IIT Roorkee Motorsports J A N U A RY 2 0 1 3
The Formula Student team of IIT Roorkee
Greetings for New Year 2013 !!!
POINTS OF INTEREST
Team’s associa on with Mercedes Benz R&D India for Safety Advisor Page 3..
INSIDE THIS ISSUE: Project Team
Sponsor Highlight : Oxigen Services (India)
Sponsor Support 4 Vehicle Design Methodology
Concept Hybrid : Design Overview
Work done so far
Target for next month
Hope you remember our team and the last project in which we had made a proto‐ type race car for an interna‐ onal compe on. We are very thankful for the support of sponsors, alumni, ins tute and our families which helped us in represen ng IIT Roorkee at Formula SAE Aus‐ tralasia held at Melbourne, Australia in December 2011. Since then, months have passed some of the team members have graduated, while others have turned a year senior and many new faces have joined the team to contribute in and enjoy a share in legacy. Planning for the second pro‐ ject started in March and a er careful considera on of the team mo va on, team capacity and resources, it
was decided to work on hy‐ brid technology. The team started working on a hybrid vehicle with an aim to par c‐ ipate in the interna onal compe on
The new logo truly reflects the team’s quest to promote green technology in India.
Formula Student to be held at Silverstone Circuit, UK in July 2013. Global automobile industry is inves ng heavily on R&D in hybrids & electric vehicles and recently Indian Govern‐ ment launched the Na onal Mission on Hybrid and Elec‐ tric Mobility 2020 which
aims to encourage the R&D and manufacturing of hybrid and electric vehicles in India. This proves that our decision to step into the areas of hybrid vehicles is jus fiable. Here is a golden opportunity for us to blend our passion AUTOMOBILES with the technology in demand HYBRIDS and open a new research fron er in IIT Roorkee for an advanced technology trend. A pla orm would be set up for future student genera ons at IIT Roorkee to learn, contribute and pursue their interest in hybrids.
To serve as a breeding ground for India's finest engineers and innova‐ tors who shall lead the na on's tech‐ nological advancements in the field of hybrids and automobiles.
To develop prototype race cars with innova ve hybrid power‐trains and represent IIT Roorkee in interna onal engineering design compe ons FSAE and Formula Student.
Dedication - Hardwork - Excellence - Achievement
The project team is working under the aegis of Mechanical and Department
This project has evolved as a mul disciplinary ac vity in the campus with more than 40 stu‐ dents ac vely learning and contribu ng in the project progress.
Electrical Engineering Department
Project Management and Sponsorship is looked a er by Digendra Singh Rathore while Chief Elec‐ trical Engineer is Akshay Sarin and Chief Mechani‐ cal Engineer is Prashant Arora, all from 4th year.
Team Faculty Advisors
In total, there are 6 members from 4th year, 11 from 3rd year and the remaining are from 2nd year. Also a pool of about 50 first year students is being trained so that they may become a part of the team next year.
Centre for Transporta on (CTRANS) ‐ IIT Roorkee
Dr. R. P. Gakkhar (Professor, Mechanical Engineering) Dr. Pramod Agarwal (Professor and Head, Electrical Engineering) Dr. Akshay Dvivedi (Asst. Professor, Mechanical Engineering) Dr. Manoranjan Parida (Professor, Center for Transporta on Systems)
Oxigen was born in July 2004, out of a vision of an Indian professional entrepreneur and a South African company, to reach services to the masses of India, through a Virtual Network for Payments and Service Distribu on. Oxigen started its opera ons in 2005. The Indian Founder, Mr. Pramod Saxena, has been associated with the Cellular Industry since its in‐ cep on in 1994 in India. He has rich & diverse experience of pioneering grass root businesses, which includes the birth Telecom in India, when he built the first ever Telecom network with Essar Group. Oxigen's overseas partner is Blue Label Telecom, South Africa, who is a market leader in distribu on of physical and virtu‐ al prepaid air me. They bring to the partnership e and market tested product technology, with a successful track record in compe
ve markets in South Africa and several other countries. In 2006, Ci bank Venture Capital Interna onal, made
investments in the company, to help Oxigen build its footprint. This was followed by Microso Corpora on, USA, who in 2008, built a strategic business & equity alliance with Oxigen. Oxigen expects to expand its business rapidly in the virtual payments and distribu on space using Point Of Sale Terminals, Web, IVR & Mobile based technologies. Pioneering the PREPAID BUSINESS in the country & Expanding it's Service por olio to lead the pack Its state‐of‐the‐art proprietary back‐end technology put Oxigen in an enviable posi on to rapidly expand and oﬀer ser‐ vices apart from just mobile recharge, with which it started its opera ons. This has helped Oxigen to blossom into a single, powerful pla orm for all payment services online as well as on the mobile phone, including bill and subscrip on pay‐ ments, booking airline/rail/bus/movie ckets, buying Value ‐Added‐Services, games, Online shopping, Making Dona ons and much more, on behalf of many companies. IIT
Alumni Support The previous project was a success story only because of the alumni sup‐ port. And this year too, alumni help is very crucial for the project success. Dr. S. S. Jain, Professor, Center for Transporta on systems IIT Roorkee has contributed Rs. 50,000 in the funding. Mr. Pramod Saxena (1975 Chemi‐ cal, IIT Roorkee), Chairman of Oxy‐ gen Services (India) Pvt. Ltd, has believed in us since incep on and was the first project sponsor last year. This year too, he has contrib‐
Mr. Sanjay Gadhalay (1986 Electri‐ cal, IIT Delhi) connected the team to Mr. Sanjay Saraswat (1988 Me‐ chanical, IIT Delhi) who is a senior execu ve in Bajaj Auto Ltd. and his eﬀorts facilitated the sponsorship of the engine for the vehicle. We are highly thankful to these gentle‐ men !!!
The project budget is Rs. 33 lakhs and neither the Ins tute support nor our pocket money is suﬃcient to meet all the expenses. Therefore, we re‐ quest you to contribute in the project funding and support us in making India’s own first‐of‐ its‐kind Series Plug‐in Hybrid Electric Vehicle (PHEV) that will compete against more than 100 interna onal teams.
their alumni who take sa sfac on and pride in the achievement of their Alma‐mater.
All the successful teams across the globe are supported by
Electrical Safety Advisor from Mercedes Benz R&D India
Mr. Ataur Rehman (1992, Mechanical, IIT Roorkee) is Addi‐ onal Commissioner, Customs and Excise at Mumbai. In Novem‐ ber, we imported the controller from China but faced problems in its custom clearance due to weak paperwork from the dealer. At that me, Mr. Rehman spoke to the custom oﬃcials in Delhi and only a er his recommenda on, we could get the controller with‐ out fine,
uted Rs. 1.25 lakh at a very crucial moment when the team needed money for registra on. We appre‐ ciate his mely contribu on and his commitment to the Alma‐mater.
Dear Alumni... You can do an online account trans‐ fer to Account Name : SAE IIT Roorkee Account # : 4044000100022924
All the donations enjoy section 80(G) Income Tax benefits.
Or you can avail 80(G) Income Tax benefits by do‐ na ng the amount through cheque in favor of REGISTRAR, IIT Roorkee. The cheque may be sent to the fol‐ lowing address: Dean of Alumni Aﬀairs
Bank : State Bank of India, IIT Roorkee
IIT Roorkee, Main Building
NEFT/RTGS Code : SBIN0001069
Roorkee – 247667
SWIFT Code : SBININBB559
District – Haridwar
U arakhand Contact‐ +91‐1332‐285240
In November 2012, the team got an opportunity to meet and discuss the project with Mr. Anshuman Awasthi (Deputy Manager, Mercedes Benz R&D India) during his visit to the campus. He visited the workshop and discussed about the project and our team. This interac on resulted into a frui ul out‐ We hear ly welcome Mr. Siva come for the team and Mr. Awasthi Prasad Gumaddi from Mercedes happily accepted to guide us on tech‐ Benz R&D India as the Electrical nical issues. Also, we made a request Safety Advisor of our tem. to MBRDI to provide us the Electrical
Safety Advisor (ESA) who would ad‐ vise the team on safety issues and, as per the compe on rules, accompa‐ ny the team to the compe on in UK. Mr. Siva Prasad Gumaddi has accept‐ ed to be our ESA. He is a 2001 gradu‐ ate from BITS Pilani and has been working with Mercedes Benz R&D India and is currently the technical lead for the ba ery team.
Sponsor Support Bajaj Auto Limited Engine is the important part of our hybrid powertrain. We needed a small sized engine which is reliable and fuel eﬃcient. A er extensive market research, we finalized the 125 CC Bajaj Discover Engine. We made a request to the company and it happily sponsored the engine. We are thankful to Bajaj Auto Ltd. for this support.
Xilinx Corpora on The vehicle controller is being implemented on FPGA pla orm which requires FPGA boards. Since these boards are costly and not easily available in India, we made a sponsorship re‐ quest to the company and to our wonder; we got two fresh boards sent to us from Xilinx USA.
ANSYS India The project requires extensive simula on and for structural analysis we could not find a be er so ware than ANSYS workbench. Since, it is costly we explained the project to the company and made a request for a sponsored so ware license exclusively for the project. The company understood how important it is to support the young engineers and welcomed our request.
Vehicle Design Methodology Target Vehicle Specifica ons (Speed, Accelera on, Weight, Dimensions) The prototype vehicle would be developed such that it is compe ve against other inter‐ na onal prototypes developed in the same vehicle category. For target performance of vehicle, the test track is Silverstone Formula‐1 circuit, UK. The track data (map, average speed, accelera on) and the target vehicle specifica ons of similar prototypes built in past would become the basis of vehicle specifica ons. While selec ng the target vehicle specifi‐ ca ons, other important parameters that should be considered are safety, sustainability, reliability, engineering design, cost, manufacturability, solo performance and high perfor‐ mance track endurance.
The velocity profile for the event at Silverstone track
Track descrip on for Endurance Event: • Straights: No longer than 77.0 m (252.6 feet) with hairpins at both ends. Passing zones at several loca ons. • Constant Turns: 30.0 m (98.4 feet) to 54.0 m (177.2 feet) diameter. Hairpin Turns: Minimum of 9.0 m (29.5 feet) outside diameter (of the turn). • Slaloms: Cones in a straight line with 9.0 m (29.5 feet) to 15.0 m (49.2 feet) spacing. • Average speed should be 48 km/hr (29.8 mph) to 57 km/hr (35.4 mph) with top speeds of approximately 105 km/hr (65.2 mph).
The competition venue : Silverstone UK
Silverstone is the premier motorsport des na on in the UK and one of the most historic circuits in the world. It is host to Formula One Bri sh Grand Prix, Le Mans Series, Superbike World Champion‐ ship, Formula Student and various other interna onal events.
GENERATOR: Brush type PMDC motor.
CONTROLLER: SHOCKS: Quarter midget (63.5 mm stroke). Quarter midget spring= 33.3 N/mm.
Synchronous rec fica on, ultra low drop and fast PWM to achieve very high eﬃciency. Support three modes of regenera ve braking: brake switch, release thro le, 0‐5K or 0‐5V analog signal
Highly eﬃcient: 300A peak 125A con nuous, air cooled.
MOTOR: 4 pole motor with output Power of 12 KW
Con nuous, 30 KW Peak, 5000 rpm
72 V, 48 Ah Li‐ion rechargeable ba ery.
Con nuous current of 125 Amps AC. Torque constant of 0.15 N‐m per Amp (peak 90 Nm).
DIFFERENTIAL: CHASSIS: AISI 1020 mild steel used to provide necessary strength.
ENGINE: Type: DTS‐i, 4‐stroke, Natural air cooled
Quaife limited slip diﬀeren al is used. It is safe, progressive and seamless in opera on and smoothly biases the engine's torque.
Displacement: 124.6 cc Max Power: 11 PS@ 8000rpm Max Torque: 10.8N‐m@5500rpm IIT
KEIZER WHEELS: Aluminium customized wheels light in weight and13" diameter, 6" width
Work Done So Far... Complete Suspension and steering design including calcula on of parameters, kinema c and dynamic simula ons and CAD models of push‐pull rods, rockers, selec on of dampers, springs and tyres Complete Roll cage design including CAD modelling and stress analysis. Complete simula on for measuring lap me of car‐run, CO2 emissions and eﬃciency of car on the track Engine ‐ generator and motor ‐ diﬀeren al coupling design. Intake ‐ exhaust design. Complete Regenera ve braking system including brake calcula‐ ons, brake‐pedal design, sensor moun ng, selec on of brake callipers, master cylinder, brake lines and its topology. Complete wheel assembly design including upright and hub CAD and stress simula ons, selec on of wheels, nuts, bearings and rod ends. Heat calcula ons for motor, ba ery, generator, engine, control‐ ler and auxiliary components Complete design of High Voltage and Low Voltage network including selec on of motor, generator, ba ery, BMS, IGBT, con‐ tactors, fuses, wires, sensors, etc.
FPGA based Vehicle Control system design complete includ‐ ing FPGA coding, simula on of parallel processing and PCB design. Design of servo controlled engine ‐ generator voltage stabi‐ lisa on including selec on of servo motor, sensors, signal condi oners and CAD modelling. Power flow simula ons for the power‐train network. Procurement of engine, motor, generator, controller, sensors for regenera ve braking, LV wires, contactors Mo‐ tor Controller integra on and tes ng at diﬀerent controller modes. Generator tes ng at no load for verifica on of characteris c curves. Fabrica on of PCB and pre‐charge, discharge circuits. Engine test moun ng and controlled electronic on‐oﬀ tes ng. Steel tube cu ng and profiling for roll cage and A‐arms. Jig fabricated and mock roll cage made from PVC pipes.
Target for next month
Payment for team registra on. Welding of roll cage and A‐arms. Procurement of Ba ery, shockers, wheels, brake components, HV – LV wiring. Integra on of engine‐generator, motor and ba ery. CNC machining of uprights, hubs, rockers. CFD flow analysis, selec on of fans and design of cooling ducts. Fabrica on of engine thro le. Engine generator coupling Intake exhaust fabrica on
Sponsorship Opportunities Being a student team, we rely heavily upon sponsorships. You can support us by providing monetary or in‐kind sponsorship in the form of products and services. And in return we oﬀer a rac ve sponsorship benefits. Following slots are open for associa on :
Contact us IIT Roorkee Motorsports
Dr. Pramod Agarwal
Dr. Akshay Dvivedi
Mechanical Department Industrial Block IIT Roorkee Roorkee (247667) ‐ U arakhand firstname.lastname@example.org email@example.com
Head Of Department Electrical engineering firstname.lastname@example.org
Assistant Professor Mechanical Engineering email@example.com
Digendra Singh Rathore
Virender Pratap Singh
Team Leader +91‐8791194290 firstname.lastname@example.org
Marke ng Execu ve +91‐7579087524 email@example.com
Marke ng Execu ve +91‐8266800562 singh.vp93 @gmail.com
This is the first newsletter from IIT Roorkee Motorsports for its 2013 project which aims to develop a hybrid vehicle for participation in t...