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- 1. − 1 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
Technical Specifications
Estimated weight of vehicle 350 kg (Frame 52.2 kg)
Estimated cost of single vehicle INR 1,40,000
Length of vehicle 2.28 m
Width of vehicle 1.10 m
Height of vehicle 1.28 m
Ground clearance of vehicle 238 mm
Tyre size 135/70 R12
Minimum turning radius 3.284 m
Maximum speed of vehicle 52 km/h
Battery specifications 12(x4) volt 90Ah
Motor Specifications 1250 watts
Battery runtime at full load and full speed 3.329 Hr
Brake oil DOT 3
- 2. − 2 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
Frame design
Isometric view of EFFICAR Side View
Top view Front View
IsometricView
Top View
CHASSIS AND
FRAME
- 3. − 3 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
Electric Drive & Power-Train
Model No. Power
(watt)
Current (A) Voltage (V) Continuous
Torque (Nm)
BLDC 125/2D 1250 26.04 48 V DC 2.7
MOTOR SPECIFICATIONS
POWER TRAIN-
BLDC CONTROLLER
•Power Rating
- 40 A
•Mosfets - 24
•Supply Voltage - 48 V
BATTERY
4 x 12 V 90 Ah Battery connected
in series.
Battery runtime = 3.329 Hr
Max. charging time = 15.613 Hr
(10% efficiency loss)
•We used Pulsar 150cc engine Gearbox
•Used Chain sprocket mechanism for
transferring of power
- 4. − 4 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
FEA & MATERIAL
IMPACT FOR
CE
(N)
DIREC
T
STRES
S
(MPA)
MAX
STRESS
(MPA)
DEFORMATIO
N
(MM)
FRONT 6000
4.5821
120.01 3.0336
SIDE 4000
26.661
39.581 0.7561
ROLL-
OVER
5000
25.468
721.21 10.851
MATERIAL AISI 1018
Density 7.8 g/cm3
Poisson’s Ratio 0.29
Ultimate Tensile
Strength
440MPa
Yield Strength 370MPa
Elongation at break 15 %
Factor of Safety 2
- 5. − 5 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
SEATS , STEERING & BRAKES
OEM Bucket Seats ,
fully reliable racing
seats , Side-to-side
seating arrangement.
Higher leg and upper
body supports.
These seats are made
for using with 4 point
racing seat belt
harnesses.
Deep thigh bolsters to
keep the driver firmly
placed in seat.
S
E
A
T
S
B R A K E S
S
T
E
E
R
I
N
G
Steering
Arrangement
Ackerman
Steering
Turning Radius 3.284m
Steering Angle
(outside)
25degrees
Steering Angle
(inside)
32degrees
BRAKING DISTANCE
Disc brake of bike discover with
four master cylinder.
braking distance, d= 15.3m when
v =15m/sec
t
α
V
F
y
- 6. − 6 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
Suspension
S . No Consideration Result
1. Front & Rear
Suspension
Double Wishbone Suspension (Unequal
arms)
2. Castor 1.5 degree (Negative)
3. Toe in 3 degree (Positive)
4. Length of upper A
arm
16 inch
5. Length of lower A
arm
10 inch
WHEEL DIAMETERS 12 INCHES
TYRE DIMENSIONS 135/70 R12
TYRE TYPE RADIAL TUBELESS TYRES FOR BOTH
FRONT AND REAR
Wheels & Tyre
- 7. − 7 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
Safety features, Ergonomics and Innovation
Analysis of roll
cage shows that
the value of
maximum
deformation is very
less.
Side members I
roll cage to avoid
harm to
passengers and
driver in case of
side collision.
Racing grade seat
for driver and
compact structure
of passenger
cabin.
Battery
compartment
sealed and
isolated from driver
with sheet metal.
S
A
F
E
T
Y
F
E
A
T
U
R
E
S E R G O N O M
I
N
N
O
V
A
T
I
O
N
• Presence of automatic sensors to detect any
spark produced and location of fire
extinguisher in the vicinity to ensure
maximum safety from fire issues.
• We have used 4 master cylinder to avoid
junction formation and hence avoid brake fail
probability.
• We have put an IR sensor in the helmet
which ensures that the driver is unable to
drive unless the helmet is on to ensure safety
of driver.
- 8. − 8 −© 2015 ZS Associates | CONFIDENTIAL EFFI-CARS 2016 VIRTUAL REPORT FORMAT v2.0
Project Time Plan
SR.
NO. TASK NAME START DATE END DATE
1 STUDY AND DESIGN 20 -03-2016 14-04-2016
2 EFFICARS RULEBOOK STUDY 15-04-2016 18-04-2016
3 ROLLCAGE DESIGN 17-04-2016 19-04-2016
4 SUSPENSION DESIGN 20-04-2016 22-04-2016
5
TRANSMISSION AND
TYRE/WHEEL DESIGN 23-04-2016 25-04-2016
6 BRAKES DESIGN 26-04-2016 28-04-2016
7 STEERING DESIGN 26-04-2016 28-04-2016
8 ANALYSIS OF COMPONENTS 29-04-2016 01-05-2016
9 MARKET SURVEY 25-03-2016 04-04-2016
10
DISCUSSION AND PLAN
IMPROVEMENT 02-05-2016 03-05-2016
11
IMPROVEMENT
IMPLIMENTATION 04-05-2016 05-05-2016
12 FINAL DESIGN 06-05-2016 14-06-2016
13 BUGGY CONSTRUCTION 15-06-2016 09-07-2016
14
MATERIAL AND SPARE
PROCUREMENT 10-07-2016 19-07-2016
15
WELD CHASSIS AND
SUSPENSION PART 20-07-2016 26-07-2016
16
BUILD FRONT AND REAR
CONTROL ARM 27-07-2016 03-08-2016
17 TYRES AND WHEELS 04-08-2016 09-08-2016
18 BRAKES 10-08-2016 15-08-2016
19 ASSEMBLY 20-08-2016 31-08-2016
20 TESTING AND COMPLETION 01-09-2016 12-09-2016