Debraj Roy, Dhaval Jain, Kulkeerty Singh,

Amit Kumar A. Singh, Deepak Kumar, Harshit Agarwal

Amity School of Engineering & Technology
Jaipur, Rajasthan

B.TECH (M & AE) VIII SEMESTER
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S.
No.
Name Designation Branch Responsibility
1. Sh. Mangal Singh
Sisodiya
Sr. Lecturer MAE Guidance, Official Help
2. Amit Kumar A. Singh B.Tech 3
rd
yr MAE Captain, Material Selection & Steering
3. Deepak Kumar B.Tech 3
rd
yr MAE CATIA Design & Material Selection
4. Debraj Roy B.Tech 3
rd
yr MAE Design Sketch, Wheel Assembly &
Suspension
5. Harshit Agarwal B.Tech 3
rd
yr MAE Brake Computation & Tires
6. Dhaval Jain B.Tech 3
rd
yr MAE Transmission
7. Kulkeerty Singh B.Tech 3
rd
yr MAE Electrical Component
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Aim
To 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 Methodology
Dividing of team into subsystems
Allocating 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-I
Removal of flaws of design-I in design-II
Assembly of data from subsystems reports, calculations.
Improvisations to vehicle aesthetics
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Other Specific Information:
Distance b/w front and rear pedal: 1446.282mm
Distance b/w front pedal and front wheel: 415.4mm
Distance b/w rear pedal and front wheel: 1030.9mm
Distance b/w rear pedal and rear wheel: 436.3mm





Vehicle Parameter Dimension
Max. Length 2470mm
Wheelbase 1460mm
Trackwidth 850mm
Max. Height 1975mm
Turning Radius 3.27m
Maximum Speed 31.6 km/h
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Design- Tadpole(2F1R) trike
Pros: Excellent braking, Easy handling, Front tyres exert less acceleration during
turning than rear tyres providing easy & stable turning
Cons: 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.



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Frame Tubes Dimensions




Member Outer diameter Wall thickness
Top tube 37.5 mm 1.25 mm
Down tube 37.5 mm 1.25 mm
Seat tube 37.5 mm 1.25 mm
Seat stays 20 mm 1.00 mm
Chain stays 20 mm 1.00 mm
Bottom bracket 54.3 mm 2.00 mm
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Material Selection Procedure for Frame
Core 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 4130
Pros
Principal 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.


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Finite Element Analysis

Loading of forces
Deformation of frame (max 1mm)
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Von Mises stress analysis
Principal stress analysis
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Rear wheel drive
A 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 : 165mm
Average 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) 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75 77.5 80 82.5 85 87.5 90 92.5

Child(mm)

110

115

120

125

130

140

145

150

155

160

160

165

170

175

175

180

180

185

Adult(mm)

100

105

110

115

120

125

130

135

140

145

150

155

160

165

170

175

180

185
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Lowering 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 : 165mm
Rear chain ring of 1
st
driver and Front chain ring of 2
nd
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


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Parameters Phase-I Phase-II
Type PMDC BLDC
Voltage Axle 24-36V 48V
Wattage 0.5HP (373W) 650W
Torque 12 kg-cm -N/A-
Current 13.6 A 38A
RPM / V 80 -N/A-
Weight 9 kg 6 kg
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Pros:
Better traction during hill-climbing due to rear wheel drive
An 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 voltage
Increasing the voltage from 24 to 36 V (50%) will increase no-load shaft speed
by 50%. With
Motor 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 Setup
o Killswitch 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.
o 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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Parameter Phase-I Phase-II
Units 2 4
Type Pb-acid rechargeable battery
Cells per unit 6
Resistance 9.3m
Operating Current 24Ah@ 2 hr-rate
Max. Discharge current 30A
Voltage per unit 12V
Weight (per unit) 7kgs
Max. Charging Current 3A
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Arrangement: Front-Rear seating position
Front:
Type: Cushion seat
Arrangement: 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.


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Direct Knuckle Steering
Features:
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 wheel b/sin B + ((a-c)/2)
Direct Knuckle Steering
Components:
Connecting Rod/Tie Rod, Steering Column, Handle with grip
Features:
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.
Pros
Simple 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.




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Cons
Increases 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.
Pros
Main linkage consists of only two rod-end bearings
Superior flexibility for adjustment
Adequate Ackerman compensation
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Need
Provide a comfort ride to drivers regardless of road conditions
Front
Components
A-arms height (Upper 18 cm) ; (Lower 23 cm) ; (Spread 7)
Combats 60% of shocks on cycle.
Double Wishbone suspension with A-arms
Pros: Limited sway due to proper damping, Increased steering response &
reduced brake dive.
Rear
Combats 1/3
rd
of shocks on cycle.
1x Mono Shock suspension between top & seat tubes.
Pros: Easy implementation, No effect on handling or steering
Calculations
Spring Rate: 262 lbs/in or 46.58 N/mm
Max. deflection: 0.45in or 1.143cm
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Aim
Provide better traction
Reduce shock to suspension
Rear
Rim diameter: 24 or 609.6mm
Tyre thickness: 2.125 or 54mm
Tyre diameter: 26.125or 663.6mm
Phase-II Modification: Introduction of thick-rimmed tire for improved load-
bearing capacity and nullifying chances of buckling.
Front
No. of tyres: 2
Rim diameter: 20 or 508mm
Tyre thickness: 1.75 or 44.45mm
Tyre diameter: 21.75558mm

Pros: Increased steering response, Comfortable ride.



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Front
Type:
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 skidding
Cons: Heavier, Prone to rubbing, Reduced effective force due to cable stretch &
cable housing compression.


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Detail of parts




Parameter Specifications
System Mechanical Disc Brake System
Actuation Conventional handle & cable
Material Ceramic composite body
Weight 96 grams / wheel
(Excludes rotor, adapter & mounting bolts)
Brake
Lever
Features
EPS Helmet
Riding Gear ( Knee pad and
Elbow pad)
Safety roll bars
Kill switch
Shields for rotating parts.





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Ride as many recumbents as you can and copy the ones you like.
Ergonomics
Anthropometric Data










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





Parameter Value
Backrest angle Front 65
Rear 90
Backrest length 600mm
Bottom bracket-Bottom of Seat 460mm
Bottom bracket height (Front) 250mm
Handle bar to Top of Seat (Front) 350mm
Handle bar to Bottom of Seat (Front) 320mm
Crank length 175mm
Seat height 340mm
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Adjustable Seat Positioners
For 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 suspension
The 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.




Aesthetics
Glass fibre for exterior covering
Headlights, 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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Thick Rimmed Heavy-Duty 24 Rear wheel
Increased 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 Motor
Adds 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 throttle
Provides 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 discs
Need: 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 Box
Size of battery box was been reduced to 1/3
rd
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 Jackshaft
It 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.



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