Team ECB Racers

Engineering College Bikaner

(AN AUTONOMUS INSTITUTE OF GOV. OF RAJASTHAN)

Our Goals
To design a vehicle which is low cost, low weight, fun to drive , easy to maintain & ecofriendly in accordance with the BAJASAE rules. To design a vehicle which can negotiate through all terrains and able to withstand worst conditions. To design a vehicle to provide maximum comfort level to its rider in vehicle handling during off road traversal.

Vehicle technical specifications

Overall dimensions: overall length : 90 in. Overall height : 60 in. ground clearance : 8 in. Track width : 52 in. Braking system: dual hydraulic disc brakes at both front and rear wheels. Steering : type : central rack and roller pinion steering ratio : 10.58:1 turning radius : 9 ft. Tires and wheels: (in inches) front : 21x10x6 rear : 22x10x8 Suspensions: double wishbone at both front and rear.

Target design and performance specifications

Speed:
For better economy, the range of speed in each gear, for driving tires of O.D 22 inches operated in normal forward orientation is: Gear First Second Speed (km/hr) 10-12 15-18

Third
Fourth Reverse

25-33
40-51 8-11

braking performance:
Time to come in the rest from position of maximum speed : 8 sec. Distance covered by the vehicle before coming to rest from maximum speed when the brakes are applied : 11 mtr.

Roll Cage Design

Objective:
Safety of the Driver Ease of fabrication & manufacture Stability of the mounting components Driver Ergonomics Roll over Prevention

Aerodynamic stability

Cost & Quality

Low Weight

Overall Attractiveness

Durability & Maintainability of the Frame

Roll cage Specifications:

LENGTH WIDTH FRONT END REAR END MAX HEIGHT WEIGHT 90in 22in 25in 37in 52in 43kg

Roll Cage View:

VOLUME
SURFACE AREA

333095.40 in3
6958.53 in2

CENTRE OF MASS

x=2.95mm y=465.99mm z=381.54mm

52

WELD JOINTS

TOTAL WELD LENGTH

ESTIMATED COST

261.48in
8400 Rs

FEA ANALYSIS
Impact Factors & load Applied:
Impact Front Impact Side Impact Rear Impact Impact factors At 15 m/s At 11m/s At 13 m/s Load Applied 6000N 4000N 5000N Result Passed Passed Passed

Front impact:

Front impact Test-Displacement

Front impact Test-F actor of Safety

Max. Displacement:1.50mm

Min. FOS: 2.01

Side Impact:

Side Impact Test- Displacement Max. Displacement-5.4 mm

Side Impact Test- FOS Min. FOS -3.21

Rear Impact

Rear Impact Test- Displacement Max. Displacement-7.463mm

Rear Impact Test- FOS Min. FOS-1.91

Material selection
Availability of Material as per Rulebook: 1.AISI 1018 2.AISI 1020 3.IS 1239 (part 1) 4.AISI 4130 Comparison of materials: Cost of per meter length of 1018 is 3.6 and 1.275 times cheaper than 4130 and IS 1239 respectively. Also Its easily available in market. Conclusions: The material we are going to use is AISI 1018 steel.

MS Project plan
Here is a brief description of the project plan team ECB racers going to follow:

Name of the job Roll cage prototype Raw material collection Rollcage fabrication

period 25 Jul. - 5 Aug. 6 Aug. - 10 Aug. 11 Aug-25 Aug

Steering fabrication
Engine mounting Wheel assembling Riders accessories Vehicle Testing

26 Aug-18Sep
19Sep-25Sep 26Sep-7Oct 8Oct-20Oct 20Oct-30Oct

Design validation plan

ROLLCAGE ANALYSIS : *FRONT IMPACT : (AT 15m/s) as per FSAE Society Rules: => F=360*15=5400N&Thus Force applied is 6000N. *SIDE IMPACT: (AT 11m/s)=> F=360*11=3960N&Force applied is 4000N * REAR IMPACT: (AT 13m/s) => F=360*13=4680 & Force applied is 5000N
FORCE ON AXELS(WHEN BREAK APPLIED) FRONT AXEL = 1800N REAR AXEL = 1200N ACCELERATION= 9.1M/S2

Suspension: Mass falling over front wheels=76.5Kg Mass falling over rear wheels=138.5Kg Max. Compression at front suspensions = 20mm Max. compression at rear suspensions = 25mm (under static conditions).

Innovations
A touch screen GPS system with quick satellite viewer enabling to have a view of vehicle position and a live picture of surface around the vehicle also with weather information plus information regarding other vehicles also. For cooling of the Engine, we are going to use funnel with tubes to focus air directly to the areas of engine where cooling is required. Using the iPhone to start/stop the vehicle engine via start smart hardware in the vehicle(range ).

Go green
Mounting the Enamel coated plate at the exhaust of the engine to decompose and reduce the emission of carbon containing gases. 75% material of vehicle parts are recyclable . HID headlights(Xenon) instead of mercury lights.

Paints that we are going to use would be lead free.

Team details
Team member Prof. M.P.Poonia Pushpendra Kumar Sharma Prabhakar pal Priyank shastri Jagrat Agar Adarsh Maurya Dinesh Chand gangawal Harshit sharma Himani jangid Task Faculty adviser Marketing, suspension Brakes, co-captain Transmission, marketing Roll cage design Roll cage design Roll cage design Suspension Braking system

Tanushree pareek Dharmraj meena

Mukesh pathak Divya suman Sanu pal Harish

Vehicle accessories Ignition System

Accessories Tires & wheels Steering system Fabrication & Mounting.

College facilities to be used

We are going to use : CUTTER MACHINE DRILLING MACHINE GRINDER MACHINE MIG WELDING & LATHE MACHINE.

Thanks