IIT Roorkee Motorsports Newsletter January 2013
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Transcript of IIT Roorkee Motorsports Newsletter January 2013
aims to encourage the R&D
and manufacturing of hybrid
and electric vehicles in India.
This proves that our
decision to step into the
areas of hybrid vehicles is
jus fiable. Here is a golden
opportunity for us to blend
our passion AUTOMOBILES
with the technology in
demand HYBRIDS and open
a new research fron er in IIT
Roorkee for an advanced
technology trend. A pla orm
would be set up for future
student genera ons at IIT
Roorkee to learn, contribute
and pursue their interest in
hybrids.
Hope you remember our
team and the last project in
which we had made a proto‐
type race car for an interna‐
onal compe on. We are
very thankful for the support
of sponsors, alumni, ins tute
and our families which
helped us in represen ng IIT
Roorkee at Formula SAE Aus‐
tralasia held at Melbourne,
Australia in December 2011.
Since then, months have
passed some of the team
members have graduated,
while others have turned a
year senior and many new
faces have joined the team
to contribute in and enjoy a
share in legacy.
Planning for the second pro‐
ject started in March and
a er careful considera on of
the team mo va on, team
capacity and resources, it
was decided to work on hy‐
brid technology. The team
started working on a hybrid
vehicle with an aim to par c‐
ipate in the interna onal
compe on
Formula Student to be held
at Silverstone Circuit, UK in
July 2013.
Global automobile industry
is inves ng heavily on R&D
in hybrids & electric vehicles
and recently Indian Govern‐
ment launched the Na onal
Mission on Hybrid and Elec‐
tric Mobility 2020 which
Vision
To serve as a breeding ground for
India's finest engineers and innova‐
tors who shall lead the na on's tech‐
nological advancements in the field of
hybrids and automobiles.
Mission
To develop prototype race cars with
innova ve hybrid power‐trains and
represent IIT Roorkee in interna onal
engineering design compe ons FSAE
and Formula Student.
The new logo truly reflects the
team’s quest to promote green
technology in India.
Greetings for New Year 2013 !!!
I N S I D E T H I S
I S S U E :
Project Team 2
Sponsor High-
light : Oxigen
Services (India)
2
Alumni Support 3
Sponsor Support 4
Concept Hy-
brid : Design
Overview
6
Work done so
far 7
Photographs 8
Target for next
month 9
Vehicle Design
Methodology
4
J ANUARY 2013 P R O J E C T U P D A T E
IIT Roorkee Motorsports
P O I N T S O F
I N T E R E S T
Team’s associa on
with Mercedes
Benz R&D India for
Safety Advisor
Page 3..
The Formula Student team of IIT Roorkee
Dedication - Hardwork - Excellence - Achievement
P A G E 2
Project Team This project has evolved as a mul disciplinary
ac vity in the campus with more than 40 stu‐
dents ac vely learning and contribu ng in the
project progress.
Project Management and Sponsorship is looked
a er by Digendra Singh Rathore while Chief Elec‐
trical Engineer is Akshay Sarin and Chief Mechani‐
cal Engineer is Prashant Arora, all from 4th year.
In total, there are 6 members from 4th year, 11
from 3rd year and the remaining are from 2nd
year. Also a pool of about 50 first year students is
being trained so that they may become a part of
the team next year.
The project team is working under the aegis of
Mechanical and Industrial Engineering Department
Electrical Engineering Department
Centre for Transporta on Systems (CTRANS) ‐ IIT Roorkee
Team Faculty Advisors
Dr. R. P. Gakkhar
(Professor, Mechanical Engineering)
Dr. Pramod Agarwal
(Professor and Head, Electrical Engineering)
Dr. Akshay Dvivedi
(Asst. Professor, Mechanical Engineering)
Dr. Manoranjan Parida
(Professor, Center for Transporta on Systems)
Oxigen was born in July 2004, out of a vision of an Indian professional entrepreneur and a South African company, to
reach services to the masses of India, through a Virtual Network for Payments and Service Distribu on. Oxigen started its
opera ons in 2005. The Indian Founder, Mr. Pramod Saxena, has been associated with the Cellular Industry since its in‐
cep on in 1994 in India. He has rich & diverse experience of pioneering grass root businesses, which includes the birth
Telecom in India, when he built the first ever Telecom network with Essar Group.
Oxigen's overseas partner is Blue Label Telecom, South Africa, who is a market leader in distribu on of physical and virtu‐
al prepaid air me. They bring to the partnership e and market tested product technology, with a successful track record
in compe ve markets in South Africa and several other countries. In 2006, Ci bank Venture Capital Interna onal, made
investments in the company, to help Oxigen build its footprint. This was followed by Microso Corpora on, USA, who in
2008, built a strategic business & equity alliance with Oxigen. Oxigen expects to expand its business rapidly in the virtual
payments and distribu on space using Point Of Sale Terminals, Web, IVR & Mobile based technologies.
Pioneering the PREPAID BUSINESS in the country & Expanding it's Service por olio to lead the pack
Its state‐of‐the‐art proprietary back‐end technology put Oxigen in an enviable posi on to rapidly expand and offer ser‐
vices apart from just mobile recharge, with which it started its opera ons. This has helped Oxigen to blossom into a single,
powerful pla orm for all payment services online as well as on the mobile phone, including bill and subscrip on pay‐
ments, booking airline/rail/bus/movie ckets, buying Value ‐Added‐Services, games, Online shopping, Making Dona ons
and much more, on behalf of many companies.
Sponsor Introduction
I I T R O O R K E E M O T O R S P O R T S
Electrical Safety Advisor from Mercedes Benz R&D India
Safety Advisor (ESA) who would ad‐
vise the team on safety issues and, as
per the compe on rules, accompa‐
ny the team to the compe on in UK.
Mr. Siva Prasad Gumaddi has accept‐
ed to be our ESA. He is a 2001 gradu‐
ate from BITS Pilani and has been
working with Mercedes Benz R&D
India and is currently the technical
lead for the ba ery team.
In November 2012, the team got an
opportunity to meet and discuss the
project with Mr. Anshuman Awasthi
(Deputy Manager, Mercedes Benz R&D
India) during his visit to the campus. He
visited the workshop and discussed
about the project and our team. This
interac on resulted into a frui ul out‐
come for the team and Mr. Awasthi
happily accepted to guide us on tech‐
nical issues. Also, we made a request
to MBRDI to provide us the Electrical
Alumni Support P A G E 3
The previous project was a success
story only because of the alumni sup‐
port. And this year too, alumni help
is very crucial for the project success.
Dr. S. S. Jain, Professor, Center for
Transporta on systems IIT Roorkee
has contributed Rs. 50,000 in the
funding.
Mr. Pramod Saxena (1975 Chemi‐
cal, IIT Roorkee), Chairman of Oxy‐
gen Services (India) Pvt. Ltd, has
believed in us since incep on and
was the first project sponsor last
year. This year too, he has contrib‐
uted Rs. 1.25 lakh at a very crucial
moment when the team needed
money for registra on. We appre‐
ciate his mely contribu on and his
commitment to the Alma‐mater.
Mr. Sanjay Gadhalay (1986 Electri‐
cal, IIT Delhi) connected the team
to Mr. Sanjay Saraswat (1988 Me‐
chanical, IIT Delhi) who is a senior
execu ve in Bajaj Auto Ltd. and his
efforts facilitated the sponsorship
of the engine for the vehicle. We
are highly thankful to these gentle‐
men !!!
Mr. Ataur Rehman (1992,
Mechanical, IIT Roorkee) is Addi‐
onal Commissioner, Customs
and Excise at Mumbai. In Novem‐
ber, we imported the controller
from China but faced problems in
its custom clearance due to weak
paperwork from the dealer. At
that me, Mr. Rehman spoke to
the custom officials in Delhi and
only a er his recommenda on,
we could get the controller with‐
out fine,
their alumni who take sa sfac on
and pride in the achievement of
their Alma‐mater.
You can do an online account trans‐
fer to
Account Name : SAE IIT Roorkee
Account # : 4044000100022924
Bank : State Bank of India, IIT Roorkee
NEFT/RTGS Code : SBIN0001069
SWIFT Code : SBININBB559
Or you can avail 80(G)
Income Tax benefits by do‐
na ng the amount through
cheque in favor of
REGISTRAR, IIT Roorkee. The
cheque may be sent to the fol‐
lowing address:
Dean of Alumni Affairs
IIT Roorkee, Main Building
Roorkee – 247667
District – Haridwar
U arakhand
Contact‐ +91‐1332‐285240
The project budget is Rs. 33
lakhs and neither the Ins tute
support nor our pocket money
is sufficient to meet all the
expenses. Therefore, we re‐
quest you to contribute in the
project funding and support us
in making India’s own first‐of‐
its‐kind Series Plug‐in Hybrid
Electric Vehicle (PHEV) that
will compete against more
than 100 interna onal teams.
All the successful teams across
the globe are supported by
Dear Alumni... All the donations enjoy section 80(G) Income Tax benefits.
We hear ly welcome Mr. Siva Prasad Gumaddi from Mercedes Benz R&D India as the Electrical Safety Advisor of our tem.
P A G E 4
Sponsor Support
Xilinx Corpora on
I I T R O O R K E E M O T O R S P O R T S
Vehicle Design Methodology Target Vehicle Specifica ons (Speed, Accelera on, Weight, Dimensions) The prototype vehicle would be developed such that it is compe ve against other inter‐na onal prototypes developed in the same vehicle category. For target performance of vehicle, the test track is Silverstone Formula‐1 circuit, UK. The track data (map, average speed, accelera on) and the target vehicle specifica ons of similar prototypes built in past would become the basis of vehicle specifica ons. While selec ng the target vehicle specifi‐ca ons, other important parameters that should be considered are safety, sustainability, reliability, engineering design, cost, manufacturability, solo performance and high perfor‐mance track endurance.
Bajaj Auto Limited
Engine is the important part of our hybrid powertrain. We needed a small sized engine
which is reliable and fuel efficient. A er extensive market research, we finalized the 125 CC
Bajaj Discover Engine. We made a request to the company and it happily sponsored the
engine. We are thankful to Bajaj Auto Ltd. for this support.
The vehicle controller is being implemented on FPGA pla orm which requires FPGA boards.
Since these boards are costly and not easily available in India, we made a sponsorship re‐
quest to the company and to our wonder; we got two fresh boards sent to us from Xilinx
USA.
ANSYS India
The project requires extensive simula on and for structural analysis we could not find a
be er so ware than ANSYS workbench. Since, it is costly we explained the project to the
company and made a request for a sponsored so ware license exclusively for the project. The
company understood how important it is to support the young engineers and welcomed our
request.
P A G E 5
Track descrip on for Endurance Event:
• Straights: No longer than 77.0 m (252.6 feet) with hairpins at both ends. Passing zones at several loca ons.
• Constant Turns: 30.0 m (98.4 feet) to 54.0 m (177.2 feet) diameter.
Hairpin Turns: Minimum of 9.0 m (29.5 feet) outside diameter (of the turn).
• Slaloms: Cones in a straight line with 9.0 m (29.5 feet) to 15.0 m (49.2 feet) spacing.
• Average speed should be 48 km/hr (29.8 mph) to 57 km/hr (35.4 mph) with top speeds of approximately 105 km/hr (65.2 mph).
Silverstone is the premier motorsport des na on in the UK and one of the most historic circuits in
the world. It is host to Formula One Bri sh Grand Prix, Le Mans Series, Superbike World Champion‐
ship, Formula Student and various other interna onal events.
The velocity profile for the event at Silverstone track
The competition venue : Silverstone UK
P A G E 6
MOTOR:
4 pole motor with output Power of 12 KW
Con nuous, 30 KW Peak, 5000 rpm
Con nuous current of 125 Amps AC.
Torque constant of 0.15 N‐m per Amp (peak 90 Nm).
CONTROLLER:
Synchronous rec fica on, ultra low drop and fast PWM to achieve very high efficiency.
Support three modes of regenera ve braking: brake switch, release thro le, 0‐5K or 0‐5V analog signal
Concept Hybrid
I I T R O O R K E E M O T O R S P O R T S
GENERATOR:
Brush type PMDC motor.
Highly efficient: 300A peak 125A con nuous, air cooled.
CHASSIS:
AISI 1020 mild steel used to provide necessary strength.
ENGINE:
Type: DTS‐i, 4‐stroke, Natural air cooled
Displacement: 124.6 cc
Max Power: 11 PS@ 8000rpm
Max Torque: 10.8N‐m@5500rpm
KEIZER WHEELS:
Aluminium customized wheels light in weight and13" diameter, 6" width
DIFFERENTIAL:
Quaife limited slip differen al is used. It is safe, progressive and seamless in opera on and smoothly biases the engine's torque.
BATTERY:
72 V, 48 Ah Li‐ion rechargeable ba ery.
SHOCKS:
Quarter midget (63.5 mm stroke).
Quarter midget spring= 33.3 N/mm.
P A G E 7
Work Done So Far... Complete Suspension and steering design including calcula on of
parameters, kinema c and dynamic simula ons and CAD models of push‐pull rods, rockers, selec on of dampers, springs and tyres
Complete Roll cage design including CAD modelling and stress analysis.
Complete simula on for measuring lap me of car‐run, CO2
emissions and efficiency of car on the track
Engine ‐ generator and motor ‐ differen al coupling design.
Intake ‐ exhaust design.
Complete Regenera ve braking system including brake calcula‐ons, brake‐pedal design, sensor moun ng, selec on of brake
callipers, master cylinder, brake lines and its topology.
Complete wheel assembly design including upright and hub CAD and stress simula ons, selec on of wheels, nuts, bearings and rod ends.
Heat calcula ons for motor, ba ery, generator, engine, control‐ler and auxiliary components
Complete design of High Voltage and Low Voltage network including selec on of motor, generator, ba ery, BMS, IGBT, con‐tactors, fuses, wires, sensors, etc.
FPGA based Vehicle Control system design complete includ‐ing FPGA coding, simula on of parallel processing and PCB design.
Design of servo controlled engine ‐ generator voltage stabi‐lisa on including selec on of servo motor, sensors, signal condi oners and CAD modelling.
Power flow simula ons for the power‐train network.
Procurement of engine, motor, generator, controller, sensors for regenera ve braking, LV wires, contactors Mo‐tor Controller integra on and tes ng at different controller modes.
Generator tes ng at no load for verifica on of characteris c curves.
Fabrica on of PCB and pre‐charge, discharge circuits.
Engine test moun ng and controlled electronic on‐off tes ng.
Steel tube cu ng and profiling for roll cage and A‐arms.
Jig fabricated and mock roll cage made from PVC pipes.
P A G E 8
I I T R O O R K E E M O T O R S P O R T S
Target for next month Payment for team registra on.
Welding of roll cage and A‐arms.
Procurement of Ba ery, shockers, wheels, brake components, HV – LV wiring.
Integra on of engine‐generator, motor and ba ery.
CNC machining of uprights, hubs, rockers.
CFD flow analysis, selec on of fans and design of cooling ducts.
Fabrica on of engine thro le.
Engine generator coupling
Intake exhaust fabrica on
Sponsorship Opportunities
P A G E 9
Being a student team, we rely heavily upon sponsorships. You can support us by providing monetary or in‐kind sponsorship in the form of products and services. And in return we offer a rac ve sponsorship benefits. Following slots are open for associa on :
Gold Sponsorship
Silver Sponsorship
Digendra Singh Rathore
Team Leader
+91‐8791194290
Saurabh Dudani
Marke ng Execu ve
+91‐7579087524
Virender Pratap Singh
Marke ng Execu ve
+91‐8266800562
singh.vp93 @gmail.com
Dr. Pramod Agarwal
Head Of Department
Electrical engineering
Dr. Akshay Dvivedi
Assistant Professor
Mechanical Engineering
IIT Roorkee Motorsports
Mechanical Department
Industrial Block
IIT Roorkee
Roorkee (247667) ‐ U arakhand
Contact us