MINI BAJA TEAM Southern Comfort

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MINI BAJA TEAMSouthern Comfort116

• Team Members
• Jason Donoghue
• Jonathan Hayes
• Jason Mabry
• Robert Weihing
• Faculty Advisor
• Dr. Engin

Machinist / Mentor Lanny McCormick
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Problem Statement

• The goal of our design project is to design and
  construct a four-wheel, single seat, off-road
  recreational vehicle intended for sale to the
  non-professional weekend off-road enthusiast.
• Upon completion, the vehicle will compete in the
  2003 Society of Automotive Engineers (SAE) Mini
  Baja Midwest competition in June of 2003 in Troy,
  Ohio.

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Design Objectives

• Meet all vehicle requirements and restrictions
• Meet all or exceed the minimum safety
  requirements
• Be familiar with competition procedures and
  regulations
• Be familiar with events and scoring

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Vehicle Requirements Restrictions

• Vehicle Configuration
• All-terrain Capability
• Required Engine

• Towing Hitch
• Vehicle Identification

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Minimum Safety Requirements

• Roll Cage
• Cockpit
• Driver Restraint
• Braking System
• Fuel System Fuel

• Steering Suspension
• Fasteners
• Guards
• Driver Equipment

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Competition Procedures Regulations

• Inspection Condition
• Governor Setting
• Drive Gear Ratios and Tire Modifications
• Post Endurance Inspection

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Event Descriptions Scoring

• Static Events 300 points
• Design
• Cost
• Dynamic Events 700 points
• Top Speed
• Acceleration
• Braking
• Maneuverability

• Sled Pull
• Hill Climb
• Endurance

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Brainstorming Decisions

• Competition
• Frame Design
• Drivetrain Design

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Competition Decision

• Midwest Event in Troy, Ohio
• Good Past Performance
• Less Complicated Design

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Frame Decision

• Modification of Existing Frame
• Efficient Design
• Low Cost
• Reduced Construction Time

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Drivetrain Decision

• Motorcycle Transmission
• Readily Available
• 5-Speed Manual Shift
• Reliable Performance

• ATV Front Differential
• Allows for Independent
• Suspension
• Reliable Performance

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Final Design Construction

• Design
• Frame Analysis
• Construction
• Testing

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Frame Design

• Generate AutoCAD drawing of Existing Frame with
  Motor Drivetrain

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Frame Analysis

• Finite Element Analysis of Frame Simulating
  Impact Forces

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Construction

• Extend Motor Mount Section Directly Behind
  Firewall

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Construction

• Developed New Pedal Arrangement

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Construction

• Developed Shifting Mechanism

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Construction

• Developed Shifting Mechanism

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Construction Complete

• Finished With Major Construction Two Months
  Prior To Event

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Drivetrain Design

• Engine
• Sprockets
• Transmission
• Coupling
• Differential

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Engine

• Briggs Stratton Intek 20
• Model No. 205432
• 10 Horsepower Maximum
• 13.75 ft-lbs Torque Maximum
• No Modifications Allowed
• Donated by Briggs Stratton

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Sprocket Assembly

• 17 tooth 16 tooth Sprockets
• Design allows for alterations to gear ratio
• Power loss is minimized with chain

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Transmission

• Yamaha 400 Motorcycle
• 5-speed Manual
• Reliable and Durable
• Widely Available
• Heavy Duty For Race Durability

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Transmission/Differential Coupling

• Fabricated Steel Coupling
• Transmission to Differential
• Connection
• Allows Imperfect Alignment
• Prevents Motor Binding
• Simple Yet Effective

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Differential

• Honda Front Differential
• Proven Tough And Reliable
• Widely Available
• 81 Gear Reduction

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Testing
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Testing,
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Testing,
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And More Testing!
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THE END
ANY QUESTIONS?