CHAPTER 3
3.0 PROJECT DESIGN
3.1 Concept Design
The main idea behind the Conceptual Design is to maximize the probability of the
final product. Hence, a conceptual design should be worked in sufficient detail to
allow estimates of cost, weight, overall dimensions and power consumption. During
this first phase of the design process, decisions should be made about major design
features such as primary sub-systems and major algorithms. The designer should also
present the rationale for making these decisions, supported by relevant experiments.
An arbitrary decision, especially early in the design process, means a wasted
opportunity for improving quality and reducing cost. By using a TRIZ or popular
method without questioning is in fact nothing but making an arbitrary decision.
During the conceptual design phase, one must question the accepted or
conventional ways of doing things and look for possible alternatives.
Broad solutions to the defined problem are developed often in the form of design
options. This phase places the greatest demand on the designer in terms of creative
thinking, since innovations can originate here. Design is not only about the final
product but also about the feasibility and cost-effectiveness of the manufacturing
process. When the designers choose a part shape, a circuit or an algorithm, they must
also think about how these will be manufactured or implemented. Is there an easier
way to achieve the same purpose with a different material, shape, circuit or
algorithm? should be a frequently recurring question in the designer's mind.
The feasibility of design decisions or their alternatives can only be validated if major
aspects of the design such as major sub-systems or algorithmic components are
verified through sub-system tests. Although it is not a guarantee, the positive results
of these preliminary tests convince the customer that the design has a high probability
of success upon integration and acts as an experimental Proof of Concept on a sub-
systems or module level.
3.1.1 Material Selection (TRIZ Method)
TRIZ methodology presents a systematic approach for understanding and defining
challenging problems, difficult problems require an inventive solution, and TRIZ
provides a range of strategies and tools for finding these inventive solutions. One of
the earliest findings of the massive research on which the theory is based is that the
vast majority of problems that require inventive solutions typically reflect a need to
overcome a dilemma or a trade-off between two contradictory elements. The central
purpose of TRIZ-based analysis is to systematically apply the strategies and tools to
find superior solutions that overcome the need for a compromise or trade-off between
the two elements.
The combination of all of these concepts together the analysis of the contradiction, the
pursuit of an ideal solution and the search for one or more of the principles which will
overcome the contradiction, are the key elements in a process which is designed to
help the inventor to engage in the process with purposefulness and focus.
The benefit of TRIZ is understanding that contradictions can be methodically solved
with application of innovative solutions. Three fundamental principles of TRIZ
conceived as follows:
a. Developed an ideal design.
b. Contradictions help to solve the problems.
c. Innovation process can be configured as systematic.
TRIZ includes analytical tools that are necessary for problem solving and it is also
knowledge-based tools that are necessary for system transformation and their
theoretical foundations. TRIZ uses algorithmic approaches for improving legacy
systems or designing new systems. Therefore, it includes to evaluate the available
data rather than estimation. The main goal of :
a. Contradictions
b. Perfection
c. Functionality
d. Use resources.
Using all the information about the problems of the products, the analytical tools of
TRIZ can be used for transforming, modelling and analysing problems. Also, it is a
special analytical tool that gathers substance-field analysis, conflict analysis, required
function analysis and other techniques.
3.1.2 Benchmarking
Benchmarking is comparing one's business processes and performance metrics to
industry bests and best practices from other companies. Dimensions typically
measured are quality, time and cost. In the process of best practice benchmarking,
management identifies the best firms in their industry, or in another industry where
similar processes exist, and compares the results and processes of those studied (the
"targets") to one's own results and processes. In this way, they learn how well the
targets perform and, more importantly, the business processes that explain why these
firms are successful.
Benchmarking is a way of discovering what is the best performance being achieved,
whether in a particular company, by a competitor or by an entirely different industry.
This information can then be used to identify gaps in an organizations processes in
order to achieve a competitive advantage. Thus, it is important for Six Sigma
practitioners to:
a. Understand fully the purpose and use of benchmarking.
b. Understand the difference between benchmarking and competitor research.
c. Gain insight to ensure that benchmarking is in alignment with the companys
management objectives.
Figure 3.1: Six Sigma Process
Define Process
Data Collection
Data Comparison
Analysis
Action (Product
Planning)
Figure 3.2: Benchmark Methodology
Table 3.1: Design benchmarking for all the purposed design and the final design selection.
Component/ Proposed Proposed Proposed Final Design
Design 1 Design 2 Design 3 Selection
Part
Frame AISI 4130 AISI 1023 ASTM A312 AISI 1023
Chrome-Alloy Stainless Steel Carbon Steel
Carbon Steel
(Chromalloy)
steel
Belt Integral Motor Belt
Spindle
Spindle Driven Driven
Hub Tool Steel Stainless Steel Mild Steel Mild Steel
Tyre 10 x 4.5 Beach 10 4.5 10 x 4.5 10 x 4.5
Buggy Rims Snowmobile Magnesium Magnesium
rims Rims Rims
Tie Rod Steel
Mounting Weld Nuts and Nuts and
Joint Bolts
Bolts
Steering Rod Tool Steel Stainless Steel Mild Steel Mild Steel
Steering Full Circle Half Circle Full Circle
Wheel
Polymer Carbon Fibre Carbon Fibre
Type Type
Seat Type Cushion
3 Point (Lap 3 Point 2 Point 2 point
and Shoulder) Retractable
Seat Belt (Lap Only) (Lap Only)
Engine 2 Stroke Fuel 4 Stroke Fuel Electric Motor Electric
Engine Engine Motor
Type
Lithium Battery Lead-Acid Zinc Carbon Lithium
Battery Battery Battery
Battery
Brake Type Scrub Brake Band Brake Disc Brake Disc Brake
Clutch and Pulley and Pulley and
Belting Belting Belting
Transmission Gear
Ball Spherical Pillow Block Pillow Block
Bearing Bearing
Bearing Bearing l Bearing
Figure 3.3: Purposed design 1
Figure 3.4: Purposed design 2
Figure 3.5: Purposed design 3
3.2 Final Design
Table 3.2: Final design materials selection.
No Component/Part Final Design
1 Frame AISI 1023 Carbon Steel
2 Spindle Belt Driven
3 Hub Mild Steel
4 Tyre 10 x 4.5 Magnesium Rims
5 Tie Rod Alloy steel
6 Mounting Joint Nuts and Bolts
7 Steering Rod Mild Steel
8 Steering Wheel Full Circle
9 Seat Carbon Fibre Type
10 Seat Belt 2 Point (Lap Only)
11 Engine Type Electric Motor
12 Battery Lithium Battery
13 Brake System Disc Brake
14 Transmission Pulley and Belting
15 Bearing Pillow Block Bearing
3.2.1 Compartment details:
1. Frame ( AISI 1023 Carbon Steel )
Many racing chassis manufacturers use
AISI 1023 (carbon steel) for
manufacturing their chassis. They,
however draw tubes at varying diameters
to accommodate bends. We will use this
material because it can easily get, cheap
and easy for mounting process.
2. Spindle
In the final design, we are using a spindle
for the turning radius of the tyre because
spindle is far cheaper on fabricate and
easier if than conventional steering
system and in go kart we not using
suspension system and is suitable to using
spindle.
3. Hub ( Mild Steel )
This external shaft locking device is a
reliable and durable component that
features high torque and impressive
concentricity. It is self-centering and the
axial hub position can be moved during
the clamping process.
4. Tyre ( 10 x 4.5 Magnesium Rims )
Magnesium alloys and magnesium
casting techniques have progressed
significantly in the last forty years. Real
Nostalgia magnesium wheels are vastly
superior to any of the old magnesium
wheels in terms of balance, consistency,
concentricity, corrosion resistance,
porosity, purity, sealing, and surface
finish.
5. Tie Rod ( Alloy steel )
Tie rods are commonly manufactured
using low carbon steel, but higher
strength assemblies can be
manufactured. Carbon or alloy steel tie
rod assemblies can be supplied either
plain finish or hot-dip galvanized, and
stainless steel tie rod assemblies are
common as well. Complete tie rod
packages are assembled in our facility to
ensure accurate thread fit before shipping
to mounting joint.
6. Mounting Joint ( Bolt and Nut )
In the final design, we using bolt and nut
as a joining because the bolts and nuts are
easier to fabricate and dismantle. We
using several sizes in the fabrication
process of the go-kart.
7. Seat ( Carbon Fibre Type )
In final design, we are using carbon fibre
seat because it is lighter then
convectional seat go kart. This seat is
quite expensive but in making of race go-
kart it is important to consider about the
weight because speed of go-kart would be
affected by the weight.
8. Seat Belt ( 2 Point Lap)
We are using two-point lap seat belt
because for this project, safety is one of
the important features of the go-kart. A
two-point lap seat belt is just enough to
ensure of the driver safety
9. Engine ( Electric Motor )
In final design, we are using a induction
single phase electric motor it is because
electric motor are more eco-friendly if
compare then two stroke and four stroke
engine. Then another conventional go-
kart also using electric motor but the
different between induction motor is it
more torque then the other electric motor.
10. Battery ( Lithium )
In final design, we are using a Lithium
Battery (LiPo) it is because induction
electric motor are using a AC current that
will converted into DC for using in go
kart so we choose to using LiPo battery
that had a Voltage more high then other
battery.
11. Brake system ( Disc Brake )
In final design, we are using a brake disc
system it is because brake disc are more
efficient then brake shoes in safety
aspect. Our go kart using only one brake
disc system at drive shaft it is because
only one disc it more enough to stop it.
12. Transmission ( Chain )
The clutch sprocket and the main drive
sprocket should be perfectly aligned so
they don't rub against the side links.
Rubbing wears the teeth down rapidly
and absorbs horsepower.
13. Bearing ( Pillow Block Bearing )
In final design, we are using a a pillow
block bearing for drive shaft bearing it is
because the pillow block are one of the
part that can connect movement part like
drive shaft then the pillow block more
easier to fabricate if compare to other.
3.2.2 Design Drawing
Below are the sketches and Computer Aided Drawings (CAD) of go-kart:
Figure 3.6: Side view sketch.
Figure 3.7: Plane view sketch.
Figure 3.8: Front view sketch.
Figure 3.9: 3D view sketch.
Figure 3.10: CAD side view.
Figure 3.11: CAD 3D view.
According to the result, we approached our design by considering all possible
alternatives for a system and modelling them in CAD software like SolidWorks and
subjected to analysis using HyperMesh software. Based on the analysis result, the
model was modified and retested and a final design was produced.
The design process of the vehicle is iterative and based on various engineering and
reverse engineering processes depending upon the availability, cost and other factors.
These are the design process objectives:
a. Safety
b. Serviceability
c. Strength
d. Ruggedness
e. Standardization
f. Cost
g. Driving feel and ergonomics
h. Aesthetics
3.2.3 Frame Design
The frame is designed to meet the technical requirements of the competition and the
objective of the chassis is to encapsulate all components of the go-kart, including a
driver, efficiency and safety. Principal aspects of the chassis focused on during the
design and implementation included driver safety, drive train integration, and
structural weight, and operator ergonomic. The number one priority in the chassis
design was for the driver safety. By the competition rules and Finite Element Analysis
(FEA), the design assured.
Figure 3.12: Final frame design.
The material AISI 1023 carbon steel is used because its relatively soft and strengthens
as well as good manufacturability. A good strength material is important in a roll cage
because the roll cage able to absorb as much energy as possible to prevent the roll
cage material from fracturing at the time of high impact. Carbon steel has chosen for
the chassis because it has structural properties that provide a low weight to strength
ratio.
3.3 Operation and Maintenance Manual
CONTENTS
1. Introduction
2. Technical details
3. Safety guidelines
4. Maintenance
4.1 Frame
4.2 Wheels and tyres
4.3 Steering system
4.3.1 Front alignment
4.4 Driving gear
4.4.1 Chain
4.5 Plastic parts
4.6 Lubrication
4.7 Maintenance and adjustment of the disc brakes
5. Safety
5.1 Wheel
6. Maintenance schedule
7. Warranty
1.0 Introduction
This operation manual contains important safety information and maintenance
information. All information, images and specifications contained in this manual are
based on the latest product information available at the time being. Most of the
maintenance work on the go-kart can be carried out by the owner.
2.0 Technical Details
Width: 1340 mm
Length: 1800 mm
Height: 830 mm
Empty weight: 32-60 kg
Carrying capacity: 90 kg
Tyre pressure (at 15C, front and rear) : 18 psi
3.0 Safety guidelines
a. Before using the go-kart, check if everything functions properly.
b. Adult supervision for children under the age of 15 years old.
c. This go-kart is not allowed on public roads. Always drive it at appropriate
speed, depending on the situation. Driving down a slope slantwise, the go-kart
may overturn. Downhill drive with a considerable speed, resulting in a longer
break path. Sharp bends at high speed also may cause the go-kart to overturn.
d. Always pay attention to the environment and surroundings during the go-kart
run.
e. Do not drive under the influence of alcohol or drugs which have a negative
effect on your perception or reaction.
f. Do not place unnecessary objects on or beside the clutch handle or the wheel.
Make sure the brake and pedal are functioning.
g. Clothes and limbs may get stuck in revolving or hinged parts. Avoid wearing
loose attire such as scarves or shoe laces. It can cause accidents.
h. Avoid contact with the wheels when driving the go-kart.
i. The brochure contains guidelines on age categories. The owner/driver is
responsible for deciding whether this go-kart is age appropriate.
j. Make sure that for every drive the driver's seat is in the right position with
regard to the pedals to allow for safe driving.
k. Do not get on or off while driving.
l. Do not overload the vehicle.
m. Do not drive in the dark without lights.
n. Protective covers having been removed for maintenance purposes should
always be put back in the original state before use.
o. When parking the vehicle, always put it in brake with the lock brake.
4.0 Maintenance
4.1 Frame
The frame is powder coated. This creates a hard coating. To prevent from corrosion, it
is important to regularly clean the frame. Grease the frame for the purpose of
conservation, only use acid-free vaseline. Minor damage may be restored with some
paint. The right varnish may be obtained from your dealer.
4.2 Wheels / Tyres
Wheels may have either needle bearings (Figure 4.1) or ball bearings (Figure 4.2).
Needle bearings should be cleaned and lubricated annually to ensure the wheels run
smoothly. Regularly check the wheel rims and tyres for damage (cuts, tears, bumps)
Attention: damage to rims and tyres may cause accidents.
Figure 4.1 Figure 4.2
Tyre pressure should be 1 bar at least and 1.5 bar max. (Remember pressure increases
at high temperatures). At the right pressure, the go-kart runs smoothly and lightly. If
there is not enough pressure the tyres tend to get punctured more easily and excessive
wear and tear occurs. If there is too much pressure the tyre can come loose. This may
lead to dangerous situations. (Be aware that pressure increases under high
temperatures and in blazing sun!) Tyres should not get into contact with oil, grease or
fuel. Make sure the valve caps are always on.
4.3 Steering system
Steering system should be regularly greased for it to run smoothly. For the adjustable
wheel, it is important that the identifying mark on the side of the inner control tube is
not visible. If it is visible, the inner control tube should be pushed back. Steering
system of the go-kart needs to be checked monthly for the following:
a. Breaking and/or damage of all parts of the steerage
b. Controls (lubricate all rotation points)
c. Alignment front wheels (see pictures next page) for models with double ball
steerage - stuck bolts
4.3.1 Front alignment for models with double ball steering system
a. Check if bottom of strip is in upright position. The correct position is
shown in Figure 4.3.
Figure 4.3
b. Then check the smallest deflection of the left and right wheel with the
front bumper (As indicated in Figure 4.4 and Figure 4.5 at the bottom of
the page).
Figure 4.4 Figure 4.5
c. Loosen the steering swivel at the side of the wheel with the smallest
deflection. In Figure 4.6 and 4.7, the left wheel can be calibrated (by
using 13 and 19 spanner). Then push against the wheel in the direction
away from the bumper. After that, tighten the steering swivel well.
Figure 4.6 Figure 4.7
4.4 Driving Gear
4.4.1 Chain
The chain needs to be greased regularly in order to have it run smoothly. It
should only be possible to push in the chain 2 to 3 cm in the middle. Make
sure the rear axle does not move when the chain is pushed in in the middle. If
the chain is pulled too tight, the go-kart will peddle heavily and the axle could
break. If the chain is not tight enough, the chain guard may be damaged.
The back chain is tightened based on Figure 4.8 and 4.9:
Remove the protective plate from the back hood. Make sure the hub remains
exactly parallel to the rear axle (maximum 1 mm difference in distance
between rear axle and the small axle of the brake hub left and right), as can be
seen in the picture below. It should be possible to push in the chain in the
middle with the thumb for about 3-4 mm.
Figure 4.8 Figure 4.9
4.5 Plastic Parts
The plastic parts will have to be checked regularly for damage and breaking. If
breaking occurs, the specific part should be replaced immediately by an original part
in order to guarantee the safety of the user.
4.6 Lubrication
Some Berg go-carts are equipped with grease nipples on the stub axle bushes. It is
recommended to grease the stub axles 1 to 2 times per year.
4.7 Maintenance and Adjustment for Disc Brake
If the brake system started to loosen grip, it needs to be squeezed furthermore. In
order to operate properly, you need to adjust the brakes. The cable connector where
the brake cables are connected is equipped with adjusting screws. By turning the
adjusting screws counter clockwise, the free movement of the brake handle decreases
and the disc brakes will perform better.
If the brake disc laterals runout, you need to adjust the brake calliper. By turning the
adjusting screw (Figure 4.10), you can move the brake calliper sideward.
Figure 4.10
5.0 Safety
This go-kart is produce for circuit use only. Each year an independent institution
checks if the products meet the required standards. This go-kart is a part of the
automotive product group. This means that the go-karts are not allowed on public
roads. Children (under the age of 15) should drive the go-kart under adult supervision.
5.1 Wheel
Check before driving, if there are any defects on the controls or whether the steering
system is smooth. If this is not the case, you need to solve this first. For instructions,
see under maintenance.
6.0 Maintenance Schedule
Description Daily Every Every 6 Every Year
Month Month
Frame
Clean and check all
the nuts and bolts
Tyres
Check for damages
and tyre pressure
Steering system
Check for
damage/wear
lubricate
Driving Gear
Check chain for
tightness
Plastic Part
Clean and check for
damages
Hubs
Clean and check for
wear
Stub Axle Bushes
Lubricate by means of
grease nipples
7.0 Warranty
a. The owner of this go kart product has the following warranty conditions on this
product.
Frame: 5 years after date of purchase.
All other parts: 2 years after date of purchase.
Parts subject to wear and tear (such as chain and tyres): no warranty.
b. The warranty only covers material or construction defects with regard to this
product or parts of the product.
c. The warranty expires in the following situations:
Incorrect and/or careless use of this product and use not according to the
intended purpose.
The product was not assembled and serviced according to the construction
manual.
Technical repairs to the product have not been carried out professionally.
Parts mounted afterwards do not meet technical specifications of the product
involved or have not been mounted correctly.
Defects as a result of climatological factors, such as corrosion or normal
ageing of the varnish.
The product is in use as a rental or is in another way available to several
persons unspecified.
e. This go kart is explicitly not liable for damage to (parts of) the product as a
result of:
Incorrect tune-up of driving mechanism, incorrect tyre pressure, incorrect
adjustment of wheel, chain and hubs.
Parts, such as chain and tyres, not replaced in time.
f. In the warranty period, all material or construction defects as determined will
either be repaired or replaced.
g. The owner of this product can only make a warranty claim by offering the
product for inspection to our dealer. The original warranty certificate (with dealer
stamp and fully completed) should be presented to the dealer at the same time, and
with original bill of purchase. If the owner has moved or the dealer is no longer
available under the name of eco-lancer.
h. If the warranty has not been presented, the owner will take care of all costs.
i. The warranty certificate is not transferable to other persons