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