6 ijaems jul-2015-11-design of a drivetrain for sae baja racing off-road vehicle

International Journal of Advanced Engineering, Management and Science (IJAEMS) [Vol-1, Issue-4, July- 2015]
ISSN: 2454-1311
Page | 27
Design of a Drivetrain for Sae Baja Racing Off-
Road Vehicle
Rishabh Jain1
, Dr. P S Ranjit2
1
Student, Department of Mechanical Engineering, College of Engineering Studies, University of Petroleum & Energy
Studies, Dehradun, India
2
Assistant Professor (Selection Grade), Department of Mechanical Engineering, College of Engineering Studies, University
of Petroleum & Energy Studies, Dehradun, India
Abstract— With growing time, the participation of the
students in SAE BAJA is increasing year by year. The
vehicle’s performance is highly dependent on the
installation and appropriate use of Drivetrain
components. Drivetrain includes powertrain (prime
mover i.e. engine/motor) and transmission components
(gearbox, shafts etc). Therefore, Drivetrain is also called
as the driving force of any vehicle. The proper design of
Drivetrain is thus a part and parcel for any vehicle. The
lack of literature available for a optimize design of
Drivetrain makes it a hard nut to crack for the students
who don’t have any past experience. Thus there is a need
for some source by which the students can learn to design
the Drivetrain for SAE BAJA. The engine vibration is
another aspect which is needed to be considered. NVH
consideration is another deciding parameter in BAJA
vehicle’s performance which if neglected could leads to
lethal results. Therefore proper installation of engine
mounts is required according to the need.
Thus, this segment aims at developing the Drivetrain for
BAJA vehicles which can boost up the performance of the
vehicle. Properly use of a powertrain and transmission
components for a vehicle along with the calculations
according to the need will be discussed in detail. This
segment also aims at developing the conceptual
understanding of the performance parameters of a BAJA
vehicle among the student which will be helpful in their
academic curriculum as well.
Keywords- Baja, Drivetrain, NVH, Powertrain,
Transmission.
I. INTRODUCTON
Due to lack of literature integrity for the Drivetrain
design, one has to explore different section from different
media in order to design even the single useful component
of Drivetrain. This process is time consuming and
extremely difficult to perform. There is a need of platform
where students can learn all the important aspects
regarding the design just like one pit stop for all the
maintenance work. This paper will allow students to
explore and learn all the design consideration and they
can design the Drivetrain of their BAJA vehicle taking
this segment as a useful handbook. The objective of this
paper is to design the powertrain for SAE BAJA Racing
off-road vehicle which should be Light weight, compact
in size and reliable. One of the deciding factors of any
vehicle’s performance is the comfort level of driver,
which comes with the less driving fatigue. The noise and
vibration is another aspect which should be worked on, to
reduce the unwanted stresses in the frame. Therefore,
NVH consideration is must and should be installed
properly. Performance parameters like gradiability,
acceleration, top speed, transmission etc will be discussed
on the basis of their influence over the vehicle under
different conditions and calculations. Various other
components like coupling, half shafts will be selected and
customize according to the need. This paper will include-
selection of Engine, transmission, differentials, half
shafts, CV joint assembly, calculation of reduction ratios
and Engine mounts.
II. POWERTRAIN
The powertrain acts as a power plant for the vehicle. Its
main purpose is to provide the driving torque at the
wheels. This applied torque at the driven wheels causes’
vehicle to move. The power source should be chosen such
that it should be able to provide high torque at low rpm
and peak power at high rpm. For such dynamic
requirement, a stock four cycles, air cooled engine would
serve the purpose. This segment has considered Briggs &
Stratton (B&S) 10 HP OHV intek Engine as a prime
mover/Powertrain. One can choose from different options
on the basis of performance curve of the engine.
Following are the Baja acceptable engine:
20S232 0036-F1
205432 0536-E9
205332 0536-E9
205332 0536-B1
This engine develops maximum torque of 18.66 N-m
at 2600rpm and peak power of 9.14 HP at 3800 rpm.

International Journal of Advanced Engineering, Management and Science (IJAEMS) [Vol
Fig. 1: Torque v/s Engine RPM
Fig. 2: power v/s engine rpm
The engine comes with mechanical governor set at
3800rpm and should not be changed.
connected to the output shaft of diameter 1’’ and
length 4’’.
III. TRANSMISSION
The main objective of the transmission is providing to the
driver more than the enough torque to the wheels from
engine to the wheels. The enough torque means
required to pull the driving wheels against the road loads.
Road loads include rolling resistance (RR)
resistance / air resistance (AR) and grade
(GR).To choose the transmission capable of producing
enough torque to propel the Baja vehicle, it is necessary
to determine the total tractive effort (TTE) requirement of
the vehicle. Let us assume an imaginary v
following specifications and model:
Table 1: Vehicle design criteria
Gross vehicle weight 2648.7N
Weight distribution 35:65(front:rear)
Tire static radius
Dynamic rolling radius
0.2921m
0.283337m
Frontal area 1.055m2
Coefficient of friction µ 1.0(concrete)
Torque v/s Engine RPM
power v/s engine rpm
engine comes with mechanical governor set at
d. The engine is
connected to the output shaft of diameter 1’’ and
TRANSMISSION
The main objective of the transmission is providing to the
driver more than the enough torque to the wheels from
engine to the wheels. The enough torque means the torque
required to pull the driving wheels against the road loads.
(RR), aerodynamic
and grade resistance
To choose the transmission capable of producing
el the Baja vehicle, it is necessary
to determine the total tractive effort (TTE) requirement of
Let us assume an imaginary vehicle with
and model:
Table 1: Vehicle design criteria
35:65(front:rear)
(concrete)
Coefficient of rolling
resistance fr
Students can take their specific values. In this segment, all
the future calculations will be done according to the
above data.
3.1 TOTAL TRACTIVE EFFORT
The vehicle performance is mainly dependent on two
variables: Engine power and Maximum adhesive force
between the road and tires (i.e. µ* load on the driving
wheels, TE Max). The maximum pull is required when
the vehicle is moving uphill at a certain gradient. The
gradiability of the vehicle is decided by the amount of
torque driving wheels can transmit with
maximum allowable tractive effort (TE Max).
wheels have such a torque applied to them that they are
on the point of slipping in the plane of the wheel, then the
value of adhesive force between tire and road surface
been reached (µ*WR), where µ
adhesion between tire and road
weight on the rear wheels. Under these conditions the
engine torque has reached the maximum useful value for
the present set of conditions, as any increase
result in slip and lower acceleration. Static friction is
higher than kinetic friction.
Total Tractive Effort (TTE) = RR+AR+GR
It is suggested to carry out all the calculations on
Microsoft Excel for different inclinations and vehicle
speed. Such set of data will provide the crystal clear
requirement of TTE and the ability of a vehicle to climb
without slipping. The TTE corresponding to maximum
inclination will be taken as maximum torque which can
be applied on wheels by Drivetrain.
3.1.1 ROLLING RESISTANCE
Rolling Resistance (RR) is the force necessary to
propel a vehicle over a particular surface. The worst
possible surface type to be encountered by the
should be factored into the equation.
RR = GVW x fr
Where:
RR = rolling resistance, N
GVW = gross vehicle weight
fr = surface friction (value from Table 1)
3.1.2 AERODYNAMIC RESISTANCE
A moving vehicle, in displacing
has a resultant resisting force called aerodynamic drag
or simply air resistance. It can
force opposing the motion of a vehicle through the air
and the work done in overcoming the force is
ISSN: 2454-1311
Page | 28
0.65(dry road)
0.014(concrete)
0.05(dry road)
can take their specific values. In this segment, all
the future calculations will be done according to the
3.1 TOTAL TRACTIVE EFFORT (TTE)
The vehicle performance is mainly dependent on two
variables: Engine power and Maximum adhesive force
tween the road and tires (i.e. µ* load on the driving
. The maximum pull is required when
the vehicle is moving uphill at a certain gradient. The
gradiability of the vehicle is decided by the amount of
torque driving wheels can transmit without reaching the
maximum allowable tractive effort (TE Max). If the rear
wheels have such a torque applied to them that they are
in the plane of the wheel, then the
value of adhesive force between tire and road surface has
), where µ is the coefficient of
adhesion between tire and road surface, and WR is the
weight on the rear wheels. Under these conditions the
has reached the maximum useful value for
the present set of conditions, as any increase would only
result in slip and lower acceleration. Static friction is
Total Tractive Effort (TTE) = RR+AR+GR
It is suggested to carry out all the calculations on
Microsoft Excel for different inclinations and vehicle
h set of data will provide the crystal clear
requirement of TTE and the ability of a vehicle to climb
without slipping. The TTE corresponding to maximum
inclination will be taken as maximum torque which can
be applied on wheels by Drivetrain.
RESISTANCE
Rolling Resistance (RR) is the force necessary to
propel a vehicle over a particular surface. The worst
possible surface type to be encountered by the vehicle
should be factored into the equation.
RR = rolling resistance, Newton
GVW = gross vehicle weight, Newton
r = surface friction (value from Table 1)
3.1.2 AERODYNAMIC RESISTANCE
A moving vehicle, in displacing the surrounding air,
has a resultant resisting force called aerodynamic drag
It can be expressed as resistive
opposing the motion of a vehicle through the air
and the work done in overcoming the force is

dissipated as energy lost to the air flow.
significance of the aerodynamic
Figure 3: air resistance v/s vehicle speed
AR = ½* ρ* V2
* A *Cd
Where
AR = aerodynamic resistance / air resistance
ρ = air density, kg/m3
, 1.122 kg/m3
V =velocity, m / sec
A = effective frontal area of the vehicle, m
Cd =aerodynamic drag coefficient, 0.44
3.1.3 GRADE RESISTANCE
Grade Resistance (GR) is the amount of force
necessary to move a vehicle up a slope or “grade”.
This calculation must be made using the maximum
angle or grade the vehicle will be expected to climb in
normal operation.
To convert incline angle, α, to grade resistance:
GR = GVW x sin(α)
Where:
GR = grade resistance, Newton
GVW = gross vehicle weight, Newton
α = incline angle, Degrees
H is the gradient resistance force acting downward.
W is the Gross Vehicle weight
K is the component of the GVW acting
to the road surface.
Fig. 4: vehicle on inclined surface.
3.2 PERFORMANCE CHARACTERSTICS
The performance characteristics of BAJA vehicle
strongly depends upon three main factors,
a. Gradiability
dissipated as energy lost to the air flow. The
Figure 3: air resistance v/s vehicle speed
/ air resistance, Newton
A = effective frontal area of the vehicle, m2
=aerodynamic drag coefficient, 0.44
Grade Resistance (GR) is the amount of force
necessary to move a vehicle up a slope or “grade”.
This calculation must be made using the maximum
angle or grade the vehicle will be expected to climb in
resistance:
H is the gradient resistance force acting downward.
K is the component of the GVW acting perpendicular
4: vehicle on inclined surface.
PERFORMANCE CHARACTERSTICS
The performance characteristics of BAJA vehicle
strongly depends upon three main factors, which are:
b. Acceleration
c. Top speed
3.2.1 GRADIABILITY
Gradiability is defined as the ability of a vehicle to
climb uphill at a certain angle without the slip occurs.
It is an important factor which decides the maximum
pulling force that can be
wheels. Generally, the maximum applied torque is not
a deciding factor rather the maximum force that a tire
can transmit is the deciding factor. Maximum gradient
that can be travel is up to when the applied pull is less
than or equal to the adhesive force between the road
and tire, beyond this point slip will occur and there will
be a loss in torque. In general automotive application,
gradiability is define in terms of percentage i.e. 30%,
40% etc. The term “X%” means that vehi
X m distance in vertical direction while moving 100 m
in horizontal direction. For example by term 60%
gradiability, it means that vehicle will cover 60m
vertical distance per 100m horizontal distance. Under
such notation, actual angle of in
α = tan-1
(X/100)
For 60% gradiability, α = 30.96
Thus gradiability can be calculated from the total road
loads acting at different speed a
maximum Tractive force i.e. TE Max.
Considering the worst case i.e. vehicle moving
maximum allowable speed of 55
surface.
RR= 0.014*2648.7 = 37.0818
AR= 1/2 *1.12*(15.27)2
1.055*0.44
GR= 2648.7*sin(30.963) =
(60% gradiability)
GR= 2648.7*sin(34.99) = 1518.9 N
(70% gradiability)
Total Road load (at 60% gradiability)
= 1424.48 N
= 1616.8 N
Since, the maximum gradiability is dependent on the
maximum tractive force (TE Max), which is given by:
TE Max = µ* WR
= 1.0*(2648.7*cos(30.96)*0.65) = 1476.3 N
= 1.0*(2648.7*cos(34.99)*0.65) = 1410 N
From the above two calculations, torque required is
less than the TE Max for 60% gradiability whereas
torque required is more than TE Max for 70%
gradiability.
Hence, maximum gradient this BAJA vehicle can
climb without slip is 60 % i.e. 30.7 degrees.
To climb this gradient, torque required at wheels to
climb 60% gradient at max speed Tw, is given by:
ISSN: 2454-1311
Page | 29
Gradiability is defined as the ability of a vehicle to
climb uphill at a certain angle without the slip occurs.
It is an important factor which decides the maximum
applied by the engine to the
the maximum applied torque is not
a deciding factor rather the maximum force that a tire
can transmit is the deciding factor. Maximum gradient
that can be travel is up to when the applied pull is less
r equal to the adhesive force between the road
and tire, beyond this point slip will occur and there will
In general automotive application,
gradiability is define in terms of percentage i.e. 30%,
40% etc. The term “X%” means that vehicle will cover
X m distance in vertical direction while moving 100 m
in horizontal direction. For example by term 60%
gradiability, it means that vehicle will cover 60m
vertical distance per 100m horizontal distance. Under
such notation, actual angle of inclination is:
α = 30.96o
Thus gradiability can be calculated from the total road
loads acting at different speed and the allowable
maximum Tractive force i.e. TE Max.
Considering the worst case i.e. vehicle moving at
maximum allowable speed of 55kmph on concrete
37.0818 N
1.055*0.44 = 0.712 N
) = 1326.7 N
34.99) = 1518.9 N
60% gradiability)
, the maximum gradiability is dependent on the
maximum tractive force (TE Max), which is given by:
= 1.0*(2648.7*cos(30.96)*0.65) = 1476.3 N
1.0*(2648.7*cos(34.99)*0.65) = 1410 N
two calculations, torque required is
less than the TE Max for 60% gradiability whereas
torque required is more than TE Max for 70%
Hence, maximum gradient this BAJA vehicle can
ut slip is 60 % i.e. 30.7 degrees.
To climb this gradient, torque required at wheels to
climb 60% gradient at max speed Tw, is given by:

ISSN: 2454-1311
Page | 30
Tw = (Total Road Load)* (dynamic rolling radius)
Tw = (1424.8)*(0.283337)
Tw= 403.69 N-m
Low gear is required while the vehicle is moving on
the gradient so that maximum torque can be achieved.
The in ratios of torque at wheels (Tw) and engine
torque (Te) are calculated to find out the overall
reduction required in low gear.
Tw = Te* iglow * ηtransmission
Where
iglow is the overall reduction in low gear
ηtransmission is the transmission efficiency
The transmission efficiency is 92% for manual
transmission whereas it is 75% for Continuous variable
transmission (CVT). This segment is considering CVT
as it has its own advantage which will be discussed
later on.
Therefore,
iglow = Tw/(Te* ηtransmission )
igllow= 403.69/(18.66* 0.75)
iglow = 28.84 = 30 (standardize)
Hence, transmission should be capable of providing
overall reduction in low gear of 30.
3.2.2 ACCELERATION
Acceleration is rate of change of velocity with respect to
time. The change can be either in magnitude or in
direction. In automotive, acceleration is also referred as
the pickup capability of a vehicle i.e. the time required to
attain certain speed from rest. From past experiences, it is
crystal clear that it’s an acceleration which is important
rather than top speed. The acceleration is always
misunderstood. The racing vehicle doesn’t require the
high top speed as the track won’t allow the driver to attain
the wide open throttle position, before that, driver will
encounter the turn and he has to partially close the
throttle. What important is acceleration i.e. how fast you
can attain maximum speed of your vehicle. That’s the
zone which makes a significant difference.
For better understanding, consider two BAJA vehicles A
and B. Vehicle A has more acceleration but less top speed
than vehicle B. Now, during a race, vehicle A will attain
its top speed before vehicle B, and as soon as vehicle B
will attain its top speed, the track will encounter a curve
and vehicle B will not only losses it time to accelerate
again but also will never reach the top speed all the time.
Hence, there should be a optimum selection between
acceleration and top speed.
So far in this segment, one thing is clear, i.e. applied pull
force on wheels should be more than the road loads and
lesser than the TE Max. The difference between the Pull
applied and pull require makes the vehicle to accelerate.
If the applied force is more than road loads, vehicle will
accelerates. If road loads are more than applied force,
vehicle will decelerates. From Fig 1, the maximum torque
is at 2600rpm, so it is understood that maximum
acceleration will attain when the engine will be running at
2600rpm, as maximum pull on the wheel will be at
maximum engine torque.
Low gear is always used for the gradient climbing and
acceleration as the reduction of speed is maximum in low
gear and the pulling force available at wheels is also
maximum, which results in maximum acceleration of the
vehicle.
F = M*a
Where
F is surplus force available at wheels, N
M is the total mass of the vehicle, Kg
‘a’ is the acceleration of the vehicle , m/s2
Calculating for maximum torque at 2600 rpm
Te =18.66 N-m
Iglow = 30
Tw = Te * iglow *ηtransmission
Tw= 419.85 N-m
Pull at wheels Fw = Tw/dynamic radius of tire
Fw = 419.8/(0.283337)
Fw = 1481.62 N
Total Tractive effort required (TTE) = RR+ AR+GR
RR= GVW* 0.05
RR = 132 N (dry road)
GR= GVW*sin(tan-1
(0)
GR = 0 N (0% Gradient track)
Vwheel =( Rw *2*∏*Nengine )/(60* iglow )
Where
Vwheel is the wheel velocity at 2600 rpm
Rw is the dynamic rolling radius of the tire
Nengine is the Engine rpm at Tmax
Vwheel =(0.283337*2*3.14*2600)/(60*30)
Vwheel = 2.5717 m/s2
AR= ½ * 1.12* (2.5717)2
* 1.055* 0.44
AR= 8.069 N
F = (Fw- TTE)
F = (1481.62-(132+0+8.069)
F = 1340 N
Acceleration, a= (1340*9.81)/(2648.7)
Acceleration, a = 4.96 m/s2
Therefore maximum acceleration, vehicle can attain is
0.505g
The acceleration can be increased by increasing the
reduction in low gear, but one has to be careful as
increasing pull on wheels during hill climb may result
into the loss of torque due to slip. Another way of
increasing the acceleration is by reducing weight which is

very important factor and can give you few more seconds
leap in your lap
3.2.3 TOP SPEED
Unlike gradiability and acceleration for which vehicle
should run in low gear, high gear is required in order to
attain the maximum speed. The vehicle sp
increase if the applied pull is more than the road loads and
it will decrease if the road loads are more than the applied
pull. The maximum top speed of a vehicle on a level
ground is dependent upon the rolling resistance,
resistance/aerodynamic resistance, maximum power at the
road wheels and the choice of a suitable final drive ration.
As mention in the earlier section, there is a tradeoff
between maximum speed and maximum acceleration.
Refer to Fig 5 on next page, the upper curve is the powe
at the road wheels and lower curve is the power loss due
to road load i.e. resistance power. The point of
intersection is the maximum attainable speed which is
55Kmph
Fig. 5: power v/s vehicle speed
Taking reference from the Fig 5, if the power curve
shifted left relative to the resistance curve, no doubt that
maximum speed will reduce as the point of intersection
will also shift to left, but in that case the power available
for the acceleration will also increase, and the vehicle will
termed as under gear. Similarly if the power curve is
shifted right relative to the resistance curve,
intersection will be at the peak power, which will increase
the maximum speed but the acceleration will decrease.
And as discuss above, it is acceleration that matters the
most.
The maximum speed is always calculated in high gear at
maximum engine rpm. To attain maximum speed of
55kmph such that:
Vwheel =55kmph =15.277 m/s
Wwheel = Vwheel / Rw
Wwheel = (15.277/0.283337) = 53.92 rad/s
Nwheel = ((Wwheel *60)/2∏ ) = 515 rpm
very important factor and can give you few more seconds
Unlike gradiability and acceleration for which vehicle
should run in low gear, high gear is required in order to
attain the maximum speed. The vehicle speed will
increase if the applied pull is more than the road loads and
it will decrease if the road loads are more than the applied
pull. The maximum top speed of a vehicle on a level
the rolling resistance, air
, maximum power at the
road wheels and the choice of a suitable final drive ration.
As mention in the earlier section, there is a tradeoff
between maximum speed and maximum acceleration.
Refer to Fig 5 on next page, the upper curve is the power
at the road wheels and lower curve is the power loss due
to road load i.e. resistance power. The point of
intersection is the maximum attainable speed which is
5: power v/s vehicle speed
, if the power curve is
shifted left relative to the resistance curve, no doubt that
maximum speed will reduce as the point of intersection
will also shift to left, but in that case the power available
for the acceleration will also increase, and the vehicle will
der gear. Similarly if the power curve is
shifted right relative to the resistance curve, the point of
intersection will be at the peak power, which will increase
the maximum speed but the acceleration will decrease.
n that matters the
The maximum speed is always calculated in high gear at
maximum engine rpm. To attain maximum speed of
= (15.277/0.283337) = 53.92 rad/s
) = 515 rpm
Nengine/ Nwheel = ighigh
Ighigh= (3800/515) = 7.378
Therefore overall reduction in high gear required to attain
maximum speed is 7.378
The graph can be potted by calculating resistance power
Pr, which is (TTE*Vwheel) and power at wheels,
(Fw*Vwheel ). It is recommended to use the Microsoft
excel to plot this graph by calculating different value of
TTE at different Vwheel corresponding to range of engine
rpm Nengine from 2000rpm to 3800rpm.
Note: while calculating TTE
.
3.3 TRANSMISSION SELECTION
The types of transmissions which are very popular among
the BAJA teams are: Manual Transmission and
Continuous Variable Transmission (CVT). Manual
transmission commonly known as gear box
installed and coupled to
transmission is easy and reliable. The top two best suited
gear boxes are Mahindra Alpha and Tata Ace. One of the
biggest disadvantages of manual gear box is the ride
comfort. The driver comfort is compromise and the
fatigue is one of the bad results of using manual gearbox.
To increase the comfortability of the driver which will
leads to increase in vehicle performance, it is
recommended to use CVT which will not only provide
the infinite gear ratios between the low and
also helps in reducing the weight and driver fatigue.
Therefore in this segment CVT will b discussed
However, based on the overall low and high gear ratio
calculated in previous segment, one can select the type of
gear box required followed
ratio which will be discussed later.
3.4 Continuous Variable Transmission (CVT)
The continuous variable transmission (CVT) is plays a
most important part in the performance of the vehicle. As
stated above, the CVT helps in
as there will b no clutch to press, no lever to shift while
changing the gear ration. Thus, it not only save the weight
of other components but also provide the smooth ride by
allowing driver to shift the infinite number of redu
between the low gear and high gear. Low gear is same as
the first gear and high gear corresponds to fourt
gear box. The selection of CVT is also due to the fact that
the shift in speed and acceleration is continuous with
CVT which is in step with gear box. The CVT also allow
the engine to run at peak power which is very much
desirable for the better performance of the vehicle and
good fuel economy of the engine.
3.4.1 CVT SELECTION
There are many manufactures of CVT like Polaris,
Yamaha, Comet, CVTech etc. One can choose from any
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= (3800/515) = 7.378
Therefore overall reduction in high gear required to attain
The graph can be potted by calculating resistance power
) and power at wheels, which is
). It is recommended to use the Microsoft
excel to plot this graph by calculating different value of
corresponding to range of engine
from 2000rpm to 3800rpm.
calculating TTE, take gradiability as 0%
3.3 TRANSMISSION SELECTION
The types of transmissions which are very popular among
the BAJA teams are: Manual Transmission and
Continuous Variable Transmission (CVT). Manual
commonly known as gear box can be easily
nd coupled to engine. Use of manual
transmission is easy and reliable. The top two best suited
gear boxes are Mahindra Alpha and Tata Ace. One of the
biggest disadvantages of manual gear box is the ride
comfort. The driver comfort is compromise and the
igue is one of the bad results of using manual gearbox.
To increase the comfortability of the driver which will
leads to increase in vehicle performance, it is
recommended to use CVT which will not only provide
the infinite gear ratios between the low and high gear but
also helps in reducing the weight and driver fatigue.
Therefore in this segment CVT will b discussed.
owever, based on the overall low and high gear ratio
calculated in previous segment, one can select the type of
gear box required followed by the design of final drive
discussed later.
3.4 Continuous Variable Transmission (CVT)
The continuous variable transmission (CVT) is plays a
most important part in the performance of the vehicle. As
stated above, the CVT helps in reducing the driver fatigue
as there will b no clutch to press, no lever to shift while
changing the gear ration. Thus, it not only save the weight
of other components but also provide the smooth ride by
allowing driver to shift the infinite number of reductions
between the low gear and high gear. Low gear is same as
the first gear and high gear corresponds to fourth gear of
gear box. The selection of CVT is also due to the fact that
the shift in speed and acceleration is continuous with
p with gear box. The CVT also allow
the engine to run at peak power which is very much
desirable for the better performance of the vehicle and
good fuel economy of the engine.
There are many manufactures of CVT like Polaris,
et, CVTech etc. One can choose from any

one of them depending upon the cost, ease of tuning and
drive ratios available. Selection of belt is also an
important parameter as it is the belt which will be
transferring the power. More or less, the belt material
same in case of all cvt. On the basis of cost and ease of
tuning, it is recommended to use CVTech AAB cvt.
CVTech CVT comes with the sponsorship for the BAJA
vehicle and is easily available worldwide. The driving
ratio of AAB CVT is 6.976, whereas the
distance of the belt can be selected as per the space.
Minimum c/c is 200mm
As mention above, the CVT has low gear and high gear as
a fixed ratio CVTech CVT comes with the low ratio of 3
and high ratio of 0.43. According to the need CVT ha
be tuned such that shifting occurs at the peak power of the
engine and engagement occurs before the peak torque of
the engine for the smooth gradual start.
Overall reduction required by transmission in low gear
was 30.
Low ratio of CVT is 3.
Therefore, final drive ratio should be igfinal
This final drive ratio is fixed all the time and normally
comprised of larger first gear of gear box
differential reduction. But in case of CVT low gear ratio
is comparably small and reduction of 10 from CVT to
differential is not attainable, hence intermediate reduction
is required such that:
CVT output shaft is coupled to an intermediate shaft of
reduction 2.5. At the end of this intermediate shaft, rest
the sprocket which drives the sprocket of differential by
reduction of 4. The net final reduction thus comes out to
be 2.5*4 = 10 (as required).
Therefore net reduction between CVT and Differential is
now in two stages. From CVT to differential via
intermediate shaft. This arrangement not on
space but also pack the entire Drivetrain assembly in
smaller area so that the net cg of Drivetrain will lie on the
centre line of the vehicle which is very much required.
Fig. 6: Drivetrain layout
Now, for the top speed, overall reduction
transmission was ighigh = 7.378
one of them depending upon the cost, ease of tuning and
drive ratios available. Selection of belt is also an
important parameter as it is the belt which will be
transferring the power. More or less, the belt material is
same in case of all cvt. On the basis of cost and ease of
tuning, it is recommended to use CVTech AAB cvt.
CVTech CVT comes with the sponsorship for the BAJA
vehicle and is easily available worldwide. The driving
ratio of AAB CVT is 6.976, whereas the centre to centre
distance of the belt can be selected as per the space.
As mention above, the CVT has low gear and high gear as
a fixed ratio CVTech CVT comes with the low ratio of 3
and high ratio of 0.43. According to the need CVT has to
be tuned such that shifting occurs at the peak power of the
engine and engagement occurs before the peak torque of
Overall reduction required by transmission in low gear
final = 30/3 =10.
This final drive ratio is fixed all the time and normally
of gear box and gear box to
differential reduction. But in case of CVT low gear ratio
on of 10 from CVT to
differential is not attainable, hence intermediate reduction
CVT output shaft is coupled to an intermediate shaft of
reduction 2.5. At the end of this intermediate shaft, rest
et of differential by
reduction of 4. The net final reduction thus comes out to
Therefore net reduction between CVT and Differential is
now in two stages. From CVT to differential via
intermediate shaft. This arrangement not only saves the
space but also pack the entire Drivetrain assembly in
smaller area so that the net cg of Drivetrain will lie on the
centre line of the vehicle which is very much required.
Now, for the top speed, overall reduction required by
Since the final drive ratio is fixed to 10, therefore high
ratio of CVT is thus needed to tune at 7.378/10 = 0.7378,
more or less equal to 0.74
Thus, tuning is needed to restrict the high ratio of CVT at
0.74 giving overall driving ratio of 3/0.74 = 4.
3.4.2 CVT TUNING
From the previous calculations, it is clear that high gear
require to attain the top speed is 0.74 whereas default top
gear of CVT is 0.43. That mean
the CVT according to this ratio. This “customization” is
nothing but what we called as “CVT TUNING”
proceeding for the tuning, one should know the detail
working of CVT. There is no rocket science behind the
working of CVT rather a primary (Driving) clutch and a
secondary (Driven) clutch conn
primary clutch has pretension springs and fly weights
which control the engagement and shift speed of the
system. The secondary clutch is a simple design doing a
complicated job. The spring and cam is the key to
performance. Before one starts working on the CVT, two
things should be finalized in mind:
1. The ratio required from the CVT at two extreme
engine speeds i.e. according to the maximum
torque and power.
2. The basic leverage of CVT should not be
compromise i.e. CVT should be shifted only at
peak power of the engine, allowing the engine to
run at its best rated condition.
From these two considerations, two graphs
should be plotted corresponding to each. In this
segment, as engine maximum torque is at
2600rpm, therefore at this instance, CVT should
be in low gear. And at 3800rpm, it should be at
high gear. Then the graph will comes out to be:
Fig. 7: CVT ratio v/s engine rpm
Here, tuning should be such that, the low gear is engaged
while engine is running at peak torque and high gear is
engage when the engine is running at peak power.
ISSN: 2454-1311
Page | 32
Since the final drive ratio is fixed to 10, therefore high
ratio of CVT is thus needed to tune at 7.378/10 = 0.7378,
Thus, tuning is needed to restrict the high ratio of CVT at
giving overall driving ratio of 3/0.74 = 4.
From the previous calculations, it is clear that high gear
require to attain the top speed is 0.74 whereas default top
gear of CVT is 0.43. That means we need to customize
his ratio. This “customization” is
nothing but what we called as “CVT TUNING”. Before
proceeding for the tuning, one should know the detailed
working of CVT. There is no rocket science behind the
working of CVT rather a primary (Driving) clutch and a
dary (Driven) clutch connected via belt. The
primary clutch has pretension springs and fly weights
which control the engagement and shift speed of the
The secondary clutch is a simple design doing a
complicated job. The spring and cam is the key to its
performance. Before one starts working on the CVT, two
things should be finalized in mind:
The ratio required from the CVT at two extreme
engine speeds i.e. according to the maximum
The basic leverage of CVT should not be
i.e. CVT should be shifted only at
peak power of the engine, allowing the engine to
run at its best rated condition.
From these two considerations, two graphs
should be plotted corresponding to each. In this
segment, as engine maximum torque is at
therefore at this instance, CVT should
be in low gear. And at 3800rpm, it should be at
high gear. Then the graph will comes out to be:
7: CVT ratio v/s engine rpm
Here, tuning should be such that, the low gear is engaged
at peak torque and high gear is
engage when the engine is running at peak power.

Fig. 8: speed diagram of CVT
The blue line represents the low gear and red line
represents the high gear. The dotted line represents the
engine speed as the vehicle speed increases. This dotted
line also represents the ideal shift curve of a engine with
peak power at 3800rpm. Two points are of importance,
the engagement speed and the shift speed.
ratio is shifted due to centrifugal action of fly weights.
Both clutches contains one movable sheave and one fixed
sheave. The belt is slide over these two sheaves of
different radius, thus reduction in speed occurs. At low
gear, primary clutch sheave is at minimum diameter and
secondary clutch sheave at maximum. This
condition of engagement, as the engine speeds up.
In order to start the vehicle moving, the engine must be
engage at a speed that has sufficient torque to propel the
vehicle. Initially for the engine speed below
centrifugal forces are overcome by pre tension of the
springs and no clutching takes place at low/idle speed. At
2600 rpm, the fly weights should overcome the pre
tension force of the springs so that, start moving the
sheaves together until enough force is exerted on the belt
to start the vehicle moving. This point is called
engagement point, and at the speed this
engagement speed. At this stage, the centrifugal force is
just equal to the pre tension of the spring. Now, after the
engagement point, as the speed of the engine increases,
the side pressure on the spring also increases from 0 to
100%. This phase is called clutching phase. When the belt
is fully engage the speed will continue to increase in low
ration up to 3800rpm. This phase is called low
acceleration phase. When the engine speed will reaches to
3800rpm, the side force on secondary clutch now exceeds
the pre tension of the driven clutch springs and the
shifting of sheaves will start takes place, hence reducing
the ratio. This phase is called a shifting
speed is shifting speed. The engine will now continuously
run at peak power and the CVT will shift from low gear
to high gear keeping the speed of engine constant.
CVT should be tuned on the above manner to attain the
maximum efficiency of both the engine and CVT.
8: speed diagram of CVT
The blue line represents the low gear and red line
represents the high gear. The dotted line represents the
increases. This dotted
line also represents the ideal shift curve of a engine with
peak power at 3800rpm. Two points are of importance,
the engagement speed and the shift speed. This change in
ratio is shifted due to centrifugal action of fly weights.
clutches contains one movable sheave and one fixed
sheave. The belt is slide over these two sheaves of
different radius, thus reduction in speed occurs. At low
gear, primary clutch sheave is at minimum diameter and
secondary clutch sheave at maximum. This is the
as the engine speeds up.
In order to start the vehicle moving, the engine must be
engage at a speed that has sufficient torque to propel the
vehicle. Initially for the engine speed below 2000rpm, the
overcome by pre tension of the
springs and no clutching takes place at low/idle speed. At
2600 rpm, the fly weights should overcome the pre
tension force of the springs so that, start moving the
sheaves together until enough force is exerted on the belt
start the vehicle moving. This point is called
engagement point, and at the speed this point is called
this stage, the centrifugal force is
just equal to the pre tension of the spring. Now, after the
the engine increases,
the side pressure on the spring also increases from 0 to
100%. This phase is called clutching phase. When the belt
is fully engage the speed will continue to increase in low
ration up to 3800rpm. This phase is called low
phase. When the engine speed will reaches to
3800rpm, the side force on secondary clutch now exceeds
the pre tension of the driven clutch springs and the
shifting of sheaves will start takes place, hence reducing
the ratio. This phase is called a shifting point and the
speed is shifting speed. The engine will now continuously
run at peak power and the CVT will shift from low gear
to high gear keeping the speed of engine constant. The
CVT should be tuned on the above manner to attain the
f both the engine and CVT.
3.4.3 CVT COUPLING AND DIFFERENTIAL
3.4.3.1 CVT COUPLING
One of the major issues faced with CVT is its coupling to
the engine. The good news is, the engine output shaft is
1’’ (25.4 mm) in diameter and the input diameter for CVT
is also 25.436 mm which means that the output shaft can
directly be used as input shaft of CVT. Refer the Fig 9
below. The flange coupling can be designed for the shaft
of diameter 1’’ if space is not a restrained.
For the shaft diameter of D, mm
Hub diameter D1= 1.8D+20;
Diameter of the bolt circle D2= D1 + 3.2D
Number of bolts, I = ((1/40)*D + 2) to ((3/80)*D + 2)
Bolt diameter, d = {(0.423D)/((sqrt(I))} + 7.5
Flange outer diameter, D3 = D1 + 6d
Hub Length, L = 1.2D + 20
Flange thickness, t= 0.35D + 9
All in mm
Fig. 9: CVTech CVT detailed drawing
3.4.3.2 DIFFERENTIAL
The deciding factor in the vehicle’s performance is the
selection of Differential. In general term, differential is a
kind of gear box which transfer the difference speeds at
different wheels so that vehicle can take turn without
slipping. From simplified type i.e. open differential to
most complex type i.e. LSD, one can choose a differential
based on the track requirement and the costing off course!
The BAJA track is rough and muddy wher
on both the wheels is required. For such requirement,
Limited Slip Differential (LSD) is preferably. There is no
correction required in its working and LSD can be
installed as it is. However, to reduce the size of layout,
differential should be chain-
shaft driven.
Next comes is the half shaft along with the CV joint
assembly. The half shaft should be design as a simply
supported beam of length half of rear track width (as in
this segment, differential is placed in
subjected to bending, torsion and axial thrust. Or in other
words, it should be design as a semi
bending loading is due to the rear weight, torsion due to
ISSN: 2454-1311
Page | 33
3.4.3 CVT COUPLING AND DIFFERENTIAL
One of the major issues faced with CVT is its coupling to
the engine. The good news is, the engine output shaft is
1’’ (25.4 mm) in diameter and the input diameter for CVT
is also 25.436 mm which means that the output shaft can
directly be used as input shaft of CVT. Refer the Fig 9
below. The flange coupling can be designed for the shaft
of diameter 1’’ if space is not a restrained.
mm
eter D1= 1.8D+20;
Diameter of the bolt circle D2= D1 + 3.2D
Number of bolts, I = ((1/40)*D + 2) to ((3/80)*D + 2)
Bolt diameter, d = {(0.423D)/((sqrt(I))} + 7.5
Flange outer diameter, D3 = D1 + 6d
Flange thickness, t= 0.35D + 9
9: CVTech CVT detailed drawing
The deciding factor in the vehicle’s performance is the
selection of Differential. In general term, differential is a
kind of gear box which transfer the difference speeds at
heels so that vehicle can take turn without
slipping. From simplified type i.e. open differential to
most complex type i.e. LSD, one can choose a differential
based on the track requirement and the costing off course!
The BAJA track is rough and muddy where the traction
on both the wheels is required. For such requirement,
Limited Slip Differential (LSD) is preferably. There is no
correction required in its working and LSD can be
installed as it is. However, to reduce the size of layout,
- sprocket driven rather than
Next comes is the half shaft along with the CV joint
assembly. The half shaft should be design as a simply
supported beam of length half of rear track width (as in
this segment, differential is placed in middle of the rear),
subjected to bending, torsion and axial thrust. Or in other
words, it should be design as a semi- floating axle. The
bending loading is due to the rear weight, torsion due to

the driving torque and axial thrust due to cornering. In
order to accommodate the suspension travel, CV joints
are needed. The most reliable CV
outboard CV joint is manufactured by Polaris Industries,
and is featured on the Sportsman and Hawkeye 300 ATV.
The joint is designed to transmit 17hp and allow for 30
degrees of articulation, which is ideal for the rear
suspension travel. The two joints and their axle
be coupled together to the correct length, using a welded
4340 steel sleeve. The joints are very small and
lightweight, and prove to be a durable and lightweight
combination.
Fig. 10: CV axle assembly
IV. NOISE, VIBRATION AND HARSHNESS
Noise, Vibration and Harshness also known as
arises when motorized equipment such as fan, pump
engine etc, energy can be transmitted from the equipment
to the structure in the form of vibrations.
often radiates from the structure as audible noise and
potentially reduces performance or damages equipment.
The vibrations can be isolated by using proper isolation
mounts. From an internal combustion Engine, the main
sources of vibration are:
1. The unequal gas pressure on the piston, this is
significant during idling;
2. Un equal reciprocating and rotating masses o
the engine components, this I significant during
high rpm;
For a single cylinder, 4-stroke Engine, the frequency of
the vibration varies from 5Hzt – 50 Hzt for 600
The maximum engine rpm of B & S engine is 3800rpm
and exact vibration can only be calculated once the engine
is dismantled. Still it is safe to use the range of 15
for the disturbing frequency. The frame frequency of the
BAJA vehicle is normally lies in the range of 27
for the vehicle shown in this paper. The two most
commonly used isolations with the engine are four elastic
or visco -elastic mounts. The former type has poor
isolation capability at low speeds and later type has
excellent capability at low speeds. But the most important
factor is cost, rubber mounts or elastomeric mounts are
cheaper. They have the isolation coefficient of 30% at
low rpm i.e. below 1000rpm. 62.5% at 2000rpm, 90% at
the driving torque and axial thrust due to cornering. In
der to accommodate the suspension travel, CV joints
joints are the
CV joint is manufactured by Polaris Industries,
Hawkeye 300 ATV.
and allow for 30
articulation, which is ideal for the rear
suspension travel. The two joints and their axle shafts will
length, using a welded
joints are very small and
to be a durable and lightweight
10: CV axle assembly
NOISE, VIBRATION AND HARSHNESS
Noise, Vibration and Harshness also known as NVH
motorized equipment such as fan, pump, and
, energy can be transmitted from the equipment
to the structure in the form of vibrations. This vibration
the structure as audible noise and
damages equipment.
The vibrations can be isolated by using proper isolation
mounts. From an internal combustion Engine, the main
The unequal gas pressure on the piston, this is
Un equal reciprocating and rotating masses of
the engine components, this I significant during
stroke Engine, the frequency of
50 Hzt for 600-6000rpm.
The maximum engine rpm of B & S engine is 3800rpm
calculated once the engine
is dismantled. Still it is safe to use the range of 15-32 Hzt
for the disturbing frequency. The frame frequency of the
BAJA vehicle is normally lies in the range of 27-32 Hzt
for the vehicle shown in this paper. The two most
monly used isolations with the engine are four elastic
elastic mounts. The former type has poor
isolation capability at low speeds and later type has
excellent capability at low speeds. But the most important
tomeric mounts are
cheaper. They have the isolation coefficient of 30% at
low rpm i.e. below 1000rpm. 62.5% at 2000rpm, 90% at
3000rpm and 93.3% at above. If you observe closely than
you can find out that, at low rpm engine frequency is
about 15 Hzt where as Frame natural frequency is about
27 Hzt which is more, therefore resonance will not occur
at low rpm. This shows that the poor damping capacity of
rubber mounts are compensated by the lower engine
frequency and at high rpm, after damping, engine
frequency will be lower than the frame frequency and
resonance will not occur. Therefore, stating that rubber
mounts can be used as engine mounts is considerable.
However for the excellent reduction, one can use the
visco- elastic mounts but they are costly.
Therefore, if the resonance condition is not reaching in
the frame, then the vehicle is safe from the unwanted
stresses and the pre mature failure of the components.
V. CONCLUSION
The main objective of this paper is to provide the in
detail knowledge about the Drivetrain of BAJA vehicle.
The first and foremost advantage of this literature is the
availability of design detailing along with the
specification of each and every components of the
Drivetrain in one segment. For the new students, who do
not have any past experience it will provide them the path
to select and design their own Drivetrain depending upon
their need. Each and every aspect of Drivetrain design has
been discussed in detail. However, the choice of few
components like CVT over manual gear b
make referral about the basic design consideration that
may vary from students to students. Second advantage is
the elaboration of various parameters and their effect on
vehicle performance. This will help students in their
curriculum as well as in the designing of any other racing
vehicle like formula student. Emphasis was more given to
use the scientific language which will create the curiosity
in the reader’s mind to discover the further about the
topic. Since Drivetrain cannot be restr
only the specific and necessary detail is discussed. So
finally, anyone having no knowledge about the Drivetrain
of the BAJA can now design and tune it by them self after
learning from this segment. All the BAJA, Formula
Students and other racing competition aspiring students
can use this as a handful tool in their learning and
process.
VI. ACKNOWLEDGEMENTS
Rishabh Jain is pursuing his B. Tech in Automotive
Design Engineering from University of Petroleum and
Energy Studies Dehradun, India and has represented the
University in National event SAE
BAJA SAE INDIA 2015 virtuals and International Event
ISSN: 2454-1311
Page | 34
3000rpm and 93.3% at above. If you observe closely than
you can find out that, at low rpm engine frequency is
as Frame natural frequency is about
27 Hzt which is more, therefore resonance will not occur
at low rpm. This shows that the poor damping capacity of
rubber mounts are compensated by the lower engine
frequency and at high rpm, after damping, engine
ncy will be lower than the frame frequency and
resonance will not occur. Therefore, stating that rubber
mounts can be used as engine mounts is considerable.
However for the excellent reduction, one can use the
elastic mounts but they are costly.
refore, if the resonance condition is not reaching in
the frame, then the vehicle is safe from the unwanted
stresses and the pre mature failure of the components.
CONCLUSION
The main objective of this paper is to provide the in
the Drivetrain of BAJA vehicle.
The first and foremost advantage of this literature is the
availability of design detailing along with the
specification of each and every components of the
Drivetrain in one segment. For the new students, who do
ny past experience it will provide them the path
to select and design their own Drivetrain depending upon
their need. Each and every aspect of Drivetrain design has
been discussed in detail. However, the choice of few
components like CVT over manual gear box etc is just to
make referral about the basic design consideration that
may vary from students to students. Second advantage is
the elaboration of various parameters and their effect on
vehicle performance. This will help students in their
well as in the designing of any other racing
vehicle like formula student. Emphasis was more given to
se the scientific language which will create the curiosity
in the reader’s mind to discover the further about the
topic. Since Drivetrain cannot be restricted to 10 pages,
only the specific and necessary detail is discussed. So
finally, anyone having no knowledge about the Drivetrain
of the BAJA can now design and tune it by them self after
learning from this segment. All the BAJA, Formula
er racing competition aspiring students
can use this as a handful tool in their learning and
NOWLEDGEMENTS
is pursuing his B. Tech in Automotive
Design Engineering from University of Petroleum and
Energy Studies Dehradun, India and has represented the
University in National event SAE-EFFICYCLE 2014,
BAJA SAE INDIA 2015 virtuals and International Event

ISSN: 2454-1311
Page | 35
Formula Student 2015 virtuals .He is also involved in the
International project ROLL ON/ROLL OFF University
payload Design Challenge for C130J super Hercules
under Lockheed Martin Corporation, USA. He has been
selected for the SAE Foundation awards- SAE student of
the year award (3rd
position) for excellent academic year
2014-2015.
Dr. P.S. Ranjit had more than 13+ years teaching as well
as Research experience in Automotive and Engine
Research. He had 33 research papers to his credit in both
National & International Journals and Conferences. His
contribution in both conventional as well as Hydrogen
fuels testing in IC Engines. He completed diploma in
Automobile Engineering from State Board of Technical
Education, Hyderabad, Under-graduation of Automobile
Engineering from Shivaji University, Maharashtra with
University second rank, post-graduation in Mechanical
Engineering from Madras University and Ph.D in
Mechanical Engineering from University of Petroleum &
Energy Studies (UPES), Dehradun. And Professional
member of Combustion Institute, Indian Society for
Technical Education, Institution of Engineers and Indian
Society for training and Development.
REFERENCES
[1] Newton .K, Steeds .W; ‘The Motor Vehicle’
[2] Reimpell, Stoll & Betzler; ‘The Automotive Chassis
Engineering Principles’.
[3] Frankovich .David; “The basics of Vibration
Isolation Using Elastomeric Materials,”
[4] Wang. Ruiping; “A study of vibration isolation of
engine mounts”,
[5] EML2322L – MAE Design and Manufacturing
Laboratory
[6] Briggs & Stratton; IntekTM
OHV Performance Data
[7] Bhandari. V B; ‘Design of Machine Elements’
[8] Mahadevan .k, Balaveera Reddy. K; ‘ Design data
Handbook’.
[9] Aaen. Olav; ‘Clutch Tuning Handbook’

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