NAME: RITHIK GOWDA M

EMAIL: rithikrahul3214@gmail.com

PROJECT REPORT
DESIGN OF ELECTRIC SCOOTER

ABSTRACT:

Electric scooters are plug-in electric vehicles with two wheels that can be recharged from any
external source of electricity, and the electricity is stored in a rechargeable battery, which
provides power to one or more electric motors to attain movement. Electric scooter, as
differentiated from scooters, do not have a step-through frame. The electricity generated from
an external source helps in acceleration of the motorcycle. The speed of this cycle is limited
(60km/h). The electricity is stored using a battery and the locomotion and movement of the
vehicle is hence propelled using an electric hub motor The electric scooter are not using an
engine, becomes an effective way of road transport as it causes no pollution.
It is ecofriendly and it definitely reduces human effort. In this project report, work
concerning product design and manufacturing process making of an electric scooter is
described, which was the outcome of a collaborative project for new product development.
The final product was satisfactory
In recent years environmental problems caused by fuel vehicles and fuel economy become
more and more serious. Electric scooters are considered a new technical green product and a
potential industry for many countries. This project is aimed at designing and developing of a
light weight electric scooter using hub motor transmission. This vehicle is designed to carry a
load of 80kg with 60 kmph speed.

INTRODUCTION:

Concern about global warming and urban air pollution have become central issues in
transport policy decision-making, and as a result much research in recent years has focused
on the development of vehicles which are environmentally friendly. Air quality in cities is
currently significantly lower than in rural areas and this has been shown to be directly link to
the level of vehicle emissions from private cars. The haze episodes in Southeast Asia in 1983,
1984, 1991, 1994, and 1997 imposed threats to the environmental management of Malaysia
and increased awareness of the environment.
 Due to the fact that urban transport policy, the design is to reduce or discourage the use of
private cars, there has been an increase in the sale of non-polluting vehicles such as electric
scooter. However, although the number of electric scooter users has increased, safety and
comfort issues need to be addressed if the number of users is to increase to a level at which a
significant effect on environmental pollution can be achieved. Researchers have studied and
improved many aspects of the electric scooter. In this study, we used computer simulation to
model the aerodynamic effect of the existing safety and comfort features and we present a
new design which integrates these features in an optimallyeffective aerodynamic shape.
Electric scooter is a vehicle empowered by electric motor in order to move. It is also known
as e-scooter. For the power source of the electric motor, certain country used different power,
because it is depends on the Law of the country. Basically, rechargeable batteries that used
for the e-scooter is 40 to 65km/h. The invention of the electric scooter is as a proof that the
engineering field keep advancing, the invention of the electric scooter make it replacing the
old scooter in the market. Although the electric scooters are using electric motor, it still called
as scooter rather than motorcycle. This is because it identity as scooter is still fixed which is
most of it part are belong to scooter. So, it not included in transportation law which require
the certification and operation as on good motor vehicle. It is not need to have license to ride
the electric scooter.
The Hub motor also commonly use by electric bike. The clearly difference between electric
scooter and electric bike which is the electric bike have a pedal to ride the bike meanwhile for
electric scooter only use a throttle to control the speed of the scooter.Hub motor Electric
scooter of using hub motor creates an all wheel drive the scooter because the motor drives
front wheel or rear wheel. The system of hub motor in electric scooter were easy to install or
remove from the scooter wheel because there no gear system to deal with chain. Hub motor
can provide for a more balanced scooter weight distribution if the battery mounted in the
middle or back part of the scooter.
An electric scooter, is a vehicle which uses one or more electric motors for propulsion.
Depending on the scooter, motion may be provided by wheels or propellers driven by rotary
motors or by linear motors. At the beginning of the 21st century, increased concern over the
environmental impact of the petroleum-based transportation infrastructure, along with the
spectre of peak oil, led to renewed interest in an electric transportation infrastructure. Electric
scooter has the potential of significantly reducing city pollution by having zero tail pipe
emissions. Vehicle greenhouse gas savings depend on how the electricity is generated. With
the energy mix using an electric scooter would result in a 30% reduction in carbon dioxide
emissions.
Electric scooters are commonly powered by on-board battery packs, and as such are battery
electric vehicles. Electric scooter are expected to cause a revolution in the auto industry given
advantages in city pollution, less dependence on foreign oil imports, and expected rise in
gasoline prices. In an electric scooter, a battery or other energy storage device is used to store
the electricity that powers the motor. Batteries must be replenished by plugging in the vehicle
to a power source.
Electric scooters are considered zero-emission vehicles because their motors produce no
exhaust or emissions. These electric scooters are commonly used for neighbourhood
commuting, light hauling, and delivery. Their use is limited to areas with 55km/h speed limits
or for off-road service on college campus or at airports or resort areas. An important goal for
electric vehicles is overcoming the disparity between their costs of development, production,
and operation, with respect to those of equivalent internal combustion engine vehicles.

COMPONENTS USED FOR DESIGN:

• Frame
• Hub motor
• Controller
• Battery
• Throttle/Accelerator
• Charger
• Speedo meter
• Brakes

FRAME:

A vehicle frame, also known as its chassis, is the main supporting structure of a motor
vehicle to which all other components are attached, comparable to the skeleton of an
organism.
The function of chasis is to
➢ To support vehicle’s mechanical component and body
➢ To deal with static and dynamic loads

In most of cheap electric scooter deck is the platform you stand on while riding. Many are
rubberized to provide better traction.

The electric scooter deck — like that of a skateboard — is the thing you stand on. Some
electric kick scooters have the battery pack built into the deck.

Most decks have some type of textured finish that provides better grip between your shoes
and the scooter. Some scooters, like the Rev pictured above, have a sloped deck that gives
you more space to place your feet.

The typical scooter deck size is 14″ by 5″ inches and gives a few inches of ground clearance.
HUB MOTOR:

electric scooters have hub motors built into one or both wheels. The powerhouse Wide Wheel
pictured above has dual 500-watt motors.

Electric scooters have brushless direct current (BLDC) electric motors that are built into the
hub of wheels. All electric kick scooters have at least one motor while more powerful ones
will have two.

Electric motors are rated based on their power consumption which is express in units of
watts. More powerful motors will have greater wattage.

An average electric scooter, like the Mi M365 will have a 250 watt motor; an intermediate
scooter like the Horizon will have a 500 watt motor; extreme performance scooters, like
the Wolf Warrior will have dual 1200 watt motors.

CONTROLLER:

The speed controller sends power to the motor based on accelerator input.

The speed controller is an electronic component buried deep inside of the scooter that
controls the flow of current from the battery to the motor. They typically look like rectangular
metal cans with many wires coming out of them. The metal enclosure serves as a heat sync.
The controller receives inputs from the accelerator and (electronic) brake controls and
translates that into a current that is sent to the motor.

Controllers are rated based on the voltage and current they are able to regulate. Scooters with
more powerful motors will have controllers with higher max voltage and higher max current
ratings.

Controllers are one of the most under-appreciated parts of the electric scooter because they
quietly do their job most of the time. They can be a huge source of headache (or make the
scooter unsafe) when things go wrong. On some poorly designed scooters controllers are
known to fail or malfunction.

BATTERY:

Electric scooter battery packs are made up of many individual cells that are assembled
together.

Batteries are the “gas tank” of an electric scooter. They store the energy that is consumed by
the electric motor and other accessories, including lights.

Most electric scooters will have a battery pack comprised of lithium-ion battery cells, though
some electric scooters for kids and other inexpensive scooters actually have lead-acid
batteries.

Batteries are rated in watt-hours, abbreviated Wh, which is a measure of their capacity.
Battery capacity is one of the important factors that determine electric scooter range. A
typical budget scooter will have a capacity of around 250 watt-hours while monster scooters
can have capacities of almost 3,000 watt-hours.
HANDLE BARS:

The handlebars are your main connection with the scooter. They are fitted with all the
controls, including the accelerator, brakes, speed/settings display, and power buttons.

The most portable electric scooters will have folding handlebars that greatly reduce their
width and get the scooter down to a very transportable and storable size

STEM:

The stem is the folding metal tube that connects that handlebars to the front wheels. On some
electric scooters the folding mechanism is a source of frustration due to instability.The stem
or neck of the electric scooter is the long tube that is connected to the front wheel and extends
up to the handlebars.

Nearly every scooter has a folding mechanism built into the stem to allow easy carrying and
storage. In our e-scooter reviews, we often spend a lot of time focusing on this unsuspecting
part. Yet, this is for good reason. The folding mechanism can be difficult work or worse it
can be loose or unstable. When you apply force to the handlebars, you’ll notice the whole
stem rocking back and fourth — a condition we call stem wobble. This is one of the huge
downsides to folding electric scooters.

SUSPENSION:

Many electric scooters have no suspension, while high performance ones, like the Zero 8X
pictured above feature a beefy coil-over-hydraulic suspension.

The suspension of the electric scooter, like that on motor vehicle or bicycle, helps to improve
ride quality and dampin bumps in the road.

There are three main types of suspension systems that are typically found on electric scooters:
spring, hydraulic or air piston, and rubber suspension. Scooters with the best suspension will
have some combination of spring and piston — a combination called coil-over-hydraulic or
coil-over-air.

Many scooters forgo suspension in favor of large pneumatic tires that provide damping
effects. Large pneumatic tires can offer be a better form of suspension that cheap spring
suspensions.

TIRES:

Tires given you traction to accelerate or brake in an emergency. Airless tires, like those
pictured above, do not perform as well as pneumatic tires.

Tires are your connection to the road and influence ride quality, traction, range, and braking
performance of your electric kick scooter.

Tires come in basically two types: pneumatic (airfilled) and airless. There are a few varieties
of airless tires and these include: honeycomb, polymer-filled, and solid.

We always recommend pneumatic tires because they give better ride quality (with or without
suspension) and their supple rubber performs much better in adverse road conditions.
BRAKES:

A quality braking system, such as the disc brake picture above, is essential for staying safe
and in control while riding an electric scooter.

Like those on a car or bicycle, brakes are what slow the electric scooter down. Electric
scooter brakes can be broken down into two categories: mechanical and electronic.

Mechanical brake systems are those that rely on a physical mechanism to slow the scooter
down and are: disc, drum, and foot brakes.

Electronic braking systems rely on using the motor itself for braking and include strictly
electronic and regenerative braking systems.

Typically mechanical braking systems will offer much stronger braking than electronic
systems. However, electronic systems benefit from not requiring any periodic adjustments or
maintenance.

Many scooters will have a combination of both electronic and mechanical braking systems.
For safety reasons, we recommend scooters that have at least two braking systems in case one
fails.
DESIGN REQUIREMENTS:

MASS OF SCOOTER: 80KG

CONSIDERED MASS: 80X1.4=112KG(always consider 1.4 times weight given )

SPEED OF VEHICLES: 60 kmph =16.66m/s

The force required for driving a vehicle is calculated as:

F total = F gradient+ F rolling + F aerodynamic drag

Force due to climbing hills ( F gradient )

Fh = W sin Φ (Angle of incline Φ is 2.5)

= Mg sin Φ

= 112 x 9.8 x sin 2.5

= 47.87N

Force due to Rolling resistance :

Fr= CrW cosΦ (for asphalt roads Cr =0.004)

= 0.004 x 112 x9.8 x cos 2.5

= 4.38N

Aerodynamic drag force:

Fd = 0.5 ρ Cd A V^2 (Cd value is 0.5 for frontal area A=0.7 m2 , ρ density
of air 1.2kg/m3)

= 0.5 x (1.2) x 0.5 x 0.7x 16.66m/s x16.66m/s

= 58.28 N

TOTAL FORCE OF THE VEHICLE:

F = Fh + Fr + Fd = 47.87+4.38+58.28

= 110.53 N Power required

= F x V=110.53x 16.66=1841.42 Watt

So we select approximately 1800W watt motor

POWER OF MOTOR: 1800W(approximately 2000W )

Battery :

Watt hour=1800x1 hour=1800 watt. hour

Battery watt.hr = 1800w.hr × 1.08 = 1944 w.hr.

Take voltage= 72 V

Current (Ah) in battery

=1944w.hr ÷ 72v = 27Ah

Motor Specification:

Volt (V) = 72 V,

Power (P) = 1800Watts

Speed of Motor In RPM

N=VX60/3.14XD

=16.66X60/3.14X0.254

=1253.32 RPM

d = Wheel Diameter in m = 0.254 m (10 in)

Torque:

T = (P×60)÷(2×𝜋×N)

=(1800×60)÷(2×3.14×1253.32)

= 13.72 Nm Torque of the wheel hub motor,

T = 13.06 Nm

Battery specification:

Voltage Rating = 72 v

Current Rating = 27 Ah

Wattage of battery = Voltage Rating × Current Rating

= 48 × 25 = 1944 wh (watt.hr.)

Selection of battery charger :

Suppose we have to charge a battery in 5 hr.

So our required wattage is 1944w.hr.

According to above condition,

Wattage of charger = 1944w.hr ÷ 5 hr = 388.8w

Hence, current rating of charger = 388.8W ÷ 72V = 5.4A

As per the above calculation to charge 72v ,27Ah battery in 5 hour we

require 72v, 5A charger
 SPECIFICATIONS AND AVAILABILITY OF BATTERY
,MOTOR AND CHARGER

SPECIFICATIONS OF BATTERY THAT SHOULD B EUSED:

INKAGE BATTERIES:2000watthour battery
PRICE=40000Rs
AVAILABILITY=aliexpress,amazon

ITEM Specifications

Charge : 0 to 50
Operating temperature (recommended recharge release < 45°C)
(surface temperature) Discharge: -20 to 75
(recommended re-discharge release < 60°C)

1.5 year -30~25°C(1*)

Storage temperature
3 months -30~45°C(1*)
(Recovery 90% after storage)
1 month -30~60°C(1*)

Items Specifications

Nominal Voltage 74V

Nominal Capacity 20.8Ah

Cell Inside Samsung 18650 26F 3.7V 2600mAh

Configuration 20S20P

Standard Charge Current 8A(0.2C)

Max. Charge Current 20A (0.5C)

Battery management System

Custom
(BMS)
Continuous Discharge Current 25A

Peak Discharge Current 50A

Full Charged Voltage 84V(4.2V per cell)

Discharge Cut-off Voltage 60V (3.0V per cell)

Net Weight 28kg

Dimensions Can be customized

Anderson connector or any other customer

Connector
required.

Charging: 0°C ~ 45°C

Operating Temperature
Discharging: -20°C ~ 55°C

Storage Temperature 0°C ~ 45°C

500 times (80% of initial capacity at 0.2C rate,

Cycle Life
IEC Standard)
SPECIFICATIONS OF MOTOR THAT SHOULD BE USED:

GOGOA1 Electric Motorcycle Conversion Kit Hub Motor 2000W 72V 17

Inch with Lithium Phosphate BLDC

PRICE:10,500Rs

Product Specification
Engine Type Brushless DC (BLDC)_ Hub Motor
Color Black/Silver
Packing Type Standard
Vehicle Model Any
Speed 60-70Km/hr
Control Mode DC Drive
Brand GoGOA1.com
Material Aluminium
Power Power
Torque 38.4Nm
Battery Capacity 18Ah
Battery 72V
Battery Type Lithium Phosphate(LiFePO4)
Motor Advantage/Features:

• 10 Paisa/Km

• Easy To Convert

• Quick Acceleration

• Speed 60-70Km

• Good Climbing Ability

• Hydraulic Disc Brake

• Brushless Maintenance Free Motor

• No Range Limitation

• Detachable Battery

• Charging Time 2 hours

 SPECFICATIONS OF MOTOR THAT SHOULD
BE USED:

BtrPower 72V 5A Ebike Battery Charger for 72V

Electric Bicycle LiFePO4 Battery Pack 87.6V Output AC110V

PRICE=3000Rs
• 72V 5A Smart Charger for 72V 24s Lifepo4 Lithium Battery
• Charging mode: constant current - Constant Voltage - trickle (floating charge) three-stage intellig
charging
• Working power: 110V/AC, 50 ~ 60Hz
• Output voltage: 87.6V (For 24S LiFePO4 Battery) , Output current: 5A
• 30-days free return and 1 year warranty.

Weight: 750g
MAIN BODY DESIGN:
CONCLUSION:

With so many benefits to owning an electric scooter, its no wonder why so many people are using them. A
there is a demand for such products, you can also expect quality and technology to continuously improve.

In larger cities, electric scooters have already become the preferred way to get around. Whether you have
adding to your existing transportation resources, or replacing current forms of transportation, an electric sc
could be the answer.

An Electric scooter is designed which is suitable for rural as well as urban areas. We can made this scoote
assembling various components.

Fuel rates are increasing day by day this electric scooter is the best replacement for conventional scooters
REFERENCE:

https://electric-scooter.guide/guides/definitive-guide-electric-scooters/

https://www.academia.edu/37902530/Electrical_Scooter_Mechanical_Engineering_Design_

https://www.slideshare.net/scooteretticompany/the-benefits-of-electric-scooters
CONCLUSION: