FABRICATION OF SOLAR BICYCLE

SUBMITTED BY

SNRNAME REG
VARUN . S 21207772
PRASANTH . S 21207739
VISHNU RAJESH . K 21207775
SHARATH KUMAR . G . U 21207760
SANJEEV . K 21207752
SRI HARI . V 21207766

Under the guidance of

Mr.Rayaparaj
Project report submitted in partial fulfillment of the requirement for the
Award of

"DIPLOMA IN MECHANICAL ENGINEERING"

of the Directorate of Technical Education, Government of Tamil Nadu.

SRI RAMAKRISHNA POLYTECHNIC COLLECE

DEPARTMENT OF MECHANICAL ENGINEERING
VATTAMALAIPALAYAM, COIMBATORE-641022.

2022-2023
 SRI RAMAKRISHNA POLYTECHNIC COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the project work entitled "FABRICATION OF SOLAR

BICYCLE " was carried by
NAME:_______________________REG NO:________________was submitted for
the "VIVA-VOCE" held on____________. In partial fulfillment of the requirement for
the award of Diploma in Mechanical Engineering of the Directorate of Technical
Education, during the academic year 2017-2018.

GUIDE HOD

Station:
Date:
Submitted for the VIVA-VOCE Examination held on_______________
INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

We would like to thank our beloved Managing Trustee Thiru.D.LAKSHMI

NARAYANASWAMY & Joint Managing trustee Thiru . R. SUNDAR for providing
us with excellent lab facilities which greatly helped us to carry our project work.

We express our sincere thanks to our beloved Principal Dr.R.N.Uma who has granted
permission for immediately starting this project work. Our grateful and sincere thanks
to our Head of our department Mr. V.Sureshkumar,ME., who has been a constant
source support for us.

Our heart full thanks to our beloved staff and guide Mr.S.Dhanasekhar, ME., for his
consistence guidance and valuable suggestions given for the successful completion of
our project work.

The various suggestions related to this project work were collected from various staff
members of Mechanical department and this kind of encouragement from our staff's
has made this project work a successful one.

This entire frame goes to our beloved parents who are really interested and has high
expectations on us to become a successful engineer. We dedicate this remarkable work
to our beloved parents.
FABRICATION OF SOLAR BICYCLE

CONTENTS

CHAPTER NO TITLE
 SYNOPSIS

1 Introduction

2 Literature review

3 Description of equipments

3.1 Solar

3.2 Battery

3.3 Spur gear

4 Components and drawing

4.1 General machine Specifications

4.2 Overall diagram

5 Working principle

6 Merits & demerits

7 Applications

8 List of materials

9 Cost Estimation

10 Conclusion

11 Photography
 SYNOPSIS

SYNOPSIS

All automobile vehicles consume the fuel for running. Nowadays the demand of
fuel and cost of fuel is increased. So we need other resources of energy is for
transportation. So that we are go for other type of energy like electric power, solar
power etc…It may be noted that solar energy is easily available with free of cost. The
one motor is used to run the cycle.
 CHAPTER-1
INTRODUCTION

.
 CHAPTER – I

INTRODUCTION

BICYCLE

Bicycles were introduced in the 19th century and now number about one billion
worldwide. They are the principal means of transportation in many regions. They also
provide a popular form of recreation, and have been adapted for such uses as children's
toys, adult fitness, military and police applications, courier services, and competitive
sports.

The basic shape and configuration of a typical bicycle has changed little since
the first chain-driven model was developed around 1885. Many details have been
improved, especially since the advent of modern materials and computer-aided design.
These have allowed for a proliferation of specialized designs for particular types of
cycling.

The bicycle has had a considerable effect on human society, in both the cultural
and industrial realms. In its early years, bicycle construction drew on pre-existing
technologies; more recently, bicycle technology has, in turn, contributed both to old
and new areas. We have to introduce our new project about “SOLAR POWERED
ELECTRIC BICYCLE” which runs with the help of sun light without any fuel. In this
project we have implemented our ideas to future generations for transportation. In our
solar bicycle solar energy is converted into electrical energy by means of solar panel,
battery, solar controller. The electrical energy is stored in the battery and supplied to
hub motor through controller. This project deals with this system, which covert solar
energy to electrical energy.
 The main objective of our project is Now a days the usage of bicycle for shorter
distance has reduced because of the pedaling, time etc. Our project about solar
powered electric bicycle which runs with help of both sunlight and the help of
pedaling. The solar energy is converted into electrical energy by solar panel, battery,
converter and the power is transmitted to the hub motor to run the cycle. We hope that
this model bicycle runs with the operation of no emission. Due to this in upcoming
years the usage of the bicycle for shorter distance will be increased and it also helps to
reduce the pollutions like air & noise
 CHAPTER-2

LITERATURE SURVEY

CHAPTER-II

LITERATURE SURVEY

HISTORY OF THE BICYCLE

 Multiple innovators contributed to the history of the bicycle by developing
precursor human-powered vehicles. The documented ancestors of today's modern
bicycle were known as push bikes (still called push bikes outside of North America),
draisines, or hobby horses. Being the first human means of transport to make use of
the two-wheeler principle, the draisine (or mistmashine, "running machine"), invented
by the German Baron Karl von Drais, is regarded as the archetype of the bicycle. It was
introduced by Drais to the public in Mannheim in summer 1817 and in Paris in 1818. Its
rider sat astride a wooden frame supported by two in-line wheels and pushed the
vehicle along with his/her feet while steering the front wheel.

In the early 1860s, Frenchmen Pierre Michaux and Pierre Lallement took bicycle
design in a new direction by adding a mechanical crank drive with pedals on an
enlarged front wheel. Another French inventor by the name of Douglas Grasso had a
failed prototype of Pierre Lallement's bicycle several years earlier. Several why-not-
the-rear-wheel inventions followed, the best known being the rod-driven velocipede
by Scotsman Thomas McCall in 1869. The French creation, made of iron and wood,
developed into the "penny-farthing" (more formally an "ordinary bicycle", a retronym,
since there were then no other kind). It featured a tubular steel frame on which were
mounted wire spoked wheels with solid rubber tires.

These bicycles were difficult to ride due to their very high seat and poor weight
distribution. The dwarf ordinary addressed some of these faults by reducing the front
wheel diameter and setting the seat further back. This necessitated the addition of

gearing, affected in a variety of ways, to attain sufficient speed. Having to both

pedal and steer via the front wheel remained a problem. J. K. Starley, J. H. Lawson, and
 Shergold solved this problem by introducing the chain drive (originated by Henry
Lawson's unsuccessful "bicyclette"), connecting the frame-mounted pedals to the rear

wheel. These models were known as dwarf safeties, or safety bicycles, for their lower
seat height and better weight distribution. Starley's 1885 Rover is usually described as
the first recognizably modern bicycle. Soon, the seat tube was added, creating the
double-triangle diamond frame of the modern bike.

Further innovations increased comfort and ushered in a second bicycle craze, the
1890s' Golden Age of Bicycles. In 1888, Scotsman John Boyd Dunlop introduced the
pneumatic tire, which soon became universal. Soon after, the rear freewheel was

developed, enabling the rider to coast. This refinement led to the 1898 invention of
coaster brakes. Derailleur gears and hand-operated cable-pull brakes were also developed

during these years, but were only slowly adopted by casual riders. By the turn of the
century, cycling clubs flourished on both sides of the Atlantic, and touring and racing
became widely popular.

Bicycles and horse buggies were the two mainstays of private transportation just
prior to the automobile, and the grading of smooth roads in the late 19th century was
stimulated by the widespread advertising, production, and use of these devices.
 CHAPTER-3

DESCRIPTION OF EQUIPMENT

CHAPTER-III
 DESCRIPTION OF EQUIPMENTS

3.1 SOLAR PANEL

A solar panel is a device that collects and converts solar energy into electricity
or heat. It known as Photovoltaic panels, used to generate electricity directly from
sunlight Solar thermal energy collection systems, used to generate electricity through a
system of mirrors and fluid-filled tubes solar thermal collector, used to generate heat
solar hot water panel, used to heat water. It is energy portal. A solar power technology
uses solar cells or solar photovoltaic arrays to convert light from the sun directly into
electricity.Photovoltaics, is in which light is converted into electrical power. It is best
known as a method for generating solar power by using solar cells packaged in
photovoltaic modules, often electrically connected in multiples as solar photovoltaic
arrays to convert energy from the sun into electricity. The photovoltaic solar panel is
photons from sunlight knock electrons into a higher state of energy, creating
electricity.
 Solar cells produce direct current electricity from light, which can be used to
power equipment or to recharge a battery. A less common form of the technologies is
thermophotovoltaics, in which the thermal radiation from some hot body other than
the sun is utilized. Photovoltaic devices are also used to produce electricity in optical
wireless power transmission.

Solar Panel 

 SKU: SO.PO.1624862

 Watt: 5 Watt

 Warranty Duration: 25 Years of warrantyRated

 Power Range: 1-30 W

 Module Voltage: 12

 VShort Circuit Current: 0.3 A

 Module Dimension (L x W x T): 304 x 184 x 15 mm

 Type of Product: Polycrystalline

 Voltage at Pmax ( V): 17.3 V

 Junction Box: Normal Junction Box With Diode

 Applications: Home, Outdoor And Commercial Use

 Open Circuit Voltage: 21.6 V

 Tolerance: 0.01Cell Efficiency: 0.176

 No. of Cells: 36Panel Type: Polycrystalline

 Warranty Type: 25 Years Power Output Warranty

3.2. BATTERY

Battery is use for storing the energy produced from the dynamo. The battery
used is a lead-acid type and has a capacity of 12v; 2.5A.the most inexpensive
secondary cell is the lead acid cell and is widely used for commercial purposes. A lead
acid cell when ready for use contains two plates immersed in a dilute sulphuric acid
(H2SO4) of specific gravity about 1.28.the positive plate (anode) is of

Lead –peroxide (PbO2) which has chocolate brown colour and the negative plate
(cathode) is leading (Pb) which is of grey colour. When the cell supplies current to a
load (discharging), the chemical action that takes place forms lead sulphate (PbSO 4)
on both the plates with water being formed in the electrolyte. After a certain amount of
energy has been withdrawn from the cell, both plates are transformed into the same
material and the specific gravity of the electrolyte (H 2so4) is lowered. The cell is then
said to be discharged. There are several methods to ascertain whether the cell is
discharged or not.

To charge the cell, direct current is passed through the cell in the reverse
direction to that in which the cell provided current. This reverses the chemical process
and again forms a lead peroxide (PbO2) positive plate and a pure lead (Pb) negative
plate. At the same time, (H2so4) is formed at the expense of water, restoring the
electrolyte (H2so4) to its original condition. The chemical changes that Occur during
discharging and recharging of a lead-acid cell.
BATTERY CIRCUIT DIAGRAM

CIRCUIT DIAGRAM DETAILS

In our project we are using secondary type battery. It is rechargeable Type. A

battery is one or more electrochemical cells, which store chemical energy and make it
available as electric current. There are two types of batteries, primary (disposable) and
secondary (rechargeable), both of which convert chemical energy to electrical energy.
Primary batteries can only be used once because they use up their chemicals in an
irreversible reaction. Secondary batteries can be recharged because the chemical
reactions they use are reversible; they are recharged by running a charging current
through the battery, but in the opposite direction of the discharge current. Secondary,
also called rechargeable batteries can be charged and discharged many times before
wearing out. After wearing out some batteries can be recycled.

Batteries have gained popularity as they became portable and useful for many
purposes. The use of batteries has created many environmental concerns, such as toxic
metal pollution. A battery is a device that converts chemical energy directly to
electrical
 energy it consists of one or more voltaic cells. Each voltaic cell consists of two
half cells connected in series by a conductive electrolyte.

One half-cell is the positive electrode, and the other is the negative electrode.
The electrodes do not touch each other but are electrically connected by the
electrolyte, which can be either solid or liquid. A battery can be simply modeled as a
perfect voltage source which has its own resistance, the resulting voltage across the
load depends on the ratio of the battery's internal resistance to the resistance of the
load.

When the battery is fresh, its internal resistance is low, so the voltage across the
load is almost equal to that of the battery's internal voltage source. As the battery runs
down and its internal resistance increases, the voltage drop across its internal
resistance increases, so the voltage at its terminals decreases, and the battery's ability
to deliver power to the load decreases.

3.3 SPUR GEAR

A gear is a rotating machine part having cut teeth, or cogs, which mesh with
another toothed part in order to transmit torque. Two or more gears working in tandem
are called a transmission and can produce a mechanical advantage through a gear ratio
and thus may be considered a simple machine. Geared devices can change the speed,
torque, and direction of a power source. The most common situation is for a gear to
mesh with another gear; however a gear can also mesh a non-rotating toothed part,
called a rack, thereby producing translation instead of rotation.

The gears in a transmission are analogous to the wheels in a pulley. An

advantage of gears is that the teeth of a gear prevent slipping.
 When two gears of unequal number of teeth are combined a mechanical
advantage is produced, with both the rotational speeds and the torques of the two gears
differing in a simple relationship.

In transmissions which offer multiple gear ratios, such as bicycles and cars, the
term gear, as in first gear, refers to a gear ratio rather than an actual physical gear. The
term is used to describe similar devices even when gear ratio is continuous rather than
discrete, or when the device does not actually contain any gears, as in a continuously
variable transmission.

The earliest known reference to gears was circa A.D. 50 by Hero of Alexandria,
but they can be traced back to the Greek mechanics of the Alexandrian school in the
3rd century B.C. and were greatly developed by the Greek polymath Archimedes
(287–212 B.C.). The Antikythera mechanism is an example of a very early and
intricate geared device, designed to calculate astronomical positions. Its time of
construction is now estimated between 150 and 100 BC.
 The definite velocity ratio which results from having teeth gives gears an
advantage over other drives (such as traction drives and V-belts) in precision machines

such as watches that depend upon an exact velocity ratio. In cases where driver
and follower are in close proximity gears also have an advantage over other drives in
the reduced number of parts required; the downside is that gears are more expensive to
manufacture and their lubrication requirements may impose a higher operating cost.

The automobile transmission allows selection between gears to give various

mechanical advantages.

An external gear is one with the teeth formed on the outer surface of a cylinder
or cone. Conversely, an internal gear is one with the teeth formed on the inner surface
of a cylinder or cone. For bevel gears, an internal gear is one with the pitch angle
exceeding 90 degrees. Internal gears do not cause direction reversal.

Spur gears or straight-cut gears are the simplest type of gear. They consist of a
cylinder or disk with the teeth projecting radially, and although they are not straight-
sided in form, the edge of each tooth is straight and aligned parallel to the axis of
rotation. These gears can be meshed together correctly only if they are fitted to parallel
shafts.
 CHAPTER-4

COMPONENTS AND DRAWING

CHAPTER-IV
 COMPONENTS AND DRAWING

4.1 COMPONENTS

The “SOLAR CYCLE” is consists of the following components to full fill the
requirements of complete operation of the machine.

1. Spur gear
2. Battery
3. Solar
 DRAWING

DRAWING FOR SOLAR CYCLE

 CHAPTER -5

WORKING PRINCIPLE
 CHAPTER-V

WORKING PRINCIPLE

In this project the solar panel is used to get an electric power from direct
sunlight. The electrical power from solar panel is used to operate the DC motor. In this
arrangement the wheel rotation is obtained by front side DC motor. So operating of the
cycle is very easy and no man power is required to drive the cycle.
 CHAPTER -6

MERITS AND DEMERIT

 CHAPTER-VI

MERITS AND DEMERIT

MERITS

 Simple Construction
 The man power is needed only to switch off/on the motor
 Sunlight is a easily available source
 Compact
 Easy maintenance
 Power is gained in two ways
 Power is ready to store in battery

DEMIRT

Solar energy can be gained only when the sun light is available.
 CHAPTER -7

APPLICATIONS
 CHAPTER-VII

APPLICATIONS
 It can be installed in all kinds of cycles for old persons and children.
 It will minimize the cost of buying new motor cycles.
 CHAPTER-8

LIST OF MATERIALS
 CHAPTER-VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed below.

1. Properties:
The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand environmental attack

from chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively affect

their selection

a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,

electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance,

impact resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness,
wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.
2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of
special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of components
which can be fabricated much more economically by welding or hand forging the
steel.

4. Availability of Material:

Some materials may be scarce or in short supply. It then becomes obligatory for
the designer to use some other material which though may not be a perfect substitute
for the material designed. the delivery of materials and the delivery date of product
should also be kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the forces involved are
high and space limitations are there.

6. Cost:
 As in any other problem, in selection of material the cost of material plays an
important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance of

the designed part are involved in the selection of proper materials.
 CHAPTER-9

COST ESTIMATION
 CHAPTER-IX

COST ESTIMATION
1. TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

= 5000+2000+2000

= 9000

Total cost for this product = Rs 9000

CHAPTER-10
CONCLUSION
 CHAPTER-X

CONCLUSION
The project carried out by us made an impressing task in the field of automobile
department. It is very useful for having the two wheeler, because they need not spend
the lot of money for the fuel.

This project will reduce the cost involved in the concern. Project has been designed to
perform the entire requirement task at the shortest time available.
PHOTOGRAPHY