AMITY UNIVERSITY

DESIGNING AND FABRICATION OF

SEGWAY
Minor Project Report

Faculty Guide :
Atul Sharma

Submitted by :
Saurav Chaudhary ( A2305412044

)
Aatish paramhans( A2305412037 )
Vishal Kumar( A2305412001 )
Anuj ( A2305412344)
1

Acknowledgement

We would like to express our deepest appreciation to all those who provided us the
possibility to complete this report. A special gratitude I give to our final year
project manager, Mr.Atul Sharma , whose contribution in stimulating suggestions and
encouragement, helped us to coordinate my project especially in writing this report.
Furthermore we would also like to acknowledge with much appreciation the crucial
role of the staff of Amity School of Engineering & Technology, who gave the
permission to use all required equipments and the necessary materials to complete the
task.

Last but not least, many thanks go to the co-ordinator of the project, Mr.Vinayak
Hemadri, who have invested his full effort in guiding the team in achieving the goal.
We have to appreciate the guidance given by other supervisor as well as the panels
especially in our project presentation that has improved our presentation skills thanks
to their comments and advices.

Certificate

This is to certify that Mr. Saurav chaudhary, Mr. Vishal kumar, Mr.Aatish
paramhans, Mr.Anuj are students of B.Tech in Mechanical and Automation
Engineering Department have carried out the work presented in the project of their
minor project titled Designing and fabrication of segway as a part of their final year
program of B.Tech in Mechanical and Automation Engineering from Amity School of
Engineering and Technology, Amity University Uttar Pradesh, Noida under my
supervision.

(Mr. Atul Sharma)

Assistant Professor
Department of Mechanical and Automation Engineering
ASET
3

Amity University, NoidaTable

of Contents

SN

Contents

Introduction

Abstract

Methodology

Resource Requirement

Parts Assembly

Dimensions

Parts Configuration

Working

9
10

Calculations
Stress and Deflection Analysis

11

Feasibility of Project

12

Uses

13

Advantages

14

Future Advancements

INTRODUCTION
At first glance, this device called the Segway ( Human Transporter) doesn't seem all that
remarkable it looks like a high-tech scooter. But people who have tried it out claim that it is
much, much more a completely different way to get around.
Segway is the human transporter which is to move from one place to another
place with a simple operation. Basically segway is a scooter like appearance but the wheel
arrangement is parallel to each other that is both the wheels are placed side by side.
The Segway is a personal transportation technology invented by Dean Kamen (DEKA, 2007).
This technology can be used for leisure or commercial purposes. It can be used by golfers on
a golf course instead of gold carts, by policeman and security and also by individuals for
sightseeing or to travel short distances. The Segway can be used on rough terrain in remote
farm areas or in the woods as well as on city pavements and streets. The company that
manufactures this product has tried to develop different types of Segways to fit different
needs. However, this technology is still in its early stages and society is going to play a huge
role in the construction of a safe Segway. This paper is going to use Bjiker's theory of the
social construction of technology to look at the Segway in its current stage of development
and the technology behind it, relevant social groups, problems and solutions, future Segway
predictions, interpretative flexibility, closure and stability and the final safe Segway (Bjiker,
1997).
The balancing technology for the operation of the segway was invented by Dean
Kamen to mimic the way the human body balances itself. Its balancing mechanism operates
like how the fluid in the inner human ear sends signals to the brain when the body shifts. This
Technology is known as dynamic stabilization (Segway Website, 2007).

Abstract

The Segway in its current stage of development is mainly used by organizations

that can afford it and individuals in a certain financial status. This is due to the fact that one
Segway costs around five thousand dollars: this amount was given by a New Jersey Segway
dealer (Segway Website, 2007). Apart from the price the way the Segway is built
marginalizes its users, because it cannot be used by elderly people, the handicap and young
children. These relevant social groups fall under non-users, however, they will have a great
impact in the continuing improvement of this artifact. The users of the Segway are also a very
important social group because in September 2003 and 2006 the Segway had to be recalled
for malfunctions, these malfunctions would not have been known if the users did not report
them (Wikipedia, 2007). Another relevant social group is the manufacturers of the Segway,
because even though the users report problems it is the manufacturer that has to be innovative
in making a better Segway.
Unlike a car, the Segway only has two wheels -- it looks something like an
ordinary hand truck -- yet it manages to stay upright by itself.
To move forward or backward on the Segway, the rider just leans slightly forward or
backward. To turn left or right, the rider turns the right handlebar forward or backward.
This project involves in designing a machine using electronic system to make an inverted
pendulum remain upright. Inverted pendulum is our system which will be used in a machine
and that machine is known as Segway. The pendulum will hang freely on an axle so that it
can swing clockwise and counterclockwise. The axle in turn will be able to move along a
straight line along the direction in which the pendulum swings. By dynamically driving a
motor which moves the axle along a track according to the motion of the segway, the segway
will be prevented from falling from the upright position. The problem of controlling an
inverted pendulum in this manner is classical to control systems, since the system is
inherently unstable the segway will not remain upright without external forces. This type of
system is also very difficult to control manually, and therefore requires the use of electronic
controls. In this project, a control algorithm will be developed and implemented digitally,
using a microprocessor and sensors, and a working demonstration will be built. Ultimately,
this project will show the effectiveness of a digital control system to stabilize a machine
quickly, and it will be used for transportation purposes.

Methodology

Two motors are placed in the opposite side of the chasis.

Motor shaft is fitted with small size sprocket and wheel shaft is fitted to large size
sprocket.

Now the sprockets are connected by chain drive so that as motor rotates, wheel also
rotates.

Handle bar is fitted in the front side of the chasis.

A DPDT switch is fixed to handle This is a great learning project. It involves:

wood working

metal working
plumbing techniques
wiring from schematics
micro controller
accelerometer/gyro basics

Resource Requirement

Hardware:
COMPONENTS USED IN SEGWAY

CHASIS

MOTOR .
CHAIN DRIVE
BATTERY
DPDT SWITCH
WOOD

Software:

Solidworks

Parts Assembly
Two motors are placed in the opposite side of the chasis.
Motor shaft is fitted with small size sprocket and wheel shaft is fitted to large
size sprocket.
Now the sprockets are connected by chain drive so that as motor rotates, wheel
also rotates.
Handle bar is fitted in the front side of the chasis.
A DPDT switch is fixed to handle

Dimensions

Base Frame
Clearance from Ground
Wheel diameter
length of handle
Length of bar connecting handle to base

25*20n
5in
12in
8in
4ft

10

Parts Configuration
MOTOR

Speed

: 375 rpm

Voltage

: 20V

Motor type : Gear headed motor

CHAIN DRIVE

Links

Length of chain : 552mm

Centre distance :180mm

: 46

STUD

Length

Diameter : 9mm

Pitch

: 76cm

: 1.25mm

NUT

Inner dia : 10mm

Outer dia : 20mm

BATTERY

Volts

Current : 5A

: 12V

11

Working
The Segway does pretty much the same thing, except it has wheels instead of legs,
a motor instead of muscles, a collection of microprocessors instead of a brain and a set of
sophisticated tilt sensors instead of an inner-ear balancing system. Like your brain, the
Segway knows when you are leaning forward. To maintain balance, it turns the wheels at just
the right speed, so you move forward
All of the tilt information is passed on to the "brain" of the vehicle, two electronic controller
circuit boards comprising a cluster of microprocessors. The Segway has a total of 10
onboard microprocessors, which boast, in total, about three times the power of a typical PC.
Normally, both boards work together, but if one board breaks down, the other will take over
all functions so that the system can notify the rider of a failure and shut down gracefully.
The Segway requires this much brain power because it needs to make extremely precise
adjustments to keep from falling over. In normal operation, the controller boards check the
position sensors about 100 times per second. The microprocessors run an advanced piece of
software that monitors all of the stability information and adjusts the speed of several electric
motors accordingly. The electric motors, which are powered by a pair of rechargeable nickel
metal hydride (NIMH) or Lithium-ion (Li-ion) batteries, can turn each of the wheels
independently at variable speeds.
When the vehicle leans forward, the motors spin both wheels forward to keep from tilting
over. When the vehicle leans backward, the motors spin both wheels backward. When the
rider operates the handlebar control to turn left or right, the motors spin one wheel faster than
the other, or spin the wheels in opposite directions, so that the vehicle rotates.

12

Calculations

13

14

15

Stress & Deflection Analysis

16

17

Feasibility of Project

Technical feasibility:
By eliminating use of cars for short distances and using Segway will reduce noise and air
pollution.
Segway can be used in malls and industries for transporting or moving from one place to the
other.
People with disabilities can also use Segway for moving from one place to the other.
It can also be used by tourist for roaming around cities .
Human Aspect : Since the transporter will be used for a single person and to reduce the
human effort in travelling from one place to another. So we need to take into consideration
the following things:
Easy to stand on.
Easy to steer.
Should not cause any fatigue to the person while moving.
Should not be too noisy.(since we are using a lot of mechanical systems instead of

electrical to reduce cost)

Should be safe.
Should not cause any damage to the environment

Economic Feasibility:

Cost of Materials

GEAR HEAD MOTOR

4000

WHEELS(2)

600
18

FRAME MATERIAL

600

BATTERIES(2)

1000

CHAIN DRIVES

400

SPROCKETS

500

STUD

100

EXTRA PARTS

500

FABRICATION

1000

TOTAL

10000-15000 approx.

Uses

19

Police purpose

Millitary purpose

Tourist purpose

20

Industrial use

Advantages

1. Become more productive: more work can be done by using the product versus walking
2. Become more recognizable: Riders stand an additional eight inches off the ground,
allowing you to be better seen and giving the rider better sight lines, over cars in a parking lot
or boxes in a warehouse.
3. low operating costs: no need for gas and inexpensive battery charging (A complete cycle
charge will take eight to ten hours)
4. reduce fatigue caused by walking
21

5. a clean, green, ecofriendly machine! (zero emission)

Future Advancements

Future advancements that can be made are:

We can put a battery which can be charged by itself when the segway is
moving downwards from a hill .
We can fit a screen on Segway which enables us to show direction .
A chip can be fitted in Segway which can be made remote control and then can
also be used by blind person. The remote controller can control the direction of
Segway.
22

References

https://en.wikipedia.org/wiki/Segway_PT
www.segway.com/
www.howstuffworks.com
www.google.com

23