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DESIGN AND FABRICATION OF THREE WHEELER ELECTRICAL VEHICLE (FOR PHYSICALLY CHALLENGED) PROJECT REPORT

PONDICHERRY UNIVERSITY

PUDUCHERRY, INDIA

Submitted in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

Submitted by AMIT KUMAR DEY

(15TB2205)

J.KARTHIK

(15TB2236)

MANOUWAR ALI ASHRAF

(15TB2244)

SHUBHAM KUMAR

(15TB2273)

Under the Guidance of I

Mr. P.MADHAVAN, M. Tech., Assistant Professor Department of Mechanical Engineering

ACHARIYA COLLEGE OF ENGINEERING TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING

PUDUCHERRY – 605 110

OCTOBER-2018

II

ACHARIYA COLLEGE OF ENGINEERING TECHNOLOGY (AFFILIATED TO PONDICHERRY UNIVERSITY)

DEPARTMENT OF MECHANICAL ENGINEERING BONAFIDE CERTIFICATE

This

is

to

certify

that

the

project

work

entitled

“DESIGN AND

FABRICATION OF THREE WHEELER ELECTRICAL VEHICLE (FOR PHYSICALLY CHANLLENGED)” is a bonafide work done by AMIT KUMAR DEY (15TB2205), J.KARTHIK (15TB2236), MANOUWAR ALI ASHRAF (15TB2244), SHUBHAM KUMAR (15TB2273) in partial fulfillment of requirement for the award of B.Tech Degree in Mechanical Engineering by Pondicherry University during the academic year 2018-2019.

PROJECT GUIDE

HEAD OF THE DEPARTMENT

III

Viva-Voce Examination held on __________________

INTERNAL EXAMINER

EXTERNAL EXAMINER

IV

ACKNOWLEDGEMENT

We take immense pleasure in thanking our chief mentor Dr.J.ARAWINDHAN of Achariya Educational Trust, for providing us with an environment to complete our project successfully.

We would like to thank Dr.L.RAMACHANDRAN, Principal, Achariya College of Engineering Technology for supporting and allowing us to do this project by providing required time to complete the same.

We thank Mr.M.THIRUMAL, Head of the Department, Department of Mechanical Engineering for their helpful and supportive role for completing the project work.

We deem it our duty to place our sincere administration and heartfelt gratitude to our guide Mr.P.MADHAVAN, Assistant Professor, Department of Mechanical Engineering for having effectively guided and supervised throughout this project.

We express our sincere thanks to Mr.S.ANBUSEZHIAN, Assistant Professor, Department of Mechanical Engineering and project coordinator for helping us throughout the project.

We also express our sincere thanks to our teaching and non-teaching staff members, Department of Mechanical Engineering for helping us throughout the project. V

Finally, we would like to take this opportunity to thank our family members, friends and well-wishers who have helped us and cooperated for the successful completion of our project.

VI

DECLARATION We affirm that the project work titled “DESIGN AND FABRICATION OF THREE

WHEELER

ELECTRICAL

VEHICLE

(FOR

PHYSICALLY

CHALLENGED)” being submitted in partial fulfillment for the award of Bachelor of technology in Mechanical Engineering is the original work carried out by us. It has not formed the part of any other project work submitted for award of any degree or diploma.

Signature of the Candidate

AMIT KUMAR DEY

(15TB2205)

J. KARTHIK

(15TB2236)

MANOUWAR ALI ASHRAF

(15TB2244)

SHUBHAM KUMAR

(15TB2273)

VII

I certify that the declaration made above by the candidate is true.

Signature of the Guide

(Mr.P.MADHAVAN, M.Tech) Assistant Professor Department of Mechanical Engineering Achariya College of Engineering Technology, Villianur.

VIII

ABSTRACT The main aim of the project is to design and fabricate a “Three wheeler electrical vehicle (for physically challenged)”. The vehicle should be easily operate by physically challenged people. The vehicle is design to be propelled by an electric hub motor mounted in the rear wheel and powered by 48V Lithium-ion battery. There can be one “Direct-Drive In-Wheel Motor” to generate the necessary torque per wheel. The main benefits of vehicle are it Eco-friendliness and ease in transportation. This vehicle helps handicapped people for their self-transportation. It is economical in electricity consumption; scooter can be driven comfortably with the help of streamline design of the body.

Keywords: Thee Wheeler Vehicle (TWV), Electrical Vehicle (EV), Electrical Motor (EM), Lithium-ion battery

IX

LIST OF TABLES

Table No

Title

Page No

4.1

Chassis Specifications

12

6.1

Cost-Estimation

22

X

LIST OF FIGURES Figure No

Title

Page No

1.1

First Electrical Vehicle

2

1.2

First Tri-wheeler Electrical Vehicle

3

1.3

Tri-wheeler Car

3

1.4

Types of Three Wheeler Vehicle

3

4.1

Top View of Chassis

11

4.2

Side View of Chassis

11

5.1

Battery

14

5.2

Motor

15

5.3

BLDc Controller

16

5.4

Disc Brake

17

5.5

Band Brake

17

5.6

Drum Brake

18

5.7

Air Brake

18

5.8

Electrical Circuit Diagram

19

5.9

Wheel

20

XI

LIST OF SYMBOLS AND ABBREVIATION

RPM : Revolution Per Minute

T : Torque

P : Power

σ : Induced Stress

M : Moment

Z : Section Modulus

V : Voltage

I : Current

FR : Feed Rate

min : Minute

s : Second

kW : Kilowatt

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TABLE OF CONTENTS TITLE

PAGE NO

ACKNOWLEDGEMENT

iii

ABSTRACT

v

LIST OF TABLES

vi

LIST OF FIGURES

vii

LIST OF SYMBOLS AND ABBREVIATIONS

viii

CHAPTER 1: INTRODUCTION

1

1.1 History

1

1.2 Electric Automobiles

2

1.3 Three Wheeler Vehicles

3

1.4 Types of Three Wheeler Vehicle

3

1.5 Scooter

4

1.6 Chassis

5

CHAPTER 2: REVIEW OF LITERATURE

6

CHAPTER 3: AIM, SCOPE AND OBJECTIVES

10

3.1 Aim of the Project

10

3.2 Scope of the project

10

3.3 Objective of the Project

10

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CHAPTER 4: METHODOLOGY

11

4.1 Design

11

4.2 Selection of Material

12

4.3 Fabrication

12

CHAPTER 5: COMPONENT DETAILS

14

5.1 Battery

14

5.2 Motor

15

5.3 Controller

16

5.4 Brake System

17

5.5 Electric Charger

19

5.6 Electric Circuit Diagram

19

5.7 Wheel

20

5.8 Lighting System

20

5.9 Handle

20

5.10 Chassis

20

CHAPTER 6: COST-ESTIMATION

22

CHAPTER 7: RUNNING COST FOR ELECTRICAL VEHICLE

23

CHAPTER 8: WORK TO BE DONE

24

CHAPTER 9: REFERENCES

25

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