Materials and mechanisms used in the construction of this all-terrain vehicle:
1) Lifan 190 internal combustion engine with a capacity of 15 hp
2) Belts A1120
3) Salute 5 gearboxes in the amount of a pair of pieces
4) Cardan shafts were taken from CV joints of vases 2108
5) from the same vases taken and brake mechanisms with hubs
6) twin sprockets with 13 teeth used as lead
7) On all-terrain vehicle it took about ten meters of chains in increments of 15.8
8) driven stars have 42 teeth
9) 8 timing belt tensioners
10) Wheels of the shell of the INB 79 and disks with cones for them, with a total weight of about 70 kg
11) the seat was removed from the UAZ
12) The main brake cylinders for the all-terrain vehicle were taken from the Gazelle clutch
13) A 40 by 20 profile was used to build the frame
14) 6 mm wire
Dimensions of friction all-terrain vehicle
length 320 cm
width 260 cm
height 200 cm
clearance 45 cm
Let's take a closer look at the design of the all-terrain vehicle and the progress of its construction.
The author decided to bring forward gearshift control using rods. traction is made of 6 mm thick wire, with the help of which the tension rollers of the clutch belt friction are controlled. The final drives of the all-terrain vehicle are copied from the author’s all-terrain vehicle with the nickname "cap".
Used coils with a capacity of 18 amperes, for a pulley, which is more designed for a tractor generator, however, the coils cope. The engine with belt clutches is also shown here:
Here you can see the levers themselves, with the help of which the clutch is controlled:
gear photo:
At the initial stage, it was planned to install all 4 tensioners, but during the construction the author realized that this would not be enough. Therefore, as a result, 8 tensioners were installed immediately on the all-terrain vehicle, however, during sudden braking by the side, incorrect operation of the chains with stars occurs, some clicks. When driving without turns, the all-terrain vehicle behaves quietly enough. Brakes are required more for sharp maneuvers, with a smooth turn they are not particularly necessary.
The first weighings of the all-terrain vehicle showed a mass of 800 kilograms, which is much more than the author calculated. although the wheelbase of the all-terrain vehicle certainly weighs under 300 kg, but the remaining 500 kg of weight must be reduced.
In addition, it is also planned to install a generator to reduce the load on the pulley.
The all-terrain vehicle has three seats for adults and one for children, but the course is quite mild on an all-terrain vehicle, so more people can be seated not on soft seats.
As for the turning process, it is implemented as follows: one of the all-terrain vehicle's brakes is braking, since the brakes are on the drive shaft, the wheels are essentially only kept from rotation by a chain. Therefore, there is a load on the chain and the chain rollers and the teeth of the sprockets run into each other, hence the noise. Chain tensioners can not cope with this problem, so its solution should be different. Perhaps it is planned to install additional brakes directly on the wheel shaft. Although the author has already selected some effective model turning and without installing additional mechanisms. To do this, it includes the first gear on one side and the rear on the other, and the turn is easy. A similar scheme is often used on tracked vehicles.
The all-terrain vehicle is also being sealed, since the author plans to use it as an amphibian. For this, the bottom was closed with a metal sheet a half millimeter thick.
In these videos, you can examine in more detail both the machine itself and its driving characteristics:
The author decided to deal with the mass of the all-terrain vehicle:
The wheels assembly weigh 320 kilograms, the frame and final drives have a mass of 120 kilograms, the engine is 30 kg, the gearbox weighs 20 kg, the drives from the VAZ 2108 in the assembly weigh 40 kilograms, the seat is 20 kg, the chain 10, the battery 30 kg, the frame plus tent under 20 kilograms, the threshold also weighs 20 kilos. That is, where 800 kilograms came from is not entirely clear, most likely it was a weight error.
Next, consider the design of the wheels of the all-terrain vehicle. The author used the semiaxis from the vases and the core of his rim, the fastening takes place on four 12 mm bolts.
Wheel mounting pictures:
When overcoming obstacles in the form of a mound, the all-terrain vehicle received serious damage. The chain lock on the rear wheel drive was unfastened, because of which the front wheel pulled too much and the mounting bolt tore off. Due to the loads, the half shaft of the left rear wheel was also broken. The key rotation was 8 mm, and the shaft 25 mm.
Therefore, the author began a full-scale repair of equipment.
The reason for the breakdown, in addition to the author’s dashing, could be too big bast shoes, for a similar half-shaft diameter.
In fact, at the time of lifting the wheels in front, they hung in the air, all the load went to the rear wheel, and mainly to the left. A 400-800kg axle load with a diameter of 25 mm is too much.
To begin repair work, the author dismantled the side of the all-terrain vehicle. then the hub and sprockets to sizes of 30 mm were bored. 305 bearings were replaced by 206. Also, the author expects to transfer the brakes directly to the wheels themselves.
As it turned out in the process of analyzing the all-terrain vehicle, the key was not the cause of damage, it was the shaft that failed.
Then the author proceeded to install standard drum brakes for each axis. In addition, such an approach does not require strong modifications to the design of the all-terrain vehicle. Although possible drive changes. additional support from the sprockets will also be installed. That is, there will be a block of leading stars on two supports and a universal joint from the gearbox. doubts arise only on the mass of such a design.
Also, couplings with splines will be attached to the gearboxes, they will be taken from UAZ. Although if brakes from Zil are found, then using them is much more efficient.
The parts were turned by a turner, since the center holes are located on the shaft, which is quite convenient for such work. A flange for the brake disc was welded to the shaft 27, the fist was cut off, and the sleeve was pressed with fits under the stars and the bearing.
According to the author’s calculations, the load on the wheel is higher than the load on the star, simply because of the aspect ratio of the diameters. But it was the axis that underwent deformation.moreover, the axis was rolled up by a wheel, and not by a star. This happened already during braking. Thus, it turns out that if you transfer the brake directly to the wheel, then those high loads that led to the breakdown of the transmission will be removed by themselves. Therefore, the entire brake assembly, which is now installed on the all-terrain vehicle, can be removed, thereby reducing the weight of the machine.
The chain is always tensioned and there is no load when reversing, unlike the classic tensioner scheme.
Work was done to replace the drive design: a shaft was machined from the AvtoVAZ shank and mounted on two bearings:
Half shafts are machined up to 30 mm, and an additional bearing support is also installed:
Here you can see the drum brakes:
The brakes were heavy, 15 kg were added in the mass of the all-terrain vehicle:
ATV photos:
The author of the all-terrain vehicle: Michael "didulya" from the Vologda region.