Design and Manufacturing of Bicar

Design and Manufacturing of Bicar

Prashant Bagmar

Student, Department of Mechanical,

METBKC College of Engineering, Nashik.

Sachin Dahake

Department of Mechanical, METBKC College of Engineering, Nashik,

Abstract As bike is cheapest as compared to the car, and thats why it uses most for daily work, but it also has some limitation such as, its hard to travel long distance and to ride in the rainy season, because the bike is not giving that much comfort which a car can give. To remove these limitations we need something which can provide the comfort of a car as well as the mileage of bike. That's why it's time to move towards a BICAR.'

Bicar is a combination of bike and car. It gives the comfort of a car with a high mileage of bike. Bicar is a small car which needs less space to park, light in weight and it is very useful in all kind of weathers such as rainy, summer and winter. As we know a disabled person is unable to drive the bike as well as car, this type of vehicle can also be useful for the handicapped person with a small change.

Keywords – Chassis, Geared Motor, Structural analysis

1. INTRODUCTION

   After the invention of Bike, Car, and Heavy vehicles, the transportation becomes very easy. Before these inventions, it 's hard to travel from one place to another location and also requires tremendous time. Thus the vehicle mentioned above reduces the efforts up to a large extent and it will also lessen the pollution up to a large extent. But these vehicles also have some limitations and to remove that bicar is needed. Bicar is a combination of bike and car. It gives the comfort of a car with a high mileage of bike. Bicar is a small car which needs less space to park; light in weight and it is very useful in all kind of weathers such as rainy, summer and winter.

2. METHODOLOGY

   • The design of chassis.

   • Model in CAD.

   • Selection of Material for Chassis

   • Selection of Welding for Chassis

   • Selection of engine.

   • Design a Balancing Mechanism.

   • Analyze Chassis for different loads.

   The chassis can be called as the skeleton of a vehicle besides its purpose being seating the driver, providing safety and incorporating other subsystems of the vehicle.

   After the study, I decided to use tubular space frame chassis which is used for the public car. Since ladder chassis is not strong enough, motor racing engineers have developed a 3-dimensional design which known as tubular space frame.

   Tubular space frame chassis employs dozens of circular-section tubes (some may use square section tubes for easier connection to the body panels though circular section provides the maximum strength), position in different directions to provide mechanical strength against forces from anywhere. These tubes are welded together and form a

   complex structure. For higher strength required by high- performance sports cars, tubular space frame chassis usually incorporate a stable structure under both doors. Tubular space frame chassis also unyielding in any direction compared with ladder chassis and monocoque chassis of the same weight.

   1. Cad Model

      I design the primary model of chassis in CATIA' in which

      An engine is located at back side of driver's seat, and balancing mechanism is between seat and engine. The following figure shows the overview of chassis.

      Figure: Primary design on CATIA

   2. Selection of Material for Chassis

      Thus after analyzing the number of materials I selected Cold Rolled Carbon Steel (CRC). It offers a range of good mechanical properties like high strength, good toughness, good surface finishing, good workability, excellent weldability and widely available.

      Figure: Cold Rolled Carbon Steel (CRC).

   3. Welding for Chassi

      For Welding, the pipes of CRC to build chassis MIG' welding is selected. CRC material is easily get welded by this type of welding, and it is cheapest and easily available.

      Figure: CO2 Welding to weld Chassi

   4. Specifications of Bicar

      The BI-CAR has following Specifications.

      • Ground clearance 1 feet (304.8mm).

      • Overall length is 7 feet.

      • Width is 850 mm.

      • Height is 1850 mm from chasse's lower end.

      • The radii of a wheel are 1 feet.

      • Engine type- Four Stroke 150cc (Bajaj Pulser).

      • Fuel Petrol.

      • Mechanism- automatic balancing without the gyroscope.

      • Numbers of Wheels- 6 Wheels (2 Primary and 4 Secondary)

      • Number Of seats- Two

      • Weight of Bi-Car- Approx 250kg

      • Cooling System- Air Cooling System

      • Expected Mileage Of Bi-Car- 35 – 40km/lit.

   5. Balancing Mechanism

      Main aim is to balance the bi-car, for that purpose, there are following options:-

      • Gyroscope mechanism.

      • Hydraulic cylinder operated on a motor with the help of sensors.

      • Geared Motor with Scissor jack.

   Gyroscope mechanism

   It is a device work on the principal of active and reactive couple. With the help of active and reactive couple, dynamic stabilization of the vehicle is possible.

   Hydraulic cylinder operated on a motor with the aid of sensors. This mechanism is operated by the hydraulic cylinder in which cylinders are work with the help of hydraulic motor and motor is managed by using sensors.

   Geared Motor with Scissor Jack

   For balancing mechanism geared motor is used with a scissor jack. Geared motor can easily operate by DC power source with 12 volts, 9-ampere current. And the capacity to lift the load is 2 tons.

   As the speed goes above the absolute limit (30 km/hr), by using, remote secondary wheels can be lifted, and the vehicle will run on two wheels. The remote can also be replaced by

   sensors in which sensor sense the speed and operate the motor to lift the wheels. And as the speed came down, wheels come downward and then the vehicle will run on six wheels, thuscompletely balanced.

   Figure: Geared Motor with Scissor Jack

   Figure: Secondary wheels for balancing

   Figure: Side view of Bicar

3. RESULTS

   As chassis is most important part in the body, so it should not fail at any load which comes on it. Thus chassis's analysis is necessary to check whether it is safe or not. To check its structure analysis is needed by using 1G and 3G load. 1G load is the load which comes on chassis at rest condition.

   It's difficult to calculate the exact load which comes on the vehicle during its motion; that's why the analysis is performed by using 3G load. 3G load three times of static load.

   Fig. Shows the stress distribution at 1G and 3G load. The stress induced in the chasse due to 1G and 3G

   load is 54.1 Mpa and 174.6 Mpa respectively, which is less than the tensile strength of material. Fig. Shows the deformation of chasse due to 1G and 3G loads is 1.4 mm and 4.3 mm respectively. As the deformation is so small, thus it is negligible. The above Fig. Shows the stress distribution at 1G and 3G load in the balancing system. The stress induced in the balancing system due to 1G and 3G load is110.8 Mpa and 332.4 Mpa respectively, which is less than the tensile strength of material. The fig. shows the deformation of balancing system due to 1G and 3G loads is

   0.9 mm and 2.8 mm respectively. As the deformation is so small, thus it is negligible.

   Fig.4.1:-Stress Distriution at 1G Load 2300N (57.1 MPa)

   Fig.4.2:-Stress Distribution at 3G Load 7000N (174.6 MPa)

   Fig.4.3:-Deformation at 1G Load 2300N (1.4mm)

   Fig.4.4:-Deformation at 3G Load 7000N (4.3mm)

   Fig.4.5:-Stress Distribution at 1G Load 2300N (110.8 MPa)

   Fig.4.6:-Stress Distribution at 3G Load 7000N (332.4 MPa)

   Fig.4.7:-Deformation at 1G Load 2300N (0.9 mm)

   Fig.4.8:-Deformation at 3G Load 7000N (2.8 mm)

4. CONCLUSION

   After completion of vehicle, it can give the following benefits.

   • Everyone (Men & Women) can drive this bi-car. Handicap person also able to drive this vehicle with the simple modification.

   • In all, whether the vehicle can be used without any environmental resistance.

   • Economical and affordable vehicle.

   • Feel of Sporty Car which is economical and affordable.

   • The face of a future of transportation.

   • Traffic problem can also be solved.

   • Pollution is reduced up to a large extent.

   • It provides huge safety to a human being as instead of a bike.

5. REFERENCES

1. Brendan. J. Waterman (2011) Design and Construction of a Space- frame Chassis School of Mechanical and Chemical Engineering University of Western Australia.

2. Costin, M., Phipps, D. (2005) Racing and Sports Car Chassis Design, Bentley Pub.

3. George, A., Riley, W. (2002) Design, Analysis and Testing of a Formula SAE Car Chassis, Cornell University, SAE technical paper.

4. Grimes, O. (2012) Design and Finite Element Analysis of a Composite Monocoque Chassis for the Shell Eco Marathon Car Project, Coventry University .

5. Lii, B. (2009) Design and Manufacture of a Composite Monocoque Chassis, University of Queensland .

6. Veloso, V.; Magalhães, H. S.; Bicalho, G. I.; Palma, E. S. Failure Investigation and stress analysis of a longitudinal stringer of an automobile chassis. // Journal of Engineering Failure Analysis. 16, 5(2009), pp. 1696-1702.

7. www.litmotor.com