bajapresentation1-1-230504024345-418b751f.pptx

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1. What Is BAJA?? BAJA SAEINDIA is an intercollegiate engineering design competition for undergraduate engineering students. The objective of the competition is to simulate real-world engineering design projects and their related challenges. Each team is competing to have its design accepted for manufacture by a fictitious firm. The students must function as a team to design, engineer, build, test, promote and compete with a vehicle within the limits of the rules. They must also generate financial support for their project and manage their educational priorities. BAJA SAEINDIA is conducted for two vehicle categories: M-BAJA – I. C. Engine Vehicle E-BAJA – Battery Operated Vehicle BAJA SAEINDIA 2023 Events will be conducted in 3 Phases – Phase 1 - Preliminary Round Phase 2 - Virtual Event Phase 3 - Physical Dynamic Event

2. DEPARTMENTS IN BAJA FRAME & ERGONOMICS SUSPENSION & STEERING POWER TRAIN BRAKES STATICS

3. SUSPENSION & STEERING

4. Types of suspension Macpherson Suspension. Double Wishbone Suspension.

5. Types of Steering: Ackerman Steering Ackermann steering is that the inner wheel (closer to ICR) should steer for a bigger angle than the outer wheel in order to allow the vehicle to rotate around the middle point between the rear wheel axis. Consequently the inner wheel travels with a slower speed than the outer wheel.

6. Dampers used in Baja Vehicle: Steering Rack Used in Baja Vehicle

7. POWER TRAIN

8. IT IS THE POWER DELIVERY SYSTEM OF A VEHICLE. BAJA VEHICLE CONSISTS OF FOLLOWING POWER TRAIN COMPONENTS: CVT (CONTINUOUSLY VARIABLE TRANSMISSION) REDUCTION GEAR BOX HALF SHAFTS ENGINE

9. ENGINE: M-BAJA ENGINE IS A STANDARD BRIGGS AND STRATTON 10HP VANGUARD ENGINE. NO MODIFICATIONS OR TUNING OF ENGINE IS ALLOWED. DRIVER GEAR PULLEY IS ATTACHED TO ENGINE OUTPUT SHAFT. CONTINUOUSLY VARIABLE TRANSMISSION (CVT): IT IS A BELT AND PULLEY TRANSMISSION SYSTEM. CENTER DISTANCE IS 242MM. LOW RATIO IS 0.43:1 AND HIGH RATIO IS 3:1. CV-TECH CVT WAS USED. CVT CASING WITH RIGID MESH OR METAL SHEET IS MANDATORY .

10. HALF SHAFTS: HALF SHAFTS ARE POWER TRANSMITTING MEMBERS TO THE WHEELS. WE HAVE USED CUP JOINT SHAFTS (OEM COMPONENT) THERE ARE TWO TYPES OF SHAFTS: CUP JOINTS UV JOINTS REDUCTION GEAR BOX: IT IS USED TO MULTIPLY THE TORQUE FROM THE ENGINE. WE USED A GEAR BOX WITH RATIO OF 13:1 GEAR BOX IS EQUIPPED WITH SPUR GEARS AND HP GEAR LUBRICANT IS USED. DRIVEN GEAR PULLEY OF CVT IS CONNECTED TO GEAR BOX.

11. STATIC DEPARTMENT

12. WHAT DOES STATIC DEPARTMENT CONTAIN? Phase 1: Design Presentation Phase 2: Design CAE Cost Sales Go Green Total static events consists of 200 points and 40 extra points if selected for final events.

13. PHASE 1: DESIGN PRESENTATION It is an online presentation which consists of preliminary design idea. In this presentation we have to brief them about our new design by comparing to our previous year design. Explain them how the new design is efficient than previous year design .

14. PHASE 2: STATIC EVENTS Design Event: this event explains our final design and we will be finalizing the design and no further changes are accepted. CAE Event: This event explains about the mechanical analysis done on the frame of the BAJA. Cost Event: This event briefs the overall cost of the vehicle. Sales Event: This event is a hypothetical event. Which means we have to float an ATV producing company and inspire the investor to invest in our company. Go Green Event: This event is an innovation event, in which we have to suggest a way to reduce pollution emitted from BAJA and we should also make a prototype of our idea.

15. OTHER MANDATORY SUBMISSIONS DVP DFMEA IPG Car maker Indemnity Bond Engineering Drawings Design Specification sheet

16. POINTS DISTRIBUTION IN STATIC EVENTS

17. FRAME & ERGONOMICS

18. Frame and ergonomics

19. Automobile frame is the skeleton (structural backbone) of any vehicle chassis. It is the foundation for carrying the engine, transmission system, steering system, brakes by means of spring, axle, rubber pads etc. Frame is the basic frame work of the automobile chassis. It supports all the parts of the automobile attached to it. All the systems related to automobile like power plant, transmission, steering, suspension, braking system etc. are attached and supported by it only. The frame should be extremely rigid and strong so that it can withstand shocks, twists, stresses and vibrations to which it is subjected while vehicle is moving on road . Functions of Chassis Frame: To carry load of the passengers, goods or cargo carried in the body. To support the load of the body, engine, gear box etc., To withstand the forces caused due to the sudden braking or acceleration To withstand the stresses caused due to the bad road condition. To withstand the centrifugal force caused by cornering of the vehicle .

20. ANSYS structural analysis software is trusted by organisations around the world to rapidly solve complex structural engineering problems with ease. Finite element analysis (FEA) tools from ANSYS provide the ability to simulate every structural aspect of a product: Linear static analysis that simply provides stresses or deformations Modal analysis that determines vibration characteristics Advanced transient nonlinear phenomena involving dynamic effects and complex behaviour All users, from designers to advanced experts, can benefit from ANSYS structural analysis software through: the renowned ANSYS Workbench intuitive workflow; wide variety of material models; element library quality; solver speed, robustness and accuracy; and the ability to model every product — from single parts to very complex assemblies with hundreds of components interacting through contacts or relative motions.

21. BRAKES

22. The type of braking system used in baja vehicle is Hydraulic braking system 1. Hydraulic braking system runs on brake fluid, cylinders, and friction. By creating pressure within, glycol ethers or diethylene glycol forces the brake pads to stop the wheels from moving. 2.The force generated in the hydraulic braking system is higher when compared to the mechanical braking system. 3.DOT 3 brake fluid is preferred because DOT 3 brake fluid will absorb less water than DOT 4 from the air over time.DOT 4 brake fluid can also be used as DOT 4 brake fluids have higher minimum dry and wet boiling points Types of brakes 1.Disc brakes 2.Drum brakes CAUTION!WITH BRAKE FLUID:Highly reactive that it can damage the skin and damage the metal easily.

23. The main components used for braking in BAJA vehicle: KBX CALIPER TANDEM MASTER CYLINDER BRAKE PEDAL BRAKE FLUID LINES 3-way splitter banjo bolts bleeder bolts

24. Problems faced 1.Assembly of the master cylinder and brake pedal 2.Sealing each and every gap with proper sealant like teflon tape 3.Bending of brake fluid lines which cause damage to brake lines 4.Broken pressure switches 5.Bleeding of the brakes again and again

25. Rules according to the SAE Baja 1.Must use Hydraulic braking system. 2.Brakes Effectiveness will be allowed only if the rotation of all 4 wheels stops and the vehicle comes to stop at a place instantly 3.Brake light must have homologation marking engraved on the lens/housing part of the lamp 4.Inboard Braking rotors should meet the rules of the powertrain Guard and should prevent the unintentional contact of hands with the rotor

26. 1.Inboard braking system is used for the present baja vehicle which makes it easy while assembling. 2.Out-Board Brakes can be used for better braking efficiency,but to use this brakes there has to be knuckles designed to support the calipers and discs. 3.Solidworks software is used to design and develop the components. 4.ANSYS is used to analyze the rotor strength,heating and cooling while braking. 5.Weight,cost and efficiency are considered all the time.

27. Calculations 1.Three equations of motion which we know in 9th standard are used to find the stopping distance and stopping time of vehicle when brakes are applied. 2.pedal ratio and master cylinder bore Length,piston diameter,rotor size,contact area,brake pads measurements,etc. are taken to calculate the braking force

28. Vacancies in departments People who are interested to join the team, has to undergo screening test and an interview. Departments with vacancies : Frame and Ergonomics Suspension and Steering Power train Brakes Static

29. Cost of main materials: 1.Registration Fees: Phase 1,2&3: 71,000/- 2.Frame : AISI tubes : approx. 22,000/- Welding charges : 35,000/- 3.Power Train: CVT: 1,00,000/- Shafts(4) : 70,000/- 4. Suspension: FOX Dampers(4): 3,20,000/- Uprights(4) : 30,000/- 5. Brakes: Wilwood master cylinder(2): 20,000/- Wilwood brake calipers(4): 40,000/- Total: 7 to 8 lac, out of which we get sponsor from college and other sources at least half of the total amount. Then we are left with around 4.5 lac per person. 4.5 lac distributed among 30 members is 15,000 rupees per person.

30. THANK YOU