Virtual BAJA SAEINDIA 2017
S E N I L E I U G N O I T A T N E S E R P
Hosted at
CHITKARA UNIVERSITY Rajpura Campus Chandigarh-Rajpura-Patiala Chandigarh-Rajpur a-Patiala National Highway, National Highway 64, Patiala, Punjab – 140401
on th th 14 & 15 July 2017
About Virtual BAJA The Virtual BAJA SAEINDIA is a filtration c riterion, through which all the registered teams are scrutinized for their knowledge and capability to participate successfully in the main event. Virtual BAJA started in the year 2009 and is supported by working professionals as judges and volunteers across the country. The Virtual BAJA SAEINDIA acts as a pre‐qualifier to participation in the BAJA SAEINDIA event. The objectives of the Virtual BAJA Event are as follows: 1. To acquaint the teams completely with the objectives of the BAJA SAEINDIA event. 2. The teams are required to familiarize themselves with the technical guidelines and limits for the design of BAJA vehicle. 3. To design the complete CAD Model of the BAJA Vehicle. The design should be complete in all respects to the extent of being considered ready‐to‐manufacturing. Based on the performance in the Virtual BAJA, the teams would be selected for participation in the main event. The selection would be purely on the basis of merit and ONLY ONE TEAM PER COLLEGE shall be allowed on the basis of comparative merit. This excludes the eBAJA registrations from those colleges. The design presented during the event if shortlisted, shall be considered as final and the team shall be considered to proceed towards fabrication activity using the same design. Failing this, the teams shall be penalized / disqualified if the fabricated vehicle does not exhibit correlation with the design report or if the teams fail to fabricate within the stipulated timeframe. Note: The Virtual BAJA is a pre‐qualifier, thus, no awards would be issued for the Virtual BAJA event.
YOY Trend of BAJA 500
S M400 A E T F 300 O R200 E B M100 27 U N
0 2007
250
260 120
327
323
125
130
198 106 59
2008
2009
146 75
80
100
2010
2011
2012
395
414
179
185
388
Virtual Baja Main Baja
2013
2014
2015
2016
2017
2018
YEAR
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Presentation Guidelines
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Virtual BAJA Guidelines Key Guidelines for Virtual BAJA SAEINDIA 2017 are listed below:
Definitions: 1. OLD TEAMS The teams / colleges / institutions which participated in the Main Event of Baja SAEINDIA 2016 and/or 2017 will be called as ‘OLD TEAMS’. ‘Participation in the Main Event’ means the team must have built the Baja vehicle, brought it to
the main event and has got their team registered at Pithampur site for o n-site stages of competition.
2. NEW TEAMS The teams / colleges / institutions which could not participate in the Main Event of Baja SAEINDIA 2016 and/or 2017 will be called as ‘New Teams’. Teams not covered under ‘Old Teams’ c riteria will be considered as NEW TEAMS.
Registrations for Virtual BAJA: a. Teams are requested to fill the Virtual BAJA 2017 Registration Form from the downloaded section of BAJA SAEINDIA Forum. b. The form should be completed in all respect and signed by respective Faculty Advisor & Team Captain/ Vice-Captain. c. Teams should send scanned copy of duly signed form along with its soft copy (Excel Format Only). d. Completed forms should be mailed using the following guidelines: FILE NAME: Team ID_College Name SUBJECT: Virtual BAJA Registration – Team ID_College Name Eg. Virtual BAJA Registration – 18999_ABC College of Engineering To: Alumni Coordinator CC:
[email protected]
Teams should attach Registration Form scanned copy & Soft Copy (Excel Format Only) while sending the e-mails to
[email protected] e. Last Date to submit Virtual BAJA Registration Form is 22nd June 2017
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Presentation Guidelines
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Virtual BAJA Guidelines (Cont…) Presentations:
DURATION: Maximum of 20 mins will be allotted per te am to present their vehicle design. This includes:
o
Presentation by team to showcase their vehicle in soft copy
–
15 mins
o
Questionnaire put up by panel to be answered by t he Team
–
05 mins
TOTAL MARKS FOR PRESENTATION : o
NEW TEAMS
=
110 marks
o
OLD TEAMS
=
150 marks
FONT STYLE & SIZE: Students to use Font Style ‘’Calibri’’ and, Font Size to be “ 14 or above“.
Presentations to be made in MS PowerPoint, and should be compatible to run in MS PowerPoint 2007. File type should be [.pptx] only.
NUMBER OF SLIDES: o
NEW TEAMS: A maximum of 12 slides can be used to present their vehicle during Virtual BAJA 2017.
o
OLD TEAMS : A maximum of 14 slides can be used to present their vehicle during Virtual BAJA 2017.
Presentation content should be in line with the topics me ntioned in the docket under Virtual BAJA Guidelines – Presentation
Teams are requested to refer the following for Virtual BAJA 2017 - Presentations o
Slide Sequence & Marking System
o
Annexure – I : Design Aggregates and specifications
NO TRANSITIONS OR ANIMATIONS ARE ALLOWED. All the slides to contain static data ONLY.
Teams would be required to mail the presentations in PowerPoint 2007 format to
[email protected] th latest by 6 July 2017, failing which, the teams would face disqualification from the event.
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Presentation Guidelines
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Virtual Baja Guidelines (Cont…)
Presentations: Slide Sequence & Marking System
Presentation by NEW TEAMS Slide # 1 2 3 4 5 6 7 8 9 10 11 12 13
Particulars Team ID/College Name Tech Specs and performance specs of proposed vehicle Roll cage design process-ergonomics CAE basic process and its application Suspension-front/rear Brakes Steering and wheel geometry Power Train Cost and weight analysis Pie-Chart Project Plan DFMEA Design Validation Plan Team composition with work allocation; Faculty advisor name, College workshop facilities. Total Marks
Marks 0 10 10 10 10 10 10 10 10 10 5 5 10 110
New Teams need to explain Design Consideration / Design process / Layout of systems for Slides 3 to 8.
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Presentation Guidelines
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Virtual Baja Guidelines (Cont…)
Presentation by OLD TEAMS
Slide # 1 2&3 4 5 6 7 8 9 10 11 12 13 14 15
Particulars Team ID & College Name Old Team ID, Car no., Endurance score , Total score& awards Lessons learnt: Roll Cage; Aggregates; Vehicle Performance in Main Event; Breakdown/ Failures Comparison for weight; Cost; Aggregate Specs, Vehicle performance specs- Old Vs Proposed Roll Cage design process-ergonomics CAE basic process and its application Suspension-front/rear Brakes Steering and wheel geometry Power Train Cost and weight analysis Pie-Chart-Old Vs Proposed Project Plan DFMEA Design Validation Plan Team composition with work allocation/highlight old members ; College workshop facilities; FA-earlier/now Total Marks
Marks 0 40 10 10 10 10 10 10 10 10 10 5 5 10
150
Old Teams need to explain Design Consideration / Design process / Layout of systems for Slides 5 to 10.
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Presentation Guidelines
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VIVA-For all teams
Duration: Maximum of 15 minutes will be allotted per team for the Viva
Team members will be same for Presentation & Viva.
Total Marks for Viva: 50, which includes, 15 Marks- General Automotive Understanding (Part I)
- 5 mins
15 Marks- General Automotive Understanding (Part-II)
- 5 mins
20 Marks- Rulebook Understanding
- 5 mins
Total
- 15 mins
The Viva will be conducted along with your presentation.
Viva will include questions on Function /Failure Modes / Construction/Working/Concepts/Design/Materials /Manufacturing/Validation of a component or system.
Feedback, Scoring & Team Change Feedback by judges
-
05 mins
Scoring & Team Change
-
05 mins
Total:
-
10 mins
Pointers to Virtual BAJA Discipline and ethical conduct are of utmost importance. Please exhibit the same during the event. 5 members per team are allowed, including Captain / Vice-Captain. One faculty member in addition to the team members would be allowed only as a silent observer during presentation/viva. Presence of Team Captain OR Vice -Captain is mandatory. Teams would have to strictly adhere to a timeline for presentation followed by Q&A Session & Viva. The total time allotted = 20 + 1 5 + 10 = 45 mins Teams have to prepare the presentation in strict adherence with the guidelines. Any deviation from the same may lead to reduction of marks. mBAJA teams must assume that they would use a common Briggs & Stratton Engine of 10 HP/305 cc. eBAJA teams must assume that they would use a common motor of capacity not great er than 6KW. Selection criteria are solely based on me rit and preference of venue during initial registrations. Only one team from an institute would be selected based on me rit. Multiple teams do not entail confirmed selection. This excludes E-Baja Teams. Following content is NOT allowed in student presentations: o Any content about institute except for te am, institute name & workshop facilities o Any content about SAE Collegiate Club or past activities o Any CAD / CAE videos are not allowed. Instead, teams should present the data in the form of mathematical or meaningful data. For E.g.: boundary conditions Crash test analysis values, present deformation value, g- values, FOS, etc. o Any content that tries to influence the judging panel for favourable consideration of team in the selection process o No report or other documents are to be submitted before or during Virtual BAJA 2017.
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Presentation Guidelines
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ANNEXURE-I Design Aggregates and Specifications
Slides should be prepared after studying and understanding following points. Questions at virtual presentation may cover all these aspects. Slides on aggregate design should be prepared to explain following points: Within: Understanding requirements and limitations of vehicle for the aggregate What: Overall vehicle performance expected from the aggregate – relevance of aggregate parameters How: Design approach and methodology for the aggregate, based on Automobile Engineering basics. Why & why not: Justifications for selecting a particular design & why not selecting alternate designs. Decision & List: Final specifications for the aggregate.
1. Overall Vehicle Details Overall dimensions: o Overall width & length o Front & Rear Track width o Wheel base o Ground clearance Wheels / Tyres o Front & Rear Overall performance of vehicle: o Maximum Speed (Kmph) o Maximum Acceleration o Gradability % o Stopping Distance Weight: o Kerb weight and Ratio FAW to RAW- laden 2. Slide on CAE Need for CAE activity and criteria t o be used for material / size selection o Material mechanical properties – Yield strength, Tensile strength, Elongation % o Equivalence of chosen material vis-à-vis recommended material o Chemical composition w.r.t. weldability risks o Proposed Factor of safety & maximum deformation CAE process o Meshing size o Beam method or Shell method? What are the advantages & disadvantages? o Choosing Solver
Load cases for crash
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Presentation Guidelines
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o o o o o
Frontal & Rear crash Side crash Roll over How to decide impact force (calculation method) for e ach load case Constraints
Results – Conclusions: Stresses, Factor of safety & Deformation
3. Suspension Type of suspension Linkage design o CG Height o Ground clearance o Roll Centre Height at FAW and RAW o Motion ratios Suspension geometry o Camber – at Kerb weight & change s with suspension travels o Castor, KPI & Scrub radius o Toe-In & Toe-Out Design of spring, damper, suspension arms etc. o Sprung and unsprung mass o Desired natural frequency (Hz) – Front & Rear o Ride rates & Spring stiffness o Spring design – wire diameter, material, Factor of safety etc. o Suspension travels o Damper – stroke & Damping value s at 0.3 m/ s o Design of Arms and uprights o CAE for load bearing parts from suspension Overall values for Suspension 4. Steering Steering system o Understeer or oversteer? o Steering Geometry – Ackerman percentage o Steering angles – Inside and outside o Turning circle radius Steering gear – R & P o LHD or RHD o Rack travel – end to end or end to centre o Turns lock to lock, rev. o Steering ratio. mm / rev. o IBJ centre distance, mm. o OBJ centre distance, mm. o Length of Tie rod.
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Steering column o o
Type – Collapsible / Tilting. with / without Power assist (as used on o riginal vehicle).
Steering wheel o o
Steering wheel diameter. Steering wheel torque.
5. Brakes Braking circuit F/R split or X-split o Brake master cylinder bore size x stroke o Brake disc or drum o Brake calliper cylinders – bore size x nos. o Brake calliper pad – mean braking radius, Area and friction coefficient o Brake fluid to be used Brake calculations o Weight transfer at 40 Kmph to 0 K mph o Static Rolling Radius for tyre o Coefficient of friction for road o Brake torque required per wheel o Force required by calliper cylinders o Balance between two braking circuit (PRV?) – Simultaneous locking? o Which wheels lock first – front or rear? Performance o Stopping distance, m o Pedal force, N & Pedal travel, mm Brake installation problems – actions? o Bleeding o Unbalanced circuits 6. Power train Engine / Electrical Motor specifications o Max power – rpm o Max Torque – rpm Transmission unit o Geared / CVT / Elec Controller / any other. o Output Ratios for Engine / Motor rpm Tyre sizes Integration o Power train layout o Mounting and installation o Coupling Engine / Motor to Gearbox o NVH considerations o
Performance o o
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Acceleration Gradability %
Presentation Guidelines
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7. Weights and BoM / costing BoM – aggregates & their weights & Kerb weigh t Costing 8. Project plan (MS Project plan) Time plan for Major activities & assigning responsibilities o Design o Procurement o Manufacture of parts o Assembly for aggregates & Vehicle assembly o Validation o Readiness at main event at Pithampur Applying Constraints Applying task dependencies (links) Define Critical path in project. 9. Workshop facilities Manufacturing Facilities at College - photos & major specs Manufacturing facilities Outside - photos & major specs Test facilities - photos & major specs 10. Testing and validation DFMEA PFMEA Testing during manufacturing Validation Plan o Performance o Strength (Destructive testing).
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Presentation Guidelines
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ANNEXURE-II List of Recommended books
Gillespie, Thomas; “Fundamentals of Vehicle Dynamics” . Jazar, Reza; ‘Vehicle Dynamics - theory & Application’. Smith, Carroll; ‘Tune to win’ . Limpert, Rudolf; ‘Brake Design and Safety’ . B. Heissing, M. Ersoy; ‘Chassis Handbook’ . Reimpell, Stoll & Betzler; ‘The Automotive Chassis Engineering Principles’ . Richard Stone and Jeffrey K. Ball; ‘Automotive Engineering Fundamentals’ . Milliken & Milliken; ‘Race car vehicle dynamics’ . Lechner Gisbert, Naunheimer Harald; ‘Automotive Transmissions’.
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