engine & powertrain

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1Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved. 1


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Engine & PowertrainBAJA SAEINDIA 2014

2Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved.

21st - 22nd June 2013

Faculty Leadership Development Workshop

Priyadarshini College of Engineering, Nagpur

Anshuman Vagesh

Mahindra Research Valley, Chennai


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BAJA SAEINDIA 2014

ENGINE

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Briggs & Stratton INTEK OHV 305 EngineSpecifications

ENGINE MODEL NO. : 20S232-0036-E1

TYPE : 202400

DISPLACEMENT : 305 cc

COMPRESSION RATIO : 8.0 : 1

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POWER : 10 hp @ 3250 rpm

TORQUE : 19.66Nm @ 2800 rpm

FLY-UP SPEED (NO LOAD) : 3800 +/- 100 rpm

IDLE SPEED (NO LOAD) : 1750 +/- 100 rpm

BORE : 79.23 mm

STROKE : 61.67 mm

FUEL : Gasoline

COOLING STRATEGY : AIR COOLED


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Rules pertaining EngineOVERALL

1. Colleges/ Institutions are eligible to receive a new Briggs &

Stratton engine on their THIRD participation only.

2. Only original equipment Briggs and Stratton replacement partsmay be used.

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3. Flywheel Rotation No flywheel rotation to advance or retardtiming is permissible.

4. Carburetor This is a fixed carburetor. Re-jetting of the

carburetor is prohibited. Idle speed adjustment is NOTALLOWED. Recommended idle engine speed = 1750 +/- 100 rpm.


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Rules pertaining EngineOVERALL

5. The peripherals

a) Air Cleaner Must be taken from Briggs and Strattonrecommended source, if required to be purchased. Also the remotekits i.e. parts to relocate the filter must be Briggs and Stratton

parts.

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b) Muffler & Exhaust System B&S engine has pre-mounted exhaustsystem, there is no need to change the mounting.

6. Technical Inspection at the main event starts with Engine check. The

B&S staff on-site is empowered to make final decisions regarding thecondition and set-up of all engines.

WINNING TEAMS ENGINE MAY BE ISOLATED AFTER THE EVENT FORDETAILED CHECK-UP.


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Rules pertaining EngineAir Filter Mounting Guidelines

1. Air filter should be located as close as possible to the engine.

2. If relocated, the parts used must be Briggs and Stratton parts / remote kits (part numbers aregiven in rulebook).

3. These parts- hoses or pre-filters must be included in the cost report and these changes mustpass Briggs & Stratton inspection.

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. e oca on o a r c eaner may ecrease eng ne per ormance. ny amage on accoun ofailure to comply with instructions is to be borne by the team.

5. Complete air intake system must be located so that its extremities lie at least 100 mm withinthe perimeter of the vehicle.

Exhaust System Mounting Guidelines

1. The mounting of the exhaust system need not be changed and kept as it comes with engine.

2. The exhaust pipe and muffler must be completely intact and operational throughout theevent, and could be grounds for penalty if not intact at the end of any event.

3. The complete exhaust must be located such that its extremities lies at least 100mm withinthe perimeter of the vehicle.


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Rules pertaining EngineEngine Governor

1. Governor setting must NOT exceed 3800 RPM as maximum speed.

2. Random inspection of governor may be conducted at any time and anyattempt to raise the engine speed will be dealt with disqualification.

3. The governor operation must remain free of obstructions at all times.

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stock Fuel Tank.

4. If fuel tank is to be remotely mounted, B&S control cover (697326) maybe used.

5. Governor spring must be placed in hole # 6.

6. After the endurance the top ten team vehicles will be impounded andengine will be checked again.

ILLUSTRATION AT THE NEXT SLIDE >>


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Rules pertaining EngineEngine Governor

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DOs & DONTs for EngineDOs

1. Check the OIL LEVEL daily.

2.In case of new engine, change the oil first 5 hrs, and then periodically after 25 hrs.

3. Check and clean air filters regularly under dusty conditions.

4. Before installing the engine read Operators Manual completely.

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. eep e essen a spares n s oc or emergency requ remen s.

6. While adding fuel, turn engine OFF and let engine cool at least for 2 minutes beforeremoving gas cap.

7. Spill prevention strategy must be incorporated as per the rulebook.

8. Before performing adjustments or repairs, disconnect spark plug wire and keep it away fromspark plug.

9. When starting engine, pull cord slowly until resistance is felt, then pull rapidly.

10. When transporting the engine, transport with fuel tank EMPTY.

11. All the rotating parts must be shielded using metal guards as per the rulebook.


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DON'Ts

1. Do not modify the engine settings in any way without B&S factory approval.

2.Do not operate engine without a muffler, inspect periodically and replace if defective.

3. Do not run engine at excessive speeds.

4. Do not tamper with Governor settings, idle speed / carburetor settings and also air filter andexhaust system.

DOs & DONTs for Engine

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5. Do not run the engine with choke ON condition.

6. Do not fill the fuel tank above limits.

7. Do not put more oil than the maximum limit.

8. Do not choke carburetor to stop engine.

9. Tie up long hairs, remove jewelry and do not wear loose-fitting clothes when operating.

10. Do not crank engine with spark plug removed.


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Spill PreventionIllustrations from rulebook

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Guards for rotating parts


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Transmission

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BAJA SAEINDIA 2014


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PowertrainDefinition

Powertrain refers to the group of components that generate power

and deliver it at the wheels, in other words, transmitting powerfrom the engine to wheels.

Primary components

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Engine

Transmission (Gear box)

Drive Shafts

Differential

Final Drive (Final shaft, Axle, Drive Wheel)


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Design Aims of PowertrainOVERALL

1. To transmit power from engine to wheels.

2. The power transferred must be able to move the vehicle up steepgrades and propel it at high speeds on level terrain.

3. Acceleration is also an im ortant characteristics controlled b

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drivetrain.

4. Simple to operate and efficient since rated power output from engine isonly 10 hp.

5. Reduction in gear shifts to save on speed and traction.

6. Minimizing weight of the assembly in order to improve acceleration anddecrease rolling resistance.

7. Maximizing serviceability by modularizing the drivetrain.


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Rules pertaining PowertrainOVERALL

1. Teams are free to use any transmission, such that the maximum

speed of the vehicle on a plain terrain in not recommended morethan 60 km/h in top gear.

2. CVT is also permitted with appropriate shielding and reverse

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.

3. Gear shifting cables, lever and shifting mechanism must beinstalled at such locations such that it is not hindering driverand his safety.

4. Adapter for Engine and Transmission coupling to be designed /installed by students as per the type of the transmission used.Engine drive/ output shaft details are available of BAJASAEINDA official website.


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Rules pertaining PowertrainOVERALL

5. All the rotating parts must be shielded to prevent injury to the driver orby-standers should the component fly apart due to centrifugal force.Material specification-

AISI 1010 steel at least 1.524mm (0.06 in) thick, or a material having equal energy absorption at rupture per unit

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width of shield

if any fiber reinforced composite material is used then a stress-strain curve must be provided for worst case tensile loading.Min thickness 3.175 mm (0.125 in).

6. The technical inspectors reserve right to impound and inspect anyvehicle during/ after the dynamic or endurance events. The vehiclesmatch the drive-train configuration as per the SCCS submitted duringtechnical inspection.


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Design ConsiderationGear Box

1. CVT or Continuously Variable Transmission is one of the common Gear Box

used in BAJA vehicles.

This transmission uses two pulleys which change their effective diameterbased upon their rotational speed.

The two pulleys are connected via belt, and transmission ratio changes

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continuously with engine speed.

Advantage It does not need any driver interaction, and that it ismechanically simple.

Disadvantage Without secondary gear box the CVT has no ability to usereverse, and the available gear ratio range is limited. This means in order tohave the versatility of a manual gear box (max. traction to max. speed), the

CVT will usually be heavier than a similar geared transmission.


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Design ConsiderationGear Box

2. Manually shifted Gear Box Usually available with up to 5 forward

speeds.

Advantage provide large range of gear ratios can selectivelydesigned. Climbing steep gradients and driving through mud and

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requirement guides the top gear.

Disadvantage They must be shifted by driver.

3. Automatic Clutches In order to avoid distractions in case of manualgear box, transmissions are available with automatic clutches. Theyengage drive plates above idle rpm, and disengage below this rpm. In

order to shift, driver only has to reduce throttle and press shift up ordown button.


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Differential

Design Consideration for other parts

1. The objective is to provide better traction while driving straight, and allowing

one tire to turn faster than the other while turning.

2. Locking differential Benefit is seen in mow traction situations when both tiresneed to turn for maximum traction. Also it helps gaining in towing performance,gradeability and straight line acceleration.

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Open type Equal torque, unequal rotational speeds (for two wheels)

Locking Type Unequal torque, equal rotational speeds.

Final Drive

1. Half shafts should be closer to symmetrically placed.

2. The axles have CV joints at each end as they afford better performance atgreater angles, which allows more suspension travel.


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THANK YOU

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