Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Design an Exemplary Ecokart

Ankit Dubey Divyanshu Vyas Pallav Mathur
Dept. Mechanical Engineering Dept. Mechanical Engineering Dept. Mechanical Engineering
Jodhpur Institute of Engineering and Jodhpur Institute of Engineering and Jodhpur Institute of Engineering and
Technology Technology Technology
Jodhpur, India Jodhpur, India Jodhpur, India

Abstract:- The paper documents the process and Types of karting can differ. In some cases, your local town
methodology to produce a high endurance ecokart which is may have a karting track where, although safety is still a major
comfortable, durable and complete in all aspects by a issue, these types of track are aimed more at people who are
profound design chassis modeled in CAD (Computer generally looking upon their visit as a fun day out. They do not
Aided Designing) and CAE (Computer Aided Engineering) need to have any prior experience nor need to wear any real
software such as SOLIDWORKS and ANSYS respectively. protective clothing, apart from a helmet which is often provided
The team focuses on a technically sound vehicle which is anyway, and these are the types of tracks that are popular with
backed by a profound design, high build quality yet light groups like stag parties and groups of children who like to go in
weight, good manufacturing practices to ensure maximum the school holidays etc.
safety of driver. This paper aims to design analysis of a
kart chassis as per calculations. The main intention is to Since its introduction in the 50's, karting has strongly
provide high safety which is ensured by static analysis of developed itself as sports and leisure opportunity. Indoor and
chassis and CFD (Computational Fluid Dynamics) analysis outdoor karting tracks accommodate thousands of people
of kart’s aerodynamic body. annually. Some even consider go-karting a stepping stone
towards professional Formula 1 sports. [1]
Keywords:- Chassis; Solidworks; ANSYS; Analysis; CFD.
While sitting in an ecokart, the trunk and extremities are
I. INTRODUCTION relatively unprotected. The accident rate during karting is
exceedingly high. Despite the substantial risk of severe injuries,
Eco kart is a single seat, motor driven vehicle which is the number of mandatory safety requirements for this sport
operated by a motor, where source of running the motor is a remains low. Compared with other high-risk sports hardly any
battery. In karts chassis is arguably the most important part of it. scientific data is available about injuries and risks concerning
A chassis consists of an internal framework that supports a karting; this might explain the limited number of safety
manmade object in its construction and use. It is analogous to an requirements.
animal's skeleton. An example of a chassis is the underpart of a
motor vehicle, consisting of the frame (on which the body is In medical literature mainly case reports, without explicitly
mounted). describing the underlying trauma mechanism are presented as
described in report three categories of trauma mechanisms have
Chassis used for designing kart is tubular space frame been defined in Table 1.
chassis which is a three-dimensional design employing number
of circular and square section tubes. Tubes are positioned in HET (High Energetic Trauma)
different sections to provide mechanical strength against forces A. Injuries to the extremities and trunk that are related to a
from anywhere. Tubes are welded together and form a complex direct collision at either side of the ecokart; these injuries are
structure which can withstand in adverse situations. Designing of mainly associated with cuts, bruises, and fractures.
ecokart is conducted in CAD software- SOLIDWORKS 17.0
and its analysis in CAE software- ANSYS 18.0. Force analysis is B. High-energetic trauma, mainly caused by frontal collision;
carried out on designed kart to simulate and analyses the actual this usually causes blunt-injury abdominal or thoracic injuries,
accidental situations as shown in Fig.1-3. Kart’s sustainability but also compression fractures of the lower extremities can be
and durability have been analyzed on impact or collision with seen.
solid structure or body. To ensure the maximum safety of driver
and kart, analyses have been conducted for extreme conditions C. Acceleration/deceleration trauma causing hyperextension
by approximately 3 times the force acting on it. Surprisingly, the injuries to the (cervical) spine. Injuries resulting from ecokart
obtained results are in permissible limits. accidents are very heterogeneous.[2]

II. SAFETY CONCERN III. DESIGN

Karting is an extremely popular activity amongst people of Firstly, chassis is designed for racings at descent speed and
all age groups. Like any sport which involves people travelling at fun purpose in amusement parks as shown in Fig.6. On
speed and near each other, there is always an element of risk and analyzing accidents during karting, a decision has been made to
danger to consider but it should be a reasonably safe sport to improve the safety of kart and design it for adverse situations.
undertake providing that people understand the rules and their On analysis of different accidental situations, iteration have been
own limitations. carried out which is shown in Fig.5.

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Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
IV. METHOD FOR IMPROVING SAFETY OF corrected to minimize air resistance on kart. Similar analysis is
FRAME conducted for kart’s speed at 50 m/s as shown in Fig.8.

A. Add additional members- VI. ITERATION

Addition of structural members increase stiffness and
decrease flexural rigidity under loading conditions. A. Side rod to plate-
Stress at ends of rod becomes high on side impact whereas
B. T joints- plate distribute force efficiently among hexagonal structure.
These joints minimize deflection, cracking and excessive Welded gussets for rear safety- welded gussets efficiently
vibrations under dynamic conditions of vehicle. manage stress due to fatigue loading at critical locations.
C. Gussets- B. Member for side safety-
Triangular gussets are used to transfer stress from small This member support seat and distribute forces and stress
members to larger members which prevents excessive bending generate from side impact.
and breakage of members.

D. Advanced design bumpers- C. Members for top safety-

Its hexagonal structure absorb the effect of impact and Maximum deformation in top/ roll over analysis is
transmit minimum amount of force to frame. analysed at battery protection members, so triangulation is used
to control it.
V. FORCE CALCULATION
D. Members for rear safety-
A. Front impact analysis- Rear impact transmit from rear end of kart to diagonal
During front impact, it is assumed that the front end of kart member joining it with roll over. This member distributes the
is colliding with the structure at maximum speed of 16.66m/s. forces concentrate at each diagonal member. Few members are
Then force is calculated for normal and extreme condition is added to rear end which supports rear bumper in force
described in (1) and (6) respectively. absorption.

B. Side impact analysis- E. Members for front safety-

On side impact analysis, it is assumed that the side faces of A diagonal member has been replaced by small members at
kart or side guard encounter with an accidental impact from front end of chassis to support front bumper in force distribution
another kart an average speed of 15.27m/s. Then force is and weight reduction.
calculated for normal and extreme condition is described in (3)
and (8) respectively. F. New bumpers-
In new bumpers, plate transfer force to hexagonal structure
C. Rear impact analysis- which gets deform to distribute forces equally.
In rear impact analysis, kart is assumed to be stationary
while another kart collides at the rear end of kart with an VII. EQUATIONS
average speed of 16.11m/s. Then force is calculated for normal
and extreme condition is described in (2) and (7) respectively.
FORCE CALCULATION AT ONE TIME IMPACT
D. Top impact analysis-
In top impact analysis, kart is assumed to be rolled in Front mvt 20016.660.5 6664N (1)
accidental case and mass of whole kart is concentrated on roll
over protection. Force from top is considering to be 2 to 3 times Rear mvt 20016.110.5 6444N (2)
the mass of kart. Then force is calculated for normal and
extreme condition is described in (4) and (9) respectively.
Side mvt 20015.270.5 6108N (3)
E. CFD Analysis-
CFD has been carried out at the front end of kart to Top 3mg 32009.81 5886N (4)
determine the airflow and tests the aerodynamic design of kart’s
body. It has been carried out on fiber body as per the ADF at 1 times  ƍCdAv2/2 1.20.041.816.662/2
calculations of fluid (air) force described in equation (5) and
(10), understands the impact of air on kart’s performance as 12N (5)
shown in Fig.7. It also shows flow direction of air from body
contours. Then areas facing maximum air resistance has been

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Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

FORCE CALCULATION AT THREE TIME IMPACT

Front mvt 200500.5 19992N (6)

Rear mvt 20048.330.5 19332N (7)

Side mvt 20045.830.5 18324N (8)

Top 6mg 62009.81 11772N (9)

ADF at 3 times  ƍCdAv2/2 1.20.041.8502/2 108N (10)

Where

ƍ=1.2kg/m3 (Density of air)

Cd=0.04 (Air drag coefficient)[3]

A=1.8m2 (Surface area in contact with air)

V=Velocity of kart [4]

ADF Air drag force

₰ Deformation

VIII. FIGURES AND TABLES

Trauma Mechanism Injury Type Specific Injury

Direct trauma Fracture, contusion, abrasion, Calcaneal or ankle fracture caused by pedals;
laceration, burn wound humeral, shoulder, or clavicular fracture after side
impact; wrist or hand fracture by steering wheel

HET deceleration trauma Blunt abdominal or thoracic Rib fracture, lung contusion, pneumothorax, fladder
trauma, compression injury thorax, cor contusion, diaphragm rupture; rupture or
to the lower extremity contusion of spleen, liver, gal bladder, pancreas,
kidney, or intestines; fracture or luxation of foot,
lower limb, hip, or pelvis

Acceleration/deceleration Flexion/extension injury Compression fracture of the spine, whiplash, injury

of the carotid or vertrebral arteries

Table 1. Trauma Mechanisms and Injuries

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Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 1:- Accident type 1

Fig 4:- Frame before iteration

Fi
Fig 2:- Accident type 2

Fig 5:- Frame after iteration

Fi
Fig 3:- Accident type 3

Fig 6:- Exploded view of bumper

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Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table 2. Front Impact Analysis Table 3. Side Impact Analysis

Parameter Normal Extreme condition Parameter Normal condition Extreme condition

condition
Before iteration Before iteration

After iteration

After iteration

Force 6664N 19992N

FOS Before 2.05 5.13
After 0.68 1.71
₰ Before 0.0006 m 0.0001m
After 0.0018m 0.00043m

Force 6108N 18324N

FOS Before 2.80 7.3

After 0.94 2.46

₰ BEFOR 0.0009M 0.00057M

E

AFTER 0.00294M 0.00042M

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Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table 4. Rear Impact Analysis Table 5. Top Impact Analysis

Parameter Normal condition Extreme Parameter Normal condition Extreme

condition condition
Before Before
iteration iteration

After iteration
After iteration

Force 6444N 19332N

FOS Before 2.16 4.46

Force 3924N 11772N

FOS Before 1.54 4.8

After
0.71 1.49
After
0.51 1.61
₰
₰ Before 0.0009m 0.00028m
Before 0.0012m 0.00022m
After 0.0027m 0.00086m

After 0.0036m 0.00067m

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Volume 3, Issue 7, July – 2018 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 10:- Driver safety gears

Fig 7:- CFD analysis on 1 time velocity
IX. SAFETY EQUIPMENT

Irrespective of achieving the highest safety in kart, it is

mandatory to wear driver’s safety gears like helmet, fire
resistance suit, gloves, shoes etc. as shown in Fig.10.

X. ACKNOWLEDGMENT

The Firstly, we would like to thank ISIE for giving us this

great opportunity to present our research paper. We are very
grateful to our college faculties; our project would never be a
success if they had not taught us so well. We are very thankful to
our Prof. Vijay Suthar who taught us and helped us for
Performing calculation and tools for successfully performing
analysis for our project. We express our gratitude to all other
teaching faculty of Mechanical Department for their kind
Fig 8:- CFD analysis on 3 time velocity support. Lastly, we would like thank all the persons directly or
indirectly involved in success of our project.

REFERENCES

[1] “KART SAFETY.” [Online]. Available:

http://www.safesport.co.uk/go-karting-safety.html.
[2] I. B. S. Hasan H.Eker, Esther M.M Van Lieshout, Dennis
Den Hartog, “TRAUMA MECHANISMS AND
INJURIES ASSOCIATED WITH Go-KARTING,” 2010.
[3] “AIR DRAG.” [Online]. Available:
https://www.engineeringtoolbox.com/drag-coefficient-
d_627.html.
[4] V. B. BHANDARI, DESIGN OF MACHINE
ELEMENTS, Third. Mc Graw Hill Education.

Fig 9:- Fire extinguisher

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