FABRICATION OF GO KART USING PVC PIPES

Submitted by

Name Reg. No
VENGADESH M 17265479
SEENIVASAN M 17265469
PREM KUMAR T 17265460
VIVEKANANHDAN U 17238521
SURESHKUMAR M 17265474
PRADEEP G 17265455

Under The Guidance of

K.MANIBALAN. M.TECH.,
LECTURER/MECH

In partial fulfilment for the award of the diploma by the Directorate of

Technical Education, Chennai-600025

DIPLOMA
in
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SRI MANAKULA VINAYAGAR POLYTECHNIC COLLEGE
PUDUCHERRY - 605 107

(Approved by AICTE New Delhi & Affiliated to Directorate of Technical Education, chennai )

APRIL - 2019
 FABRICATION OF GO KART USING PVC PIPES

Submitted by

Name Reg. No
VENGADESH M 17265479
SEENIVASAN M 17265469
PREMKUMAR T 17265460
VIVEKANANDHAN U 17238521
SURESHKUMAR M 17265474
PRADEEP G 17265455

UNDER THE GUIDENCE OF

K.MANIBALAN.B.TECH,M.E.,
LECTURER/MECH

In partial fulfilment for the award of the diploma by the Directorate of

Technical Education, Chennai-600025

DIPLOMA
in
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SRI MANAKULA VINAYAGAR POLYTECHNIC COLLEGE
PUDUCHERRY - 605 107

(Approved by AICTE New Delhi & Affiliated to Directorate of Technical Education, Chennai )

APRIL - 2019
 DEPARTMENT OF MECHANICAL ENGINEERING
SRI MANAKULA VINAYAGAR POLYTECHNIC COLLEGE
PUDUCHERRY - 605 107

(Approved by AICTE New Delhi & Affiliated to Directorate of Technical Education, Chennai )

BONAFIDE CERTIFICATE

This is to certify that this project work “Fabrication of go kart using

pvc pipes” is a bonafide work done by Mr. VENGADESH M(17265479) in
partial fulfilment for the award of Diploma in Mechanical Engineering of the
SRI Manakula Vinayagar Polytechnic College and who carried out the project
under my supervision.

Mr.K.MANIBALAN,M.Tech., Mr.G.SURESH KUMAR.M.Tech.,

Project Guide-Lecturer/MECH Head of the Department

Submitted for the Board Examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

 DEPARTMENT OF MECHANICAL ENGINEERING
SRI MANAKULA VINAYAGAR POLYTECHNIC COLLEGE
PUDUCHERRY - 605 107

(Approved by AICTE New Delhi & Affiliated to Directorate of Technical Education, Chennai )

BONAFIDE CERTIFICATE

This is to certify that this project work “fabrication of go kart using pvc pipes” is a
bonafide work done by
VENGADESH M 17265479
SEENIVASAN M 17265469
PREM KUMAR T 17265460
VIVEKANANDHAN U 17238521
SURESHKUMAR M 17265474
PRADEEP G 17265455

in partial fulfilment for the award of Diploma in mechanical Engineering of the Sri
Manakula Vinayagar Polytechnic College and who carried out the project under my
supervision.

Mr K.MANIBALAN.M.TECH., Mr.G.SURESH KUMAR.M.TECH.,

Project Guide-Lecturer/MECH Head of the Department

Submitted for the Board Examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We express our deep gratitude to the Honorable Chairman and Managing

Director Shri.M.Dhanasekaran., and our dynamic Vice Chairman

Shri.S.V.Sugumaran., and also our charming Shri.Dr.K.Narayanasamy for

providing an amazing environment for the development and promotion of diploma

education in our college.

We take this opportunity to express our thanks to the Principal

TMT.R.Kanchana, M.E., whose undying sprit is our complementary force, we wish

to place on our records, our sincere gratitude to Mr.G.Sureshkumar, B.Tech,M.E.,

Head of the Department for his encouragement and support to carry out this work

effectively.

We render our whole hearted thanks to our guide Mr.K.Manibalan,M.Tech.,

Lecturer who has been the guiding force in completing the project successfully.

We extend our sincere thanks to all staff of mechanical engineering

Department, friends and parents for their encouragement in doing this project.

We wish to express my sincere thanks to those who helped me in making this

project successfully.
 ABSTRACT

This paper aims to the review of design analysis of a go kart chassis. The main
intention is to do modelling and static analysis of go-kart chassis. The maximum
deflection is obtained by analysis. The go-kart chassis are different from chassis of
ordinary cars on the road .The paper highlights the material used and structural
formation of chassis. The strength of material, rigidity of structure and energy
absorption characteristics of chassis is discussed.Based structure of this project is
made of pvc pipe and wood. The pvc serves as the frame of the Go Kart while the
wood serves as the chassis that holds the motor. The chassis that contains the motors
drives the two rear wheels of the Go Kart, while the front wheels are set with
mechanical system that correspond to Go Kart movement direction. A 3-position
momentary rocker switch is used for moving forward or reverse, while a type of
potentiometer is used to control the speed of the motor. For stop, motor is short circuit
by the controller in which it will freeze the motor so no need for brakes. This Go
Kart / Electric Car is powered by 12V DC batteries.

This project is an excellent reference for DIY and further development of electric car. It
illustrate the capability of some basic materials that can be considered for the development.
Also, a development related to electric car supports sustainable energy system . This
undergraduate thesis documents the design considerations and specifications of building a
personal battery powered go kart.
CHAPTER NO PARTICULARS PAGE NO

1
INTRODUCTION

2
LITERATURE REVIEW

3
LINE DIAGRAM

4
COMPONENTS

5
WORKING

6
ADVANTAGE,DIADVANTAGE,APLLICATION

7
CONCLUSION

8
COST ESTIMATION

9
REFERENCE

10
PHOTOGRAPHY

TITLE OF FIGURE PAGE NO

FIGURE NO
 CIK-FIA Commission
1.1
International De Karting

3.1 Go kart line diagram

Diagram of Ackermann
4.1
steering geometry

4.2.1.1 Manual steering

4.2.1.2 Power steering

4.3.1 Wiper motor

4.4.1.1 Primary Batteries

4.4.1.2 Nickel-cadmimum battery

4.4.1.3 Ni-MH Battery

4.4.1.4 Lithium-Ion Battery

4.4.1.5 Lead Acid Battery

LIST OF ABBREVATIONS

PVC POLY VINYL CHLORIDE

NMC NATIONAL METEOROLOGICAL CENTER

NIMH NATIONAL METEOROLOGICAL CENTER

NICADS NICKEL CADMIUM

CIK-FIA COMMISSION INTERNATIONAL DE KARTING

CHAPTER 1
INTRODUCTION

1.INTRODUCTION
My motivation for choosing this topic as my thesis stems from a
variety of interests. Ever since I got my driver’s license, learning about automobiles has been
a passion of mine. Along with watching shows about cars and frequently visiting online
automobile blogs. I joined the Electric Vehicle Team where I helped with the battery-electric
conver . As I worked with the team over the summer, I was exposed to a plethora of other
student groups and personal projects . Since then, I have always wanted to build my own
vehicle but never could find the time between classes and personal obligations.

During my senior year, I began to design to formulate ideas for an

electric go-kart. At that point, the required thesis for undergraduates pursuing a full
mechanical engineering degree was far from my motivation. However, as graduation creeped
closer and closer, it became obvious that my goal of building my own vehicle would only get
done if I committed to it as my thesis project. I wanted to combine my hands-on experience
with a modern project that represented my talents and personality. Thanks to support from
several friends, I was able to accomplish my goal.

For this project, I wanted to demonstrate my accumulated engineering

knowledge. This would combine not only the academic mechanical teachings that I learned in
class, but also integrate electrical systems that I picked up while working on various projects.
This combination is necessary for many real world applications, and working on this area will
hopefully prove helpful after I graduate.

Everything in life begins with hope. Hope backed by effort is what

made “PRAYAAS” tangible. PRAYAAS is a coalition of all our endeavors and uphill battles.
It is the shape, given to efforts of the students of Department of Mechanical Engineering,
Sikkim Manipal Institute of Technology, who thought to fabricate a vehicle in college campus
situated at very isolated place.By definition of International Karting Commission

Federation International Automobile (CIK-FIA), a kart is defined as a land vehicle with or

without a bodywork, with 4 non-aligned wheels in contact with the ground, two of which
control the steering while the other two transmit the power.

Its main parts are the chassis (which consists of a body frame work that is made up of
a set of bent steel pipes that are welded together) with an engine, four wheels and tires
attached on it. According to Wikipedia, a go-kart (sometimes known as a "go-cart" or just
kart) is a small four-wheeled vehicle. Go-karts come in all shapes and forms, from motor less
models to high-powered racing machines, some, like Super karts, being able to beat racing
cars on long circuits. Gravity racers, usually referred to as Soap Box Derby carts, are the
simplest type of go-karts.

They are propelled by gravity, with some races taking place down a single hill.
Amusement park go-karts can be powered by 4-stroke engines or electric motors, while
racing karts use small 2-stroke or 4-stroke engines. Most of them are single seated but
recreational models can sometimes accommodate a passenger. In some countries, go-karts
can be licensed for use on public roads. Typically there are some restrictions, e.g. in the
European Union a gokart on the road needs head light (high/low beam), tail lights, a horn,
indicators and a maximum of 20hp. Besides traditional kart racing, many commercial
enterprises offer karts for rent, often called "recreational" or "concession" karts. The tracks
can be indoor or outdoor.

Karts are rented by sessions (10 to 15 minutes usually), they use sturdy chassis
completed with dedicated bodywork providing driver safety. Most of these enterprises use an
"Arrive and Drive" format which provide customers with all the safety gear (helmets, gloves
and driver outfits) where necessary and allow them to show up any time to race at a
reasonable price, without the hassle of owning one's own equipment and gear. Outdoor tracks
can offer low speed karts strictly for amusement (dedicated chassis equipped with low
powered 4-stroke engines or electric motors), to faster, more powerful karts similar to a
racing kart (powered by 4-stroke engines up to 15 hp and more rarely by 2-stroke engines)
but designed to be more robust for rental use. Typically, these outdoor tracks may also be
used for traditional kart races. Indoor kart tracks can be found in many large cities in different
parts of the world. These tracks are often located in refurbished factories or warehouses and
are typically shorter than traditional outdoor tracks. Indoor karts are typically powered by a
4-stroke gasoline engine producing anywhere from 5 to 13 horsepower, or sometimes by an
electric motor. Many tracks offer competitive races and leagues. At the top level, an Indoor
Karting World Championship (IKWC) exists
 Figure 1.1 CIK-FIA Commission International De Karting

CHAPTER 2
LITERATURE REVIEW

Go-kart technology has been widely developed since the introduction of wheels. But, it
was not fully implemented in racing activity until the past three hundred years in America.
 The first go-kart was simply a cart consisting of wheels and handles jointed together as
children pushed from behind when learning to walk or a four-wheeler platform where
children where children can sit on it while another push the kart around .Go-kart was
invented in California by Art Ingels and Lou Borelli using 100cc mower engines and strong
steel frames. Then, newly designed karts were beginning to gain popularity in Britian around
the year 1959-1960.

Go-kart has long existed in our world whether used insport or recreation .According to
Graham Smith (2002), Art Ingels who was a veteran hot rod and race carbuilder at Kurtis
Kraft in California, America invented the first ever go-kart in 1956. Initially,karting is a
leisure motorsport enjoyed by airmen during the post-war period. The sport is quickly caught
on with Go Kart Manufacturing Co. Inc. Being the first company to manufacture and
distribute go-karts after two years. In 1959, McCullough also jump in the bandwagon of the
industry, by becoming the first company to manufacture go-kart engines. Although go-kart
originated from United States, it has also gain interests from countries all over the worlds
especially Europe.

For example, according to Tony Kart’s company profile in its website from Italy, they
have been producing gokart since 1958 and emerged as one of the main manufacturer to date.
Today, kart racing is governed by CIK-FIA which was founded in 1962 is the current primary
international sanctioning body for kart racing. It is also a part of FIA since 2000 which is a
governing body for motorsport across the globe. CIK-FIA plays an important role in
regulating kart racing related matters such as technical regulations.

CHAPTER 3
PROJECT LINE DIAGRAM
 Fig3.1 go kart line diagram

CAPTER 4
COMPONENTS

4.1 FRAME
4.2 STREEING
 4.3 MOTOR
4.4 BATTERY

4.1 FRAME
I wanted the frame to be strong because Eli-Kart would need to carry at least 100 kgs
safely to account for one passenger. From previous projects I was familiar with box
extrusions, which are strong beams that are suitable for structural applications. I chose pvc
pipe but there is no high load cannot be sit so i also added steel frame below the pipe frame
because it is much tougher and easier to weld than materials such as aluminum. Uprights for
steering and mounting other components could be welded to the main structure. Picture of the
frame On top of the frame there needed to be a platform for sitting on. I decided on ½” thick
acrylic for several reasons. It would be clear, allowing for a view of the components under,
and also be structural enough to allow for direct mounting of seats and other parts. I chose the
dimension of the cart to fit within current handicap accessible areas, allowing it to go through
doors and fit in a bike lane. I also wanted it to be just long enough to fit one people sitting
one behind the other. A 24” by 48” fulfilled both of these criteria and had a convenient size
and a rectangular 1:2 ratio.

Frame design was first implemented by keeping in mind the safety requirement of the
event. The first primary safety standard focused on during design was maintaining the proper
clearance of the driver’s body rest to the other rigid parts like motor compartment and panel
bracing of the vehicle. Once the basic requirements fulfilled the other safety design were
implemented. The chassis was designed to give occupant extra space to operate the vehicle
easily.

4.2 STREEING
Steering is another very important mechanical aspect of any vehicle. I decided to
use a steering linkage similar to that on a colleague's go-kart, Shane Colton. It works by
attaching each wheel to a steering rod, and connecting each rod to a part on the end of the
steering wheel. When the steering wheel turns, the part on the end rotates, pushing one
steering rod away while pulling the other rod closer. For two wheel steering, an Ackermann
steering geometry accounts for the different turning radius of each wheel. The basis of the
geometry is shown in Figure 4.1

Fig 4.1 : Diagram of Ackermann steering geometry.

Once assembled, I found that there were several problems with the steering. At first, the
steering worked smoothly because it was unloaded. However, once the go-kart was loaded
with my weight, the flange bearing holding the steering wheel shaft in place began shifting
because it had an adjustable housing. To correct this, I made a large bushing to be mounted to
the bottom of the go-kart to help support the steering shaft

4.2.1 TYPES OF STEERING SYSTEMS

 4.2.1.1 MANUAL STEERING

The steering system converts the rotation of the steering wheel into a swivelling movement of
the road wheels in such a way that the steering-wheel rim turns a long way to move the road
wheels a short way.The system allows a driver to use only light forces to steer a heavy car.
The rim of a 15 in. (380 mm) diameter steering wheel moving four turns from full left lock to
full right lock travels nearly 16 ft (5 m), while the edge of a road wheel moves a distance of
only slightly more than 12 in. (300 mm). If the driver swivelled the road wheel directly, he or
she would have to push nearly 16 times as har

FIG 4.2.1.1 MANUAL STEERING

4.2.1.2POWER STEERING
On a heavy car, either the steering is heavy or it is inconveniently low geared - the steering
wheel requiring many turns from lock to lock.Heavy gearing can be troublesome when
parking in confined spaces. Power-assisted steering overcomes the problem.
The engine drives a pump that supplies oil under high pressure to the rack or the steering
box.Valves in the steering rack or box open whenever the driver turns the wheel, allowing oil
into the cylinder. The oil works a piston that helps to push the steering in the appropriate
direction.As soon as the driver stops turning the wheel, the valve shuts and the pushing action
of the piston stops.The power only assists the steering - the steering wheel is still linked to the
road wheels in the usual way.So if the power fails, the driver can still steer but the steering
becomes much heavier.

FIG 4.2.1.2 POWER STEERING

4.3. MOTOR
 The drive train is a fundamental engineering problem for all vehicles. The
drivetrain consists of the motor, transmission, and any drive wheels. Drivetrain components
need to be mounted robustly and operate efficiently to be safe and effective. I designed the
frame so that a motor could be easily mounted to the steel tubing. For the brushless hobby a
wiper motor I had, it would only take a single mounting plate to secure. After directly bolting
a to the steel frame, I drilled mounting holes that matched with the motor, and milled slots
into the plate to allow for proper tensioning of the chain drive. For simplicity and ease of
operation, there would only be one gear. I decided to use a chain to transmit power from the
motor shaft to the drive wheel. I chose chain because they are slightly more efficient and
quieter than their main competitor in small electric vehicles, chains.

Electrical Motor

The motor or an electrical motor is a device that has brought about one of the biggest
advancements in the fields of engineering and technology ever since the invention of
electricity. A motor is nothing but an electro-mechanical device that converts electrical energy
into mechanical energy. It’s because of motors, life is what it is today in the 21st century.
Without the motor, we had still been living in Sir Thomas Edison’s Era where the only
purpose of electricity would have been to glow bulbs. There are different types of motor have
been developed for different specific purposes.
In simple words, we can say a device that produces rotational force is a motor. The very basic
principle of functioning of an electrical motor lies on the fact that force is experienced in the
direction perpendicular to magnetic field and the current, when field and current are made to
interact with each other.
Ever since the invention of motors, a lot of advancements has taken place in this field of
engineering and it has become a subject of extreme importance for modern engineers. This
particular webpage takes into consideration, the fact as mentioned above and provides a
detailed description of all major electrical motors and motoring parts being used in the
present era.

CLASSIFICATION OR TYPES OF MOTOR

History of Motor

In the year 1821 British scientist Michael Faraday explained the conversion of electrical
energy into mechanical energy by placing a current carrying conductor in a magnetic field
which resulted in the rotation of the conductor due to the torque produced by the mutual
action of electrical current and field. Based on his principal the most primitive of machines a
DC (Direct Current) machine was designed by another British scientist William Sturgeonin
the year 1832. But his model was overly expensive and wasn’t used for any practical purpose.
Later in the year 1886, the first electrical motor was invented by scientist Frank Julian
Sprague. That was capable of rotating at a constant speed under a varied range of load and
thus derived motoring action.

Electric motors are now more diverse and adaptable than ever before. When planning a
motion control system, the choice of motor is extremely important. The motor must align
with the purpose and overall performance goals of the system. Luckily, there is a motor
design suitable for any imaginable purpose.
Some of the most common electric motors used today include:
AC Brushless Motors

AC brushless motors are some of the most popular in motion control. They use induction of a
rotating magnetic field, generated in the stator, to turn both the stator and rotor at a
synchronous rate. They rely on permanent electromagnets to operate.
DC Brushed Motors

In a DC brushed motor, brush orientation on the stator determines current flow. In some
models, the brush’s orientation relative to the rotor bar segments is decisive instead. The
commutator is especially important in any DC brushed motor design.

DC BRUSHLESS MOTORS

DC brushless motors were first developed to achieve higher performance in a smaller space
than DC brushed motors, and they are smaller than comparable AC models. An embedded
controller is used to facilitate operation in the absence of a slip ring or commutator.
DIRECT DRIVE

Direct drive is a high-efficiency, low-wear technology implementation that replaces

conventional servo motors and their accompanying transmissions. In addition to being far
easier to maintain over a longer period of time, these motors accelerate more quickly.
LINEAR MOTORS

These electric motors feature an unrolled stator and motor, producing linear force along the
device’s length. In contrast to cylindrical models, they have a flat active section featuring two
ends. They are typically faster and more accurate than rotatory motors.
SERVO MOTORS

A servo motor is any motor coupled with a feedback sensor to facilitate positioning; thus,
servo motors are the backbone of robotics. Both rotary and linear actuators are used. Low-
cost brushed DC motors are common, but are being superseded by brushless AC motors for
high-performance applications.
Stepper Motors

Stepper motors use an internal rotor, electronically manipulated by external magnets. The
rotor can be made with permanent magnets or a soft metal. As windings are energized, the
rotor teeth align with the magnetic field. This allows them to move from point to point in
fixed increments.
Before work begins on any new system, think carefully about the competing properties of the
different motors. The selection of the right motor gets any project off to a better start.

An electric motor is an electrical machine that converts electrical energy into mechanical
energy. Most electric motors operate through the interaction between the motor's magnetic
field and electric current in a wire winding to generate force in the form of rotation of a shaft.
Electric motors can be powered by direct current (DC) sources, such as from batteries, motor
vehicles or rectifiers, or by alternating current(AC) sources, such as a power grid, inverters or
electrical generators. An electric generator is mechanically identical to an electric motor, but
operates in the reverse direction, converting mechanical energy into electrical energy.

Electric motors may be classified by considerations such as power source type, internal
construction, application and type of motion output. In addition to AC versus DC types,
motors may be brushed or brushless, may be of various phase (see single-phase, two-phase,
or three-phase), and may be either air-cooled or liquid-cooled. General-purpose motors with
standard dimensions and characteristics provide convenient mechanical power for industrial
use. The largest electric motors are used for ship propulsion, pipeline compression
and pumped-storage applications with ratings reaching 100 megawatts. Electric motors are
found in industrial fans, blowers and pumps, machine tools, household appliances, power
tools and disk drives. Small motors may be found in electric watches.

In certain applications, such as in regenerative braking with traction motors, electric motors
can be used in reverse as generators to recover energy that might otherwise be lost as heat and
friction.

Electric motors produce linear or rotary force (torque) and can be distinguished from devices
such as magnetic solenoids and loudspeakers that convert electricity into motion but do not
generate usable mechanical force, which are respectively referred to as actuators and
transducers
The first electric motors were simple electrostatic devices described in experiments by
Scottish monk Andrew Gordon and American experimenter Benjamin Franklin in the
1740s. The theoretical principle behind them, Coulomb's law, was discovered but not
published, by Henry Cavendish in 1771. This law was discovered independently by Charles-
Augustin de Coulomb in 1785, who published it so that it is now known with his name. The
invention of the electrochemical battery by Alessandro Volta in 1799[5] made possible the
production of persistent electric currents. After the discovery of the interaction between such
a current and a magnetic field, namely the electromagnetic interaction by Hans Christian
Ørsted in 1820 much progress was soon made. It only took a few weeks for André-Marie
Ampère to develop the first formulation of the electromagnetic interaction and present
the Ampère's force law, that described the production of mechanical force by the interaction
of an electric current and a magnetic field. The first demonstration of the effect with a rotary
motion was given by Michael Faradayin 1821. A free-hanging wire was dipped into a pool of
mercury, on which a permanent magnet (PM) was placed. When a current was passed through
the wire, the wire rotated around the magnet, showing that the current gave rise to a close
circular magnetic field around the wire.[7] This motor is often demonstrated in physics
experiments, substituting brine for (toxic) mercury. Barlow's wheel was an early refinement
to this Faraday demonstration, although these and similar homopolar motors remained
unsuited to practical application until late in the century.

In 1827, Hungarian physicist Ányos Jedlik started experimenting with electromagnetic coils.
After Jedlik solved the technical problems of continuous rotation with the invention of
the commutator, he called his early devices "electromagnetic self-rotors". Although they were
used only for teaching, in 1828 Jedlik demonstrated the first device to contain the three main
components of practical DC motors: the stator, rotor and commutator. The device employed
no permanent magnets, as the magnetic fields of both the stationary and revolving
components were produced solely by the currents flowing through their windings

The drum rotor was introduced by Friedrich von Hefner-Alteneck of Siemens & Halske to
replace Pacinotti’s ring armature in 1872, thus improving the machine efficiency. The
laminated rotor was introduced by Siemens & Halske the following year, achieving reduced
iron losses and increased induced voltages. In 1880, Jonas Wenström provided the rotor with
slots for housing the winding, further increasing the efficiency.

In 1886, Frank Julian Sprague invented the first practical DC motor, a non-sparking device
that maintained relatively constant speed under variable loads. Other Sprague electric
inventions about this time greatly improved grid electric distribution (prior work done while
employed by Thomas Edison), allowed power from electric motors to be returned to the
electric grid, provided for electric distribution to trolleys via overhead wires and the trolley
pole, and provided control systems for electric operations. This allowed Sprague to use
electric motors to invent the first electric trolley system in 1887–88 in Richmond, Virginia,
the electric elevator and control system in 1892, and the electric subway with independently-
powered centrally-controlled cars. The latter were first installed in 1892 in Chicago by
the South Side Elevated Railroad, where it became popularly known as the "L". Sprague's
motor and related inventions led to an explosion of interest and use in electric motors for
industry. The development of electric motors of acceptable efficiency was delayed for several
decades by failure to recognize the extreme importance of an air gap between the rotor and
stator. Efficient designs have a comparatively small air gap. The St. Louis motor, long used in
classrooms to illustrate motor principles, is extremely inefficient for the same reason, as well
as appearing nothing like a modern motor. Electric motors revolutionized industry. Industrial
processes were no longer limited by power transmission using line shafts, belts, compressed
air or hydraulic pressure. Instead, every machine could be equipped with its own power
source, providing easy control at the point of use, and improving power transmission
efficiency. Electric motors applied in agriculture eliminated human and animal muscle powe
 FIG 4.3.1 WIPER MOTOR

4.4 BATTERY

A battery is a device consisting of one or more electrochemical

cells with external connections provided to power electrical devices such as flashlights, smart
phones, and electric cars.[1] When a battery is supplying electric power, its positive terminal is
the cathode and its negative terminal is the anode.[2] 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.[3] 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.[4]

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. Examples include the lead-acid batteries used in vehicles and lithium-
ion batteries used for portable electronics such as laptops and smartphones.

Batteries come in many shapes and sizes, from miniature cells used to power hearing aids and
wristwatches to small, thin cells used in smartphones, to large lead acid batteries or lithium-
ion batteries in vehicles, and at the largest extreme, huge battery banks the size of rooms that
provide standby or emergency power for telephone exchanges and computer data centers.

According to a 2005 estimate, the worldwide battery industry generates US$48 billion in
sales each year,[5] with 6% annual growth.

Batteries have much lower specfic energy (energy per unit mass) than common fuels such as
gasoline. In automobiles, this is somewhat offset by the higher efficiency of electric motors in
converting chemical energy to mechanical work, compared to combustion engines.

4.2.1 TYPES OF BATTERY

 Batteries generally can be classified into different categories and types, ranging
from chemical composition, size, form factor and use cases, but under all of these are two
major battery types;

1. Primary Batteries
2. Secondary Batteries

1. PRIMARY BATTERIES

Primary batteries are batteries that cannot be recharged once depleted. Primary
batteries are made of electrochemical cells whose electrochemical reaction cannot be
reversed. Primary batteries exist in different forms ranging from coin cells to AA batteries.
They are commonly used in standalone applications where charging is impractical or
impossible. A good example of which is in military grade devices and battery powered
equipment. It will be impractical to use rechargeable batteries as recharging a battery will be
the last thing in the mind of the soldiers. Primary batteries always have high specific energy
and the systems in which they are used are always designed to consume low amount of
power to enable the battery last as long as possible.

FIG 4.4.1.1 PRIMARY BATTERIES

Some other examples of devices using primary batteries include; Pace makers, Animal
trackers, Wrist watches, remote controls and children toys to mention a few.

The most popular type of primary batteries are alkaline batteries. They have a high specific
energy and are environmentally friendly, cost-effective and do not leak even when fully
discharged. They can be stored for several years, have a good safety record and can be carried
on an aircraft without being subject to UN Transport and other regulations.
The only downside to alkaline batteries is the low load current, which limits its use to devices
with low current requirements like remote controls, flashlights and portable entertainment
devices.

2. SECONDARY BATTERIES

Secondary batteries are batteries with electrochemical cells whose chemical reactions can be
reversed by applying a certain voltage to the battery in the reversed direction. Also referred to
as rechargeable batteries, secondary cells unlike primary cells can be recharged after the
energy on the battery has been used up.

They are typically used in high drain applications and other scenarios where it will be either
too expensive or impracticable to use single charge batteries. Small capacity secondary
batteries are used to power portable electronic devices like mobile phones, and other gadgets
and appliances while heavy-duty batteries are used in powering diverse electric vehicles and
other high drain applications like load levelling in electricity generation. They are also used
as standalone power sources alongside Inverters to supply electricity. Although the initial
cost of acquiring rechargeable batteries is always a whole lot higher than that of primary
batteries but they are the most cost-effective over the long-term.Secondary batteries can be
further classified into several other types based on their chemistry. This is very important
because the chemistry determines some of the attributes of the battery including its specific
energy, cycle life, shelf life, and price to mention a few.

There are basically four major chemistries for rechargeable batteries;

1. Lithium-ion(Li-ion)
2. Nickel Cadmium(Ni-Cd)
3. Nickel-Metal Hydride(Ni-MH)
4. Lead-Acid

1. NICKEL-CADMIUM BATTERIES

The nickel–cadmium battery (NiCd battery or NiCad battery) is a type of rechargeable

battery which is developed using nickel oxide hydroxide and metallic cadmium
as electrodes. Ni-Cd batteries excel at maintaining voltage and holding charge when not in
use. However, NI-Cd batteries easily fall a victim of the dreaded “memory” effect when a
partially charged battery is recharged, lowering the future capacity of the battery.

FIG 4.4.1.2 NICKEL-CADMIMUM BATTERY

In comparison with other types of rechargeable cells, Ni-Cd batteries offer good life cycle
and performance at low temperatures with a fair capacity but their most significant advantage
will be their ability to deliver their full rated capacity at high discharge rates. They are
available in different sizes including the sizes used for alkaline batteries, AAA to D. Ni-Cd
cells are used individual or assembled in packs of two or more cells. The small packs are used
in portable devices, electronics and toys while the bigger ones find application in aircraft
starting batteries, Electric vehicles and standby power supply.

Some of the properties of Nickel-Cadmium batteries are listed below.

 Specific Energy: 40-60W-h/kg

 Energy Density: 50-150 W-h/L
 Specific Power: 150W/kg
 Charge/discharge efficiency: 70-90%
 Self-discharge rate: 10%/month
 Cycle durability/life: 2000cycles

2. NICKEL-METAL HYDRIDE BATTERIES

Nickel metal hydride (Ni-MH) is another type of chemical configuration used

for rechargeable batteries. The chemical reaction at the positive electrode of batteries is
similar to that of the nickel–cadmium cell (NiCd), with both battery type using the
same nickel oxide hydroxide (NiOOH). However, the negative electrodes in Nickel-Metal
Hydride use a hydrogen-absorbing alloy instead of cadmium which is used in NiCd batteries

FIG 4.4.1.3 NI-MH BATTERY

NiMH batteries find application in high drain devices because of their high capacity and
energy density. A NiMH battery can possess two to three times the capacity of a NiCd battery
of the same size, and its energy density can approach that of a lithium-ion battery. Unlike the
NiCd chemistry, batteries based on the NiMH chemistry are not susceptible to the
“memory” effect that NiCads experience.

Below are some of the properties of batteries based on the Nickel-metal hydride chemistry;

 Specific Energy: 60-120h/kg

 Energy Density: 140-300 Wh/L
 Specific Power: 250-1000 W/kg
 Charge/discharge efficiency: 66% - 92%
 Self-discharge rate: 1.3-2.9%/month at 20oC
 Cycle Durability/life: 180 -2000
3. LITHIUM-ION BATTERIES

Lithium ion batteries are one of the most popular types of rechargeable batteries. They are
found in different portable appliances including mobile phones, smart devices and several
other battery appliances use\d at home. They also find applications in aerospace and military
applications due to their lightweight nature.
 Fig 4.4.1.4 Lithium-Ion Battery

Lithium-ion batteries are a type of rechargeable battery in which lithium ions from the
negative electrode migrate to the positive electrode during discharge and migrate back to the
negative electrode when the battery is being charged. Li-ion batteries use an intercalated
lithium compound as one electrode material, compared to the metallic lithium used in non-
rechargeable lithium batteries.Lithium ion batteries generally possess high energy density,
little or no memory effect and low self-discharge compared to other battery types. Their
chemistry alongside performance and cost vary across different use cases for example, Li-ion
batteries used in handheld electronic devices are usually based on lithium cobalt oxide
(LiCoO2) which provides high energy density and low safety risks when damaged while Li-
ion batteries based on Lithium iron phosphate which offer a lower energy density are safer
due to a reduced likelihood of unfortunate events happening are widely used in powering
electric tools and medical equipment. Lithium ion batteries offer the best performance to
weight ratio with the lithium sulphur battery offering the highest ratio.Some of the attributes
of lithium ion batteries are listed be

4. LEAD-ACID BATTERIES

Lead acid batteries are a low-cost reliable power workhorse used in heavy duty applications.
They are usually very large and because of their weight, they’re always used in non-portable
applications such as solar-panel energy storage, vehicle ignition and lights, backup power and
load levelling in power generation/distribution. The lead-acid is the oldest type of
rechargeable battery and still very relevant and important into today’s world. Lead acid
batteries have very low energy to volume and energy to weight ratios but it has a relatively
large power to weight ratio and as a result can supply huge surge currents when needed.
These attributes alongside its low cost makes these batteries attractive for use in several high
current applications like powering automobile starter motors and for storage in backup power
supplies.

Fig 4.4.1.5 Lead Acid Battery

CHAPTER 5

WORKING

It is a small four wheeler run by motor using battery. Streering wheel consists of slider
mechanism .To Move the vechile using a push button switch .Wiper motor is connected with
the 12battery and switch also connected with the motor and battery Push the switch button
switch continously go cart will move relaese switch It will stop. Change the battery
connection wire for reverse movement.

4.5 PIPES

Polyvinylchloride (/ˌpɒlivaɪnəl ˈklɔːraɪd/; colloquial: polyvinyl, vinyl]; abbreviated: PVC)

is the world's third-most widely produced synthetic plastic polymer,
after polyethylene and polypropylene. About 40 million tonnes are produced per year.

PVC comes in two basic forms: rigid (sometimes abbreviated as RPVC) and flexible. The
rigid form of PVC is used in construction for pipe and in profile applications such as doors
and windows. It is also used in making bottles, non-food packaging, and cards (such as bank
or membership cards). It can be made softer and more flexible by the addition of plasticizers,
the most widely used being phthalates. In this form, it is also used in plumbing, electrical
cable insulation, imitation leather, flooring, signage, phonograph records,[8]inflatable
products, and many applications where it replaces rubber.[9] With cotton or linen, it is used to
make canvas.

Pure polyvinyl chloride is a white, brittle solid. It is insoluble in alcohol but slightly soluble
in tetrahydrofuran

CHAPTER 6

6 ADVANTAGES

Acceleration is usually better than thermic model and the speed is sufficient for use
on most kart circuits. Torque in electric motors are greater than that of the gas engine. They
are ideal for quick take offs and off road climbing.Electric go-karts are low maintenance,
requiring only that the lead-acid batteries of the cars be plugged into an array of chargers
after each run. Since they are pollution-free and emit no smoke, the racetracks can be indoors
in controlled environments. Most fully charged electric karts can run a maximum of 20
minutes before performance is affected. An expensive alternative is the use of Lithium iron
phosphate LiPO4 lithium batteries. They last much longer and carry more power per pound
than lead acid batteries.Electric power Go-Karts do not have hot engines or a tank full of gas
which can prove to be safer in an accident.

6.1 DISADVANTAGES

Batteries are still very expensive and the autonomy is not that good. However, charging
can be achieved in about 30 minutes and it is possible to swap batteries.

6.2 APPLICATION

Fun drifting ,off road riding ,f-1 Racing ,Desert Racing ,short Distance
travelling ,used in big temples

CHAPTER 7

CONCLUSIONS
 The purpose of this project was to fabricate a fixed axle/single axle go kart based on a
conceptual design which is optimized to increase the stability and maneuverability of the
vehicle on the racing track. The design is based on rulebook which is affiliated to CIK-FIA.
The design and fabrication of the Go-kart focuses on developing a simple, lightweight and
easily operated vehicle. Aspects of ergonomics, safety and reliability were incorporated into
the design specifications. Analysis were conducted on all major components to optimize
strength and rigidity, improve vehicle performance and to reduce complexity and
manufacturing costs.

Through this project, I’ve found that personal electric vehicles are very comprehensive
projects. When completed, they can be very fun and even practical if used for transportation.
However, building a motor took much more time and effort than I initially expected. For use
in an open space under a go-kart , a commercial motor would be much easier and potentially
cheaper. Only for truly specific purposes can a custom motor be well justified. Still,
designing and building go kart was a great learning experience that will remain a memorable
part of my time at SMVPTC

CHAPTER 8
 COST ESTIMATION

COMPONENTS PRICE

PVC PIPES 1370

BEARING 310

STEEL PIPES 650

WHEELS 1500
WIPER MOTOR 3270
BATTERY 700
CHAIN 100
PUSH BUTTON 50
OTHER COMPONENTS 100

TOTAL = 8100

CHAPTER 9

PHOTOGRAPHY
 CHAPTER 10

REFERENCE

1]. Anjul Chauhan, Lalit Naagar , Sparsh Chawla, Design And Analysis Of A Go-Kart,
International Journal of Aerospace and Mechanical Engineering Volume 3 – No.5, September
2016 ,29

[2] Sandeep Ramini, Mohan Rentala ,Sneha Gulab Mane B.Tech (Mechanical Engineering),
Design and Structural Analysis of a Go-Kart Vehicle Chassis , International Journal &
magazine of engineering , technology and management research , Volume 2 – No.10, october
2015 ,1373

[3]. Harshal D. Patil, , Saurabh S. Bhange ,Ashish S. Deshmukh, Design and Analysis of Go-
Kart using Finite Element Method , International Journal of Innovative and Emerging
Research in Engineering Volume 3, Special Issue 1, ICSTSD 2016

[4]. Ravindra Laxman Gaikwad, Prathmesh Vishwas Waghmare, Lalit Daulatrao Deore,
Akshay Mukesh Mutake , DESIGN OF GO-KART VEHICLE SYSTEMS , international
conference on emerging trend in engineering and management research , ICETEMER-16 ,
23rd march 2016