–

Design And Simulation Of Drive Train For An

Electric Two Vehicle
Submitted in partial fulfilment of the requirements for the degree of

Bachelor of Technology
In

MECHANICAL ENGINEERING

By

Dhruvjyot Singh Cheema (18BME0818)

Saloni Saxena (18BEM0105)
Shristi Pandey (18BME0794)

Under the guidance of Prof. Anandavel K

School of Mechanical Engineering, VIT, Vellore.
 ACKNOWLEDGEMENT

It gives us a great sense of pleasure to present the report of the B. Tech Project undertaken
during. Tech. third Year. We owe special debt of gratitude to Professor In charge Prof
Anandavel K, School of Mechanical Engineering, Department of Manufacturing
Engineering, Vellore Institute of Technology, Vellore (Tamil Nadu) for his constant support and
guidance throughout the course of our work. His sincerity, thoroughness and perseverance
have been a constant source of inspiration for us. It is only his cognizant efforts that our
endeavors have seen light of the day. We also do not like to miss the opportunity to
acknowledge the contribution of all faculty members of the department for their kind
assistance and cooperation during the development of our project. Last but not the least, we
acknowledge our friends for their contribution in the completion of the project.
 CONTENTS:

1. ABSTRACT
i. BACKGROUND
ii. STATEMENT OF PROBLEM

2. LITERATURE SURVEY
i. REDUCTION GEAR BOX
ii. HOW INSERTING A REDUCTION GEAR BOX CAN IMPROVE THE
EFFICIENCY OF AN ELECTRIC VEHICLE
iii. LIMITATIONS IN ALREADY EXISTING PRODUCT
iv. OUR APPROACH TO IMPROVE THE ALREADY EXISTING PRODUCT
(ELECTRIC VEHICLES)

3. MARKET ANALYSIS
i. ELECTRIC VEHICLES MARKET SCENARIO
ii. STEADY DEMAND FROM TRHE AUTOMOTIVE INDUSTRY TO
CONTRIBUTE TO THE GROWTH OF THE GLOBAL REDUCTION GEARBOX
MARKET

4. CALCULATIONS
i. OPTIMUM LAP TRACTION LAP
ii. GEAR RATIO
iii. RESISTENCE CALCULATIONS
iv. POWER AND RPM CALCULATIONS
v. ITERATIONS AS PER DIFFERENT GEAR RATIOS
vi. CHAIN CALCULATIONS (I)
vii. CHAIN CALCULATIONS (II)

5. CAD DESIGN MODEL

6. SIMULATIONS
 i. PINION
ii. TOTAL DEFORMATION OF MESHING OF TWO GEARS
iii. SAFETY FACTOR OF MESHING OF TWO GEARS
iv. STATIC STRUCTURAL ANALYSIS OF THE CONSTANT REDUCTION GEARS
v. SAFETY FACTOR OF CONSTANT REDUCTION BOX
vi. STATIC STRUCTURAL ANALYSIS (I)
vii. STATIC STRUCTURAL ANALYSIS (II)
viii. STATIC STRUCTURAL ANALYSIS (III)

7. SWOT ANALYSIS

8. FMEA ANALYSIS

9. COST ANALYSIS

10. CONCLUSION

11. REFERENCES
 BACKGROUND:

Electric vehicles are the future of transportation which offers multiple advantages

over petrol and diesel transportations currently available. The benefits of using

electric vehicles are huge in terms of running costs, performance and comfort: much

faster acceleration, no vibrations, low cost per mile of charging. Depletion of natural

resources like fossil fuels which run the entire transportation system can now be

replaced with much effective and environment friendly transportation system.

STATEMENT OF PROBLEM:

As an engineer it is our duty to build as well as improve such products which are

beneficial for our humanity. Therefore, our aim in this project is to improve the

already existing electric vehicles in the market by incorporating gear box reduction

in order to improve its efficiency.

 LITERATURE SURVEY:

REDUCTION GEAR BOX:

A reduction gear is an arrangement by which an input speed can be lowered for a
requirement of slower output speed, with more output torque. Reduction gear
assembly consists of a set of rotating gears connected to a wheel work. The high-
speed incoming motion from the wheel work is transmitted to the set of rotating
gears, wherein the motion or torque is changed. The number of gears used in the
reduction gear assembly depends on the output speed requirement of the
application.

HOW INSERTING A REDUCTION GEARBOX CAN IMPROVE THE

EFFICIENCY OF AN ELECTRIC VEHICLE:

1. If the load connected to the motor does not require the full rated torque of the

motor, it will spin slightly faster, draw less current, and produce only enough

torque to meet the needs of the load. If the load exceeds the rated capacity of

the motor, it will run slower than the nameplate full-load speed, draw more

than the rated current, and will run hotter. If the load significantly exceeds the

torque capacity of the motor, it may stall.

2. All a gearbox does is change the output speed of the motor, and - consequently

- the torque that can be produced. A 10 Hp 1750 RPM motor is rated to produce

30 ft.lbs of torque. Apply a 2:1 reduction gearbox to it and the rated output

speed drops to 875 RPM and the torque capacity doubles to 60 ft.lbs - ignoring

efficiency losses in the gearbox.

LIMITATION OF ALREADY EXISTING PRODUCT (ELECTRICAL
VEHICLE):

1. Total system efficiency (motor plus gearbox) is neither clearly understood nor
easily calculated. This makes gearbox efficiency specifications found in product
catalogues unreliable.

2. In a system, where motor drives a load to achieve precise positioning, velocity or

torque; the Ratio of the load inertia to motor inertia plays a significant role in
determining the motor’s ability to effectively and efficiently control the load.

3. Therefore, vehicles without constant reduction box, the inertia ratio will be too
high, i.e. if load Inertia is much higher than the motor inertia, it will cause
position accuracy and control of Velocity and torque.

OUR APPROACH TO IMPROVE THE ALREADY EXISTING PRODUCT

(AN ELECTRIC VEHICLE):

Most of the two-wheeler electric vehicles does not have gear reduction box, therefore,
in order to improve our product:

1. Our transmission system consists of duplex chain to transmit power from

motor to a reducer box. The power further is transmitted to wheels using
chain.
2. The reducer will be having two or three Speed reduction sequences and then
there will be a speed reduction in the final drive ratio.
3. For review 1 we have worked using optimum lap software. We have analysed
the best gear reduction which would give us best top speed and best torque
reduction.
 MARKET ANALYSIS
(SURVEYS AND SCENARIO ANALYSIS)

Talking about ‘The Electric Vehicles Market’, it is projected to reach 26,951,318 units
by 2030 from an estimated 3,269,671 units in 2019, at a CAGR of 21.1% during the
forecast period. The base year for the report is 2018, and the forecast period is from
2019 to 2030. The electric vehicle market has witnessed rapid evolution with the
ongoing developments in automotive sector. Favourable government policies and
support in terms of subsidies and grants, tax rebates and other non-financial benefits
in the form of car pool lane access, and new car registration (specifically in China
where ICE engine new car registration are banned in some urban areas) the increasing
vehicle range, better availability of charging infrastructure and proactive participation
by automotive OEMs would drive the global electric vehicle sales.
 STEADY DEMAND FROM THE AUTOMOTIVE
INDUSTRY TO CONTRIBUTE TO THE GROWTH OF
THE GLOBAL REDUCTION GEARBOX MARKET

Reduction gearbox offers huge reduction ratio as compared to standard motors. This
allows huge turning of the main gear with a little directional shift of the worm gear in
the worm reduction gear box. This permits the user to decrease the speed while
simultaneously increasing the torque. This enables efficient handling, convenient
direction changes and reduced downtime of the engine. In addition, need for a
backstop is eliminated as the setup is easily simplifies with a worm reduction gearbox.
This is due to its low reverse power that enables the gear to move in one direction.
Relatively in a standard gear set up, power reversing more components in the machine
along with a backstop. Worm reduction gearbox is ideal preference for a machine that
requires less speed and more torque, for example, a conveyor belt system. Second
benefit lies in its simplicity as additional gears are not required to carry out to increase
or decrease the speed of the machine.

The key stakeholders in the global reduction gearbox market include:

• Precision Gears Inc.

• Gear Manufacturing Inc
• Essor Precision Company
• HPC Gears
• Avon Gear and Engineering
• Berg
• Mitsubishi and Gear Motions

REGIONAL SEGEMNTS ANALYSED INCLUDES:

• North America (U.S., Canada)

• Latin America (Mexico. Brazil)
• Western Europe (Germany, Italy, France, U.K, Spain)
 • Eastern Europe (Poland, Russia)
• Asia Pacific (China, India, ASEAN, Australia & New Zealand)
• Japan
• Middle East and Africa (GCC, S. Africa, N. Africa)

Apart from high-torque, the reduction gearbox (particularly worm type) is durable,
highly efficient, wear resistant, high strength, and requires low maintenance and less
lubrication. These factors are expected to earn high traction in the reduction gearbox
market. The worm reduction gearbox plays an important role in construction of
windmills; continuous emphasis on harnessing of renewable wind energy will possibly
fuel growth of the worm reduction gearbox in the near future. As product innovation is
readily adopted in the market, manufactures are focusing on incorporation of
advanced technologies to improve the quality and usage, thereby accelerating the
growth prospects of reduction gearbox market.
CALCULATIONS

Optimum lap traction lap

Gear Ratio
 Resistance Calculation

Power and RPM Calculation

Iterations as per different gear ratios

Chain calculation (I)

Chain calculation (II)
CAD DESIGN
 SIMULATIONS

PINION

TOTAL DEFORMATION OF MESHING OF TWO GEARS

 SAFETY FACTOR OF MESHING OF TWO GEARS

STATIC STRUCTURAL ANALYSIS OF THE CONSTANT REDUCTION GEARS

SAFETY FACTOR OF CONSTANT REDUCTION BOX

STATIC STRUCTURAL ANALYSIS (I)

STATIC STRUCTURAL ANALYSIS (II)

STATIC STRUCTURAL ANALYSIS (III)

 SWOT Analysis

Strengths Weaknesses Opportunities Threats

• Quality: The • Expense: It • Electric Vehicle • Even though the

constant reduction requires a have a potential probability of error
box has the significant initial market for our is very low, Since it
capacity to investment for mass product. is a mechanical
dramatically production of the parts moving if
improve the product. • Using this will lubrication is not
product quality. result in high provided in regular
• Return on performance with basis then it could
• Production: It Investment: simple structure. break leading to
helps giving more Without planning injuries while
torque than usual companies can have riding.
which would help some difficulties
us reduce load on achieving their
the motor. goals.

• Safety: Since it Will not be able to

does not have more give high
parts than a Gear performance when
box, so it is safer. compared to a Gear
box
• Savings: Less
parts than in a
Gearbox so more
saving.
 FMEA ANALYSIS

We have considered the following failure modes detecting the effects and finding the
solutions of the problem caused is our sole purpose of creating the FMEA analysis.
 COST ANALYSIS
In most companies, product design and manufacturing groups generally operate as
separate, autonomous functions. Whether it concerns machining parts, developing jigs
and fixtures or making models, manufacturing engineers, machinists and production
personnel typically do not get involved in the development of a product until the design
is released for production by a design engineer.

The product development transition from design to manufacturing is almost always a

handoff of 3D design and tooling data and associated 2D drawings. Since designers and
manufacturing engineers use different tools for handling design data—one uses CAD
software to design the product and the other uses another application to create tool
paths and machine models. The handoff has typically not been clean, requiring data
imports, translations and conversions. Moreover, once the handoff is made, a virtual
wall in terms of communication can go up between design and manufacturing. This lack
of communication is the basic problem that we are willing to overcome by drawing out a
cost analysis beforehand. However, the potential positive ramifications of the solution
are much more widespread.

Disclaimer: The above cost analysis uses data based on industry averages and typical
manufacturing practices, and should therefore be viewed only as a guide. Actual costs
may vary based on the specific manufacturer, equipment, geographical location, and
prevailing market conditions.

MATERIAL Minimum cost Maximum cost

Mild Steel Rs. 45/kg Rs. 50/kg
Stainless Steel Rs. 130/kg Rs. 150/kg

Weight of one gear = 25-50 pounds

= 18-22 kg
MATERIAL Minimum cost/ piece Maximum cost/ piece
Mild Steel Rs. 810 Rs. 2250
Stainless Steel Rs. 2340 Rs. 2700

Gear Manufacturing cost = Rs. 800 (approximately)

No. of gears in usage= 4
Total manufacturing cost= Rs. 4*800 = Rs. 3200
Casing cost= Rupees 2800

Bearings cost=Rupees 200

Cost of rods Rupees 90/kg to 298/kg (for 3 meters)
Total cost= Rupees 6290
 CONCLUSION

The conclusion that we derive from our project are as follows:

The constant reduction box increases the torque and therefore if we increase the load,
due to more torque the motor would not stall or burn out, this is possible because of
constant reduction box.
The application of constant reduction box in electric vehicles will at last contribute
towards the performance and efficiency of electric vehicles.
 REFERENCES

1. http://cybra.lodz.pl/Content/3714/DesignBasicInd.pdf

2. https://www.ckit.co.za/secure/conveyor/troughed/drive_units_complete/drive_
units_beginners.html

3. https://www.automobileinformer.com/2019/11/what-is-gearbox-and-types-of-
gearbox.html

4. https://www.factmr.com/report/710/worm-reduction-gearbox-market

5. https://www.marketsandmarkets.com/Market-Reports/electric-vehicle-market-
209371461.html#:~:text=The%20Electric%20Vehicles%20Market%20is,is%20fro
m%202019%20to%202030.

6. http://cybra.lodz.pl/Content/3714/DesignBasicInd.pdf

7. https://www.researchgate.net/publication/324264515_Characteristics_of_Redu
ction_Gear_in_Electric_Agricultural_Vehicle