DESIGN AND FABRICATION OF A PLUG-IN HYBRID SYSTEM IN A TWO WHEELER

Objective The objective of our project is to implement Hybrid technology using a PLUG-IN concept in a scooter. Concept Hybrid literally means having different entities coupled together.A vehicle that has two or more energy sources and energy converters is called a hybrid vehicle. A hybrid vehicle with an electrical power train is called an HEV. Proper usage of fuel at the ideal condition will enhance not only the efficiency but also reduce the pollution. The type of hybrid which we have planned to use is the parallel Hybrid system. The difference in the schematic of our proposed model and the current model of implementation can be seen below.

Progress and Changes Initially we planned on using a separate motor and transmission for the front wheel, but after some extensive studies it is found that having a separate motor and transmission has the following problems, Weight of the transmission and the motor gets added to the whole vehicles weight. Control of the vehicle gets affected since we are connecting both to the front wheel. Maintaining equilibrium (i.e. vehicle balancing) is quiet difficult. Therefore we have decided on using a HUB motor instead. There are two types of hub motors: Direct drive Internally geared The direct drive motors are simpler and generally cost less. Although they are not as efficient as an internally geared motor, they are quieter and possibly more reliable as they have fewer moving parts. The internally geared motors are more efficient, and so will perform like a direct drive motor that uses higher power. They also have more torque for climbing hills. In addition to the already proposed three modes Namely, Gasoline operated vehicle. Electric vehicle. Hybrid vehicle.

We are introducing another mode which uses the power of both motor and engine simultaneously. Combined power output of both will give better performance while climbing hills or slopes. The existing alternator will be removed and 48V alternator will be installed. This alternator will be used to charge the battery when the engine is operated. Thus this acts as a second source of charging the battery in addition to the plug-in system.

Components

Scooter Battery Plug-in charger Electric motor

: Kinetic Honda : 12Ah 48V Sealed Lead Acid battery : 48V 2A battery charger : 450W, 48V DC Direct Hub Motor

Electric Components : 40A Motor controller, Drive Unit, Micro Controller 89C51

Expected Performance graph for the given motor and battery specification

Methodology
The hub motor in the front wheel will be controlled by the 40A controller and the drive unit controls the speed of the vehicle by means of accelerator. Motor and its components are connected to a 48V 12Ah SLA battery. The charging unit is attached to the battery to charge it on the go. Rear wheel is connected to the engine which runs on gasoline. In the 1st mode the vehicle runs using gasoline similar to the conventional two-wheeler. In the 2nd mode the vehicle runs on the battery similar to that of an electric bike. In the 3rd mode the vehicle combines both the engine and the motor simultaneously propelling the vehicle. This mode will be useful when climbing hills and slopes as better torque will be obtained. The 4th mode is the hybrid mode where we are using both the sources effectively. Electric power will provide the initial torque after which the engine propels the vehicle. Until the vehicle reaches 25kmph it runs on electric power. When it crosses 25kmph the engine operates the vehicle. If the speed of the vehicle falls below 25kmph then the mode of operation shifts back to electric. Initial operation of the vehicle at lower speeds results in lower efficiency and higher pollution as the fuel is not completely burnt. To overcome this limitation, electric power is used at that point of time. After this the load increases hence we use the engine. This is due to the fact that at higher loads the efficiency of the engine is more and also pollution is reduced since there is complete combustion.

Cost Estimation
Contents
Two-wheeler 48V battery Recharging inverter unit DC Direct Hub electric motor Electronics(programming, Microcontrollers, transducers etc) Miscellaneous Total estimated cost

Price (Rs.)
5000 7000 2500 7000 7500* 1000 30000

Schedule and Progress

S.No Tasks accomplished / Tasks to Scheduled time be performed
1 2 3 4 5 6 7 8 Decided the field & title of the project Background literature analysis Gathered info about the components Enquired the price & Availability of components Procurement of components Assembly of components Performing electronic works To handle crisis & prepare report 31st July11 25th Aug11 15th Sept11 20th Oct11 31st Dec11 30th Jan12 15th Feb12 29th Feb12

Status
Completed Completed Completed Completed Completed Completed Ongoing

Name S.Karthik K. Kaushik M. Lakshmanan

Reg. No 311081140 45 311081140 47 311081140 50

Email-id karthik2050@gmail.com kaushik.060690@gmail. com latchu331@gmail.com

Phone No 99402513 77 90032501 04 90030385 52

Signatur e