Design and Fabrication of Bio-Hybrid Vehicle

10 I January 2022
https://doi.org/10.22214/ijraset.2022.40040
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue I Jan 2022- Available at www.ijraset.com
Design and Fabrication of Bio-Hybrid

Vehicle
Sumit S. Surve1, Akshay P. Shikhare2, Suraj D. Vedre3, Sushant V. Shinde4
1
Asst. Professor, 2, 3, 4Student, Dept. of Automobile Engineering, Rajendra Mane College of Engineering & Technology,
Ambav, Maharashtra, India
Abstract: The present work intends to study and create a solution to be used as a means of transportation adapted to the
metropolis environment. With the zero-emission, agile and space-saving Bio-Hybrid combining electric propulsion with human
muscle power, we offer an approach to solving urban mobility issues because cities will change. This Paper reviews the design
and fabrication of bio-hybrid vehicle. The points of the car I decided to specifically focus on were the chassis, components are
used in this car. The most time and effort went into designing and implementing these components of the vehicle . During the
entire design process, consumer interest through innovative, inexpensive, and effective methods was always the primary goal.
Keywords: Bio-hybrid, zero-emission, ev etc.,
I. INTRODUCTION
With conventional fossil fuel consuming rides posing a threat to the existence of life on earth, it is high time to develop alternate and
greener modes of transportation for a sustainable future.
As the name suggest it is a Bio-hybrid which can be operated by two ways either by manually i.e., by pedaling or by the means of
battery, motor. Generally, in rural areas it is seen that people travel long distances by bicycle which is considered as essential means
of transport & the ways in which people get from A to B in metropolitan areas will change. There’s a clear trend toward new,
compact mobility solutions.
They offer major opportunities for small vehicles that can close the gap between electric cars and bicycles. We are involved in
actively shaping this trend and in the process of investigating future requirements, possible fields of application, as well as concepts
and solutions for personal mobility today. In such case if we implement biohybrid it will nearly overcome all their problems and
will definitely help in travelling long distances. The search and evolution of electrical vehicles is growing more and more as the
days go by. New technological breakthroughs allied with growing concerns with the environment and physical health had led to
huge developments around this concept.
Electrical vehicles are claiming a place in several industries, especially in the fields of transportation. The application of electrical
motors in bicycles and cars opens up new possibilities and a large number of advantages.
Electric motor vehicles are a concept to take into account in the present and even more in the future, as they can open new
possibilities or even replace the possibilities given nowadays by the common internal combustion engines. In the current days, fully
electrical cars can already directly compete with an internal combustion car or even overcome and make them look obsolete in
several aspects. Human powered hybrid vehicle presents the new milestone in the realm of “Green Technology”
A. Objective
1) Due to its four wheels, the concept of the Bio-Hybrid delivers exceptional driving stability.
2) Being electrical, they are not causing any damage to the environment.
3) To provide protection from weather conditions.
4) To maneuver easily through traffic.
5) To requires minimum parking space.
6) To less capital required for purchasing.
7) To develop new form of modern transportation in urban areas
8) Must be given 30-35km average on single charge.
9) Lowest running and maintenance cost.
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II. COMPONENTS
The components used in this project are motor, DC motor controller, Lithium-ion batteries, ignition switch, accelerator, wiring kit.
A. BLDC Motor
Motors are an interesting development which could offer benefits such as compactness, noiseless operation, and high efficiency for
electric vehicles.
Here, we select 48V 750W BLDC motor. These motors have stators fixed at the axle, with the permanent magnet rotor embedded in
the wheel. The traditional “exterior rotor” design has the hollow cylindrical rotor spinning around a stator axle. There is a “radial air
gap” between the stator and rotor. The stator consists of stacked laminated steel plates with wound coils. Pulse width modulated
current is used to supply current to the stator. motors must run at relatively low speed – equal to the actual rotation of wheel if there
is no final gearing stage. The benefit is about a 10% increase in efficiency due to the lack of transmission. The main reason for
choosing a BLDC motor is that it does not require a transmission system which helps in reducing the transmission losses. Since it
has no brushes to wear out the life of motor is increased. It has a greater traction control. The back emf created by BLDC motor can
easily be stored in the batteries supplied by 48v 23Ah lithium-ion battery through controller for testing purpose. Two independent
propelling sources are being employed for obtaining total propulsion of the vehicle.
Figure 1 . BLDC MOTOR

B. Controller
The controller connects the power source to the motor. It controls speed, direction of rotation, and optimizes energy conversion.
While batteries produce constant voltages, which decrease as they are used up, some controllers require a DC-to-DC converter to
step down this changeable voltage to the motor’s expected constant operating voltage, but other controllers incorporate a DC- to-DC
converter and can accept a varying voltage. Converter efficiencies are typically greater than 90%. The controller for the motor is
being interfaced with the motor speed regulation. The speed controlling throttle is being interfaced through the motor controller
circuit. The motor used here is 48V, 750W motor. The controller for the motor is also Ampere made suitable for controlling the
specified motor. The throttle is an ampere made throttle for speed regulation of the specified motor. The input to the motor is
Figure 2 . DC CONTROLLER
C. Lithium Ion Battery

A lithium-ion battery or Li-ion battery is a type of rechargeable battery in which lithium ions move from the negative electrode
through an electrolyte to the positive electrode during discharge, and back when charging. Li-ion batteries use an intercalated
lithium compound as the material at the positive electrode and typically graphite at the negative electrode.
Figure 3 . Li-ion Battery
In this project, 48V 23Ah lithium-ion batteries are used. Lithium-ion batteries are common in consumer electronics.
They are one of the most popular types of rechargeable battery for portable electronics, with one of the best energy- to-weight ratios,
high open circuit voltage, low self- discharge rate, no memory effect and a slow loss of charge when not in use. Beyond consumer
electronics, lithium-ion batteries are growing in popularity for military, electric vehicle, and aerospace applications due to their high
energy density.
D. Ignition Switch
An ignition switch is a switch in the control system of motor vehicle that activates the main electrical systems for the vehicle. It also
usually switches on power to many accessories. The ignition switch usually requires a key be inserted that works a lock built into
the switch mechanism. It may be bypassed by disconnecting the wiring to the switch and manipulating it directly. This is known as
hot wiring.
Figure 4 . Ignition Switch
E. Accelerator
The accelerator mode is similar to how a motorcycle operates. When the accelerator is engaged the motor provides power and
propels you and the bike forward. It allows you to kick back and enjoy a free ride. Most accelerators can be fine-tuned like a volume
dial between low and full power.
Figure 5 . Accelerator
F. Wiring Kit
The wiring kit place a major role in an electric bike. The main connecting unit is DC controller.
The Connections to DC controller:
1) Three wire throttle control for speed control
2) Brake control for controlling supply to motor
3) Input supply from battery
4) Output to motor
Figure 6 . Wiring Connection
III. BLOCK DIAGRAM
Figure 7 . Block Diagram
A. Methodology
Bio-hybrid name itself suggest that a Bio means healthful to environment and hybrid means vehicle which can be operated by two
ways either by manually i.e., by pedaling or by the means of battery, motor.
Above Block diagram provide brief information about working of our propulsion system. In this system ,battery is main component
it send electric current to power electronic converter .This power electronic converter is to process and control the flow of electric
energy by supplying voltage and currents in a form that is optimally suited for different load condition and then it provide to motor .
Controller is electronic device that operate between batteries and the motor to control the electric vehicle speed and acceleration
.and it will be connected other electrical system (lighting system, horn etc.,). Then motor rotates as per driver gives acceleration.
motor is connected to differential with the help of chain drive system and vehicle moves in desired direction. Driver can reduce
consumption of battery with the help of pedaling. that will reduce load on motor. Also, if battery get fully discharged then driver can
drive the vehicle with the help of pedals, the force used by pedaling enables the gears of a vehicle to spin the back wheel. As the
back wheel rotates, the tire uses friction to grip the area and move the bike in the desired direction.
IV. DESIGN
A. Chassis
The chassis is the component in charge of supporting all other vehicle’s subsystems with the plus of taking care of the driver safety
at all time. The chassis design need to be prepared for impacts created in any certain crash or rollover. It must be strong and durable
taking always in account the weight distribution for a better performance
We use IS 4923 (Commonly Known As GI) Pipe, Carbon Steel IS 4923 YST 240 Seamless Pipes has a unique composition and
mechanical properties depending upon the ISO standards bearing 0.12% max. Carbon, 0.50% max. Manganese, 0.03% to 0.08%
Silicon, 0.05% Phosphorous and silicon each.
1) Chassis Design Consideration

Consideration Priority Reason
Light Weight Essential A light car moves faster

Durable Essential Must not deform during rugged
driving and loading condition
Cost Essential Car needs to be within budget
Figure 8 CAD Model Of Chassis
2) Finite Element Analysis (FEA): Finite element is a method for the approximate solution of partial differential equations that
model physical problems such as: Solution of elasticity problems , Determine displacement, stress and strain fields. Static,
transient dynamic, steady state dynamic, i.e. subject to sinusoidal loading, modes and frequencies of vibration, modes and loads
of buckling.
3) FEA of Chassis: A geometric model of the Chassis was constructed in Autodesk Inventor and analysis also done in Autodesk
Inventor 2019 professional.
Figure 9 . 1St Principal Stress
Figure 10 . Deformation
Figure 11 . Von Mises Stress
Figure 12 . Safety Factor
B. Complete CAD Model
Figure 13 CAD Model of BIO-HYBRID

C. Fabrication
The frame is fabricated successfully according to the design specifications. Fabrication techniques included arc welding, bending,
cutting, grinding, drilling and assembly of various parts required.
Fabrication was carried out in two phases, namely phase-I which included initial spot welding of all the joints for assuring proper
shape of the frame and phase-II included complete welding of all the joints in the frame, along with custom paint job and finally the
assembly of all the parts.
Figure 14 . Final Actual Model

V. TESTING OF MODEL
After the complete design was fabricated, it was necessary that the controls be tested extensively & in various conditions.
The team decided to perform the first test on the vehicle in the local village road. The purpose of using this particular road as a test
track is the fact that it contains gradients, up and down hill, turns as well as straight roads. Hence, nearly all types of road conditions
can be simulated without the need for going elsewhere.
The team performed following simulations successfully on the vehicle:

1) Starting the vehicle from rest on level road surface
2) Making sharp turns while driving at 10-15 km/hr.
3) Braking the vehicle on downward slope & starting again
4) Checking Top Speed
VI. CONCLUSION
With the increasing consumption of natural resources of petrol, diesel it is necessary to shift our way towards alternate resources like
the Bio-Hybrid Vehicle and others because it is necessary to identify new way of transport.
The final goal of our project was to design and fabricate BIO-HYBRID Vehicle which will allow modification of the existing cycle
by using electric energy and it would sum up to increase in energy production. Since it is energy efficient, and light weight which is
cheaper and affordable to anyone. It can be used for shorter distances by people of any age (12- 60 yrs.). It can be contrived
throughout the year. The most vital feature of the Bio-Hybrid is that it does not consume fossil fuels thereby saving currencies. The
second most important feature is it is pollution free, eco – friendly and noiseless in operation. Our project is inspired by those people
who have lot of interest in vehicles; especially in electric vehicle.
For the final design of our project, we decided to use waste material for roof, seat stand etc., The reason behind the use of waste
material is that it would be cost efficient.
A. Scope for Future Works

1) Higher voltage, high Ah batteries and suitable motors of higher power but lesser weight can be used for running the vehicle with
greater performance.
2) More comfortable wider seating arrangements can be provided for comfort of the rider. Also extra seat arrangement possible.
3) We can use solar panel to charge the battery and also provide auto-charging feature to charge battery while pedaling.
4) Smart features via a dedicated app that will make life easier for the operator.
REFERENCES
[1] http://www.lightfootcycles.com/archive/products/at c/ [IR-4]
[2] http://www.treehugger.com/bikes/13-quadracycles- four-wheeled-bike-round-up/page2.html
[3] http://www.treehugger.com/clean- technology/toyota-unveil-hybrid-pedal-electric- concept-a-caratm.html
[4] http://www.tandem-bicycle- central.com/quadricycle.html
[5] Design & Development Of E-Bike - A Review (irejournals.com)
[6] Electrically-assisted bikes: Potential impacts on travel behaviour – ScienceDirect
[7] Schaeffler Bio-Hybrid pedal-assist light electric vehicle- electrive.com
[8] E-Bike Market Growth, Industry Trends, and Statistics by 2026 | MarketsandMarkets
[9] Quadracycle design project 2 project guide by –prof. Nishant Sharma IDC, IIT Bombay/ {2}.

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10 I January 2022

Design and Fabrication of Bio-Hybrid

Figure 1 . BLDC MOTOR

C. Lithium Ion Battery

Figure 3 . Li-ion Battery

Figure 4 . Ignition Switch

Figure 6 . Wiring Connection

III. BLOCK DIAGRAM

Figure 7 . Block Diagram

1) Chassis Design Consideration

Light Weight Essential A light car moves faster

Figure 8 CAD Model Of Chassis

Figure 9 . 1St Principal Stress

Figure 11 . Von Mises Stress

Figure 12 . Safety Factor

B. Complete CAD Model

Figure 13 CAD Model of BIO-HYBRID

Figure 14 . Final Actual Model

The team performed following simulations successfully on the vehicle:

A. Scope for Future Works

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