The document summarizes a student project to design a 3-wheeled human and electric powered vehicle. Key points: - The vehicle has a front wheel manual drive, rear wheel electric motor drive configuration. It can carry 2 passengers up to 25 kph. - Students focused on safety, lightweight design, efficiency and affordability. Components include a 400W motor, disc/drum brakes, shock absorbers, and 5-speed pedal transmission. - Innovation is a charging mechanism via pedaling, with a diode connecting the motor/battery to the rear axle to allow charging while riding.

1. SAE NIS EFFI-CYCLE 2014
VIRTUAL ROUND
14031- PETROLHEADS
WALCHAND INSTITUTE
OF TECHNOLOGY
SOLAPUR, MAHARASHTRA
SOUTH ZONE
College or Team Logo
1

2. • Project Objectives
• Design
• Transmission
• Steering
• Brakes
• Suspension
• Queries
Outline
2

3. Project Objectives
• To build a human & electric powered three wheeled Vehicle.
• An attempt to replace vehicles running on fuel.
• To experience the problems faced while working in real time projects.
• Widen the perspective of typical approach adopted in common
towards given problem statement.
3

4. Performance targets
VEHICLE CONFIGURATION TYPE
Configuration Tadpole (2F1R)
Type of drive Front wheel manual drive
Rear wheel motor drive
Wheelbase 62 inches
Track width 33 inches
Motor BLDC 400W , 24v ,6 N-m
Steering Ackermann
Brakes Disc and V brakes
Suspension Hydraulic Shock Absorber
Passenger Capacity 2
Weight 3139.2N ( 320kg)
Weight without driver 882.9 N (90kg)
Top speed 25 kmph
Braking distance 4 m 4

5. Methodologies adopted
• Safety of driver
• Inside out approach
• Simple design
• Long lasting
• Lightweight
• Ergonomics and aesthetic consideration
• Economical
• DFMEA
Design
5
• Ergonomic considerations as per ILO norms & SAE standards.
• Safe design for front, side & roll over impact for a force value of 3G
(375N).
• CAD, analysis, selection of appropriate material & prototype.
Design requirements

6. Material selection
0
50000
100000
150000
200000
250000
300000
AISI
1018
AISI
1020
AISI
1025
AISI
1040
AISI
1215
AISI 304 AISI
4130
Strength/weight ratio
Strength/weight ratio
Material
Strength/weight

7. 7
Richness Volume
Straight vision
Eye level
7

8. Parts Dimensions
Seat length 900 mm
Seat width 430 mm
Seat base angle with
horizontal
7°
Back rest height 500 mm
Inclination of back rest
with horizontal
110°
Head rest width 220 mm
Head rest height 150 mm
Thickness 70 mm
Seat
Type of seat: Bench seat
8

9. Front impact in ANSYS
9
F = 3G
DMX = 0.31E-03
SMX = 126.4MPa

10. 10
Max. axial and bending stress = 228.82 MPa
Front impact in SOLID WORKS

11. Side impact in ANSYS
11
F = 3G
DMX = 0.374E-03
SMX = 1265.82

12. 12
Side impact in SOLID WORKS
Maximum axial and bending stress = 38.561 MPa

13. Roll over in ANSYS
13
F = 3G
DMX = 0.508E-04
SMX = 0.508E-04

14. 14
Roll over in SOLID WORKS
Maximum axial and bending stress = 906.911 MPa

15. Frame after modification
15
Material = AISI 1018
Yield strength = 365 MPa

16. Final cad of vehicle
16

17. Power train Human Drive Calculations
• Total resistance:
• Centre distance:
Where,
17

18. Gear ratio & CV-Joints
• Geometric gear steps
• Progressive gear steps
• Availability in the market
• Type of CV joint employed and its advantages.
18

19. Motor Transmission :
Motor Specification: BLDC Motor (400 watt -1500rpm-24v dc)
Battery: 24 volt ,18Ahr
Pedal Transmission: 5 Speeds.
Gear shifting: Derailleur
Performance parameters :
Maximum speed: 21 km/ph
Gradeability: 30%
Braking: 21 km/h to 0 km/h in 2 seconds
(stopping distance=12m)
Turning radius: 3.28 m 19
Motor

20. Advantages of BLDC motor:
• High speed
• High efficiency
• Minimum temperature rise
• Smooth operation
• Robust
• Customization available
• Electronic communication
20

21. Battery
• Purpose:
Source of Energy.
Power storage.
• Classification:
Non rechargeable batteries.
Rechargeable batteries.
Batteries by application.
• Lead Acid Battery:
Inexpensive.
Reliable.
Simple to manufacture.
Low maintenances.
Capable of high discharge rate.
21

22. • Specification:
Voltage: 24 V
Capacity:18Ah
Size: 7-1/8" long x 3" wide x 6-5/8"
Type: Sealed Lead-Acid / SLA
Connectors: Nut and bolt post connectors / T4
Weight: 13.1 pounds
Item # BAT-12V18A
• Calculation:
(Ah) = Device's Wattage (W) x Time to run (Hours) /
Battery Voltage (V)
Run time=1.08hr per Battery
The total run time for two batteries in series is 2.16hr
22

23. Tire Selection
• Selection parameters:
1) Type of tire
2) Contact patch
3) Aspect ratio
• Front wheels:
1) Type of tire employed
2) Specifications: (24 inch*(1/2)inch)
• Rear wheels:
1) Type of tire employed
2) Specifications: (28 inch*(1/2)inch)
23

24. Steering system
24

25. Objective & Calculations
• Objective:
1) Effective handling
2) Simplicity
3) Reduced space & cost
4) Reduces turning radius
• Calculation:
Turning radius =[(-b/sin Ѳ)^2+c^2+(2bc/tan Ѳ)]^1/2+(a-c)/2
= 3.037 m
25

26. Steering Angle v/s Turning Radius
0
2
4
6
8
10
12
14
16
18
20
0 10 20 30 40 50
Turning Radius(m)
Turning Radius(m)
Steering
Angle
(Ѳ)
Turning
Radius(m)
5 17.9
10 8.93
15 6.54
20 5.02
25 4.26
30 3.69
35 3.28
39 3.03
40 2.98
45 2.74 26

27. Front brakes: Disc brakes
Rear brakes: V- brakes
• Advantages of disc brakes:
•Greater braking power
•Reduces braking distance
•Less prone to brake fade
•Advantages of V- brakes:
•Lighter & cheaper
•Easy to install
27
Brakes used on front and rear wheel
Brakes

28. 0
2
4
6
8
10
12
14
0 2 4 6 8 10 12 14
Velocity v/s Stopping Distance
velocity
Vel.
(m/s)
Stopping Distance (m)
28

29. Graph
29
0
1000
2000
3000
4000
5000
6000
7000
8000
0 2 4 6 8 10 12 14
Stopping Distance(m)
stopping time(sec)
Braking Power(KW)
Brake Force(N)
Brake Torque(Nm)
deceleration(m/s^2)

30. 30
Suspension
• Type of suspension used: HYDRAULIC SHOCK ABSORBER
Wheel Force
Front wheel 820 N
Rear wheel 1350
Force acting on front and rear wheel

31. 31
Part Dimensions
Wire diameter 6 mm
Mean coil diameter 30 mm
No. of active coils 16
Total no. of coils 18
Free length 145 mm
Spring rate 32 N/mm
Suspension used only on rear wheel

32. Safety Features:
• Types:
1. Active Safety
2. Passive Safety
32

33. • Driver’s safety:
Element of safety
1. Helmet
2. Eye Protection
3. Seat belts
4. Elbow and knee pads
5. Mud-guards for every wheel, Chain covers
6. Head lights, Horn, Mirror
• Electric Safety:
1. Insulation to electric wires
2. Kill switch
33
33

34. Innovation
• The charging mechanism of the battery is the innovation.
• The charging is done by pedalling. The diode is connected to
motor and battery by terminal block; this is connected to the
second rear axel through which the charging phenomenon
occurs.
34

35. 35
Team structure
NAME BRANCH YEAR OF DEGREE ROLE IN PROJECT
HIMANSHU U
GORE
MECHANICAL THIRD YEAR DESIGN
AJIT S DIGHE MECHANICAL THIRD YEAR POWER TRAIN-
HUMAN DRIVE
ABHIJIT G
ALMELKAR
MECHANICAL THIRD YEAR ERGONOMICS/SUS
PENSION
NOOSRAT S
SHAIKH
MECHANICAL THIRD YEAR POWER TRAIN -
ELECTRIC DRIVE
CHAYYA DHERE MECHANICAL THIRD YEAR STEERING
RAJSHREE
HUNGUND
MECHANICAL THIRD YEAR BRAKES