CHAPTER 1

I N T R O D U C T I O N TO S E G WAY
1 . 1 S E G WAY O R H I - T E C H S C O O T E R
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.

Figure 1.1: Segway model

Motor-scooter like device

Powered by electric motors

Movement by shifting weight, turning wrist

Turning radius of zero

Designed by inventor Dean Kamen (150 patents)

Max speed 10.0 - 12.5 mph

Maximum distance 14 - 17 miles (single charge)

Device weighs 69 - 95 lbs

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).
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.
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.
When Dean Kamen unveiled the Segway on ABC's "Good Morning America," he
described the machine as "the world's first self-balancing human transporter."
When you look at the machine in motion, you get an idea of what he's talking
about.
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.
1.2 EARLIER STAGE OF SEGWAY

Figure 1.2: Earlier Balancing method

In an earlier stage of man trying to stand with their own
balancing capability, but day by day improvement attains segway to balance with
the help of sensor in it to increase the speed of motor.
VARIOUS SERIES IN SEGWAY
e series - Expeditor (cargo)
i series - Industrial (business)
p series - Personal (consumer)
For example i-series which is used in military is shown below:

Figure 1.3: HT il80 segway

Figure 1.4: Parts of HT il80 segway

1.3 BALANCING CONCEPT :
This balancing act is the most amazing thing about the Segway, and it is
the key to its operation. To understand how this system works, it helps to consider
the human body.
EXAMPLE: (Human Body)
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.

Figure 1.5: Balancing segway

S E G WAY S A M E AS H U M A N
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.
CHAPTER 2
SEGWHEELS

2.1 INTRODUCTION:
The first problem with the Segway is the price. This technology is
not affordable to low-income individuals. The biggest market for the Segway
would be college students, however, this market has not been tapped into.
University campuses are usually big and getting from one class to the next and
back to dormitories can be a long distance when one has to walk, but college
students cannot afford to buy the Segway for their use. The solution to this
problem is for manufacturers to use cheaper but safe technology in order to
decrease the price. A second problem is lack of advertising; few people know about
Segway dealerships, the cost and the great invention that it is, the solution would
be to advertise more. The Segway is not only a great innovation, but it is also
environmental friendly since it is fully electrical and does not release any
emissions and this would appeal to a lot of people if they knew it existed. The final
problem with the Segway is that the technology is so new and when it breaks down
the manufacturers are forced to recall all Segways and this can be costly. Unlike
cars where there is an abundant of mechanics to fix them when they break down,
the Segway does not enjoy the same benefit, the solution to this problem would be
to provide users with very simplified manuals and an excellent technical support
team that can be easily reached by dialing a toll free number.
The Segway has a bright future, because after most of the problems
are taken care of, it will eventually be widely used and accepted as a form of
transportation that is better than the bicycle. Some of the improvements in the
future would be the addition of an umbrella that is attached to the handlebars and
can be opened at a touch of a button. Segways will be modified to transport more
than one person, there will be room for a passenger. Also, the manufacturers will
make smaller Segways for young kids, Segways with retractable covers to shield
the user from bad weather and proper nightlights so it can be safely used twenty
four hours a day. Lastly, when the Segway is widely used there will have to be
Segway lanes for the riders.
The Segway is still in the stage of interpretative flexibility, as per Bjiker's
theory of Social Construction of Technology (Bjiker, 1995). Society is going to
play a major role in creating the best and safe Segway.
In conclusion, it is only after the Segway passes this phase of interpretative
flexibility will it reach closure and stability. It is after this last stage that the
diffusion of this technology will take place in a big way. The best way for this

diffusion to take place is by using opinion leaders via the wide range of media
available to us (Rogers, 1995).
2.2 MAIN OBJECTIVE:
The starting price of any type of segway is above Rs
2,00,000/-. It is suitable only for high class people. In a country like India where
high class people are short in number compared to middle class and low class
people, it is not preferable. If it available for low cost it will be preferred by all.
That is the ultimate aim of our project.
To make a segway with a cost around of Rs 10,000/-. We
named it as segwheels or human transporter or homemade segway.
2.3 SCOPE OF PROJECT:
The scope of the project is as follows,
1. To study about the manufacturing and fabrication process of Segway
2. To build segway with self balancing with relatively very low cost.
CHAPTER 3
COMPONENTS AND SPECIFICATIONS
3.1 COMPONENTS USED IN SEGWHEELS
CHASIS
Chasis is made of wooden block and four wooden blocks are used to
make the frame. To make chasis to be balanced,four wooden blocks of equal
weights are used. It is engaged firmly with the help of stud . Stud is to connect the
wooden block together with the nut. Wheels are attached to the middle of frame in
order to withstand the load capacity. Handle is also made of same wood to which
DPDT switch is fixed.
MOTOR
Motor is fixed with the chasis through screwed bolt and it is the
main source of power with is to drive the vehicle. There are two motors , each for
one wheel. Each motor is driven by a separate 12v battery.
CHAIN DRIVE

Chain drives are used to transmit power between motor and wheel. Type of
chain used is Power transmitting chains (Bush Roller Type).

Chain drives are used because it has the following advantages:

No slip
Occupy less space
High transmission efficiency
Highly preferable for small shaft distance

STUD &NUT
A stud is a round bar threaded at both ends . Stud is a screwed rod to
connect the wooden block together in order to make the chasis.
BATTERY
Battery is a main power source. Two 12V-DC battery is used in segwheels.
Each battery is connected with each motor. Battery supplies power to each motor
to run the wheels. Battery is rechargeable whenever necessary.
DPDT SWITCH
Double Pole Double Throw (DPDT) switch. It is used to guide the direction
of rotation of motor shaft. By operating the switch the direction of vehicle can be
controlled. Connecting wires are used to connect switch with motor.
WOOD
The type of wood used to make frame is COUNTRY WOOD. Four
wooden blocks are jointed with the help of stud and screwed with bolts. Motor and
battery are mounted on frame with help of screws.

3.2 SPECIFICATIONS
MOTO
R

Speed

: 375 rpm

Voltage
: 20V
Motor type : Gear headed motor
Figure 3.1: Motor
CHAIN DRIVE
Links
: 46
Length of chain : 552mm
Centre distance :

180mm
Figure 3.2: chain drive
STUD
Length
: 76cm
Diameter : 9mm
Pitch
: 1.25mm
Figure 3.3: stud

NUT
Inner dia : 10mm
Outer dia : 20mm

Figure 3.4: Nut

WOODEN BLOCK
Length
: 500mm
Width
: 60mm
Thickness : 20mm
Figure 3.5: wooden block

BATTERY
Volts
: 12V
Current : 5A
Figure 3.6: Battery
3.3 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 so that
Table 3.1 : COMPARISON OF EXISTING WITH NEW SYSTEM:
S.NO

HI-TECH SEGWAY

SEGWHEELS

1)

Consists of hi-tech motors,

sensors,gear transmission etc.,

Consists of motors, chain drives,etc.,

2)

System is complicated due to more

number of parts.

System is not so much complicated.

3)

Cost is very high.

Cost is low.

4)

Used for any purpose (millitary,

offices,etc.,)

Used for home purpose , universities

etc.

5)

High speed

Low speed

CHAPTER 4
ECO-FRIENDLY
As a leader in two-wheeled electric mobility, it's always been Segway's
vision to produce environmentally friendly short-distance transportation
alternatives. Today, more and more people are using the Segway PT as a purelyelectric eco-friendly alternative for many of the short journeys that are typically
made by car. In fact, The EPA estimates that Americans take 900 million car
journeys every day, but did you know that half of these trips are less than five
miles long and are by solo drivers? Here is what would happen if you replaced
some of those car trips with a Segway PT:
If we are able to replace 10% of 900 million 3 mile car trips with an ecofriendly Segway PT there would be:
6.2 million fewer gallons of gas consumed.
286 million fewer pounds of CO2 emitted everyday.
The Segway PT has many benefits for you and the environment: less gas to
buy, easier to park, and less wear on your car. It can also help reduce the impact of
global warming by reducing our greenhouse gas output and consumption of
imported fossil fuels. Read our whitepaper for a detailed look (PDF).
Zero-emissions are given off during operation, allowing you to go indoors
with your Segway PT. It does draw electric power during recharge, but that
electricity causes fourteen times less greenhouse gas emissions (PDF) than driving
a car. After one year on your Segway PT you would have literally saved a ton of
CO2 from being released into the atmosphere. (in fact it's probably more than that,
a ton is based on average MPG, while most short distance driving results in much
lower mileage.)
When gliding on a Segway PT, you're doing more than just shifting your
consumption from petroleum to electric. Everything about the PT was designed to
use electricity as efficiently as possible. When you dig a little deeper, and compare
the source fuel (petroleum vs. the fuel mix used to produce electricity), plus the

cost of distributing or transporting the power, the Segway PT is eleven times more
efficient than the average American car, and over three times more efficient than
even the highest-mileage scooters.
ROLE OF THE SEGWAY PERSONAL TRANSPORTER (PT) EMISSION
REDUCTION AND ENERGY EFFICIENCY
In December 2001, renowned inventor Dean Kamen unveiled the
Segway
Personal Transporter (PT). Since then the way society looks at transportation has
changed considerably. Fuel prices have risen, there is a greater awareness of the
damage caused by carbon dioxide and other greenhouse gas emissions, and
environmental and political forces have de-stabilized the global petroleum
Supply .The Segway PT can help reduce dependence on foreign oil, use the
existing energy supply more efficiently, and reduce pollution. Drivers in the United
States take approximately 900 million car trips per day. The EPA estimates that
half of those trips are less than five miles long and transport only one passenger
trips perfectly suited to the Segway PT. As there are many forms of powered
transportation available today, this paper seeks to compare their relative impact on
the environment, both in emissions created and energy consumed .The methods for
computation are explained in detail in the following sections, but let us first present
a summary of statistics regarding the relative emissions output and energy
efficiency of the Segway PT compared to other well-known transportation devices.
The Segway PT does not produce any emissions during operation. Its
batteries do consume electricity during recharge, and we have used the emissions
created during the generation and delivery as the basis of our analysis. By
comparing this to the emissions generated during the refinement, transportation
and combustion of automotive fuel, we can compare the Segway PT to traditional
internal combustion engines. This analysis also allows us to measure relative
source fuel efficiency.
Table 4.1: COMPARISON OF EMISSION AND ENERGY CONSUMED
Emissions Output Summary

Energy Consumption Summary

Operating a Segway PT creates:

The Segway PT is:

5.6 times less greenhouse gas per mile 4.5 times more energy efficient than a
than a Toyota Prius (82% reduction)
Toyota Prius
14 times less greenhouse gas than the 11 times more energy efficient than the
average American car (93% reduction)
average American car
20 times less greenhouse gas than a large 17 times more energy efficient than a
Sport Utility Vehicle (SUV) (95%
large SUV
reduction)

Safety measurement :
Know the Knows of the Segway PT:
Know how the machine operates
Know your riding environment
Know to wear a helmet and to use good judgment while riding
No knows = No rides

CHAPTER 5
COST ANALYSIS
TABLE 5.1: COST DETAILS OF SEGWAY
Components

Cost (Rs)

Gear head motor (Nos=2)

4000

Wheels (Nos=2)

600

Frame materials(wood)

600

Battery(Nos=2)

1000

Chain drives (Nos=2)

200

Sprocket (Nos=2)

500

Stud

100

Extras parts

100

Fabrication

400

Total

7500

CHAPTER 6
DESIGN CALCULATIONS
STUD
Compression or crushing stress on threads: The compression or crushing stress
between the threads (c) may be obtained by using the relation :
c=P/[d2-dc2]n
d = Major diameter=9mm
dc = Minor diameter=7mm
n = Number of threads in engagement=7
c=18.16N/mm2
from PSG Design Data book, page no: 1.9,

Assume C45 steel for Stud material

(c)allowable = 710 Mpa
c < (c)allowable
Therefore, design is safe.
Diameter of Stud = 9mm
From DDB , (coarse series),
Core dia of thread corresponding to M9 is dc = 0.84d
dc= 7.56 mm
load is given by,
P = 1420d = 12780N
P = /4(d/c)2 * t
t = 284.70 N/mm2
t =284.70 MPa
from PSG Design Data book, page no: 1.9,
Assume C45 steel for Stud material
(t)allowable = 710 Mpa
t < (t)allowable
Therefore, design is safe.
CHAIN DRIVE
D= Diameter of the pitch circle=24mm
T1 = Number of teeth on the small sprocket=12
T2= Number of teeth on the large sprocket=18
d1=Dia of chain roller=8mm
p= pitch of the chain=12mm
Length of the chain L= K.p
Number of chain links K={( T1+T2)/2}+(2x/p)+[(T2-T1)/2]2. p/x
K =46
L=46*12=552mm
Length of chain L=552mm

CHAPTER 7
CONCLUSION:
In the course of this project, the design and fabrication of segwheels was
done. The attempt to change the existing design of hi-tech Segway was
successfully completed.
This project was implemented with an idea to find an effective solution to
transportation problem. The main objective is to achive space utilization and
minimise the fuel consuption especially for commuting over shortest distance.
By list survey, the basic concept of segwheel is studied