Electric Solar Tricycle

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Introduction:-
Electric vehicles, which use 100% electric power, use electric motors instead of an
internal combustion engine to provide motive force. Solar-powered vehicles (SPVs) use
photovoltaic (PV) cells to convert sunlight into electricity. The electricity goes either directly to
an electric motor powering the vehicle, or to a special storage battery. PV cells produce
electricity only when the sun is shining. Without sunlight, a solarpowered car depends on
electricity stored in its batteries. Since the 1970s, inventors, government, and industry have
helped to develop solar-powered cars, boats, bicycles, and even airplanes. In 1974, two brothers,
Robert and Roland Boucher, flew an extremely lightweight, remote-controlled, pilotless aircraft
to a height of 300 feet. It was powered by a PVarray on the wings. (The U.S. Air Force funded
the development of these aircraft with the hope of using them as spy planes.) The first totally
solar-powered car was built in 1977. It was small, lightweight, and cost relatively little.
Experimental SPV‘s, equipped with advanced technology, have been built with the backing of
major auto manufacturers, including General Motors, Ford, and Honda. There will be a big area
at the agi campus wardha when it is fully built and operates. So students need a vehicle to move
from one side to another. In state of using car or motorcycle that are costly, student will be prefer
to used tricycle as their vehicle. There several types of tricycle that can be chosen such as paddle
tricycle, motorized tricycle and electric tricycle. But there are some weaknesses about that type
of tricycle. To overcome the weakness this project will develop a better tricycle. Because of
India is located in the topic of Capricorn area, this project will make used the energy of the sun
that rarely used in India to generate the tricycle. As what had been mention earlier, there are
several types of tricycle that can be categories that is paddle tricycle, motorized tricycle, and
electric tricycle. The weakness of the tricycle make people do not like to used tricycle. First,
paddle tricycle needs a lot of energy to paddle the tricycle. The user will surely be tired after
used the tricycle. This will not suitable for student to use to go to the class because they will be
tired when they are in the class and will lost their concentration while hearing the lecture. Next,
motorize tricycle that used fuel as it prime mover. The tricycle use fuel that is costly. As a
student, their allowance is limited and only can be used for their study material and for their food
to survive at the campus. Besides that, motorize tricycle will make pollution that can be very bad
for our environment especially in this period that global warming happen to the earth. Lastly,

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electric tricycle that generate by battery can be only be sufficient for about an hour. The user
needs to find power supply to recharge the battery or else they need to paddle the tricycle that
used more energy compare to the normal tricycle because of the weight.
Literature Review

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LITERATURE REVIEW
BACKGROUND AND RELATED WORK
This chapter discusses the history of the bicycle and other types of vehicles, switched-
mode power supplies (SMPS), DC-DC converters, and different charging techniques for
batteries. There is also discussion of human energy and comparisons between the different types
of transportation for humans. Furthermore, this chapter presents background information on
power supplies, MOSFETs, and drivers as well as previous and existing work on switched-mode
power supplies. 2.1 Human Energy and the Bicycle Human beings have the capability of
generating enough power to propel many different types of vehicles. The most common type of
vehicle that humans use as transportation is the bicycle. Bicycles are the most efficient form of
transportation available. This can be seen from the chart in Figure 2.1, which compares many
different and common types of transportation for humans. The only form of transportation that is
remotely close to the efficiency of the bicycle is either walking or running. However, a bicycle
can be up to five times more efficient than a human walking or running. Humans. around the
world have recognized the usefulness and effectiveness of the bicycle. There are over one billion
bicycles worldwide to attest to this (Exploratorium, n.d.). Figure 2.1: Comparison of the energy
cost at different speeds for various types of transportation (Exploratorium, n.d.). The engine
powering a bicycle in most cases is a human. In order to provide the energy necessary to propel
the vehicle, humans must use some sort of fuel. Unlike an automobile that uses non-renewable
resources like fossil fuels, humans rely on the food that they eat to generate the required amount
of energy. As an example of how much more efficient a bicycle is compared to an automobile, it
takes about 100 calories to power a cyclist 3 miles where the same amount of calories could only
power a car for 280 feet. It is important to maintain a healthy balance of water, protein,
carbohydrates, fats, vitamins, and minerals to be able to maintain enough energy to power a
bicycle far
A Low Cost Mobility Solution for Physically Challenged People;
“Pranchal Srivastava, Raj Kumar Pal”
The most common approach used in most powered wheelchairs is having two motors
for traction each driving a wheel on either side of the machine. Forward motion is
achieved by keeping the speeds of the motors identical in one direction

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and the other direction for reverse motion. Turns are executed by making the speeds of the
motors different. The radius of turn depends on the speed difference. This system depicts
three novel approaches for cost effectiveness and efficient working, firstly having a
powered wheel chair drive with a gear mechanism which is used to generate proper
speed of the wheels on the either side with single power motor. The advantage of this
system is that it makes the system control easy and cheap. Secondly, utilization of
waste brake energy for battery charging which lead to reduced cost of powered wheel
in the long run.
.
Dual Steered Three Wheeler For Differently Able People;
“Arun Raju C , Anish Raman C , Veerappan K.R. Venkat Narayanan
The aim of this study is to design and fabricate a 3 wheeler with dual steering system
for people with locomotive disabilities .A greater steering effort is required in the case
of a four wheeler compared to a three wheeler. Hence, a three wheeler was selected
instead of a four wheeler. In this case, handle bar steering system and leg steering
system can be individually steered with hands and legs respectively, enabling its
utility people with disabilities in upper extremities. Sprocket chain system was use
d in leg steering system. A 98cc Kinetic Honda Engine was used as the power source and
the engine was placed towards the rear end of the vehicle. Single Rated and double
rated suspension spring was used in the front and rear drive shaft respectively.
Sprocket chain system was used in leg steering system.
An Efficient Car Driving Controller System Design
for Physically Challenged People Using Arm Processor;
“Katari Ramaiah, T. Mallikarjun”
The aim of the technology is to help those handicapped who don’t have healthy hands
to run a vehicle by giving the voice commands. In this the driver need not use the
steering instead his head. This vehicle is only for those handicapped those who can

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nod head well. Four switches are interfaced over the neck of the driver, and the vehicle can be
controlled by the head movement. Corresponding tactile switches are activated according to the
movement of the head, and towards the conclusion the practical difficulties are described and the
possible solutions are discussed.

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Construction

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CONSTRUCTION:-
It consists of the following parts
D.C. MOTOR(PERMANENTMAGNET):
DESCRIPTION OF DC MOTOR
An electricmotoris a machine whichconvertselectrical energytomechanical energy. Itsaction
is based on the principle that when a current-carrying conductor is placed in a magnetic field, it
experiencesamagneticforce whose directionisgivenbyFleming’slefthandrule.
When a motor is in operation, it develops torque. This torque can produce mechanical rotation.
DCmotors are also like generatorsclassified into shunt wound or serieswound or compound wound motors.
FLEMING’S LEFT HAND RULE:
Keep the force finger, middle finger and thumb of the left hand mutually perpendicular to one
another. If the fore finger indicates the direction of magnetic field and middle finger indicates direction of
current in the conductor, then the thumb indicates the direction of the motion of conductor.
PRINCIPLE OF OPERATIONOF DC MOTOR:
Figure I show a uniform magnetic field in which a straight conductor carrying no current is placed.
The conductor is perpendicular to the direction of the magnetic field.
In figure II the conductor is shown as carrying a current away from the viewer, but the field due to
the N and S poles has been removed. There is no movement of the conductor during the above two
conditions. In figure III the current carrying conductor is placed in the magnetic field. The field due to the

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current in the conductor supports the main field above the conductor, but opposes the main field below the
conductor.
Movementof
Conductor
Magneticflux current carrying
Conductor
The result is to increase the flux density in to the region directly above the conductor and to
reduce the flux density in the region directly below the conductor. It is found that a force acts on the
conductor, trying to push the conductor downwards as shown by the arrow. If the current in the
conductoris reversed,the strengtheningof fluxlinesoccursbelow the conductor,andthe conductorwill
be pushedupwards(figure-IV).
N S

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Now consider a single turn coil carrying a current as shown in the above figure. in view of the
reasons given above, the coil side A will be forced to move downwards, whereas the coil side B will be
forcedtomove upwards. The forcesactingonthe coil sidesA andB will be of same magnitude. Buttheir
directionisopposite toone another. Asthe coil iswoundonthe armature core whichissupportedbythe
bearings, the armature will now rotate. The commutator periodically reverses the direction of current
flowthroughthe armature. Therefore the armature will have acontinuousrotation.
A simplifiedmodel of sucha motor isshown infigure VI. The conductors are woundover a soft
iron core. DC supplyis givento the fieldpolesforproducingflux. The conductors are connectedto the
DC supplythroughbrushes
Let's start by looking at the overall plan of a simple 2-pole DC electric motor. A simple motor
has 6 parts, as shown in the diagram below.
 An armature or rotor
 A commutator
 Brushes
 An axle
 A fieldmagnet
 A DC powersupplyof some sort

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An electric motor is all about magnets and magnetism: a motor uses magnets to create
motion. If you have ever played with magnets you know about the fundamental law of all magnets:
Opposites attract and likes repel.
Wheel
A wheel is a circular component that is intended to rotate on an axial bearing. The wheel is one
of the main components of the wheel and axle which is one of the six simple machines.
Wheels, in conjunction with axles, allow heavy objects to be moved easily facilitating
movement or transportation while supporting a load, or performing labor in machines. Wheels
are also used for other purposes, such as a ship's wheel, steering wheel, potter's wheel and
flywheel.
Common examples are found in transport applications. A wheel greatly reduces friction
by facilitating motion by rolling together with the use of axles. In order for wheels to rotate, a
moment needs to be applied to the wheel about its axis, either by way of gravity, or by the

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application of another external force or torque.
1. BEARING WITH BEARING CAP:-
The bearings are pressed smoothly to fit into the shafts because if hammered the bearing
may develop cracks. In our project, the 6202 bearing with bearing cap is used. The bearings are
pressed smoothly to fit into the shafts because if hammered the bearing may develop cracks.
Bearing is made upof steel material and bearing cap is mild steel.
INTRODUCTION
Ball and roller bearings are used widely in instruments and machines in order to minimize
friction and power loss.
While the concept of the ball bearing dates back at least to Leonardo da Vinci, their design
and manufacture has become remarkably sophisticated.
This technology was brought to its p resent state o f perfection only after a long period of
research and development. The benefits of such specialized research can be obtained when it is
possible to use a standardized bearing of the proper size and type.
However, such bearings cannot be used indiscriminately without a careful study of the
loads and operating conditions. In addition, the bearing must be provided with adequate mounting,
lubrication and sealing. Design engineers have usually two possible sources for obtaining
information which they can use to select a bearing for their particular application:
a) Textbooks
b) Manufacturers’

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Catalogs Textbooks are excellent sources; however, they tend to be overly detailed and
aimed at the student of the subject matter rather than the practicing designer. They, in most cases,
contain information on how to design rather than how to select a bearing for a particular
application. Manufacturers’ catalogs, in turn, are also excellent and contain a wealth of information
which relates to the products of the particular manufacturer.
These catalogs, however, fail to provide alternatives – which may divert the designer’s
interest to products not manufactured by them. Our Company, however, provides the broadest
selection of many types of bearings made by different manufacturers.
For this reason, we are interested in providing a condensed overview of the subject matter
in an objective manner, using data obtained from different texts, handbooks and manufacturers’
literature. This information will enable the reader to select the proper bearing in an expeditious
manner. If the designer’s interest exceeds the scope of the presented material, a list of references
is provided at the end of the Technical Section. At the same time, we are expressing our thanks
and are providing credit to the sources which supplied the material presented here.
Construction and Types of Ball Bearings:-
A ball bearing usually consists of four parts: an inner ring, an outer ring, the balls and the
cage or separator. To increase the contact area and permit larger loads to be carried, the balls run
in curvilinear grooves in the rings. The radius of the groove is slightly larger than the radius of
the ball, and a very slight amount of radial play must be provided. The bearing is thus permitted
to adjust itself to small amounts of angular misalignment between the assembled shaft and
mounting.

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The separator keeps the balls evenly spaced and prevents them from touching each other
on the sides where their relative velocities are the greatest. Ball bearings are made in a wide variety
of types and sizes. Single-row radial bearings are made in four series, extra light, light, medium,
and heavy, for each bore, as illustrated in Fig. 1-3(a), (b), and (c).
100 Series 200 Series 300 Series Axial Thrust Angular Contact Self-aligning
Bearing Fig. 1-3 Types of Ball Bearing
The heavy series of bearings is designated by 400. Most, but not all, manufacturers use a
numbering system so devised that if the last two digits are multiplied by 5, the result will be the
bore in millimeters. The digit in the third place from the right indicates the series number. Thus,
bearing 307 signifies a medium-series bearing of 35-mm bore. For additional digits, which may
be present in the catalog number of a bearing, refer to manufacturer’s details.
Some makers list deep groove bearings and bearings with two rows of balls. For bearing
designations of Quality Bearings & Components (QBC), see
special pages devoted to this purpose. The radial bearing is
able to carry a considerable amount of axial thrust.
However, when the load is directed entirely along the
axis, the thrust type of bearing should be used. The angular contact bearing will take care of both

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radial and axial loads. The self-aligning ball bearing will take care of large
amounts of angular misalignment.
An increase in radial capacity may be secured by using rings with deep grooves, or by
employing a double-row radial bearing. Radial bearings are divided into two general classes,
depending on the method of assembly.
These are the Conrad, or non filling-notch type, and the maximum, or filling-notch
type. In the Conrad bearing, the balls are placed between the rings as shown in Fig. 1-4(a). Then
they are evenly spaced and the separator is riveted in place. In the maximum-
type bearing, the balls are a (a) (b) (c) (d) (e) (f) 100 Series Extra Light 200 Series Light 300
Series Medium Axial Thrust Bearing Angular Contact Bearing Self-aligning Bearing Fig. 1-
3 Types of Ball Bearings Fig. 1-4 Methods of Assembly for Ball Bearings (a) Conrad or non-
filling notch type (b) Maximum or filling notch type
SPUR GEAR:
The spur gears, which are designed to transmit motion and power between parallel shafts,
are the most economical gears in the power transmission industry.
APPLICATION:
 Material handling
 Feed drives
 Machine tools

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 Conveyors
 Marine hoists

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Design
Design
Design consists of application of scientific principles, technical

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information and imagination for development of new or improvised machine or
mechanism to perform a specific function with maximum economy & efficiency .
Hence a careful design approach has to be adopted . The total design work
, has been split up into two parts;
 System design
 Mechanical Design.
System design mainly concerns the various physical constraints and ergonomics,
space requirements, arrangement of various components on main frame at system,
man + machine interactions, No. of controls, position of controls, working
environment of machine, chances of failure, safety measures to be provided,
servicing aids, ease of maintenance, scope of improvement, weight of machine
from ground level, total weight of machine and a lot more.
In mechanical design the components are listed down and stored on the basis of
their procurement, design in two categories namely,
 DesignedParts
 Parts to be purchased
For designed parts detached design is done & distinctions thus obtained are
compared to next highest dimensions which is readily available in market. This
amplifies the assembly as well as postproduction servicing work. The various
tolerances on the works are specified. The process charts are prepared and passed
on to the manufacturing stage.
The parts which are to be purchased directly are selected from various catalogues
& specified so that any body can purchase the same from the retail shop with
given specifications.

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SYSTEM DESIGN:
In system design we mainly concentrated on the following parameters: -
1) System Selection Basedon Physical Constraints
While selecting any machine it must be checked whether it is going to be used in
a large-scale industry or a small-scale industry. In our case it is to be used by a
small-scale industry. So space is a major constrain. The system is to be very
compact so that it can be adjusted to corner of a room.
The mechanical design has direct norms with the system design. Hence the
foremost job is to control the physical parameters, so that the distinctions obtained
after mechanical design can be well fitted into that.
2) Arrangement of Various Components
Keeping into view the space restrictions the components should be laid such that
their easy removal or servicing is possible. More over every component should
be easily seen none should be hidden. Every possible space is utilized in
component arrangements.
3) Components of System
As already stated the system should be compact enough so that it can be
accommodated at a corner of a room. All the moving parts should be well closed
& compact. A compact system design gives a high weighted structure which is
desired.
4) Man Machine Interaction
The friendliness of a machine with the operator that is operating is an important
criteria of design. It is the application of anatomical & psychological principles to
solve problems arising from Man – Machine relationship. Following are some of
the topics included in this section.
 Design of foot lever
 Energy expenditure in foot & hand operation
 Lighting condition of machine.
4.Chances of Failure

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The losses incurred by owner in case of any failure is an important criteria of
design. Factor safety while doing mechanical design is kept high so that there are
less chances of failure. Moreover periodic maintenance is required to keep unit
healthy.
5) Servicing Facility
The layout of components should be such that easy servicing is possible.
Especially those components which require frequents servicing can be easily
disassembled.
6) Scope of Future Improvement
Arrangement should be provided to expand the scope of work in future. Such as
to convert the machine motor operated; the system can be easily configured to
required one. The die & punch can be changed if required for other shapes of
notches etc.
7) Height of Machine from Ground
For ease and comfort of operator the height of machine should be properly
decided so that he may not get tired during operation. The machine should be
slightly higher than the waist level, also enough clearance should be provided
from the ground for cleaning purpose.
8) Weight of Machine
The total weight depends upon the selection of material components as well as the
dimension of components. A higher weighted machine is difficult in transportation & in
case of major breakdown, it is difficult to take it to workshop because of more weight.

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POWER CALCULATIONS
Motor Selection
Thus selecting a motor of the following specifications
phase DC motor
Power = 12 watt
Speed= 150 rpm.
To calculate arbor Shaft Torque
POWER = 2 𝜋 NT/60
Motor is 12 watt power, run at 150 rpm, connected to shaft by GEAR
arrangement of 1:3 ratio, considering 65% efficiency of Gear drive , torque at the shaft is given
by,
Tmotor x 3 x 0.65= 2.48 x 3 x 0.65 = 1.52 N-m
Check for Tortional Shear Failure of Shaft
Assuming minimum section diameter on input shaft = 12 mm
d = 12 mm
Td = 𝜋/16 x fs act x 𝑑3
.
Fs act =
15×𝑇𝑑
𝜋×𝑑3
Fs act =
16×1.52×103
𝜋×123
Fs act= 4.48 N/𝑚𝑚2
.

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Fs act= fs all.
I/P shaft is safe under torsional load
MATERIAL SELECTION : -Ref :- PSG (1.10 & 1.12) + (1.17)
DESIGNATION ULTIMATE TENSILE
STRENGTH
N/mm2
YEILD STRENGTH
N/mm2
MS 800 680
ASME CODE FOR DESIGN OF SHAFT.
Since the loads on most shafts in connected machinery are not constant , it is necessary to
make proper allowance for the harmful effects of load fluctuations
According to ASME code permissible values of shear stress may be calculated form
various relation.
fs max = 0.18 fult
= 0.18 x 800
= 144 N/mm2
OR
fs max = 0.3 fyt
=0.3 x 680
=204 N/mm2
considering minimum of the above values ;
 fs max = 144 N/mm2
Here we are using 16 mm shaft to transmit power.

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List of Materials

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 LIST OF MATERIALS:-
SR Description Qty Material
1. DC Motor 02 STD
2.. wheel 03 STD
3. Angle 02 MS
4. Bearing 02 S.T.D
5. Shaft 01 MS

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Time activity chart

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Time activity chart /project Completion schedule:
Work Task July 18-
Aug 18
Sept 18-
Oct 18
Nov 18-
Dec 18
Jan 19 –
Feb 19
Information Gathering -Literature
Survey.
Finalization of the Aims and
Objectives or Title .
Development Experimental Set
Up and Instrumentation or Case
Study
Experimentation / Data
Collection
Formulation of Model / Analysis
of Model/ Data
Critical Analysis of the
Formulated Model / Optimization
and Sensitivity Analysis
Initial Report Writing and
Publication
Final Report Writing and
Publication

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MANUFATCURING PROCESS

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MANUFATCURING PROCESS
For different parts of machine there are different machining process which is
described as per parts.
BEARING HOLDER SHAFT:-
There is M.S 16 mm round bar taken for making shaft .
Process Sheet of bearing holder shaft:-
SR NO:- DESCRIPATION OF
OPERATION
TOOL MACHINE USED
1. Facing Facing tool Lathe machine
2. O.D turning of dia 15mm Turning tool Lathe machine
SPROKET HOLDER:-
There is M.S round bar taken for making holder.
Process Sheet of SPROKET holder:-
OPERATION
TOOL MACHINE USED
2. O.D turning Side tool Lathe machine
3. Center Drilling (14. mm) Drill 14.mm Lathe machine
4. Boring 15 mm dia Boring tool Lathe Machine
5 Threading 24 TPI V tool Lathe Machine.

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BEARING CAP:-
There is M.S square bar taken for making support bearing caps.
Process Sheet of Bearing Cap:-
OPERATION
TOOL MACHINE USED
2. Drilling 20mm Dill 20mm Lathe machine
4. Step Bore Machining as per
bearing size.
Bore tool Lathe machine
BEARING CAP:-
There is M.S Round bar taken for making support bearing caps.
Process Sheet of Bearing Cap:-
OPERATION
TOOL MACHINE USED
2. Drilling 20mm Dill 20mm Lathe machine
4. Step Bore Machining as per
bearing size.
Bore tool Lathe machine

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Cost Estimation

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COST ESTIMATION
1. MATERIAL COST:-
SL.NO. NAME OF PARTS MATERIAL QUANTITY AMOUNT (RS)
1 GEARS MS 04
2 Motor STD 02
3 Frame Stand M.S 1
4 Bearing STD 2
Total= -
2. LABOUR COST
LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:
Cost =
3. OVERHEAD CHARGES
The overhead charges are arrived by “Manufacturing cost”

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Manufacturing Cost = Material Cost + Labour cost
=
=
Overhead Charges = 20% of the manufacturing cost
=
TOTAL COST
Total cost = Material Cost + Labour cost + Overhead Charges
=
=

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References

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BIBLIOGRAPHY
1. Faculty of Mechanical Engineering, PSG Tech., “Design Data”, DPV Printers,
Coimbatore, 1998.
2. K. Balasundaram, “Industrial management”, Parthian Publishers, Coimbatore-12,
1999, pp.116
3. “TVS 50 XL Service Manual”.
4. Automotive Electrical, pp.32-94.
5. The Hindu Daily, “SCIENCE / TECHNOLOGY”.

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