5.

POWERTRAIN

The goal of a well-designed powertrain is to deliver (N1)Drive sprocket 21

the necessary torque and speed to the wheels. Transmission ratio 2
The selection of an appropriate motor, accumulator, (N2)Number of teeth on 42
driven sprocket
drive system is part of the powertrain design.
Chain type Roller chain (ANSI 35)
Pitch 9.525
5.1. Parameters:
Total mass of vehicle 160 kg
Coefficient of rolling resistance (Crr ) 0.015 a. Length of Chain:
Rear wheel diameter 11 inch
Weight distribution (R:F) Centre distance, C = 30P to 50P
Top speed 80 kmph Take C = 32p = 32 × 9.525 = 304.8mm

5.2. Calculations:
a. Desired acceleration:
No of links (nL) =
p
+
2
+(
2 c (n 1+n 2) n 2−n 1
2π
× )
( n 2−n
2π ) c
v = u + a×t 1 p
22.22 = 0 + a×12 +
a = 1.85 m/s 2 2× 305 21+ 42 42−21
b. Torque calculation: + +( )×
9.525 2 2× 3.14
Total tractive force required = (mtotal × g × Crr) + (mtotal × 42−21 9.525
a) + W sinƟ ( )+
2× 3.14 305
= (140 × 9.81×0.015) + (140×
=106.75
1.85)
+ (140×9.81× sin(1)) ̴ 106(considering even number of links)
Total tractive force required at wheels = 346.9 N Length of chain (LC) = nL × p
=106 × 9.525
Torque on live axel = Frear × rwheel ( =1009.65mm
= 347 × 0.1397 Corrected centre distance,
=48.47 N-m p n 1+ n 2 n 1+ n 2 2
c. Speed calculation: C=
4
(
Lc -
2
+ √ (Lc -
2
)
) +8׿)2
60× v
N= 9.525 21+ 42 21+ 42 2
2 πr =
4
( 1009.65-
2
+√ (1009.65 -
2
) +
60 ×22.2
= 8×
2× 3.14 ×0.1397
42−21 2
=1518.86 rpm ( ))
2× 3.14
d. Table
= 4656.102 mm
Motor type BLDC
b. Sprocket:
Power 3kw (nominal), 6kw (peak)
p
Torque 9.6Nm (continuous torque)
28Nm (peak torque)
Driven sprocket diameter = 180
sin ⁡( )
Z2
Speed 3000rpm 9.525
= sin ⁡( 180 ) = 127.458 mm
e. Transmission ratio: 42
48.47
Transmission ratio =
28
=1.73 ̴2 p
Driver sprocket diameter = 180
sin ⁡( )
Z1
5.3. Chain drive 9.525
Chain drive is a method of moving mechanical energy = 180 = 63.908 mm
from one location to another. As a sequence of sin ⁡( )
21
chordal links, the chain wraps around the sprocket.3 5.4. Vehicle endurance and battery capacity required
This action is akin to wrapping a non-slip belt around
a revolving polygon.
 a. To cover a range of 25km at an average speed
of 40kmph
25
Time required =
40
b. Battery specifications:
Total battery capacity required for 3kw motor
= 3×0.625 =1.875kwh
Considering 48V battery pack then the
Required Ah rating of battery is W1 = 1.2154 N
1.875× 10 00 W2 = 49.05 N
= =39.06Ah
48 W3 = 5.19 N
W4 = 11.772 N

Battery type Lithium-ion battery pack Finding reaction RB and RF

Capacity of each cell 2.25Ah
Nominal voltage of each 3.6V From loading diagram,
cell RB + RF = 2W2 + 2W4 + W3 + (W1 × l) → (1)
Ah rating of battery pack 40Ah or 54Ah ∴ Taking moment about B, ΣMB = 0
We have ,
(W2 × 120) + (RF × 720)
5.5. Shaft Calculations: = (W4 × 360) + (W3 × 90)
The weight of functioning components such as the + (W3 × 630) + (W2 × 805.5)
disc rotor sprocket and rear axle wheels has been + (W1 × 720×360)
taken into account (shaft). We evaluated braking ∴ RF = 534.297 N
torque for the purpose of shaft design along with the Hence from (1), RB = RF = 534.297 N
kart's rear weight distribution because braking torque
is substantially bigger than driving torque. Shear force and Bending Moment Calculations
I. For vertical loads:
The various loads on the shaft are (SF)A = −W2 =- 49.05N taking ↓ as (−ve)
1. Rear weight distribution of kart’s mass acts as an (BM)A= 0 Nmm taking ↑ as (+ve)
UDL on the shaft between the support bearings. Where, (SF) is Shear force.
60× 160 (BM) is Bending moment.
Total Mass of rear = =96kg
100
Total Weight of rear =96×9.81 =941.76N (SF)B = −W2 + RB = 485.247 N
941.7 (BM)B = ( −W2 × 120)
UDL load(W1) = 720 = 1.308 N/mm = −5886Nmm = −5.886Nm
¿
¿
2. Mass of wheel = 5kg (each) (SF)C = −W2 + RB = +485.247 N
Weight of wheel = 5 ×9.81 =49.05N (BM)C = [(−W2 × 120) + (RB × 90)]
3. Weight of sprocket, = +37786.23 Nmm = +37.7862 Nm
W3 = 0.800 ×0.66×9.81 = 5.19 N
4. Weight of disc rotor (SF)D = −W2 + RB − W4 − W3 − (W1 × 360)
W4 = 1.2 × 9.81 = 11.772 N = −2.595 N
(BM)D= [(−W2 × 480) + (RB × 360) + (−W4 × 270)
360
+ (−W1 × 360 × ( ))]
2
= +80866.08 Nmm = +80.866 Nm

(SF)E = −W2 + RB − W4 − W3 – W3 − (W1 × 630)

= −367.527 N
(BM)E= [(−W2 × 750) + (RB × 630)
+ (−W3×540) + (-W4 × 270)
 + (−W1 × 630 ׿))]
= +32488.83Nmm = +32.488 Nm According to ASME standards,
(SF)F = −W2 + RB − W4 − W3 – W3 + RF− (W1 × 720) Shear strength of the material is lesser value among
= +49.05 N i. 0.30 × σyp = 0.30 × 1138 = 341.4 MPa
(BM)F = [(−W2 × 840) + (RB × 720)+ (−W4 × 360) + ii. 0.18 × σult = 0.18 × 1310 = 235.8 MPa
(−W3 × 630)+ (−W3 × 90)+ (−W1 × 720× ∴ τal= 235.8 MPa
720 As there are keyways, strength is reduced by 25%,
( ) ¿]
2 ∴ τal = 235.8 × 0.75 = 176.85 MPa
= −5886 Nmm = -5.886 Nm Torque on shaft = 500.85 Nm = 500850 Nmm
(SF)G = −W2 + RB − W4 − W3 − W4 + RF− (W1 × 678) Bending Moment on shaft = 66.142 Nm
= +49.05 N
= 66142 Nmm
(BM)G= 0 16 ×√ (( Cm × M )2 + ( Ct ×T )2)
∴ We have d3=
π × τ al
For rotating shaft with heavy shock and suddenly
applied load,
Cm = 2 and Ct = 1.5

316 ×√ (( 2 ×6614 )2+ ( 1.5 ×500850 )2 )

∴d=
π × 176.85

∴ d ≥ 28.08 mm
Considering defects in material, referring standard
shaft size, arrived
d = 30 mm

The horizontal load on the shaft is the chain load:

power (H . P)× 396000
Chain load =
number of teeth × pitch(inch) × RPM
=27.75 N at position D
27.7 5
(BM)D = ×360
2
=4995Nm
(SF)D= +13.885 N
(SF)B = −13.885 N
(SF)F = 0 N
(BM)B = 0 Nm
(BM)F= 0 Nm
Therefore, maximum bending moment experienced
by shaft is at point D, the resultant bending moment is
M = √80866.082 + 499952
= 81020.2 Nmm = 81.0202 Nm

5.6. Design of the shaft:

Material = SAE 4140

Tensile yield strength (σyp) = 1138 MPa
Tensile ultimate strength (σult) = 1310 MPa