EFFI-CYCLE SAENIS 2013

Debraj Roy, Dhaval Jain, Kulkeerty Singh, Amit Kumar A. Singh, Deepak Kumar, Harshit Agarwal

Amity School of Engineering & TechnologyJaipur, Rajasthan

B.TECH (M & AE) VIII SEMESTER

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DESIGN & FABRICATION OF HYBRID TRICYCLEAEROJET A-01BTM-860 PROJECTPRESENTATION2

AEROJET A-01

3PICTORIAL PRESENTATION

S. No.NameDesignationBranchResponsibility1.Sh. Mangal Singh SisodiyaSr. LecturerMAEGuidance, Official Help2.Amit Kumar A. SinghB.Tech 3rd yrMAECaptain, Material Selection & Steering3. Deepak KumarB.Tech 3rd yrMAE CATIA Design & Material Selection4.Debraj RoyB.Tech 3rd yrMAEDesign Sketch, Wheel Assembly & Suspension5.Harshit AgarwalB.Tech 3rd yrMAEBrake Computation & Tires6.Dhaval JainB.Tech 3rd yrMAETransmission7. Kulkeerty SinghB.Tech 3rd yrMAEElectrical ComponentTEAM STRUCTURE4AimTo design and fabricate an energy efficient Hybrid-human powered- three wheeled-electric vehicle which is aerodynamic, highly engineered, safe and ergonomically designed. Such human powered hybrid vehicles present the new milestone in the realm of "Green Technology". The vehicle that is cheap to buy, cheap to run and can be used from a track racer to a grocery seller everybody contributing towards a green environment.

Design MethodologyDividing of team into subsystemsAllocating target dates to achieve specific goals involving market research, component listing, procurement cost estimation, manufacturing facilities sorting.Brainstorming sessions for obtaining design.Preparation of CAD model of design-IRemoval of flaws of design-I in design-IIAssembly of data from subsystems reports, calculations.Improvisations to vehicle aestheticsINTRODUCTION5Other Specific Information:Distance b/w front and rear pedal: 1446.282mmDistance b/w front pedal and front wheel: 415.4mmDistance b/w rear pedal and front wheel: 1030.9mmDistance b/w rear pedal and rear wheel: 436.3mm

Vehicle ParameterDimensionMax. Length2470mmWheelbase1460mmTrackwidth850mmMax. Height1975mmTurning Radius3.27mMaximum Speed31.6 km/h6TECHNICAL SPECIFICATIONS7Design- Tadpole(2F1R) trikePros: Excellent braking, Easy handling, Front tyres exert less acceleration during turning than rear tyres providing easy & stable turningCons: Complicated steering mechanism, Restrictions on design, Costly maintenance.Features: Full triangulated seat stays for improved vertical & side loading.Unique combination of Recumbent & standard bike frames.Use of high strength Cr-Mo 4130 steel with great resilience.Adjustable seat positioners to prevent cramping of front rider.Use of TIG double butt welding for improved weldability & strength.

FRAME8Frame Tubes Dimensions

MemberOuter diameterWall thickness Top tube37.5 mm1.25 mmDown tube37.5 mm1.25 mmSeat tube37.5 mm1.25 mmSeat stays20 mm1.00 mmChain stays20 mm1.00 mmBottom bracket54.3 mm2.00 mm

9Material Selection Procedure for FrameCore to the bicycle as a complete functional unit. Material selection importance lays with strength and weight (i.e. strength/density materials and processing). Major consideration is the tube frame design. Material selected: Cr-Mo steel 4130/ AISI 4130ProsPrincipal Design Features: AISI 4130 is a low carbon steel containing molybdenum and chromium as strengthening agents. The carbon content is nominally 0.30%. The alloy can be hardened by heat treatment.Machinability: Machinability is best with the alloy in the normalized and tempered condition. Although the alloy may be machined in the fully heat treated condition, machinability becomes more difficult with increasing strength (hardness) of the alloy.Welding: 4130 alloy is noted for its weldability by all of the commercial methods.Aging: Not applicable to this alloy.Easily available across India.

10Finite Element Analysis

Loading of forcesDeformation of frame (max 1mm)

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Von Mises stress analysisPrincipal stress analysis12Rear wheel driveA series of idle wheels are used to route the chain from front axle to the rear wheel. The chain is almost twice the conventional cycle chains.Pros: High performance & reliability, Use of light-weight bearings, Low cost, Lesser no. of Universal joints.Cons: Adding of unwanted dynamic weight of drive train, less traction.

Chain Drive Specifications (Driver I)Front Chain Ring (Sprocket): 44T - 7 Crank size : 165mmAverage human height in India is 166cm for male and 155cm for female. Average human leg is 80cm. Thus crank size 160mm +5mm(extra)=165mm Pros: 44T chain ring is easily available in market at low cost and to obtain greater gear ratio for high speed.

Leg(cm)5052.55557.56062.56567.57072.57577.58082.58587.59092.5Child(mm)110115120125130140145150155160160165170175175180180185Adult(mm)100105110115120125130135140145150155160165170175180185

TRANSMISSION13Lowering or raising of gear ratio isnt possible as Rear chain ring is bolted to Front chain ring of 2nd driver.Low gear ratio will need 2nd driver to increase his paddling speed(cadence) and it would be difficult for him. Higher gear ratio will cause the front driver to increase his paddling speed(cadence).Thus gear ratio 44/44=1 is selected.

Chain Drive Specifications(Driver II)Front Chain Ring (Sprocket): 44T - 7 Crank size : 165mmRear chain ring of 1st driver and Front chain ring of 2nd driver bolted to each other as shown in figure.

Freewheels (21T) with index type shift is used to transmit power from rear driver to rear wheel.Pros: Smoother, quieter, faster shifting: Sprocket design allows the chain to engage two adjacent sprockets simultaneously. The sprocket meshes before it disengages from the old one. Differently shaped individual teeth on the same sprocket & ramps formed into the sides of the sprockets facilitate downshifting. While in conventional derailleur systems, shift occurs by the chain moving sideways until it can no longer mesh with the sprocket it is on.Motor Specifications

14ParametersPhase-IPhase-IITypePMDCBLDCVoltage Axle24-36V48VWattage0.5HP (373W)650WTorque12 kg-cm-N/A-Current 13.6 A38ARPM / V80-N/A-Weight9 kg6 kg15Pros:Better traction during hill-climbing due to rear wheel driveAn average adult can put out about 100 watts on a continuous basis. About 200 to 300 W continuously for an hour working up a sweat. And about 500 W in a 30s burst. A bicycle racer can put out 600 W continuously for an hour.Our bicycle with a 0.5HP W motor was able to attain the speed of a human-power only bicycle pedalled hard by a healthy adult (27.2 km/h). Motor rpm on a DC motor is directly related to voltageIncreasing the voltage from 24 to 36 V (50%) will increase no-load shaft speed by 50%. WithMotor produces more heat, so continuous current and therefore power should not be expected to increase by 50%.Pros: Light weight, Economical, Low power consumption.

Electrical SetupKillswitch is attached to the +ve terminal of battery & the wire extends to the charger & motor controller which completely puts all electrical connections to sleep upon killswitch triggering.Mobile charging can also be added and can be switched from pedal power to battery mode by the help of the switch as in the fig.

Battery Specifications

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17SEATSArrangement: Front-Rear seating positionFront: Type: Cushion seatArrangement: 303mm from front axle; 385mm from ground with inclination of 98 for increased driver comfort.H-Point: 22 from ground (well below 30)Rear: Arrangement: 1253mm from front axle & 990mm from ground.H-point: 46 from ground. Pros:Light weight & no hard spots.Dont retain heat or moisture.Better aesthetics & aerodynamics due to low height.Adequate height with no compromise to riders vision.Low centre of gravity upon mounting of driver.Cons:Less firmness.No head rest.No lateral support to keep driver in place.

18STEERINGDirect Knuckle SteeringFeatures: Directly attached to kingpin/knuckle of the wheel. Both kingpin/knuckle have a connecting rod that keep them sync with each other.Handle bar is horizontal to ground, like traditional bike because it gives rider better handling and turning capability.Handle is kept low to reduce 'twitchiness'/ shocks of the road.Angle of steering bar is extended to improve handling at higher speed.Gear changer is mounted on the handle to add comfort to the rider.Max inner wheel angle:Max outer wheel angle:Effective turning radius:

Where, Wheel base, b =Pivot centre, c =Track, a = Inner wheel angle, A =Outer wheel angle, B =

Turning Radius ( R ) Formula Value Inner front wheel b/sin A * ((a-c)/2)Outer front wheelb/sin B + ((a-c)/2)Direct Knuckle SteeringComponents: Connecting Rod/Tie Rod, Steering Column, Handle with gripFeatures: Directly attached to kingpin/knuckle of the wheel. Both kingpin/knuckle have a connecting rod that keep them sync with each other.Handle bar is horizontal to ground, like traditional bike because it gives rider better handling and turning capability.Angle of steering bar is extended to improve handling at higher speed.Gear changer is mounted on the handle to add comfort to the rider.ProsSimple and inexpensive implementation, uses single tie-rod system.Gives rider good and safe feel as the direct steering is responsive and offer good road feel.Direct steering is responsive and gives you a good road feel.Less complicated system as compare to indirect steering system, easy for maintenance.Low cost and less weight then other.

19ConsIncreases the Frontal Area making the trike less aerodynamic.Geometry & Mechanism

Knuckle-to-knuckle Drag Link provides continuity between the wheels.Main linkage consists of only two rod-end bearings.ProsMain linkage consists of only two rod-end bearingsSuperior flexibility for adjustmentAdequate Ackerman compensation

20SUSPENSIONNeedProvide a comfort ride to drivers regardless of road conditions FrontComponentsA-arms height (Upper 18 cm) ; (Lower 23 cm) ; (Spread 7)Combats 60% of shocks on cycle.Double Wishbone suspension with A-armsPros: Limited sway due to proper damping, Increased steering response & reduced brake dive.RearCombats 1/3rd of shocks on cycle.1x Mono Shock suspension between top & seat tubes.Pros: Easy implementation, No effect on handling or steeringCalculationsSpring Rate: 262 lbs/in or 46.58 N/mmMax. deflection: 0.45in or 1.143cm

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22TYRESAimProvide better tractionReduce shock to suspensionRear Rim diameter: 24 or 609.6mmTyre thickness: 2.125 or 54mmTyre diameter: 26.125or 663.6mmPhase-II Modification: Introduction of thick-rimmed tire for improved load-bearing capacity and nullifying chances of buckling.FrontNo. of tyres: 2Rim diameter: 20 or 508mmTyre thickness: 1.75 or 44.45mmTyre diameter: 21.75558mm

Pros: Increased steering response, Comfortable ride.

23FrontType: Phase I: Mechanical cable disc brakes with double barrel brake levers at front to lock shoes on both front tyres simultaneously.Phase II: Mechanical cable disc brakes with independent barrel brake levers at front to lock shoes on both front tyres independently to accommodate customized heavy-duty tire at rear. Improved braking effort achieved at front.Pros: Excellent, Reliable braking, Optimized for tadpole design, Proportional & smooth braking without skiddingCons: Heavier, Prone to rubbing, Reduced effective force due to cable stretch & cable housing compression.

BRAKES

24Detail of parts

ParameterSpecificationsSystemMechanical Disc Brake SystemActuationConventional handle & cableMaterialCeramic composite bodyWeight96 grams / wheel(Excludes rotor, adapter & mounting bolts)Brake Lever

FeaturesEPS HelmetRiding Gear ( Knee pad and Elbow pad)Safety roll barsKill switchShields for rotating parts.

25SAFETY FEATURES

26ERGONOMICS & AESTHETICSRide as many recumbents as you can and copy the ones you like.ErgonomicsAnthropometric Data

Providing horizontal handles to direct steeringReduces chance of confusion while riding, easy to steer mechanism

ParameterValueBackrest angleFront65Rear90Backrest length600mmBottom bracket-Bottom of Seat460mmBottom bracket height (Front)250mmHandle bar to Top of Seat (Front)350mmHandle bar to Bottom of Seat (Front)320mmCrank length175mmSeat height340mm

27Adjustable Seat PositionersFor front rider the privilege to adjust seat backrest position gives an opportunity to accommodate people of varying sizes to enjoy a ride. Providing double wishbone suspensionThe main purpose of investing in this is to remove fear of road bumps & potholes which are a threat to front driver. Provided system provides a smooth, carefree drive even on the harshest terrain.

AestheticsGlass fibre for exterior coveringHeadlights, indicators to give an automobile experience.Compact shape to fit easily into tight parking spots.Head Shade being given for looks of carriage to a trike with performance of a velo-mobile

Production Plan Layout

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29PHASE-II MODIFICATIONSThick Rimmed Heavy-Duty 24 Rear wheelIncreased load-bearing capacity of tricycle and less chances of buckling of rear wheel under load. It replaces the standard 26 tire used initially. A heavy-duty frame from manufactured mountain-terrain bicycle has been incorporated at rear with major customizations.

650W BLDC MotorAdds up to the torque and consequently increases load-bearing capacity of the tricycle. It has replaced 0.5HP PMDC motor. Pros: Current-to-torque ratio increases linearly while that of PMDC which is static. Helps overcome steeper gradients easily.

DC controller (MOSFET) with throttleProvides gradual acceleration to tricycle. The throttle helps regulating the current flow to the motor and helps operate the motor within safety limits Also provides ease of controlling the speed of motor. Initially in phase-I, the PMDC motor had to be operated in 3 modes On, Half load, Full load.

Optimization of front discsNeed: Alleviate issues in braking caused by malfunction of calipers at rear and deformity under heavy braking force at front discs, proper re-installation of front discs has been performed. The double-barrel brake lever have been modified to remove chances of elongation of brake wire during movement caused by steering.

Reduction in size of Battery BoxSize of battery box was been reduced to 1/3rd of initial. This lightened up the load by another 12kgs and reduced the cantilever effect caused by heavy load of battery box upon carrier.

Removal of JackshaftIt was positioned vertically above PMDC motor and used to pull the rear wheel under force of motor using a chain drive.Cons: Caused inadequate rear suspension travel.

3031FABRICATION PROCESS

32SAENIS EFFI-CYCLE2013 UIET CHANDIGARH