We present a design project of a walking buggy designed on the basis of B2908.
In my opinion, there are a number of significant shortcomings in the design, but this is a good example of what a designer can do .... and if a competent engineer sits next to him, then a really cool thing can turn out.
The design was carried out in several stages:
- overview of buggy types;
- selection of a suitable prototype;
- processing of ergonomics, design and layout of the prototype;
- modeling and design calculation;
- visualization.
Overview of buggy types
- sports. For these models, the driving characteristics are the most important.
- the second class - these are models of well-known foreign manufacturers. They, as a rule, combine both good technical parameters and an attractive appearance. However, they have a rather significant drawback - a high price.
- and finally - home-made models, which are increasingly spreading in recent years, which, by the way, indicates a growing interest in this topic.
The prototype for the development of the overall layout, the structure of the power frame and suspensions for the new buggy model was taken by the sports model B2908, which has proven itself in competitions.
SKETCHES. DESIGN. ERGONOMICS.
I would like to draw your attention to the fact that the development of the appearance of the car is inextricably linked with ergonomics and design.
Since our model is designed for entertainment and not for sports, it must have an attractive design. It is obvious that the design of the body presented in the sketches and the fact that the model being developed should be two-seater led to the need for a significant revision of the prototype.
It is obvious that the design of the body presented in the sketches and the fact that the model being developed should be two-seater led to the need for a significant revision of the prototype. The main bearing element of the buggy is a welded frame. The engine, wheel suspensions, body, windshield and all other parts are attached to it.
Since buggies are mainly intended for off-road driving, their feature is high ground clearance and large wheel suspension travel.
Suspensions, which are a system of levers, provide such moves. The frame is welded from a steel pipe. Body panels are glued from fiberglass impregnated with polyester resin.
The designed car is assembled on the basis of standard VAZ units, in connection with this, its cost is significantly reduced.
3D MODELING. VISUALIZATION.
The 3D model of the buggy was designed in 3ds Max.
Body modeling was carried out taking into account the chassis design previously modeled in Solid Works.
The interior of the salon has also been worked out in accordance with the general concept and ergonomic requirements. In the body design, I wanted to create the impression of a one-piece protective shell, similar to those found in nature, which should be most organically combined with the environment where the buggy will be operated.
Vray was used to visualize this project. To show it in a real environment, as it will be in life, the integration of three-dimensional graphics and photography was used. To give the car a more natural look in global illumination, I used HDRI as an environment map and specular map.
As a result, the designed car at a relatively low price has an interesting design while maintaining functionality.
Sports, pleasure or utilitarian. Sports cars are designed to compete. As a rule, single-seat, the engine is usually located at the rear. The frame should be light, but strong and rigid under extreme loads. When designing a sports car, it is necessary to take into account the requirements of the racing series in which it is supposed to participate. Walking or beach buggy as a rule. Its purpose is rest. Such a machine is preferable, because. with the same parameters of geometric cross-country ability and almost the same mass, passive safety is much higher. The driver and passenger are protected by a strong tubular roll cage, and four-point belts do not allow them to fly out of the seat. Utility buggies are quite widespread in farms. Equipped with a platform for them, they provide a cheap alternative to traditional tractors and SUVs.
Disassemble the donor. For a pleasure buggy, the maximum use of regular components and parts is possible. Cossack". Loosen wheel nuts. Raise the car on a lift. Remove wheels. Remove the engine and transmission. Disassemble the running system - it will be used without changes. Remove the brake system and electrics. If driving on public roads is expected, bumpers, lighting and instrument cluster will be required. When disassembling, remember the location of components and assemblies. Don't lose fasteners. Try to label all removed parts on the tag. At the end of the disassembly, hand over the body to the scrap metal - it will no longer be needed.
Design the frame of the buggy. Do not try to immediately start creating in metal - you will have to redo it. Take dimensions from the components and elements of the suspension, transmission, engine mount, steering gear. The main task in the design of the frame is to provide mounting sites for the installation of components and assemblies. Care must be taken to ensure the mechanical strength of the structure. Be sure to include rollover bars to protect passengers in the event of a rollover. The engine must also be protected by arcs from above.
Buy materials for the frame and start assembling. It is best to assemble everything “on tacks” first, without making continuous welds. Then install the main nodes and elements, and check how they fit together. Make design adjustments as needed. After the control assembly, it is necessary to perform welds. Then the paint can be applied. After assembling the frame, the most difficult and responsible process of creating a buggy with your own hands is over.
Install the spare parts removed earlier by the Cossack. If necessary, disassemble the engine and transmission to make sure that their life is sufficient. Tires are best replaced with similar ones with a rough tread pattern to facilitate off-road driving. It is not advisable to put rubber with a very high ribbed tread, because. when driving on paved roads, it wears off very quickly.
In order to feel the rush of adrenaline, saturate life with positive and relieve stress, there is a great way - riding a buggy.
Buggy is the best way to travel during summer holidays on the coast or in the mountains.
Buggy is an original frame vehicle, characterized by small dimensions and lightness. This vehicle with large wheels has a high cross-country ability, and incredible stability, mobility and carrying capacity. The low weight of the machine makes it easy to control, a powerful engine provides high speed, and the design features of the steering and suspension allow you to quickly maneuver around corners.
History of creation
The first developers of the buggy were the Americans. Their goal was to create a vehicle capable of moving quickly over sandy terrain and off-road during combat.
The American models ALSV, FAV, LSV, used by the Air Force, reached speeds of up to 130 km / h. The cars weighed 2 tons and were powered by a 140 horsepower diesel engine. With a full crew of 4 passengers on board, these cars reached a speed of 50 km / h 5 seconds after a jerk from a standstill.
Later, cars of this type began to be used as a sports mode of transport.
Modern buggies are open cars with tubular frames. Models differ from each other: some have a roof and a windshield, others have a trailer mount.
Design features
The body shape of the buggy can be different, but providing the comfort and safety of the driver. For this, a special frame is used, consisting of front and rear arcs connected by jumpers. Front and rear suspensions are attached to the frame. The body usually consists of several panels of fiberglass or sheet metal.
The car must be equipped with a safety arc passing over the driver's head at a distance of more than 0.5 m.
The arc is made of steel cold-rolled seamless pipe.
The dependence of the pipe size on the mass of the machine:
For the manufacture of brackets, scarves, stiffeners, a steel sheet with a thickness of more than 2.5 mm is used. For the bottom and partitions, steel or aluminum alloy sheets with a thickness of 0.6 mm or more can be used.
Buggy wheels do not have independent suspension, usually it is serial or homemade. The reassignment of the car dictates the choice of tires with a winter pattern or the NIISHP type for rally. For light vehicles (up to class 4), it is allowed to use motorcycle wheels with a diameter of not more than 0.5 m and a width of 0.1 m.
Models of classes 5-10 are equipped with automobile wheels with a width of at least 0.3 m and a bore diameter of more than 0.4 m.
The braking system of the buggy is reliable. The brakes have a separate dual-circuit drive and a parking hand brake. On machines of classes 0-1, the use of a single-circuit drive for all wheels is allowed.
The engine is often located at the rear of the car behind the driver's seat. With rear drive wheels, the propeller shaft is fed through an intermediate gearbox, which allows you to change the gear ratio of the transmission to adapt to track conditions.
Fans are not used to cool the engine. On the buggy, this happens with the help of a stream of air entering through special guides located under the bottom. Fans close to the cylinders operate to prevent overheating.
The instrument panel is equipped with a speedometer, tachometer, thermometers (external and showing the temperature of the cylinder head), an ammeter.
For safety while driving, buggies are equipped with protective screens.
Cross-country buggies must have clearance lights, 2 brake lights located at a height of more than 0.5 m above the ground, a fire extinguishing system, towing hooks.
Application
Basically, these machines are used for cross-country cross-country cross-country buggies. Participate in a race on an unpaved ring track or with an embankment of sand, soil or gravel.
Walking buggies move well on asphalt.
Also, these cars are chosen by lovers of extreme recreation - caravanning. A trip along the river, along a country road, a field, along winding roads with an unexpected ascent and descent on this transport will seem surprisingly comfortable and pleasant.
A variety of buggies are crawlers designed for trial (overcoming obstacles) and rock crawling (driving on rocky terrain).
Specifications
Different models have different performance characteristics. Let's take the Bugfaster BC 600 buggy as an example.
Technical specifications
What is needed for the construction
First of all, it is necessary all-metal frame from steel pipes of round section or a profile pipe. Before the frame is welded, the attachment points for the future components and assemblies are laid in its design. For the price of such a frame for a buggy with parameters length 2 x width 1 x height 1.2, when ordering from a welder according to your drawings and with his material, it will cost around 40 thousand rubles.
Second in importance and importance is, of course, engine and gearbox. A set of new engine + manual transmission for VAZ Kalina costs 90 thousand rubles. You can find a cheaper foreign contractor with a transmission for the engine and it will cost all but no more than 50 thousand rubles + delivery.
Third - suspension the suspension of the bagia is simple 4 welded arms attached to the frame. These levers are easily made by a welder. For all 4 with material - 7 thousand rubles. Drive wheels rear. But the racks for the rear and front axles will have to be purchased, you will also need assembled hubs, ball bearings. I lay 11 thousand rubles for this. Racks (shock absorbers and springs) - 20 thousand. rub on all 4 sides.
Fourth steering all the same VAZ Kalina - steering rack with rods and tips with power steering - 12 thousand rubles, without power steering - 4 thousand rubles. Steering wheel with shaft - 3 thousand rubles.
Fifth brakes the drive goes to the rear wheels, so if you take all the app. parts from modern cars, you will have to swap both the transmission and the brakes all parts from the front to the rear and vice versa. But for greater safety, we take all disc brakes, brakes assemblies for 4 wheels cost - 20 thousand rubles, an amplifier, a master brake cylinder with a reservoir, and working cylinders, pipes and tubes - 9 thousand rubles.
sixth wheels- off-road tires with discs 21 thousand rubles on 4 sides.
seventh small things- headlights, seat, pedals, mounting material, wires, dashboard, and maybe some other little thing, I lay 20 thousand rubles for this.
Total 245 thousand rubles the cost of the model.
Where is a buggy useful?
We can say the following about this vehicle: mobile, safe, economical, light, all-terrain, in some way convenient, but not aesthetically pleasing, an open pilot's seat. And we get that the open pilot's seat makes the buggy not for ordinary roads and not for everyday commuting. But all these features ideal for relaxation and entertainment. It is ideal for moving along the beach and along the beach, it can be used as a tow for surfers and water skiers. Its all-terrain ability allows on it ride not only on the sand, but also go on trips to the mountains.
In the conditions of modern Russia, when tourists from the northern federal district and from the Urals and from Western and Eastern Siberia travel by train and arrive by plane for many kilometers on vacation on the Black Sea coast or the Caspian coast or in the Crimea, then for sure many people want a short vacation see a lot and go around the entire coast and visit the mountainous areas and see the sights. But this requires a personal vehicle, many of which are left at home, and here a buggy can come to the aid of inquisitive tourists as a cheap, mobile, individual vehicle.
In youth circles, the buggy is not only a means of entertainment, but also riding it as entertainment event. What young man would not like to come to the sea not to rest both in body and soul, to ride with his friends and his soul mate along the Black Sea coast with a breeze? After all, youth recreation is not lying on the beach, it’s a drive, it’s getting up with the dawn of the sun to go swimming in the sea, take a parachute, water, friends, stay in a buggy and go to the mountains, to the highest peak, which you can reach from there jump with a parachute or walk on a tightrope over a cliff.
If you decide to make a buggy with your own hands, you should know that there are two types of drawings: sports (racing) and tourist. When assembling the structure, do not forget that certain proportions must be observed, the parts must match one another in size, weight, load, etc. A self-assembled car should be light (about 300 kg).
The racing model must have a reinforced tubular frame. A reliable frame is required to protect the driver in the event of a collision or rollover at difficult distances. Such a car is made single. Tourist buggy "dresses" in the body and has two seats.
What tool do we need
Before you start assembling at home, you need to prepare everything you need. You will need a set of tools for work:
Welding(for the initial setting of the frame elements and the final welding of the pipes). Remember! During welding, metal stress occurs. Therefore, make sure that the frame does not lead.
Bulgarian(pipes will need to be cut and the edges aligned for welding).
pipe bender(they are different both in price and in the amount of work that they can perform: manual, manual hydraulic, electro-hydraulic, electric). Pipes will have to be bent in different places, according to the drawing.
Attention!When buying a pipe bender, ask what diameter and thickness of pipes it can work with, what is the maximum bending angle and bending angle accuracy.
Drill.
Beams and cutting boards(for lifting or fixing various elements during construction).
Milling machine.
Crown for metal.
Frame material:
Pipes(approximately 50 m of pipe, diameter 40 mm, wall thickness 3 mm). Pipes can be seam or seamless.
What we take as a basis
You can assemble the buggy yourself, taking as a basis the supporting frame of the motorcycle, Oka, Zaporozhets, Niva or VAZ. You need a body, a frame, wheels, a fuel tank, an engine, a brake system, a shock absorber, an exhaust pipe, an air filter, a steering wheel (you can take it from a racing kart), a seat (preferably equipped with a headrest). This is not a complete list of everything you need.
In a homemade buggy model there will be no hood, trunk, doors. The windshield will be replaced by a metal fine mesh.
Attention! The engine and fuel tank are separated from the driver's seat by a partition made of refractory material. A fire extinguisher is fixed on the right side of the driver (one pipe is directed towards the engine, the second towards the driver). Fire protection should be launched from two sides (from two levers).
Motorcycle buggy
If we take an old IZH or Ural motorcycle as a basis, then as a result of the assembly, we can get a compact 300 kg buggy that can travel off-road at a speed of 80 km / h. To assemble a buggy, you will need a motorcycle engine (although this is a somewhat noisy option) and small car parts.
"Oka" is a good donor for the buggy
"Oka" is a very profitable donor for the buggy. The Oka engine is liquid-cooled, and therefore protected from overheating, the hubs are lightweight, the steering rack has a sufficient margin of safety. For your buggy, the brake system and shock absorbers from Oka are suitable.
Attention!When disassembling the car for parts for the buggy, do not forget to keep the certificate of deregistration.
The seat from Oka is suitable only for extreme sportsmen (it is too hard). It is best to look for a seat with good lateral support during disassembly. At the same time, we must not forget about the headrest - this is the protection of your cervical vertebrae during off-road driving. The buggy based on the Oka is characterized by high cross-country ability.
"Zaporozhets" for buggy, ready-made version
If we take the Zaporozhets as a basis, then this will turn out to be a finished rear-engine model. The engine must be mounted backwards (this will improve its cooling and evenly distribute the weight along the axes). The differential will have to be turned over (swap the right and left sides). Remake the gearshift drive (since the gearbox stem turns towards the rear bumper from the driver - and this complicates the backstage system).
Make a buggy from a VAZ
If you are afraid of problems with electronics, then it is better to take the carburetor VAZ as a basis. The motor, like on all buggies, is attached to the back of the driver. The rear axles and VAZ hubs are used to drive the rear wheels. The axle shafts are attached to the cropped bridge from the VAZ 2106.
The trunnions on the rear axle are fixed without the ability to turn. And the front ones are like in a car. The differential is blocked (for uniform transmission to axles). If you take the front struts with springs from the 41st "Moskvich", then the rigidity of the rear suspension will increase. The upper part of the buggy frame will need to be welded from seamless water pipes (section 30 - 50 mm).
Buggy based on "Niva"
If you are going to use the buggy as a transport for fishing or in the forest, then you can take the Niva as a basis. On the basis of the Niva, you can build an all-wheel drive buggy. As a suspension, both front suspensions from the Niva are taken (the entire front suspension assembly weighs 130 kg). UAZ tires are put on the overcooked disks from the Niva. To increase the travel, you can lengthen the suspension arms as much as possible (the track can be increased up to 1550 mm).
Choosing a suspension
Independent suspension is a great option for a buggy. The levers are suitable longitudinal and transverse (you can take the front suspension from Japanese cars). This is a triangular lever: one side of it is attached across the machine through one silent block, and the second serves as a strut that takes on the load. On sports buggies, it is recommended to install a suspension with one trailing arm. This option is the simplest and easiest. With such a suspension, body roll is minimized, and the weight of the machine is evenly distributed.
Good to know! If you plan to cut into buggies on public roads, you will have to put headlights, a bumper, direction indicators (everything is like on a regular car, so as not to violate the rules of the road).
In an independent suspension of the candle type, the elastic element is a spring that moves along the vertical guides at the ends of the bridge beam. If there is an independent suspension on the driving wheels of the buggy, then the cardan joint is used to transmit torque from the main gear to the wheels. The most commonly used cardan with two hinges. On simpler structures, one cardan joint is placed in the axle shafts.
Front
The front suspension of the buggy is best done in the form of the letter "A" on long wishbones. It is this design that gives the wheels a lot of travel and allows you to change the angle of inclination of the spring with the shock absorber (thus, the stiffness of the suspension is regulated).
When assembling the pendulum arm, pay attention to the material and quality of the welds, because very heavy loads are coming to this part. Levers count on the maximum width of the base of the letter "A" (this will extend the life of silent blocks). The width of the lever should not interfere with the rotation of the wheel. The disadvantage of the design is that the stroke of the lower ball joint pin in its seat is limited (up or down, it will not be in the place where we would like).
rear
For the rear suspension of the buggy, we select a trailing arm that keeps the wheel from shifting (the wheel sits rigidly on the cardan). True, there is one flaw: the camber of the wheel is changing for the worse.
To achieve stability in motion, variable values \u200b\u200bof the angle of inclination of the wheels are needed. The levers will allow movement in two planes. If there is such a suspension on the rear axle, then the front suspension can be any. If in such a suspension the swing axis of the lever passes through the center of the cardan shaft, then there is no need to install a second cardan at the wheel hub.
My friend offered to make a real buggy in the right way smile.gif Having thought a little, I agreed to his provocation. A comrade bought 99.9% parts for a buggy, and I helped with welding-ideas-tools with a room and, most importantly, a company (it’s not enough for one to do all this)
So here is the uprooted motor with a box. Heart so to speak...
Start. So, as usual, the soul required rational decisions, so the buggy from the Soviet magazine "Modelist Constructor" was taken as the basis, it was called AB-82, and had most of the spare parts from the kindest ghost in the world with a motor, ZAZ 968, i.e. Zaporozhets.
For a while we found tools, did a mega-cleaning in the garage and looked for a donor. Tools (the most necessary ones) were found It is possible to work in the garage (they cleaned it, they made a light, etc.) Purchased ZAZ 968, red rear-engined coupe.
So we drove the ghost around the city, it rides, it's alive. They cut it in the garage (there is no photo of the cut, apparently we were very passionate about the process)
We arrived at the garage, cleaned up, made a light, it seems like more or less decent working conditions came out ... We bought ordinary iron profiles at the metal depot, (profile pipe) And we began to sculpt with a welding machine, which means ... Art
Art grew, first the bottom was welded, here the drawings were observed by 90%. The frame was made a little larger than in the drawings.
Somewhere in the process, there was a rear suspension. These are native Zaporizhzhya levers with hubs, and on native "ears", carefully removed from the body of the donor in advance. There was an opportunity to move to my garage, which we did. They worked so that there was light, order and beauty, nothing happens for free.
As it was
How did it become
Pay attention to the high-tech wall painting technology (they thought to make it brighter, such as beauty and light is reflected) The technology is like this, one randomly paints in one place, the second in another, the paint suddenly ends (the sellers are such sellers ... they promised that for the whole garage 10 layers is enough for a bucket .. but really ...) and the event is over))
Front arms and suspension were made.
Roar pipes - rods from the rear suspension of the VAZ classic. With silent blocks.
The ears on the frame for silents are homemade from metal 2mm.
The ball mounts from below are a piece of the VAZ front lever.
Ball vase of course.
Above the relay tip of the vase instead of the ball.
The camber adjustment bushing is welded into the upper arm (the bushing was made by a turner)
The turner also made a spacer for the upper ball-tip (they have different cones)
Initially, IZHP 4 shock absorbers were installed, but this is too weak an option.
Later changed.
So far, what rubber is there to ride.
Suspension, I must say, was not welded from the bulldozer. The kinematics of the levers are measured in such a way that the contact patch of the tire with the road is always maximum. Check suspension travel. This is already a very interesting moment when the design is already at least somehow possible to roll! Joy as in 7 year old children.
Fiery heart, engine i.e. Trying on. Motor and gearbox mounts remain factory, with minor modifications.
A general photo with a suspension and a homemade metal bucket 0.8 according to drawings from our wonderful Internet (what would we do without it ?!)
Again, erotic fantasies on topics with a roof ... Design and engineering (from the word engineer or fig?))
Time has passed. We chose how beautiful it would be.
Space gravity cap. The snapshot is intermediate, meaningless, cool.
By the way, here are the motor mounts closer. Just in case)
We began to make pedals, fastening tanks, cylinders. Alas, there are no high-quality photos of the process left, either scribbled or in between, like here. But the main thing is there is gas)) The steering rack is also fixed offhand. This moment is regulated for a long time so that the balls in the steering rack are in a certain place relative to the suspension mounting lines. In short, what would you steer the car, and not she steered you over bumps. Steering rack OKA (1111) Cardan steering VAZ 2107, very comfortable, and for safety + Steering tips VAZ classic.
The first descents from the hill, the steering wheel on a stick with electrical tape, no seats, no brakes, nothing ... Do not do this, it is dangerous for everything in general)))) Of course, the ocean of joy. The front wheels are normal, VAZ, the rear ones are ZAZ (VAZ is a temporary dummy for the photo, in reality only ZAZ wheels are on the hub)
Bottom. For nefik to ride without it is dangerous. Sheet of metal, 0.8 in my opinion. Initially, it was attached to self-tapping screws with a drill, but as practice has shown, they are not suitable for these purposes, they fall out from vibration, and are often cut off by the ground when jumping and so on. And then another mystery of who will assemble them with wheels ... Later, the bottom was welded with dots. By the way, from the start, the project was cooked with electrodes. And with the move to a new home, the machine was created only by a semi-automatic CO2 and 0.8mm wire. More convenient, faster, lighter, this type of welding has a lot of advantages.
After the first tests, hopes for compact lightweight shock absorbers dissolved. We put two of these on the side, it became better, we rode them for a while, but not that. By the way, out of the corner of your eye you can notice that there is a gas cable, clutch reservoirs, brakes, brake pipes and a steering rack is fixed with high quality. These kinds of moments require a lot of thinking and creativity, so they forgot about the photo campaign. On the floor of the buggy - linoleum)) Type cultivated temporarily.
