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Vol.04,Issue.02
January-2015,
Pages:0214-0222
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Designing and Fabrication of Gearless Electric Car for Handicaps

ER.KANWAR J S GILL1, VISHU GARG2, JASPREET SINGH3, JASPREET SINGH4, DARSHPREET SINGH5,
SEHAJPREET SINGH6, MANISH KUMAR7, PRINCE BIDALIYA8, UPENDERA KUMAR9, DEEPAK MOUDGILL10
1
Operations Head (Technical) & Assistant Professor, Dept of Mechanical Engineering, Gulzar Group of Institutes, India,
E-mail: Kanwarjabar.singh@ggi.ac.in.
2
Students, Dept of Mechanical Engineering, Gulzar Group of Institutes, Ludhiana, India, E-mail: vgarg744@gmail.com.

Abstract: The development of internal combustion engine vehicles, especially automobiles, is one of the greatest achievements
of modern technology. Automobiles have made great contributions to the growth of modern society by satisfying many of its
needs for mobility in everyday life. The rapid development of the automotive industry, unlike that of any other industry, has
prompted the progress of human society from a primitive one to a highly developed industrial society.[1] The automotive
industry and the other industries that serve it constitute the backbone of the words economy and employ the greatest share of
the working population. However, the large number of automobiles in use around the world has caused and continues to cause
serious problems for the environment and human life. Air pollution, global warming, and the rapid depletion of the Earths
petroleum resources are now problems of paramount concern. In recent decades, the research and development activities related
to transportation have emphasized the development of high efficiency, clean, and safe transportation. Electric vehicles, hybrid
electric vehicles, and fuel cell vehicles have been typically proposed to replace conventional vehicles in the near future. This
paper describes the work done in designing and fabrication of gearless drive electric car which is meant specially for handicaps,
not only limited to this feature this vehicle can be used as multiutility vehicle.

Keywords: Gearless, Electric Car, Handicaps, Multiutility, Designed, Fabricated.

I. INTRODUCTION such as methane, in the atmosphere. These gases trap the

At present, all vehicles rely on the combustion of
hydrocarbon fuels to derive the energy necessary for their
propulsion. Combustion is a reaction between the fuel and
the air that releases heat and combustion products. The heat
is converted to mechanical power by an engine and the
combustion products are released into the atmosphere. A
hydrocarbon is a chemical compound with molecules made
up of carbon and hydrogen atoms. Ideally, the combustion
of a hydrocarbon yields only carbon dioxide and water,
which do not harm the environment. Indeed, green plants
digest carbon dioxide by photosynthesis. [2]Carbon
dioxide is a necessary ingredient in vegetal life. Animals do
not suffer from breathing carbon dioxide unless its
concentration in air is such that oxygen is almost absent.
Actually, the combustion of hydrocarbon fuel in combustion
engines is never ideal. Besides carbon dioxide and water,
the combustion products contain a certain amount of
nitrogen oxides (NO2), carbon monoxides (CO), and
unburned hydrocarbons (HC), all of which are toxic to
human health. Highlight a section that you want to designate
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II. GLOBAL WARMING
Global warming is a result of the greenhouse effect
induced by the presence of carbon dioxide and other gases,
Suns infrared radiation reflected by the ground, thus
retaining the energy in the atmosphere and increasing the
temperature. An increased Earth temperature results in
major ecological damages to its ecosystems and in many
natural disasters that effect human populations. Among the
ecological damages induced by global warming, the
disappearance of some endangered species is a concern
because it destabilizes the natural resources that feed some
populations. There are also concerns about the migration of
some species from warm seas to previously colder northern
seas, where they can potentially destroy indigenous species
and the economies that live off those species. This may be
happening in the Mediterranean Sea, where barracudas from
the Red Sea have been observed[3]. Natural disasters
command our attention more than ecological disasters
because of the amplitude of the damage they cause. Global
warming is believed to have induced meteorological
phenomena such as El Nio, which disturbs the South-
Pacific region and regularly causes tornadoes, inundations,
and dryness. The melting of the polar icecaps, another major
result of global warming, raises the sea level and can cause
the permanent inundation of coastal regions, and sometimes
of entire countries.
III. ELECTRIC VEHICLES
Electric vehicles (EVs) use an electric motor for traction,
and chemical batteries, fuel cells, ultra capacitors, and/or

Copyright @ 2015 IJSETR. All rights reserved.

 ER.KANWAR J S GILL, VISHU GARG, JASPREET SINGH, JASPREET SINGH, DARSHPREET SINGH, SEHAJPREET SINGH,
MANISH KUMAR, PRINCE BIDALIYA, UPENDERA KUMAR, DEEPAK MOUDGILL
flywheels for their corresponding energy sources.[4] The source voltage. After the base speed, the motor voltage is
electric vehicle has many advantages over the conventional kept constant and the flux is weakened, dropping
internal combustion engine vehicle (ICEV), such as an hyperbolically with increasing speed. Hence, its torque also
absence of emissions, high efficiency, independence from drops hyperbolically with increasing speed.
petroleum, and quiet and smooth operation. The operational
and fundamental principles in EVs and ICEVs are similar. B. Tractive Effort and Transmission Requirement
There are, however, some differences between ICEVs and The tractive effort developed by a traction motor on
EVs, such as the use of gasoline tanks vs. batteries, ICE vs. driven wheels and the vehicle speed are expressed as
electric motor, and different transmission requirements.

IV. PERFORMANCE OF ELECTRIC VEHICLES (1)

A. Traction Motor Characteristics
A vehicles driving performance is usually evaluated by
its acceleration time, maximum speed, and grade ability. In
EV drive train design, proper motor power rating and
transmission parameters are the primary considerations to
meet the performance specification. The design of all these
parameters depends mostly on the speedpower (torque)
characteristics of the traction motor. A vehicles driving
performance is usually evaluated by its acceleration time,
maximum speed, and grade ability. In EV drive train design,
proper motor power rating and transmission parameters are
the primary considerations to meet the performance
specification. [5]The design of all these parameters depends
mostly on the speedpower (torque) characteristics of the
traction motor. Variable-speed electric motor drives usually
have the characteristics shown in Fig.1. At the low-speed
region (less than the base speed as marked in Fig.1. the
motor has a constant torque. In the high-speed region
(higher than the base speed), the motor has a constant
power. This characteristic is usually represented by a speed
ratio x, defined as the ratio of its maximum speed to its base
speed.
And
(2)
Where Tm and Nm are the motor torque output and speed in
rpm, respectively, ig is the gear ratio of transmission, i0 is the
gear ratio of final drive, t is the efficiency of the whole
driveline from the motor to the driven wheels, and rd is the
radius of the drive wheels.
The use of a multi gear or single-gear transmission
depends mostly on the motor speedtorque characteristics.
That is, at a given rated motor power, if the motor has a long
constant power region, a single-gear transmission would be
sufficient for a high tractive effort at low speeds.[6]
Otherwise, a multi gear (more than two gears) transmission
has to be used. Fig.2 shows the tractive effort of an EV,
along with the vehicle speed with a traction motor of x=3
and a three-gear transmission. The first gear covers the
speed region of abc, the second gear covers def, and
the third gear covers gfh.

Fig.1.Typical variable-speed electric motor character-

istics.
In low-speed operations, voltage supply to the motor
increases with the increase of the speed through the
electronic converter while the flux is kept constant. At the
point of base speed, the voltage of the motor reaches the
Fig.2. Tractive effort vs. vehicle speed with a traction
motor of x= 3 and three-gear transmission.
C. Vehicle Performance
Basic vehicle performance includes maximum cruising
speed, gradeability, and acceleration. The maximum speed

International Journal of Scientific Engineering and Technology Research

Volume.04, IssueNo.02, January-2015, Pages: 0214-0222
 Designing and Fabrication of Gearless Electric Car for Handicaps
of a vehicle can be easily found by the intersection point of
the tractive effort curve with the resistance curve (rolling
resistance plus aerodynamic drag), in the tractive effort vs.
vehicle speed diagram shown in Fig.2. It should be noted
that such an intersection point does not exist in some
designs, which usually use a larger traction motor or a large
gear ratio.[7] In this case, the maximum vehicle speed is
determined by the maximum speed of the traction motor as
(3)
Where Nm max is the allowed maximum rpm of the traction
motor and ig min is the minimum gear ratio of the
transmission (highest gear).
Gradeability is determined by the net tractive effort of the
vehicle, Ft-net (Ft-net=FtFrFw), as shown in Fig.2. At mid- and
high speeds, the gradeability is smaller than the gradeability
at low speeds. The maximum grade that the vehicle can
overcome at the given speed can be calculated by
(4)
Where Ft is the tractive effort on the driven wheels, Fr is the
tire rolling resistance, and Fw is the aerodynamic drag.
However, at low speeds, the gradeability is much larger.
Calculations based on (=2) will cause significance error;
instead, equation (=3) should be used:
(5)
Where d(FtFw)/Mvg, which is called the vehicle performance
factor, and fr is the tire rolling resistance coefficient.
Acceleration performance of a vehicle is evaluated by the
time used to accelerate the vehicle from a low-speed V1
(usually zero) to a higher speed (100 km/h for passenger
cars). For passenger cars, acceleration performance is more
important than maximum cruising speed and gradeability,
since it is the acceleration requirement, rather than the
maximum cruising speed or the gradeability that dictates the
power rating of the motor drive. Referring to Figure 2, the
acceleration time for an EV can be expressed as
(6)
Where Vb and Vf are the vehicle base speed as shown in
Fig.2, and the final acceleration speed, respectively, and Pt is
the tractive power on the driven wheels transmitted from the
traction motor corresponding to the vehicle base speed. The
first term on the right-hand side of (=6) is in correspondence
with the speed region lower than the vehicle base speed; the
second term is in correspondence with the speed region
beyond the vehicle base speed.
International Journal of Scientific Engineering and Technology Research
Volume.04, IssueNo.02, January-2015, Pages: 0214-0222
It is difficult to obtain the analytical solution from
equation (3.6). For initial evaluation of the acceleration time
vs. the tractive power, one can ignore the rolling resistance
and the aerodynamic drag and obtain
(7)
where the vehicle mass factor, , is a constant. The tractive
power, Pt, can then be expressed as
(8)
To determine the tractive power rating accurately, the
power consumed in overcoming the rolling resistance and
dynamic drag should be considered. The average drag
power during acceleration can be expressed as
(9)
Referring to Fig.2, the vehicle speed V can be expressed
using time t, as
(10)
Substituting (=10) into (=9) and integrating, one obtains
(11)
The total tractive power for accelerating the vehicle from
zero to speed Vf in ta seconds can be finally obtained as
(12)
Equation (12) indicates that for a given acceleration
performance, low vehicle base speed will result in small
motor power rating. However, the power rating decline rate
to the vehicle base speed reduction is not identical.
Differentiating equation (12) with respect to the vehicle
speed Vb, one can obtain
(13)
Fig.3, shows an example of the tractive power rating and the
power rating decline rate to the vehicle speed reduction
(dPt/dVb) vs. the speed fact x.
Fig.3. Power rating vs. speed factor.
 ER.KANWAR J S GILL, VISHU GARG, JASPREET SINGH, JASPREET SINGH, DARSHPREET SINGH, SEHAJPREET SINGH,
MANISH KUMAR, PRINCE BIDALIYA, UPENDERA KUMAR, DEEPAK MOUDGILL
In this example, acceleration time is 10 sec, the vehicle TABLE III: Gear-1 Specification
mass is 1300 kg, the rolling resistance coefficient is 0.01,
the aerodynamic drag coefficient is 0.3, and the front area is
3 m3. This figure clearly indicates that a low x (high Vb)
reduction in Vb will result in a significant decline in the
power rating requirement. But with a high x (low Vb), x=3
for example, it is not so effective. Fig.4 gives an example of
the acceleration time and the distance vs. the vehicle speed,
using equation (6) and numerical methods.

TABLE IV: Gear-2 Specification

TABLE V: Gear-3 Specification

Fig. 4. Acceleration time and distance vs. final speed.

V. SPECIFICATIONS
TABLE I: Vehicle Specification

TABLE VI: Gear-4 Specification

TABLE II: Battery specifications

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Volume.04, IssueNo.02, January-2015, Pages: 0214-0222
 Designing and Fabrication of Gearless Electric Car for Handicaps
TABLE VII: Coupling Specification

VI. ANALYSIS
The static structural analysis of gears was done in
ANSYS 14.0 version and all the designing work was done
in Solid works. Analysis was done of the following parts
shown in bellow Figs.5 to 20.
A.Gear-1 Analysis
B. Gear-2 Analysis
C. Gear-3 Analysis
D. Gear-4 Analysis

A.Gear-1 Analysis

Fig.7. Equivalent stress.

Fig.5. Meshing.

Fig.8. Total deformation.

Result-
Magnitude =75 MPa
No of Nodes =35285
No of Elements =19709
Min.Principal stress =-51.274 MPa
Max.Principal stress = 393.91 MPa
Min.Equivalent stress =0.02764MPa
Max.Equivalent stress =306.23 MPa
Min deformation = 0 m
Max. deformation = 12.82 m
Fig.6 Max.Principal stress.

International Journal of Scientific Engineering and Technology Research

Volume.04, IssueNo.02, January-2015, Pages: 0214-0222
 ER.KANWAR J S GILL, VISHU GARG, JASPREET SINGH, JASPREET SINGH, DARSHPREET SINGH, SEHAJPREET SINGH,
MANISH KUMAR, PRINCE BIDALIYA, UPENDERA KUMAR, DEEPAK MOUDGILL
B.Gear-2 Analysis

Fig.12 Total deformation.

Result-Magnitude =75 MPa
No of Nodes =103400
No of Elements =59482
Fig.9. Meshing.
Min.Principal stress =-323.0 MPa
Max.Principal stress =1571.8 MPa
Min.Equivalent stress =0.0579 MPa
Max.Equivalent stress =1227.8 MPa
Min deformation = 0 m
Max. deformation = 192.72 m

C. Gear-3 Analysis

Fig.10 Max.Principal stress

Fig.13. Meshing.

Fig.11. Equivalent stress. Fig.14. Max.Principal stress.

International Journal of Scientific Engineering and Technology Research

Volume.04, IssueNo.02, January-2015, Pages: 0214-0222
 Designing and Fabrication of Gearless Electric Car for Handicaps

Fig.15. Equivalent stress. Fig.18 Max.Principal stress.

Fig.16. Total deformation.

Fig.19. Equivalent stress.
Result-Magnitude =75 MPa
No of Nodes =71436
No of Elements =41685
Min.Principal stress =-931.1 MPa
Max.Principal stress =30925 MPa
Min.Equivalent stress =0.0106MPa
Max.Equivalent stress =48041 MPa
Min deformation = 0 m
Max. deformation = 114.75m

D. Gear-4 Analysis

Fig.20. Total deformation.

Result-Magnitude =75 MPa

No of Nodes =138515
No of Elements =78833
Min.Principal stress =-424.68 MPa
Max.Principal stress =1476.1 MPa
Min.Equivalent stress =0.0166 MPa
Max.Equivalent stress =1154.7 MPa
Min deformation = 0 m
Fig.17. Meshing. Max. deformation = 30.191 m

International Journal of Scientific Engineering and Technology Research

Volume.04, IssueNo.02, January-2015, Pages: 0214-0222
 ER.KANWAR J S GILL, VISHU GARG, JASPREET SINGH, JASPREET SINGH, DARSHPREET SINGH, SEHAJPREET SINGH,
MANISH KUMAR, PRINCE BIDALIYA, UPENDERA KUMAR, DEEPAK MOUDGILL
VII. CONCLUSION in his name. He is recipient of Rashtriya Gaurav Award
The automotive industry is always evolving and at Constitutional Club of India, New Delhi, Rajiv Gandhi
engineering new technologies. Maximizing efficiency and Excellence Award at India International Club of India,
minimizing the harmful effects of vehicles on the New Delhi for outstanding achievements and contributions
environment and society are the primary goals of in the field of Mechanical Engineering. For consecutive two
automotive engineers. The internal combustion engine (ICE) years he is decorated with Best teacher award-2013 and
is constantly being tweaked for these reasons. However, the 2014 (I.S.T.E).Not only limited to this his paper,
electric vehicle (EV) is a new technology being Designing and fabrication of fossil fuel saving eco-friendly
implemented to reach these goals. The effects and impacts vehicle got Best paper presentation award at (Desh
Bhagat University).He has got 1st and 2nd prize at Science
that EVs have on the environment and society from an
city, kapurthala for camless rotating cylinder engine and for
engineering point of view were discussed, and the
designing and fabrication of fossil fuel saving eco-friendly
information presented here served to be informative. Almost
vehicle. During his teaching period he is quiet busy in
all aspects of a EV were scrutinized, such as how EVs work designing, fabrication and analysis work and has undertook
and what they are, the complexities and impacts of the more than 52 projects few of which have got patent. He is a
batteries used in them, and the cost of owning and EV and life member of very prestigious society I.S.T.E. Presently
how it effects the economy. More over the gears which were he is working as operations Head (Technical) and
used for transmission of power from motor to the wheels Assistant Professor at Gulzar Group of Institutes,
were also analyzed and had proved to be satisfactory. Ludhiana.

VIII. REFERENCES Vishu garg is student of department of

[1].C.C. Chan and K.T. Chau, Modern Electric Vehicle
Technology, Oxford University Press, New York, 2001.
[2].K.M. Rahman and M. Ehsani, Performance analysis of
electric motor drives for electric and hybrid electric vehicle
application, IEEE Power Electronic in Transportation, 29
26, 1996.
[3].Y. Gao, H. Maghbelli, M. Ehsani, et al., Investigation of
proper motor drive characteristics for military vehicle
propulsion, Society of Automotive Engineers (SAE)
Journal, Paper No. 2003-01-2296, Warrendale, PA, 2003.
[4].Z. Rahman. M. Ehsani, and K. Butler, An investigation
of electric motor drive characteristics for EV and HEV
propulsion systems, Society of Automotive Engineers
(SAE) Journal, Paper No. 2000013062, Warrendale, PA,
2003.
[5].Z. Rahman, M. Ehsani, and K. Butler, Effect of
extended-speed, constant-power operation of electric drives
on the design and performance of EV-HEV propulsion
system, Society of Automotive Engineers (SAE) Journal,
Paper No. 2000011227 , Warrendale, PA, 2003.
[6].D.A.J. Rand, R. Woods, and R.M. Dell, Batteries for
Electric Vehicles, Research Studies Press, Ltd., Baldock,
Hertfordshire, United Kingdom, 1998.
[7]. Y. Gao, H. Maghbelli, M. Ehsani, et al., Investigation of
proper motor drive characteristics for military vehicle
propulsion, Society of Automotive Engineers (SAE)
Journal, Paper No. 2003-01-2296, Warrendale, PA, 2003.
mechanical engineering. He has got
Best student of the year award by
I.S.T.E and has been associated in
designing work with Er. Kanwar J.S
Gill for designing of electric vehicle for
handicaps. He is a meritorious student
throughout his carrier. He along with his team members
have applied for patent of electric vehicle and has got first
prize by I.S.T.E for the above said vehicle.
Jaspreet Singh is also student of
department of mechanical engineering.
He has been associated in fabrication
work and analysis work with Er.
Kanwar J.S Gill for designing of
electric vehicle for handicaps. He is a
meritorious student throughout his
carrier. He along with his team
members have applied for patent of electric vehicle and has
got first prize by I.S.T.E for the above said vehicle.

Authors Profile:
Er. Kanwar J.S Gill is Chartered
Engineer (C.E) and has a vast
industrial and teaching experience of
more than 15 years. He has published
more than 08 books and 26 research
papers in international/ Inational
conferences/journals, 03 patents filed

International Journal of Scientific Engineering and Technology Research

Volume.04, IssueNo.02, January-2015, Pages: 0214-0222