A Project Report on

Design and Development of Solar

Operated Mechanical Segway
By

Mr. Sanket Shrikant Khule Mr. Santosh Gitaram Hargule

Mr. Shubham Yuvraj Borade Mr. Indrajit Vikas Ransing

Guide
Prof. Chetanraj Patil

Department of Mechanical Engineering

Dr. D. Y. Patil Institute of Technology, Pimpri,
Pune -411 018
[2020 - 2021]

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 Dr. D. Y. Patil Institute of Technology, Pimpri,
Pune -411018.
Department of Mechanical Engineering

CERTIFICATE
This is to certify that the Mr. Sanket Shrikant Khule, Mr. Santosh Gitaram Hargule, Mr. Indrajit
Vikas Ransing and Mr. Shubham Yuvaraj Borade has successfully completed the Project entitled
“Design and Development of Solar Operated Mechanical Segway” under my supervision, in
the partial fulfilment of Bachelor of Engineering - Mechanical Engineering of Savitribai Phule
Pune University during the academic year 2020-2021.

Date:
Place: Pune

Prof. Chetanraj Patil ___________

Guide External Examiner

Dr. K. K. Dhande Dr. Pramod D. Patil

Head of Department Principal
Dr. D.Y. Patil Instt. of Tech. Dr. D.Y. Patil Instt. of Tech.
Pimpri, Pune Pimpri, Pune
Seal

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 Acknowledgement
We express our sincere thanks to our guide Prof. Chetanraj Patil, for his constant encouragement
and support throughout our B.E project, especially for the useful suggestion given during the
course of the project period and having laid down the foundation for the success of this work.

We would like to thank our project coordinator for his assistance, genuine support and guidance
from early stages of the project.

We would like to thank Dr. K. K. Dhande, Head of Mechanical Engineering Department for his
unwavering support during the entire course of this project work.

We are very grateful to our principal Dr. Pramod D. Patil for providing us with a positive
environment.

We also thank to our staff members of our college and technicians for their help in making this
project a success. Finally, we take this opportunity to extend our deep appreciation to our family
and friends, for all they meet to us during the crucial times of the completion of our project.

Mr. Sanket Shrikant Khule

Mr. Santosh Gitaram Hargule
Mr. Indrajit Vikas Ransing
Mr. Shubham Yuvaraj Borade

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 Contents
Sr. No. Topic Page
No.

Introduction 8-16

1.0 Introduction 8-11

1.1 Problem Statement 11-14

1 1.2 Objectives 14

1.3 Scope 15

1.4 Methodology 15-16

2 Literature Review 20-23

Design Work

3 (Expected CAD Model/ Drawing and their description)

3.1 Component Description 25-29

3.2 Design Work & Calculation 30-36

3.3 Software Simulation Result 37-39

4 Cost of The Project 41-42

5 Possible Outcome 44

6 Concluding Remarks and Scope for the Future Work

5.1 Concluding Remarks 46

5.2 Scope for the Future Work 46

7 References 48-49

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 List of Figures

Figure No. Figure Name Page No.

1 Basic Two & Three wheeled Segway 9

2 Applications of Segway PT 11

3 The Concept of third wheel 12

4 A 360˚ swivel wheel with double bearing 14

5 DC Square Motor 25

6 Gear 26

7 Battery 26

8 Pneumatic tyre 27

9 Swivel Wheel 28

10 Solar panel 29

11 Cad Parts and Assembly Drawings 30-32

12 Analysis Result: Stress 37

13 Analysis Result: Strain 38

14 Analysis Result: Deformation 39

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 List of Tables

Sr.No Name of Table Page no

1 Methodology Work-Flow Chart 16

2 Tyre Speed Rating 28

3 Cost of The Project 41

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 Chapter – 1

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Introduction

1.1 What is a Segway?

A Segway is an electrically powered stand-up scooter with higher degree of freedom than
normal vehicles and mostly used for personal transportation in urban environment. This was
invented by Dean L. Kamen, an American entrepreneur and first produced by Segway Inc. of
New Hampshire. Segway have had success in niche markets such as transportation for police
departments, military bases, warehouses, corporate campuses and industrial sites. The legal
roadworthiness of the Segway varies with different jurisdictions classification of the device as a
motor vehicle. There are many variants available in Segway. However, the most popular and
commonly used ones are the two wheeled Segway, known as the Segway PT. It is an electric,
self-balancing human transporter with a computer-controlled gyroscopic stabilization and control
system. The device is balanced on two parallel wheels and is controlled by moving body weight.
Generally rural people need to travel mid-range distances to reach at the destination, the students
living in the rural areas need to travel longer distances for taking education. Also, in some places
like college, office, plant people need to travel in long distance by walking the mini electrical
vehicle for single person is solution of this problem. Thus, aim is to produce something which
will be useful in such above situation for travelling longer distances, which will be portable, and
of low cost.

In this project, "Solar Operated Mechanical Segway" vehicle has been built as a part of
the course applied control and mechanical and electrical fusion. The goal of this project is that
everyone should know about the Segway, how it is manufactured, fabricated and how is the
working system of the Segway and another one is the how is to ride and balance of the Segway
vehicle. The project is aimed at making a two wheeled and one small wheel balancing electric
vehicle and applying some mechanical concepts to it. By using switch, circuit board and electric
supply to go forward and go backward direction easily with the help of perfect balancing using
this third wheel. The vehicle has electric motors powered by dry batteries. It balances with the
help of small wheel.

There is no used of Microcontroller, gyroscopic sensors and any type of sensors for the
rider accelerates or decelerates by using push up switch go forward and backwards in the

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direction he or she wishes to travel. Non-conventional source of energy is used in the form solar
energy to charge the batteries using a solar panel kit to convert the solar energy into electric
energy.

Fig. 1.1 Basic Two & Three wheeled Segway

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1.2 Advantages
Segway personal transporter has many advantages over the conventional vehicles,
because of its higher degree of freedom and compact design. Some of the major advantages of a
Segway over the conventional vehicles are:

1.2.1 Higher degree of freedom: A Segway has more degrees of freedom than normal vehicles.
It can be steered and controlled more precisely than the conventional vehicles with mechanical
steering.

1.2.2 Zero turn radius: It is a very interesting property of Segway PT. Zero turn radius helps the
vehicle to turn about its own axis. This helps the Segway to steer through very narrow spaces
very easily.

1.2.3 Low operating costs: The operating costs of a Segway are much lower than the
conventional vehicles, which makes it economical to use.

1.2.4 Zero emissions: Since, Segway is electrically powered; there are no emissions from the
vehicle that could affect the environment. However, it does draw electricity during recharge, but
that electricity is fourteen times less greenhouse gas emissions than a conventional IC engine
powered vehicle.

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1.3 Applications

A Segway is as accurate as human walking and as fast as conventional vehicles. This

makes it special with wide range of applications where accurate mobility is needed. Some of the
applications are given below.

1.3.1 Urban police patrol: Since its inception, the Segway Patroller has been readily deployed
by law enforcement and private security agencies across the globe. Patrol all sorts of indoor and
outdoor environments while better connecting with the citizens.

1.3.2 Military: Because of its high degree of freedom and accuracy Segway finds its applications
in military.

1.3.3 Logistics: Equipped with optional hard cases the Segway PT is the ideal transport vehicle
for corporate use on ample premises, for example airports, train stations, large warehouses - or
for increased mobility on hospital grounds.

1.3.4 Off road riding: Segway PT makes off road riding much easier than with conventional
vehicles.

1.3.5 Sports coverage Cameramen: In recent times the popularity of Segway in sports coverage
has been tremendous. Its free and higher degree of freedom helps the camera men to cover the
sport in various angles without using any complicated equipment.

1.3.6 Urban sight-seeing: Segway are been used in many countries to attract the tourists for
sightseeing. Sightseeing on Segway makes the mobility easy and the experience more
comfortable.

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1.3.7 Segway polo: Segway polo is similar to horse polo, except that instead of playing on
horseback, each player rides a Segway PT on the field. Although not a major sport, Segway polo
is gaining popularity and teams have begun forming in many parts of the world. The
International Segway Polo Association (ISPA) has been established as the official governing
body for Segway Polo.

Fig. 1.2 Applications of Segway PT

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1.4 Problem Statement & Solutions:

1.4.1 Problem Statement:

First duty of Automobile engineer is to fulfil the requirement of people about automobile
vehicle. Being an Automobile engineer our responsibility is to give the output as per
requirement of people in the form of vehicle. This vehicle should be easy to operate.
Engineer must design this vehicle by considering the person's easy point of view and easy
handling characteristics as well as ride comfort such as hand brake, ease of balancing, low
cost, better assembly, easy operation etc. In the existing Segway, the usage of electronic
components is more.

The complex electronics like accelerometers, gyroscopic sensors and highly accurate
control system makes the Segway as highly expensive. Segway requires technical
maintenance regularly otherwise there may be a possibility of failure of electronic
components.

Any failure in these electronics system makes it unstable and may lead to serious
accidents which cause serious injuries to the user. In user point of view, it is also difficult to
do the technical maintenance. The electronic components are also not a serviceable one. It
leads to increase the E-waste quantity.

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1.4.2 Solution of Problem Statement

The simplest answer to this problem could be just adding the third wheel (a swivel
wheel) which eliminates all the complicated and costly electronics that balance the Segway
making the Segway more stable, economical and failsafe.

Fig. 1.3 The Concept of third wheel

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1.2.1 Advantages of three-wheel Segway

Stability: The third wheel increases the stability of the vehicle. Even in low battery conditions
and sudden electronics failure the vehicle remains absolutely stable unlike the two-wheel
Segway.

Easy Riding: As the three-wheel Segway does not involve gyroscopic sensors and
accelerometers. It eliminates the complex riding mechanism of two-wheel Segway and makes
the vehicles easy to ride even for the new users.

Easy Reversing: Direct reversing was a big problem in a two-wheel Segway. Reversing the
Segway directly is not a comfortable task for the rider on a two-wheel Segway. The stability in a
three-wheel Segway makes the reversing easy and comfortable for the rider.

Economical: As the third wheel eliminates the complex electronics like accelerometers,
gyroscopic sensors and highly accurate control system it reduces the cost of the Segway by many
times, making more economical and affordable.

Less Maintenance: three-wheel Segway eliminates self-balancing sensors and other steering
equipment that requires regular maintenance. So, this reduces the maintenance time and cost to
great extent, making it much user friendly.

Fail-Safe: In the case of three-wheel Segway Sudden failure in the control system or problems in
electronics can cause the Segway to lose its balance completely and can lead to severe accidents.
This is not the case with three-wheel Segway which does not lose its balance remains stable
under any failure of electronics. The failsafe feature of the three-wheel Segway makes it more
reliable than the two-wheeled one.
All these reasons give the three-wheel Segway technical and commercial advantages to compete
with the two-wheel Segway.

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1.2.2 Disadvantage of the third wheel

The swivel wheels are generally rigid in nature unlike the pneumatic tires. So, when any
obstacle comes in the way of the third wheel there are chances that the wheel gets stuck and
obstructs the motion of the Segway. This third wheel can also cause unnecessary vibrations and
noise while travelling on rough terrain.

Fig. 1.4 A 360˚ swivel wheel with double bearing

1.2.3 Overcoming the disadvantage

This disadvantage of the 3rd wheel can be minimized by adding Suspension to the swivel
wheel. By Adding a spring suspension, the vibrations are absorbed. This reduces the vibrations
noise during the operation.

This also allows the wheel to move over the small obstacles allowing the Segway to move
smoothly, making it comfortable for the rider.

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1.3 Objectives

1 To develop an accurate mathematical model and control system for MINI VEHICLE.
2 To implement manual braking system for the vehicle.
3 To make vehicle portable and easy to repair.
4 To kept weight of vehicle as low as possible.
5 To cover at least of 10km when fully charged.
6 To make design of less cost.

1.4 Scope

Our project is “DESIGN & DEVELOPMENT of SOLAR OPERATED MECHANI CAL

SEGWAY”. In our project, we are generally focusing on manufacturing of a 3 wheeled self -
balancing Segway. In this project, we will collect data related to mechanism, steering, designing
of frames, shafts according to the standard parameters. The main highlight of the project is going
to be the installation of solar energy system and implementation of manual braking system.

After that, we will be doing calculations based on the standard designing steps
considering stresses and other parameters. We will be doing calculations to design a strength of
the base plate, perfect dimensions of very elements of the vehicle optimum speed of the vehicle
on one full charge.

After doing calculations, we will design all the essential parts and assembly by Catia
software and then will analyse it by means of Ansys Software. After the complete design, the
model will be made accordingly and will be on different testing environments like slopes rough
surfaces.

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1.5Methodology

The aim of this project is to make a mechanical based Segway to work with economical,
reliable, stable and fail-safe. Here the methodology is to just introduce a third wheel for
stability purpose which eliminates all the complicated and costly electronics parts which are
all used for the same stability purpose. As there is a limited electronic component the
technical maintenance may be reduced. The advantage of adding third wheel leads to
Stability, Easy reversing, less maintenance and fail safe.

Research on the recent ideas of innovation.

Design of separate parts of the vehicle using Catia

software

Analysis to check the deformation, stresses and strains

induced due to loading on the footplate of the Segway

Developments such as SOLAR energy and braking

systems.

Actual fabrication of the parts and assemblies

Manufacturing of vehicle.

Testing of vehicle on different cases.

Fig. 1.5 Methodology Work-Flow Chart

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 Chapter – 2

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Literature Review:

Summary of the related papers

Rajesh kumar:

This Paper includes how the compressed air is produced by using vehicle suspension.
We know Pneumatic energy is the readily available and low-cost energy. Now-a-days non-
conventional energy system is very essential to the world. So here we are focusing on pneumatic
type of energy for this project. In this project compressed air can be produced with the help of
vehicle suspension system.

Then this compressed air is used to operate the vehicle. Compressed air production
using ssuspension system does not require any fuel for its motion. This air operated vehicles are
the new innovative concept to run vehicle by using the compressed air. So in this paper we are
making one type of device that is used for producing compressed air for different purposes by
using vehicle suspension.

The compressed air may be used for running the vehicle and for air conditioning
purposes. Here we start with an introduction to pneumatic; it’s various applications and units and
briefly explains a few devices capable of utilizing air effectively and their relative merits. The
pneumatic operated vehicle is very useful to save the conventional type of fuel and after few
years these things will play a very important role.

Dinesh Jadhav:

In this paper in today’s industrial world man’s innovative ideas has taken him towards
all directions concerning about the production and safety in industrial establishments. Some
instruments are of shear excellence where as others are the result of long research and persistent
work, but it is not the amount of time and money spent in the invention of device or the
sophistication of its operation, but its convenience, utility and operational efficiency that are
important in considering the device.

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 During times of emergency, especially during journeys if the air pressure of our vehicle
decreases then it poses a great problem to the rider. In order to help during such emergencies
portable equipment is required which can help the rider to easily pump air into the vehicle tyre to
the required air pressure without any excess effort and power requirement.

Ganesh Shirsath:

The paper is concerns with increase in transportation of goods and public transportation. The
adverse effects are known and well documented. Discussions about various views of the best
solutions for these problems are taking place around the world.
One of these visions involves the use of advanced technology based on the public transit as the
basis for all sustainable solutions. In this search for different methods, MPTDs could help
promote a modal transfer away from the automobile for short-distance trips.
Electric scooters and Segway are two, user friendly, “in” modes of transportation that facilitate
effortless travel and could provide suitable transportation in metro cities. Our aim is to make a
design and fabrication of Segway personal transporter.
The Segway is based on the principle of inverted pendulum that will keep an angle of Zero
degrees with vertical at all times.

Mayank Sharma:

The paper is about the general idea of a Segway. The Segway Human Transporter is one of
several low-speed transportation devices (e.g., bikes, scooters, wheelchairs) that, under certain
circumstances, travel on sidewalks, roadways, and other shared -use paths. The objective of this
research was to examine the primary operating characteristics of the Segway.

In this thesis, we designed and constructed mechanically based system for a two-wheel
balancing Segway robot. In this paper they have presented a Segway based on gyro sensor,
accelerometer along with a microcontroller and use of mechanical and electrical hardware’s.

The dynamics of the vehicle is similar to the classical control problem of an inverted
pendulum, which means that it is unstable and prone to tip over. This is prevented by electronics
sensing the pitch angle and its time derivative, controlling the motors to keep the vehicle
balancing.

This kind of vehicle is interesting since it contains a lot of technology relevant to an eco-
friendly and energy efficient transportation industry. This thesis describes the development of a

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similar vehicle from scratch, incorporating every phase from literature study to planning, design,
vehicle construction and verification.

The main objective was to build a vehicle capable of transporting a person weighing up to 70-
80 kg and capable of travelling to some km distance with varying speed .

Ankit S. Khanzode:

In this project work, two wheeled and one small supporting wheel self-balancing as well as
manually balancing Mechanical Segway vehicle is prepared which is also known as a personal
transporter Segway.
The system is able to operate in transporter mode and robotic mode. The first goal is to
maintain stabilization in pitch dynamic. This project focuses on to manufactured Segway without
using any type programming & Sensors a state feedback to stabilize system on transporter mode.
The system consists of forward and backward movement when the driver operating DPDT
switch in transporter mode in order to stabilize body. Small wheel is used so that there is no need
of gyroscope for balancing purpose.
The aim of this project work is to build up at a very low cost, highly efficient rate and easy to
handle and operating also. The tests are performed on mechanical Segway to confirm that
Mechanical Segway operating very well and highly efficient rate.

Sandesh Pitambare:

In the present days, we are dealing with a problem of increase in number of vehicles with
ever-lasting demand of fuel to run them. If this situation remains with time, it would be difficult
for us to save our future from increasing pollution and fuel demand. With time the population on
earth increases obviously; which cannot be controlled so, to fulfil the demands of fuel or energy
in future world, effective steps should be taken as soon as possible.
Our dependence on fuel can be reduced with an alternative such as, use of battery-operated
vehicles. The aim of this project work is to build up a Tri-wheel electric Segway at a very low
cost, highly efficient rate and easy to handle and operating also.

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 Three wheels Segway is an electric scooter of future technology; it is often used to transport
a user across mid-range distances in urban environment. It has more degrees of freedom than car
or bike and is faster than pedestrian. They are more efficient than fuel powered vehicles for
shorter distance and time of travelling.

R. Hiremath:

Two-wheeled, self-balancing systems are studied in many different concepts. They can be
considered as robotic platform or as electric vehicle/transporter. Researchers focus on various
issues besides the main problem stability. Segway Human Transporter (HT), which is invented
by Dean Kamen, is known as the first two-wheeled, self-balancing system in the literature.
Flexibility, safety and performance are important due to being commercial product. Also,
Segway brings out two wheeled self-balancing robotic platform which is called Robotics
Mobility Platform (RMP). Moreover, human scaled robots exist. Some of them are driven by an
operator while rests are driven autonomously. As a transporter system, it is driven semi-
autonomously by the driver on it.
The driver determines the speed and direction of movement of the vehicle by leaning forward
and backward. Most of the transporters are combined of standing base and handlebar which
make the driver feel comfortable. Also, steering mechanism is generally mounted on the
handlebar. However, the vehicle only consists of a standing base. Steering is provided by shift ing
Centre of gravity (COG) of driver.
The discusses the system both as a transporter and as a robotic platform which carries goods.
Some studies which are inspired by Segway emphasize creating lightweight and low-cost
systems.

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 Chapter-3

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3.1 Component Description:

A) Segway baseplate and material properties:

Baseplate is made up of mild steel section.Wheels are attached to the side of frame in order to
withstand the load capacity. Handle is also made up of mild steel material to which DPDT
switch is fixed.

1) Atomic Weight (g/mol) – 54.93

2) Thermal Conductivity(0-1000C) (W/mk) – 50.2
3) Electrical Resistivity at 200C (Ω.cms) - 2.69
4) Density (g/cm3) – 7.85
5) Modulus of Elasticity (GPa) – 200

B) Adjustable Rod with Handle:

The Adjustable rod is used to vary the height according to the rider’s comfort. Handle refers to
the steering mechanism for Segway, the equivalent of a steering wheel. Besides steering, handle
also often support a position of the rider’s weight, depending on their riding position .

C) DC Square Motor:
Square geared DC motor is a very high torque motor used in Household appliances, automatic
system etc. Gear box is built to handle the stall torque produced by the motor. Drive shaft is
supported from with metal bushes. We used two 12V, 30Rpm DC Square Motor.

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 D) Battery:
Battery is the main power source of our three wheeled Mechanical Segway. 12V DC Battery is
used in our Segway. The two motors are connected to a battery through a Switch.

E) Gears:
Gears are used to alter or vary the speed of the output shaft. We have used two gears for our
project. The driver gear has 24 teeth and driven gear has 48 teeth’s so, the gears are in the ratio
of 2:1.

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 F ) Drive wheels

The maximum speed of the segway is limited to around 15 kmph. So, the diameter of the
drive wheels should be around 8-10 inch for a typical 150-200 rpm drive motor.
As the segway has been designed to carry a user weighing 100kg, and some suspension in the
tyres would help smooth the ride for such a large mass. Aesthetic considerations required the
diameter of the wheels to be at least 8inch (0.23m).
Typical pneumatic tyres with good suspension that are designed to take 60 kg load each
comfortably works good for the segway.
However, most of the tyres are rated with speed ratings and load index, which can be helpful in
selecting the tyre based on the speed and load requirements. Since, the speed of the segway is
very low, there is no problem with the speed rating. Taking load index as major factor to select
the tyre, an 8” 30B pneumatic tyre will take the load comfortably.

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G) Swivel Wheel:
The purpose of the Swivel wheel (third wheel) is just to provide balance to the Segway. It
eliminates the need of Gyroscope sensor. So, the cost is considerably reduced because
Gyroscope sensor costs more.

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H) Solar plate:

Mechanical Segway one advance function is used for the battery charging i.e., solar plate. The
purpose solar plate to charge the battery with help of electric socket and solar plate.

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3.2 Design Work & Calculation

The Individual components of the Three Wheeled Mechanical Segway are modelled separately
and assembled using Catia software.

3D Modelling:

The Main components of the Three Wheeled Mechanical Segway is modelled separately and
assembled.

.1. Construction

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 Fig: Part and assembly design

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CALCULATIONS:

A) Chassis Stress Calculation:

1)The weight acting on the Segway= (weight of the Segway + weight of the user)

Weight of the Segway = 20kg

Max. Weight of the user = 80kg

Total weight acting on the Segway = (20 + 80) kg

So, total weight acting on the Segway is = 100 kg

2) Load acting on the chassis = Total weight acting on the Segway × 9.81

Load acting on the Segway chassis=100× 9.81

So, load acting on the Segway chassis=981N

3)Area of the Segway chassis = Length of chassis × Width of chassis

Length of the chassis=650mm

Width of the chassis=500mm

Area of the Segway chassis= (650×500) mm

So, area of the Segway chassis=325000 mm2

4) Allowable stress =yield strength/FOS

yield strength=250 N/mm2

FOS=2

Allowable stress =250/2

Allowable stress =125 N/mm2

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5) Stress acting on the chassis= (Load acting on chassis / area of chassis)

Stress acting on the chassis=981 / 325000

Stress acting on the chassis=3.018x10^-3 N/mm2

The stress acting on the Frame of the Segway is very less than the allowable stress. So, the
design is safe.

B) Factor of Safety:

Factor of safety is the ratio of ultimate load to allowable load.

1)The ultimate load acting on the Segway chassis= Max. allowable weight on segwayx9.81

Max. allowable weight on the Segway=150kg

The ultimate load acting on the Segway chassis=150x9.81

So, the ultimate load acting on the Segway chassis=1472 N

The allowable load acting on the Segway chassis=981 N

2) Factor of safety=Ultimate load / allowable load

FOS=1472/981

FOS=1.5

Design factor of safety=2

The Factor of safety for our Segway is less than the designed Factor of saf ety. Hence the
Segway design is safe.

C) Calculations for Drive Motor Specifications:

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Considering, Total mass as 100kg, maximum incline as 20 degree and efficiency of motors as
85%, the output required from the motors is calculated.

Taking,

1)Total mass, m = 100 kg

2)Angle of inclination, ϴ = 20˚

3)Total efficiency, e = 85%

4)Radius of the wheel, r = 0.1524 m

5)Supply voltage, V = 24V

6)Desired acceleration, a = 0.2 m/s²

7)Let, the Segway speed, v = 2m/s = 120m/min.

So, 2πrN=120m/min.

2x3.14x0.1524xN=120

So, N=126 rpm

ω= 13.123 rad/sec.

8)Starting torque is given by,

T=(100/e) x ((a+ g x sin(θ)) x m x r) / N

T = (100/85) x ((0.2+9.81x sin(20) x100x0.1524)/126

T=31.871 Nm

9) Maximum current induced is given by,

I=T x ω/V

I=31.871x13.123/24

I=17.428 A

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10) Battery capacity is given by ,

C=I x T

C=17.428 A x 31.871

C= 17.428 × (30/60)

C=8.714 Ah.

This is the battery capacity needed for each motor. To calculate battery capacity needed
for entire Segway, this should be multiplied by no. of motors.

C= 8.714 × 2 = 17.428 Ah.

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3.3 Software (Simulation) Result:
3.3.1 Stress-Strain Analysis

The Fig. below shows the resultant stress distribution on the plate for the given load and
boundary conditions.

Fig. Analysis results: Stress distribution on the foot plate (Type: Von- Mises)

From the above results the maximum stresses are induced at the holes drilled for swivel wheel
mounting. This maximum stress developed is not more than 16MPa.

Maximum stress value: 16MPa

However, this maximum stress value is very less than the ultimate tensile strength (841MPa) and
yield strength (247 MPa) of the Mild Steel.

Developed stress (16MPa) << Yield strength (247Mpa)

Since, the maximum developed stress is almost 17 times less than the tensile yield strength; there
is minimum or no possibility of failure. So, the design is Safe.

The Fig. below shows the equivalent elastic strain of the foot plate for given load and boundary
conditions.

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Maximum strain for the above condition is around 0.00026 or (0.026%). For most of the Mild
Steel, 0.2% of strain is allowable. The resultant strain is almost 10 times lesser than the
allowable strain. Resultant strain (0.026%) << Allowable strain (0.2%)

Fig. Analysis results: Equivalent Elastic strain of the foot plate

3.3.2 Deformation

The Fig. below shows the total deformation of the footplate in m. under the give conditions of
loading and boundary conditions.

The resultant deformation style can be seen in Fig. 5.9. The maximum deformation is found at
the bottom corners of the plate. The value of this maximum deformation is around 0.3mm.

Maximum deformation areas = Bottom corners of plate

Maximum deformation value = 0.3 mm

Since, the deformation is very small, it will not have much effect on the structure of the plate under
loading and there are no chances that this minute deformation affects the motion or stability of the
Segway.

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 Fig. Analysis results: Total deformation of the footplate

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 Chapter-4

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Cost of the project:

The following Table shows the cost of the individual components and the total cost of
components required to fabricate a Segway.

S.No. Component Quantity (specification) Cost (in Rs.)

1 Foot plate (Mild Steel) 1 750

2 DC Motors (320W H-Class) 2 10000 (approx.)

3 12V lead acid batteries (10AH) 2 1200

4 Pneumatic tyres (8inch) 2 1100

5 Swivel wheel (4inch 100kg) 1 350

6 Plumber block bearings 2 250

7 Electrical throttle 1 500

8 Solar panel 1 2000

9 Keys, pipes and couplings - 500

10 Electrical equipment - 500

11 Fasteners - 500

12 Other components - 500

Total Cost 18,200

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 However, this total cost doesn’t include the cost of machining and handling cots. If all the
other costs of manufacturing are included the cost the vehicles could go up to Rs.25, 000.

Using much efficient components could increase the cost of the product even more. However,
mass production of the product could reduce the cost.

Based on the cost of a typical two-wheel Segway (Rs.1, 00, 000) available in the market, the cost
of equally efficient three-wheel Segway could be available at much lower cost around Rs.35,
000. This proves three-wheel Segway could be much economical than the two-wheel version.

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 Chapter – 5

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Possible Outcome

➢
User can travel to nearby distance easily without any problem.

➢
Segway is very useful for patrolling in an area.

➢
Main Development is that it is emission free/green vehicle.

➢
Manual braking system for easy handling and controlling of the system.

➢
No any risks like leakage of fuel or explosions.

➢
Easily repairable with low maintenance cost.

➢
A big step towards development and pollution control.

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 Chapter - 6

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Concluding Remarks and Scope for the Future Work

6.1 Concluding Remarks

The Human being’s requirement is easy transportation with accident-free ride. Also, the cost of
the equipment used for that purpose should be very low. In order to fulfil the above things, a new
Mechanical based three-wheel Segway is designed in this project.

To identify the difficulties in existing models, a thorough literature study was made. The
modelling is done with Autodesk Fusion360 software and dimensions are finalized based on design
calculations. The main objective is to minimize the fuel consumption especially for commuting over
shortest distance and to fabricate a low cost, accident free three-wheeled mechanical Segway.

6.2 Scope for the Future Work

• Implementation of optimum transmission mechanism for the vehicle and a

formulated design approach for a robust configuration.

• Static analysis of important components on Ansys Software and checking the stress limits.

• Actual manufacturing of the vehicle by all standard manufacturing method and keeping
the crucial factors like aesthetics, ergonomics to reduce all integration problems, cost.

• Analysis of performance of solar energy system and manual braking system consid ering
the overall efficiency of the vehicle.

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 Chapter-7

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 Savitribai Phule Pune University

Chapter-7

1. Ankit S. Khanzode, Ashish G. Masne, Mohd. Shahzad Gulam Ali, Akshay P.

Tale, Kamalkishor G Maniyar, “Mechanical Segway”,International Journal of
Engineering and Technical Research (IJETR),

ISSN:2321-0869 (O) 2454-4698 (P), Volume-4,

Issue-3, March 2016.

2. Manikandan T, Mani T, Kanagaraj E. and Velmurugan S.

VSRD International Journal of Mechanical, Civil, Automobile and

Production Engineering, Vol. VIII Issue II February 2018 / 41

e-ISSN: 2249-8303, p-ISSN: 2319-2208 © VSRD International Journals:

www.vsrdjournals.com

3. Kapoor K, Pandey KK, Jain AK and Nandan A, "Evolution of solar energy in

India: A review" Renewable and Sustainable

Energy Reviews, 40(2014)475-487.

4. Veeraboina P and Ratnam GY, "Analysis of the opportunitiesand challenges of

solar water heating system (SWHS) in India:

Estimates from the energy audit surveys & review" Renewableand Sustainable
Energy Reviews, 16 (2012) 668-676.

5. Pandey S, Singh VS, Gnagwar NP and Vijayvergia MM, "Rajasthan India

Renewable and Sustainable Energy" Reviews16 (2012) 3593- 3598,

6. Sharma NK, Tiwari PK and Sood YR, "Solar energy in India: Strategies,
policies, perspectives and future potential" Renewable and Sustainable Energy
Reviews 16 (2012) 933-941

7. International Journal of Innovative Research in Advanced Engineering (IJIRAE)

ANALYSIS OF SOLAR POWERED SELF BALANCING

VEHICLE Prof. Chetan V. Papade*, Akshay R. Hiremath

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 Savitribai Phule Pune University

8. Rashid, A. (2014) Overview of disc brakes and related phenomena – a review.

International Journal of Vehicle Noise and Vibration, 10(4): 257-301
http://dx.doi.org/10.1504/IJVNV.2014.065634

Internet:

• www.vsrdjournals.com

• www.segway.com

• www.robotplatform.com

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