“Design, Development and Fabrication of

Transmission and Steering System for Four Wheel

Electric Scooter for Handicapped for Indoor and
Outdoor Use”
Submitted in partial fulfilment for the requirement
of the degree of

Bachelor of Engineering
by

Khan Altamash (12ME23)

Khan Farooq (12ME25)
Khan Faisal (12ME24)
Shaikh Soofyan (12ME58)

Supervisor:

PROF. ZIA MOMIN

Department Of Mechanical Engineering

Anjuman-I-Islam
Kalsekar Technical Campus New Panvel,
Navi Mumbai-410206
UNIVERSITY OF MUMBAI
2015-2016
 ANJUMAN-I-ISLAM
KALSEKAR TECHNICAL CAMPUS NEW PANVEL
(Approved by AICTE, recg. By Maharashtra Govt. DTE,
Affiliated to Mumbai University)
PLOT #2&3, SECTOR 16, NEAR THANA NAKA, KHANDAGAON, NEW PANVEL,NAVI MUMBAI-
410206, Tel.: +91 22 27481247/48 * Website: www.aiktc.org

CERTIFICATE

This is to certify that the project entitled

“DESIGN, DEVELOPMENT AND FABRICATION OF TRANSMISSION
AND STEERING SYSTEM FOR FOUR WHEEL ELECTRIC SCOOTER
FOR HANDICAPPED FOR INDOOR AND OUTDOOR USE”
Submitted by
KHAN ALTAMASH
KHAN FAROOQ
KHAN FAISAL
SHAIKH SOOFYAN
To the Kalsekar Technical Campus, New Panvel is a record of bonafide work carried
out by him under our supervision and guidance, for partial fulfillment of the requirements for
the award of the Degree of Bachelor of Engineering in Mechanical Engineering as prescribed
by University Of Mumbai, is approved.

Project co-guide Internal Examinar External Examiner

( Prof. Zia Momin ) (Prof._____________ ) (Prof._____________ )

Head of Department Principal

(Prof. Zakir Ansari ) (Dr. Abdul Razzak Honnutagi )

i
 ANJUMAN-I-ISLAM
KALSEKAR TECHNICAL CAMPUS NEW PANVEL
(Approved by AICTE, recg. By Maharashtra Govt. DTE,
Affiliated to Mumbai University)
PLOT #2&3, SECTOR 16, NEAR THANA NAKA, KHANDAGAON, NEW PANVEL,NAVI MUMBAI-
410206, Tel.: +91 22 27481247/48 * Website: www.aiktc.org

APPROVAL OF DISSERTATION

This is to certify that the thesis entitled

“DESIGN, DEVELOPMENT AND FABRICATION OF TRANSMISSION
AND STEERING SYSTEM FOR FOUR WHEEL ELECTRIC SCOOTER
FOR HANDICAPPED FOR INDOOR AND OUTDOOR USE”
Submitted by
KHAN ALTAMASH
KHAN FAROOQ
KHAN FAISAL
SHAIKH SOOFYAN

In partial fulfillment of the requirements for the award of the Degree of Bachelor of
Engineering in Mechanical Engineering, as prescribed by University of Mumbai approved.

(Internal Examiner) (External Examiner)

_________________ _________________

Date: __________
ii
 DECLARATION

We declare that this written submission represents our ideas in our own words and
where others' ideas or words have been included, we have adequately cited and referenced the
original sources. We also declare that we have adhered to all principles of academic honesty
and integrity and have not misrepresented or fabricated or falsified any idea/data/fact/source in
our submission. We understand that any violation of the above will be cause for disciplinary
action by the Institute and can also evoke penal action from the sources which have thus not
been properly cited or from whom proper permission has not been taken when needed.

KHAN ALTAMASH (12ME23) ______________________

(Signature)

KHAN FAROOQ (12ME25) ______________________

(Signature)

KHAN FAISAL (12ME24) ______________________

(Signature)

SHAIKH SOOFYAN (12ME58) ______________________

(Signature)

Date: ______________

iii
 ABSTRACT

In this project, we have designed and developed transmission system and steering
system of a 4 wheel electric mobility scooter for handicapped for indoor and outdoor use.
Moreover, it has been specifically designed for a particular patient who is disabled by lower
limbs. Therefore we have made it customized that is according to the patient body dimensions,
needs or requirements. In this project, the electric scooter circuits were designed and made
simple to operate. Other than that, the maintenance of the designed electric scooter in this
project is low because the components used are connected to one set of batteries. Proper circuit
diagrams and connections were made using various electronic components to solve the issue
of operating two controllers through a single throttle and reversing of the motor. In this project
the power supply of the motor and the microcontroller is from a single input. Next, a
microcontroller is used to control the direction and speed of DC motor. In addition, an interface
is used between the user and the controller of electric scooter, toggle switch and limit switch.
Finally, the transmission and steering system were assembled on the chassis and testing and
tuning were done for successful completion of the project.

iv
 Table of Content

Certificate ……………………………………………………………………… i

Approval of Dissertation ……………………………………………………… ii

Declaration …………………………………………………………………… iii

Abstract ……………………………………………………………………….. iv

Table of Contents ……………………………………………………………… v

List of Figures ………………………………………………………………… vii

Chapter 1: Introduction …………………………………………………. 1

1.1 Introduction ……………………………………………….. 1

1.2 Problem Statement ………………………………………... 2

Chapter 2: Literature review ……………………………………………. 3

2.1 Literature review ………………………………………….. 3

2.2 Scooter operation …………………………………………. 4

Chapter 3: Methodology ………………………………………………... 5

3.1 Methodology ……………………………………………… 5

3.2 Flow Chart ………………………………………………… 7

Chapter 4: Components of Transmission system ……………………….. 8

4.1 Motor ……………………………………………………… 8

4.2 Controller ………………………………………………….. 8

4.3 Converter ………………………………………………….. 9

4.4 Battery …………………………………………………….. 9

4.5 throttle ……………………………………………………... 9

Chapter 5: Motor Selection …………………………………………….. 10

v
Table of Contents

5.1 Design aspects …………………………………………… 10

5.2 Motor selection …………………………………………... 11

Chapter 6: Battery Selection …………………………………………… 13

6.1 Battery selection …………………………………………. 13

Chapter 7: Electrical Circuits …………………………………………... 15

7.1 Main wiring harness ……………………………………… 15

7.1.1 Connection with single throttle ……………………. 15

7.2 Reversing of motor ………………………………………. 17

Chapter 8: Steering System ……………………………………………. 20

8.1 Ackermann-type steering mechanism ……………………. 20

8.2 Steering drawing …………………………………………. 22

8.3 Steering assembly ………………………………………... 23

Chapter 9: Cost Details ………………………………………………… 24

Chapter 10: Future Scope ……………………………………………… 25

Chapter 11: References ………………………………………………… 26

Publications …………………………………………………………………... 27

Appendix I ……………………………………………………………………. 28

Acknowledgment ……………………………………………………………... 30

Photos ………………………………………………………………………… 31

vi
 List of Figures

Figures

5.1 HERO electric Hub Moto ……………………………………………… 12

5.2 Controller of motor ……………………………….……………………. 12

6.1 Lead Acid Battery (TRONTEK) ………………………………………. 14

6.2 Four Batteries in series ………………………………………………… 14

7.1 Power wires ………………………………………………………….… 15

7.2 Throttle signal and supply wires ……………………………………….. 15

7.3 Main wiring harness …………………………………………………… 16

7.4 Reversing of motor with DPDT relay …………………………………. 19

7.5 Two DPDT relays between phase and sensor wires …………………… 19

8.1 Steering drawing with 1:2 scale (Left turn) ……………………………. 22

8.2 Activa’s front wheel assembly ………………………………………… 23

8.3 Arrangement of front wheel with fork on chassis ……………………… 23

8.4 Ackermann assembly ………………………………………………….. 23

vii
 Chapter 1

Introduction

1.1 Introduction
Disabled people and the elderly need to face their daily life just like normal people.
But, they need to be assisted by others to move back and forth. But, it is not always possible
for people to assist them all the time. By having a mobility scooter, they can move everywhere
by themselves. Although nowadays there are many assistive mobility that exist for disabled
people such as manual wheelchair but they may be reluctant to use because it makes them
different from normal person. So, a trendy look like scooter can increase their confidence to
mingle like a normal person.

Assistive and small sit-down motor scooters provide important advantages to people
with mobility problem throughout the world. Scooters are a subclass of motorcycles and are
very popular as urban and rural means of transportation. There are several types of scooters
that we will find zooming up and down the highways and city streets.

A scooter is also useful for person without the stamina or arm flexibility necessary to
use a manual wheelchair. Swiveling the seat of an electric scooter is generally easier than
moving the foot supports on most conventional wheelchairs. A mobility scooter is very helpful
for persons with systemic or whole-body disabling conditions.
Chapter 1, Section 2

1.2 Problem Statement

The main purpose of this scooter is to make a disabled or aged person to be self-
dependent. Mobility scooters are famous and available in foreign markets but in India there are
no manufacturers of mobility scooter and so only few suppliers are available. And since it is
imported it becomes costly and most of the people can’t afford to buy it. Therefore scooters
that are available with suppliers are expensive and not according to Indian roads (friction
between tire and road, speed, shock absorber and many other factors).So we have designed it
In such a way that it becomes feasible without compromising the actual need of the disabled
person which includes comfort, speed, reliability, aesthetic appeal and is according to Indian
roads.

2
 Chapter 2

Literature Review

2.1 Literature Review

According to a survey done by WHO it was found that around 7 lac accidents occur
every year in India. Out of these 2.3 lac people becomes permanently disabled. Out of these
permanently disabled peoples around 50% are disabled by lower limbs. The person with such
a disability are laid on the bed for rest of their life. They cannot take part in any social activity.
They are dependent on others for their needs. As time passes by they are isolated by the society.
Due to which they starts feeling lonely, and eventually results in the death of the disabled
person due to depression. This can be avoided by bringing them to their social life. In order to
overcome this problem, the solution is a mobility scooter which can be used by the disabled
person not only for outdoor purpose but also for indoor. This mobility scooter will help them
to return to normal life. It will also make them independent.

An electric scooter is a battery-operated one-person capacity vehicle that is specially

designed for people with low mobility. It is generally used by those who have difficulty walking
or standing for long periods of time. Scooters are available in three common designs, those
intended for indoor use, those for outdoor use, and those that are used for both. An electric
scooter is different from a motorized wheelchair, in that the wheelchair is generally intended
for indoor use and usually costs a great deal more. Some people are a little wary of purchasing
an electric scooter because they fear it will be difficult to operate. In fact, the control console
makes it quite simple once a person gets the feel for it.
3
Chapter 2, Section 2

2.2 Scooter Operation

Generally, there is several type of scooter. The way how to produce power for this kind
of transport is depend on its want to use. High power scoter usually use small engine with
gasoline. Another type is using electric motor operation whether dc or ac motor. This kind of
bike usually use in small area and for recreation.

2.2.1 Engine Powered Scooter

This type of scooter usually use small capacity engine. Normally around 40 to 60 cubic
capacities (cc). This kind of engine can be found whether four-stroke or two stroke engine.
This small engine scooter usually looks like small super bike. It can speed up until 50 to 60
km/h. Safety clothes should be used for precaution safety while ride this type of bike. This kind
of scooter usually can be found at place which already has their club track. The sound of this
bike is little bit noise but it looks very nice.

2.2.2 Electric Motor Scooter

Generally, the source of power for the electric motor has been batteries, but
development in fuel cell technology has created several prototypes. Some examples are: the
ENV from Intelligent Energy, Honda's scooter using the Honda FC Stack, and the Yamaha FC-
AQEL. Also, petroleum hybrid-electric motorcycles are under development. Some examples
are the E-cycle, and Yamaha's Gen-RYU. Figure 2.3 is example of scooter using electric motor
with stand riding operation.

2.2.3 Mobility Scooter

This is a modified version of the electric scooter and is made for special people like the
disabled and the aged people. These scooters are extremely stable, as they have more than two
wheel or four wheel

4
 Chapter 3

Methodology

3.1 Methodology
Flow of our work is as follows:

1. Literature Review
a. Make review on other model and type of scooters
b. Focusing on how to make it simple and relevance to the project title.

2. Design Calculation
a. Calculation of torque and power required to drive the vehicle.
b. Estimating wheel size

3. Design Layout
a. Designing of block/circuit diagram
b. Arrangement on chassis

4. Market Survey
a. As per our design calculation we visited few suppliers and as per the availability
and cost - motor , battery , tyre and controller selection is done

5
Chapter 3, Section 1

5. Modification Design
a. As per the parts available the design has been modified

6. Fabrication model refinement

a. Fabricate the scooter according to the design.
b. Mount the transmission system on the chassis

7. Prototyping Development
a. Assemble all the part to the design.

8. Testing
a. Run the model
b. Tuning of prototype according to problem if any

9. Documentation
a. Preparing a report for the project

6
 Methodology
3.2 Flow Chart

LITRATURE
REVIEW

DESIGN
CALCULATION

DESIGN
LAYOUT

MARKET
SURVEY

MODIFICATION

FABRICATION

PROTOTYPE
DEVELOPMENT

TUNING TESTING

DOCUMENTATION

Figure 3.1 Flow Chart

7
 Chapter 4

Components of Transmission System

4.1 Motor
A motor is an electrical machine which converts electrical energy into mechanical
energy. The principle of working of a DC motor is that "whenever a current carrying conductor
is placed in a magnetic field, it experiences a mechanical force". The direction of this force is
given by Fleming's left hand rule and its magnitude is given by

F = BIL

Where, B = magnetic flux density,

I = current and

L = length of the conductor within the magnetic field.

Fleming's left hand rule: If we stretch the first finger, second finger and thumb of our
left hand to be perpendicular to each other AND direction of magnetic field is represented by
the first finger, direction of the current is represented by second finger then the thumb
represents the direction of the force experienced by the current carrying conductor.

8
 Components of Transmission system
4.2 Controller
The core function of a DC motor controller is to periodically read the throttle setting
and adjust the current being supplied to the motor. It does this with a technique called pulse-
width modulation or PWM (more on this later).

Other functions of the controller include:

1) Low-voltage cutoff: Monitor the battery voltage and shut down the motor if the battery
voltage is too low. This protects the battery from over-discharge.
2) Over-temperature cutoff: monitor the temperature of the FET power transistors and shut
down the motor if they become too hot. This protects the FET power transistors.
3) Over-current cutoff: reduce the current to the motor if too much current is being
supplied. This protects both the motor and the FET power transistors.
4) Brake cutoff: shut down the motor when the brake is applied. This is a safety feature.
if the user applies brake and throttle, the brakes win

4.3 Converter (DC to DC)

A DC-to-DC converter is an electronic circuit or electromechanical device which
converts a source of direct current (DC) from one voltage level to another. It is a type of electric
power converter. Power levels range from very low (small batteries) to very high (high-voltage
power transmission).It is used in electric scooters to reduce the voltage to 12v, since the
electrical accessories (headlight, taillight, side indicators, etc.) works on 12v and the motor
requires a high voltage.

4.4 Battery
A battery is an electrical cell device that converts chemicals energy into electricity. The battery
also consists of two or more cells connected in series or parallel, but the term is also used for
single cells. A battery has positive electrode and negative electrode.

4.5 Throttle
A throttle for an electric bike is used to control the speed of the motor. The throttle
changes the motor speed as per the input from the user. Basically it consists of Hall Effect
sensor, which senses the change in position of the throttle and limits the voltage supplied to the
motor. It is one of the essential part of an electric scooter.

9
 Chapter 5

Motor selection

5.1 Design Aspect

Max. Velocity (V) = 15 km/h

Wheel Diameter (D) = 16"

Therefore, Speed (N) = 200 (aprox.)

5.1.1 Power and Torque

Total vehicle weight (GVW) = 250 kg

Acceleration time = 6 sec
Maximum incline angle = 15 degree

i. Rolling Resistance (RR) = 1.25 kg

ii. Grade resistance (GR) = 51.97 kg
iii. Acceleration Force (FA) = 18 kg
iv. Total tractive Effort (TTE) = 71.22 kg
v. Torque on wheel (Tw) = 78.08 Nm
vi. Torque at motor ™ = 6.02N-m
vii. Power (P) = 250 W

10
 Motor Selection
5.2 Motor Selection
HUB MOTOR - ideally, the term hub motor refers to a motor that replaces the hub of
a wheel. Some times this can be a flat disk motor, other times it is not a disk motor. In either
case, the motor is the hub, instead of being mounted beside it or near it.

Table 5.1 Comparisons of different type of motors with advantages and disadvantages

TYPE ADVANTAGES DISADVANTAGES APPLICATIONS TYPICAL

DRIVE

BRUSHLESS Long lifespan High initial cost Hard drives Multiphase

DC MOTOR requires a controller CD/DVD players D.C
High efficiency
Electric vehicles
Low
maintenance

BRUSHED Low initial cost High maintenance Treadmills PWM(pulse

DC MOTOR (brushes) limited exercisers width
Simple speed
lifespan automotive modulation
control
starters toys

HUB No interaction Adds weight to Electric bikes Direct

MOTOR with the primary wheels
Electric bicycles
scooter chain
Torque factors can
required
enter operational
No additional considerations
transmission
system required

11
Chapter 5, Section 2

Hence, this is very compact and suitable for our requirements therefore based on the
information listed in table 250-W rear hub motor is selected with the following performance
details:

• Model: Hero Optima++

• Rear Hub Motor Voltage: 48 V (brushless)

• Power Rate: 250 W

• Weight: 10 Kg

Figure 5.1 HERO electric Hub Motor Figure 5.2 Controller of Motor

12
 Chapter 6

Battery Selection

6.1 Battery Selection

Sealed Lead Acid Battery

The lead acid battery consists of three or six cells connected in series is used in
automobile, trucks, aircraft, or other vehicles. It chief advantage is it can deliver strong
electrical current for starting an engine, however it runs down quickly. Figure shows the lead
acid battery.

ADVANTAGES

i. Inexpensive and simple to manufacture

ii. Mature, reliable and well-known technology among the lowest in rechargeable
batteries.
iii. Low self-discharge—the self-discharge rate is among the lowest in rechargeable
batteries.
iv. Gel lead acid batteries can be used at any inclination.
v. The electrolyte is in the form of gel rather than liquid, due to which there is no spilling
of acid in case of battery breakage.
vi. Life cycle <= 3000 cycles

<= 70000 km

13
Chapter 6, Section 1

Figure 6.1 Lead Acid Battery (TRONTEK)

Figure 6.2 Four batteries in series

14
 Chapter 7

Electrical Circuits

7.1 Main Wiring Harness

Batteries, motors, controller, converter, throttle, Ignition switch, and all the lights are
connected through the main wiring harness.

7.1.1 Connection With Single Throttle

For controlling two motors with single throttle we have connected the three power
wires(i.e thick black,thick red,thin red) of the two controller to a single pin which is connected
to the main harness. We have also connected the throttle signal and supply wires of the two
controller to a single pin which is connected to the main harness.

Figur 7.1 Power wires Figure 7.2 Throttle signal & supply wire

15
Chapter 7, Section 1

Figure 7.3 Main Wiring Harness

16
 Electrical Circuits
7.2 Reversing of Motor
For reversing the motor we have to interchange two phase wires (i.e. green and yellow)
and also two hall sensor wires of the motor (i.e. blue and green). This is done by using a DPDT
(Dual Pole Dual Throw) relay. During forward motion of the motor the phase and hall sensor
wires are connected as per their colour. During reversing the coil in the relay gets actuated and
interchanges the wires.

7.2.1 What is a Relay?

A relay is an electrically operated switch. Many relays use an electromagnet to

mechanically operate a switch, but other operating principles are also used, such as solid-state
relays. Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where several circuits
must be controlled by one signal.

A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron
core, an iron yoke which provides a low reluctance path for magnetic flux, a movable iron
armature, and one or more sets of contacts (there are two in the relay pictured). The armature
is hinged to the yoke and mechanically linked to one or more sets of moving contacts. It is held
in place by a spring so that when the relay is de-energized there is an air gap in the magnetic
circuit. In this condition, one of the two sets of contacts in the relay pictured is closed, and the
other set is open. Other relays may have more or fewer sets of contacts depending on their
function. The relay in the picture also has a wire connecting the armature to the yoke. This
ensures continuity of the circuit between the moving contacts on the armature, and the circuit
track on the printed circuit board (PCB) via the yoke, which is soldered to the PCB.

When an electric current is passed through the coil it generates a magnetic field that
activates the armature, and the consequent movement of the movable contact(s) either makes
or breaks (depending upon construction) a connection with a fixed contact.
If the set of contacts was closed when the relay was de-energized, then the
movement opens the contacts and breaks the connection, and vice versa if
the contacts were open. When the current to the coil is switched off, the
armature is returned by a force, approximately half as strong as the
magnetic force, to its relaxed position. Usually this force is provided by a
spring, but gravity is also used commonly in industrial motor starters.

17
Chapter 7, Section 2

7.2.2 Pole & Throw of a Relay

Normally-open (NO), contacts connect the circuit when the relay is activated; the circuit is
disconnected when the relay is inactive. It is also called Form A contact or "make" contact. NO
contacts may also be distinguished as "early-make" or NOEM, which means that the contacts
close before the button or switch is fully engaged.

Normally-closed (NC), contacts disconnect the circuit when the relay is activated; the circuit
is connected when the relay is inactive. It is also called Form B contact or "break" contact. NC
contacts may also be distinguished as "late-break" or NCLB, which means that the contacts
stay closed until the button or switch is fully disengaged.

Change-over (CO), or double-throw (DT), contacts control two circuits: one normally-open
contact and one normally-closed contact with a common terminal. It is also called a Form C
contact or "transfer" contact ("break before make"). If this type of contact utilizes a "make
before break" functionality, then it is called a Form D contact.

DPDT – Double Pole Double Throw. These have two rows of change-over terminals.
Equivalent to two SPDT switches or relays actuated by a single coil. Such a relay has eight
terminals, including the coil.

7.2.3 Application of DPDT Relay

The DPDT relay (Double Pole Double Throw) is quite interesting and can be used in various
scenarios, including for changing the direction of a motor as you can see in the picture below.
It has 2 terminals and 4 connectors and you can look at the DPDT relay as the equivalent of 2
Single Pole Double Throw SPDT relays.

7.2.4 Change motor direction with DPDT relay

As you can see in the schematic the 12V battery (or use other voltages) is connected with the
plus at terminal T1 and minus at terminal T2. The contact 1 and 4 are connected together as 2
and 3 are too.

Without voltage applied to the coil the battery plus is connected to contact 1 (and 4) and minus
to 3 (and 2) therefore the motor is turning in one direction (let’s say clockwise). When voltage
is applied to the coil then the relay switches and now T1 (plus) is connected to contact 2 (and
3) and T2 (minus) is connected to 4 (and 1) therefore the motor is changing the direction of
rotation.

18
 Reversing of motor

Figure 7.4 reversing of motor with DPDT Relay

Figure 7.5 Two DPDT relays between phase and sensor wires

19
 Chapter 8

Steering System

8.1 Ackermann-type steering Mechanism

The generally used steering mechanisms for four-wheel vehicles are four-bar linkages
which are often called Ackermann-type steering mechanisms. The input motion from the driver
at the steering wheelies transmitted via a steering box and the steering control linkage to one
of the steering knuckles and then transmitted to the other one through the Ackermann Steering
linkage. The main kinematic requirement of the steering linkage of a vehicle is to provide the
steer-able wheels a correlated pivot such that their axes intersect at a point on the rear wheel
axis.

The objective for the synthesis of steering mechanism is to minimize the difference
between the centers over the full range of steering angle inputs while fitting into a reasonable
space. To obtain the target, several con-flicking requirements should be simultaneously
considered.

A possible formulation of the optimization-based synthesis problem is to search for the

values of Parameters. In addition, differential mechanism coupled to a higher pair, resolves the
single input coming from the steering wheel into two outputs satisfying the condition of correct
steering.

20
 Steering System
8.1.1 Advantages
The intention of Ackermann geometry is to avoid the need for tires to slip sideways
when following the path around a curve. The geometrical solution to this is for all wheels to
have their axles arranged as radii of circles with a common Centre point. As the rear wheels
are fixed, this centre point must be on a line extended from the rear axle. Intersecting the axes
of the front wheels on this line as well requires that the inside front wheel is turned, when
steering, through a greater angle than the outside wheel.

Rather than the preceding "turntable" steering, where both front wheels turned around
a common pivot, each wheel gained its own pivot, close to its own hub. While more complex,
this arrangement enhances controllability by avoiding large inputs from road surface variations
being applied to the end of a long lever arm, as well as greatly reducing the fore-and-aft travel
of the steered wheels. A linkage between these hubs pivots the two wheels together, and by
careful arrangement of the linkage dimensions the Ackermann geometry could be
approximated.

8.1.2 Angle Calculation

We take the following aspects for steering design by keeping mind the Indian road
conditions, like bums in road, sharp and blind turns, and also the Indian road traffic situations.

Turning radius (R) = 65”

Wheel base (L) = 40”
Wheel track (t) = 22”

Outer Angle = L / ( R + (t/2) )

= 30 degree

Inner Angle = L / ( R - (t/2) )

= 42 degree

21
Chapter 8, Section 2

8.2 Steering Drawing

To the scale drawing as per design requirements

Figure 8.1 Steering drawing with 1:2 scale (Left turn)

22
 Steering system
8.3 Steering Assembly
As wish bone arrangement take more space and makes system even complex with
independent suspension system. Therefore we chose the fork type arrangement like front
wheels of 2-whheeled scooters, for both the front wheel of our mobility scooter.

We took Activa’s front wheel arrangement. Assembled on chassis as shown in figure

8.3 below.

Figure 8.2 Activa’s front wheel assembly Figure 8.3 Arrangement of front wheel
with Fork on chassis

Figure 8.4 Ackermann steering

23
 Chapter 9

Cost Details

9.1 Cost Details

PARTS NUMBER COST (₹)

Motor 2 29500

Battery 4 12000

Controller 2 10000

Throttle 1 500

DC – DC converter 1 1000

Tyre (rear) 2 5000

Steering (+front wheels) 2 10000

Electric system - 6500

TOTAL 74500
 Chapter 10

Future Scope

10.1 Future Scope

a. The scooter can be made a two seater.
b. Safety devices such as air bags, GPS etc. can also be employed.
c. Facility to send emergency messages.
d. A remote controller can be used to control its functions.

25
 Chapter 11

References

Book,

[1] Automobile Engineering, Kirpal Singh Vol. I & II, Standard publisher
Distributors, Delhi

[2] Automobile Engineering, R.K. Rajput, Luxmi Publishing CO

Journal Paper,

[1] Mohammad aizzad: intelligent mobility scooter

[2] John bird: science for engineering

[3] Electric Wheel chair, Popular Mechanics, November 1954,,P. 101

26
 Publications

[1] International Journal of Management and Information Technology, VOL 11: No 3

Track Id eca985

Author Name Momin Zia,Khan Altamash,Khan Farooq,Khan Faisal,Shaikh Soofyan

Paper Title Design,Development and Fabrication of Transmission And Steering

System for Four wheel Electric Scooter for Handicap for Indoor and
Outdoor Use

Email [email protected]

Journal Name IJMIT

Status Accepted

27
 Appendix I

Calculation of torque and power of motor

GVW
i. Rolling Resistance (RR) =
Crr
250
= (Crr=Surface friction=0.005)
0.005
= 1.25 kg

ii. Grade resistance (GR) = 𝐺𝑉𝑊 ∗ sin 𝑎

= 250* Sin 15

= 51.97 kg

𝐺𝑉𝑊∗𝑉
iii. Acceleration Force (FA) =
9.81∗𝑡
250∗4.16
=
9.81∗6

= 18 𝑘𝑔

iv. Total Tractive Effort (TTE) = RR+GR+FA

= 1.25+51.97+18

TTE = 71.22 kg

v. Torque on wheel (Tw)

Tw = TTE*Rw*Rf

Tw = 71.22*8*0.0254*1.1*9.81 (Rf =1.1)

Tw = 78.08N-m

28
 Appendix I

vi. Torque at motor:

Tw = Tm*Pr*G

Tm =Torque on motor

Pr =Transmission efficiency = 1

78.08 = Tm*1*13

Tm = 6.02N-m

vii. Motor Power:

2∗𝜋∗𝑁∗𝑇𝑚
P =
60
2∗3.14∗200∗6.02
=
60

= 500 watt

29
 ACKNOWLEDGEMENT

After the completion of this work, we would like to give our sincere thanks to all those
who helped us to reach our goal. It’s a great pleasure and moment of immense satisfaction for
us to express my profound gratitude to our guide Prof. Zia Momin whose constant
encouragement enabled us to work enthusiastically. His perpetual motivation, patience and
excellent expertise in discussion during progress of the project work have benefited us to an
extent, which is beyond expression.

We would also like to give our sincere thanks to Prof. Zakir Ansari, Head Of
Department, and Prof. Rizwan Shaikh, Project co-ordinator from Department of Mechanical
Engineering, Kalsekar Technical Campus, New Panvel, for their guidance, encouragement and
support during a project.
I am thankful to Dr. Abdul Razzak Honutagi, Kalsekar Technical Campus New
Panvel, for providing an outstanding academic environment, also for providing the adequate
facilities.

Last but not the least I would also like to thank all the staffs of Kalsekar Technical
Campus (Mechanical Engineering Department) for their valuable guidance with their interest
and valuable suggestions brightened us.

KHAN ALTAMASH (12ME23)

KHAN FAROOQ (12ME25)
KHAN FAISAL (12ME24)
SHAIKH SOOFYAN (12ME58)

30
 Photos

Tuning of motor speed

Steering arrangement on Chassis

31
Final Mobility Scooter

32