DESIGN OF ELECTRIC GO KART

ABSTRACT
The aim of this project is the fabrication of an electric GO kart vehicle. The main aim
of this project is to reduce the usage of organic fuel powered vehicles and to design a vehicle
which works efficiently in the emerging electric vehicle sector. Each and every day the prices
of petrol and diesel keeps on fluctuating. They increase with higher rate but rarely falls down.
This is tremendously depleting the fuel reserves. So basically, it is important to design such
vehicle that could work on electric energy rather than fuels. Main objective behind designing
and fabricating the electric go -kart is to make it available in cheap price, making it simple in
working for even nonprofessional drivers, increasing is strength so that it can sustain more
weight and providing it with all the best available facilities in lower cost. This project mainly
focuses on designing of cheaper electric system compared to other electric go karts vehicle.
The project includes design of ideas, imaginary concept, designing, analysis, teamwork,
project management and development, costing and budgeting. The main objective of Caris to
make that car within a time, without any loss of time. All the parameters like Reliability,
safety, Cost, Performance, aesthetics, ergonomics, Standard dimensions & material were also
taken in consideration on the same time. Where ever possible finite element analysis (FEA)
was done on the regularly loaded parts & modifications were done accordingly to avoid any
type of design failure. Also, while designing every individual part DFMEA and DVP has
been done which improved our quality standard, factor of safety and other safety parameters
also. The designed go-kart is able to withstand against any adverse condition on road as each
component is designed specifically considering all types of failures and safety issues. Power
train is specially designed to get maximum speed and torque for high performance which can
be given by the any other geared vehicle.

INTRODUCTION TO ELECTRIC GO-KART

The general definition of any kart, a vehicle without suspension and differential. It is a
vehicle specially designed for a flat track race. A wide range of engine karts were on track
since the mid of the twentieth century. The present automotive scenario encourages eco-
friendly vehicles to minimize the damage done by the emissions. An effective alternative for
the engine is the electric motor which in comparison can give the same output power. This
can be implemented in the karting field. Motor replaces the engine and hence the kart gets
dramatically changed in both design and performance. The vehicle, hence runs only on
electricity and is designed to meet the necessary requirements for karting. The design of the
frame indicates that it is an open kart with a straight chassis. The frame acts as a suspension
in karts. It must also be rigid not to break under extreme load conditions. Hence, flexibility
should be compromised with stiffness.

The primary objective is to design a stable and safest vehicle for the driver. Every
subsystem is designed based on the primary objective and then integrated into a final
blueprint. 3D modelling and assembly of the whole vehicle is done in PTC CREO 2.0 and
rendering is done in SOLIDWORKS 13. Finite Element Analysis is carried out on the frame
model in cases of front, side and rear impact in ANSYS 14.5. Based on the result obtained
from the above tests the design is modified accordingly. The center of gravity is kept as low
as possible to obtain maximum stability. The length of the vehicle is shortened so as to
reduce the weight of the vehicle. The wheelbase and track width of the vehicle are chosen
accordingly. The front track width is minimized to reduce the turning radius of the vehicle
and to increase the manoeuvrability. The isometric view of CAD model of the vehicle is
shown in figure.

COMPONENTS OF CART WITH BRIEF EXPLANATION

Frame Design

Design of the frame consists of numerous factors like material selection, pipe size
selection, safety of the driver, weight reduction, size and cost. [3] The crucial objective of the
frame is to provide a safe driving environment to the driver keeping in mind the weight,
space and cost. The chassis frame was designed to withstand driver weight, bump loads (the
frame acts as a suspension in karts), motor weight and transmission weight. It is also required
to maintain a ground clearance of 3 inches. Pedals of brake and accelerator were installed at
the extreme front position to reduce the length of the vehicle. Taking into account all the
necessary dimensions such as
wheelbase, track width, driver
dimensions and motor
dimensions, the initial pencil
sketches and 2D drawings for
the frame were drawn.
Fulfilling all the factors, the
3D model was designed.
Primary analysis was done and
changes were made on the
frame to obtain double the strength. The isometric view of the 3D model of chassis frame of
the vehicle is shown in figure.

To ensure that our frame is double in strength and structurally rigid to withstand the
impacts while in the state of rest (or) motion, Finite Element Analysis was done on the frame.
[4] Various impact tests were conducted in the frame to find the strength, reliability and
safety of the kart. The frame was subjected to front impact, side impact and rear impact. The
impact load for these tests were calculated from the mass-momentum equation. The impacts
are purely elastic collision and the velocities for the impact tests were taken according to The
European New Car Assessment Program. The Basic frame of Electric Go-Kart is shown in
the figure below.

STEERING SYSTEM

The essentials still remaining the same, the importance of steering mechanism cannot be
compromised with. The stability of the steering system and response time are vital factors in
deciding vehicle’s run. Considerations of mounting ease, compact frame and simplicity in
design, made us to go with the linkage type steering. The main goal of our steering system is
to provide directional control with minimum turning radius. Simplicity and safety were the
main design considerations of our steering system. The steering system includes steering
wheel, steering column, steering arm, tie rod and knuckle. Common inner wheel angle for
any automobile is 41 degrees and outer wheel angle ranges from 28 to 29 degrees. In order to
achieve those angles, the stoppers were attached, intentionally on both sides of the frame such
that the angular movement of steering arms is restricted to desired position. From the known
inner wheel and outer wheel angles, reverse engineering process is carried out to find the
turning radius of the kart by using the simple Ackermann principle.The steering wheel has a
led display, reverse gear toggle switch and buttons to set desired vehicle speed attached to it.
Steering calculations were shown in table-4. The reduced front track provides a turning radius
of 1.65 m. The simple model of our steering system and CAD model of Steering system
employed in the kart is shown in figure.
TRANSMISSION SYSTEM

 Electrical Transmission

The PMDC motor that we are implementing in our kart is a 2.5 kW powered 48 V motor. An
equivalent of 48V, 42A-hr lead acid battery is used to quench its thirst. The electrical circuit
consists of a microcontroller, and series of resistors, capacitors and diodes and the controller
have been programmed based on Pulse width modulation (PWM). The battery is connected to
the motor through the PWM circuit and the main reason to use PWM method is that
controlling analog circuits digitally reduce system costs and power consumption. A two-way
switch attached to the steering wheel is used as a reversing key to reverse the vehicle’s
motion. Four secondary rechargeable 12V Sealed Lead Acid batteries in series connection are
used. A 5A battery charger is fixed in the kart to charge the batteries. The battery’s open
circuit voltage is used in our kart to estimate the amount of charging and discharging.
Keeping safety as our ultimate perspective, we have provided electrical hand brake, fuses
wherever needed and two kill switches, one on the steering wheel and the other on the left
side of the driver seat so that it seizes the electrical functionality of the vehicle. A display is
mounted on the steering wheel that shows the driver, the vehicle’s speed and the battery
level.
  Mechanical Transmission

The ultimate aim is to select an efficient and reliable drive for power transfer. Comparisons
of various transmission elements have been done. Commonly used drives for power
transmission are belt drive and chain drive. Primary comparison results proved that belt drive
is more efficient than chain drive. Secondary analysis between the types of belts, finalized
timing belt for our kart. Timing belt drives are durable, reliable and work over a wide range
of speeds and torques with minimum maintenance and re-tensioning. The transmission
system comprises of timing belt, pulley and driving shaft and bearings. The design and
selection of timing belt are based on output power. The pitch of the belt corresponding to the
output power is 5mm.Taking the pitch as reference all other parameters involved in
transmission system has been designed. The material chosen for timing belt pulley is
aluminium alloy to reduce the dynamic weight and to increase the acceleration of the kart.
Design stress acting on the pulley is less than the yield stress of the material. Hence the
design of pulley is safe under dynamic conditions.
 Mechanical Transmission in Electric Go-Kart

DC MOTOR

   Mophorn 2000 W Electric Go-Kart

Motor:

Specifications

 Power: 2,000 W
 Voltage: 60 V
 Current: 42 A
 Speed: 5,600
RPM
  Sprocket Teeth: 11
The Mophorn 2000 W Electric Motor Kit is the best electric motor for go-karts in our
list, due to its power, superb build quality and it’s high performance-to-cost ratio. Not only is
this electric motor powerful and reliable, but it comes in a set that includes many components
for your go-kart. This electric go-kart motor kit contains a 2,000 watt brushless electric
motor, a speed controller, a screw set and wrenches for easy installation. 

The Mophorn electric go-kart motor has an output of 2,000 watts. Additionally, it features a
rated voltage of 60 volts and has a rated current of 42 amps. The rated speed of 5,600 RPM
ensures high working efficiency and is suitable for mid to heavy electric go-karts. It also
features an 11-teeth sprocket that is compatible with a #8 chain (8mm pitch).

The speed controller has many different features including a 3-speed and reverse function, as
well as brake lamp, lock and throttle features. The great thing about this electric go-kart
motor kit is that it includes a speed controller, which means that you don’t need to source for
a compatible speed controller yourself. It deservingly takes the number one spot in our list.

Compatibility:

 Suitable for mid or large-sized go-karts

 Fits a #8 roller chain

BATTERY

Most of the electric karts on the market equip lead acid batteries. However, even
though more than 90% of the sector is concentrated on this type of batteries as they are more
economical, acquiring lithium batteries will make the investment much more profitable
because of its multiple advantages.

Lead acid batteries are the most common large-capacity rechargeable batteries. They
are very popular because they are dependable and inexpensive on a cost-per-watt base. There
are few other batteries that deliver bulk power as cheaply as lead acid, and this makes the
battery cost-effective for automobiles, electrical vehicles, forklifts, marine and uninterruptible
power supplies (UPS). Lead acid batteries are built with a number of individual cells
containing layers of lead alloy plates immersed in an electrolyte solution, typically made of
35% sulphuric acid (H2SO4) and 65% water (Figure 1). Pure lead (Pb) is too soft and would
not support itself, so small quantities of other metals are added to get the mechanical strength
and improve electrical properties. The most common additives are antimony (Sb), calcium
(Ca), tin (Sn) and selenium (Se). When the sulphuric acid comes into contact with the lead
plate, a chemical reaction is occurring and energy is produced.
Mighty Max Battery YTX4L-BS:

Features

 Lead-Acid battery
 12 Volts
 3 Ah rechargeable

Lead acid batteries are heavy and less durable than nickel (Ni) and lithium (Li) based
systems when deep cycled or discharged (using most of their capacity). Lead acid batteries
have a moderate life span and the charge retention is best among rechargeable batteries. The
lead acid battery works well at cold temperatures and is superior to lithium-ion when
operating in sub-zero conditions. Lead acid batteries can be divided into two main classes:
vented lead acid batteries (spillable) and valve regulated lead acid (VRLA) batteries (sealed
or non-spillable).

Electric car battery technology

EV batteries undergo cycles of 'discharge' that occur when driving and 'charge' when
the car's plugged in. Repeating this process over time affects the amount of charge the battery
can hold. This decreases the range and time needed between each journey to charge. Most
manufacturers have a five to eight-year warranty on their battery.
However, the current prediction is that an electric car battery will last from 10 – 20
years before they need to be replaced.

How a battery and the car's electric motor work together is surprisingly simple – the
battery connects to one or more electric motors, which drive the wheels. When you press the
accelerator the car instantly feeds power to the motor, which gradually consumes the energy
stored in the batteries.

Electric motors also work as generators, so when you take your foot off the throttle
the car begins to slow down by converting its forward motion back into electricity – this
happens more strongly if you hit the brakes. This regenerative braking recovers energy that
would otherwise be lost, storing it in the battery again and so improving the car's range.

Electric car battery lithium-ion

A Lithium-ion (Li-ion) battery is a type of rechargeable battery used in electric
vehicles and a number of portable electronics. They have a higher energy density than typical
lead-acid or nickel-cadmium rechargeable batteries. This means that battery manufacturers
can save space, reducing the overall size of the battery pack.

Lithium is also the lightest of all metals. However, lithium-ion (Li-ion) batteries

contain no lithium metal, they contain ions. For those wondering what an ion is, an ion is a an
atom or molecule with an electric charge caused by the loss or gain of one or more electrons. 

Lithium-ion batteries are also safer than many alternatives and battery manufacturers have to
ensure that safety measures are in place to protect consumers in the unlikely event of a
battery failure. For instance, manufacturers equip electric vehicles with charging safeguards
to protect the batteries during repeated rapid charging sessions in a short period of time.

BRAKING SYSTEM

1. Mechanical Brakes-

It is the type of braking system in which the brake force applied by the driver on the
brake pedal is transferred to the final brake drum or disc rotor through the various mechanical
linkages like cylindrical rods, fulcrums, springs etc. In order to de accelerate or stop the
vehicle.
  Mechanical brakes were used in various old automobile vehicles but they are
obsolete now days due to their less effectiveness.

2. Hydraulic Brakes- 

It is the type of braking system in which the brake force applied by the driver on
brake pedal is first converted into hydraulic pressure by master cylinder than this hydraulic
pressure from master cylinder is transferred to the final brake drum or disc rotor through
brake lines.

 3.Electrical Brakes-

It is type of braking used in electric vehicle in which braking is produced using the
electrical motors which is the main source of power in electric vehicles, it is further divided
into 3 types-

(i) Plugging Brakes-When the brake pedal is pressed in the electric vehicle equipped with
plugging braking, the polarity of the motors changes which in turn reverses the direction of
the motor and causes the braking.

(ii) Regenerative Braking- It is the type of electrical braking in which at the time of braking
the motor which is the main power source of the vehicle becomes the generator i.e. when
brakes are applied, the power supply to the motor cuts off due to which the mechanical
energy from the wheels becomes the rotating force for the motor which in turn converts this
mechanical energy into the electric energy which is further stored in the battery.

 Regenerative braking saves the energy and are widely used in today’s electric
vehicles.
 Tesla Model-S provides the most effective regenerative braking.
(iii) Dynamic or Rheostat Braking- 

It is the type of electrical braking in which resistance provided by the rheostat causes
the actual braking, in this type a rheostat is attached to the circuit that provides the resistance
to the motor which is responsible for de acceleration or stopping of the vehicle.

DESIGN CALCULATIONS FOR MOTOR, BATTERY,

CHARGER, STEERING MECHANISM, DISC BRAKE
Factors Affecting The Required Torque When selecting drive motor for the electric vehicle, a
number of factors must be taken into account to determine the maximum torque required.
These factors are:
1.Rolling resistance
2.Grade resistance
3.Acceleration force

ROLLING RESISTANCE
RR = GVW*Crr
Where,
RR = Rolling Resistane
GVW = Gross Vehicle Weight
Crr = Co-efficient of Rolling Resistance

GRADE RESISTANCE
THE GRADE RESISTANCE Grade resistance is the form of gravitational force. It is
the force that tends to pull the vehicle back when it is climbing an inclined surface.

GR = GVW*Sinθ
Where,
GR = Grade Resistance
θ = Grade or inclination angle

ACCELERATION FORCE

Acceleration force is the force that helps the vehicle to reach a predefined speed form
rest in a specified period of time. The motor torque bears a direct relationship with the
acceleration force. Better the torque, lesser the time required by the vehicle to reach a given
speed. The acceleration force is a function of the mass of the vehicle.

FA=mxa

Where,
m=GVW/g
FA= Acceleration force
m = mass of the vehicle
g= acceleration due to gravity(9.81m/sec²)
a = required acceleration

DC MOTOR

 Weight of the vehicle W = 2000Lambda

 Radius of the tire = 16.5cm
 Based on the above formulas the BLDC motor is selected with the following
parameters.

For Electric kart we use 4KW BLDC motor type, and some of these are specifications
of the motor are mentioned below.

 Type: Permanent Magnet BLDC

 Voltage (Volts): 48 V
  Rated Speed (RPM): 3000 100
 Rated Torque (Nm): 15.5
 Rated Power (W): 4000
 Efficiency (n): >87% on full load and full rpm
 Motor weight (kg): 15

BATTERY
 Motor power is 4KW
 So we have to select 4kw hr capacity battery
 If battery 60 V 70Ah Lithium Iron Phosphate is suitable.

STEERING SYSTEM

 Ackerman angle (a)

α=tan¹(c/2b) ;(c-759.21 mm, b=1219.2 mm)
α = 17.28"

 Turning radius (R)

R=b/2sin α; (α = 17.28")
R = 2.052meters

 Inner wheel angle (θ)

θ =tan (b/R+a/2); (a-1143 mm)
θ =29.76

 Outer wheel angle (ϕ)

cot ϕ -cotθ = c/b
ϕ =22.86

HERE; a-track width, b-wheelbase, c-distance

between stub axle

BRAKING SYSTEM

The brake system design includes the single disc at rear axle to stop the vehicle. It is
mounted in one third part of rear axle with opposite position of drive train sprocket hence
also enables the good balancing requirement.
Master cylinder is used at the front near the brake pedal providing the occupant to
easily accessible space.

Calculations:

1. Gross weight of the vehicle

2. W=weight of the vehicle (with load conditions) in kgs *9.81 =200*9.81-1962 N
3. Brake line pressure:
4. P = force on the brakes/area of master cylinders (as pedal ratio is 4:1)
(Assume the normal force applied on the pedal: 350 N)-pedal ratio force on the pedal/ area of
master cylinder)
 = 4*350 (π /4)*(0.01)
= 17.82 MPa
5. Clamping force (CF):
CF=brake line pressure*(area of calliper piston*2)
= 17.82*(( π /4) (25.4*10²)²*2)
= 18059 N

BRAKINFG SYSTEM

1. Rotating force:
RF CF number of caliper pistons *coefficient friction of brake pads
=18059 0.3*2
=10835.4 N
2. Braking torque:
BT rotating force effective disc radius
=10835.4 0.09 -975.186 N-m
3. Braking force (braking torque/tire radius)*0.8
=(975.18/0.179)*0.8
=4358.37 N
4. Deacceleration
f= -ma(-ve sign indicates force opposite direction)
a-BF/m-4358.37/200
= -21.79 m/s²
5. Stopping distance:
v²-u² = 2as (v=0, u=15m/s)
so, Stopping Distance = 5.23 meters

TRANSMISSION SYSTEM

TRANSMISSION SYSTEM DESIGN:

Power developed by the engine/motor is transferred to the wheels by transmission
system. The main function of transmission system are:
 It must provide varying gear ratios.
 It must provide a reverse gear for moving vehicle in reverse direction. We are
using BLDC motor of 4000 watt.

Power=Torque*Angular Velocity

Angular Velocity = 21 IN/60

=(2*3.14 3000)/60 314.15 rad/sec.

Velocity (V) = r Ω

Wheel radius = 5.2 inches

=5.5 * 25.4 mm

= 132.08mm =0.132m
V= 0.132 * 314.15 = 41.49m/s

Torque = Force * Perpendicular Distance

F = 13/0.13208

F = 98.42N

Frictional Force, f= umg

µ = 0.6 = Coefficient of friction

m = mass= 180kg

g = Acceleration due to gravity

f=0.6*180*9.81

= 1059.48N

Total force = F + f

= 1157.9N

Acceleration of vehicle (a) = F/m

= 1157.9/130

= 8.906m2/sec

Wheel Speed = []D/60

= (3.14 * 13 * 25.4 *10-3)/60

= 0.013 m/sec

Tractive force acting on wheel

=(Te * Ga)/RW

=(13*2.8)/0.0889

=364N

Power = Torque * Angular velocity

=13* 314.15

= 4.08 kW
Torque on the Wheel = n* r1* rd* Te

=0.85*1*4 * 13

= 44.2 Nm

CHAIN DRIVE CALCULATION:

 Chain number: #33

 Length of chain: 33cm

 Chain pitch: 1.5cm

 Chain roller diameter: 0.6cm

 Teeth on driver sprocket: 13

 Teeth on Axle sprocket: 36

 Gear ratio: 2.8

 Higher the gear ratio then higher its acceleration.

 Lower the gear ratio then higher its speed.

MOTOR, BATTERY AND CHARGER SPECIFICATIONS AS PER
AVAILABILITY IN THE MARKET AND WITH
MANUFACTURER DETAILS

BLDC MOTOR

4KW, 42V
BATTERY

CHARGER
CONCLUSIONS
 The selection of motor to achieve the required. starting torque and top speed was a
challenging task. Finally a BLDC Motor of 4KW and battery. of 60V/72Ah was
selected.
 Hence, both speed and torque requirements are compromised and hence the speed
control is achieved through a BLDC based voltage controller.
 To make the kart more effective and efficient in performance, timing chain drive is
selected for power transmission is considered to be a master stroke.