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Mini Project Report On

DESIGN AND FABRCATION OF


ELECTRIC TWO-WHEELER
SUBMITTED TO THE FACULTY OF
DEPARTMENT OF MECHANICAL ENGINEERING

Submitted by

KSHETHRAGNYA UDHBHAV NARLANKA (17R11A0331)

Under the esteemed guidance of

Dr. Devaiah Malkapuram, Professor, ME

Dr. S.SHYAM KUMAR, HoD, ME

DEPARTMENT OF MECHANICAL ENGINEERING


GEETHANJALI COLLEGE OF ENGINEERING
TECHNOLOGY
Cheeryal (V), Keesara (M), Medchal-Malkajgiri. DIST. 501 301
1
(Permanently Affiliated to JNTUH, Approved By AICTE, Delhi, Accredited by NAAC with Grade ‘A’ and NBA)
2020 - 21

2
DECLARATION

We hereby declare that the whole work done in completing this project is my own effort and we

have not copied it from anywhere. During the project, our project guide Dr. Devaiah Malkapuram

and his team guided us to complete our project taking his valuable time.

PROJECT BY:

KSHETHRAGNYA UDHBHAV NARLANKA (17R11A0331)

iii
ACKNOWLEDGEMENT
It is our privilege to express our sincerest regards to our project coordinator, Dr. Devaiah
Malkapuram, professor of Mechanical Department of Geethanjali College of Engineering and
Technology for their valuable inputs, able guidance, encouragement, and whole-hearted
cooperation throughout the duration of our project. We deeply express our sincere thanks to our
Head of the Department Dr.S. Shyam Kumar for encouraging and allowing us to present the project
on the topic “Design and Fabrication of Electric Two-Wheeler ”.

We pay our respects and love to our parents and friends for their encouragement. Finally, we
express our thanks to our friends for their cooperation and support.

We also express our heart full gratitude to the faculty in the successful completion of the project.
We owe a deep respect of gratitude to our family members and friends for their loving
encouragement, timely suggestions, and constant support in finishing this project within time.

By
Kshethragnya Udhbhav Narlanka(17R11A0331)

iv
ABSTRACT

Project title: Design and Fabrication of Electric Two-Wheeler

The issue of global warming and air-pollution being caused to the environment by humans is
paramount and its prime time that we address this major problem by finding an alternative to
automobiles that run on fossil fuels. Therefore, we intend to bring in electric vehicles, to substitute
the use of automobiles running on fuels. There is a major need for electric vehicles as they possess
many advantages when compared to their counterparts. In this paper, a traction system useful for an
Electric Vehicle of individual use is described. The developed system is constituted in a first
approach by Electric power sources which is constituted by Li-ion batteries. In the developed
system, the batteries run as element that store energy and that can be used to retrieve energy.
Starting from the functional characteristics of typical electrical vehicles and characterization of a
typical routing profile, the energy consumption is obtained. In order to characterize and design the
system, this is described in detail, the battery, the power converters and the implemented strategy of
control. According to the obtained results, a control strategy that allows an effective management
of the stored energy in the system regarding the vehicle ' s optimal functioning and increasing its
autonomy is also presented and discussed. Based on experimental and simulation results, the
advantages and disadvantages of the proposed solution will be presented.
It’s never too late to protect our planet from our deeds, this is the best time and opportunity to
switch completely into electric from fossil fuel powered vehicles and fulfill our responsibility.

v
TABLE OF CONTENT

TITLE Page No
DECLARATION ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

CHAPTER 1-INTRODUCTION
1.1 4
Introduction

1.2 Frame design 4


1.3 4
Chassis design consideration

1.4 4
Tyre size

1.5 4
Chassis tube diameter

CHAPTER 2-DESIGN AND ANALYSIS OF CHASSIS


2.1 5
Sketches
2.2 5
Design and Analysis of
Chassis
2.3 5
Analysis and Impact
Calculations
2.3.1 5
Front stress
2.3.2 6
Side impact test
2.3.3 7
Rear impact test
CHAPTER 3- CIRCUTE DIAGRAM OVERVIEW AND WORKING OF
BLDC MOTOR
3.1 9
Electric circuit diagrams
3.2 10
Brushless dc (bldc) motor
overview
3.3 10
Key characteristics of the
bldc motor
3.4 11
Working
1
CHAPTER-4 DRAFTING OF COMPONENTS
4.1 10
Drafting of battery
components

4.2 Drafting of wheel 11

4.3 Drafting of swing arm 12

4.4 Drafting of front suspension 13

4.5 Drafting of rear suspension 14

4.6 Drafting of chassis 15

4.7 Master draft look 16

CHAPTER- 5 MATERIAL
5.1 Material data sheet 17

5.2 Composition 17

5.3 Mechanical properties 17

CHAPTER-6 COMPONENTS AND IT’S SPECIFICATIONS


6.1 List of components 18

6.2 Technical specifications chart 20

6.3 Braking report 20

6.4 21
Drum brake

6.5 Disc brakes 21

6.6 21
Transmission calculations

6.7 Innovation 22

6.8 Final master look 24

2
CHAPTER 1

INTRODUCTION
1.1 INTRODUCTION
The objective of this project is to build an E-BIKE which is strong, durable, smart and
modular. The focus is to provide smart and safe technology to the rider. It comes with the
latest technology that i have assembled in this E-BIKE. We had tested the bike frame with
ANSYS and got good result.

1.2 FRAME DESIGN


 The frame is designed to meet the technical requirements of competition the objective
of the chassis is to encapsulate all components of the E-BIKE including a 95th
percentile driver, efficiently and safely.
 Principle aspects focused during the design of chassis are driver safety, power train
simulations and structural weight of the total bike and operator ergonomic. The design
was ensured as per the given parameters of the rule book and the first priority was
given to driver's safety and weight of the bike.

1.3 CHASSIS DESIGN CONSIDERATION


 Wheelbase <1400mm
 Ground clearance > 150mm
 Handlebar height > 750mm

1.4 TYRE SIZE


 Front: 3.00-16”
 Rear: 3.00-16”:

1.5 CHASSIS TUBE DIAMETER


 Inner diameter= 47.8 mm
 Outer diameter= 50.8 mm

3
CHAPTER 2
Design and Analysis of chassis
2.1 Sketches:
 As per the mentioned dimensions we have drawn several sketches for the chassis of which one
is selected.

2.2 Design and Analysis of Chassis:


 Selecting specified tubular cross section of a specified material with design in NX CAD and
dumped into AUTO CAD.

 After completion of design analysis of the chassis was done in ANSYS Software.

2.3 Analysis and Impact Calculations:

2.3.1 Front impact test


 Front impact is tested by collision of E-BIKE with a stationary rigid wall until it comes to
rest. So the load is applied on the front part of the bike and the D.O.F’s of the back portion
were constrained of the E-BIKE. V (top velocity of the vehicle) =
Calculations:
M (mass of the vehicle) =120kgs
V (top velocity of the vehicle) =35kmph=9.722m/sec
Δt (impulse time) =0.18sec
Front impact load (F) = (m*v)/Δt
= (120*9.722)/0.18
=6481.48N
Factor of safety (FOS) = (yield strength/working stress)
=1110MPa/75*9.81
=1.508
Impact load=F*FOS
=6481.48*1.508
=9774.07N

4
FRONT STRESS

FRONT TOTAL DEFORMATION

2.3.2 Side impact test:


 In today`s traffic around the world and especially in India the side impact is much regular
and frequent to occur. Collision of an E-BIKE with another bike which are no stationary as
assumed in front impact test. Referring to the automotive industry safety testing, makes an
equivalent assumption that the load applied in side impact would be half that of a
stationary object.
 In side impact test, the forces were applied on the sides of the bike during collision with
another bike and all degrees of freedom of other side are constrained.
Calculations: As it is assumed that 50% load is applied Therefore,
Let us assume that the velocity has been reduced to 30kmph
Mass (m) =120kg
Velocity (v) =30kmph=8.33m/sec
Impulse time (Δt) =0.18sec
Side impact load= (m*v)/Δt
5
= (120*8.33)/0.18
=5553.33N
Factor of safety (F.O.S) =1.508
Now total load=side impact load*F.O.S
=5553.33*1.508
=8374.42N

SIDE STRESS

SIDE TOTAL DEFORMATION

6
2.3.3 Rear impact test:

 In rear impact test the E-BIKE is assumed to be stationary and another bike with
same mass and velocity of 35kmph is impacted on the rear side of the former
bike resulting in constraining of the front parts of the E- BIKE.
Calculations:
Consideration of the velocity is same as for the front impact test
Mass (m) =120kg
Velocity (v) =35kmph=9.722m/sec
Impulse time (Δt) =0.18sec
Rear impact load= (m*v)/Δt
= (120*9.722)/0.18
=6481.48N
Factor of safety (F.O.S) =1.508
Now total load= rear impact load*F.O.S
= 6481.48*1.508
=9774.07N
REAR STRESS

7
REAR TOTAL DEFORMATION

8
CHAPTER 3
CIRCUTE DIAGRAM,
OVERVIEW AND WORKING
OF BLDC MOTOR

3.1 ELECTRIC CIRCUIT DIAGRAMS

This is a circuit diagram of Motor and speed controller. In this diagram an Ampere
Regulator is used to control the speed of the motor and to maintain it under 35kmph
according to the rules where a Throttle is used for Ampere Controller for pickup of the
vehicle. Ampere Controller is assembled in a main controller which controls tale light,
head light, battery indicator and side indicators.
A lead-acid battery is a source of direct-current (DC) electricity. When the battery
begins to lose its charge, it must be recharged with another DC source. An electric
motor, though, is as an alternating- current (AC) source. For the electric motor to
provide DC energy, its output has to pass through an electronic circuit called a rectifier.
An electric motor can be used in conjunction with a source of mechanical energy and a
rectifier to recharge a battery. So we can conclude that using an rectifier we can charge
the battery easily.

9
3.2 BRUSHLESS DC (BLDC) MOTOR OVERVIEW

A Brushless DC (BLDC) motor is a Permanent Magnet Synchronous Motor with unique back EMF
waveform that allows them to behave similarly to a brushed DC motor. Some confusion can arise from the
name, as a brushless DC motor does not directly operate off a DC voltage source. However, the basic
principle of operation is similar to a DC motor.

A Brushless DC Motor has:

 A rotor with permanent magnets and a stator with windings


 A BLDC motor is essentially a DC motor turned inside out
 Brushes and commutator have been eliminated and the windings are connected to the control
electronics
 Control electronics replace the function of the commutator and energize the proper winding
 Windings are energized in a pattern which rotates around the stator
 The energized stator winding leads the rotor magnet and switches just as the rotor aligns with the
stator

3.3 KEY CHARACTERISTICS OF THE BLDC MOTOR

 There are no sparks


 Potentially cleaner, faster, more efficient, less noisy
and more reliable
 Heat is generated in the stator: easier to remove and maintain
 Rotor has permanent magnets vs. coils thus lighter less
inertia: easier to start/stop
 Linear torque/current relationship smooth acceleration
or constant torque
 Higher torque ripple due to lack of information between sectors
 Low cost to manufacture
 Simple, low-cost design for fixed-speed applications
 Clean, fast and efficient
 Speed proportionate to line frequency (50 or 60 Hz)
 Complex control for variable speed and torque
 Require electronic control

10
3.4 WORKING:

The Brushless DC Motor does not operate directly off a DC voltage source. The brushless DC
motor has a rotor with permanent magnets, a stator with windings and commutation that is
performed electronically. Typically, three Hall sensors are used to detect the rotor position and
commutation is performed based on Hall sensor inputs.
The motor is driven by rectangular or trapezoidal voltage strokes coupled with the given rotor
position. The voltage strokes must be properly applied between the phases, so that the angle
between the stator flux and the rotor flux is kept close to 90° to get the maximum generated
torque. The position sensor required for the commutation can be very simple, since only six
pulses per revolution (in a three-phase machine) are required. Typically, the position feedback is
comprised using three Hall Effect sensors aligned with the back-EMF of the motor. In sensor less
control, back-EMF zero crossing is used for commutation.

11
CHAPTER-4
DRAFTING OF COMPONENTS

4.1 DRAFTING OF BATTERY COMPONENTS

12
4.2 DRAFTING OF WHEEL

13
4.3 DRAFTING OF SWING ARM

14
4.4 DRAFTING OF FRONT SUSPENSION

15
4.5 DRAFTING OF REAR SUSPENSION

16
4.6 DRAFTING OF CHASIS

17
4.7MASTER DRAFT LOOK

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CHAPTER 5
MATERIALS, COMPOSITION AND MECHANICAL
PROPERTIES

5.1 MATERIAL DATA SHEET

NAME STANDARD
GRADE AISI 4340

5.2 COMPOSITION

COMPONENT WT% COMPONENT WT% COMPONENT WT%

C 0.37-0.43 Mn 0.7 P Max 0.035

Cr 0.7-0.9 Mo 0.2-0.3 S Max 0.04

Fe 96 Ni 1.83 Si 0.23

MECHANICAL PROPERTIES

Hardness, Brinell 321 321 -


Hardness, Knoop 348 348 Converted from Brinell hardness.
Hardness, Rockwell B 99 99 Converted from Brinell hardness.
Hardness, Rockwell C 35 35 Converted from Brinell hardness.
Hardness, Vickers 339 339 Converted from Brinell hardness.
Tensile strength, Ultimate 110M Pa 161000PSi -
Tensile strength, Yield 710M Pa 103000PSi -
Elongation at break 13.2% 13.2% -
Reduction of area 36% 36% -
Modulus of elasticity 205G Pa 29700KSi Typical for steel.
Bulk modulus 140G Pa 20300KSi Typical for steel.
Poisson's ratio 0.29 0.29 Calculated
Machinability 50% 50% Annealed and cold
drawn. Based on 100%
machinability for AISI 1212steel.

19
CHAPTER 6

6.1 LIST OF COMPONENTS

SL NO PART GROUP/NAME SPECIFICATIONS ACTUAL FINAL COST


COST
Fork/Steering
1 Assembly 7000/- 2800/-
• Handle bar Straight handel bar
• Fork
telescopic fork
• Suspension front dual suspension
Fram
2 e Outer diameter-25.4mm 5000/- 3500/-
• Frame Tubes Inner diameter-19.05mm
(AISI 4340)
• ACP Sheets
3 Brake Assembly 1500/- 600/-
disc type
• Disc Brakes
4 Transmission System Chain drive mechanisam 2500/- 1000/-
• Sprockets
• Chain Gear
ratio-44:13
5 Front Wheel Assembly 3000/- 1200/-
• Tyres
Tubeless Tyres
• Rim
3"-16"
• Mud Guard
6 Rear Wheel Assembly 3000/- 1200/-
• Tyres
Tubeless Tyres
• Rim
3"-16"
• Mud Guard
7 • Side Stand - 5500/- 2200/-
• Head Light
led head light
• Rear Light led tail light

20
• Single Seat
• Side Mirrors
• Footrest
8 Electrical Systems Led indicators 1500/- 600/-
• Horn digital display
• Indicators
• Display

9 Throttle Controller 1000/- 400/-


10 Traction Battery 48V 30 Ah Li-Ion 15000/- 6000/-
With Battery
Specs
11 Innovation 10000/- 4000/-
pro helmet
smart pulse system
alcohol detection
12 Traction Motor 1kW BLDC Mid Drive 5000/- 2000/-
With Motor
Specs
13 Fabrication Welding bending 10000/- 7000/-
painting
works
TOTAL 61,000/- 32,500/-

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6.2 TECHNICAL SPECIFICATIONS CHART

Bike type Commercial two-wheeler

Start type Electric

Maximum torque 3.98 N-m

Front suspension Telescopic fork

Rear suspension Dual shock

Front and rear braking Disc(hydraulic)

Acceleration 0-35kmph

Dimension 1200mm*1012.6mm*665.3mm

Seat height 50mm

Top speed 35kmph=9.72m/s

Wheelbase 1158.7mm

Ground clearance 324.1 mm

6.3 BRAKING REPORT


A disc brake is a type of brake that uses calipers to squeeze pairs of pads against a disc in order to
create friction that retards the rotation of a shaft, such as a vehicle axle, either to reduce its
rotational speed or to hold it stationary. The energy of motion is converted into waste heat which
must be dispersed. Hydraulic disc brakes are the most used form of brake for motor vehicles, but
the principles of a disc brake are applicable to almost any rotating shaft.

Compared to drum brakes, disc brakes offer better stopping performance because the disc is
more readily cooled. As a consequence, discs are less prone to the brake fade caused when
brake components overheat. Disc brakes also recover more quickly from immersion (wet
brakes are less effective than dry ones).

22
Types of brakes: -
• Drum brake
• Disc brake

6.4 DRUM BRAKE

A drum brake is a brake that uses friction caused by a set of shoes or


pads that press outward against a rotating cylinder-shaped part called a brake drum. The term
drum brake usually means a brake in which shoes press on the inner surface of the drum. When
shoes press on the outside of the drum, it is usually called a clasp brake. Drum brakes consist of a
brake drum attached to the wheel, a wheel cylinder, brake shoes, and brake return springs.
Hydraulic pressure from the master cylinder causes the wheel cylinder to press the brake shoes
against the brake drum. This creates friction between the shoes and drum to slow or stop your
car. Advantages Drum brakes are still used in modern cars. There can be engineering and cost
advantages. Drum Brakes allow simple incorporation of a parking brake. Disadvantages Drum
brakes with internal shoes have a particular disadvantage, when the drums are heated by hard
braking. The diameter of the drum increases due to the expansion of the material and the brakes
must be further depressed to obtain effective braking action. This is known as brake fade and can
lead to driver panic and brake failure in extreme circumstances. Under normal driving conditions
it is seldom noticed, especially when drums of appropriate size are fitted. The Pontiac GTO is
one vehicle often cited as having undersized drums. Before 1984, it was common to re-arc brake
shoes to match the arc within brake drums; the machinery used has been phased out. This
practice, however, was controversial as it removed friction material from the brakes and caused a
reduction in the life of the shoes as well as creating hazardous asbestos dust. It is much better to
use shoes for the proper diameter drum, and if the procedure was needed. The drums were so
worn that they should have been replaced, as the thickness of the drum contributes to the strength
And the heat absorption and dissipation ability of the drum.

6.5 DISC BRAKES


Working somewhat like bicycle brakes, disc brakes work by using caliper’s to clamp brake pads
against either side of the spinning disc. Disc brakes are good because when they warm up, the
disc gets larger and is therefore closer to the pads, meaning you don't have to push as hard on the
pedal to get good braking. Also, if you drive through water, it just falls off the disc so you get
your stopping power back very quickly. They are also generally more efficient than drum brakes
and are easier to set up. You may hear about 'cross drilled' disc brakes, this means they have
small holes drilled through the face of the disc as in the picture below. The holes were originally
designed to help remove gas caused by brake pads heating up, but with modern pads being much
more efficient.

6.6 TRANSMISSION CALCULATIONS


Motor power = 1 kW

23
Voltage = 48V, brushless, mph = 58.5
Torque = 3.2 N-m
Gear ratio = N1/N2 = T2/T1 => 3000/N2 = 44/13 =3.38(reduction ratio)
N2 = 886.36 r.p.m
ῳ1 = 2 π N1 / 60
ῳ1 = 314 rad/s
ῳ2 = 92.819 rad/s
Design power = rated power ×service factor (k)
p = 1000×1.3

Specifications Driver sprocket Driven sprocket

No.of teeth 13 44

Diameter 0.05m 0.17m


R.P.M 3000 886.36
Power 1kw 990w
Torque 3.2 N-m 10.74N-m

6.7 INNOVATION

PRO-HELMET
According to the rules of the Indian government a helmet is must while driving, and no one
follows this rule. By considering this we have come front with a helmet which consist of a low-
tension spring and a alcohol sensor. Low Tension Spring is used a wireless switch to the main
controller, and alcohol sensor attached to it. When a person wears this helmet, it passes a signal to
the bike and allows to start the motor in case he is drunk, the alcohol sensor present in the helmet
captures the reading and stops the signal from helmet. It also has a safety feature of anti-theft.

SMART PULSE DETECTION

Our Bike has a smart pulse detection system which reads the Rider pulse and stores the data. If he is
24
supposed to get any strokes due to low pulse or high pulse, then the pulse indicator tracks the GPS
immediately and responds to the nearby hospitals and local police station.

25
6.8 FINAL MASTER LOOK

26
27
Applications
 E-Bikes are majorly used when we need to travel shorter distances.
 these bikes are driven in small and low speeds.

Advantages
 E-Bikes emit lower pollution per kilometer than motorcycles and cars
 E-Bikes are eco-friendly.
 They are safe and are available at low cost.
 They are light in weight and are very comfortable in riding.
 They are cost saving compared to gasoline engine vehicles.

Disadvantages
 The speed is very low compared to gasoline engine vehicles.
 Cannot be preferred for longer rides.
 Charging points for these bikes are low at present. So, it is considered as a disadvantage.
 Time taken for charging is high compared to gasoline vehicles.

CONCULSION

We have successfully made an E-Bike with the given parameters. Initially for the material selection
we made many chassis designs by using NX CAD software and selected one from them. This made
us to improve our knowledge on the base of software.

In addition to this, the project work has provided us an excellent opportunity and experience, to use
our limited knowledge. We gained a lot of practical knowledge regarding, designing, assembling
and fabrication while doing this project work. We feel that the project work is good solution to
bridge the gates between institutions and industries.

From this project, we have got an idea of mechanical designing software/tools i.e NX CAD. The
software is easy to learn, use and geared up to enhance concept design, planning and assembly will
be functional and powerful to satisfy the needs of engineering design and industrial necessity.
Software enabled us to grasp knowledge about the real time mechanism designs. We are proud that
we have completed the work with limited time successfully. We have done to our ability and skill
making work.

28

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