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' (! (M) M'M+ ,'-''.. / / M. '!,M

The objective of TEAM INGENIUM is to design, analyze and simulate a prototype BAJA vehicle for a production rate of 4000 vehicles per year without compromising on reliability, strength, driver ergonomics or customer budget. The roll cage design follows rule book constraints while incorporating innovative features. Analyses were conducted on the roll cage and A-arms to evaluate stresses and safety factors. The project plan outlines the phases, tasks and implementations. Design validation includes impact testing, load testing, thermal analysis, and driver ergonomics testing. Innovations include a splined transmission axle, aerodynamic shape for drafting, and a bolt-on bumper arrangement. The team aims to make the vehicle more environmentally friendly

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Vipin Singh
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44 views16 pages

' (! (M) M'M+ ,'-''.. / / M. '!,M

The objective of TEAM INGENIUM is to design, analyze and simulate a prototype BAJA vehicle for a production rate of 4000 vehicles per year without compromising on reliability, strength, driver ergonomics or customer budget. The roll cage design follows rule book constraints while incorporating innovative features. Analyses were conducted on the roll cage and A-arms to evaluate stresses and safety factors. The project plan outlines the phases, tasks and implementations. Design validation includes impact testing, load testing, thermal analysis, and driver ergonomics testing. Innovations include a splined transmission axle, aerodynamic shape for drafting, and a bolt-on bumper arrangement. The team aims to make the vehicle more environmentally friendly

Uploaded by

Vipin Singh
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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The objective of TEAM INGENIUM is to design, analyze & simulate a prototype of a BAJA vehicle for a fictitious firm having

production rate of 4000 vehicles per year without compromising with :


RELIABILITY STRENGTH DRIVER EGRONOMICS CUSTOMER BUDGET

RULE BOOK CONSIDERATION


The roll cage aptly follows the rule book constraints but is full of innovative & creative features.
Vehicle specification: Max. speed = 45 km/hr Track width = 63 inches Wheelbase = 96 inches  Bend Radius: Maximum=22 inches Minimum=8 inches Material selection : ASTM E1507 Why?? Comparative results and load analysis cheap and better availability. Better weld-ability and machinability.  Pipe diameter: OD - 1.05 inches. Thickness - 0.112 inches

DRAFT TECH SPECIFICATIONS


 STEERING: Four wheel, Rack and pinion type collapsible steering column

with no kick - back effect. Steering ratio = 18:1. Avg. steering angle - 38 deg. Turning radius = 12 ft. Radius of curvature = 49 inches

 SUSPENSION: Independent type with

unequal A Arms. Front: Double wishbone. Rear: Double wishbone.


 TRANSMISSION: Mahindra Alfa

4 Forward and 1 reverse.

TARGET DESIGN AND PERFORMANCE SPECIFICATION


 BRAKES:

Front: Disc Rear: Disc Hub assembly of Maruti 800 and calipers of Bajaj Pulsar are used.

 WHEELS AND TYRES: Rim: SS 106 Alloy Wheel

Tyres: ITP Mudlite XL. ( 25 x 12 x 8)

ROLL CAGE DESIGN


Keeping in mind the roll cage structure as the crux of safety for the driver, base of mounting points for the various systems & even ergonomics following design considerations has been laid:
 Weight  Driver safety and compatibility  Strength and stiffness  Impact load test  Driver ergonomics

 Initial roll cage.

 Final roll cage.

2D VIEW OF ROLL CAGE

ANALYSIS OF ROLL CAGE


Equivalent stress in impact test without load. Factor of safety in impact test without load.

Equivalent stress in impact test with load.

 Factor of safety in impact test with load.

ANALYSIS OF A- ARMS
 Arm 1 Von mises stress.  Factor of safety.

 Arm 2 Von mises stress.

 Factor of safety.

MS PROJECT PLAN
The roadmap that led Ingenium to the current platform involving several phases, tasks and implementations that we will like to share.

DESIGN VALIDATION PLAN


 MODEL TESTING:  Impact test  Load test 

Thermal analysis

 VEHICLE DYNAMICS TESTING:  Roll centre  Roll axis  Centre of gravity  Weight transferred on wheels  DRIVER ERGONOMICS:  Comfortable and fully adjustable seat  Proper clearance is given to drivers elbow and knees from

SIM

3D VIEW OF THE VEHICLE

INNOVATIONS
The innovations that are bound to break the stigma of conventional mechanics and make us excel over other.  Transmission: C.V joint is replaced by the splines type of cutting arrangement in transmission axle.

 Fabrication: Aerodynamic shape is introduced which produce natural draft.  Bumper arrangement with nut and bolts.

THE MOTTO |GO GREEN}


Keeping in mind the theme of BAJA 2011 Ingenium has decided to give it a new look.
 Exhaust system: Catalytic converter will

be produced in the muffler only by cutting its net into pieces and flowing the charge.
 We have decided to use TIG Welding

technique thus making manufacturing pollution free.


 Providing natural draught at the air cleaner position which will increase the air pressure

at inlet .

TEAM DETAILS
Captain: Bir Vikram Singh. Research & Study  Bir Vikram Singh  Sanjeev Kr. Singh  Ved Vyas  Shivanshu Mishra Design & Analysis  Gyan Singh Yadav  Sanjeev Kr. Singh  Bir Vikram Singh

INGENIUM

Finance & Sponsorship  Mohd. Abbas Jafri  Prabhat Mishra  Zubi Majeed  Garima Singh.

Marketing & Surveying  Amrish Jangra  Naman Rastogi  Ajay  Abhay

HELP!!!
No task is accomplished without some helping hand lending some much required support.
 The knowledge, guidance and advice provided by our learned faculty members in:
 Automobile sector  Prioritizing design issue  Material selection

We extend our heartiest gratitude to our college & SAE club for their financial, technical & above all complacent support.

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