PRODUCT DESIGN SPECIFICATION

CONTENTS

1. Foreword
2. Introduction
3. Scope of the Project
4. Body of the PDS
4.1. Performance Requirements
4.2. Manufacturing Requirements
4.2.1. Material Requirements
4.2.2. Engine Requirements
4.2.3. Assembly
4.3 Accepted Standards
4.4 Disposal
4.5 Operational Requirements
4.2.4. Installation
4.2.5. Use
4.2.6. Maintenance
4.2.7. Safety
5. Appendix
6. References


1. Foreword

Evidently in the past few years, an appreciable number of mass transportation modes are being used in practice. Investigation on the problems faced by the people and the performance of these modes, reveal that an efficient and economic means of mass transport is yet to be designed. The drawback shows a direct impact on all standards of people in the society and our existing surrounding, which intends to convey that, our environment is polluted and the dependent people are expected to get satisfactory results.

2. Introduction

This project has been taken up in order to fulfill certain requirements of the people in an eco-friendly and an efficient way.

The objectives of this project are:

i. To design a environment friendly mass transportation.
ii. To design the mode which would be faster in exhibition of it’s purpose and provide satisfactory results to most of its users.
iii. To make sure that the range of accessibility of the mode is affordable by all standards of people.
iv. To facilitate, the existence (lifespan) of the product is well above average.


3. Scope of the Project

i. The final product can be used as a means of convenient public transport in many countries across the world.
ii. The concept of using hydrogen generated from other sources other than fossil fuels will fetch more importance.


4. Body of the PDS

4.1. PERFORMACE REQUIREMENTS

i. The vehicle must provide comfortable seating arrangements for at least 100 people.

ii. The fuel which is used should be efficient in comparison with the fuel used in the existing vehicles.

iii. The efficiency of the fuel should be about 60%.

iv. If the vehicle loses its path and meets with an accident there are emergency breaks provided in every compartment and emergency exits. Efficient compartment separators are required when there is mishap in next compartment.

v. Even under high temperature conditions, the vehicle should have proper air conditioners. Instant heating and cooling must be possible and the bus temperature must be maintained constant at comfortable temperatures during varying seasons.

vi. The weight is sufficient to hold the vehicle intact on road.

vii. The product should use efficient fuel.

viii. The appearance of the vehicle must be sharp and appealing to the mass.

ix. The colors used should be able to prevent corrosion and make the vehicle look attractive at the same time.

x. There should be a ticket counter at the entry itself. Passes must have an electronic equipment to confirm their validity and originality.

xi. The vehicle, under proper maintenance, should be intact for about 15-20 years.

xii. The vehicle must have emergency first aid kits easily available to the passengers in any case of small accidents inside the vehicle like a person falling down and so on.

xiii. The optimum working temperature would be 25 degree Celsius. But, it should be able to withstand a temperature of anything between 10 and 45 degree Celsius without facing any problems.

xiv. The seats should be very comfortable. The materials from which they are made must be soft yet durable. They should have low maintenance costs.

xv. The height of the vehicle is around 7-7.5 ft, using of standing steel rods within the vehicle, display boards which shows details about next stop or any advertisements. The announcements will be made in both regional and standard languages.

xvi. The vehicle must always be on time . A list of the vehicle's arrivals and departures and their respective timings should be displayed at every stop making it convenient for the passengers to travel. Delays in any case should be updated at these stops.

xvii. The quality of raw materials used for building the vehicle must be good, and they must be strong, eco-friendly, and bio-degradable.

xviii. The noise generated by the vehicle while driving should be as low as 60-65 db. This is a very comfortable loudness level and will considerably reduce the amount of sound pollution due to traffic when achieved.

4.2. MANUFACTURING REQUIREMENTS

Working:

Fuel: Hydrogen fuel

Intake: Hydrogen combines with oxygen from air in the engine ( hydrogen gas filling station for obtaining fuel)

Emission gases: water. Thus being eco-friendly .

This is because hydrogen combines with oxygen to form water.

2 H2 + O2 → 2 H2O

4.2.1. Material Requirements

Aluminum sheet metal: Aluminum is a soft and ductile metal. The strength, light weight, coupled with its corrosion resisting properties renders aluminum suitable for fabrication of automobiles.
Thickness: 3 mm.
Paint: Berger paint (stoving method).
Epoxy Coating: To absorb heat radiations and provide cool temperature. (Thickness: 0.5 - 1 mm)
Head light: High beam and low beam.
Indicators: Right and left indicators.
Tyres: Radial tyre with shock absorbers. Beloth rubber is covered on the shock absorber as the outer covering.
Windows: Glass and steel rods are used.
Glass: Toughened glass of thickness 3 - 4 mm.
Steel rods: Coated with white paint to avoid corrosion. (Thickness: 15 mm)
Windshield: It is made of glass and rubber to make it tougher.
Doors: Automatic doors are used. Totally 4 doors are used, two doors for entry and exit and the other door for driver.
Emergency exit provision is also provided at the back side of the vehicle.
Rear view mirror: Concave mirrors are used for higher viewing range.
Gears: The gears used are made out of steel because of their strength.
Horn: Loud and clear sound.
Wiper: A wiper generally consists of an arm which is strong and rubber used has maximum plasticity.
Seats: Coir or thermoses balls can be used, which are eco friendly.
Rods: Vertical and horizontal rods are fixed inside the vehicle to hold. These rods are made of steel and coated with paint (Color: green) or powder coating (long lasting).
Power steering: PVC coated steel is used in the manufacture of steering. Power steering is used in order to make the movement of the steering easier.
Ventilators: These are located on the roof of the vehicle and it can be opened and closed whenever needed.
First aid box in both compartments.
Floor carpeting, drinking water, magazines can be provided to make the passengers comfortable. LCD display
Brake pad, brake lining and brake caliper are used.

4.2.2. Engine Requirements

Hydrogen Internal Combustion Engine:

Exhaust valve, valve seal, valve guide, shim, roller guide, lube oil, roller tappet, keeper, spring, spring, spring seat, intake main fold, valve seat, Cylinder, Hardened valves, strong connecting rods, spark plug, ignition coil, fuel injectors designed for a gas instead of a liquid, larger Crankshaft, piston made out of string material so that the impulse of expanding gas is converted into mechanical energy.

Piston rings made to maintain the pressure, flywheel designed for storing maximum energy storing device. Stronger head gasket material, positive pressure supercharger and high temperature engine oil.

4.2.3. Assembly

The batteries of the engine should be prepared first. Other parts of the engine should be manufactured and assembly of the engine should take place. This should not take more than 10 days including the manufacturing of all the batteries and other parts.

Next the parts related to driving should be assembled. This should take less time, not more than 7 days as it just requires the assembling of the already sourced parts.

Next the whole body of the vehicle should be constructed. The vehicle will have two compartments. Devices used to join the compartments should also be very strong and preferably made of iron. This will take about 7 days.

The proper positioning and constructing of windows will be the next process which will take about 3 days.

The next step would be setting of seats firmly on the floor of the vehicle. The vehicle will have two columns of seats; each row will have two seats in it. Each seat will have two arm rests. Each compartment will have 2 columns. Each column will have 13 rows. This will take around 7 days.

Now, installing of steel rods vertically from roof to the floor and horizontally from the front end to the back end of the vehicle to lend support to the people who are standing is the next step. Later comes the painting of the outer body and placing all sign boards.
Finishing process:
This needs to test on a testing road. After the test, the machine should be certified. If any malfunction, the vehicle should be sent back manufacturing industry.
Delivery date:
It can be fixed around 2 and half months away from the date of manufacturing.
Packing and shipment:
SUV cab covers are used with tough ending if required. These covers block harsh UV rays and bad weather. For the transportation of the vehicle heavy machines are used or they are driven to the destined places by skillful driver.

4.3 ACCEPTANCE STANDARDS

i. All the machine parts are inspected separately prior to assembly. All the products should meet their acceptance standards respectively.
ii. The products should follow alll the national, international or company standards.
iii. Noise level is below standard i.e. 90db. The material which comes in contact with human isn’t harmful. Ph of the material is around 6-7.5.
iv. The emission of combustion gases shouldn't cross the minimum pollution level. The gases shouldn't be hazardous.
v. The emission of 'smog', nitrous oxides, hydrocarbons, soot etc gases released are in limits such that it doesn't harm health of mass and pollute the environment.

4.4. DISPOSAL

i. The product after its life span should be reusable. Practically there can be no end for the product.
ii. In advertising the product companies various disposal methods are highlighted.
iii. Company’s legal policies are followed so that the solid waste is treated properly and then released to environment.
iv. The material such as steel, iron, cast iron etc are melted and reused for making the parts again.
v. The direction for the proper disposal of the parts, which cannot be recycled, should be clearly mentioned.
vi. HC(Hydrocarbons), CO2 and CO is reduced with increase in hydrogen combustion. But Nitrogen oxides emission will gradually be increased using a catalyst convertor even these oxides can also be decreased extremely low, finally zero emission standards is reached.

4.5 OPERATIONAL REQUIREMENTS:

Installation:

Instructions for installation of the various parts like
i. The parts of internal combustion engine.
ii. The parts related to the driving of the vehicle.
iii. The body of the vehicle (including compartments, seats, and so on).
iv. The wheels of the vehicle.
v. The windows, ventilators and other body related parts will be provided during the assembly itself.

Use:

i. The vehicle's cost might range from 4-5 lakhs.
ii. Coming to the use of the vehicle, the drivers will attend a learning course as usual to learn driving. This implies that instructions regarding the driving of the vehicle are not necessary.
iii. The instructions to use the first aid boxes and compartment separator in each of the compartments will be specified.

Maintenance:

i. The routine maintenance will include regular cleaning of the vehicle with soap water to maintain hygiene.
ii. Once in a month servicing of the vehicle will include oiling of the part that experience friction, cleaning of the internal parts of the vehicle like the engine parts, parts related to driving and so on. This will require a proficiency in the mechanical aspects of the engine as it requires dismantling of the various parts.
iii. Apart from the above instructions, an operational and user manual will also be supplied by the manufacturing company.

Safety:

i. In case any compartment catches fire, the instructions to use the available fire extinguisher along with the first aid kit will be specified on it.
ii. The separators will provide complete safety when required in case of an accident in a compartment or the whole vehicle.

5. APPENDIX

A short note about the concept of using hydrogen as fuel has been provided in this section.

A hydrogen internal combustion engine (HICE) vehicle is an alternative fuel vehicle which uses hydrogen as its main fuel. Hydrogen is basically an energy carrier and not an energy source in the form of a gas. In vehicles that consume fossil fuels, a lot of exhaust gases are released at the time of propulsion and gradually even during the running of the vehicle, which pollute the environment. But in HICE, Carbon-di-oxide and other gases are not released at the time of propulsion and even during the running of the vehicle.

The engine used in the product is a conventionally driven HICE.


6. REFERENCES:

Internet.
Books.
Suggestions from professors at Indian Institute of Science and MSRIT [Chemistry Department].
Referred the PDS format from the book Engineering Design Principles by Ken Hurst.

DONE BY:

Archana K 1MS09IS016

Padmashree Bhat 1MS09IS062

Reshma R 1MS09IS076

Sandhya V 1MS09IS082

Sangeetha K J 1MS09IS083

N Shashwathi 1MS09IS057

Sheetal Monica 1MS09IS087