Automobile and Roll Cage Analysis Essay

Efficycle 2012 is a national take aim technical event, whose objective is to bring out the creative and innovative ideas of objective students. It aims out at creating a fomite which is economical and eco- affable. It also provides us a platform where we are applying the basic engineering skills we had learned. Our task is to design and build a three wheeled fomite, powered by humankind and galvanic means. The design should be commerci completelyy viable as a p terminaluct and should be attractive to the consumers. It can be driven every alternatively or simultaneously by ii mechanical and electrical means.This report details the con lieurations and processes behind our all-terrain vehicle. INTRODUCTION EFFI-CYCLE 2012 is an intercollegiate design tilt for undergraduate students which are aimed at designing and fabricating an energy efficient loanblend human powered three? wheeled electric vehicle. It provides us an probability by setting up a trend of using eco? friendly vehicles in India and come up with some innovative designs. We, GREEN RHINOS, consists of 8 undergraduate 3rd year students from Mechanical and Production department of governing body College of Technology, Tamil Nadu.The team was keen on utilizing the platform to learn, innovate and implement. The spare-time activity paper outlines the design and analysis of the Efficycle 2012 Green Rhinos three wheeled vehicle. send off METHODOLOGY The designing of the vehicle has been carried after studying the various designs of the fore-mentioned trikes, followed by its advantages and disadvantages. All the design issues were studied and an attempt has been made tosolve them in the set out design. Then, the design is subjected to various load conditions at the posts and front with finite section analysis using ANSYS.It was also made sure that the components utilise where quickly available so that without a major modification, we can use it in the manufacturing process. SOFTWARE USED ? Designing and Assembly of the vehicleSolid disciplines-2012 ? wreathe cage in analysis ANSYS TECHNICAL SPECIFICATIONS ?Frame IS1239 MS 1 inch rod ?Welding symbol MIG ?Bending Mechanical type bending ?b paceen Hub pasture brake and Rim brake ?Steering Rack and Pinion ? push 0. 5 HP , 24V PMDC ?Battery 12V, 35 am-hr ?Suspension Spring-arm dangling type ?Drive train Sprockets and chain ?Controller unit PWM unit ?Tyres stave tyre 28 inch diameter?SALIENT FEATURES ?Individual fracture system to the front two wheels. ?Rack and pinion steering system. ?IS1239 MS frame ?Seating position enabling complete view to both drivers. DESIGN system of rules The design section is classified as follows 1. Roll cage design and analysis 2. Drivetrain 3. Steering 4. Suspension 5. Tires 6. Brakes 7. ramble Assembly 8. Aerodynamics ROLL CAGE DESIGN ?Roll hencoop Model Using Solid hammers Roll cage provides three dimensional constancy and base hit to the drivers. The roll cage was designed with utmost care to nullify the weight without compromising the safety of driver.The rules for designing the roll cage were guardedly revived and the design was made in such a sort that each and every member falls within the rules. The square for the rollcage is elect as IS1239 mild-steel after considering various materials in terms of material strength, its availableness and cost. Table showing the list of various available materials MATERIALYIELD STRENGTH (KSI)MODULUS OF snatch (KSI)COST PER METER (RS) AISI 101853. 729700600 AISI 102042. 7297002200 IS 123959. 1229700150 AISI 413065. 1297002500 Of all the available materials, the chosen one is IS 1239 MS holler because of its weight and cost.It weighs around 0. 8 kg per m. Moreover, we had chosen seamless organ pipe manufactured by drawing process, owing to its high strength earlier than the pipe manufactured by rolling process. ?Roll cage analysis using ANSYS Roll cagewas analyzed in the ANSYS software. Cage was analyzed at eac h and every stage and the extra members were provided in order to trim the stress concentration. The roll cage is initially meshed and the nodes are found. utmost design is tested at 2000N in case of front and side impact which is very sufficient to ensure safety. The cage also passed all other tests and had a serious factor of safety.The stress diagrams are effrontery up below. Analysis Results Type of TestForce appliedResult Front impact2000Passed Side impact2000. Passed Roll over2000Passed DRIVETRAIN The drive infection is facilitated with the assistant of chains and sprockets. It is a rear wheel drive vehicle. The transmitting is alternatively or simultaneously driven by motor or manual pedaling. Manual drive type The drive train plays a major key role in every vehicle. In our vehicle, we had utilise the pedaling system found in boats which is simply attached to the frame with the benefactor of bearings on both sides.At the centre of the crank, a sprocket of 48 teeth h ad been fitted which is accountly connected to the left freewheel, (where threading is done manually) of the rear tyre, providing a simple transmission system as found in public cycles. Electrical drive type The simpler the electrical drive is, the simpler the manufacturing process goes on. A 0. 5 hp motor mounted under the right side of the seat is connected to the right freewheel of the rear tyre. It is connected with the help of cycles chains and sprockets. Three reduction has been given to the motor.Under the left seat, intravenous feeding 12 v 35 am-hr batteries has mounted and connected in series to provide power to the motor. Further, a PWM circuit controller mode has been installed to the system, so that a efficient way of control is provided with the least losses. STEERING SYSTEM The main objectives of the steering system are to provide the driver with an accurate, predictable, and original method for navigating a vehicle over rough terrain. A elfin turning radius pro vides the driver with a responsive and controllable ride. The rack and pinion system is a proven method of steering that is direct and reliable.In addition, the steering system does not interfere with the suspension, allowing for optimal duologue of off-road conditions. SUPENSION Suspension is the term given to the system of springs, shock absorbers and linkages that connects a vehicle to its wheels. It is the critical part of an automobile which absorbs shocks and vibrations and gives smooth ride. It also control the wad transmitted by sprung and unsprung mass. Therefore it becomes important to have very good design of suspension system based on non-linear parameters and design variables. As concerned with our three wheeled vehicle, a spring arm suspension system has been used.Spring arm type shock absorbers are so easily available and has good shock absorbing characterisitics. It is connected at one time to the wheels and the frame, providing a jerk-less driving. TYRES Selectin g the tires is one of the most important things as the whole vehicle is in contact with the road on these points. Tyres provide the required bobby pin for the vehicle. We had chosen ordinary three-wheeler tyres and made a modifications over the tyres replacing the exchange hub of the wheel. Front and back tires Diameter28 inches Width2 inches HUB BRAKES Brakes are the frictional devices used to retard the motion of the vehicle.It converts the kinetic energy of the vehicle into heat energy. agree to the EFFICYCLE 2012 rules, all the wheels should be locked when braking is applied. While designing the brake system, simplicity was given prime importance and itwas decided to use hub brakes for the front two tyres that are attached over the hub assembly. Then for the rear wheel, rim brake has been given. SEATING ARRANGEMENT Two seats are arranged tally aside one another so that the complete view of the roads are clearly visible to both the drivers. Seats have been so arranged so tha t it provides a good back support.The seats are good designed and readily available in the market. AERODYNAMICS The compliance of the vehicle so designed is such that the aerodynamic mechanism would work better. Fairings had been added to enrich the look and style of the vehicle. ASSEMBLED VIEW OF OUR DESIGN SUMMARIZED COST compensate S. NOSYSTEMCOST 1ROLL CAGE2800 2STEERING5800 3SUSPENSION1000 4DRIVE TRAIN20000 5WHEELS3500 6BRAKES800 7OTHERS2000 TOTAL37000 PROJECT PLAN Sl noDateDescription 14-8-12 to 8-8-12 Discussion about the efficycle and analysing about the problems on the deceitfulness of our model and making plan and scheduling according to the problem.29-8-12 To 16-8-12 Selection of the material 317-8-12 To 20-8-12Market research 527-8-12 To 4-9-12 Fabrication of Roll cage 65-9-12 To 10-9-12Steering, suspension and wheel work 711-9-12 To 20-9-12 Drive chain work 825-9-12 To 27-9-12 Electronic work on motor, assault and battery and controller unit. CONCLUSION Our cycle ha s been designed so that it meets all the needfully of the consumers. The roll cage has been designed completely for the safety factor and it provides ultimated safety for the riders. Efficient braking system had been installed. Simple steering system.