Muhammad Farid Riyanto, Juni Noor Rohman, Sutiman

Engineering Design and Performance Evaluation of a Transmission System for the UG 24 Urban Energy Vehicle

Introduction

Engineering design and performance evaluation of a transmission system for the ug 24 urban energy vehicle. Engineered and evaluated a new transmission system for the UG 24 urban energy vehicle, solving drivetrain failures. Improved gear shifting performance by 75% for student competitions.

Abstract

The development of energy-efficient vehicles in student competitions encourages innovation in lightweight and high-performance automotive systems. The Garuda UNY Team, representing Universitas Negeri Yogyakarta, has been actively involved in national competitions such as the Kontes Mobil Hemat Energi (KMHE). In recent evaluations, the team identified a critical weakness in their vehicle's drivetrain, specifically the Internal Gear Hub (IGH) used in the UG-24, which failed to withstand engine torque during acceleration, leading to gear slippage and mechanical failure. To address this issue, a new transmission system was designed and manufactured using the 4D development framework: Define, Design, Develop, and Disseminate. The Define phase identified the mismatch between the IGH design and engine torque requirements. In the Design phase, a new gearbox layout was modeled using Autodesk Inventor, incorporating components such as a crankcase, cover, and custom gear ratios. The development phase involved selecting materials, laser cutting, machining, and assembling transmission parts from mild steel and aluminum. Finally, the Dissemination phase consisted of installing the system in the UG-24 vehicle and conducting a performance evaluation through structured interviews with drivers. Evaluation results showed improved gear shifting performance, with a 75% success rate across ten indicators. Despite positive outcomes, some issues, such as shifting resistance and gear engagement noise, were observed. These were linked to cable friction and dog clutch geometry. Design improvements such as optimized routing and chamfering were recommended for future iterations. This research highlights the impact of tailored transmission systems in student-built energy-efficient vehicles. It provides insight into practical, scalable drivetrain solutions.

Review

This paper presents a detailed engineering endeavor focused on resolving a critical transmission failure in the UG-24 Urban Energy Vehicle, a student-built entry for national energy-efficiency competitions. The authors clearly articulate the problem: an Internal Gear Hub (IGH) that was unable to withstand engine torque, resulting in gear slippage and mechanical failure. This highlights a common challenge in student-led innovation, where off-the-shelf components may not meet specific design requirements. The research aims to overcome this limitation by designing and implementing a bespoke transmission system, demonstrating a practical approach to enhancing vehicle performance and reliability. The methodology adopted, the 4D development framework (Define, Design, Develop, Disseminate), provides a robust structure for addressing the engineering challenge. The Define phase meticulously identified the mismatch between the existing IGH and engine demands, while the Design phase leveraged CAD software (Autodesk Inventor) to model a new gearbox with custom ratios and components. The practical strength of this work is evident in the Development phase, involving hands-on material selection (mild steel, aluminum), laser cutting, machining, and assembly of the new transmission. The subsequent evaluation, based on driver feedback and performance indicators, positively confirmed improved gear shifting, achieving a 75% success rate across ten indicators, thus validating the effectiveness of the custom design. Despite the significant positive outcomes, the abstract commendably acknowledges remaining issues, such as shifting resistance and gear engagement noise, attributing these to specific design elements like cable friction and dog clutch geometry. This transparency strengthens the paper by identifying clear areas for future refinement, with concrete recommendations like optimized routing and chamfering. Overall, this research provides valuable insights into the practical application of engineering principles within a competitive student environment. It underscores the profound impact of tailored transmission systems on the performance of energy-efficient vehicles and offers a scalable model for addressing specific drivetrain limitations through innovative and practical design solutions.

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