The document describes the design and fabrication of an electric vehicle. It discusses the goals of developing a low-weight and safe frame at a low cost. It then details the design considerations including reliability, weight, safety, and materials. Dimensions and technical specifications of the chassis, powertrain, battery, braking, steering, and suspension systems are provided. Finally, it summarizes the fabrication process and provides a breakdown of costs.

1. DESIGNING AND FABRICATION
OF AN
EV VEHICLE
1
Made By: Bhanu Arora

2. 2
• Objective & Goals
• Design Considerations
• Chassis
• Steering/ Brakes/ Body
• Budget
• Innovations

3. • To develop a frame that is low-weight and safe for the driver and other
passengers
• Cost effectiveness.
3

4. • Cost Effective
• Vehicle Reliability
• Endurance
• Weight
• Safety
• Speed
• Construction Material
• Compact
• Initial Design
• Battery Life
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5. 5
Dimensions & Weight
Length 1905mm
Width 889mm
Height 1422mm
Wheel Base 1397mm
Ground Clearance 127mm

6. TopView Side View Front View
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7. 7

8. A differential is a gear train with three shafts
that has the property that the angular velocity of
one shaft is the average of the angular velocities
of the others, or a fixed multiple of that average.
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9. The rear drive differentials of electric rickshaws
are made of iron and aluminium. The available
sizes:
28”
29”
30”
31”
32”
33”
35”
37”
38”
39”
40”
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10. Parameters
Motor 1.5kW
Type Brushless
Motor Power 1500 watt
Maximum RPM 3000 +/- 5% rpm
Transmission Differential
Tire 18X2.5-8"
Maximum Speed 30 +/- 5 kmph
Maximum Torque 3.2 Nm
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11. Motor ControllerSpecification
ControllerType 36 Tube
Rated Voltage 48V
Rated Current 32A
Rated Power 1500watt
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12. The vast majority of golf kart battery bank wiring
is done in series circuit. To wire in a series circuit
means to connect multiple batteries in such a
manner that the entire battery bank acts as a
single battery, but with the total sum of the
voltages of each individual battery.
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13. We have used the four 12V battery connected in
series which adds up to 48V battery system.
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14. 14
Considerations
• Disc Brakes
Pros: Better heat dissipation than drum brakes.
Unlike drum brakes, disc brake system are
completely self adjusting
Cons: Requires assisted braking systems
Initial cost is high

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Standard Parts & Details Quantity
Disc 2
Brake Shoes 4
Master Cylinder 1
Brake Callipers 2
Specification Braking
Leverage Ratio 1:4
Tire Outer Diameter Front Rear
18” 18”

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Considerations
• Rack and Pinion
Pros: Small space required
Cons: Relatively expensive and heavy
• Ackerman Style Setup
Pros: Improves rolling efficiency when turning
Cons: Requires more precision to work correctly
Parameters
Steering Type Rack & Pinion
Steering Ratio 11:1
Max SteeringAngle 40
Minimum Turning Radius 1874mm
Steering Column Height 750mm
Steering Column Length 596mm

17. Suspension is the system of tires, tire
air, springs, shock
absorbers and linkages that connects
a vehicle to its wheels and allows relative
motion between the two.
Consideration: Leaf Spring
Pros: Lightweight, extremely strong
Corrosion & chemical resistance
Cons: High cost of Fabrication
Repair procedure is complex
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Test Name Reason Inspection Acceptance Criteria
Roll Cage Theoretical Software Results
Theoritical Analysis No bends or cracks developed
Physical Visual No bends or cracks developed
Transmission Practical Test Visual Not more than 20kmph
Practical Test Visual NIL
Brake Practical Test Visual
Steering Practical Test Visual Maximum turning without
skidding
Practical Test Visual Easy turning without hitting
cones
Suspension Practical Test Visual Comfortable ride over bumps

19. 19

20. • Arc Welding Set
• Power Hacksaw
• Hand Grinder
• Lathe Machine
• Drilling Machine
• Grinding Wheel
• 40 pieces Tool Kit
• MS Rods and Strips Used
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21. TRANSMISSION COST
WHEEL &TYRE Rs4,400/-
SUSPENSION
SYSTEM (FRONT&
REAR)
Rs6,000/-
AXLES (FRONT&
REAR)
Rs6,500/-
FRABICATION
AND BODY
COST
FIBER Rs2,500/-
MS SHEET Rs2,700/-
MS PIPES Rs2,000/-
OTHER
MATERIALS
Rs6,000/-
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22. STEERING &
BRAKING
COST
RACK AND PENION
STEERING COLOUM
Rs3,000/-
BRAKING SYSTEM
&
MASTER CYLINDER
Rs 3,500/-
FRONT ANDREAR
LIGHTS
Rs2,000/-
ELECTRICAL
SYSTEM
COST
BATTERY Rs15,000/-
CHARGER Rs6,000/-
MOTOR
CONTROLLER
Rs4,000/-
MOTOR Rs5,700/-
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Total Cost Rs69,300/-

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• We have created a 3D design of our golf kart using CATIA software.
• We have performed analysis on our 3D design:
1.Front Impact
2.Rear Impact
3.Side Impact
•
We have identified all the parts in the manufacturing
and fabrication of the EV Vehicle.