To design and fabricate an eco- friendly all-terrain vehicle MAJOR PROJECT - MECHANICAL ENGINEERING PREPARED BY – AMANDEEP SINGH PIYUSH PARMAR PRAKHAR KIYAWAT ROHIT SONI SAKET GUPTA VIKAS LODHI GO GREEN PROJECT GUIDE – Dr. KESHAVENDRA CHOUDHARY
To design and fabricate an eco-friendly all-terrain vehicle
MAJOR PROJECT - MECHANICAL ENGINEERING
PREPARED BY –AMANDEEP SINGHPIYUSH PARMARPRAKHAR KIYAWATROHIT SONI
SAKET GUPTAVIKAS LODHI
GO GREENPROJECT GUIDE –Dr. KESHAVENDRA CHOUDHARY
OBJECTIVE The purpose is to design and build a prototype of a rugged, single seat, off road, ‐
eco-friendly recreational vehicle intended for sale. The vehicle is safe, easy to transport, easy to maintain and fun to drive. An ATV negotiates rough terrain in all types of weather without damage.
DEPARTMENTS INCHARGE
DESIGNING of ROLL CAGE Prakhar Kiyawat, Amandeep Singh, Rohit Soni
ANALYSIS of ROLL CAGE Prakhar Kiyawat, Vikas Lodhi
FABRICATION of ROLL CAGE Saket Gupta,Rohit Soni
ENGINE and TRANSMISSION Vikas Lodhi,Saket Gupta
STEERING and SUSPENSION Amandeep Singh,Saket Gupta Prakhar Kiyawat
WHEELS and TYRES Amandeep Singh, Vikas Lodhi
BRAKES and CONTROL SYSTEMS Rohit Soni, Vikas Lodhi
ECO-FRIENDLY SYSTEMS Piyush Parmar , Saket Gupta
AESTHETICS and GRAPHICS Prakhar Kiyawat, Piyush Parmar
COST REPORT and BOM Saket Gupta, Amandeep Singh
DESIGNING of ROLL CAGEDESIGNING SOFTWARE :PRO-E WILDFIRE 5.0
MATERIAL : Mild Steel IS 1239Carbon Content – 18%
TYPE : Tubular Pipe
SPECIFICATION MEASURE
OD of Tubular Pipe 25.40 mm
ID of Tubular Pipe 19.30 mm
Overall Length – ATV 2490 mm
Overall Width – ATV 1575 mm
Wheel Base 1651 mm
Wheel Track – Front 1295 mm
Wheel Track – Rear 1372 mm
Height of ATV 1448 mm
ANALYSIS of ROLL CAGEANALYSIS SOFTWARE –
ANSYS 11
FRONT IMPACT ANALYSISModel: Full model
(Coordinate Generated)Loading : 8000 N on frontMax. Stress : 214.82 MPaMax. Displacement: 0.965E-03 inFactor of safety : Incorporated FOS
Ultimate Stress/Max Stress= Syt / Smax = 450/214.82 = 2.09
F.O.S. > 2Design is safe.
ANALYSIS of ROLL CAGEANALYSIS SOFTWARE –
ANSYS 11
REAR IMPACT ANALYSISModel: Full model
(Coordinate Generated)Loading : 8000 N on frontMax. Stress : 188.18 MPaMax. Displacement: 0.681E-03 inFactor of safety : Incorporated FOS
Ultimate Stress/Max Stress= Syt / Smax = 450/188.18 = 2.39
F.O.S. > 2Design is safe.
ANALYSIS of ROLL CAGEANALYSIS SOFTWARE –
ANSYS 11
SIDE IMPACT ANALYSISModel: Full model
(Coordinate Generated)Loading : 8000 N on frontMax. Stress : 161.86 MPaMax. Displacement: 0.288E-03 inFactor of safety : Incorporated FOS
Ultimate Stress/Max Stress= Syt / Smax = 450/161.86= 2.78
F.O.S. > 2Design is safe.
ENGINELOMBORDINI LGA 340cc engine is used for the ATV.
WHY THIS ENGINE:
The specifications of this ENGINE fulfills the requirement of our ATV.
The size and shape of the engine is compatible with the design of our vehicle.
ENGINE - LGA 340 Lombardini Kohler
Type Single Cylinder, 4- Stroke, Spark Ignition Engine
Bore x Stroke 84 mm X 64 mm
Displacement 338 CC
Compression Ratio
8:1
Rated Power 8 KW @ 4400 RPM
Max Torque 19 NM @ 3000 RPM
Lubrication Forced Lubrication Vane Pump
Lube Oil 15W40 CF4 Multi Grade Oil
Lube Oil Capacity
1.7 litres
Starting System Electric Start with Auto - Decomp on camshaft
Electric System 12V, 18 Amps Flywheel Mounted Alternator
Recommended Battery
12 V, 44 Ah
Weight of Engine 30.5 Kg
TRANSMISSION Mahindra Alfa Champion transmission having constant mesh type gear
assembly is used. It is a transaxle unit. A transaxle is a major mechanical component that combines the functionality
of the transmission, the differential, and associated components of the driven axle into one integrated assembly.
It is having a 4+1 gear box assembly.
WHY THIS TRANSMISSION:
Desired gear ratios for the ATV are very similar to the gear ratios of this transmission.
Low weight due to transaxle unit.
Excellent performance on rough conditions.
Cheap and easy service.
STEERING SYSTEMRACK and PINION STEERING SYSTEM is used in the ATV.
WHY RACK and PINION ?
Greater Steering Ratio.
Simple Mechanism
Light in Weight and Occupies less Space
MODIFICATIONS DONE:
Turning Radius Reduced.
Steering Effort Reduced.
SPECIFICATIONS Measure
Rack Travel (end to end) 10 cms
Steering Ratio 19.44 : 1
Minimum Turning Radius 3.13 mts
SUSPENSIONSINDEPENDENT UNEQUAL DOUBLE A-ARM WISHBONE SUSPENSIONS are used in the ATV.
Why this Suspension ?Better Stability.
Larger Wheel Travel.
Adjustable Camber and Caster angles. Better control over parameters as camber angle, caster angle, toe pattern, roll center height, scrub radius, scuff.
SPECIFICATIONS
Front Suspension Angle 62.3 deg
Rear Suspension Angle 42 deg
Ground Clearance 20 cms
WHEELS - TYRESREAR WHEELS and TYRES:
•BAJA TRAX tubeless tyres used.•Tread pattern such so as to increase traction.•Tyre Rating – 25 x 8 x 12
FRONT WHEELS and TYRES:
•Tubeless front tyres used of smaller radii.•The turning effort is reduced.•Increased Stability.•Tyre Rating – 145/70 – R12
BRAKESAll 4 wheels are Calibrated with DISC BRAKES.•Disc brakes dissipate heat better (brakes work by converting motion energy to heat energy).•Disc brakes also perform better in wet weather, because centrifugal force tends to fling water off the brake disc and keep it dry.•Under severe usage, disc brakes take longer to lose effectiveness (a condition known as brake fade).
GO GREEN – ECO-FRIENDLY SYSTEMSFUEL TANK NECK ASSEMBLY (FTNA)©
FTNA is an assembly of 2 concentric cylinders fixed over the inlet of fuel tank which helps in reduction of evaporative losses due to refueling in motor vehicles.
Since there is no unburnt fuel emission in the atmosphere during vaporization, thereby increasing the safety of the vehicle and the personnel.
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95
96
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100
0.5Hrs.
1 Hrs. 1.5Hrs.
2 Hrs. 2.5Hrs.
3 Hrs. 3.5Hrs.
4 Hrs. 4.5Hrs.
Cylinder w ith opening Dia. 2.5 cm
Cylinder w ith opening Dia. 1 cm
3D Model of FTNAGraph shows reduction in fuel quantity that evaporates over interval of 30 minutes.
CATALYTIC CONVERTER• A catalytic converter is a device used to reduce the toxicity of exhaust
emissions from an internal combustion engine.
• A catalytic converter provides an environment for a chemical reaction wherein toxic combustion by-products are converted to less-toxic substances.
• A two way bed catalytic converter is used in our ATV which reduces hydrocarbon and carbon monoxide emissions.
The catalytic converter consists of the following components:
• Core or Substrate – Ceramic/Stainless Steel Honeycomb structure .• Washcoat – used to make converters more efficient, often as a mixture of
silica and alumina.• Catalyst – Platinum, Palladium, Rhodium.
SAFETY – PRIME IMPORTANCESafety is the primary consideration in the design of the ATV and we have included safety considerations in all parts of the Vehicle and the Driver:
•All elements of Roll Cage Dimensions meeting conformance to SAE.•All Sub Systems incorporated are according to SAE Rules.•All Safety equipment are SFI 3.3 Rated.•Fasteners – SAE Grade 5, 6, 7 and 8.•Safer Fuel Tank Assembly.•Steering Lock.•Firewall.•Kill Switch.•Lock Nuts.•5 restraint harness system incorporated for the safety of the driver.•5 seconds evacuation off the vehicle.
CONCLUSION• We have managed to successfully design, fabricate and test
our All-Terrain Vehicle.• We gave foremost importance to the Safety measures.• EMA is an environment friendly vehicle and can withstand
high values of load.• EMA negotiates rough terrain of all types and passed all the
tests very efficiently including the– Engine Test– Emission test– Brake Test– Acceleration Test– Hill Climbing Test (Angle of hill - 45 degrees)– Maneuverability Test– Endurance Test
• Thank you for giving us your precious time and listening to us so patiently.