The team designed an eco-friendly three-wheeled vehicle called Efficycle for the EFFI-CYCLE 2013 competition. [1] They focused on simplicity, efficiency, ergonomics and safety while keeping the design affordable. [2] Key aspects of the design included a durable 1018 steel roll cage, BLDC motor and lithium battery power train, disc brakes, front and rear suspension, and an under-seat steering system. [3] Extensive analysis and testing was conducted to validate the design.

1. EFFICYCLE SAE INDIA 2013
VIRTUAL ROUND
MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY
JAIPUR,RAJASTHAN
West zone

2. Design Report
Abstract
Design methodology
Vehicle structure
Power train
Cad/ caE
Fabrication plan
Ergonomics and aesthetics
Project plan

3. ABSTRACT
The focus has been laid on the simplicity in design, easy maintenance,
efficiently driven by two drivers, eco-friendly, ergonomic and safety at
every reasonable price. Every final action has been taken into account
keeping in mind the availability of the components and performance
parameter as per the norms of EFFI-CYCLE 2013 RULEBOOK. This
presentation provides details about our team’s work-flow and results we
have come across to provide a vehicle that contributes to environment
sustainability.

4. RULEBOOK CONFORMANCE
Safety first: We have designed our vehicle which not only adheres to all related
parameters in the rulebook but also exceeds them.
Durability: To make the frame more durable all required strength provisions were
exceeded at critical points of our frame.
Quality: The build quality of each component is ensured while choosing and
designing various components.
Ergonomics: Special care has been take for the utmost comfort of the driver. The
vehicle is designed to be spacious, countenancing easy entry and exit of driver.
Ecological: For our vehicle, we’ve given extra attention to environmental factors to
make it more eco-friendly.
Dimensional: Following slides describe the specifications of the vehicle which are in
absolute conformance to the rulebook.

5. DESIGN METHODOLOGY
1.)
• Low cost
• Bulk prod. and durability
2.)
• Nice look
• Turning and aerodynamic
3.)
• Quality at any cost
• Nice look
1.)
• Less material
• Easy and quick to assemble
2.)
• Front light, under seat steer
• Curved cage
3.)
• Shape optimization and analysis
• Odometer and side mirror
 Consumer and customer
requirements
 Problem statement:

6. DESIGN CONSIDERATION
Both the trikes have their pros and cons. But Tadpole design is better than delta in
every realm like:-
Tractive effort available
from share of weight
Tadpole
Better grip
available for
both
steering and
braking
Comfort and
practicality
Excellent
handling as
CG is lower

7. ROLL CAGE
Material- 1018
Mild Steel alloy
OD= 1 inch
Thickness= 0.12
inch
Chemical composition
Element weight %
C 0.14-0.20
Mn 0.6-0.9
P 0.04 (max)
S 0.05 (max)
Fe 98.81-99.26

8. JUSTIFICATION FOR THE SELECTION OF MATERIAL

9. CAD models

10. VEHICLE STRUCTURE
BRAKES
Since most of the braking power is governed by the front
brakes, we are using disc brake in both the front wheels as
well as in rear wheel in our tadpole design.
SPECIFICATIONS OF DISC BRAKE
Mechanically actuated light weight system.
Material of rotor- Stainless Steel
(to overcome rusting).
Diameter of rotor- 160 mm.
Thickness of rotor- 2 mm(approx.).
Dual actuation disk brake.
IS 6 bolts disk rotor mounting

11. Pros of
Disc
Brakes
Strong action
Less affected by
mud and water
Unaffected by
warped rims
No heated rims
or tire blowouts
on long descents
Not always as
strong as disc
No rim wear and
Pads last a long
time
tear
Cons of Rim
Brakes
Wear and tear
on rims
Risk of tire
blowout from
heating up rims
on long descents
Affected by
water and mud

12. TIRES:
FRONT WHEEL
Outer Diameter of tire- 24 inches
Tire width- 1.5 inches
REAR WHEEL
Outer Diameter of tire- 26 inches Semi Slick Tyre
Tire width- 2.0 inches
 All wheels carry 24 spokes because less weight on wheel and aerodynamically better as
compared to 36 spokes.

13. SPECIFICATIONS (FRONT)
TYPE SEMI SLICK TYRES (24 OD-1.5 W)
TREAD DEPTH 0.25 INCHES
ASPECT RATIO 0.0625
NUMBER OF SPOKES 24
RIMWIDTH 1.2 INCHES
SPECIFICATIONS (REAR)
TYPE SEMI SLICK TYRES– (25 OD-2 W)
TREAD DEPTH 0.25 INCHES
ASPECT RATIO 0.0769
NUMBER OF SPOKES 24
RIM WIDTH 1.2 INCHES

14. Front suspension:
It will be double wishbone strut mounted directly on the chassis of the tricycle with pin
joints.The upper V arm will be kept a little shorter to provide better contact with the ground.
Type Double Wishbone Suspension (with unequal Parallel arms)
Upper Arm Length 12.6 inches
Lower Arm Length 14.2 inches
Roll Centre Height 6 inches
Shocker Travel 5.6 inches
Spring Constant(K) 19 N/mm
Rear suspension:
simple spring suspension connected between the shaft of rear wheel and the chassis of
the tricycle at an angle such that the bumps do not effect the chassis and rider.
Type Simple Spring Suspension
End 1 Type Square
End 2 Type Tangential
Bar Diameter .828 inches
Install Height 13 inches

15. Advantages of Double Wishbone Strut suspension
Fairly easy to work out the effect of moving each joint, so the
kinematics of the suspension can be tuned easily and wheel
motion can be optimized.
Easy to work out the loads that different parts will be subjected
to which allows more optimized lightweight parts to be designed.
Provide increasing negative camber gain all the way to full
jounce travel.

16. STEERING
We are using under seat steering.
This design also offers good Ackerman
compensation.
Single Tie Rod and Drag Link System
The main linkage consists of
only two rod-end bearings. This
allows the steering to remain
relatively tight.
It is very flexible and provides
adequate Ackerman
compensation

17. POWER TRAIN:
Sprocket specifications:
Where to
establish
No. of sprockets type Cog’s Diameter(cm) No. of teeth
Projecting towards
front
2 Plain plate 20 50
Below the seats 2 Plain plate 12 30
Below the seats 2 Plain plate 16 40
At the common shaft 2 Split hub body 10 25
Middle of the shaft 1 Solid hub body 12 30
At the rear wheel 2 Hub on both sides 8.5 21
At the shaft of motor 1 Plain plate 12 30
Selected on the basis of No. of teeth, hub size and required rpm.

18. POWER TRAIN:
1
2
3
4
5
6

19. CHAIN
SIZE:
We are using ANSI standard#40 chain having:
Pitch=1/2” ; roller diameter=5/16”
Roller width=5/16” ;Lw=810lbs
Justification for use of chain:
 Best fitted with the available sprockets.
 High tensile strength and good load capacity.
Chain type No. of chain Length of chain(cm)
Crank part to seat 2 150.87
Seat to common shaft 2 141.57
Common shaft to rear wheel 1 106.78
Motor to rear wheel 1 157.76
Transmission system
 Independent transmission system for both drivers.
 Unbalance has been deduced using mirrored distance from middle and avoiding use
of gears.
 Chain cover used for safety perspective.

20. Motor and Battery
Motor used in our tricycle is BLDC Motor
stator length=16cm, rotor length=5cm
total length=24cm
Max. diameter=14cm, rotor diameter=1.5cm
power output=400watt
Why BLDC not PMDC???
• BLDC motor have extremely long motor life, high torque and compact size.
• The design life of BLDC motors can approach the design life of their ball
bearing components.
• Unlike PMDC motors, BLDC motors use solid state circuitry to control the
voltage and current in the armature windings.
• BLDC motors are more versatile, mainly because of their savvy in the speed
and torque departments.
• Other unique uses include electric bicycles where motors fit in the wheels or
hubcaps, industrial positioning and actuation, assembly robots, and linear
actuators for valve control.

21. Features:
• Speed control of one BLDC motor (12/24/48V, up to 25A)
• User configurable to suit various motor specifications
• Bridge-type inverter uses Pulse Width Modulation
• Self-recoverable hardware short-circuit protection provides
extra safe operation.
• Operational from -40 to 85°C (-40 to 185°F)
• Suitable for moist, high shock and vibration environments
ADVANTAGES:
require less and sometimes no maintenance due to the lack of brushes.
They beat brush motors in the speed/torque trade-off with their ability to maintain or
increase torque at various speeds.
Importantly, there’s no power loss across brushes, making the components significantly
more efficient.
Other BLDC advantages include high output power, small size, better heat dissipation,
higher speed ranges, and low-noise (mechanical and electrical) operation.

22. Vehicle Specifications
GENERAL SPECIFICATIONS:
Curve Weight 43.869kg
Transmission Side by side recumbent trike
Power BLDC motor with dynamo and speed regulator
Maximum velocity 28kmph(140rpm by motor and 110 manual)
Steering Single Tie Rod and Drag Link System
(under seat steer)
Turning Radius 4.72 meter at 17.63° turning
Brakes Disc brakes
Wheels and tyres Front – 24x1.5 Mud tyres; Rear – 26x2 Semi Slick
Tyres
Gradeability 60 % OR 60 degrees
Ground clearance 12 inches or 304.8 mm
Track width(max.) 51inches or 1310mm
Wheel base(max.) 70.57 inches or 1792.47 mm

23. Trike assembly and material specification:
Parts material weight cost
Roll cage frame 1018 steel 43.87kg 4000
Sprockets,idler, chain with cover and hub 1045 steel, cast iron and Al alloy 7 kg(approx) 1500
Wheel(tyre & tube, rim, spokes) (nylon cord, butyl rubber, steel alloys) 6.5 kg 900
bearings Stainless steel 440C 500 gm 400
Steering column, arms and fork 1018 steel 3 kg 500
tie rods and ball studs Steel and high grade steel alloy (1.5+.3)kg 400
Brakes, brake lever and cable Stainless steel, Al alloy &nylon bracket, Teflon
covering
2 kg 2550
Springs and damper(suspension) Steel and alloy 7 kg 3500
Seats and seat belts Cotton and Nylon (2+.5) kg 1100
Motor magnetic parts and dynamo, battery Neodymium Boron Iron and plastic cover 6.5 kg 8500+8000
Fender, grip and Front lights Polycarbonate, plastic 1.2 kg 350
Side mirrors and
Miscellaneous(windscreen,lock etc.)
available material 2 kg 600
Uprights, pivots, Nuts and bolts, joints, screw,
washer
available material 1 kg(approx) 400
Speed regulator, first aid kit, pedal available material 1 kg(approx) 2000+200
Gross total:- 85.87kg 34900

24. SUBSYSTEMS OF VEHICLE

25. ERGONOMICS AND AESTHETICS
SAFETY COMFORT AESTHETICS
Product
differentiation
Pride of ownership,
fashion or image
Team motivation
Ease of use and operation
Ease of maintenance
Control of recognized
hazards

26. SAFETY
Providing OEM conversion 3-point Seat belts ,Helmets , Safety goggles , knee and elbow
guards.
COMFORT
Providing Recumbent seats,
ERGONOMICS
Use of clear windscreen for better vision, providing individual fork steering mechanism for
better handling,, incorporating indicators and front light for ease of use.
To increase performance use of Disc brakes , lowering positioning of drivers ,and providing
streamlined rollover to reduce aerodynamic drag.
Roll cage is designed in order to enhance overall safety in case of front or rollover impact and
side impact.

27. FABRICATION PLAN:
Suspension
steering
Roll
cage
Power
train
Wheel
Brakes

28. Fabricated efficycle

30. PROJECT PLAN
Sr.
No
ACTIVITY WEEK
1
WEEK
2
WEEK
3
WEEK
4
WEEK
5
Week
6
1. • GOT NEWS ABOUT EFFICYCLE
• DOWNLOAD OF RULEBOOK AND OTHER RELATED MATERIALS.
2. • CONSULTING WITH SAE COLLEGIATE CLUB
FACULTY ADVISOR
• PERMISSION
• TEAM SELECTION AND DIVISION
3. • REGISTRATION
4.
• NET SEARCH ON VARIOUS 3-WHEEL VEHICLES TOGET ROUGH
IDEA
• REFERING THEORY AND SEARCH FOR VARIOUS AUTOMOBILE
BOOKS
5. • VALIDATION OF DESIGN
6. • DETAIL HAND DRAWING OF THE DESIGN.
• ROUGH CALCULATIONS
7. • FINALISATION OF FRAME DESIGN.
• DECISION ON VARIOUS PARTS AND EQUIPMENTSTO BE
ATTACHED IN THE CYCLE

31. Sr.No ACTIVITY WEEK
1
WEEK
2
WEEK
3
WEEK
4
WEEK
5
8. LIST OUT OF ALL NECESSARY DEVICES AND HARDWARE MATERIALS TO
BE USED ACCORDING TO BICYCLE SCIENCE
9.
• COLLECTION OF DETAILS REGARDING THE USE OF FINALISED
MATERIALS.
• MEASUREMENTS OF VARIOUS CYCLE PARTS ACCORDING TO
HUMAN ERGONOMIC POINT OF VIEW
10. CALCULATIONS AND ENQUIRY OF AVAILIBILITY OF ALL THOSE
MATERIALS IN LOCAL MARKET
11. REDESIGNING OF THE NECESSARY CYCLE PARTS FOR BETTER
PERFECTION WHEN EVER REQUIRED
12. DETAIL COMPUTER DESIGN (INVENTOR) OF VARIOUS PARTS
SEPARATELY
13. ASSEMBLY OF ALL PARTS TO FORM THE ENTIRE CYCLE
14. DETAIL ANALYSIS OF THE ENTIRE FRAME UNDER VARIOUS LOADED
CONDITIONS BOTH STATIC AND DYNAMIC
15. BRAIN STORMING ON POWER TRAIN.
16. VALIDATION AND FINALISATION OF DESIGN FORPOWER TRAIN

32. Sr.No. ACTIVITY
WEEK
1
WEEK
2
WEEK
3
WEEK
4
WEEK
5
17. DESIGN REPORT PREPARATION
18. COST REPORT PREPARATION
19. COST REDUCTION SUGGESTIONS AND NEGOTIATIONS.
20. FACULTY ADVISOR CONSULTANCY AND DATACOLLECTION
REGARDING THE VARIOUSWORKSHOP FACILITIES AVAILABLE FOR
THECYCLE FABRI CATION IF SELECTED
21. FINAL REPORT SUBMISSION WITH ALL DETAILS,NECESSARY
CALCULATIONS AND ANALYSIS.

33. Market strategy
Design has been evaluated with 3 main market visits.
specifications
technical general comfort other
Easy to fabricate Speed≈25kmph Thigh and entire torso Chain cover
supports
Assemble within minutes Nice look Under seat steer Unique product
Negative camber angle Carriage Front light Low weight
Rear wheel drive Low cost Electrical powered Easy turning
Shock absorbent rubber Roll cover for rainy powerful braking Covered for
season safety

34. VALIDATION

36. TEAM LEADER: SANDEEP SONI FACULTY ADVISOR: Dr. AMIT SINGH