garuda 2012

Go Green .Think Lean !!

PROJECT GARUDARVCE SUPERMILEAGE TEAM

20082009

20102011

Go GreenThink Lean !!


2008 2009 2010 2011

Functional Upgrade

20132012Proto Concept Vehicle Urban Concept Vehicle



SI Targets 2012

1 To achieve 500 Kmpl

2 To compete at Shell Eco Marathon Malaysia

3 To Build a platform to develop and test propulsion systems-Ethanol & Electric

SI Targets 2013

1 To build an Urban Concept Vehicle

2 Meant for road worthiness.2 seater and 4 Wheels

3 Target to reach 300kmpl

4 Propulsion by Ethanol and Electric

Shell Eco Marathon provides us the ideal platform to achieve these dreams



Urban Concept

Electric Power Source

Ethanol EngineMonocoque

Design



Garuda 2012 Prototype- Gasoline•The 2012 car will be an optimized version of the 2011 car.•We have been testing the car for the last few months have proposed changes in the following systems.

System Issues Measure Analysis Implement Design Changes

Target

Transmission Chain Popping off

For every 3 Kms pops off 1 time

No Tension on Chain

Chain Tensioner

New Transmission System

Chain Shouldn't Pop

Steering Turning Radius of 9mts

No auto correction of steering

Wrong Camber and King pin Angle

New C Clamp Design

NewC Clamp with Camber and caster angles

Turning radius of 5.8mts

Shell 1. Weight of shell.

2. Driver isolation

Weighs 23 kgs. 1. Material for Shell

2. Roll hoop Clearance

Monocoque with a lighter material

New Shell Design

Net Car Weight less than 50 kgs

Brakes Not enough Brake force

Did not hold on inclined surface

Caliper Mounting

New Caliper Mounting

Should hold on inclined Surface



WEIGHT ANALYSIS OF 2011 CAR

System Current 2012 Car

Shell and Chassis 30.4 13

Engine 12.3 10

Transmission 7.3 5

Steering 5.0 4

Wheels 4.7 4.7

Brakes 1.3 1.3

Auxiliary systems 10.8 8

72 kgs 46 kgs

35% Reduction in weight from the current car!!



MECHANICAL ENERGY STORAGE SYSTEM•This system recoils a spring during braking and this energy is used to propel the car when the engine is switched off.

•The spring is attached to the hub of the wheel, during braking the spring gets engaged and coils as the speed decreases.

•When this lever is pressed the spring unwinds energy is transferred to the wheels.

• This helps us recover energy during braking.



Current Status

1.The team has registered with two cars for the next year event.

•The Petrol Prototype will be a updated version of the 2011 car.•The Electric Prototype will be based on the same platform and share most of its parts with other prototype except the propulsion system.

2.We have completed the Technical Submission for both the cars.



Project MilestonesDuration

Start Date Finish Date

Phase 1:Prototype Optimization Electric Prototype

1-11-2011 1-2-2012

Phase 2:Mileage Test 1-2-2012 25-2-2012

Phase 3:Checkpoint • Assessment of Prototype • Durability Study

2-3-2012 30-3-2012

Phase 4:Final Prototype Completion • Focus on Electricals , Aesthetics

and Packaging

30-3-2012 1-6-2012

Phase 5:Shipment 2-6-2012 25-6-2012

Phase 6:Shell Eco Marathon 2012 4-7-2012 7-7-2012

Project Timelines and Milestones



Recap of the Year 2010-2011

•We were one among 6 Indian teams to be selected for the Shell Eco-Marathon competition held in Malaysia.

•We were the best Indian Team at the event we all the static events .

•We were rewarded 2500 USD for our performance.

•We also developed a Chassis Dynamometer to test the vehicle’s performance characteristics.



Chassis Dynamometer

•Chassis Dynamometer is an equipment which is used to simulate road conditions.•It is used to find the horsepower and torque at the wheels of the vehicle.•The equipment was designed and fabricated by the team.



Vertical -1

Logistics•Car shipment, lodging , Team travel

Fund Management•Fund allocation for resources and accounting

Vertical -2

Interaction•College ,Sponsors ,etc

Sponsorship•Financial and material requirements

Vehicle Testing and Validation

Vertical -3

Design•Documentation•Specification

Procurement and Manufacturing

Project Mentor team

Team Structure



ESTIMATED PROJECT EXPENDITURE

Component Cost

Petrol Prototype 1,50,000

Electric Prototype 2,20,000

Ethanol Engine Development 70,000

Urban Concept-1 4,00,000

Vehicle Shipment 3,50,000

The Estimate is 12.90 lakhs. Majority of the systems will common for both the platform , the

helps standardize parts.



OUR ALUMINI NETWORK



Project Mentor :Prof. R.S. Kulkarni, Dept. of Mechanical Engineering, RVCE Bharat Sharma , Ashok Leyland.(Garuda Team 08,09)

Team 2012:S Karthik Raja Nitesh PSharanSamarthShishiraShrirangSankranthAditya s

Project RVCE Super mileage, Department of Mechanical Engineering, R.V. College of Engineering, 8th Mile, Mysore road, Bangalore : 560059, Karnataka, India.

Prof. R.S. Kulkarni : +91-9945602861 Email : [email protected]

S Karthik Raja: +91-9886915927 Email :[email protected]



CONTACT US



Project Garuda thanks you for providing us with the opportunity

to present ourselves .



Electric Prototype

•Electric Prototype is being build to study the Plug-in energy management system. This concept will help us integrate systems for our 2013 urban concept.•Specifications:

1.5 KW Brushless DC Hub Motor48V 20 Ah Lion batteryIs mated to an on board energy recovery system

•The Urban concept will be based on the same platform.



Ethanol EngineEthanol is used to power Internal Combustion engines world wide. As it is a non fossil source of energy .This year we plan to develop an engine that runs on purely Ethanol.

Ethanol vs Petrol

Disadvantages of Ethanol As the Calorific value of Ethanol is low more fuel needs to be burnt to

equal the energy produced petrol. Therefore 1.4kgs of Ethanol needs to be burnt for 1 kg of petrol.

Ethanol Petrol

CV of 29700 KJ/Kg CV of 43000 KJ/Kg

Produces 1.5 kg of CO2 /Kg of Fuel Produces 2.4 Kg of CO2 /Kg of Fuel



Engine Modifications •The engine is equipped with Electronic Fuel Injection System to control the air/fuel ratio.

•The cylinder has to be lined with anti-corrosive lining such as molybdenum oxide.

•The compression ratio has to be increased to increase volumetric efficiency of the engine.

•We plan to run this engine on our urban concept.

CH3CH2OH + 3 O2 → 2 CO2 + 3 H2O + heat



MONOCOQUE DESIGN•Monocoque is a construction technique that supports structural load by using an object's external skin, as opposed to using an internal frame or truss that is then covered with a non-load-bearing skin or coachwork.•This helps us integrate the components better and ensure structural integrity.•The components can be directly bolted on to the frame hence reducing material weight and cost.•Weight of the car can be reduced by a close 12 kgs.•The possible materials considered are Fibre reinforced plastic or Carbon fibre.

garuda 2012

Technology

garuda team

project timelines

best indian team

fabricated bythe team

current car

prototype optimization1

prototype gasoline

propelthe car