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TEAM ACRO STREAKTeam ID : NKRC15-065

ACROPOLIS INSTITUTE OF TECHNOLOGY AND RESEARCH

Technical & Performance SpecificationSPECIFICATIONS

Overall Width 1110

Overall Length 1530

Overall Height 927

Front Track Width 988.06

Rear Track Width 1060

Wheel Base 1099.8

Ground Clearance 50.8

Tube Dimension 25.4

Roll cage Mass 13

Overall PerformanceMaximum Speed 80Stopping Distance(40kmph)

4.91

Wheels & Tyres Front 10*4.5*5inch

Rear 11*7.5*5inch

Weight

Kerb Weight 72kg

Ratio FAW to RAW laden 0.67

Overall Weight 132kg

Front view Side view

Top view Isometric view

S.NO PARAMETERS OUR DESIGN RULEBOOK

1. Tube outer diameter 25.4 mm 25.4mm

2. Wheelbase 1099.82 mm 1066.8-1422.4 mm

3. Ground clearance 50.8 mm Min .25.4 mm

4. Track width 988.06 Min .75%

5. Distance of seat from firewall. 76.2 mm Min .76.2 mm

6. Kill switch 3 nos. Min. 2 nos.

7. Kerb weight 72kg Min.60kg

8. Max. capacity of engine 125cc 125cc

9. Distance of firewall from engine 76.2mm Min 76.2mm

10. Max.speed of vehicle 80 KMPH 80 KMPH

11. Driver’s suit SFI Rated SFI Rated / FIA standard

12. Driver’s helmet Snell’s Rated Snell/SFU/FIA Rated

13. Driver’s shoes SFI Rated SFI/FIA Rated

Design methodology Design started considering rulebook and by drawing conceptual sketches

An iterative optimization processes used for attaining design objectives

Technique used – triangulation method is employed

Modeling software :- CREO parametric 2.0

Roll Cage Design & Process‐ergonomics

Case Total Applied Force(N)

Max. Stress(MPa)

FOS Max. Deformation(mm)

Meshing Size

Front

12949.2

356.62 1.22 4.3

10Side 12949.

2353.25 1.23 .98

Rear 12949.2

378.5 1.15 5

Front impact analysisRear impact analysis

Side impact analysis

Material:- chromoly 4130

ERGONOMICS

Spacious Cockpit

Sufficient Legroom

Integration of 95 Percentile male in comfortable position

Unhindered Line of vision

Sufficient Reach Envelope

SAFETY

Fire Extinguisher within reach

Complete Driver’s Kit

Kill switch

Foam Padding on bumpers

SFI rated driver’s suit

Driver’s seat belt

ERGONOMICS AND SAFETY

Steering and Wheel GeometrySpecifications Dimensions

Steering Ratio 1:1

Length of Track Rod 440mm

Track Width 988.06

Wheel Base 1099.82mm

Steering wheel dia. 260mm

Steering wheel torque 2.6Nm

Steering Inclination 50

Inner turning angle(Ɵ)

Outer turning angle(ø)

Ackermann % Turning radius

Inner (mm) Outer(mm)

30° 22.69 88.74% 2066.29 2984.5

35° 25.59 87.4% 1784.13 2679.65

40° 28.37 86.2% 1577.67 2447.9

44° 30.53 85.54% 1449.9 2298.39

THE STEERING MECHANISM WHCH WE ARE USING IS FOUR BAR MECHANISM.

BRAKE SYSYTEM

Short Stopping Distance Effective Braking in light Vehicles Good Performance in Wet

Conditions

CONSIDERATIONOUTER DIA. OF DISC

DIMENSIONS

TYRE RADIUS 0.254 m

TMC PISTON DIA.

19.05 mm

CALIPER PISTON DIA.

20 mm

LEVERAGE 6:1

DRIVER EFFORT

225 N

CALIPER FORCE

2976.03 N

FRICTIONAL FORCE (disc and pad)

4166.45 N

BRAKING TORQUE

749.96 Nm

DECELARATION 11.40 m/s^2

velocity 40 KM/H 50 KM/H 60 KM/H 70 KM/H 80 KM/H

Stopping Distance (m)

4.91 7.67 11.07 15.04 19.64

Stopping Time(Sec)

1.61 2.20 2.42 2.83 3.23

HEIGHT OF CENTRE OF GRAVITY Dimensions

WHEEL BASE 1099.82 mm

DYNAMIC LOAD ON FRONT WHEELS 870.26 N

DYNAMIC LOAD ON REAR WHEELS 424.20 N

Power train

Specifications Dimensions/Values

Vehicle Weight 132 KgTyre size RAD 13.97cmRolling Radius 13.4112 cmFrontal area for drag(Firewall Area)

2.78x10⁵mm²

Transmission Line 1 down 3 upMaximum Velocity 80.088

Gear Overall Gear Ratio

Maximum Speed

(Max. Speed) 3.0001.6841.2080.875

23.33641.66558.33180.088

Engine Specifications

• Model :Bajaj DTSS-i• Power : 10 Hp• Volume : 125CC• Strokes : 4• Torque : 10.85 Nm @ 5000 rpm• Compression Ratio : 9.5 : 1

Milling Machine

Surface Grinder

Shaper

Lathe

MIG Welding

Electric Arc Welding

Pipe Bending machine

Universal Testing Machine

College Workshop FacilitiesCOMPONENT PREOCESS AND

MACHINES INVOLVED

Chassis Cutting, cutter, Pipe bender,Bending, Welding,

Rear axle Lathe machine ,turning., threading

Wheel hub Lathe machine , drilling, step turning, reaming.

Disc hub Lathe machine, Turning

Sprocket hub Lathe machine, Turning

Mounting bracket Cutting, grinding

Steering linkage Lathe machine, Turning

TEAM STRUCTURE

11

Faculty Advisor

• Mr. Aatish Rajore

CAPTAIN

• Suyash Gupta

VICE CAPTAIN

• Ashwini Motiwale

11

DESIGN

Suyash

Abhishek M

Abhishek Y

STEERING

Shashwat

Nitin

Sarthak

Shreyas

BRAKING

Ashwini

Nishchay

Shubham D

Pratyaksh

ENGINE AND TRANSMISSION

Yash

Tanmay

Shubham J

Tushar

ERGONOMICS AND SAFETY

Suryansh

Nihar

Prateek

Sagar

Amit

Validation Plan DVP

Text ID Scope Test Validation Method Team Allocation

Vt 01 Prototyping PVC Pipe Structure for manufacturability Check interference Manufacturing team

Vt 02 Inspection

1. Dimension Inspection (Multistage) 1. Tapes, Flex

Inspection team2. Quality of welded joints 2. Visual Inspection

3. Overall Dimension 3. Go - No Go gauges

Vt 03 Weight Distribution Test for front and rear weight distribution Weighting machine Design Team

Vt 04 Electricals Possibility of planned innovation Rough prototype testing for shorter ranges Electrical team

Vt 05 Leakages Elimination of any leakages in the system before finals Testing on incline Inspection team

Vt 06 Fasteners Validating tight connection Torque wrench Inspection team

Vt 07 Stability Straight line stability test Test rig and turn tables Design Team

DFMEA

Sr. No. Item Potential

Failure modePotential effect of

failureSevert

yPotential cause/

MechanismOccurre

nceCurrent design

controlDetection RAN Recommonded

actionResponsibility

1 Steering

Improper turning of front

and rear wheels,

bending of track rod

Difficult handling 7Accident

possibility ,nil manoeuvrability

6Proper Bearing

support is provided

3 126 Replacement/ machining

Assembly team

2 Brakes Less efficient braking Difficulty in stopping 8 Leakage in break

fluid line 4Four

independent brake lines are

provided4 128

Remedies in leakages and performing

bleeding again

Assembly team

3 Transmission

Vehicle speed exceeding 80

KmphExceeding rule book

limits 4Vehicle weight

lighter than design load

5Designed to get speed under 60

Kmph4 80

Reduce engine max speed by

governor

Power train team

4 Engine Improper performance

Low eficiency, reduced torque 7 Improper

maintenance 6 - 4 168 Send engine to repair

Power train team

5 Electricals Short circuit Fire in vehicle 7 Uncovered wire

harness 5Use of

insulated wirings

2 70Providing

insulations, pressing kill

switches

Electrical team

6 Fuel Leakage Fire in vehicle 7 Banking of vehicle 6 Spill prevention 5 210

Blocking leakage immediately

press kill switch

Driver /Power train team

Thank - You