fiu design report - 2012(1)

7/25/2019 FIU Design Report - 2012(1)

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EML 4905 Senior Design Project

A B.S. THESISPREPARED IN PARTIAL FULFILLMENT OF THE

REQUIREMENT FOR THE DEGREE OFBACHELOR OF SCIENCE

INMECHANICAL ENGINEERING

SHELL ECO-MARATHON

100 % of Final Report

Bryand AcostaMarco BetancourtFernando Pinheiro

Advisor: Professor Igor Tsukanov

February 20, 2012

This B.S. thesis is written in partial fulfillment of the requirements in EML4905. The contents represent the opinion of the authors and not the

Department of Mechanical and Materials Engineering.


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Ethics Statement and Signatures

The work submitted in this B.S. thesis is solely prepared by a team consisting of MarcoBetancourt, Bryand Acosta, and Fernando Pinheiro and it is original. Excerpts from

others work have been clearly identified, their work acknowledged within the text andlisted in the list of references. All of the engineering drawings, computer programs,formulations, design work, prototype development and testing reported in this documentare also original and prepared by the same team of students.

Marco BetancourtTeam Leader

Bryand AcostaTeam Member

Fernando PinheiroTeam Member

Dr. Igor TsukanovFaculty Advisor


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Table of Contents

LIST OF FIGURES """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #

LIST OF TABLES """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" $

ABSTRACT """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %

1 INTRODUCTION """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" &

1.1PROBLEM STATEMENT """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""#1.2MOTIVATION """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""#1.3LITERATURE SURVEY"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" $$

!"#"! %&'()*+,-. %&/(,0&1&.+2 """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" !!

!"#"3 4-15&+,+-0 622&221&.+ """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" !!

1.3.3 Background Theory""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" !7

$"%&'()*' '+*,-.-& """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" /0

2. DESIGN ALTERNATIVES """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" '%

2.1OVERVIEW OF CONCEPTUAL DESIGN """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" /12.2PROPOSED DESIGN ALTERNATIVES """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" /#

2.2.1 Engine """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 38

2.2.2 Clutch and Transmission """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #7

2.2.3 Fuel Delivery System"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 9:2.2.4 Fuel"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 93

2.2.5 Starter""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 9#

2.2.6 Electrical System """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 9#

2.2.7 Tires """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 99

2.2.8 Frame"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" 9;

2.2.9 Steering system"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""


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:"0


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List of FiguresFigure 1 - Evo Supermileage"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #$Figure 2 - Alerion Supermileage""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #%Figure 3 - Project Infinity""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #%Figure 4 - Univ of Malaysia"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #&

Figure 5 - Eco Illini""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #'Figure 6 - Team Green"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #'Figure 7 - Ecolancers"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" #(Figure 8 Distribution of energy in a vehicle"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" $)*+,-./ 0 1 2.3, 45 6/789+:; """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %%*+,-./ #) 1 ?,+?/ @8A 6+/= """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %(*+,-./ #$ 1 >?,+?/ 5+B/ 4+/= """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %(*+,-./ #% 1 >?,+?/ 8? C:3?B """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %D*+,-./ #& 1


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*+,-./ &( 1


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List of Tables@3U7/ # 1 [+5: 8M A3.3L/:/.5 """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %)@3U7/ $ 1 >?/.,; 3?B A8=/. 9379-73:+8?5 """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %$Table 3 - Engine selection""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" %&@3U7/ & 1 >WA/9:/B >WA/?5/5 """""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" D#

@3U7/ ' 1 K-../?: >WA/?5/5 """"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""" D$


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Abstract

The main objective of this project is to design a fuel-efficient car prototype moved by an

internal combustion engine to participate in the 2013 Shell Eco Marathon in Houston,

Texas during the dates of March 29th- April 1st. Panther Killer used Panther Rage G2

and Panther Rage cars as reference but a new car was build from scratch envisioning an

efficient transition to the internal combustion category of the competition. Abiding by the

extensive rules and regulations of the competition, our group modeled, manufactured and

tested a vehicle with optimum aerodynamics, minimum weight and reasonable budget

that fit the realistic guidelines of the project.


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1 Introduction

1.1 Problem StatementOne of the main concerns of our generation is the gradual increase of the earths

temperature, in other words, the phenomenon called Global Warming. This constant

elevation of the earths thermometers could lead to catastrophic results in a matter of

decades, such as the melting of the poles, disappearing of islands and extinction of races.

The biggest catalyst to this phenomenon is the emission of greenhouse gases. Greenhouse

gases, such as carbon dioxide and methane, are mainly generated due to the combustion

of fossil fuels, one of them being oil that moves our cars. The accumulation of those

gases in the layers of the atmosphere is called the greenhouse effect.

Keeping in mind the threats our environment is currently under, Shell created a

few decades ago the Shell Eco-Marathon competition, challenging students to not only

look for other alternatives of energy but also, to improve and optimize the ones that can

be found today. Even though our government invests over $51 billion dollars per year in

renewable energiesi

, over 80% of the energy we use in the world today, still comes from

fossil fuels against 9% from renewable sources. Therefore, keeping in mind oil will still

be the main source of energy for our cars in the near future; the Shell Eco-Marathon has

helped students to explore ways to improve mileage per gallon in such vehicles. ii

1.2 Motivation

The project was first introduced to the group by one of the teams members,

Bryand Acosta. Bryand, who had contacted members that were part of Panther Rage G2

team in the previous year, saw a great opportunity in this project to keep the tradition at

Florida International University (FIU) of participating and representing the school in this


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internationally recognized competition. Last years team had nothing but great feedback

to give to Panther Killer, and after surpassing their own expectations in the

competition, they highly recommended the experience for the present team.

Made up of members that had previously few or no hands on experience with

the concepts learned throughout our engineering courses at FIU, our team was

immediately attracted by the chance of building a car prototype. This project involves

basic concepts of real sized cars such as design of a chassis, a body, steering and braking

systems and most importantly putting it all to work with an engine. Combining these

elements with the challenges of reducing weight, increasing aerodynamics and respectingthe rules of the competition, this years team saw in the Eco Shell Marathon the perfect

components to fulfill the requirements of Senior Design Project.

Panther Killer has utilized concepts learned not only in the classroom but also in

computer programs, such as Solid Works and CAD, which were essential in order to

make some of the simulations of the car.

Last, the team that is representing FIU this time around, is looking forward to

travel to a different state and network with students from different countries and

exchanging ideas and different concepts that are utilized in the engineering world. The

team sees the competition as a rewarding experience for all the months of hard work put

into it.


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1.3 Literature Survey

This survey has the purpose of letting the team members become informed on the

theory behind the basic functionality and operation of the different components and

systems that come together to make an automobile. Furthermore this survey will extend

into assessing the technologies used by the top ranking competitors in the Shell Eco-

Marathon over the years.

*+,+* -./0123456 -.7048.9.63:

Shell provides access to a comprehensive publication of all the rules and

regulations of each years competition, the team will have to constantly reference this

book to make sure every design requirement is met before manufacturing can take place.

A copy of this rulebook is not provided within the body of this document so as not to

dilute its content, but is available in appendix A.

*+,+; '59


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Figure 1 - Evo Supermileage

Results:

673km/L

Body:

Monocoque carbon fiber, with 3 wheels

Engine:

modified briggs &Stratton engine with custom overhead cams and valves, 47cc of

displacement, 13.7:1 compression ratio, sequential electronic fuel injection with

programmable ECU and electric starter.

Transmission:

Centrifugal clutch, single gear ratio 10:1, with replaceable gears to vary from 9:1 to 13:1

Vehicle Weight:

47kg

Cost:

50000$ Canadian dollars and 8000 hours of fabrication


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Alerion Supermileage

Figure 2 - Alerion Supermileage

Results:

1347km/L

Body:


Vehicle Weight:

94lb

Project Infinity

Figure 3 - Project Infinity

Results:

1347km/L
http://www.mecano.gme.usherbrooke.ca/~supermileage/images/Fils5.jpg


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Body:


Wheels:

Michelin 44-406

University of Science of Malaysia

Figure 4 - Univ of Malaysia

Body:

Aluminum frame on composite honeycomb sandwich for the floor pan

Wheels:

Custom made hubs for ceramic angular contact bearings, as replacement for OEM wheel

hub

Results:

Could not finish race because the car could not travel up a steep slope for lack of a lower

gear ratio


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Eco Illini

Figure 5 - Eco Illini

Body:


Engine:

Saito 57cc 2 cylinder boxer engine for hobby aircraft, with custom throttle body for

electronic fuel injection, with Megasquirt 3 ECU, and electric start

Transmission:

Single reduction transmission with a 451c wheel size sprocket

Team Green

Figure 6 - Team Green

Results:

6603 mpg


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Body:


Engine:

34cc single cylinder engine customized with 2 sparkplugs, variable inlet valve timing and

fuel injection with an engine management system provided by General Engine

Management Systems Ltd

Transmission:

Centrifugal Clutch

Wheels:20in modified BMX style bicycle wheels with Michelin low rolling resistance tires, and

custom hubs.

Weight:

42kg

Ecolancers

Figure 7 - Ecolancers

Results:

318 mpg

Body:

Aluminum structure with sheet metal body and 3 wheels


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Engine:

GXH Honda 49cc single cylinder engine with fuel delivery via carburetor

Transmission:

Extreme Duty Centrifugal Clutch coupled with a single gear 12:1 reduction as large as

the wheel itself

Wheels:

Bicycle wheels with Michelin low rolling resistance tires.

Weight:

42kg

1.3.3 Background Theory

Engine Efficiency

Competition guidelines state that every internal combustion engine used to compete must

use a four-stroke cycle to produce power.

In theory the internal combustion engine efficiency is limited to that of the Carnot-cycle

The efficiency for a Thermodynamically reversible Carnot cycle engine is given by the

equation:

where: is the efficiency

TC is the absolute temperature in the cold heat reservoir

THis the absolute temperature in the hot heat reservoir


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The Carnot Cycle theorem states that:

An engine operating between two heat reservoirs can not be more efficient than a

Carnot engine operating between these same reservoirs.iii

The temperature of the cold reservoir is given by the ambient temperature outside the

engine, which should be between 15C and 25C during the month of April in Houston,

Texas.ivOn the other hand the maximum temperature that could be achieved would be

limited by the metallurgic properties of the engine and this temperature is also referred to

as the adiabatic flame temperature, which is itself a function of the products of

combustion used. The adiabatic flame temperature is both difficult to quantify in practice

and theoretically due to hysteresis in temperature sensors and due to the fact that

incomplete combustion will change the molar ratio of products of combustion being

produced.

Furthermore the engine of choice for this competition has to be a four stroke, which

makes it an Otto cycle engine for which the efficiency equation is given by

where: r is the compression ratio

is the specific heat ratio

The compression ratio is specific to the engine design and higher values increase the

engine efficiency, yet it is limited by the fact that higher ratios may cause the combustion

in the cylinder to occur prematurely, this is a phenomenon called engine knock and it will

adversely affect engine efficiency and life expectancy. Engine efficiency is in most part a

function of this value since for air/fuel mixtures is usually taken to be 1.4, but it is

important to note that this value rises with increasing temperature.vThis equation gives


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the thermal efficiency of the engine, which is the heat energy it can actually extract from

the products of combustion to transform into mechanical work.

Non the less the efficiencies that can be derived from the above equations far exceed the

real world efficiency measured from a real world engine which initially has an inefficient

combustion, and then has to overcome friction, aerodynamic drag of gases inside the

engine, parasitic losses from accessories, alternators and pumps, poor valve timing

causing vacuums during the intake stroke or pressure loss during compression and

expansion, all this while loosing heat through the cylinder walls. This real worldefficiency is termed the brake specific fuel consumption and is the ratio between the fuel

consumed and power produced, and it is measured in

Where: r is the rate of fuel consumed in g/s

is the torque produced by the engine in NewtonMeters

is the engine speed in radians/second

Note that by knowing the energy density of the fuel in terms of its mass it is possible to

calculate how much energy is actually stored in that fuel in order to get a number in terms

of strict energy efficiency.


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Vehicle Efficiency

Figure 8 Distribution of energy in a vehicle

The energy that the engine can convert to mechanical work is limited by its thermal

efficiency and the mechanical losses inside the engine, but not all the energy produced by

the engine is available to energize the transmission, there are also parasitic losses that

arise from using energy from the engine to pump fluids throughout the vehicle and create

electricity in order to power the cars electrical system.

The powertrain efficiency is given by the product of the efficiencies of all mechanical

components starting at the engine and ending at the wheels axle. For our design this

includes the engines thermodynamic efficiency, its mechanical efficiency, and that of the

transmission plus the parasitic losses. It can also be calculated as the ratio between the

powertrain output, and the power associated with the fuel consumption rate.


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After all this losses the power that is available at the wheels also has to overcome

aerodynamic drag, rolling resistance forces, and the weight of the vehicle unless the

surface is perfectly flat, together this make up the forces required for the vehicle to

maintain a given speed, any power available at the wheels, in excess of this will be

available for acceleration

Steering System

Defining the steering of our car was a challenging task and one that required plenty oftime and attention since this component is so crucial to the performance of any fuel-

efficient vehicle. The steering is a key component for a few different reasons. First, it

places the wheels in a manner that will reduce the rolling resistance force of the overall

car. Also, this is the most important component of driver interface and must allow the

pilot to perform the task in an efficient manner and most importantly, having a reliable

steering will play a major role in the drivers safety.

The first question that our group asked was weather we would opt for front wheel or back

wheel steering. Since our engine is directly connected to the back tire, which is heavier

and thicker for being an original scooter slick tire, we immediately discarded the option

of rear steering. Once we had decided the steering would go on the front two wheels, we

still had to analyze several different options available in the marker in order to find the

most cost efficient one.

Immediately after starting our literature survey, we considered having a hydraulic

breaking system (mainly because it is the one recommended by the organizers of the


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competition). The hydraulic was certainly a reliable one, however, our team did not find

this option cost/weight efficient since it would require an extra system to pump the liquid

necessary to make the calipers function. Therefore, we withdrew this option as well. The

following steering option that caught our attention was steering by wire. This is by far the

most weight efficient technique since steering mechanism is replaced by electronic

control. At first, this sounded like a great option since removing all the usual components

of a mechanical system would reduce the vehicles weight. Unfortunately, this method

also had its downsides. First the amount of electricity to be provided by a battery to make

the system work would require a battery that physically did not fit our car. Second,previous groups that performed tests with this kind of system proved a slow response to

the drivers commands and it was unreliable. Since we did not have the resources to buy

the system and test it ourselves, we trusted previous competitors assessments and opted

for something more efficient. Our last frustrated attempt was to make a custom made

system similar to last years, which resembled a pulley system to turn the spindles. Since

our teams concept design envisions to provide steering in only one hand, rather than both,

this option was forgotten.

Finally, our group opted for a mechanical system. We evaluated different designs that

were inspired in go-karts. The problem we encountered in this case was the availability of

products that could be purchased online to match wheels. Most specifically, the diameter

of the spindle axles were too thick to fit in any bicycle wheels that we could purchase.

We had the option of manufacturing our own parts but that would require time and some

resources that were not easily available to us. Therefore, we finally found something that

would be perfect to our design; we decided to go with a steering system extremely similar


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to recumbent bikes and tadpole trikes. All the details about the selected steering will be

explained on the proposed design section of the report.

Wheels

Wheel selection to our car came almost simultaneously with the steering system since we

needed to find a hub that would comply with the diameter of the spindle axle. As briefly

mentioned above, our team spent countless hours looking for the perfect combination of

wheels and bearings to our car. In order to find that, the following parameters were taken

into account:

The wheel must have optimal aerodynamics to minimize energy loss

It had to fit our Michelin ultra low resistance tires (20 x 1.75)

Made of lightweight material

Strong enough to sustain loads and keep the tires in the correct place

First we had to consider the option of having wheels with spokes against disk wheels.

Unfortunately, due to the limited resources available to our team, manufacturing our own

disk wheels had to be taken out of question, so we agreed on purchasing a pair of wheels

already available in the market. It is important to remember that the back tire wheel was

part of a package that was purchased with the engine and therefore, those decisions

would only affect the front two. The previous two teams at FIU had used bicycle wheels,

which are a viable option for the job especially cost-wise. Our team could not proceed

with the same choice since the diameter of the axle of bicycle wheels was extremely

small for our steering ideas. It was possible to get those custom made; however the price

and the difficulty of incorporating a braking system to it forced our team to move on to a

different option. Finally, we found the option of recumbent bikes and tadpole trikes,


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which use a wheel with the specifications, that we needed and meets all the criteria

described in the bullet points above.

Another important decision relating to the wheels used in the car were the wheel

bearings. Even though the drag produced by those is relatively small when compared to

the ones produced by the tires, it helps to select the correct bearings in order to optimize

your vehicles result. Since the vehicle will run at low speed and will yield a relatively

low amount of loads, ball bearings seem to be the most viable option due to smaller

frictional moment. Also, using ceramic bearings rather than steel would be beneficial

since it reduces the overall weight and friction.

Improving Vehicle Efficiency

Since the thermodynamic efficiency is dictated by the engines compression ratio it is

ideal to have higher values of such, but for any given fuel there exists a limit to which

this compression can be achieved without self-igniting the air/fuel mix prematurely,

which is known as engine knock, different types and grades of fuel have distinct anti-

knock characteristics.

It is important to also note that internal combustion engines are most efficient at a certain

operational speed that is particular to each engine, with small engines having particularly

high values for such ranging around 5000RPM to 7000RPM. Furthermore, the

relationship between the engines operating RPM and the power/torque output is not

linear, and there exists a point where the engine operates at maximum efficiency.


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Keeping the engine operating at this speed thus provides better power output

characteristics.

Being able to control how much fuel is fed to the engine for each combustion cycle will

directly contribute to fuel economy by being able to provide the exact amount of fuel to

keep combustion occurring at the proper stoichiometric ratio or in a lean-burn regime

where there is a slight excess of air over which is required to maintain stoichiometry.

This fine degree of control can be achieved by implementing fuel injection controlled by

an onboard computer for the engine named an electronic control unit, or ECU, that makesdecisions based on its programming and input from different sensors that relay

information about the engine timing, and the oxygen content of the intake and exhaust.

Further efficiency can be gained by the use of bearings that produce less friction within

the engine and in the hubs of free rolling wheels. Reducing or eliminating the electrical

and fluid pumping loads on the engine can further cut parasitic losses. Reducing the mass

of the vehicle offers a great advantage not only because it lowers the kinetic energy of the

vehicle at any given speed and it offers an especially significant advantage when driving

on an incline. Minimizing the effects of wind resistance, using low rolling resistance tires

and avoiding drag due to the vehicles braking systems, can further reduce the drag forces

acting against the vehicles motion.

Finally it is crucial to understand that it is the driver and the driving style implemented

that ultimately define the fuel economy that the vehicle will actually achieve, and it is


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important to train the driver in the implementation of highly efficient driving methods.

The most common method implemented in the competition is the drive-and-glide method

where the driver accelerates the car to 20MPH, he then shuts off the engine, and allows

the car to coast down to a speed of 10MPH, at which point the engine is restarted and

accelerated again, this is all keeping in mind that the average velocity during the

competition must remain above 15MPH.

*+= >15?21 @.28646/

This project would not have been possible without the teams effort to engineer

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H: =35 3 4/.; +?:/./5:+?, /W/.9+5/ :8 7/3.? 3U8-: ?/= A3.:5^ :8875^ 3?B :/9N?+`-/5

=/ =/./ ?8: M3L+7+3. =+:N" C8L/:+L/5 =/ 93? -?B/.5:3?B :N3: =/ ?//B 58L/:N+?, +?

8.B/. :8 B/4/7op a function, but closer inspection reveals that those specialized parts,

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/WA/?5/ :N3: +: =8-7B N34/ :3F/? :N/ :/3L :8 B/4/78A +:" @N+5 =35 4/.; +LA8.:3?: U/93-5/


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=/ L3B/ +: 3 A8+?: :8 :.; :8 U-+7B :N/ 4/N+97/ M.8L 35 L3?; 5:3?B3.B+a/B A3.:5 35 =/ 98-7B

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+L3,+?/B U; :N/ /?,+?//.^ :N/ B/4+7 :.-7; +5 +? :N/ B/:3+75"

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=35 ?/3.7; +LA855+U7/ =+:N8-: .+5F+?, N34+?, 97/3.3?9/5 /?B+?, -A :88 78=^ 5A/9+377;

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-?B/.5:3?B+?, 8M =N3: :N/ 4/N+97/ 3/.8B;?3L+95 5N8-7B U/ 7+F/"

*-.:N/.L8./ 9N885+?, 3?B +LA7/L/?:+?, :N/ +B/37 L3?-M39:-.+?, L/:N8B5 :8 F//A

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/WA/.+/?9/^ :N3: L3B/ -5 +LA7/L/?: L3?; 8M :N/ 5F+775 =/ N34/ U//? /WA85/B :8 35

engineering students, while forcing us to go beyond the classrooms scope and into real

7+M/ 3AA7+93:+8?5^ =N+9N ?8: 8?7; +?97-B/ /?,+?//.+?, B/4/78AL/?:^ 3?B A3.: 58-.9+?,^ U-:

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5-A/.+8.5^ 3?B :/3L L/LU/.5^ :8 ?3L/ 3 M/="

2. Design Alternatives

2.1 Overview of conceptual design

Weight:

The target weight of our vehicle is less than 100 lbs, with a 150lb being a worst possible

case scenario

Body:

The body and frame should combine to make a sturdy and structurally safe aerodynamic

shell. Its construction must consist of a mixture of lightweight materials that can be

shaped into complex parts: plastic sheets, aluminum, carbon, and glass-reinforced plastics

are being considered. Rigidity and strength would be achieved by using honeycomb cores

or tubular frame structures.

Engine:

Must be a small and fuel efficient engine under 50cc


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Fuel Delivery System:

Electronic fuel injection is preferred over carburetion to achieve stoichiometric

combustion, since Maximum flame temperature occurs at the 14.7:1 air/fuel mixture

combustion ratiovi

Transmission:

Must allow for the engine to be started under unloaded conditions even if the vehicle is in

movement, and should at least provide one reduction gear to have the engine operating in

the most efficient range of its power band while making the vehicle drivable in the speed

range of 0-20 MPHStarter

The starter must allow for a single person inside the cabin to turn the engine on without

taking their hands of the steering wheel.

Wheels and tires:

Michelin designs and manufactures ultra low rolling resistance tires specifically for this

competition, these are meant to fit over standard bicycle wheels, outfitting such wheel

with ultra low friction bearings and making this whole assembly as light as possible

would be ideal for the design.

2.2 Proposed Design Alternatives

2.2.1 Engine

In order to select the engine it is necessary to first examine the power

requirements to move our vehicle at the speed required by the competition. For the

preliminary analysis there will be several assumptions made, and these will be clearly


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stated. The power requirements of our vehicle for any given speed are given by the

product of the sum of the forces acting against our vehicles motion and the vehicles

velocity and acceleration; therefore the power calculations were made using the

following parameters:

1)23- 4 5 6/7+ #. 8)")(-+-"7

FrontalAreaOfCar 0.42

PercentGrade 2

VehicleMass 136.36Drivetrain efficiency 0.8

Tire rolling resistance coefficient 0.0025

Brake and Steering Resistance 0.003

DragCoefficient 0.15AirDensity 1.225

Wheel Radius 0.254

It was assumed that the total mass for the car, and a driver with an average mass

of 150lbs, will be a maximum of approximately 300 lbs, or its equivalent value of 136.6

kg. CRRis found from the Michelin specifications for the ultra low resistance tire that will

be used in the car. The density of 1.225 for air is using standard temperature and pressure

(STP) guidelines. CD, the coefficient of drag, was selected as 0.15 considering a worst-

case scenario of an aerodynamic body design, based on previous competitors with similar

body shapes that have tested their cars and calculated this value. The area used of 0.42 m2

is an approximation of the frontal area of the car, according to preliminary solid works

models of possible designs of our car. Furthermore, R is the outer radius of the Michelin

tire that will be used in the car. Also, an assumed drivetrain efficiency of 80%, was again

chosen assuming a relatively inefficient transmission for the vehicle to err on the high

range of our numbers, and prevent an underpowered vehicle. The brake and steering


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resistance coefficient was estimated after doing extensive research on previous

competitors cars.

The next step in the analysis is to calculate the forces acting on the prototype

according to the speed of the same. Keeping in mind the rules of the competition that

require an average speed of 15 mph, increments of 2 mph were used to calculate the three

component of total force:

As shown above, the force (Fdrag) that acts against the vehicle can be divided in

several different components. First FRR, or force due to rolling resistance, which is

represented as the sum in between tire, steering and brake resistances. Also, another force

that acts against the car at all times is the force due to air friction, F air. Last, we have

Finclinewhich is due to the weight of the car parallel to the the roads incline, since there is

no information about the topography of the track, a small assumption must be made

considering that the competition is takingn place in a track built in the urban setting of a

Downtown Houston park.

After calculating all the forces that act against the car, it is possible to begin the

calculations for the power required to move the vehicle. The power required to maintain

the car at this constant speed was found using the following formula:

!"#$= 0.5 %& ' (2

!)) =* + (%)) +%,-))

!#./0#.1

=* + 23

!4$"+= !


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\O]

Once the power to keep the car moving at a constant speed has been calculated both in

Watts and horsepower (diving the above formula by a conversion factor), It is possible to

continue with the calculations of the kinetic energy and power required to accelerate the

vehicle. After researching average acceleration times for the same engine in similarly

sized vehicles and learning that it usually takes it 8s to get from zero to 20MPH, under

full throttle, we decided to use this time to do the following calculations:

\X]

\O]

Finally, we can use these values to calculate the total power required by the car in

Watts and in Horsepower. With this information, we are able to select a properly sized

engine that we will try to make as efficient as possible to fit the needs of the competition.

1)23- 9 5 !*-":; )*, 8#


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Y5+?, :N/ ?-LU/.5 3U84/^ +: +5 A855+U7/ :8 A78: ,.3AN5 8M :N/ ?-LU/.5 M8-?B :8

U/::/. -?B/.5:3?B :N/ ./73:+8?5N+A5 U/:=//? :N/ 4/789+:; 8M :N/ 93. 3?B :N/ B/L3?B M8.

A8=/. 3?B /?/.,;"

?/:>"- @ 5 A"): B7 C-3#=/+;

From the graph shown above, it is possible to analyze the main sources of

resistance towards the movement of the car. From Figure (3), the drag force will increase

with an increase in velocity. However, it is important to note that this increase is

relatively small. An increase of 4 N in between the velocities of 2 mph to 24 mph makes

it clear that the main source of force resisting vehicular movement does not come from

aerodynamic drag. Furthermore, the components of Fdrag, which are show in Appendix A,

show that Finclineis responsible for about 70% of the total force. Since we can not control

the tracks topography, we can say that the total weight of the car is the major component

causing inefficiency on a vehicle that is not traveling on a level surface.


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34

?/:>"- 4D 5 E#


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35

The GY6 style engines are popular in the small scooter, ATV and Go-kart

markets. There are various performance upgrade parts and documented modifications for

this type of engines available, including fuel injection conversions. This engine has a

higher compression ratio, which is something desired for higher thermodynamic

efficiency. The power rating and maximum torque are also the highest in the list with

almost a 33% advantage over the comparable Honda GXH50. On the downside; its fuel

consumption is about 10% higher. This engine is sold ready for a drum brake setup, and

comes equipped with an electric starter, and a continuously variable transmission (CVT).

The Honda engines are made in different sizes from 25cc to 50cc, and include a recoilstarter, and a centrifugal clutch. For the competitions purposes this starter would have to

be changed to an electric type in order to make it possible for the driver to turn the engine

on and off from the cockpit while the vehicle is in motion. On the other hand the

centrifugal clutch might come in useful for the development of a discrete reduction

gearing system with automatic engagement. Nonetheless the amount of support material

and documented modifications for this type of engines is also scarce, and the

nonexistence of an aftermarket part market means that tuning and performance part

upgrades would require more development and custom manufacturing.

Taking these factors into account and the expected power requirements of our

vehicle, the team has decided to opt for the GY6 engine.


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?/:>"- 44 5 !*:/*- 1#8 C/-"- 49 5 !*:/*- 7/,- B/-"- 4F 5 !*:/*- #* G+)*,

2.2.2 Clutch and Transmission

The GY6 engine comes with a proprietary centrifugal clutch and a continuously

variable transmission, or CVT. This transmission consists of a pulley on the engine shaft,

and another on the output shaft with a belt transmitting power between them. The way

different gear ratios are achieved is by having the pulleys be made of independent conical

halves (sheaves) that can move relative to each other increasing or decreasing the gap

between them so that the belt sits at different pitch circles, the ratio between the two pitch

circles would give us the gear ratio for that specific configuration, to obtain higher

understanding of the device is an exploded view in the diagram below:


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?/:>"- 4H 5 E)"+7 &"-)',#


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39

Changing the weight of the rollers, and the stiffness of the clamping spring can control

the rate at which the changes occur. This is unfortunately something that we cannot

model mathematically unless we know several dimensions, and material properties about

the transmission that are currently not available. Most of the data that will help us

optimize this transmission will come from obtaining direct measurements through

experimentation and what is referred to as tuning in the racing world.

The final drive ratio is the product of this reduction and two more that occur

inside a gearbox after the CVT, the stock gear ratios for these are in the table below and

the overall gear ratio describes the overall range:Table 3 Transmission gearing range

The centrifugal clutch consists of two main parts; the clutch swing arm assembly,

which rotates with the driven pulley, as the angular speed increases the arms swingoutward due to the centrifugal force and ultimately engage with the clutch bell. The

clutch bell being linked to the CVTs output shaft delivers the power to the gearbox and

after the compound reduction; it delivers it to the wheel. This clutch is extremely

important and needs to be tuned to achieve the following goals:

1. The clutch must be disengaged when the engine is idling, to comply with the

competitions guidelines

2. The clutch must engage quickly as the engine is throttled and must disengage

instantly when the engine is turned off. These two things are extremely important

for transmission efficiency and to enable the vehicle to coast freely without being

CVT Drive Ratio 0.8-2.0

First Gear Box Reduction 3.4

Second Gear Box Reduction 3.25

Overall Gear Ratio 8.84-26.1


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40

subjected to braking forces due to compression in the engine piston when the

engine is off.

To achieve this goal it is necessary to try different clutch springs in order to find

the appropriate stiffness for the ones that will satisfy the design.

Unfortunately while a CVT offers very simple operation with virtually no driver

interaction, it is important to note that these transmissions can be very inefficient, with

values as low as 75%, mainly due to belt slippage, other sources that contribute to this

inefficiencies are friction at surface contacts of bushings and bearings, which the team

will attempt to reduce once the engine is physically dissected, and the parts measured, inorder to assess if suitable replacements can be found

2.2.3 Fuel Delivery System

The engines above come carbureted and the team is considering having a fuel-

injected design that would be satisfied by implementing small engine fuel injection and

ECU kits sold by Ecotrons or MBE Motorsports.

?/:>"- 4I 5 ?>-3 J*K-=+/#* L/+

The kits sold by both companies come equipped with an electric fuel pump to

pressurize the fuel before it reaches the injector, but using this pump goes against the


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rules and regulations of the competition and a pre-pressurized fuel delivery system must

be implemented instead.

The guidelines stipulate that the maximum pressure this system can have is 5bar

or 72.5psi, furthermore the pressurized air must be stored in a clear container, and be

filled through a Schrader valve, the system must include safety valves, shutoff valves,

regulator, and gages, and everything must be easily drained, and removed from the

vehicle for inspection purposes.

The vehicles system will use a regular soda bottle outfitted with a Schrader valve

to accumulate air at up to 70psi, a safety relief valve will be set to release any excesspressure, and a shutoff valve will be placed inline, as per competition guidelines. This

pressure will then be reduced to 36psi with a regulator, to satisfy the operational pressure

requirements of the injector, and will then be routed to the competition-sanctioned fuel

tank. The pressurized fuel then travels through a line equipped with a shutoff valve, and

fuel-filter, before reaching the injector. A diagram of this system must be supplied to

Shell for the competition and can be seen below.

?/:>"- 4M 5 N#(83-+- ?>-3 A-3/B-"; G;7+-( A/):")(


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42

@N/ 355/LU7/B M-/7 5;5:/L 5//L5 :8 N34/ 58L/ A./55-./ 7/3F =/ N34/ ;/: :8

B/:/9:^ 3?B :N/ 487-L/ 8M 3+. +? :N/ A./55-.+a/B #(8a 58B3 U8::7/ A.84/B :8 U/ +?5-MM+9+/?:

:8 L3+?:3+? 399/A:3U7/ A./55-./ B8=?5:./3L 8?9/ :N/ 4374/ =35 8A/?" @N/ 3+. :3?F =+77

U/ /W9N3?,/B M8. 3 $ [+:/. U8::7/ +? 8.B/. :8 98LA/?53:/ M8. :N/ 7/3F5 3?B :N/ 487-L/:.+9

/WA3?5+8? 8M :N/ ,35 B8=?5:./3L"

?/:>"- 4O5 ?>*=+/#*)3 .>-3 7;7+-(

2.2.4 Fuel

Two types of liquid fuel are available for spark-ignited engines, and the engine

and fuel injection kit can handle both types of fuel, these are 87-octane regular gasoline

and pure ethanol (E100).

Regular gasoline has an octane rating of 87 while pure ethanol has an equivalent

slightly over 115. The higher the octane rating, the higher compression the engine can

achieve before the air/fuel mix self-ignites creating engine knock which will hinder


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performance and create more wear on the engine. On the other hand gasoline has a higher

energy density when compared to E100.

The team will choose to run 87-octane regular gasoline in our vehicle because

although it is recommended to modify the engine to achieve higher compression it is not

expected that this will happen due to time constraints, therefore we choose gasoline due

to its effectiveness and higher energy density that ethanol. Note that to this date the team

has not been able to find tables or equations that can help predict how much compression

an engine can achieve before inducing knock when using fuel with a given octane rating.

2.2.5 Starter

The engine considered comes with an electric starter, which is needed so that the

driver and/or computer can control when the engine turns on and off, allowing the car to

cruise with the engine off and then be started from within the cockpit when the speed

falls below a predetermined level.

2.2.6 Electrical System

The Vehicles electrical system consists of a 12v charging system comprised of a

battery and the AC magneto/stator integrated in the engine. The battery selected is the

smallest Lithium Ion battery manufactured for motosports and weights 0.5lbs at a cost of

50$, while an equivalent Lead/acid battery would have costed $30 but would have

weighted 3lbs.

The wiring harness was obtained from the same scooter that the engine was pulled

from, and was later simplified, spliced, and readapted to our vehicles needs. The

diagram below accurately represents the final product, and it is ready to be submitted to

the competitions authorities for review. The team made sure to include kill switches for


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44

the engine accessible from the cockpit and from the vehicles exterior, plus a dedicated

toggle switch for the ECU, buttons were also included to spool the starter engine while

illuminating the starter signal light, and another one to sound the horn.

?/:>"- 4P 5 C-Q/=3- R/"/*: ,/):")(

b8:/ :N3: :N/ >7/9:.8?+9 *-/7 H?I/9:+8? 5;5:/L 98L/5 =+:N 3? /W:/?5+4/ 3?B

98LA7/W N3.?/55 8M +:5 8=?^ U-: :N/ 98??/9:+8?5 5N8=? 399-.3:/7; A+9:-./ N8= U8:N

N3.?/55/5 +?:/.39: =+:N /39N 8:N/."

2.2.7 Tires

As for the rear tire the GY6 engine under consideration uses a distinct type of

tires that is designed for scooters, and compatible wheels include a hub for an expanding

internal drum brake that is built into the engine, these must also have a distinct spline

pattern that must match the one on the engines output shaft, and :N/5/ :=8 A3::/.?5 3./


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45

?8: 98?5+5:/?: U/:=//? 377 #%0cSE /?,+?/5 8. :N/ =N//75 :N3: 3./ 3B4/.:+5/B 35

98LA3:+U7/^ =N+9N 98LA7+93:/5 :N/ +55-/ 8M M+?B+?, 98../9: L3:9N/5.

The options to reduce rolling resistance in the rear tire would be to procure a high

pressure slick racing tire meant for scooters, for which there are only two manufacturers

worldwide, Savatech and Heideneau, and which would also produce a heavier assembly

which would not be as efficient as the one achieved with the Michelin tires, but to be able

to put this type of tire on the engine the team would have to be willing to invest time and

money in manufacturing it. So far the team has opted to procure the scooter racing

Heideneu tire and the wheel was inexpensively purchased along with the engine toguarantee a proper mate, but it was later realized that it is made of iron, so finding a cast

aluminum one would be the a viable improvement in weight reduction. Below is an

image of the slick tire mounted on the engine:

?/:>"- 4@ 5 !*:/*-


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2.2.8 Frame

@N/ B/5+,? 3?B L3?-M39:-.+?, 8M :N/ M.3L/ =35 -?B8-U:/B7; 35 /W:/?5+4/ 35 +:

=35 9N377/?,+?," b8?/:N/7/55^ +: =35 +LA/.3:+4/ :N3: L-9N /MM8.: =/?: +?:8 :N+5 A3.: 8M :N/

A.8I/9: B-/ :8 +:5 +LA8.:3?9/" H: =35 97/3. :N3: :N/ M.3L/ 8M :N/ 93. =8-7B U/ :N/ .88: 8M

:N/ 93.^ 35 377 :N/ 8:N/. 98LA8?/?:5 =8-7B U/ 3::39N/B :8 :N/ M.3L/" *-.:N/.L8./^ :N/

M.3L/ =8-7B ,+4/ :N/ 93. +:5 5:.-9:-.37 +?:/,.+:; 3?B F//A :N/ B.+4/. 53M/ +? :N/ 935/ 8M 3?

399+B/?:"

J//A+?, +? L+?B :N3: U/93-5/ :N+5 +5 3 5-A/. L+7/3,/ 98LA/:+:+8?^ :N/ 93. N3B :8

U/ 35 7+,N: 35 A855+U7/ =N+7/ 3758 U/+?, 53M/" @N/ M+.5: 5:/A +? B/5+,?+?, :N/ 93. =35 :8

39F?8=7/B,/ :N/ 98LA/:+:+8? ./`-+./L/?:5 M8. :N/ 9N355+5^ 3?B B/5+,? 3.8-?B :N/L"

Fortunately, the competitions only r/`-+./L/?:5 M8. :N/ 9N355+5 =/./ :N3: :N/ .877 U3.

extend 5cm around the drivers helmet, and be large enough to protect the driver in the

935/ 8M 3 9877+5+8?" O+:N 58 M/= B/5+,? ./`-+./L/?:5^ :N/./ =35 A7/?:; 8M M.//B8L :8

B/5+,? :N/ M.3L/^ 8. 58 :N/ :/3L :N8-,N:" @N.8-,N8-: :N/ B/5+,? 3?B L3?-M39:-.+?,

process many constrictions were found that reduced the teams choices for the design of

:N/ M.3L/" @N/5/ 98?5:.3+?:5 =+77 U/ L/?:+8?/B 377 :N.8-,N8-: :N/ /WA73?3:+8? 8M :N/

B/5+,? A.89/55"

R?9/ :N/ ./`-+./L/?:5 =/./ F?8=?^ +?+:+37 B/5+,?5 U/,3?" @N/ M+.5: 98?5+B/.3:+8?

was to follow in the previous teams footsteps and build a chassis out of aluminum and

=/7B :N/ :-U/5 :8,/:N/." H? :N/ +?:/./5: 8M /W9/7+?, :N/ A./4+8-5 :/3L^ M-.:N/. ./5/3.9N =35

L3B/ :N3: 7/3B :8 98?5+B/.3:+8?5 8M 93.U8? M+U/. :-U+?, =N+7/ -5+?, 93.U8? M+U/. A73:/5


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47

=+:N 98LA85+:/5 +? U/:=//? \M+,-./ dd] 35 :N/ U35/ 8M :N/

9N355+5" *8. :N/ 98LA85+:/^ L3?; 9N8+9/5 =/./ 98?5+B/./B

+?97-B+?, U3753^ U+.9N^ N8?/;98LU ?8L/W^ 3?B M83L" @N/

3L8-?: 8M L3:/.+375 3778=/B M8. L3?; 8A:+8?5 :N3: 43.+/B +?

A.+9/^ =/+,N:^ 3?B 5:./?,:N" Y7:+L3:/7;^ U/93-5/ :N/ :/3L =35

-?3U7/ :8 M+?B 3 A73:/ 3?B 98LA85+:/ 98LU+?3:+8? A.+9/B

-?B/. e#))) :N3: 53:+5M+/B :N/+. B/5+./B A3.3L/:/.5^ :N/

9N8+9/ =35 L3B/ :8 U-+7B :N/ M.3L/ 8-: 8M 93.U8? M+U/.

:-U+?," @N+5 7/3B :8 98?9/.? 35 =/7B+?, =35 ?8 78?,/. 3?

8A:+8? 35 +: +5 +LA855+U7/ :8 =/7B 93.U8? M+U/." *8.:-?3:/7;^ ./5/3.9N -?4/+7/B 3 4/.;

-?+`-/ 3?B +??843:/ L/:N8B :8 I8+? 3?; :;A/ 8. 5+a/ 8M :-U+?," "- 9D 5 S#*-;=#(2

G+">=+>"-


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@N/ A.89/55 8M B/5+,?+?, :N/ 93. =35 8?/ 8M

L-9N :.+37 3?B /..8." C/4/.37 B/5+,?5 M8. :N/

93. =/./ L3B/ -?:+7 3 M+?37 B/5+,? =35 9N85/?"

>4/? :N/?^ +: =35 B/9+B/B :N3: :N/ 3:1:+L/ M+?37

B/5+,? ./`-+./B 3BB+:+8?37 5-AA8.:5" @N/ 4/.;

M+.5: B/5+,? 93? U/ 5//? +? M+,-./ dd" @N+5

B/5+,? 5/.4/B 35 3 5:3.:+?, A8+?: M8. M-:-./

B/5+,?5^ U-: =35 ?8?/:N/7/55 B+593.B/B 35 :N/ :/3L M/7: :N3: 3 M-?9:+8?37 M.3L/ 98-7B U/

39N+/4/B =+:N L8./ 5+LA7+5:+9 98?M+,-.3:+8?5 3?B 7/55 L3:/.+375" *.8L :N/./^ 3 5/98?B

B/5+,? =35 L3B/ 3?B 93? U/ 5//? +? M+,-./dd" Q5 /4+B/?9/B U; :N/ M+,-./^ 3M:/. :N/ +?+:+37

B/5+,?^ L8./ 5+LA7+5:+9 B/5+,?5 =/./ 58-,N:" @N+5 B/5+,? M/3:-./5 :=8 M.8?: B+3,8?375 :N3:

98??/9: 3: :N/ M.8?: 4/.:+9/5 3?B :N/ :8A 4/.:+9/5 8M :N/ .877 U3." *-.:N/.L8./^ 3

`-3B.+73:/.37 .877 U3. =35 B/5+,?/B 5+?9/ 93.U8? M+U/. :-U/.5 =8-7B U/ -5/B 3?B :N85/

93??8: U/ L87B/B +?:8 3 9+.9-73. 5N3A/" E/93-5/ :N/ /?,+?/ N3B 37./3B; U//? 5/7/9:/B 3:

:N+5 A8+?:^ :N/ 98??/9:+?, A8+?:5 =/./ F?8=?^ 3?B =/./ 98?5+B/./B =N/? -5/B M8. :N+5

B/5+,?" @N/ :=8 B+3,8?37 78=/. :-U/5 :N3? 93? U/ 5//? +? 3 93?:+7/4/. 5:3:/ =8-7B 5/.4/

35 :N/ 78=/. L8-?:+?, A8+?:5 M8. :N/ /?,+?/" [+F/=+5/^ :N/ N8.+a8?:37 :-U/ 7893:/B 3: :N/

M3. U39F 8M :N/ M.3L/ =8-7B 5/.4/ 35 :N/ -AA/. L8-?:+?, A8+?: M8. :N/ /?,+?/" @N+5

mounting point would be to the tires shock absorber. As pointed out in the description of

:N/ /?,+?/^ :N+5 98??/9:+8? +5 ?8: +? :N/ 9/?:/. A73?/ 8M :N/ L8:8. 3?B :+./ 98?M+,-.3:+8?"

@N/ B/9+5+8? =35 :N/? L3B/ :8 A.89//B 3?B A-.9N35/ %( M//: 8M 93.U8? M+U/. :-U+?," @N/

A-.9N35/ =35 L3B/ M8. ( :-U/5 8M ( M//:^ /39N :-U/ 985:+?, I-5: 3U8-: e#))^ M8. 3 :8:37 8M

I-5: -?B/. e())"

?/:>"- 94 5 ?/"7+ ?")(- A-7/:*


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@N/ M8778=+?, M+,-./5 5N8= 58L/ 8M :N/

A./7+L+?3.; 5+L-73:+8?5 A/.M8.L/B" @N+5 M+,-./5

5N8= 58L/ 3?37;5+5 ./5-7:5 :N3: 5N8= M39:8. 8M

53M/:;^ :8:37 B+5A739/L/?:^ 3?B 5:./55/5"

?/:>"- 9F T*)3;7/7 U4V

?/:>"- 99 5 G-=#*, ?")(- A-7/:*


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?/:>"- 9H T*)3;7/7 U9V

?/:>"- 9I T*)3;7/7 UFV


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?/:>"- 9M T*)3;7/7 UHV

?/:>"- 9O T*)3;7/7 UIV


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?/:>"- 9P T*)3;7/7 UMV

According to this analysis, the tentative dimensions of the carbon fiber tubes

showed that the structure would be quite overbuilt, and choosing a smaller pipe diameter

might have been a good option to reduce size, weight, and cost. Nonetheless the team

decided against this in order to be conservative, since we knew that our simulations did

not accurately represent the anisotropic nature of the material or the joining method to be

used.

R?9/ :N+5 B/5+,? =35 L3B/^ 3?B :N/ :-U/5 N3B 3..+4/B^ :N/ :/3L 9377/B :N/ B.+4/.

3?B U/,3? :/5:+?, :N/ 9-../?: 355-L/B B+L/?5+8?5 3?B M.3L/ 98?M+,-.3:+8?^ 35 B/A+9:/B +?

:N/ M+,-./" 28+?, :N+5 A.84/B :8 U/ :N/ 98../9: 9N8+9/ 35 :/5:+?, :N+5 98?M+,-.3:+8? =+:N

:N/ 39:-37 B.+4/. ./4/37/B 5/4/.37 9N3?,/5 ?//B/B :8 U/ L3B/" *+.5:7;^ :N/ -AA/.

N8.+a8?:37 :-U/ -5/B M8. :N/ .877 U3. A.84/B :8 U/ :88 5L377" @N+5 93-5/B :N/ B+3,8?375 :N3:

connect to the upper vertices of the roll bar to collide with the drivers helmet and thus


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?8: 3778=+?, :N/ N/7L/: :8 M+:" C/98?B7;^

:N/ N/+,N: 8M :N/ .877 U3. 3758 A.84/B :8

U/ +?5-MM+9+/?:^ 35 +: B+B ?8: A.84+B/ :N/

97/3.3?9/ M.8L :N/ N/7L/: ./`-+./B U;

:N/ 98LA/:+:+8?" S8./84/.^ :N/ +?+:+37

allocated length for the drivers

98LA3.:L/?: 8M ' M//: ( +?9N/5 A.84/B

:8 U/ -??/9/553.+7; 78?," C+?9/

:N/ B.+4/. +5 ' M//: :377 3?B

93A3U7/ 8M U/?B+?, N/. F?//5 3778=+?, :N/ 98LA3.:L/?: :8 U/ /4/? 5N8.:/.^ :N/ +?+:+37

377893:/B 7/?,:N =35 ./B-9/B"

O+:N 377 :N/5/ 8U5/.43:+8?5^ 3 ?/= 9N355+5 =35 B/5+,?/B" [3:/. 8? :N+5 ?/= B/5+,? =8-7B

U/ B/5+,?3:/B :N/ M+?37 B/5+,?" @N+5 ?/= B/5+,? 98?5+5:/B +? 9N3?,+?, :N/ 98??/9:+8? 8M

:N/ M.8?: B+3,8?375 :8 :N/ N8.+a8?:37 :-U/ U/?/3:N^ .3:N/. :N3? :N/ 98.?/." @N+5 =35 B8?/

U/93-5/ +: 3778=/B M8. 7/55 L3:/.+37 :8 U/ -5/B 35 :N/ ./`-+./B :-U/5 =8-7B U/ 5N8.:/. 3?B

3758 U/93-5/ :N+5 ?/= 98?M+,-.3:+8? =8-7B 39:-377; =+B/? :N/ B+5:3?9/ M.8L :N/ B+3,8?37

:-U/5 3?B :N-5 3778=+?, L8./ .88L M8. :N/ N/7L/: :8 M+:" E; B8+?, :N+5 3?B =+B/?+?, :N/

M.8?: 8M :N/ M.3L/ U; L/./7; $ +?9N/5 A.84/B :8 U/ L8./ :N3? /?8-,N M8. :N/ N/7L/: :8 M+:"

Q758^ 35 93? U/ 5//? +? :N/ M+,-./^ :N/ 7/?,:N 8M :N/ B.+4/. 98LA3.:L/?: =35 ./B-9/B :8 '&

inches, less than the drivers height of 5 feet. The driver would bend her knees and fit,

?8?/:N/7/55" @N+5 3778=/B :N/ 93. :8 U/ 5N8.:/. =N+9N 3778=/B M8. U/::/. 3/.8B;?3L+95^

7/55 L3:/.+37 M8. :N/ U8B; 3?B M.3L/^ 3?B 7/55 9N3?9/5 M8. :N/ :/3L :8 /W9//B :N/

?/:>"- 9@ 5 W7/*: A"/B-" +# !X+")=+

A/(-*7/#*7


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98LA/:+:+8? ./`-+./L/?:5 8M 3 L3W+L-L 7/?,:N" [35:7;^ 3: :N+5 A8+?: :N/ ./3. B+3,8?375

N3B :8 U/ ./L84/B 35 +: =35 B+5984/./B :N3: :N/; 9877+B/B =+:N :N/ /?,+?/" @N+5 =35 3

:./L/?B8-5 84/.5+,N: U; :N/ :/3L =N+9N L/3?: :N3: =+:N8-: :N85/ 5-AA8.:5^ :N/ :-U/5 :N3:

98??/9: B+./9:7; :8 :N/ /?,+?/ =8-7B U/ +? M-77 93?:+7/4/. 5:3:-/5" @N+5 93-5/B :N/ :/3L :8

M/3. :N3: :N/ :8.`-/ =8-7B U/ /?8-,N :8 93-5/ /?8-,N 8M 3 5N/3. :8 L3F/ :N/ /A8W; ./5+?

:N3: N/7B :N/ A3.:5 :8,/:N/. M3+7" @N+5 =35 73:/. 3BB./55/B U; N34+?, :N/5/ B+3,8?375

98??/9: 3: :N/ L+BB7/ 8M :N/ .877 U3. .3:N/. :N3? :N/ 78=/. 4/.:+9/5" @N+5 735: L+?-:/

./+?M8.9/L/?: 93? U/ 5//? 97/3.7; +? :N/ M8778=+?, M+,-./"

?/:>"- FD 5 !*:/*- Y-/*.#"=-(-*+7

2.2.9 Steering system

While researching and designing the steering system, the team took into

consideration the radius of turning and how it would impact the size and design of the


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frame and body of the car. When considering the steering system, the group took into

consideration Ackermann turning where the larger the distance between the front and

back wheels of the car, the larger the radius of turning is. This goes against the teams

goal as they strive for the lowest turning radius for highest efficiency. Also, having a

lower turning radius means the wheels need to turn more in order to compensate, and this

in turn forces the car design to be wider in order to allow for the extra space needed for

the wheels to turn.

2.2.10 Body

X-5: 7+F/ :N/ M.3L/^ :N/ U8B; =35 3 4/.; 98LA7+93:/B 35A/9: 8M :N/ 93." S-9N /?/.,; +5

785: :8 M.+9:+8? =+:N :N/ 3+.^ L3F+?, +: +LA/.3:+4/ :N3: :N/ B+MM+9-7:+/5 U/ 84/.98L/ =+:N :N/

U/5: ./5-7:5 A855+U7/" b8?/:N/7/55^ +: +5 +LA/.3:+4/ :8 53; :N/ :/3L =35 A./55/B 8? :+L/

3?B :N3: B+B ?8: 3778= :N/ :/3L :8 B/5+,? :N/ U8B; 35 /W:/?5+4/ 3?B :N8.8-,N7; 35

8.+,+?377; +?:/?B/B" R.+,+?37 A73?5 +?97-B/B .-??+?, B.3, 5+L-73:+8?5 8? Q?5;5 58M:=3./

+? 8.B/. :8 M+?B :N/ 98/MM+9+/?: 8M B.3,^ 3?B .-??+?, =+?B :-??/7 5+L-73:+8?5 8? 3 5937/B

L8B/7 +? 8.B/. :8 98LA3./ :N/ A.39:+937 ./5-7:5 =+:N :N/ 8?/5 M.8L :N/ 5+L-73:+8?5"

*-.:N/.L8./^ :N/ A3?:N/. .3,/ V$ :/3L 5-,,/5:/B :8 :/3L AN3?:8L :8 U/,+? 3?B 98LA7/:/

:N/ B/5+,? 8M :N/ 9N355+5 U/M8./ :N/; U/,3? B/5+,?+?, :N/ U8B; 8M :N/ 93." @N+5

./98LL/?B3:+8? =35 A-: :8 A.39:+9/ 3?B +: =35 :N/ .+,N: 9N8+9/" 2/5+,?+?, :N/ U8B; 8M

:N/ 93. U/M8./ B/5+,?+?, :N/ +?:/.+8. =8-7B N34/ U//? 3 N-,/ L+5:3F/ :N3: +?/4+:3U7;

=8-7B N34/ 7/3B :8 :N/ U8B; 9877+B+?, =+:N :N/ 8?/ 8M :N/ L3?; +?:/.+8. 98LA8?/?:5"

Q7:N8-,N B8+?, :N/ M.3L/ M+.5: =35 98?5+B/./B :N/ U/5: +B/3^ :N+5 ./5-7:/B +? A-5N+?, U39F


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377 :N/ =8.F 8? :N/ U8B; -?:+7 :N/ M.3L/ =35 98LA7/:/B" E/93-5/ :N/ 98LA/:+:+8? =35 :8

U/ N/7B :N/ M+.5: =//F 8M QA.+7^ :N/ 93. N3B :8 U/ 5N+AA/B U; :N/ 735: =//F 8M S3.9N^ 3?B

:N/ M.3L/ =35 ?8: 98LA7/:/B -?:+7 /3.7; S3.9N^ :N+5 ./5-7:/B +? 3 5L377 =+?B8= 8M 8?7; 3

M/= =//F5 :8 98LA7/:/7; B/5+,? 3?B L3?-M39:-./ :N/ U8B; M.8L 59.3:9N"

>4/? :N8-,N :N/ :/3L B+B ?8: /WA/9: :8 L3F/ 3 M+?37 B/9+5+8? 8? :N/ U8B; 8M :N/ 93. -?:+7

:N/ M.3L/ =35 98LA7/:/^ L3?; B+MM/./?: U8B; B/5+,?5 =/./ L3B/ =+:N :N/ +?:/?:+8? 8M

:/5:+?, :N/L 3?B B/:/.L+?+?, =N+9N N3B :N/ U/5: 3/.8B;?3L+95" E; B8+?, :N+5^ :N/

A.89/55 8M B/5+,?+?, 3?B L3?-M39:-.+?, 98-7B U/ /WA/B+:/B" *-.:N/.L8./^ U; B/5+,?+?,

:N+5 /3.7; +? :N/ 98LA/:+:+8?^ L-9N /WA/.+/?9/ =8-7B U/ ,3+?/B +? :N/ A.89/55 8M

B/5+,?+?, 98LA7/W 5N3A/5" @N+5 A.84/B :8 U/ :N/ 935/" Q7:N8-,N :N/ +?+:+37 B/5+,?5 =/./

?8: A+9F/B^ :N/ 8MM+9+37 B/5+,? =35 L3B/ A855+U7/ U/93-5/ 8M :N/ /WA/.+/?9/ 3?B A.39:+9/

M.8L :N/ /3.7+/. L8B/75"

H?+:+377;^ :N.// B+MM/./?: L8B/75 =/./ L3B/" @N/5/ :N.// L8B/75^ 35 93? U/ 5//? +? :N/

?/W: M+,-./^ 3./ 377 L3B/ =+:N 377 :N.// =N//75 +?5+B/ :N/ U8B;" @N/ L3+? B+MM/./?9/

U/:=//? :N/ :N.// +5 N8= :N/ ./3.5 /?B" Z/5/3.9N ./4/37/B :N3: :N/ :.3+7+?, /B,/ 8M 3

8UI/9: 93? N34/ 35 L-9N +?M7-/?9/ 8? +:5 3/.8B;?3L+95 35 :N/ M.8?: 8M :N/ 8UI/9:"

*-.:N/.L8./^ 3?8:N/. B+MM/./?9/ +5 :N/ A85+:+8? 8M :N/ =N//75 ./73:+4/ :8 :N/ U8B;" H? :N/

:8A .+,N: L8B/7^ +: 93? U/ 5//? :N3: :N/ U8B; 98LA7/:/7; 984/.5 :N/ :8A N37M 8M :N/ =N//7^

3778=+?, M8. 3 98?:+?-8-5 3?B M78=+?, 5-.M39/" ON/./35^ +? :N/ 8:N/. :=8 M+,-./5^ :N/

=N//75 A.8:.-B/ M.8L :N/ 5-.M39/ 8M :N/ U8B; :N-5 93-5+?, 58L/=N3: 8M 3 B+598?:+?-+:;

:N3: :N./3:/?5 :N/ B/5+./B .3+?B.8A17+F/ 5N3A/"


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?/:>"- F4 5 ?/"7+ 1Q"-- ,; A-7/:*7

Q5 L/?:+8?/B U/M8./^ :N/5/ =/./ 8?7; A./7+L+?3.; B/5+,?5" R?9/ :N/ M.3L/ U/,3? :8 :3F/

5N3A/ 3 L8./ 98?9./:/ +B/3 =35 M8.L/B U-: 5:+77 +?5-MM+9+/?: :8 L3F/ 3 M+?37 B/5+,?"

Z/,3.B7/55^ 3 ?/= U8B; 35 5//? +? :N/ ?/W: M+,-./ =35 B/5+,?/B" Q: :N/ :+L/ 8M

98LA7/:+8?^ :N+5 ?/= B/5+,?/B =35 /WA/9:/B :8 U/ M+?37^ 8. 3: :N/ 4/.; 7/35: 4/.; 9785/ :8

:N/ M+?37 A.8B-9:" T8=/4/.^ +: +5 +LA/.3:+4/ :8 53; :N3: 8?9/ :N+5 L85: ./9/?: L8B/7 =35

M+?+5N/B^ 3?B & B+MM/./?: 8A:+8?5 =/./ 343+73U7/ :8 :/5:^ :N/ B/9+5+8? =35 L3B/ :8 348+B

.-??+?, 5+L-73:+8?5 M8. B.3, 98/MM+9+/?:5" Q7:N8-,N -?8.:N8B8W^ :N/ :/3L U/7+/4/B :N3: +:

=8-7B U/ U/::/. :8 =3+: -?:+7 3 M+?37 M.3L/ 3?B 3? +?98.A8.3:/B 5://.+?, 5;5:/L =+:N :N/

=N//7 =/./ B/5+,?/B +? 8.B/. :8 U/,+? 5+L-73:+8?5" Q: :N/ :+L/^ +: 5//L/B -?+?:-+:+4/ :8

.-? 5+L-73:+8?5 8? B+MM/./?: U8B+/5 :N3: A8:/?:+377; =8-7B U/ +LA855+U7/ :8 +?98.A8.3:/

=+:N :N/ 8:N/. 98LA8?/?:5 8M :N/ 93." O+:N :N/ 93. 98LA7/:/B^ +: 93? ?8= U/ 53+B :N3: +:


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=35 97/3.7; :N/ .+,N: B/9+5+8?^ 35 ?8?/ 8M :N/ M8-. +?+:+37 B.3M:5 =/./ -5/B" @N+5 =+77 U/

/WA73+?/B M-.:N/."

?/:>"- F9 5 ?#>"+Q )*, !X8-=+-, A-7/:*

3.

Proposed Design

3.1Brakes selection

One of the most important things to keep in mind when defining the brakes of the

car was the overall usage of the same. During a fuel-efficient race, since the cars run at

very low speed, there are only two times when the brakes are mainly used. First, hours

before the race where you need to pass the inspection, which in the case of Shell Eco

Marathon is to make sure the system will support your car on a 20 degree slope, and

second, to keep your car stopped before the begin of a trial. Other than that, the brakes


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are rarely used and therefore must be as weight and cost efficient as possible. As

mentioned above, the back tire comes with a drum breaking system already mounted,

which for convenience and cost purposes, did not have to be touched. For the two front

wheels, since we were using a model inspired in a tricycle, our team was able to

incorporate two low cost efficient disk braking systems alongside with the wheels

provided by the manufacturer, who also provided us with the necessary cables and brake

levers, in order to connect the system to the drivers hand. A picture very similar to the

braking system used in the car is shown below:

?/:>"- FF 5 &")'/*: 7;7+-(

3.2 Wheels, Tires, and Hubs:

There are three wheels to be used in our vehicles design. One of this wheels, the

rear one, is to be the powered wheel and two other wheels in the front will be used to

steer the car and will be free rolling.


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The tires should cause the least rolling resistance possible and the Michelin ultra low

rolling resistance 44-406 tires are the best in its class for this application. Shell has a

partnership with Michelin to offer these to the participating teams for purchase at $78 per

tire. Our group was fortunate enough to be able to borrow last years Michelin two front

tires for our car. Some important characteristics of these tires are vii:

Rolling resistance: 2 kg/t (kilogram/ton)

Suitable pressure: 50PSI

Weight: About 150 grams

Suitable crochet-type rim reference: 20x1.75

Section Width: 45 mm

Overall diameter: 500 mm

?/:>"- FH 5 Z/=Q-3/* HH5HDMTaking into account the tires requirements, we solidified our choices for the two

front wheels. Inspired on a tadpole tricycle, two 20", non-machined rim wheels with

20mm trike hubs were purchased from PowerOnCycling to go in the front. In order to


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optimize the design, we decided to customize with ceramic bearings, which also

minimizes dissipationviii. Together with the wheels, the same manufacturer was able to

provide us the hub mounts that will fit perfectly the diameter of wheel axle, which is

ideal for our steering system. It is important to remember that the back wheel and the

back tire have been purchased as package with the engine as explained in its designated

section.

?/:>"- FI 5 RQ--3


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?/:>"- FM 5 S>2 Z#>*+

,+, (3..846/ (G:3.9

@N/ 5://.+?, 5;5:/L B/5+,?/B 3 M/= =//F5 U/M8./ :N/ 98LA/:+:+8? =35 +?5A+./B +?

./9-LU/?: :.+F/5 3?B ,8 F3.:5" C+?9/ :N/ 399/7/.3:+8? 8M :N/ 93. =35 B8?/ +? 8?/ 8M :N/

N3?B5^ :N/ 3U5/?9/ 8M A/B375 9N377/?,/B 8-. :/3L :8 9./3:/ 3 5;5:/L :N3: =8-7B :-.? U8:N

8M :N/ =N//75 =+:N :N/ L8:+8? =+:N 8?/ N3?B 8?7;" @N/ 98?9/A: -5/B 93? U/ 58L/=N3:

./73:/B =+:N :N/ A+9:-./ U/78=f

?/:>"- FO 5 [#5')"+ 7+--"/*:


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63

R? :N/ 7/M: 5+B/ 8M :N/ A.8:8:;A/^ 3::39N/B :8 :N/ M.3L/^ 3? 37-L+?-L :-U/ =35 A-:

:8,/:N/. A/.A/?B+9-73.7; :8 3 93.U8? M+U/. :-U/ \53L/ 8?/ -5/B +? :N/ M.3L/] -5+?, 93.U8?

M+U/. :8= 3?B /A8W;" R? :N/ 8:N/. 5+B/ 8M :N3: :-U/^ 3 L/:37 5:.+A =35 =/7B/B :8 3?8:N/.

5+B/ 8M :N/ 37-L+?-L :-U/ +? 8.B/. :8 U/ 98??/9:/B :8 8?/ 8M :N/ :+/ .8B5" @N/ A+9:-./

U/78= 93? U/ -5/B 35 3? +77-5:.3:+8? 8M :N/ 5;5:/L"

?/:>"- FP 5 G+--"/*: =#**-=+/#*7

@N+5 :+/ .8B^ =N+9N +5 3AA.8W+L3:/7; & +?9N/5 78?,^ =35 98??/9:/B :8 3 U87: 8? +:5

8:N/. /?B" @N+5 U87: ,8/5 :N.8-,N 3?8:N/. L/:37 A73:/^ =N+9N +:5/7M =35 =/7B/B +?:8 :N/

N-U" @N+5 8MM5/: M.8L :N/ N-U5 +5 ./5A8?5+U7/ M8. :N/ Q9F/.L3?? :-.?+?, 8? :N/ 4/N+97/"

@N+5 U87:^ =N+9N 93? U/ 5//? 3U84/ 3758 ,8/5 :N.8-,N 3 $& +?9N/5 :.+LL3U7/ :-U-73. :+/


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64

.8B^ =N+9N 98??/9:5 U8:N N-U5 :N/./M8./^ ,+4+?, :N/ :-.?+?, L8:+8? 8M :N/ 93. =+:N 8?/

L84/L/?:"

@N/ =3; :N+5 5;5:/L 98??/9:5 :8 :N/ M.3L/ +5 4/.; 5+L+73. :8 :N/ :/9N?+`-/ -5/B :8

98?5:.-9: :N/ U8B;" Q 93.U8? M+U/. :-U/^ 7/?,:N 8M 3AA.8W+L3:/7; $( +?9N/5 =35 7+?F/B :8

37-L+?-L ()(# K1K73LA5 \L8./ B/:3+75 8? :N/ L3?-M39:-.+?, 5/9:+8? 8M :N/ ./A8.:]"

@N/5/ K1K73LA5 3./ :N/? 98??/9:/B :8 :N/ N-U5 :N.8-,N :N/ F+?, A+? 5N8=? +? :N/ N-U

L8-?:"

?/:>"- F@ 5 R-3,-, Q>27

T8=/4/.^ 3M:/. ,/::+?, :8 T8-5:8?^ 8? :N/ M+.5: ?+,N: 8M :N/ 98LA/:+:+8?^ 8-. ,.8-A

L8-?:/B :N/ :8A A3.: 8M :N/ U8B; :8 :N/ U8::8L^ 7/34+?, 7+::7/ .88L M8. :N/ 5://.+?,

98?:.87^ =N+9N N3B U//? B/5+,?/B M8. 3 U8B; :N3: =8-7B N34/ 5:3;/B 8? :N/ 8-:5+B/ 8M :N/

=N//75" *39+?, :N+5 3B4/.5+:;^ =/ N3B :8 +LA.84+5/" 2-.+?, :N/ 98LA/:+:+8?^ =/ 93L/ -A

=+:N 3 5+LA7/ A-77/; 5;5:/L^ =N+9N =8-7B .8:3:/ U8:N =N//75 =+:N 3 M8.=3.B 3?B

U39F=3.B5 L8:+8? \.3:N/. :N3? 7/M: 3?B .+,N: =N+9N =35 7+L+:/B B-/ :8 :N/ U8B; 5N3A/]"


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65

QM:/. .-5N+?, :8 N8L/ B/A8: 3?B U-;+?, :N/ A3.:5^ 3 5;5:/L =+:N M8-. A-77/;5 3?B 3 =+./

=35 U-+7:" Q5 =/ N3B /WA/9:/B^ :N/ ?/= 5;5:/L =8.F/B M3?:35:+9377; B-.+?, :N/ =//F/?B"

?/:>"- HDE>33-;

,+= I5JG

Q5 L/?:+8?/B U/M8./^ :N/ B/5+,? 8M :N/ M.3L/ =35 4/.; 98LA7+93:/B 3?B M-77 8M :.+37 3?B

/..8." @N/ :./L/?B8-5 3L8-?: 8M 9N3?,/5 :8 :N/ M.3L/ L3B/ +: 58 :N3: :N/ /WA/9:/B

B/5+,? M8. :N/ U8B; U/93L/ ./?B/./B -?B/5+.3U7/" S8./ 5A/9+M+9377;^ :N/ 8.+,+?37

+?:/?:+8? 8M N34+?, :N/ =N//75 +?5+B/ 8M :N/ 93. U/93L/ -?7+F/7; 35 9379-73:+8?5 ./4/37/B

:N3: N34+?, :N/ =N//75 8? :N/ +?5+B/ 8M :N/ U8B; =8-7B 7/3B :8 :N/ 5://.+?, M8.9+?, :N/

U8B; :8 U/ 84/. %% +?9N/5 =+B/" Q7:N8-,N 935:8. 3?,7/5 =/./ 3BB/B +? 3? /MM8.: :8 ./B-9/

:N/ 8-:/. B/M7/9:+8? 8M :N/ =N//7 35 +: :-.?/B^ +: A.84/B :N3: 37:N8-,N :N/ /MM8.:5 B+B L3F/


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66

:N/ B/M7/9:+8? 7/55/.^ +: =35 ?8: 5-MM+9+/?: :8 3778= :N/ U8B; :8 U/ 7/55 :N3: %) +?9N/5 =+B/"

E/93-5/ 8M :N+5^ :N/ :/3L M/7: 4/.; 8U7+,3:/B :8 L3F/ 3 735: L+?-:/ 9N3?,/ :8 :N/ 93. 3?B

N34/ :N/ =N//75 8? :N/ 8-:5+B/ 8M :N/ U8B;" @N+5 =35 3 N-,/ B/9+5+8?^ 3?B 8?/ :N3: =35

L3B/ =+:N ?8: L-9N :+L/ :8 5A3./" E; :N/ :+L/ :N/ B/9+5+8? :8 7/34/ :N/ =N//75 8-:5+B/ 8M

:N/ U8B; =35 L3B/^ :N/./ =35 I-5: -?B/. 3 L8?:N -?:+7 :N/ :/3L N35 :8 5N+A :N/+. 93."

O+:N+? :N+5 8?/1L8?:N :+L/ M.3L/^ 3? /?:+./7; ?/= U8B; N3B :8 U/ B/5+,?/B 3?B

L3?-M39:-./B"

H: 93??8: U/ 84/.5:3:/B N8= 9N377/?,+?, :N+5 =35 U/93-5/ 8M :N/ :+L/ 98?5:.+9:+8?5" @N+5

=35 M-.:N/. 9N377/?,+?, :N3?F5 :8 :N/ 8U5:397/5 :N3: N3B :8 U/ 84/.98L/^ ?3L/7;

98?M8.L+?, :8 :N/ 8:N/. 98LA8?/?:5 8M :N/ 93." Q7:N8-,N N34+?, :N/ =N//75 8? :N/

8-:5+B/ 8M :N/ U8B; B+B ?8: /?:3+7 L3?; 9N3?,/5 :8=3.B5 :N/ ./3. 8M :N/ 93.^ +: L/3?: 3

5-U5:3?:+37 3L8-?: 8M 9N377/?,/5 3?B 9N3?,/5 :8=3.B5 :N/ M.8?: 8M :N/ 93." S8./

5A/9+M+9377;^ :N/ ?/= U8B; N3B :8 U/ B/5+,?/B 58 :N3: +: =8-7B ?8: 9877+B/ =+:N :N/ =N//75

B-.+?, 5://.+?,^ ;/: U/ U+, /?8-,N :8 M+: :N/ =+B/ .877 U3. 3?B N34/ /W:.3 5A39/ :8 A739/

:N/ 5://.+?, 3?B 399/7/.3:+?, 5;5:/L5 M8. :N/ 93." @N/ 8U5:397/ N/./ 7+/5 +? L3F+?, :N/ 93.

U/ 5N3A/B 7+F/ 3 .3+?B.8A^ 35 =35 B/5+./B U; :N/ B/5+,?/." T34+?, :N/ 93. U/ 5N3A/B 7+F/ 3

.3+?B.8A =35 B+MM+9-7: 35 :N/ :-.?+?, =N//75 M8.9/B :N/ 93. :8 U/ :N+??/. 8? :N/ M.8?:^

=N+7/ :N/ .877 U3.^ U/+?, :N/ =+B/5: A3.: 8M :N/ 93.^ M8.9/B +: :8 U/ 3: +:5 =+B/5: =/77 U/N+?B

:N/ L+BB7/ 8M :N/ U8B;" *-.:N/.L8./^ :N/ /?,+?/ =35 ?8: 37+,?/B =+:N :N/ 9/?:/. 8M :N/

93.^ L/3?+?, :N3: +: M-.:N/. M8.9/B :8 93. :8 U/ ./73:+4/7; =+B/. ?/3. :N/ ./3. /?B"

*8.:-?3:/7;^ 3M:/. L-9N =8.F 3 B/5+,? =35 98LA7/:/B :N3: =35 -53U7/" Q7:N8-,N :N/

.3+?B.8A 5N3A/ =35 ?8: 8U:3+?/B^ :N/ :/3L =35 53:+5M+/B =+:N :N/ ./5-7:+?, B/5+,?" Q :N.//


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67

B+L/?5+8?37 L8B/7 93? U/ 5//? +? :N/ M+,-./ U/78="

?/:>"- H4 5 ?/*)3 A-7/:*

V+4/? :N3: :N+5 L8B/7 :88F 57+,N:7; 84/. $ =//F5 :8 B/5+,? B-/ :8 +:5 98LA7/W+:; 3?B

98?5+5:/?: 9N3?,/5 :8 98?M8.L :8 :N/ M.3L/ 3?B 5://.+?,^ 7/55 :N3? $ =//F5 =/./ 7/M: -?:+7

:N/ 93. =35 5N+AA/B" Q5 5:3:/B U/M8./^ :N+5 L/3?: :N3: :N/ :/3L -?M8.:-?3:/7;^ B+B ?8: N34/

:N/ :+L/ :8 .-? :N/ 5+L-73:+8?5 :8 8A:+L+a/ :N+5 5N3A/ 35 :N/; 8.+,+?377; +?:/?B/B" @N/

5+L-73:+8?5 =/./ 5F+AA/B^ 3?B :N/ A.89/55 8M L3?-M39:-.+?, U/,3?"

,+K L4621 %.:4/6

?/:>"- H9 5 N)" ?/*)3 4


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68

4 Project Management

4.1 Overview

Q5 3 :/3L =8.F+?, :8,/:N/. M8. :N/ U/5: 8-:98L/ +? :N/ 98LA/:+:+8?^ :N/ :/3L

/?4+5+8?5 :8 A-: +? :N/ 53L/ 3L8-?: 8M =8.F +? :N/ A.8I/9:" Q77 L/LU/.5 3./ M-77; 3=3./

8M 377 L//:+?,5^ /WA/9:3:+8?5^ 8UI/9:+4/5 3?B :35F5 :N3: L-5: U/ L/: +? 8.B/. :8 L3F/ :N+5

I8-.?/; 3 5-99/55M-7 8?/ 3?B N34/ 377 98LL+::/B +? A-::+?, /`-37 :+L/ 3?B /MM8.: +?:8

B8+?, 58"

4.2 Breakdown of Work into Specific Tasks

b3:-.377; U-+7B+?, 3 93. A.8:8:;A/ =+77 +?4874/ A-::+?, 5/4/.37 A+/9/5 8M 3 A-aa7/

:8,/:N/. 5-99/55M-77; +? 8.B/. M8. :N/ M+?37 A.8B-9: :8 M-?9:+8? +B/377;" @N/ A.8:8:;A/ 93?

U/ B+4+B/B +? 5/4/.37 B+MM/./?: 5L377 5/9:+8?5 5-9N 35 >?,+?/ C/7/9:+8?^ E8B; 2/5+,?^

S3:/.+37 C/7/9:+8?^ KN355+5 \*.3L/]^ C://.+?, C;5:/L^ E.3F+?, 5;5:/L^ ON//7 3?B Z+L

5/7/9:+8?" C+?9/ :N/ A.8I/9: B/5+,? +?4874/5 A3.:+9+A3:+8? +? 3 98LA/:+:+8?^ +: +5 3758 4/.;

+LA8.:3?: :8 355+,? L/LU/.5 :35F5 :N3: =+77 355-./ :N/ :/3L +5 98LA7;+?, =+:N :N/

./,-73:+8?5 3?B B/3B7+?/5 +LA85/B U; :N/ 8.,3?+a/.5"

4.3 Project Timeline


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69

?/:>"- HF 5 E"#K-=+ 1/(-3/*-

4.4 Breakdown of Responsibilities

*8. :N/ $)#% >98 CN/77 S3.3:N8? :/3L^ :N/ :35F5 N34/ U//? B+5:.+U-:/B 35 M8778=5f

S3.98 E/:3?98-.:f >?,+?/ ./5/3.9N 3?B 5/7/9:+8?^ *-/7 5/7/9:+8? 3?B B/7+4/.;

5;5:/L 3?B @.3?5L+55+8? 5;5:/L"

E.;3?B Q985:3f Q/.8B;?3L+9 ./5/3.9N^ U8B; B/5+,?^ L3:/.+37 5/7/9:+8? 3?B M.3L/

B/5+,?"

*/.?3?B8


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70

\:N.// N-?B./B 3?B M8.:;] N8-.5" *8. :N/ 5/98?B A3.: 8M :N/ A.8I/9: C/?+8. 2/5+,? HH^

98-?:7/55 N8-.5 =/./ 5A/?: +? :N+5 93." C:3.:+?, +? :N/ 735: =//F 8M X3?-3.;^ =N/? :N/ M+.5:

A3.:5 5:3.:/B :8 3..+4/^ :N/ ,.8-A L/: 98?5+5:/?:7; % 8. & :+L/5 3 =//F M8. 5/4/.37 N8-.5^

58L/:+L/5 /4/? #( N8-.5 3 B3;" Q5 :N/ 98LA/:+:+8? 5:3.:/B :8 3AA.839N^ :N/ =8.F 783B

8?7; +?9./35/B" 2-.+?, CA.+?, E./3F M8. /W3LA7/^ :N/ ,.8-A L/: M8. #$ N8-.5 8. L8./ M8.

3: 7/35: ' :+L/5" H? :N/ 735: :=8 =//F5 U/M8./ :N/ 98LA/:+:+8?^ +: +5 ?8: 3? /W3,,/.3:+8? :8

53; :N3: D$ N8-.5 =/./ 5A/?: 98?5/9-:+4/7; 3L8?, :N/ % 8M -5 +? :N+5 93."


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71

5. Engineering Design and Analysis

5.1 Estimated Cost Analysis

*HY >98 CN/77 $)#% ,.8-A +5 9-../?:7; 3: :N/ 5:3,/ 8M A-.9N35+?, L85: 8M :N/ A3.:5 :N3:

=+77 U/ L3?-M39:-./B :8 :N/ 93." E/78=^ 3 U./3FB8=? 8M :N/ /WA/9:/B /WA/?5/5 U/M8./ =/

5:3.:/B :N+5 A.8I/9: 35 =/77 35 3 L8./ B/:3+7/B :3U7/ 8M :N/ /WA/?5/5 =/ N34/ N3B 58 M3. 3./

5N8=?f

1)23- H 5 !X8-=+-, !X8-*7-7

!"#$%&$' !"#$)*$*

+,&-. /0-**1* !"#$)*$* "#$$%$$+,&-. 2,'3 40$.. !"#$)*$* "&'(&$%$$

+,&-. !)51)$ !"#$)*$* "($$%$$

+,&-. 26-7$ 43*&$8 !"#$)*$* "))$%$$

+,&-. 4&$$61)5 43*&$8 !"#$)*$* "*&+%$$

+,&-. +6-9$. !"#$)*$* "*'($$%$$

+,&-. :,)$3 ;


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72

5.2 Actual Cost Analysis

1)23- I 5 N>""-*+ !X8-*7-7

>%&


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73

QDI:812 O:R1 "&%++ & "&%++

QDI:812 />R3 "&-%++ & "&-%++

O0>6 ".-%+) & ".-%+)

G:2234S "-+%+) & "-+%+)

V:5MN: =3234 ".*+%$$ & ".*+%$$Q534E3;HSCL>2HI "*%++ & "-%.*

J>43 T:4;311 "+$%$$ & "+$%$$

+,&-. !)51)$ !"#$)*$* "&'.*,%)+

26-7$ 43*&$8

G4:1H1 "*$%$$ . "($%$$

V3@34 \R:>4] "&,%++ & "&,%++

T3>N:;:8 9>43 "+(%&- & "+(%&-

()BB O:M631 "&%&$ . ".%.$

.$BB JI3361 "++%.$ . "&+#%-$

O34:5>H M3:4>;E1 "($%$$ . "&.$%$$

+,&-. 26-7$ 43*&$8 !"#$)*$* "-+-%,*

4&$$61)5 43*&$8

T8M =08;2 "*,%)$ . ",)%$$

C5:66 2>3 40N ".)%++ & ".)%++G>E 2>3 P0N "&,%++ & "&,%++

[6 M60H63 CI>RR>;E "&'-*$%$$ & "&'-*$%$$

+,&-. +6-9$. !"#$)*$* "*'(,(%)$

401##1)5 !"#$)*$*

=:4H0 ").%)* & ").%)*

734;:;N0 "-.%,. & "-.%,.

G4S:;N "-$%,( & "-$%,(


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74

+,&-. 401##1)5 !"#$)*$* "&*(%$&

>%,88,'-&1,)

T0236 ",(&%*$ & ",(&%*$

>%,88,'-&1,) +,&-. ",(&%*$

=&0$6 $"#$)*$*

=:4H0 J36N>;E'VQA1'TA'P:N>0CI:H< "&+&%-$

734;:;N0 J:6E433;1'TA "(-%,$

G4S:;N J:6E433;1' TA "()%*$

902:6 ^2I34 QDR3;131 "*.&%-$

+=+>? !@A!B4!4 ")'+-*%(*

+=+>? !@!:A+ "*'(,(%)$

+=+>? /=4+ ")'+-*%(* * "&'+#&%.&


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75

6. Manufacturing

M+* (3..846/ (G:3.9

@N/ L3?-M39:-.+?, A.89/55 8M :N/ 5://.+?, 5;5:/L +?4874/B 5/4/.37 5L377 5:/A5" @N/

M+.5: 8?/ =35 :8 9./3:/ K1K73LA5 :8 U/ 3::39N/B :8 :N/ N-U" H? 8.B/. :8 9./3:/ :N85/^ :=8

U789F5 8M 37-L+?-L =/./ 8.B/. =+:N #"' W #"' +?9N/5 5+B/ 3?B % +?9N/5 7/?,:N" O+:N :N85/

U789F5^ =/ =/./ 93U3U7/ 8M -5+?, 3 L+77 :8 9-: 8MM 3 5L377 ./9:3?,7/ M.8L :N/ +?5+B/^

:N/./M8./ ./5-7:+?, +? :N/ K 5N3A/ ?//B/B"

?/:>"- HH 5 N5N3)(87 (/33/*:


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76

QM:/. 8U:3+?+?, :N/ /WA/9:/B ./5-7:5^ =/ 5:+77 N3B A.8U7/L5 B-/ :8 :N/ M39: :N3: :N/

:-.?+?, =35 7+L+:/B U; :N/ 5N3.A 3?,7/5 8M :N+5 5-AA8.:" H? 8.B/. :8 5874/ :N+5^ 3 ,.+?B/.

=35 -5/B :8 9./3:/ M+77/:5 +? 377 5+B/5 8M :N+5 A+/9/^ 9./3:+?, 3 5/L+9+.9-73. 5N3A/ 8? U8:N

5+B/5" R?9/ :N/ K1K73LA5 =N/./ ./3B;^ :N/./ =/./ =/7B/B :8 3? 37-L+?-L A+A/ =+:N "G)&

8-:5+B/ B+3L/:/.^ I-5: U+, /?8-,N :8 U/ M+::/B +?:8 :N/ 93.U8? M+U/. :-U/5 :N3: =/./

3::39N/B :8 :N/ M.3L/" @N+5 :/9N?+`-/ =35 -5+?, U/93-5/ =/ 98-7B ?8: =/7B 93.U8? M+U/.

:8 :N/ K1K73LA 3?B =/ =3?:/B :8 534/ 58L/ =/+,N: U; ?8: -5+?, 3 78?, 37-L+?-L .8B" H?

8.B/. :8 L3F/ 5-./ :N/ 37-L+?-L =8-7B 5:+9F :8 :N/ 93.U8? M+U/.^ /A8W; =35 -5/B"

?/:>"- HI 5 N5=3)(87


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77

?/:>"- HM 5 TX3- =#**-=+/#*

M+; I82N46/ (G:3.9

CL377 L3?-M39:-.+?, =35 B8?/ +? 8.B/. :8 39N+/4/ :N/ B/5+./B U.3F+?, 8-:98L/"

H? 8.B/. :8 ./5A/9: :N/ .-7/5 8M :N/ 98LA/:+:+8?^ +: =35 ./`-+./B :8 -5/ U8:N U.3F/5 +? :N/

M.8?: =+:N 8?/ L/9N3?+5L" @N/ 587-:+8? :8 :N3: =35 =/7B+?, :=8 U.3F+?, 7/4/.5 :8,/:N/.^

:N/./M8./ A./55+?, U8:N =+:N 8?/ L8:+8?"

M+, L829.

@N/ A.89/55 8M L3?-M39:-.+?, U/,3? =+:N :N/ A./4+8-57; L/?:+8?/B A3:/?: U; J8:7+?5F+"

Q5 L/?:+8?/B U/M8./^ :N/ A.89/55 /?:3+7/B -5+?, 93.U8? M+U/. :8= 35 3 L/3?5 :8 9./3:/ -1

I8+?:5 3?B 3::39N :N/L :8 :N/ 37./3B; A-.9N35/B 93.U8? M+U/. :-U+?," @N/ A.89/55 93? U/

U/5: B/A+9:/B +? :N/ ?/W: M+,-./^ 98-.:/5; 8M :N/ +?4/?:8.^ J8:7+?F5+f


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78

?/:>"- HO 5 Z-+Q#, \. T,K#/*/*: +>2-7

@N/ M8778=+?, :N.// M+,-./5 B/A+9: 58L/ ./37 7+M/ 3AA7+93:+8?5 35 5N8=? U; J8:7+?5F+" @N/

M+.5: 8M :N/ :N.// B/A+9:5 N8= :N/ I8+?:5 3./ .+,N: 3M:/. U/+?, :+/B :8,/:N/.^ =N+7/ :N/

5/98?B 3?B :N+.B 5N8= 3 M+?+5N/B A.8B-9: 3?B :N/ A.8B-9: +? -5/^ ./5A/9:+4/7;"

?/:>"- HP 5 Y-7>3+] !X)(83- 4


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79

?/:>"- H@ Y-7>3+] !X)(83- 9

?/:>"- ID Y-7>3+] !X)(83- F

Q5 93? U/ 5//? +? :N/ A./4+8-5 M+,-./5^ :N+5 L/:N8B 3778=5 M8. L-7:+A7/ :-U/5 :8 98??/9: 3:

3 5+?,7/ 4/.:/W^ 8. 9./3:/ 3 98??/9:+8? A8+?: 378?, 3 :-U/" H: +5 L3+?7; U/93-5/ 8M :N/5/


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80

./358?5^ :N/ 3MM8.B3U+7+:; 8M :N+5 L/:N8B^ 3?B :N/ 3U+7+:; :8 98??/9: L3?; :-U/5 3: 3?;

3?,7/ :N3: :N/ :/3L +LL/B+3:/7; B/9+B/B :8 3AA7; :N+5 L/:N8B"

Q7:N8-,N :N+5 L/:N8B +5 +??843:+4/ 3?B N/?9/ ?8: L-9N +?M8.L3:+8? 8? +: +5 343+73U7/^ :N/

:/3L A.89//B/B :8 -5/ +:" E-: :N+5 739F 8M U39F,.8-?B F?8=7/B,/ L3B/ M8. L-9N .88L

M8. /..8." @N/ 5:/A5 =N/./ M8778=/B 35 9785/7; 35 A855+U7/ M8778=+?, :N/ B/59.+A:+8?

A.84+B/B +? :N/ A3:/?:" Q5 3 5:3.:+?, A8+?:^ :N/ :/3L 9./3:/B :N/ L39N+?/ 5-,,/5:/B U; :N/

+?4/?:8. :8 =.3A :N/ L3?B./75 =+:N :N/ :8=" @N/ L39N+?/^ 35 U/78=98?5+5:5 8M 3 .877 8M

:8= U/+?, N/7B +? A739/^ =N+7/ 5:.+?, +5 A-77/B :N.8-,N 58L/ N88F5 :N3: 5/.4/ :8 9./3:/

:/?5+8?" Q5 :N/ :8= +5 U/+?, =.3AA/B 3.8-?B :N/ 5A+??+?, 98LA8?/?: :N3: N87B5 :N/

L3?B./75 :8 :N/ .+,N:^ +: +5 3758 A355+?, :N.8-,N 3 5L377 98?:3+?/. :N3: N8-5/5 3 L+W:-./ 8M

/A8W; ./5+? L+W:-./" @N/ A.89//B+?, M+,-./ +5 :N/ 39:-37 L39N+?/ U/+?, -5/B 3M:/. +: =35

M+?+5N/B"

?/:>"- I4 R/*,/*: Z)=Q/*-


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?/:>"- I9 R/*,/*: Z)=Q/*-

H: 5N8-7B U/ 5:3:/B :N3: 37:N8-,N :N+5 L39N+?/ =35 4/.; N/7AM-7 +? :N/ A.8B-9:+8? 8M :N/ -

I8+?:5^ 5/4/.37 98LA7+93:+8?5 =/./ L/: :N.8-,N8-: :N/ =3;" *+.5:^ 35 93.U8? M+U/. :8= N35

3 ./73:+4/7; 73.,/ L8B-7-5 M8. :/?5+8? U-: 4/.; 78= M8. 98LA./55+8? 3?B 5N/3.^ :N/ :8=

=35 A.8?/ :8 9-::+?, /35+7;" @N3: +5^ :N/ M.+9:+8? 3,3+?5: :N/ L/:377+9 N88F5 -5/B =35 L8./

:N3? /?8-,N :8 93-5/ :N/ :8= :8 U./3F 8? 5/4/.37 89935+8?5" Q758^ +: A.84/B :8 U/ `-+:/

:N/ 9N377/?,/ :8 N34/ :N/ 3M8./L/?:+8?/B 98?:3+?/. N8-5/ :N/ ./5+? L+W:-./ 3?B N34/ :N/

:8= A355 :N.8-,N =+:N8-: 93-5+?, :N/ ./5+? :8 /593A/ :N.8-,N :N/ /W+: N87/ 8M :N/ :8="

S8./84/.^ :N/ 5A+??+?, A3.: 8? :N/ .+,N: ./`-+./B :N3: :N/ :8= U/+?, =.3AA/B U/

98?5:3?:7; ,-+B/B +? 8.B/. :8 B+5:.+U-:/ :N/ :8= /4/?7; 378?, :N/ L3?B./7" R.+,+?377; :N/

:/3L +?:/?B/B :8 A-: 3 5L377 L8:8. 8? :N+5 L84+?, A3.: U-: U/93-5/ 58 L-9N /W:/.?37

,-+B3?9/ =35 ?//B/B M8. :N/ :8=^ +: A.84/B :8 U/ L-9N /35+/. :8 348+B :N/ L8:8. 3?B B8

:N/ 5A+??+?, L3?-377;" Q7:N8-,N :+L/ 98?5-L+?,^ :N+5 ./5-7:+?, - I8+?:5 =/./ 8M

399/A:3U7/ `-37+:;" @N/ M8778=+?, M+,-./ 5N8=5 :N/ ./5-7:+?, - I8+?:" @N/ A+9:-./ 5N8=5

8?7; 8?/ -1I8+?:^ U-: L8./ :N3? %) =/./ A.8B-9/B" Q758 +LA8.:3?: :8 ?8:+9/^ :N/ 788A N35


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fiu design report - 2012(1)

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