SEGWAY (2 WHEEL BALANCING VEHICLE):

Project Report
Submitted By:

GAJJAR PRUTHIL RAKESHKUMAR (136540319517)

JIVANI MEET VALLABHBHAI (136540319521)

ASODARIYA JAYDIP MAHESHBHAI (136540319502)

GHODASARA AEMI JAYANTILAL (136540319518)

GONDALIYA PARTH VIJAYBHAI (136540319519)

GUIDED BY: MR. HARDIK R RATHOD

In partial fulfilment for the award of the

DIPLOMA
IN
MECHANICAL ENGINEERING

V.P.M.P POLYTECHNIC, GANDHINAGAR

SECTOR-15
GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD
YEAR 2015-2016
VPMP POLYTECHNIC
Mechanical Department

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 CERTIFICATE

DATE:

This to certify that the dissertation entitled SEGWAY

(2 WHEEL BALANCING VEHICLE) has been carried out by GAJJAR PRUTHIL R
under guidance in fulfillment of the Diploma Engineering in Mechanical
Department of (5th semester/6th semester) of Gujarat Technological
University, Ahmedabad during academic year 2015-2016.

Guided By: Head Of The Department:

MR. Hardik R Rathod MR. Kamlesh K Mehta

(Lecturer ME Department) (H.O.D of ME Department)

External Faculty:

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 ACKNOWNLEDGEMENT

— This inclusion of UDP curriculum and is great pleasure to express thanks

and give Heartiest gratitude to all those help us during full periodic for
development of the project.
— I want to give our gratitude to V.P.M.P POLYTECHNIC, GANDHINAGAR
to carry out activity in its true sense.
— I want to give sincere thanks to our MR. Hardik R Rathod who helped us
in every period of developing this project. He was really a grateful guide
for giving inspiration & motivation for developing this project. I am able
to carry out successfully our project through our professor in due to
course of time.
— Nevertheless, I would like to thank our MR. kamlesh K Mehta, head of
department of mechanical department for hi inspiration & motivation. I
would also like to thank to EE department lecturer who helped us to give
their knowledge to me for this throughout model.

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 ABSTRACT

— 2 wheel balancing vehicle (Segway) is a transportation device which is

used worldwide. This is based on automobile engineering field.
— Segway is a non-polluting device which runs with the help of Battery and
Motor.

WORKING PROCESS:
— Through 24-48 volt battery and 250-500 watt motor this device
accelerates. User stands and balances in between of total length of
Segway. Acceleration is done through controller. Angle for turning is set
appropriately by User.

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 TABLE CONTENTS
Certificate (i)
Acknowledgement (ii)
Abstract (iii)
Table contents (iv)
List of Figures (v)

Chapter Topics Page No.

1. Introduction 7
2. Block Diagram 9
3. Design 10
3.1.1 DC Motor 11
3.1.2 Gear 13
3.1.3 Battery (Power) 14
3.1.4 Mechanical structure 16
3.1.5 Wheels 17
3.1.6 Control Shaft 18
3.1.7 Handle 19
3.1.8 ESC DC motor Controller 20
3.1.9 Transient Assembly 23
4. Hardware 24
4.1.1 Segway 24
4.1.2 Tool Kit 25
5. Applications 27
6. Advantages & Disadvantages 28
7. Conclusion 29
8. Future Development 30
9. References 31

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 LIST OF FIGURES:
No. Figures Page no.
1. Block diagram 9
2. Brushless DC motor 12
3. Gear 13
4. Battery (gel) 16
5. Mechanical Structure 17
6. Wheels 18
7. Control Shaft 19
8. Handle 20
9. ESC DC motor Micro-controller 21
10. Transient Assembly 23
11. Hardware 24
12. Tool kit 25

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 CHAPTER 1:
INTRODUCTION

— Segway is the leader in personal, green transportation, developing

products that transform the way you work, play and live. Since the
introduction of the Segway® Personal Transporter (PT), Segway has
established itself as a leader in the emerging small electric vehicle (SEV)
space. Our approach to congestion and environmental challenges is
balanced with a strong understanding of the functional needs of our
customers, enabling them to do more with less.
— Today, we are focused on serving our customers by developing safe,
unique products that are redefining personal transportation for
consumers and businesses. Segway works with commercial
and municipal organizations to realize the benefits of zero-emission
personal transportation that increase productivity and utilize existing
infrastructure. Together with our customers, we help government leaders
create the framework to adopt these new technologies and safely and
wisely integrate them into society. For our investors and dealers, we
create successful new business opportunities with an exciting roadmap to
the future.
— We continue to focus our research and development efforts on creating
green personal transportation solutions that challenge convention. Our
commitment to the development of small purely-electric transportation
solutions, including our collaboration on the GM Opel Flextreme project in
2007, demonstrates our expertise and success in this space. This
Project represe ts et a other u o e tio al approa h to toda ’s ur a
congestion and environmental challenges. The result is a fully-functional
two-person vehicle with advanced dynamics, connectivity, and sensory
capabilities that demonstrate technology that exists today and can be
developed quickly.
— Segway is passionately committed to innovation and the future of mobility
to move you – easily, efficiently, intelligently, simply.

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 — The result is electric transportation that does ’t look, feel or o e like
a thi g that has o e efore. A d of all the o e tio al isdo e’ e
left in pieces behind us, none has been shattered more fully than the
elief that e ust hoose et ee ore a d less .
— In 2001, Dean Kamen announced the arrival of the first self-balancing,
zero emissions personal transportation vehicle: the Segway® Personal
Transporter (PT). Founded on the vision to develop highly-efficient, zero-
emission transportation solutions using dynamic stabilization technology,
“eg a ’s resear h a d de elop e t as fo used o reati g de i es that
took up a minimal amount of space, were extremely maneuverable and
could operate on pedestrian sidewalks and pathways.
— In 2006, the second generation Segway was introduced. All the products
feature reakthrough Lea “teer™ te h olog a d a ireless I foKe ™
controller that enhance the Segway experience by making the ride even
more intuitive and adding new and useful functions.
— Today, Segway continues to develop safe, unique transportation solutions
that address urban congestion and pollution and leverage our in-house
expertise. No matter the platform, our products allow you to experience
more with less.

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 CHAPTER 2:
BLOCK DIAGRAM:

Fig. 1 Block Diagram

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 CHAPTER 3:
DESIGN:
Components Used:

1. Motor
2. Gear
3. Battery
4. Mechanical Structure
5. Wheels
6. Control Shaft
7. Handle
8. ESC DC motor Controller
9. Transient Assembly

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EXPLAINATION ABOUT COMPONENTS:

3.1.1 Brushless DC Motor:

Two 250W brushless dc hub motors are used. They have been selected over
normal Dc motors as they have a better power/weight ratio, greater efficiency
and hence are more compact, robust and reliable. The absence of a
commutator and carbon brushes (which are subjected to mechanical wear and
tear due to friction) enables this type of motor to have a longer life. The
armature is the stationary part and has three coils, while the rotor is a
permanent magnet. Each motor has three hall sensors used to detect the
position of the rotor. The stator speed Ns and the rotor speed Nr are both the
same at steady state as this is a synchronous motor. The rotor speed Nr is
measured by taking feedback from the hall sensors while the stator speed Ns is
the frequency at which you alternately switch the coils. By taking feedback Nr
and Ns are kept the same.

— Hence the speed of the rotor is directly proportional to the frequency of

switching and the output torque is inversely proportional to the frequency
of switching.

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 Fig.2 Brushless DC Motor

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3.1.2 Gear:
— A gear or cogwheel is a rotating machine part having cut teeth, or cogs,
which mesh with another toothed part to transmit torque, in most cases
with teeth on the one gear being of identical shape, and often also with
that shape on the other gear.
— Two or more gears working in a sequence (train) are called a gear
train Geared devices can change the speed, torque, and direction of
a power source.
— The most common situation is for a gear to mesh with another gear
— The gears in a transmission are analogous to the wheels in a crossed
belt pulley system. An advantage of gears is that the teeth of a gear
prevent slippage.
— When two gears mesh, and one gear is bigger than the other (even though
the size of the teeth must match), a mechanical advantage is produced,
with the rotational speeds and the torques of the two gears differing in an
inverse relationship.

Fig.3 Spur Gear

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3.1.3 Battery:
A VRLA battery (valve-regulated lead-acid battery), more commonly known
as a sealed battery (SLA) or maintenance free battery, is a type of lead-acid
rechargeable battery. Due to their construction, they can be mounted in any
orientation, and do not require constant maintenance. The term "maintenance
free" is a misnomer as VRLA batteries still require cleaning and regular
functional testing. They are widely used in large portable electrical devices, off-
grid power systems and similar roles, where large amounts of storage are
needed at a lower cost than other low-maintenance technologies like lithium-
ion.
— There are two primary types of VRLA batteries, gel cells and AGM. Gel
cells add silica dust to the electrolyte, forming a thick putty-like gel. These
are sometimes referred to as "silicone batteries". AGM (absorbed glass
mat) batteries feature fiberglass mesh between the battery plates which
serves to contain the electrolyte. Both designs offer advantages and
disadvantages compared to conventional batteries, as well as each other.
— Specs of Gel Form Battery:
Co po e t……Ra aterial
Positi e………..Lead dio ide
Negati e……….Lead
Co tai er……..AB“
Co er………….AB“
“eala t………..Epo Resi
“afet al e…..EPDR
Ter i al………Copper
“eparator……..Fi er glass
Ele trol te……“ulfuri a id
— CHARGING VIA THE ELECTRICITY “Y“TEM’“ INBUILT GENERATOR
- A 7.2V control voltage is used for 6V systems
- A 14.4V control voltage is used for 12 V systems
- A 28.8V control voltage is used for 24 V systems

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 Fig.4 Rechargeable Battery

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3.1.4 Mechanical Structure:
The entire structure is made of mild steel. After both the motors are
individually connected to the wheels three rectangular sections are connected
between them. They are welded at both the ends. A rectangular platform is
fitted on these sections. A vertical rod is screwed on this platform with a
rectangular rod welded at the top end. The rider stands on the platform and
takes support from the vertical rod.

Fig.5 Mechanical structure

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3.1.5 Wheels:
Two Scotty ES wheels are used. The outer diameter of the motor almost
matches the rim size and hence mounting the motor in these wheels is
considerably easier. By using a circular 10mm thick plate of mild steel the
motor is mounted between the wheels.

Fig.6 Wheel

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3.1.6 Control Shaft:

Fig.7 Control Shaft

— It is a vertical axle or support which controls the handle for vehicle.

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3.1.7 Handle:

Fig.8 Handle for Segway

— A handle is a part of, or attachment to, an object that can be moved or
used by hand.
— Handles for tools are an important part of their function, enabling the
user to exploit the tools to maximum effect.

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3.1.8 ESC Brushless Controller:

Fig.9 ESC controller

— ESC systems for brushed motors are very different by design; as a result
brushed ESC’s are not compatible with brushless motors. Brushless ESC
systems basically create a tri-phase AC power output of limited voltage
from an onboard DC power input, to run brushless motors by sending a
sequence of AC signals generated from the ESC’s circuitry, employing very
low impedance for rotation. Brushless motors, otherwise called out
runners or in runners depending on their physical configuration, have
become very popular with electroflight radio-control aero
modeling hobbyists because of their efficiency, power, longevity and light
weight in comparison to traditional brushed motors. However, brushless
AC motor controllers are much more complicated than brushed motor
controllers.

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 — The correct phase varies with the motor rotation, which is to be taken into
account by the ESC: Usually, back EMF from the motor is used to detect
this rotation, but variations exist that use magnetic (Hall Effect) or optical
detectors. Computer-programmable speed controls generally have user-
specified options which allow setting low voltage cut-off limits, timing,
acceleration, braking and direction of rotation. Reversing the motor’s
direction may also be accomplished by switching any two of the three
leads from the ESC to the motor.

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3.1.9 Transient Assembly:

Fig.10 Transient Assembly

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 CHAPTER 4
HARDWARE:
4.1.1 Segway:

Fig.11 View of Segway

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4.1.2 Tool Kit:
1. Spanner

2. Pliers

3. Wire Cutter

4. Screw Driver

5. Fitter

6. Hammer

7. Scissor

8. Adjustable Wrench

9. Fix Wrench

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 Fig.12 Tool Kit

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 CHAPTER 5
APPLICATIONS:

— More than 1,000 security firms and law enforcement agencies use
“eg a ’s for patrolli g arou d the orld. Rather tha patrolli g a area
on foot or in vehicles, patrol officers can ride around on a Segway and
respo d to e erge situatio s. “eg a ’s are able to travel up to 12.5
miles per hour, and law enforcement agencies, such as the Washington
Metro Police Department, have developed training programs to teach
offi ers ho to operate “eg a ’s safel .
— The advantages of using a Segway while patrolling is that it improves
response times, reduces officer fatigue and lowers fuel and maintenance
costs
— I di iduals a use “eg a ’s as a for of perso al tra sportatio to go to
ork, ru erra ds a d isit frie ds. “eg a ’s that are full harged a
travel up to 24 miles, and a standard outlet wall can charge the batteries.
Individuals can ride Segway in all types of weather.
— According to Segway.com, Segway are zero-emissions devices that are 11
times more efficient than a standard American vehicle.
— Responsiveness
— Mobility
— Approachability
— Visibility

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 CHAPTER 6
Advantages & Disadvantages:

•Advantages:
1. Become more productive: more work can be done by using the product
versus walking.

2. Become more recognizable: Riders stand an additional eight inches off the
ground, allowing you to be better seen and giving the rider better sight lines,
over cars in a parking lot or boxes in a warehouse.

3. Low operating costs: no need for gas and inexpensive battery charging (A
complete cycle charge will take eight to ten hours)

4. Reduce fatigue caused by walking

5. A clean, green, eco-friendly machine! (Zero emission).

•Disadvantages:

1. Slow, having a max speed of 12.5 mph.

2. Does not exactly say how far the Segway will go with riders of different
masses.

3. Heavy, weighing around 100lbs.

4. Unlike bicycles, a drained Segway cannot be pedaled home or a charger.

5. Expensive, this costs around $3000-$5000

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 CHAPTER 7

CONCLUSION:

— From this project, we successfully make out the model having its capacity
that user can stand and it sustain its load. Also we identify the model
beyond its limit capacity. As well as we also came to know about electrical
& computer engineering field.

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 CHAPTER 8

FUTURE DEVELOPMENT:

1. “eg a ’s are hu a tra sportatio devices that operate on two wheels

and run on electric power.
2. Motors and computers in the base of the device keep the Segway upright,
and as an individual leans forward, the device moves forward.
3. User can travel to nearby distance easily without any problem.
4. Segway is very useful for patrolling in an area.
5. Main Development is that it is emission free/green vehicle.

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 CHAPTER 9

REFERENCES:
1. http://www.ghsa.org/html/stateinfo/laws/segway_laws.html
2. http://www.segway.com/business/products-solutions/i2.php
3. http://www.washingtoncitypaper.com/blogs/citydesk/2013/04/26
/the-answers-column-how-are-segways-regulated-in-d-c/
4. OFFICIAL WEBSITE: www.Segway.com

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