Amrit Dhungana

BAJA e-ATV Vehicle “NYAPOLLO”

Project Overview

The Nyapollo ATV is a single-seat, off-road electric recreational vehicle developed for the BAJA SAE India 2021 competition. This collegiate event challenged engineering students to design and build vehicles adhering to stringent SAE guidelines. The Nyapollo was designed with a focus on safety, durability, and performance, ensuring its ability to withstand rugged terrains while providing rider comfort and maintaining optimal traction.

Sales Presentation Award

The Nyapollo ATV project also won the Sales Presentation Award at the competition for presenting an excellent sales and financial projection strategy. The detailed financial analysis, market positioning, and cost-effectiveness of the vehicle impressed the judges, highlighting its potential as a sustainable and market-ready product.

Key Features and Specifications

1. Technical Specifications

  • Ground Clearance:
    • Front: 350 mm
    • Rear: 285 mm
  • Wheelbase: 58 inches
  • Curb Weight: 205 kg
  • Motor:
    • Rated Power: 4.5 kW
    • Peak Power: 9 kW
    • Maximum Torque: 29.5 Nm
  • Battery:
    • Capacity: 100Ah
    • Fast charging capability
  • Braking System:
    • Hydraulic brakes with 220 mm (front) and 200 mm (rear) disc rotors
    • Pedal ratio: 6:1
  • Suspension: Pneumatic shock absorbers

2. Performance Targets

  • Top Speed: 60 km/h
  • Turning Radius: 2.8 m
  • Impact Resistance: Withstands a drop from 3 meters without significant damage
  • Battery Range: Operates for at least 2 hours at 80% Depth of Discharge (DOD)

3. Vehicle Features

  • High Ground Clearance: Suitable for rough terrains.
  • Emission-Free Operation: Electric drivetrain ensures zero emissions.
  • Lightweight Design: Optimized weight without compromising durability.
  • Ergonomic Driver Safety Features: Enhanced safety for the driver with careful design considerations.

Design Validation and Testing

  • Crash Test: Simulated using Ansys, ensuring structural integrity during collisions.
  • Brake Test: Achieved a stopping distance of 8 meters at 45 km/h.
  • Battery Range Test: Successfully maintained 2 hours of operation under off-road conditions.
  • Gradeability Test: Smooth uphill performance demonstrated on 35° slopes.

Challenges and Solutions

  • SAE Compliance: Ensured all dimensions, weight, and safety features adhered to guidelines.
  • Weight Optimization: Balanced performance and durability while keeping the overall weight within the 205 kg limit.
  • Durability Testing: Simulated extreme off-road conditions to validate vehicle resilience.

Responsibilities as a Mechanical CAD Designer

  1. Roll Cage, Suspension, and Powertrain Design:
    • Designed critical components in SolidWorks with manufacturability and safety in mind.
  2. Material Selection and Weldment Design:
    • Selected materials to enhance structural strength while reducing weight.
  3. Component Integration:
    • Selected purchased components (e.g., wheels and suspension systems) and integrated them seamlessly into the design.
  4. Simulation and Testing:
    • Used Carmaker software to simulate durability, crash scenarios, and hinderances under extreme conditions.
  5. Iterative Design Process:
    • Revised designs based on simulation feedback to optimize performance, weight, and compliance.

Impact and Achievements

  • Successfully adhered to SAE standards, achieving all performance targets.
  • Demonstrated innovation in lightweight structural design and durability.
  • Delivered a high-performing ATV that was durable, emission-free, and efficient for the BAJA SAE competition.
  • Key Milestones Achieved:
    • Improved handling and rider safety.
    • Optimized for endurance and rugged terrain durability.