Mechanical Design of a Two-Wheeler Electric Vehicle

Abstract

The mechanical design of a two-wheeler electric vehicle (EV) is a multidisciplinary exercise that must balance performance, efficiency, safety and cost-effectiveness. This paper presents the design considerations adopted for a two-wheeler EV, covering the chassis and frame, suspension, braking system, wheels and tyres, and the associated fabrication processes of welding and painting. A double-cradle chassis was selected and fabricated for the prototype, and its structural adequacy was verified through impact-load and factor-of-safety calculations for front, side, rear and torsional loading. Helical compression springs for the rear shock absorbers were sized from the static and dynamic load on the vehicle. The relative merits of drum and disc braking systems, and of the four common shock-absorber configurations used in two-wheelers, are compared to justify the choices made. The resulting design yields a lightweight, structurally sound and rider-comfortable platform suited to sustainable urban mobility.