Modeling and Assembling of Electric Cargo Vehicle

Good evening sir,

Objective: This is the final Individual project report of Ultimate Solidworks course about ideation, design, modelling, assembly and rendering of Electrical L5 cargo vehicle in Solidworks. The main aim of this project is to design all parts of the Electric L5 cargo vehicle and do the assembly work in solidwork.

Introduction:

L5 vehicle: L5 - A three wheeled motor vehicle with maximum speed exceeding 25 kmph andengine capacity exceeding 25 cc if fitted with a thermic engine, or motor power exceeding 0.25 kW if fitted with electric motor.

Cargo Vehicle: used for delivering goods.

Parts of L5 vehicle -

• Chassis
• Front part
• Differential
• Front fork
• Leaf spring
• Goods carrying box
• Motor
• Battery
• Controller
• Brake drum
• Wheels
• Hinges
• Front cabin doors and box doors

Explanation of parts-

Chassis: Chassis is the main support structure of the vehicle which is also known as ‘Frame’. It bears all the stresses on the vehicle in both static and dynamic conditions. In a vehicle, it is analogous to the skeleton in living organisms. The origin of the word Chassis lies in the French language. Every vehicle whether it is a two-wheeler or a car or a truck has a chassis-frame. However, its form obviously varies with the vehicle type.

It consists of a number plate indicator and lights.

Features used to build Chassis

• Sweep thin.
• Extrude thin.
• Cut-Extrude.
• Delete body.
• Boss_extrude
• Surface-Extrude
• Ruled surface.
• Surface knit.
• Thicken.
• Dome.
• Mirror

Fig 1.1 Chassis

Front part and cabin(Hood)- Front part consist of driver seat, windshield, headlight, indicator, fender and wiper and roof of the driver cabin.

Features used to build Front Part(Hood)

• Projected curve
• Surface loft
• Ruled surface
• Surface fill
• Surface extrude
• Surface knit
• Surface Thicken
• Split
• Split Line
• Boss Extrude
• Dome
• Mirror
• Cut extrude
• Surface trim

Fig 2.2 Front part and cabin(Hood)

Differential-As part of the front and/or rear axle assembly, the differential plays an integral role in how your car makes turns. The differential is designed to drive a pair of wheels while allowing them to rotate at different speeds. This function provides proportional RPMs between the left and right wheels. If the inside tire rotates 15 RPM less in a turn than going straight, then, the outside tire will rotate 15 RPM more than going straight.

For example, when your vehicle goes around a corner, the wheel on the outside must travel faster than the wheel on the inside. The differential distributes equal amounts of torque to both wheels. This permits the wheels to react to resistance, or provide traction, to give the wheel more resistance to rotate less. The wheel with less resistance rotates faster.

It consists of a gear train which has (sun and planetary gear) known as a crown wheel. crown wheel Gears are in attachment with another gear which is attached with the motors gear. And the crown wheel having 2 holes with gears the axle are attached with those gears. Another part of the gear is attached with the brake drum.

Feature used to build Differential

• Revolve.
• Boss extrude.
• Cut-Extrude.
• Mirror.
• Fillet.

Fig 1.3 Differential with brake drum

Front fork-A tricycle fork/3-Wheeler is the part of a 3-wheeler that holds the front wheel.

A fork typically consists of two blades which are joined at the top by a fork crown. The crown is often at the front. Most suspension forks have an arch connecting the two sides of the lowers (the part connected to the axle.) It is often in front of the stanchions (shaft the lowers slide on) but not always. Above the crown, a steerer tube attaches the fork to the bicycle and the handle bars allowing the rider to steer the bicycle. The steerer tube of the fork interfaces with the frame/chassis via bearing.

Features used to build Front fork

• Boss Extrude
• Projected Curve
• Sweep
• Cut Extrude
• Helix/Spiral
• Mirror
• Revolve thin
• Dome

Fig 1.4 Front fork

Leaf spring-A leaf spring is a simple form of spring commonly used for the suspension in Vehicles . Originally called a laminated or carriage spring, and sometimes referred to as a semi-elliptical spring, elliptical spring, or cart spring, it is one of the oldest forms of springing, appearing on carriages

Fig 1.5 Leaf Spring

Goods carrying box- Goods carrying box is a rectangular box where we can load the Goods.

Features used to build Box

• Sweep
• Extrude thin
• Surface extrude
• Surface knit
• Thicken
• Fillet
• Mirror

Fig 1.6 Goods carrying Box

Electric Motor- An electric vehicle (EV), also referred to as an electric drive vehicle, is a vehicle which uses one or more electric motors for propulsion. Depending on the type of vehicle, motion may be provided by wheels or propellers driven by rotary motors, or in the case of tracked vehicles, by linear motors.

Featured used to build Electric Motor

• Revolve
• Boss extrude
• Curve pattern

Fig 1.7 Motor

Battery- An electric-vehicle battery (EVB) (also known as a traction battery) is a battery used to power the electric motors of a Battery electric vehicle(BEV) or Hybrid electric Vehicle (HEV). These batteries are usually rechargeable batteries , and are typically Lithium-Ion batteries. These batteries are specifically designed for a high ampere-hour (or kilowatt-hour) capacity.

Electric-vehicle batteries differ from starting-Lighting and ignition (SLI) batteries as they are designed to give power over sustained periods of time and are Deep-Cycle Batteries. Batteries for electric vehicles are characterized by their relatively high power to weight ratio, specific energy and energy density ; smaller, lighter batteries are desirable because they reduce the weight of the vehicle and therefore improve its performance. Compared to liquid fuels, most current battery technologies have much lower specific energy, and this often impacts the maximum all-electric range of the vehicles.

Fig 1.8 Battery

Controller- The electric vehicle controller is the electronics package that operates between the batteries and the motor to control the electric vehicle‘s speed and acceleration much like a carburetor does in a gasoline-powered vehicle. The controller transforms the battery’s direct current into alternating current (for AC motors only) and regulates the energy flow from the battery. Unlike the carburetor, the controller will also reverse the motor rotation (so the vehicle can go in reverse), and convert the motor to a generator (so that the kinetic energy of motion can be used to recharge the battery when the brake is applied).

Fig 1.9 Controller

Brake drum

Fig. 1.10 Brake drum (Wheel hub)

Front Cabin Door: These are the splitted part from the front cabin.

Fig 1.11 Front cabin Door

Good carrying Box Door:

Fig 1.12 Box door

Assembly: In it we assemble part one by one we started with the inserting chassis in first

And then other parts one by one.

Rendering: Rendering is done by using Photo view 360 and SolidWorks visualize

For rendering we setup the camera.

Sheets:

Conclusion:

Designed, modeled the L5 components

Assembled the L5 Components

Rendered to give the photo-realistic view

Thank You