Imperial Society of Innovative Engineers

HYBRID VEHICLE CHALLENGE

2017-18

Maulana Azad National Institute of Technology, Bhopal

Team MACTRON
Team ID: HVC 18 H050
Design Report

Jai Verma
Ashwini Dixit
Gule Haider
Kuldeep Singh Tanwar
Gopala Soni
Design Report
Abstract-Hybrid Vehicle championship provides the opportunity for
undergraduate students to showcase their proficiency in the automotive
world and develop engineering skills. This report focuses on explaining
engineering and design process behind each system in the vehicle that is
to be developed. The ultimate aim of the team “MACTRON” is to design
and fabricate Hybrid vehicle within the specifications quoted in the rule
book. The factors that motivated us to design this Hybrid vehicle are
Minimum Air Pollution, Save Gas and Money, Save Time, Sustainable
Development, Combat Global Warming, and Protect the Environment.
We have used several designing softwares to design and examine the
performance of each and every part of our vehicle. This design report is
an effort to explain the design process to readers.
Introduction- The “Hybrid Vehicle” competition tasks the teams to
design, fabricate and validate a single seated Four-wheeled Hybrid
vehicle to take part in various static and dynamic events that tests the
vehicle for the sound engineering practices that have gone into it, ability
of the vehicle in terms of speed, acceleration and endurance. Team
“MACTRON” began the task of designing by conducting extensive
research of each main component of the vehicle. Our team did not want
to design certain areas such as the frame, and then make the rest to fit.
We considered each component to be significant, so we designed the
vehicle as a whole trying to optimize each component while constantly
considering how other components would be affected. Combining this
design methodology with the standard engineering design process
enabled us to achieve a perfect match of aesthetics, performance, safety
and ease of operation. The following technical report presents the
complete design process considerations and analysis of each subsystem
and overall vehicle.
The design softwares used are SolidWorks 2016 and Catia V5 & Adams for
Suspension Analysis. The machines which are needed to fabricate the
designed model like lathe, drilling and welding machines, CNC milling

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 Design Report
machine, rapid prototype machine are available in our college so we
believe we could come with a well-designed and fabricated model.

Vehicle Specification
Parameter Value Parameter Value
Vehicle Length 97 inch Battery 48V- 30Amh
Vehicle Width 61 inch Motor 1KW
Max. Rpm-3000
Vehicle Height 46.5 inch Suspension Double wishbone
pushrod
Wheelbase 64.9 inch Steering Rack & Pinion
Front Track width 52.5 inch Front Brakes Drum
Rear Track width 52.5 inch Rear Brakes
Roll Cage Material AISI 4130
Total Mass of 270kg. Powertrain Mahindra Alpha gear
Vehicle box, open differential
Vehicle Speed 67kph included

Ground Clearance 3 inch Tire Dimension 19inch O.D,

Thickness: 5.13 inch

TARGET VEHICLE PERFORMANCE

The expected target performance for our vehicle were determined
while focusing on the following factors –

❖ Driver safety
❖ Adventurous ride and low cost
❖ Manoeuvrability & Endurance
❖ Track study
❖ Easy manufacturability
❖ Avoid over engineering
❖ The basic calculations and readings are as follows -

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Design Report
o Maximum- Speed – 67kmph
▪ Max. Acceleration from IC engine – 3.83m/s^2
▪ Max Acceleration from motor – 2.142m/s^2
❖ Stopping Distance at max. Speed-16.83m
❖ Min. Turning Circle radius 2.47 m
o Min. Ground Clearance -3 inch

CHASIS FRAME DESIGN

OBJECTIVE:-
The function of the chassis is safety and comfort of the driver and support
all operator control systems (steering and braking), engine and drive
train.

DESIGN CONSIDERATIONS:-
The primary objective of the frame is to provide a protected space around
the driver that will keep the driver safe. The chassis are compact and
λ-Joints are introduced between the members joining bulk head and
front roll hoop. The front part of chassis is raised by 60mm to decrease
the height of centre of gravity so that rolling can be reduced. The
introduction of pentagonal front hoop provides larger field of view and
more comfort by providing the support better than rectangular of square
roll hoop. The widen main hoop aims to provide larger space that is a
spacious driver compartment and at the same time follows the template
considerations mentioned in the rule book.

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Design Report

UNIQUE FEATURES

Its secondary objectives are to provide reliable mounting locations for

components, be appealing, low in cost, and low in weight. We met these
objectives by choosing a frame material that exceeds the strength
requirements, but still gives us an advantage in weight reduction. We
provided a low cost frame through material selection and incorporating
more continuous members with bends rather than a collection of
members welded together to reduce manufacturing costs. Solid works
and Catia was used to model a frame that is aesthetically appealing and
meets all requirements defined in Rulebook. While designing the
chassis, component spacing, driver`s comfort and high torsion rigidity
were given special considerations. The suspension points are not
directly connected to main hoop bracing so that the driver is not
affected by the sudden shocks transmitted through the members
of chassis.

MATERIAL SELECTION:-
We felt that one of the key design decisions of our frame that would
greatly increase safety, reliability and performance is material selection.
To ensure that we chose the optimal material, we did extensive research
and compared materials in multiple categories. Our key categories for
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Design Report
comparison were strength, weight, cost and availability. Thus we
narrowed down our options and two materials were considered for the
construction of the chassis: AISI 4130 seamless tubing based on the
bending stiffness and strength requirements.
4130 steel with O.D. 1 inch and thickness 2.4mm was finally selected
considering the FEA analysis results, easy availability and lower cost.

PROPERTIES:-
1. Material - AISI 4130
2. Yield Stress - 370 MPa
3. Poisson Ratio – 0.29
4. Mass Density – 7850 Kg/m3

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Design Report
CHASSIS TYPE- SPACE FRAME CHASSIS
SPACE FRAME CHASSIS GIVE MAXIMUM STRENGTH AT MINIMUM
WEIGHT.
SPACE FRAME
CONSIST OF
MINIMUM
POSIBLE
TRIANGALS
WHICH INCREASE
THE FACTOR OF
SAFTY.

Triangulation and its need:

Stress at 1000N force : Stress at 1000N force :

Max stress =84 MPa Max stress= 7.6MPa

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Factor of safety=31 Factor of safety=45

Iterations:
1st iteration 2nd Iteration

3rd Iteration 4th Iteration

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FINAL ITERATION

FINITE ELEMENT ANALYSIS:-

Finite Element Analysis is a method for predicting how a product

reacts to real world. It shows whether an element breaks, wears out
or work the way it is designed. It helps in prediction of behaviour of
products during Mechanical stresses, fatigue, motion , the
calculation of various loading constraints applied and the results
obtained are described
below-

FRONTAL IMPACT
Forces during the frontal impact
were calculated using Newton’s second law of motion considering an
impact time of 0.25 sec and velocity of the vehicles colliding to wall is
67kmph (18.61m/s)

Initial velocity u=18.61m/s

Final velocity v=0m/s
Stopping time =.25sec
g=9.81
Acceleration = (v-u)/t
= (18.61-0)/.25
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Design Report
= 74.44
Newton’s second law =F=ma
F=340x74.44
=25311 N
G force = weight x g
=340x9.81
=3335N
Front impact in G force = 25311/3335
=7.51G-force
Approx. = 7.5 G.
Similarly, impact forces for various other conditions such as side
impact, rear impact, torsion test & modal test were calculated.

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Rear impact –rear impact of the vehicle is due to impact of another

vehicle during competition. We consider that driver of other vehicle is
decrease the speed at rear impact. 5G force consider at rear impact.

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Side impact – it is similar to the rear impact so 5G force apply at side

impact

Bending stiffness- bending stiffness of vehicle is due to self-weight of

vehicle and driver.1.4G force consider for bending stiffness.

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Torsional rigidity – this test is done due to unexpected barrier at a side of

front or rear wheel. 2G force consider for torsional rigidity.

Dynamic Analysis:
Computational Fluid Analysis of Front Fairing:

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