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PHOENIX
Width - 62 at widest point Length - 108 end to end Capable of carrying 1 person 190.3 cm weighing 113.4 kg Proposed to use Briggs & Stratton Engine Reverse light (white visible at min10m) and reverse alarm equipped Towing Hitch Points 2 (Front & Rear) Drivers helmet to be 6 inches away from a straightedge applied to any two points on the cockpit of the car. The drivers torso, knees, shoulders should be 3 inches from envelope of car. Minimum vertical clearance = 6 provided from top of the helmet and bottom of the roll cage top tube members Roll cage materials: Steel tubing OD - 1 ; Wall thickness - .120 ; carbon content - .18% Roll cage Foam material Polyethylene with minimum thickness - .5 A clearance of 3 between firewall, side impact members and seat is maintained Ingress & Egress -5 secs Emergency Kill Switches 2 5 point restraint harness with 3 wide lap belt and shoulder harness straps along with 5th anti submarine belt Positive wheel lock-to-lock stops located at wheel kingpins to be mounted Equivalent bending stiffness and bending strength in accordance with SAE 1018
VEHICLE SPECIFICATION
Overall height = 1180mm Overall width = 1403 mm Overall length = 1915 mm Wheel base = 1450 mm Track width = 1200 mm Weight (approx) = 290 kg (without driver) Ground Clearance = 10 Turning Radius = 3.820m Maximum Speed = 57.25 Kmph @ 3600 rpm Acceleration = 1.775 m/s^2 Maximum Gradability = 31.186 @ 3600 rpm at 1st gear
Suspension
Front : Unequal double wishbone with coil springs Rear : Unequal double wishbone with coil springs Material :ASTM A106B Section : Circular 33.4mm OD , 30.02mm ID , 3.38mm thickness
Front Spring Stiffness = 17 N/ mm Travel =150 mm Max Possible Force=2920N Mean Dia of Coil=90mm Wire Dia = 10mm Spring Length =260 mm No. of active coils = 8
Rear Spring Stiffness = 27 N/ mm Travel = 128 mm Max Possible Force=4468N Mean Dia of Coil=98mm Wire Dia =12mm Spring Length =260mm No. of Active Coils =8
WHEEL GEOMETRY
Rim Dia =14 Front Tires = 25 X 8 X 14 Rear Tires = 25 X 8 X 14 Tires to be used BAJATRAX TIRES
TRANSMISSION
Type Rear Wheel Drive Gearbox - 4 speed manual constant mesh gearbox with 1 reverse Model Piaggio Ape Ratio / Kmph per 2400 rpm 1st 35.298 / 8.134
2nd20.053 / 14.32
3rd 11.382 /25.23 4th 7.523 / 38.17
E=205 Gpa Outside diameter: 33.4 mm Wall thickness: 3.38 mm Total no. of welds = 57 Weld Length = 5.98 m TIG Welding
HEAVE TEST
LOAD APPLIED=600 N
3D-VIEW
Cost report
ITEM NAME Frame Hardware Brackets Supports Engine Manual transmission A-arms Front & Rear Spring Shock Absorbers Rack & Pinion CV joints Steering Column Brake system Kit Pedals Steering wheel Electrical Wires & Sensors Transponder Driver Seat Hub Tires Rims Neck Support Goggles Gloves Helmet Wrapping Foam Fire Extinguisher TOTAL USED IN Structural Structural Structural Structural Drivetrain Drivetrain Suspension Suspension Suspension Controls Controls Controls Controls Controls Controls Accessories MAKE BUY MATERIAL ASTM A106B STEEL STEEL STEEL N/A N/A ASTM A 106B N/A STEEL STEEL STEEL STEEL COMPOSITES ALUMINIUM ALUMINIUM ELECTRONICS QUANTITY 4 N/A N/A N/A 1 1 2 4 4 1 2 1 1 2 1 N /A ESTIMATED COST(IN RUPEES) 3750 4200 4000 5500 17000 9500 2000 6500 9500 4400 800 4500 8500 1400 1200 5750
Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories Accessories
N/A PLASTIC ALUMINIUM RUBBER ALUMINIUM PLASTIC PLASTIC FABRIC PLASTIC STYROFOAM N/A
1 1 4 4 4 3 3 3 3 1 2
N/A 4500 2400 11000 7000 3000 3300 3600 6000 1000 5500 135800
MS Project Plan
AUTOMATIC ACTUATION OF KILL SWITCH DURING FIRE EMERGENCY USING TEMP SENSORS
To actuate the kill switch automatically in the event of fire accidents, using temperature sensors. Temperature difference during accidental fire breaks Sensor actuates the kill switch Binary sensor mounted at various points that provide signal to a micro controller
CAUSE CAUSE
Too much load or shock applied leading to excess axial stress Too much load or shock applied leading to excess axial stress Excess load or vibration causing excess bearing and yielding stress Too much load or shock applied leading to excess axial stress Lack of clean air and fuel to maintain operation Too much load or shock applied leading to excess axial stress
FRAME
STRUCTURAL/ SAFETY
10
80
HARDWARE
STRUCTURAL
10
80
DFMEA
BRACKETS
STRUCTURAL
10
80
SUPPORTS
STRUCTURAL
10
80
ENGINE
MECHANICAL
10
10
A-ARMS
MECHANICAL
Suspension compromised
72
DFMEA
ITEM NAME
EFFECT
Suspension compromised
SEVERITY
CAUSE
Wrong spring chosen for application Debris damaging component
OCCURANCE
DESIGN CONTROL
Diligent testing to ensure functionality Verification of desired specifications of component Verification of desired specifications of component Verification of desired specifications of component Relatively high factor of safety to ensure mechanical integrity Diligent testing to ensure functionality Relatively high factor of safety to ensure mechanical integrity Verification of desired specifications of component
Verification of desired specifications of component
DETECTION
RPN
SPRINGS
36
SHOCK ABSORBERS
MECHANICAL
Suspension compromised
81
MECHANICAL
Inability to steer
64
DFMEA
STEERING COLUMN
MECHANICAL
Inability to steer
N/A
18
MECHANICAL
10
Inability to provide sufficient braking force Excess load applied by driver to component Excess load applied by driver to component Lack of structural integrity under cyclic
20
PEDALS
MECHANICAL
Inability to operate
10
20
STEERING WHEEL
MECHANICAL
Inability to steer
N/A
16
TRANSMISSION
MECHANICAL
Inability to OPERATE
216
DFMEA
CV JOINTS
MECHANICAL
Inability to operate
72
ITEM NAME
DRIVER SEAT
EFFECT
Driver's safety compromised
SEVERITY
9
CAUSE
Excess load leading to bearing yield
OCCURANCE
2
DESIGN CONTROL
Diligent testing to ensure functionality
Verification of desired specifications of component Verification of desired specifications of component Verification of desired specifications of component Constant checking
DETECTION
1
RPN
18
DFMEA
DFMEA
TYRES
MECHANICAL
Inability to operate
Puncture by debris
48
RIMS
MECHANICAL
Inability to operate
Damaged by debris
24
HELMET
SAFETY
DRIVERS SAFETY COMPROMISED Can lead to excess fire damage VEHICLE WILL BE BLACK FLAGGED
10
20
SAFETY
N/A
27 21
ELECTRICAL
N/A
Electrical circuits
DESIGN VALIDATION
Steering-Rack and pinion -light weight -simple design -low cost - relatively small size Suspension -It gives more movement of the tires and hence the vehicle for the same movement of the spring -Independent suspension -Force is distributed at 5 points in the roll cage unlike at only one point in Mcpherson strut -Can be slightly adjusted for different parameters of suspension tuning like camber angle, ground clearance at the time of testing and then finally proper adjustments are made at the time of fabrication.
Brakes -Ventilated disc for higher heat dissipation rather than a single disc