CHAPTER NO.

1
INTRODUCTION
The Segway PT is a two-wheeled, self-balancing, battery-powered electrivehicle invented
by Dean Kamen. It is produced by Segway Inc. of New Hampshire. The name Segway is
derived from the word segue, meaning smooth transition. PT is an abbreviation for personal
transporter. Segways perform best in areas with adequate sidewalks, curb cuts at
intersections, and ramps. They are used in some theme parks by visitors and employees.
Dean Kamen, the machine's inventor, held especially high hopes for the Segway. In an
interview with Time Magazine, he claimed that his machine "will be to the car what the car
was to the horse and buggy."Although the Segway hasn't quite lived up to its hype, it's most
definitely an amazing machine. In this article, we'll find out what sets the Segway apart from
earlier vehicles, and we'll see why its inventor thought it could change the world.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.If you
stand up and lean forward, so that you are out of balance, you probably won't fall on your
face. Your brain knows you are out of balance, because fluid in your inner ear shifts, so it
triggers you to put your leg forward and stop the fall. If you keep leaning forward, your brain
will keep putting your legs forward to keep you upright. Instead of falling, you walk forward,
one step at a time.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. The rider controls forward and backward movement
by leaning the Segway relative to the combined center of mass of the rider and Segway, by
holding the control bar closer to or farther from their body. The Segway detects the change in
the balance point, and adjusts the speed at which it is balancing the rider accordingly. On
older models, steering is controlled by a twist grip on the left handlebar, which simply varies
the speeds between the two motors, rotating the Segway PT (a decrease in the speed of the
1

left wheel would turn the Segway PT to the left). Newer models enable the use of tilting the
handle bar to steer. . The speculation created an unexpected advance buzz about the product
that was, at times, hyperbolic. Steve Jobs was quoted as saying that it was "as big a deal as
the PC", though later sources quoted him as saying when first introduced to the product that
its design "sucked". John Doerr speculated that it would be more important than the Internet

Fig No 1 : Complete Project view

1.1 History
The Segway PT was known by the names Ginger and IT before it was unveiled. Ginger came
out of the first product that used Kamen's balancing technology, the iBOT wheelchair. During
development

at

the University

of

Plymouth,

in

conjunction

with BAE

Systems and Sumitomo Precision Products, the iBot was nicknamed Fred Upstairs (after Fred
Astaire) because it can climb stairs: hence the name Ginger, after Astaire's regular film
partner, Ginger Rogers, for a successor product.

The invention, development, and financing of the Segway was the subject of a narrative
nonfiction book, Code Name Ginger (in paperback as Reinventing the Wheel), by journalist
Steve Kemper. The leak of information from that book led to speculation about the "IT"
device prior to release. The speculation created an unexpected advance buzz about the
product that was, at times, hyperbolic. Steve Jobs was quoted as saying that it was "as big a
deal as the PC", though later sources quoted him as saying when first introduced to the
product that its design "sucked". John Doerr speculated that it would be more important than
the Internet. Articles were written in major publications speculating on it being a Stirling
engine. South Park devoted an episode to making fun of the hype before the product was
released.The product was unveiled 3 December 2001, in Bryant Park, the privately managed
public park located in the New York City brought of Manhattan, on the ABC News morning
program Good Morning America

1.2 Idea Generation:

Due to large expansion of automobile industry, numbers of vehicles is also increases. By
increasing the vehicle, pollution is also increases. So there must be a need of that type of
vehicle which have zero emission. So we think and try to make a Segway which is battery
operated and having zero emission. Segway is good for transporting single person from one
place to other. The major advantage of Segway is that there is no pollution, no fuel consumes,
so its saves the environment as well as petrol too. Segway Provides a Clean, Fast and reliable
alternatives to traditional truck, Scooter and buses.Large multinational companies are now
making good use of Segway PTs. The segway has many benefits for environment also. It also
reduces the impact of global warming by checking greenhouse gas output and global
warming

CHAPTER NO 2
INFORMATION
2.1 Technology:
The dynamics of the Segway PT are similar to a classic control problem, the inverted
pendulum. The Segway PT (PT is an initialism for personal transporter while the old
suffix HT was an initialism for human transporter) has electric motors powered by Valence
Technology phosphate-based lithium-ion batteries, which can be charged from household
current. It balances with the help of dual computers that run proprietary software, two tilt
sensors, and five gyroscopic sensors developed by BAE Systems' Advanced Technology
Centre. The servo drive motors rotate the wheels forwards or backwards as needed for
balance or propulsion. The rider controls forward and backward movement by leaning the
Segway relative to the combined center of mass of the rider and Segway, by holding the
control bar closer to or farther from their body. The Segway detects the change in the balance
point, and adjusts the speed at which it is balancing the rider accordingly. On older models,
steering is controlled by a twist grip on the left handlebar, which simply varies the speeds
between the two motors, rotating the Segway PT (a decrease in the speed of the left wheel
would turn the Segway PT to the left).

2.2 Subject used in project:

I.

II.
III.

Strength of Material:
Frame that support the weight of person is made with the help of balancing of
shear force which require knowledge of strength of material .
Basic of Electronics:
Motor and battery that are used which require knowledge of electronics.
Machine Design:
4

Designing of project require concept of machine design.

CHAPTER 3
PROJECT WORK
Different Components used:
The following components are used in our project:
1)
2)
3)
4)
5)
6)

Wheel
Motor
Battery
Frame
Wooden board
Wheel

3.1 Wheel:
We use two tubeless wheel in our project. Wheels are for running the Segway. A wheel is a
circular component that is intended to rotate on an axial bearing. The wheel is one of the
main components of the wheel and axle which is one of the six simple machines. Wheels, in
conjunction with axles, allow heavy objects to be moved easily facilitating movement or
transportation while supporting a load, or performing labor in machines. . Wheels are for
running the Segway. A wheel is a circular component that is intended to rotate on an
axial bearing. The wheel is one of the main components of the wheel and axle which is one
of the six simple machines

Fig No 2 : Wheels

3.2 Motor:
It is a 12V D.C Motor. Basically it is a heavy loaded vehicle wiper motor. It produces the
enough torque to rotate the tyres. We can rotate in both direction i.e. clockwise and
anticlockwise direction. It is capable of high torque and low r.p.m. motor.
A DC motor is any of a class of electrical machines that converts direct current electrical
power into mechanical power. A DC motor's speed can be controlled over a wide range,
using either a variable supply voltage or by changing the strength of current in its field
windings.The most common types rely on the forces produced by magnetic fields. Nearly all
types of DC motors have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor. Most types produce
rotary motion; a linear motor directly produces force and motion in a straight line.

Fig No 3 : D.C. Motor

6

DC motors were the first type widely used, since they could be powered from existing directcurrent lighting power distribution systems. A DC motor's speed can be controlled over a
wide range, using either a variable supply voltage or by changing the strength of current in its
field windings. Small DC motors are used in tools, toys, and appliances. The universal
motor can operate on direct current but is a lightweight motor used for portable power tools
and appliances. Larger DC motors are used in propulsion of electric vehicles, elevator and
hoists, or in drives for steel rolling mills. The advent of power electronics has made
replacement of DC motors with AC motors possible in many applications.
Table no 1 :Motor Specification
Sr No.
1.
2.

Name
Voltage
R.P.M.

Value
12 V
500

Motor works on the principal of Fleming's left-hand rule

Fleming's left-hand rule (for motors), and Fleming's right-hand rule (for generators) are a
pair of visual mnemonics. They were originated by John Ambrose Fleming, in the late 19th
century, as a simple way of working out the direction of motion in an electric motor, or the
direction of electric current in an electric generator.
When current flows in a wire, and an external magnetic field is applied across that flow, the
wire experiences a force perpendicular both to that field and to the direction of the current
flow. A left hand can be held, as shown in the illustration, so as to represent three mutually
5orthogonal axes on the thumb, first finger and middle finger. Each finger is then assigned to
a quantity (mechanical force, magnetic field and electric current). The right and left hand are
used for generators and motors respectively. A DC motor's speed can be controlled over a
wide range, using either a variable supply voltage or by changing the strength of current in its
field windings . They were originated by John Ambrose Fleming, in the late 19th century, as
a simple way of working out the direction of motion in an electric motor, or the direction of
electric current in an electric generator.
7

The direction of the mechanical force is the literal one

The direction of the magnetic field is from north to south
The direction of the electric current is that ofconventional current: from positive to
negative.

Fig No 4 : Left hand diagram

3.3 Battery:
An automotive battery is a type of rechargeable battery that supplies electric energy to
an automobile. An automotive SLI battery (starting, lighting, ignition) powers the starter
motor, the lights, and the ignition system of a vehicle's engine. Automotive SLI batteries are
usually lead-acid type, and are made of six galvanic cells in series to provide a 12volt system. Each cell provides 2.1 volts for a total of 12.6 volts at full charge. Lead-acid
batteries are made up of plates of lead and separate plates of lead dioxide, which are
submerged into an electrolyte solution of about 38% sulfuric acid and 62% water. This
causes

a chemical

reaction that

releases electrons,
8

allowing

them

to

flow

through conductors to produce electricity. As the battery discharges, the acid of the
electrolyte reacts with the materials of the plates, changing their surface to lead sulfate. When
the battery is recharged, the chemical reaction is reversed: the lead sulfate reforms into lead
dioxide and lead. With the plates restored to their original condition, the process may now be
repeated.
Battery recycling of automotive batteries reduces the need for resources required for
manufacture of new batteries, diverts toxic lead from landfills, and prevents risk of improper
disposal.
3.3.1 Battery Specification:
We use 12V battery . These battery have two terminals, one side wire is attached with
motors of separate tyres.

Fig No 5 : Battery

3.4 Frame:
Frame is the heart of our project. Mainly the Segway design is based on the frame. Firstly we
take the mild steel angle and then make a rectangular section by welding.
9

Fig No 6 : Frame

3.5 Wooden Block

Wooden block of dimension 19*26 is used for supporting the weight of person.

Fig No 7 : Wooden Block

10

3.6 Sprocket Pinion:

Sprocket is the major component of this system because it is power transmitting device. It
gets power from the chain drive and makes this system to work.

Fig No 8 :Sprocket with bearing

It is the device which transmits the linear motion of meshing chain drive into rotary motion
by means of the tooth found on it. The sprocket with ball bearings is said to be FREE
WHEEL. Since it is a free wheel it allows the toothed part to rotate free from central portion
in a direction. Hence this type of sprocket is used as the rear power transmission device in by
cycle that makes the wheel to rotate and also allows toothed area to rotate in anticlockwise
when pedaled anticlockwise direction. This action of sprocket allows attached lifting lever
to adjust freely automatically or manually when it does not engage with properly.

3.7 Caster Wheel :

There are two way to balance our project. One is gyroscope and other is caster wheel we use
caster wheel to balance the project. Caster wheel is placed at the back of the Segway just to
support the mechanism.

11

Fig No. 9 Castor Wheels

Caster wheel is act like a third whee A caster (or castor) is an undriven, single, double, or
compound wheel that is designed to be mounted to the bottom of a larger object (the
"vehicle") so as to enable that object to be easily moved. They are available in various sizes,
and are commonly made of rubber,plastic, nylon, aluminum, or stainless steel. Casters are
found in numerous applications, including shopping carts, office chairs, and material
handling equipment. High capacity, heavy duty casters are used in many industrial
applications, such as platform trucks, carts, assemblies, and tow lines in plants. Generally,
casters operate well on smooth and flat surfaces. A basic, rigid caster consists of a wheel
mounted to a stationary fork. The orientation of the fork, which is fixed relative to the
vehicle, is determined when the caster is mounted to the vehicle. An example of this is the
wheels found at the rear of a shopping cart in North America. Rigid casters tend to restrict
vehicle motion so that the vehicle travels along a straight line

12

CHAPTER 4
MACHINES USED
4.1 CUTTER: Especially cutter is used to cut square shaped pipe into various dimensions
for manufacturing of Segway frame and Wheel base. A friction circular disc is used for
cutting metal parts which is operated by electricity and can be moved to any horyjontal place.

Fig 10 : Cutter machine

4.2 GRINDER:
It is used for grinding sharp edges of parts of segway for reducing hazard from edges.
A grinding machine, often shortened to grinder, is any of various power tools or machine
tools used for grinding, which is a type ofmachining using an abrasive wheel as the cutting
tool. Each grain of abrasive on the wheel's surface cuts a small chip from the workpiece via
shear deformation. Grinding is used to finish workpieces that must show high surface
quality (e.g., low surface roughness) and high accuracy of shape and dimension. As the
13

accuracy in dimensions in grinding is on the order of 0.000025 mm, in most applications it

tends to be a finishing operation and removes comparatively little metal, about 0.25 to 0.50
mm depth. However, there are some roughing applications in which grinding removes high
volumes of metal quite rapidly. Thus, grinding is a diverse field.

Fig 11 : Grinder machine

4.3 Drilling Machine :

Drill machine is used for doing necessary holes in the design of project . A drill is
a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill
bit or driver bit, used for boring holes in various materials or fastening various materials
together with the use of fasteners. The attachment is gripped by a chuck at one end of the
drill and rotated while pressed against the target material. The tip, and sometimes edges, of
the cutting tool does the work of cutting into the target material. Drills are commonly used
in woodworking, metalworking, construction and do-it-yourself projects. Specially designed
drills are also used in medicine, space missions and other applications. Drills are available
with a wide variety of performance characteristics, such as power andcapacity.
14

Fig No 12 : Drill Machine

4.3.1Types of Drilling Machines
Drilling machines are classified on the basis of

Their constructional features, and

The type of work they are required to do.

Various types of drilling machines are

a.

Portable drilling machine

b.

Bench drilling machine

c.

Sensitive drilling machine

d.

Upright drilling machine

e.

Radial drilling machine

f.

Multiple spindle drilling machine

g.

Deep hole drilling machine

h.

Gang drilling machine

i.

Automatic drilling machine

15

In this project work, we have shown bench drilling machine setup. So let us directly come to
bench drilling machine.
Bench type Drilling Machine:
It is the simplest type of drilling machine. The machine can hold drills up to 12.5mm
diameter either in a chuck or directly in the taper nose of the spindle.
The drill spindle axis is at right angle to the working table. If a hole is to be drilled at an
angle, the drilling table can be provided with a tilting mechanism.
Coming to the Project, here the drilling mechanism is operated by manual input with the help
of bevel gears. The pinion is mounted on the shaft on the same side having handle fixed at its
end. Moreover, the follower gear is fixed at right angle to the pinion in mesh.
The spindle is attached on the followers shaft. When we rotate the handle, the pinion gets
motion and transmits it to the other gear in mesh. Hence the drilling operation is done. The
working table is fixed to the base of the model. The rpm of the drill vary with the speed of
handle rotation.

16

CHAPTER 5
DESIGNING AND COST OF PROJECT
Notifications :
r.p.m

= revolution per minute

Kmph

= Kilometer per hour

= Watt

= Torque of Motor

= Power of Motor

= width of wheel

= Coefficient of friction between road and tyre

N-m

=Newton Meter

= Volt

D.C

= Direct Current

PT

= Personal transportation

SLI

= Starting lighting ignition

Calculations :
Power of the Motor (P)
= 17 W
R.P.M. Of Motor (n)
=500
:- We Know that
P= (2**n*T)/60
17 = (2**52*T)/60
T= 3.12 N-m
Now, we know that
T1 = 18
T2 = 44
d = 0.08 m
17

:- D = d * (T2/T1)
D = 0.08*(44/18)
D = 0.195 m
Using *d*n = *D*N
Putting all the values
*0.08*52 = *0.195*N
:-

N= 21.27 rpm

Speed of Segway :
Revolution of sprocket gear in one minute

= 21.27

Circumference of wheel

= D = 0.95 m

Hence, Segway moves in one minute is

= (DN)(60) 1000 = 1.212 mph

Load Capacity :Torque available = 3.12 n-m

Let W= Weight supported by frame
:- Torque induced by weight = *W*r
Where r= radius of tyre
:- 3.12 =*W*r
W= 3.12/(*r)

Table no 2 : Cost Of Project

18

Sr. No. Name

Quantity

1.
2.
3.
4.
5.
6.
7.
8.
9.

2
2
2
1
---------------2
------

D.C. Motor
Tyres
Switches
Battery
Framing
Wiring
Extra expensis
Caster wheels
Wastage
TOTAL COST

19

Cost/piece
(in Rs)
600
75
30
1000
500
100
1000
100
1000

Total Cost
(in Rs)
1200
150
60
1000
500
100
1000
200
1000
5210 /-

CHAPTER 5
CONCLUSION
At last we summarise that , our project is based on the personal transpoter by using battery
and motor .In it two wheels are used generally .
Hence we concluded that , project is quite economical as we can use it on a small distance
traveler and it is environment friendly. Our project involves lots of technical subjects as
mentioned earlier Its being a good experience to feel both theoretically and practically

20

REFERENCES

www.segway.com
en.m.wikipidia.org/wiki/wheel
en.m.wikipidia.org/wiki/sprocket
en.m.wikipidia.org/wiki/motor
en.m.wikipidia.org/wiki/ segway_pt
en.m.wikipidia.org/wiki/12_volt_battery

21