SCRIPT BS9 E-HPVC 22

SLIDE SHOW

Slide 1 - Introduction

A very pleasant morning to one and all present here. Hope everyone is doing well. I, Subhasish
Panda, along with my teammate Anisha Mohapatra are going to present the Critical Design
Presentation on behalf of team BLUESTREAK 9.0 from the National Institute of Technology,
Rourkela, India.

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Slide 2 - Design goals

This year our team has strictly adhered to the design criteria and constraints set by the ASME
e-HPVC rulebook. Additional constraints and modifications were also taken into account based
on performance and safety, some of which are as follows -

- a top speed of 35 kmph

- Installation of brakes on both front and rear wheels to achieve a maximum braking distance of
5.5m
- A maximum turning radius of 7m
- total cost of the vehicle to be less than Rs 40,000
- Electric assist on the rear wheel with an additional landing gear to provide low speed stability
- Ensuring that deformation of the roll cage does not exceed 1cm, under both topload and
sideload conditions, with a minimum factor of safety of 1.2

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Slide 3 - Vehicle configuration

We compared vehicle configurations of low, mid and high racer bikes, along with delta and tadpole
trikes and quads. After preparing a decision matrix, the 2-wheel mid racer type design was finalized.
This design provides optimal performance, keeping various aspects like high and low-speed stability,
aerodynamic advantages, simplicity in design, cost, and manufacturing in mind. An optimal wheel
base would be good for agility during endurance races.

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Slide 4 - Ergonomics

The vehicle was designed after selecting rider posture and analyzing its ergonomics. A background
study of rider height was done to get the minimum and maximum rider height of 164 cm and 175 cm.
A back seat angle of 40 degrees was selected after various iterations in CATIA software, ensuring the
best possible balance between comfort and rider’s field of view. The body configuration angle of 130
degree combined with a -10 degree hip orientation angle is bound to give good power output.
Besides this, Vision window was verified to get a field view for the rider, body angles were measured
and RULA analysis was done and a score of 3 was obtained which ensures postural safety and
comfort. An adjustable handle will provide a balance between vision and comfort.

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Slide 5 - Chassis

The frame of BlueStreak 9.0 has been designed to minimize vehicle weight without compromising
structural strength and rider’s safety.

Considering aerodynamics and stability an optimal wheelbase was chosen with a head tube angle
of 68 degrees. Numerous research papers were studied and essential parameters like mass
density, yield strength, modulus of elasticity, machinability and weldability were considered using
the ASHBY method for material selection. A survey was also conducted to assess the cost and
market availability of the material after which AISI 4130 was finalized as the primary frame
material. During the pre initial stages a 2D sketch of the frame was prepared considering vital
parameters like optimal wheelbase, front wheel drive and pedal arm radius. Then, anthropometric
data like rider height was collected and a 3D frame was generated using tubes of 25.4 mm outer
diameter and 2mm thickness.

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Slide 6 - RPS Analysis

The roll-over protection system is an integral part of a HPV as it protects the rider during accidents.
To ensure a RPS with optimal strength, Finite element analysis was performed on ANSYS static
structural and the results obtained were highly satisfactory considering the lightweight frame.

For both top load and side load cases, the guidelines provided in the ASME HPVC rulebook were
strictly adhered to and static structural modeling and boundary conditions were set as mentioned.

During top loading, a maximum deformation of 1.504mm was obtained with a minimum factor of
safety of 1.265 whereas under side load condition, a maximum deformation of 0.606mm was
observed with a minimum factor of safety of 1.745 with no body part of the rider touching the RPS
after deformation in both cases. The maximum stresses were also far below the yield stress of AISI
4130 which indicated that there was hardly any chance of fracture or failure.

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Slide 7 - STRUCTURAL ANALYSIS 1

Apart from the RPS analysis, other structural analyses were also performed to ensure structural
integrity of the frame.

The frame was tested to withstand a front OR rear impact for a tremendous force of 2100N. It was
also tested to sustain a reaction force of 3087N, which is 4.5 times the rider weight, during a bump
impact.

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Slide 8 - STRUCTURAL ANALYSIS 2

Rider safety was also improved further by testing the frame’s seat belt attachment point. Here, forces
could reach as high as 525N on the corresponding frame member during sudden braking.

Further, modal analysis was performed in ANSYS mechanical to make sure that the natural frequency
of the vehicle frame was higher than the external applied frequency, as otherwise the frame could fail
due to resonance.

Now, my teammate Anisha will be taking over the presentation.

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Slide 9 -DRIVETRAIN 1

BlueStreak 9.0 utilizes a hybrid powertrain. For manual drive, a front wheel drive system with a fixed
bracket configuration was selected after a lot of research, considering its better efficiency, good
Alignment and optimal cost as compared to RWD. We are using a 56 Teeth Front Sprocket mated to a
12-28, teeth range 7 speed cassette . Two idler gears connected via a revolute joint provide and
maintain alignment of the chain. Pedal arm analysis, revolute joint analysis and gear ratio calculation
were performed meticulously for various conditions according to our design goals and the results
hence obtained were optimum for our design.

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Slide 10 - ELECTRIC DRIVETRAIN

We have chosen a class 2 electric bike for our hpv and thus the throttle assistance allows the motor to
be operated with or without pedaling.The electric drivetrain uses a 250W 36V Rear wheel drive hub
motor powered by a 36 v battery pack.

The cadence sensor measures the RPM of the rear wheel and sends a feedback signal to the
microcontroller. If the RPM of the rear wheel is more than the target 334 RPM for a maximum speed
limit of 32kmph, then the power supply to the motor is cut off by the relay, ensuring the rider’s safety

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Slide 12- STEERING AND FORK

Front wheel steering with an overseat steering configuration was selected keeping aspects like
ride-handling, cost and complexity in mind. The steering head tube angle was chosen for optimal
trAil to provide better handling and with a short wheel base of 1125mm. After doing various
iterations

4.94m of turning radius was obtained for steering..

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Slide 11- AERODYNAMICS

To get minimum drag force and streamlined flow of the vehicle, a fully faired design was considered.
Among various streamlined shapes for aerodynamics, NACA 66-021 was used layer by layer to avoid
wake regions, and turbulent flow generation. Addition of various profiles was done in the top plane at
regular lengths to furnish a smooth surface and to achieve least frontal area. Carbon fiber was used
as the material for fairing to provide proper strength and weight, and Lexan polycarbonate was used
for transparency and scratch resistance.

Aero Analysis:

The objective of the aerodynamic analysis was to reduce the drag coefficient, and minimize lift by the
weight of the fairing. Fully faired, semi-faired and without fairing designs were compared for optimal
aerodynamic performance. After many iterations, a relatively pointed surface at the front to curl the
wind sideways and towards the top and a pointed edge towards the end, was considered.

The analysis was carried out in a headwind of 14 m/s, in the k- epsilon model, which gave a drag
coefficient of 0.13 for the frontal area of 0.58 m^2.

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Slide 13- VEHICLE DESCRIPTION

Bluestreak 9.0 was designed as a two wheel midracer with an optimal wheelbase of 1125mm having
a rear wheel of 508mm dia and front wheel of 457.2mm diameter. A landing gear has been added to
provide low speed stability. The drivetrain uses front wheel drive with fixed bracket design having
56T FS x 7 speed cassette, For aerodynamics, a fully faired fairing is made up of carbon fiber and
lexan polycarbonate is used. The frame is made up of aisi 4130 material with a 40 degree back seat
angle which allows for optimal comfort for riders of height 164cm to 175 cm. A RULA score of 3 was
obtained which ensures postural comfort and Safety.

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Slide 14 -Innovation

For innovation we have focused on implementing a landing gear system that could be electronically
deployed for low-speed stability as well as during vehicle standstill. The frame of the landing gear
and the linear actuator are connected using revolute joints, and the whole mechanism acts as a
crank.

As seen in the circuit diagram, the linear actuator is linked with the motor driver which is connected
to the battery. The potentiometer determines the extent of elongation as per the signals provided by
the Arduino Uno. The rider can electronically operate the landing gear with a switch depending on
the road conditions and speed of the hpv. This eliminates the manual assistance that was previously
required by a team member during start of the vehicle.

The mathematical model was developed in MATLAB-Simulink. A combination of revolute and

prismatic joints gives the model one degree of freedom where the input is provided by the signal
block. Various rigid transformations were done to align the bodies to the required frame and the
required analysis was done to validate the working of the landing gear prototype.

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Slide 15- COST

The price of all major components was estimated and the total cost was Rs 38,591.We did a survey of
the market and focused on reducing cost without any compromise on performance. We tried to use
products from the nearby market which would further reduce the transportation cost and thus overall
cost.

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Slide 17- COMPARISON BETWEEN DESIGN GOALS AND RESULTS

At last we could say that the results obtained during the analysis clearly indicated that Bluestreak
9.0 satisfies the design criteria laid down by the team considering the hpvc rule book. With a
maximum speed of 40.11kmph, a theoretical turning radius of 4.94m, a braking distance of 2.45m,
a drag coefficient of 0.13, and a rps strong enough to protect the rider during an accident. With
physical testing, we assure that we can come up with a better vehicle that can be used in the future
ensuring the betterment in the hpvc arena.

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Slide 17- THANK YOU