International Journal of Scientific Research and Engineering Development-– Volume 3 Issue 3, May – June 2020 Available at www.ijsred.com ISSN : 2581-7175 ©IJSRED:All Rights are Reserved Page 198 Design and Fabrication of Electric-Cargo Vehicle D. V. Sreekanth 1 , D. Sai Prratyush 2 , Amrith Konda 3 , B. Vikas Pawar 4 , G. Manoj Kumar 5 , N. Varshini 6 1,2,3,4,5,6 Department of Mechanical Engineering, St. Martin’s Engineering College, Secunderabad, India Abstract— In recent years, the automotive industry has been looking forward to manufacture electric vehicles (EV) which are completely pollution free. This project mainly concentrates on conversion of an IC Engine Vehicle to a Completely Electric vehicle (Cargo/Commercial Goods vehicle). Here, The IC engine is replaced with a 3Kw 60v 3- Phase BLDC Electric Motor (Brushless D.C) fitted to the Gearbox of IC Engine. Gearbox has four Forward Gears and one Rear Gear. The BLDC motor is connected to a 60v Controller which controls the motor. Li-Ion Battery of 60v 100Ah is used. A 10Amp charger is used to charge the battery, which usually takes 6 to 8 hours to fully charge. Battery is placed under the Driver's Seat with a proper cooling system and protection from water. This paper consists of details of the design and development of electro cargo vehicle which make use of electric energy as primary source. Keywords — BLDC Electric Motor; Li-Ion Battery; 60V Controller; Electric Vehicle I. INTRODUCTION (Heading 1) Electric Vehicles (also known as electric cars or Plug-in electric vehicles) are connected, fun, and practical. They reduce pollution and are even very cheap to use and maintain when compared to Conventional I.C Engine Vehicles. Using electricity as fuel has a few merits which are not available in Conventional I.C Engine vehicles. We know that electric motors react quickly and instantaneously, Electric Vehicles have instant high torque and are quite responsive. They are also digitally connected with the option to control charging from a smartphone app. Just like a Mobile Phone, you can plug in your EV when you get home and have it ready for you to use the next morning. By charging often, you may never need to go to a Petrol bunk again! The infrastructure for electric vehicles charging in India has not been fully developed yet. Few initiatives have been taken to set up community charging stations, as in the case of Plugin India facilitated charging stations. News reports have indicated plans to provide solar-powered charging points at the existing Petrol Bunks of the country. India stands at 4th Place in No. of Barrels used in a day with 37.35 Lac Barrels/day. In 2017, Transport Minister Nitin Gadkari shocked the world (and the automobile industry) when he announced that he intended for India to move to 100% electric cars by 2030.EVs provide more than just individual benefits. Electric Vehicles can also reduce the emissions that contribute to climate change and smog, improving public health and reducing ecological damage. These emissions can be minimized by Charging your EV on renewable energy such as solar or wind. The above are the few main reasons behind this project. We know that, in India, 60% of the goods and cargo are transported by road. Electric vehicles on road include Trains, Buses, Cars, Autos and Bikes. Very few industries like BHEL, Visakhapatnam Steel Plant designed and developed cargo vehicles for their own use. Our project will be available for a common man to commence Cargo Transportation within the city. Our project consists of a BLDC motor fitted to a 4-speed Sequential gearbox which is connected to the rear axle of the vehicle. A Li-ion battery supplies the electric power to run the BLDC motor through a 60V Controller Hub. This controller hub acts as an operating Centre. The accelerator is connected to the controller itself. The Li-ion Battery is charged using a 10Amps Charger. Fig.1 Electric Cargo Vehicle A. Components of Electric Cargo Vehicle The following are the components of Electric-Cargo Vehicle ● BLDC Motor: The full form of BLDC Motor is Brushless DC Motor which are powered by Direct current (DC) Electricity via Battery which produces electricity in the form of alternating current (AC) to drive each phase of the motor via a controller. The Speed and Torque are controlled by Pulses of current which are provided by the controller to the motor windings. The brushless motors have an advantage over brushed motors. Brushless Motors have a high power- to-weight ratio, high speed, electronic control, and low RESEARCH ARTICLE OPEN ACCESS