effi-cars 2016 rule book - updated

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FIRST EDITION

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Published By:

EFFI-CARS

Website: www.efficars.org

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Table of Content

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1 Design and build 2 seater, 4 wheeled vehicles running solely on electric power

2 Create a practical city vehicle which could be used for day to day commutation

3Provide a platform to engineering students to put their knowledge into practise and

showcase their talent

ObjectiveThe objective of the event is to:

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Section A

A1.1 Rules Interpretation and Resolution

1Any discrepancies or doubts in understanding any section of this rulebook shall be resolved by

consulting the EFFI-CARS Organizing Committee.

2The team members, faculty advisor or any other accompanying members must comply with all

the rules issued by EFFI-CARS Organizing Committee

3During the vehicle inspection, static and dynamic events, all the participants are required to

cooperate with, and follow the instructions given by EFFI-CARS Organizing Committee and

judges

4 Vehicles not complying with the rulebook will not be allowed to participate in any event

A1.2 Eligibility Criteria

1 Current undergraduate and graduate engineering students can take part in the competition.

2 Team size of 7 to 10 members is allowed

3In case a participant gets graduated before the main event and is no more a student of that

college, he/she will be considered as a visitor and not a team member during the main event.

4Each participant present on-site for the main event will have to sign a liability waiver at the time

of registeration on the event venue

A1.3 Team Drivers

1Two drivers per team are allowed. At the time of any competition, the second driver must be

present in the vehicle as a passenger

2 Team Drivers must hold valid, government issued driving license at the time of the event.

3 The drivers must have a valid Life insurance.

A1.4 Faculty Advisor

1 Each team must have one faculty advisor accompanying the team for the main event

2 Faculty advisors are expected to guide their teams on engineering as well as financial aspects

3Faculty advisor must not indulge in direct designing or fabrication of the vehicle. Strict actions

shall be taken against the teams in such cases

A1.5 Violations

1 Any violation of a rule or an intent of violation shall be treated as a serious offence.

2Any team if found violating the rules, might face severe actions such as impounding of their

vehicle.

3The penalties can be modified by the technical committee without the consent of the teams or

any prior notice

Rules and Regulations

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Section A

A1.6 Registration

1Registration for SAE-UIET EFFI-CARS must be performed according to the guidelines available on

www.efficars.org

2There is no limit to the number of teams from one college participating in the virtuals but a

student can be a part of only one team

3 Teams must visit the website: www.efficars.org to know about the last date of registrations.

4 The Fees for Virtual round is INR 5,000 and for the main event is INR 15,000

5 For regular updates, keep visiting the official website: www.efficars.org

A1.7 Technical Queries

1 All technical queries must be emailed to: [email protected]

2 All teams and event related queries must be emailed to: [email protected]

3Teams are requested to carry a hard copy of all the queries they have posted and the replies

they have received to the technical inspection as a proof, in case some changes have been

permitted to them.

Rules and Regulations (Continued..)

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Section B

B1.1 Vehicle Configuration

1 Vehicle must have 4 wheels - 2 in front and 2 on rear. All 4 wheels must not be in a straight line

2Vehicle must have seating capacity for a driver and a passenger (2 seater) in a side by side

configuration

3 It should be able to carry 2 persons with 190.3 cm (6'3") height and 115 Kg weight each.

4Vehicle must have an arrangement / space available to place a load of 30 Kg with dimensions

36"x24'" (LXB)

5 Maximum vehicle dimensions should not exceed 120"X54" (LXB)

6 Vehicle should be able to cross small obstacles of height not more than 4"

Vehicle Specifications

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Section B

B1.2 Frame and Chassis

1

The vehicle frame must have 3 compartments totally separated from each other.

1) Battery Compartment - The battery compartment should be properly shielded with metal

sheets and the passengers must not be able to access (or come in contact with) the batteries

from within the passengers' cabin. Sheet separating the two compartments must be properly

insulated.

2) Passenger Cabin - Driver and passenger are to be seated inside the passenger cabin. All

vehicle controls should be present inside this cabin.

3) Boot Space - This space should be able to carry the load as specified in section B1.1 - 4. The

space should be shielded from driver's cabin so that the load doesn't fall inside the drivers' cabin

2

Passenger cabin must have the following elements -

1) Side bracing member to protect the passengers in case of side impact. These should be

continuous tubes (without any joints). Driver's thighs should not be more than 3" higher than

the side bracing member when sitting in the upright position

2) Roll-over protection - The roll over protection member should be at minimum of 4" height

from the tallest passengers' head along with the helmet. It should be capable of protecting

driver's head in roll-over conditions from any direction.

The driver's helmet must be below the straight line drawn from top of the roll bar to the

highest structural point of the vehicle

3) Front impact members - Front impact members must be present to protect the driver in case

of a vehicle head-on collision

3All material used for the main frame and chassis should be seamless metal tubes with outer

diameter of 1" and minimum wall thickness of 2.5mm

4All material used for the supporting members should be seamless metal tubes with outer

diameter of 0.75" and minimum wall thickness of 2 mm

5Safety of the passengers is paramount in designing this vehicle. The passenger cabin must be

properly sheeted to protect the passengers from any impact or debris while the vehicle is in

operation

6Battery compartment, passenger cabin and payload carrier should be separated from each other

using metal / composite sheets which can also protect the passengers in case of fire

Vehicle Specifications (Continued..)

CROSS SECTION OF A METAL TUBE

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Section B

B1.3 Electric Motor

1 Vehicle must run on electrical power only.

2 BLDC motor of maximum 850 Watt with 48V input is allowed

3 The OEM specification plate on the motor should always be available and not tempered with

B1.4 Transmission & Drive-train

1Teams are free to use automatic or manual transmission systems to reduce motor RPM and

increase torque

2 It is advisable not to exceed top speed of the vehicle by 50 kmph.

3Both, 2 wheel drive (front wheel drive or rear wheel drive) and 4-wheel drive vehicles are

allowed

4 Appropriate differential mechanism should be used on the drive wheels

5All the moving parts of drivetrain such as chains, belts, sprockets or flywheel must be properly

shielded so as not to cause any harm to passengers or other participants in case of collision or

impact. The guards must extend on the entire length of chain or belt.

B1.5 Steering

1All vehicles must be right hand driven (with driver sitting on the right hand side). Only the driver

is allowed to control the vehicle steer.

2 The minimum recommended turning radius of the vehicle is 14.5 ft.

B1.6 Tyres and Wheels

1 Teams are free to choose wheels and tyres of any width and diameter

B1.7 Seats

1 Use of only OEM used seats or similar fabricated seats is allowed

2 Seats must be rigidly mounted to the main frame of the vehicle3 Both the seats must be equipped with 4 point seat belts

B1.8 Brakes 1 Teams are allowed to use both hydraulic or non-hydraulic brakes.

2Foot brakes must be installed on all 4 wheels and should be capable of locking ALL FOUR

WHEELS in static as well as dynamic state.

3 The vehicle should not roll if pushed with the brakes applied

4 Use of regenerative braking is permitted.

5 Vehicle should be fitted with brake lights (red in colour) at rear of the vehicle

6 The brake lights should work even if the kill switch is pressed

B1.9 Fasteners

1 All the fasteners used must be at least metric grade 8.8 equivalent

2 Use of only Nylon lock nuts and cottered nuts is allowed

3 At least 3 threads should be visible on the bolt after tightening the nut


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Section B

B1.10 Electrical System

1

A 48V battery pack with on board charging system is required.

The battery must not be removed from the vehicle in case it needs a charging .

Battery must be mounted rigidly.

Use of hinges or floating batteries are prohibited.

2Use of multiple batteries is allowed but the net voltage and current rating should not exceed

48V & 90 Ah

3All types of gel / dry / leak-proof lead acid batteries are allowed. Lithium-ion, lithium-polymer or

Nickel-cadmium battery packs (OEM manufactured) can also be used.4 Batteries must not be tampered in any form

5

Battery charging through solar cells or any other energy storage device is not allowed. 'EFFI-

CARS' organizing team will provide 220V 15A AC power sockets for connecting the chargers. The

teams are required to carry their own chargers which will connect to the on-board charging

system.

6Batteries must be securely mounted to the frame of the vehicle so as not to become loose in

case of any impact

7 All the electrical devices must be connected to the battery through a separate fuse

8Each vehicle must be fitted with 2 kill switches, one inside the driver cabin and in reach of driver

while seated with seat belts on and another on outside of right side of the vehicle. Each kill

switch must instantly terminate the current flow through the battery.

9The kill switches should be mounted on red coloured solid plates of minimum dimensions 5"X5"

and should be in contrast to the vehicle colour

10 No loose wires should be present in the vehicle.

B1.11 Tow Bar

1 Vehicle should be fitted with tow bars in front and rear of the vehicle

2 The distance between tow bar and vehicle body should be at least 3 inches

B1.12 Safety Measures

1The vehicle must be fitted with mirrors which allows the driver to clearly see the rear on both

sides of the vehicle

2Seat belt must be mounted to a structural support point at least 3 inches below the driver's

waist and shoulder straps should be mounted at least 3 inches below the driver's shoulders.

3 Above rule also applies for the passenger seat belt

4All the metal tubes that can come in contact with the passengers must be padded with

minimum padding thickness of 0.5 inch.

5There should be no sharp edges or protruding elements that can hurt or cause injury to the

passengers and the crew members

6Both the driver and passenger must wear helmets (ISI marked), seat belts, shoes, long sleeve

shirts and pants, gloves and eye protectors

B1.13 Vehicle Identification

1Each vehicle should have college name, team name and team number (allotted by EFFI-CARS

Organizing Committee) on front, both sides and rear of the vehicle.

2 The vehicle number must be of at least 5" in height and 1" line thickness

3 College name must be displayed on the front of the vehicle with a minimum of 2" height

4 A space of at least 10'X10' should be available to paste EFFI-CAR and sponsors' logos


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Section C

C1.1 Battery Output Test

1 All the battery packs will be tested for the output power available

C1.2 Vehicle design (200 points)

1 Vehicle ergonomics (40 points)

2 Craftsmanship (35 points)

3 Innovation (50 points)

4 Design report (75 points)

5 CAD /CAE model (50 points)

C1.3 Cost Challenge (75 points)

1For any remarkable vehicle to go into production, cost certainly plays a very important role. The

teams are required to submit the cost report in the prescribed format.

Actual receipts for all purchases to fabricate the EFFI-CAR must be retained.

C1.4 Production plan (75 points)

1

Each team is required to make a production plan. The aim is to setup a facility for producing

2,000 vehicles in the first year. The production plan should highlight all the important aspects of

a product lifecycle and cost to final consumer.

C1.5 Minimum Weight (50 points)

1 Vehicle with minimum weight with all the equipment (without the drivers)

Vehicle Design Tests (450 points)

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Section D

D1.1 Eligibility

1The vehicle should be running solely on electric power and the circuit breaker (Kill switch) is

working as intended

2 All Electric Tests will be performed with both the drivers seated inside the vehicle

D1.2 Braking Efficiency

1 Braking efficiency test is a qualifying test for all other electric tests

2An EFFI-CAR has to be driven on a straight road for a particular stretch to gain speed and then

brought to rest through braking. All 4 wheels must be locked must be locked at the time of

braking

D1.3 ZERO to FIFTY (100 points)

1The objective is to check the time taken by a vehicle to cover 100 feet distance on a straight

course starting from rest

2 Best time from 2 runs will be counted

D1.4 CITY Run (150 points)

1 The objective is to check the vehicle's ability to be able to maneuver into crowded cities.

2 The track will have multiple obstacles, sharp bends, small holes etc.

3 The vehicle will have to be parked in a defined space after completing the run on the track

4 The vehicle will be loaded with a payload of 30 Kg for CITY run

5 Touching the track lines or traffic cones will invite penalty points

D1.5 Highway Challenge(300 points)

1The objective is to assess a vehicle's ability to run for a specified amount of time continuously

and on variable turfs.

2 This is a lap type race with approximately 2 hours of run time.

3 The winner of the race will be determined by counting the maximum number of laps covered

4 In case of a technical breakdown, no special time privilege shall be given to the teams.

5Rash driving is prohibited in the run and teams may be disqualified at the discretion of judges

and EFFI-CARs organizers

6Teams are allowed to change the driver only in the driver change zone where vehicle has to be

brought to rest and kill switch pressed to shut down the power supply

Electric Tests (550 points)

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effi-cars 2016 rule book - updated

Documents

team members

efficars website

team size

efficarssection aa1

passenger2 team drivers

team drivers1two drivers

saeuiet efficars

efficars1 design