TEAM KAIZEN

KIIT UNIVERSITY

Mission:
Experience..Educate..Excite !!
Compete and represent KIIT University at
the renowned Indo-Asian Solar Challenge.
Collaborate between multiple disciplines
and the community in order to achieve
the
monumental
goal
of
gaining
recognition in the competition.

Vision:
Take advantage of the opportunity to
learn skills beyond the scope of the
classroom.
Learn the concept of renewable energy
and its application in a practical way.
To continue research and development in
the field in order to make a retarding
impact on the degrading status of the
environment.

KAIZEN Team Members and

Management
1. Asis Das (Captain)
2. Pratyush Subhasit (viceCaptain)
3. Abhishek Mazumdar
4. Debesh Kumar
5. Sahan Saurav
6. Satya Swaroop Panda
7. Shovna Mahapatra
8. Subhangee Sahoo
9. Ankita Dey
10.Nivetha Selvaraj
Organizational Structure

Task Distribution:
Chassis and Design: Pratyush Subhasit
Abhishek
Mazumdar
Design analysis
Braking
Suspension
Panda

: Asis Das
: Sahan Saurav
: Satya Swaroop

Steering

Motor

: Shovna Mohapatra

Solar System

: Subhangee Sahoo

MPPT

: Nivetha Selvaraj

Battery

Work Schedule:

Debesh Kumar

Ankita Dey

The project is planned to be completed

within a time frame of two and half
months (construction part) excluding
gaps left for semester exams of the
university.

Assembled View:-

Chassis Design:

The chassis is designed keeping in mind

the safety of the driver which is outmost
importance and is designed on the basis
of minimum number of welds. It is
strengthened
with
moderate
triangulation and straight struts among
all load bearing components thus
covering a large surface area for solar
panel mountings.
Mechanical Analysis:

The designed components are analyzed

using ANSYS 13.0 simulating the
following load conditions.
Front Impact
Rear Impact
Side Impact
Torsion Test
And the results are portrayed graphically

Analysis Results:
Analysis Results
Maximum Stress
193.31 MPa
Maximum
0.1630 mm
Displacement

Load

800 Kgf (UDL)

Material Selection

Parameters for Material Selection

1) Optimum level of triangulation
design.
2) Structural pods for rigidity and
impact safety.
3) Being light weight but cost effective
material.
4) Compact inclusive of all systems
packaging.
5) High Torsional Rigidity.

Material Options Available

1) IS 3074
2) AISI 4130
3) ASTM 106
4) AISI 1018

On the basis of evaluation over the

selected
parameters
AISI
1018
seamless pipes were selected for
construction.

Material Specification- AISI 1018

Outer Diameter 1 inch
Width
0.095 inch
Youngs Modulus 208 GPa
Yield Strength
373 MPa
Density
6100 kg/m^3

Vehicle Dynamics and Control

System
Steering
Steering is the term applied to the
collection of components, linkages, etc.
which will allow a vehicle to follow the
desired course. An automobile is steered
with the help of steering gears and
linkages, which transfer the motion of the
hand operated steering wheel to the
pivoted front wheel hubs via steering
column. We employ the rack and pinion
type of gear box in order to achieve the
following reduction gear ratio of 10:1.

Inputting the values of the track width

and wheel base to the above equation
and equating it. The Ackermann angle is
found out to be 17 degrees.

Braking
A vehicle brake is used to slow down a
vehicle by converting its kinetic energy
into heat energy. We are employing a
disc brake calliper induced mechanism
powered by a hydraulic mechanism.
Specification

Value

Disc Diameter

200mm/170mm

Master
Diameter

Cylinder 20mm

Brake Force

2750N

Pedal Force

40kg

Pedal Ratio

7:1

Cylinder Pressure

7.87 MPa

Master
losses

Cylinder 0.125cc

Suspension
The suspension system enables the
vehicle to traverse bumpy terrain by
isolating the body from the wheels. The
suspension system dissipates the kinetic
energy as heat in the coil spring damper
assembly.
Type:
Outboard Equal (FRONT), double A arms, Coil
over Damper
Swing
Arm
type
(REAR),
absorber, Coil over Damper

Twin-Shock

Electric and Solar system

Working of Solar Array Circuit:

Silicon solar cells produce electricity
when exposed to sunlight. Each solar
cell generates 0.5 Volt, and the

current
(amps)
generated
is
proportional to the cells surface area.
The cells power is rated at full
sunlight. When the sky is overcast,
the power of the sun is lower, and the
amount of amps produced is less, but
the voltage remains the same:
0.5volts.
Each of the sections in the panel has 3
cells, connected in series, to give 1.5
Volt. The panel is designed to be 0.3
Amps at full sunlight.
At full sunlight, when the solar panels
four sections are connected in series
the motor will spin very fast, and the
car will run fast. As the sunlight
diminishes, the speed will gradually
diminish until the vehicle finally stops,
because the current is too low. To

avoid this battery regenerative system

is applied in place.
When the current is too low, with the
sections in series, reconnect the 4
sections in parallel. This gives more
current -and the SOLAR CAR will start
running again although slower, due
to reduced voltage.

SOLAR PANEL - WITH A SOLAR PANEL

POWER CONTROLLER:

Switch (S1) closed:

The motor operates directly from
solar power, as the SPPC is bypassed.
Switch (S2) opened:
The junction of resistor R1 and zener
diode Z1 provide a reference voltage
to the op-amp IC1 (pin 2).
The junction of resistors R2, R4 and
RV1 provide an input voltage signal to
the opamp IC1 (pin 3). Variable

resistor RV1 allows the circuit to be

tuned.
When the circuit is turned on,
capacitor C1 is discharged and
transistor Q1 is not conducting. The
solar cells charge capacitor C1. When
the voltage across capacitor C1 as
detected by pin 3 on IC1 exceeds the
voltage on pin 2 on IC1, IC1 changes
state and switches on transistor Q1.
When the voltage across C1 drops
below the threshold voltage, IC1 stops
conducting and switches off transistor
Q1.
When the voltage across C1 drops
below the threshold voltage, IC1 stops
conducting and switches off transistor
Q1.
The capacitor is then charged, and it
is turned off when the capacitor is

discharged, providing power to the

motor. In bright sunlight this switching
will occur very rapidly.

Battery
The solar energy is stored in batteries in
order to derive this stored energy in the
absence of the solar energy. We have
decided upon using Valve Regulated
Lithium Acid (VRLA) batteries in order to
gain maximum storage capacity at a
lower rate of discharge.

Innovation
Management
Program

Innovation:

Adopt-a-Cell

A unique way of attracting donors for the

team is our Adopt-a-Cell initiative.
Instead of large scale sponsorships this
methodology aims at larger number of
small scale individual sponsorships by
contributing an amount equivalent to a
single solar cells. Donors may wish to
adopt their desired number of cells.
Electronics
array

Innovation:

Flexible

solar

The use of flexible solar array is to be

used upon the solar car in order to
increase the solar energy capturing area

at the same time is directed at improving

the aesthetics of the vehicle.

Design Validation Plan

Facto Design
r
Require
ment

Value

Complia
nce/NonComplia
nce

Dime Width
nsion
170cm

Width
=158cm

Complia
nce

Length=
Length 287cm
290cm

Mate AISI
or AISI
rial
ASTM
1018
seamles

Complia
nce

s pipe
Lock
Nuts

On
critical
compon
ents

Present

Complia
nce

Moto Power
Power=1 Complia
r
1500w 500watt nce
att
Voltage
Voltage =48volts

48volts
Solar Voltage
Panel 55volt

Voltage Complia
=36volts nce

Brak To
be Attache
e
attached d
Light

Complia
nce

Batte Voltage Voltage

ry
48volt =48volt

Complia
nce

Capacity Capacity
80Ah
=75Ah
Kill
To
be Installed Complia
Switc installed
nce
h
Seat
Belt

3-point
Seat
Belt

3-point
Seat
Belt

Complia
nce

Cost

1,00,00 79,200
0 INR
INR

Complia
nce

Design Failure Effect mode analysis

Item
Nam
e

Failu Failur Opera Preca

re
e
tional utions
Mod Cause Effect
e

Weldi Bend Stres Struct Maxim

ng
ing, s,
ural
ize
joint Teari Impro Integr single

s of ng
roll
cage

per
weld

Tie
Bend Impro
Rods ing, per
Twist Desig
ing
n

Mast
er
Cylin
der

Impr
oper
Brak
e
actu
ation

ity at struct
risk
ural
compo
nents
Loss
of
steeri
ng
contro
l

Proper
streng
th
of
materi
al

Leaka Failur
ge,
e
of
Impro Brake
per
sealin
g

Proper
sealin
g and
adequ
ate
brake
fluid
in
reserv
oir

Shoc
k
Abso
rbers

Bend
ing,
Fract
ure,
Buck
ling

Gener
ation
of
mome
nt

Impro
per
handli
ng
and
ride

Proper
diame
ter of
shock
absor
bers

Whe
els

Fricti Impro Loss

on
per
of
press contro
ure,
l
punct
ure

Check
air
pressu
re,
spare
tires

Moto Elect Exces

r
rical sive
curre
nt

Failur
e
of
Drivet
rain

Install
MPPT
with
overch
arge
protec
tion

Batte Ther Exces Electri Maint

ry
mal sive
cal
ain
heat
fire,
chargi
Explos ng
ion
voltag
e

Cost REPORT

Particulars

Bill Amount (INR)

Material (AISI1018)

7,000

Fabrication

5,000

Steering

3,500

Suspension
Assembly

and 5,000

Brakes

4,000

Tyres

2,500

Fiber Glass

2,000

Fasteners

1,700

Solar Panels

25,000

Motor

7,000

MPPT

6,500

Battery

9,000

Electrical components 1,000

TOTAL

79,200