📌 Project Overview
Designed, analyzed, fabricated, and validated a tadpole-configuration Electric Human Powered Vehicle (EHPVC) for the ASME E-FX Competition. The concept integrated pedal-powered motion with an auxiliary electric propulsion system, targeting high efficiency, safety, and manufacturability under event regulations.
👤 Role & Responsibilities
Design & Fabrication Engineer as I contributed to the complete CAD development, simulation, and fabrication of the chassis and powertrain subsystems.
- Collaborated in chassis modeling, RPS design, and aerodynamic profiling using SolidWorks and ANSYS.
- Conducted finite element validation and ensured the fabricated frame matched FEA predictions.
- Participated in battery-motor integration, wiring layout, and drivetrain assembly.
- Assisted in testing, troubleshooting, and on-track evaluation of the hybrid drive and braking system.
- Supported team coordination during design reviews, welding operations, and component sourcing.
🖥️ Design & CAD Development
- Assisted in modelling some parts of the vehicle in SolidWorks, integrating ergonomic positioning, steering geometry, and drivetrain clearances.
- Implemented a 500 W Brushless DCBLDC) hub motor with a 13,000 mAh lithium battery pack for hybrid operation.
- Balanced weight distribution, ground clearance, and wheelbase to achieve optimal handling and stability.
- Incorporated RPS geometry and aerodynamic fairing surfaces adhering to competition constraints.
⚙️ Finite Element Analysis (FEA)
- Performed structural FEA on chassis and RPS using ANSYS to assess deformation and stress under static and rollover conditions.
- Achieved > 5000 N load capacity versus the 2800 N minimum requirement, ensuring high safety margins.
- Optimized tubing layout, weld thickness, and joint placement to minimize stress concentrations and align with fabrication feasibility.
🌬️ Computational Fluid Dynamics (CFD)
- Coordinated with the team members to conduct aerodynamic simulations to evaluate pressure distribution, drag, and lift forces.
- Obtained results of Cd = 4.69 and Cl = 0.1, confirming stable aerodynamic performance.
🛠️ Fabrication
- Contributed to welding and assembly of the chassis using mild-steel tubing, ensuring dimensional accuracy and RPS conformity.
- Integrated drivetrain, steering, and braking subsystems, resolving issues in chain alignment and component clearances.
- Verified structural integrity through visual inspection, static loading, and functional testing.
🔋 Testing & Validation
- Performed on-road testing to evaluate battery discharge rates, pedal assist performance, and braking stability.
- Addressed real-world challenges including chain slack adjustment, ride comfort optimization, and DFM improvements.
- Ensured the vehicle satisfied competition benchmarks for performance and safety.
🏆 Outcome & Achievements
- Secured 1st Place in the ASME E-FX Competition among university-level teams.
- Successfully completed the full engineering cycle — CAD modeling → FEA/CFD → fabrication → testing.
- Enhanced technical proficiency in vehicle dynamics, hybrid power integration, and precision manufacturing.
- Helped in validating the structural and aerodynamic design through real-world operation and competition success.
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