Journal of Production Research & Management

ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

Volume 10, Issue 1
www.stmjournals.com

Design and Development of Electric Two-Wheeler

Sukhadip Chougule1,*, Sohan Patil2, Prathmesh Lotekar3,
Durgesh Limbhore4, Rohit Vhatkar5
1
Professor, 2-5Student, Department of Mechanical Engineering, Pimpri Chinchwad College of
Engineering & Research, Pimpri- Chinchwad, Maharashtra, India

Abstract
Presently, the fuel can exceed just for a particular period and it also becomes costlier and
creates environmental issues. Due to these constraints, alternate fuels and other source of
energy like solar, wind, etc. bringing car industry to subsequent level. Also, the electrical
vehicles are developing rapidly. The electricity stored during a rechargeable battery, which
provides power to electric motor & this power helps in propulsion of motorcycle. This study is
aimed to developing frame of a two-seater motorcycle, whereas considering strength, safety,
optimum performance of vehicle. The said study has been administered with a two-step
approach. the primary step includes modelling considering aesthetic point of view as well as
determination of loads working on frame. The second step is about stress analysis using FEA
software & style modifications for weight reduction without affecting structural strength. we
propose an answer to Vehicle Security problem by employing a fingerprint authenticated
vehicle starting system by using Arduino UNO. The biometric system provides a secure and
hassle-free access to start/stop the motor and therefore the system only allows authorized
users to start the vehicle. Additionally, The GSM Module is connected via telephonic network
with vehicle owner. Motor Controller are often started/stopped by sending a SMS to GSM
Module.

Keywords: Electric Vehicle, Chassis, Battery ,GSM module, lead-acid.

*Author for Correspondence E-mail: patilsohan4@gmail.com

INTRODUCTION increasing for vehicle reliability so automobile

The electrification is most believable way to companies thinking about requirements and
achieve clean and efficiently transportation find better ways to design better vehicle at
that crucial to sustainable development of minimum cost with shorter period of time.
whole world. The history of electrical vehicle
propelled back to 19th century but interest of The automotive chassis is one of the most
electrical vehicle increased with growing important structure of any propelled vehicle
factor for damage of environment by internal because of its multifaceted role on vehicle
combustion vehicle from 21th century. The dynamic behaviour. Our aim is to presents the
automotive industry today facing with some of design and the development of a chassis, for
the most significant technical challenge in the one-seated prototype electric vehicle. The
history. Most of the countries in the world main target is to evaluate chassis deformation,
there are rules and regulations are changed based on static analysis and modal analysis, in
because if emissions of vehicles. In most of order to reduce weight and at the same time
region in world regulation and legislation are achieve proper vehicle operation in a
enacted to enforce the higher fuel economy demanding low energy consumption race.
and lower emissions of vehicle so most of the
countries are focusing on improving fuel Problem Statement
economy. These challenge along with quickly The Matter of depletion of Fossil Fuels in the
changes customers preference and world also the problem of air pollution
increasing market demand for better vehicle produced by conventional internal combustion
performance and also market demand engine; motivate to seek alternative energy

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Design and Development of Electric Two-Wheeler Chougule et al.

sources to propel the vehicle. One promising In this paper main focus is on analysis on
way is to replace conventional combustion Impact, Torsional and Harmonic response by
engine with an electric motor, which is known using Ansys software. Based on the
as an electric vehicle. It‟s crucial to design and requirement of the customer How to design
develop electric vehicle to compete the and analysis of frame can be done is
conventional vehicle. mentioned. as availability, machinability, cost,
reliability, feasibility and ergonomics for all
Objectives this factor data is collected. The total length,
 Main Objectives height and weight are also taken for
The main purpose of this research is to considerations. In this main focus is on
develop EV with smart technologies analysis under the Impact test and Torsional
researched by various researchers. In order to test. For analysis of this test they use Ansys
approach this purpose, we follow, software. By using this result of stresses has
 Design & develop chassis (AutoCAD been found. In this paper they have used the
2014 & CATIA V5R20.) impact test to gain after impact damage results
 Check chassis safety using analytical of the chassis. the material absorbs some
methods (Student Version ANSYS 15.0) amount of energy during impact test. If the
 Implementation of driver reorganization, absorbed energy exceeds the nominal limit of
using biometric. the material then breakage takes place. thus,
 Use of battery protection kit for over- the amount of energy that material could
charging & discharge. absorb can be determined from Harmonic
 Vehicle mains supply on / off using response analysis we conclude overall design
mobile SMS. is safe or not. [2]
 Testing of complete developed system.
Main focus is to reduce weight of Bike
 Basic Objectives
chassis. According to chassis dimensions CAD
 To maximize the speed and efficiency.
model is developed and analysis can be done
 To optimize the cost. by FEA method. Design of any vehicle
 Smart battery charging & discharge under involving aerodynamics, fluid dynamics,
controlled condition. thermodynamics,stress analysis, vibration
analysis, selection of materials, etc. Any
LITERATURE REVIEW mechanical system will always produce some
In this paper They mainly focus on Designing vibration while in working. So that our focus
and developing of a light weight multi-utility is to that reduce the vibration of system. The
electric vehicle. They use Brushless DC hub dynamic characteristics of bike chassis like
motor and Trolley which is use to carry load. natural frequency and mode shape were
But we are not focus trolley because we calculated by using FEA method. The FFT
developed Electric Vehicle not a Electric load analyser is connected to a sensor which reads
carrier. We all know motor is „heart‟ of an the vibrations on the component. By using
electric vehicle. Power is given to driving external source Bike chassis is hammered to
wheel from battery with the help of motor. We produce vibrations. If vibrations flow in the
use Brushless DC hub motor. It is a permanent bike chassis there will be at maximum
magnet DC motor with brushes replaced by amplitude which is the natural frequency of
rotor sensors and semiconductor switches. this the component. FEA forces are calculated and
DC motor is placed directly in the wheel, the FEA analysis of conventional model is
smooth torque is obtained. Frictional losses, performed. Natural frequency of the. bike
wear and tear are minimized. Battery packs are chassis is extracted. The result of the
like „fuel‟ which provides the power to the analytical and the experimental values are
vehicle. Based on availability and cost, Deep compared and validated. [3]
discharge lead acid battery was chosen for the
purpose. Analysis can be done by using FEA They performed analysis on three different
by applying boundary condition. [1] chassis and static and modal analysis are done

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Journal of Production Research & Management
Volume 10, Issue 1
ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

on that and result obtained is compared wheeler. As motor employed in project is

between them. In this paper author design a hubmotor hence the space required for motor
chassis for the one-seated prototype electric iseliminated. The major structural difference
vehicle. The main focus is to Analyse chassis between a standard IC engine two-wheeler and
deformation, based on static and modal an electrical two-wheeler is that the power
analysis, in order to reduce weight. The developing system of the vehicle. The
modelling process is conducted using the components of the IC engine two-wheeler like
ANSA pre-processor, in order to run the FEA. the engine, exhaust and the fuel tank are
Static loads are placed on the frame. replaced by a battery pack system and an
EPILYSIS solver is used. And by using electrical controller. the planning and
META results are evaluated. A modal incorporation of varied mechanical systems
analysis is also set up and run, to calculate the just like the front and the rear suspension,
natural frequencies and the mode shapes of the transmission, braking and seating systems of
chassis, so to partly understand the dynamic the vehicle are similar for both types of two-
behaviour of this structure. The static analysis wheeler. Thus, the two-wheeler frame must be
for each model is set to calculate the Von designed in such a way that the space
Mises stresses and deformations. The results accommodated for the engine, exhaust and the
presented, point out that the out of three which fuel tank earlier will now be taken by the
one has higher and which one is lower battery bank system and an electrical
strength. According to that they can conclude controller without affecting the performance of
which one is high or low value [4] the other related vehicle systems.

DESIGN SELECTIONS & Table1: Mechanical Properties of MSIS2062

CONSIDERATIONS E250A.
 Material Selection Parameters Metric Values
Density 7870 kg/m3
Steel is a cheap material which can be used Brinell Hardness 126
easily. It is popularly used as the frame in 70s Knoop Hardness 140
and 80s. It is fine and heavy material to work. Hardness Rockwell B 70
Even though they are cheap, the material gets Tensile Strength (Ultimate) 410 MPa
eroded easily. The steel is stronger but harder to Tensile Strength (Yield) 250 MPa
form. In light weight motorcycles the steel Elongation at Break (in 50mm) 23%
Modulus of Elasticity 200 GPa
cannot be used as frame. It can get oxidized Bulk Modulus 140 GPa
easily and cannot be used for a long time. It has Machinability Easy
good impact during crush situation, but the Shear Modulus 79.3 Goa
increased weight reduces the fuel economy of Bend test 3t (t- Thickness)
motorcycle. Many improvements have been
done in steel to make it light weight and not Table 2: Chemical Properties of MSIS2062
affected by corrosion as it lasts longer. E250A.
Meanwhile it is used in cheap motorcycles and Elements Amounts (in %)
not mostly in sports motorcycles.The selected Carbon 0.23
Manganese 1.5
material for the manufacturing is IS2062 E250 A Silicon 0.40
Sulphur 0.045
 Design Consideration Phosphorus 0.045
While designing a chassis or frame for an Deoxidation Killed
electrical two-wheeler, it's vital to take into
consideration the various kinds of chassis  CAD & CATIA Model
structures which will be appropriate to mount
the various components required for electric MATHEMATICAL MODELLING
mobility like the four battery packs, controller, A. Calculation of Rolling Resistance
etc. as well as the essential components like Rolling Resistance = Gross Vehicle Weight *
brakes and systems like horn & indication Crr [6]
system that are present in a conventional two- Here,

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Design and Development of Electric Two-Wheeler Chougule et al.

Fig. 1: CAD Model.

Fig. 2: CATIA Chassis Model.

Gross Vehicle Weight is 200 kg = 19.62 N a = Final velocity – Initial velocity / time
Co - efficient of Rolling Resistance is 0.010 Final velocity = 20 kmph = 5.56 m/s
RR = 1962 * 0.010 RR Initial velocity = 0 m/s
RR = 19.62 N Time = 45 sec
B. Calculation of Grade Resistance a = 5.56 – 0 /45 a = 0.123 m/s²
Grade Resistance = Gross Vehicle Weight * FA = 200 * 0.123
sin ø FA = 24 N
Grade or inclination angle ø = 0° [Considering D. Calculation of Total Tractive Effort
the surface is Flat] TTE = Rolling Resistance + Grade Resistance
GR = 1962 * sin (0°) + Acceleration Force [6]
GR = 0 N TTE = 19.62 + 0 + 24
C. Calculation of Acceleration Force TTE = 43.62 N
FA = m * a m = Gross Vehicle Weight / g E. Calculation of Torque Required on The
Here, Drive Wheel
FA = Acceleration Force Torque = Rf * TTE * r (wheel)
m = Mass of the vehicle Rf = Friction factor = 0.7
g = Acceleration due to gravity (9.81 m/sec²) r (wheel) = Radius of the drive wheel =
a = Required acceleration 0.225m
m = 200 kg Torque = 0.7*43.62 * 0.45

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Journal of Production Research & Management
Volume 10, Issue 1
ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

Torque = 13.74 Nm = Velocity/Maxi. Dec.= 14.137/1*9.81 = 1.44

F. Motor Calculations seconds
Power output of motor = 1000 watt. J. Net Braking Force is Produced While
Efficiency of motor = 80% Braking Is
Power input to motor = mass*deceleration
Pi = 1000/0.8=1250 Watt = 200*1*9.81
Load torque = (output power)/ (2πN) = 1962 N
=1000*60/(2π*600) =15.915 N.m. K. Net Power Absorbed of The Wheel
Load current = Pi/ V= 1250/48 = 26.0416 A During Braking
Speed = (π*D*N)/60= 3.14*0.4064*600/60 = = (mass of vehicle /2) *((velocity²)/ (time for
14.137 m/s = 50.893 kmph change velocity))
G. Battery Calculations When Batteries = (200/2) *((14.137²)/1.44)
Are Connected In Series = 13878.80 Watt.
Terminal voltage V = 12*4= 48 Volt L. Stopping Distance
Ampere-hour of batteries Q = 30 Ah = (v2) / (2µg) [7][8]
Power input for charging Pi = 500 Watt = (14.1372) / (2*0.65*9.81)
Time required for charging = (V*Q)/ Pi = = 15.67 m.
(48*30)/500= 2.88 hrs. = 2 Hr 50 min.
Total Power Consumption We have only SIMULATION AND RESULTSOF
BLDC hub motor for power consumption in CHASSIS
our vehicle so power consumption is 1250
watt only Table 3:FEAM Results
H. Discharging Time for Battery S. N. MSIS2062 E250A
= (V*Q)/ (total power consumption) 1 Yield Stress Maximum Obtained stress
= (48*30)/1250 = 1.2 hr = 1 Hr 10 min Stress 250 94.785
I. Time for Velocity Change 2 Weight 4.1402 KG.

Fig. 3: Equivalent Stress.

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Design and Development of Electric Two-Wheeler Chougule et al.

Fig. 4: Total Deformation.

CONSTRUCTION & WORKING ignition circuit can only be controlled by

PRINCIPLE providing an authorized users fingerprint. The
An electric car is powered by an electric motor system verifies and unlocks the ignition circuit
instead of a petrol engine. The electric motor in 0.3 seconds which makes the system robust.
gets energy from a controller responsible for
the power supply based on the driver‟s use of SAFETY TESTS
an accelerator pedal. The electric Propulsion  Crash Test
Vehicle uses energy stored in its rechargeable In automobile design, crash and structural
batteries, which are recharged by common analysis are the 2 most important engineering
household electricity. processes in developing a high-quality vehicle.
simulation technologies have greatly enhanced
Thus an electric vehicle will have three basic the security, reliability, and luxury,
components: environmental and manufacturing efficiency
 Energy Storage Unit of today's automobiles. This achievement was
 Controller realized with the use of advanced software‟s
 Propulsion system and powerful computers that are available
within the last twenty years. the first concern
The energy storage unit will have a way to for drivers and passengers is safety.
store power. A chemical battery is the most Governments have skilled this key concern
common energy storage technology currently, and expectation with an increasing number of
although it can be different - for example - A regulations. Although the small print may vary
fuel cell (which gets its electricity from slightly from country to country, the elemental
hydrogen rather than a battery pack), can be requirements are almost similar. A vehicle is
used instead of a chemical battery as the predicted to supply adequate protection to
energy storage unit. The biometric ignition drivers and passengers during a not so serious
system is developed in such a way to provide accident. To protect the occupants of a car,
high security and safety to the vehicle. The there are many new tangible safety features

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Journal of Production Research & Management
Volume 10, Issue 1
ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

like airbags; ABS control brakes, traction A frequency range of interest, represent an
less tangible feature that can't easily be seen entire dynamic description of the structure.
by drivers and passengers is that the crash By using the modal parameters for the
response behaviour. In a propelling vehicle, component, the model can subsequently be
the chassis and various components are the used to come up with possible solutions to
protective layers for the riders of the vehicle. individual Problems. Modal frequency
response analysis is an alternative approach
 Modal Analysis to determining the frequency response of a
Modal analysis is an effective tool for structure. Modal frequency response analysis
describing, understanding, and modelling considers the mode shapes of the structure to
structural dynamics of chassis. The dynamic scale back the dimensions, uncouple the
behaviour of a structure during a given equation of motion and makes the problem
frequency range Can be modelled as a set of solution more efficient & effective. Due to
individual modes of vibration. The modal the mode shapes are typically computed as a
parameters that describe each mode such as part of characterization of the structure,
natural frequency, resonance frequency, modal frequency response Analysis may be a
damping, and mode shape. The modal natural extension of a traditional mode
parameters of all the modes, within the analysis [5]

Fig. 5: Working Flow Diagram.

Fig. 6: Assembled Vehicle.

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Design and Development of Electric Two-Wheeler Chougule et al.

Fig. 7: Front Crash Test Result.

Fig. 8: Side Crash Test Result.

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Journal of Production Research & Management
Volume 10, Issue 1
ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

Fig. 9: Rear Crash Test Result.

Fig. 10: Mode Distribution & Natural Frequency.

FUTURE SCOPE  Special design of electric engines/ Motors.

The most important possibilities for increasing  Using supercapacitors, fuel cells and new
energy efficiency of EV would be considered, generation batteries.
regarding energy savings within the vehicle  Route selection on the criteria of minimum
itself & increasing the range of performance of consumption in real time.
the vehicle with following initial resources.  Extraction of energy from the suspension
Some of the chances that thought to provide
springs.
progress in EV nowadays are
 Using waste heat energy generated in
The Further Limitations can be taken into
Brake drums.
consideration for future improvement.
 Additional supply by solar cells.
 Improvement in mechanical energy  The Market Comparative study
transmission system. wasn‟tthrough with respect to
 Improvement in cars shell design. manufacturing cost & Various Processes
 Increasing of efficiency of power utilized in large scale industries. The cost
convertors such as AC/DC, Controller was predicted according to the commonly
Processes. used processes & methods.

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Design and Development of Electric Two-Wheeler Chougule et al.

 The Loads/Forces are considered as ACKNOWLEDGEMENT

acting in ideal condition which is The acknowledgement is a just drop of the
practically impossible. sense of gratitude within our heart for the
 The slope maybe considered in people who help us out of the most
calculations to beat the sudden climbing embarrassing part of life when we are
like in hilly areas. standing on the last and most difficult step
towards our life. we would like to take
CONCLUSION opportunity to express our heartfelt thanks to
 Analysis of Chassis was carried out on all those peoples who encouraged us during
various loading case, it was clear from this Project completion path. We feel great
analysis chassis will be safe. pleasure to present the Project entitled
“Design and Development of Electric Two-
 By using Ansys result we conclude
Wheeler”. But it would be unfair on our part
overall design is safe.
if we do not acknowledge efforts of some
 Electrical vehicle is more environment
people without the support of whom, this
friendly than IC Engine Vehicle.
Project would not have been a success. First
 The results obtained by FEAM Method & and for most we are very much thankful to
Analytical Method are found within the our respected Guide Prof. S. M. Chougule sir
permissible limits & the design can be for his leading guidance in this Project topic.
concluded as safe. We are also thankful to our Head of
Department Prof.Dr. S. H. Mankar sir, also he
The Concept Developed by us is a prototype has been persistent source of inspiration to us.
of an electric vehicle propelled by the hub We would like to express our sincere thanks
motor which can be used as a personal and appreciation to our Principal Dr.
mobility vehicle preferable for a ride within H.U.Tiwari sirand for his valuable support.
60-70 Kms like for visiting University Most importantly we would like to express
Campus, Grocery Shops & nearby Places. our sincere gratitude towards or Friends &
The design is finalized by keeping in mind Family for always being there when we
that a vehicle should be pollution free, should needed them most.
provide better efficiency & comparatively
reasonable cost. The prototype vehicle also REFERENCES
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ISSN: 2249-4766 (Online), ISSN: 2347-9930 (Print)

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