B.

TECH FINAL YEAR PROJECT

Design,Finite Element Analysis and Fabrication of

a Human Powered Hybrid Tricycle

Group Members :

Under
2014-2015

Dhruba jyoti Das -MEB11002

Arun Kumar Shukla -MEB11049
Madhurjya Dutta-MEB11065
the guidance of :
Dr. Partha Pratim Dutta
Associate Professor
Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Table of content

1. Introduction
2.Literature review
3.Objective
4.Design methodology
5.Result and discussion
6.Conclusion
7.Future scope

8.References

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Introduction
Background Analysis :
In India 65% of available fuel is used for transportation. India compelled to import
over 75% of its domestic fuel requirement.
The air and noise pollution caused by transport vehicles, especially petrol and
diesel-powered two and three-wheelers
The team worked towards designing a highly efficient human electric hybrid
vehicle as an alternative to local city transportation using locally available parts.
Approaches Adopted :
The main approach that we took is to study, design and analyze
We studied about different tricycle and other two wheeler and three wheeler
automobile used for transportation in India. Then we analyze the thing to need to
achieve our aimed vehicle.
Design Methodology :
We sketched a number of innovative designs. We discussed on these designs
and choose the best one.
Then we calculated the different parameters to fulfill the aimed specification of the
vehicle. After that we start CAD designs. We use different design software's like
AUTODESK INVENTOR and CATIA for designing of parts. We used ANSYS for
analysis of the designs.
2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Literature review
1. Hickmen studied on India tricycle rickshaws for design improvement. He observed that
rickshaws are not designed for driver comfort and safety.
2. These studies discussed different techniques like addition of an electric drive, multiple
gear ratio chain and sprocket, regenerative capability, use of a flywheel or spring for
energy conservation and delivery as per load, etc., had been discussed
3. Alam et al., studied significance of aerodynamic design and comfortable riding of human
powered tricycle. Wind tunnel testing was performed to find out the key characteristics
of this human powered vehicle.
Objectives
1. Theoretical study of hybrid tricycle.

2. Design and finite element analysis of hybrid tricycle.

3. Fabrication of hybrid tricycle.
2014-2015

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B.TECH FINAL YEAR PROJECT

Tricycle Design Layout

Recumbent tricycles come in two configurations:
1.Tadpole having two wheels forward and one rear (2F1R),
2. Delta having a single wheel forward and two rear (1F2R)

Delta Configuration.
Advantage:
1. Easy to design, concepts follow that of a standard bicycle.
2. Lower cost to manufacturer, uses standard bicycles components.
Disadvantage:
1.Quick moment of inertia causes excessive roll.
2. Braking is compromised by a single front wheel which must provide the majority of
braking for the vehicle.

Tadpole Configuration
Advantage:
1.Two wheels in front offer excellent overall braking
2. Overall excellent handling
Disadvantage:
1.Steering systems are more complicated and require unique parts
2. Design is complicated and dependent on many contingencies
2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Design methodology

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

TECHNICAL SPECIFICATION

Fig1 Render view of Tricycle

Fig2 CAD Model of Frame

Fig3 Different View of the Vehicle

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Technical Specification
Dimensions and Weight
Configuration : 2-Seater Tadpole
Kerb weight: 100 kg
Total weight: 100+95+95+60 = 350kg
Wheel base : 64 inch
Track width: 45 inch
Material : AISI 1018
Pipe thickness : 0.125 inch
Pipe outer diameter: 1.2 inch

SUSPENSION
Front suspension
Type: Unequal A- arm double
whisbone suspension
UCA: 8.5 in
LCA : 11 in
Camber: -3
Caster: +4
Toe: 1.5 (in)
Stiffness: 32.814 N/mm

Rear Suspension :
Trailing arm suspension

Braking
Type: Disc brakes
Weight distribution : 60 : 40
Rotor dia:160mm
Total brake Force:150N (approx)
Total brake torque : 1554.4 N-m

STEERING
Type of steering : Modified Rack
and pinion steering
Steering ratio : 15:1
Outer turning angle:24.303 deg
Inner turning angle : 32.276 deg

Wheels and tires

Rear Wheel diameter: 26
Front Wheel diameter: 26

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Dimensions and Material Selection

Design constraints considered while making the roll cage: Light weight
Spacious and comfortable to accommodate the
tallest driver.
Total Length

90 in

Breadth

39.05 in

Height

48 in

Track width

45 in

Wheelbase

64 in

Height of COG

20 in

Overall weight of vehicle(including

passengers)

350 kg

2014-2015

Material Selection Criteria

1. Strength to weight ratio
2. Fatigue Limit/ Yield Strength
3. Corrosion resistant
4. Ease of Manufacturing
5. Cost
6. Availability
7. Weight

Material Selected :
AISI 1018
mild steel

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Drive Train
Gear no.

Ratio

Speed
Km/hr

8.039

32.15

Fig CAD Model of Full Drive Train

Crank length = 175mm = 6.899 inch

Teeth in crank = 44
Teeth in freewheel = 22
Crank speed= 60 rpm for speed
calculations
Wheel diameter = 28 inch
2014-2015

Fig Block Diagram of Drive Train

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B.TECH FINAL YEAR PROJECT

Finite Element Analysis

Youngs Modulus

204774.3 MPa

Poissons Ratio

0.29

Element Type

3 node 285

Total Number of nodes

776
M1 and M2 are two vehicles with similar
masses of 350 kg and the vehicle M2 is
at rest
U1 =22.4 km/hr , U2 = 0 km/hr
1
Energy transfer on impact =2

M1 M2 (U2 U1 )2
(M1 +M2 )

2014-2015

F = Energy / time ; time = 1s

Putting these values we get a F=7056 N
Taking FOS 1.5 we get F = 10584 N, which
was taken as 11600 N
Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Front Bump
A force equal to half the weight of the vehicle
was put at the front suspension points.
F = Mg/2 * FOS
= 1750 * 1.5
= 2625 N

Roll Over
A force equivalent to the gross weight of the
vehicle 3500N * 1.5 (FOS) i.e, 7500 was used.
It was applied at the top corner after
constraining the base.

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Roles of the Suspension :
Maximize the friction between tires and
road surfaces.
Provide good steering ability with good
handling.
Provide comfort to the passengers.
Suspension Terminologies

Caster

Camber

Toe
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Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Type of Suspensions
Front : Unequal arm double whisbone (
independent)

Rear : Trailing arm

Advantages :
Arms can be fixed at different angles.This helps to control:
Roll center position
Camber adjustments
Swing arm length
Low unsprung weight.
Good handling and cornering characteristics.
2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Roll Center Analysis

Roll Center position must be optimized

DONTs :
Roll centers position must not go below the
ground as the moment arm will increase.
Roll center must not be too close to center of
mass as this would give rise to jacking forces
during bumps.

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Static Weight Transfer
1
a
Fz1= 2 2 ( front)
L =a1 + a2
a1 = 25 in a2 =34 in

Fz2=

a1

(Rear)

Fz1 = 92.9 kg

FZ2(rear wheel)=136.7kg

Spring Design Calculations

1.
2.

Force(P) = Fz1 *1.5 (FOS)

Deformation =

3.

Wahls factor K=44 +

4.
5.
6.
7.

Shear stress = K* < Permissible design is valid

Coil diameter,D=C*d
No. of turns,N= Gd4/8*D3 *Ks
Length = Solid length + Total axial gap + deformation

41

2014-2015

0.615

here,C=6

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Results

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B.TECH FINAL YEAR PROJECT

Spring damping & stiffness calculations

(damping ratio) = 0.4
Natural frequency, f = 2.8 (assumed)
n = 17.6 rad / sec
Ks = Fz * n2 ( stiffness) N/mm
C= 2* Fz* n*
Kf = 28.776 N/mm
Cf = 1308 Ns/mm
Kr = 57.584 N/mm
Cr = 2617 Ns/mm
Spring material
Modulus of rigidity(G)

+4 deg

Camber

-3 deg

Toe

1.5 deg (in)

Ride height

11.25 inch

UCA

8.75 inch

LCA

11 inch

Roll center
height

5 inch

King pin angle

3.7 inch

Scrub

5 inch

Cold drawn and patented

steel
81370 Gpa

Factor of safety

1.5

Spring constant

28.776 N/mm

Spring diameter

6 mm

Length

250 mm(approx.)

2014-2015

Caster

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Seat
Configuration: semi- recumbent, side by side
Comfortable seating arrangement, good for people with back pain, good
for long distance/time ride.
Lower sitting height of 22 inch to lower center of gravity and minimize
aerodynamic drag, still tall enough to give good visibility.

SEAT BELTS :Use of 3-point OEM seat belts

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Steering Geometry
L = Track width
B = Wheel
base
R = Turning radius
= Inner
turning angle
= outer turning angle

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Results
Left wheel
steer angle

40.440

Steering
ratio

15:1

Right
wheel
steer angle

36.290

Outer
turning
angle

240

Lock to
Lock

3.2

Turning radius
Steering wheel turn in
one side

2014-2015

Inner
320
turning
angle
116.inch
5760

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Brake design
TYPE : Disk brake

Weight distribution =70:30

Vehicle speed : 11.1 m/s (40 km/h)

Stopping distance = 7.5 m T = 2 sec
Coefficient of friction (road & tire)=0.82
v=u+at v=0, u= 11.1m/s
a (Deceleration)= -5.55 m/s2

Total brake force = 1943 N

Disc diameter = 160 mm
Total Brake Torque = 1554.4 N-m

2014-2015

Fig: Brake Circuit Diagram

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Ergonomics
The pedal is designed in such a way that
the force is evenly distributed on the foot
The height between our head and the ceiling is
five fingers(a hand width) for proper forward

vision
Headrest is as close to the head as possible (23cm).

Low seat position to preserve stability in turns.

Clearance of 30cm between the center of the
steering hub and the base of the breastbone

(sternum).

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Safety
Mechanical Safety
3 point OEM seat belts for both the drivers.
Integrated structure and Roll Cage to protect drivers in case of

accident.

Mudguards on all three wheels

Chain tubes for the part near drivers legs.

Electrical Safety
Major electrical parts like battery and motor are properly covered .
Kill switches are provided .

2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

Conclusions
An analysis has been performed with in house developed tadpole type hybrid electric
tricycle.
A clearance of 30 cm between the center of the steering hub and the base of the
breastbone (sternum) headrest is as close to the head as possible (2-3 cm).
Maximum load applied is 10780 N and the factor of safety is found to be 1.4 from front
impact test.
For roll over test maximum load is 7000 N and factor of safety is 2.4. This ensures that
the frame is safe against. Suspension parameters have been devised as such to ensure
maximum comfort.
Regarding utility, such a light wheel vehicles may be used for short distance
transportation. It is high time to develop ecofriendly transportation for a sustainable
future. Finally, this may be integrated to the cycle rickshaws that are used today for short
distance transportation.
2014-2015

Department of Mechanical Engineering,TU

B.TECH FINAL YEAR PROJECT

References
[1] Dutta, P.P., Sharma, S.,Gogoi, T.K., Gogoi, R.Barman, K., Mahanta, M., Choudhury, A., Baruah,D.,
Gupta, S., Das, A. (2013), Design and development of a hybrid tricycle, National Conference on Recent
Advances in Mechanical Engineering, November 0809 2013, NERIST, Itanagar.
[2] Hickman, M.R. (2001), A Study of Power Assists for Bicycle Rickshaws in India, Including Fabrication
of Test Apparatus, BS, Mech. Engg. Project Report, MIT, USA.
[3] Rajvanshi, A.K. (2002), Electric and improved cycle rickshaw as a sustainable transport system for
India, Current Science, Vol. 83, pp. 703707.
[4]http://www.ihpva.org/Projects/PracticalInnovations/weld.html#BasicTrikeFrameDesign,
Accessed_13/09/2014
[5] Bhandar, V.B. (2010), Design of Machine Element, Tata McGraw-Hill, New Delhi.
[6] Gulati, V., Mehta, S. (2012), Design and FEA of a recumbent trike, International Journal of Applied
Engineering Research, Vol. 7, pp. 275279.
[7] Caiying Shen, Peng Shan, and Tao Gao (2011), A comprehensive overview of hybrid electric vehicles,
International Journal of Vehicular Technology, Vol. 2011.
[8] Pacejka, H. (2012), Tire and Vehicle Dynamics, Elsevier, London.
[9] Khan M.H. and Islam M.N. (2011), Comparative study on the material selection process for rickshaw
frames by weighted property method using modified digital logic and analysis of failure, Bangladesh
Journal of Scientific and industrial research,Vol. 2011, pp. 415424.
[10]http://en.wikipedia.org/wiki/Mesh_generation,Accessed_13/09/2014.http://en.wikipedia.org/wiki/
Finite_element_method, Accessed_13/09/2014

2014-2015

Department of Mechanical Engineering,TU