1

“MINIATURE ELECTRIC
VEHICLE” SUBMITTED BY:
Dantani Ravi N.(239060319002)
Thakor Hasmukh K.(239860319022)
Solanki Yavan K (239860319021)
Od Sagar S (239860319010)
Vaghela Sahil m.(219860319028)

Guided by:
Kaushik prajapati

A Project Report Submitted To Gujarat Technology University Fulfilments of

The Requirements For The Degree Of
Diploma in Mechanical Engineering

MECHANICAL ENGINEERING DEPARTMENT SHREE

SWAMINARAYAN POLYTECHNIC SECTOR-22, GANDHINAGAR –
382022
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“Miniature electric vehicle”

Submitted by:
Dantani Ravi N.(239060319002)
Thakor Hasmukh K.(239860319022)
Solanki Yavan K (239860319021)
Od Sagar S (239860319010)
Vaghari Sahil P.(239060319024)

As Partial Fulfilment Of The Requirement For The Award Of Diploma In

Mechanical Engineering At Shree Swaminarayan Polytechnic. It Is The Record
Of The Work Carried Out Under Our Supervision And Our Guidance. This
Project Work Was Carried Out At The Institute And By Taking Help From The
College Work-Shop And Other Faculties.

Guided by: Kaushik prajapati Head OF Department

Kaushik prajapati
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Gujarat technological university chandkheda

A
Project report on
“Miniature EV

As part of term work project-x for current academic term NOVEMBE-2025 at

shree swaminarayan polytechnic & taking the help from college workshop and
project guide kaushik prajapati from mechanical engineering department.

Project Guide External Examiner

Date: Date:
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ACKNOWLEDGEMENT
We are thankful to the head of mechanical engineering department kaushik prajapati for kind
co - operating and permission complete our mini project work successfully. So we would
like to like to take this chance to thank our project guide, lab assistants and college with
whose support and skillfull guidance has made us such as that we would be proud of
whatever we go and always be confident in achieving our goals.
Firstly we would like to give our sincere regard to all faculty members of mechanical
engineering department for giving their excellent guidance and who to carry out project work
being offered to us.

In these years of diploma engineering our faculty kaushik prajapati guided us to achieve a
goal and made us capable to give us the confidence that we can complete this project
successfully. All Faculties of mechanical branch have shared their valuable ideas and
industrial knowledge about for this project and that's why we are also thanking them for their
help. We are thankful to our project guide Kaushik prajapatI. We are thankful that we got the
chance to work under his guidelines and our sincere and heartily regards to them. Finally last
but not the least we are very much thankful to our Parents, Team Members, Friends and our
Principal Prof NAME & Prof. NAME for their kind support and co- ordination during the
entire span of Education till now in Shree Swaminarayan Polytechnic.

SIGNATURE
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Certificate
Abstract
Acknowledge
TABLEOF CONTENT

Sr No. Name Page No

Introduction
1 7

2 Principles of Electric Energy 10

3 Components Overview 15

4 Design&Planning 18

6 Mechanical Assembly 21
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7 Testing&Troubleshooting 24

8 Maintenance&Storage 27

9 FutureEnhancements 29
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CHAPTER-1
INTRODUCTION

A mini electric vehicle project focuses on designing and developing a small-scale battery-powered vehicle that
demonstrates the fundamental working principles of modern electric mobility. Unlike conventional internal
combustion engine vehicles, electric vehicles operate using an electric motor powered by rechargeable batteries,
making them energy-efficient and environmentally friendly.

This project involves key components such as a DC motor, battery pack, motor controller, chassis, and
transmission system. It helps students understand core concepts of electric propulsion, energy storage, power
transmission, and vehicle dynamics in a simplified and practical way.

The mini electric vehicle serves as an educational model to study sustainable transportation technologies, reduced
emissions, and improved energy efficiency. It also provides hands-on experience in mechanical design, electrical
systems, and basic control mechanisms, making it highly relevant in today’s shift toward greener automotive
solutions.
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⮚ 1.2-FUNDAMENTALS FOR ELECTRIC VEHICLE

1. Electric Motor:

Converts electrical energy into mechanical motion. Commonly DC motors are used in mini EVs due to simplicity.

2. Battery System:

Stores electrical energy (usually lithium-ion or lead-acid). It determines range and runtime.

3. Motor Controller:

Regulates power from battery to motor, controlling speed and torque.

4. Power Transmission:

Transfers motor output to wheels (chain drive, belt drive, or gears).

5. Chassis & Frame:

Supports all components and provides structural strength.

6. Wheels & Suspension:

Ensure stability and smooth movement.

7. Braking System:

Used to stop the vehicle safely (mechanical or regenerative).

8. Basic Electrical System:

Includes wiring, switches, and safety components like fuses.

These fundamentals together define how a mini EV operates efficiently and safely.
Loss factors: Temperature rise lowers battery pack voltage; shadows drastically cut current; wiring,
connectors, and gearing add losses. Small models benefit from short wires, good solder joints, and
low‑friction drivetrains.
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Vehicle Energy Flow & Physics at Small Scale
Energy Flow:

Chemical energy in the battery → electrical energy → controlled by motor controller → converted into
mechanical energy by motor → transmitted to wheels → vehicle motion. Some energy is lost as heat at each stage
(battery, wiring, motor).

Key Physics Concepts:

1. Newton’s Laws:
Vehicle moves when motor torque overcomes inertia and resistive forces.

2. Force Balance:
Driving force must overcome rolling resistance and air drag. At small scale, rolling resistance dominates.

3. Torque & Power:

Torque = force to rotate wheels. Power = rate of energy use.

4. Efficiency:
Not all input energy becomes motion; losses occur due to friction and heat.

5. Scaling Effect:
Smaller vehicles face proportionally higher friction losses and lower aerodynamic impact.

6. Energy Consumption:

Depends on load, speed, and terrain. More weight = more energy required.
This explains how a mini EV converts energy into motion with real-world physical limit
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CHAPTER 2 – Principles of Electric Energy

⮚ Introduction

Electric energy is the power obtained directly from battery power. In the miniature electric car, this energy is
converted into electrical energy using a electrical (EV) battery pack, which then powers the motor to drive
the wheels.

Principle of Electric Energy

Principle of Electric Energy

Electric energy is based on the movement of electric charges (usually electrons) through a conductor due to a
potential difference (voltage).

Core Principle:
When a voltage is applied, it creates an electric field that pushes electrons to flow, producing current. This flow of
charge carries energy, which can be converted into other forms like mechanical, heat, or light.

Working Idea:
In a system like a mini EV, the battery provides voltage, current flows through circuits, and devices (like a motor)
convert this electrical energy into useful work.
Energy Conversion:
Electric energy is not created but converted from other forms (chemical → electrical in batteries, electrical →
mechanical in motors).
This principle governs all electrical systems.
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Factors Affecting Electric Power Output

Electric power output depends on both electrical and physical conditions of the system:

1. Voltage (V):

Higher voltage → higher power (if current is maintained).

2. Current (I):

More current flow increases power, but is limited by circuit capacity and heating.

3. Resistance (R):

Higher resistance causes energy loss as heat, reducing useful power.

4. Efficiency of Components:

Motor, controller, and wiring losses reduce actual output power.

5. Battery Condition:

Charge level, internal resistance, and battery type affect how much power can be delivered.

6. Temperature:

High temperatures increase resistance and reduce efficiency.

7. Load Demand:

Heavier load or more torque requirement draws more power.

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Power Estimation

Power required mainly depends on forces acting on the vehicle and its speed.

Basic Formula:

P=F×v

Forces to be Considered:

F_r = C_r × m × g

F_d = (1/2) × ρ × A × C_d × v^2

Total Force:

F = F_r + F_d

P = (F_r + F_d) × v

Practical Insight:

P ≈ C_r × m × g × v

Add Efficiency:

P_input = P / η\
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Advantages of Using Electric Energy in Miniature Cars

1. Environment Friendly:
Produces zero tailpipe emissions, reducing air pollution.

2. Energy Efficient:
Electric motors have higher efficiency compared to fuel engines.

3. Low Operating Cost:

Electricity is cheaper than petrol/diesel and maintenance cost is low.

4. Simple Design:
Fewer moving parts → less complexity and easier manufacturing.

5. Quiet Operation:
Produces very less noise compared to IC engine vehicles.

6. Compact & Lightweight:

Ideal for small-scale applications and educational projects.

7. Easy Control:
Speed and torque can be controlled easily using controllers.

8. Renewable Compatibility:
Can be charged using renewable energy sources like solar.

9. Low Maintenance:
No oil changes, fewer wear parts.
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Limitations

1. Limited Range:
Battery capacity restricts how far the vehicle can travel.

2. Charging Time:
Takes longer to recharge compared to refueling petrol vehicles.

3. Low Power Output:

Not suitable for high-speed or heavy-load applications.

4. Battery Weight:
Batteries add significant weight relative to vehicle size.

5. Battery Life:
Performance degrades over time and requires replacement.

6. Energy Losses:
Losses occur in motor, controller, and wiring as heat.

7. Cost of Batteries:
Initial cost can be high, especially for better battery types.

8. Limited Speed:
Mini EVs are generally designed for low-speed operation.

9. Temperature Sensitivity:
Battery performance drops in extreme temperatures.
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CHAPTER 3 – Components Overview

Introduction

A miniature electric car consists of several interconnected subsystems. Each component plays a crucial role
in ensuring the car converts electric energy into smooth, efficient motion.

⮚ Main Components

⮚ 1. Battery Pack:

Stores electrical energy and supplies power to the system.

24v 150ah

Type – lead acid

2. Electric Motor:
Converts electrical energy into mechanical motion to drive wheels.
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3. Motor Controller:
Controls speed and torque by regulating power from the battery.

4. Transmission System:
Transfers motor power to wheels (chain drive).

5. Chassis/Frame:
Structural base that supports all components.
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6. Wheels & Tires:
Enable movement and provide traction.

7. Braking System:
Used to slow down or stop the vehicle.

9. Throttle/Control Unit:
User input device to control speed.
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CHAPTER 4 – Design & Planning

⮚ Introduction
Designing a miniature electric car involves balancing energy availability, mechanical efficiency, and weight.
Careful planning ensures that each component works together for maximum performance.

⮚ Key Design Consideration

2. Weight directly affects rolling resistance and required power. Use lightweight

materials (balsa, foam, carbon fiber).

3. Simple design overview

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⮚ TOP AND SIDE Views :
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Front: Wheels + lightweight axle.

Center: Motor and gear system.

Rear: Drive wheels powered by motor.

BELOW: Electric battery pack AND motor

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CHAPTER 6 – Mechanical Assembly

⮚ Introduction

Mechanical assembly is where your design takes physical shape. This stage
involves constructing the chassis, mounting the components, and ensuring
smooth, efficient motion with minimal friction.

⮚ Tools and Materials Needed

Tools: Screwdrivers, pliers, mini hand drill, soldering iron (for electrical
connections), glue gun, ruler, and cutter.

Materials: Chassis frame material (balsa, foam board, carbon fiber), wheels, axles,
bearings, motor mount, gears/belt, and electric battery pack mount.
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⮚ Assembly Steps

Step 1 – Chassis Construction

Cut the chassis base according to your design .

Ensure it is lightweight but stif to prevent bending.
Drill axle holes accurately to maintain wheel alignment.

Step 2 – Mounting the Motor

Fix the motor to a secure bracket or mount.

Ensure the motor shaft aligns perfectly with the drive axle .

Avoid excessive tension in belts or gears to reduce load.

Step 3 – Installing the Axles and Wheels

Use smooth, straight axles to reduce rolling
resistance.

Fit wheels tightly but without wobble.

Check for smooth rotation by spinning each wheel by hand.

Step 4 – Wiring and Cable Management

Route wires along the chassis edges.
Use clips or tape to secure wires so they don’t drag on the ground.
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Connect according to the circuit design from Chapter 5.

⮚ Alignment and Testing

Place the car on a flat surface and push it gently forward. It should roll straight
without veering.
Check for any rubbing parts, loose wheels, or misaligned gears.
Adjust mounts and tighten screws as needed.

⮚ Safety and Durability Tips

Avoid excessive glue that adds weight.

Protect the electric battery pack from scratches and
impacts. Keep moving parts free from dust and debris.
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CHAPTER 7 – Testing & Performance

Evaluation

⮚ Introduction

Once the miniature electric car is assembled, it’s essential to test it under real
operating conditions. Testing helps identify issues, fine-tune performance, and
ensure reliability before a race or demonstration.

⮚ Pre-Test Checklist

Before placing the car in battery power,

confirm: Mechanical parts are tight and
aligned.
Wheels spin freely with minimal resistance.
Electrical connections are secure and insulated.
Electric battery pack surface is clean and dust-
free Switch works properly to turn the motor
on/off.

⮚ Testing Procedure

Step 1 – Static Testing

Place the car in direct battery power without moving it.

Check if the motor starts smoothly when the switch is [Link] electric battery
pack output voltage using a multimeter (should be close to rated voltage).
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Step 2 – Dynamic Testing

Place the car on a flat, smooth track.

Release and observe its motion:

Straight line running → Good alignment.

Veering or wobbling → Adjust wheel alignment.

Jerky motion → Check gears/belts for tension or debris.

Step 3 – Performance Measurements

Speed Test: Measure the time to travel a fixed distance (e.g., 2 meters).

Endurance Test: Track how long the car runs under consistent battery

power.

Load Test: Add a small weight (within design limit) and observe speed reduction.
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⮚ Common Problems & Fixes

Problem Possible Cause Solution

Motor not running Loose wire, faulty battery pack

Recheck connections, test battery pack
Car moves slowly Low battery power, dirty battery pack
Clean battery pack, test at noon
Car veers left/right Uneven wheels/axles Adjust or
replace wheel
Motor overheats Excessive load, friction Reduce load,
lubricate axles

⮚ Optimization Tips
1Reduce vehicle weight for faster acceleration.
2. Use high-efficiency, low-RPM motors for better torque.
Keep tires clean for maximum grip.
⮚
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CHAPTER 8 – Maintenance & Troubleshooting

⮚ Introduction

Proper maintenance ensures your miniature electric car stays functional, efficient,
and ready for demonstrations or competitions. Troubleshooting skills help
identify and fix problems quickly.

⮚ Routine Maintenance Tasks

⮚ Cleaning

Electric Panel: Wipe gently with a soft, damp cloth to remove dust and fingerprints. Wheels & Axles: Remove

dirt or hair that may cause friction.

Chassis: Keep free from debris to reduce unnecessary weight.

⮚ Lubrication
Apply a small drop of light machine oil to axles and gears every few weeks. Avoid over-lubrication
as it can attract dust.

⮚ Battery Care (If Using)

Recharge after each use if a rechargeable battery is included. Avoid deep discharge to
extend lifespan
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Storage tips
Store in a cool, dry place to prevent rust and electronic damage.
Keep the electric battery pack covered when not in use to avoid unnecessary UV
exposure. Transport in a protective box to prevent damage to delicate parts.

⮚ Troubleshooting Guide

Problem Likely Cause Solution

Motor doesn’t start Loose connection, faulty motor, low

battery power Check wiring, replace motor, test in
bright battery power
Car runs very slowly Dirty battery pack, worn motor, high
friction Clean battery pack,
replace motor, check
wheel alignment
Car veers off course Uneven wheel size, bent axle Replace
wheels, straighten or replace axle
Panel produces no voltage Broken cell, loose wire Test with
multimeter, repair or replace battery pack
Overheating motor Excessive load, gear ratio too high
Reduce weight, use lower gear ratio

Tips for Longevity

Use a soft case for carrying to competition.

Keep spare parts (wheels, motor, wires) ready for quick replacemen
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CHAPTER 9 – Future Enhancements

Possible Enhancements

1. High-Efficiency solar Panels

Replace standard battery packs with monocrystalline electric cells for higher energy conversion, especially in
low-light conditions.

2. Rechargeable Battery Integration

Add a small Li-ion or NiMH battery pack with a charge controller to store electric energy, allowing the car to
run even without battery power.

3. Lightweight Chassis Materials

Use carbon fiber sheets, balsa wood, or lightweight 3D-printed plastic to reduce weight and improve speed.

4. Aerodynamic Body Design

Create a streamlined shell to reduce air resistance, using CAD design and wind tunnel testing (miniature scale).

5. Two-Motor Drive System

Install a motor for each rear wheel with differential control to improve turning ability.
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6. Remote Control Feature
Integrate an RF or Bluetooth control module to manually steer or stop the car.

7. Maximum Power Point Tracking (MPPT)

Use an MPPT circuit to ensure the electric battery pack always operates at its most efficient voltage.

⮚ Adjustable solar Panel Tilt

Add a small hinge mechanism to adjust the battery pack angle according to the sun’s position.

⮚ Closing Note

The miniature electric car is not just a final product — it’s a platform for
creativity and experimentation. Every modification teaches new engineering
skills, pushing the design closer to real-world applications like electric-powered
vehicles.