The objective of this project was to design and fabricate an electric load-carrying cart to minimize manual effort, reduce time for transporting goods, and provide an eco-friendly, low-maintenance alternative to conventional trolleys

Overview

• Powered by a 1 kW AC motor with gearbox, running on a 48 V battery pack.

• Transmission via chain and sprocket drive; ladder-type MS chassis frame; Ackermann steering system.

• Features: variable speed control, braking system (cycle disc), carrying capacity of ~50 kg.

• Focused on improving ergonomics, reducing strain compared to manual trolleys, and enabling industrial applicability in manufacturing plants and warehouses

My key involvement

• Contributed to chassis design, ensuring ladder frame stability and weight balance.

• Assisted in motor selection and calculation of torque, current, and speed to match load capacity.

• Participated in fabrication (cutting, welding, drilling, assembling components).

• Helped in wiring setup for motor–battery–controller integration.

• Documented results, prepared diagrams, and assisted in presenting findings in the project report

My additional responsibilities

• Coordinated cost estimation, including material, machining, and labor (~₹13,524).

• Conducted market study and ergonomics research to justify design choices.

• Managed workshop scheduling, tool procurement, and ensured team adherence to deadlines.

• Assisted with final documentation (Black Book, presentation, viva prep).

Role & impact

• Drove chassis design and stability analysis; performed torque/current/speed calculations for motor–load matching.

• Actively involved in fabrication and integration (welding, drilling, assembly, wiring).

• Co-prepared technical documentation and cost analysis, ensuring industrial feasibility.

Methods & tools

• Powertrain: AC brushless motor (1 kW, 48 V) + gearbox + chain drive.

• Chassis: Ladder frame, MS hollow bars.

• Systems: Ackermann steering geometry, disc brake, speed regulator, 48 V battery pack.

• Calculations: Motor efficiency (~80%), load torque (~19 N·m), max speed ~38 km/h, battery backup ~1 hr 16 min

Results that matter

• Operational cart fabricated and tested within budget (~₹13.5k).

• Significantly reduced manual labor, ergonomic strain, and time for material transfer.

• Eco-friendly & low maintenance, though with load/charging limitations.

Outcome

• Successfully fabricated a working electric material handling cart capable of transporting loads with less human effort.

• Achieved design targets: eco-friendly, user-friendly, cost-effective (~₹13.5k).

• Identified limitations (battery requires frequent charging, 50 kg capacity cap).

• Demonstrated industrial application in warehouses, workshops, and logistics

Deliverables & learnings

• Delivered a functioning prototype, technical report, and presentation.

• Learned practical aspects of design, machining, assembly, cost analysis, and ergonomics.

• Experience bridged classroom theory with hands-on mechanical engineering and sustainability applications.