Design and fabrication of electric scooter

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DESIGN AND FABRICATION OF ELECTRIC

SCOOTER
A Project Report Submitted in Partial Fulfillment of the Requirements for
the Degree of
Bachelor of Technology (B. Tech.)

in
Mechanical Engineering
by
Anshul Singh Titoriya Abhijeet Sharma

(1402940027) (1402940004)
Bhupesh Kumar Ahirwar Anoop Mohan Sharma

(1402900049) (1402940026)
Under the Supervision of
Prof. Manoj Singh Bhist

Assistant Professor
KIET GROUP OF INSTITUTIONS
GHAZIABAD
to the
Faculty of Mechanical Engineering
DR. A.P.J. ABDUL KALAM TECHNICAL
UNIVERSITY, UTTAR PRADESH, LUCKNOW MAY,
2018
Mechanical Projects : Learnmech.com
CERTIFICATE
This is to certify that Anshul Singh Ttoriya (1402940027), Anoop Mohan Sharma
(1402940026), Bhupesh Kumar Ahirwar (1402900049) and Abhijeet Sharma
(1402940004) have carried out the research work presented in this report entitled “Design
and Fabrication of Electric Scooter” for the award of Bachelor of Technology from
Dr. A.P.J. Abdul Kalam Technical University, Lucknow under my supervision. The report
embodies results of original work, and studies are carried out by the students themselves
and the contents of the report do not form the basis for the award of any other degree to
the candidate or to anybody else from this or any other University/Institution.
Signature:
Manoj Singh Bhist
Asst. Professor
Department of Mechanical Engineering
KIET Group of Institutions
Date:
i
DECLARATION
We hereby declare that this submission is our own work and that, to the best of our
knowledge and belief, it contains no material previously published or written by another
person nor material which to a substantial extent has been accepted for the award of any
other degree or diploma of the university or other institute of higher learning, except where
due acknowledgment has been made in the text.
Signature: Signature:
Name: Anshul Singh Titoriya Name: Anoop Mohan Sharma
Roll No.: 1402940027 Roll No.: 1402940026
Name: Bhupesh Kumar Ahirwar Name: Abhijeet Sharma
Roll No.: 1402900049 Roll No.: 1402940004
Date:
ii
ABSTRACT
In today’s world, the infrastructure of College and Industries are becoming large
so if one has to travel or visit from one place to another he has to walk a long distance
and sometimes it becomes very hasty and inconvenient. Sometimes after too many
travelling on campus, it causes strain and pain in the body. So to travel these distances
two-wheeled or three-wheeled electric scooter like Segway PT, Irrway were introduced.
But, these scooters are very costly such as they start from ₹ 50,000. Another problem
with that vehicle is that they are difficult to handle when we drive the first time. So in
alternate to this product, we developed whole newly designed product and this is
Reliable, Eco-friendly, a Compact vehicle for the campus. Its utilities are college
campus, Airports, Industries, Recreational Parks, Sanctuaries, Museums, Palaces,
Villas etc. So our project is on design and fabrication of three-wheel vehicle and also its
multipurpose utility among the society.
The concept of the model taken from children’s scooter bicycle. The complete
body looks like a scooter bicycle in which platform is provided for standing and driving
the powered scooter. This product is a battery powered and motor-driven vehicle. The
scooter is intended to use in indoors areas as well as in outdoor areas, due to the
absence of any type of pollution causing drive mechanism such as petrol engines.
iii
ACKNOWLEDGEMENT
It gives us a great sense of pleasure to present the report of the B. Tech Project undertaken
during B. Tech. Final Year. We owe special debt of gratitude to Asst. Professor Manoj
Singh Bhist, Department of Mechanical Engineering, KIET, Ghaziabad for the constant
support and guidance throughout the course of our work. His sincerity, thoroughness and
perseverance have been a constant source of inspiration for us. It is only his cognizant
efforts that our endeavors have seen light of the day.
We also do not like to miss the opportunity to acknowledge the contribution of all faculty
members of the department for their kind assistance and cooperation during the
development of our project. Last but not the least, we acknowledge our friends for their
contribution in the completion of the project.
Name: Anshul Singh Titoriya Name: Anoop Mohan Sharma
Roll No.: 1402940027 Roll No.: 1402940026
Name: Bhupesh Kumar Ahirwar Name: Abhijeet Sharma
Roll No.: 1402900049 Roll No.: 1402940004
Date:
iv
LIST OF FIGURES
Figure No. Description Page No.
Figure No.1.1 Design Methodology
Figure No.1.2 PMDC Motor
Figure No.1.3 BLDC Motor
Figure No.1.4 Lead Acid Battery
Figure No.1.5 Li-Ion Battery
Figure No.1.6 Wheel
Figure No.1.7 Steering
Figure No.1.8 Sprocket
Figure No.1.9 Bearing
Figure No.2.1 EV Rider
Figure No.3.1 Mild Steel Pipes
Figure No.3.2 Chromoly Pipes
Figure No.3.3 Carbon Fibre
Figure No.4.1 Types of Welding
Figure No.4.2 GMAW Circuit Diagram
Figure No.4.3 Types of Metal joining process
Figure No.5.1 SolidWorks Model (Isometric View)
Figure No.5.2 SolidWorks Model (Side View)
Figure No.6.1 Total Deformation (Torsional Analysis)
Figure No.6.2 Directional Deformation (Torsional Analysis)
v
LIST OF FIGURES
Figure No. Description Page No.
Figure No.6.3 Equivalent Stress (Torsional Analysis)
Figure No.6.4 Safety Factor (Torsional Analysis)
Figure No.6.5 Directional Deformation (Bump Analysis)
Figure No.6.6 Total Deformation (Bump Analysis)
Figure No.6.7 Equivalent Stress (Bump Analysis)
Figure No.6.8 Safety Factor (Bump Analysis)
Figure No.7.1 Scooter Frame
Figure No.7.2 Wheel Assembly
Figure No.7.3 Rear wheel and chain drive mechanism
Figure No.7.4 Motor
Figure No.7.5 Controller
vi
LIST OF TABLES
Table No. Description Page no.
Table No.3.1 Composition of AISI 1020
Table No.3.2 Composition of AISI 4130
Table No.5.1 Comparison between BLDC and PMDC Motor
Table No.5.2 Comparison between Li-ion and Lead acid Battery
vii
LIST OF SYMBOLS AND ABBREVIATIONS
Symbols/Abbreviations Meaning
hp Horsepower
rpm Revolutions per minute
W Watt
V Volt
Wh Watt-hour
Ah Ampere-hour
MPH Miles per hour
mm Millimetre
kg Kilogram
kgf Kilogram-force
m/s Metre per second
= Is equal to
A Ampere
cm Centimetre
viii
Table of Contents
Certificate ..................................................................... i
Declaration ................................................................... ii
Abstract ........................................................................ iii
Acknowledgements .............................................................. iv
List of Figures ................................................................. v
List of Tables .................................................................. vii
List of Symbols and Abbreviations……………………….viii
1 Introduction ........................................................................... 1
1.1 An Electric Scooter ......................................................... 1
1.2 Problem Statement .......................................................... 2
1.3 Objectives ........................................................................ 2
1.4 Scope of Work................................................................. 3
1.5 Methodology ................................................................... 3
1.6 Components of Electric Scooter ..................................... 5
1.6.1 Chassis .................................................................. 5
1.6.2 Motors…………………………………………..6
1.6.3 Battery…………………………………………...8
1.6.4 Wheels………………………………………….10
ix
1.6.5 Steering…………………………………………11
1.6.6 Sprocket………………………………………12
1.6.7 Bearing………………………………………..12
2. Literature Review .............................................................. 13
2.1 Literature ....................................................................... 13
2.2 EV Riders ...................................................................... 14
2.2.1 EV Riders Stand N Ride ................................................... 14
3. Material Selection.................................................................... 16
3.1 Material Selection ......................................................... 16
3.1.1 AISI 1020 ....................................................................... 16
3.1.2 AISI 4130 ....................................................................... 17
3.1.3 Carbon Fibre .................................................................. 18
4. Joining Process ............................................................... 20

4.1 Welding ......................................................................... 20
4.2 Gas Metal Arc Welding ................................................ 21
4.2.1 GMAW welding ........................................................... 21
4.2.2 Power Supply ................................................................22
4.2.3 Electrode .......................................................................23
4.2.4 Shielding Gas ............................................................... 24
4.3 Factors affecting the choice of Joining process ............ 26
4.4 Advantages of welding over other joining proesses ..... 27
5. Design ............................................................................... 28
5.1 Design of prototype ....................................................... 28
5.1.1 Design of main frame components .............................. 29
5.1.2 Design of sprockets ...................................................... 29
5.2 Basic Calculations ......................................................... 29
5.2.1 Initial torque requirements ........................................... 29
x
5.2.2 Drivetrain ..................................................................... 30

5.2.3 Acceleration…………………………………………..30
5.2.4 Electric Motor…………………………………………30
5.2.5 Battery…………………………………………………32
5.2.6 Battery runtime………………………………………..33
5.2.7 Wire Diameter…………………………………………..33
5.2.8 Static Weight Distribution………………………………34
5.3 Selection of size of wheels ............................................ 34
5.4 CAD Modelling............................................................. 35
5.5 Analysis ................................................................. 36

5.6 Torsional Rigidity Analysis .......................................... 36
5.7 Bump Analysis .............................................................. 38
6. Fabrication ............................................................................... 41
6.1 Scooter Unit .................................................................. 41
6.1.1 Frame .................................................................. 41
6.1.2 Front wheel assembly ......................................... 42
6.1.3 Steering Unit……………………………………42
6.1.4 Rear Wheel Assembly………………………….43
6.2 Chain Drive Mechanism ............................................... 43
6.3 Electrical Unit…………………………………………44
6.3.1 Motor…………………………………………...44
6.3.2 Battery………………………………………….45
6.3.3 Controller……………………………………….45
7. Advantages & Disadvantages.................................................. 46

7.1 Advantages .................................................................... 46
7.2 Disadvantages…………………………………………46
xi
8. Future Scope & Improvement ................................................. 47

8.1 Future Scope…………………………………………47
8.2 Future Improvement…………………………………..47
9. Conclusions ............................................................................. 48
10. References……………………………………………………49
xii
CHAPTER 1
INTRODUCTION
1.1 AN ELECTRIC SCOOTER
An electric scooter is a battery-operated one-person capacity vehicle which is

specially designed for people with low mobility. It is generally used by those who have
difficulty in walking for long periods of time. Scooters are available in three common
designs, those intended for indoor use, those for outdoor use, and those that are used for
both.
An electric scooter may have three wheels or four. Since it runs on battery power, it
does not create pollution. A typical electric scooter requires a pair of batteries, but the
batteries are rechargeable. The length of time an electric scooter can run on each charge
depends significantly on its battery's type, rating and capacity. The most common batteries
are advertised to run for about eight hours, and between 20-30 miles, before needs to be
charged.
Some people are a little wary of purchasing an electric scooter because they fear it
will be difficult to operate. In fact, the control console makes it quite simple once a person
gets the feel for it. Electric scooters are also equipped with advanced brake systems, so
stopping is simple and comfortable. The brake begins to engage as soon as the operator
lets off the throttle, so there is little chance for abrupt or jarring stops. Most scooters also
have a parking brake to keep the electric scooter from rolling when parked.
1
1.2 PROBLEM STATEMENT
Nowadays, small scooter becomes popular especially during recreation time,

relaxing and for human exercise after they had faced their office job. There is a lot of
scooter type around us like have seated or stand while riding the scooter. Most of that is
operation by motor electric or just using our leg to move scooter like playing skate board.
The problem is, most of that scooter is not flexible although it is already small.
Even though some manufacturer make it can be flip, but there is just only a few part to be
that like seat, handle, and sometime arm bar. Most of flip small scooter are operate by
swinging rider leg to move it. Some of the scooter looked not so ergonomic and cannot
be use for a long time.
Even for an electric scooter, most of that can’t be flip. Usually just their seat and
handle can be up and down to flip. Sometime this will cause a lot of space for storage and
difficult to bring far from house like to put it into the car and so on.
1.3 OBJECTIVES
The objectives of our project are:
• To reduce time and fasten the movement
• To reduce the use of non-renewable energy sources
• To control the pollution
• To be used for transportation on airports, colleges and at places of tourists

intrests.
2
1.4 SCOPE OF WORK
The following studies are including in the design and development of single seater
electric scooter:
i. Literature study
ii. Conceptual design
iii. CAE analysis
iv. Fabrication model refinement
v. Material Selection
vi. Prototype Development
vii. Running
viii. Report preparation
1.5 METHODOLOGY
i. Literature study
• Make review on other model and focusing on how to make it simple and
relevance to the project title.
ii. Conceptual design

• Sketching several type of design based on concept that being choose.
• State the dimension for all part.
• Draw the sketching model using SOLIDWORKS software
iii. Computer Aided Engineering (CAE) analysis

• Analysis the design for strain stress structure by using ALGOR.
• Define critical point.
3
iv. Fabrication model refinement

• Fabricate the scooter according to the design.
• Refinement at several part of joining and sharp edge.
v. Materials selection
• Selected the true material based on model design and criteria.
• Light, easy to joining and easy to manufacture.
vi. Prototyping Development

• Assemble all the part to the design.
SKETCHING &
ITERATION SELECTION OF
MODELLING FURTHER
S CROSS-SECTION ITERATIONS ON
BY FOS/WEIGHT
OBJECTIVE CRITERIA
FRAME
MATERIAL SELECTION
FEA &
FINAL FRAME ERGONOMICS
ANALYSIS
Fig. 1.1 Design Methodology
4
1.6 COMPONENTS OF ELECTRIC SCOOTER
We made a scaled-down model of the actual Electric Scooter prototype. So, we have made
some changes accordingly. The main components of the treadmill bicycle are as follows:
1.6.1 Chassis
From the various types available, the chassis can be selected on the basis of design
requirements and the intended use of the vehicle. There are basically four types of frame
available to be selected. On the basis of required design specification and the need, the
following out of the four can be selected. They are:
i. Ladder
A ladder frame is a common type of frame that is mostly used for constructing the
base for vehicles by connecting the solid members in the way that resembles to a
ladder.
ii. Backbone
This chassis design is similar to body on fame design. In this the front and rear
end of the vehicle are joined by the means of a heavy tubular like structure.
iii. Monocoque
A monocoque chassis is one that uses metal that is molded from sheets of the
material, which is the same method used to build other parts of the frame. This
type of chassis is similar to a unibody type.
iv. Space
A space chassis can also be known as tubular even though it is not tubular in the
true sense. The components are welded together to create a strong frame that
comprises some flexibility. It is a truss like structure that provides greater strength
compared to the ladder type.
5
1.6.2 Motors
Motors are the devices that convert the electrical energy into mechanical energy and
causes the vehicle to propel. Basic working principle of DC motor is based on the fact
that whenever a current carrying conductor is placed inside a magnetic field, there will
be mechanical force experienced by that conductor. Out of the various options available,
the options available with us were two of its type. They are:
• PMDC motor
When permanent magnet is used to create magnetic field in a DC motor, the
motor is referred as permanent magnet DC motor or PMDC motor. This battery
operated motor is nothing but a permanent magnet DC motor or PMDC motor.
These types of motor are essentially simple in construction. These motors are
commonly used as starter motor in automobiles, windshield wipers, washer, for
blowers used in heaters and air conditioners, to raise and lower windows, it also
extensively used in toys.
As the magnetic field strength of a permanent magnet is fixed it cannot be

controlled externally, field control of this type of DC motor cannot be possible.
Thus permanent magnet DC motor is used where there is no need of speed control
of motor by means of controlling its field. Small fractional and sub fractional KW
motors now constructed with permanent magnet.
A PMDC motor mainly consists of two parts. A stator and an armature. Here
the stator which is a steel cylinder. The magnets are mounted in the inner
periphery of this cylinder. The permanent magnets are mounted in such a way that
the N-pole and S-pole of each magnet are alternatively faced towards armature
6
Fig. 1.2 PMDC Motor
• BLDC motor
Brushless DC electric motor (BLDC motors) also known as electronically
commutated motors, or synchronous DC motors, are synchronous motors powered
by DC electricity via an inverter or switching power supply which produces
an AC electric current to drive each phase of the motor via a closed loop controller.
The controller provides pulses of current to the motor windings that control
the speed and torque of the motor.
The construction of a brushless motor system is typically similar to

a permanent magnet synchronous motor (PMSM), but can also be a switched
reluctance motor, or an induction (asynchronous) motor. The advantages of a
brushless motor over brushed motors are high power to weight ratio, high speed,
and electronic control. Brushless motors find applications in such places as
computer peripherals (disk drives, printers), hand-held power tools, and vehicles
ranging from model aircraft to automobiles.
7
Fig. 1.3 BLDC Motor
1.6.3 Battery
Battery is the main fuel source for our vehicle that supplies energy for its
functioning, the scooter been electric powered requires the supply of DC current
source and for this purpose one of the two types of battery is available for use. They
are:
• Lead acid battery:
The lead acid storage battery is formed by dipping lead peroxide plate and
sponge lead plate in dilute sulfuric acid. A load is connected externally between
these plates. In diluted sulfuric acid the molecules of the acid split into positive
hydrogen ions (H+) and negative sulfate ions (SO4 − −). The hydrogen ions when
reach at PbO2 plate, they receive electrons from it and become hydrogen atom
which again attack PbO2 and form PbO and H2O (water). This PbO reacts with
H2 SO4 and forms PbSO4 and H2O.
8
Fig. 1.4 Lead Acid Battery
• Lithium ion battery:

Lithium-ion batteries (LIB) are a family of rechargeable batteries having high
energy density and commonly used in consumer electronics. Unlike the
disposable lithium primary battery, a LIB uses intercalated lithium compound
instead of metallic lithium as its electrode. Usually, LIBs are significantly
lighter than other kinds of rechargeable batteries of similar size. LIBs are
heavily used in portable electronics. When a LIB is discharging, lithium ions
move from the negative electrode (anode) to the positive electrode (cathode).
When a LIB is charging, lithium ions move in the opposite direction, and the
negative electrode becomes the cathode, while the positive electrode becomes
the anode.
Fig. 1.5 Li-ion Battery
9
1.6.4 Wheels
A wheel is a circular component that is made to rotate on an axle bearing.
The wheel is one of the major components of the wheel and axle which is one of
the six simple machines. Wheels along with the axles, allow heavy objects to be
moved easily allowing movement or transportation while supporting a load or
performing labor in machines. Wheels are also utilized for other objectives such
as a ship's wheel, steering wheel, potter's wheel and flywheel.
A wheel greatly lessens friction by facilitating motion by rolling together

with the use of axles. For rotations of the wheel, a moment must be applied to the
wheel about its axis, either by way of gravity or by the application of another
external force or torque. The outline is the "outer edge of a wheel will be holding
the tire." It will construct the outer circular design of the wheel on which the
inside edge of the tire is mounted on vehicles such as automobiles. For example,
on bicycle wheel, the periphery is a large hoop attached to the outer ends of the
spokes of the wheel that holds the tire and tube.
This electric scooter comprises of three wheels, out of which two of them
are rearly located and one is at front. The three wheels used can be of same
dimeter or of different. Generally the front wheel used are small in size compared
to rear to obtain an approach angle. The sizes of the wheels depends upon the
design conditions and requirements and is greatly determined by the factor such as
height of C.G., torque and rpm obtained by the motor and speed of the vehicle
required and many more.
10
Fig. 1.6 Wheel
1.6.5 Steering
Steering can be referred to as a mechanism through which we can turn and change
the direction of a vehicle which is being driven in a straight direction. The primary
objective of steering system is to achieve angular motion. This is done through
linkage and steering gear which converts the rotatory motion of the steering wheel
into angular motion of the front road wheels. There are various options available
for the steering that includes tilt steer, direct steering and by the use of motors.
The conditions for perfect steering is achieved by using the correct steering
geometry conditions that is “Ackerman Geometry”.
Ackerman steering geometry was developed by German carriage builder Georg
Lankensperger in Munich in 1817, then patented by his agent in
England, Rudolph Ackermann (1764–1834) in 1818 for horse-drawn carriages.
This geometry is used to avoid the tyres to slip sideways when moving around a
curves path. This problem is solved by the geometric aspect for all the wheels to
have their axles arranged as radius of circles with a common centre point.
Fig. 1.7 Steering
11
1.6.6 Sprocket
A sprocket or sprocket wheel is a profiled wheel which has teeth, cogs, or even sprockets
that mesh with a chain, track or other perforated or indented material. The name 'sprocket'
applies usually to any wheel upon which radial projections retain a chain passing over it.
It is different from a gear in that the sprockets are never conjugated together directly, and
differs from a pulley, in that sprockets which has teeth and pulleys are smooth.
Fig. 1.8 Sprocket
1.6.7 Bearings
A bearing is machine element which holds another moving machine element. The moving
machine element called as a journal. Bearing allows a relative motion between the contact
surfaces of the members while transferring the load. A certain amount of power is wasted
in removing frictional resistance. So as to reduce frictional resistance and wear and to
carry away the heat generated, a lubricant may be utilized. The lubricant used is often a
mineral oil refined from petroleum. In order to cut the cost, we have not used bearings in
the model but it is a main component in the actual prototype.
Fig. 1.9 Bearing
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CHAPTER 2
LITERATURE REVIEW
2.1 LITERATURE
The project aims to underscore the importance of tapping alternative and clean energy
sources to address various energy issues confronting the global environmental landscape.
The major objective of the projects to design and fabricate an Electric Tri-Wheel Scooter.
Project is primarily designed for green mobility thus it will also help to control the
pollution which is one of the major crises nowadays.. Increasing interest from large
manufacturers and decreasing battery costs offer an opportunity to drastically change the
current market landscape for electric motorcycles and electric scooters. With well-known
players such as Yamaha and Harley Davidson poised to expand offerings into this space,
and low battery costs making products more affordable, sales of these vehicles are
expected to experience stable and continuous growth in the coming decade.
According to a recent report from Navigant Research, sales of electric motorcycles and
scooters are expected to total 55 million from 2015 to 2024. In the India recently three-
wheel electric scooters, designed for short distance mobility, was introduced on an
experimental basis at the Mysore palace and the zoo during the Dussehra season in 2016.
The manufacturers are also in talks with the Tourism Department about introducing the
scooter in different places of tourist interest across the State. After reviewing this we can
finally say that wheel motor in electric scooter can be effectively used. And it also
occupies less space compare to conventional drive and having less weight which is major
advantages for this motor. Also lead acid battery is suitable for small utility vehicle as it
has low maintenance cost and large current density. Which directly said that it can suitable
with our three-wheel campus vehicle. After this whole reviewing process, we started
working our next phase of proposed methodology.
The companies like Segway & Irrway have launched their electrical models since last few
years. Their concept was very authentic and reliable for using in campus especially for
the employees of organization. But, their price was very hefty and it caused much capital
13
to invest for the large scale amount and that was not affordable by the buyers and dealers.
And thus it became major problem and drawback for the companies that they couldn’t
even reach the break-even point for their production and eventually they were in loss.
2.2 EV RIDERS
EV Rider has been in the electric mobility scooters business since 1996. It started with
the design and distribution of battery powered scooters for all ages like the original City
bug, followed by products for active seniors like the Helper and the City Shuttle. They
provide a wide range of options for travelling for all age groups. EV Riders are mainly
into the construction and distribution of electric scooter of various specs.
2.2.1 EV RIDERS – STAND N RIDE

It is theirs one of the best selling electric recreational pre-mobility scooter. Excellent for
warehouse applications, school/college campus, shopping complexes, enclosed parking
garages, security officers for patrol, or just about any application that you need silent (no
emission) green transportation. Being electric powered gives it advantage, to be used at
any place whether outdoor or even for indoor applications. Being motor driven makes it
eco friendly as it do not contributes in any type of tailpipe emission, making it clean for
use.
The Stand N Ride recreational pre-mobility scooter is the one of the most easily to
transport scooters in the market with the heaviest part weighing only 43 lbs and can be
dismantled to fit in the trunk of a small car. This recreational pre-mobility scooter comes
apart in less than 30 seconds into light weight pieces, tiller, base frame, battery pack,
basket and seat without any tools. It will easily fit into the back of any compact car making
transportation a breeze. The scooter handlebars are quickly adjustable making it easy to
ride for people of different heights and children.
The model uses a powerful brushless DC motor of 500 watt and 24 Volts. The motor is a
outrunner type hub motor, locted at the hub of the front wheel making the model to be
front wheel driven. The motor controller is provided for both the directional control that
is front and reverse speeding. This can be accomplished only with the help of a single
switch, only by pushing the switch reverses the direction of speed. The vehicle uses a
powerful battery for driving the motor providing the vehicle to cover a range of 15 to 20
14
miles on a single charge. The model uses a compact battery situated at a position to
provide minimum centre of gravity. The battery pack is light in weight and is lithium ion
battery making it compact and providing less discharge rate. The 2014 Stand N Ride
scooter easily achieves 15 mph with a 15-20 miles range trip on a full charge of its battery.
The models provided with two mode switch that is half mode and full mode switch
providing two range of upper speed limits by altering the torque and the RPM. The model
is designed to have the delta configuration of wheels, that comprises of a single front
wheel and a pair of rear wheel with the handle bar steering mechanism that provides direct
steering with the steering ratio of 1:1 to obtain the rapid response while steering the
vehicle.
Fig. 2.1 EV Rider
15
CHAPTER 3
MATERIAL SELECTION
3.1 Materials
3.1.1 AISI 1020
AISI 1020 is a low hardenability and low tensile carbon steel with Brinell
hardness of 119 – 235 and tensile strength of 410-790 MPa. It has high
machinability, high strength, high ductility and good weldability. It is normally used
in turned and polished or cold drawn condition. Due to its low carbon content, it is
resistant to induction hardening or flame hardening. Due to lack of alloying
elements, it will not respond to nitriding. However, carburization is possible in order
to obtain case hardness more than Rc65 for smaller sections that reduces with an
increase in section size. Core strength will remain as it has been supplied for all the
sections. Alternatively, carbon nitriding can be performed, offering certain benefits
over standard carburizing. AISI 1020 steel can be largely utilized in all industrial
sectors in order to enhance weldability or machinability properties. It is used in a
variety of applications due to its cold drawn or turned and polished finish property.
Fig. 3.1 Mild Steel Pipes
In the cold drawn or turned and polished condition, AISI 1020 steel has high
machinability. As per recommendations of machine manufacturers, AISI 1020 steel
can be used for drilling, turning, milling and tapping operations using suitable feeds,
tool type and speeds. AISI 1020 can be welded by performing the most common
welding processes. In the cold drawn or turned and polished condition, it has better
16
weldability. It has been suggested that the welding process should not be performed
in heat treated or carburized condition.
Table. 3.1 Content of Elements in AISI 1020
3.1.2AISI 4130
Alloy steels are designated by AISI four-digit numbers. They are more responsive to
mechanical and heat treatments than carbon steels. They comprise different types of
steels with compositions which exceed the limitations of B, C, Mn, Mo, Ni, Si, Cr,
and Va in the carbon steels. AISI 4130 alloy steel contains chromium and
molybdenum as strengthening agents. It has low carbon content, and hence it can be
welded easily. The datasheet given below provides more details about AISI 4130
alloy steel. AISI 4130 steel can be easily machined using conventional methods.
Welding of AISI 4130 steel can be performed by all commercial methods.
Fig. 3.2 4130 Pipes
17
AISI 4130 steel is heated at 871°C (1600°F) and then quenched in oil. This steel is
usually heat-treated at temperatures ranging from 899 to 927°C (1650 to 1700°F).
Hot working of AISI 4130 steel can be done at 816 to 1093°C (1500 to 2000°F). It
steel can be cold worked using conventional methods. AISI 4130 steel can be
annealed at 843°C (1550°F) followed by air cooling at 482°C (900°F).Tempering of
AISI 4130 steel can be performed at 399 to 566°C (750 to 1050°F), depending on the
desired strength level. Hardening of AISI 4130 steel can be done with cold working
or heat treatment.
Tables. 3.2 Content of Elements in AISI 4130
3.1.3 CARBON FIBRE
Carbon fibre reinforced polymer (or often simply carbon fibre, carbon composite or
even carbon), is an extremely strong and light fibre-reinforced plastic which
contains carbon fibres. CFRPs can be expensive to produce but are commonly used
wherever high strength-to-weight ratio and rigidity are required, such as aerospace,
automotive, civil engineering, sports goods and an increasing number of other
consumer and technical applications. The binding polymer is often a thermoset resin
such as epoxy, but other thermoset or thermoplastic polymers, such
as polyester, vinyl ester or nylon, are sometimes used.
18
The composite may contain aramid (e.g. Kevlar, Twaron), aluminium, ultra-high-
molecular-weight polyethylene (UHMWPE) or glass fibres in addition to carbon
fibres. The properties of the final CFRP product can also be affected by the type of
additives introduced to the binding matrix (the resin). The most frequent additive is
silica, but other additives such as rubber and carbon nanotubes can be used. The
material is also referred to as graphite-reinforced polymer or graphite fibre-
reinforced polymer.
Fig. 3.3 Carbon Fibre
19
CHAPTER 4
JOINING PROCESSES
4.1Welding
Welding can be defined as the coalescence of two or more similar or dissimilar metals
at a particular temperature with or without the application of pressure and with or without
the use of filler rod.
The welding processes can be broadly classified into the following categories as shown
in the figure 3.1
Fig. 4.1 Types of welding
20
4.2 GAS METAL ARC WELDING
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which
an electric arc forms between a consumable wire electrode and the workpiece metal(s),
which heats the workpiece metal(s), causing them to melt and join.
Along with the wire electrode, a shielding gas feeds through the welding gun, which
shields the process from contaminants in the air. The process can be semi-automatic or
automatic. A constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be used.
Originally developed for welding aluminium and other non-ferrous materials in the
1940s, GMAW was soon applied to steels because it provided faster welding time
compared to other welding processes. The cost of inert gas limited its use in steels until
several years later, when the use of semi-inert gases such as carbon dioxide became
common. Today, GMAW is the most common industrial welding process, preferred for
its versatility, speed and the relative ease of adapting the process to robotic automation.
4.2.1 GMAW WELDING
The typical GMAW welding gun has a number of key parts—a control switch, a
contact tip, a power cable, a gas nozzle, an electrode conduit and liner, and a gas hose.
The control switch, or trigger, when pressed by the operator, initiates the wire feed,
electric power, and the shielding gas flow, causing an electric arc to be struck. The contact
tip, normally made of copper and sometimes chemically treated to reduce spatter, is
connected to the welding power source through the power cable and transmits the
electrical energy to the electrode while directing it to the weld area.
21
It must be firmly secured and properly sized, since it must allow the electrode to pass
while maintaining electrical contact. The gas nozzle directs the shielding gas evenly into
the welding zone. Inconsistent flow may not adequately protect the weld area. Larger
nozzles provide greater shielding gas flow, which is useful for high current welding
operations that develop a larger molten weld pool. A gas hose from the tanks of shielding
gas supplies the gas to the nozzle. Sometimes, a water hose is also built into the welding
gun, cooling the gun in high heat operations.
The wire feed unit supplies the electrode to the work, driving it through the conduit
and on to the contact tip. Most models provide the wire at a constant feed rate, but more
advanced machines can vary the feed rate in response to the arc length and voltage. Some
wire feeders can reach feed rates as high as 30.5 m/min (1200 in/min), but feed rates for
semiautomatic GMAW typically range from 2 to 10 m/min (75 – 400 in/min).
4.2.2 Power supply

Most applications of gas metal arc welding use a constant voltage power supply. As
a result, any change in arc length (which is directly related to voltage) results in a large
change in heat input and current. A shorter arc length causes a much greater heat input,
which makes the wire electrode melt more quickly and thereby restore the original arc
length. This helps operators keep the arc length consistent even when manually welding
with hand-held welding guns.
To achieve a similar effect, sometimes a constant current power source is used in

combination with an arc voltage-controlled wire feed unit. In this case, a change in arc
length makes the wire feed rate adjust to maintain a relatively constant arc length. In rare
circumstances, a constant current power source and a constant wire feed rate unit might
be coupled, especially for the welding of metals with high thermal conductivities, such as
aluminum. This grants the operator additional control over the heat input into the weld,
but requires significant skill to perform successfully.
22
Alternating current is rarely used with GMAW; instead, direct current is employed
and the electrode is generally positively charged. Since the anode tends to have a greater
heat concentration, this results in faster melting of the feed wire, which increases weld
penetration and welding speed. The polarity can be reversed only when special emissive-
coated electrode wires are used, but since these are not popular, a negatively charged
electrode is rarely employed.
4.2.3 Electrode
Electrode selection is based primarily on the composition of the metal being welded,
the process variation being used, joint design and the material surface conditions.
Electrode selection greatly influences the mechanical properties of the weld and is a key
factor of weld quality. In general the finished weld metal should have mechanical
properties similar to those of the base material with no defects such as discontinuities,
entrained contaminants or porosity within the weld.
To achieve these goals a wide variety of electrodes exist. All commercially available
electrodes contain deoxidizing metals such
as silicon, manganese, titanium and aluminum in small percentages to help prevent
oxygen porosity. Some contain denitriding metals such as titanium and zirconium to
avoid nitrogen porosity. Depending on the process variation and base material being
welded the diameters of the electrodes used in GMAW typically range from 0.7 to 2.4 mm
(0.028 – 0.095 in) but can be as large as 4 mm (0.16 in).
The smallest electrodes, generally up to 1.14 mm (0.045 in) are associated with the
short-circuiting metal transfer process, while the most common spray-transfer process
mode electrodes are usually at least 0.9 mm (0.035 in).
23
4.2.4 Shielding gas
(1) Welding torch, (2) Workpiece, (3) Power source, (4)Wire feed unit, (5) Electrode
source, (6)Shielding gas supply.
Fig. 4.2 GMAW Circuit diagram.
Shielding gases are necessary for gas metal arc welding to protect the welding area
from atmospheric gases such as nitrogen and oxygen, which can cause fusion defects,
porosity, and weld metal embrittlement if they come in contact with the electrode, the arc,
or the welding metal. This problem is common to all arc welding processes; for example,
in the older Shielded-Metal Arc Welding process (SMAW), the electrode is coated with
a solid flux which evolves a protective cloud of carbon dioxide when melted by the arc.
In GMAW, however, the electrode wire does not have a flux coating, and a separate
shielding gas is employed to protect the weld. This eliminates slag, the hard residue from
the flux that builds up after welding and must be chipped off to reveal the completed weld.
The choice of a shielding gas depends on several factors, most importantly the type
of material being welded and the process variation being used. Pure inert gases such
as argon and helium are only used for nonferrous welding; with steel they do not provide
adequate weld penetration (argon) or cause an erratic arc and encourage spatter (with
helium). Pure carbon dioxide, on the other hand, allows for deep penetration welds but
encourages oxide formation, which adversely affects the mechanical properties of the
weld. lts low cost makes it an attractive choice, but because of the reactivity of the arc
plasma, spatter is unavoidable and welding thin materials is difficult.
24
As a result, argon and carbon dioxide are frequently mixed in a 75%/25% to

90%/10% mixture. Generally, in short circuit GMAW, higher carbon dioxide content
increases the weld heat and energy when all other weld parameters (volts, current,
electrode type and diameter) are held the same. As the carbon dioxide content increases
over 20%, spray transfer GMAW becomes increasingly problematic, especially with
smaller electrode diameters.
Argon is also commonly mixed with other gases, oxygen, helium, hydrogen and
nitrogen. The addition of up to 5% oxygen (like the higher concentrations of carbon
dioxide mentioned above) can be helpful in welding stainless steel, however, in most
applications carbon dioxide is preferred. Increased oxygen makes the shielding gas
oxidize the electrode, which can lead to porosity in the deposit if the electrode does not
contain sufficient deoxidizers. Excessive oxygen, especially when used in application for
which it is not prescribed, can lead to brittleness in the heat affected zone. Argon-helium
mixtures are extremely inert, and can be used on nonferrous materials. A helium
concentration of 50–75% raises the required voltage and increases the heat in the arc, due
to helium's higher ionization temperature. Hydrogen is sometimes added to argon in small
concentrations (up to about 5%) for welding nickel and thick stainless steel workpieces.
In higher concentrations (up to 25% hydrogen), it may be used for welding conductive
materials such as copper. However, it should not be used on steel, aluminum or
magnesium because it can cause porosity and hydrogen embrittlement.
Shielding gas mixtures of three or more gases are also available. Mixtures of argon,
carbon dioxide and oxygen are marketed for welding steels. Other mixtures add a small
amount of helium to argon-oxygen combinations, these mixtures are claimed to allow
higher arc voltages and welding speed. Helium also sometimes serves as the base gas,
with small amounts of argon and carbon dioxide added. However, because it is less dense
than air, helium is less effective at shielding the weld than argon—which is denser than
air. It also can lead to arc stability and penetration issues, and increased spatter, due to its
much more energetic arc plasma. Helium is also substantially more expensive than other
25
shielding gases. Other specialized and often proprietary gas mixtures claim even greater
benefits for specific applications.
The desirable rate of shielding-gas flow depends primarily on weld geometry,

speed, current, the type of gas, and the metal transfer mode. Welding flat surfaces requires
higher flow than welding grooved materials, since gas disperses more quickly. Faster
welding speeds, in general, mean that more gas must be supplied to provide adequate
coverage. Additionally, higher current requires greater flow, and generally, more helium
is required to provide adequate coverage than if argon is used. Perhaps most importantly,
the four primary variations of GMAW have differing shielding gas flow requirements—
for the small weld pools of the short circuiting and pulsed spray modes, about 10 L/min
(20 ft³/h) is generally suitable, whereas for globular transfer, around 15 L/min (30 ft³/h)
is preferred. The spray transfer variation normally requires more shielding-gas flow
because of its higher heat input and thus larger weld pool. Typical gas-flow amounts are
approximately 20–25 L/min (40–50 ft³/h).
4.3 Factors affecting the choice of joining process:
1. The material being joined - similar or dissimilar, aluminum, iron, copper, etc.
2. Type of assembly- Temporary or permanent.
3. Economy
4. Service Condition, Load etc.
26
Fig. 4.3 Types of Metal Joining Process
4.4 Advantages of welding over other joining processes:
1. The welded structures are usually light in weight compared to riveted structures. This
is due to the reason, that in welding, gussets or other connecting components are not
used.
2. The welded joints provide high efficiency, which is not possible in the case of riveted
joints.
3. Alterations and additions can be made easily in the existing structures.
4. Welded structures are smooth in appearance, therefore it looks pleasing.
5. A welded joint has a great strength. Often a welded joint has the strength of the parent
metal itself.
6. It is easily possible to weld any part of a structure at any point. But riveting requires
enough clearance.
7. The process of making welding joints takes less time than the riveted joints.
8. The welding provides very strong joints. which can’t be bended easily. This is in line
with the modern trend of providing rigid frames.
27
CHAPTER 5
DESIGN
5.1 DESIGN OF THE PROTOTYPE
In our attempt to design the prototype, we have adopted a very careful approach. Total
design work has been divided into two parts mainly,
• System Design.
• Mechanical Design.
System design mainly concern with the various physical concern and ergonomics, space
requirements, arrangement of various components on the main frame of treadmill,
arrangement of tread belt and rollers, position of braking system, arrangement of motor,
sprockets, ease of maintenance, scope of further improvements, ground clearance etc.
In mechanical design, the components are categorized into two parts.
• Design parts
• Parts to be purchased
For design parts, detailed design is done and dimensions thus obtained are compared to
next highest dimensions which are readily available in the market. This simplifies the
assembly as well as post production servicing work. The various tolerances on work pieces
are specified in the manufacturing drawing. The process sheets are prepared and passed
on to the manufacturing drawing. The process sheets are prepared and pass on to the
manufacturing stage.
28
5.1.1 Design of Main Frame Components
Frame design: Material - Mild Steel 1020. Frame design is done according to an Average
Human Being. As per space availability and clearance for reduction of friction, frame size
is (1090*410) mm.
We considered a Human being of about 6 feet tall and having weight of 70 kgs max.
Considering that we calculated that how much strength the material should have, and we
came on conclusion to use M.S 1020.
5.1.2 Design of Sprockets
According to the standard available sprocket size the sprockets were procured and the
number of teeth was 16 and 42, as per reduction ratio.
5.2 Basic Calculations
5.2.1 INITIAL TORQUE REQUIREMENT
The torque required in moving the vehicle from static condition is given below:
Rolling resistance= Cr*mg=0.0046*100*9.81=4.513 N
Torque required=4.513*0.355= 1.602 Nm
Inertial torque = 8.44 Nm
Total torque required = 1.602+8.44
= 10.042 Nm
Where,
Cr= Coefficient of Rolling Resistance=0.0046
(Reference - www.analyticcycling.com)
m= estimated mass of vehicle
g= acceleration due to gravity= 9.81m/s^2
29
5.2.2 DRIVETRAIN
The basic aim in designing the power train arrangement is to have smooth and
efficient transmission with minimum losses and achieving the targeted speed.
Target: Maximum velocity of 10km/h
Options for powered wheel
Front Wheel Drive
Rear Wheel Drive
Selected: Rear Wheel Drive
5.2.3 Acceleration
Considering the track of 50m (s) with maximum speed to be 10km/h the minimum time
required can be calculated using,
s=ut+0.5at2 and v=u+at
s=50m, t=36secs
Where,
u= initial velocity i.e. 0m/s
Acceleration, a= 0.08 m/s2
5.2.4 ELECTRC MOTOR
Options Available for motor:

PMDC Motor
BLDC Motor
30
Table. 5.1 Comparison between BLDC and PMDC motor
Selected Motor: Considering above points BLDC Motor has been

selected
Selected Motor Specification:

To gain desired power and velocity, motor with following specification has been
selected.
Maximum power output = 350W
Operating maximum voltage= 36V
Motor calculations:
Power = Torque*2*3.14*N/60
Therefore,
torque = Power*60/(2*3.14)
Where,
rpm of motor shaft N= 300 rpm (according to motor quotation)
Hence,
Torque at motor shaft=12.6 Nm
31
5.2.5 BATTERY
Options Available for Battery:
Lithium ion Battery
Lead Acid Battery
Table. 5.2 Comparison between Li-ion and Lead acid Battery
Selected Battery: Considering above points Lithium Ion Battery has

been selected
Selected Battery Specification:

To gain maximum rum-time and velocity, battery with following specification has been
selected.
Amp-h Rating = 14.4A-hr
Voltage Rating = 36V
32
5.2.6 Battery Runtime
Voltage Supplied, V =36V

Power of motor, P= 350W
Capacity of battery =14.4Ah
Current drawn from battery, I = P/V
=350/36
= 9.7A
Li-Ion battery generally drains at 60%
(Reference - H.J. Bergveld, Battery management systems design by modeling)

So,
effective capacity of battery = 0.6*14.4Ah
= 8.64Ah
Now runtime, t
t =effective capacity of battery/current drawn from battery
Runtime, t= 0.89hr
Therefore,
battery can run for 0.89 hr with these specifications under given conditions.
5.2.7 Wire diameter:

For electric power transmission we can use wires of different material but among all we
have chosen copper wire due to following reasons
Availability
Conductivity
Low cost
Resistivity of copper, r = 1.79 *10-8 ohm m

(Reference - www.hyperphysics.phy-astr.gsu.edu)
Peak current, I = 9A
33
Battery voltage, V = 36V

Potential drop in wire is 3% of 36V (National Electrical Code, www.ieee.org)
=1.08V
Since,
V/I = R
R = 1.08/9
= 0.12 ohm
Now according to AWG Chart for Copper wire (www.engineersedge.com/copper_wire)
Thickness of wire = 2.58 mm (10 gauge)
5.2.8 STATIC WEIGHT DISTRIBUTION
In our vehicle,
Wheelbase, L= 24inch
lr= CG distance from rear tire = 6 inch
lf= CG distance from front tire= 4 inch
m=weight of Scooter (100 kg)
F (front) = mg lr /2L = 100*9.8*4/20 = 392.4 N
F (rear) = mg lf /2L = 588.6 N
% weight distribution at static condition is 40% at front and that at rear 60%.
5.3 Selection of size of wheels:
Factors-
-height of center of gravity
-height of bumps
-rotational velocity of wheel
-load capacity of wheel
Considering above factors, sizes of wheels selected

Diameter of Front wheels = 4 inches
Diameter of rear wheel = 8 inches
34
5.4 CAD MODELING
The CATIA
model of the prototype is shown below:
Fig. 5.1 Solidworks Model (Isometric View)
Fig. 5.2 Solidworks Model (Side View)
35
CHAPTER 6
ANALYSIS
6.1. TORSIONAL RIGIDITY ANALYSIS

a) Assumption & Considerations:
The material taken is homogenous and isotropic. Forces are uniformly distributed over
impact member. The rear most part is fixed for the analysis and mountings such as of
utility box, seat belt, etc are not taken. The forces are applied on both wheels in the
form of couple. Mesh size is 4 mm with tetrahedron mesh shape.
b) Calculation of Impact Forces:
T=torsion = 1078 Nm
y= torsional stiffness
α= angular deflection
= 0.341 rad
T=α*y
= .0.341*y
Solving,
y= 3161.29 Nm/rad
c) Analysis Results:
Total Deformation= 0.92 mm (Refer Fig 5.1)

Directional Deformation= 0.71 mm (Refer Fig 5.2)
Stress = 121.99 MPa (Refer Fig 5.3)
FOS= 2.094 (Refer Fig 5.4)
Fig. 6.1 Total Deformation (Torsional Analysis)
36
Fig. 6.2 Directional Deformation (Torsional Analysis)
Fig. 6.3 Equivalent Stress (Torsional Analysis)
37
Fig. 6.4 Safety Factor (Torsional Analysis)
6.2. BUMP ANALYSIS

a) Assumption & Considerations:
The material taken is homogenous and isotropic. Forces are uniformly distributed over
impact member. The rear most part is fixed for the analysis and mountings such as of
utility box, seat belt, etc are not taken. The forces are applied on both wheels in the
form of couple. Mesh size is 4 mm with tetrahedron mesh shape.
b) Impact Forces:
The amount of force considered for this testing is 5G.
c) Analysis Results:
Directional Deformation= 0.7139 mm (Refer Fig 5.5)

Deformation= 0.7152 mm (Refer Fig 5.6)
Stress = 157.28 MPa (Refer Fig 5.7)
FOS= 1.5895 (Refer Fig 5.8)
38
Fig. 6.5 Directional Deformation (Bump Analysis)
Fig. 6.6 Total Deformation (Bump Analysis)
39
Fig. 6.7 Equivalent Stress (Bump Analysis)
Fig. 6.8 Safety Factor (Bump Analysis)
40
CHAPTER 7
FABRICATION
7.1 SCOOTER UNIT

Scooter unit consists of following components – Scooter frame, wheel
assembly, steering system and electrical unit.
7.1.1 Frame
The scooter frame is fabricated as a rectangular shaped frame of dimension 90cm x
30cm. Square hollow mild steel (AISI 1020) tubes of 1inch x 1inch are used for the
fabrication because of the less weight and less cost. Also the material can withstand
the load capacity of what we needed. The rectangular frame is constructed with all side
closed. The frame is provided with an approach angle to lower the C.G. and provide
stability. The front end of the frame consists of motor and battery mountings on the
left and right side respectively. Similarly, the wheels are mounted at the rear end of
the frame which is also made from the same square section if the same specifictions.
All the members of the frame are joined to each other with the help of metal inert gas
welding (MIG welding).
Fig. 7.1 Frame
41
7.1.2 Front Wheel Assembly
The front wheel consists of a small wheel that was a castor wheel which is converted
to our used by locking its 360 degrees movement by using the welding processes
(MIG). Front wheel used has a diameter of 3 inches which is welded from the top to
the steering handle. The front wheel being smaller than the second provides a negative
approach angle. This helps in lowering the centre of gravity and maintains the vehicle
stability.
The rear wheel of the scooter consists of a pair of wheels that have a diameter of 9
inches. The rear wheels are supported on the wheel mounted that are attached to the
frame at the rear end. They are supported on the mountings by the help of wheel axles.
The centre distance between both the rear wheels are 18 inches. The rear wheels are
plastic wheels with the rubber tyres. The rear wheel mounting are made up of mild
steel (AISI 1020) of square cross section with side of 1 inches.
7.1.3 Steering Unit

The steering unit consists of handle bar, steering column with the bearing elements
consisted of steel balls. It consists of a steering handle bar that is used to steer the
vehicle in the desired direction of travel. The steering unit consists of bearing
element which consists of steel balls that helps us in lowering the friction and helps
in smooth rotation. The handle bar is made from mild steel tube of diameter 1 inches
and wall thickness 2mm. The turning radius is 24 inches when measured from the
outer wheel when measured while travelling along a curved path.
All the wheel alignment angles (such as castor, camber and toe) were set to 0 degrees
while fabrication
42
7.1.4 WHEEL ASSEMBLY
The wheel assembly includes the fabrication of front wheel and rear wheel and
associated supports. The rear wheel shaft is directly coupled to the motor shaft. The
intermediate sprocket is fitted on the same bolt as rear wheel using nuts. An extended
piece of mild steel is attached to the middle of front portion of main frame. The front
wheel assembly is attached to this extended part. Front wheel is made to rotate freely
wheel shaft with the help of hub.
Fig. 7.2 Wheel Assembly
7.2 CHAIN DRIVE MECHANISM
The power transmission to the rear wheel is done by using chain drive. There are a
total of 2 sprockets used to drive the chain, of different size. All sprockets are
connected using a single chain. The input sprocket is a sprocket 11 teeth which is
concentrically fixed to the motor with the help of bolt on its axle. The motor supplies
the input power to the chain drive when throttled. Output sprocket is a chain drive
element of 28 teeth which is use to deliver power from the chain to the rear wheel. The
rear wheel sprocket is welded to the collar with is fixed to the rear wheel with the help
of glue stick.
43
Fig. 7.3 Rear Wheel and Chain Drive Mechanism
7.4 ELECTRICAL UNIT
The electrical unit consists of following components – Motor, controller, throttle, and
battery.
7.4.1 Motor
A brushless DC motor (BLDC) of 250W, 24V is used. The motor has a rpm of 1250
at its shaft at no load which is then further reduced by a gear ratio of approximately
2.5. The motor mounting is made from L-section. The mounting is placed in front of
the left wheel which is fixed their by welding process(MIG). The wheel shaft is fixed
which holds the wheel in its position and allowing the wheel to rotate freely about
thewheel shaft axis.
Fig. 7.4 Motor
44
7.4.2 Battery
A battery of 24V, 10Ah specification is used which is mounted at the front of the frame
just on the opposite side of the motor. L-section of mild steel is used of thickness 1.5
mm with the flange width of 1 inch. It is fixed in its position with the help of clamping
bolts.The mounting is fixed in its position on the frame with the help of welding
process (MIG). This type of battery is used in motorcycles.
7.4.3 Controller
Controller is the heart of an electric vehicle, and it is the key for the realization of the
high performance vehicle with an optimal balance of maximum speed, acceleration
performance and driving range per charge. The controller connects the power source
(battery) to the actual motor. It controls speed and direction and optimizes energy
conversion. Controller generally controls the ratio between torque and speed. Torque
is controlled by controlling armature current and speed is controlled by controlling
armature voltage. Voltage control is achieved by chopping source current- the voltage
is switched on and off, with the ratio of on-to-off determining the average voltage.
The number of constant-width “on” pulses per unit time can be varied, or the width
(duration) of the pulses can be varied. Chopping is performed by power electronics
circuitry diodes and thyristors and silicon control rectifiers (SCRs).Controller
efficiencies are typically greater than 90%.
Fig. 7.5 Controller
45
CHAPTER 8
ADVANTAGES AND DISADVANTAGES
8.1 ADVANTAGES
A Electric Scooter has following advantages:
• It is Eco-Friendly.
• It can easily be used for short-distance travels i.e. College tours, factory tours
etc.
• The Electric Scooter has a predictable surface that is much easier to negotiate
than sidewalks, curbs or trails and the risk of tripping is reduced.
• Multiple users can use the same equipment without adjusting the structure.
• It can be used at the places where is the risk of contamination due to

emission.
8.2 DISADVANTAGES
A Electric Scooter has following disadvantages:
• On sudden application of brakes jerking and accident can occur.

• Main disadvantage of Electric Scooter is its discharging battery. Due to
sudden discharge of battery in between of travelling many problems are
faced.
• Not optimal for long distance.
46
CHAPTER 9
FUTURE SCOPE AND IMPROVEMENT
9.1 FUTURE SCOPE
• It can be used as an indoor locomotive device infrastructure with large roof

span i.e. malls, warehouse, open markets, large office spaces, etc.
• By using such product pedestrian cops can save themselves from getting
exhausted.
• Pedestrians in large campuses can benefits from this product the same way.
• Can replace cycle as an energy efficient vehicle for those who cannot drive a
cycle.
9.2 FUTURE IMPROVEMENT
• Due sudden discharge of battery in between of travelling leads to face many

problems to overcome this disadvantage we can do some improvements in
present model. To overcome this discharge problem we can install a solar panel
to the system it will recharge the battery and continuous movement of walking
bike can be possible. Solar panel is one of the simplest ways to charge the
battery.
• Another way is generation of electricity by using dynamo generator. The
mechanical energy generated by human due to walking on tread belt is
converted to electrical energy by using dynamo generator. It will produce a
small amount of energy. Small increment of energy in rechargeable battery will
move the bike continuously.
47
CHAPTER 10
CONCLUSION
The project deals with the design and fabrication of Electric Scooter that promotes
economical and eco-friendly means of transport for everyone. As the initial step, a
literature survey on related systems and projects were conducted. A suitable design
was proposed but due to infeasibility incurred in making the model, we decided to
make a scaled-down prototype changing the design accordingly. The design
dimensions and aspects were successfully calculated and analyzed. Materials and
components for the fabrication of the project were compared and selected. The vehicle
is used to reduce the manual effort i.e. in place of conventional cycle; and gives more
displacement with lesser effort. This scooter has only three wheels, looks robust and
lets you take it for a ride according to its design. Many systems can be improved in the
future to optimize the manufacturing of the vehicle. Solar panels and Dynamo
generators can be incorporated with the vehicle for charging while driving. Light
weight carbon fiber can be used to reduce the overall weight of the vehicle and
improves strength. This system can be efficiently used anywhere whether it is outdoor
or indoor. This utilizes highly fuel-saving technology which is a major requirement of
this era. We developed a branch and bound approach which is coupled with quick,
effective bounds to optimize the Electric Scooter which serves the purpose of
travelling and also use the non- renewable energy resources. On the whole, we are
satisfied with our project.
48
REFERENCES
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Design and fabrication of electric scooter

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Mechanical Projects : Learnmech.

DESIGN AND FABRICATION OF ELECTRIC

Bachelor of Technology (B. Tech.)

Anshul Singh Titoriya Abhijeet Sharma

Bhupesh Kumar Ahirwar Anoop Mohan Sharma

Under the Supervision of

Prof. Manoj Singh Bhist

KIET GROUP OF INSTITUTIONS

Faculty of Mechanical Engineering

DR. A.P.J. ABDUL KALAM TECHNICAL

UNIVERSITY, UTTAR PRADESH, LUCKNOW MAY,

Manoj Singh Bhist

Department of Mechanical Engineering

KIET Group of Institutions

Name: Anshul Singh Titoriya Name: Anoop Mohan Sharma

Roll No.: 1402940027 Roll No.: 1402940026

Name: Bhupesh Kumar Ahirwar Name: Abhijeet Sharma

Roll No.: 1402900049 Roll No.: 1402940004

Name: Anshul Singh Titoriya Name: Anoop Mohan Sharma

Roll No.: 1402940027 Roll No.: 1402940026

Name: Bhupesh Kumar Ahirwar Name: Abhijeet Sharma

Roll No.: 1402900049 Roll No.: 1402940004

Figure No.1.2 PMDC Motor

Figure No.1.3 BLDC Motor

Figure No.1.4 Lead Acid Battery

Figure No.1.5 Li-Ion Battery

Figure No.1.6 Wheel

Figure No.1.7 Steering

Figure No.1.8 Sprocket

Figure No.1.9 Bearing

Figure No.2.1 EV Rider

Figure No.3.1 Mild Steel Pipes

Figure No.3.2 Chromoly Pipes

Figure No.3.3 Carbon Fibre

Figure No.4.1 Types of Welding

Figure No.4.2 GMAW Circuit Diagram

Figure No.4.3 Types of Metal joining process

Figure No.5.1 SolidWorks Model (Isometric View)

Figure No.5.2 SolidWorks Model (Side View)

Figure No.6.1 Total Deformation (Torsional Analysis)

Figure No.6.2 Directional Deformation (Torsional Analysis)

Figure No.6.4 Safety Factor (Torsional Analysis)

Figure No.6.5 Directional Deformation (Bump Analysis)

Figure No.6.6 Total Deformation (Bump Analysis)

Figure No.6.7 Equivalent Stress (Bump Analysis)

Figure No.6.8 Safety Factor (Bump Analysis)

Figure No.7.1 Scooter Frame

Figure No.7.2 Wheel Assembly

Figure No.7.3 Rear wheel and chain drive mechanism

Figure No.7.4 Motor

Figure No.7.5 Controller

Table No.3.2 Composition of AISI 4130

Table No.5.1 Comparison between BLDC and PMDC Motor

Table No.5.2 Comparison between Li-ion and Lead acid Battery

LIST OF SYMBOLS AND ABBREVIATIONS

rpm Revolutions per minute

MPH Miles per hour

m/s Metre per second

Abstract ........................................................................ iii

List of Figures ................................................................. v

List of Tables .................................................................. vii

List of Symbols and Abbreviations……………………….viii

4. Joining Process ............................................................... 20