AN INITITATIVE BY

EFFI-CYCLE 2012
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RULEBOOK
EFFI-CYCLE C/o SAEINDIA

Rules for

EFFI-CYCLE SAEINDIA12
Contents
1. Overview................................................................................................................................................... 4 1.1 Introduction....................................................................................................................................... 4 1.2 Purpose.............................................................................................................................................. 4 1.3 Competition Summary ....................................................................................................................... 4 1.4 Vehicle Design, Analysis, and Construction .......................................................................................... 4 2. EFFICYCLE SAEINDIA Rules and Organizing Authority............................................................................. 4 2.1 Authority of the Rules......................................................................................................................... 4 2.2 Rules Validity......................................................................................................................................... 4 2.3 Rules Compliance ...................................................................................................................................5 2.4 Understanding the Rules........................................................................................................................5 2.5 Participating in the Competition ........................................................................................................... 5 2.6 Violations on Intent................................................................................................................................ 5 2.7 Right to Impound .................................................................................................................................. 5 2.8 General Authority ................................................................................................................................. 5 3. Eligibility ....................................................................................................................................................5 3.1 Eligibility Limits .................................................................................................................................... 5 3.1.1 Student Status.................................................................................................................................... 5 3.1.2 SAE Membership................................................................................................................................ 6 3.1.3 Age .................................................................................................................................................... 6 3.1.4 Drivers License .................................................................................................................................. 6 3.1.5 Liability Waiver..................................................................................................................................... 6 3.1.6 Medical Insurance ................................................................................................................................ 6 3.1.7 Registration Procedure.......................................................................................................................6 3.2 Faculty Advisor........................................................................................................................................ 6 3.2.1 Status..................................................................................................................................................... 6 3.2.2 Responsibilities .................................................................................................................................. 7 3.2.3 Limitations......................................................................................................................................... 7

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4. Vehicle Eligibility....................................................................................................................................... 7 4.1 Student Developed Vehicle................................................................................................................ 7 4.2 Information Sources........................................................................................................................... 7 4.3 Professional Assistance ........................................................................................................................ 7 4.4 Kit Vehicles Prohibited ......................................................................................................................... 7 4.5 Student Fabrication............................................................................................................................... 7 4.6 Registration ............................................................................................................................................. 7 4.7 Maximum Entries per college ............................................................................................................... 7 4.8 Registration Fees*.................................................................................................................................. 8 5. Vehicle Requirements ............................................................................................................................... 8 5.1 Vehicle Configuration............................................................................................................................. 8 5.2 Maximum vehicle dimension ................................................................................................................. 8 5.3 Power...................................................................................................................................................... 8 5.4 Drive train.... 8 5.5 Brakes................................................................................................................................................... 9 5.6 Steering system ................................................................................................................. 9 5.7Roll cage......................................................................................................................................... 9 5.8 Real roll hoop.. 9 5.9 Drivers seat ................................................................................................................................ 10 5.10 Kill Switch......................................................................................................................... 10 5.11 Drive equipment requirement .......................................................................................................... 10 5.12 Aerodynamic Devices.. 10 5.13. Fasteners .. 10 5.13.1 Fastener Grade Requirements.. 10 5.13.2 Thread Exposure ... 10 5.13.3 Socket head cap.. 11 6. Vehicle Identification .............................................................................................................................. 11 6.1 College Name ...................................................................................................................................... 11 6.2 EFFICYCLE SAE INDIA Logo ................................................................................................................. 11 6.3 Rider Clothing/safety ........................................................................................................................... 11 6.4 Rider Rules ......................................................................................................................................... 12

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1. Overview
1.1 Introduction
EFFI-CYCLE is an intercollegiate design competition for undergraduate students which are a ime d at designing and fabricating an energy efficient hybrid human powered three wheeled electric vehicle. The vehicle must be aerodynamic, highly engineered and ergonomically designed. The design should be commercially viable as a product and should be attractive to the consumers because of its visual appearance, performance, reliability and ease of operation.

1.2 Purpose
Provide an opportunity for engineering students by setting up a trend of using ecofriendly vehicles in India and come up with some innovative designs. Students have to tackle real world engineering problems, work in multidisciplinary teams, practise design for manufacturing.

1.3 Competition Summary

The Competition includes designing, validating and fabricating a three wheeled vehicle driven by two drivers. The vehicle would be capable to be driven simultaneously as well as alternatively by two drivers and also alternatively or simultaneously on electricity. The vehicle would be evaluated for its design and performance and the teams compete against each other. The cumulative scores of all the events would decide the overall ranking of the teams in the event.

1.4 Vehicle Design, Analysis, and Construction

The research, analysis, and design of all vehicles entered by a college must be performed solely by current SAEINDIA student members of that college. Only fabrication assistance for things requiring outside assistance is allowed. Teams are expected to have full participation from all concerned people.

2. EFFI-CYCLE SAE INDIA Rules and Organizing Authority

2.1 Authority of the Rules
The EFFI-CYCLE SAEINDIA Rules are the responsibility of the EFFI-CYCLE SAE Rules Committee and are issued under the authority of SAE INDIA. Official announcements from the EFFI-CYCLE SAE Rules Committee, SAE or the other EFFI-CYCLE SAE organizing bodies shall be considered part of and shall have the same validity as these rules. Ambiguities or questions concerning the meaning or intent of these rules will be resolved by the EFFI-CYCLE SAE Rules Committee, SAE or by the individual competition organizers as appropriate.

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2.2 Rules Validity

The EFFI-CYCLE SAE Rules posted on the SAE website and dated for the calendar year 2012 of the competition are the rules in effect for the competition.

2.3 Rules Compliance

By entering EFFI-CYCLE SAE INDIA, the team, members of the teams as individuals, faculty advisors and other associated personnel agree to comply with and be bound by these rules and all the rule interpretations or procedures issued or announced by SAE, the EFFICYCLE SAE INDIA Organizing Committee and the other Organizing bodies. All team members, faculty advisors and other associated representatives are required to cooperate with and follow all instructions from competition organizers, officials and judges.

2.4 Understanding the Rules

Teams are themselves responsible for reading, interpretation and understanding the rules of the competition.

2.5 Participating in the Competition

Teams, team members as individuals, faculty advisors and other representatives of a registered college who are present onsite at a competition are considered to be Participating in the competition from the time they arrive at the event site until they depart from the site at the conclusion of the competition or earlier by withdrawing.

2.6 Violations on Intent

The violation on intent of a rule will be considered a violation of the rule itself. Questions about the intent or meaning of a rule may be addressed to the EFFI-CYCLE SAE INDIA Organizing Committee or by the individual competition organizers as appropriate.

2.7 Right to Impound

EFFI-CYCLE SAE and other competition organizing bodies reserve the right to impound any onsite registered vehicle at any time during the competition for inspection and examination by the organizers, officials and technical inspectors.

2.8 General Authority

SAE and the competition organizing bodies reserve the right to revise the schedule of the competition and/or interpret or modify the competition rules at any time and in any manner that is in their sole judgment, required for the efficient operation of the event or the EFFI-CYCLE SAE.

3. Eligibility
3.1 Eligibility Limits
Eligibility limited to undergraduate students to ensure that this is an engineering competition rather than a race.

3.1.1 Student Status

Team members must be enrolled as degree seeking undergraduate students in a college or university. Those who have graduated are not eligible to participate. 5 | effi-cycle

3.1.2 SAE Membership

Team members, faculty advisor and other representative must be member of SAE INDIA, the proof of which (such as Membership card) is required at the competition. In addition, the participating college must have an active SAE Collegiate Club. If not, then the students are advised to form an SAE Collegiate Club in their colleges. The students shall bring their proof of active membership at the event, failing which they will not be allowed to participate for the event.

Note: More information regarding the SAE Membership and Collegiate Clubs can be found
at www.saeindia.org

3.1.3 Age
Team members must be at least eighteen (18) years of age.

3.1.4 Drivers License

Team members (at least 2) who will drive the vehicle at any time during the competition must hold a valid, government issued drivers license.

3.1.5 Liability Waiver

All onsite participants, including students, faculty and volunteers, are required to sign a liability waiver upon registering onsite. The form will be provided to teams who will qualify for the main event and it is mandatory for all teams to send it back to the organizing committee before the main event.

3.1.6 Medical Insurance

Individual medical insurance coverage is required and is the sole responsibility of the participant. No medical Insurance will be provided by EFFI-CYCLE SAEINDIA.

3.1.7 Registration Procedure:

Teams are required to register online at the EFFI-CYCLE SAE INDIA website www.effi.saenis.org. A Maximum of 8 members is allowed per team to participate in the competition. At the time of onsite registrations, all participants must provide the following documents A valid driving license issued by the Government as a photographic proof for the Drivers. For non drivers, college ID or any other substitute alternate document for a photographic identification. Medical insurance (provider, policy/ID number, telephone number) Emergency contact data (point of contact (parent/guardian, spouse), relationship, and phone number).

3.2 Faculty Advisor 3.2.1 Status

Each team is supposed to have a Faculty Advisor appointed by the university. The Faculty Advisor is required to accompany the team to the competition and will be considered by competition officials to be the official university representative.
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3.2.2 Responsibilities
Faculty Advisors may advise their teams on general engineering and engineering project management theory and act as guide to them for this project.

3.2.3 Limitations
Faculty Advisors should not design any part of the vehicle nor directly participate in the development of any documentation or presentation. Additionally, Faculty Advisors may not fabricate nor assemble any components, nor assist in the preparation, maintenance, testing or operation of the vehicle. In Brief Faculty Advisors may not design, build or repair any part of the vehicle.

4. Vehicle Eligibility
4.1 Student Developed Vehicle
Vehicles entered into competitions must be conceived, designed, fabricated and maintained by the student team members without direct involvement from professionals, automotive engineers, racers, professional fabricators, technicians machinists or related professionals.

4.2 Information Sources

The student team may use any literature or references related to vehicle design and information from professionals or from academics as long as the information is given as a part of discussion of available alternatives with their pros and cons.

4.3 Professional Assistance

Professionals should not make design decisions, drawings or fabrication. Those vehicles found to be professionally made will be disqualified from the competition.

4.4 Kit Vehicles- Prohibited

Vehicles fabricated from a kit or published designs are ineligible to compete.

4.5 Student Fabrication

EFFI-CYCLE SAE INDIA is intent of the SAE Collegiate Design Series competitions to provide direct handson experience t o the s t ude nts . Therefore, students should t hemse lves pe rfo rm all fabrication tasks whenever possible.

4.6 Registration
The teams are required to register at the EFFI-CYCLE SAE INDIA website: www.effi.saenis.org. All updates would be put up on the website and its the responsibility of the teams to check for the updates.

4.7 Maximum Entries per college

Only one entry per college is allowed in the final event. However multiple teams may enter the pre-qualification stage.
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4.8 Registration Fees*

The registration amount will be updated on the website as soon as registration process will begin (http://effi.saenis.org/updates.html) . The registration will be done for Prelim round in April and one registration will be done after the Prelims for those who are selected for the main event which will be aired just after the declaration of Prelims results. *Registration fees is non refundable.

5. Vehicle Requirements
5.1 Vehicle Configuration
The vehicle must have three wheels that should not be in a straight line. The vehicle must be capable of carrying two riders, of at least of 190.3 cm (63) height and weighing 115 kg.

5.2 Maximum vehicle dimension

Vehicles participating in the completion can have a maximum dimension of 90 inch x 50 inch (L x B).Teams will have to pass the vehicle through a Go / No-GO Gauge at the main event.

5.3 Power
Vehicles must be driven by human and electric power both. Use of PMDC Motor Permanent Magnet DC motor is must and max power of motor should not be more than 400 WATTS. Teams can use a battery source of up to 48V and up to 35Aphr. Teams must not use hub motor or any other type of motor. Teams are free to use any kind of controlling devices (drive train, gear box, CVT or any electronic devices) to control the speed of PMDC motor. Teams can install systems to charge the battery (Optional) while they are driving the vehicle. Teams have to use charged batteries. Internal Combustion engines and solar cells are excluded from the competition. During the safety inspection each team must be prepared to explain the features of safety of the storage device, especially in case of a high speed impact. Teams whose vehicles present an unacceptable risk in the perception of the judges will not be allowed to utilize the energy storage device in the competition.

NOTE: Dry batteries should be used. The mounting of battery must prevent the battery from
coming loose during a roll over & must be properly insulated. Failing this, the technical inspectors may debar the team from the dynamic events.

5.4 Drive Train

Normal operating components involved in the drive train (chain sprockets, chains, or other power transmission devices, wheels, etc.) are permitted. All moving parts such as belts, chain, and sprocket, must be shielded, to prevent injury to the driver or bystanders, from the metal / chips that may fly apart due to centrifugal force. These guards/shields must extend around the periphery of the belt or chain. They must be mounted with sound engineering practice, in order to resist vibration. All the wires and electrical systems should be well insulated to prevent any shocks.
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5.5 Brakes
All vehicles are required to have brakes on all wheels. Teams can use both hydraulic and non hydraulic brakes that satisfy the minimum defined criteria of locking of brakes in a static condition. Brakes may be tested by pushing the vehicle in forward direction, by the volunteers. Drivers will be asked to apply the brakes. All wheels are required to be locked during this test. Also, brakes may be tested by allowing the vehicle to stop within the predefined distance (3m) after covering a specified distance in a set time.

NOTE:
If team is using hydraulic brakes then following conditions must be meet, 1. Rigid brake pipes must be mounted securely along the roll cage / other members as required. Loosely hanging / pipes located by using ties / tapes etc shall not be permitted. 2. The bleed point location must lie on top of the calliper cylinders, without exception. 3. Braking on a jackshaft or through an intermediate reduction stage is prohibited. In the case of non hydraulic brakes: 1. The wire should have the proper plastic covering. No wire should be open throughout from lever to the brakes. All the covering must be tied up with the roll cage. No loosen wires are allow

5.6 Steering system

Teams are free to use any type of the steering. All the rotating parts must be in the proper covering.

5.7 Roll cage

The main purpose of the roll cage is to provide a 3D cage around the driver and to get all the body mounts for the subassembly. The drivers torso, knees, shoulders, elbows, hands, and arms must have a minimum of 7.62 cm (3 in) of clearance from the envelope created by the structure of the vehicle.

5.8 Rear roll hoop (RRH) RRH is must and has to be incorporated in the vehicle. Each vehicle must be equipped with roll over protection system to keep driver safe in case of accidents. Roll over protection system should be able to absorb energy during collision to minimize neck injuries during collisions, also design should be able to protect driver during side impact or in case the vehicle topples. Roll over protection system could be applied in any form given the desired purpose is solved. It should have a minimum of 4 inches distance between the drivers head and the roll over bar.
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5.9 Drivers seat

The use of a driver seat is mandatory; cushioning or padding attached to the frame will not be accepted as a seat. The seat shall be fastened to the frame.

5.10 Kill switches

The kill switch is mandatory and should be accessible to both the drivers. The electrical system must get dead by activating the kill switch.

5.11 Driver equipment requirement

All must wear the well fitted helmet with an integrated (one composite shell) belt to tighten the helmet.

Also wear the knee and elbow pads during any event of the competition.

5.12 Aerodynamic Devices

Each vehicle shall include components, devices, or systems engineered specifically to reduce aerodynamic drag. Front fairings, tail sections, and full fairings are encouraged. Other devices may be permitted providing they clearly demonstrate that the device or system significantly reduces aerodynamic drag. The effectiveness of such devices must be justified in the design report. These should not at any point during the competition be hanging freely from the vehicle.

5.13 Fasteners
All fasteners used in the systems must be captive; defined as requiring NYLON locknuts, cotter nuts or safety wired bolts (in blind applications). Lock washers or thread sealant do not meet this requirement.

5.13.1 Fastener Grade Requirements

All bolts used in the system must meet SAE grade 5, metric grade M8.8 or AN military specifications.

5.13.2 Thread Exposure

All threaded fasteners used in the system must have at least two (2) threads showing past the nut. Compliance shall be checked and any vehicle failing to comply shall not be allowed to start any dynamic event.

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5.13.3 Socket Head Cap Screws

Socket head cap screws, also known as internal wrenching bolts or Allen head bolts used, must meet one of the following requirements: 1. The bolt head is clearly marked with the letters NAS, 12.9, or 10.9 indicating a military / aircraft or high-strength metric fastener. No other markings will be accepted. 2. Proper documentation is supplied, which must include a purchase receipt, and manufacturers documentation indicating the bolt strength.

NOTE: No vehicle discard any part after the vehicle is in motion. Any vehicle found with unsafe
part during judging will be disqualified for the event.

6. Vehicle Identification
Vehicle Number and Logos each vehicle will be assigned a number. The number, college name, and EFFI-CYCLE SAEINDIA logo must be clearly visible from both sides of the vehicle. If these are lost or obscured, the vehicle will be removed from the competition until they are repaired. If a vehicle number is obscured during the endurance race any laps run without a number will not be counted. Teams should contact the EFFI-CYCLE SAEINDIA competition organizers.

6.1 College Name

All vehicles must display their college name or initials on each side of the vehicle in characters at least 10.1 cm (4 inch) high.

6.2 EFFI-CYCLE SAE INDIA Logo

An EFFI-CYCLE SAE logo must be displayed on both sides of the vehicle. This logo will also be provided by SAE INDIA.

6.3 Rider Clothing/safety

Any rider/team found unsafe in the opinion of the inspectors, would not be allowed to take part in dynamic event until approved by respective inspectors. Clothing intended for cycling use or to decrease wind resistance is allowed (skin suits). Riders are advised NOT to wear loose clothing during the dynamic events. The use of a cyclist helmet is compulsory. The riders to be secured to their vehicles by safety harness, subject to requirement and decision of inspecting authority, for rider safety. Commercially available safety harnesses are accepted. Vehicle should be free from any kind of sharp edges and protrusions that can harm the rider or crew members. Riders should have his eyes protected while driving either by visor in helmet or by separate safety glasses. Riders are required to wear shoes and gloves while driving. Use of knee and elbow guards and shin guards is compulsory.

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6.4 Rider Rules

A rider may not receive any type of pushoff from another person or vehicle. Exception: Team riders may push or sling another teammate when exchanging riders while driving. A rider may not receive pacing of any form within sight of the rider (on foot, by bicycle or anything else) from a crew member or another person. A rider may ride a vehicle with a flat tire or other mechanical problems. If a Race Official deems the problem unsafe, the rider must stop or proceed on foot thereon with the bike until the vehicle is replaced or repaired. A rider may proceed on foot along the track as long as the vehicle is present on track (carried, dragged, or pushed). A rider separated from his vehicle may not proceed along the race route, but may travel backward by any means along the route. Riders must not block or impede the progress of another competitor. Moving riders may not be tethered by electrical wiring, feeding tubes, oxygen tubes, or other attachments either to a vehicle or pedestrian. Riders must stop for drug or medical testing, or imposition of punitive penalties when directed by an EFFI-CYCLE SAEINDIA Official. The time required for such stops will not be deducted from the riders time.

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