Internal

Internal
Internal
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Awesome, Sandip! Let’s build your Final Year Black Book so you can paste it straight into Word (or I can
generate a ready-to-print DOCX/PDF if you want).

Below is a complete, polished and formatted structure with all front matter and the main report content
tailored to your project. I’ve included clear placeholders wherever your team needs to insert
photos/measurements.

📘 1) FRONT MATTER

✅ Title Page

Project Title:
“3-Wheeler Electric Material Picker for Warehouse Use (E-Cart Vehicle)”

Students:

1. Hemant Tawde

2. Sandip Ghuge

3. Sandip Rupanur

4. Akshay Amkar

5. Girish Mohite

Department: Mechanical Engineering

College: Yadavrao Tasgaonkar Polytechnic
Guide: Prof. Ajith Dange
HOD: Mr. Aditya Saraf
Academic Year: 20XX–20YY
[College Logo Here]

Tip: Keep this page centered; use 16–18 pt for title, 12–14 pt for the rest.

✅ Certificate Page

This is usually on the college letter template. You can paste the text below and leave space for stamps
and signatures.

CERTIFICATE

This is to certify that the project entitled “3-Wheeler Electric Material Picker for Warehouse Use (E-Cart
Vehicle)” submitted by Hemant Tawde (Roll No. ___), Sandip Ghuge (Roll No. ___), Sandip Rupanur
(Roll No. ___), Akshay Amkar (Roll No. ___), and Girish Mohite (Roll No. ___) to the Department of
Mechanical Engineering, Yadavrao Tasgaonkar Polytechnic, is a record of their original work carried out
under the guidance of Prof. Ajith Dange during the academic year 20XX–20YY.
 Internal

This work has not been submitted to any other institute or university for the award of any
diploma/degree.

Project Guide
Name & Sign: ____________________ Date: ___________

Head of Department (HOD)

Name & Sign: ____________________ Date: ___________

Principal
Name & Sign: ____________________ Date: ___________

Department Seal Institute Seal

✅ Declaration Page (as requested)

DECLARATION

We, the undersigned students of the Department of Mechanical Engineering at Yadavrao Tasgaonkar
Polytechnic, hereby declare that the project titled:

“3-Wheeler Electric Material Picker for Warehouse Use (E-Cart Vehicle)”

is an original work carried out by us under the guidance of Prof. Ajith Dange.
This report has not been submitted to any other institute or university for the award of any
diploma/degree/certificate. All data and results presented are true to the best of our knowledge and are
based on our design, fabrication, and testing.

Students:

1. Hemant Tawde

2. Sandip Ghuge

3. Sandip Rupanur

4. Akshay Amkar

5. Girish Mohite

Signatures:

Date: ___________ Place: Yadavrao Tasgaonkar Polytechnic

✅ Acknowledgement
 Internal

We express our sincere gratitude to Prof. Ajith Dange for his guidance, valuable suggestions, and
continuous encouragement throughout this project. We thank our Head of Department, Mr. Aditya
Saraf, for providing departmental support and access to laboratory facilities. We are grateful to our
Principal for institutional resources and motivation.

We also acknowledge the help received from lab assistants for fabrication and testing support. We
appreciate the cooperation of our team members for their collective effort and dedication. Finally, we
thank our families for their constant support and understanding during the course of this work.

✅ Abstract

This project aims to design and fabricate a 3-Wheeler Electric Material Picker for warehouse operations,
specifically for e-commerce applications. Manual picking and movement of goods in warehouses
demand significant human effort and time, especially when pushing loaded pallets. To overcome this, an
electric e-cart system is developed to improve productivity, reduce operator fatigue, and enable smooth
material transport in narrow aisles.

The vehicle integrates an electric motor, lithium-ion battery pack, motor controller, throttle, and a
compact chassis to provide efficient, zero-emission movement. The tri-wheel configuration offers tight
turning radius, stable handling, and suitable load-carrying capacity for confined environments. The final
model demonstrates clean, efficient, and safe material handling using electric propulsion while aligning
with modern warehouse sustainability goals.

✅ Index / Table of Contents (Detailed)

1. Front Matter
1.1 Title Page
1.2 Certificate
1.3 Declaration
1.4 Acknowledgement
1.5 Abstract
1.6 List of Figures
1.7 List of Tables
1.8 List of Abbreviations

2. Introduction
2.1 Background & Context
2.2 Need for Material Handling Equipment (MHE) in Warehouses
2.3 Growth of E-commerce & Faster Order Picking
2.4 Rise of Electric Vehicles in Industrial Logistics
2.5 Rationale for a 3-Wheeler Design
2.6 Importance in Narrow Aisles
2.7 Project Scope & Deliverables
2.8 Report Organization
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3. Problem Statement

4. Objectives of the Project

5. Literature Review
5.1 Electric Industrial Vehicles (Tuggers, Pickers, AGVs)
5.2 Warehouse Automation & Order Picking Methods
5.3 Existing E-Rickshaws & Industrial Pickers (Benchmarking)
5.4 Material Handling Equipment (MHE) Classifications
5.5 EV Motors, Controllers & Battery Technologies (BLDC, Li-ion)
5.6 Ergonomics in Warehouse Operations (Fatigue, Safety, Productivity)
5.7 Gap Identification & Project Positioning

6. System Architecture / Block Diagram

6.1 Functional Block Diagram
6.2 Power Flow & Control Flow
6.3 Safety Interlocks & Protections

7. Components Used
7.1 Mechanical Subsystem
7.1.1 Chassis Frame
7.1.2 Steering + Front-Wheel Drive Assembly
7.1.3 Rear Solid PU Wheels
7.1.4 Material Platform / Cage
7.1.5 Braking System (Front) + Regenerative Braking
7.2 Electrical Subsystem
7.2.1 Electric Motor (BLDC / DC)
7.2.2 Battery Pack (Li-ion)
7.2.3 Motor Controller
7.2.4 Throttle
7.2.5 Wiring Harness, MCB/Fuse, Connectorization
7.2.6 Charger (On-board / Off-board)

8. Design & Calculations

8.1 Performance Targets (Speed, Gradient, Load, Range)
8.2 Traction Calculations (Rolling Resistance, Tractive Effort)
8.3 Motor Sizing & Torque Calculation
8.4 Gear Ratio / Direct Drive Selection
8.5 Battery Capacity & Range Estimation
8.6 Energy Consumption (Wh/km, Wh/cycle)
8.7 Chassis Sizing & FOS Considerations
8.8 Turning Radius & Stability Check
8.9 Brake Sizing (Stopping Distance)
8.10 Summary of Selected Specifications

9. Fabrication Process
9.1 Chassis Design & Drawings
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9.2 Material Cutting, Jigs & Fixtures

9.3 Welding & Dimensional Inspection
9.4 Drilling & Mounting Interfaces
9.5 Motor Mounting & Chain/Belt Alignment (if used)
9.6 Wheel/Tyre Fitting
9.7 Electrical Wiring & Controller Mounting
9.8 Testing & Troubleshooting
9.9 Surface Preparation & Painting
9.10 Final Assembly Photos

10. Working of the E-Cart

10.1 Power-up & Throttle Operation
10.2 Forward Drive & Regenerative Braking
10.3 Steering & Maneuvering in Aisles
10.4 Safety Features (MCB, E-stop, Fuse)
10.5 Charging Cycle & SOC Indication

11. Results & Testing

11.1 Top Speed (No-load & Loaded)
11.2 Maximum Load Carried
11.3 Range per Charge
11.4 Charging Time & Efficiency
11.5 Maneuverability (Turning Radius, Aisle Width)
11.6 Energy Consumption (Measured)
11.7 Photos & Test Readings

12. Cost Estimation

12.1 Component Costs
12.2 Fabrication Costs
12.3 Labour Costs
12.4 Total Project Cost

13. Applications

14. Advantages

15. Limitations

16. Future Scope

17. Conclusion

18. References

19. Annexures
A. Datasheets (Motor, Controller, Battery)
B. Drawings (Chassis, Mounts, Platform)
C. Test Log Sheets & Calculations
D. User & Maintenance Guidelines
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📗 2) MAIN PROJECT REPORT

⭐ 1. Introduction

1.1 Background & Context

Warehouses are shifting to high-throughput, low-error operations driven by e-commerce and

omnichannel distribution. Manual trolleys and pallet pushers are labor-intensive, slow in peak hours,
and often struggle in narrow aisles.

1.2 Need for MHE in Warehouses

Material Handling Equipment (MHE) reduces human effort, increases pick rate, and improves safety. For
carton-level picking and short-haul in-aisle moves (zone picking, batch picking), compact powered carts
fill the gap between manual trolleys and expensive AGVs.

1.3 Growth of E-commerce & Demand for Faster Picking

Order profiles demand shorter lead times and rapid fulfillment. Electrified in-aisle movers help
operators maintain consistent speed and reduce fatigue, improving lines per hour.

1.4 Rise of Electric Vehicles in Industrial Logistics

Industrial EVs offer zero local emissions, lower noise, regenerative braking, and lower operating cost
(electricity vs. fuel). Maintenance (no engine oil, fewer moving parts) is also reduced.

1.5 Why a 3-Wheeler Design is Suitable (Detailed)

 Tight Turning Radius: A single steered drive wheel at front enables pivot-like turns, perfect for
<1.2–1.5 m aisle widths.

 Weight & Cost Efficiency: Two rear idler wheels + one drive wheel reduces material, complexity,
and cost versus 4-wheel steering.

 Sufficient Stability: For low/medium speeds in indoor, level floors, triangular wheelbase
provides adequate static stability; battery can be mounted low to lower CG.

 Simpler Kinematics: Single motor + direct drive/gear reduction minimizes drivetrain losses and
simplifes control and maintenance.

 Operator Ergonomics: Stand-on or walk-behind handle with twist throttle gives precise creep
control for docking at shelves.

1.6 Importance of Compact Electric Pickers in Narrow Aisles (Detailed)

 Aisle Utilization: Narrower aisles increase storage density; compact carts operate without layout
changes.

 Safety & Visibility: Low profile, front drive, and slow-speed torque ensures controlled
movement around workers and racks.
 Internal

 Energy Efficiency: Frequent stop-go cycles benefit from instant torque and regeneration.

 Noise Reduction: Quiet operation enhances communication and reduces operator stress.

1.7 Project Scope & Deliverables

Design, fabricate, and test a 3-wheeler electric material picker with:

 Rated load (e.g., 150–250 kg payload — confirm)

 Target speed 6–10 km/h indoor

 Turning radius suitable for narrow aisles

 Battery-based operation with on/off-board charging

 Demonstration of safe, reliable operation

⭐ 2. Problem Statement (Updated)

Manual picking in warehouses leads to: (i) higher fatigue, (ii) slow movement, (iii) difficulty with heavy
pallets, (iv) low productivity, (v) safety risks, and (vi) inefficiency in narrow aisles.
Goal: Replace manual pushing with a compact, electric-powered solution to improve throughput and
safety.

⭐ 3. Objectives of the Project

1. Design & fabricate a 3-wheel electric vehicle for warehouse material handling.

2. Reduce manual effort and improve picking efficiency.

3. Provide a compact, zero-emission, energy-efficient solution.

4. Improve maneuverability in narrow pathways.

5. Demonstrate EV technology in industrial use.

⭐ 4. Literature Review (Detailed)

Below is an academic-style narrative you can keep as is. If you want citations to specific
papers/standards, I can add them.

Electric Industrial Vehicles:

Industrial EVs, including tuggers, order pickers, and pallet movers, have matured with BLDC motors and
MOSFET/IGBT controllers. Advantages include high torque at low speed, regenerative braking, and
reduced maintenance compared to ICE or brushed DC systems. Battery cost reductions and compact
motor designs enable smaller chassis with adequate payload.
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Warehouse Automation Systems:

While AGVs/AMRs automate point-to-point tasks, there remains a strong need for human-in-the-loop
equipment for flexible, short-distance picking. Walk-behind or stand-on powered carts improve pick
rates without the complexity/cost of full automation.

Existing E-Rickshaws & Pickers (Benchmarking):

E-rickshaw architectures show the viability of low-voltage (24–48 V) systems for carrying loads at
modest speeds using BLDC hub or mid-drive motors. Industrial pickers often use narrow chassis, short
wheelbase, and tiller-type throttles for precise control.

Material Handling Equipment (MHE):

MHE classification includes transport equipment (carts, tuggers), positioning equipment (lifters), unit
load formation (pallets, containers), and storage systems (racks). The proposed cart falls in transport
equipment optimized for in-aisle movements.

EV Motor & Battery Technologies:

BLDC motors offer high efficiency (85–92% typical), compact size, and excellent speed control with
electronic commutation. Lithium-ion (NMC/LFP) batteries provide high cycle life, high
depth-of-discharge, fast charging, and BMS-enabled safety (over-current, over/under-voltage,
temperature protection).

Ergonomics in Warehouse Operations:

Reducing push/pull forces lowers risk of MSDs (musculoskeletal disorders). Electrification reduces
operator strain, improves task consistency, and maintains output across shifts. Features like belly
switch, E-stop, speed limiting, and regen braking enhance safety and ergonomics.

Gap Identified:
Existing solutions are either manual (fatigue, slow) or costly automated (AGV/AMR). A compact,
low-cost, 3-wheel electric picker addresses the middle ground—agile, ergonomic, and affordable.

⭐ 5. System Architecture / Block Diagram

Functional Blocks:

 Battery Pack (Li-ion + BMS) → DC Power

 Main MCB/Fuse → Over-current protection

 Motor Controller (BLDC/DC) → Speed/torque control

 Throttle (Hall sensor) → Speed command

 Drive Motor (Front wheel) → Traction

 Chassis & Wheels → Support & motion

 Braking System → Mechanical front brake + Regenerative braking in controller

 Charging Unit → CC/CV charger (on-board or off-board)

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Power Flow: Battery → MCB/Fuse → Controller → Motor → Wheels

Control Flow: Throttle → Controller → PWM/commutation to Motor
Safety: E-Stop → Cuts controller enable; BMS protections; MCB/Fuse

I can also give you a clean block diagram image (PNG/SVG) if you’d like.

⭐ 6. Components Used

Note: Add your exact vendor/datasheets in Annexures. I’ll keep the specs generic so you can map to your
parts.

6.1 Mechanical Components

(a) Chassis Frame

 Type: Welded mild steel (MS) rectangular hollow sections (e.g., 25×25×2 mm; confirm)

 Dimensions (example): L 1100–1300 mm × W 550–650 mm × H platform 300–500 mm

 Working: Supports payload, battery, and drive assembly with low CG.

 Purpose: Structural integrity, mounting points for motor, controller, and platform.

 [Insert diagram / CAD]

(b) Steering + Front Wheel Drive Assembly

 Type: Single steered, powered front wheel; tiller handle steering.

 Specs: Steering angle ±60–70°, knuckle with motor mount; handle-top throttle and E-stop.

 Working: Converts handle input to steering yaw; motor provides tractive effort.

 Purpose: Tight maneuverability and precise docking.

 [Insert diagram]

(c) Rear Solid PU Wheels

 Type: Solid polyurethane 10–12″ (example)

 Load rating: >150 kg per wheel (confirm)

 Working: Low rolling resistance on epoxy/concrete floors; puncture-free.

 Purpose: Stable support and durability on indoor floors.

 [Insert diagram]

(d) Suspension

 Not required due to flat epoxy/concrete floors; simplifies design and reduces weight.

(e) Material Platform / Cage

 Internal

 Type: MS platform with anti-skid mat / optional mesh cage

 Size: Fit standard cartons; optionally pallet-sized

 Purpose: Secure load carriage; tie-down points if needed.

 [Insert diagram]

(f) Braking System

 Type: Front mechanical disc brake + regenerative braking via controller

 Working: Lever-actuated mechanical brake for stopping; regen for speed control and energy
recovery.

6.2 Electrical Components

(a) Electric Motor (BLDC or DC)

 Type: BLDC preferred for efficiency/torque control

 Nominal Voltage: 24/36/48 V (confirm your kit)

 Rated Power (example): 500–1000 W (confirm)

 Working: Converts electrical power to mechanical torque at the front wheel.

 Purpose: Traction source.

(b) Battery Pack (Lithium-ion)

 Chemistry: NMC/LFP with BMS

 Nominal Voltage: Matches controller (e.g., 24–48 V)

 Capacity (example): 20–40 Ah (confirm)

 Working: Supplies DC power; BMS manages protections and balancing.

 Purpose: Energy storage for shift operations.

(c) Motor Controller

 Type: BLDC FOC/sine wave preferred

 Features: Regen braking, current limit, low-voltage cutoff, throttle mapping

 Purpose: Controls speed/torque, implements safety.

(d) Throttle

 Type: Hall-effect twist/lever throttle (0.8–4.2 V signal)

 Purpose: Operator speed command.

(e) Wiring Harness & Protection

 Internal

 MCB/Fuse: Sized to controller max current (e.g., 30–40 A)

 Cables: Appropriately gauged, crimped lugs, insulated conduits

 Purpose: Safe power distribution.

(f) Charger

 Type: CC/CV charger; matches pack voltage (e.g., 48 V, 5 A)

 Purpose: Recharges battery; may be on-board or off-board.

For each component, paste the datasheet snippet and your actual specifications once finalized.

⭐ 7. Design & Calculations

⚠️Share your actual motor & battery ratings and I’ll compute precise numbers. Below is the flow you’ll
follow—ready to fill with your values.

1. Assumptions / Targets

o Payload (e.g.) 200 kg; Vehicle mass 60–80 kg → Gross mass 260–280 kg

o Target speed 8 km/h; Floor: epoxy/concrete (flat)

o Aisle width target: ≤1.2–1.5 m; Turning radius target ≤1 m (front-pivot)

2. Rolling Resistance (RR)

Frr=Crr×m×gF_{rr} = C_{rr} \times m \times g
Typical Crr for PU on smooth floor ≈ 0.01–0.02 (use your wheel spec).

3. Tractive Effort & Motor Torque

Fdrive≥Frr+FaccF_{drive} \ge F_{rr} + F_{acc}
Motor torque T=Fdrive×rwheel/ηdrivetrainT = F_{drive} \times r_{wheel} / \eta_{drivetrain}

4. Motor Power
P=Fdrive×vηP = \frac{F_{drive} \times v}{\eta} at target v (m/s).

5. Battery Sizing

o Energy per hour at typical duty: E=Pavg×tE = P_{avg} \times t

o Capacity (Ah): C=EVnomC = \frac{E}{V_{nom}} (add 20–30% buffer)

6. Range / Runtime Estimation

o Wh per km: Measure or estimate from P_avg / speed

o Runtime: Battery Wh/Pavg\text{Battery Wh} / P_{avg}

7. Brake Sizing
Stopping distance at 8 km/h with given disc brake—verify friction and lever ratio.
 Internal

8. Chassis Dimensions & FOS

o Bending stress under distributed load; choose section modulus for FOS ≥ 2.

o Check CG height vs. wheelbase for tipping limits during turns.

If you share: motor rated power, motor KV or rated RPM, wheel diameter, battery voltage & Ah, I’ll
return a complete, step-by-step calculation sheet and graphs.

⭐ 8. Fabrication Process (Detailed)

1. Chassis Design

o Draft layout (overall L×W×H, platform size, handle height)

o Create 2D drawings and cut list; mark motor mount slots.

2. Material Cutting

o Cut MS RHS as per cut list; deburr; verify lengths with ±1 mm tolerance.

3. Welding

o Tack weld base rectangle on a flat table; square the frame; complete welds; control
distortion.

4. Drilling

o Drill motor mount slots, controller holes, platform mounts; add cable clamps.

5. Motor Mounting

o Align motor sprocket/hub (if chain) or fix hub motor; ensure concentricity and clearance.

6. Tyre/Wheel Fitting

o Fit front drive wheel and two rear PU wheels; verify toe/track and free rotation.

7. Electrical Wiring

o Route main positive through MCB/Fuse to controller; connect BMS leads; throttle signal;
e-stop in enable loop; loom & label.

8. Controller Fixing

o Mount for airflow and splash protection; set parameters: current limit, regen, throttle
curve.

9. Testing

o No-load spin; brake test; short run with 25% load; thermal checks; then full-load test.

10. Painting
 Internal

 Surface prep (degrease, prime, enamel/PU coat); apply safety stickers and cable guards.

📸 Insert your actual fabrication photos at each step.

⭐ 9. Working of the E-Cart

 Power Flow: Battery → MCB/Fuse → Controller → Motor → Wheel.

 Throttle Operation: Hall throttle sends analog voltage; controller modulates current (PWM/FOC)
to motor.

 Forward Movement: Controlled torque output provides smooth start; speed capped for safety.

 Braking: Mechanical disc brake for final stop; regen for deceleration and energy recovery.

 Safety Features: E-stop, MCB/Fuse, BMS protections, speed limit, audible buzzer (optional
reverse).

 Charging Cycle: Connect charger; CC to set current, CV to voltage; SOC indicator via BMS/LEDs.

⭐ 10. Results & Testing (Template – fill with your readings)

 Top Speed: ____ km/h (no-load), ____ km/h (loaded)

 Maximum Load Carried: ____ kg (continuous), ____ kg (short-term)

 Range per Charge: ____ km or ____ hours at average duty

 Charging Time: ____ hours with ____ V, ____ A charger

 Maneuverability: Turning radius ____ m; minimum aisle width ____ m

 Energy Consumption: ____ Wh/km (measured)

 Observations: Thermal stability OK/needs finning; braking distance ____ m from ____ km/h

 Photos & Test Readings: [Insert images, log sheets]

If you give me your raw logs, I can convert them into charts and a neat test summary table.

⭐ 11. Cost Estimation

Sr Item Cost (₹)

1 Components 20,000

2 Fabrication 10,000

3 Labour 5,000
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Sr Item Cost (₹)

Total Project Cost 35,000

If you share actual invoices, I’ll replace row-level values and add a per-component table.

⭐ 12. Applications

 Warehouse carton/pallet movement

 Manufacturing plants (intra-shop movement)

 Airports & logistics hubs (back-of-house)

 Shopping malls (after-hours stocking)

 Internal factory transport

⭐ 13. Advantages

 Zero local emissions

 Reduced operator fatigue

 Compact, easy to maneuver in narrow aisles

 Low running cost and noise

 Low maintenance (no ICE parts)

 Regenerative braking capability

⭐ 14. Limitations

 Limited load/speed (indoor duty)

 Dependent on charging infrastructure

 Not suited for rough outdoor surfaces

 Range limited by battery capacity

⭐ 15. Future Scope

 Higher-capacity Li-ion pack or LFP for longer cycle life

 Solar-assist charging (dock-side)

 Internal

 IoT tracking & usage analytics

 Collision sensors / bumpers

 Improved suspension for mixed floors

 Automatic pallet lift / scissor platform

⭐ 16. Conclusion

A compact 3-wheeler electric material picker was conceptualized, designed, and fabricated to serve
narrow-aisle warehouse operations. The vehicle demonstrates reduced operator fatigue, improved
maneuverability, and clean operation through electric propulsion. With appropriate motor-battery
sizing, braking, and safety features, the prototype validates the feasibility of cost-effective electrified
MHE for e-commerce and industrial logistics. Future enhancements (IoT, sensors, advanced batteries)
can further increase safety, uptime, and analytics-driven efficiency.

Want me to package this as a professionally formatted Word (DOCX) or PDF?

I can generate:

 Title page with logo placement and borders,

 Auto-generated ToC, List of Figures/Tables,

 Proper styles, page numbers, headers/footers, and

 Annexures ready for your photos and datasheets.

Next inputs I need from you (to finalize calculations & specs):

1. Motor: type (BLDC/DC), rated power (W), rated voltage (V), rated RPM, wheel/hub diameter

2. Battery: chemistry (NMC/LFP), voltage (V), capacity (Ah), charger current (A)

3. Target payload (kg) and cart mass (approx)

4. Wheel diameter and tyre type (PU size)

5. Any measured test logs you already have

Share these and I’ll produce a calculation sheet + graphs and a print-ready Black Book file.

Here are your first-stage design calculations, directly computed from your motor–battery specifications
using Python.

I’ve assumed cart mass = 60 kg, since you mentioned “approx.”

(If your exact mass differs, tell me and I’ll recompute automatically.)
 Internal

✅ Design Calculations for Your 3-Wheeler Electric Material Picker

1. Input Specifications (as given)

Motor (BLDC, Non-Geared)

 Rated Power = 350 W

 Rated Voltage = 24 V

 Rated Speed = 800 RPM

 Motor Efficiency ≈ 83%

 Rated Current = 14 A

 Motor Type = IP4 protection

 Wheel Diameter = 10 inch = 0.254 m

Battery

 Type = NMC Lithium-ion

 Voltage = 24 V

 Capacity = 20 Ah

 Charger = 24 V, 5 A

Mass

 Payload = 200 kg

 Cart Mass (assumed) = 60 kg

 Total mass = 260 kg

✅ 2. Python Output (Computed Values)

Parameter Value

Rolling Resistance Force (F_rr) 38.26 N

Motor Torque at 350W (T_motor) 4.18 N·m

Max Wheel Force from Motor (F_drive) 32.90 N

No-Load Theoretical Speed 10.64 m/s ≈ 38.3 km/h

(Note: true loaded speed will be MUCH lower, explained below.)

 Internal

🚨 IMPORTANT INTERPRETATION

✔ Rolling Resistance vs. Available Drive Force

 Required force to overcome floor rolling resistance: 38.26 N

 Motor can produce (direct drive): 32.9 N

➡ Conclusion:
At direct wheel drive, the 350 W motor cannot overcome rolling resistance for a 260 kg load.

🔧 Solution:
You must use a gearing reduction (typically 1:2 to 1:5) to multiply wheel torque.

I can compute the ideal gear ratio after you confirm whether the drive is:

 Hub motor (direct) OR

 Mid-drive motor + chain/sprocket

✔ Loaded Speed Estimation

Theoretical no-load speed: 38.3 km/h, but this is irrelevant because:

 Under load torque demand > motor torque

 Speed will drop sharply

 Expected realistic speed with 260 kg mass: 4–7 km/h

We can compute exact speed once you confirm gear ratio.

✔ Battery Runtime Estimation

Battery Energy =

24 V×20 Ah=480 Wh24\text{ V} \times 20\text{ Ah} = 480\text{ Wh}

Typical warehouse EV consumption at low speed & frequent stop/start = 120–200 Wh per hour.

Estimated runtime:

480/150 Wh=3.2 hours (approx.)480 / 150\text{ Wh} = 3.2 \text{ hours (approx.)}

Estimated range at 5 km/h:

5×3.2=16 km5 \times 3.2 = 16 \text{ km}

✔ Charging Time
 Internal

20 Ah/5 A=4 hours20\text{ Ah} / 5\text{ A} = 4 \text{ hours}

📌 SUMMARY OF CALCULATIONS (Based on Your Specs)

Parameter Value Comment

Total mass 260 kg OK

Rolling Resistance 38.26 N Good floor assumptions

Motor Torque 4.18 N·m Direct from 350 W at 800 RPM

Wheel Force 32.9 N Insufficient in direct drive

Required Force >38.2 N Needs gearing

Required Solution Gear reduction (1:3 recommended) Will compute for you

Battery Energy 480 Wh

Runtime ~3.2 hours Good for warehouse use

Charging Time 4 hours

📘 NEXT STEP — I CAN COMPUTE:

✔ Ideal gear ratio (so motor can move 260 kg easily)

✔ Actual loaded speed after gearing

✔ Start-up torque and gradeability

✔ Regenerative braking effect

✔ Full table for your Black Book Chapter 7

❓ Please confirm one thing:

👉 Is your 350 W BLDC motor a hub motor or a mid-drive motor with sprocket/chain?
(Your message says “non-geared”, but not whether it is hub-type.)

Select one:

1. Hub motor (front wheel) – direct drive

2. Mid-drive side-mounted motor with chain

3. Belt drive
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4. Not sure (you can upload a photo)

This will allow me to compute gear ratio, actual torque, final speed, and generate your complete
“Design & Calculations” Black Book chapter.
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