Event Report

Formula Bharat 2020

 To the future team and everyone
associated with TVP4.0

2
TVP4.0 thevayuputras.com
 Table of Content
List of images…………………………………………………………………………………04

Acknowledgement……………………………………………………………………………05

Formula Student (FS)/FSAE………………………………………………………………….06

India and Formula Student……………………………………………………………………07

About the Team………………………………………………………………………………10

Main event: Formula Bharat 2020……………………………………………………………16

Lesson Learnt………………………………………………………………………………...25

Area of Development………………………………………………………………………....26

Technical Errors Pointed at TI………………………………………………………………..27

3
TVP4.0 thevayuputras.com
 List of images
The Vayuputras at Kari Moter Speedways 05

Team The Vayuputras with TVP4.0 09

Team Structure 10

Electrotherm logo 12

Education USA logo 12

Zydus logo 13

Lyka Laser Tech logo 13

Vehicle at photography submission 14

Vehicle at videography submission 15

Entrance Gate at FB 2020 16

Registration Desk at FB 2020 17

Team going for Technical Inspection 18

Cost Report going on the Pits 19

Design Report of team Vayuputras 20

Vehicle Design Explanation to Technical Judges 21

Technical Inspection line-up Photo 1 22

Technical Inspection line-up Photo 2 23

Kari Motor Speedway 24

4
TVP4.0 thevayuputras.com
 Acknowledgment
Team TheVayuPutras would like to thank everyone involved in this year’s project. Without the
significant contributions made by our alumni and sponsors, the students, staff, and faculty of
Indus University, the program would not be made possible this year. We would like to
individually thanks Prof. Tejas Raval (Faculty Mentor) for his immense support and dedicated
time throughout the session, it was under his mentorship and guidance that the team performed
well in the event. , Dr. Suketu Jani (HOD, Automobile) for his priceless guidance, K.S.R
Swamy Sir, and Hemancy ma’am from the T&P department for their support and Dr. R.K
Singh Sir(Registrar) to always believe in students and supporting them from the very inception.
You were always a motivation. Also, A huge thanks to Anshul Bhavsar Sir from the IT
department along with students from the IU design department. We would further like to
express our gratitude to Dr. Umang Patdiwala (HOD, Mechanical) and the whole mechanical
department to permit us to work in their respected workshop. We would also like to thank
Bhanu Pratap Sharma (HOD, Architecture) and his entire department to let us have a hand at
their 3D printer. We would like to express our humble gratitude to Mr. Viren Sir from Lyka
Laser Tech for dedicating his workshop to us and always cheering for us in hard times. A huge
Thanks to Mr. Hardip Sir from PowerPistons for always being a helping hand for us. We would
like to thank Electrotherm, Education USA, and Zydus Wellness for their role as our proud
sponsors’.We would like to thank the whole Indus Family without whom we would have hardly
reached where we are today.

Finally, we would like to thank everyone who believed in us.

The Vayuputras at Kari Motor Speedways

5
TVP4.0 thevayuputras.com
 Formula Student (FS)/FSAE
What is FSAE?
Formula SAE® is a student design competition organized by SAE International (Formula
Society of Automotive Engineers). The first competition was started back in 1979 after Mark
Marshek, then at the University of Houston (Texas) contacted the SAE Educational Relations
Department in 1978 to discuss adding a variant event of the Mini Baja; the name Mini Indy was
founded. As many organizers have found, the work in building a car can be exceeded only by that
to organize the event; 1980 failed to produce an organizer. Having seen the potential of the event,
Mike Best, Robert Edwards, and John Tellkamp, students at the University of Texas at Austin,
approached Dr. Ron Matthews with an idea - how about another Mini-Indy, but with some changes?
Make the rules more open; let it be as unlimited as possible. It was desired that this new competition
would take the cars to the next level of engineering. The Baja competition was great for chassis
design, but many students wanted to work on engines as well. The new rules would keep engine
restrictions to a bare minimum. Any four-stroke engine was allowed for the first four years with
power limited by a 25.4 mm intake restriction.
With grassroots support from his students, Dr. Ron Matthews contacted the SAE
Educational Relations Department and set the wheels in motion. To differentiate this new event
from the Mini-Indy, a new name was sought. To reflect better the road-racing nature of the event
and its increased engineering content, the Formula SAE name was adopted.
The concept behind Formula SAE is that a fictional manufacturing company has contracted
a design team to develop a small Formula-style race car. The prototype race car is to be evaluated
for its potential as a production item. The target marketing group for the race car is the non-
professional weekend autocross racer. Each student team designs builds and tests a prototype based
on a series of rules whose purpose is both to ensure onsite event operations and promote clever
problem-solving.
Formula SAE promotes careers and excellence in engineering as it encompasses all aspects
of the automotive industry including research, design, manufacturing, testing, developing,
marketing, management, and finances. Formula SAE takes students out of the classroom and allows
them to apply textbook theories to real work experiences.
As a student, taking part in Formula Student gives them the chance to demonstrate their
technical, engineering design, and manufacturing skills. They will also learn important lessons on
team working, time management, project management, budgeting, and presentation: all things that
any prospective employer will be looking for Formula Student graduates also find that the
professionalism they gain as practicing engineers means they are well equipped for their future
engineering careers.
The team is tasked to produce a prototype for a single-seat race car for autocross or sprint
racing, and present it to a hypothetical manufacturing firm. The car must be low in cost, easy to
maintain, and reliable, with high performance in terms of its acceleration, braking, and handling
qualities. During the competition, the team must demonstrate the logic behind their proposal and
must be able to demonstrate that it can support a viable business model for both parties.
Today, the competition has expanded and includes several spin-off events. In the United
States, there are two locations: California and Michigan; Michigan being the largest event and
longest-running.

6
TVP4.0 thevayuputras.com
India and Formula Student:

FSAE/FS started in 1981 in the United States of America under the Society of Automobile
Engineers. It took 30 years for a team from India to get to that platform and showcase Indian
Engineering at such an event. FSAE/FS is all about learning and experiencing what it will be
like to work in a real-world scenario, thus the most important lesson is to learn from
yours/other's previous mistakes and ensure you do not repeat them. Some of the first teams to
be formed in India were:

1. Defianz Racing, Delhi College of Engineering - 2002

2. Ashwa Racing, RCVE, Bangalore - 2005

3. Orion Racing, K. J. Somaiya, Mumbai - 2007

4. Formula Manipal, Manipal University - 2008

By this time there were a few participants from India in various parts of the globe. Till
then there was no good show by any Indian team at such a major event. Reasons were still
unknown but a lot of teams were to follow the path shown by these few teams. Orion Racing
India and Ashwa Racing were making better progress than other teams, but their progress went
up to the mark to deliver a car that could compete against the Universities from Germany or
the USA.

With Consecutive failure of Indian Teams an International Judge, Pat Clarke once
posted over FSAE forums; “In a discussion with Steve Fox on how our 1st car will be if we
were Indian team, we concluded that we would build a car that would pass all the requirements,
would finish all events and would not finish last for just 2000$. It would not be pretty and it
would not have any unobtanium or unavailable on it. It would roll on street wheels and Tires
….. but it would ROLL!!!!”.

This was the start of a new Era with students now having an inspiration and a goal for
how the 1st car should be. On the other end an affiliate body to SAE International, namely
SAEINDIA after the successful start of SAE India BAJA, started their discussion on having an
Indian Version of the International FSAE Competition under the Name „SUPRA (Super
Racing) SAE INDIA‟. After a couple of meetings and discussions on the framework, safety,
and flow of the event, the hard work of Prof. Sudhir Gupte & SAE India President Mr. M. S.
Kumar's first-ever Indian Formula Collegiate Series Competition took shape. The 1st Virtual
SUPRA was organized in 2009, where 28 teams participated in the final race event held at
Madras Motorsports Race Track, Chennai in 2011. The event was not compliant with the
International Rules but served as a good platform for young teams to get in. Supra SAEINDIA
was highly criticized for being unsafe and uneducated because of its framework and not
meeting up the standards of other FSAE/FS events internationally. Here was where Indian
“Jugaad Engineering” was challenged to be converted into “Pure Engineering”. Some took

7
TVP4.0 thevayuputras.com
the ownership to perform better and started working on the same but on the other end No. of
teams rose exponentially and the same issues continued. No successful car yet.

After nearly 10 years, in 2011, the team IIT Roorkee Motorsports developed a car and
represented India in FSAE Australasia 2011 competition held in Melbourne, Australia, and
became the first-ever car from India to complete the 22 km endurance race, The team also stood
1st in Efficiency.

Over the years some well engineered cars were going to international events like the
UK, Germany & Italy. Teams like Orion Racing, Pravega racing, Formula Manipal, Raftar
Formula racing, etc raised the Indian flag internationally. Pravega Racing, Vellore was the first
team to grab awards at an international event. 3rd in Manufacturing and Cost Event, FS Italy-
2012, 2nd in Manufacturing and Cost Event, FS Italy-2013. This was just the beginning,
students of India hope to see a podium finish by an Indian team soon in the near future. In 2017,
the 1st season of FORMULA BHARAT with 73 teams from across India took place at Kari
Motor Speedway, Coimbatore in January. Seeing the concern issues with Supra SAEINDIA
the international competition (FSAE/FS) was also introduced to India under the name Formula
Bharat (FB). The event followed the strict norms of the international rulebook and proved to
be a good learning experience for teams that could not travel to these foreign destinations. After
the US, India is the second country to have two such events happening in a year.

In July 2017, the 6th edition of SUPRA SAEINDIA 2017 was held at Buddh
International Circuit, Noida from 26 June to 1 July where 126 teams from various engineering
colleges from all over India had participated. 111 teams had registered onsite with their vehicles
to participate in the event.

8
TVP4.0 thevayuputras.com
Season 2020
TVP 4.0.

Team The Vayuputras with TVP4.0

9
TVP4.0 thevayuputras.com
About the TEAM
THE VayuPutras the name itself represents energy, speed, and enthusiasm. With an obsession to fly high
and settle for nothing less than the excellence itself.

Team Vayuputras is one of the best teams in India filled with young engineers carrying out the legacy and
motto of "A Team of undying spirit”.

For the past 3 years, our team with students drawn from a cross-section of semesters is working on building
a bespoke single-seat racing car to participate in Formula racing events like SAE SUPRA and Formula Bharat
to expose our inherent talents and skills to the automotive world.

The new phase of TheVayuPutras started to take its form after its previous participation in SAE Supra 2019.
The team was eager to expand its boundaries by recruiting a new batch of students willing to take part in
carrying out this legacy.

Team Structure
It needs an efficiently organized structure for any team to function successfully. Resources are pooled and
the skills of the fellow students from various branches are combined. The team is divided into
departments including Management, Powertrain, Body, Aerodynamic, and Suspension. These
departments are split again into different categories.

Team Structure
10
TVP4.0 thevayuputras.com
 Team list:-
Sr. Name Designation
No
1 Nandish Patel Team Captain
2 Vivek Singh Marketing Head/Planning
3 Tushar Chavda Powertrain/Machining
4 Maanshinh Jhala Design Head/Suspension
5 Vinay Ghevariya Powertrain
6 Arihant Shiju Intake & Exhaust/Cost Report
7 Garv Patel Wheels & Tyre/Manual Machining
8 Harit Trivedi Electrical & Electronics
9 Harsh Jain Fabrication Head
10 Yagnesh Marketing/Finance
11 Keyur Donga Inventory/Cost Report
12 Vishal Tolani Powertrain/Marker Research
13 Vinit Agrawal Suspension/Design
14 Siddharth Gandhi Driver
15 Parth Shah Cost Report/Brake Head
16 Nem Shah Brake
17 Meet Dubey Inventory/Market Research
18 Jeemit Trivedi Marketing/Business Report
19 Mrugesh Desai Electronics
20 Darshil Patel Machining
21 Kevin Patel Steering
22 Harjot Maan Accommodation & Transportation
23 Divyesh Solanki Cooling System
24 Darshan Bhatia CAM
25 Tejas Raval Faculty Advisor

11
TVP4.0 thevayuputras.com
Research and Designing phase was further bifurcated into:
● Chassis
● Engine and Drivetrain
● Suspension and VD
● Brakes
● Electricals
● Steering
● Cooling
● Intake and Exhaust
● Tires

The design and marketing team were set to achieve what we couldn't in the previous
year. The marketing team had their share of success after successfully pitching the
Zydus Wellness group as their major sponsor this year. All along the team was
successful in bagging help from companies like Electrotherm, Zydus Wellness, and
Education USA by an amount of 4.5lac rupees. Also, we got to turn our dream into
reality by the massive support of Lyka Laser Tech, Power pistons, Belts, and Bearing
House.

Electrotherm logo Education USA logo

12
TVP4.0 thevayuputras.com
 Zydus Wellness logo

Learning from the previous events the design team was ready with its new design.
With the help of the Marketing team and team members, the purchasing team was
ready to bring in the required set of machined / OEM parts.

We owe humble gratitude towards Lyka Laser Tech who has continuously supported
us throughout the manufacturing and build of our car. TVP 4.0 had its complete build
and manufacturing at this Laser Cutting specialized industry.

Lyka Laser Tech logo

13
TVP4.0 thevayuputras.com
The build was completed within 3 months. By the end of
November 2019, we were done with the basic build and the testing began.
Finally, the team was done with photo submissions.

Vehicle at photography submission

We weren’t at a good luck point during the video submission due to failure in
transmission. We were penalized for submitting the video submission late due to the
errors which were later resolved with the help of guys from KTM and Power Pistons.

14
TVP4.0 thevayuputras.com
 Vehicle at videography submission

The dawn of Jan 2020 brought with it new hopes for the team. We were finally ready
with our car transported safely to the event place at Kari Motor Speedway,
Coimbatore.

15
TVP4.0 thevayuputras.com
Main Event: Formula Bharat 2020

Day: 1 - 21st January’20:-

The day arrived for what we were striving for. For the past few months. Day 1 for us,
started in a manner no one expected. Traveling to Coimbatore didn't toll us as it
usually does. It was quite the opposite, every one bearing the same expression; the
sheer expression of anxiety and overfilled with energy.
We checked in at our stay; all the way discovering Coimbatore and its perks. Soon
we left for what would become our place of sanctity -"Kari Motor Speedway."
We reached the place and quickly started to unload our car. All the teams that
reached were engrossed for final preparations needed for their cars.
The day winded up with everyone checking out each other's cars and forming the
bond that comes with motorsports culture.

Entrance Gate at FB 2020

16
TVP4.0 thevayuputras.com
Day: 2 - 22nd January’20:-

The next morning, we along with all the teams crowded the registration desk for
further processes needed to finally get us to our respective pits. After all the
paperwork was done, we finally towed our respective cars to our pits, quickly
arranged ourselves with all the tools and equipment. Everyone quickly began
twerking their cars as per requirement. The technical inspection was ahead of us
next. We ended the day at our stay preparing for the static events.

Registration Desk at Formula Bharat 2020

17
TVP4.0 thevayuputras.com
Day: 3 - 23rd January’20:-

Day 3 started with teams lining up with their cars for a photo shoot. After the photo
shoot ended, it was our turn for cost report and presentation.
The judges soon started their way around pits for teams to share their cost reports.
Within a short span of time, we were approached by one of the judges. Our cost
representation started with us giving all the data while being questioned. As time
ticked it got more interesting and we tuned ourselves with the judge who turned out
to be one of the great guys who guided us throughout the process. Soon it all got
over and we were contemptuous with his advice for the future. While the cost report
wound up, it soon brought us our opportunity to present ourselves at the business
presentation.
Suited up with confidence we soon approached the venue where the presentation
was to be pitched. The business presentation started with a good flow of
communication between us and the judges. Being a novice team we surely
faced a bit of difficulty. Answering the hotshots fired by the judges was a task by
itself apart from making them understand our concepts under their given time.
Altogether at the end of the eve, we had ourselves filled with a sense of
contempt. Apart from this the rest of the teams had their hands occupied with
Technical Inspection going on.

Team going for the Technical Inspection

18
TVP4.0 thevayuputras.com
 Cost Report going on the Pits

19
TVP4.0 thevayuputras.com
Day: 4 - 24th January’20:-

As the time for design reports inched towards us, we grew more and more anxious
as to what the consequences of our hard-work would bring us. Finally, we were
encountered by the man himself 'Claude Roulle'. The level of scrutiny was beyond
our experience and imagination. His questionnaire made us aware of our mistakes
and helped us to view the bigger picture of the future. To sum it up, the design
report helped us to set our perspective more focused on perfection for the next
time.
At the other end, we faced hard-luck clearing our technical inspection. We couldn't
end our day as it was supposed to. The next day was the last day for us to have a
final technical inspection. We had to add some changes to our car for us to clear
our technical inspection. So we transported our car to a nearby workshop where
we could amend it. It was going to be a long day for us. Some of the teammates
spent all night and the next whole day preparing for the one last try at our TI.
Coimbatore does bring with it a sense of calmness which aided us in those tense
moments.

Design Report of Team Vayuputras

20
TVP4.0 thevayuputras.com
 Vehicle Design Explanation to Technical judges

21
TVP4.0 thevayuputras.com
Day:5 - 25th January’20:-

Day 4 didn't end well which continued for us. Finally, early morning the car was
transported back to the pits with all the teammates. The car was taken to the
technical inspection area and finally!!!! We could clear our technical scrutiny. The
joy on everyone's faces was clear.
But owing our debt to luck, we failed the tilt test!
The issue according to them was our Non-Return Valve (NRV). So they had to
scrutinize us again and due to this new unexpected issue, we couldn't make it
through.
The sense of despair among us was just indescribable. After what we had gone
through… after all the toiling we couldn't clear technical inspection which meant we
couldn't proceed for the dynamic events for which we were prepared.
Soon we accepted this dire situation of ours and came through the conclusion
that not everything can make through only with sheer hard work. Luck counts!

Technical Inspection Line

22
TVP4.0 thevayuputras.com
 Technical Inspection Line-up photo 2

23
TVP4.0 thevayuputras.com
Day: 6 – 26th January’20:-

Although we couldn’t make it through to the track, we did enjoy the ultimate pleasure
any motorsports has to give an automobile enthusiast. After all the events wrapped
up, we loaded our car in the truck to safely return to Ahmedabad. Altogether it was
a hell of an experience for all of us. The team is currently working on for the next
Formula Bharat i.e. FB2021

Kari Motor speedway

24
TVP4.0 thevayuputras.com
 Lessons Learnt:
1. Do not listen to people who say you can’t do it.
2. A Motivated team can overcome the highest bureaucracy.

3. Don’t Stick with Plan A for the event site. Consider Contingencies and Keep a backup plan
ready for possible Breakdowns.

4. Stay Updated with the rulebook. There can be slight changes in the rules each time and can
cause serious damage.

5. Hard work always pays off. Don’t lose hope until the last moment.
6. Keep the whole team intact. Stay in touch with senior members and carry along the juniors
with you.

7. Documentation. Every minute detail should be documented and maintained well be it

Design Decisions, Fabrication, Marketing, or Management.

8. Focus evenly towards Static Events along with the Dynamic events. They can cause a huge
difference in overall Standings. This is an Engineering Design Event and not a Motor
Racing Event. Focus more on learning than Competing.

9. Practice makes a Machine Perfect. Test the Vehicle in similar track conditions. All failures
must happen in the testing phase only. More Testing will give you more data for
improvements.

10. Segregate the Cost Report into multiple parts and mark the Key Components for easy access
during the presentation.

11. Dedicate few Students for Static Events well in advance. They are Cash points no matter
how your car is you can score maximum in this.

12. Don’t get carried away. Follow protocols strictly and ensure safety.

13. Every part including the last NUT & BOLT must be modeled in CAD.

14. Launch Event must be decided a month in Advance. Proper management to be ensured by
the team. Don’t miss out on any detail. Invitations to be sent in person and follow up should
be taken.

15. “Straight Trees are cut first”. Avoid Bureaucracy of any level and authority. You might
have a good intention but it can go other ways and shoot against you.

25
TVP4.0 thevayuputras.com
Areas of Development for Team VayuPutras
Below mentioned is a list of problem statements or new areas where the team will be working
and need helps from other faculties and Industry:

1. Design & Development of Engine Air Intake System for Formula Student Vehicles.
2. Design & Development of Engine Exhaust System for Formula Student Vehicles.
3. Mathematical Modelling of Engine for better understanding & simulation of designs.
4. Development of lightweight and high Thermal Efficient Water cooling system for the KTM
390 engine.
5. Understand and implement new-age materials like Plastics and Composites in
Manufacturing of vehicles.
6. Understand and implement modern Race Car Aerodynamics to upgrade the performance of
the vehicle.
7. Train Students on Computer-Aided machining & Gain hardware help from the industry for
the same.
8. Understand and learn various Load Case Scenarios for Analysis and Validation of designed
components.
9. Design and develop a custom wiring harness for the vehicle.
10. Custom ECU Programing and Engine tuning using an Engine Dynamometer.
11. Live Time Data Acquisition for Engine & Vehicle Performance.
12. Design & Development of Electro-Pneumatic or Electro-Magnetic Gear Shifter for the
vehicle.
13. Incorporating Tyre Data for deriving actual load cases acting on the vehicle.
14. Developing a functional simulation of Aerodynamic package which will include front wing,
rear wing, and diffuser. This will further aid in achieving higher cornering speeds.
15. High weight reduction in the outboard department by reducing rim size and tire size. Thus,
decreasing the unsprung mass.

26
TVP4.0 thevayuputras.com
 Technical Errors Pointed at the TI

1. Pressure Sensor & T joint in Impact Zone

2. NRV not working properly
3. Sharp Edges on Nose cone
4. Exhaust Shielding
5. Lap belt not properly routed
6. Gaps in firewall
7. A specific type of hose clamp for holding pipes

27
TVP4.0 thevayuputras.com