THE CRIMSON GLADIATORS TEAM

PROJECT MANAGEMENT
Team Members and Roles: Team Budget Planning:
The team budget was split according to the following table and the total cost required

Electric Systems Specialist: was AED 57 only, which includes spares!

Responsible for the electronics, Detailed Item Costing

programming and any custom software for
the mechanisms that suit the team’s Detailed Item Costing
requirements and identity.
Batteries - 15 pcs

PLA - 350g

Innovations & Creativity Manager: Solar Panel - 1 pc - Upcycled

Responsible for media management and Servo - 1 pc

investigating where unconventional Laser Diode - 1 pc - Upcycled

strategies can be implemented for Relay - 2 pcs - Upcycled

optimization of the car. 0 5 10 15 20 25 30 35

Mechanical Design Strategist: After sessions of brainstorming, it was identified that the vehicle must be able to
Responsible for ensuring that the design of emulate real-life scenarios and be optimized by simulating the natural behavior of
the vehicle was enough to fulfill the vehicles and maintain easy drivability. Moreover, fulfilling sustainable goals
technical criteria whilst maintaining the (environmental, social, techno-economical) was also a major part of this project. Ideas
appropriate aesthetic. were strategized and sorted with time and a Gantt chart was generated.

Material & Fabrication Engineer:

Responsible for analyzing the best-suited
materials for the project and assessing the
most suited methods of assembling the
vehicle.
 RESEARCH
4x4 Vehicle Systems and Engineering Principles
4. High-Grip Tires:
It was important for us to research into the car we were provided with before any
Designed with aggressive tread patterns which provide better grip on loose surfaces
solutions could be implied and hence, we studied the following parameters. such as dirt, sand, or rocks.

1. Four-Wheel Drive (4WD) System: 5. Weight Distribution:

Power is transmitted to all four wheels simultaneously. This allows for better Balanced weight distribution is known to enhance traction and stability.
traction, especially in off-road conditions. Torque distribution among the wheels is This is made possible with strategic positioning of additional batteries, motors and
optimized to achieve increased stability. other components within the chassis.

Cg

2. Off-road suspension:
Makes use of specialized suspension systems including heavy-duty springs and 3D Printing
suspension clips. Upgrades such as increased ground clearance and improved wheel
articulation were noticed. We conducted research on 3D Printed PLA materials to determine the optimal nozzle
Suspension diameter, infill pattern and build orientation. The results pointed out that square
Clips pattern printed with a nozzle diameter of 0.8 mm and 0 degree build orientation gave
out the most optimum mechanical properties. Thus, we incorporated these
parameters for the outer shell along with the rack and pinion mechanism.

3. Brushless Motors:
Higher efficiency, more power, and increased longevity provide smoother and more
responsive acceleration, well suiting an off-road vehicle’s needs.
 RESEARCH DESIGN SPECIFICATIONS
Our team used innovative ideas to build upon the basic guidelines and baseline
Solar Charging Battery models supplied by the competition. Taking critical dimensions such as weight and
- Solar panel selection: We researched and identified the most efficient and compact lengths into account, we customized the following designs according to our needs.
solar panels that can be integrated into the RC car's design without compromising its Table1 – Design Specifications: Base line and Modified Design
performance. Base Line Modified Design
- Charging circuitry: We developed a robust charging system that efficiently converts Battery and Arduino mounts Batteries zip tied to optimize weight
solar energy into electrical power and charges the LiPo battery. and space. Customized circuit housing
for Arduino and complex circuitry
Tow bar design Tow bar mechanism incorporated
within vehicle design
Baseline App Customized Bluetooth App

Comprehensive selection process was implemented to select the body design, body
material, and tow bar design. Different materials were analyzed, and prototypes were
made to test and understand mechanical advantages of each material.

Table 2 – Pugh Chart – Shell material selection process

Tow bar Mechanism: Criterion/Solution Glass Fiber Cardboard ABS PLA Aluminum
We examined and analyzed the performance of different gears in the rack and pinion (Datum)
configuration attached to a 9g Servo motor. We also examined various gear tooth Strength 0 -2 1 1 1
profiles, such as involute or modified profile, to determine the most suitable profile Cost Effective 0 1 0 0 0
for rack and pinion systems. We researched about gear module and tooth size
selection to achieve the desired gear ratio while maintaining optimum flexural Precision 0 -1 1 1 0
strength and contact area. Ease of Use 0 0 0 1 -1
3D Models & Printing prototypes of gear and pinion configuration.
Weight 0 1 1 1 0

Sustainable 0 1 0 1 -1

TOTAL (/6) 0 0 3 5 -1

Based on the Pugh chart, PLA (Polylactic Acid) was the obvious choice when making
the decision to manufacture our vehicle shell. Not only is it easy to use and strong, but
it is also biodegradable and available in a multitude of colors!
 IDEAS
Circuits Schematics:
2D and 3D Sketches:
BASE CIRCUIT IMPROVED FINAL CIRCUIT
Drawings and models were prepared for the shell. These played a crucial role in
CIRCUIT
visualizing and refining design concepts to ensure accurate dimension.
The tow bar mechanism was also re-imagined, incorporating a rack and pinion
system. The tow bar, shaped like a spare rear tire, allowed seamless integration with
the vehicle design while maintaining functionality.

While the team strived towards continuous improvement and refinement of the
overall design, special consideration was given to optimize the designs for 3D
printing. CAD models were prepared in Autodesk Inventor, sliced in Ultimaker Cura
application, while the Wanhao Duplicator 9 3D printer meticulously manufactured
the finalized designs.

OLD 2D DESIGN OLD 3D DESIGN SCAN QR CODE FOR THE DETAILED DIAGRAMS:

Tow bar Mechanism:

For the towbar mechanism, a design innovation was implemented wherein the spare
wheel carrier was designed as a disguise to house the towbar mechanism. This
includes a rack and pinion, which was 3D printed too, for its lightweight and precision
manufacturing. The amount of vertical movement of the towbar was calculated based
on the technical regulations of the trailer provided and height of the spare wheel
carrier. With this, the appropriate gear ratio was chosen and printed. Due to the heavy
weight of the trailer, 3D printed material would not be sufficient to pull it and hence
a nail was attached, which can withstand higher tensile forces and has higher load-
bearing capacities too.
NEW 2D DESIGN NEW 3D DESIGN
DETAILED SCHEMATICS
Once the features for the vehicle were selected, the next logical step was to draw up a
schematics diagram for the electronic components in order to study the feasibility of all
the components existing in the environment harmoniously. A circuit housing was
developed on CAD software and 3D printed so that everything could rest onto it easily.

The Arduino code was developed further with the help of the provided Yas in Schools code
online and a compatible android app was also created from scratch to greatly enhance
the experience of towbar mechanism. After many revisions, the application was perfected
as it allowed for connectivity to only the team’s Bluetooth module due to its unique MAC
address.

PLEASE SCAN THE BELOW QR CODE

FOR THE FULL ARDUINO CODE
 DEVELOPMENT, TESTING & MANUFACTURING
3D Model vs Physical Model:
Table 3 – Testing Parameters
Several changes were made to the initial 2D and 3D models that were created on
Autodesk Inventor. Initial physical models made in cardboard were undependable in Initial Reading Improved Reading
terms of reliability and strength. Thus, the models were 3D printed after careful Time taken to Before attaching guide - 1.5 After attaching guide -
considerations as seen in Table 2. hook onto the min 30 sec
trailer
Bluetooth Unstable connection before Stable connection after
Connection relay relay
Longer wait time between Shorter wait time
commands between commands
Annealing Strength: 9.6MPa Strength: 10.5 MPa

Manufacturing Processes:
Different manufacturing processes were used throughout the course of the project
such as annealing and 3D printing. In the case of trailer, the tow bar mechanism alone
was not enough to accurately hook onto the trailer. Due to this reason, a guide was
Testing: created which aided in proper alignment between the trailer and the tow bar. It was
accomplished using various machines at the workshop. It reduces the time required
Due to our dedication to keep improving our designs, once the pieces were for coupling significantly, which is an important parameter in the tow bar challenge.
manufactured, we tested them and improved multiple different avenues such as: Not only that, it also reduces any wear and tear associated with misalignment, which
1. The time taken for the car to hook onto the trailer. This was achieved by adding could have led to scraping and other forms of contact. Lastly, it also allows the tow
a guide. bar to hook to the trailer at any angle and does not necessitate it to be perfectly
2. The stability achieved by the bluetooth connection. We faced a lot of problems aligned at 0 degrees. During this process, we used the band saw, hack saw and grinder
with the bluetooth connection which was significantly improved with the help to shape the metal sheet effectively.
of the relay.
3. The strength of the 3D printed parts, which were improved through the process
of annealing.
These improvements were tested and analyzed as mentioned in the table below.
 SUSTAINABILITY
The team took careful considerations of the sustainability aspect in all avenues. The 2. Creative Problem-Solving: To think outside the box and find alternative solutions
three avenues of focus regarding sustainability are People, Profit and Planet. that do not rely on monetary resources – E.g.: The guide for the towbar was made
through a metal sheet that was easily available in the workshop.
People
1. Multidisciplinary Learning: Our car involves a blend of mechanical engineering,
electrical engineering and financial management. This multidisciplinary focus caters
to a wider audience of students and at the same it exposes them to different
engineering disciplines and helps them develop a well-rounded skill set.
2. Innovation, Design Thinking & Hands-on Experience: The incorporation of
multiple technologies ranging from 3D printing all the way to annealing enables
students to explore different avenues of engineering. This will encourage young
engineers to apply their knowledge into practical life projects and our experience can
mold them for future challenges. Young engineers will be encouraged by the
innovative solutions implemented in our car and will foster an innovative mind when
they go on to tackle different challenges in their own projects. Planet
1. Sustainable Technology: The use of a solar panel in our car facilitates charging of
our battery without contributing to the GHG emissions. This idea aligns with our goal
towards a sustainable future! Another reason for using solar panels is its availability.
These vehicles are meant to go on difficult terrains and are often used in deserted
areas where fuel may not be easily accessible. In these cases, solar panels can also be
used as an emergency alternative.
2. 3D Printed PLA Body: PLA being a derivative of renewable resources is
biodegradable and will break down into natural elements when disposed properly.
3D printing facilitates on-demand manufacturing, reducing material wastage and
disposal when compared to traditional manufacturing methods. This method also
allows us to print complex geometries at ease without the need for subtractive
manufacturing.
Profit
Crimson Gladiators are proud to showcase the remarkable achievement of minimal
spending goals, which align with our economic sustainability and resource
optimization goals.
1. Upcycling: A great percentage of resources used for our car are upcycled from our
local workshop. This reduces the need to purchase newer parts and minimizes our
negative impact on the environment.