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Electric Workshop Trolley Design Report

The document outlines the design report for a cost-effective and efficient electric workshop trolley capable of transporting 500–1000 kg in industrial settings. It includes specifications such as a top speed of 5 km/h, a range of 30 km, and a total cost under ₹80,000. The trolley features a ladder frame chassis, electric mobility, and safety mechanisms, making it suitable for various industrial applications.

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ayushankit2004
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88 views13 pages

Electric Workshop Trolley Design Report

The document outlines the design report for a cost-effective and efficient electric workshop trolley capable of transporting 500–1000 kg in industrial settings. It includes specifications such as a top speed of 5 km/h, a range of 30 km, and a total cost under ₹80,000. The trolley features a ladder frame chassis, electric mobility, and safety mechanisms, making it suitable for various industrial applications.

Uploaded by

ayushankit2004
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

ELECTRIC WORKSHOP TROLLEY

DESIGN REPORT
COST-EFFECTIVE & EFFICIENT LOAD TRANSPORT SOLUTION
01
INTRODUCTION
INTRODUCTION
Purpose: Design a motorized
trolley to transport 500–1000 kg
in industrial settings
Goals:
Enhance efficiency
Reduce manual labor
Improve safety
Minimize cost
PROJECT OBJECTIVES
Capacity: 500–1000 kg
Mobility: Electric forward/reverse
movement
Safety: Mechanical & regenerative
braking
Usability: Simple throttle-based control
Efficiency: 25–30 km per charge
Affordability: Under ₹80,000
Durability: Steel chassis with corrosion
resistance
KEY DESIGN SPECIFICATIONS
Category Specification

Load Capacity 500–1000 kg

Platform Size 1200–1400 mm × 800–1000 mm

Top Speed 3–5 km/h

Battery Type Lithium Iron Phosphate (LFP)

Charging Time ≤ 4 hours

Range 25–30 km
CHASSIS DESIGN
LOGO HERE

Type: Ladder Frame


Material: Mild/Alloy Steel with
Powder Coating
Benefits:
High strength
Modular for mounting
components
Even weight distribution
Proven durability in
industrial use
SYSTEM ARCHITECTURE OVERVIEW

Mechanical System: Electrical System:


Ladder frame chassis High-torque DC motor
Drive + caster wheels LFP battery (~30 km range)
Rear axle with optional Manual throttle with emergency
differential cutoff
Headlights, horn, battery
indicator
SYSTEM ARCHITECTURE OVERVIEW
Motor Comparison

Criteria DC Motor PMSM

Cost Low High

Efficiency 70–85% 85–95%

Maintenance High Low

Regenerative Braking Difficult Easy

Suitability Budget/Basic EVs Precision/High-efficiency EVs


02
MARKET ANALYSIS
Market Benchmarking

Model Capacity Speed Range Price

Smith ETWSB 1000 kg 5 km/h 30 km ₹1.8–2.3 L

Presto Truck 600 kg 4.5 km/h 20–25 km ₹1.2–1.6 L

BharatBenz E-Trolley 750 kg 5 km/h 30 km ₹2.2–2.6 L

Our Design 1000 kg 5 km/h 30 km ₹78,100

Presentation by Aaron Loeb


Cost Breakdown
S. No. Component Unit Cost (INR) Quantity Total Cost (INR)

1 Base Frame 4,500 1 4,500


2 Platform Sheet 2,500 1 2,500
3 Side Barriers 1,000 4 4,000
4 Fasteners 500 1 500
5 DC Motor 17000 1 17,000
6 Motor Mounts + Couplings 750 4 3,000
7 Drive Wheels 2,000 2 4,000
8 Caster Wheels 1,500 2 3,000
9 Rear Axle with Differential 3,500 1 3,500
10 Battery Pack (LFP) 18,000 1 18,000
11 Battery Enclosure 1,200 1 1,200
12 Motor Controller 6,000 1 6,000
13 Manual Throttle 900 1 900
14 Emergency Cutoff Switch 450 1 450
15 Wiring Harness + Connecto 1,000 1 1,000
16 Mechanical Brakes 1,200 2 2,400
17 Regenerative Braking Circu 0 1 0
18 Headlight / Indicator 600 1 600
19 Horn / Buzzer 250 1 250
20 Handlebar / Control Panel 500 1 500
21 Battery Level Indicator 800 1 800
22 Onboard Charger 2,500 1 2,500
23 Paint / Powder Coating 1,500 1 1,500
Use Cases Conclusion
Workshops: Gearboxes, tools Efficient and low-cost
EV Manufacturing: Battery design
modules Safe and easy to use
Warehouses: Inventory Ideal for industrial
movement settings
Assembly Lines: Component Scalable and
delivery customizable

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