A

Major Project Report

On

DESIGN AND FABRICATION OF HYBRID ELECTRIC VEHICLE (TWO WHEELER)

Submitted to

CHHATTISGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY,

BHILAI
in partial fulfillment of requirement for the award of degree of

Bachelor of Technology
In

Mechanical Engineering
SEMESTER 8th
By
Anurag Yadav, 301303719004, BH5210

Prem Verma, 301303719013, BH5219

Shashank Dwivedi, 301303719022, BH5337

Shubham Kumar, 301303719020, BH5226

Krishna Kumar, 301303719006, BH5212

Under the Guidance of

Dr. Rakesh Himte

(Principal)

DEPARTMENT OF MECHANICAL ENGINEERING,

RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY,

KOHKA-KURUD ROAD, BHILAI, CHHATTISGARH, INDIA

Session : 2022-2023
-1-
 DECLARATION

We, the undersigned, solemnly declare that this report on the project work entitled
“DESIGN & FABRICATION OF HYBRID ELECTRIC VEHICLE (TWO WHEELER)”, is based
on our own work carried out during the course of our study under the guidance of Dr. Rakesh
Himte (Principal).

We assert that the statements made and conclusions drawn are an outcome of the project
work. We further declare that to the best of our knowledge and belief the report does not contain
any part of any work which has been submitted for the award of any other degree/diploma/
certificate in this University or any other University.

Signature

ANURAG YADAV
Roll No. -301303719004
Enrollment No. –BH5210

PREM VERMA
Roll No. -301303719013
Enrollment No. –BH5219

SHUBHAM KUMAR
Roll No. -301303719020
Enrollment No. –BH5226

SHASHANK DWIVEDI
Roll No. -301303719022
Enrollment No. –BH5337

KRISHNA KUMAR
Roll No. -301303719006
Enrollment No. –BH5212

i
 CERTIFICATE

This is to certify that this report on the project submitted is an outcome of the project work entitled
“DESIGN AND FABRICTION OF HYBRID ELECTRIC VEHICLE (TWO WHEELER)”,
carried out by the students in the DECLARATION, is carried out under my guidance and
supervision for the award of Degree in Bachelor of Technology in MECHANICAL
ENGINEERING of Chhattisgarh Swami Vivekanand Technical University, Bhilai (C.G.), India.

To the best of my knowledge the report...

i) Embodies the work of the student(s) themselves,

ii) Has duly been completed,

iii) Fulfills the requirement of the Ordinance relating to the B.Tech. degree of the University,
and

iv) Is up to the desired standard for the purpose for which it is submitted.

Dr. RAKESH HIMTE

(Principal)

This project work as mentioned above is hereby being recommended and forwarded for
examination and evaluation by the University,

Dr. SANJAY G SAKHARWADE

Head of Department,
Department of Mechanical Engineering ,
Rungta College of Engineering & Technology,
Kohka - Kurud Road, Bhilai(C.G.), India

ii
 CERTIFICATE BY THE EXAMINERS

This is to certify that this project work entitled “DESIGN AND FABRICATION OF HYBRID
ELECTRIC VEHICLE (TWO WHEELER) ”,

submitted by…

ANURAG YADAV, 301303719004, BH5210

PREM KUMAR VERMA, 301303719013, BH5219

SHUBHAM KUMAR, 301303719020, BH5226

SHASHANK DWIVEDI, 301303719022, BH5337

KRISHNA KUMAR, 301303719006, BH5212

is duly examined by the undersigned as a part of the examination for the award of Bachelor of
Technology degree in Mechanical Engineering of Chhattisgarh Swami Vivekanand Technical
University, Bhilai.

Internal Examiner External Examiner

Name & Signature Name & Signature

Date: Date:

iii
 ACKNOWLEDGEMENT

It is a matter of profound privilege and pleasure to extend our sense of respect and deepest
gratitude to our project guide Dr. RAKESH HIMTE, Department of MECHANICAL
ENGINEERING under whose precise guidance and gracious encouragement we had the privilege
to work.

We avail this opportunity to thank respected Dr. SANJAY G SAKHARWADE, Head of the
Department of Mechanical Engineering for facilitating such a pleasant environment in the
department and also for providing everlasting encouragement and support throughout.

We acknowledge with the deep sense of responsibility and gratitude the help rendered by respected
Dr. Rakesh Himte, Principal, Rungta College of Engineering and Technology, Bhilai for infusing
endless enthusiasm & instilling a spirit of dynamism.

We would also like to thank many people in our college, faculty members of our department, and
the supporting staff for always being helpful over the years.

Last but not least, we would like to express our deepest gratitude to our parents and the
management of Rungta College of Engineering and Technology, Bhilai respected Shri Santosh Ji
Rungta, Chairman, respected Dr. Sourabh Rungta, Director, Technical, and respected Shri
Sonal Rungta, Director, Finance & Administration for their continuous moral support and
encouragement.

We hope that we will make everybody proud of our achievements..

ANURAG YADAV, 301303719004, BH5210

PREM KUMAR VERMA, 301303719013, BH5219

SHUBHAM KUMAR, 301303719020, BH5226

SHASHANK DWIVEDI, 301303719022, BH5337

KRISHNA KUMAR, 301303719006, BH5212

iv
 ABSTRACT

Electric vehicles are considered a new technical green product and a potential industry for many
countries. With the highest scooter per capita density and the major producer of motor scooters
around the world, Taiwan possesses sufficient conditions for developing electric scooters. In this
article, work concerning product design and prototype making of an electric scooter is described,
which was the outcome of a collaborative project for new product development. The final product
was satisfactory, and was designed according to the aesthetic principle of golden section
proportion, and subsequently outer housings were produced with fiber reinforced plastics (FRP) by
hand lay-up process. Not only the product appearance was created, but a prototype of an electric
scooter was also built using various traditional modeling and engineering techniques.

v
 LIST OF TABLES

Table No. Caption Page No.

Table 5.1 Engine specification 17

Table 6.1 Comparisons of different type 18

of motors with advantages and
disadvantages

Table 7.1 Specification of different 20

batteries

Table 8.1 Material chemical composition 21

Table 8.2 Material Mechanical Properties 22

Table 10.1 Cost Details 29

vi
 LIST OF FIGURES

Figure No. Caption Page No.

Fig.6.1 HERO electric Hub Motor & 19
Controller of Motor

Fig.8.1 Standard Dimensions to Be 22

Followed

Outer body Side &

Fig.8.2 Front View 24

Fig.8.3 Chassis Isometric View 24

Fig.8.4 Chassis Side View 25

Fig.8.5 Chassis Top View 25

Fig.8.6 Chassis Front View 26

Fig.8.7 Chassis Back View 26

vii
 TABLE OF CONTENTS

Abstract v
List of Tables vi
List of Figures vii

CONTENTS PAGE No.

CHAPTER 1
Introduction…………………………………………………………………………. 1
1.1. Introduction…………………………………………………………………. 1
CHAPTER 2
Literature Review…………………………………………………………………… 3
2.1. Working principle of HEVs………………………………………………... . 3
2.2. Advantages of HEVs………………………………………………………. . 5
2.3. Challenges Ahead…………………………………………………………… 6
2.4. Opportunities Ahead……………………………………………………….... 7
2.5. Lithium Reserves Revolutionize EVs Sector In India………………………. 8
CHAPTER 3
Problem Identification………………………………………………………………. 9
3.1. Electric vehicles cut your emissions……………………………………….... 9
3.2. Electric vehicles offer you a better driving experience……………………….9
3.3. Electric vehicles cut your oil use……………………………………………..9
3.4. Electric vehicles are convenient………………………………………………9
3.5. Electric vehicles save you money……………………………………………10
3.6. Light weight……………………………………………………………….....10
CHAPTER 4
Methodology……………………………………………………………………….. 12
4.1. Methodology……………………………………………………………….. 12
4.2. Flow chart ………………………………………………………………... 14
CHAPTER 5
Components of Transmission System……………………………………………... 15
5.1. Motor………………………………………………………………………. 15

viii
 5.2. Controller…………………………………………………………………. 16
5.3. Convertor…………………………………………………………………. 16
5.4. Battery…………………………………………………………………….. 16
5.5. Throttle……………………………………………………………………. 16
5.6. Vehicle Theft Detection…………………………………………………….17
5.7. Engine specifications……………………………………………………….17
CHAPTER 6
Motor Selection…………………………………………………………………… 18
6.1. Motor Selection…………………………………………………………… 18
CHAPTER 7
Battery Selection………………………………………………………………….. 20
7.1. Battery Selection………………………………………………………….. 20
CHAPTER 8
Design…………………………………………………………………………….. 21
8.1. Chassis……………………………………………………………………. 21
8.2. Material selection…………………………………………………………. 21
8.3. Standard Dimensions to Be Followed……………………………………. 22
8.4. Outer body design………………………………………...………………. 24
8.5. Chassis Modeling by Using SOLID WORKS 2021……………………... 24
CHAPTER 9
Calculations………………………………………………………………………. 27
9.1. Weight Calculation……………………………………………………….. 27
9.2. Motor Selection Calculation……………………………………………… 27
CHAPTER 10
Cost Details……………………………………………………………………….. 29
10.1. Cost Details……………………………………………………………….. 29
CHAPTER 11
Result……………………………………………………………………………….30
CHAPTER 12
Conclusion………………………………………………………………………… 31

References………………………………………………………………………… 32

ix
x
 CHAPTER -1
INTRODUCTION

1.1 Introduction

The transport sector plays a significant role in air pollution resulting in climate change due to
greenhouse gases (GHG) emissions mostly in urban regions; this has necessitated road transport
electrification, whereby replacing internal combustion vehicles with new energy vehicles like
electric vehicles (EV) seems to be a promising step towards envisaging urban sustainability.
Technologies related to electric-mobility have been changing exponentially; therefore, literature
covering these changes have also increased significantly. Studies covering multiple dimensions of
EV adoption across countries, including charging infrastructure (Chen et al., 2017; Dorcec et al.,
2019), policies and incentives (Sierzchula et al., 2014; Bjerkan et al., 2016; Melton et al., 2017),
business models (Wu, 2019; Nian et al., 2019; Yoon et al., 2019), among others. Review articles
focused on specific aspects of EV adoption have started emerging. For instance, Hardman (2019),
Biresselioglu et al. (2018), and Rezvani et al. (2015) respectively explored the role of reoccurring
and nonfinancial incentives for plug-in hybrid electric vehicle (PHEV) adoption, electric mobility
in the European context, and the drivers and barriers for EV adoption based on theoretical
perspectives.

Although the relatively ample empirical evidence available on the various factors of EV adoption
and advantages of EV has been widely recognized, a question remains: why is the EV adoption so
difficult? What are other critical factors that are still mostly unexplored? For instance, most of the
previous studies have focused on either the antecedents or consequences (Sierzchula et al., 2014;
Berkeley et al., 2018) with less focus on mediating or moderating variables. The relationship
among these variables is still mostly unmapped. Additionally, previous literature mostly focused
on the survey-based studies (Adnan et al., 2018; Sovacool et al., 2019), optimization techniques
(Onat et al., 2016), or secondary data analysis and predictions (Onat et al., 2018; Choi et al., 2018)
to understand the EV adoption in some specific country or regions and may have limited policy
implications. Thus, there is a need to collate these regional insights and draw conclusions
judiciously.

Air pollution is one of the greatest threats in the global context, and in a country comprising of
world second largest population of almost a 130 million (equivalent to 17.7% of world’s
population), people are finding problematic to breath in most of the metropolitan cities. India is
facing some serious air pollution issues since a decade and it is increasing at an alarming rate. The
main cause of this exponential increase in the pollution levels is poor fuel quality, old vehicles,

1
inadequate maintenance, congested traffic, poor road condition and old automotive technologies
and traffic management system. The major pollutants emitted from the automobiles are
hydrocarbons, nitrogen dioxide, lead, carbon monoxide, sulphur dioxide, and particulate matter.
Reason behind large share of vehicular pollution is India’s gigantic automotive industry that is 4th
largest in the world.

2
 CHAPTER-2
LITERATURE REVIEW

Air pollution is one of the greatest threats in the global context, and in a country comprising of
world second largest population of almost a 130 million (equivalent to 17.7% of world’s
population), people are finding problematic to breath in most of the metropolitan cities. India is
facing some serious air pollution issues since a decade and it is increasing at an alarming rate. The
main cause of this exponential increase in the pollution levels is poor fuel quality, old vehicles,
inadequate maintenance, congested traffic, poor road condition and old automotive technologies
and traffic management system.
The major pollutants emitted from the automobiles are hydrocarbons, nitrogen dioxide, lead,
carbon monoxide, sulphur dioxide, and particulate matter. Reason behind large share of vehicular
pollution is India’s gigantic automotive industry i.e., 4th largest in the world. According to the Ref.
[1], the population of electric vehicle in India is increasing at the rate of 37.5%. And the
government is focusing the more concern towards the Electric Vehicles [2] and charging stations
[3]. In reference [4], placement of charging station has been proposed to optimize the charging
stations and provide the maximum power as per the requirement.

2.1. Working principle of HEVs

The working principle of hybrid electric vehicles (HEVs) involves combining the use of an
internal combustion engine (ICE) with an electric motor and battery system. The goal is to
optimize fuel efficiency, reduce emissions, and improve overall vehicle performance. Here's a
basic overview of how HEVs work:

1. Internal Combustion Engine (ICE): HEVs still have a conventional ICE, which can be
powered by gasoline or diesel fuel. The ICE provides the primary source of power for the vehicle
and is responsible for driving the wheels and charging the electric motor's batteries.

2. Electric Motor: HEVs incorporate an electric motor that works in conjunction with the ICE.
The electric motor is used to assist the ICE during acceleration and provide additional power when
needed. It can also operate independently, powering the vehicle solely using electricity.

3
3. Battery System: HEVs have a high-voltage battery pack, usually a rechargeable lithium-ion
battery, that stores electrical energy for the electric motor. The battery pack is charged by
regenerative braking (explained below) and by the ICE, which acts as a generator while running.

4. Powertrain Control Unit (PCU): The PCU is the brain of the HEV's hybrid system. It manages
the power flow between the ICE, electric motor, and battery pack, optimizing efficiency and
performance. The PCU determines when to use the electric motor, ICE, or both, based on factors
such as speed, load, and driver input.

5. Regenerative Braking: HEVs utilize regenerative braking, which converts the kinetic energy
produced during braking into electrical energy. When the driver applies the brakes, the electric
motor switches to generator mode, capturing the energy that would otherwise be wasted as heat
and storing it in the battery pack for later use.

6. Start-Stop System: HEVs often feature a start-stop system that automatically shuts off the ICE
when the vehicle is stationary, such as at traffic lights. When the driver releases the brake pedal,
the electric motor powers the vehicle, and the ICE restarts when needed. This reduces fuel
consumption and emissions during idle periods.

7. Energy Management: HEVs employ sophisticated energy management systems to determine

the most efficient power source for any given situation. The system continuously monitors the
vehicle's parameters, including speed, load, battery charge, and driver input, and optimizes the
power distribution between the ICE and electric motor accordingly.

By combining the ICE, electric motor, and battery system, HEVs can achieve improved fuel
economy compared to conventional vehicles. The electric motor provides additional power during
acceleration, allowing the ICE to operate in a more efficient range. The battery pack stores and
delivers electrical energy, reducing reliance on the ICE and enabling all-electric operation at low
speeds or short distances. This hybridization results in reduced fuel consumption, lower emissions,
and enhanced overall performance for hybrid electric vehicles.

4
2.2. Advantages of EVs
Hybrid electric vehicles (HEVs) offer several advantages compared to conventional vehicles. Here
are some key advantages of HEVs:

1. Improved Fuel Efficiency: HEVs combine the use of an internal combustion engine (ICE) with
an electric motor and battery system, allowing them to optimize fuel efficiency. The electric motor
assists the ICE during acceleration and operates during low-speed driving, reducing the reliance on
the ICE. This combination results in reduced fuel consumption and increased mileage, saving
drivers money on fuel costs.

2. Reduced Emissions: HEVs produce fewer greenhouse gas emissions and pollutants compared
to conventional vehicles. The electric motor assists the ICE, reducing the load on the engine and
allowing it to operate in a more efficient range. Additionally, HEVs can operate in electric mode at
low speeds or in stop-and-go traffic, producing zero tailpipe emissions. This reduction in emissions
contributes to improved air quality and helps combat climate change.

3. Regenerative Braking: HEVs utilize regenerative braking, which converts the kinetic energy
generated during braking into electrical energy. Instead of dissipating the energy as heat, the
electric motor acts as a generator and stores the energy in the battery pack. This feature improves
overall energy efficiency and extends the vehicle's range by recapturing energy that would
otherwise be wasted.

4. Enhanced Performance: HEVs often have a combination of an ICE and an electric motor,
providing a power boost during acceleration. The instant torque of the electric motor improves the
vehicle's responsiveness, resulting in quicker acceleration and a smoother driving experience. This
combination of power sources allows HEVs to offer comparable or even superior performance to
conventional vehicles.

5. Flexibility and Range: HEVs provide the flexibility of operating in different modes. They can
run solely on the electric motor, solely on the ICE, or a combination of both, depending on the
driving conditions and battery charge. This flexibility eliminates range anxiety associated with
pure electric vehicles (EVs) and allows HEVs to be used for longer trips without the need for
frequent recharging.

5
6. Potential for Future Transition: HEVs serve as a transitional technology in the move towards
fully electric vehicles. They help bridge the gap between conventional vehicles and EVs by
familiarizing drivers with electric propulsion while still offering the convenience of a conventional
refueling infrastructure. HEVs also contribute to the development of advanced battery and electric
motor technologies that can be applied to EVs.

Overall, hybrid electric vehicles provide improved fuel efficiency, reduced emissions, enhanced
performance, and flexibility, making them an attractive option for environmentally conscious
drivers who seek a balance between fuel economy and the benefits of electric propulsion.

2.3. Challenges Ahead

Presently, there are many more challenges to establish the Electric Vehicle future. The major role
to run the Electric Vehicle in India is power generation. Without electricity, we cannot imagine
Electric Vehicle future. Therefore, responsibility of distribution network increases to supply the
proper electric power without failure. Which can be possible by proper monitoring of the network.
Phasor Measurement Unit (PMU) [6-10] measure the voltage and current in real time and protect
the network from any failure. In reference [11], voltage stability problem has been discussed and
resolve by using the PMU which is installed and the power system buses.
A. High cost:
The cost of buying EV is quite high when compared to that of an ICE vehicle i.e., the average cost
of electric cars in India is around 13 Lakh (INR), which is much higher than the average INR 5
Lakh for economical cars that run on traditional fuel. These are mainly due to the lithium import
for battery making and since batteries make up to about 50% cost of the vehicle therefore EVs are
costlier. Lithium is a rare metal which has its high reserves in countries like Chile, Australia, and
Argentina.
B. Lack of charging infrastructure:
The main hindrance behind commercial viability of EVs in India is inadequate charging
infrastructure. India only had 650 charging stations in 2018, whereas China had over 456K
charging points in the same year. Other reason creating issue is charging time. Battery charger
efficiency according to the present available technologies all over the world varies in percentage
from low 70s to high 90s [12].

6
C. Range anxiety:
Range anxiety is one of the most significant roadblocks to EV adoption. EVs generally have
shorter range which causes charging fear in consumer’s mind. At present longest-range EV
available is Tesla’s model S which has a range of 370 miles per charge. But since Tesla has not
entered the Indian market so Indians do not have reach to this high range vehicle. EVs available in
India do not have range more than 500 km per charge. This is deeply associated to the lack of
charging infrastructure in the country, and while conventional vehicles can be refueled at petrol
stations, such is not the case when it comes to EVs.

2.4. Opportunities Ahead

The hybrid electric vehicle market is set to expand owing to the ambitious plans and initiatives of
the government. The government has taken a number of steps to incentivize and promote the
deployment of electric vehicles and public charging infrastructure to achieve significant
electrification by 2030. India is targeting to reduce its excessive oil imports and curb pollution
levels across cities in the coming years. Hybrid electric vehicles will play an important role in
achieving this target.

INDIA’S POLICY ON ELECTRIC VEHICLES:

In 2012, the National Electric Mobility Mission Plan (NEMMP) 2020 was established, under
which an incentive scheme, Faster Adoption and Manufacturing of Hybrid and Electric Vehicles
(FAME), was launched in 2015 to reduce the cost of hybrid and electric vehicles and to encourage
their penetration in the market. The FAME scheme offers a subsidy on the retail price of passenger
cars. These subsidies range from INR 11,000 – 24,000 for mild hybrids, from INR 59,000 – 71,000
for strong hybrids; and from INR 60,000 – 1, 34,000 for electric vehicles. Subsidies are also
available for two-wheelers, three-wheelers, light-commercial vehicles and buses. The subsidy from
the FAME scheme is not the only incentive mechanism that impacts the market for hybrid and
electric vehicles in India. The Central Government of India and some state governments, such as
the Government of National Capital Territory of Delhi (NCT of Delhi), provide tax incentives that
treat hybrid and electric vehicles preferentially over conventional technologies. As per the recent
announcements made by finance minister Nirmala Sitharaman, during the union budget 2020
presentation, the government has increased the import duty on electric vehicles to promote make in
India.

7
2.5. Lithium Reserves Revolutionize EVs Sector in India
Reserves of lithium, a rare metal critical to build batteries for electric vehicles, have been
discovered in Mandya, 100 km from the Bangalore. This will be the breakthrough in local
manufacturing of EV batteries. Researchers at the Atomic Minerals Directorate, a unit of India's
Atomic Energy Commission, have estimated lithium reserves of 14,100 tonnes in a small patch of
land surveyed in the Southern Karnataka district. Among the other countries, Chile is estimated to
have lithium reserves of up to 8 million tonnes while 2.8 million tonnes have been found in
Australia. Argentina is reported to have lithium reserves of up to 1.7 million tonnes. According to
the data, Portugal also has 60,000 tonnes of lithium reserves, which are substantially higher in
number when compared to the lithium reserves in India. The details of lithium-ion battery have
been given in [13].

8
 CHAPTER-3
PROBLEM IDENTIFICATION

3.1. Electric vehicles cut your emission: Even when the electricity used to fuel an EV
comes from the dirtiest coal-dominated grid in the US, EVs still produce less global warming
pollution than their conventional counterparts. The average EV in the US today produces emission
equivalent of a gasoline car that gets 73 miles per gallon. The emission performance of EVs is set
to only improve as wind and solar power displace coal-fired electricity generation. Many EV
owners are also choosing to pair their EV with rooftop solar panels and home energy storage units.
When powered exclusively by renewable energy, an EV can operate nearly emissions free.

3.2. Electric vehicles offer you a better driving experience: An electric engine
generates instant torque, which means that electric vehicles zoom off starting lines and provide
smooth, responsive acceleration and deceleration. Electric vehicles also have a low center of
gravity, which improves handling, responsiveness, and ride comfort.

The driving performance of electric vehicles has been recognized in race series like Formula
E or local drag strips and attested to by thousands of electric vehicle drivers across the country.

3.3. Electric vehicles cut your oil use: Electric vehicles are an essential part of the UCS
plan to cut the nation's oil use in half in twenty years. Using oil causes an array of problems, and
transportation remains reliant on oil as the dominant energy source. Electric vehicles offer the
potential to disrupt this status quo relationship between transportation and oil, and offer a cleaner,
better way to fuel transportation for everyone. Overall, electric vehicles can cut US oil use by 1.5
million barrels a day by 2035.

3.4. Electric vehicles are convenient: Instead of searching for a gasoline station with the
cheapest prices, you can charge at home at a cheaper and much more predictable cost. And
plugging in at home takes only a few seconds and lets you wake up with a “full tank” every
morning. EVs also have other convenient advantages. Battery electric vehicles are mechanically
much simpler than a conventional gasoline car, so the maintenance requirements are often much
simpler and, for this reason, cheaper to maintain. Drivers of electric cars do not have to change
their car’s motor oil every 5,000 to 10,000 miles, and they never have to schedule spark plug

9
changes, timing belt replacements, or other engine tune up items. Depending on your location, EVs
have additional benefits, like access to restricted express lanes on highways and bridges, special
parking spots, and reduced or free tolls.

3.5. Electric vehicles save you money: No matter where you plug in across the country,
electric vehicles are cheaper to fuel than their gasoline-powered counterparts. Every electricity
provider in the 50 largest US cities offers a rate plan that makes filling up on electricity cheaper
than gasoline, adding up to a median yearly savings of over $770.

Electric vehicles can also save you on maintenance costs. Battery EVs have no gasoline engine,
they do not need oil changes, spark plugs, or timing belts, and unlike gasoline motors, electric
motors required no routine maintenance. These reduced maintenance costs can save an EV owner
over $1,500 over the life of the vehicle, compared to a gasoline-powered version of their vehicle.

3.6. Light weight: Vehicle weight is a major determiner of drive range. A 10% weight
reduction can improve fuel economy up to 8%. Unfortunately, electric drive trains and batteries are
significantly heavier than ICE power trains. To counteract the increased weight of electric power
trains, vehicle manufacturers are incorporating advanced lightweight materials into the vehicle
body. Replacing conventional materials with lightweight magnesium and aluminium alloys or
carbon fiber can reduce the weight of a vehicle body and chassis by up to 50%. Vehicle
manufacturers must incorporate these materials intelligently and ensure that weight reductions do
not compromise vehicle safety.

Drive range is also impacted by the size and chemistry of the vehicle batteries. Many EVs
currently on the market are adapted from pre-existing ICE vehicles. Due to differences in the
packaging of ICE and electric power trains, these non-native EVs compromise battery size to fit
into the existing architecture. Manufacturers are shifting to modular native EV platforms, both to
better accommodate electric power trains and to support high-volume production. Native EV
platforms can accommodate battery packs that are up to 25% larger, providing greater drive range,
and support flexible power train configurations.

According to a report, many entrepreneurs and start-up companies are scrambling to develop
innovative EV motor technology. One of them is Saietta Group, a UK-based firm pinning its hopes
on a new motor that is suitable to a wide range of electric vehicle applications. Its axial flux

10
traction (AFT) motor is modular, lightweight and affordable. The unique design features a dual
rotor, axial flux permanent magnet combined with distributed windings and a yokeless stator.
Saietta’s first commercial offering, the AFT 140, is designed for use in mid-sized motorcycles and
final-mile delivery vehicles. But the company claims that other versions of the AFT motor caused
in other types of EVs.

11
 CHAPTER-4
METHODOLOGY
4.1. Methodology
Flow of our work is as follows:
1. Literature Review
a. Make review on other model and type of scooters
b. Focusing on how to make it simple and relevance to the project title.

2. Design Calculation
a. Calculation of torque and power required to drive the vehicle.
b. Estimating wheel size

3. Design Layout
a. Designing of block/circuit diagram
b. Arrangement on chassis

4. Market Survey
a. As per our design calculation we visited few suppliers and as per the availability and cost -
motor, battery, tyre and controller selection is done.

5. Modification Design
a. As per the parts available the design has been modified

6. Fabrication model refinement

a. Fabricate the scooter according to the design.
b. Mount the transmission system on the chassis

7. Prototyping Development
a. Assemble all the part to the design.

8. Testing
a. Run the model

12
b. Tuning of prototype according to problem if any

9. Documentation
a. Preparing a report for the project

13
 4.2. Flow Chart

LITRATURE
REVIEW

DESIGN
CALCULATION

DESIGN
LAYOUT

MARKET
SURVEY

MODIFICATION

FABRICATION

PROTOTYPE
DEVELOPMENT

TUNING
TESTING

DOCUMENTATION

14
 CHAPTER-5
COMPONENTS OF TRANSMISSION SYSTEM
5.1. Motor

A motor is an electrical machine which converts electrical energy into mechanical energy. The
principle of working of a DC motor is that "whenever a current carrying conductor is placed in a
magnetic field, it experiences a mechanical force". The direction of this force is given by Fleming's
left-hand rule and its magnitude is given by
F = BIL
Where, B = magnetic flux density,
I = current and
L = length of the conductor within the magnetic field.

Fleming's left-hand rule: If we stretch the first finger, second finger and thumb of our left hand to
be perpendicular to each other and direction of magnetic field is represented by the first finger,
direction of the current is represented by second finger then the thumb represents the direction of
the force experienced by the current carrying conductor.

15
5.2. Controller
The core function of a DC motor controller is to periodically read the throttle setting and adjust the
current being supplied to the motor. It does this with a technique called pulsewidth modulation or
PWM (more on this later).
Other functions of the controller include:
1) Low-voltage cutoff: Monitor the battery voltage and shut down the motor if the battery voltage
is too low. This protects the battery from over-discharge.
2) Over-temperature cutoff: monitor the temperature of the FET power transistors and shut down
the motor if they become too hot. This protects the FET power transistors.
3) Over-current cutoff: reduce the current to the motor if too much current is being supplied. This
protects both the motor and the FET power transistors.
4) Brake cutoff: shut down the motor when the brake is applied. This is a safety feature. if the user
applies brake and throttle, the brakes win.

5.3. Converter (DC to DC)

A DC-to-DC converter is an electronic circuit or electromechanical device which converts a source
of direct current (DC) from one voltage level to another. It is a type of electric power converter.
Power levels range from very low (small batteries) to very high (high-voltage power transmission).
It is used in electric scooters to reduce the voltage to 12v, since the electrical accessories
(headlight, taillight, side indicators, etc.) works on 12v and the motor requires a high voltage.

5.4. Battery
A battery is an electrical cell device that converts chemicals energy into electricity. The battery
also consists of two or more cells connected in series or parallel, but the term is also used for
single cells. A battery has both positive electrode and negative electrode.

5.5. Throttle
A throttle for an electric bike is used to control the speed of the motor. The throttle changes the
motor speed as per the input from the user. Basically, it consists of Hall Effect sensor, which
senses the change in position of the throttle and limits the voltage supplied to the motor. It is one
of the essential parts of an electric scooter.

16
5.6. Vehicle Theft Detection
The main purpose of this project is to prevent vehicle theft. This functionality is achieved by
detecting vehicle status in theft mode and by sending an SMS which is generated automatically.
This SMS is then sent to the owner of the vehicle. The owner can then send back the SMS tin order
to disable the ignition of the vehicle. Thus, in this way crimes can be reduced to a great extent as
vehicles today are being stolen in large number.

5.3. Engine Specification

Displacement 109.2 cc
Max. Power 8 bhp @ 7,500 rpm
Max. Torque 8.83 Nm @ 5,500 rpm
Mileage - ARAI 61 kmpl
Mileage - Owner Reported 45 kmpl
Riding Range 300 km
Top Speed 82 kmph
Transmission Automatic
Transmission type V-matic
Gear Shifting Pattern --
Cylinders 1
Bore 50 mm
Stroke 55 mm
Valves Per Cylinder 2
Compression Ratio --
Ignition --
Spark Plugs 1 Per Cylinder
Cooling System Air Cooled
Clutch --
Fuel Delivery System --
Fuel Tank Capacity 5.3 Litres
Reserve Fuel Capacity --
Emission Standard --
Fuel Type Petrol

Table 5.1 Engine specification

17
 CHAPTER-6
MOTOR SELECTION
6.1. Motor Selection
HUB MOTOR - Ideally, the term hub motor refers to a motor that replaces the hub of a wheel.
Sometimes this can be a flat disk motor, other times it is not a disk motor. In either case, the motor
is the hub, instead of being mounted beside it or near it.

TYPE ADVANTAGES DISADVANTAGES APPLICATIONS TYPICAL

DRIVE

BRUSHLESS Long lifespan High initial cost Hard drives Multiphase

DC MOTOR requires a controller CD/DVD players D.C
High efficiency
Electric vehicles
Low
maintenance

BRUSHED Low initial cost High maintenance Treadmills PWM

DC MOTOR (brushes) limited exercisers (pulse
Simple speed lifespan automotive width
control starters toys modulation

HUB No interaction Adds weight to Electric bikes Direct

MOTOR with the primary wheels
scooter chain Electric bicycles
required Torque factors can
enter operational
No additional considerations
transmission
system required

Table 6.1 Comparisons of different type of motors with advantages and disadvantages

18
Hence, this is very compact and suitable for our requirements therefore based on the information
listed in table 250-W rear hub motor is selected with the following performance details:
• Model: Hero Optima++
• Rear Hub Motor Voltage: 48 V (brushless)
• Power Rate: 250 W
• Weight: 10 Kg

Figure 6.1 HERO electric Hub Motor & Controller of Motor

19
 CHAPTER-7
BATTERY SELECTION

7.1. Battery selection

• Batteries are electrochemical devices that store energy in form of chemical energy and
convert it into the form of electrical energy.
• The above table shows that Lithium-Ion batteries have the high energy density,
efficiency, energy density, and also it is light in weight, compact size which helps to
determine the type of battery required i.e. Li-on battery.

SPECIFICATION Ni-Cd Ni-MH Li-ion

Specific Energy 45-60 6-120 100-260
(Wh/kg)
Energy Density 50-150 150-300 250-700
(Wh/L)
Specific Power 150 260-1000 250-350
(W/Kg)
Charge/Discharge 70-80 65 80-90
Efficiency (%)
Cycle Durability 2000 200-2000 1200
(cycle)

Table 7.1 – Specification of different batteries

20
 CHAPTER-8
DESIGN
8.1. Chassis
• Chassis is the structural foundation of a vehicle upon which all other components are
getting to be fabricated.
• The main function of the Chassis is to provide safety, carry the utmost load, and hold
all the components during running.
8.2. Material selection
• Here “Mild carbon Steel (AISI 1018.)” is used for manufacturing the chassis because
of following reasons –
i. Less density
ii. Good strength
• We used 1.25-inch diameter, 2mm thickness seamless pipes for the complete frame.

Element Content

Carbon, C 0.14 - 0.20 %

Iron, Fe 98.81 - 99.26 %

Manganese, Mn 0.60 - 0.90 %

Phosphorus, P ≤ 0.040 %

Sulphur, S ≤ 0.050 %

Table 8.1 -Material chemical composition

21
 PROPERTY VALUE

Density 7.87 g/cc

Ultimate Tensile 440 MPa

Strength
Yield Strength 370 MPa

Modulus of elasticity 205 GPa

Table 8.2-Material Mechanical Properties

8.3. Standard Dimensions to Be Followed-

Fig. 8.1. Standard Dimensions to Be Followed

Where,
L1: Wheelbase =1200 mm

L2: Overall length = 1240 mm

22
HI: The height between the wheel axle and ground -235 mm

H2: The height between the pivot of the rear absorber and ground -520 mm

H3: The height between the rear end of the main frame and ground -645 mm

H4: The height between the absorber head of the front forks and ground=610 mm

H5: The height between the steering bearing and ground=745 mm

H6: The height between the joint of the handlebar and ground=870 mm

H7: The height between the outer sides of the handlebar and ground=1020 mm

WI: Wheel width = 120 mm

W2: Handlebar width =555 mm

W3: Main frame width=320 mm

u: The included angle between the axle center line of the front absorber and the perpendicular =28°

v: The included angle between the axle center line of the rear absorber and the perpendicular =38°

23
8.4. – Outer Body Design -

Fig8.2 – Outer body Side & Front View

8.5. Chassis Modeling by Using SOLIDWORKS 2021-

Fig8.3 – Chassis Isometric View

24
Fig8.4 - Chassis Side View

Fig8.5- Chassis Top View

25
Fig8.7- Chassis Front View

Fig8.8- Chassis Back View

26
 CHAPTER-9
CALCULATIONS
9.1. Weight Calculation
To calculate the weight of the vehicle built the following values are taken into consideration.
1. Chassis weight: 35 kg
2. Weight of ancillary components: 4 kg
3. Weight of brakes: 3.9 kg
4. Weight of suspension systems: 6.5 kg
5. Weight of battery: 20 kg
6. Weight of Motor: 4.5 kg
7. Engine weight : 20 kg
Therefore, the total kerb weight is: 97.7 kg
The weight of passengers (75 kg x 2) = 150 kg
Therefore, gross vehicle weight = Kerb weight + Passenger weight = 97.7 + 150 = 247.7 kg
Hence GVW constraint of 300 kg is maintained.
9.2. Motor Selection Calculation
To calculate the motor power and torque rating the given parameters are considered.
• Gross Vehicle Weight (kgs): 300
The power required to move the vehicle from standstill (0 km/h) to (30 km/h) is calculated as
follows:-
The three contributing forces are computed –
1. Rolling Force = Co-efficient of rolling friction * vehicle mass (m) * acceleration due to
gravity (g)
= 0.022 * 300 * 10 = 66 N (For asphalt roads Cr=0.022)

2. Gradient Force = m * g * gradient angle

= 300 * 10 * sin (5) = 261 N (Angle of incline Φ is 5)

3. Aerodynamic Force = 0.5 * Co-efficient of air friction * Cross sectional area * Air
density * Square of air velocity
(Cd value is 0.34 for
= 0.5 * 0.34 * 0.1875 * 1.2 * 8.3 * 8.3 = 2.63 N
frontal area A=0.187
m2)

(Density of air 1.2 kg/

m3)

27
 Ftotal = Frr + Fgrad + Faero
= 66 N + 261 N + 2.63 N
= 329.63 N
 Total Power = (Ftotal * Average-speed)/3600
= (329.63 N * 30)/3600
= 2.74691 kW

28
 CHAPTER-10
COST DETAILS
10.1. Cost Details

PARTS COST (₹)

Motor 12000

Battery 28000

Controller 3500

Throttle 500

Converter Circuit 500

Rear +front wheel 5000

Anti-Theft System 800

Chassis 3000

Shock Absorber 1000

Light Equipment 1500

Wiring 1500

Charger 3000

G.P.S. 1000

TOTAL 61300

Table 10.1. Cost Details

29
 CHAPTER-11
RESULT
The following observations are obtained as a result –
 Peak power – 2500 watt (BLDC Motor)
 Speed – 60 Kmph
 Range/Charege – 80 km
 Charging Time – 3.5 hour

30
 CHAPTER-12
CONCLUSION
Electric scooters are considered a new technical green product and a potential industry for many
countries. With the highest scooter per capita density and the major producer of motor scooters
around the world, Taiwan possesses sufficient conditions for developing electric scooters. In this
article, work concerning product design and prototype making of an electric scooter is described,
which was the outcome of a collaborative project for new product development. The final product
was satisfactory, and was designed according to the aesthetic principle of golden section
proportion, and subsequently outer housings were produced with fiber reinforced plastics (FRP) by
hand lay-up process. Not only the product appearance was created, but a prototype of an electric
scooter was also built using various traditional modeling and engineering techniques.

31
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