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Objective

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Design Detail

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Main Gear

Front cover

Sprocket

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Bearing

Pinion

Shaft

Rear Cover

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The gearbox has a fixed ratio gear system. For every revolution of the spur gear the

 pinion does 6.5 revolutions.

The gearbox holds a spring loaded clutch mechanism to engage and disengage the spur 

gear with the pinion.

The clutch is controlled by the rider using a shifter provided in the handle.

Main gear (72 teeth,dia 12.5cm)

Pinion(11

teeth,dia2.5cm)

Gearbox

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Flywheel

The flywheel used here is a 6 kg mild steel disc with a diameter of 25cm.

The flywheel is attached to the pinion in the gearbox in the rear hub.

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WheelThe wheel uses a standard rim of 622 mm dia and 37 mm tire width.

The is attached to the hub by 32 spokes of stainless steel.

Tire and Tube suited for the rim is used.

FrameThe frame used here is that of a Japanese cycle named ‘Lumala POWER ’. 

The frame was modified by welding to hold the rear wheel.

Shifter

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Design

ChainBased on the power to be transmitted and standard chain size of cycle chain type 08B was selected

it had the following features

Pitch = p1 = 12.70mm

Roller diameter = d1 = 8.51mm

Width between inner plates = b1 = 7.75mm

Transverse pitch = p1 =13.92mm

Breaking load =17.8kN

Factor of safety=7

Permissible speed of smaller sprockets=2400rpm (for 19 teeth sprocket)

Maximum Power Transmission = 0.64kW (at 100rpm)

The chain was then checked for design safety by finding the load on the chain.

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Design

The chain is checked for safety and the various parameters of the chain and sproket system found out like

Load on the chain

Roller seating radius(R i)

Roller seating angle(α)

Tooth height above the pitch polygon(ℎ) 

Root diameter()  Tooth width () 

Tooth side radius() 

Pitch line velocity

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Design

Helical gear

The helical gear is designed based on the following parameters

rated power = 200W 

helix angle = 15◦ 

number of teethpinion = 11

main gear = 72

gear ratio = 6.5:1

material = steel C30 ,heat treated

Using the above factors module of the gear is found out and using which the following parameters are

found Dynamic tooth load  

Dynamic strength of gear  

Limiting Load for wear  

The Design is checked for safety by verifying ≥ and ≥  

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Design

Flywheel

Using the rated power 200Watts and Ce we calculate the change in energy using the equation

change in energy = E =∗1000∗

 

where Ce = coefficient of energy fluctuation

n = mean speed

Then using change in energy E =(1−2)

2 

the above equation is used to find the weight of the most favorable flywheel

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Brakeengaginglever

Clutch engaging lever

Flywheel

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Gearbox

Pinion

Clutch

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Fabrication Procedure

PhaseI

•

Selection of a suitable Cycle frame• Obtaining the hub and gearbox system of a LUNA 

moped

Phase II

• Cleaning and lubrication of gearbox• Choosing the suitable spokes for mounting

PhaseIII

•

 Assembling the rear wheel•  Alignment of crank and freewheel

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Phase IV 

• Choosing a flywheel of suitable weight•  Assembling the rear wheel to the frame by welding

Phase V 

• Fixing the the clutch and brake mechanism into thecycle

•  Attaching shifter and pedal or lever mechanism formanual control of clutch and brake system

Fabrication Procedure 

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 Analysis 

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Scope for improvement

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Source

1. http://www.gizmag.com/flywheel-bicycle-regenerative-braking/19532/

2 http://www.bikeradar.com/news/article/cooper-union-flywheel-powered-bike/  

3 http://www.explainthatstuff.com/how-regenerative-brakes-work.html

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