Design And Fabrication of battery Electric Vehicle

In the modern era of technology, a lot of changes and modification are being made in the automobile industry. Due to the depletion in the availability of fossil fuels, many automobile industries change their trends from convectional to electric vehicles. It?s not only fulfilling our requirements but

Project Title

Design And Fabrication of battery Electric Vehicle

Project Area of Specialization

Mechanical Engineering

Project Summary

In the modern era of technology, a lot of changes and modification are being made in the automobile industry. Due to the depletion in the availability of fossil fuels, many automobile industries change their trends from convectional to electric vehicles. It’s not only fulfilling our requirements but also provide us green and toxic-free environment. So, keeping that in our mind, our team brought up the best ideas related to this field. But to implement our ideas we need a platform that can help us to present the best of our skills. We found shell-Eco marathon to be the most suitable platform to present our skills and knowledge. It is the place where we can open the doors of new and beneficial technology, to make our future secure and eco-friendly. So, me and my team mates decided to design and fabricate a prototype battery electric vehicle for single person capacity which gives 60 miles when a battery is fully charged. And the battery use in this project is lithium ion because of its high efficiency compared to other batteries. And motor use in this project is high torque BLDC motor 48v 18 A.

Project Objectives

• Designing of chassis for single person loading capacity (Static Analysis)
• Designing of Vehicle body (CFD Analysis)
• selection of material 
• selection of motor 
• selection of battery 
• fabrication of chassis 
• fabrication of Vehicle body

Project Implementation Method

  Our project is based on both hardware and software work so first of all we design the whole chassis under single person capacity loading condition and from there we find the required diameter for the hollow pipe required to fabricate the chassis and then we simulated the chassis in solid works software for finding stress. And then we design the vehicle body and carry out CFD analysis using Solid works software for finding drag forces and resultant forces. Now the next part is to select the motor for this we calculate the required toque and then we select the desire motor which fulfill our Torque as well as RPM requirements. After selecting motor, the next part is to select the battery suitable for the selected motor. After this we design a Controller and BMS system which controls our motor RPM, Torque and also manage the battery power where it is required. The controller and BMS system decide when and where power is delivered to the vehicle its charging and discharging capacity and also control the motor torque and its RPM. We are also numerically design the Steering Assemblies use in front wheel and also transmission system through chain and sprocket mechanisms. Here we completed our theoretically part after this we start our fabrication. The fabrication process consists of two parts the first one is mechanical components like chassis, Vehicle body, BLDC motor, chain sprocket mechanisms, tires the wheel assembly, Steering assembly, Shock absorber assemblies. And the second part in fabrication is electric like, lithium-Ion battery, MS circuit, Motor Controller, and propulsion system circuit. And finally charging board which charge the battery.      

Benefits of the Project

• Eco-Friendly.
• low cost of maintainance. 
• Reduction in noice pollution. 
• Use of junk materials into usefull products.
• most of our project assemblies and parts are from junk so we can made a electric car with low cost as compared to the electric car with new parts.

Technical Details of Final Deliverable

Length of vehicle = 2200 mm

Width of vehicle = 880mm

Height of vehicle  = 700mm

Capacity = single person

Total weight = 90 kg

Chassis = Hollow pipe (1 inch 18 guage)

Chain Sprocket (Teeth ratio 3/1)

Suspension type=  Shock Absorbers

Spokes Rims =(17 inch rare 15 inch front)

Brakes =( front disk , back drum )

Steering system = Link joints system 

Body type= 20 guage steel sheet 

Motor = BLDC (48v 16A 2800 RPM )

Lithium ion battery = (48v)

Motor contoller= Mega controller  

BMS System

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Core Technology

Others

Other Technologies

Sustainable Development Goals

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com