The document details the project of a hybrid, eco-friendly, and lightweight tricycle designed by a team from Sri Shakthi Institute of Engineering and Technology. It includes specifications, design methodologies, safety protocols, and the estimated costs of various components used in the construction of the vehicle. The project emphasizes the use of innovative materials and design techniques to meet engineering requirements while ensuring efficiency and safety.

1. SAE NIS EFFI-CYCLE 2015
>>>Light Weight Season<<<
VIRTUAL ROUND
15134 ZEHN RACERS
Sri Shakthi Institute of
Engineering and Technology,
Coimbatore, Tamil Nadu.
Indore Virtual Round Zone

2. INTRODUCTION:-
TEAM STRUCTURE:-
Name
Branch/ Year
of Degree
Team
Designation
Role in Project
Jai
Krishna
B.E.
Mechanical/
3rd year
Captain Roll cage &
Safety
Arun B Vice-Captain
Ashok Member
Steering control
Gughan Member
Edwin Member Power train
(Human &
Electric)
Guna Member
Giri Member
Kathirvel Member Suspension &
WheelsArun R Member
Akilesh Member Brake & seat
Zehn Racers aimed to design a hybrid, eco- friendly, ergonomically designed &
light weighed tricycle by finding solutions to the current & future engineering
requirements & problems. We used Solid Works and ANSYS for design and analysis
respectively. We tried to reduce weight to the minimum without compensating the
efficiency of vehicle.

3. PROJECT PLAN:-
21 Apr 28 Apr05 May12 May19 May26 May02 Jun 09 Jun 16 Jun 23 Jun 30 Jun 07 Jul 14 Jul 21 Jul 28 Jul 04 Aug11 Aug18 Aug25 Aug01 Sep08 Sep
Team selection
Registration
Basic study of Tricycle
Knowledge of rule book
Design & Calculation
Analysis & Review
Assembly & Review
Market survey & Review
PPT Preparation
Virtual round preparation
Frame Material purchase
Other componets purchase
Fabrication of Frame
Frame Assembly
Cycle Testing:
Rule book/ Safety check
Weight Analysis
Figure '8' test
Electric Drive inspection
Brake Test
Design Evaluation
Cost Analysis
Acceleration Test
Gradient Test
Utility Test
Preparation for Final Race
Expected working period

4. ROLL CAGE
SPECIFICATIONS RULE BOOK
OUR
VEHICLE
Length <=100 ” 83.6 ’’
Height <=60 ” 58 ’’
Breadth <=55 ” 53.3 ’’
H – point <=28 ” 18 ”
Ground clearance >=8 ” 9.3 ’’
Sm lateral >=8 ” 10 ”
Sm longitudinal 4 ” 4 ”
Clearance gap between
2 drivers
>=3 ” 4 ”
Configuration TADPOLE TADPOLE
KNOWLEDGE OF RULEBOOK:-
BATTERY
SPEC. RULE BOOK OUR VEHICLE
Voltage 12-48V 36V
Current <=35A-hr 13.6 A-hr
STEERING CONTROL
SPEC. RULE BOOK OUR VEHICLE
Turning radius
of vehicle
<=4 m 3.6m
Outer circle
diameter
8 m 7.2m
MOTOR
SPEC. RULE BOOK OUR VEHICLE
Type
PMDC/
BLDC
BLDC
Output power <=400W 350W

5. LIGHT WEIGHT FEATURES:-
Lithium battery is used
Light weighed Disc brake
Light weighed Barnett William Seat
Macpherson suspension
Honey Comb Utility Box
Light weighed Tubeless Tyre
COMPONENT
ESTIMATED
WEIGHT (kg)
Frame 49.00
Steering 3.00
Human Power Train 7.50
BLDC motor system 4.00
Li Ion Battery 3.00
Brake 1.00
Suspension 5.00
Wheel Assembly 2.00
Seats 7.00
Utility Box 0.50
Other Components
(Fasteners)
1.50
Total 83.5
ESTIMATED
KERB WEIGHT
83.5 kg
FRAME:-
Cromoly 4130 Steel (Light alloy) with
Yield Strength: 460 MPa
SAE GRADE: AISI 4130
Weaker normalized temper is used to maintain fine
balance of longevity & strength

6. FRAME:-
Outer Dia.: 26.7mm
Thickness : 2.9mm
Bending strength: 250 Pa
FRONT IMPACT FRONT IMPACT FRONT IMPACT
SIDE IMPACTSIDE IMPACTSIDE IMPACT
ROLL
OVER
ROLL
OVER
ROLL
OVER

7. POWER TRAIN (HUMAN):-
A Hybrid Vehicle
6 Speed gear mechanism
Chain used for efficient power
transmission
Rear wheel drive
Total power combined in power
axle
Gear
no.
T1:
T2
Speed
ratio
Force
acting on
pedal
Mechanical
Advantage
Power
required
1 42:14 3.00 116.97 0.67 310.68
2 42:16 2.65 133.16 0.77 402.30
3 42:18 2.33 149.23 0.86 505.74
4 42:21 2.00 173.44 1.00 683.06
5 42:24 1.75 197.64 1.14 886.98
6 42:28 1.50 229.91 1.32 1200.26

8. POWER TRAIN (ELECTRICAL):-
MOTOR SPECIFICATIONS
Type BLDC
Voltage 36V
Rated current 3.53A
Continuous Current 14.8A
Rated power 350W
Torque 1.2Nm
Starting Torque 3.6Nm
No load speed 4500 RPM
Rated speed 3000 RPM
Longer lifetime
High torque to weight ratio
Motor placed below the seat
V belt for power transmission
LITHIUM ION BATTERY SPECIFICATIONS
Charging time 5 hours
Voltage 36V
Continuous discharge current 15A
Weight 3 Kg
Size 245.00x110.00x75mm
Compact in size & Shielded
Less in weight
Lasts up to 30 minutes
Motor:
Battery:

9. STEERING:-
STEERING SPECIFICATIONS
Wheel base 65”
Track width 52”
Steering wheel
diameter
350mm
Steering ratio 16:1
Steering lock to lock 1.5 turns
RACK AND PINION
 Simple in construction
 Economical
 Easy to manufacture
ARRANGEMENT
GEOMETRY
ACKERMAN GEOMETRY
 Caster Angle - 12deg
 Camber Angle - Neutral
CALCULATION
 Critical Speed – 23.07 km/h
 Turn Radius - 3.68m

10. BRAKE:-
Decelerat
ion 4.16
m/s
Stopping
distance
3m
Stopping
time 2 s
Braking
force 23
N
Ceramic
composite
body
Single
fixed
caliper
Disk brakes
Light weight and effective
6 holes hub disk, standard, post mount
frame and fork mount
Disc OD=16.5 mm, Thickness=2.5 mm
Dynamic weight distribution while braking
Reliable, proportional and smooth braking
without skidding

11. SUSPENSION:-
DESCRIPTION
REAR
SUSPENSION
FRONT
SUSPENSION
Material Spring steel Spring steel
Modulus of rigidity - N/mm2 78600 78600
Mean dia. Of coil - mm 55 36
Diameter of wire - mm 8 6.5
Height - mm 119 79.5
Total no. of coils 7 7
Weight of bike (Aprox.) kg 131 131
Deflection- mm 9.3 5.9
Total force acting on the spring
(one side) N
1289.69 1574.35
Open coil helical spring
Macpherson suspension
Less space required
Reduced weight comparatively
Ease of operation
Low manufacturing cost

12. WHEELS & TYRES:-
SEATS:-
SPECIFICATIONS FRONT REAR
Outer Diameter 24” 26”
Rim size 11.25” 10.25”
Tyre size 2.125” 1.75”
Spoke thickness 3.2mm
Max. Load/ Tyre 150Kg
Tubeless tyres
Decrease in rolling resistance
Less vibration
Less heat generation
Sudden burst of tyres is avoided
SEAT SPECIFICATIONS
Type
Barnett William
Seat
Arrangement Adjacent
Material PUR[polyurethane]
Length*Breadth 18 ” * 22 ”
Tensile strength 4*10 7 N/m2
Mass density 1260kg/m3
Lightweight
High resilence
Low cost
Easily available
material is used

13. SAFETY:-
Entire electrical system can be made dead using Kill Switch which is
accessible to both the driver
3 point Original Equipment manufacturer (OEM) seat belts
Covering for all rotating objects
Side & front mirrors are provided
Battery is shielded
Sockets for withdrawing current
 As Solid Lithium Ion Battery is used, there is no leakage
Polystyrene ( EPS) helmet
 Shin guard, knee pad, elbow pad, cycling gloves and safety glasses
ERGONOMY:-
Suspension system is give a good performance
Head rest to avoid direct hit with frame
Mirrors for viewing nearby vehicles
4 ’’ spacing between the drivers to avoid the
direct contact with drivers
Seat- Steering 13”
Seat – Pedal 13.5”
Seat Backrest length 28”
H-Point 20”
Space between seats 4”

14. VEHICLE FABRICATION PROCESS:-
Procurement
of round
frame pipes
Bending of
pipes
Welding
of frame
Welding of
Suspension
Chain fitting
Assembly of gears
& Sprocket
Assembly of
Suspension, Frame &
Hub
Fitting of Brake,
Wiring & Levers
Handle & Seat
Assembly
Fitting of BLDC
Motor & Battery
Wiring, Connecting
Kill switch &
Controller
Assembly of Sub systems to FrameFabrication of Vehicle ExteriorsTesting of Vehicle Setup

15. COST ANALYSIS:-
POWER TRAIN
COMPONENTS
COST
(Rs)
Chain 300
Chain Guard (2) 150
Gear set (2) 2000
Pedal set (2) 160
TOTAL 2610
ELECTRICAL SYSTEM
COMPONENTS
COST
(Rs)
Motor 7000
BLDC controller 2500
Pulleys (2) 1200
Belt 600
Battery 23000
Kill switch 300
Wires 500
TOTAL 35100
DRIVERS’
SAFETY
COST
(Rs)
Helmet (2) 1250
Kneepad & Elbow
Pad (2)
750
Safety Glasses (2) 320
Shin Guard (2) 400
Gloves (2) 500
Shoes (2) 1200
TOTAL 4420
OTHER
COMPONENTS
COST
(Rs)
Brake (3) 4000
Suspension (3) 6000
Seat (2) 3000
Seatbelt (2) 4000
Fasteners (grade 5
M8.8)
500
TOTAL 17500
COMPONENTS COST (Rs)
Frame 20000
Steering 3000
TOTAL 23000
THANK YOU