TEAM KAIZEN report.docx

7/21/2019 TEAM KAIZEN report.docx

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TEAM KAIZEN

KIIT UNIVERSITY



Mission:

Experience..Educate..Excite !!

Compete

and represent KIIT University at

the renowned Indo-Asian Solar Challene.

Collaorate etween multiple disciplines

and the community in order to achieve

the monumental oal o" aininreconition in the competition.

Vision:

Ta#e advantae o" the opportunity tolearn s#ills eyond the scope o" the

classroom.

$earn the concept o" renewale enery

and its application in a practical way.

To continue research and development inthe %eld in order to ma#e a retardin

impact on the deradin status o" the

environment.



KAIZEN Team Members and

Management

&. Asis 'as (Captain)*. +ratyush Suhasit (vice-

Captain),. Ahishe# aumdar/. 'eesh Kumar0. Sahan Saurav1. Satya Swaroop +anda2. Shovna ahapatra3. Suhanee Sahoo

4. An#ita 'ey&5.6ivetha Selvara7

Organizational Struture







The pro7ect is planned to e completed

within a time "rame o" two and hal"

months (construction part) excludin

aps le"t "or semester exams o" theuniversity.

Assembled Vie%:&



'$assis "esign:



The chassis is desined #eepin in mind

the sa"ety o" the driver which is outmostimportance and is desined on the asis

o" minimum numer o" welds. It is

strenthened with moderate

trianulation and straiht struts amon

all load earin components thus

coverin a lare sur"ace area "or solar

panel mountins.

Me$anial Anal(sis:



The desined components are analyed

usin A6S:S &,.5 simulatin the"ollowin load conditions.

;ront Impact

<ear Impact

Side Impact Torsion Test

And the results are portrayed raphically



Anal(sis Results:

Analysis <esultsaximum Stress )*+,+) M-aaximum'isplacement

.,)/+. mm

$oad 0.. Kg1 2U"34

Material Seletion



+arameters "or aterial Selection

&) =ptimum level o" trianulation

desin.*) Structural pods "or riidity and

impact sa"ety.,) 9ein liht weiht ut cost e>ective

material.

/) Compact inclusive o" all systemspac#ain.

0) ?ih Torsional <iidity.

aterial =ptions Availale

&) IS ,52/

*) AISI /&,5

,) AST &51

/) AISI &5&3

=n the asis o" evaluation over the

selected parameters AISI &5&3seamless pipes were selected "or

construction.



Material S5ei6ation& AISI ).)0Outer "iameter & inch#idt$ 5.540 inch

Youngs Modulus *53 @+a

Yield Strengt$ ,2, +a"ensit( 1&55 #mB,



Ve$ile "(namis and 'ontrol

S(stem

Steerin

Steerin is the term applied to thecollection o" components lin#aes etc.

which will allow a vehicle to "ollow the

desired course. An automoile is steered

with the help o" steerin ears and

lin#aes which trans"er the motion o" the

hand operated steerin wheel to the

pivoted "ront wheel hus via steerin

column. De employ the rac# and pinion

type o" ear ox in order to achieve the

"ollowin reduction ear ratio o" &58&.



Inputtin the values o" the trac# width

and wheel ase to the aove euation

and euatin it. The Ac#ermann anle is

"ound out to e &2 derees.



9ra#in

A vehicle ra#e is used to slow down a

vehicle y convertin its #inetic enery

into heat enery. De are employin a

disc ra#e calliper induced mechanism

powered y a hydraulic mechanism.

Speci%cation Falue

'isc 'iameter *55mm&25mm

aster Cylinder

'iameter

*5mm

9ra#e ;orce *2056

+edal ;orce /5#

+edal <atio 28&

Cylinder +ressure 2.32 +a

aster Cylinder

losses

5.&*0cc



Suspension

The suspension system enales the

vehicle to traverse umpy terrain y

isolatin the ody "rom the wheels. The

suspension system dissipates the #inetic

enery as heat in the coil sprin damper

assemly.

Type8

=utoard Eual (;<=6T) doule A arms Coilover 'amper

Swin Arm type (<EA<) Twin-Shoc#

asorer Coil over 'amper





current (amps) enerated is

proportional to the cellGs sur"ace area.

The cellGs power is rated at H"ullsunliht. Dhen the s#y is overcast

the power o" the sun is lower and the

amount o" amps produced is less ut

the voltae remains the same8

5.0volts.• Each o" the sections in the panel has ,

cells connected in series to ive &.0

Folt. The panel is desined to e 5.,

Amps at "ull sunliht.

• At "ull sunliht when the solar panelGs

"our sections are connected in series

the motor will spin very "ast and the

car will run "ast. As the sunliht

diminishes the speed will raduallydiminish until the vehicle %nally stops

ecause the current is too low. To



avoid this attery reenerative system

is applied in place.

•Dhen the current is too low with thesections in series reconnect the /

sections in parallel. This ives more

current -and the S=$A< CA< will start

runnin aain Jalthouh slower due

to reduced voltae.

S=$A< +A6E$ - DIT? A S=$A< +A6E$

+=DE< C=6T<=$$E<8



S%it$ 2S)4 losed:

• The motor operates directly "rom

solar power as the S++C is ypassed.

S%it$ 2S74 o5ened:• The 7unction o" resistor <& and ener

diode & provide a re"erence voltae

to the op-amp IC& (pin *).

• The 7unction o" resistors <* </ and

<F& provide an input voltae sinal to

the opamp IC& (pin ,). Fariale



resistor <F& allows the circuit to e

tuned.

•Dhen the circuit is turned oncapacitor C& is dischared and

transistor L& is not conductin. The

solar cells chare capacitor C&. Dhen

the voltae across capacitor C& as

detected y pin , on IC& exceeds thevoltae on pin * on IC& IC& chanes

state and switches on transistor L&.

• Dhen the voltae across C& drops

elow the threshold voltae IC& stops

conductin and switches o> transistor

L&.

• Dhen the voltae across C& drops

elow the threshold voltae IC& stops

conductin and switches o> transistor

L&.

• The capacitor is then chared and it

is turned o> when the capacitor is



dischared providin power to the

motor. In riht sunliht this switchin

will occur very rapidly.

8atter(

The solar enery is stored in atteries inorder to derive this stored enery in the

asence o" the solar enery. De have

decided upon usin Falve <eulated

$ithium Acid (F<$A) atteries in order to

ain maximum storae capacity at alower rate o" dischare.





Inno9ation

anaement Innovation8 Adopt-a-Cell

+roram

A uniue way o" attractin donors "or the

team is our Adopt-a-Cell initiative.

Instead o" lare scale sponsorships thismethodoloy aims at larer numer o"

small scale individual sponsorships y

contriutin an amount euivalent to a

sinle solar cells. 'onors may wish to

adopt their desired numer o" cells.

Electronics Innovation8 ;lexile solar

array

The use o" Mexile solar array is to e

used upon the solar car in order toincrease the solar enery capturin area



at the same time is directed at improvin

the aesthetics o" the vehicle.

"esign Validation -lan

ator

"esignRe;uire

ment

Value 'om5liane<Non&

'om5lia

ne

"imension #idt$=

)>.m

3engt$=

7*.m

#idt$?)@0m

3engt$?

70>m

'om5liane

Mate

rial

AISI or

ASTM

seamles

AISI

).)0

'om5lia

ne



s 5i5e

3o!

Nuts

On

ritial

om5on

ents

-resent 'om5lia

ne

Moto

r

-o%er

= )@..%att

Voltage

=

09olts

-o%er?)

@..%attVoltage

?09olts

'om5lia

ne

Solar

-anel

Voltage

=@@9olt

Voltage

?+/9olts

'om5lia

ne

8ra!

e

3ig$t

To be

atta$ed

Atta$e

d

'om5lia

ne

8atte

r(

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= 09olt

Voltage

?09olt

'om5lia

ne



'a5ait(

= 0.A$

'a5ait(

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Kill

S%it

$

To be

installed

Installed 'om5lia

ne

Seat

8elt

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'ost =)B..B..

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"esign ailure ECet mode anal(sis

Item

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'ost RE-ORT



-artiulars 8ill Amount 2IN

Material 2AISI).)04 >B...

abriation @B...

Steering +B@..

Sus5ension and

Assembl(

@B...

8ra!es B...

T(res 7B@..

iber Glass 7B...

asteners )B>..

Solar -anels 7@B...

Motor >B...

M--T /B@..

8atter( *B...

Eletrial om5onents )B...



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TEAM KAIZEN report.docx