TEAM ROADRUNNER

National Institute of Technology Rourkela

When given some intelligence, a cycle can be more efficient and safe.

EXTRACTS FROM RULE BOOK

Design and fabricate an energy efficient Hybrid human powered threewheeled electric vehicle. The vehicl e must be aerodynamic, highly engineered and ergonomically designed. The design should be commerci ally viable as a product and should be attractive to the consumers because of its visual appearance, performance, reliability and ease of operation. The vehicle must have three wheels that should not be in a straight line. The vehicle must be capable of ng two riders, of at least of 190.3 cm (63) height and weighing 115 kg. Vehicles participating in the completion can have a maximum dimension of 90 inch x 48 inch (L x B). To the dimension, teams may be asked to drive the vehicle through a gate of defined width. carryi check

Team ROADRUNNER-National Institute of Technology, Rourkela

Vehicles must be driven by human power and electric powered (Use of PMDC Motor Permanent Magn et DC motor is must and max power of motor should not be more than 400 watts). Teams can use a battery so urce of d12V48V and up to 35Amhr. Teams are allowed to use only mechanical KERS systems in their vehicles. KERS is allowed to be used only duri ng the race and teams are not allowed to keep the system in a charged state during start. All vehicles are required to have brakes on all wheels. Teams can use both hydraulic and non hydraulic s that satisfy the minimum defined criteria of locking of brakes in a static condition. brake

Each vehicle must be equipped with rollover protection system to keep riders safe in case of accidents irres pective of whether the vehicle is open or having a roof. No vehicle may discard any part after the vehicle is in motion. Vehicles participating in the main event should be capable of carrying a load of 50 kg. Vehicles need to have a proper mounting system with a clamp to carry a sand bag of dimension 20 inches x 12 inches with thickness of 6 inches. The load should be properly clamped during running condition and hung load would not be allowed. The Overall cost of the vehicle shall not exceed by INR 20,000. Penalty in the form of points will be imposed if the amount of the vehicle increases by INR 20,000.

Efficycle Events

Presentation

Sprint

Maneuverability

Circuit

TECHNICAL SPECIFICATIONS
Kerb weight: : 64 kg (approx without riders & load) Total weight: 64+70+70+50 = 254kg Bounding box volume: 208.6 cm x 100 cm x 102.4 cm Wheel base : 144.6 cm, Track width: : 98 cm Front suspension Double super shox suspension Length :42cm Rear suspension Closed coil helical torsion beam spring Spring travel: 2 inches Spring Rate : 64.8 N/mm Length:18.5cm Team ROADRUNNER-National Institute of Technology, Rourkela

Material for the frame of the vehicle : Aluminum 6061 T6 tempered Material used for axle :structural steel 45 grade

Fork length:45cm Offset:4cm Head angle:70 degree Mechanical trail:6.45cm Wheel static chamber: 2 degree (negative on both rear wheels) Handle to seat distance:74cm

Mass:4.175kg Thickness: 3.4cm

Fixed caliper disc brakes Rotor diameter:160mm Force by caliper:150N(approx)

Mass:1.5kg Diameter: 1.5 inches

Wheel diameter:28 Wheel width:1.5

GEAR NUMBER (REAR)

DIAMETER(C M)

NO.OF TEETH

CHAIN SPECIFICATION

1st person 85.5cm

172

2nd person 33.5cm

87

1st 2nd 3rd 4th 5th

10.5 9.5 8.5 7.5 6.5

28 24 21 18 15

CENTER DISTANCE
NO.OF LINKS=(K=(T1+T2)/(2)+(2* x)/(p)+(T2T1)2/(2*3.14)*(p)/x) LENGTH OF CHAIN

213.33cm

110.5cm

6th

5.5

12

WEIGHT OF CHAIN

1.3671kg

0.69kg

TARGET PERFORMANCE SPEC

Top Speed : 52.7 = 53 kmph
Team ROADRUNNER-National Institute of Technology, Rourkela

Gear No. 1st gear 2nd gear

Speed (m/s) 6.27 m/s 7.32 m/s

Speed (kmph) 22.57 km/hr 26.35 km/hr

3rd gear
4th gear 5th gear 6th gear

8.36 m/s
9.76 m/s 11.71 m/s 14.64 m/s

30.09 km/hr
35.14 km/hr 42.16 km/hr 52.70 km/hr

Average speed supposed to be attained throughout : 35 kmph

53 kmph 0 braking : 18.2 m

52.7 kmph = 14.64 m/s According to equations of motion v2 = u2 + 2as where v = 14.64 m/s u=0 a = g = 0.6 * 9.81 m/s2 = 5.89 m/s2 Braking Distance :

s = v2 / 2a
= 18.19 m

Team ROADRUNNER-National Institute of Technology, Rourkela

DESIGN OF VEHICLE (FULL DESIGN)

Team ROADRUNNER-National Institute of Technology, Rourkela

ELECTRONIC CIRCUIT FLOWCHART

Team ROADRUNNER-National Institute of Technology, Rourkela

DESCRIPTION OF DRIVE TRAIN ALONG WITH PICT.

UNIQUE SELLING PROPOSITION (USP)

Team ROADRUNNER-National Institute of Technology, Rourkela

Get your money back in 3 years and start earning afterwards !!

Most of the people across the world spend a lot of money in travelling from their homes to their workplace. They do this by scooters, motorcycles, and cars(mostly in foreign countries). Not only does this result in a lot of wastage of money but also results in air pollution and today it is in fact the major cause of air pollution due to automobiles. This also results in tremendous dependence on petroleumbased resources and hence is the reason for non-preventable rise in the prices of both petrol and diesel. When people drive cars to drive to their workplaces, they are surely wasting a lot of energy in driving those huge-sized vehicles to carry them to their destination. This vehicle can solve this problem to a great extent. First of all, it is a light weight vehicle weighing only XXXX kg. This is because it is made of aluminum alloy which is very light. Again, it can be driven mechanically, or if you are tired, then it can be driven electrically as well, without disturbing you with any noise or polluting the environment. No need to waste money in buying cycles and a vehicle. This vehicle itself acts as both a two-seated tricycle(more stable than bicycle) and as a two-seated vehicle. So, you can now not only save energy consumption but also your money. For students, this vehicle is great since this vehicle has a proper speed control and cannot be driven faster that XXXX km/hr which enhances their safety. They will be able to carry their bags simply by keeping it in the rear carrier. This vehicle can also act as an inspiration to them to make efficient and environment-friendly vehicles in future.

*Assuming

that you spend Rs. 417 per month in nearby travelling, and the vehicle costs Rs. 15,000.

PROJECT PLAN & PROCESS FLOW DIAGRAM

We ek 1 Activity ROUND PIPE PROCURED AND CUTTING PRESSING OF ROUND PIPES INTO OVAL PIPES Got news about event Efficycle. Download of Rulebook and other materials provided by the event organizers. Consulting with the SAE Collegiate Club Faculty Advisor. Permission. Team selection and division. Registration for the Efficycle event. Net search on various existing 3-wheeled vehicles to get a rough idea. Referring Theory and search for various Automobile books. WEILDING ON FIXTURES(MAIN FRAME) WEILDING OF REAR FRAME ASSEMBLY OF MAIN AND REAR FRAME WITH SUSPENSION FRONT FORK ASSEMBLY WITH SUSPENSION 2 Planning the general design. Detail hand drawing of the design. Finalization of frame design. Decision on various parts and equipments to be attached to the vehicle. List out all necessary devices and hardware materials to be used. Planning, how well the electrical and electronic parts can be integrated with the vehicle and in which way their use will make the vehicle better.

Process flow diagram

GEAR AND SPROCKET ASSEMBLY ON MAIN FRAME

CHAIN AND PEDAL FITTING REAR AXEL FITTING WITH KERS,GEARS , AND CLUTCH SYSTEM BRAKE FITTING ALONG WITH FITTING OF BRAKE CABLES WITH BRAKE LEVERS MUD GUARD, CHAIN FITTING,AND COVERING OF OTHER MACHINE PARTS ERGONOMICS CHECKING CONNECTING ELECTRONICS

Collection of details regarding the use of finalized materials. Assigning measurements of various parts of the cycle according to human ergonomic point of view. Enquiry of availability of materials in the local market and in the Internet. Estimation of total cost of fabrication. Designing the parts to make the vehicle simple and have increased load bearing capacity. Performing analysis of each part separately. (Using 3DS CATIA)

Assembly of all parts to form the entire vehicle. Detail ANSYS analysis of the entire frame under various loaded conditions, both static and dynamic. Finalizing on the design of drive train. Design of drive train. Planning for motor fitting and all electrical switches and controls. Planning and designing the electronic circuit design and determining the parts that are cheap and can be used. Validation of entire vehicle design.

WHEEL ASSEMBLY CARRIER ASSEMBLY ACCORDING TO THE REQUIREMENT HANDLE AND SEAT ASSEMBLY WHEEL ,SEAT ,BRAKE,BRAKE CABLE ,GEAR ALLIGNMENT DRIVE TEST, BRAKE TEST,AND ELECTRONIC TEST PAINT, OILING,GREASING AND FINAL TOUCH UP

Design Report preparation. Cost Report preparation. Presentation preparation. Consulting Faculty Advisor and data collection regarding the various workshop facilities available for the vehicle fabrication if selected. Final Report submission with all details, and analysis.

COMPLETE PRODUCT.

VALIDATION PLAN
TEST NAME TEST METHOD TEST COMPONEN TS
Space frame with rear swing arm and rear suspension
Total chain drive and derailleurs gear system Rear axle with gear arrangement

TEST REQUIREMENT

ACCEPTANCE CRITERIA

ASSIGNED TO
Chitta Ranjan Meher

Team ROADRUNNER-National Institute of Technology, Rourkela

Strength, FEA via stiffness and ANSYS deflection analysis

Drive train analysis Fair calculation using machine design formulas Fair calculation using machine design formulas Fair calculation using machine design formulas Approximation and calculation using device characteristics

Confirms stress bearing capacity Elastic moduli should & ensures tolerance of not show much straightness & orientation variation.

Confirm maximum power transmission from the pedals of both the drivers

Minimum energy loss during transmission and minimum slacking of chain. Torsional rigidity, bending moment should not show much variation Capability of storing the kinetic energy & delivering it when required

Satya Prakash Pradhan & Chitta Ranjan Meher Satya Prakash Pradhan & Chitta Ranjan Meher Satya Prakash Pradhan

Rear axle analysis

Confirm the ability of the axle to bear the total weight of the vehicle, torque and moment created by the chain drive. Confirm the ability of the flywheel to store kinetic energy &to minimize fluctuation is energy Confirm usability of electronic circuit with 36V high voltage and 400W high power motor

Fly wheel design analysis

Fly wheel

Electronic Circuit design analysis

High power MOSFETs, 555 Timer, H-bridge motor controllers & Atmega32 ADC output

Each device has a Subhajit Sahu sufficient voltage and current margin in working condition from breakdown.

INNOVATIONS PROPOSED
AUTO-MOTOR MODE WHEN DRIVING THE VEHICLE IN ELECTRICAL MODE
Team ROADRUNNER-National Institute of Technology, Rourkela

The new feature of this vehicle is its Auto-Mode operation of motor. In this mode of operation the microcontroller (Atmega32) automatically switches the motor between motor mode and generator mode automatically as per the requirement. This is achieved with the help of difference de-amplifier, a comparator, a microcontroller, and high power MOSFETs. What the circuit essentially does is measure the back-emf generated by motor to determine at what speed the vehicle is running. It then compares this speed with the speed required as set by the accelerator. If, the speed is more than needed (or set), then the microcontroller automatically switches form motor mode to generator mode by the help of high power MOSFETs. In this generator mode the battery charge is replenished. Thus, energy is restored during down hills, slopes, slowing down the vehicle or braking. PARALLEL DERAILLEURS DESCRIPTION Two rear axle derailleur were connected in the same shaft. Front rider drives one derailleur via a flip flop and the back rider drives the another derailleur. But both the derailleur were controlled by the front rider through a parallel connection of the derailleurs cable. due to common, parallel control and single control of both the derailleur there is no probability of mismatch in power transmission. INDIVIDUAL PEDALLING Special ball bearing and flip flop arrangement in the rear pedal, gives the freedom of individual pedaling to the passenger. Individual pedaling means ,if the passenger dont want to pedal he or she can rest without rotating the pedal along with the driver which is a common problem in most of the two seated cycles, which makes it very uncomfortable and tiring for the passenger. So such an arrangement is proposed so that passenger and driver both gets total comfort while driving. It also includes multiple gears and gearbox to increase the load carrying capacity of the vehicle even when driven by a small boy. It also includes an electrical accelerator to control the speed of vehicle when the motor is switched on. There are many other switches for various purposes and this also includes mechanical disc brakes and electrical brakes for safety. Other features include shock absorbers, topple protection bar and comfortable seats. Hence, these features increase the efficiency of the vehicle and thus can be called an EFFI-CYCLE.

WHY GO GREEN

WITH

ROADRUNNER
Team ROADRUNNER-National Institute of Technology, Rourkela

This is a mechanically and electrically driven vehicle. It does not pollute the environment since it does not use any petroleum-based motor, but uses a simple DC motor. This vehicle also has higher efficiency when compared with other electrical bikes available in the market. This is because of its new auto-motor mode which also enhances battery life of the battery being used. In every day life, people normally travel short distances between their home and their workplace. For this purpose, they use scooters, motorcycles, and cars. This results in a lot wastage of energy, particularly is they use cars. Instead, if they start to travel with this vehicle, the pollution level in the country can greatly reduce for sure. (In fact about 80% of pollution caused by automobiles is due to people using their vehicles for short distance travel) The vehicle can also be set in generator mode in which one or two persons can ride the vehicle and then energy is produced by the motor as it now acts as a generator. The energy produced is stored in the battery. Hence the battery can be recharged without having to plug it into a socket and thus it allows the people to be more environmentally friendly. The frame of the vehicle is made of aluminum alloy which can be recycled. Fly wheel or KERS, used helps in restoring energy fluctuation and in storing energy which when used properly can make the vehicle more efficient. The rear rack/ carrier enhances utility and are perfect for heavier loads. As it is above the rear axle, it proves to be excellent an carrier. This vehicle is expected to be used by students, teachers, workers, auto-rickshaw drivers, people who dont earn much money, environmentally-aware people, or those who only need to travel small distances (i.e., from their home to their workplace). This cycle is itself an efficient cycle because it requires lesser energy for a ride and also for luggage and good transport because of the gear arrangements . This vehicle has a sufficiently large rear rack where people can carry some luggage in it. Hence this vehicle is also expected to be used by local business men to transport their goods at a cheaper rate and earn greater profit. Industrial workers can use it for their transportation purposes. This vehicle can also be a part of campaigning , in public awareness programs and also in the zoos by the care takers. In general, anywhere there is a need of short distance travel, this vehicle can be the easiest and the most environmentally friendly way of doing it.

POTENTIAL MARKETS AND CUSTOMERS

TEAM DETAILS
No. Name Designation Branch Responsibility Role

Team ROADRUNNER-National Institute of Technology, Rourkela

Name Faculty Advisor

Associate Professor

Mechanical Engineering

Guidance and Help Design and Analysis Marketing Design and Analysis Fabrication Marketing Electrical and Electronics Fabrication Aerodynamics

Faculty Advisor

Satya Prakash Pradhan

B.Tech. 3rd Year

Mechanical Engineering

Captain & Driver

Chitta Ranjan Meher Subhajit Sahu

B.Tech. 3rd Year B.Tech. 1st Year

Mechanical Engineering Electronics & Communication Engineering Mechanical Engineering Mechanical Engineering Mechanical Engineering

Captain & Driver Team Member

D Jaswant Kumar Protsahan Pradhan Rajat Kumar Nayak

B.Tech. 1st Year B.Tech. 1st Year B.Tech. 1st Year

Team Member Team Member Team Member

Shaikh Tarik Mobin Saurav Kumar Kachriya

B.Tech. 1st Year B.Tech. 1st Year

Mechanical Engineering Mining Engineering

Driver Team Member