C HAPTER 1

INTRODUCTION
1
1. INTRODUCTION
A solar vehicle is an electric vehicle powered b a tpe o! renewable ener"# $b solar
ener" obtained !ro% solar panels on the s&r!ace $"enerall# the roo!' o! the vehicle'(
Photovoltaic $P)' cells convert the *&n+s ener" directl into electrical ener"( The
desi"n o! a solar vehicle is severel li%ited b the ener" inp&t into the car $batteries and
power !ro% the s&n'(
The electrical sste% is the %ost i%portant part o! the car+s sste%s as it controls all o!
the power that co%es into and leaves the sste%( The batter pac, plas the sa%e role in
a solar car that a petrol tan, plas in a nor%al car in storin" power !or !&t&re &se( *olar
cars &se a ran"e o! batteries incl&din" lead-acid batteries# nic,el-%etal hdride batteries
$Ni.H'# Nic,el-Cad%i&% batteries $NiCd'# /ithi&% ion batteries(
PRINCIP/E O0 OPERATION
*olar cars are powered b the s&n+s ener"( The %ain co%ponent o! a solar car is its solar
arra# which collect the ener" !ro% the s&n and converts it into &sable electrical ener"(
The solar cells collect a portion o! the s&n1s ener" and store it into the batteries o! the
solar car( 2e!ore that happens# power trac,ers converts the ener" collected !ro% the
solar arra to the proper sste% volta"e# so that the batteries and the %otor can &se it(
A!ter the ener" is stored in the batteries# it is available !or &se b the %otor 3 %otor
controller to drive the car( The %otor controller ad4&sts the a%o&nt o! ener" that !lows
to the %otor to correspond to the throttle( The %otor &ses that ener" to drive the wheels(
2
C HAPTER 5
6ENERA/ DE*CRITION
2. GENERAL DESCRIPTION
3
*olar powered %&lti &tilit vehicle$*P.U)' is driven b hi"h powered %otor which is
powered b batteries char"ed b solar cells( The solar cell %od&les can be attached and
detached !ro% the *P.U)( An area o! 5(78%
5
has been provided !or carrin" the load as
the %ain p&rpose is to carr the loads in the wor,shops(
The c&rb wei"ht o! the *P.U) is 9:;,"s and can p&ll a load o! abo&t 7<<,"s( The speed
at which it can r&n varies inversel with the load carried b it( 2 varin" the volta"e and
c&rrent o! the %otor the speed# tor=&e# power o! the %otor can be !l&ct&ated accordin" to
the necessit(
The *P.U) needs to be char"ed !or 7 ho&rs in order to attain co%plete char"e o! the
batteries( The additional area provided at the rear side !or the solar cells will help in
attractin" %ore s&nli"ht conse=&entl deliverin" %ore power( It can r&n !or abo&t 7<,%s
&nder !&ll char"ed condition( In case o! a clo&d da or d&rin" the ni"hts# the batteries
can be char"ed thro&"h re"&lar AC s&ppl(
The *P.U) is %ainl desi"ned !or the &se in local pre%ises i(e( in ind&stries#
wor,shops# colle"e ca%p&ses etc( Utilit vehicles o! this sort will be "reatl &se!&l in
carrin" the load !ro% one place to other# transportin" %aterial to their destination.
4
C HAPTER 9
CHAN6E* .ADE
3. CHANGES MADE
The need !or re%odelin" the *P.U) rose as the !ollowin" points have been observed as
drawbac,s in the previo&s *P.U)(
5
1. >ei"ht o! the vehicle is enor%o&s(
2. Unplanned desi"n o! chassis(
3. I%proper load distrib&tion(
?( Use o! b&l, %aterial at &nwanted re"ions(
D&e to the above reasons the previo&s desi"ned vehicle was %ovin" at e@tre%el low
speed# bowed towards the !ront o! the vehicle(
In order to overco%e these drawbac,s a new plan has been desi"ned !or the s&ccess!&l
r&nnin" o! *P.U)(
The %a4or chan"es that are %ade are#
1( Chassis desi"n
5( %aterial &sed
3. altered !ront s&spension sste%
4. Increased area !or solar panels(
5. Increased area !or acco%%odatin" load(
Chassis has been desi"ned and thoro&"hl revised ,eepin" in %ind o! the load
distrib&tion# &sin" the space e!!ectivel !or load#
The %aterial &sed !or the constr&ction o! *P.U) consists o! di!!erent di%ension at
di!!erent places accordin" to the re=&ire%ent( 0or the places o! that do not &nder"o heav
stress a %aterial o! low thic,ness has been &sed and !or the places that &nder"o "ood
a%o&nt o! stress a considerabl %ore thic,ness has been &sed( The %aterial selection has
been done a!ter a thoro&"h co%pression and hardness tests(
The s&spension sste% at the !ront side o! *P.U) has been altered !ro% lea! sprin" to
.cPherson tpe( This chan"e has been %ade %ainl to as it is a %&ch si%pler sste%#
"ives %&ch space# ,eepin" the &nspr&n" wei"ht lower(
The area !or the solar panels has been "reatl increased b providin" an area o! 9(;5%
5
at
top acco%%odatin" ? panels( Placin" the panels on the top# %ore a%o&nt o! solar power
can be capt&red(
As the %ain ai% o! *P.U) is to carr load# a vast space at the rear side has been
provided !or carrin" the load(
6
C HAPTER ?
*PECI0ICATION*
4. SPECIFICATIONS
7
DI.EN*ION* )A/UE
/en"th $%%' 99<<
>idth $%%' 1??<
Hei"ht $%%' 1;;<
>heelbase $%%' 5<;<
0ront Trac, $%%' 1<5<
Rear Trac, $%%' 11A<
.ini%&% T&rnin" Radi&s $%' ?(?
.ini%&% 6ro&nd Clearance $%%' 5<<
>EI6HT
Berb >ei"ht $B"' 9:;
6ross )ehicle >ei"ht $B"' :9;
CAPACITC
*eatin" capacit 5
/oadin" capacit area $%
5
' 5(78
/oad capacit $,"s' 7<<
.OTOR
Tor=&e $N-%' 5?
Power $HP' A(<7
*peed $RP.' 58<<
)olta"e $)' ?A
C&rrent $A' 17<
TRAN*.I**ION
8
Tpe rear wheel drive
2ATTERC
C&rrent $A' 17<
)olta"e $)' 15
*TEERIN6
Tpe Rac, and Pinion
*U*PEN*ION *C*TE.
0ront .cPherson str&ts and
coil sprin"
Rear lea! sprin"s
2RABE*
0ront Disc
Rear Dr&%
TCRE*
Tre speci!ication 1?7D;< R15 8:T
9
C HAPTER 7
0EATURE* O0 *P.U)
5. FEATURES OF SPMUV
10
The *P.U) has &ni=&e !eat&res co%pared to the other vehicles(
The !eat&res o! *P.U) are as !ollowsE
1( It is an eco-!riendl vehicle(
5( It has no r&nnin" cost(
9( It does not prod&ce an noise poll&tion d&e to the absence o! en"ine(
4. The speed can be %odi!ied as per the re=&ire%ent 4&st b si%ple switch
%echanis%(
7( It is a %ini%al %aintenance vehicle( Does not need %aintenance cost also(
8( Delivers hi"h power with absol&tel no poll&tion(
;( 2atteries can be char"ed even while r&nnin" thro&"h panels(
Tho&"h the &se o! the batter operated vehicles has increased# the &se o! solar powered
vehicles is ver less( It is ,nown !act that there is a shorta"e !or the electricit in
co&ntries li,e India(
As there is a ver less prod&ction o! !&els# petrol cannot be a!!orded to &se( *o the &se o!
available renewable ener" li,e solar ener" sho&ld be %ade to save the little electricit
and petrol that we have(
11
C HAPTER 8
P/AN O0 THE PROFECT
6. PLAN OF THE PROJECT
12
13
C HAPTER ;
DE*I6N 3 0A2RICATION
7.1 CHASSIS
The chassis o! the *P.U) is %ade &p o! .* bars( The *P.U) is 99<<%% lon" and
1??<%% wide( The chassis is speciall desi"ned to end&re heav loads as it is a load
14
carrin" vehicle( The chassis was initiall desi"ned &sin" IRONCAD so!tware and later
has been !abricated accordin" to the desi"n(
The above !i"&re shows the desi"ned %odel o! the chassis in IRONCAD( 0or the load to
be distrib&ted eno&"h space has been provided !or the batteries# and space !or e@tra tre
and tools has been provided at the botto%( The are inserted to the botto% thro&"h an
openin" at the top( There is a door provided on the base thro&"h which the batteries can
be ta,en o&t( Ri"ht an"&lar bars are &sed in this space !or a ri"id s&pport o! batteries(
There are two %ain GC1 sections &sed o! di%ensions $?<H;7H?<' %%
9
with ?%%
thic,ness and other GC1 sections are o! the di%ensions $9<H9<H9<' %%
9
with 9%%
thic,ness( The %aterial chosen has been con!identl &sed !or the constr&ction a!ter
testin" it !or co%pression and hardness tests( All these rods are connected to one another
b weldin"(
>E/DIN6 *PECI0ICATION*
Tpe Arc weldin"
C&rrent - 7<<<-8<<< C
Electrode- 1< "a&"e# 9(17%% dia%eter .ild *teel rods(
Accordin" to I(*( 5A;:-1:;7 the .ild *teel electrode core wires have the !ollowin" I o!
ele%ents in the co%position(
Carbon <(1I
*ilicon <(<9I
15
.an"anese <(9AI to <(85I
*&lph&r <(<9I
Phosphor&s <(<9I
Copper <(17I
Iron re%ainin" I
0or the base o! the chassis# plwood sheet o! 15%% thic,ness has been &sed and inserted
at di!!erent sections !or the eas re%oval and placin"( To avoid incon"r&o&s elevations
the sectors o! the plwood sheets have been chiseled and placed into the chassis as the
sheet has to "o alon" with the thic,ness o! the horiJontal rods that have been placed !or
s&pport( Plwood sheets act as ins&lation to the electrical shoc,s also(
7.2 BODY
The !ra%e !or the bod o! the *P.U) is %ade o! %ild steels bar GC1 sections o!
di%ension 9<H9<H9< %%
9
and with a thic,ness o! 5%%( 0o&r rods at the bac,side o!
16
11<<%% hei"ht# two rods at the !ront side o! hei"ht 1<<<%% have been !abricated( >ith
the help o! these two dissi%ilar rods a provision !or a transparent "lass has been provided
!or the driver to see thro&"h it and protect the driver !ro% winds# d&st(
On the top# ? solar panels o! siJe 181AHA<A %%
5
have been placed( The bod is so
desi"ned that it can acco%%odate two people $incl&din" the driver' at the !ront and a
s&!!icient area o! 5(78 %%
5
!or the "oods(
17
C HAPTER A
.ECHANI*.*
8.1 DIFFERENTIAL
In a&to%obiles and other wheeled vehicles# a di!!erential is a device consistin" o! "ears#
which allows each o! the drivin" wheels to rotate at di!!erent speeds# while s&pplin"
18
e=&al tor=&e to each o! the%( In one wa# it receives one inp&t and provides two o&tp&tsK
this is !o&nd in %ost a&to%obiles( In the other wa# it co%bines two inp&ts to create an
o&tp&t that is the s&%# di!!erence# or avera"e# o! the inp&ts(
P&rposeE
A vehicle1s wheels rotate at di!!erent speeds# especiall when t&rnin" corners( The
di!!erential is desi"ned to drive a pair o! wheels with e=&al !orce while allowin" the% to
rotate at di!!erent speeds( In vehicles witho&t a di!!erential# s&ch as ,arts# both drivin"
wheels are !orced to rotate at the sa%e speed# &s&all on a co%%on a@le driven b a
si%ple chain drive %echanis%( >hen cornerin"# the inner wheel travels a shorter distance
than the o&ter wheel# res&ltin" in the inner wheel spinnin" andDor the o&ter wheel
dra""in"( This res&lts in# di!!ic&lt and &npredictable handlin"# da%a"e to tires and roads#
and strain on $or possible !ail&re o!' the entire drive train(
The di!!erential has three 4obsE
1( To trans%it the en"ine power to the wheels(
19
2. To act as the !inal "ear red&ction in the vehicle# slowin" the rotational speed o!
the trans%ission one !inal ti%e be!ore it hits the wheels(
9( To trans%it the power to the wheels while allowin" the% to rotate at di!!erent
speeds $This is the one that earned the di!!erential its na%e('
0&nctional DescriptionE
Power is s&pplied !ro% the en"ine# via the trans%ission# to the di!!erential sha!t( A pinion
"ear at the end o! the propeller sha!t is encased within the di!!erential itsel!# and it
en"a"es with the lar"e rin" "ear( The rin" "ear is attached to carrier# which holds a set o!
three s%all planetar "ears( The three planetar "ears are set &p in s&ch a wa that the
two o&ter "ears $the side "ears' can rotate in opposite directions relative to each other(
The pair o! side "ears drive the a@le sha!ts to each o! the wheels( The entire carrier
direction as the rin" "ear# b&t within that %otion# the side "ears can co&nter rotate relative
to each other(
>hen the vehicle is travelin" in a strai"ht line# there will be no di!!erential %ove%ent o!
the planetar sste% o! "ears other than the %in&te %ove%ents necessar to co%pensate
!or sli"ht di!!erences in wheel dia%eter# &nd&lations in the road# etc( L9M
8.2 BRAES
A !"#$% is a device !or slowin" or stoppin" the %otion o! a %achine or vehicle# or
alternativel a device to restrain it !ro% startin" to %ove a"ain( This is done b
20
convertin" ,inetic ener" o! the vehicle into the heat ener" which is dissipated into the
at%osphere( In *P.U) Disc bra,es are &sed !or the !ront wheels and Dr&% bra,es are
&sed !or the rear wheels(
2ra,in" Re=&ire%ents :
1( The bra,es %&st be stron" eno&"h to stop the vehicle within a %ini%&% distance in an
e%er"enc( The driver sho&ld have proper control over the vehicle d&rin" e%er"enc
bra,in" and the vehicle %&st not s,id(
5( The bra,es %&st have "ood anti-!ade characteristics i(e( their e!!ectiveness sho&ld not
decrease with constant prolon"ed application e("( while descendin" hills(
0&nctional Description o! dr&% bra,esE
A bra,e dr&% is attached concentric to the a@le h&b whereas on the a@le casin" is
%o&nted a bac, plate( A bac, plate is bolted to the steerin" ,n&c,le( The bac, plate is
%ade o! pressed steel sheet and is ribbed to increase ri"idit and to provide s&pport !or
the e@pander# anchor and bra,e shoes( It also protects the dr&% and shoe asse%bl !ro%
%&d and d&st( .oreover# it absorbs the co%plete tor=&e reaction o! the shoes d&e to
which it is so%eti%es called Gtor=&e plate1(
21
Two bra,e shoes are anchored on the bac, plate( 0riction linin"s are %o&nted on the
bra,e shoes( A reactive sprin" is &sed which serves to ,eep the bra,e shoes awa !ro%
the dr&% when the bra,es are not applied( The bra,e shoes are anchored at one end#
whereas on the other ends !orce 0 is applied b %eans o! so%e bra,e act&atin"
%echanis%# which !orces the bra,e a"ainst the revolvin" dr&%# thereb applin" the
bra,es( L:M
No%enclat&re
0 N Applied 0orce $N'
P N 2ra,e Power ,>
T N Tor=&e $N%'
0 N Applied 0orce $N'
0
!
N 0riction 0orce $N'
0
n
N Nor%al !orce between dr&% and !riction pad $N'
O N Coe!!icient o! 0riction(
b N 2and width $%'
c N Distance dr&% pivot to centre o! dr&%$%'
.0
!
N 0riction %o%ent abo&t shoe pivot $N%'
.0
n
N Nor%al 0orce %o%ent abo&t shoe pivot $N%'
n N Rotational *peed $RP.'
p N press&re !or !riction s&r!ace $ND%
5
'
p
%a@
N .a@i%&% press&re !or !riction s&r!ace$ND%
5
'
P N 2ra,e shoe contact an"le
r N Radi&s o! bra,e wheel'$%'
The press&re distrib&tion eval&ation !or the bra,e shoe ass&%es that the shoe ar% is ri"id
and the press&re is directl related to the distance !ro% the pivot point( The press&re is
proportional to c sin P or p N , sin P where# , is so%e constant(
22
0or a speci!ic bra,e %aterial the %a@i%&% press&re N p
%a@
( There!ore#
, N p
%a@
Dsin P
%a@
and
p N sin P $p
%a@
Dsin P
%a@
'
The val&e o! %ini%&% P is &s&all set to above 1<
<
and the %a@i%&% press&re when the
val&e o! sin P is :<
<
( above this an"le the press&re red&ces( There!ore i! the %a@i%&%
val&e o! P is less than :<
<
then sin P
%a@
N sin P( i! the %a@i%&% an"le is "reater than :<
<
then sin P
%a@
N sin :<
<

T&"'(% C#)#*+,- .&" B"#$% S/&%
The tor=&e capacit o! a bra,e shoe is obtained b inte"ratin" the prod&ct o! the !rictional
!orce and the dr&% radi&s
A*,(#,+01 .&"*% "%'(+"%2 .&" B"#$% S/&%
The act&atin" !orce is calc&lated b ta,in" %o%ents abo&t the bra,e shoe pivot point(
.0
n
is the %o%ent d&e to the nor%al !orce between the shoe and the dr&%( .0
!
is the
%o%ent d&e to the !riction !orce(
D&e to nor%al !orce 0
n
#
.0
n N
p w r dP csinP N

N

w r c
D&e to !riction !orce 0
!#
23
.0
!
N

N
N

O))&3+,% /#02%2 !"#$% 3/&%
The opposite handed bra,e shoe as shown below res&lts in the !riction %o%ent bein" o!
opposite to the nor%al !orce %o%ent and the bra,e sste% is to so%e e@tent sel!
ener"iJin" with a possibilit o! sel! loc,in"(
To obtain the %a@i%&% tor=&e !or each bra,e shoe L1<M


0&nctional Description o! disc bra,esE
To stop the wheel# !riction %aterial in the !or% o! bra,e pads $%o&nted on a device called
a !"#$% *#4+)%"' is !orced %echanicall# hdra&licall# pne&%aticall or
electro%a"neticall a"ainst both sides o! the disc( 0riction ca&ses the disc and attached
wheel to slow or stop( The bra,e sste% re=&ires hdra&lic !orce which is %an ti%es
"reater than the !orce applied b the !oot( This added hdra&lic !orce is achieved b
levera"e %&ltiplication( The %&ltiplin" !orce can be chan"ed b varin" the relative
location o! the bra,e %aster clinder rod pivot as it relates to the lever(
In the hdra&lic !orce %&ltiplication %ethod# the !orce which is applied at one point is
trans%itted b inco%pressible bra,e !l&id to another point( This basic sste% consists o!
24
two pistons $%aster clinder and wheel caliper or clinder'# which are !illed with bra,e
!l&id and are connected b a bra,e line o! an len"th or shape( >hen the bra,e pedal is
!orced down bra,e !l&id !ro% the %aster clinder is trans!erred to the bra,e caliper
piston# press&riJed !l&id is trans%itted thro&"h the bra,e caliper to the bra,e pads or
shoes# which are %o&nted to the bra,e caliper or wheel clinder( LAM
No%enclat&re
0 N Applied 0orce $N'
P N 2ra,e Power ,>
. N Tor=&e $N%'
0 N Act&atin" 0orce $N'
O N Coe!!icient o! 0riction(
P
1
# P
5
N 2ra,e pad an"les $rad'
r N Radi&s o! bra,e rin" thic,ness dr $%'
r
i
# r
o
N Inner# O&ter radi&s o! bra,e( $%'
n N Rotational *peed $RP.'
p N Press&re !or !riction s&r!ace$ND%
5
'
p
%a@
N .a@i%&% press&re !or !riction s&r!ace$ND%
5
'
Theor
There are two operatin" conditions applicable to dis, bra,es(
Uni!or% wear - Applicable !or practical bra,es a!ter period o! operation
Uni!or% press&re - Applicable !or new bra,es(
Uni!or% wear
The wear $>' at an location on a bra,e is ass&%ed to be proportional to the press&re
intensit $p' and the associated relative velocit $v'o! the local rin" o! contact(
25
The tor=&e capacit o! a bra,e is the inte"ral o! the !riction !orce $O 0' @ Radi&s $r'
Uni!or% press&re
>hen considerin" the capacit o! a dis, bra,e s&b4ect &ni!or% press&re# ever point on
the bra,e !ace is s&b4ect to the %a@i%&% desi"n press&re !or the !riction %aterial( This
condition applies %ainl to new bra,es(
The tor=&e capacit o! a bra,e is the inte"ral o! the !riction !orce $O 0' @ Radi&s $r' L11M
26

8.3 STEERING
27
0or a per!ect steerin" we %&st alwas have an instantaneo&s centre abo&t which all the
wheels %&st rotate( 0or this p&rpose inner wheel has to rotate less than the o&ter wheel to
achieve this condition# Ac,er%ann steerin" %echanis% has been &sed in *P.U)(
The Ac,er%ann steerin" %echanis% consists o! cross lin, connected to short a@les o! the
two !ront wheels thro&"h short ar%s and !or%in" bell cran, levers( >hen the vehicle is
r&nnin" strai"ht the cross lin, is parallel to the short ar% and both %a,e an"les to the
horiJontal a@is o! the chassis(
>hen a vehicle is steered# it !ollows a path which is part o! the circ&%!erence o! its
t&rnin" circle# which will have a centre point so%ewhere alon" a line e@tendin" !ro% the
a@is o! the !i@ed a@le( The steered wheels %&st be an"led so that the are both at :<
de"rees to a line drawn !ro% the circle centre thro&"h the centre o! the wheel( *ince the
wheel on the o&tside o! the t&rn will trace a lar"er circle than the wheel on the inside# the
wheels need to be set at di!!erent an"les(
The Ac,er%ann steerin" "eo%etr arran"es this a&to%aticall b %ovin" the steerin"
pivot points inward so as to lie on a line drawn between the steerin" ,in"pins and the
centre o! the rear a@le( The steerin" pivot points are 4oined b a ri"id bar# the tie rod#
which can also be part o! the# !or e@a%ple# rac, and pinion steerin" %echanis%( This
arran"e%ent ens&res that at an an"le o! steerin"# the centre point o! all o! the circles
traced b all wheels will lie at a co%%on point( L?M
0or correct steerin"#
1D tanQ
o&t
- 1D tanQ
in
N 2D/
>here
2N distance between conver"ent point and !ront a@le
/Ndistance between !ront and rear a@le
Q
o&t N
t&rn an"le o! the wheel on the o&tside o! the t&rn
Q
in
N t&rn an"le o! the wheel inside o! the t&rn
Q
o&t
N Arc tan L 1D $ 2D/' R $ 1D tanQ
in
' M
R N 2D5 R /D tanQ
in
The val&es o! 2D/ is between <(? and <(7
28
29
8.4 SUSPENSION
S(3)%03+&0 is the ter% "iven to the sste% o! sprin"s# shoc, absorbers and lin,a"es that
connects a vehicle to its wheels( This s&spension connects an a&to%obile to its wheels(
The s&spension sste%s not onl help in the proper !&nctionin" o! the car1s handlin" and
bra,in"# b&t also ,eep vehicle occ&pants co%!ortable and %a,e the drive s%ooth and
pleasant( It also protects the vehicle !ro% wear and tear(
There are two tpes o! s&spension sste%s- dependent and independent( A dependent
s&spension co%prises a bea% that holds wheels parallel to each other and perpendic&lar
to the a@le( An independent s&spension helps in the risin" and !allin" %ove%ent o! the
wheels( L1M
The s&spension tpes &sed !or *P.U) are two di!!erent sste%s( At the !ront an
independent sste% .cPherson str&ts are &sed and at the rear a dependent sste% lea!
sprin"s are &sed(
0ront s&spension sste%
The M*P/%"3&0 3,"(, is a tpe o! car s&spension sste% which &ses the a@is o! a
telescopic da%per as the &pper steerin" pivot# widel &sed in %odern vehicles( It consists
o! a wishbone or a s&bstantial co%pression lin, stabiliJed b a secondar lin, which
provides a botto% %o&ntin" point !or the h&b or a@le o! the wheel( This lower ar%
sste% provides both lateral and lon"it&dinal location o! the wheel( The &pper part o! the
h&b is ri"idl !i@ed to the inner part o! the str&t proper# the o&ter part o! which e@tends
&pwards directl to a %o&ntin" in the bod shell o! the vehicle( The str&t will carries both
the coil sprin" on which the bod is s&spended and the shoc, absorber# which is &s&all
in the !or% o! a cartrid"e %o&nted within the str&t( L5M L;M
No%enclat&re
C N *prin" Inde@ DDd
d N wire dia%eter $%'
D N *prin" dia%eter $%'
> N A@ial 0orce $N'
6 N .od&l&s o! Ri"idit $ND%
5
'
n N N&%ber o! active coils
S)"+01 I02%5
30
DN 71(;%%#dN A%%
c N
C N 8(?857
*prin" Rate
The sprin" rate N A@ial 0orce DA@ial de!lection
S N
In "eneral#
N 1# so this val&e is ne"lected(
> N .H" N 7<< H :(A1 N ?:<7N
2&t wei"ht on each wheel N
Ri"idit %od&l&s !or carbon steel N A< H 1<
9
, ND%%
5
n N n&%ber o! active coils N A
S N
S N
S N 99%%
Now we ,now#
*ti!!ness rate# B N
B N 1558(57 D 99
B N 9;(17:ND%%
31
Rear s&spension sste%
A 4%#. 3)"+01 is a si%ple !or% o! sprin"# co%%onl &sed !or the s&spension in wheeled
vehicles( It is also one o! the oldest !or%s o! sprin"in"( 0or ver heav vehicles# a lea!
sprin" can be %ade !ro% several leaves stac,ed on top o! each other in several laers#
o!ten with pro"ressivel shorter leaves( /ea! sprin"s serve locatin" and to so%e e@tent
da%pin" as well as sprin"in" !&nctions(
/ea! sprin"s consistin" o! 11 leaves %ade o! steel plates# o! increasin" len"ths !ro% the
centre# and side cla%ps at the sides are &sed so that the leaves be in position( .ain lea! is
the lon"est one havin" bent ends# called sprin" ees( The sprin" ee is connected to the
shac,le( The lea! sprin"s &sed are se%i elliptical shape(
The sprin" is s&pported on the rear a@le &sin" U- bolts( On one end the sprin" is
s&pported &sin" si%ple pin while on the other end# it is connected with a shac,le( >hen
the vehicle co%es across a pro4ection on the road s&r!ace# the wheels %ove &p# de!lectin"
the sprin"( This chan"es the len"th between the sprin" ees( The shac,le at one end "ives
a !le@ible connection( L7M L5M
No%enclat&re
EN Co&n"+s .od&l&s $ND%
5
'
> N applied 0orce $N'
t N thic,ness o! lea! $%'
b N width $%'
/N len"th between the s&pports N1%
l N len"th o! the plate or distance o! load !ro% cantilever end $%' N /D5
t N thic,ness o! lea! $%'
S N de!lection $%'
, N sprin" rate $sti!!ness' >DS $ND%'
32
The relevant e=&ations !or the se%i-elliptic sprin" as shown below are
The de!lection o! the lea! sprin"s#
6 7
> N .H" N 7<< H :(A1 N ?:<7N
2&t wei"ht on each wheel N
l N /D5 N1D5 N <(7%
S N N <(<?<:8%
S N ?<(:8%%
Now we ,now#
*ti!!ness rate# B N
B N 1558(57 D ?<(:8
B N 5:(:9 ND%%
33
C HAPTER :
CORE PART*
8.1 MOTOR
An %4%*,"+* 9&,&" &ses electrical ener" to prod&ce %echanical ener"# nearl alwas b
the interaction o! %a"netic !ields and c&rrent-carrin" cond&ctors(
The classic division o! electric %otors has been that o! Alternatin" C&rrent $AC' tpes
vers&s Direct C&rrent $DC' tpes( A DC %otor is desi"ned to r&n on DC electric power(
2 !ar the %ost co%%on DC %otor tpes are the br&shed and br&shless tpes# which &se
internal and e@ternal co%%&tation respectivel to create an oscillatin" AC c&rrent !ro%
the DC so&rce -- so the are not p&rel DC %achines in a strict sense(
34
Principle o! operationE
In an electric %otor# operation is based on si%ple electro%a"netis%( A c&rrent-carrin"
cond&ctor "enerates a %a"netic !ieldK when this is then placed in an e@ternal %a"netic
!ield# it will e@perience a !orce proportional to the c&rrent in the cond&ctor# and to the
stren"th o! the e@ternal %a"netic !ield( This can be "iven b the e=&ation
Force, F = B I l N
>here 2 is the %a"netic !ield in >eberD%
5
(
I is the c&rrent in a%peres and
l is the len"th o! the coil in %eter(
As we all are well aware that opposite $North and *o&th' polarities attract# while li,e
polarities $North and North# *o&th and *o&th' repel( The internal con!i"&ration o! a DC
%otor is desi"ned to harness the %a"netic interaction between a c&rrent-carrin"
cond&ctor and an e@ternal %a"netic !ield to "enerate rotational %otion( L8M
An hi"hl e!!icient %otor called the lnch %otor is &sed !or the *P.U)(
The speci!ications o! the %otor areE
Tor=&eE 5? N-%
PowerE 87<< >
*peedE 58<< rp%
)olta"eE ?A )
C&rrentE 17< A%ps
The speed o! the %otor chan"es directl with the c&rrent s&pplied to the %otor(
The power and tor=&e o! the %otor chan"e directl with the volta"e s&pplied to the
%otor(
The sha!t o! the %otor is connected to the di!!erential sha!t o! the *P.U) &sin" a chain
drive( A sproc,et is !i@ed on the %otor sha!t and another sproc,et is !i@ed on the
di!!erential sha!t( The power is trans%itted !ro% the %otor &sin" a chain which is placed
lin,in" both the sproc,ets(
35
The below shown "raph is a representation o! the c&rves that wo&ld obtain !or a DC
.otor(

8.2 BATTERIES
A !#,,%"- or :&4,#+* *%44 is a co%bination o! one or %ore electroche%ical 6alvanic cells
which store che%ical ener" that can be converted into electric potential ener"# creatin"
electricit(
2atteries can be broadl classi!ied into two cate"ories#
36
Primary batteries irreversibl $within li%its o! practicalit' trans!or% che%ical
ener" to electrical ener"( >hen the initial s&ppl o! reactants is e@ha&sted#
ener" cannot be readil restored to the batter b electrical %eans(
Secondary batteries can be rechar"edK that is# the can have their che%ical
reactions reversed b s&pplin" electrical ener" to the cell# restorin" their
ori"inal co%position(
The secondar batteries &sed !or the *P.U) are !o&r 15)# 17<A lead -acid batteries( All
the !o&r batteries are connected in series# the c&rrent re%ains constant and the volta"e can
be varied( This helps in r&nnin" the %otor at vario&s speeds(
/ead- acid batteries are the oldest tpe o! rechar"eable batter( This batter is notable in
that it contains a li=&id in an &nsealed container# re=&irin" that the batter be ,ept &pri"ht
and the area be well ventilated to ens&re sa!e dispersal o! the hdro"en "as prod&ced b
these batteries d&rin" overchar"in"( Despite havin" the second lowest ener"-to-wei"ht
ratio and a correspondin"l low ener"-to-vol&%e ratio# the lead-acid batter is also ver
heav !or the a%o&nt o! electrical ener" it can s&ppl( Despite this# its low
%an&!act&rin" cost and its hi"h s&r"e c&rrent levels %a,e its &se co%%on where a lar"e
capacit is re=&ired# their abilit to s&ppl hi"h s&r"e c&rrents %eans that the cells
%aintain a relativel lar"e power-to-wei"ht ratio( These !eat&res# alon" with their low
cost# %a,e the% attractive !or &se in cars(
Operation o! /ead Acid 2atteries
A lead acid batter consists o! a ne"ative electrode %ade o! spon" or poro&s lead( The
lead is poro&s to !acilitate the !or%ation and dissol&tion o! lead( The positive electrode
consists o! lead o@ide( 2oth electrodes are i%%ersed in an electroltic sol&tion o! s&l!&ric
acid and water( In case the electrodes co%e into contact with each other thro&"h phsical
%ove%ent o! the batter or thro&"h chan"es in thic,ness o! the electrodes# an electricall
ins&latin"# b&t che%icall per%eable %e%brane separates the two electrodes( This
%e%brane also prevents electrical shortin" thro&"h the electrolte( /ead acid batteries
store ener" b the reversible che%ical reaction shown below(
The overall che%ical reaction isE
37
At the ne"ative ter%inal the char"e and dischar"e reactions areE
At the positive ter%inal the char"e and dischar"e reactions areE
2eca&se o! the open cells with li=&id electrolte in %ost lead-acid batteries# overchar"in"
with e@cessive char"in" volta"es will "enerate o@"en and hdro"en "as b electrolsis
o! water# !or%in" an e@plosive %i@( This sho&ld be avoided b openin" the caps o! the
batteries while char"in"( Ca&tion %&st also be observed as s&l!&ric acid is e@tre%el
corrosive in nat&re(
Capacit o! the batter
2eca&se o! the che%ical reactions within the cells# the capacit o! a batter depends on
the dischar"e conditions s&ch as the %a"nit&de o! the c&rrent# the d&ration o! the c&rrent#
the allowable ter%inal volta"e o! the batter# te%perat&re and other !actors( The available
capacit o! a batter depends &pon the rate at which it is dischar"ed( I! a batter is
dischar"ed at a relativel hi"h rate# the available capacit will be lower than e@pected(
A batter capacit ratin" is alwas related to e@pected dischar"e d&ration(
>here#
Q is the batter capacit $tpicall "iven in %ATh or ATh'(
38
I is the c&rrent drawn !ro% batter $%A or A'(
t is the a%o&nt o! ti%e $in ho&rs' that a batter can s&stain(
The relationship between c&rrent# dischar"e ti%e and capacit !or a lead acid batter is
e@pressed b Pe&,ert+s law( Theoreticall# a batter sho&ld provide the sa%e a%o&nt o!
ener" re"ardless o! the dischar"e rate# b&t in real batteries# internal ener" losses ca&se
the e!!icienc o! a batter to var at di!!erent dischar"e rates( >hen dischar"in" at low
rate# the batter+s ener" is delivered %ore e!!icientl than at hi"her dischar"e rates(
8.3 SOLAR PANELS
*olar panels are the solar photovoltaic %od&les &se solar cells to convert li"ht !ro% the
s&n into electricit( A photovoltaic %od&le or photovoltaic panel is a pac,a"ed
interconnected asse%bl o! photovoltaic cells# also ,nown as solar cells( An installation
o! photovoltaic %od&les or panels is ,nown as a photovoltaic arra( Photovoltaic cells
tpicall re=&ire protection !ro% the environ%ent( 0or cost and practicalit reasons a
n&%ber o! cells are connected electricall and pac,a"ed in a photovoltaic %od&le# while
a collection o! these %od&les that are %echanicall !astened to"ether# wired# and
desi"ned to be a !ield-installable &nit# so%eti%es with a "lass coverin" and a !ra%e and
bac,in" %ade o! %etal# plastic or !iber"lass# are ,nown as a )/&,&:&4,#+* )#0%4 or
39
si%pl 3&4#" )#0%4( A photovoltaic installation tpicall incl&des an arra o! photovoltaic
%od&les or panels# an inverter# batteries and interconnection wirin"(
Photovoltaic $P)' cells are %ade o! special %aterials called se%icond&ctors s&ch as
silicon# which is c&rrentl the %ost co%%onl &sed( 2asicall# when li"ht stri,es the cell#
a certain portion o! it is absorbed within the se%icond&ctor %aterial( This %eans that the
ener" o! the absorbed li"ht is trans!erred to the se%icond&ctor( The ener" ,noc,s
electrons loose# allowin" the% to !low !reel( P) cells also all have one or %ore electric
!ields that act to !orce electrons !reed b li"ht absorption to !low in a certain direction(
This !low o! electrons is a c&rrent# and b placin" %etal contacts on the top and botto% o!
the P) cell# we can draw that c&rrent o!! to &se e@ternall( 0or e@a%ple# the c&rrent can
power a calc&lator( This c&rrent# to"ether with the cell+s volta"e de!ines the power $or
watta"e' that the solar cell can prod&ce(
Photovoltaic panels# the %ost co%%on !or% o! solar panels in the pro!essional electrical
"eneration ind&str# are able to absorb ener" !ro% the s&n thro&"h a variet o! s%aller
solar cells on their s&r!ace( .&ch li,e how a plant is able to absorb ener" !ro% the s&n
!or photosnthetic p&rposes# solar cells behave in a si%ilar !ashion( *olar panels are
co%prised o! several individ&al solar cells( These solar cells !&nction si%ilarl to lar"e
se%icond&ctors and &tiliJe a lar"e-area p-n 4&nction diode( >hen the solar cells are
e@posed to s&nli"ht# the p-n 4&nction diodes convert the ener" !ro% s&nli"ht into &sable
electrical ener"( As the photons !ro% the s&n+s ras hit the solar cells on a photovoltaic
panel# the ener" is trans!erred to a silicon se%icond&ctor( The ener" "enerated !ro%
photons stri,in" the s&r!ace o! the solar panel allows electrons to be ,noc,ed o&t o! their
orbits and released# and electric !ields in the solar cells p&ll these !ree electrons in a
directional c&rrent# !ro% which %etal contacts in the solar cell can "enerate electricit(
The photon is then trans!or%ed into electricit and then passed thro&"h connectin" wires
to !inall enter a power "eneration !acilit( At this point we have "enerated electricit#
b&t the process is not co%plete et( One sho&ld %a,e s&re the store this ener" !or
ti%es when either there is little or no s&nli"ht# s&ch as at ni"ht( This can be done b
storin" this ener" in batteries( Here in *P.U)# /ead Acid batteries are &sed !or this
p&rpose(
P&re silicon is a poor cond&ctor o! electricit beca&se none o! its electrons are !ree to
%ove abo&t( Instead# the electrons are all loc,ed in the crstalline str&ct&re( The silicon in
a solar cell is %odi!ied sli"htl so that it will wor, as a solar cell( A solar cell has silicon
with i%p&rities i(e( other ato%s %i@ed in with the silicon ato%s# chan"in" the wa thin"s
wor, a bit( >e &s&all thin, o! i%p&rities as so%ethin" &ndesirable# b&t in o&r case# o&r
cell wo&ldn+t wor, witho&t the%( >hen silicon co%bines with an ele%ent that has !ive
electrons to share# s&ch as phosphor&s# a ne"ative char"e is created( *ilicon can onl ta,e
!o&r o! the !ive electrons( This leaves one !ree electron loo,in" !or a spot( These
additional electrons are ,nown as !ree carriersK the carr an electrical c&rrent(
40
On the other hand# when silicon is co%bined with an ele%ent that has three electrons a
positive char"e is created( 2oron is a %aterial which s&its this p&rpose( >hen silicon and
boron are co%bined# holes are created( These silicon co%binations and their di!!erin"
char"es are &sed to %a,e solar panels(
EUP/ANATION
The process o! addin" i%p&rities on p&rpose is called 2&)+01# and when doped with
phosphoro&s# the res&ltin" silicon is called N;,-)% $VnV !or ne"ative' beca&se o! the
prevalence o! !ree electrons( N-tpe doped silicon is a %&ch better cond&ctor than p&re
silicon is(
The other part is doped with boron# which has onl three electrons in its o&ter shell
instead o! !o&r# to beco%e P;,-)% silicon( Instead o! havin" !ree electrons# P-tpe silicon
$VpV !or positive' has !ree holes( Holes reall are 4&st the absence o! electrons# so the
carr the opposite $positive' char"e( The %ove aro&nd 4&st li,e electrons do(
The interestin" part starts when o& p&t N-tpe silicon to"ether with P-tpe silicon(
Ever P) cell has at least one electric !ield( >itho&t an electric !ield# the cell wo&ldn+t
wor,# and this !ield !or%s when the N-tpe and P-tpe silicon are in contact( *&ddenl#
the !ree electrons in the N side# which have been loo,in" all over !or holes to !all into# see
all the !ree holes on the P side# and there+s a %ad r&sh to !ill the% in(
Anato% o! a *olar Cell
2e!ore now# o&r silicon was all electricall ne&tral( O&r e@tra electrons were balanced o&t
b the e@tra protons in the phosphoro&s( O&r %issin" electrons $holes' were balanced o&t
b the %issin" protons in the boron( >hen the holes and electrons %i@ at
the 4&nction between N-tpe and P-tpe silicon# however# that ne&tralit is disr&pted(
Ri"ht at the 4&nction# the do %i@ and !or% a barrier# %a,in" it harder and harder !or
electrons on the N side to cross to the P side( Event&all# e=&ilibri&% is reached# and we
have an electric !ield separatin" the two sides.
The effect of the electric field in a PV cell

41
This electric !ield acts as a diode# allowin" $and even p&shin"' electrons to !low !ro% the
P side to the N side# b&t not the other wa aro&nd( It+s li,e a hill -- electrons can easil "o
down the hill $to the N side'# b&t can+t cli%b it $to the P side'(
*o an electric !ield actin" as a diode in which electrons can onl %ove in one direction is
attained(
>hen li"ht# in the !or% o! photons# hits the solar cell# its ener" !rees electron-hole pairs(
Each photon with eno&"h ener" will nor%all !ree e@actl one electron# and res&lt in a
!ree hole as well( I! this happens close eno&"h to the electric !ield# or i! !ree electron and
!ree hole happen to wander into its ran"e o! in!l&ence# the !ield will send the electron to
the N side and the hole to the P side( This ca&ses !&rther disr&ption o! electrical
ne&tralit# and i! an e@ternal c&rrent path is provided# electrons will !low thro&"h the path
to their ori"inal side $the P side' to &nite with holes that the electric !ield sent there# doin"
wor, alon" the wa( The electron !low provides the *(""%0,# and the cell+s electric !ield
ca&ses a :&4,#1%( >ith both c&rrent and volta"e# we have )&<%"# which is the prod&ct o!
the two(
Operation of a PV cell
There are a !ew %ore steps le!t be!ore we can reall &se o&r cell( *ilicon happens to be a
ver shin %aterial# which %eans that it is ver re!lective( Photons that are re!lected can+t
be &sed b the cell( 0or that reason# an antire!lective coatin" is applied to the top o! the
cell to red&ce re!lection losses to less than 7 percent(
The !inal step is the "lass cover plate that protects the cell !ro% the ele%ents( P)
%od&les are %ade b connectin" several cells $&s&all 98' in series and parallel to
achieve &se!&l levels o! volta"e and c&rrent# and p&ttin" the% in a st&rd !ra%e co%plete
with a "lass cover and positive and ne"ative ter%inals on the bac,( L15M
42
Basic structure of a generic silicon PV cell

The solar panels &sed !or *P.U) are !o&r o! 1;<># 5?) panels o! area 181AHA<A %%
5
(
This can "enerate a power o! 8A<> which is s&!!icient !or the *P.U) to r&n(
43
C HAPTER 1<
E/ECTRICA/
CO.PONENT*

1=.1 ELECTRICAL CONNECTIONS
There are !o&r batteries o! 15) each !or *P.U)( The volta"e o! the %otor is ?A)( Three
switches have been &sed !or the vehicle to r&n in !o&r di!!erent speeds( Each switch has
two contacts( The !irst switch has the two contacts as !orward and reverses represented as
0 3 R on the switch( The second and third switches have their two contacts as two
di!!erent speeds# in total !o&r speeds( These !o&r speeds are attained b s&pplin"
di!!erent volta"es Lrepresented as15)# 5?)# 98)# ?A)M to the correspondin" switch( The
44
15) and 5?) wires are connected to switch n&%ber 1( The 98)# ?A) wires are connected
to switch n&%ber 5(
Decidin" the drive to be !orward D reverse the switch . sho&ld be operated accordin"l(
Ca&tion sho&ld be ta,en while operatin" the switches 1 and 5( As the total volta"e sho&ld
not e@ceed ?A)# one o! the switches i(e( either 1 or 5 sho&ld alwas be ,ept in O00
position at an ti%e o! the drivin"( That is i! switch 1 is in ON position# switch 5 sho&ld
be ,ept in O00 position and vice versa(
The "reen wire indicates as 15)( 2l&e wire indicates as 5?)( As 98) and ?A) are the top
%ost speeds these are indicated b &sin" red color wire(
The panels are o! 5?) each( To obtain ?A) panel A and panel 2 are connected in series#
li,ewise panel C and panel D are connected in series( These both are in t&rn connected in
parallel to have a total volta"e o! ?A)(
CONNECTIONS TO S>ITCHES AND PANELS
45
1=.2 AC CHARGER
46
The ac char"er is &sed to char"e the batteries o! the *P.U) in the absence o! s&nli"ht#
&sin" the re"&lar AC s&ppl(
An Aa%p AC char"er is &sed !or this p&rpose( It ta,es 15 hrs to char"e the ? batteries
co%pletel# as the batteries never "et co%pletel dischar"ed(
The c&rrent and the volta"e o&tp&t !ro% the AC char"er can be varied accordin" to the
re=&ire%ent(
At ti%es# li,e on a clo&d da# when solar power is not available# the batteries can be
co%!ortabl char"ed thro&"h this wa( This helps in restorin" the ener" in the batteries
and &ses it when necessar(
47
C HAPTER 11
)I2RATION ANA/C*I* IN
AN*C*
48
11. VIBRATION ANALYSIS IN ANSYS
.odal analsis $.A'
.odal analsis is &sed to deter%ine the vibration characteristics $nat&ral !re=&encies and
%ode shapes' o! a str&ct&re or a %achine co%ponent while it is bein" desi"ned( It also
can be a startin" point !or another# %ore detailed# dna%ic analsis# s&ch as a transient
dna%ic analsis# a har%onic response analsis# or a spectr&% analsis(
.odal analsis is &sed to deter%ine the nat&ral !re=&encies and %ode shapes o! a
str&ct&re( .odal analsis# while bein" one o! the %ost basic dna%ic analsis tpes
available in AN*C*# can also be %ore co%p&tationall ti%e cons&%in" than a tpical
static analsis( The nat&ral !re=&encies and %ode shapes are i%portant para%eters in the
desi"n o! a str&ct&re !or dna%ic loadin" conditions( The are also re=&ired to do
spectr&% analsis or a %ode s&perposition har%onic or transient analsis( .&ltiple ti%e
savin" %odal sol&tion %ethods are available in AN*C* !or %ode e@traction !ro% the
red&ced sol&tion# s&ch as#
2loc, /ancJos %ethod
PC6 /ancJos %ethod
Red&ced $Ho&seholder' %ethod
Uns%%etric %ethod
Da%ped %ethod
WR da%ped %ethod
2 doin" a %odal analsis# which calc&lates the nat&ral !re=&encies and %ode shapes#
o& can learn how the str&ct&re responds when those %odes are e@cited( The nat&ral
!re=&encies are also &se!&l !or calc&latin" the correct inte"ration ti%e step(
To validate the res&lts o! the %odal analsis# the nat&ral !re=&encies# a%plit&de ratios and
the partic&lar sol&tion are also co%p&ted analticall( 0&rther%ore# AN*C* is &sed to
deter%ine the sste% response res&ltin" !ro% a har%onic e@citation(
M ?5 @ 5 7 =
It is c&sto%ar to per!or% %odal analsis on %echanical sste%s witho&t d&e re"ards to
their stress state( It is believed that the stress sti!!enin" can chan"e the response
!re=&encies o! a sste% which i%pacts both %odal and transient dna%ic responses o!
the sste%( This is e@plained b the !act that the stress state wo&ld in!l&ence the val&es o!
the sti!!ness %atri@( L19M
49
It is i%portant to investi"ate the e!!ect o! pre-stress on the vibration behavior o! si%ple
str&ct&res &sin" !inite ele%ent pac,a"e AN*C*( This is achieved b !irst per!or%in" a
str&ct&ral analsis on a loaded str&ct&re then %a,es &s o! the res&ltin" stress !ield to
proceed on a %odal analsis(
The %ain steps involved in analJin" the str&ct&re !or vibrations contain the !ollowin"#
1( *tartin" AN*C*
5( DE0ININ6 THE .ATERIA/ PROPERTIE*
De!inin" ele%ent tpes
The !ollowin" ele%ents are &sed in the analsis(
1. 2ea% ele%ents E representin" the GC1 channel sections o! the str&ct&re
5( 0lat shell ele%ents E representin" the plates o! the str&ct&re(
9( *prin" ele%ents E with relevant sti!!ness representin" s&spension sste%
and tres(
4. .ass ele%ents E to indicate position o! loadin"
De!inin" real constants
The real constants !or vario&s ele%ents are as !ollows#
1. 2ea% ele%entE area# I# IJJ !or the correspondin" GC1 channel sections
$attached in anne@&re'(
2. 0lat shell ele%entE ta,in" thic,ness as &ni!or%(
3. *prin" ele%entE ta,in" lea! sprin" and tre as in series# sti!!ness is ta,en as
real constant(
4. .ass ele%entE %ass correspondin" to loadin" capacit is distrib&ted
&ni!or%l in the loadin" area at relevant nodes(
50
.aterial properties
9( CREATE 6EO.ETRC
Be points
/ines
De!inin" attrib&tes o! the lines
Creatin" .ass ele%ents
However in the present case nodes 3 ele%ents are directl de!ined( The 0E %odel has ?1
nodes# 5: ele%ents(
?( *O/UTION
De!inin" the analsis tpe
De!inin" the constraints
Per!or%in" the analsis
7( RE)IE>IN6 THE RE*U/T*
Tab&lar
6raphical
Ani%ation
8( CHAN6IN6 THE CON*TRAINT* 0OR .ODI0IED ANA/C*I*
;( RE)IE>IN6 THE RE*U/T*
51
D&rin" the operation o! the %otor r&nnin" at 58<<rp% indicated no vibrations o! the
chassis str&ct&re as shown in the %odal analsis there is no !re=&enc near the operatin"
!re=&enc o! the %otor and hence resonance has not occ&rred which otherwise leads to
hi"h vibrations(
The res&lts are as !ollows#
HHHHH INDEU O0 DATA *ET* ON RE*U/T* 0I/E HHHHH
*ET TI.ED0REW /OAD *TEP *U2*TEP CU.U/ATI)E
1 :(7?77 1 1 1
5 1A(5?9 1 5 5
9 5<(1:9 1 9 9
? 5A(?71 1 ? ?
7 9<(A7A 1 7 7
8 99(89? 1 8 8
; ?<(;1? 1 ; ;
A ?;(:9; 1 A A
: 71(9<< 1 : :
1< 78(?A1 1 1< 1<
11 7A(??7 1 11 11
15 8<(8;; 1 15 15
19 88(75; 1 19 19
1? ;1(7?A 1 1? 1?
17 ;9(;<: 1 17 17
18 ;8(9A5 1 18 18
1; ;A(;A8 1 1; 1;
52
1A A9(<?? 1 1A 1A
1: A9(7;? 1 1: 1:
5< :9(:8? 1 5< 5<
51 :7(;AA 1 51 51
55 :A(A<9 1 55 55
59 1<<(:7 1 59 59
5? 1<9(9: 1 5? 5?
57 1<;(88 1 57 57
58 1<:(?5 1 58 58
5; 1<:(;9 1 5; 5;
5A 11?(<9 1 5A 5A
5: 11A(:8 1 5: 5:
9< 151(7< 1 9< 9<
91 155(7A 1 91 91
95 15:(:< 1 95 95
99 19?(;7 1 99 99
9? 197(;8 1 9? 9?
97 197(A9 1 97 97
98 1?1(51 1 98 98
9; 1?9(<< 1 9; 9;
9A 171(:7 1 9A 9A
9: 178(89 1 9: 9:
?< 18<(?? 1 ?< ?<
?1 18;(?; 1 ?1 ?1
?5 1;5(81 1 ?5 ?5
53
?9 1A<(<? 1 ?9 ?9
?? 1A1(18 1 ?? ??
?7 1A?(A: 1 ?7 ?7
54
C HAPTER 15
CA/CU/ATION*
12. CALCULATIONS
The %otor has been connected to the di!!erential &sin" a set o! chain drives to red&ce the
speed to a certain e@tent( This has been done to red&ce the load on the %otor# since at
hi"h speeds the %otor cannot p&ll the heav vehicle( The !ollowin" calc&lations have
been done to ,now this red&ced speed(
>e ,now#
D
.
DD
D
N N
D
DN
.
>here#
D
.
N Pitch dia%eter o! the sproc,et attached to the %otor sha!t N 1:c%
D
D
N

Pitch dia%eter o! the

sproc,et attached to the di!!erential N ;(7c%
N
%
N *peed o! the %otor sha!t N 58<<rp%
55
ND N speed o! the di!!erential sha!t(
D
.
DD
D
N N
D
D N
.
1:D;(7 N 58<<DN
D
5(7N 58<<DN
D
N
D
N 58<<D5(7
N
D
N 1<?< rp%
In the trans%ission process we &sed two sta"es o! "ear red&ction hence the speed is
divided b 5(7( Hence the !inal speed at the di!!erential sha!t is "iven b#
N
D
N1<?<D5(7 rp%
N
D
N ?18 rp%
0or ever one revol&tion o! the wheel the di!!erential "ear revolves b two ti%es hence#
N
>
N N
D
D5
N
>
N ?18D5
N
>
N 5<A rp%
Hence the speed o! the wheel is 5<Arp%(
C HAPTER 19
56
CO.PRE**ION 3
HARDNE** TE*T*
13. COMPRESSION TESTS AND HARDNESS
TESTS AND RESULTS
The %aterial that has to be &sed !or the constr&ction %&st &nder"o an acc&rate testin" as
it plas the vital role in b&ildin" the vehicle( An da%a"e to the %aterial at an part o!
the vehicle %a lead to %al!&nctionin"( There!ore# tests are carried o&t to the speci%en+s
!ail&re# in order to &nderstand a speci%en+s str&ct&ral per!or%ance or %aterial behavior
&nder di!!erent loads(
*tress testin" has been per!or%ed here !or the %aterial( It is a !or% o! testin" that is &sed
to deter%ine the stabilit o! a "iven entit( It involves testin" beond nor%al operational
capacit# o!ten to a brea,in" point# in order to observe the res&lts(
The %aterial there!ore has been tested !or co%pression and hardness &nder relevant
%achines( Considerabl satis!actor res&lts have been obtained(
CO.PRE**ION TE*T
57
0or the co%pression test the %aterial was tested &nder HCDRAU/IC CO.PRE**ION
TE*TIN6 .ACHINE( The %aterial bein" placed in the re=&ired slot# hdra&licall load
$in ter%s o! ,"!' bein" applied# the %a@i%&% load that the %aterial can withstand
witho&t crac,in" has been noted(
The sa%e test was per!or%ed on the di!!erent bea%s o! varin" thic,ness that are &sed
!or the constr&ction o! the vehicle(
58
DI.EN*ION* CO.PRE**ION
TE*T RE*U/T
*TRE** IT CAN
2EAR
?<H;7H?< GC1 *ection
o! ?(7%% thic,ness
A7BN 5<5(9A ND %%X5
9<H9<H9< GC1 *ection
o! 9%% thic,ness
5<BN ;?(<; ND %%X5
HARDNE** TE*T
0or the hardness test# the %aterial was tested &nder ROCB>E// HARDNE**
TE*TIN6 .ACHINE( The test is cond&cted in a speciall desi"ned %achine that
applies the load thro&"h a sste% o! lever "ives the Hardness N&%ber directl( The
indenter &sed here is the dia%ond cone( The hardness val&e as read !ro% a speciall
"rad&ated dial indicator is an arbitrar n&%ber that is related to the depth o! indentation(
The %aterial bein" placed on the even level# the press&re $in ter%s o! ,"' was applied
over a partic&lar contact area between the indenter and the %aterial bein" tested( 3 the
instance at which indentation be"ins to occ&r the correspondin" Roc,well n&%ber has
been noted(
59
The test res&lts are as &nder !ollow#
DI.EN*ION* ROCB>E// HARDNE**
)A/UE
?<H;7H?< GC1 *ection o!
?(7%% thic,ness
;<HRC
9<H9<H9< GC1 *ection o! 9%%
thic,ness
7:HRC
60
C HAPTER 1?
CO.PARI*ON
61
14. COMPARISON
A!ter %a,in" the %entioned %odi!ications to the *P.U)# let1s observe the co%parison(

PREVIOUS CHASSIS PRESENT CHASSIS
Trac, width Y >heel 2ase $1(5' .odi!ied to opti%&% ratio $<(;'
Carrier area is less# Relativel lar"e Carrier area(
2ea% thic,ness 7%%( 2ea% thic,ness 5%%#9%%(
*heet thic,ness 5%%( *heet thic,ness 1 %%(
2atteries >ei"ht actin" at !ront( 2atteries wei"ht distrib&ted(
Heav s&spension &sed at !ront and rear( .odi!ied s&spension sste%(
/ess area provided !or solar panels( Increased area !or solar panels(
Overall wei"ht 87<,"s( Overall wei"ht 9:;,"s
)olta"e re"&lator &sed !or startin" and
r&nnin"
*witch %echanis% bein" &sed !or startin"
and r&nnin"(
As %entioned be!ore# the chan"es re=&ired !or the previo&s vehicle have been envisa"ed
and have been i%ple%ented( The o&tco%e o! re%odelin" the vehicle accordin" to the
planned chan"es has been achieved with noticeable co%parisons as shown above(
62
C HAPTER 17
CONC/U*ION
15. CONCLUSION
63
Hence we wo&ld li,e to concl&de that the %ain ai%s o! the pro4ect have been achieved b
re%odelin" the vehicle b alterin" certain parts(
At present sit&ation# as we all are aware !ossil !&el prod&ction rate !ar less than
cons&%ption rate(
At this point o! ti%e we are !orced to chan"e to renewable so&rces o! ener"(
In other words cons&%ption is "rowin" at a hi"her rate( *o# we are !orced to %ove to
renewable so&rces o! ener"( *ince solar ener" co%es hand# we pre!erred ta,in" &p
this challen"in" pro4ect(
As the vehicle is desi"ned !or carrin" loads# it can certainl be &sed in and aro&nd the
ca%p&s b char"in" it thro&"h either o! the was i(e( solar ener" 3 AC char"in"(
The load can now be easil trans!erred !ro% one place to another &sin" *P.U)(
>e have been s&ccess!&l in reachin" the tar"ets that were planned at the initial sta"e(
The scope !or !&rther i%prove%ent o! *P.U)#
1( Hei"ht o! the base can be decreased i(e( "ivin" less "ro&nd clearance(
5( Usin" e!!icient "ear trans%ission sste% the speed o! the vehicle can be increased(
9( The wei"ht o! the vehicle can be !&rther decreased b replacin" the lead acid batteries
with lithi&% ion batteries(
?( The vehicle can be desi"ned to be operated &sin" re%ote control(
7( Dna%os can be &sed !or char"in" the batteries &nder %otion(
64
C HAPTER 18
PHOTO 6A//ERC
65
16. PHOTO GALLERY

Chassis o! previo&s *P.U)( O&ter parts re%oved to analJe the str&ct&re
66
2atteries wei"ht actin" onl at !ront !or the previo&s *P.U)(
67
2atteries wei"ht distrib&ted in present *P.U)(
68
0ront a@le o! previo&s *P.U) &sin" lea! sprin"s as s&spension sste%(
0ront a@le o! present *P.U) &sin" str&ts as s&spension sste%(
69

*hell ele%ents "enerated 2ea% ele%ents "enerated(
70
6enerated sprin"s in place o! s&spension sste% $lea! sprin"s and str&ts' and tres(
0abricated chassis(
71
0abricated chassis with rear a@le asse%bled(
Rear s&spension sste% $lea! sprin"s' o! *P.U)(
72

0ront s&spension sste%( /e!t and Ri"ht str&ts(
2od o! the *P.U) a!ter asse%blin" o! !ront 3 rear a@le# batteries(
73
)ast space provided !or the carrin" o! load(
0i@in" plwood sheets !or the base o! chassis(
74
Observin" val&es in ROCB>E// HARDNE** %achine(
0ront bra,in" sste% $Disc bra,es'(
75
Rear a@le with %otor and lea! sprin"s( *peed red&ced b 5(7 ti%es with the help o! these "ears(
76
SPMUV >ITH SOLAR PANELS
BIBLIOGRAPHY
1( Birpal *in"h# 5<<;# A&to%obile En"ineerin" vol&%e 1 3 5# standard p&blishers#
Delhi(
5( R(*( Bh&r%i 3 F(B(6&pta# 5<<A# .achine Desi"n# E&rasia p&blishers# Delhi(
9( httpEDDen(wi,ipedia(or"Dwi,iDDi!!erentialZ$%echanicalZdevice'
?( httpEDDen(wi,ipedia(or"Dwi,iDAc,er%annZsteerin"Z"eo%etr
7( httpEDDen(wi,ipedia(or"Dwi,iD/ea!Zsprin"
8( httpEDDwww(ncert(nic(inDht%lDlearnin"Zbas,etDelectricitDelectricitD%achineD%otor(ht%
77
;( httpEDDen(wi,ipedia(or"Dwi,iD.acPhersonZstr&t
A( httpEDDa&to(howst&!!wor,s(co%Da&to-partsDbra,esDbra,e-tpesDdisc-bra,e(ht%
:( httpEDDa&to(howst&!!wor,s(co%Da&to-partsDbra,esDbra,e-tpesDdr&%-bra,e(ht%
1<( httpEDDwww(ro%ech(co(&,DUse!&lZTablesDDriveDDr&%Z2ra,es(ht%l
11( httpEDDwww(ro%ech(co(&,DUse!&lZTablesDDriveDDis,Z2ra,es(ht%l
15(httpEDDwww(howst&!!wor,s(co%Dsolar-cell(ht%
19( httpEDDwww(aa&e(d,Db%DanssD!e%-lesson19(pd!
ANNEAURE
*ECTION ID NU.2ERE 1
2EA. *ECTION TCPEE Channel *ection
2EA. *ECTION NA.E I*E
2EA. *ECTION DATA *U..ARCE
Area N 7;(<<
I N (777;?ER<8
IJ N <(1A77?E-<:
IJJ N :;;?
78
>arpin" constant N (A;599ER<A
Torsion constant N 7<5(?
Centroid C N 1(:;8
Centroid [ N ;(7<<
*hear center C N 11(AA;
*hear center [ N ;(7<<
*hear correction- N (97;1?
*hear correction-J N (5??55E-1?
*hear correction-JJ N (?1?:<
2ea% *ection is o!!set to CENTROID o! cross section
*ECTION ID NU.2ERE 5
2EA. *ECTION TCPEE Channel *ection
2EA. *ECTION NA.E I*E channels
2EA. *ECTION DATA *U..ARCE
Area N ?(<<<
I N 5A7(9
IJ N <(:59;1E-19
IJJ N 57(99
>arpin" constant N A8:?
Torsion constant N 8(551
Centroid C N (7<<<
Centroid [ N <(<<<
*hear center C N 1(5;A5
*hear center [ N <(<<<
*hear correction- N (9<;:A
79
*hear correction-J N <(7AA8:E-1?
*hear correction-JJ N (75;51
2ea% *ection is o!!set to CENTROID o! cross section
*ECTION ID NU.2ERE 9
2EA. *ECTION TCPEE Channel *ection
2EA. *ECTION NA.E I*E 9%%c
2EA. *ECTION DATA *U..ARCE
Area N 575(<<
I N 989:8
IJ N <(89887E-11
IJJ N 55:5;
>arpin" constant N <(91<8;ER<;
Torsion constant N ;8A(:?
Centroid C N 11(1?9
Centroid [ N 17(<<<
*hear center C N -1<(?78
*hear center [ N 17(<<<
*hear correction- N <(78999
*hear correction-J N <(9:517E-17
*hear correction-JJ N <(55A71
2ea% *ection is o!!set to CENTROID o! cross section
*ECTION ID NU.2ERE ?
2EA. *ECTION TCPEE Channel *ection
80
2EA. *ECTION NA.E I*E 5%%c
2EA. *ECTION DATA *U..ARCE
Area N 1;5(<<
I N 58?A:
IJ N -<(78A?9E-15
IJJ N 1815A
>arpin" constant N <(55:;:ER<;
Torsion constant N 595(:1
Centroid C N 1<(;8;
Centroid [ N 17(<<<
*hear center C N -11(995
*hear center [ N 17(<<<
*hear correction- N <(7?8A1
*hear correction-J N <(:?795E-19
*hear correction-JJ N <(55;<<
2ea% *ection is o!!set to CENTROID o! cross section
81