ABSTRACT

ABSTRACT
This project relates to the find out the location of defects in the cracks in the
metal. In our venture “METAL CRACK DETECTOR” creatures with a prologue to
track Inspection and it’s different applications. The sensors are utilized to
recognize the split in the track naturally and this flag is given to caution unit. This
is an exceptionally proficient strategy for checking the splits in the railroad track
and this is to be utilized as a part of present-day designing ventures. The manual
endeavours can be totally kept away from by utilizing this advanced gear.
INTRODUCTION
 CHAPTER 1

INTRODUCTION

A crack is the separation of an object or material into two or more pieces

under the action of stress. The fracture of a solid usually occurs due to the
development of certain displacement discontinuity surfaces within the solid. If a
displacement develops perpendicular to the surface of displacement.
Automation has touched every aspect of our daily life. More and more
advancement is being introduced in almost each and every field to reduce human
efforts and to save time. Thinking about the same we are trying to introduce
automation in the field of railway track inspection system. Railway track form a
very critical part of any company’s asset base, as it provides them with the required
business operability. The mishaps taking place due to problems in the railway track
need to overcome.
1.1 Introduction to metals
Iron machines and materials are used in most of industries for manufacturing
products. In industries these iron materials come into contact with humidity and
pollution, therefore increases the rusting of iron. Corrosion takes place when the
mechanical materials come into contact with humidity and pollution in industries.
Due to the attack of the corrosion, these mechanical materials undergo the fatigue
that affects the integrity of the metallic surfaces. This rusting caused by corrosion
causes wastage of iron materials, reduction inefficiency and costly maintenance.
Different departments make use of materials that are made up of iron. In Civil
department, for maintaining the good quality of steel bridges, it is important to
detect rust defects in advance. By detecting rust defects in advance, with these
bridge managers can make important decisions whether to paint bridges
immediately or later .

1.2 Metallic contents:

Metallic objects like dental implants, surgical clips, or steel-hip prostheses
lead to severe shadow and streak artifacts in CT images that superimpose the
structures of interest and deteriorate image quality. The reason is that metallic
objects have a very high density in the human body, which creates a barrier to the
transmitted x-ray beam during CT examination. It results a lack of data in the
projection data that lead to the production of streak in CT images. This photo
deficiency caused by metallic object would become more severe under low dose
scanning. During the last decade, many approaches have been proposed to reduce
these artifacts. These methods can be roughly classified into iterative and
interpolation-based methods. If material is heated with infrared radiators, the
temperature of the surface will rise suddenly.
1.3 Characterization of cracks
Crack detection in concrete can be easily performed by using water for
contrast enhancement. The surfaces to be investigated can either be watered from
the surface or from the back. In the latter instance, water appears at the surface by
capillary moisture transport through the crack. As water has a higher emissivity
than concrete, the crack can be detected by an infrared camera directly or, with
better contrast, through the reflection of additional infrared radiation, which is
projected onto the surface.
1.4 Manual Detection
Transport is a key necessity for specialization that allows production and
consumption of products to occur at different locations. The recent trend used by
the Indian railway is manual inspection of this railway track which requires much
of man power and consumes time. Our project finds its main application here. This
vehicle would run over the railway tracks inspecting the tack and finding the fault
if any. With the introduction of such and automated vehicle we are trying to reduce
the human efforts, save time and provide a much accurate and precise output.
1.5. Effects that influence Metal Defects and Failure
There are two causes of cracks in metal i.e. Natural and Artificial. Natural
causes are like weather, floods, cyclone, landslides etc. Artificial causes are like
manmade, acts of load based on its application etc.
Detection and maintenance of rail defects are major issues for the rail
community all around the world. The defects mainly include weld problems,
internal defects worn out rails, head checks, squats, palling and shelling,
corrugations and rolling contact fatigue (RCF) initiated problems such as surface
cracks.
One effect that can cause crack propagation is the presence of water and
other liquids. When a fluid fills a small crack and a train passes over, the water
becomes trapped in the void and can expand the crack tip. Also, the trapped fluid
could freeze and expand or initiate the corrosion process.
1.6 Techniques used for Identification of Damages
In general, there exist two main categories of techniques excitingly used for
damage identification and condition monitoring of railway tracks. These include:
 Non-destructive testing
  Graphical inspections

1.7 Non-Destructive Testing

Such as acoustic emissions or ultrasonic methods, magnetic field methods,
radio graphic, eddy existing techniques, thermal field methods, dye penetrate fiber
optic sensors of various kinds.

Fig 1.1 Non-Destructive Testing

 Non-destructive testing (NDT) is a testing and analysis technique used by
industry to evaluate the properties of a material, component, structure or system for
characteristic differences or welding defects and discontinuities without causing
damage to the original part.
It is a wide group of analysis techniques used in science and technology
industry to evaluate the properties of a material, component or system without
causing damage.
1.8 Graphical inspections
Graphical inspection is the primary technique used for defect identification
in tracks, and is effectively used in specialized disciplines. This method can be
costly, time consuming and ineffective for large and complex structural systems.
Understanding the Basics covers the process and technology of inspecting
metal parts, with emphasis on final part inspection at the manufacturing facility or
on receipt at the user's facility. The unique feature of this book is that it provides an
intermediate level introduction to the different methods used to inspect metals and
finished parts and a more detailed review of the specific inspection methods for
important metal product forms.
 Fig 1.2 Graphical Testing

It is a process or procedure used to check composition of an unknown

metallic substance. There are destructive processes and nondestructive
processes. Metal testing can also include, determining the properties of newly
forged metal alloys. This type of testing is nondestructive. Visual inspection
provides a means of detecting and examining a variety of surface flaws, such as
corrosion, contamination, surface finish, and surface discontinuities on joints (for
example, welds, seals, and solder connections). Visual inspection is also the most
widely used method for detecting and examining surface cracks that are
particularly important because of their relationship to structural failure .
LITERATURE REVIEW
 CHAPTER 2
LITERATURE REVIEW

Iyer et al. have designed a three-step method for the crack detection from
the high contrast images. The proposed method detects the crack like pattern in the
noisy environment using curvature evaluation and mathematical morphology
technique. It was based on mathematical morphology and curvature evaluation that
detects crack-like patterns in a noisy environment. In their study, segmentation is
done defining the crack like pattern with respect to a precise geometric model.
Nondestructive examination (NDE), or nondestructive testing (NDT), are a number
of technologies used to analyze materials for either inherent flaws (such as
fractures or cracks), or damage from use. Machine vision emerged as an important
new technique for industrial inspection and quality control.

Sinha et al. have investigated the cracks by using the two-step approach.
They have developed a statistical filter design for the crack detection. After the
filtering, they have got to the two-step approach at which the crack feature
extraction was done locally at the first step of the pre-processing and then they
have fused the images. The second step is to define the crack among the image
segment by the process of cleaning and linking. They have overcome their
previous work disadvantage where the morphological approach was used. the wide
variety of surface flaws that may be detectable by visual examination, the use of
visual inspection can encompass different techniques, depending on the product
and the type of surface flaw being monitored. The methods of visual inspection
involve a wide variety of equipment, ranging from examination with the naked eye
to the use of interference microscopes for measuring the depth of scratches in the
finish of finely polished or lapped surfaces.
 Zou et al. have developed a fully automatic method to detect crack the
pavement images. They used geodesic shadow removal algorithm to remove the
pavement shadows by preserving the crack. After shadow removal, using the tensor
voting methods crack probability map was built. Then by mapping crack
probability map were represented by a graph model. Once the model was
represented, Minimum Spanning Trees were derived from which the crack
extraction data can be taken off by conducting recursive tree-edge pruning.

Gunkel et al. have developed a detection algorithm for the accuracy over
the variability of the crack numbers and crack lengths over the similar image. The
micro crack was detected using the shortest path algorithm in a situation where the
cracks are surrounded by deformations. They have initially detected the crack
clusters with a threshold value. Then the Dijkstra’s algorithm was used to
determine the crack paths. The linear paths of the linked path were determined by
their algorithm.
PROBLEM IDENTIFICATION

AND

OBJECTIVE
 CHAPTER 3
PROBLEM IDENTIFICATION AND OBJECTIVE
The inspection of fine pitch surface-mounted devices by comparison of
defect-free and defective packages is a promising area of research. The types of
defects considered include missing pins, bent pins, broken pins, and bad solder
connections on mounted packages. The feature extraction steps include
morphological filtering for thresholding, skeletonization. The diffusion method is
used as input for detecting the defects. In texture classification the goal is to assign
an unknown sample image to one of a set of known texture classes. Texture
classification is one of the four problem domains in the field of texture analysis.

The basic objective of this project is to give an indication or alarm to us that

there is a breakage of Metal Cracks or Failure.
METHODOLOGY
 CHAPTER- 4

METHODOLOGY

Literature survey

Design of the electric mini bike

Material selection

Fabrication of electric mini bike

Testing on electric mini bike

Comparison of results
COMPONENTS USED Conclusion

 FRAME

 WHEEL

 BRAKES

 BATTERY

 HUB MOTOR

 CONTROLLER

 WIRES

 BOLTS AND NUTS

COMPONENTS DESCRIPTION
 CHAPTER 5

COMPONENTS DESCRIPTION

5.1 FRAME

Structural steel is a category of steel used as a construction material for

making structural steel shapes. A structural steel shape is a profile, formed with a
specific cross section and following certain standards for chemical
composition and mechanical properties. Structural steel shapes, sizes, composition,
strengths, storage practices, etc., are regulated by standards in most industrialized
countries.
 Fig no: 5.1 Frame

Structural steel members, such as I-beams, have high second moments of

area, which allow them to be very stiff in respect to their cross-sectional area.

COMMON STRUCTURE

The shapes available are described in many published standards worldwide, and
a number of specialist and proprietary cross sections are also available.

Fig no: 5.2 L-angle

A steel I-beam, in this case used to support timber joists in a house

  I-beam (I-shaped cross-section - in Britain these include Universal
Beams (UB) and Universal Columns (UC); in Europe it includes the IPE,
HE, HL, HD and other sections; in the US it includes Wide Flange (WF
or W-Shape) and H sections)

 Z-Shape (half a flange in opposite directions)

 HSS-Shape (Hollow structural section also known as SHS (structural

hollow section) and including square, rectangular, circular (pipe)
and elliptical cross sections)

 Angle (L-shaped cross-section)

 Structural channel, or C-beam, or C cross-section

 Tee (T-shaped cross-section)

 Rail profile (asymmetrical I-beam)

While many sections are made by hot or cold rolling, others are made
by welding together flat or bent plates (for example, the largest circular hollow
sections are made from flat plate bent into a circle and seam-welded).

5.2 WHEEL

In its primitive form, a wheel is a circular block of a hard and durable

material at whose center has been bored a circular hole through which is placed
an axle bearing about which the wheel rotates when a moment is applied by gravity
or torque to the wheel about its axis, thereby making together one of the six simple
machines. When placed vertically under a load-bearing platform or case, the wheel
turning on the horizontal axle makes it possible to transport heavy loads; when
placed horizontally, the wheel turning on its vertical axle makes it possible to
control the spinning motion used to shape materials. When mounted on a column
connected to a rudder or a chassis mounted on other wheels, one can control the
direction of a vessel or vehicle, when connected to a crank, the wheel produces or
transmits energy.

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Fig no: 5.3 wheel

Early wheels were simple wooden disks with a hole for the axle. Some of
the earliest wheels were made from horizontal slices of tree trunks. Because of the
uneven structure of wood, a wheel made from a horizontal slice of a tree trunk will
tend to be inferior to one made from rounded pieces of longitudinal boards.

5.3 BRAKE LINK

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Fig no: 5.4 Brake link

A brake is a mechanical device which inhibits motion working of brakes

a common misconception about brakes is that brakes squeeze against a drum or

disc, and the pressure of the squeezing action slows the vehicle down. This is in

fact a part of the reason for slowing down a vehicle. Actually, brakes use friction of
brake shoes and drums to convert kinetic energy developed by the vehicle into heat

energy. When we apply brakes, the pads or shoes that press against the brake

drums or rotor convert kinetic energy into thermal energy via friction.

TYPES OF BRAKES

 MECHANICAL BRAKES

 DRUM BRAKES

 DISC BRAKES

 HYDRAULIC BRAKES

 POWER BRAKES

 AIR BRAKES

 AIR HYDRAULIC BRAKES

 VACCUM BRAKES

 ELECTRIC BRAKES

5.3.1 MECHANICAL BRAKES

Mechanical brakes are assemblies consisting of mechanical elements for the

slowing or stopping of shafts in equipment drives. They use levers or linkages to
transmit force from one point to another. Braking slows or stops the movement of
the coupled shafts. There are several types of mechanical brakes.
 Fig no: 5.5 Mechanical Brake

 DRUM BRAKES

A drum brake is a brake that uses friction caused by a set

of shoes or pads that press outward against a rotating cylinder-shaped part called a
brake drum.

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Fig no: 5.6 Drum Brake

 The term drum brake usually means a brake in which shoes press on
the inner surface of the drum. When shoes press on the outside of the drum, it is
usually called a clasp brake. Where the drum is pinched between two shoes, similar
to a conventional disc brake, it is sometimes called a pinch drum brake, though
such brakes are relatively rare. A related type called a band brake uses a flexible
belt or "band" wrapping around the outside of a drum.

 DISC BRAKES

A disc brake is a type of brake that uses calipers to squeeze pairs

of pads against a disc or "rotor" to create friction. This action slows the rotation of
a shaft, such as a vehicle axle, either to reduce its rotational speed or to hold it
stationary.

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 Fig no: 5.7 Disc Brake

The energy of motion is converted into waste heat which must be dispersed.
Hydraulically actuated disc brakes are the most commonly used form of brake for
motor vehicles, but the principles of a disc brake are applicable to almost any
rotating shaft.

5.3.2 HYDRAULIC BRAKES

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Fig no: 5.8 Hydraulic Brake

A hydraulic brake is an arrangement of braking mechanism which

uses brake fluid, typically containing glycol ethers or diethylene glycol, to transfer
pressure from the controlling mechanism to the braking mechanism.

5.3.3 POWER BRAKES

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Fig no: 5.9 Power Brake

Power brakes are a system of hydraulics used to slow down or stop most
motor vehicles. It uses a combination of mechanical components to multiply the
force applied to the brake pedal by the driver into enough force to actuate the
brakes and stop a vehicle that can weigh several tons.

 AIR BRAKES
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Fig no: 5.10 Air Brake

An air brake or, more formally, a compressed air brake system, is a type of
friction brake for vehicles in which compressed air pressing on a piston is used to
apply the pressure to the brake pad needed to stop the vehicle.

 AIR HYDRAULIC BRAKES

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Fig no: 5.11 Air Hydraulic Brake

A hydraulic brake is an arrangement of braking mechanism which

uses brake fluid, typically containing glycol ethers or diethylene glycol, to transfer
pressure from the controlling mechanism to the braking mechanism.

 VACCUM BRAKES
A vacuum brake is a type of brake that works by atmospheric pressure acting
on a piston in a vacuum cylinder. Vacuum brake equipment has been replaced with
modern air brake equipment. A vacuum brake system is operated by
a vacuum taken from the intake manifold or carburetor at a point just above the
throttle valve.
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Fig no: 5.12 Vacuum Brake

 ELECTRIC BRAKES

An electric friction brake, often referred to as just electric

brake or electric trailer brake is a brake controlled by an electric current and can be
seen on medium duty trailers like caravans/RVs and consumer-grade car trailers.

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Fig no: 5.13 Electric Brake

5.4 BATTERY

A battery is a device consisting of one or more electrochemical cells with

external connections provided to power electrical devices such as flashlights,
smartphones, and electric cars. When a battery is supplying electric power, its
positive terminal is the cathode and its negative terminal is the anode. The terminal
marked negative is the source of electrons that will flow through an external
electric circuit to the positive terminal. When a battery is connected to an external
electric load, a redox reaction converts high-energy reactants to lower-energy
products, and the free-energy difference is delivered to the external circuit as
electrical energy. Historically the term "battery" specifically referred to a device
composed of multiple cells, however the usage has evolved to include devices
composed of a single cell

Primary (single-use or "disposable") batteries are used once and discarded;

the electrode materials are irreversibly changed during discharge. Common
examples are the alkaline battery used for flashlights and a multitude of portable
electronic devices. Secondary (rechargeable) batteries can be discharged and
recharged multiple times using an applied electric current; the original composition
of the electrodes can be restored by reverse current. The battery used in this system
is 12V, 7.5 Ah capacity.

Fig no: 5.14 Battery

5.5 HUB MOTOR

Hub motor electromagnetic fields are supplied to the stationary windings of

the motor. The outer part of the motor follows, or tries to follow, those fields,
turning the attached wheel. In a brushed motor, energy is transferred by brushes
contacting the rotating shaft of the motor. Energy is transferred in a brushless
motor electronically, eliminating physical contact between stationary and moving
parts. Although brushless motor technology is more expensive, most are more
efficient and longer-lasting than brushed motor systems.

A hub motor typically is designed in one of three configurations. Considered

least practical is an axial-flux motor, where the stator windings are typically
sandwiched between sets of magnets. The other two configurations are both radial
designs with the motor magnets bonded to the rotor; in one, the inner rotation
motor, the rotor sits inside the stator, as in a conventional motor. In the other, the
outer-rotation motor, the rotor sits outside the stator and rotates around it. The
application of hub motors in vehicular uses is still evolving, and neither
configuration has become standard.

Fig no: 5.15 Hub motor

5.6 CONTROLLER

Brushless DC electric motor (BLDC motors, BL motors) also known as

electronically commutated motors (ECMs, EC motors), or synchronous DC
motors, are synchronous motors powered by DC electricity via an inverter or
switching power supply which produces an AC electric current to drive each phase
of the motor via a closed loop controller. The controller provides pulses of current
to the motor windings that control the speed and torque of the motor.

The construction of a brushless motor system is typically similar to a

permanent magnet synchronous motor (PMSM), but can also be a switched
reluctance motor, or an induction (asynchronous) motor. The advantages of a
brushless motor over brushed motors are high power to weight ratio, high speed,
and electronic control. Brushless motors find applications in such places as
computer peripherals (disk drives, printers), hand-held power tools, and vehicles
ranging from model aircraft to automobiles.

Fig no: 5.16 Controller

5.7 WIRES
 A wire is a single, usually cylindrical, flexible strand or rod of metal. Wires
are used to bear mechanical loads or electricity and telecommunications signals.
Wire is commonly formed by drawing the metal through a hole in a die or draw
plate. Wire gauges come in various standard sizes, as expressed in terms of a gauge
number. The term wire is also used more loosely to refer to a bundle of such
strands, as in "multistrand wire", which is more correctly termed a wire rope in
mechanics, or a cable in electricity.

Wire comes in solid core, stranded, or braided forms. Although usually

circular in cross-section, wire can be made in square, hexagonal, flattened
rectangular, or other cross-sections, either for decorative purposes, or for technical
purposes such as high-efficiency voice coils in loudspeakers. Edge-wound coil
springs, such as the Slinky toy, are made of special flattened wire.

Fig no: 5.17 Wires

5.8 BOLTS AND NUTS

 A nut is a type of fastener with a threaded hole. Nuts are almost always used
in conjunction with a mating bolt to fasten multiple parts together. The two
partners are kept together by a combination of their threads' friction (with slight
elastic deformation), a slight stretching of the bolt, and compression of the parts to
be held together.In applications where vibration or rotation may work a nut loose,
various locking mechanisms may be employed: lock washers, jam nuts, specialist
adhesive thread-locking fluid such as Loctite, safety pins (split pins) or lockwire in
conjunction with castellated nuts, nylon inserts (nyloc nut), or slightly oval-shaped
threads.

Bolts are often used to make a bolted joint. This is a combination of the nut
applying an axial clamping force and also the shank of the bolt acting as a dowel,
pinning the joint against sideways shear forces. For this reason, many bolts have a
plain unthreaded shank (called the grip length) as this makes for a better, stronger
dowel. The presence of the unthreaded shank has often been given as characteristic
of bolts vs. screws, but this is incidental to its use, rather than defining.

Fig no: 5.18 Bolts and nuts

WORKING PRINCIPLE
 CHAPTER 6

WORKING PRINCIPLE

The battery has been charged by turn on the switch the electric motor gets
excited to rotate and the battery is connected to the motor. By the use accelerator
the motor runs and variable speed. Here the rotor is fixed and the stator rotates to
give the motion. By these principle the electric mini bike had been run.
CAD MODELING
 CHAPTER 7

CAD MODELING

Fig 7.1 3d modeling

Fig 7.2 Chassis design
PROCESS DESCRIPTION
 CHAPTER 8

PROCESS DESCRIPTION

PROCESS UNDERGONE:

 Cutting
 Welding

8.1 CUTTING
Metalworking is the process of working with metals to create individual
parts, assemblies, or large-scale structures. The term covers a wide range of work
from large ships and bridges to precise engine parts and delicate jewelry. It
therefore includes a correspondingly wide range of skills, processes, and tools.

Metalworking is a science, art, hobby, industry and trade. Its historical roots
span cultures, civilizations, and millennia. Metalworking has evolved from the
discovery of smelting various ores, producing malleable and ductile metal useful
tools and adornments. Modern metalworking processes, though diverse and
specialized, can be categorized as forming, cutting, or joining processes. Today's
machine shop includes a number of machine tools capable of creating a precise,
useful workpiece.
 Metalworking generally is divided into the following categories, forming,
cutting, and, joining. Each of these categories contain various processes.

Prior to most operations, the metal must be marked out and/or measured,
depending on the desired finished product.

Marking out (also known as layout) is the process of transferring a design or

pattern to a workpiece and is the first step in the handcraft of metalworking. It is
performed in many industries or hobbies, although in industry, the repetition
eliminates the need to mark out every individual piece. In the metal trades area,
marking out consists of transferring the engineer's plan to the workpiece in
preparation for the next step, machining or manufacture.

Calipers are hand tools designed to precisely measure the distance between
two points. Most calipers have two sets of flat, parallel edges used for inner or
outer diameter measurements. These calipers can be accurate to within one-
thousandth of an inch (25.4 μm). Different types of calipers have different
mechanisms for displaying the distance measured. Where larger objects need to be
measured with less precision, a tape measure is often used.

Fig 8.1 cutting

8.2 WELDING
 Welding is a fabrication or sculptural process that joins materials, usually
metals or thermoplastics, by using high heat to melt the parts together and allowing
them to cool causing fusion. Welding is distinct from lower temperature metal-
joining techniques such as brazing and soldering, which do not melt the base metal.

In addition to melting the base metal, a filler material is typically added to

the joint to form a pool of molten material (the weld pool) that cools to form a joint
that, based on weld configuration (butt, full penetration, fillet, etc.), can be stronger
than the base material (parent metal). Pressure may also be used in conjunction
with heat, or by itself, to produce a weld. Welding also requires a form of shield to
protect the filler metals or melted metals from being contaminated or oxidized.

Many different energy sources can be used for welding, including a gas
flame (chemical), an electric arc (electrical), a laser, an electron beam, friction, and
ultrasound. While often an industrial process, welding may be performed in many
different environments, including in open air, under water, and in outer space.
Welding is a hazardous undertaking and precautions are required to avoid burns,
electric shock, vision damage, inhalation of poisonous gases and fumes, and
exposure to intense ultraviolet radiation.

Until the end of the 19th century, the only welding process was forge
welding, which blacksmiths had used for millennia to join iron and steel by heating
and hammering. Arc welding and oxy-fuel welding were among the first processes
to develop late in the century, and electric resistance welding followed soon after.
Welding technology advanced quickly during the early 20th century as the world
wars drove the demand for reliable and inexpensive joining methods. Following
the wars, several modern welding techniques were developed, including manual
methods like shielded metal arc welding, now one of the most popular welding
methods, as well as semi-automatic and automatic processes such as gas metal arc
welding, submerged arc welding, flux-cored arc welding and electroslag welding.
Developments continued with the invention of laser beam welding, electron beam
welding, magnetic pulse welding, and friction stir welding in the latter half of the
century. Today, the science continues to advance. Robot welding is commonplace
in industrial settings, and researchers continue to develop new welding methods
and gain greater understanding of weld quality.

8.2.1 ARC WELDING

Arc welding is a welding process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses a welding power
supply to create an electric arc between a metal stick ("electrode") and the base
material to melt the metals at the point of contact. Arc welders can use either direct
(DC) or alternating (AC) current, and consumable or non-consumable electrodes

The welding area is usually protected by some type of shielding gas, vapor,
or slag. Arc welding processes may be manual, semi-automatic, or fully automated.
First developed in the late part of the 19th century, arc welding became
commercially important in shipbuilding during the Second World War. Today it
remains an important process for the fabrication of steel structures and vehicles.
 Fig 8.2 Arc welding

DESIGN CALCULATION
 CHAPTER 9

DESIGN CALCULATION

BATTERY:

Each Battery capacity 12 V and it is connected in series

Ah(amp hours) X V(volts) = 7 X 48

= 336 Wh

POWER = WORK / TIME

TIME = WORK / POWER

MOTOR POWER = 250 W

 TIME = 336 Wh / 250 W

= 1 Hour

DISTANCE TRAVELLED:

POWER = 2π NT / 60

AVAILABLE or MOTOR TORQUE = 1.136 N-M

MAX.SPEED (N) = 25 KM/HR

DISTANCE = SPEED X TIME

= 25 X 1

= 25 KM
 ADVANTAGES

CHAPTER 10

ADVANTAGES

ADVANTAGES

 Easy to commute with low fatigue.

 Less maintenance cost.
 Deployable batteries – can be taken inside house.
 Cost of the unit is very low.
 Easy to carry since it is portable.
 Less energy consumed.
 High efficiency can be obtained if inverter is used.
 If using solar panel, free utilization of energy can be done.
 CHAPTER 11

CONCLUSION

This project work has provided us an excellent opportunity and

experience, to use our limited knowledge. We are feeling that we have completed
the work within time successfully. This is working with satisfactory conditions.
Thus, we have prepared an “Electric mini bike” which helps to know the how to
achieve low cost product.

With the increasing consumption of natural resources of petrol, diesel it is

necessary to shift our way towards alternate resources like the Electric bike and
others because it is necessary to identify new way of transport.
Since it is energy efficient, electric bike is cheaper and affordable to anyone. It
can be also used for shorter distances by people of any age.
 Fig 11.1 final assembly

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