DESIGN AND ANALYSIS OF HYBRID VEHICLE

International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 5, May 2017, pp. 237 248, Article ID: IJMET_08_05_026 Available online at http://www.ia aeme.com/ijmet/issues.asp?jtype=ijmet&vtyp pe=8&itype=5 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication Scopus Indexed DESIGN AND ANALYSIS OF HYBRID VEHICLE N.Siva teja Assistant Professor, Mechanical Engineering Department, KL University, A.P., India. B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha Bachelor of Technology, Mechanical Engineering Department, K L University, A.P., India. ABSTRACT Hybrid vehicle is a small four wheeled vehicles with suspension and differential. It is light powered vehicle which is generally used for racing. This. The hybrid vehicle chassis is different from paper is intended to show and play out the dynamic examination of the hybrid vehicle body which is developed with round bars. Demonstrating and investigation are performed in SOLIDWORKS and ANSYS separately ordinary car chassis. Quality and light weight are the fundamental thought for picking the frame material. AISI 1018 is the best material to be used for hybrid vehicle. The paper also describes the ergonomics for driver. In relevant to be rule book of Hybrid Vehicle Design Challenge (HVDC). It converts to store energy from IC engine to battery Key words: AISI 1018, Ansys, battery, chassis, ergonomics, solid works. Cite this Article: N.Siva teja, B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha Design and Analysis of Hybrid Vehicle. International Journal of Mechanical Engineering and Technology, 8(5), 2017, pp. 237 248. http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&i IType=5 1. INTRODUCTION The hybrid vehicle is simple, lightweight and compact and easy to operate. We have taken some references from international journals and about the design and analysis of go kart and electrical kart which helps us to prepare a project. Departments for Design of hybrid vehicle: - Modelling and Analysis Fabrication Steering Brakes and tyres Suspension Transmission http://www.iaeme.com/ijmet/index.asp 237 editor@iaeme.com

Design and Analysis of Hybrid Vehicle 2. CHASSIS OF HYBRID VEHICLE Chassis Material selection is a very important step of a vehicle design because it has a direct impact on economy and safety of the vehicle. There are few parameters we have considered before selecting the material of the chassis. They are availability, strength, weld ability, machinability etc. after a search we found AISI 1018 steel normalized. Other physical properties of this material are listed below. Wheel base = 68.5 Inch = 1739.9mm Track width = 56 Inch = 1422.4mm 2.1. Chemical properties 2.2. Mechanical properties 3. MODELLING OF CHASSIS Chemical properties AISI 1018 Carbon 0.17% Manganese 0.80% Silicon 0.27% Sulphur 0.050max Phosphous 0.05max Density 7.87% g/cm^3 Poisson s ratio 0.29 Tensile strength, 394.72mpa ultimate Tensile strength, yield 294mpa Bulk modulus 140gpa Elongation at break 36.5% The modelling of chassis is done in SOLIDWORKS software and the model is designed according to the requirements and it should be imported in ANSYS for analysis and with stands all sort of strengths stresses included ought to be given due thought so it withstands under these powers without crack or undue bending. Figure 1 Chassis of hybrid vehicle http://www.iaeme.com/ijmet/index.asp 238 editor@iaeme.com

N.Siva teja, B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha Figure 1.1 Complete hybrid vehicle The seat is kept almost parallel to the fire wall. It is the average height for any racer above calculations are done according to the investigation. Figure 1.2 Ergonomics of the driver 4. MESHING AND ANALYSIS OF CHASSIS Finite element analysis Configuration prepare subsequent to choosing different frameworks to be planned and other options to those frameworks by displaying them in CAD delicate products like strong works and Analysis were done in Ansys Workbench. Our design mainly focuses on the strength, durability, safety, driver comfort, and pleasing look of the vehicle. 4.1. Chassis impact analysis In order to prejudice the impact forces for the chassis that we have modelled in SOLIDWORKS it is then analysed through static structural analysis using FEA tool ANSYS. Front impact analysis Side impact analysiss Rear impact analysiss Roll over analysis Torsional rigidity 4.2. Force calculation: Consider the weight of the chassis as 350 kg including driver http://www.iaeme.com/ijmet/index.asp 239 editor@iaeme.com

Design and Analysis of Hybrid Vehicle From moments equation F= Ma Force = Mass* acceleration due to gravity F = 350*3*9 10300.5 N (3g loads) F = 350*4*9.81 13734 N (4g loads) F = 350*2*9.81 6867 N (2g loads) 4.3. Chassis Front impact MAX stress (von misses) - 255 Mpa Factor of safety 1.44 Status safe Side impact MAX stress (von misses) -263.8 Mpa Factor of safety 1.406 Status safe http://www.iaeme.com/ijmet/index.asp 240 editor@iaeme.com

N.Siva teja, B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha Rear Impact MAX stress (von misses) 84.8Mpa Factor of safety 4.35 Status safe Torsion rigidity ( 2g load) Front impact( 4g load) MAX stress (von misses) - 251Mpa Max stress (von misses) 391Mpa Factor of safety 1.44 Factor of safety 1.12 Status safe Status - safe Side impact (2g load) Rear impact (2g load) Max stresses 148Mpa Max stresses 60Mpa Factor of saftey 2.5 Factor of safety 6.16 Status safe Status - safe(max stress distributed at rear bumper) http://www.iaeme.com/ijmet/index.asp 241 editor@iaeme.com

Design and Analysis of Hybrid Vehicle Roll over (2g load) Max stresses 80.4mpa Factor of safety 4.08 4.4. Steering Steering is the gathering of segments, linkages, and so on which permit a vehicle to take the desired direction. The fundamental point of controlling is to guarantee that the wheels are indicating in the coveted bearings. This is normally accomplished by a progression of linkages, poles, rotates and outfits. One of the principal ideas is that of caster edge each wheel is guided with a rotate point in front of the wheel; this makes the controlling have a tendency to act naturally trotting towards the course of travel. We are using Rack and pinion steering. 4.5. Rack-and-pinion steering Figure 1.3 Rack and pinion Calculation: We have Tan (α) = L/(R-t/2) Tan(40)=1739.9/(R-1422.4/2) R=2784.73mm=2.78meters Tan (β) = L/(R +t/2) Tan (β) = 1739.9/ (2784.73 +1422.4/2) β = 26.45 degrees where L= Wheel base t = Track width α = Outer steer angle β = Inner steer angle http://www.iaeme.com/ijmet/index.asp 242 editor@iaeme.com

N.Siva teja, B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha R = Turning radius Steering ratio = 12:1 Assume front wheel turned = 40 degrees (maximum) Steering turned = 40*12 = 480 degrees (Only one wheel) Therefore, weight acting on the front wheels = 40% of total weight of the car. = (40/100)*280 = 112kg Weight acting each front wheel = R = 112/2 kg R= 56 kg We have F=µR Assume µ=1, F = 1*56=56kg=56*9.81N =549.36 N We know that, Torque=Force * Steering wheel radius = 549.36 * 0.1143 = 62.791 N-m 4.7. Suspension The primary target of a proficient suspension framework is to give solace to the general population in the vehicle and provide comfort damping impact by not permitting the knocks to go to the vehicle and subsequently expanding the life of the vehicle. The principle groupings are needy and autonomous suspension sorts, however, this naming tradition truly just applies to conventional or simple suspension frameworks. Indeed, even autonomous frameworks are ordinarily joined over the auto by a hostile to move bar as are not really free. We are using pushrod suspension. And further suspension is tested in Lotus software Figure 1.6 Suspension testing in Lotus software http://www.iaeme.com/ijmet/index.asp 243 editor@iaeme.com

Design and Analysis of Hybrid Vehicle Calculation Front condition T = K[8 2] d = 9mm D = C*d = 64mm To calculate no. of coils the below formula is used K = ^48 3 n a = 8 n in = 2 nt = 10 l solid = (nt)*(d) = 90mm l free = + = 152.5mm pitch = L free / na 19.06mm spring travel = lfree l solid = 62.5mm damper co-efficient Cc = 2 = 314.6 Rear Condition T = K[8 2] d = 9.02mm D = C*d = 65.82mm K = ^48 3 n a = 9 n in = 2 n t = 11 l solid = (nt)*(d) = 101.2mm l free = + = 156.771mm pitch = L free / na = 17.4196mm spring travel= l fre ee l solid = 55.571mm 4.8. Transmission The hybrid vehicle works on both electrical motor and engine. A hybrid vehicle becomes the main sources in future and hybrids is also use an internal combustion engine and fueled like normal cars but have an electrical motor with battery. At present Toyota prius hybrid work amid start-up and low speeds, the Prius is fueled just by the electricc engine, which is encouraged by the battery. As the battery charge is drained, the gas motor reacts by fuelling the electric generator, which revives the battery. We have internal combustion engine about 220cc and electrical motor with 50Ah Transmission layout Figure 1.7 Transmission layout Figure 1.8 Parameters 4.9. Calculations of Electrical motor Power=4.5 kw N=1828 rpm Driving sprocket teeth=17 Service factor, k s =1.3 http://www.iaeme.com/ijmet/index.asp 244 editor@iaeme.com

N.Siva teja, B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha 1) kw rating of chain For 17 teeth, k 2 =1.00 Kw rating of chain= =.. = 4.64. 2) Selection of chain From power rating of simple roller with 4.64kw & pm Pitch, p=12.70mm Roller diameter, d1=7.95mm Width, b1=7.85mm Transverse pitch, pt=14.38mm 3) Pitch circle diameter Driving sprocket:- Driven sprocket:- D 1 =. = 69.11mm =. D 2 = = =145.71mm 4) Number of chain links 5) Correct centre distance Centre distance range 30p-50p Assume, a=40p=40(12.70) =508mm Ln=2. + +. Ln=106.72ᴝ107 links = 106.72 =80.22mm a=(p/4){[ln-((z1+z2)/2)]+[ln-((z1+z2)/2)] 2-8((Z2-Z1)/(2π)) 2 ] (1/2) } a=471.18mm a=416.34mm (or) 16.41inches 6) Tension in chain Chain tension, V= =.. =6.25m/s 4.10. Calculations of an IC Engine P= =. = 742.4N. Engine Power = =. http://www.iaeme.com/ijmet/index.asp 245 editor@iaeme.com

Design and Analysis of Hybrid Vehicle =8.636 watts Gear Ratio =. h. h = = 2.47 Velocity Ratio = no. of driver gear teeth / no. of driven gear teeth = = 0.403 Final Speed = = 3600*0.403 = 1460.8 rpm 1) KW rating of Chain KW of chain = (KW to be transmitted)(k 5 ) / (k 1 *k 2 ) = (8.6*1.4)/(1.0*1.26) =9.55 KW 1. Selection of Chain: According to power rating of simple roller chain table Chain Number = 10A Here 10 = pitch of the chain A = American Standards For 10A chain Pitch (p) = 15.875 mm Roller Diameter (d 1 ) = 10.16 mm Width (b 1 ) = 9.4 mm Transverse Pitch (p 1 ) = 18.11 mm Simple Chain (Breaking Load) = 21800 N a. Pitch circle diameter Diameter of driving sprocket Diameter of Driven Sprocket D 1 =. = =106.51 mm D 2 = =. =262.92 mm http://www.iaeme.com/ijmet/index.asp 246 editor@iaeme.com

N.Siva teja, B.Yogi Anvesh, Ch.Mahesh, D.Sai Kiran, and D.Satya Harsha b. Number of Chain links Pitch of the chain (p) = 15.875 mm L n = 2*(a/p) + ((z+ z 2 )/2) + ((z 2 z 1 )/2) 2 * (p/a) = 2. + + 2. = 116.50 links 1) Correct centre distance [L n ((z 1 + z 2 )/2)] = 116.5 = 116.50-36. = 80.5 a = (p/4)*[[l n ((z 1 + z 2 )/2)] +[ ( L n ((z 1 + z 2 )/2)) 2 8*(z 2 - z 1 )/2*π) 2 ] ] =15.875 4 80 +2 = 396.27 mm a = 0.998*396.27 2) Tension in chain v = ((z*p*n)/60*10 3 ) = (21*15.875*1450.8)/60*10 3 Vmax = 8.061 m/s Chain tension p 1 = (1000*Engine Power) / v max = (1000*8.63)/8.061 = 1070.58 N a= 396.477 mm 4.11. Braking Braking is the system in the engine vehicle which is accustomed to backing off and ceasing the vehicle to rest in the most limited conceivable separation. We are utilizing pressure driven brakes in our vehicle to get more productivity. The circle brake is a considerable measure like the brakes on a bike. Bike brakes have a caliper, which crushes the brake cushions against the wheel. In a circle brake, the brake cushions crush the rotor rather than the wheel, and the drive is transmitted using pressurized water rather than through a link. Erosion between the cushions and the plate backs the circle off. http://www.iaeme.com/ijmet/index.asp 247 editor@iaeme.com

Design and Analysis of Hybrid Vehicle We have decided to use DOT 3(Department Of Transportation) brake fluid. It is completely compatible with DOT 3 and DOT 5.1. 4.11.1. Parameters 1. Pedal force 250N 2. Pedal ratio 6:1 3. Master cylinder bore size 5/8 in 4. Calliper bore size 3/4in 5. Inner radius of tire 6in 6. Outer radius of tire 10 in 7. Stopping distance 10m 8. Mass of vehicle 250kg 5. CONCLUSION Hybrid vehicles are more environmentally friendly naturally amicable than inward ignition vehicles. Where our hybrid vehicle has consisted every department such as power train with battery and motor and carries human weight more than 90 kgs and adding all the weights it exceeds 250kgs. It also works on parallel hybrid and its maximum speed is 75kmph REFERENCES [1] Rule book of Hybrid vehicle design challenge, ISIE [2] Anjul Chauhan, LalitNaagar, Sparsh Chawla Design and Analysis of Go-Kart, International Journal Of Scientific Engineering And Technology ISSN: 2393-8609, 5 September, 2016. [3] D.Raghunandan, A.Pandiyan, ShajinMajeed. Design and Analysis on Go kart chassis, International Journal of Scientific Engineering and Technology ISSN: 2277-9655, 5 November, 2016. [4] Shithin PV and Uma Syamkumar Four Switch Three Phase Brushless Dc Motor Drive For Hybrid Vehicles International Journal of Mechanical Engineering and Technology, 5(11), 2017, pp. 65 75. [5] Sathish Kumar And Vignesh, Design And Analysis Of An Electric Kart, International Journal Of Research In Engineering And Technology EISSN: 2319-1163 PISSN: 2321-7308. http://www.iaeme.com/ijmet/index.asp 248 editor@iaeme.com