Powertrain & drivetrain design report

Introduction

A powertrain is essentially the entire system that generates power in a vehicle and transmits it to the
wheels.

The powertrain, which typically consists of the engine, clutch (if applicable), and drive system (chain
or belt and sprockets) in a go kart, is crucial for its performance. It directly affects how much power
gets to the wheels and ultimately determines a kart's acceleration, top speed, and overall handling.

A well-tuned powertrain translates engine power into efficient forward motion, allowing you to
achieve quicker bursts off the line, maintain speed on straights, and power through corners.

In essence, it's the heart of the go kart, responsible for translating the driver's input into exhilarating
performance.

Engine

 Criteria considered for selecting engine:

 Displacement
 Ignition system
 Cooling system
 Fuel system
 Max torque at rpm
 Max power at rpm
 Bore * stroke
 Compression ratio
 Mileage & weight

 After considering these all-technical criteria we selected below five engines:

1. Bajaj pulser 150

 Norm: bs4 (Bharat stage-4)
 Displacement: 150cc
 Ignition system: D-TSI (dual twin spark ignition system)
 Cooling system: air cooled
 Fuel system: carburettor
 Maximum power: 14 Ps at 8500 rpm
 Maximum torque: 13.4 Nm at 6000rpm
 Bore x stroke: 57mm x 56.7mm
 Compression ratio: 9.8:1
 Mileage: 45km/l (on paper)
 Weight: 35kg

2. Bajaj discover 150f

 Norm: bs4 (Bharat stage-4)
 Displacement: 144cc
 Ignition system: D-TSI
 Cooling system: air cooled
 Fuel system: fuel injection / carburettor system
  Maximum power: 14.3 Ps at 8500 rpm
 Maximum torque: 12.73 Nm at 6500 rpm
 Bore x stroke: 55mm x 58.8mm
 Compression ratio: 9.8:1
 Mileage: 60km/l (on paper)
 Weight: 40kg

3. Yamaha r15
 Norm: bs4 (Bharat stage-4)
 Displacement: 155cc
 Ignition system: t-ci (transistor-controlled ignition)
 Cooling system: liquid cooled
 Fuel system: fi
 Maximum power: 16.8 ps at 8500 rpm
 Maximum torque: 14.1nm at 7000 rpm
 Bore x stroke: 58mm x 58.7mm
 Compression ratio: 10.8:1
 Mileage: 50km/l (on paper)
 Weight: 40kg

4. Yamaha FZ (old model)

 Norm: bs3 (Bharat stage-3)
 Displacement: 149cc
 Ignition system: t-ci (transistor-controlled ignition)
 Cooling system: air cooled
 Fuel system: carburettor
 Maximum power: 14 ps at 7500 rpm
 Maximum torque: 13.6 nm at 6000 rpm
 Bore x stroke: 56mm x 58.9mm
 Compression ratio: 9.5:1
 Mileage: 35km/l (on paper)
 Weight: 45kg

5. Suzuki gs150
 Norm: bs4 (Bharat stage-4)
 Displacement: 149cc
 Ignition system: t-ci (digital capacitor discharge ignition)
 Cooling system: air cooled
 Fuel system: carburettor
 Maximum power: 13.8 Ps at 8500 rpm
 Maximum torque: 13.4 nm at 6000 rpm
 Bore x stroke: 57mm x 58.6mm
 Compression ratio: 9.35:1
 Mileage: 50km/l (on paper)
 Weight: 40kg
 Final selection of engine
After comparing this all engines which are acceptable and fitted in FKDC criteria, We
selected pulsar 150-bs4 engine respectively which is perfectly suitable as well as exactly
fitted in our criteria for our go kart as per the rules.

Reasons behind selecting pulsar 150 bs4 engine are it gives high torque and power at low
RPM as compared to other engines. Also, it gives good compression ratio and have fewer
complex systems. Which includes ignition system, fuel system and the cooling system.

Our engine size is approx. 15 inch * 13 inches

 Position:

Position for an engine in a go kart depends on a few factors, but generally it should be
mounted with weight distribution in mind for optimal handling.

Weight distribution for best handling, you want roughly equal weight on the front and rear
tires. This allows the kart to corner effectively. Placing the engine too far back throws weight
off balance and hinders turning.

So, our engine is sated at rear right side of go kart. Placing the engine in the rear helps to
achieve a balanced weight distribution between the front and rear wheels, which is crucial for
good handling.

 Calculations:

 Data for calculation:

Engine efficiency: 88%

Chain efficiency: 98%

Primary reduction: 3.47

Wheel radius: 0.14m

Final drive ratio: 35/15 = 2.33

Gear ratios
1st gear 2.92
2nd gear 1.88
3rd gear 1.38
4th gear 1.08
5th gear 0.92

 Equations we are using:

 For torque at wheel:

Tw = engine torque*engine efficiency*chain efficiency*primary reduction*
  For traction force
f(t)= tw / rw

 For angular velocity

w=wheel rpm*2*3.14/60

 For linear velocity

V=w*rw

GEAR NO. Tw F(t) W V(m/sec) V(Km/H)

1ST 272.82 Nm 1948.73 N 28.78 rad/sec 4.02 m/sec 14.74 Km/H

2ND 175.65 Nm 1254.64 N 44.69 rad/sec 6.25 m/sec 22.5 Km/H

3RD 128.93 Nm 920.97 N 60.91 rad/sec 8.52 m/sec 30.67 Km/H

4TH 100.9 Nm 720.76 N 77.87 rad/sec 10.9 m/sec 39.24 Km/H

5TH 85.95 Nm 613.98 N 91.37 rad/sec 12.79 m/sec 46.044 Km/H

 Wheel torque vs vehicle speed graph:

 Calculations for force acting on a go kart:

 Rolling resistance
fr = f*m*g
=23.54 n
 Aerodynamic drag:
fae=0.5pcda(v+vn) ^ 2
=50.92 n
 Climbing resistance
Fa=mgsinθ
=784 n
 Total force:
= fr+ fae+ fa
 =858.46 n

 3d scene / cad model

Transmission

 Introduction:
"Transmission," is a vital part of a vehicle's powertrain. Its job is to regulate the power
delivered from the engine to the wheels.

By adjusting gear ratios, the transmission allows the engine to operate at its most efficient
rpm (revolutions per minute) for the desired speed and conditions. In some gears, the
transmission can multiply the engine's torque, providing extra pulling power for starting or
climbing hills. Neutral gear allows the engine to run without engaging the wheels, useful for
starting the engine or idling.

Transmissions come in various types, such as manual, automatic, continuously variable (c.vt),
and dual-clutch (dct), each offering different characteristics and functionalities. As we have to
be used constant mesh transmission with synchromesh gears.

We have selected manual gear shifting mechanism for our go kart so as to attain high
performance while enduring our go kart. This type of transmission will help to generate speed
and acceleration as per our need by shifting the gears.

 Selection of transmission selecting mechanism

In a manual transmission vehicle, the shifting mechanism translates the driver's input from the
gear shifter to physically change the gears engaged within the transmission.

 Shifting mechanism
We selected a four-bar chain mechanism for the shifting of transmission mechanism. This
mechanism gives us the advantage of workability, formability, machinability, leverage, etc.

Leverage works on principle that states, that the force applied (by you) and the distance it
travels (through the lever's movement) is related to the force exerted at the other end (to move
the gear selector mechanism in the transmission) and the distance it travels.
Leverage is the most convincing reason for the selection of above given mechanism.

Drivetrain

 Introduction
Drivetrain is one of the essential parts of your go-kart it delivers your power to your rear axle.
This is achieved by using a chain drive system.

A chain-type drivetrain is a specific type of drivetrain that utilizes a chain and sprockets to
transmit power between components. It's a common and reliable system found in various
applications, from bicycles and motorcycles to industrial machinery.
 Chain-type drivetrains offer a reliable and efficient way to transmit power. Their simplicity,
versatility, and durability make them a popular choice across various applications.

 Selection
A driving sprocket and driven sprocket are both made of material en 8 or en 24 (depending on
the arability).

En 8 high carbon alloy steel which achieves a high hardness with compressive strength and
abrasion resistance and en 24 nickel chromium molybdenum high tensile steel.

Has good wear and shock resistance and is suitable for tensile ranges up to 1550 n/mm2.
These materials are selected as per there specification the driving teeth has 14 teeth and
driven has 33 teeth this provides us the gear ratio of 2.75.

The distance between the driving and driven sprocket are __.

 Material
The material for the hub is aluminium 6083 t5 this was used for its light weight and good
strength compatibility the dimension of the keyway is 6mm length and 6mm breadth ms is
used in key.

The axle used is mild steel and its annealed this provides a good strength to it the diameter of
axle is 30mm and has a keyway for fixing the hubs.

 Calculations

R1 = 138mm d1 = 276mm
R2 = 30mm d2 = 60mm

C = 276 – 60 / 2× cos 75 ˚
C = 216mm

Length of chain = Π (r1+r2) + {(r1-r2)2/c} + 2c

= 3.14(138+30) + {(138-30) 2/216} + 2(216)

= 3.14(168) + {(108) 2/216} + 2(216)
=1013.52mm

Now in inches = 3.14(6.614) + {(4.25) 2/8.50} + 2(8.503)

=39.89 inches
 No. Of links = length of chain/pitch
= 1013.52/12.7 or 39.89/0.5 = 79.78

Considering even no. Of links = 80 links

Actual length of chain = 80/2

= 40 inches = 1016mm

Inner centre distance = {l- Π (r1+r2) – ( Π -2ᶲ)(r1 – r2)}/sinᶲ

= 40”-3.14(5.43+1.18) – (3.14-2(1.30)) × (5.43-1.18)/sin 75 ˚
=17.0261/2(1.931)
cf = 8.81 inches or 223.7mm

 Cad and Ansys of sprocket and sprocket hub, rear axle

Fuel tank

 CAD MODEL:

 SIZE: 22.5 width*30 height * 22 lengths

 Position:

Intake

 Type: carburettor type

A carburettor is a device used in spark ignition combustion engines to control and mix air and
fuel entering the engine.

It operates based on Bernoulli’s principle, where the static pressure of intake air decreases at
higher speeds, drawing more fuel into the airstream. The carburettor contains components
such as a choke, throttle, and fuel feed chamber.

The choke regulates the mixture during cold starts, while the throttle controls the airflow. The
fuel feed chamber ensures the right amount of fuel enters the engine.

 Position
Same as per provided by Bajaj pulsar 150 bike.
Exhaust (pending)

 Selection
The exhaust system on go kart is designed to efficiently remove exhaust gases while reducing
the backpressure. This uses single exhaust pipe design. The exhaust system is attached to the
kart to support it.

Heat shields may be present around the exhaust pipe to protect nearby components from heat.

 Material: SS 304:

 Criteria for selecting:

• Availability
• High temp. withstands
• Corrosive resistance
• High ductility
• Spinning and bending properties
• Non-magnetic
• Low carbon content
• Less carbide precipitation
• Rate:
• 265/kg plain sheet
• Melting temp.: 1400–1455-degree Celsius
• Withstand temp.: 300-500 degree Celsius
• Muffler material:
• Ceramic wool:
• Lightweight
• Low thermal conductivity
• Withstand temp. – 1300 degree Celsius
• Low thermal shrinkage at high temp.
• Easy to cut

Temp. points in an exhaust:

Exhaust port:

Design of bend pipe need to be good for smooth flow, maximize horsepower & torque.

Compatibility with muffler size is very important.

Pressure in exhaust is not more than 10% set pressure.

Generally allowable back pressure is 1 to 2 psi

Battery

 Type:
 Our go kart is equipped with a 12V, 8A LA (Lead-Acid) battery. This type of battery provides
reliable starting power for the go kart self-electric start system.

 Position
The position of the battery in a go-kart can significantly impact its performance.
In our go kart our battery placed at lower right side of a seat.