1

FABRICATION OF GO KART USING PVC PIPES

Submitted by

Name Reg. No

AJAY SHARMA E1711434300060

AMIT UPADHYAY E1711434300011
ANSHUL KUMAR E1711434300036
GOVIND KUMAR E1711434300005
VIKRANT KUMAR E1711434300042

Under The Guidance of

Mr. ABHAY SINGH
LECTURER/MECH

In partial fulfilment for the award of the diploma by Uttar Pradesh board of
Technical Education, Uttar Pradesh.

DIPLOMA in
PRODUCTION ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC FIROZABAD
UTTAR PRADESH

(Approved by AICTE New Delhi & Affiliated to Board of Technical Education, Up)
AUGUST - 2020
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BONAFIDE CERTIFICATE

This is to certify that this project work “fabrication of go kart using pvc pipes” is a
bonafide work done by
AJAY SHARMA E1711434300060
AMIT UPADHYAY E1711434300011
ANSHUL KUMAR E1711434300036
GOVIND KUMAR E1711434300005
VIKRANT KUMAR E1711434300042

in partial fulfilment for the award of Diploma in mechanical Engineering of the Government
Polytechnic College firozabad and who carried out the project under my supervision.

Mr. ABHAY SINGH Mr. RAVINDER KUMAR

Project Guide-Lecturer/MECH Head of the Department

Submitted for the Board Examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

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ACKNOWLEDGMENT

We take this opportunity to express our thanks to the Principal Shri Hari Singh, whose

undying sprit is our complementary force, we wish to place on our records, our sincere

gratitude to Mr.Ravinder Kumar Head of the Department for his encouragement and

support to carry out this work effectively.

We render our whole hearted thanks to our guide Mr.Abhay Singh,

Lecturer who has been the guiding force in completing the project successfully.

We extend our sincere thanks to all staff of mechanical engineering

Department, friends and parents for their encouragement in doing this project.

We wish to express my sincere thanks to those who helped me in making this

project successfully.
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ABSTRACT

This paper aims to the review of design analysis of a go kart chassis. The main
intention is to do modelling and static analysis of go-kart chassis. The maximum
deflection is obtained by analysis. The go-kart chassis are different from chassis of
ordinary cars on the road .The paper highlights the material used and structural formation
of chassis. The strength of material, rigidity of structure and energy absorption
characteristics of chassis is discussed.Based structure of this project is made of pvc pipe
and wood. The pvc serves as the frame of the Go Kart while the wood serves as the chassis
that holds the motor. The chassis that contains the motors drives the two rear wheels of
the Go Kart, while the front wheels are set with mechanical system that correspond to Go
Kart movement direction. A 3-position momentary rocker switch is used for moving
forward or reverse, while a type of potentiometer is used to control the speed of the motor.
For stop, motor is short circuit by the controller in which it will freeze the motor so no
need for brakes. This Go Kart / Electric Car is powered by 12V DC batteries.

This project is an excellent reference for DIY and further development of electric car. It illustrate
the capability of some basic materials that can be considered for the development. Also, a
development related to electric car supports sustainable energy system . This undergraduate thesis
documents the design considerations and specifications of building a personal battery powered go
kart.
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CHAPTER NO. PARTICULARS PAGE NO.

1 7-9
INTRODUCTION

2 10
LITERATURE REVIEW

3 11
LINE DIAGRAM

4 12-28
COMPONENTS

5 29
WORKING

6 30
ADVANTAGE,DIADVANTAGE,APLLICATION

7 31
CONCLUSION

8 32
COST ESTIMATION

9 33-34
PHOTOGRAPHY

10 35
REFERENCE
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FIGURE NO. TITLE OF FIGURE PAGE NO.

CIK-FIA Commission 9
1.1
International De Karting

3.1 Go kart line diagram 11

Diagram of Ackermann 13
4.1
steering geometry

4.2.1.1 Manual steering 14

4.2.1.2 Power steering 15
4.3.1 Wiper motor 22
4.4.1.1 Primary Batteries 23
4.4.1.2 Nickel-cadmimum battery 25
4.4.1.3 Ni-MH Battery 26
4.4.1.4 Lithium-Ion Battery 27
4.4.1.5 Lead Acid Battery 28

LIST OF ABBREVATIONS

PVC POLY VINYL CHLORIDE

NMC NATIONAL METEOROLOGICAL CENTER

NIMH NATIONAL METEOROLOGICAL CENTER

NICADS NICKEL CADMIUM

CIK-FIA COMMISSION INTERNATIONAL DE KARTING

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CHAPTER.1

INTRODUCTION

My motivation for choosing this topic as my thesis stems from a variety

of interests. Ever since I got my driver’s license, learning about automobiles has been a passion
of mine. Along with watching shows about cars and frequently visiting online automobile blogs.
I joined the Electric Vehicle Team where I helped with the battery-electric conver . As I worked
with the team over the summer, I was exposed to a plethora of other student groups and personal
projects . Since then, I have always wanted to build my own vehicle but never could find the time
between classes and personal obligations.

During my senior year, I began to design to formulate ideas for an electric

go-kart. At that point, the required thesis for undergraduates pursuing a full mechanical
engineering degree was far from my motivation. However, as graduation creeped closer and
closer, it became obvious that my goal of building my own vehicle would only get done if I
committed to it as my thesis project. I wanted to combine my hands-on experience with a modern
project that represented my talents and personality. Thanks to support from several friends, I was
able to accomplish my goal.

For this project, I wanted to demonstrate my accumulated engineering

knowledge. This would combine not only the academic mechanical teachings that I learned in
class, but also integrate electrical systems that I picked up while working on various projects.
This combination is necessary for many real world applications, and working on this area will
hopefully prove helpful after I graduate.

Everything in life begins with hope. Hope backed by effort is what made
“PRAYAAS” tangible. PRAYAAS is a coalition of all our endeavors and uphill battles. It is the
shape, given to efforts of the students of Department of Mechanical Engineering, Sikkim Manipal
Institute of Technology, who thought to fabricate a vehicle in college campus situated at very
isolated place.By definition of International Karting Commission
 8

Federation International Automobile (CIK-FIA), a kart is defined as a land vehicle with or without
a bodywork, with 4 non-aligned wheels in contact with the ground, two of which control the
steering while the other two transmit the power.

Its main parts are the chassis (which consists of a body frame work that is made up of a set
of bent steel pipes that are welded together) with an engine, four wheels and tires attached on it.
According to Wikipedia, a go-kart (sometimes known as a "go-cart" or just kart) is a small four-
wheeled vehicle. Go-karts come in all shapes and forms, from motor less models to high-powered
racing machines, some, like Super karts, being able to beat racing cars on long circuits. Gravity
racers, usually referred to as Soap Box Derby carts, are the simplest type of go-karts.

They are propelled by gravity, with some races taking place down a single hill. Amusement
park go-karts can be powered by 4-stroke engines or electric motors, while racing karts use small
2-stroke or 4-stroke engines. Most of them are single seated but recreational models can
sometimes accommodate a passenger. In some countries, go-karts can be licensed for use on
public roads. Typically there are some restrictions, e.g. in the European Union a gokart on the
road needs head light (high/low beam), tail lights, a horn, indicators and a maximum of 20hp.
Besides traditional kart racing, many commercial enterprises offer karts for rent, often called
"recreational" or "concession" karts. The tracks can be indoor or outdoor.

Karts are rented by sessions (10 to 15 minutes usually), they use sturdy chassis completed
with dedicated bodywork providing driver safety. Most of these enterprises use an "Arrive and
Drive" format which provide customers with all the safety gear (helmets, gloves and driver outfits)
where necessary and allow them to show up any time to race at a reasonable price, without the
hassle of owning one's own equipment and gear. Outdoor tracks can offer low speed karts strictly
 9

for amusement (dedicated chassis equipped with low powered 4-stroke engines or electric
motors), to faster, more powerful karts similar to a racing kart (powered by 4-stroke engines up
to 15 hp and more rarely by 2-stroke engines) but designed to be more robust for rental use.
Typically, these outdoor tracks may also be used for traditional kart races. Indoor kart tracks can
be found in many large cities in different parts of the world. These tracks are often located in
refurbished factories or warehouses and are typically shorter than traditional outdoor tracks.
Indoor karts are typically powered by a 4-stroke gasoline engine producing anywhere from 5 to
13 horsepower, or sometimes by an electric motor. Many tracks offer competitive races and
leagues. At the top level, an Indoor
Karting World Championship (IKWC) exists

Figure 1.1 CIK-FIA Commission International De Karting

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CHAPTER. 2

LITERATURE REVIEW

Go-kart technology has been widely developed since the introduction of wheels. But, it was
not fully implemented in racing activity until the past three hundred years in America.

The first go-kart was simply a cart consisting of wheels and handles jointed together as
children pushed from behind when learning to walk or a four-wheeler platform where children
where children can sit on it while another push the kart around .Go-kart was invented in California
by Art Ingels and Lou Borelli using 100cc mower engines and strong steel frames. Then, newly
designed karts were beginning to gain popularity in Britian around the year 1959-1960.

Go-kart has long existed in our world whether used insport or recreation .According to
Graham Smith (2002), Art Ingels who was a veteran hot rod and race carbuilder at Kurtis Kraft in
California, America invented the first ever go-kart in 1956. Initially,karting is a leisure motorsport
enjoyed by airmen during the post-war period. The sport is quickly caught on with Go Kart
Manufacturing Co. Inc. Being the first company to manufacture and distribute go-karts after two
years. In 1959, McCullough also jump in the bandwagon of the industry, by becoming the first
company to manufacture go-kart engines. Although go-kart originated from United States, it has
also gain interests from countries all over the worlds especially Europe.

For example, according to Tony Kart’s company profile in its website from Italy, they have
been producing gokart since 1958 and emerged as one of the main manufacturer to date. Today,
kart racing is governed by CIK-FIA which was founded in 1962 is the current primary
international sanctioning body for kart racing. It is also a part of FIA since 2000 which is a
governing body for motorsport across the globe. CIK-FIA plays an important role in regulating
kart racing related matters such as technical regulations.
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CHAPTER. 3

PROJECT LINE DIAGRAM

Fig3.1 go kart line diagram

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CHAPTER. 4

COMPONENTS

4.1 FRAME
4.2 STREEING
4.3 MOTOR
4.4 BATTERY

4.1 FRAME
I wanted the frame to be strong because Eli-Kart would need to carry at least 100 kgs
safely to account for one passenger. From previous projects I was familiar with box extrusions,
which are strong beams that are suitable for structural applications. I chose pvc pipe but there is
no high load cannot be sit so i also added steel frame below the pipe frame because it is much
tougher and easier to weld than materials such as aluminum. Uprights for steering and mounting
other components could be welded to the main structure. Picture of the frame On top of the frame
there needed to be a platform for sitting on. I decided on ½” thick acrylic for several reasons. It
would be clear, allowing for a view of the components under, and also be structural enough to
allow for direct mounting of seats and other parts. I chose the dimension of the cart to fit within
current handicap accessible areas, allowing it to go through doors and fit in a bike lane. I also
wanted it to be just long enough to fit one people sitting one behind the other. A 24” by 48”
fulfilled both of these criteria and had a convenient size and a rectangular 1:2 ratio.

Frame design was first implemented by keeping in mind the safety requirement of the event.
The first primary safety standard focused on during design was maintaining the proper clearance
of the driver’s body rest to the other rigid parts like motor compartment and panel bracing of the
vehicle. Once the basic requirements fulfilled the other safety design were implemented. The
chassis was designed to give occupant extra space to operate the vehicle easily.
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4.2 STREEING
Steering is another very important mechanical aspect of any vehicle. I decided to use
a steering linkage similar to that on a colleague's go-kart, Shane Colton. It works by attaching
each wheel to a steering rod, and connecting each rod to a part on the end of the steering wheel.
When the steering wheel turns, the part on the end rotates, pushing one steering rod away while
pulling the other rod closer. For two wheel steering, an Ackermann steering geometry accounts
for the different turning radius of each wheel. The basis of the geometry is shown in Figure 4.1

Fig 4.1 : Diagram of Ackermann steering geometry.

Once assembled, I found that there were several problems with the steering. At first, the steering
worked smoothly because it was unloaded. However, once the go-kart was loaded with my
weight, the flange bearing holding the steering wheel shaft in place began shifting because it had
an adjustable housing. To correct this, I made a large bushing to be mounted to the bottom of the
go-kart to help support the steering shaft
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4.2.1 TYPES OF STEERING SYSTEMS

4.2.1.1 MANUAL STEERING

The steering system converts the rotation of the steering wheel into a swivelling movement of the
road wheels in such a way that the steering-wheel rim turns a long way to move the road wheels
a short way.The system allows a driver to use only light forces to steer a heavy car. The rim of a
15 in. (380 mm) diameter steering wheel moving four turns from full left lock to full right lock
travels nearly 16 ft (5 m), while the edge of a road wheel moves a distance of only slightly more
than 12 in. (300 mm). If the driver swivelled the road wheel directly, he or she would have to push
nearly 16 times as har

FIG 4.2.1.1 MANUAL STEERING

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4.2.1.2POWER STEERING

On a heavy car, either the steering is heavy or it is inconveniently low geared - the steering wheel
requiring many turns from lock to lock.Heavy gearing can be troublesome when parking in
confined spaces. Power-assisted steering overcomes the problem. The engine drives a pump that
supplies oil under high pressure to the rack or the steering box.Valves in the steering rack or box
open whenever the driver turns the wheel, allowing oil into the cylinder. The oil works a piston
that helps to push the steering in the appropriate direction.As soon as the driver stops turning the
wheel, the valve shuts and the pushing action of the piston stops.The power only assists the
steering - the steering wheel is still linked to the road wheels in the usual way.So if the power
fails, the driver can still steer but the steering becomes much heavier.

FIG 4.2.1.2 POWER STEERING

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4.3. MOTOR

The drive train is a fundamental engineering problem for all vehicles. The
drivetrain consists of the motor, transmission, and any drive wheels. Drivetrain components need
to be mounted robustly and operate efficiently to be safe and effective. I designed the frame so
that a motor could be easily mounted to the steel tubing. For the brushless hobby a wiper motor
I had, it would only take a single mounting plate to secure. After directly bolting a to the steel
frame, I drilled mounting holes that matched with the motor, and milled slots into the plate to
allow for proper tensioning of the chain drive. For simplicity and ease of operation, there would
only be one gear. I decided to use a chain to transmit power from the motor shaft to the drive
wheel. I chose chain because they are slightly more efficient and quieter than their main
competitor in small electric vehicles, chains.

Electrical Motor

The motor or an electrical motor is a device that has brought about one of the biggest
advancements in the fields of engineering and technology ever since the invention of electricity.
A motor is nothing but an electro-mechanical device that converts electrical energy into
mechanical energy. It’s because of motors, life is what it is today in the 21st century. Without the
motor, we had still been living in Sir Thomas Edison’s Era where the only purpose of electricity
would have been to glow bulbs. There are different types of motor have been developed for
different specific purposes.
In simple words, we can say a device that produces rotational force is a motor. The very basic
principle of functioning of an electrical motor lies on the fact that force is experienced in the
direction perpendicular to magnetic field and the current, when field and current are made to
interact with each other.
Ever since the invention of motors, a lot of advancements has taken place in this field of
engineering and it has become a subject of extreme importance for modern engineers. This
particular webpage takes into consideration, the fact as mentioned above and provides a detailed
description of all major electrical motors and motoring parts being used in the present era.
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CLASSIFICATION OR TYPES OF MOTOR

History of Motor

In the year 1821 British scientist Michael Faraday explained the conversion of electrical energy
into mechanical energy by placing a current carrying conductor in a magnetic field which resulted
in the rotation of the conductor due to the torque produced by the mutual action of electrical
current and field. Based on his principal the most primitive of machines a DC (Direct Current)
machine was designed by another British scientist William Sturgeonin the year 1832. But his
model was overly expensive and wasn’t used for any practical purpose. Later in the year 1886,
the first electrical motor was invented by scientist Frank Julian Sprague. That was capable of
rotating at a constant speed under a varied range of load and thus derived motoring action.
 18

Electric motors are now more diverse and adaptable than ever before. When planning a motion
control system, the choice of motor is extremely important. The motor must align with the purpose
and overall performance goals of the system. Luckily, there is a motor design suitable for any
imaginable purpose.
Some of the most common electric motors used today include:

AC Brushless Motors

AC brushless motors are some of the most popular in motion control. They use induction of a
rotating magnetic field, generated in the stator, to turn both the stator and rotor at a synchronous
rate. They rely on permanent electromagnets to operate.

DC Brushed Motors

In a DC brushed motor, brush orientation on the stator determines current flow. In some models,
the brush’s orientation relative to the rotor bar segments is decisive instead. The commutator is
especially important in any DC brushed motor design.

DC BRUSHLESS MOTORS

DC brushless motors were first developed to achieve higher performance in a smaller space than
DC brushed motors, and they are smaller than comparable AC models. An embedded controller
is used to facilitate operation in the absence of a slip ring or commutator.

DIRECT DRIVE

Direct drive is a high-efficiency, low-wear technology implementation that replaces conventional

servo motors and their accompanying transmissions. In addition to being far easier to maintain
over a longer period of time, these motors accelerate more quickly.

LINEAR MOTORS

These electric motors feature an unrolled stator and motor, producing linear force along the
device’s length. In contrast to cylindrical models, they have a flat active section featuring two
ends. They are typically faster and more accurate than rotatory motors.
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SERVO MOTORS

A servo motor is any motor coupled with a feedback sensor to facilitate positioning; thus, servo
motors are the backbone of robotics. Both rotary and linear actuators are used. Lowcost brushed
DC motors are common, but are being superseded by brushless AC motors for high-performance
applications.
Stepper Motors

Stepper motors use an internal rotor, electronically manipulated by external magnets. The rotor
can be made with permanent magnets or a soft metal. As windings are energized, the rotor teeth
align with the magnetic field. This allows them to move from point to point in fixed increments.
Before work begins on any new system, think carefully about the competing properties of the
different motors. The selection of the right motor gets any project off to a better start.

An electric motor is an electrical machine that converts electrical energy into mechanical energy.
Most electric motors operate through the interaction between the motor's magnetic field and
electric current in a wire winding to generate force in the form of rotation of a shaft. Electric
motors can be powered by direct current (DC) sources, such as from batteries, motor vehicles or
rectifiers, or by alternating current(AC) sources, such as a power grid, inverters or electrical
generators. An electric generator is mechanically identical to an electric motor, but operates in the
reverse direction, converting mechanical energy into electrical energy.

Electric motors may be classified by considerations such as power source type, internal
construction, application and type of motion output. In addition to AC versus DC types, motors
may be brushed or brushless, may be of various phase (see single-phase, two-phase, or three-
phase), and may be either air-cooled or liquid-cooled. General-purpose motors with standard
dimensions and characteristics provide convenient mechanical power for industrial use. The
largest electric motors are used for ship propulsion, pipeline compression and pumped-storage
applications with ratings reaching 100 megawatts. Electric motors are found in industrial fans,
blowers and pumps, machine tools, household appliances, power tools and disk drives. Small
motors may be found in electric watches.
 20

In certain applications, such as in regenerative braking with traction motors, electric motors can
be used in reverse as generators to recover energy that might otherwise be lost as heat and friction.

Electric motors produce linear or rotary force (torque) and can be distinguished from devices such
as magnetic solenoids and loudspeakers that convert electricity into motion but do not generate
usable mechanical force, which are respectively referred to as actuators and transducers

The first electric motors were simple electrostatic devices described in experiments by Scottish
monk Andrew Gordon and American experimenter Benjamin Franklin in the 1740s. The
theoretical principle behind them, Coulomb's law, was discovered but not published, by Henry
Cavendish in 1771. This law was discovered independently by CharlesAugustin de Coulomb in
1785, who published it so that it is now known with his name. The invention of the electrochemical
battery by Alessandro Volta in 1799[5] made possible the production of persistent electric currents.
After the discovery of the interaction between such a current and a magnetic field, namely the
electromagnetic interaction by Hans Christian Ørsted in 1820 much progress was soon made. It
only took a few weeks for André-Marie Ampère to develop the first formulation of the
electromagnetic interaction and present the Ampère's force law, that described the production of
mechanical force by the interaction of an electric current and a magnetic field. The first
demonstration of the effect with a rotary motion was given by Michael Faradayin 1821. A free-
hanging wire was dipped into a pool of mercury, on which a permanent magnet (PM) was placed.
When a current was passed through the wire, the wire rotated around the magnet, showing that
the current gave rise to a close circular magnetic field around the wire. [7] This motor is often
demonstrated in physics experiments, substituting brine for (toxic) mercury. Barlow's wheel was
an early refinement to this Faraday demonstration, although these and similar homopolar motors
remained unsuited to practical application until late in the century.

In 1827, Hungarian physicist Ányos Jedlik started experimenting with electromagnetic coils. After
Jedlik solved the technical problems of continuous rotation with the invention of the commutator,
he called his early devices "electromagnetic self-rotors". Although they were used only for
teaching, in 1828 Jedlik demonstrated the first device to contain the three main components of
practical DC motors: the stator, rotor and commutator. The device employed no permanent
magnets, as the magnetic fields of both the stationary and revolving components were produced
solely by the currents flowing through their windings
 21

The drum rotor was introduced by Friedrich von Hefner-Alteneck of Siemens & Halske to replace
Pacinotti’s ring armature in 1872, thus improving the machine efficiency. The laminated rotor was
introduced by Siemens & Halske the following year, achieving reduced iron losses and increased
induced voltages. In 1880, Jonas Wenström provided the rotor with slots for housing the winding,
further increasing the efficiency.

In 1886, Frank Julian Sprague invented the first practical DC motor, a non-sparking device that
maintained relatively constant speed under variable loads. Other Sprague electric
inventions about this time greatly improved grid electric distribution (prior work done while
employed by Thomas Edison), allowed power from electric motors to be returned to the
electric grid, provided for electric distribution to trolleys via overhead wires and the trolley pole,
and provided control systems for electric operations. This allowed Sprague to use
electric motors to invent the first electric trolley system in 1887–88 in Richmond, Virginia,
the electric elevator and control system in 1892, and the electric subway with
independentlypowered centrally-controlled cars. The latter were first installed in 1892 in Chicago
by
the South Side Elevated Railroad, where it became popularly known as the "L". Sprague's motor
and related inventions led to an explosion of interest and use in electric motors for
industry. The development of electric motors of acceptable efficiency was delayed for several
decades by failure to recognize the extreme importance of an air gap between the rotor and
stator. Efficient designs have a comparatively small air gap. The St. Louis motor, long used in
classrooms to illustrate motor principles, is extremely inefficient for the same reason, as well as
appearing nothing like a modern motor. Electric motors revolutionized industry. Industrial
processes were no longer limited by power transmission using line shafts, belts, compressed
air or hydraulic pressure. Instead, every machine could be equipped with its own power
source, providing easy control at the point of use, and improving power transmission efficiency.
Electric motors applied in agriculture eliminated human and animal muscle powe
 22

FIG 4.3.1 WIPER MOTOR

4.4 BATTERY

A battery is a device consisting of one or more electrochemical cells with

external connections provided to power electrical devices such as flashlights, smart phones, and
electric cars.[1] When a battery is supplying electric power, its positive terminal is the cathode and
its negative terminal is the anode.[2] The terminal marked negative is the source of electrons that
will flow through an external electric circuit to the positive terminal. When a battery is connected
to an external electric load, a redox reaction converts highenergy reactants to lower-energy
products, and the free-energy difference is delivered to the external circuit as electrical energy. [3]
Historically the term "battery" specifically referred to a device composed of multiple cells,
however the usage has evolved to include devices composed of a single cell.[4]

Primary (single-use or "disposable") batteries are used once and discarded; the electrode materials
are irreversibly changed during discharge. Common examples are the alkaline battery used for
flashlights and a multitude of portable electronic devices. Secondary (rechargeable) batteries can
be discharged and recharged multiple times using an applied electric current; the original
composition of the electrodes can be restored by reverse current. Examples include the lead-acid
batteries used in vehicles and lithiumion batteries used for portable electronics such as laptops
and smartphones.

Batteries come in many shapes and sizes, from miniature cells used to power hearing aids and
wristwatches to small, thin cells used in smartphones, to large lead acid batteries or lithiumion
batteries in vehicles, and at the largest extreme, huge battery banks the size of rooms that provide
standby or emergency power for telephone exchanges and computer data centers.
 23

According to a 2005 estimate, the worldwide battery industry generates US$48 billion in sales
each year,[5] with 6% annual growth.

Batteries have much lower specfic energy (energy per unit mass) than common fuels such as
gasoline. In automobiles, this is somewhat offset by the higher efficiency of electric motors in
converting chemical energy to mechanical work, compared to combustion engines.

4.2.1 TYPES OF BATTERY

Batteries generally can be classified into different categories and types, ranging from
chemical composition, size, form factor and use cases, but under all of these are two major battery
types;

1. Primary Batteries
2. Secondary Batteries

1. PRIMARY BATTERIES

Primary batteries are batteries that cannot be recharged once depleted. Primary batteries are
made of electrochemical cells whose electrochemical reaction cannot be reversed. Primary
batteries exist in different forms ranging from coin cells to AA batteries. They are commonly
used in standalone applications where charging is impractical or impossible. A good example of
which is in military grade devices and battery powered equipment. It will be impractical to use
rechargeable batteries as recharging a battery will be the last thing in the mind of the soldiers.
Primary batteries always have high specific energy and the systems in which they are used are
always designed to consume low amount of power to enable the battery last as long as possible .
 24

FIG 4.4.1.1 PRIMARY BATTERIES

Some other examples of devices using primary batteries include; Pace makers, Animal trackers,
Wrist watches, remote controls and children toys to mention a few.

The most popular type of primary batteries are alkaline batteries. They have a high specific
energy and are environmentally friendly, cost-effective and do not leak even when fully
discharged. They can be stored for several years, have a good safety record and can be carried on
an aircraft without being subject to UN Transport and other regulations.

The only downside to alkaline batteries is the low load current, which limits its use to devices with
low current requirements like remote controls, flashlights and portable entertainment devices.

2. SECONDARY BATTERIES

Secondary batteries are batteries with electrochemical cells whose chemical reactions can be
reversed by applying a certain voltage to the battery in the reversed direction. Also referred to as
rechargeable batteries, secondary cells unlike primary cells can be recharged after the energy on
the battery has been used up.

They are typically used in high drain applications and other scenarios where it will be either too
expensive or impracticable to use single charge batteries. Small capacity secondary batteries are
used to power portable electronic devices like mobile phones, and other gadgets and appliances
while heavy-duty batteries are used in powering diverse electric vehicles and other high drain
applications like load levelling in electricity generation. They are also used as standalone power
sources alongside Inverters to supply electricity. Although the initial cost of acquiring
rechargeable batteries is always a whole lot higher than that of primary batteries but they are the
most cost-effective over the long-term.Secondary batteries can be further classified into several
other types based on their chemistry. This is very important because the chemistry determines
some of the attributes of the battery including its specific energy, cycle life, shelf life, and price
to mention a few.

There are basically four major chemistries for rechargeable batteries;

1. Lithium-ion(Li-ion)
 25

2. Nickel Cadmium(Ni-Cd)
3. Nickel-Metal Hydride(Ni-MH)
4. Lead-Acid

1. NICKEL-CADMIUM BATTERIES

The nickel–cadmium battery (NiCd battery or NiCad battery) is a type of rechargeable battery
which is developed using nickel oxide hydroxide and metallic cadmium as electrodes. Ni-Cd
batteries excel at maintaining voltage and holding charge when not in use. However, NI-Cd
batteries easily fall a victim of the dreaded “memory” effect when a partially charged battery is
recharged, lowering the future capacity of the battery.

FIG 4.4.1.2 NICKEL-CADMIMUM BATTERY

In comparison with other types of rechargeable cells, Ni-Cd batteries offer good life cycle and
performance at low temperatures with a fair capacity but their most significant advantage will be
their ability to deliver their full rated capacity at high discharge rates. They are available in
different sizes including the sizes used for alkaline batteries, AAA to D. Ni-Cd cells are used
individual or assembled in packs of two or more cells. The small packs are used in portable
devices, electronics and toys while the bigger ones find application in aircraft starting batteries,
Electric vehicles and standby power supply.

Some of the properties of Nickel-Cadmium batteries are listed below.

▪ Specific Energy: 40-60W-h/kg

▪ Energy Density: 50-150 W-h/L
▪ Specific Power: 150W/kg
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▪ Charge/discharge efficiency: 70-90%

▪ Self-discharge rate: 10%/month
▪ Cycle durability/life: 2000cycles

2. NICKEL-METAL HYDRIDE BATTERIES

Nickel metal hydride (Ni-MH) is another type of chemical configuration used for rechargeable
batteries. The chemical reaction at the positive electrode of batteries is similar to that of the nickel–
cadmium cell (NiCd), with both battery type using the same nickel oxide hydroxide (NiOOH).
However, the negative electrodes in Nickel-Metal Hydride use a hydrogen-absorbing alloy instead
of cadmium which is used in NiCd batteries

FIG 4.4.1.3 NI-MH BATTERY

NiMH batteries find application in high drain devices because of their high capacity and energy
density. A NiMH battery can possess two to three times the capacity of a NiCd battery of the same
size, and its energy density can approach that of a lithium-ion battery. Unlike the NiCd chemistry,
batteries based on the NiMH chemistry are not susceptible to the “memory” effect that NiCads
experience.

Below are some of the properties of batteries based on the Nickel-metal hydride chemistry;

▪ Specific Energy: 60-120h/kg

▪ Energy Density: 140-300 Wh/L
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▪ Specific Power: 250-1000 W/kg

▪ Charge/discharge efficiency: 66% - 92%
▪ Self-discharge rate: 1.3-2.9%/month at 20oC
▪ Cycle Durability/life: 180 -2000

3. LITHIUM-ION BATTERIES

Lithium ion batteries are one of the most popular types of rechargeable batteries. They are found
in different portable appliances including mobile phones, smart devices and several other battery
appliances use\d at home. They also find applications in aerospace and military applications due
to their lightweight nature.

Fig 4.4.1.4 Lithium-Ion Battery

Lithium-ion batteries are a type of rechargeable battery in which lithium ions from the negative
electrode migrate to the positive electrode during discharge and migrate back to the negative
electrode when the battery is being charged. Li-ion batteries use an intercalated lithium compound
as one electrode material, compared to the metallic lithium used in nonrechargeable lithium
batteries.Lithium ion batteries generally possess high energy density, little or no memory effect
and low self-discharge compared to other battery types. Their chemistry alongside performance
and cost vary across different use cases for example, Li-ion batteries used in handheld electronic
devices are usually based on lithium cobalt oxide (LiCoO 2) which provides high energy density
and low safety risks when damaged while Liion batteries based on Lithium iron phosphate which
offer a lower energy density are safer due to a reduced likelihood of unfortunate events happening
 28

are widely used in powering electric tools and medical equipment. Lithium ion batteries offer the
best performance to weight ratio with the lithium sulphur battery offering the highest ratio.Some
of the attributes of lithium ion batteries are listed be

4. LEAD-ACID BATTERIES

Lead acid batteries are a low-cost reliable power workhorse used in heavy duty applications. They
are usually very large and because of their weight, they’re always used in non-portable
applications such as solar-panel energy storage, vehicle ignition and lights, backup power and
load levelling in power generation/distribution. The lead-acid is the oldest type of rechargeable
battery and still very relevant and important into today’s world. Lead acid batteries have very low
energy to volume and energy to weight ratios but it has a relatively large power to weight ratio
and as a result can supply huge surge currents when needed. These attributes alongside its low
cost makes these batteries attractive for use in several high current applications like powering
automobile starter motors and for storage in backup power supplies.

Fig 4.4.1.5 Lead Acid Battery

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CHAPTER. 5
WORKING

It is a small four wheeler run by motor using battery. Streering wheel consists of slider mechanism
.To Move the vechile using a push button switch .Wiper motor is connected with the 12battery
and switch also connected with the motor and battery Push the switch button switch continously
go cart will move relaese switch It will stop. Change the battery connection wire for reverse
movement.

4.5 PIPES

Polyvinylchloride (/ˌpɒlivaɪnəl ˈklɔːraɪd/; colloquial: polyvinyl, vinyl]; abbreviated: PVC) is

the world's third-most widely produced synthetic plastic polymer, after polyethylene and
polypropylene. About 40 million tonnes are produced per year.

PVC comes in two basic forms: rigid (sometimes abbreviated as RPVC) and flexible. The rigid
form of PVC is used in construction for pipe and in profile applications such as doors and
windows. It is also used in making bottles, non-food packaging, and cards (such as bank or
membership cards). It can be made softer and more flexible by the addition of plasticizers, the
most widely used being phthalates. In this form, it is also used in plumbing, electrical cable
insulation, imitation leather, flooring, signage, phonograph records,[8]inflatable products, and
many applications where it replaces rubber.[9] With cotton or linen, it is used to make canvas.

Pure polyvinyl chloride is a white, brittle solid. It is insoluble in alcohol but slightly soluble in
tetrahydrofuran
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CHAPTER. 6

6 ADVANTAGES

Acceleration is usually better than thermic model and the speed is sufficient for use on
most kart circuits. Torque in electric motors are greater than that of the gas engine. They are ideal
for quick take offs and off road climbing.Electric go-karts are low maintenance, requiring only
that the lead-acid batteries of the cars be plugged into an array of chargers after each run. Since
they are pollution-free and emit no smoke, the racetracks can be indoors in controlled
environments. Most fully charged electric karts can run a maximum of 20 minutes before
performance is affected. An expensive alternative is the use of Lithium iron phosphate LiPO4
lithium batteries. They last much longer and carry more power per pound than lead acid
batteries.Electric power Go-Karts do not have hot engines or a tank full of gas which can prove
to be safer in an accident.

6.1 DISADVANTAGES
Batteries are still very expensive and the autonomy is not that good. However, charging can
be achieved in about 30 minutes and it is possible to swap batteries.

6.2 APPLICATION

Fun drifting ,off road riding ,f-1 Racing ,Desert Racing ,short Distance
travelling ,used in big temples
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CHAPTER. 7

CONCLUSIONS

The purpose of this project was to fabricate a fixed axle/single axle go kart based on a
conceptual design which is optimized to increase the stability and maneuverability of the vehicle
on the racing track. The design is based on rulebook which is affiliated to CIK-FIA. The design
and fabrication of the Go-kart focuses on developing a simple, lightweight and easily operated
vehicle. Aspects of ergonomics, safety and reliability were incorporated into the design
specifications. Analysis were conducted on all major components to optimize strength and
rigidity, improve vehicle performance and to reduce complexity and manufacturing costs.

Through this project, I’ve found that personal electric vehicles are very comprehensive
projects. When completed, they can be very fun and even practical if used for transportation.
However, building a motor took much more time and effort than I initially expected. For use in
an open space under a go-kart , a commercial motor would be much easier and potentially cheaper.
Only for truly specific purposes can a custom motor be well justified. Still, designing and building
go kart was a great learning experience that will remain a memorable part of my time at SMVPTC
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CHAPTER. 8

COST ESTIMATION

COMPONENTS PRICE

PVC PIPES 1370

BEARING 310

WOOD SHEET 650

WHEELS 1500
WIPER MOTOR 3270
BATTERY 700
CHAIN 100
PUSH BUTTON 50
OTHER COMPONENTS 100

TOTAL = 8100
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CHAPTER. 9

PHOTOGRAPHY
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CHAPTER. 10

REFERENCE

1]. Anjul Chauhan, Lalit Naagar , Sparsh Chawla, Design And Analysis Of A Go-Kart,
International Journal of Aerospace and Mechanical Engineering Volume 3 – No.5, September
2016 ,29

[2] Sandeep Ramini, Mohan Rentala ,Sneha Gulab Mane B.Tech (Mechanical Engineering),
Design and Structural Analysis of a Go-Kart Vehicle Chassis , International Journal &
magazine of engineering , technology and management research , Volume 2 – No.10, october
2015 ,1373

[3]. Harshal D. Patil, , Saurabh S. Bhange ,Ashish S. Deshmukh, Design and Analysis of
GoKart using Finite Element Method , International Journal of Innovative and Emerging
Research in Engineering Volume 3, Special Issue 1, ICSTSD 2016

[4]. Ravindra Laxman Gaikwad, Prathmesh Vishwas Waghmare, Lalit Daulatrao Deore,
Akshay Mukesh Mutake , DESIGN OF GO-KART VEHICLE SYSTEMS , international
conference on emerging trend in engineering and management research , ICETEMER-16 ,
23rd march 2016
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