Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved.

Engine & Powertrain

BAJA SAEINDIA 2014
21st - 22nd June 2013 Faculty Leadership Development Workshop Priyadarshini College of Engineering, Nagpur

Anshuman Vagesh Mahindra Research Valley, Chennai

Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved.

ENGINE
BAJA SAEINDIA 2014

Specifications
Briggs & Stratton INTEK OHV 305 Engine
ENGINE MODEL NO. TYPE DISPLACEMENT COMPRESSION RATIO POWER TORQUE FLY-UP SPEED (NO LOAD) IDLE SPEED (NO LOAD) BORE STROKE FUEL COOLING STRATEGY : : : : : : : : : : : : 20S232-0036-E1 202400 305 cc 8.0 : 1 10 hp @ 3250 rpm 19.66Nm @ 2800 rpm 3800 +/- 100 rpm 1750 +/- 100 rpm 79.23 mm 61.67 mm Gasoline AIR COOLED
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Rules pertaining Engine

OVERALL

1. Colleges/ Institutions are eligible to receive a new Briggs &

Stratton engine on their THIRD participation only.

2. Only original equipment Briggs and Stratton replacement parts

may be used.

3. Flywheel Rotation No flywheel rotation to advance or retard

timing is permissible.

4. Carburetor This is a fixed carburetor. Re-jetting of the

carburetor is prohibited. Idle speed adjustment is NOT ALLOWED. Recommended idle engine speed = 1750 +/- 100 rpm.

Rules pertaining Engine

OVERALL

5. The peripherals a) Air Cleaner Must be taken from Briggs and Stratton
recommended source, if required to be purchased. Also the remote kits i.e. parts to relocate the filter must be Briggs and Stratton parts.

b) Muffler & Exhaust System B&S engine has pre-mounted exhaust

system, there is no need to change the mounting.

6. Technical Inspection at the main event starts with Engine check. The
B&S staff on-site is empowered to make final decisions regarding the condition and set-up of all engines. WINNING TEAMS ENGINE MAY BE ISOLATED AFTER THE EVENT FOR DETAILED CHECK-UP.
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Rules pertaining Engine

Air Filter Mounting Guidelines
1. Air filter should be located as close as possible to the engine. 2. If relocated, the parts used must be Briggs and Stratton parts / remote kits (part numbers are
given in rulebook).

3. These parts- hoses or pre-filters must be included in the cost report and these changes must
pass Briggs & Stratton inspection.

4. Relocation of air cleaner may decrease engine performance. Any damage on account of
failure to comply with instructions is to be borne by the team.

5. Complete air intake system must be located so that its extremities lie at least 100 mm within
the perimeter of the vehicle.

Exhaust System Mounting Guidelines

1. The mounting of the exhaust system need not be changed and kept as it comes with engine. 2. The exhaust pipe and muffler must be completely intact and operational throughout the
event, and could be grounds for penalty if not intact at the end of any event.

3. The complete exhaust must be located such that its extremities lies at least 100mm within
the perimeter of the vehicle.
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Rules pertaining Engine

Engine Governor

1. Governor setting must NOT exceed 3800 RPM as maximum speed. 2. Random inspection of governor may be conducted at any time and any
attempt to raise the engine speed will be dealt with disqualification.

3. The governor operation must remain free of obstructions at all times.

The governor area must be shielded from debris which is served by stock Fuel Tank.

4. If fuel tank is to be remotely mounted, B&S control cover (697326) may

be used.

5. Governor spring must be placed in hole # 6. 6. After the endurance the top ten team vehicles will be impounded and
engine will be checked again. ILLUSTRATION AT THE NEXT SLIDE >>
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Rules pertaining Engine

Engine Governor

DOs & DONTs for Engine

DOs
1. Check the OIL LEVEL daily. 2. In case of new engine, change the oil first 5 hrs, and then periodically after 25 hrs. 3. Check and clean air filters regularly under dusty conditions. 4. Before installing the engine read Operators Manual completely. 5. Keep the essential spares in stock for emergency requirements. 6. While adding fuel, turn engine OFF and let engine cool at least for 2 minutes before
removing gas cap.

7. Spill prevention strategy must be incorporated as per the rulebook. 8. Before performing adjustments or repairs, disconnect spark plug wire and keep it away from
spark plug.

9. When starting engine, pull cord slowly until resistance is felt, then pull rapidly. 10. When transporting the engine, transport with fuel tank EMPTY. 11. All the rotating parts must be shielded using metal guards as per the rulebook.
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DOs & DONTs for Engine

DON'Ts
1. Do not modify the engine settings in any way without B&S factory approval. 2. Do not operate engine without a muffler, inspect periodically and replace if defective. 3. Do not run engine at excessive speeds. 4. Do not tamper with Governor settings, idle speed / carburetor settings and also air filter and
exhaust system.

5. Do not run the engine with choke ON condition. 6. Do not fill the fuel tank above limits. 7. Do not put more oil than the maximum limit. 8. Do not choke carburetor to stop engine. 9. Tie up long hairs, remove jewelry and do not wear loose-fitting clothes when operating. 10. Do not crank engine with spark plug removed.

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Illustrations from rulebook

Spill Prevention

Guards for rotating parts

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Transmission
BAJA SAEINDIA 2014

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Powertrain
Definition

Powertrain refers to the group of components that generate power and deliver it at the wheels, in other words, transmitting power from the engine to wheels. Primary components Engine Transmission (Gear box) Drive Shafts Differential Final Drive (Final shaft, Axle, Drive Wheel)
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Design Aims of Powertrain

OVERALL

1. To transmit power from engine to wheels. 2. The power transferred must be able to move the vehicle up steep
grades and propel it at high speeds on level terrain.

3. Acceleration is also an important characteristics controlled by

drivetrain.

4. Simple to operate and efficient since rated power output from engine is
only 10 hp.

5. Reduction in gear shifts to save on speed and traction. 6. Minimizing weight of the assembly in order to improve acceleration and
decrease rolling resistance.

7. Maximizing serviceability by modularizing the drivetrain.

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Rules pertaining Powertrain

OVERALL

1. Teams are free to use any transmission, such that the maximum
speed of the vehicle on a plain terrain in not recommended more than 60 km/h in top gear.

2. CVT is also permitted with appropriate shielding and reverse

gear is optional.

3. Gear shifting cables, lever and shifting mechanism must be

installed at such locations such that it is not hindering driver and his safety.

4. Adapter for Engine and Transmission coupling to be designed /

installed by students as per the type of the transmission used. Engine drive/ output shaft details are available of BAJA SAEINDA official website.
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Rules pertaining Powertrain

OVERALL

5. All the rotating parts must be shielded to prevent injury to the driver or
by-standers should the component fly apart due to centrifugal force. Material specification-

AISI 1010 steel at least 1.524mm (0.06 in) thick, or a material having equal energy absorption at rupture per unit
width of shield if any fiber reinforced composite material is used then a stressstrain curve must be provided for worst case tensile loading. Min thickness 3.175 mm (0.125 in).

6. The technical inspectors reserve right to impound and inspect any

vehicle during/ after the dynamic or endurance events. The vehicles match the drive-train configuration as per the SCCS submitted during technical inspection.

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Gear Box
Design Consideration

1. CVT or Continuously Variable Transmission is one of the common Gear Box

used in BAJA vehicles.

This transmission uses two pulleys which change their effective diameter based upon their rotational speed. The two pulleys are connected via belt, and transmission ratio changes continuously with engine speed. Advantage It does not need any driver interaction, and that it is mechanically simple. Disadvantage Without secondary gear box the CVT has no ability to use reverse, and the available gear ratio range is limited. This means in order to have the versatility of a manual gear box (max. traction to max. speed), the CVT will usually be heavier than a similar geared transmission.

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Gear Box
Design Consideration

2. Manually shifted Gear Box Usually available with up to 5 forward

speeds.

Advantage provide large range of gear ratios can selectively

designed. Climbing steep gradients and driving through mud and sand guides the tallest gear and max speed and acceleration requirement guides the top gear.

Disadvantage They must be shifted by driver. 3. Automatic Clutches In order to avoid distractions in case of manual
gear box, transmissions are available with automatic clutches. They engage drive plates above idle rpm, and disengage below this rpm. In order to shift, driver only has to reduce throttle and press shift up or down button.
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Design Consideration for other parts

Differential
1. The objective is to provide better traction while driving straight, and allowing
one tire to turn faster than the other while turning.

2. Locking differential Benefit is seen in mow traction situations when both tires
need to turn for maximum traction. Also it helps gaining in towing performance, gradeability and straight line acceleration.

Open type Equal torque, unequal rotational speeds (for two wheels) Locking Type Unequal torque, equal rotational speeds.

Final Drive
1. Half shafts should be closer to symmetrically placed. 2. The axles have CV joints at each end as they afford better performance at
greater angles, which allows more suspension travel.

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THANK YOU

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