B6 Report
B6 Report
Project Report
on
“DESIGN AND ANALYSIS OF SOLAR POWERED
ELECTRIC VEHICLE”
Submitted in partial fulfillment of the requirement for the award of
the degree of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
by
JESWIN BIJU 4JK19ME019
NITHIN P. 4JK19ME032
SHARVARI 4JK19ME045
Under the Guidance of
DR. SREEJITH B. K.
Associate Professor
CERTIFICATE
Certified that the project work entitled “DESIGN AND ANALYSIS OF SOLAR
POWERED ELECTRIC VEHICLE” carried out by JESWIN BIJU (4JK19ME019),
NITHIN P. (4JK19ME032), and SHARVARI (4JK19ME045), the bonafide students
of A.J. Institute of Engineering and Technology in partialfulfillment for the award of
Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya
Technological University, Belagavi, during the year 2022-2023. It is certified that all
corrections/suggestions indicated for Internal Assessment have been incorporated in the
Report deposited in the departmental library. The project report has been approved as it
satisfies the academic requirements in respect of Project Work prescribed for the said
Degree.
1.
2.
DECLARATION
SHARVARI 4JK19ME045
I
ABSTRACT
With the increased trends of industrialization and global economic growth leading to the
ever-changing petrol prices and other price hikes, private transport system has become a
costly affair. All these problems can be addressed with innovation. One of the most feasible
solutions is turning towards renewable energies to solve the issues i.e., increasing the use of
renewable energies like solar power in the place of fossil fuels. Everyone’s dream of owning
a commercially viable solar vehicle is slowly becoming a reality. Electric vehicles are now
available at an affordable price. This opportunity is taken towards the design of a Solar
powered Vehicle Designing a solar vehicle is a multidisciplinary subject that covers the
broad and complex aspects from various subjects. In this Vehicle, solar panel is used as the
power source and developed voltage, stored in the battery, is used to the drive the permanent
magnet DC motor which drives the rear wheel of the vehicle.
II
TABLE OF CONTENT
ACKNOWLEDGMENTS ..........................................................I
ABSTRACT ............................................................................... II
LIST OF FIGURES.................................................................. IV
CHAPTER 6 CONCLUSIONS……………………………………… 52
REFERENCES………………………………………... 53
APPENDIX 1 Working……………………………………………….. 55
III
LIST OF FIGURES
FIGURE NO. FIGURE NAME PAGE NO
4.5 Properties 10
IV
4.18 Maximum Deformation of 0.9167mm 18
4.26 Creating diagonal support at the corner edge of the chassis base 22
V
4.37 10 kg load applied on the back side of the structure 37
VI
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
CHAPTER 1
INTRODUCTION
The quests for an everlasting, safer, cleaner and an environmental-friendly fuel is never-ending. The
carbon-based fuels, like the fossil fuels that are widely used nowadays are unsustainable and unsafe.
They pose a serious threat to the environment. The best alternatives to these are renewable energy
sources like the sun, wind, tides, hydropower and biomass. Amongst these elements, solar power is
the most preferred since it could provide the cleanest sustainable energy for the longest duration of
time – at least for the following few billion years. Photovoltaic production doubles every two years
globally; it has increased by a mean of 48 percent annually ever since 2002. Thanks to its
innumerable benefits with regards to the environmental, economic and social aspects, PV systems
have become the world’s fastest-growing energy technology. It can be said that the sole limitation
to alternative energy as an energy source is our understanding of developing efficient and cost-
effective technology which must be used for the implementation. Nothing on this planet comes free
of cost, but what we could find the simplest way to implement free rides. Indeed it'd be wonderful
if our two-wheelers could still run without us having to spend billions on fossil fuels each year and
to pander to natural hazards that their combustion leave behind. If we could drive a solar-powered
vehicle, that dream would come true.
A solar vehicle would harness energy from the sun via solar panels. A solar panel is nothing but a
packaged, and connected assembly of solar cells also called the photovoltaic cells which are the
solid-state devices that use quantum mechanical transitions to convert the available solar power
directly into the needed electric power. they're noise-free and pollution-free with no rotating parts
and requiring minimum maintenance. The electricity thus generated is used to run the vehicle’s
motor by storing it in the battery. Thus, we get a vehicle driven electrically which travels on “free”
energy with no harmful emissions, which could utilize its full power at all speeds and would have
extremely little maintenance costs. The planet Earth has awfully limited amount of energy resources
which would soon become extinct. Fortunately, population models have suggested that the world's
population will level out at two to three times the current numbers over the subsequent hundred
years. The demands of the population increase as the total population count increases. The lingering
question is whether the earth's resources will be sufficient to sustain the earth’s population with a
high standard of living for all. Energy is the key issue in this.
Now-a-days, people dealing with natural resources like fuel, coal etc. face a tough time to stay at
pace with the increasing demand. At one hand, there are more cars and motor vehicles, dominating
the transport medium, while on the opposite hand these vehicles are being dominated by the fuel.
As a result, the limited resources are being quashed by the producers and dealers to satisfy this need
which is leading us to an uncertain future with the scarcity of fuel and minerals. So, it's clear that
present trends in energy consumption, especially oil, can't be sustained for much longer. Also, these
are the most contributing factors for global warming, environmental imbalances, depletion of the
ozone layer, etc., which eventually challenges the survival of humans. The fossil fuels also play the
antagonist role with regards to global warming. Therefore, under this circumstance, it's quite
necessary to create a brand-new exploration of natural resources of energy and power.
The question now is the need for exploration when the resources are right in front of our eyes. They
are effective, less costly and specially, they are an endless source of energy. With greatly improved
energy efficiency, a transition to the present energy-based economy capable of sustaining the
anticipated growth within the world economy is feasible. This effective source is ―Solar Energy.
This work focuses on designing a solar powered vehicle aiming to tackle the issues that are related
to pollution and shortage of fuel. When a solar powered vehicle is considered, it removes the burden
of vehicle maintenance of the shoulders while ensuring both the safety and comfort for drivers as
well as passengers Delhi, the capital city of India is one of the most heavily polluted cities in India.
Recent study shows that pollution caused by the road dust and vehicles account for about 50% of
total pollution of the city. Numerous solutions were proposed to face this which mainly includes
afforestation and restriction on the usage of the vehicles.
CHAPTER 2
LITERATURE REVIEW
I. Journal of Physics: Conference Series 2070 (2021) 012105 IOP Publishing
doi:10.1088/1742-6596/2070/1/012105 Arulious Jora A , Earlina D , Harish D , Sakthi
Priya P , Inba Rexy A , Nancy Mary J S
Design Of Solar Powered Electric Vehicle
In this Paper the presented results as well as the design for a solar powered vehicle makes
the usage of these vehicles feasible and practicable in developing countries. The solar
powered electric vehicle using a PMDC motor is a good choice for the Indian market. The
solar powered electric vehicle stands with higher safety, high performance as well as
remains cost efficient. Use of charge controller and speed controller in the vehicleimproves
the efficacy of power system. The presented eco-friendly solar powered electricvehicle can
be a good choice for future generations.
II. International Research Journal of Engineering and Technology (IRJET) e-ISSN:
2395-0056 Volume: 08 Issue: 08 | Aug 2021Suraj Kumar1, Ravi Girgoswami2,
Abhishek Shukla3, Pranit Shinde4, Mr. N.T. Rathod5
Design And Analysis of Chassis For Electric Vehicle
• This document focuses on the design and analysis of the electric Eco-Drive chassis.
• The main goal is to use static and modal analysis to evaluate chassis deformation to
reduce weight and improve vehicle performance in challenging low energy races
• The 3D modelling and FE analysis of the chassis was done using Catia V5 software. The
main framework is the focus of this analysis.
un-laden (without passengers that is the KERB weight of the vehicle) condition and the
laden (with passengers and miscellaneous weight also called gross weight) condition
• Analysis had resulted with various variables of stress indicating the stress levels minimum
in unladen case as 3.00E-17 and maximum in laden case as 29.8662, in case of space frame
analysis the stress in minimum for steel with laden chassis as 0.001558 and maximum in
case of composite material as 7.8447.
• These results would be useful with in selection of material for automotive frames.
solar panel and a battery to store the electrical itality. The sun based cells gather a bit of
the sun's vitality and store it into the batteries of the solar based vehicle. After the vitality
is stored in the batteries, it is accessible for use and the engine and controller is made to
drive the vehicle.
v
Department of Mechanical Engineering, AJIET, Mangaluru
5
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
v
Department of Mechanical Engineering, AJIET, Mangaluru
6
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
CHAPTER 3 OBJECTIVES
v
Department of Mechanical Engineering, AJIET, Mangaluru
7
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
CHAPTER 4
METHODOLOGY
DESIGN
v The planned Chassis Design was executed in CAD modelling software FUSION360
.
v The Pipe Command was Applied to the Sketch with Specific Properties like
CircularSection (25mm Dia) with Section Thickness of 2mm.
v After Inserting Pipe Command Required Material was Selected Galvanized Steel was Selected
as Chassis Material. The Purpose of Choosing 1 inch GI Pipe was because it had lot of
Advantages like Cost Effectiveness Long Life Reliability and So on.
v Further Material Properties was Updated It was noted that The Overall Weight of Chassis was
Found to be 36kg.
Area=1.467×106mm2
Density=8×10-6 g / mm3
Mass=36.70kg
Volume=4.676×106 mm3
Physical Material-Steel
Appearance-Steel - Satin
Bounding Box
Length = 1925.40 mm
Width =1125.40 mm
Height =388.10 mm
ANALYSIS
v Static analysis done by applying load of 100kg and the following results are obtain as shownin
below:
v Due to the unsafe design structure the redesign of the tubular chassis is done as shown in below.
REDESIGN
v The chassis design was first drawn in A4 sheet with required length, width and height.
v Further the design was executed in Fusion 360 which is CAD modelling software with
specified dimensions.
v The Pipe Command was Applied to the Sketch with Specific Properties Specific
Properties like Circular Section (25mm Dia) with Section Thickness of 2mm.
v After Inserting Pipe Command Required Material was Selected. Galvanized Steel was
Selected as Chassis Material. The Purpose of Choosing 1 inch GI Pipe was because it had
lot of Advantages like Cost effectiveness Long Life Reliability and So on.
14
Department of Mechanical Engineering, AJIET, Mangaluru
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
Area=4.664×106 mm2
Mass=35.90 kg
Volume=4.572×106 mm3
Physical Material=Steel, Galvanized
Bounding Box
Length = 2425.00 mm
Width = 1026.129 mm
Height= 1025.00 mm
Center of Mass=169.576 mm, 268.221 mm, -0.012 mm
v Static analysis was done on the chassis by applying the constraints a load of 140 kg.
v It was observed that the maximum deformation of 0.9167mm was obtained with
maximum stress of 39.54Mpa
v This concluded that chassis design was safe.
Fig 4.17: Maximum and Minimum stress distribution along the chassis
Fig. 4.19: Maximum and Minimum stress distribution along the chassis
v As it was observed that the suspension mounts were unable to mount on the chassis
and in order to make the Chassis Stiffer and Increase the Load withstand Capacity
the section thickness of the base pipe was changed from 25mm to 50mm
Fig 4.21: Modified Structure of the base from the Top View
v As like the Normal Cars at the back bottom leaf spring suspension mounts
were provided and coil spring suspension mounts were provided at the front
bottom of structure.
Fig 4.22: Leaf Spring suspension at the back bottom Fig 4.23: Coil spring suspension
at the front
v At the back bottom leaf spring suspension support was provided While at the front bottom coil
spring suspension support was provided as a result of increasing the strength of the base the
deformation decreased to 0.3421mm
Fig. 4.25: Maximum and minimum stress distribution along the chassis
v It was found out that the maximum stress distribution happened at the corner
edges of the chassis hence in order to minimize this support fixture were given at
the edges.
Fig 4.26: Creating diagonal support at the corner edge of the chassis base
MESH
Solids 1
MATERIALS
MESH
LOAD CASE 1
CONSTRAINTS
v The Constraints were applied at the Front and Back bottom of the Suspension
mounts
Type Fixed
Ux Fixed
Uy Fixed
Uz Fixed
LOAD: FORCE 2
v Further Increased the load acting on the base of the chassis by applying 200kg
Type Force
Magnitude 1961 N
X Value 0N
Y Value -1961 N
Z Value 0N
LOAD: FORCE 2
v Applied a load of 6kg at the top of the chassis indicating the weight of solar panel
being installed
Type Force
Magnitude 58.86 N
X Value -10.22 N
Y Value -57.97 N
Z Value 0N
v As the Stress obtained is 36.92MPa which is less than Yield strength of the Material
which is 207MPa the Design is considered Safe
Z -0.0352 mm 0.03203 mm
Reaction Force
Total 0N 160.6 N
X -114.7 N 66.86 N
Y -59.51 N 137.8 N
Z -82.36 N 85.52 N
Strain
Equivalent 1.372×10-8 3.149×10-4
1st Principal -7.456×10-6 2.978×10-4
3rd Principal -2.6×10-4 1.42×10-5
Normal XX -8.695×10-5 9.864×10-5
Normal YY -1.004×10-4 1.82×10-4
Normal ZZ -1.04×10-4 1.157×10-4
Shear XY -1.699×10-4 1.372×10-4
Shear YZ -2.401×10-4 2.07×10-4
Shear ZX -8.34×10-5 9.185×10-5
Contact Force
Total 0N 0N
X 0N 0N
Y 0N 0N
Z 0N 0N
Fig 4.33: Leaf spring suspension at both front and back bottom
MESH
Solids 1
MATERIALS
MESH
Type Nodes Elements
CONSTRAINTS
Type Fixed
Ux Fixed
Uy Fixed
Uz Fixed
Fig 4.34: Constraints applied at the front and back suspension support
LOADS
FORCE1
v By considering weight of passenger as well as the components.
Type Force
Magnitude 4905 N
X Value 0N
Y Value -4905 N
Z Value 0N
FORCE2
v Due to the circumstances two solar panels are mounted at the top as well asat
the back
v Hence load of 10kg was applied on the top as well as at the back.
Type Force
Magnitude 98.1 N
X Value -17.03 N
Y Value -96.61 N
Z Value 0N
Magnitude 98.1 N
X Value 75.14 N
Y Value -63.07 N
Z Value 0N
Fig 4.37 :10 kg load applied on the back side of the structure
Z -0.04847 mm 0.05285 mm
Reaction Force
Total 0N 112.6 N
X -42.39 N 51.93 N
Y -60.71 N 93.32 N
Z -49.42 N 68.9 N
Strain
Equivalent 5.421×10-9 5.392x04×10-4
1st Principal -2.591×10-5 3.567x04×10-4
3rd Principal -6.004×10-4 8.907x06×10-6
Normal XX -1.76×10-4 9.997x05×10-5
Normal YY -3.698×10-4 2.771x04×10-4
Total 0N 0N
X 0N 0N
Y 0N 0N
Z 0N 0N
Ø Front axle carries the weight of front part of the Automobile, as well as facilitates
steering and absorbs shocks due to road surface variations.
Ø The front axle is designed to transmit the weight of the Automobile front the spring to
the front wheels, turning right and left as required.
Ø Hence proper design of front axle beam is extremely crucial
v The Front Axle was Designed in FUSION 360 with appropriate Dimensions
Bounding Box
Length :715.000 mm
Width :102.000 mm
Height :50.000 mm
MESH
Solids 1
MATERIALS
STEEL,MILD
LOAD CASE 1
CONSTRAINTS
Ø Constraints were applied to bottom plate where the leaf spring mounts which is the
support for axle
Type Fixed
Ux Fixed
Uy Fixed
Uz Fixed
LOADS
FORCE1
Ø Since 50% of the Chassis load acts on the Front axle a load of 250kg which is half the load
applied to chassis is applied at both ends of the Front Axle.
Type Force
Magnitude 2452 N
Y Value 0N
Z Value -2452 N
Total 0N 0N
X 0N 0N
Y 0N 0N
Z 0N 0N
Ø As the Stress obtained is 2.361MPa which is less than Yield strength of the Material
which is 207MPa the Design is considered Safe.
CHAPTER 5
RESULT
A load of 4905N was applied to base indicating The weight of all the components and
passenger weight acting on it and load of 98.1N was applied at the top and rear structure of
the chassis indicating the weight of the solar panel installed at the rear and top, it shows that
no critical or dangerous point happens at the chassis structure.
Driver position is in a safe condition after analysis, the result shows that the driver cage is not
in critical damage. If the red colour sign appears on the chassis structure, it means the structure
has a maximum von misses stress or maximum translational displacement vector. In addition,
there have various factors to be considered such as the selection of material, restraint, and load
before applied to the FEA analysis.
Obtained optimum result from the analysis of the chassis are maximum stress=83.74MPa, and
total displacement=1.158mm at top of the chassis and displacement of 0.25 at bottom of the
chassis
From the results of the analysis, it shows the yield strength of the material is 207MPa. The
maximum point of the analysis is 83.74MPa and the minimum point is 0MPa. According to
the maximum and minimum points, stresses from the analysis is below the yield strength of
the material used. It means chassis structure in a safe condition after placing load on the
chassis.
According to the analysis that been done on the Front Axle, the results shows that no critical or
dangerous point happens at the axle structure.
A load of 2452N was applied at both ends of front axle and static analysis was performed which
shows that the axle is in a safe condition. Obtained optimum results from the analysis are the
maximum stress= 2.36MPa and total displacement= 1.418x10–⁴mm.
From the results it shows the yield strength of the material is 207MPa. The maximum point of the
analysis is 2.36MPa and minimum point is 0MPa. According to the minimum and maximum point,
stresses from the analysis is below the yield strength of the material used, Hence the axle is in a
safe condition after placing the load
CHAPTER 6
CONCLUSION
• The Results and analyzation show that the Safe chassis structure depends on the
stresses in that particular frame and also its stiffness.
• The obtained optimum result from the analysis is maximum stress=83.74MPa, and
total displacement=1.158mm at top of the chassis and displacement of 0.25 at bottom
of the chassis.
• And obtained optimum result from the analysis of the Front Axle are maximum
stress=2.361MPa, and total displacement= 1. 279x104mm
• As compared to that of the yield point of the material, the obtained theoretical results
above are very much lesser which means the Design is Safe
• This indicate that the Designed Chassis and Front Axle Satisfy the Safety
Requirements needed to Fabricate the Solar Powered Car
REFERENCES
https://www.academia.edu/15860808/Design_Analysis_and_Optimization_of_a_Multi
- Tubular_Spaceframe
5. International Journal of Recent Technology and Engineering (IJRTE) ISSN: 2277-3878,
Volume-7 Issue-4S, November 2018, Sasikumar C, Aswath C, Surendrakumar K,
Suryaprakash A .
https://www.ijrte.org/wp-content/uploads/papers/v7i4s/E2042017519.pdf
7. 2nd Joint Conference on Green Engineering Technology & Applied Computing 2020
IOP Conf. Series: Materials Science H Radhwan1 , Z Shayfull, S M Nasir, Abdellah
el-hadj Abdellah and A R Irfan
https://www.researchgate.net/publication/342848652_Design_and_Analysis_of_Sola
r_Car_Chassis
TEA M ME M
APPENDIX-I
Working
55
Department of Mechanical Engineering, AJIET, Mangaluru
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
APPENDIX-II
TEAM MEMBERS
Email ID : [email protected]
Name : NITHIN P
: Parayanthil house Muthukuda (PO) Pattuvam ,Kannur,
Address
Kerala 670141
USN : 4JK19ME032
Phone No. : 9747055431
Email ID : [email protected]
Name : SHARVARI
Address : Bangera Garden Ashoknagar , Mangalore 575006
USN : 4JK19ME045
Phone No. : 9141061259
Email ID : [email protected]
56
Department of Mechanical Engineering, AJIET, Mangaluru
DESIGN AND ANALYSIS OF SOLAR POWERED ELECTRIC VEHICLE
56