I

DESIGN, DEVELOPMENT & FABRICATION OF A

MOTORISED HOVERBOARD
Major Project
Submitted in partial fulfillment of the requirement for the award of the Degree of
Bachelor of Technology
In
MECHANICAL ENGINEERING

Submitted to

RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA, BHOPAL (M.P.)

Submitted by

SURAJ MANDAL

Enrollment No. - [0132ME213D84]

Under the Supervision of

Prof. Bhagwat Dwivedi

Department of Mechanical Engineering

RADHARAMAN INSTITUTE OF TECHNOLOGY & SCIENCE, BHOPAL
NOVEMBER-2023
 II

RADHARAMAN INSTITUTE OF TECHNOLOGY & SCIENCE

BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

CANDIDATE’S DECLARATION

We hereby declare that the Major Project entitled “DESIGN,

DEVELOPTMENT AND FABRICATION OF A MOTORISED
HOVERBOARD” is my own work conducted under the supervision of Prof.
Bhagwat Dwivedi Department of Mechanical Engineering Department of
Mechanical Engineering, Radharaman Institute of Technology & Science,
Bhopal.

We further declare that to the best of my knowledge this report does not contain
any part of work that has been submitted for the award of any degree either in
this university or in other university / Deemed University without proper
citation.

SURAJ MANDAL (0132ME213D84)

 III
RADHARAMAN INSTITUTE OF TECHNOLOGY & SCIENCE

BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the “DESIGN, DEVELOPTMENT AND

FABRICATION OF A MOTORISED HOVERBOARD” being submitted by
SURAJ MANDAL (0132ME213D84), in partial fulfillment of the requirement
for the award of Bachelor of Technology in Mechanical Engineering to Rajiv
Gandhi Proudyogiki Vishwavidyalaya, Bhopal (M.P.) is a record of authentic
workdone by him under my supervision.

APPROVED & SUPERVISED BY:

Dr. Ajay Singh Prof. Bhagwat Dwivedi

HOD Project Guide
Dept. of Mechanical Engg.

FORWARDED BY:
Dr. R K Pandey
Director
 IV
RADHARAMAN INSTITUTE OF TECHNOLOGY & SCIENCE

BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

PLAGIARISM’S DECLARATION

We hereby declare that the Major Project entitled “DESIGN,

DEVELOPTMETN AND FABRICATION OF A MOTORISED
HOVERBAORD” is our own work conducted under the supervision of Prof.
Bhagwat Dwivedi, Assistant Professor Department of Mechanical Engineering
Department of Mechanical Engineering, Radharaman Institute of Technology &
Science, Bhopal.

We further declare that to the best of my knowledge this report does not contain
any part of work that has been submitted for the award of any degree either in
this university or in other university / Deemed University without proper
citation.

We also declare that a check for plagiarism has been carried out on the Major
Project and is found within the acceptable limit and report of which is enclosed
here with.

Date: Signature of Candidate

This is to certify that the above statement made by the candidate is

correct to the best of my knowledge.

Dr. Ajay Singh Prof. Bhagwat Dwivedi

HOD
Dept. of Mechanical Engg. Project Guide

FORWARDED BY:
Dr. R K Pandey
Director
 V

RADHARAMAN INSTITUTE OF TECHNOLOGY & SCIENCE

BHOPAL (M.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE OF APPROVAL

The Major Project entitled “Design, Developtement and Fabrication of a

Motorised hoverboard” being submitted by SURAJ MANDAL
(0132ME213D84), has been examined by us and is hereby approved for the
award of degree “Bachelor of Technology in Mechanical Engineering”, for
which it has been submitted. It is understood that by this approval the
undersigned do not necessarily endorse or approve any statement made, opinion
expressed or conclusion drawn therein, but approve the Major Project only for
the purpose for which it has been submitted.

(Internal Examiner) (External Examiner)

Name: Name:

Date: Date
 VI

ACKNOWLEDGEMENT

We express our deepest sense of gratitude to my guide Prof. Bhagwat Dwivedi,

Assistant Professor, Department of Mechanical Engineering and Dr. Ajay
Singh, Professor & Head, Department of Mechanical Engineering, Radharaman
Institute of Technology & Science, Bhopal, for their valuable guidance and
encouragement towards the completion of this work.
We are grateful to Dr. R K Pandey, Director, Radharaman Institute of
Technology & Science, Bhopal for his blessings and encouragement.
We are very thankful to Dr. Parag mishra Assistant Professor, Department of
Mechanical Engineering, Radharaman Institute of Technology & Science,
Bhopal. Furthermore, I would like to thank my friends and those who have
helped directly or indirectly to me in accomplishing this task.
We also gratefully acknowledge all inspiring efforts of my family who
constantly encouraged me to maintain the level of enthusiasm for completing
this dissertation work at various stages. I also thank God for being kind to me
and blessing me through this journey.
We would also like to express my gratitude to all the faculties & staff members
of Department of Mechanical Engineering, RITS, Bhopal, for their cooperation
in my work.

SURAJ MANDAL (0132ME213D84)

 VII
CONTENTS
PAGE NO.

1. Abstract
2. Introduction 01-09
3. Literature review 10-11
4. Experimental setup 12-20
5. Methodology 21-25
6. Conclusion 26
 ABSTRACT VIII

A hover-board is a self-balancing personal transporter consisting of two

motorized wheels with a typical gyroscopic-stabilized system. Emissions from
internal combustion vehicles are on the rise every day. Urban vehicular traffic
has increased tremendously over the years. Traffic congestion leads to higher
vehicle emissions and lower ambient air quality. There can be no immediate
solution to this issue, but another solution for conventional personal transport is
Hoverboard. So the hoverboards are becoming more popular day by day. But
the complex electronics like accelerometer and gyroscope make it too
expensive. This project involves the design, analysis, and fabrication of an
electric three-wheeled hovercraft. The system moves back and forth using the
DPDT switch. A small wheel is used to balance the vehicle such that a
gyroscope is not needed for balancing purposes. This project work aims to build
a low-cost and efficient Hoverboard.
c 1

INTRODUCTION

A Short board that travels above the surface of the ground, that you ride on in a
standing position typically, these devices functions like powered skateboard and
consist of a platform for the rider, situated between two wheels and powered by
battery.

Hover-board is two-wheeled, electric, portable device that are also commonly

known as self-balancing scooter. These is a levitating board used for personal
transportation, first describe in science-fiction, and made famous by the
appearance of a skateboard like Hover board in film back to the future part II.

Many attempts have been made to invent a functioning hover-board.

The main purpose was to design and construct a fully functional two wheeled
balancing vehicle which can be used as a means of transportation for a single
person. It should be driven by natural movements; forward and backwards
motion should be achieved by leaning forwards and backwards. Turning should
be achieved by tilting the handlebar sideways. To provide untethered operation
the vehicles’ energy source was designed to be a battery. One of the goals was
to implement easy recharging of this battery.
c 2

Other new research has been done lately to improve the working of the hover-
board. 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.

This represents Get another unconventional approach to today’s urban

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.

The designing a concealed device which would allow Jibril to move slowly and
eerily across the floor. Due to the angel’s long and wide costume, it would be
possible to hide it from sight beneath the loose fabric. The most important
consideration for the device is balance. It is important that the performer will
not fall off from the device. The impact of such a blunder during the
performance would not only harm the scene in which the angel is present. The
entire show’s integrity would be compromised and harshly received by the
audience, potentially as a comedic act, which would seriously damage the
performance’s reputation.

The device that could most accurately perform the required movements is the
Vecaro Hoverboard. It is a self balancing motorized two-wheeled balance
scooter that uses innovative gyroscopic technology. With some modifications to
prevent the costume from getting stuck under the wheels, the Hoverboard would
likely accomplish the task successfully, but the price is out of the show’s
budget. The entry level model Glide 65 Vecaro Hoverboard is priced at $599,
and more powerful and precise versions reach the $799.
c 3

On the hover-board heelys are shoes that have at least one wheel embedded in
each sole, allowing the user to walk by shifting their weight to their heels and
roll across the floor. It is a simple device which does not require a motor for
movement, although it is necessary for the user to initially move their legs to
spin the wheel. This movement broke the main requirement of the device and
was therefore not considered for the design. However, it inspired a design
concept which was ultimately not selected for implementation .

In a resent search the number of vehicles Bhopal. India has increased

considerably in the past five years, resulting in increase in pollution too.
According to regional transport office, every day 500 new non-commercial
vehicles get registered including two wheelers and four wheelers. In the recently
press released of the WHO report on pollution in India, the present situation of
the city is not so encouraging when pollution in the air comes to picture. Due to
increase in number of vehicles over the years, the city roads witness frequent
traffic congestions, but above all, the vehicles emitting pollutants are affecting
environment badly. "The air pollution consists of many pollutants, among other
particulate matter. These particles are able to penetrate deeply into the
respiratory tract and therefore constitute a risk for health by increasing mortality
from respiratory infections and diseases, lung cancer, and selected
cardiovascular diseases," says the WHO report. New patients with respiratory
problems are constantly being reported in hospitals. The two wheelers are the
major contributors of vehicular air pollution followed by four-wheeler (e.g., car,
jeep, taxi etc.), trucks and buses in decreasing order of magnitude.
c 4

Hover-boards were first described by author M. K. Joseph in a 1967 science

fiction novel. In 1984, a hover-board appeared in the shoot 'em up arcade video
game SWAT, developed by Core land and distributed by Sega in Japan
and Bally Midway in North America.

Hover-boards have appeared in various other media since the 1990s. For
example, video games such as the beat 'em up arcade game Riding Fight (1992),
manufactured by Taito, and the sports video game Air Blade (2001), and
developed by Criterion Games.

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, “segway’’
research and development was focused on creating vehicles that took up a
minimal amount of space, were extremely maneuverable and could operate on
pedestrian sidewalks and pathways.

Just like the new models, the Segway HT consisted of four major elements: the
wheel and motor assembly, the sensor system, the circuit board brain and the
operator control system. What separated the Segway HT from its
contemporaries was that it had five gyroscopic sensors, though it only needed
three to detect forward and backward pitch as well as leaning to the left or right.
These extra sensors added redundancy which made the vehicle more reliable.
Additionally, the Segway HT had two tilt sensors filled with electrolyte fluid.
Like an inner ear, this system figures out its own position relative to the ground
based on the tilt of the fluid surface.

Since then, the hover boards became overwhelmingly fashionable. In the early
1990s, some companies managed to produce and marketed hovercraft vehicles
as hoverboards. However, these products have not been able to demonstrate the
same experience as shown in the movies. By 2014, a Canadian inventor named
Catalin Duru developed a hover board. This hover board, as shown in coincided
c 5

with its development and production by companies such as Lexus and Hendo.
The latter made use of magnetic field system to power their hover boards while
Catalin Duru’s hover board (known as Omni) focused on the use of propellers to
keep its passengers in the air. In May 2015, Catalin Duru’s hover board attained
a world record of being the only hover board to fly more than 50 meters in the
air. However, back in the 1950s, the “Flying Platform” was invented by an
aircraft manufacturing company known as Hiller aircraft. When this invention
was compared to the modern concept of a hover board, they were found to have
many similarities. Information that got in circulation in 2001 confirmed that
Ginger, an invention by Dean Kamen of Hiller Aircraft, was a real Segway
human transporter; hence, this invention was a self-balancing two-wheeled
electric transportation device.

The most finished type of a two-wheeled hover-board is also known as a

Segway. The 80 lbs (36 kg) device lifts the user 8 inches (20 cm) off of the
ground and can travel at speeds up to 12.5 mph (20 km/h) with impressive
levels of stability. This ideal two-wheeled hover-board model boasts small
fenders to prevent flying gravel and mud, and each has rubber tires similar to a
gas powered scooter. The Segway’s revolutionary balance-control system works
in tandem with a pair of electric motors, one powering each wheel. The
principle is simple: as the rider shifts his or her balance, the Segway adjusts
itself to keep it from tipping over. The same algorithm governs the turning
radius at various speeds, preventing the driver from tipping over while
cornering.

The hoverboard market has witnessed significant growth in recent years, driven
by factors such as increasing urbanization, advancements in technology, and the
growing trend of eco-friendly and efficient transportation solutions. The rising
adoption of hoverboards among the youth and millennials for recreational
purposes has been a major driver for the market. Additionally, the increasing
preference for electric vehicles with zero carbon emissions has further fueled
the demand for hoverboards.
c 6

In 2006, the second generation Segway was introduced. All the products feature
breakthrough leansteer technology and wireless info key controller that enhance
the Segway experience by making the ride even more intuitive and adding new
and useful functions.

In 2004 Jamie hyenman and his team built a makeshift hovercraft

for MythBustersdubbedthe HynemanHoverboard,froma surfboard and leafblow
er. However, Jamie's hoverboard was not very effective.

In 2005, Jason Bradbury created a "hoverboard" for The Gadget Show, using a
wooden board that was levitated by means of a leafblower. The original design
was not propelled and could also not be steered. In 2009, a second version was
made which was propelled/steered by a small jet engine (rather than a fan as
with an air boat), and also contained two (more powerful) leafblowers.

In 2011, French artist Nils Guadagnin created a hovering board that floats by
magnetic repulsion between it and its base but cannot carry a load. The board
includes a laser system which ensures stabilization, in addition to an
electromagnetic system which makes the levitation possible.
.
c 7

In October 2011, the Université Paris Diderot in France presented the "Mag
surf", a superconducting device which levitates 3 cm (1.2 in) above two
magnetized repulsing floor rails and can carry up to 100 kg (220 lb).

In October 2014, American inventor Greg Henderson demonstrated a prototype

hoverboard working on a magnetic levitation system using
the electrodynamics principle. Similar to maglev trains, the hoverboard requires
a surface of non-ferromagnetic metal such as copper or aluminum to function,
carrying up to 140 kg (300 lb) while hovering 2.5 cm (1 in) above the surface.
Four engines were used to power the magnetic levitation, with the option of
applying thrust and spin to the board under user control. The prototype was
promoted in a campaign on Kick starter the day of the news coverage, with a
price of $10,000 for the first ten boards.The New York Times said that although
the board worked, Greg Henderson had no personal interest in skateboarding
and that the Kickstarter was "basically a publicity stunt," designed to call
attention to his company.

In May, 2015, Guinness World Records announced that the Romania-born

Canadian inventor Cătălin Alexandru Duru had set a new record for continuous
travel as a controlling pilot on an autonomously powered hoverboard, travelling
over a distance of 275.9 m (302 yd) at heights up to 5 m (16 ft) over Lake in the
province of Quebec, Canada. Video of the flight leading to a controlled splash-
down is offered. Duru had designed and constructed the hoverboard himself
over the course of a year. Its lift is generated by propellers, and the pilot
controls the craft with his feet.

On 24 December 2015, ARCA Space Corporation claimed it developed a

hoverboard named Arc aboard, and the batteries can provide energy enough for
six minutes of hovering at height of up to 30 centimeters (12 in). It has 36
electric motors that power 36 fans.
c 8

On June 24, 2015, Lexus released a video as part of their "Amazing in Motion"
series purporting to show a real hover-board they had developed, the Slide. It
was stated by Lexus that the board worked using liquid-nitrogen-cooled
superconductors and permanent magnets. The board was shown moving over a
conventional-looking concrete skateboard park surface, which led to some
skepticism. Lexus apparently later admitted that it only works on special
metallic surfaces and the surface shown was not just concrete.On August 4,
2015, Lexus revealed the working principles of the Slide hoverboard with a
promotional campaign, filmed in Barcelona and starring Ross McGouran, a
professional London skateboarder. Lexus released a series of videos explaining
the technology and the whole engineering, research, and development process in
association with all its partners.

In March 2014, a company called HUVr claimed to have developed the

technology for hoverboards, and released a video advertising the product
on YouTube featuring Christopher Lloyd, Tony Hawk, Moby, Terrell Owens,
and others riding hoverboards through a parking lot in Los Angeles. Special
effect failures such as incomplete wire removal have conclusively identified the
video as a hoax or joke, traced to the Funny or Die website through
identification of the cast and public references to the project.

In the 1986 The Transformers: The Movie, there is a scene where Daniel
Witwicky rides a hoverboard.
c 9

On January 7, 2021, the YouTube channel Hacksmith Industries uploaded a

video of a functional hoverboard capable of sustaining the weight of a human. It
usesseveral electrodynamicwheels to induce eddy currents on an aluminum plate
floor.

In the 2002 disney animated film treasure planet, Jim Hawkins rides a
hoverboard also known as a solar surfer with a sail doing daredevil stunts in the
mines. Later on , he quickly contructs a hoverboard and uses it to reach the door
control before the tutular planet explodes.

In the 2004 CGI animated film Pinocchio 3000, Mayor scamboli , Marelene ,
Cab and rodo all ride hoverboards at the opening of scamboland.
c 10

LITERATURE REVIEW

Wael Younis (2009):- The aim of this research is to study the theory behind
building Segway vehicles based on the stabilization of an inverted pendulum.
An experimental model has been designed and implemented through this study.
The model has been tested for its balance by running a Proportional Derivative
(PD) algorithm on a microprocessor chip. The model has been identified in
order to serve as an educational experimental platform for Segway’s. The
system is basically made up of a platform that is mounted on two wheels
activated independently by two DC motors.

Prof. Shakil Tadavi (2015):- The Segway personal transporter is a device that
transports one person at relatively low speeds. The low-speed (limited to
approximately 20 kmph) operation combined with its electric propulsion system
makes the Segway a candidate for providing short distance transportation on
city streets, sidewalks, and inside buildings. When a Segway is in use, the
device is driven by two wheels that are placed side-by-side, rather than the
standard in-line configuration of a bicycle or a motorcycle. When the operator
pushes the switch, the wheels turn in unison in the same direction to provide
forward motion. In order to stop the wheels the available braking system can be
used. Experiments were performed to study the dynamic behavior of the
Segway human Transporter.

Under small disturbances, the Segway-Human system has a very predictable

behavior. In such cases, pitch angle and speed responses showed almost linearly
under-damped responses. However, when stronger forces were involved, the
human dynamics started to play a role. In such cases, the responses were
difficult to predict due to the movements performed by the rider, showing the
importance of their role in controlling the vehicle.
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Ankit S. Khanzode(2016) :- In this research paper Ankit S. Khanzode and his

team did research on a Two wheeled Segway Hoverboard . The aim of their
project was to manufacture a low cost and highly efficient Segway hoverboard
without use of any complex and electronic part such as microcontroller and
gyroscope .They successfully attained their goal .The overall functionality and
performance of the vehicle was evaluated by doing no of tests and they
concluded that this vehicle can be used for day to day transportation for short
distances.

Pravin Kumar Singh (2016):-. It This paper describes the design and fabrication
of Segway hoverboard wheeler. The Self balancing two wheeler is based on the
principle of Segway. It describes the way to balance a hoverboard using a small
supporting wheelis an eco-friendly mode of transport which causes zero
pollution. This project was implemented with an idea to find an effective
solution to the transportation problem. The main objective is to achieve space
utilization and minimize the fuel consumption especially for short distances. It
focuses on parts that can be minimized so that weight can be minimized.

A.Dineshkumar(2017) :- In this research paper A.Dineshkumar and his team

learned about the available methods of personal mobility such as electric
bicycle, Segway hoverboard, Unicycle etc. According to them the biggest
disadvantage of PEV is its high price. Higher price can be compensated by
lower operational cost. The Socio-technical transition proves that the people are
changing towards electric vehicles. Many factors such as Demographic graph,
Health status, Mobility status, Life quality were studied. Nearly 88% of the
people were found normal with the electric vehicle.
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EXPERIMENTAL SETUP

The main purpose was to design and construct a fully functional two wheeled
balancing vehicle which can be used as a means of transportation for a single
person. It should be driven by natural movements; forward and backwards
motion should be achieved by leaning forwards and backwards. Turning should
be achieved by tilting the handlebar sideways. To provide unlettered operation
the vehicles’ energy source was designed to be a battery. One of the goals was
to implement easy recharging of this battery.

COMPONENTS USED
NAME Quantity Approx. Price

PLYWOOD ( 12”inch *12inch) 4*2 1200$

18V DC Mega Torque Geared Motor 6500*2

( RPM: 300, Watt: 250W, Torque: 92 1*2
Kg/cm) = 12,00$

PVC pipe with 2 cap

20$
(Size: 1 inch) 1*1

Bicycle wheel
1*2 50$
{Quantity: 1 pair, size: 10 “ (inches) }

Pillar Type Rubber Castor wheel

{Quantity: 2 pieces, size: 4” (inches) 1*2 30$

}

12V DC Battery
1*1 130$
( Ampere: Minimum 7 Ah )
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7.Momentary Push Button

{Quantity: 2 pieces, Ampere: 10A }, ................. ........ Approx cost.......
Wire, Screw, and other equipment

PLYWOOD:-

Plywood is an engineered wood from the manufactured boards family which

includes particle board and oriented strand board (OSB). It is made of thin sheet
peeled from debarked wood. These thin layers, also called plies, are glued together
Tin alternating right angles to create a cross-grain pattern. This pattern adds
Strength and stability that resists shrinkage and expansion caused a by moisture.
Plywood is a popular choice in construction because of its strength and low cost. It
is used in areas hidden from view that offer support such as floors, walls,roofs and
garages in residential construction. When used for roofing, plywood panels are
covered and protected by other materials that keep the elements at bay, including
roof felt, underlayment, flashing and shingles. When used in flooring, plywood
creates a subfloor that supports hardwoods, tile and carpet floors. sustainable and
paintable plywood is ideal for shelving, cabinets and furniture. Outside the home,
plywood can be transformed into fencing materials, packaging materials,
scaffolding, sheds and shipping containers.

Hardwood plywood is made from hardwoods like birch, maple and oak. The
plies are glued at right angles to one another, making the plywood very strong
and stable. It can be heavier than other types of plywood. Use hardwood
plywood for furniture and anything that requires a strong load-bearing frame.

A ply refers to a layer of veneer used to create plywood’s various thicknesses.

More ply creates a thicker and stronger board. Plywood has an odd number of
plies and needs at least three plies. Although specialty plywood can have any
c 14

number of plies above three, most plywood is categorized as 3-ply, 5-ply or

multi-ply.

3-ply is one of the most common types of plywood. It is about 2- to 3-

millimeters thick and is generally used indoors, since it looks more decorative
than thicker plywood boards.

5-ply is a versatile type of plywood that is about 4-millimeters thick. Use it

indoors or outdoors, but avoid using for framing permanent structures, such as a
shed or a home.

Multi-ply is a catchall term for plywood with seven or more plies. This plywood
is strong and durable enough for use in roofing, framing and other exterior,
structural projects.

Tip: Plywood with fewer plies is weaker than a plywood with more plies, even if
they have the same thickness.

There are five important ratings that convey where and how to use plywood:
Exterior, Exposure 1, Exposure 2, Interior and Structural 1.

Exterior means the panels have been waterproofed and can withstand inclement
weather. Use exterior rated plywood for permanent outdoor structures that will
be exposed to water long-term.

Exposure 1 means the panels have been waterproofed and can withstand
exposure to the elements during construction. However, they are not suitable for
long-term exposure post-construction.

Exposure 2 means the panels are made with an intermediate glue that is not fully
waterproof. These panels can withstand occasional moisture but are otherwise
intended for interior use.

Interior means the panels are not waterproof and are designed for interior use
only. They should not be exposed to moisture.
c 15

Structural 1 is rated for seismic retrofit work, meaning it is designed to be

earthquake resistant. Unless they have a Structural 1 rating, other plywood
panels of any width are not suited for seismic retrofitting.

Plywood Grades:

There are four grades of plywood: A, B, C and D. The grade refers to the quality
and appearance of the plywood’s face and back veneers. A has the highest
quality and is the most expensive, and D is the least expensive.

A-grade plywood features a smooth, sanded surface without knots. Any wood
defects have been repaired with synthetic filler, so the veneer can be painted. A-
grade plywood is ideal for furniture or cabinet doors.

B-grade plywood also features a smooth, sanded surface, but may have more
repaired defects up to 1-inch across.

C-grade is unsanded and may have several minor defects that will need to be
repaired with knots up to 1 1/2 inches across, discoloration and sanding defects.
C-grade plywood should be used when appearance is not important, such as for
subfloors or garages.

D-grade is also unsanded with defects that have not been repaired and knot holes
up to 2 1/2 inches across, discoloration and sanding defects.

You may also find ratings with two-letter classifications, such as BC. BC-grade
is a mix grade plywood with one side graded a B, while the other side is graded
a C.

Plywood Sizes:

The most common plywood sizes are 4- x 8-feet sheets and 5- x 5-feet sheets.
In this project we have used b grade plywoods and the thickness of plywood’s
are 3 inches width. Seeing as the device would use four wheels in total, it made
c 16

sense for the platform to be rectangular. The width allowed for comfortable
feet placementon the platform, with the user placing their heels together and

pointing their feet slightly outward. The 12” length allowed for more room on
the underside of the platform for electrical and other structural components. As
for the material, simple plywood was selected due to its high strength and
resistance to cracking and bending. Its light weight was also a positive factor as
it helped exert a lower load on the wheels.
c 17

MOTOR:-
We are using 18 volt mega torque planetary DC geared motor this motor
provide high torque with required rpm to run the wheels the motor is very
powerful.
Motor is fixing with the chassis through screwed bolt and it is the main source
of power with is to drive the vehicle. There are two motors, each for one wheel.
Both motor is driven by a 24v battery.

Specifications:
 Rated Voltage: 18VDC
 No load speed: 291RPM
 No Load current: 2.7Amps
 Gear Ratio: 1:61
 Rated Torque: 92kgcm
 Rated Speed: 260RPM
 Rated Current: 18.7Amps
 Motor length without Shaft: 125mm
 Shaft Length: 20mm
 Motor Diameter: 46mm
 Shaft Diameter: 8mm
 Gearbox Breaking Torque: 200kgcm
 Stall current: 130Amps
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MECHANICAL SEGWAY TYRES:-

In mechanical Segway two tyres is used in both the sides. Scooter wheels are
used in Segway reason behind that cost is less, easy to available and friction
property is also less. Also higher amount of weight gaining capacity and
movements is also very smooth.

Tyre Specifications:
 Wheel diameter- 177.8mm
 Material- Combination of rubber and leather.
 Casing material – combination of fiber and plastic.
 Thickness of tyre- 100mm

Fig. Segway wheels

Due of their large size, these models are not particularly popular. They weigh
between 15 and 18 kg, which is comparable to most 8-inch models. however,
it’s usual to come across those who weigh 20 kg. They are sturdy and capable
of supporting at least 150 kg. Inflatable tyres are included with the 10-inch
version. When cycling on gravel surfaces and on grass this kind of
hoverboard wheels are preferable. Different riding styles can be used to make
up for discrepancies in larger wheel sizes. There are silent riding techniques
that are slower but have greater handling. As an alternative, can choose a
hard mode, which offers less comfort but offers excellent take-off speed. As
you gain experience, you will frequently choose the hard option, whereas
beginners who are still perfecting their balance and timing for getting on and
off the large 10-inch hover-board should stick with the gentle mode.
c 19

Supporting wheel is used on Mechanical Segway. The purpose of small

supporting wheel is to balance properly; there is no need to gyroscope for the
balancing purpose. Also easy to assemble and disassemble.[Supporting small
wheel.
Specification:
 Wheel diameter- 63.5mm
 Material - Plastic hard rubber
 Metal casing is used to supporting the wheels and one fixing socket is
provided.

Fig. supporting small wheel

BATTERY: -

Battery is a main power source. One 12V DC battery is used in Mechanical

Segway. Battery connected with each motor. Battery supplies power to each
motor to run the wheels. Battery is rechargeable in electric socket . We are using
lithium ion battery for this project.
c 20

 Battery Specifications: -

 Voltage range- 12V-24V DC (22Ah)

 Current – 2-5Amp.

 Battery weights- 5.9kg

 Grid alloy lead- Calcium tin Alloy

 Container cover- ABS resin

 Electrolyte- Lithium ion

 Size- 181*76*167mm

 Battery type- AGM (Absorbent Glass Mat)

Fig. Lithium ion battery

DPDT (Double Pole Double Throw) SWITCH:-

 Double Pole Double Throw (DPDT) switch. It is used to guide the direction of
rotation of motor shaft. By operating the switch the direction of vehicle can be
controlled. Connecting wires are used to connect switch with motor.
c 21

 DPDT Switch Specifications:  Circuit- DPDT

 Switch Function- On-off-on

 Actuator type- concave (curved)

 Panel cutout dimensions- 30*22.20mm

 Operating temperature- -200C ~550C

 Current rating- 15A (AC)

 Voltage rating- 125V (AC)

Fig. DPDT switch

 22

METHODOLOGY
This project involves the design, analysis, and fabrication of an electric
motorized hoverboard. We used the ply board for outer covering with rider
standing platform and handle. The total four wheels are used in this project the
two man wheels which are powered through the motor and also two Pillar Type
Rubber Castor wheels are provided to balance of the Vehicle in the place of
Gyroscope.

The four-wheeled hoverboard is designed based on the fundamentals of machine

design. After carrying out the required machining operations, the motors, bearings,
drive wheels, swivel wheel, and springs are mounted onto the footplate. Then after
mounting the components under the footplate, the handle is fixed on top of the
footplate. Two DPDT switches are placed in the handle to control the direction of
the hoverboard, and a speed governor is placed in the handle to adjust the speed of
the motor. After making the circuit wiring and connecting the electronics, the
assembly of the segway is shown in the figure. All the switches and the controls of
the motors which kept at the handle to operate are connected with wires. The
wheel motors have two different switches for each wheel so that for turning of
each motor is controlled. When both the switches are pressed forward the segway
will move forward. If the rider wants to turn left the right wheel motor switch will
be used to turn towards the left. If the rider wants to turn right the left wheel motor
switch will be used to turn towards the right.

The speed governor will help to control the speed of the hoverboard.
 23

DESIGN

Fig. Dimensions of Hoverboard

 24

Working principle

The hoverboard base is shaped as shown in Figure to make the object light
in weight as compared to the other materials used for the other bases.
Since the hoverboard is mostly made out of wood, and using
this shape that is made out of wood, it will be easier to support heavy riders
with weights in the range of 60kg to 70kg. The fenders of the hover board
are also made out of wood which provides more than enough protection for
the wheel. The wheels used for this concept are the narrow/thin wheels.
These wheels are Carbon black based which strengthens the elastomer that
encases the cords to protect them from abrasion and hold them in place. This
type of thin wheel is mostly used for flat and smooth surfaces. The thinner t
he wheels, the more the hoverboard become faster. The grip mat used is a
high performance, non-slip, anti-static rubber tool mat keeping the feet in
place, no matter where you need to put them it provides stability.

CALCULATION
Power, P = 2πNT / 60
200 = 2*π*500*T / 60
T = 4 N.m Range = 30 kilometers
Top speed = 25 kmph (in test conditions)
Laden weight = 80 kilograms.
Force, F = ma = 80*25*0.278 / 20 F = 28 N.

Torque required = FR = 28*0.18 = 5.04Nm

Battery working hours (without loss) = volt * ampere hour / motor
Power = 24*18 / 200 = 2 hour.

Motor Specifications RPM = w x r w= 157.0796 rad/s

∴v=157.0796×2=314.159m/s

Force Specifications F = m x V Where, m = mass of user, kg V = velocity,

m/s ∴F=65×31.4159=2042 N
 25
Torque Specifications Torque = F x r
Where, F = Force, N r = Radius of the wheel, m
∴Torque=2042×0.20=408.4 N

Stepping Platform Specifications

Where, W = User Weight, N R = Wheel Support Reaction,

N ¿+ve↻∑ MB=0
∴( RA×0.3 )−(W ×0.15=0 0.3 RA−(65×9.81×0.15)=0 0.3
RA=95.6475
❑⇒ RA=318.825 N

Design Stress Specifications

Where, M = Maximum Bending moment,
Nm y = Half of the profile,
m I = moment of inertia, m4 I= b h 3 12 = 0.3x 0.063 12 =5.4 x 10−6 m 4 ∴σ
d=
My I = (65 x 9.81 x 0.15) x 0.03 5.4 x 10−6 ¿531375Nm2 ¿0.531375 MNm2
 26
Comparing Design Stress with Maximum Allowable Stress

Using the measured values recorded, the value for design stress (σ d ) and
maximum allowable stress (σ a) is calculated using the formulas shown above. The
safety factor calculated is 1.71846. This value is in turned used to calculate the
max. allowable stress. The values obtained for the design stress and the max.
allowable stress has a very slight difference where σ d <σ d This indicates that the
estimated values are correct and the wheels can support the 65 kg person
 27

CONCLUSION

Personal electric vehicles are technically possible now. The price of a personal
electric vehicle that is available on the market is very higher for its range, it uses
cutting-edge technologies which has increased the price. In this project, fabrication
methods are changed. For balancing purposes a sensor is used in the hoverboards
available on the market, but in this project, a support wheel is used to balance the
vehicle. The charging time is higher in this project because a strong battery is
preferable to lower the cost. Thus, the feasibility of a personal electric vehicle
depends on reducing the cost and making it available for every person and
in every place.
Traffic congestion leads to higher vehicle emissions and lower ambient air
quality. There can be no immediate solution to this issue, But another situation
for conventional personal transport is Hoverboard. So the hoverboard are
becoming more popular day by day. But the complex electronics like
accelerometer and Gyroscope make it too expensive.
The project involves the design, analysis, and fabrication of an electric
motorized hoverboard. The total four wheels are used, two power and two
smaller wheel is used to balance the vehicle such that gyroscope is exchange
with pillar type rubber caster wheel for balancing purpose. So our hoverboard is
less expensive with durability and multifunctioning.
In future we are trying to make Hoverboard attached wheel chair for Disable
and elderly person.

Advantages:-

 It is eco-friendly and produces zero carbon emission

 Light weight and good for personal use
 Riding a hoverboard is adventurous
 It improves the posture of the rider for healthy life
 It does not any emit harmful gases
 Lower running cost
 Low maintenance cost
 Easy to drive and quiet
 28
Disadvantage
 The disadvantage of hoverboard is that they are battery powered and needed to be
discharged
 Electrical components may get damaged due to water contact
 Due to battery powered doesn’t have high power to carry heavy duty load
 REFERENCES

1. https://en.wikipedia.org/wiki/Self-balancing_scooter
2. www.ijra.net
3. www.linkedin/marketinghoveroard/.in
4. www.acko.com
5. www.ijarrit.com
6. www.instrucables.com
7. www.voltes.eu
8. www.hoverboards.co.in
9. www.robokits.in
10. www.transporthistory.wordpress.com