generated
by brush arcing
Higher rotor inertia which limits dynamic
characteristics
Periodic maintenance required
(brush cleaning and replacement is essential)
Lower construction cost
Maintenance cost is higher
Based on the above criteria Brush Less DC (BLDC) Motor was selected.
Analyzing our requirements of providing 400W and motoring the estimated 350 kg
vehicle( fully loaded with two passenger each weighing 115 kg), the motor with the
following performance curve was selected
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The motor specifications(as given by the manufacturer, Tachometric Controls Ltd.) are
stated below :
Voltage rating: 24 V
Rated Speed: 1500 rpm
phase resistance : 3 ohm
Max. torque: 3 Nm
phase inductance : 10.07 mH
continuous current : 1.81 A
weight : 2.6 kg
rated phase current : 1.81 A
max current : 5.45 A
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As the torque value of the motor of this range are insufficient to power the vehicle, a
planetary step-down gear unit is employed to amplify the torque to at least 15 N.m
A planetary gear set of step-down ratio of 6:1 is used to increase the torque to 18 Nm
An increase in torque is obtained by either locking the rim and using sun gear as
input and carrier plate as output or locking the sun gear and using rim as the input
and carrier plate as the output
Battery Pack:
Four batteries each rated at 12V, 35Ahr is arranged in series to provide a net
rating of 48V,35 Ahr.
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Contrary to the figure shown above the differential unit would have a direct drive
from the motor in order reduce the complexities of a derailleur gear system.
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Seating System
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Given layout has ergonomic advantages as the torso rests on a section which is
inclined at an angle of 30 degs with the vertical and the thigh rests on the section
which is inclined at 6 degs with the horizontal
The H-point is determined at 661.954 mm above ground, which is within the limit
prescribed in the rulebook.
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The seat is mounted on to the chassis by suitably placing it on the cross members
and exoskeleton of the chassis
As per the rulebook instruction, 3-point seat belts are provided in the seating
arrangement.
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Steering System
Based on the fact that by implementing the steering system on the front wheels,
the tractive force available for steering( cornering traction ) is increased when
compared to a single steerable-wheel(rear-wheel steering),the vehicle is designed
front wheel steering system based in Ackermann geometry.
The Steering system is designed to achieve 100% Ackermann geometry, with the
specifications as shown in the figure
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Allowances had been provided in the chassis exoskeleton to facilitate the steering
angle of upto 35 deg
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Braking system
u = 50m/ 15 seconds
= 3.33 m/s
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N.m
where is the static laden radius of the tire and is the ratio of the radius of the brake
disc to the static laden radius of the wheel.
here,
= 0.3302 m and = 0.08 m / 0.3302 m 0.242
= 524.6 Nm
Friction force()= mass of the vehicle
= 622.22
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where, is the weight of the vehicle, is the coefficient of friction, is the height of
the center of gravity and is the wheelbase.
for the vehicle, = 114 kg
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Suspension system
with passenger comfort as the top priority, the vehicle features the following
suspension systems
front wheels- Double Wishbone suspension
rear wheel- Double-sided Swing-arm suspension
The reasons for providing the suspension systems are:
1.) Passenger comfort
2.) Roll stability in execution of turns and thus the safety of the passengers
3.) Reduce the undesirable shocks on the vehicular frame, thus increasing its
reliability and durability
Front Suspension
- features the following illustrated geometry
- unequal wishbones in non-parallel arrangement
- geometry is designed to have the lowest possible distance between the roll-centre
and the CoG, thereby reducing the roll-angle of the vehicle when under the action
cornering forces
In the suspension geometry, the distance between the roll-center and CoG is 0.38 m
i.e, the roll-force creates a torque with an arm of radius 0.38 m.
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The geometry provides neutral camber, which was validated given the 1.95 width of
the tire and also the increased rate of wear and tear if camber angle was nonneutral.
The Kingpin inclination of 3.938 deg. is provided to produce a scrub radius of
0.07m,which helps in achieving appreciable self-centering ability of the steering
linkages and the directional stability of the vehicle
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The Upright is manufactured from 0.01m thick steel plates and the geometry is
fabricated by welding.
The wishbone attachments are positioned to facilitate the 3.98 deg. Kingpin
inclination.
The coil-over springs are selected on the basis market availability and vehicle
requirement.
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1.) Deformation
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1.) Deformation
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the motion ratio and the deflection of the spring at different attachment points.
Double-sided Swing-arm
-
the coil-over spring for the rear suspension is that of Honda Unicorn with spring
travel of 3 inch.
Tire Specifications
Based on the market survey, cost analysis and reliability, the 26 MTB tire with
1.95 tread are used in the vehicle
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Safety Features
Ergonomic Features
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INNOVATIONS
An innovative Kinetic Energy Recovery System is employed, which utilizes the
4th quadrant operation of the BLDC motor.
-apart from the BLDC motor, its controller drive and the battery, the other main
components involved are:
Power conditioner
Change-over switch
The BLDC motor would be operating in the 4th quadrant due to the
braking / deceleration, the voltage so induced is directed to the
power conditioner, which in turn charges the battery. Thus
harnessing the energy dissipated during braking and deceleration,
constituting the KERS.
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Fabrication Plan
The Gantt chart was prepared for the fabrication of the vehicle, considering the
market availability of the components and the duration for synchronizing the
different systems.
Tasks
Start Date
Duration (Days)
Virtual Round
7/13/2013
7/31/2013
End Date
8/1/2013
8/7/2013
8/8/2013
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8/22/2013
8/23/2013
8/29/2013
8/23/2013
8/29/2013
Fixing suspension
8/30/2013
9/2/2013
Fixing steering
9/3/2013
9/6/2013
9/7/2013
9/10/2013
9/11/2013
9/14/2013
9/15/2013
9/21/2013
9/22/2013
9/25/2013
9/26/2013
9/28/2013
Tyre
9/29/2013
10/2/2013
Road Test
10/3/2013
10/9/2013
10/16/2013
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College Facilities
The mechanical engineering lab at our institute houses a well equipped CAD lab and
all fabrication departments like fitting, welding ,lathe-machining workshops.
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DESCRIPTION
ACCEPTANCE CRITERIA
RESPONSIBILITY
TEST SOURCE
Kevin Sebastian
Chassis Fabrication
Anuvind Surendran
Engineering Drawing
Steering System
Anwar Naseef
Software Analysis
Suspension System
Kiran Kumar C
Powertrain
Theoretical Analysis
and Protyping
Brakes
Jeeva Mathew
Visual Inspection
Tires
Mareena Antony
Visual Inspection
Safety
Vinu Chandra
Visual Inspection
Proper Mounting
Arun Mohan
Prototype
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Development of KERS
Proper Design
Jithu K S
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COST REPORT
STRUCTURAL
MATERIALS
ELECTRICAL
EQUIPMENTS
POWER TRANSMISSION
EQUIPMENTS
OTHER EQUIPMENTS
COST REPORT
STRUCTURAL MATERIALS
5000.00
ELECTRICAL EQUIPMENTS
21000.00
POWER TRANSMISSION
45890.00
OTHER EQUIPMENTS
5480.00
77370.00/-
Market Plan
Unique Selling Proposition
"A
Get to your work and back home at half the cost by burning a few calories to stay
healthy.
Why buy petrol/diesel when you can charge the battery at low cost and be on your
merry way.
Parking has been never this easy.
With no doubts, one big thing which will surely revolutionize the three wheeler
market and make a lot of heads turn.(Sporty and eye catching design)
Safe and cozy, no reason why one shouldnt buy it.
No harm to Mother Earth.
Get the advantage of the latest Kinetic Energy regenerative system (KERS).
Uncompromised Safety and Comfort
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Tourism Department
i)
ii)
Two men boat riding can be replicated with the PHOENIX E-COZI
Scenic tour in Natural Parks and Sanctuaries without polluting
the environment.
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High efficiency.
Increased safety , stability, and speed control than ordinary
cycle.
Variants
Single seated models.
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