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DEVELOPMENT OF BATTERY POWERED TRICYCLE
T1LAKISWARAN A/L SAMURGAM
A report submitted in partial fulfilment
of the requirements for the award of the degree of
Bachelor of Mechanical Engineering
FACULTY OF MECHANICAL ENGINEERING
UNIVERSITI MALAYSIA PAHANG
NOVEMBER, 2007
ABSTRACT
Electrical energy is one of alternative energy used in automotive industry
now days. A battery is a device consisting of one or more electrochemical cells,
which store chemical energy and make it available in an electrical form and used to
move loads. Usage of electrical energy in automotive field has many advantages; it
can reduce pollution, more quite and cheaper. The objective of this project is to
design and develop a battery powered tricycle. The common problems faced by
current tricycles have been identified. Methods of Finite Element Analysis (F.E.A)
have been carried out to identify the strength of material .A prototype of Battery
powered tricycle is fabricated at end of the period as a fulfilment of the project.
Among the fabrication processes which are involve in this project are drilling,
turning, bending and welding. The design and prototype of this project will be used
to commercialize soon.
vi
ABSRAK
Pengunaan tenaga eletrik merupakan salah satu altematif baru dalam industri
automotif sekarang.Tenaga elektrik yang disimpan dalam bated mempunyai
keupayaan untuk mengerakkan beban.Pengunaan tenaga elektrik mempunyai
beberapa kelebihan seperti tidak mencemarkan alam sekitar, lebih senyap dan ianya
adalah percuma. Objektifprojek mi adalah untuk menghasilkan sebuah trisikal yang
menggunakan tenaga elektrik sepenuhnya. Projek mi cuba mengkaji masalah-
masalah yang dihadapai oleh trisikal sedia ada yang mengunakan kuasa bated.
Kaedah 'Finite Analysis (F.E.A)' digunakan ke atas rekabentuk dan pengiraan
dilakukan untuk membuktikan kekuatan bahan yang digunakan. Satu prototaip
trisikal dihasilkan di akhir tempoh sebagai memenuhi syarat projek. Antara proses
pembuatan yang terlibat di dalam melaksanakan projek mi adalah proses menebuk
lubang, pembengkokan, dan kirnpalan.Rekabentuk dan produk akhir daripada projek
mi akan dikomersialkan kelak.
VI'
TABLE OF CONTENTS
CHAPTER
TITLE
PAGE
TITLE PAGE 1
SUPERVISOR DECLARATION 11
STUDENT DECLARATION 'U
DEDICATION 'V
ACKNOWLEDGEMENTS V
ABSTRACT Vi
ABSTRAK VII
TABLE OF CONTENTS VIII
LIST OF TABLES XII
LIST OF FIGURES Xw
LIST OF SYMBOLS XVI
1
INTRODUCTION
1.1 Project Background
I
1.2 Problem Statement
2
1.3 Objective of the Project
2
1.4 Scope of the Project
3
1.5 Examples of the Current Tricycle 4
1.6 Summary 4
2 LITERATURE REVIEW
viii
2.1 Introduction 5
2.2 Common Problems Faced In Current Motorized 5 Tricycle 2.2.1 Cost 6
2.2.2 Weight 6
2.2.3 Vibration 6
2.2.4 Stability 7
2.3 How Does A Battery Powered Tricycle Works? 7
2.3.1 Important in Design Considerations 8
2.4 Requirement For A Battery Powered Tricycle 9
2.4.1 Body / Chassis 9
2.4.2 Body! Chassis Strength, Rigidity 10
2.4.3 Battery 12
2.4.3.1 Introduction 12
2.4.3.2 Battery Parameters 12
2.4.3.3 Energy Stored 13
2.4.3.4 Battery Geometry 14
2.4.3.5 Battery Life and Number of 14 Deep Cycles
2.4.3.6 Types of Batteries 15
2.4.4 Electric DC Motor 19
2.4.4.1 Brushed Electric DC Motor 20
2.4.4.2 Brushless Electric DC Motor 20
2.4.5 Brake System 22
2.4.5.1 Drum Brakes 23
2.4.5.2 Disc Brakes 24
2.4.5.3 Caliper Brake 26
2.4.6 Suspension System 26
2.4.7 Steering System 27
2.4.8 Wheels and Tires 28
2.4.8.1 Spokes Wheels 28
2.4.8.2 Disc Wheels 29
2.4.8.3 Clinchers Rims 29
2.4.9 Chain Drive 30
2.5 Mathematical Model of Tricycle Performance: 31 Power Required 2.5.1 Hill Climbing Force 31
2.5.2 Force to Overcome Wind Resistance 32
2.5.3 Force to Overcome Rolling Resistance 32
2.5.4 Acceleration Force 34
2.5.5 Total Tractive Effort 36
2.6 Modeling Vehicle Performance 37
2.6.1 Acceleration performance parameters 37
3 METHODOLOGY
3.4 Introduction 39
3.1 Flow Chart 40
3.2 Gantt Chart Semester 1 41
3.3 Gantt Chart Semester 2 42
3.4 Literature Review 43
3.5 Conceptual Design! Sketching 43
3.6 Modeling 43
3.7 Analysis 44
3.7.1 Introduction to Finite Element Analysis 44
3.7.2 Linear Static Analysis 45
3.7.3 General Procedure of F.E.A process 46
3.7.3.1 Build/Mesh a Model 46
3.7.3.2 Element and material Type 47
3.7.3.3 Load Application 47
3.7.3.4 Analyze Model 47
3.8 Fabrication Process 48
3.8.1 Tube Bending 48
3.8.2 Cutting and Burning 49
3.8.3 Machining 50
3.8.3.1 Lathe 50
3.8.3.2 Drilling Machine 51
3.8.3.3 Welding 51
i. Shielded Metal Are Welding 52
ii. Gas Metal Arc Welding 53
3.8.4 Grinding 54
3.8.4.1 Surface Treatment 54
3.8.5 Painting 55
3.9.6 Final Assembly 55
3.10 Documentation 55
3.10 Summary 56
4 RESULTS AND ANALYSIS
4.1 introduction 57
4.2 Discussion on finalized design and components 58 selection 4.2.1 Weight 58
4.2.2 Weight Distribution 59
4.2.3 Center of Gravity 59
4.2.4 Wheel base and wheel track 60
4.2.5 Wind Drag 60
4.2.6 Gear ratio determination and roller chain 61 selection 4.2.7 Motor selection 62
4.2.8 Battery 64
4.2. 10 Steering system 65
4.2.11 Braking system 66
4.3 Battery Powered Tricycle Modeling 67
4.3.1 Rolling resistance 67
4.3.2 Aerodynamic Drag 68
4.3.3 Hill climbing force 69
4.3.4 Acceleration Force 69
4.3.5 Total Tractive Effort 70
4.5 Modeling Vehicle acceleration 71
4.6 Static Analysis 77
4.7 Fabrication 86
4.8 Testing 86
5 CONCLUSION AND RECOMMENDATION
5.1 Introduction 87
5.2 Accomplishment 87
5.2.1 Accomplishment of Part 1 88
5.2.2 Accomplishment of Part 2 89
5.3 Recommendation .90
5.3.1 Weight 90
5.3.2 Battery 91
5.3.3 Motor 91
5.3.4 Speed Controller 92
REFERENCES 94
APPENDICES 95
LIST OF TABLES
TABLE NO. TITLE PAGE
2.1 Comparison of material properties. 12
2.2 Parameters Values for Coefficient of Rolling 33 Resistance
4.1 Dimension of selected standard roller chain 63
4.2 Nominal battery parameters for lead acid batteries 65
4.3 Torque needed for various loads 71
4.4 Speed and time for various weight of rider 77
4.5 Weight distribution for the various weights of rider 79
4.6 Von Misses stress on various load 81
4.7 Von Misses stress on various load of main hollow 82 pipe
4.8 Von Misses stress on various load of main body part 84
4.9 Von Misses stress on various load of main body part 85
xlii
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Recent Recumbent Trike 4
1.2 Tn-i Tricycle 4
2.1 Important in design consideration 8
2.2 A hollow cylinder under torsion and bending loads 10
2.3 Simple equivalent circuit of a battery 13
2.4 A sealed lead acid battery 15
2.5 Li-Polymer Battery 19
2.6 Diagram to explain the operation of the simple DC 21 brushed motor
2.7 Diagram showing the stator and rotor of a BLDC motor 22
2.8 Drum Brake. 23
2.9 A front disc brake, mounted to the fork and hub 25
2.10 Caliper Brake 26
2.11 Shock Absorber 27
2.12 Single Wheel Steering 27
2.13 Spokes wheel 29
xiv
2.14 Engagement of a chain and sprocket. 30
2.15 Arrangement of electric vehicle transmission 31
2.16 The forces acting on tricycle moving along a slope 34
2.17 Arrangement for connecting a motor to a drive wheel 35
3.1 Flow chart of FYP 40
3.31 Gantt chart for FYP 1 41
3.32 Gantt chart for FYP 2 42
3.2 General Procedure of F.E.A using ALGOR 46
3.3 Illustration of Tube Bending Process 49
3.4 illustration of SMAW weld area 52
3.5 Illustration of GMAW welding process. 53
4.1 Single wheel steering system 66
4.2 Torque/speed for brushed DC motor 73
4.3 The graph showing the acceleration of designed 75 tricycle
4.4 Distance / Time graph for designed tricycle 76
4.5 Free body diagram of designed tricycle 78
4.6 Stress Von Misses of fork 80
4.7 Stress Von Misses of main body roller pipe 81
4.8 Stress Von Misses of main body part 83
4.9 Stress Von Misses of back frame 85
5.1 Levels in accomplishment of project in part 1 88
5.2 Levels in accomplishment of project in part 2 89
5.3 Motor speed controller circuit 93
LIST OF SYMBOLS
A Frontal area
a Acceleration
C Amphour capacity
Cd Coefficient of drag
Cr Rolling resistance
e 2.7138
E Fixed voltage
E Young's Modulus
Fad Force to Overcome Wind Resistance
Fhc Hill climbing force
Fla Acceleration force
FM Tractive effort
G Elevation change over distance traveled
G Rigidity modulus
h Elevation above sea level, km
I Second moment of the area
J Polar moment of area
L Length
M Total mass of the tricycle
P Power
Pr Power consumed in overcoming bearing and friction
Pu Hill climbing power
xvi
R Internal resistance
Wheel radius
Rw Force of the wind drag
S Distance
T Applied torque
Urr Coefficient of rolling resistance
V Different voltage
W Work
Maximum deflection
9 Angle of twist
P Density of air
00 The initial velocity
Vg Ground speed in meters per second
Vr Relative speed in air
CO Uniform weight/length
CHAPTER 1
INTRODUCTION
1.1 Project Background
At present many exciting development in electric vehicle technology are
taking place. Some of these have advanced sufficiently to be commercially
available, whilst others remain for the future. The first demonstration electric
vehicles were made in 1830s and commercial vehicles were available by the end of
the 19th century. Today's concerns about the environment , particularly noise and
exhaust emissions, coupled to new developments in batteries, fuel cells, motors and
controllers may swing the balance of electric vehicles.
There are many types of electric vehicles such as railway trains, ships,
airerafis, cars, bikes, bicycles, wheel chair and many more. But in this project is
focused on electrical powered tricycle which is categorized under Low Speed
Vehicles (LVSs) are an environmentally friendly mode of transport for short trips.
This vehicle is particularly targeted at fairly active retired people, who still want to
get about to see their friends, but who do not travel so hurry and can be used inside a
institution like large factories.
The objective of the project is to design and develop a concept battery
powered tricycle for multipurpose use and to choose the best concept to reduce the
mass expensive batteries required. Besides that, to design a tricycle with high
efficiency and greater flexibility to place components in tricycle to optimize weight
positioning and minimize aerodynamic drag.
1.2 Problem Statement
i. Battery powered tricycle normally expensive and required a lot of
money.
ii. The mass of an electrical vehicle has critical effects on the
performance, range, and cost of an electrical vehicle.
iii. Most tricycles have vibration problem due to inherent unbalance
design.
13 Objective of the Project
The main purpose of this project is to develop a battery powered electric
motor tricycle which can be used as a simple transportation and for economy
reasons.
The objectives are:
i. To design and develop a battery powered electric motor tricycle
speed of 20km/h.
3
ii. To design a tricycle which is far more stable in braking turns by
reducing the centre of the gravity.
iii. To design a battery powered tricycle particularly suitable for short-
distance use (1-3km).
1.4 Scope of the Project
The scope of the project:
i. Review various literatures about the tricycle designs, function and its
components.
ii. Learn to use various kind of software like Solidwork, and Algor.
iii. Model building using Solid work.
iv. Mathematical simulation using Matlab program.
V. Failure analysis on body structure to identify the maximum loading
capability (50-70 kg) using Algor program.
vi. Analysis on motor and battery performance to choose proper
motor and battery.
vii. Develop, fabricate and assemble all parts of the tricycle.
viii. Testing the final product
as mentioned.
4
1.5 Example of Tricycles
Figure 1.1: Recent recumbent trike
Figure 1.2: Tr-1 Tricycle
1.6 Summary
This chapter is generally about project background, problem statement,
Objectives of the project and scope of the project in order to achieve the objectives
The objective of the project is to design and develop a concept battery
powered tricycle for multipurpose use and to choose the best concept to reduce the
mass expensive batteries required. Besides that, to design a tricycle with high
efficiency and greater flexibility to place components in tricycle to optimize weight
positioning and minimize aerodynamic drag.
1.2 Problem Statement
i. Battery powered tricycle normally expensive and required a lot of
money.
ii. The mass of an electrical vehicle has critical effects on the
performance, range, and cost of an electrical vehicle.
iii. Most tricycles have vibration problem due to inherent unbalance
design.
13 Objective of the Project
The main purpose of this project is to develop a battery powered electric
motor tricycle which can be used as a simple transportation and for economy
reasons.
The objectives are:
i. To design and develop a battery powered electric motor tricycle
speed of 20km/h.
3
ii. To design a tricycle which is far more stable in braking turns by
reducing the centre of the gravity.
iii. To design a battery powered tricycle particularly suitable for short-
distance use (1-3km).
1.4 Scope of the Project
The scope of the project:
i. Review various literatures about the tricycle designs, function and its
components.
ii. Learn to use various kind of software like Solidwork, and Algor.
iii. Model building using Solid work.
iv. Mathematical simulation using Matlab program.
v. Failure analysis on body structure to identify the maximum loading
capability (50-70 kg) using Algor program.
vi. Analysis on motor and battery performance to choose proper
motor and battery.
vii. Develop, fabricate and assemble all parts of the tricycle.
viii. Testing the final product
4
1.5 Example of Tricycles
Figure 1.1: Recent recumbent trike
Figure 1.2: Tn-i Tricycle
1.6 Summary
This chapter is generally about project background, problem statement,
objectives of the project and scope of the project in order to achieve the objectives as mentioned.
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
The main purpose of this literature review is to get information about the
project from the reference books, magazines, journals, technical papers and web
sites. One of that was from (www.pashley.co.uk/gallery/tricycle.html), where it
helps me to generate ideas on new design. In this chapter, I want to discuss all the in
formations that I found from many sources.
2.2 Common Problems Faced In Current Motorized Tricycle
The common problems faced by consumers by using current motorized or
battery powered tricycles can be divided into:
6
2.2.1 Cost
Manufacturing of battery powered tricycle normally expensive and required
lot of money. This is because the components that used for produce a tricycle
normally are very expensive. The components consist of electric cells, battery
charger, electric motor (DC or AC), motor controller and power transmission
system. If the performance is high, of course the cost will double up.
2.2.2 Weight
The mass of an electrical vehicle has critical effects on the performance,
range, and cost of an electrical vehicle. If the tricycle is too heavy, the electric motor
will require more power to move. So it is important to design a light, strong and
rigid tricycle framework which can reduce the total weight of the tricycle. Besides
that it is also important to choose a better electric motor mass and proper battery
mass that can reduce the weight of tricycle, increase transmission efficiency and
double the vehicle range.
2.2.3 Vibration
Most tricycles have vibration problem due to inherent unbalance design. The
unbalance may be due to faulty design or poor manufacture. Naturally, a frame of
tricycle designed to support heavy load like motor and battery, are also subjected to
vibration. In this entire situation, the structure or components subjected to vibration
can fail because of material fatigue resulting from the cyclic variation of the induced
Stress. Furthermore, the vibration causes more rapid wear of tricycle parts such as
bearings and gears also creates excessive noise. It also causes fasteners such as nuts
7
and bolts to become loose. Due to vibration, its also causes some electrical parts fail
to work.
2.2.4 Stability
As well as being rigid and crash-resistant, it is clearly important that a
tricycle design should also be stable. For maximum stability, wheels should be
located at the vehicle extremities and the centre of gravity should be kept as low as
possible. This is one area where the weight of the batteries can be beneficial, as they
can be laid along the bottom of the vehicle, making it extremely stable.
2.3 How Does A Battery Powered Tricycle Works?
A motorized tricycle is a three wheeled bicycle with an attached motor used
to assist with pedaling. Generally considered as a vehicle, tricycles are usually
powered by electric motors or small internal combustion engines and have function
as electric bicycles. Some can be propelled by the motor alone if the rider chooses
not to pedal; while in others the motor will only run if the rider pedals. Electric
bicycles are generally powered by rechargeable batteries. These are normally
charged from the utility supply (mains), with perhaps the option of using the motor
to effect regenerative braking or charging while being pedaled or rolling downhill.
Electric motorized bicycles are either power-on-demand, where the motor is activated by a handlebar mounted throttle, or pedelec (from pedal electric), where
the electric motor is regulated by pedaling. These may have a mechanism such as a
crank sensor to detect when the user is pedaling, or a more sophisticated torque
Sensor. But, for this project, no pedal is used to run the tricycle and fully powered by battery and electric.
2.3.1 Important in Design Considerations
Comfortable P "In ̂ , Process
Ergomciic
Weight
(rrmre
L
,Important in Design Cusideration
Ecstatic El:,ctdcal and
SM-MME-th of
tsp"acneframe
system r^ )
Attractive-
Mctor
batteiy
Figure 2.1: Important in designing consideration
8
