Design and Analysis of Roll Cage For An Electric Hybrid Tricycle
Design and Analysis of Roll Cage For An Electric Hybrid Tricycle
Design and Analysis of Roll Cage For An Electric Hybrid Tricycle
Abstract— With the growing concern of steep dip in and material cross section determination. The detailed
the fuel reserves worldwide and alarming rates of procedure is explained below.
pollution, green technological trends are being
progressively adopted to promote eco-friendly A. Material Selection
spirits. Efficycle is an electrically assisted, dual Roll Cage material is one of the key aspects in
human pedal powered three wheeled vehicle, design which greatly affects the safety, reliability and
designed to facilitate daily mobility needs. performance. The roll cage material should possess
The vehicle frame was to be high strength to weight ratio along with low carbon
ergonomically designed, engineered for content and good weldability.
performance and safety. Enhancing the structural
integrity and overall aesthetics were the focal points The cost is an important deciding factor in the
in the design and analysis of the roll cage. This material selection process. Thus a material selection
paper deals with the roll cage material selection decision matrix was formulated to aid the process.
process and finite element static structural analysis Table 1: Material Selection decision matrix
of the roll cage under predetermined conditions in
FEA software Ansys 15.0 to determine its structural AISI HSLA Chromoly
Property
strength. The roll cage material selection was 1018 340 4130
carried out with an aim to optimize strength, weight Yield
3 2 1
and cost. The key parameters taken under Strength
consideration were safety driver ergonomics, weight UTS 3 2 1
reduction and cost of manufacturing the chassis. Carbon% 2 1 3
Weldability 1 2 3
Keywords — Efficycle, FEA, 3D Modelling, Roll Cost 1 2 3
cage, Static Analysis Total 10 9 11
I. INTRODUCTION Hence, we selected HSLA 340 micro alloy steel
for our chassis because of its high weldability,
The primary function of the roll cage is to ensure
strength & low cost.
driver safety in case of a crash or roll over. The
secondary objective in chassis design is to provide The selected material specifications:
mountings for all the components, keeping in mind a
Table 2: HSLA 340 properties
low centre of gravity while doing so. Moreover the
driver comfort and ergonomics should be taken into Property Value
consideration while designing of the frame.
Material HSLA 340
These objectives are met by proper material Carbon% 0.080%*
selection, designing a low weight reliable frame and Density 7.87 gm/cm3
carrying out extensive finite element analysis of roll Poisson ratio 0.3
cage against various modes of failure to verify its Elastic Modulus 210 GPa
safety. Based on the results the roll cage is modified Yield Strength 571.92 MPa*
accordingly. After finalizing the roll cage design it is UTS 651.95 MPa*
fabricated.
*practically tested from an NABL accredited lab
The CAD model of the chassis was prepared in
PTC Creo 3.0 and finite element analysis was B. Frame Design
performed in Ansys Workbench 15.
In the initial frame design period, the transmission
II. DESIGN METHODOLOGY of vehicle, driver's ergonomics and placement,
suspension and manufacturing methods were set.
The design procedure of roll cage is a manifold There was a requirement to keep a minimum
process. It involves material selection, frame design clearance of 3 inches between the drivers and the roll
Fig 7: Front Impact Analysis Maximum Combined Fig 9: Side Impact Analysis Total Deformation
Stress
Maximum deformation= 7.94 mm
Maximum Combined Stress= 336.11 MPa According to analysis, deformation at the time of
Incorporated Factor of Safety collision does not affect the driver safety.
= σyt/ Maximum Combined Stress
=571.92/336.11
=1.701
As the FOS is greater than 1.2, the design is safe
against specified stress for front impact.
E. Side Impact Analysis
This test is performed to see the behaviour of the
roll cage in the condition of collision from side and
thus check drivers' safety in the condition of a side
impact.
Calculation of Impact forces:
Assuming 3G force for a vehicle/driver mass of
240 kg,
F = 3×m×g
F = 3×230×10 Fig 10: Side Impact Analysis Maximum Combined
F = 6900 N Stress
Maximum Combined Stress= 306.54 MPa
Incorporated Factor of Safety
= σyt/ Maximum Combined Stress
=571.92/306.54
=1.86
As the FOS is greater than 1.2, the design is safe
against specified stress.
F. Roll Over Analysis
This analysis is performed to analyse the behaviour
of roll cage in the condition of vehicle toppling.
Calculation of Impact forces:
Assuming 3G force for a vehicle/driver mass of
240 kg,
Fig 8: Side Impact Analysis Constrained model F = 3×m×g
F = 3×230×10
We applied the calculated 3G force of 6900N to F = 6900 N
the side impact protection members of the chassis
while applying the Boundary conditions. The
translation and rotation of all suspension mounts is
locked.
Analysis Result:
Analysis result:
REFERENCES
[1] Herb Adams, "Chassis Engineering", Berkley Publishing
Group New York.
[2] SAE –NIS Efficycle 2016® rulebook.
[3] R. K. Bansal, "A Textbook of Strength of Materials",
Laxmi Publications New Delhi.
[4] Linder, Astrid; Avery, Matthew. “Change of Velocity and
Pulse Characteristics in Rear Impacts: Real World and
Vehicle Tests Data,” The Motor Insurance Repair and
Research Centre. Thatcham, United Kingdom.'
IV. CONCLUSION
We have successfully analysed the roll cage for its
strength for its safety against collision from front and
side and under rollover condition. The roll cage was
deemed safe for front impact load of 5G, side impact
load of 3G, rollover loading of 3G and torsion of
magnitude 2G. The deformation & stresses are under
limit. Hence this roll cage was finalised for
manufacturing and fabrication of the vehicle.