Project Description

1. Competition Overview

This challenge requires participants to design a complete Electric Vehicle (EV)—either a Bike, Three-Wheeler, or Car—from scratch using CAD + CAE + MATLAB/Simulink.

You will digitally design the frame/chassis, battery pack integration, suspension system, steering system, and powertrain layout, and then simulate the vehicle dynamics using model-based design techniques.

This challenge replicates a real OEM pre-design R&D process used in companies like Mahindra Electric, Ola Electric, Bajaj Auto, Maruti Suzuki EV Division, Ather Energy etc.

This is a virtual-only round. Winning teams will receive prize money and will be shortlisted for the Prototype Round + Internship interview with industry partners.

2. Objectives

Participants must:

1. Design a complete EV platform (Bike/3W/Car) using CAD.
   
2. Integrate battery pack, motor, controller, and drivetrain layout.
   
3. Perform structural analysis (FEA) for chassis, roll cage, or frame.
   
4. Build a full vehicle model in MATLAB/Simulink including:
   
   
   • Longitudinal vehicle dynamics
     
   • Acceleration, braking, energy consumption
     
   • Motor-load matching
     
   • Battery discharge on driving cycles (UDDS/WLTP/IDC)
     
5. Simulate performance under real driving conditions.
   
6. Submit a detailed engineering report + simulation files for evaluation.
   

3. Who Can Participate

• DIYguru students
  
• Engineering undergraduates
  
• Diploma students
  
• Postgraduates & working professionals
  
• Anyone with EV, CAD, Mechanical, Electrical, Mechatronics, or CS/AI interest
  

4. Team Size

• Individual participation allowed
  
• Teams of 2–5 members are allowed
  
• Cross-disciplinary teams are encouraged
  

5. Duration

• Total challenge duration: 3 months
  
• Can be completed in: 8–12 weeks (recommended)
  

6. Technical Scope of Work (Detailed Requirements)

A. CAD MODELLING (Mandatory)

Participants must design a complete CAD model of the chosen EV type including:

1. Frame / Chassis / Roll-cage
   
2. Suspension system (Front + Rear)
   
3. Steering system (Ackermann for 4W/3W, handlebar geometry for 2W)
   
4. Battery pack housing + mounting
   
5. Motor integration (hub motor or mid-drive)
   
6. Controller housing
   
7. Wheel assembly & brakes
   

Software options:
SolidWorks / CATIA / Autodesk Fusion / NX / Onshape / Creo

B. CAE ANALYSIS (Mandatory)

Perform simulations on:

1. Static structural analysis
   
2. Dynamic loads (braking & cornering)
   
3. Modal analysis (optional but bonus points)
   
4. Battery pack enclosure structural integrity
   

Tools:
ANSYS / SolidWorks Simulation / HyperMesh / Inventor / Fusion

C. MATLAB & SIMULINK MODELLING (Mandatory)

Build the complete vehicle model including:

1. Longitudinal EV Model

• Mass
  
• Rolling resistance
  
• Aero drag
  
• Wheel dynamics
  

2. Motor Model

• Torque–speed curve
  
• Efficiency map
  
• Power matching
  

3. Battery Model

• SOC estimation
  
• Voltage/Current dynamics
  
• Efficiency & losses
  

4. Driving Cycle Simulation

Use ANY ONE:

• IDC (Indian Drive Cycle)
  
• UDDS
  
• WLTP
  
• Custom city cycle
  

Output required:

• Range estimation
  
• Energy consumption (Wh/km)
  
• Acceleration 0–40, 0–60, 0–100
  
• Gradeability
  

D. Design Justification (Mandatory)

Participants must justify:

• Material selection
  
• Geometry selection
  
• Motor–battery–controller matching
  
• Weight & cost considerations
  
• Stability & safety parameters
  

7. Deliverables 

Participants must submit the following:

A. One ZIP Folder Containing:

1. CAD Files (Native + STEP)
   
2. CAE Files + Screenshots
   
3. MATLAB/Simulink models + scripts
   
4. Driving cycle analysis report
   
5. Performance graphs
   

B. Mandatory PDF Engineering Report (20–40 pages)

Include:

1. Objective & Scope
   
2. Vehicle type selected
   
3. Architecture diagrams
   
4. CAD snapshots with dimensions
   
5. Suspension, steering, frame calculations
   
6. FEA results
   
7. Simulink block diagrams
   
8. Performance analysis
   
9. Cost & feasibility analysis
   
10. Improvements for prototype phase
    

C. 8–12 Min Presentation Video

• Explanation + screen recording
  
• Must show CAD + Simulink working

8. Evaluation Criteria (100 Marks)

Category	Marks	Criteria
CAD Design Quality	20	Completeness, accuracy, engineering relevance
CAE Analysis	15	Correct load cases, validation, safety factors
Simulink Modelling	25	Correct architecture, parameterization, results
Performance & Driving Cycle Simulation	10	Accuracy, clarity, interpretation
Innovation	10	Unique concepts, novel engineering
Report Quality	10	Clarity, professionalism, engineering rigor
Video Presentation	10	Communication + completeness

Minimum score to qualify for prototype round: 70/100

9. Tools Allowed

CAD

• SolidWorks
  
• CATIA
  
• Fusion 360
  
• Creo
  
• Onshape
  

Simulation

• MATLAB
  
• Simulink
  
• Simscape
  
• ANSYS / Hypermesh
  

Optional

• Python for post-processing
  
• Excel for BOM
  

10. Rules & Eligibility

General Rules

1. All submissions must be original.
   
2. Internet resources can be used but no direct copying of CAD or Simulink models.
   
3. Team must submit all files before the deadline.
   
4. Late submissions will not be evaluated.
   
5. Every team must select ONE vehicle type only.
   

Design Rules

1. Frame/chassis must follow basic safety standards.
   
2. Lithium-ion battery modelling must include SOC estimation.
   
3. Simulink models must be executable without errors.
   

Plagiarism Rules

• CAD similarity > 40% = disqualification
  
• Copy-paste report = 0 marks
  

Intellectual Property

• Participants retain IP ownership.
  
• DIYguru may publish top submissions with credit to the team.