TABLE OF CONTENT

Sr. No. Title Page No.

• ABSTRACT

Chapter 1 INTRODUCTION
• INTRODUCTION
• BLOCK DIAGRAM
• TYPES
• PROBLEMS SOLVED
• OBJECTIVES
• APPLICATION
• ADVANTAGES
• DISADVANTAGES

Chapter 2 Literature Survey

• Actual literature survey

THEORETICAL VIEW & PROJECT

Chapter 3 BACKGROUND

Chapter 4 MATERIALS AND MACHINES USED

Chapter 5 PROPOSED METHODOLOGY

Chapter 6 RESULT AND DISCUSSION

Chapter 7 CONCLUSION
Chapter 8 REFERENCE & BIBLOGRAPHY
 ABSTRACT

Electric scooters also give increased mobility to individuals who suffer from various
health issues. These conditions may make it difficult for them to walk, bike, drive or use
other
modes of transportation. In these cases, electric scooters provide the best replacement.
This is because they require no peddling or frequent movement, which means users rarely
get fatigued using it .

Additionally, an electric scooter also opens up other options for users. Most disabled
people find it difficult to walk to public transport stations. However, with an electric
scooter, they
can travel and access these stations much easier.

This electric three wheeler scooter consists of a electric motor , metal links attached on
the frame of scooter . the electric motor is mounted on the front handle with the help of
bolt in such a way that when the ignition switch is on then the power is supplied to the
electric motor and the scooter able to move forward .

The Key Components in Electric Scooter Following are the key components in Electric
Scooter:-

• Metal frame
• Battery Charger
• Battery
• Motor Controller
• Motor
• DC-DC Converter
• Disc brake
• Throttle and ignition switch
• CHAPTER -1
INTRODUCTION
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

1.1 INTRODUCTION

Fig.1

In these project the simple component parts, an electric -scooter consists of a battery, motor,
throttle and controller. And out of these parts, the battery and motor are two of the most
essential components of an electric scooter.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

When a rider twists the throttle on the handlebar, the controller reacts by commanding the
battery to send electric energy to the motor which is mounted on the hub of the wheels. The
motor uses this energy to rotate the gear which then moves the wheels of the electric scooter
forward.
Like regular kick scooters, some e-scooters need to be pushed off the ground using a foot
while twisting the throttle to engage the motor. They might also need to be maneuvered using
the t-stem handlebars and stopped using brakes. The speed at which the scooter can go will
depend on the throttle.
The battery is the main energy storage. The battery charger is to convey the electricity from
mains to charge the battery. The battery voltage is DC and current (I) is inverted into
switched-mode signal through power electronic controller to drive the motor. The other
electronic components in a vehicle can be supplied to the battery through DC-DC converter
that step down the voltage from the battery pack to lower voltage such as 5V-20V .
Specific design elements are dictated by the power source.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

1.2 BLOCK DIAGRAM

Fig.2

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

1.3 Types of electric scooters / (e-bikes)

There are four kinds of e-bikes/scooter available as per automobile classification :-

1. An electric cycle (e-cycle)
2. An electric moped (e-moped)
3. An electric scooter (e-scooter) with 25 kmph as the maximum speed
4. An e-scooter with >25 kmph as the maximum speed

Electric cycle (e-cycle)

The e-cycle can be used by anybody of any age and requires no driving license, vehicle
registration, or vehicle insurance. It has a maximum speed of 25 kmph. It can be used by
only one person, the rider; the power is insufficient to carry a pillion rider. The rider may
need to pedal when riding uphill or against a headwind, again because of limitations of
power.
Electric moped (e-moped)
The e-moped has 25 kmph as the maximum speed. It is equipped with a low wattage (<250
W) motor and a low capacity battery. Like the e-cycle, users do not require a license, and
the bike requires neither motor vehicle registration nor motor vehicle insurance.

The e-moped cannot carry a pillion rider because the battery capacity is too low. It has a
modest range per charge, again because the battery capacity is low. The 25 kmph speed
limit can be frustrating when there is little traffic. It is only practical for young riders whom
parents do not wish to trust with a regular scooter.

Electric scooter (e-scooter) with restricted speed

The e-scooter with 25 kmph as the maximum speed is very similar to the e-moped except in
that it has the body of a scooter rather than that of a moped. It is also equipped with a larger
capacity battery. This allows it to carry a pillion rider. This also allows it a range that is
greater than that of a regular e-scooter (see below). The reason for the greater range is that
the battery capacity is the same but the maximum speed is less; so energy utilization
becomes more efficient.

This scooter is little different in general appearance from ordinary petrol scooters.

Like the e-moped, users of this vehicle do not require a license, and the bike requires
neither motor vehicle registration nor motor vehicle insurance. As with the e-moped, the 25
kmph speed limit is frustrating when there is little traffic. It is only practical for young
riders whom parents do not wish to trust with a regular scooter.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

Electric scooter (e-scooter) with higher speed

The e-scooter which can exceed 25 kmph is a practical vehicle for regular commuters.
These e-bikes comfortably cruise at 30-40 kmph and some can cross 50 kmph. These bikes
are powered by a 500-750 W motor. These bikes are little different in appearance from
ordinary petrol scooters. The batteries are located under the seat.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

1.4 PROBLEMS SOLVED FROM THESE PROJECT

• E-bikes are nothing but vehicles that run on electricity. India is one of the largest two-
wheeler marketplaces in the world, and as concerns about pollution and fuel prices
have grown, electric scooters have gained popularity as an alternative to classic
gasoline-powered scooters.

• Electric scooters are produced and sold by a number of businesses in India, with prices
ranging from affordable alternatives to high-performance versions. In India, there are
several popular brands that are into electric vehicle manufacturing and it is easy to
pick your desired one.

• Electric scooters have grown to popularity in India in recent years. This is due to its
cost-effectiveness and environmental friendliness and many more. Let us look at some
of their benefits.

• Electric scooters check all the tick boxes and save so much concerning to the
environment.

• Since they produce zero emissions, they have not impact in damaging the air quality
—solving a significant air problem “The Air Pollution”.

• Using electric scooters can significantly reduce air pollution in a nation where it has
risen to dangerous levels.

• Apart from it, its rechargeable batteries lower the usage of non-renewable resources
like petrol and diesel.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

1.5: Applications
Following are some of the applications where this electric scooter can be used:-
• Use in a production line for transporting the finished workpieces .
• Can be used to travel in short distances 5 km to 10 km .
• Use in workshops for transport the small Quantity load about 100kg .
• Use in daily transport for saving time in traffic jams .
• Use in airports to carry the goods and load of the passengers .
• Use in the military .
1.6: Advantages
• Safe, convenient, and easy to use
• Light and portable
• Relatively eco-friendly
• Low operating costs
• Easy repair and maintenance
• Perfect for short distances
• Can skip traffic jams
• Less noise pollution
• No need for permits or a license
1.7: Disadvantages

• Lack of exercise.
• There can be battery issues.
• Lack of insurance.
• Only for short distances
• Low weight capacity

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1.8: Future Scope

Following are some of the improvements and enhancement that can be made:-

• The battery and the load carrying capacity of the vehicle can be increased .
• The size of the vehicle can be increased as per the requirement .

• Many large two-wheeler manufacturers are spending millions of dollars on research and
development to improve the technologies used in e-scooters .

• When it comes to operating costs, e-scooters are significantly less expensive. You might
be surprised to learn that a single kilometer on an electric bike cost only Rs 0.35. On the
other hand, petrol-powered bikes will cost you around Rs 2.20 to travel one kilometer.

• In an effort to boost e-scooter sales, the central government announced a vehicle cost
subsidy under the revised Faster Adoption and Manufacturing of Hybrid and Electric
Vehicles-II (FAME-II) scheme.

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CHAPTER -2
LITRERATURE SURVEY
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

2.1 Actual Literature Survey

TOPIC :-Design and Development of Electric scooter

Date of published:- 05 may 2020 in international journal of engineering and

technology

Author :
Prof. Mahesh S. Khande , Mr. Akshay S. Patil , Mr. Gaurav C. Andhale , Mr. Rohan S. Shirsat .

Abstract:
This Paper studies about design and development and the comparison of different part
of components. Also electric two wheeler components like Battery, Charger, BLDC
motor, Controller, Dc-Dc Converter explain in this paper. Indian two-wheeler industry
has embraced the new concept of Electric Bikes and Scooters that are very popular
mode of personal transport in the developed countries like America, Japan and China.
So the electrically charged bikes or scooters have very bright future in area of personal
transportation.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

TOPIC :- Recent Development on Electric Vehicles

Date of published :- 15 April 2016 at International Conference on Power Electronics

Systems and Applications, Hongkong

Author: K.W.E CHENG

Abstract:

This paper provide an overview of the recent work of electric vehicle in the region.
The paper describes the development and the comparison of different part of components.
The major components in battery technology, charger design, motor, steering and braking
are examined. The paper finally shows some electric vehicle prototype as a conclusion of
the papers.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

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• CHAPTER 3
THEORETICAL VIEW &
PROJECT BACKGROUND
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

3.1Theoretical View & project background:

An electric scooter, also called e-scooter, is a battery-powered motor-driven two-wheeler. The

main source of energy to propel the electric scooter is electricity which is considered the cleanest
form of energy.

An electric scooter does not have an engine to drive the wheels, instead it consists of an electric
motor that turns the wheels.

Since, there is need of electricity to drive the motor of the e-scooter. Hence, a rechargeable
battery is used that provides required electrical energy.

However, the design of the electric scooter looks similar to a traditional scooter, but the internal
architecture and mechanism are completely different.

Today, electric scooters are gaining popularity as an easy to drive and eco-friendly mode of
transportation.

Firstly, the electric scooter is started by supplying DC power from battery to the electric motor,
for this a start button is provided on the control panel.

Then, the rider moves the throttle control that sends an electric signal to the controller. The
controller releases a controlled amount of electrical energy from the battery pack to an electric
motor.

The electric motor drives the wheels of the scooter using the electric power and propels it
forward. This is how an electric scooter works.

Let us now discuss the components used in an electric scooter and their function.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

Component of Electric Scooter

An electric scooter consists of a large number of mechanical and electronic components to

perform various functions like propulsion, control, etc.

Some major components of an electric scooter and their functions are explained below −

Outer Frame

Fig.2

It is the main body of the electric scooter that provides complete housing and support to all the
components of the scooter. It is usually made up of a lightweight material like aluminum.

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Electric Motor

Fig.3

In electric scooters, the electric motor is the main device that produces propulsion power to
rotate the wheels. It can be a brushed dc motor or brushless dc motor (mostly preferred).

Battery Pack

Fig.4

The battery pack stores electrical energy to power the motor and other electronic systems of the
electric scooter. It typically consists of batteries of 150 W/h to 625 W/h capacity. However, this
capacity can be of up to a hundred Wh. The most common type of battery used in electric
scooters is the rechargeable lithium-ion battery due to mature technology.

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Troller Control / throttle

It is nothing but the accelerator device used to control the speed of the scooter. It sends control
signals to the main controller.

Fig.5
Controller

Fig.6

It is another important component of an electric scooter. The controller is an electronic system

that controls the speed and other functioning of the scooter according to rider’s instructions. One
of the primary functions of the controller is to regulate the electric current supplied to the motor
as per the throttle control.

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Charging Port

It is the component provided to plug the battery charger to recharge the scooter’s battery pack.
It is located on the outer frame of the scooter and covered with a protective lid.

Control Panel

Electric scooters typically consist of a control panel with graphical user interface. It mainly has
a digital display to show information like speed, battery level, and more. Also, it has various
switches to control different functions.

An electric scooter consists several other components as well depending on the model and
manufacturer. All these components work together to provide a convenient and eco-friendly
mode of mobility.

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 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

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• CHAPTER 4
MATERIALS &
MACNINES
USED
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

4.1 LIST OF MATERIALS USED FOR FABRICATION

Sr.no Name of parts/material used Quantity

1. Mild steel bar 01
2. Fork of bicycle 01
3. Mild steel round bar 02
4. Nuts & bolts of different sizes -
5. Wooden ply sheets 02
6. Electric motor 01
7. Batteries 02
8. Wheels 02
9. Sprockets 02
10. Disc Brake 01
11. Throttle 01
12. Controller 01

4.2 LIST OF MACHINES USED FOR FABRICATION

Sr.no Name of machine used Quantity

1. Arc welding machine 01
2. Cutting machine 01
3. Drilling machine 01
4. Grinding machine 01

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• CHAPTER 5
PROPOSED
METHODOLOGY
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

5.1 METHODOLOGY:

1. First of all make the list of required materials for the project and prepare the costing
bill of the material .

2. Fix/ weld the square bar in to the rectangle shape for the base of the chassis .

3. Then we prepared the fork for both the wheels for rear & front wheel .

4. The disc of the disc brake is mount on the front wheel of the scooter .

5. After the braking system the holes are to be drilled for fixing the suspensions on the
rear wheels .

6. The rod is to be welded on the rectangular body on which the four holed plate is
welded on which the motor is to be clamped by nut & bolts .

7. The whole circuit i.e. Battery packs &controller is fixed in the rectangle frame .

8. The whole circuit is located below the wooden ply sheet on which the driver is to be
stand .

9. The accelerator / throttle is mounted on the handle and the brake lever is also located
on the handle .

10.With the help of the grinder we grind the extra welded parts for good finishing as
well as for polishing the parts of the frame .

11.Then the primer and paint coating is to be applied on the body of the electric scooter
.

12.So these above methodology is followed by us while fabricating the electric scooter
.

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Cost & estimation of the project:

Sr.no Name of parts/material Quantity cost

used
1. Mild steel bar 01 500

2. Fork of bicycle 01 100

3. Mild steel round bar 02 100

4. Nuts & bolts of - 200

different sizes
5. Wooden ply sheets 02 500

6. Electric motor 01 2000

7. Batteries 02 1000

8. Wheels 02 1000

9. Sprockets 02 300

10. Disc Brake 01 800

11. Throttle 01 400

12. Controller 01 600

13. Fabricating charges - 2500

14. paint 03 310

15. Other expenses - 2000

Total = 12310

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5.1Precautions to be followed during Assembly of the Project :

❖ The Apron is worn at every process during Fabrication.

❖ Face shield and welding gloves are used during the welding process.

❖ Proper coolant is supplied during the Drilling process.

❖ Gloves are used to project hands during the Grinding process.

❖ The materials were handled very carefully during the Fabrication.

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• CHAPTER 6 RESULT
AND DISCUSSION
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

6.1 RESULTS:

• After testing of the fabricated electric two wheeler scooter we have came to
know that it is a very economical scooter as compared to the petrol bikes and
scooter .

• The total energy i.e. Electrical energy of the battery is to be get converted in
to the mechanical work for rotating the wheel via chain drive .

• The fabricated vehicle has nearly about 30 to 40 km/hr speed and the weight
carrying capacity of the vehicle is approximately 200 kg with its self -weight
.

• The lithium ion batteries were used in electric scooter which has small range
up to 50 to 60 km approximately . the batteries are compact in size and easy
to handle .

• The fabricated vehicle is compact in size, simple in construction and

environment friendly i.e. no emission of harmful gases . the maintenance of
these e-vehicle is nearly about zero only the battery charging is to be carried
out properly .

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6.2 Discussion:

• The qualities which are regarding to the good electric – vehicle in a point of
auto-mobile vehicle are to be kept in consideration like sufficient friction
between wheels and road , aerodynamic thrust , aerodynamic drag , etc. are to
be followed while fabricating the scooter .

• It is light in weight as compared to the regular petrol vehicles the shock absorbers
are provided to absorb the sudden shocks & jerks and to provide the comfort to
the driver & parts of the vehicle .

• The lithium ion battery is used which is very economical to charge it after the
50 – 60 km approximately . due these small batteries the power capacity is small
thus, small children’s from the age of 12-18 years also can use it & for driving
it does not required any license .

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• CHAPTER7
CONCLUSION
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

7.1 CONCLUSION :

Now a days, utilization of fuel vehicles are increased rapidly which result into
more air pollution. To control this, utilization of EV is must because it’s several
advantages like electric scooter is an eco-friendly product, It is more suitable for
city as it can avoid the emission of harmful gases and thereby it can reduce the
atmospheric pollution. Due to frequent increase in fuel prices, the electrically
charged vehicle seen to be the cheapest one compared to the traditional vehicle.
E-scooters are more suitable for rural areas where the numbers of petrol bunks are
not adequate, so that the rural people can charge the vehicle with the help of
electricity. To understanding the EV technology, this study helps to provide
outline of EV (Scooter) and there various components.

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• CHAPTER 8
REFRENCE &
BIBLIOGRAPHY
 FABRICATION OF THE ELECTRIC TWO WHEELER SCOOTER

8.1References:

• Ji-Young Byung-Chul Woo, Jong-Moo Kim and Hong Seok Oh “In-wheel Motor
Design for an Electric Scooter” J Electr Eng Technol. Nov.2017 .

• Zhai Haizhou Heze University, Heze, China “Modeling of Lithium-ion Battery for
Charging/Discharging
• Characteristics Based on Circuit Model” Article submitted 05 March 2017.
Published as resubmitted by the author 17 April 2017 .

• K.W.E Cheng, “Recent Development on Electric Vehicles”, Department of

Electrical Engineering, The Hong Kong Polytechnic University, Hong Kong. June
2009 .

• Md. Rifat Hazari, Effat Jahan, “Design of a Brushless DC (BLDC) Motor Controller”,
Department of Electrical and Electronic Engineering American International
University-Bangladesh (AIUB) Dhaka, Bangladesh. Oct 2014 .

• R.S.Khurmi “Design of Machine Elements”, Eurasnia publishing house 3 Pvt Ltd, 14th
revised edition.
• Prof. Nitinchandra R. Patel, Mohammed A. Vasanwala, Balkrushna B. Jani,
Miteshkumar D. Rathwa & Ravi A. Thakkar “Material selection and testing of
hacksaw blade based on mechanical properties’ international journal of innovative
research in science, engineering and technologyvol. 2, issue 6, June 2013
• S.M.Moghe & K.S.Zakiuddin (2013) “Design and Development of Turmeric Polishing
Machine Energized
• By Human Power Flywheel Motor.”-A past review, Proceedings of the 1st
International and 16th National
• Conference on Machines and Mechanisms IIT Roorkee, India, Dec 18-20 2013
• Bicilavadora: The Pedal-Powered Washing Machine - IDEAS 2005 Proposal.
• Bruzzone, M. & Wieler, A. (2010) “Reflecting on an Intercultural Design-Build
• Project in the Kathmandu Valley” Final Draft, February 5, 2010.

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Figures after complete fabrication process of project :-

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