Abstract—

Day to day energy demand is increasing in automotive industry. Because of that problems occurring
such as, lack of fossil fuels and the pollution generated from the use of the fossil fuels. Now,
automotive industry needs some alternative system or technology which is not depends on the fossil
fuels and also not produces air pollutants. Combined human and electric powered vehicle could be a
good example of such kind of alternative solution and we can use it in future for small distance
transportation. Efficycle is hybrid vehicle which is electric and human powered. It is an eco-
friendly vehicle.
INTRODUCTION
The initiative towards EFFICYCLE was taken with aim to have hands on experience in
designing a Hybrid Human-Electric cycle keeping in view the ease of manufacturing and
economy. The design was made by the use of modeling software PRO-E WILDFIRE 4, and
design was analyzed by FEM analysis software ANSYS 12.0.Simplicity of design and Hybrid
drive train were the key parameters in the vehicle design

1 Overview

Introduction-REVISED

Efficycle is an intercollegiate design competition which is intended to engage engineering

students in developing the eco-friendly future mobility solutions for India. The event gives
participant a challenge of conceptualizing, designing and fabricating a 3-wheeled, 2-seater
vehicle.In2022competition,thefullyelectricvariantisintroducedunderadvancedformat.
Hencethevehiclemaybeprovidedeitherwithahybrid drivetrain(human power+electric power)
or a fully electric powertrain. The competition calls participation of undergraduate and
graduate engineering students from the institutes and universities across the country. The
students participate in competition in form ofa team guided by the faculty advisor
recognized bytheinstituteoruniversity.Teamsareexpected toapplyengineering
concepts in developing the vehicles suitable for the needs of a real worlduser.

Purpose-REVISED

Teamsaregivenachallengetodesignavehiclewhichcanbeutilizedinrealworld
applications including day-to-day personal mobility as well as commercial requirements of
passenger transportation and goods transportation. The vehicle designed for this purpose
must be aerodynamic, highly engineered, safe and ergonomic.

Teams can consider themselves working for a fictitious firm manufacturing the vehicles
(Efficycle) at mass production level. Hence the design should be commercially viable as a
marketproductandshouldbeattractivetotheconsumersbecauseofitsvisualappearance,
performance,reliabilityandeaseofoperation.

CompetitionSummary-REVISED

The Competition includes designing, fabricating and validating the vehicle developed by
them according to this rulebook. The vehicle would be evaluated for its design,
performance, safety, durability, practical usage and commercial viability. All participating
teamscompete againsteachotherwherethe cumulativescoresofalltheeventswould
decidetheoverallrankingoftheteams.Also,thebestperformancesofeachcategoryof
evaluations are awarded. The competition will have following variants:
(i) AdvancedHybridEfficycle(Human+ElectricPowered)
(ii) AdvancedElectricEfficycle(onlyElectricPowered)
VehicleDesign,Analysis,andConstruction

The research, analysis design, fabrication and validation of the vehicle

must be performed solely by a team constituting current SAE
INDIA student members of that
college/university.InternalorExternalfabricationassistanceisallowedo
nlyforthose
thingswhichrequirespecializedoperations.Useofsoundengineeringpractice
sisexpected in design and manufacturing of the vehicle.
BASIC DESIGN PROCEDURE
Care was taken to accurately define the goals and constrains of the project
before we engineer the solution to meet these goals. The basic design procedure
followed is as below.
A. Assumptions
Here basically considering the constrains of dimensions we first of all
assumed the dimensions of the vehicle.
B. Ergonomics
After assuming the dimensions our main area of interest was to make the
vehicle ergonomic for an average adult person.
C. Design
Here we actually designed the vehicle in modeling software PRO-E WILDFIRE 4.
D. Analysis
The analysis of the design was carried out by FEM analysis software ANSYS
12.0 in order to ensure that the designed vehicle is safe.
E. Modification in design
Based on the results obtained from analysis modifications were done in the
existing design.
F. Analysis
Again the analysis was done of the modified design and it was found to be safe.
G. Manufacturing
During manufacturing various parameters like serviceability, craftsmanship
and cost reduction were considered.
H. Aesthetics
In order to make the vehicle more attractive and convincing its aesthetic
considerations like appearance were given atmost importance.
SELECTION & DESIGN OF SUB-SYSTEMS

Selection of the drive train includes the sprockets, chains, intermediate shafts, motor, gear
cassette. Motor is selected on basis of torque, speed and battery is selected keeping in mind the
endurance time, weight and cost and maintenance. Selection of the steering system was done
considering light weight system, the linkage steering is used (Ackerman steering), it has 1:1 ratio, the
steering is constructed in such a way keeping in mind the natural tendency of human while steering the
vehicle Selection of the suspension, forks and mono-shock, the fork is selected as it is light weight, easy
to select according to the terrain and the vehicle run.
Mono shock is selected which takes lot of load as the distribution of weight is more at rear after
drivers seated Selection of the braking system was done for better quality, cycle hydraulic brakes are
selected. Selection of wheels was done considering that the terrain will be a mix of smooth and rough
roads, although thinner tyres would create less friction, they would provide less stability to the vehicle.
Wider tyres would provide more stability but would be more tiresome for the drivers to pedal.
Hence we have decided to use an option which would provide the best of both worlds, tyres of 40mm
width and 20 inch diameter will be used at the front and the rear tyre will be of 29 inches diameter. A.
Drivetrain –
Human Vehicle has chain drive for human transmission as it more efficiency and less costly.
Driver crank sprockets will be OEM type having 48 teeth and Driven sprockets have 18 teeth. This
system is same for both the drivers. Power will be transferred from pedals to rear wheel through
intermediate shaft.