FINAL INDEPENDENT PROJECT

Design Modification and Making SAN-H100 In to Solar Powered E-Vehicle by using SolidWorks 2020

Thasleem Ansari_ Shaik                                                                                                       (thasleem.ansari1872@gmail.com)

Cick_here_to_view_the_project

 

1-Objective:

• The main objective of this Project work is to Modify the Design of SAN-H100 in order to increase the onboard space, by using minimum Sketch tools and Features of SolidWorks 3D CAD Software.
• Making SAN-H100 in to solar powered E-vehicle, by applying solar panels on top of the vehicle.
• And to learn how to use features with great precession.
• To use the photo view 360 in SolidWorks and Rendering tools.

2-Introduction:

• SolidWorks:

SolidWorks is a solid modeler, and utilizes a parametric feature-based approach which was initially developed by PTC (Creo/Pro-Engineer) to create models and assemblies. The software is written on Parasolid-kernel. SolidWorks is a solid modeler, and utilizes a parametric feature-based approach which was initially developed by PTC (Creo/Pro-Engineer) to create models and assemblies. The software is written on Parasolid-kernel.

• SAN-H100:

1. The San H100 bus was developed at the SFA Design Office headed by Eng. Kazimierz Galeza in a short period of several months. The first batch of production was launched at the end of 1966.
2. Vehicle is fundamentally different from its predecessors
3. San H100 with diesel engine were marked with H100 with a body symbol. Previously the car running with gasoline engine are marked with the body symbol H100.1.

• Project:
• In this project Design of SAN-H100 is Modified by using SolidWorks 2021.And made it in to Solar powered E-Vehicle.
• Feature modeling options are used completely in-order to get good insight in part Modeling tools.

 

3-Design Methodology:

                                             

                                                               Fig1: Design Methodology of Assembly and Photo Rendering

The parts, which are shown above in flow chart are designed by using the latest version of SolidWorks Software. After designing Parts of SAN-H100, they got assembled by using Assemble parts option.

3.1-Assembly:

Assemble Parts option is shown directly when we start creating the new document.

                                                                  

                                                                                   Fig 2: Visibility of Assembly Option

The parts are call in to the assembly by simply clicking the insert component option, which is available in the menu. The part are inverted individually or we can call it bulk, but inserting individual is more preferrable than the bulk.

3.2-Mate:

The mate option is used mainly to set the parts of the SAN-H100 in their required location. By using mate option, we give tangency, distance, coincide, or even give angle to the mating parts. We can even mate planes by using the mate option.

                                                                                  

                                                                                     Fig 2.1: Visibility of Mate Option

Mate option plays very important role during assembling the parts. The options are shown in the figure are used in assembling the SAN-H100.

3.3-Photo Rendering:

Rendering or image synthesis is the process of generating a photorealistic or non-photorealistic image from a 2D or 3D model by means of a computer program. The resulting image is referred to as the render. Multiple models can be defined in a scene file containing objects in a strictly defined language or data structure.

Rendered images has a nice graphics compared with normal assembly

                                       

                                                                           Fig 2.2: Normal and Rendered Image of the SAN-H100

Above shown images are rendered and normal images. The right image of SAN-H100 has applied a nice graphics.

Rendering of assembly should be done by going in to photo view 360 and rendering tools. Photo view 360 is located in SolidWorks add inn.

4-Description:

• SAN-H100 Body
• Chassis
• Front Axle
• Rare Axle
• Swing Slide Door
• Passenger Seat
• Driver Seat
• Front wheel Hub
• Rare Wheel hub
• Mirrors
• Luggage Holder
• Windscreen Wipers
• Wheel

are the above parts which are made by using SolidWorks 2020.

Sketch Tools Used:

Line:

It helps to draw a line of the graphics sketch area. In side drag menu centerline option also available. This tool helps to create center line for the 2d drawing. The centerline representation follows the engineering graphics drawing tools. The new version of SolidWorks contains Midline which helps to make lines on both sides.

Rectangle:

It helps to create rectangle box in the sketch area. In the side down drag menu, you can see the different rectangle drawing methods such as Corner rectangle, Center Rectangle, 3 Point Corner Rectangle, 3 Point Center Rectangle and Parallelogram.

Arc:

It enables to draw arc. It contains 3 arc drawing methods and they are Center point Arc, Tangent Arc and 3 Point Arc.

Circle:

It helps to draw a circle. IT contains two circle drawing method such as, center point circle and Perimeter circle.

Spline

Splines are used in mechanical for mating the rotating parts. It is two types internal and external splines. This tool helps to draw highly smooth curves or lines of the sketch.

Straight Slot:

It helps to draw a straight slot in 3D object. It also contains arc slot tool which create an arc slot. It have two types of slot drawing methods such as centerline method, center point, 3 Point arc and Center point arc method.

Ellipse:

This tool helps to draw Ellipse on the drawing interface. You can also draw partial ellipse and parabola form the down drag menu.

Smart Dimension:

The smart dimension is one of the useful tools to create sketches as mentioned in your drawing. You don’t need to care about the dimension of the sketch profile while drawing. It will adjust using Smart Dimension tool in later action.

Plane:

It helps to insert a plane in a 3D sketch.

Sketch Fillet:

If you want to adjust the corners or make round at the corners of sketch, use the Sketch fillet tool. You can enter the fillet parameters through the property manager.

Convert Entities:

It helps to convert selected model edges or sketch entities into sketch segments.

Offset Entities:

It enables to insert the SolidWorks sketch entities offset to face or edge or curves or specified distance from it.

Features used:

Extrude Boss/Bass:

The Extrude Boss/base is one of the most frequently used tools in SolidWorks, which enables to convert a 2D sketch into 3D model. It helps to add material to your sketch files. It is represented by icon When you click on the Extrude button, the property manager opens where we can control everything about extrude.

Revolve Boss/Base:

The revolve feature enables to add materials to your 2D sketch by revolving a long as centerline or axis. The revolve boss/base is actually rotate the sketch along an axis. It helps to create parts shows the symmetry like cylinder, sphere, pulleys etc.

Swept Boss/Base:

It is sweep feature which sweeps a closed profile through a open or closed path for making solid object. This feature helps to make solid part by guiding through a definite path.

Loft Boss/Base:

It helps to create solid model between two profiles in a certain distance. It needs two or more profiles to add materials into it.

Extrude Cut:

Unlike the extrude boss, the Extrude cut removes the material from 3Dmodel by using a closed sketch (Circle or rectangle etc.). You can do the cut in one or two directions the using the property menu.

Revolved Cut:

Using the Revolved Cut, you can remove the material by revolving a closed sketch around an axis.

5-Parts of SAN-H100:

5.1-SAN-H100 Body:

                                

                                                                                                    Fig 3: SAN-H100 Body

The above part is the body of the SAN-H100, which is Usually made of Metal Sheet of variable Thickness. This parameter is change according to the company and the model they are going to Manufacture.

Sketch Tools used to design SAN-H100 body:

1. Line:
2. Rectangle
3. Circle
4. Spline

 

Feature used to design SAN-H100 Body:

1. Combine
2. Extrude cut
3. Extrude

5.2-Swing Slide Door:

                                       

                                                                                         Fig 3.1: Swing Slide Door

Swing Slide door are also known as Sliding Swing Doors, are widely used as Entrance doors, these are generally used at mall’s, houses etc. this concept is now using by the Bugatti, they are replacing the doors with the swing slide doors in order to reduce the complications which the users felt with the doors.

Sketch Tools Used to Swing Slide Door:

1. Line
2. Circle
3. Arc

Features Used to Swing Slide Door:

1. Extrude
2. Extrude cut
3. Mirror entities

 

5.3-Chassis:

                                 

                                                                                          Fig3.2: SAN-H100 Chassis

Chassis are used as supporting structure for the whole vehicle, Where the parts of vehicle are generally mount on the chassis.  Chassis are generally made with the aluminum alloy which has high stiffness and the high compressive strength. frequently stainless-steel alloy and tungsten alloys are used. The material selection is totally depending up to load of the vehicle. Chassis are different for the different vehicles.

Tools Used to Design the Chassis:

1. Line
2. Circle
3. Mirror
4. Spline
5. Arc
6. Rectangle

Features Used to Create the Chassis:

1. Extrude cut
2. Extrude
3. Swept
4. Project curve

 

5.4-Front Axle:

                                     

                                                                                            Fig 3.3: Front Axle of SAN-H100

Front axle is used to hold the steering mechanism and the Wheels. There are several parts mount on the front axle.

Sketch Tools Used to Design the Front Axle:

1. Line
2. Circle
3. Arc
4. Rectangle

Features Used to Create the Front Axle:

1. Combine
2. Shell
3. Save bodies
4. Extrude cut
5. Extrude

5.5-Rare axle:

                                         

                                                                                             Fig 3.4: Rare Axle of SAN-H100

Rare axile is used to hold the differentiator, rare wheels, leaf springs. Differentiator is used to transfer the power from the engine to the wheels with the help of mechanism contained in it.

Sketch Tools Used to Design the Superstructure:

1. Line
2. Circle
3. Arc
4. Rectangle

Features Used to Construct the Superstructure:

1. Extrude
2. Extrude cut
3. Combine

 5.6-Seats:

                                       

                                                                                                          Fig 3.5: Passenger Seat

                                     

                                                                                             Fig 3.6: Driver Seat of SAN-H100

 

Sketch Tools Used to Design the Seats:

1. Line
2. Circle
3. Arc
4. Rectangle
5. Spline

Features Used to Create the Seat:

1. Extrude cut
2. Extrude
3. Swept
4. Revolve
5. Combine

5.7-Wheel:

                                          

                                                                                                    Fig 3.8 Wheel of SAN-H100

Sketch Tools Used to Design the Wheel:

1. Line
2. Circle
3. Arc
4. Rectangle
5. Text insert

Features Used to Create the Wheel:

1. Extrude
2. Extrude cut
3. Revolve
4. Fillet

5.8-Windscreen Wiper:

                                       

                                                                         Fig 3.9: Windscreen Wiper of SAN-H100

Wipers are used to clean the Windscreen when dust falls on it, with that it provides the clear view to the driver.

Sketch Tools Used to Design the Windscreen Wiper:

1. Line
2. Circle
3. Arc
4. Rectangle

Features Used to Create the Windscreen Wiper:

1. Extrude
2. Extrude cut
3. Revolve
4. Fillet

5.9-Wheel hub:

                                   

                                                                                      Fig:3.10: Wheel Hub of SAN-H100

 Front and rare wheel hubs has the same mechanism to hold up the wheel. The wheel hubs are interlinked with the steering mechanism.

Sketch Tools Used to Design the Wheel hub:

1. Line
2. Circle

Features Used to Create the Wheel hub:

3. Extrude
4. Extrude cut
5. Fillet
6. Helix
7. Sweep cut

 5.10-Mirrors:

                                   

                                                                                               Fig 3.11: Mirrors of SAN-H100

Sketch Tools Used to Design the Mirror:

1. Line
2. Circle

Features Used to Create the Mirror:

3. Extrude
4. Extrude cut
5. Fillet

5.11-Luggage Holder:

                                 

                                                                                             Fig 3.12: Luggage Holder

Sketch Tools Used to Design the Luggage Holder:

1. Line
2. Rectangle

Features Used to Create the Luggage holder:

3. Extrude
4. Extrude cut
5. Fillet

 

6-Assembly of SAN-H100:

The above parts are arranged in a way to build the SAN-H100 not only that photo view 360 is used to apply more graphics on the SAN. The below shown are the views of the SAN-H100.

                                      

                                                                                                  Fig 4.1: Views of SAN-H100.

                                        

                                                                                                 Fig4.2 :Cam Image of SAN-H100

 

7-Rendered Imagaes of SAN-H100:

 Cam view :

                                                                      

Fornt View:

                                                                      

Top view:

                                                                     

Side view :

                                                       

Isometric view:

                                                                

8-Conclusion:

 Successfully Modified, Assembled and applied photo realistic rendering on the SAN-H100 by using SolidWorks 3D CAD Software.