Nowadays, the intensity of traffic on Indian roads is increasing at high pace. As in this date there are many options for transportation available for physically challenged persons like, Motorized wheel chair, Hand powered tri-cycle, Scooters, etc. The problem associated with motorized wheel chair is that it way too costly and is not suitable for commuting. Hand powered tri-cycle requires heavy human effort and in Moped there is Continuous Variable Transmission (CVT) system for power transmission purpose. With the help of CVT we only obtain forward motion. There is no provision of reverse motion in moped. To overcome this drawback, we have designed and fabricated reverse gear box in moped to make physically challenged person self-dependent.

Mainly the CVT has Primary and Secondary clutches which are connected by belt in which the primary clutch is connected with engine. In scooty, there is CVT arrangement for speed variation. Hence there is no provision of reverse gear in scooty. A figure (2) shows how the variation of speed ratio can be achieved in CVT. At staring when the speed of the engine is minimum, the belt is at minimum diameter in primary clutch and at maximum diameter in secondary clutch so have maximum speed reduction, which is shown in Fig.2.2 by minimum position.

Now when the speed of engine increased due to throttling the belt shifts in clutches such that have contact at maximum diameter in primary clutch and minimum diameter in secondary clutch so have minimum speed reduction, which is shown in Fig.2.1 by maximum position.

In reverse gear system, we mainly used Epicycle gear train for providing reverse motion in the moped. An epicyclic gear train consists of two gears mounted so that the center of one gear revolves around the center of the other. A carrier connects the centers of the two gears and rotates to carry one gear, called the planet gear, around the other, called the sun gear. The planet and sun gears mesh so that their pitch circles roll without slip. A point on the pitch circle of the planet gear traces an epicycloid curve. In this

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An epicyclic gear train can be assembled so the planet gear rolls on the inside of the pitch circle of a fixed, outer gear ring, or ring gear, sometimes called a ring gear. In this case, the curve traced by a point on the pitch circle of the planet is a hypocycloid. The combination of epicycle gear trains with a planet engaging both a sun gear and a ring gear is called a planetary gear train. In this case, the ring gear is usually fixed and the sun gear is driven.

• In Scooty there is Continuous Variable Transmission (CVT) system for power transmission purpose. With the help of CVT we only obtain forward motion. • There is no provision of reverse gear in scooty or any other mopeds.so handicapped person wants to take help of others for taking their vehicle back from parking. • The project is mainly aimed for Mopeds of handicapped person. • We have effectively used the epicyclical gear train for providing reverse motion in mopeds. • The point of research is to provide reverse motion which is not present in mopeds which operates on Continuous Variable Transmission (CVT). • The gear box which we have designed is compact and easily attachable to the system • It is expected that our project will provide Reverse gear system in Mopeds which help

Most important mechanical properties usually encountered in material selection process are fatigue strength, tensile strength, yield point, hardness, stiffness, toughness, creep resistance and density. After analysing above concepts we have chosen 30C8 as material for the gear. It is one of the suitable material that can be used for the production of gear and has good manufacturability.

The engine drive provides the power to the gear box and the gear gives out the power to the rear wheel in two directions. When output in clockwise direction the vehicle moves forward and when the output is in counter clockwise direction vehicle moves backward. Thus reversing of the vehicle can be achieved. The design parameters are as follows- Moped - TVS Pep Plus Power - 3.6 kw Max. Speed - 6500 rpm Max. Torque - 5.8 N-m Speed ratio - 1:1 (forward) 2:1 (reverse)

Design of sun gear is based on the beam strength of gear. Gear used in this drive is spur gear. Planet gear is smaller than sun gear. so we design smaller planet gear. We design for 20▫ full depth system. Material = 30C8 Power = 3.68 kw. Minimum no. teeth on planet gear = 18 Minimum no. teeth sun gear = 27 Minimum no. teeth ring gear = 63

Kazi Samir P.1*, Diwan Altmansh I.2, Kolekar Amol V.3 3

calculated as follows, For Z = 18 Cs = 1.5 Cv = 3 ÷ (3 + v)

= 0.375

M = 2.05 mm 6.2 Dimension of other gear as follows (mm) i. Pitch diameter of sun gear - 54 ii. Pitch diameter of planet gear - 36 iii. Pitch diameter of ring gear - 126 iv. Addendum of gear (m) - 2 v. Deddendum of gear (1.25m - 2.5 vi. Pressure angle - 20 vii. Working depth (2m) - 4 viii. Whole depth (2.25m) - 4.5 ix. Tooth thickness - 3.14 x. Fillet radius (0.4m) - 0.8

Input shaft is designed on the basis of torsional stress induced in the shaft.

D = 16.77

pressure. Torsional moment is as follows

Mt = 5.8 N-m

N = 8

Di = 17 mm Mt = P * Rm Rm = ( Di+Do ) /2

Do = 22 mm

Di = 18 Dm = 22 Do = 26

Di = 44 Do = 58

For input shaft (dia.=17) – 6003 For output shaft (dia. = 45) – 6009

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1- Input shaft 2- Fixed shaft 3- Planet shaft 4- Ring gear with output shaft 5- Sliding sleeve 6- Sun gear 7- Planet gear 8- Planet carrier 9- Support plate

The sun gear is fixed on input shaft. Planet carrier is fixed on input shaft using sliding sleeve to make planet gear fix so that there is no relative motion between sun, planet and ring gear. Now sun, planet and ring

The planet carrier is fixed on fixed shaft using sliding sleeve so that planet gear will rotate about its own axis. Then motion transferred from sun gear to ring gear is in reverse direction. Thus the vehicle will get reverse motion.

The inclusion of our project in moped vehicles will not reduce the speed of the vehicle; hence the performance of the vehicle is not affected. Since no

Kazi Samir P.1*, Diwan Altmansh I.2, Kolekar Amol V.3 3

use for physically challenged people. By doing this, we recognize that this system will be very helpful to the handicapped people. Designed gear box is portable and easy to fix in the mopped vehicle. The reverse gear box is compatible with all mopped vehicles. Mechanism is simple and constructed according to the convenience of handicapped peoples. By this we have introduced a new idea in automobile industry with future modification favourable to physically challenged people.

[1] G. Satish Kumar, ―Development and Implementation of Reverse Drive Mechanism in Bikes‖, International Journal of scientific research, To fabricate the designed gear mechanism, volume 3, Issue 11, ISSN No-2277-8179, NOV 2014. [2] Sandesh G. Ughade, Literature Review on Solar Powered Tricycle for Handicapped Person‖, International Journal for Innovative Research in Science & Technology, Volume 1, Issue 10, March 2015. [3] Vinod K. Banthia, ―Design of Three Wheeler Vehicles for Physically Challenged People‖, SAS Tech Journal, Volume 12, Issue 1, April 2013. [4] Arpit Mehra, Arindam Ghosal, A 3- Wheels Electric Car For Physically Disabled People‖, International Journal of Innovative Technology And Exploring Engineering, ISSN: 2278-3075, Volume-3, Issue-11, April 2014. [5] R. S. Khurmi, Gupta - ―Design of Machine Elements‖, 14TH Revised Edition, 2013. [6] V. B. Bhandari - ―Design of Machine Elements‖, 3rd edition, 2010. Mc Graw Hill Education

UG Student, Government College of Engineering, Karad, Maharashtra, India