Model MINI Project Report Ud3
Model MINI Project Report Ud3
Model MINI Project Report Ud3
Submitted by
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:
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
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
1.4 4
Tyre size
1.5 4
Chassis tube diameter
CHAPTER- 5 MATERIAL
5.1 Material data sheet 17
5.2 Composition 17
6.4 21
Drum brake
6.6 21
Transmission calculations
6.7 Innovation 22
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.
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.
After completion of design analysis of the chassis was done in ANSYS Software.
4
FRONT STRESS
SIDE STRESS
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
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.
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
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
18
CHAPTER 5
MATERIALS, COMPOSITION AND MECHANICAL
PROPERTIES
NAME STANDARD
GRADE AISI 4340
5.2 COMPOSITION
Fe 96 Ni 1.83 Si 0.23
MECHANICAL PROPERTIES
19
CHAPTER 6
20
• Single Seat
• Side Mirrors
• Footrest
8 Electrical Systems Led indicators 1500/- 600/-
• Horn digital display
• Indicators
• Display
21
6.2 TECHNICAL SPECIFICATIONS CHART
Acceleration 0-35kmph
Dimension 1200mm*1012.6mm*665.3mm
Wheelbase 1158.7mm
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
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
No.of teeth 13 44
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.
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