1

CHAPTER NO-01

LITERATURE SURVEY

2

1. LITERATURE SURVEY

After forming the project group, we thought of some ideas and topics for

project. And major attention was on the problems of deficiency of atomization in

automobiles and use of abundantly available renewable energy resources (e.g. solar

energy etc). Regarding the topics, we had discussed some ideas, such as Exhaust

gas recirculation for petrol engines, modification in over head projector, conversion of

load into electricity by using piezoelectric material, modification of air bike etc.

These are discussed, in short, as follows:

1.1 MODIFICATION OF OVER HEAD PROJECTOR

1.1.1. CONCEPTUAL SKETCH:

Fig. 1.1.1- Modification of over head projector

3

1.1.2: CONCEPT STUDY:

Due to load shedding it is quite difficult to run the overhead projector.Many

complicated sketches & animations are need to be explained on projector.So frequent

power cut off leads to problematic situation. By considering above problem we are

thinking to give power to the overhead projector by using wheel of sewing machine

Further discussion on this concept we observed that it is very difficult to get the

required power to run the overhead projector from rotation of wheel of sewing

machine.

1.2: EXHAUST GAS RECIRCULATION FOR PETROL ENGINES

1.2.1: CONCEPT STUDY:-

Exhaust gas recirculation means use of exhaust gas to preheat the petrol to prepare the

homogeneous mixture with air. Because of heat present in exhaust gas, the exhaust

gas will evaporate the petrol to form vapor which will mix with air to form

homogeneous mixture.

1.3: MODIFICATION OF AIR BIKE:-

1.3.1: CONCEPT STUDY

The air bike prepared in our college runs on compressed air stored in tank, which

gives power to pneumatic motor, which propels the wheel. It has some disadvantages

as

1. Limited range

2. Limited speed

3. No sophisticated control

4. Less available space

We thought that limited range can be extended by fitting small air compressor on

tank, which will run on battery. Speed limitation can be overcome by fitting a nozzle.

4

1.4:-FUEL+SELF CHARGED VEHICLE (HYBRID BIKE)

1.4.1:-CONCEPT STUDY

Currently our world is facing major problem of fuel scarcity. India is dependent on

Arab countries for its 75% oil need. Because of which oil prices are continuously

hiking. To overcome this hybrid mode is introduced in four wheeler sector. But it is

not introduced in two wheeler sector. In India two wheelers are present in very large

numbers. If hybrid mode is introduced in two wheelers it will save about 40% of fuel

if parallel hybrid mode is used & if series hybrid mode is used it will save about 70%

of fuel. Series mode is very costly to imply in two wheelers because it will increase

the cost of two-wheeler. But parallel mode is relatively cheaper than series mode. The

basic of parallel mode consists of using engine power to charge electric batteries, &

using this stored electric power to propel the electric motor, ultimately which gives

power to wheels.

Fig:-1.4.1:-Parallel hybrid mode

5

CHAPTER – 02

SELECTION OF PROJECT

6

2.0:-SELECTION OF PROJECT

After discussion with our guide, we have selected the concept “FUEL+SELF

CHARGED BATTERY OPERATED VEHICLE” other concepts dropped due to

following reasons

2.1:-MODIFICATION OF OVER HEAD PROJECTOR

We observed that it is very difficult to get the required power to run the overhead

projector from rotation of wheel of sewing machine.

2.2:- EXHAUST GAS RECIRCULATION FOR PETROL ENGINES

Further discussion with guide we concluded that exhaust gas recirculation will lead to

loss of power, wastage of petrol due to more heating.

2.3:-MODIFICATION OF AIR BIKE

Further discussions concluded that to increase speed we must have to increase motor

capacity, air tank capacity which was increasing cost of project which was beyond our

budget.

2.4:-FUEL+SELF CHARGED BATTERY OPERATED VEHICLE

(HYBRID BIKE)

We have selected this project because there is no existence of such model in world. If

it is introduced, it will save cost of precious fuel plus decrease the level of pollution in

city. Consider yearly sale of HERO HONDA in November 2012.It states that HERO

HONDA sold 11 lakh units. If our project becomes a grand success & if it is

implemented only in HERO HONDA models we will save 40% fuel of each bike plus

it will decrease emission from those bikes. Plus it will save foreign exchange of India.

Advantages

1) Less fuel consumption 3) Range extension of electric bike mode

2) Less pollution in city

7

CHAPTER – 03

INTRODUCTION OF

PROJECT

8

3.0 INTRODUCTION OF PROJECT:

3.1 TITLE

“FUEL+SELF CHARGED BATTERY OPERATED BIKE”

(HYBRID BIKE)

3.2 OBJECTIVE

1. To operate a bike on petrol or battery as per requirements

2. To achieve the fuel savings

3. To reduce the pollution

3.3 RELEVANCE

1. Currently world is facing two major problems: - Fuel scarcity & pollution.

Electric vehicles are becoming good solution to these problems.

2. But electric vehicle has some constraints like speed limit, limited range. To

overcome this hybrid mode came in picture. In hybrid mode the vehicle is

powered by both: Fuel & electric power.

3. This combination helped to overcome speed limit & limited range problem.

4. Also this combination saves precious fuel, reduces pollution. Let’s see how.

When running bike in city, because of traffic situations the relative speed is

low. Many interrupts occurs which leads to unnecessary engine idling. Engine

idling leads to wastage of 15% Indian fuel per year (As per ARAI).It can be

eliminated by using electric mode in city. On highway we can switch to engine

mode. During travel, the battery will get charge which we may use in city to

run bike on electric motor.

5. Because of combination of fuel & battery mode we are combining the

advantages of both modes. Fuel mode offers large load capacity than electric

mode. More mileage covering capacity than electric mode. More speed than

electric mode. Electric mode offers clean running than petrol mode. In Electric

9

mode as supply to motor gets off when we release the accelerator so there is

no condition of unnecessary idling, which wastes fuel in petrol mode

3.4 WORKING

Fig: 3.4: Proposed Layout

1. We are planning to use Permanent magnet DC motor. It has a

characteristic that when current is supplied to it, it acts as motor. When

revolutions are given to motor it acts as generator. In our project we

will supply current to propel the bike. While using bike on I.C Engine,

as the motor is coupled to rear wheel, the rear wheel will supply

rotation to motor shaft thus generating the current.

2. The current generated by generator will be stored in batteries.

3. Currently scooters with continuous variable transmission have belt

drive to transmit power of engine to rear wheel. We are coupling

permanent magnet dc motor to belt drive system as shown in fig. When

running on engine mode the power will be given to rear wheel & motor

which will generate current. While switching to electric mode the belt

connecting engine to rear wheel will be removed & bike will run solely

on electric motor.

10

CHAPTER NO-04

LITERATURE REVIEW

11

LITERATURE REVIEW:

4.1: LITERATURE REVIEW FROM TECHNICAL PAPERS

4.1.1: TOPIC: - USHERING IN AN ERA OF SOLAR-POWERED

MOBILITY

ABSTRACT:-

Modern mobility, for both humans and commodities, relies almost exclusively on

fuels derived from petroleum. At the same time the world is experiencing soaring

demand for mobility, environmental and resource constraints have become

increasingly acute. This article discusses the role that electric drive, initially in the

form of hybrid electric vehicles, can play in addressing the mobility challenge. This

article discusses the opportunity that electric drive vehicles create to use solar and

wind power for transportation. The potential of the emerging vehicle integrated PV

concept is discussed along with the importance of connecting cars to the electric grid.

4.1.2:-TOPIC:-HYBRID VEHICLE

ABSTRACT

Considering that we live in a very mobile society, it's probably safe to assume that

you have car. While pumping gas, you've undoubtedly noticed how much the price of

gas has soared in recent years. Gasoline, which has been the main source of fuel for

the history of cars, is becoming more and more expensive and impractical (especially

from an environmental standpoint). But cost is not the only problem with using

gasoline as our primary fuel. It is also damaging to the environment, and since it is not

a renewable resource, it will eventually run out. These factors are leading car

manufacturers to develop cars fueled by alternative energies. One possible alternative

is the air-powered car. There are at least two ongoing projects that are developing a

new type of car that will run on compressed air. One among them is the e.Volution

Cars. After more than thirty years experience with combustion engines, the French

12

engineer Guy Negre has developed a concept of a totally non-polluting engine for use

in urban areas. This invention, which uses high pressure (300 bars) compressed air to

store the energy needed for running the engine. When the air is injected into the

cylinder chamber, it expands to provide motive power. Oddly, the problem with a

conventional four-stroke engine is that compression, combustion and expansion all

take place in a single cylinder. But here the engine divides these functions into a

three-chamber system,with one cylinder for compression, a small chamber for

combustion and a much larger cylinder for expansion. Zero Pollution Motors is also

working on a hybrid version of their engine that can run on traditional fuel in

combination with air. Mono-energy engine have demonstrated the viability of the new

concept, the air and fuel, bi-energy, engine will be introduced to major car

manufacturers in order to study its adaptation for their common models.

4.2:-LITERATURE REVIEW FROM TECHNICAL WEBSITE

www.howstuffworks .com TOYOTA PRIUS:-The Toyota Prius, which came out in Japan at the end of 1997, is

designed to reduce emissions in urban areas. To accomplish this, Toyota has designed

a parallel hybrid power train, called the Toyota Hybrid System (THS) that adds some

of the benefits of a series hybrid. The Prius meets California's super ultra low

emissions vehicle (SULEV) standard. It is a four-door sedan that seats five, and the

power train is capable of accelerating the vehicle to speeds up to 15 mph (24 kph) on

electric power alone. This contributes to the better city mileage than highway mileage.

The Prius was the 2004 North American Car of the Year.

Fig 4.1:-TOYOTA PRIUS

13

CHAPTER NO-05

DESIGN OF PROJECT

14

5.0DESIGN OF PROJECT:

5.1 CONCEPTUAL SKETCH

Fig 5.1.Conceptual Sketch of Hybrid Bike

5.2 LIST OF PARTS REQUIRED FOR ASSEBLY

PART NAME NO.OF REQUIRED

ENGINE 1

ELECTRIC MOTOR 1

BELT DRIVE(V BELT) 2

BATTERIES 1

MOTOR CONTROLLER 1

SQUARE PIPES FOR FRAME 5

15

5.3. PARTS TO BUY:-

PART

NAME

SPECIFICATIONS

REQUIRED

NUMBERS

REQUIRED

SELECTED

MATERIAL

ENGINE 1)P=4-5 bhp

2)Engine speed(max) 6000 rpm

1 M80 engine

P=4.5 bhp

MAX RPM=6000

ELECTRIC

MOTOR

1)POWER:-250 W

2)TORQUE-8-9 Nm

3)SPEED-20 kmph

4)LOAD CARRYING

CAPACITY-90 Kg

5)MOTOR SHOULD ACT AS

GENERATOR WHEN

REVOLUTIONS ARE GIVEN

1 PERMANENT

MAGNET DC

MOTOR

1)P=250W

2)TORQUE=8.45

Nm

BATTERY 24 VOLTS 14 Ah 1 24 VOLTS 14 Ah

BELT

DRIVE

TO TRANSMIT POWER OF

4.5 bhp & TORQUE OF 5.5 Nm

at 4500 RPM

2 SCOOTY ES

TRANSMISSION

DRIVE

5.4. PROBLEMS FACED BY PREVIOUS LAY-OUT

1) No space available to mount the motor.

There is no space remained to mount the motor in Bike frame.As current bikes have

not considered the need for such arrangement.

2)The permanent DC magnet motor was not available in our budget.

16

3)The belt drive mounting demanded special arrangement.It is required to mount

special pulley on existing transmission system.

So we changed layout.Instead of mounting on bike frame,we decided to make frame

like table as shown.Because it will provide space for mounting electric hub

motor,chain drives,batteries,motor controller.

Fig 5.4:-Decided layout of frame

5.5 BOUGHT OUT ITEMS

PART NAME SPECIFICATIONS

REQUIRED

NUMBERS

REQUIRED

SELECTED

MATERIAL

ENGINE 1)P=4-5 bhp

2)6000 rpm

1 M80 engine

P=4.5 bhp

MAX RPM=6000

ELECTRIC

MOTOR

1)POWER:-250 W

2)TORQUE-8-9 Nm

3)SPEED-20 kmph

4)LOAD CARRYING

CAPACITY-90 Kg

1 BRUSHLESS DC

HUB MOTOR

1)P=250W

2)TORQUE=8.45

Nm

17

BATTERY 24 VOLTS 14 Ah 1 2x12 VOLTS 14 Ah

CHAIN DRIVE TO TRANSMIT POWER OF

4.5 bhp at 6000 RPM

2 ISO chain no 10B

ALTERNATOR TO GENERATE 24V AT

2000 RPM

1 TRUCK

ALTERNATOR

24V

5.5 CHAIN SELECTION:-

5.6 CHAIN SELECTION FOR ENGINE TO REAR HUB DRIVE

The M80 engine developes 4.5 bhp at 6000 rpm

Power in Kw=3.356 Kw

Design power= Rated power x Ks

Ks=K1K2K3

K1(Load factor)=Variable load with heavy shock=1.5

K2(Lubrication factor)=Periodic lubrication=1.5

K3(Rating factor)=continuous use=1.5

Ks=1.5*1.5*1.5=3.375

Design power=3.375*3.356=11.325 Kw

The alternator requires 2000 rpm to generate the electricity of 24V.

Let’s assume engine speed of 1200 rpm,

Velocity ratio=Driven rpm/driver rpm

=2000/1200

=1.67

18

From table no 21.2 page no 767 of M/C Design by Khurmi Gupta

Pitch of chain for 2000 rpm=14.8 mm.

Let’s find no.of teeth on driven sprocket

From table no 21.5 page no 770

For roller chain,velocity ratio=1.6 approx.=2

No of teeth on driven sprocket=27

So no.of teeth on driver sprocket=40.

#Now finding out center distance:-

=p/4[K-������� �+√� � ������� ��� 8 ��� �����.���

��]

Where

P=pitch of chain

K=no.of chain link

=������� �+ (��� ) + ��� �����.���

�*(p/x)

T1= no of teeth on driven

T2=no of teeth on driver

Solving simultaneously we get

x=440 mm

Centre distance=440 mm

5.7 CHAIN SELECTION FOR HUB MOTOR TO REAR HUB

DRIVE

By using process performed in 5.5.1 the statistics of chain drive for Hub motor to rear

hub are

19

1) No of teeth on driver=44

2) No of teeth on driven=24

3) Centre distance=315 mm

5.7 Electric Hub Motor

Fig 5.6:-Hub motor

The requirements were

1. Speed of 20 to 25 kmph. 2. Range of 25 to 30 km per charge 3. Load carrying capacity:-2 person

For reference we searched in the list of available motors for electric bikes.We

selected the motor of Yo Electron. The specifications are:-

1. Maximum Speed 25 Km/Hr

2. Pay load Capacity 75 Kg

3. Motor Power 250 Watt

5.8 Alternator (For generation of electricity)

Because of unavailability of Permanent magnet DC motor we opted for mounting of

alternator to generate electricity while travelling.

20

The alternator should possess following characteristics

Rated output = 24 Volts to charge batteries of voltage 24 volts at max.2000 rpm.

Those requirements were satisfied by a truck alternator.

5.9 PARTS TO BE FABRICATED

TABLE FRAME:-

REQUIREMENTS:-

1) It should sustain weight of engine, motor, batteries, two chain drives, hub motor,

and alternator.

2) It should sustain vibrations developed due to engine.

3) It should facilitate mounting of chain drive having centre distance of 440 mm from

engine to alternator.

4) It should facilitate the angular mounting of chain drive having centre distance of

315 mm.

By considering above requirements the table dimensions were finalized as follows

1) Length of table= 930 mm

2) Height of table= 920 mm

3) Breadth of table= 620 mm

21

CHAPTER NO: 06

THEORY

22

6.0THEORY

6.1:-ELECTRIC HUB MOTOR

How does a hub motor differ from an ordinary motor?

In an ordinary motor, you have a hollow, outer, ring-shaped permanent magnet that

stays static (sometimes called the stator) and an inner metallic core that rotates inside

it (called the rotor). The spinning rotor has an axle running through the middle that

you use to drive a machine. But what if you hold the axle firmly so it can't rotate and

switch on the motor? Then the rotor and the stator have no choice but to swap roles:

the normally static rotor stays still while the stator spins around it. Try it with an

electric toothbrush. Instead of holding the plastic case of your toothbrush (which,

broadly speaking, connects to the static part of an electric motor), try holding only the

bristles and then turn on the power. It's quite tricky to do, because the brush moves so

fast, but if you do it right you'll find the handle slowly rocks back and forth. This is

essentially what happens in a hub motor. You connect the central, normally rotating

axle to the static frame of a bicycle or the chassis of a car. When you switch on the

power, the outer part of the motor rotates, becoming a wheel (or wheels) that power

the vehicle forward.

How does a brushless DC (BLDC) motor work?

Ordinary electric motors use a mechanical device called a commutator and two

contacts called carbon brushes to reverse the electric current periodically and ensure

the axle keeps turning in the same direction. Hub motors are typically brushless

motors (sometimes called brushless direct current motors or BLDCs), which replace

the commutator and brushes with half-a-dozen or more separate coils and an

electronic circuit. The circuit switches the power on and off in the coils in turn

creating forces in each one that make the motor spin. Since the brushes press against

the axle of a normal motor, they introduce friction, slow it down, make a certain

amount of noise, and waste energy. That's why brushless motors are often more

efficient, especially at low speeds. Getting rid of the brushes also saves having to

replace them every so often when friction wears them down.

23

fig 6.1 HUB MOTOR ASSEMBLY

Here are some photos of a typical brushless DC motor. First, look at the fully

assembled motor shown in the top picture. In a normal motor, you'd expect the inner

coil to rotate (it's called the rotor) and the outer magnet to stay static (that's called the

stator). But in this motor, the roles and reversed: the inner part with the coils is static

and the gray magnet spins around it. Now look inside and you can see exactly how it

works: the electronic circuit sends power round the nine copper coils in turn, making

the gray outer case (which is a magnet split into a number of sections, bent round into

a circle) spin around the copper coils and circuit board (which remain static). How

does the circuit know which of the nine coils to switch on and off—and when? You

can't really see in this photo, but there are several tiny magnetic field sensors (known

as Hall-effect sensors) positioned between some of the coils. As the permanent

magnets on the outer rotor sweep past them, the Hall-effect sensors figure out where

the north and south magnetic poles of the rotor are and which coils to activate to make

it keep spinning. The trouble with this is that it means the motor does need an

electronic circuit to operate it, which is something you don't need for an ordinary DC

motor.

What are the advantages of hub motors?

It depends whether you're talking about an electric bicycle or an electric car. Adding a

hub motor and batteries to a bicycle is a mixture of pro and con: you increase the

bicycle's weight quite considerably but, in return, you get a pleasant and effortless

ride whenever you don't feel like pedaling. Where electric cars are concerned, the

benefits are more obvious. The weight of the metal in a typical car (including the

engine, gearbox, and chassis) is perhaps 10 times the weight of its occupants, which is

24

one reason why cars are so very inefficient. Swap the heavy engine and gearbox for

hub motors and batteries and you have a lighter car that uses energy far more

efficiently. Getting rid of the engine compartment also frees up a huge amount of

space for passengers and their luggage—you can just stow the batteries behind the

back seat! Vehicles powered by hub motors are a whole lot simpler (mechanically less

complex) than normal ones. Suppose you want to reverse. Instead of using elaborate

arrangements of gears, all you have to do is reverse the electric current. The motor

spins backward and back you go! What about four wheel drive? That's quite an

expensive option on a lot of vehicles—you need more gears and complicated

driveshafts—but it's very easy to sort out with hub motors. If you have a hub motor in

each of a car's four wheels, you get four-wheel drive automatically. In theory, it's easy

enough to make the four motors turn at slightly different speeds (to help with

cornering and steering) or torque (to move you through muddy or uneven terrain).The

emphasis was on making a fold-up vehicle light enough to take to the Moon. Electric

power was not only a practical choice: with no air in space to power an internal

combustion engine, it was the only real option. Photo by courtesy of NASA Marshall

Space Flight Center (NASA-MSFC).

What are the problems with hub motors?

Hub motors are bigger, bulkier, and heavier than ordinary wheels and change the

handling and ride of an electric car or bike. Another problem is with torque (turning

force). A gasoline engine works best turning over quickly (making lots of revolutions

per minute), no matter what speed you're actually doing on the road. You use a

gearbox to convert the engine's power into high speed or high force (torque)

depending on whether you're starting off from a standstill, racing along the freeway,

driving slowly uphill, or whatever. Hub motors have to be able to produce any

combination of speed and torque without a gearbox—which is quite a tall order, if

you think about it, because most electric motors are designed to rotate at very high

speeds all the time. So you need quite a special motor that can potentially provide

both high torque at low speed (for driving off from a standstill or climbing a hill) and

low torque at high speed (for racing down the straight). Some hub motors have gears

built into the wheels to increase torque, but since that adds weight, cost, and

25

complexity, many do not, so generating enough torque can sometimes be a problem.

You also need to be sure the rest of your wheel is strong enough to cope with the

forces a hub motor can deliver, particularly if you're converting something like an

ordinary bicycle wheel into a hub motor. Suppose you mount an electric motor on the

hub of a basic bike and switch on the power. Since you weigh quite a lot and there's

plenty of friction between the tire and the ground, the motor could simply bend the

spokes instead of moving you along the ground! So an electric bicycle typically needs

stronger wheels (with stronger spokes) than an ordinary one.

6.2 ALTERNATOR

Fig6.2 Alternator

Principle of operation of the alternator:-

Rotating a coil within a magnetic field induces a voltage at the coil terminals [1, 2, 3],

which allows powering a load connected to these terminals. If the coil rotates at

constant speed within a uniform magnetic field, an AC voltage with zero mean value

is induced at its terminals. The periodic change of the voltage polarity is due to the

change of the position of the coil relatively to the magnetic poles. The amplitude of

the voltage depends on the magnetic field strength and the rotation speed. This is the

26

principle of operation of an alternator. Typically, an electromagnet has a coil with

iron core and the strength of the generated magnetic field depends on:

•the number of turns of the coil

•the amplitude of the current that flows in the coil;

•the type of iron core used

The current flowing in an alternator electromagnet, which is called the excitation

current,may come from an external energy source – a battery, for instance – or from

the electric circuit of the alternator itself. The principles described so far explain the

operation of a single-phase alternator. The alternator used in this project is three-

phase: it has three identical coils symmetrically mounted on the rotor, (with an

electrical 120º angle between each two coils). As long as the rotor keeps turning, three

alternating currents of the same frequency and amplitude are generated. These

currents are displaced by an angle of 120º. Usually, a three-phase alternator would

require six wires to conduct the currents induced in the three coils. It is possible to

reduce the number of wires to three by connecting the coils between each other. They

may be connected in electrical delta or in electrical star. A delta connection only

requires three wires out of the coils. A star connection requires three or four wires. In

car alternators, the coils where the voltages are induced are usually mounted in the

stationary part of the equipment (the stator). The coils that produce the magnetic field

are placed in the mobile part (the rotor) of the equipment.

27

CHAPTER NO-07

FABRICATION

28

7.0 FABRICATION

7.1FABRICATION OF FRAME

THE FINALISED DIMENSIONS OF FRAME ARE

1) LENGTH= 930 mm

2) HEIGHT= 920 mm

3) WIDTH= 630 mm

Material used for fabrication of table is Mild Steel L section of dimension 35x35x4

mm.

Fig 8.1 Table frame

7.2 ENGINE MOUNTING:

7.2.11PROBLEMS FACED:

1) It was not feasible to mount the engine at the center of the frame because starting

engine with the help of kick was not possible .so we decided to mount the engine at

corner of the frame.

2) There was no any kind of provision to mount the engine so we welded 2 plates of

dimension (165mmx25mm)as support at front and 2 plates of dimension

(95mmx25mm)at rear.

29

Fig 8.2 Engine Mounting

7.3 SPROCKET AND REAR HUB MOUNTING:

7.3.1PROBLEM FACED:

1) At first we had mounted sprockets at rear end of the frame but we came to know

that mounting at the rear end was becoming problem to couple the alternator. so we

reduced the distance of engine sprocket and rear sprocket.

2) There was no any kind of provision to mount the sprockets so we welded 2 plates

of dimension (180mmx25mm) as support at rear.

Fig 8.3 Sprocket & Rear Hub Mounting

30

7.4 HUB MOTOR MOUNTING:

7.4.1 PROBLEM FACED:

1) At first we had mounted hub motor at 120mm from top of the frame, but we

came to know that mounting at that position was leading in increase of chain

length and also in time for transforming motion from hub motor to rear wheel,

so we changed the position of the hub motor by increasing the distance

between top of the frame and motor axle.

Fig 8.4 Hub Motor

7.5 ALTERNATOR MOUNTING

7.5.1 PROBLEMS FACED

1) Initially there was no any provision to mount the alternator.So we welded one plate

of dimension 80x4 mm horizontally & one plate of dimension 110x25 mm vertically

as shown.

Fig 8.5 Alternator Mounting

31

7.6 FABRICATED MODEL

Fig 8.6 Fabricated model

32

CHAPTER NO-08

PROJECT TESTING

33

8.0PROJECT TESTING

8.0.1 ENGINE TESTING

Initially the engine is fitted to m80 bike.The mileage test of engine is carried out with

following conditions

a) Speed of 45 kmph

b) Pay-load of 90 kg (As motor takes load of 90 kg)

c) No alternator coupled

Initial odometer reading=7285 km

Odometer reading at the end of test=7320 km

The petrol tank is filled with 1 liter mixture of Petrol + 2S Oil

The mileage given by engine was 35 kmpl.

Then the alternator is coupled to rear wheel hub.

The initial odometer reading= 7334 km

Final odometer reading= 7364 km

The mileage given by engine when alternator is coupled=30 kmpl.

Loss in mileage due to alternator coupled = 5kmpl.

8.0.2 BATTERY CHARGING TEST

Fig 8.1 Battery Charging Test

34

Before carrying out battery charging test the battery charge level is brought to 2V

from 24V. Then voltage is supplied by turning on engine.After starting engine

alternator started rotating. This generated the electric voltage supply. When alternator

is reached to 2000 rpm the voltage is generated & supplied to battery.

Battery took half hour to charge completely from 2V to 24V.

8.1 RESULT

8.1.1 MILEAGE

1) Initial mileage of engine without alternator=35 kmpl

2) Mileage of engine when alternator coupled=30 kmpl

From this we get that there is loss of 5 kmpl.

But in this 5 kmpl loss we are charging battery for use of 25 km.

Hence we are saving net

=25-5

=20 kmpl

Now let’s refer a table submitted by IIT Delhi students to Indian Oil Corporation

Vehicle

type

Age of

vehicle(years)

CO

(gm/km)

HC

(gm/km)

NOx

(gm/km)

PM

(gm/km)

2 wheeler 0-5 4 3.3 0.06 0.1

5-10 6.5 3.9 0.03 0.23

10-15 6.5 3.9 0.03 0.23

Table 8.1 Pollutants emitted by 2 wheelers per km

From table the pollutants emitted by 2 wheeler of age of 10-15 years are

Calculated.

So let’s calculate amount of pollutants prevented per 25 km (As range of electric

mode is 25 km)

1) CO

For 25 km =25x6.5

=162.5 gm

2) HC

For 25 km =25x3.9

=97.5 gm

35

3) NOx

For 25 km = 0.03x25

=0.75 gm

4) Particulate matter

=0.23x25

= 5.75 gm

This much amount of pollutants are prevented from entering into atmosphere.

36

CHAPTER NO-09

EXPENDITURE

37

9.1 EXPENDITURE:-

Sr.

No. Description

Numbers

Expense (In Rs.)

1

Electric Hub Motor (250W 24V) with

controller

1 6300

2 Steel L Section 8 1290

3 Batteries (12V x 2) 2 3000

4 Engine (1,M80, 5 hp) 1 2400

5 Engine mounting components 4 170

6 Chain (ISO 10B) 2 150

7 Sprockets (2 No 40 Teeth) 2 400

8 Sprocket ( 1 No.14 Teeth) 1 250

8

Fabrication (frame,engine

mounting,motor mounting,alternator

mounting)

_

6500

9

Finishing( Grinding of extra material on

welded joints)

_ 100

10 Paint (Black 250 ml 1) 1 65

11

Miscellaneous cost (petrol, traveling,

rejection etc.)

_ 2000

Total Cost 22 17500/-

38

CHAPTER NO-10

FUTURE SCOPE

39

10. FUTURE SCOPE

1. The power of motor is only meant for pay load of 75 kg.The pay load

can be increased by either increasing motor power or by increasing

motor current.

2. The speed can also be increased by using electric motor of higher

power & current.

3. The range of bike on electric mode can be increased by increasing

battery capacity.

4. Efficiency of bike can be increased by changing 2 Stroke Engine by 4

Stroke engine.

5. We can also opt for using Engine solely for charging. In this we will

power the alternator by using engine. The drive to the bike will be

given by electric motor.

40

CHAPTER NO-11

CONCLUSION

41

11. CONCLUSION:-

We like to finally conclude that our project has saved the precious amount of fuel

which will be wasted in unnecessary idling,continuous braking & gear change; also

we have reduced the amount of pollutants entering into atmosphere when it is running

on battery mode. It was impossible to gain these achievements by one

system(Mechanical or electrical) so we combined two systems(Mechanical &

electrical) which was a grand experiment in two wheeler sector and which was never

done before in the world with the readings we gave. Our project has a wide working

scope. Because more precise and effective reading can be obtained by minor

modifications.

42

CHAPTER NO-12

REFERENCES

43

REFERENCES

Web sites

• www.howstuffworks.com,Date:-1/7/2012,Time:-3.30 pm

• www.goldenmotor.com ,Date:-1/7/2012 Time:-3.38 pm

• www.powerstream.com Date:-1/7/2012 Time:-3.45 pm

• http://www.millbrook.co.uk/Page/Hybrid-and-Electric-Vehicles Date:-

1/7/2012 Time 4.30 pm

• http://www.motortrend.com/roadtests/27/hybrid/ Date:-1/7/2012 Time:-4.45

pm

• www.automobilemag.com/reviews/27/hybrid_cars Date:-5/8/2012 Time 12

am

• www.ukipme.com/mag_electric.htm Date:-5/8/2012 Time:- 8.00 am

• www.cnet.com › Reviews › Car tech Date:-5/8/2012 Time:-2.30 pm

• http://www.horiba.com/us/en/automotive-test-systems/hybrid-testing/video-

hybrid-vehicle-testing/ Date:-14/8/2012 Time:-10 am

• http://tripp.iitd.ernet.in/rp/report/cng_changover_ioc.pdf Date:-25/8/2012

Time:-6 pm

• http://www.iata.org/whatwedo/cargo/dgr/Pages/lithium-batteries.aspx Date:-

5/10/2012 Time 3.56 pm

• http://www.amco.co.in/ Date:-5/9/2012 Time:-5.55 pm

• http://www.nycewheels.com/batteries1.html Date:-11/11/2012 Time:-2.1 pm

• http://www.allcelltech.com/products/electric-bike Date:-20/12/2012 Time 9

am

• http://ebikes.ca/batteries.shtml Date:-29/12/2012 Time:-5 pm

• http://www.heroelectric.in/ev-technology.php?eID=1 Date:-30/12/2012 Time:-

7.45 pm

44

• http://www.ncert.nic.in/html/learning_basket/electricity/electricity/machine/ac

_generator.htm Date:-31/12/2012 Time:-2.56 pm

• http://www.todayifoundout.com/index.php/2010/01/how-to-test-a-car-

alternator/ Date:-5/1/2013 Time:- 5.6 am

REFERENCE BOOKS

• THEORY OF MACHINE;R S KHURMI;J K GUPTA;GEAR

TRAIN;pp 312-330

• ELECTRICAL TECHNOLOGY;B L THERAJA,A K THERAJA,DC

DRIVES;pp 200-250

45