A Major Project Report on

Fabrication Of Foot Ball Launcher Machine

Submitted in partial fulfilment of the requirement of the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

Under

JNTU Hyderabad
By

MOHAMMED ILYAS KHAN 15M21A03BO

Under the esteemed Supervision of

Mr. Sarap Raghavendra
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Accredited by NBA & NAAC ‘A’ Grade, Approved by AICTE & Affiliated to
JNTU-Hyderabad SY.NO.32, Himayathsagar, Golconda Post, Near Appa
Junction, Hyderabad-500091, India.
2020
 i

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC - Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate

This is to certify thatthe project report entitled DESIGN AND FABRICATION OF

ELECTRIC GOLF CART,is bonafide record of the work successfully and submitted by

MOHAMMED ILYAS KHAN 15M21A03BO Under the guidance of supervisor,

Mr.MOHD YOUSUF AHMED, Assistant Professor, of Mechanical Engineering

Department, for the requirement of partial fulfillment for the award of degree of

Bachelor of Technology in Mechanical Engineering during the academic year 2016-

2020 from JNTU, Hyderabad.

Mr. Md Misbahuddin Dr. Syed Azam Pasha Quadri

Internal Guide Vice Principal &Head of the Department

Dr. Mohammed Yusuf Ali

Principal External Examiner
 ii

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to
JNTUH/Estd.2002. Accredited ‘A’
grade by NAAC - Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Declaration

We hereby declare that major project report entitled “DESIGN AND

FABRICATION OF ELECTRIC GOLF CART” is being submitted by us in
partial fulfilment for the award of Bachelor of Technology in the Department of
Mechanical Engineering at the Lords Institute of Engineering and Technology,
Telangana-500091, is the result of investigations carried out by us under the
Guidance of Mr. Md Misbahuddin, Assistant Professor Department of
Mechanical Engineering, Lords Institute of Engineering and Technology.

The work is original and has not been submitted for any Degree or
Diploma for this or any other university.

MOHAMMED ILYAS KHAN 15M21A03B0

 iii

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to
JNTUH/Estd.2002. Accredited ‘A’
grade by NAAC - Accredited by NBA
DEPARTMENT OF MECHANICAL ENGINEERING
Acknowledgement

MOHAMMED ILYAS KHAN

15M21A03B0
khanilyaskhan62@gmail.com

In the name of almighty, the most beneficent and the most merciful, we
thank the lord for helping us in all the stages of this thesis work.

We would like to thank our guide Mr. Md Misbahuddin, Assistant Professor

for his aspiring guidance and friendly advice during the project work. He was a
constant motivation throughout the project and took out some of his valuable time
whenever it was required for which we are very grateful to him. We would be
grateful for his motivation and co-operation at various stages, which provided us
the knowledge base and the understanding of the potential projects in this field
finally. We also appreciate the concern of my parents, friends and other staff
members at the college.

We express our sincere and deep gratitude to Dr. Syed Azam Pasha Quadri,
Vice Principal & Head of the Department for his support throughout our project
 iv

and all the teaching and non-teaching staff of Lords Institute of Engineering
and Technology who has helped and cooperated with us. It gives us great
pleasure in

acknowledging the support and help from my guide for his immense
guidance throughout the project.
Our experience here has been full of opportunities to learn from faculty
with a wide and deep expertise in Engineering. We would like to thank our
beloved Principal Dr. Mohammed Yousuf Ali. And we would like to directly
thank those people in the department who were particularly instrumental in
contributing to our experience at Lords Institute of Engineering and
Technology.

We thank both teaching and non-teaching staff members of mechanical

department for their kind cooperation and all sorts of help to bring out this
project work successfully.

Lastly, we drive great pleasure and we would like to specially thank our
parents for their patience, continuous encouragement, support and love given
towards completion of our research work.
 v

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC - Accredited by NBA

Major Project Assessment Process

PROGRAMME: UG DEGREE: B.TECH (MECHANICAL)

COURSE: MAJOR PROJECT Year: IV SEM: II CREDITS: 15

COURSE CODE: A80088 UNIVERSITY: JNTUH REGULATION: R15

CONTACT HOURS: 3 Hours/Week.

Vision and Mission of the Department

Vision:

To impart high standards of quality education which enhance students

career efficaciously, to become a holistic well qualified engineers who are
competent, innovative, entrepreneurial and research oriented to meet the
standards of new millennium.

Mission:

DM1: An integrated educational approach that blends knowledge of engineering

fundamentals, technical skills, practical knowledge and research.

DM2: To enrich undergraduate experience of distinctive academic curriculum

through interaction with major stake holders, hands-on learning, team work,
management and multidisciplinary skill set.

DM3: To make students aware of professional responsibilities, ethics, global

demands, sustainable solutions, environmental, technological challenges and the
needs of lifelong learning.

DM4: To prepare students in developing solutions of global standards through

research and innovation, design and development of demand based projects,
entrepreneurial skills and employability capabilities.
 vi

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC - Accredited by NBA

Program Educational Objective (PEO)

To establish themselves as successful professionals with strong

fundamental knowledge in basic and engineering sciences to find
PEO 1 suitable
solutions of technological and real life challenges using innovative
tools.

To enhance technical competency and problems solving skills

through
state of art facilities for adequate solutions to technical problems.
PEO 2

Acquire high skill-set by continuous training, multi-disciplinary

PEO 3 activities,
team work, effective communications, Information Technology tools
usage, ethics and research and development facility so that students
shall
acquire good job opportunities and also will help in their higher
education.

Giving Research and consultancy services to industrial and societal

challenges and promoting department-industry interactions, by
PEO 4
enhancing technical, managerial, environmental responsibilities and
lifelong learning with sustainable development.
 vii

Program Outcomes (POs)

Engineering Graduates will be able to:

Program outcomes (POs):

1 Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex
engineering problems
2 Problem analysis: Identify, formulate, review research literature, and analyse
complex engineering problems reaching substantiated conclusions using first
principles of mathematics, natural sciences, and engineering sciences
3 Design/Development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified
needs with appropriate consideration for the public health and safety, and the
cultural, societal, and environmental considerations
4 Conduct investigations of complex problems: Use research-based knowledge
and research methods including design of experiments, analysis and interpretation
of data, and synthesis of the information to provide valid conclusions.
5 Modern tool usage: Create, select, and apply appropriate techniques, resources,
and modern engineering and IT tools including prediction and modelling to complex
engineering activities with an understanding of the limitations
6 The engineer and society: Apply reasoning informed by the contextual knowledge
to assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.

7 Environment and sustainability: Understand the impact of the professional

engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development
8 Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice
9 Individual and team work: Function effectively as an individual, and as a member
or leader in diverse teams, and in multidisciplinary settings
10 Communication: Communicate effectively on complex engineering activities with
the engineering community and with society at large, such as, being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions.

11 Project management and finance: Demonstrate knowledge and understanding of

the engineering and management principles and apply these to one’s own work, as
a member and leader in a team, to manage projects and in multidisciplinary
environments.

12 Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of
technological change
 viii

Program Specific Outcomes (PSO’s)

Professional Skills: An ability to understand the basic concepts in

Mechanical
PSO
Engineering and to apply them to various areas, like production, thermal,
1
designing etc., in the design and implementation of complex systems

Problem-Solving Skills: An ability to solve complex Mechanical

Engineering
PSO
2 problems, using latest hardware and software tools, along with analytical
skillsto arrive cost effective and appropriate solutions.

Details
The progress in the project work is to be presented by the middle of 4th year
2 semester before the evaluation committee. By this time, the students will be in
nd

a position to publish a paper in international/ national journals/conferences. The

EC can accept, accept with modification, and request a resubmission. The
progress of project work if found unsatisfactory by the EC during the middle of the
semester presentation, such students has to present again to the EC at the end of
the semester and if it is also found unsatisfactory an extension of the project work
can be given to the students.
The student’s sessional marks for project will be 100 which will be awarded
based on the presentation of the project by the students before an evaluation
committee, and external examiner.
 ix

Course Objectives:

SL NO Course Objectives

CO-1 To give a platform for the students to apply the theoretical knowledge they
gained during the course and conduct fabrication of experimental setup,
testing of the experimental setup and results are plotted on the graphs

CO-2 To enable the students to use different platforms for fabrication ofproject.

CO-3 To give a chance to improve communication skills and enable the

students to express the theoretical knowledge to defend.

CO-4 To impart theoretical knowledge about Vapour Compression Refrigeration

CO-5 System, Components of Refrigeration System

CO-6 To give the students a feel of working in a team environment and

contribute to the success of the project.
 x

Course Outcomes: C424. Major Project Work

S.No DESCRIPTION Bloom’s

Taxonomy Level

C426.1 Ability to effectively gather and interpret information from UnderstandLevel

literature survey. And use this knowledge to identify, formulate and 2
solve complex problems.

C426.2 Gain the ability to communicate effectively with written, oral, and Apply
visual means in a technical setting. Level 3

C426.3 Ability to use modern softwares to design braking system. Evaluate

Level 5
C426.4 Students will be able to carry out calculations of braking system, Apply
approches and procedure. Ability to fabricate system components Level 3
related to engineering problems.

C426.5 Ability to serve as effective team member to plan and complete the Analyse
project/task within a specified budget and time. Level 4

CO-PO AND CO-PSO MAPPING

PO PO PO PO PO PO PO PO PO PO PO PO1 PSO PSO

1 2 3 4 5 6 7 8 9 10 11 2 1 2
C426.1 3 3 2 2 1 - - - 2 - - 3 3 2
C426.2 - - - - - - - - - 3 - - - -
C426.3 - 2 2 2 2 - - - - - - - - 3
C426.4 - 2 1 2 - - - - 3 - - 3 3 2
C426.5 - - - - - - - - 3 - 3 2 - -
 xi

JUSTIFICATIONS FOR CO-PO MAPPING

MAPPING Levels JUSTIFICATION

C426.1-P01 H Students will be able to use the fundamental knowledge in the field of engineering to
solve the problems related to project work.
C426.1-P02 H Students will be able to formulate and can solve complex problems.
C426.1-P03 M Students will be able to design solutions for complex engineering problems.
C426.1-P04 M Students will be able to conduct a thorough research, design and fabrication of
experiment setup and analysis of the obtained result.
C426.1-P05 L Students will be able to apply appropriate techniques for braking system.
C426.2-P010 H Students will be able to effectively communicate their ideas and clarity the technical
details behind design and implementation of project.
C426.3-P02 M Students will be able to use modern design tools prior to modelling for braking
mechanism.

C426.3-P03 M Students will be able to use modern tools to design a product which is customer
friendly.
C426.3-P04 L Students will be able to use advance designing software to conduct a check on the
functionality of the product.
C426.4-P02 M Student will be able to make necessary design calculations and proper selection of
suitable materials.
C426.4-P03 L Student will be able to design and develop products which give utmost important to
social.
C426.4-P04 M Students will be able to design, fabricate and conduct performance testing on the
developed products.
C426.4-P09 H Students will be able to analyze the data and can prepare in a format for
presentation
C426.5-P011 H Students will be evolved as a good team players with better managerial skills.
 Xii

JUSTIFICATION FOR CO-PSO MAPPING

MAPPING LEVELS JUSTIFICATION

C426.1-PSO1 H Students will be able to apply their knowledge in fundamentals to find

suitable solution to the problems.
C426.1-PSO2 H Students will be able to make use of their understanding in the core areas
of mechanical engineering during the design and analysis.
C426.4-PSO1 H Students will be able to make use of the advance technologies to develop
new product which can sustain for a long time.
C426.4-PSO2 H Students will be able to come up with the products that has customer
acceptance

Mr. Md Misbahuddin Dr. Syed Azam Pasha Quadri

Internal Guide Vice Principal & Head of the Department

 xiii

Abstract

The world is suffering from vehicular pollution causing deadly respiratory

diseases, switching to electric vehicles will have no carbon emissions and also
would be eco friendly. For indoor uses and on short routes we can use an
electric cart to make commute easy.
The purpose of this project is to design and build Solar Equipped electric
buggy. This is a new configuration for a electric buggy and it requires an
entirely new chassis design that supports the loads placed on it and also
should be lighter in weight due to increase the output of the battery as less
work would be done. The chassis design implements structural battery boxes
which have the dual purpose of protecting the driver from the batteries and
adding strength to the frame, using the stressed battery boxes beneath the
floor gives the chassis excellent torsion stiffness.
This cart having rechargeable batteries could also be charged using solar panel
so apart from conventional battery charger it can be powered by mounting a
photovoltaic or thin film panel on top of the existing roof or using a photo
voltaic panel as the roof itself. A controller converts the sun's energy to charge
the golf carts 36-volt or 48-volt battery bank. Not only does the solar power
take the cart off the electric grid, it also increases the driving distance and
extends the life of the batteries.
Keywords: Chassis, batteries, controller, solar panel, electric
 Content

Certificate i
Declaration ii
Acknowledgement iii
Project Assessment process iv
Abstract v
List of Figures x
List of Tables xi
Abbreviations xii
Nomenclature xii

Chapter 1. Introduction 1
1. Introduction 2
1.1 .Solar Panel 3
1.2 Chassis 5
1.2.1. Types Of Chassis 6
1.2.1.1. Ladder Type Chassis 6
1.2.1.2 Backbone Type Chassis 6
1.2.1.3 Monocoque Type Chassis 7
1.2.1.4 Space Type Chassis 7
1.2.1.5 Combination Type Chassis 7
1.2.2 Chassis Used in Buggy 7
1.2.3. Chassis Material 8
1.2.3.1. Stainless Steel 8
1.2.3.2. Advantages Of Stainless Steel 9
1.2.3.3. Disadvantages Of Stainless Steel 9
1.2.3.4. Properties of Stainless Steel 10
1.3 Electric Motor 11
1.3.1.Types of Electric Motor 11

1.3.1.1. Brushless DC Motor 12

 1.3.2. Battery 14
1.3.2.1. Types Of Battery 15
1.3.2.2. Lead Acid Battery 15
1.3.3. Battery Charger 16
1.3.3.1. Voltage Regulator Knob 17
1.3.3.2.Current Regulating Knob 17
1.3.3.3. Miniature Circuit Breaker 17
1.4. Steering Mechanism 18
1.4.1 Function Of Steering Mechanism 18
1.5. Braking 20
1.5.1. Mechanical Braking 20
1.5.1.1. Disc Brakes 20
1.5.1.2. Drum Brakes 21

Chapter 2. Literature Survey 24

2.1. Literature Review 25

Chapter 3. Theoretical Analysis 28

3. Objective 29
3.1. Layout Description 29
3.1.1. Designing Stage 29
3.1.2 . Collection Of Raw Material 30
3.1.3. Marking Of weld points 31
3.1.4. Carrying Out Fabrication Work 31
3.2. Design Calculations 33
3.2.1. Basic Design Calculations For Chassis Frame 33
3.3. Fabrication Process 34
3.3.1. Cutting Of Metals 34
3.3.2. Drilling 35
3.3.3. Welding 36
3.3.4. Grinding 38
3.4. Electrical Connections 38
3.5. Fabrication of Chassis and Frame 39
3.6. Steering system Analysis 41
3.7. Fabrication of Braking System 42
3.8. Fabrication of Wheel Hub 43
3.9. Solar Panel Calculations 44

Chapter 4. Experimental Investigations 45

4.1. Testing Of Material 46
4.2. Electrical Connections 46

Chapter 5. Experimental Results 47

5.1. Frame Material Test Result 48

Chapter 6. Results& Discussion 50

6.1. Results and Discussion 51

Chapter 7. Summary & Conclusions 52

7.1. Summary 53
7.2. Conclusion 53
7.3. Future Scope Of Work 53

References 54
Appendices 56
1

Chapter 1.

Introduction
 2

1. Introduction

The electric vehicles are the best alternative mode of transport to the
present carbon emitting vehicles. The use of electric vehicles does not
cause any harm to the atmosphere and are completely eco friendly. Zero
Emissions means no use of combustible fuels and lesser dependence on
crude.

The Solar equipped Electric Buggy is the combination of usage of two

major scientific advancements i.e. Solar Energy use and Elimination of
combustible fuels. This vehicle runs on BLDC Motor connected to
Batteries and solar energy is used to recharge the batteries. Electric
Vehicles are gaining much popularity due to its low maintenance cost,
low operating cost where the fuel prices are sky rocketing these vehicles
proves to be a boon for the society.

This Solar equipped electric buggy runs on four batteries connected to

Brushless Direct Current (BLDC) Motor along with a differential to make
the rotation of rear wheels movement intact when turns are taken at
sharp corners. The Motor has the capability to reverse and thus can
make the vehicle move forward or backward. The vehicle is made of rigid
Chassis comprising of Stainless steel rods welded together to form the
frame. Apart from this the vehicle has slots beneath the passengers to
hold four batteries and the wiring which are invisible to the passengers.

The electric vehicle can easily accommodate six passengers along with
the driver in the front. Due to bigger ground clearance a footrest is
provided to board in or out of the buggy easily. The rear passengers can
face each other easily on either sides and without any inconvenience due
to good amount of legroom.

The placement of solar panel is above the entire length of the buggy
such that maximum solar radiating energy is reflected upon the solar
board and can be used to recharge the batteries. Solar equipped electric
 3

buggy is noiseless and does not require cooling methods or transmission

like other vehicles. This vehicle has the capability to turn sharply thanks
to its small turning radius. Overall the vehicle is beneficial for use in
various outdoor premises and is mostly suitable for indoor ones as the
motor does not have to do much work and the strain on the differential is
less on the smoother surface than on a rough surface.

The costs of such vehicles are currently costly due to the use of
batteries which are quite expensive and also various insulations on the
wires are to be done to avoid fire hazards as the entire operation is with
electrical connectivity and there is no room for error. A single spark is
enough to bring the entire vehicle into flames. Thus utmost precautions
are to be made when constructing such vehicles and various safety
devices are to be used. To avoid electrical hazards we have attached
Miniature Circuit Breakers (MCB) to shut down the electrical
conductivity in case of over load of power also cut off switches to the
motor which can also be used to turn the motor off to avoid mishaps just
with the press of a button.

1.1. Solar Panel

The Solar panel is used to recharge the batteries as an alternative

source to recharge the batteries apart from AC Charger. The panel runs
across the entire top of the Buggy making maximum availability of Solar
radiation onto the top of the vehicle. The output of solar panel is used
directly to recharge the batteries simultaneously during the operation of
batteries.
 4

Table No.1. Specifications of Solar Panel

S. No. Description Specification

1. Manufacturer VEGA SOLAR

2. Module No. VEGA-1224

3. Maximum Power (W) 24

4. Open Circuit Voltage (V) 22

5. Short Circuit Current (A) 1.60

6. Voltage At Max Power (V) 17.50

7. Current At Maximum Power 1.38

(A)

8. Maximum System Voltage (V) 200

9. Tolerance (%) +/-5

The solar panel is silicon based called mono crystalline silicon. It has
high tendency to absorb the solar power. There are two solar boards on
the top. Solar buggy are buggy powered by mounting a photovoltaic or
thin film panel on top of the existing roof or using a Photo voltaic panel
as the roof itself. A controller converts the sun's energy to charge the
Buggy's 36-volt or 48-volt battery bank. Not only does the solar power
take the buggy off the electric grid, it also increases the driving distance
and extends the life of the batteries.
 5

Fig:1. Solar Panel Used On Top Of Buggy

1.2. Chassis

A chassis of the vehicle is called the backbone of the vehicle .The

entire strength rigidity depends upon the type of chassis used and its
material. It consists of internal framework that supports man-made
object. It is the under part of the vehicle which consists of frame and
running gear like engine, transmission system, suspension system
etc. The type of chassis used in the project is ladder frame chassis.
 6

This is a new configuration for a electric Buggy and as such requires

an entirely new chassis design that both supports the loads placed on it
but also weights. The chassis design implements structural battery boxes
which have the dual purpose of protecting the driver from the batteries
and adding strength to the frame. Using these stressed battery boxes
gives the chassis excellent torsion stiffness, yet the entire frame still
weighs just over 300kg.

1.2.1. Types of Chassis

• Ladder

• Backbone

• Monocoque

• Space

• Combination

1.2.1.1. Ladder type chassis

A ladder frame car chassis is a common type of frame used as a

base for vehicles creating a solid base from the shape that the name
suggests. The ladder frame is one of the best that uses the two large
longitudinal beams, which is name as long members. They connected
with the numbers steps like connections, which known as cross
members.

1.2.1.2. Backbone type chassis

Backbone chassis is a type of automobile construction chassis that

is similar to the body-on-frame design. Instead of a two-
dimensional ladder-type structure, it consists of a strong tubular
 7

backbone (usually rectangular in cross section) that connects the front

and rear suspension attachment areas

1.2.1.3. Monocoque type chassis

Monocoque is a structure which integrates body

and chassis together to form a composite structure which has better
stiffness as well as weight advantage.

1.2.1.4. Space type chassis

Space In architecture and structural engineering, a space
frame or space structure is a rigid, lightweight, truss-like structure
constructed from interlocking struts in a geometric pattern. Space
frames can be used to span large areas with few interior supports.

1.2.1.5. Combination type chassis

Combination chassis is a chassis which takes elements from a

range of different types to create a version that is best suited to the car
frame.

1.2.2. Chassis Used in Buggy

Ladder type chassis is used in the project these are the best
solution for the stiffest frames could be carbon fiber or chassis
that has welded with a roll cage. This makes the chassis stiffer
and both the terms of extensions and bending stiffness. A tubular
frame helps to attach and carry the body and the suspension
assembly. They help for many vehicles with less stiffness. It
behaves like a strong tubular bone that help the body placed on
the structure properly. The chassis ladder frames do not have the
rigidity in torsion because of the two dimensional design
frameworks. This has little importance on road that helps better
 8

contact with the ground when needed to go off road. However,

this chassis is heavier at the same time than a single body. The
chassis does not provide any protection against any side impacts.
It helps to withstand the torsion twist and effectively reduce the
lifespan of the vehicles.

Fig: 3. Ladder Type Chassis

1.2.3. Chassis Material

1.2.3.1. Stainless Steel

Stainless steels are notable for their corrosion resistance, which

increases with increasing chromium content. Molybdenum additions
increase corrosion resistance in reducing acids and against pitting
attack in chloride solutions. Thus, there are numerous grades of
stainless steel with varying chromium and molybdenum contents

Austenitic stainless steels contain 15%-30% chromium and 2%-20%

nickel for better surface quality
 9

• Excellent corrosion resistance.

• Increased resistance to chloride attack.

• Good resistance to stress corrosion cracking.

• Tensile and yield strength higher than austenitic or ferrite grades.

• Good weld ability.

• Good formability.

1.2.3.2. Advantages of Stainless Steel

• Corrosion resistance.

• Fire and heat resistance.

• Smooth texture

• Aesthetic appearance.

• Strength to weight advantage.

• Ease of fabrication.

• Impact resistance.

• Long term value.

1.2.3.3. Disadvantages of Stainless Steel

1. Large section size steel inter granular corrosion after welding is

very sensitive.

2. C1-containing water including wet air is very sensitive to stress

corrosion.

3. Low mechanical strength, such as poor cutting performance.

 10

1.2.3.4. Properties of Stainless Steel

Like steel, stainless steel is a relatively poor conductor of

electricity, with significantly lower electrical conductivity than copper.
Other metals in contact with stainless steel, particularly in a damp or
acidic environment, may suffer galvanic corrosion even though the
stainless metal may be unaffected.

Fig: 3. Front View of Buggy

Fig: 4. The Solar equipped electric buggy

 11

1.3. Electric Motor

The power of a vehicle electric's motor, as in other vehicles, is

measured in kilowatts . 100 kW is roughly equivalent to 134 horsepower,
although electric motors can deliver their full torque over a wide RPM
range, so the performance is not equivalent, and far exceeds a 134
horsepower fuel powered motor, which has a limited torque curve.
Energy is lost during the process of converting the energy from electric to
mechanical energy. 70% of the energy from the batteries is converted to
mechanical energy. 30% of the energy is lost during the process is due to
the shape and the materials used in the vehicle.

Usually, direct current electricity is fed into a DC or AC inverter

where it is converted to alternating current electricity and this AC
electricity is connected to a 3phase AC motor. For electric trains, forklift
trucks, and some electric cars, DC motors are often used. In some cases,
universal motors are used, and then AC or DC may be employed. In
recent production vehicles, various motor types have been implemented,
for instance induction motors in vehicles and permanent magnet motors
are widely being used.

1.3.1. Types Of Electric Motor

 Brushed DC Motor

 Brushless DC (BLDC)

 Permanent Magnet Synchronous Motor (PMSM)

 AC Induction Motor (ACIM)

 12

1.3.1.1. Brushless DC (BLDC) Motor

Brushless DC electric motor also known as electronically commutated

motors or synchronous DC motors. These type of motors are
synchronous motors powered by DC electricity via an inverter or
switching power supply which produces. An AC electric current to drive
each phase of the motor via a closed loop controller. The controller
provides pulses of current to the motor windings that control the speed
and torque of the motor.

The construction of a brushless motor system is typically similar to a

permanent magnet synchronous motor , but can also be a switched
reluctance motor, or an induction motor. The advantages of a
brushless motor over brushed motors are high power to weight ratio,
high speed, and electronic control. Brushless motors find
applications in such places as computer peripherals, handheld
power tools, and vehicles ranging from model aircraft to automobiles.

Fig: 5. BLDC Motor with Controller

 13

Table No. 2. Specifications of Motor

S. No. Description Specification

1. Type Permanent Magnet BLDC

2. Voltage (V) 48/60

3. Load Current (A) 6

4. Rated Current (A) 67

5. Rated Speed (RPM) 3000±100/4000±100

6. Rated Torque (Nm) 9.6

7. Rated Power (W) 3000

8. Max. Power Output (W) 4000

9. Efficiency (%) 83

10. Number of poles (No.) 8

Table No. 3. Specifications of Controller

S. No. Description Specification

1. Rated voltage(V) 48/60

2. Peak protection current (A) 90

3. Rated power(W) 4500

4. Throttle voltage(V) 1 to 4.5

 14

1.3.2. Battery

An electric vehicle battery or traction battery is a battery used to

power the propulsion of battery electric vehicles. Vehicle batteries are
usually a secondary battery. Traction batteries are used in
forklifts, electric golf buggy’s, riding floor scrubbers, electric
motorcycles, electric cars, trucks, vans, and other electric
vehicles. Electric vehicle batteries differ from starting, lighting, and
ignition batteries because they are designed to give power over
sustained periods of time. Deep cycle batteries are used instead of
starting lighting and ignition batteries for these applications. Traction
batteries must be designed with a high ampere hour capacity.

Batteries for electric vehicles are characterized by their relatively high

power to weight ratio, energy to weight ratio and energy density
smaller, lighter batteries reduce the weight of the vehicle and
improve its performance. Compared to liquid fuels, most current
battery technologies have much lower specific energy, and this often
impacts the maximal all electric range of the vehicles. However,
metal air batteries have high specific energy because the cathode is
provided by the surrounding oxygen in the air.

Rechargeable battery used in electric vehicles include

lead acid, nickel cadmium, nickel metal hydride, lithium-ion, Li-ion
polymer, and, less commonly, zinc and molten salt batteries. The
amount of electricity stored in batteries is measured in ampere
hours or in coulombs, with the total energy often measured in watt
hours. Rechargeable traction batteries are routinely used all day and fast
charged all night. Forklifts, for instance, are usually discharged and
recharged every 24 hours of the work week. On an energy basis, the price
 15

of electricity to run an electric vehicles is a small fraction of the cost of

liquid fuel needed to produce an equivalent amount of energy . The cost
of replacing the batteries dominates the operating costs.

1.3.2.1. Types of Battery

• Lead Acid.

• Nickle Metal Hybrid.

• Lithium ion battery

1.3.2.2. Lead Acid Battery

Flooded lead acid batteries are the cheapest and in past most
common traction batteries available. There are two main types of lead
acid batteries: automobile engine starter batteries, and deep cycle
batteries. Automobile alternators are designed to provide starter
batteries high charge rates for fast charges, while deep cycle batteries
used for electric vehicles like forklifts or Buggys, and as the auxiliary
house batteries in recreational vehicle, require different multistage
charging. No lead acid battery should be discharged below 50% of its
capacity, as it shortens the battery's life. Flooded batteries require
inspection of electrolyte level and occasional replacement of water which
gases away during the normal charging cycle.

Traditionally, most electric vehicles have used lead acid batteries due
to their mature technology, high availability, and low cost Like
all batteries, these have an environmental impact through their
construction, use, disposal or recycling. On the upside, vehicle
battery recycling rates top 95% in the United States. Deep cycle
 16

lead batteries are expensive and have a shorter life than the vehicle itself,
typically needing replacement every 3 years.

Lead acid batteries in electric vehicle applications end up being a

significant portion of the final vehicle mass. Like all batteries, they have
significantly lower energy density than petroleum fuels in this case,
30 to 40 W hour per kg. While the difference isn't as extreme as it
first appears due to the lighter drive train in an electric vehicle, even the
best batteries tend to lead to higher masses when applied to vehicles
with a normal range. In the Buggy we have used 4 lead acid batteries 12v
and 80Ampere-hour each.

Fig: 6. Batteries Placed Inside A slot Fabricated Beneath The Floor.

1.3.3. Battery Charger

A Battery Charger is used supporting up to 10Amps of current and

voltage of 96 Volts. Also two terminals are provided for a plug and play
mechanism and for ease of charging red is for positive connection socket
green is for negative terminal connection socket. An Ammeter is provided
for to check live current reading up to 10 A and 50Hz.
 17

Fig: 7. Battery Charger

1.3.3.1. Voltage Regulator Knob

The knob in the charger helps us to select accurate voltage needed

to charge either a single battery of 12V or even multiple batteries at once
and can support up to 96 Volts.

1.3.3.2. Current Regulating Knob

The current can be regulated using current regulating knob from

as low as 2 A and up to 10 A.

1.3.3.3. Miniature Circuit Breaker

The MCB is used so as to avoid excess current entering into the

circuit by creating an open circuit also making it much safer.
 18

1.4. Steering Mechanism

1.4.1. Function of Steering System

The most basic function of the steering system is to allow the driver to
safely and precisely steer the vehicle. Beyond this, the steering system
also provides a way to reduce driver effort by making the act of steering
the vehicle easier. The components of the steering system also absorb
some of the road shock before it gets to the driver. Very little has
changed in the operation of the steering system or in some of the
components since the earliest automobiles. The things that have changed
primarily have to do with increased ease and effectiveness of operation
and long lasting components that require less maintenance.

The function of a steering system is to convert the rotary movement of

the steering wheel in driver’s hand into the angular turn of the
front wheels on road. Additionally, the steering system should provide
mechanical advantage over front wheel steering knuckles, offering driver
an easy turning of front wheels with minimum effort.

Fig: 8. Steering Linkage

 19

Ackerman steering geometry is utilized to change the dynamic toe

setting, by expanding front wheel toe out as the auto is transformed into
the corner. Racers are intrigued as a result of the possibility to impact
the treatment of the auto on corner section and mid corner.

The typical steering system, in a road or race car, has tie-rod linkages
and steering arms that form an approximate parallelogram, which skews
to one side as the wheels turn. If the steering arms are parallel, then
both wheels are steered to the same angle.

If the steering arms are angled, this is known as Ackerman geometry.

The inside wheel is steered to a greater angle then the outside wheel,
allowing the inside wheel to steer a tighter radius. Different designs
may use more or less percentage pro Ackerman, anti Ackerman,
or Ackerman may be adjustable.

Fig: 9. Ackerman Steering Mechanism

 20

1.5. Braking

1.5.1. Mechanical Braking

Mechanical brakes works by creating frictional powers as two

surfaces rub against each other. The ceasing force or limit of a brake
depends to a great extent on the type of brake used and the braking
power. The wear and tear experienced by the working surfaces are
extreme. Therefore, the sturdiness of a brake or life between support
depends intensely on the kind of material used to line the shoe or
cushion.

Mechanical brakes are congregations comprising of mechanical

components for the moderating or ceasing of shafts in hardware drives.
They utilize levers or linkages to transmit compel starting with one point
then onto the next. Braking moderates or stops the development of the
coupled shafts. There are a few kinds of mechanical brakes. Band
brakes, the most straightforward brake setup, have a metal band
fixed with warmth and wear safe rubbing material. Drum brakes, which
are generally utilized on vehicle raise wheels, work when shoes press
against a turning surface called a drum. Circle brakes are built of brake
cushions, a caliper, and a rotor. Amid task, the brake cushions are
crushed against the rotor. Cone brakes are made with a container and a
cone, which is fixed with warmth and wear safe material. Amid
activation, the cone is squeezed against the mating glass surface. These
are of two types disc brake and drum brakes.

1.5.1.1. Disc Brakes

The plate brake is a gadget for abating or halting the revolution of a

wheel while it is in movement. A brake plate is generally made of solid
 21

metal , yet may now and again be made of composites, for example,
fortified carbon or earthenware framework composites. This is
associated with the wheel or the pivot. To stop the wheel, contact
material as brake cushions mounted on a gadget called a brake caliper is
constrained using pressurized water, pneumatically or
electromagnetically against the two sides of the plate. Grating makes the
plate and connected wheel moderate or stop. Brakes change over
movement to warm, and if the brakes get excessively hot, they turn out
to be less compelling, a wonder known as brake blur.

1.5.1.2. Drum Brakes

A drum brake is a brake in which the erosion is caused by an

arrangement of shoes or cushions that press against a turning drum
molded part called a brake drum. The drum brake as a rule implies a
brake in which shoes push on the internal surface of the drum. At the
point when shoes push outwardly of the drum, it is typically called a
fasten brake. Where the drum is squeezed between two shoes, like a
traditional plate brake, it is once in a while called a squeeze drum brake,
such brakes are moderately uncommon. This is the type of the brake
used in the electric buggy.

Drum brakes are likewise once in a while fitted as the stopping and
crisis brake not withstanding when the back wheels utilize plate brakes
as the primary brakes. Numerous back plate stopping mechanisms
utilize a stopping brake in which the cylinder in the caliper is impelled by
a cam or screw.

In crossover vehicle applications, wear on stopping mechanisms

is incredibly diminished by vitality recuperating engine generators see
regenerative braking, so some mixture vehicles, some vehicles with the
exception of the third era utilize drum brakes at the back wheels. Drum
 22

brake return springs give more positive activity and, balanced

accurately, frequently have less drag when discharged.

Fig: 10. Brake Drum

Fig: 11. Pedals (Accelerator & Brake)

 23

Fig: 12. Brake Pedal Connected To Piston & Cylinder

24

Chapter 2.

Literature Review
 25

2. Literature Survey

Cheng et al. [1] the paper describes the development and the
comparison of different part of components. The major components in
battery technology, charger design, motor, steering and braking are
examined. The paper finally shows electric vehicle prototype as a
conclusion of the papers. He has suggested using two motors in front
and rearing of the wheel vehicle in the wheel base. However we have
powered the vehicle with a single motor at the rear but with a differential
which provide greater traction and reduces the overall weight of the
buggy. The rest suggestions made by him are highly informative in
choosing the motor, wheel hubs, batteries etc.

Sapundzhiev et al. [2] the paper presents an upgraded methodology for

determination of the electric motor power considering the time for
acceleration. The influence of the speed factor of electric motor on the
value of needed power at same acceleration time is studied. Some
calculations on the basis of real vehicle were made. The numeric and
graphical results are given. They show a decrease of needed power with
the increase of the speed factor of motor, because the high speed factor
allows the use of a larger range of the characteristic with the maximum
power of the motor. Hence in this paper we get to know more about the
motor and the load it can bear, the calculations we require to bear given
loads. The research work done makes it easy to choose a suitable motor
and the characteristics to look for in a motor. It also shows the ill effects
that may occur if less efficient motors are used causing heating up or
even sparks being generated and causes fire hazards.

Orestes Anastasia et al. [3] the research paper is based on the Hybrid
Electric vehicles and how the convention internal combustion engines
 26

can be replaced by hybrid technology. Hybrid Electric Vehicles combine

the internal combustion engine of a conventional vehicle with the battery
and electric motor of an electric vehicle. This combination offers the
extended range and rapid refuelling that consumers expect from a
conventional vehicle, with a significant portion of the energy and
environmental benefits of an electric vehicle. The practical benefits of
HEVs include improved fuel economy and lower emissions of the full host
of criteria pollutants, as well as CO2, compared to conventional vehicles.
The inherent flexibility of HEVs will allow them to be used in a wide
range of applications, where electric-only vehicles cannot, from personal
and public transportation to commercial hauling. However the idea of
using battery to power the vehicle is a great idea but we completely
switched to electrical option and completely removed any emission
causing system. Therefore no internal combustion engine used and has
reduced weight and is noise less.

T. Allen Prasad et al. [4] the paper describes the use of dynamo to
electric powered vehicles so as in cases where we might run out of charge
in batteries the use of dynamo would further increase the distance to be
travelled with its help. Dynamo converts mechanical energy into
electrical and could be used to charge batteries. However we used solar
panel as secondary power source.

Jing-Shan Zhao et al. [5] this article focuses on the synthesis of a

steering mechanism that exactly meets the requirements of Ackermann
steering geometry. It starts from reviewing of the four-bar linkage, then
discusses the number of points that a common four-bar linkage could
precisely trace at most. After pointing out the limits of a four-bar steering
mechanism, this article investigates the turning geometry for steering
wheels and proposes a steering mechanism with incomplete noncircular
gears for vehicle by transforming the Ackermann criteria into the
 27

mechanism synthesis. The pitch curves, addendum curves, dedendum

curves, tooth profiles and transition curves of the noncircular gears are
formulated and designed. This Ackerman steering mechanism has been
used to calculate the various parameters of steering system.

Daniel Akinyele et al. [6] this study first presents an overview of

batteries and compares their technical properties such as the cycle life,
power and energy densities, efficiencies and the costs. It proposes an
optimal battery technology sizing and selection strategy, and then
assesses the environmental impact of batteries in a typical renewable
energy application. This research leads us to choose lead acid battery
which is quite safe.

Dainis Berjoza et al. [7] this paper shows charging parameters and their
changes in time are important in charging a battery for a two wheel
vehicle. It tells us a research has to be conducted in order to choose a
proper charging device, to optimally load the electric wiring network as
well as to choose power and other parameters for alternative energy
devices in order to ensure the charging process so we decided to use
conventional battery charger and solar panel as well.

Nand Mangukia et al. [8] this paper shows that the brake pedal is again
a very crucial component of an all terrain vehicle as it would control the
overall braking of the vehicle. Proper braking is very crucial in rough
terrains with all four wheels locking so that the stopping distance is
minimum. However we switched to cable operated drum brakes as they
are convenient and also no fluid is to be used for hydraulics. Also the
motor is capable to shut itself on non application of acceleration causing
braking effect.
28

Chapter 3.
Theoretical Analysis
 29

3. Objective

The objective of the solar equipped electric buggy is to run a vehicle

which has no emissions and is noise less working on BLDC motor
connected to batteries and also makes use of solar panel to recharge
them. The modern day pollution levels rise cause a serious threat to the
environment hence development of such a vehicle is a boon to the
society.

3.1. Layout Description

3.1.1. Designing Stage

Framing of the chassis was really a strenuous job as the design was
not simple and has to carry the load of batteries as well as 6 members
simultaneously .We want to make the frame compact as well as elegant
in look so we decided to go for ladder type of chassis. While working on
chassis we faced allot of problems due the arrangement of differential.
The differential we used in this kart is attached with a BLDC motor and
was completely fixed so we had to design the rear section of the chassis
that the hubs connected to the differential fits in our layout designed in
the software.

The steering setup used in the buggy is Ackerman’s steering so we

designed in such a way that rear and front wheels come into same axis.
Placing of batteries was also major task because we wanted to hide the
storage of batteries completely. So it was decided to make a section
underneath the flooring of the vehicle.
 30

To hide the batteries we had to make a section in the chassis frame to

carry 4 batteries with the motor controller which is attached to the motor
differential.
We designed a chamber long enough to carry them and it must be
light weight as we made it under the flooring the ground clearance was
decreased so we raised the height of the frame and increased the
diameter of the tyre used .So we got enough clearance to pass the vehicle
from the speed breakers.

3.1.2. Collection of Raw Materials

The project starts with the collection of raw material with desired
properties and requirements. We wanted a material that is very light in
weight and can bear the required weight and can be fabricated easily as
well can be grinded to give good finishing. So our survey team surveyed
the market for the desired materials for example chrome alloy steel,
aluminium, cast iron, mild steel, stainless steel etc. We selected stainless
steel because it has all the properties we were looking for. Another plus
point of this material was we don’t need to paint it after fabrication or
formation of chassis.

Stainless steel is easily available in market and fits in our budget.

This material is available in different sizes shapes and dimensions.
According to the design of the kart we needed oval capsule shape pipes
in the centre of the chassis to carry centre loads.

These pipes were hollow pipes with the thickness of 1mm and do not
easily bend compared to other materials the welded joint in stainless
steel can bear heavy loads and the finishing after grinding is smooth in
texture. At the whole the material that is stainless steel was all we were
looking for.
 31

3.1.3. Marking of Weldpoints

Marking of weld points is not simple as it looks because we need to

calculate the load on each point and divide the stress over the chassis
Our chassis also consists of seating which is permanently weld to the
base of the frame and the load is carried out through out the chassis.
The marking of weld joints should be marked perfectly to attain stability
in frame.

3.1.4. Carrying Out the Fabrication Work

After thorough calculations the fabrication work was taken up

according to the design specifications and there was no room for error.
Everything was intact and there were no loose joints or welds as these
were excessively checked so as to avoid any problems that may incur due
to these. The sequence had to be followed for timely assembly of all the
parts. However a slot had to be later redesigned to hide the batteries.
Also the front of the kart had an anti Ackerman steering mechanism
which required few tweaks in the front part of the kart to accommodate
the steering assembly. The Following Layout helped us to determine the
progress of work to be done in each stage.
 32

Fig: 13. Layout of Project

 33

3.2. Design Calculations

For analysing the stress and deformation of the frame, the frame of
the buggy is modelled with the help of solid modelling software package
Solid Works. This model is then imported into the ANSYS workbench.
Load on each longitudinal member is taken as half the total weight
acting on chassis. Eight fixed support are given at the point of
suspension mounts. After that, for the three different cross section and
rectangular box hollow type of cross members, max deflection, von
miss stress and natural frequency with different mode shape are
determined keeping the longitudinal members same C section. Also, the
weight of cross members is kept constant.

3.2.1. Basic Design Calculations for Chassis Frame

3.2.1.1. Capacity of Buggy

For five persons (Assume average weight of each person to be 80kg) = 5*

80 = 400 kg

Factor of safety 25% = 1.25 * Total Load = 1.25 * 400 = 500 kg

Cumulative Weight of Body, BLDC Motor and Differential = 300kg

Total load acting on chassis = (500+300) = 800

=800* 9.81 = 7848 N

Due to two longitudinal members the load acting on each longitudinal

member shall be = 7848/ 2 N = 3924 N
 34

3.3. Fabrication Process

 Cutting of metal
 Drilling
 Welding
 Grinding

3.3.1. Cutting Of Metal

Metal working is the process of working with metals to create

individual parts, assemblies, or large scale structures. The term covers
a wide range of work from large ships and bridges to precise engine parts
and delicate jewellery. It therefore includes a correspondingly wide range
of skills, processes, and tools. There are many technologies available to
cut metal, including Manual technologies, saw, chisel, shear or snips,
turning, milling, drilling, grinding, and sawing.

Cutting machine was used in order to cut the stainless steel rods as
the metal can be easily cut by using this machine. This process provides
an adequate cut with good finish and obtains the cut quickly. Thus use
of cutting machine helps us to get precise cuts as per our dimensions.

Every metal working method has its limitations in accuracy, cost,

and effect on the material. For example, heat may damage the quality of
heat treated alloys, and laser cutting is less suitable for highly reflective
materials such as aluminium. Laser cutting sheet metal produces flat
parts and etches and engraves parts from complex or simple designs. It
is used over other cutting options for its quick process and customizable
abilities.
 35

Fig: 14. Cutting Of Workpiece using cutting machine

3.3.2. Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of

circular cross section in solid materials. The drill bit is usually a rotary
cutting tool, often multi point. The bit is pressed against the work piece
and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the work piece, cutting off
chips from the hole as it is drilled.

In rock drilling, the hole is usually not made through a circular

cutting motion, though the bit is usually rotated. Instead, the hole is
usually made by hammering a drill bit into the hole with quickly
repeated short movements. The hammering action can be performed
from outside the hole or within the hole. Drills used for horizontal drilling
are called drifter drills.

In rare cases, specially shaped bits are used to cut holes of non
circular cross section a square cross section is possible.
 36

Fig: 15. Drilling A Hole Using Drilling Machine

3.3.3. Welding

Arc welding is a process that is used to join metal to metal by using

electricity to create enough heat to melt metal, and the melted metals
when cool result in a binding of the metals. It is a type of welding that
uses a welding power supply to create an electric arc between an
electrode and the base material to melt the metals at the welding point.
They can use either direct or alternating current, and consumable or non
consumable electrodes.

The welding region is usually protected by some type of shielding gas,

vapour, or slag. Arc welding processes may be manual, semi automatic,
or fully automated.

To supply the electrical energy necessary for arc welding processes, a

number of different power supplies can be used. The most common
 37

classification is constant current power supplies and constant voltage

power supplies. In arc welding, the voltage is directly related to the
length of the arc, and the current is related to the amount of heat input.
Constant current power supplies are most often used for manual welding
processes such as gas tungsten arc welding and shielded metal arc
welding, because they maintain a relatively constant current even as the
voltage varies.

This is important because in manual welding, it can be difficult to

hold the electrode perfectly steady, and as a result, the arc length and
thus voltage tend to fluctuate. Constant voltage power supplies hold
the voltage constant and vary the current, and as a result, are most often
used for automated welding processes such as gas metal arc welding,
flux cored arc welding, and submerged arc welding.

Fig: 16. Welding the frame

 38

3.3.4. Grinding

Grinding is an abrasive machining process that uses a grinding wheel

as the cutting tool. It is a process which is highly used in fabrication
process. Grinding practice is a large and diverse area of manufacturing
and tool making. It can produce very fine finishes and very accurate
dimensions. It is usually better suited to the machining of very hard
materials than is regular machining, cutting larger chips with cutting
tools such as tool bits or milling cutters, and until recent decades it was
the only practical way to machine such materials as hardened steels.

3.4. Electrical Connections

The electrical connections were made according to the wiring diagram.

Fig: 17. Circuit Diagram of 3Kw Motor Connection

 39

3.5. Fabrication of Chassis and frame

The chassis material used was stainless steel and with the help of
electric arc welding the chassis and frame was fabricated.

Fig. 18. Chassis Model

The chassis model was created and analysed to see if it can bear
the load and the maximum load it can bear. Hence this pre requisite
knowledge help us understand the design without leading to problems in
the future.
 40

Fig.19. Chassis and Frame model

After successfully fabricating the frame the entire body was welded
together and then it could be finally move on to interior works.

Fig.20. Body of solar equipped electric buggy

 41

3.6. Steering System Analysis

The ackerman steering mechanism was tested and finally

fabricated with the help of steering geometry calculations.

Fig. 21. Analysis of steering mechanism

Fig. 22. Centre of turning centre

 42

3.7. Fabrication of Braking System

The brake used in the solar equipped electric buggy is a drum

brake connected with stainless steel cable from the pedal to the rear
wheel brake drums. As soon as the accelerator pedal is released the
motor tends to brake itself and hence this causes the motor to come to a
complete halt. The buggy is also equipped with circuit cut off switch in
case where the motor misbehaves and turn into any catastrophe. Thus
the brake is used to reduce the speed of the buggy at any instant of time.

The brake is fabricated with the help of stainless steel hollow pipes
with a piston and cylinder mechanism connected with a spring. When
the brake is pressed the spring expands and the piston pushes the
cylinder which pulls the cable and in turn applies brake to rear drums.

Fig. 23. Brake pedal connected with piston and cylinder mechanism
 43

Fig. 24. Brake cable attached to rear wheel drum

The brake pedal has been fabricated and fixed on to the floor panel
to the right of accelerator so as to ensure quick braking. The use of hand
brake or parking brake has been eliminated as the motor connected to
differential gives stability to rear wheels and prevent rolling.

3.8. Fabrication of Wheel Hub

The wheel hub was fabricated to the tie rods of steering rack. This
are designed to support a rim of up to 19 inches.

Fig.25. Wheel hub

 44

3.9. Solar Panel Calculations

The graph below shows the Current and voltage at respective
intervals of time.

Fig.4. Solar Cell I-V Characteristics for Maximum Power

The graph below shows the current being induced in the solar panel
during 0600 hrs to 1900 hrs.

Table No.5. Power – Time Chart

 45

Chapter 4.
Experimental Investigations
 46

4.1. Testing Of Material

The material being used in chassis and frame had to be lighter in

weight and also should support weight of batteries and also 5
passengers. Thus a test was conducted on a sample of thick pipe of
dimension of 1 inch outer diameter and 1.50 mm wall.

Different tests were conducted such as tensile test, chemical analysis

by spectro and hardness test in a technical laboratory so as to ensure
the material is strong enough to hold the load. The elements tested as
sample were found to be within the limits of AISI 304 specifications. The
element was tested on universal testing machine bearing load up to 400
KN.

4.2. Electrical Connections

As the electric Buggy involves use of motor and PLM controller the
wiring to be used had to have proper gauge and the connections was
checked thoroughly to avoid any kind of short circuits. The Circuit
diagram was verified by expert faculty so as to ensure proper functioning
of the motor. However MCB was added and also a motor cut off switch
was added for emergency braking or if the motor fails abruptly or heats
during its operation. Thus all the connections were intact when checked
and the motor was ready to use.
47

Chapter 5.
Experimental Results
 48

5. Test Results

Table No. 6. Chemical Composition of SS Material

Chemical Composition in %
C Mn Si P Ni Cr S Mo
0.056 1.66 0.36 0.016 8.12 18.19 0.36 <0.001

Table No. 7. Mechanical Test Results

S. No. Particulars Specification
1. OD X ID Of Test Bar (mm) 25.42 x22.56
2. Area (mm2) 107.77
3. Initial Gauge Length (mm) 50
4. Yield Load (N) 76420
5. Maximum Load (N) 96140
6. Final Gauge Length (mm) 65.50
7. Yield Strength (MPa) 709.1

8. Tensile Strength (MPa) 892.1

9. Elongation (%) 31

5.1. Hardness Test

Hardness of Material Is Found to Be 260 BHN

 49

5.2. Tensile Test Results

Specimen Shape Hollow Round

Material Type AISI 304
Specimen Description 1” OD x 1.50 mm Wall Pipe

Table No. 8. Tensile Test

S. No. Particular Specification
1. Load At Yield (kN) 76.42
2. Elongation At Yield (mm) 20.460
3. Yield Stress (N/mm2) 709.073
4. Load At Peak (kN) 96.140
5. Tensile Strength (N/mm2) 892.048
6. Load At Break (kN) 1.020
7. Elongation At Break (mm) 45.570
8. Reduction Area (%) 42.87
9. Elongation (%) 31.00
10. Elongation At peak (mm) 27.050
50

Chapter 6.
Results & Discussion
 51

6.1. Result and Discussions

With the various tests the buggy is found to be suitable to carry the
passenger and bearing their load. The motor is efficient enough and the
voltage from batteries is perfect to run the motor, The Steering setup is
properly aligned to turn even in short distances as the buggy is generally
for use in indoor purpose. The mechanical drum connected through
stainless steel cable from the brake pedal. Overall the Solar equipped
electric buggy performs well and there is no room for error.
52

Chapter 7.
Summary & Conclusions
 53

7.1. Summary
The buggy is fabricated so as to be eco friendly, light in weight and
rechargeable through solar panel.

7.2. Conclusion

The Solar equipped electric buggy is made according to the design

specification that is powered by electric motor and rechargeable through
conventional battery charger and also through solar panel.

7.3. Future Scope of Work

The buggy can be equipped with windshields in front and back so as

to be more convenient in outdoors and prevent water or debris in the
compartment.
54

Reference
 55

References

[1] K. W. E. Cheng, X. D. Xue and N. C. Cheung Selection of Electric

Motor Drives for Electric Vehicles, Department of Electrical Engineering,
the Hong Kong Polytechnic University Hung Hom, Kowloon Hong Kong,
China.

[2] M Sapundzhiev, Determination of the needed power of an electric

motor. 2017 IOP Conf. Ser.: Mater. Sci. Eng. 252 012063.

[3] Orestes Anastasia, Battery-Powered Electric and Hybrid Electric

Vehicle Projects to Reduce Greenhouse Gas Emission. Prepared for the
National Energy Technology Laboratory (NETL).

[4] T. Allen Prasad, Lokesh Ramesh Powering the Electric Cars with
Dynamos IOSR Journal of Mechanical and Civil Engineering (IOSR-
JMCE)
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[5] Design of an Ackermann type steering mechanism Jing-Shan Zhao ,

Xiang Liu, Zhi-Jing Feng and Jian S Dai Part, Mechanical Engineering
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[6] Daniel Akinyele, Juri Belikov and Yoash Levron, Battery Storage
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[7] Dainis Berjoza, Inara Jurgena, Research In Charging Parameters Of

Batteries For Two-Wheel Electric Vehicles

[8] Nand Mangukia, Nandish Mangukia, Design and Fabrication of Brake

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[9] SAE’s Brake Technology Handbook

[10] N. Mohan, Book of Electric Machines and Drives: A First

Course, Wiley, 2012.
56

Appendices
 57

Chemical Analysis, Hardness and Tensile Test Report

 58

Tensile Test Report