IARJSET ISSN (Online) 2393-8021

ISSN (Print) 2394-1588

International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

Design of Transmission system for an Electric

Go Kart
Ujwal Jaya Amin
Student, Mechanical Engineering, Terna Engineering College, Mumbai, India

Abstract: Traditional go kart has the same components as an electric go kart but the major change is the engine. As in
the electric go kart we replace it by a battery and a motor, the main difference now is in the transmission system. This
paper will take the practical approach about how to decide your chain, sprocket ratios and all the motor specifications
required to maximise the output speed of an electric go kart. This paper will take both the approaches about how to
determine your motor from top speed required to the tire size and also the approach where you already have a motor.
Electric go karts are the future and this paper focuses on how to build a transmission system for future racing go karts
and what parameters are to be considered.

Keywords: Go kart, transmission, gear ratio, sprocket, calculation, electric vehicles.

.

I. INTRODUCTION

A transmission system is a system that actually transfers energy from the engine to the tires. But in an electric go kart it
changes a bit. The transmission system of an electric go kart has the following parts a battery, a motor, two sprockets, a
chain and the axle. This paper helps you to decide the proper distance to be kept between the motor and the axle, the
gear ratios to be considered for optimum speed, the motor selection and the calculation of torque and force from the
motor to the tires. The design of the sprockets are done on the SOLIDWORKS and also an online tool is used for the
determination of the centre distance, also OPTIMUM LAP software is used for virtual results of the go kart in a drag
race. The transmission of an electric go kart should be designed in such a way that if there are no changes in gear ratios
then it should be selected in such a way that it helps the kart to clear the corners well and also complete the drag race in
efficient time.

II. OBJECTIVE

The main objective of this paper is to encourage the students in pollution free battery operated system of an electric go
kart and make them aware of the main difference in the transmission system and all the required calculations for the
same. The designs of sprockets that are done on the SOLIDWORKS are included with calculations and the analysis of
the system on the OPTIMUM LAP software is also included.

1) To determine the motor

2) To determine gear ratios
3) Design of sprockets
4) All the required calculations

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 IARJSET ISSN (Online) 2393-8021
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International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

III. METHODOLOGY

The chart below shows how the paper proceeds with the solution for all the problems related to the transmission
calculations of an electric go kart

1st deciding the top speed and the weight of our kart

Then finalising the motor and starting calculations

using available softwares to compare our calculated results with the software output

IV. ELECTRIC POWER HOUSE

The design of an electric go kart’s power house is very simple. It consists of a motor, motor controller and the chain
drive system so finalizing the motor is the 1 st part.

After comparison between two 3kW Motors we can confirm the best motor for the go kart

1. Mechatronic trading 3kW BLDC Motor 2. Compage Automations Systems 3kW BLDC Motor
• Weight : 14 kg Weight : 12.5 kg
• Rated Torque : 9.6 Nm Rated Torque : 9.5 Nm
• Max Torque : 38.4 Nm for 2 seconds Max Torque : 28 Nm for 10 seconds
• Rated speed : 3000 RPM Rated speed : 3000 RPM
• Max speed : 4000 RPM Max speed : 3500 RPM
• Peak current : 100 A Peak current : 112.5 A

Depending on the weight to power ratios of both the motors the 2 nd motor from Compage Automation Systems is more
powerful compared to its weight. Continuing calculations depending on the values of the 2nd motor.

The design of the chain sprocket should be considered by taking the top speed and the weight of the kart. Once the gear
ratios are fixed in the calculations, we can find the optimum distance between the motor and the axle sprocket also we
can find the number of chain links that has to be in a chain for proper functioning of the transmission system. Both the
sprockets can be designed on SOLIDWORKS and can be manufactured in a CNC machine. The material used to
manufacture sprockets should be of a very tough material.

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 IARJSET ISSN (Online) 2393-8021
ISSN (Print) 2394-1588

International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

V. CALCULATIONS

❖ Motor to Gear Ratio

After deciding the motor we have the required torque values. Now if we determine the top speed required by the kart
we can find the gear ratio. Considering the top speed to be 61 km/hr or 16.96 m/s and the mass as 160 kg
𝑅𝑃𝑀×𝜋×𝑡𝑖𝑟𝑒 𝑟𝑎𝑑𝑖𝑢𝑠 3000×𝜋×0.270
We have the formula G.R. (gear ratio) = = = 2.5
60×𝑠𝑝𝑒𝑒𝑑 60×16.96
This is the simplest method to determine the gear ratio if the motor specifications are known but if the motor has to be
decided then this lengthy process has to be followed.

❖ Tires to Gear Ratio

1) The first part is to find the total power required to move the vehicle and achieve the maximum speed required
Cr is rolling resistance coefficient, Cd is coefficient of drag, v is the velocity, A is the frontal area

• Rolling resistance force (Fr) = Cr×m×g = 0.01×160×9.81 = 15.696 N

• Air resistance force (Fd) = Cd×0.5×d×𝑣 2 ×A = 0.8×0.5×1.2×16.962 ×1.174 = 162.17 N
• Gradient resistance force (Fg) = m×g× sin 𝜃 = 0 (since the angle in which the kart is running is flat and has no
elevation)

Now total power is calculated by

• Power required for rolling resistance (Pr) = Fr × v = 15.696 ×16.96 = 266.2 W

• Power required for drag (Pd) = Fd × v = 162.17×16.96 = 2750.4 W
• Power required for gradient force (Pg) = Fg × v = 0
• Total power = Pr + Pd + Pg = 266.2 + 2750.4 + 0 = 3016.6 W
So the selected motor should provide us a power of around 3000W to reach a speed of 16.96 m/s if the weight is
considered as 160 kg.

2) To find the required RPM

𝑠𝑝𝑒𝑒𝑑×60 16.96×60
RPM = = = 599.83 RPM
𝑙𝑖𝑛𝑒𝑎𝑟 𝑤ℎ𝑒𝑒𝑙 𝑡𝑟𝑎𝑣𝑒𝑙(2𝜋𝑟) 2×𝜋×0.270

This is the required RPM at the wheel,so the RPM required at the axle is (599.83 × 2) = 1199.66 RPM
Now to decide the gear ratio,as the motor with 3kW power has the RPM of 3000,after dividing the motor RPM with the
3000
axle RPM the gear ratio is = 2.5
1199.66

3) To find the torque required

The total force calculated is Fr + Fd + Fg = 15.696 + 162.17 = 177.86 N

This force is now divided into 2 equal parts as the axle rod divides the torque into both the rear tires
177.86
Force on 1 tire = = 88.93 N
2
Torque on 1 tire = F × r = 88.93× 0.270 = 24.011 Nm
Therefore total torque required on Axle is 24.011× 2 = 48.02 Nm

Dividing it by the gear ratio 2.5 we get 19.209 Nm.This is the maximum torque required by the motor to move the kart.
As the power and RPM are known, the torque could be calculated.
𝑃×60 3000×60
T= = = 9.54 Nm.This is the nominal torque of the motor.
2𝜋×𝑅𝑃𝑀 2𝜋×3000

By calculating and considering the values as per the electric kart we can choose the best motor and decide the gear ratio
required but the weight and the maximum speed should be decided first.

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 IARJSET ISSN (Online) 2393-8021
ISSN (Print) 2394-1588

International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

❖ Acceleration, speed and time calculations

Now since the motor and the gear ratios are decide we can complete the calculation from engine to the tire in this
manner

• Nominal condition

The nominal torque is 9.5 Nm. so not considering the maximum condition for now ,the motor is providing 9.5 Nm of
torque which will be multiplied by the gear ratio of 2.5 and the axle will be provided with a torque of 9.5 × 2.5 = 23.75
23.75
Nm . Now the axle will divide this torque in to two parts , so the torque on a single tire will be =11.875 Nm . The
2
total force produced by the both tires will be 23.75 ÷ 0.270 = 87.96 N

• Maximum condition

If the maximum condition is considered for the 1 st 10 seconds then the torque changes to 28 Nm and the Torque on axle
will be 28 × 2.5 = 70 Nm. this will be divided by the axle and the torque and on a single wheel will be 35 Nm. The total
force produced by both the tires will be 70 ÷ 0.270 = 259.25 Nm

Now taking the selected motor and calculating the time required to reach the top speed and also the time required to
complete 100 meters and 400 meters of a race track.

Gear ratio = 2.5 , top speed = 16.96 m/s

So at the initial condition for 1st 10 seconds motor gives a torque of 28 Nm
Torque at axle as calculated above will be 70 Nm and the force is 259.259 N
𝑓𝑜𝑟𝑐𝑒 259.259
Therefore , acceleration (a) = = = 1.62 m/𝑠 2
𝑚𝑎𝑠𝑠 160

Now using kinematic equations speed and distance covered in 1 st 10 seconds will be
v = u + at ; v = 0 + 1.62 × 10 ; v = 16.2 m/s
1 1
s = ut + a𝑡 2 ; s = 0 + × 1.62 ×102 ; s = 81 m
2 2

After 10 seconds , the nominal condition of motor starts

Motor gives a torque of 9.5 Nm and torque at axle will be as calculated before 23.75 Nm and the force is 87.96 N
𝑓𝑜𝑟𝑐𝑒 87.96
Therefore , acceleration (a) = = = 0.55 m/𝑠 2
𝑚𝑎𝑠𝑠 160

Now using the kinematic equations to find the time required to reach the top speed and time to complete 100 meters
1
and 400 meters as original drag race is of of a mile
4
v = u + at ; 16.96 = 16.2 + 0.55 × t ; t = 1.38 seconds , but adding the initial 10 seconds the final time will be
t = 1.38 + 10 = 11.38 seconds . So time required to reach the maximum speed is 11.38 seconds

For 100 metres ( acceleration will be zero once top speed is achieved )
1
s = ut + × 𝑎𝑡 2 ; 100-81 = 16.96×t+ 0 ; t = 1.12 seconds
2
Adding the initial 10 seconds we have t = 10 + 1.12 = 11.12 seconds to complete 100 metres

For 400 metres ( acceleration will be zero once top speed is achieved )
1
s = ut + × 𝑎𝑡 2 ; 400-81 = 16.96 × t + 0 ; t = 18.80 seconds
2
Adding the initial 10 seconds we have t = 10 + 18.80 = 28.80 seconds to complete 400 metres

Also the no slip condition of our kart can be checked by the below formula
TE is the tractive force and φ is the adhesion coefficient

TE(max) = φ×Wr = 0.7 × 160 × 9.81 = 1098.72 N

𝐸𝑡×𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦×𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 ×𝑑𝑟𝑖𝑣𝑒 𝑟𝑎𝑡𝑖𝑜 28 ×0.88 ×2.5 ×1

TE = = = 228.14 N
𝑅 0.270

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 IARJSET ISSN (Online) 2393-8021
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International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

Since TE(max) ≥ TE there will be no slip in the vehicle .

All this is also showed in the graph and values from the OPTIMUM LAP software

Motor Torque Graph

100 metres drag strip

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DOI: 10.17148/IARJSET.2021.85114

400 metres drag strip

Time v/s Distance graph

Detailed information about the kart running on both the tracks

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DOI: 10.17148/IARJSET.2021.85114

From the analysis results on the OPTIMUM LAP software, the results are almost equal as calculated above

Calculated time for 100 m = 11.12 sec From software analysis = 13.38 sec
Calculated time for 400 m = 28.80 sec From software analysis = 32.93 sec

The difference in time is due to the varying motor torque in the 1 st 10 seconds when it is maximum
For analysis purpose the data sheet of the motor is entered in the engine data but for calculation purpose the maximum
torque is considered as 28 Nm for 1st 10 seconds.

❖ Calculation and design of Chain and Sprockets

The gear ratio decided is 2.5 and the chain to be used is 520 Chain
• Pitch (p) = 15.88 mm
• Roller width = 6.35 mm
• Roller diameter (d1) = 10.16 mm

Let the number of teeth on Motor sprocket be z1 = 14

Therefore number of teeth on axle sprocket should be 14 × 2.5 = 35
𝑝 15.88
▪ Diameter of z1 = D1 = 180 = 180 = 71.36 mm
sin sin
𝑧 14

𝑝 15.88
▪ Diameter of z2 = D2 = 180 = 180 = 177.15 mm
sin sin
𝑧 35

Optimum centre distance will be = 71.6 + 177.15 = 248.75/2 = 124.375 mm = a

▪ Now centre distance should be between a + 30 and a + 50
▪ 154 mm ≤ centre distance ≤ 204 mm
▪ Considering two possible cases of centre distance 170 mm and 203 mm

Now chain length can be calculated by using formula

𝑧1+𝑧2 𝑧2−𝑧1⁄ 2
2𝜋
▪ l(p) = 2×a(p) + +
2 𝑎(𝑝)

𝑐𝑒𝑛𝑡𝑟𝑒 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
▪ a(p) =
𝑝𝑖𝑡𝑐ℎ

▪ Length of chain (l) = l(p) × p

▪ Chain length for 170 mm as centre distance = 747 mm
▪ Chain length for 203 mm as centre distance = 808.93 mm

All the above calculated values can be confirmed using an online tool box, pictures of which are given below

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 IARJSET ISSN (Online) 2393-8021
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International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

When centre distance is taken as 170 mm

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International Advanced Research Journal in Science, Engineering and Technology

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DOI: 10.17148/IARJSET.2021.85114

When centre distance is 203 mm

With the help of the following table the calculation of all the required values to design both the sprockets on
SOLIDWORKS can be found.

The required value d1 (roller diameter) is taken as 10.16 mm for 520 Chain.

Using all the above formulae we design the motor sprocket as

• D = 71.36 mm
• D(a) = 75.26 mm ≤ x ≤ 81.05 mm
• r(i) = 5.13 mm ≤ x ≤ 5.28 mm
• r(e) = 19.5 mm ≤ x ≤ 30.56 mm
• α = 113.57 mm ≤ x ≤ 133 mm
• h(a) = 2.86 mm ≤ x ≤ 5.75 mm

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DOI: 10.17148/IARJSET.2021.85114

Sketch of motor sprocket

Model of motor sprocket on SOLIDWORKS

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International Advanced Research Journal in Science, Engineering and Technology

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DOI: 10.17148/IARJSET.2021.85114

In the same way , design of the axle sprocket.

Sketch of axle sprocket

Model of axle sprocket on SOLIDWORK

VI. CONCLUSION

The paper concentrated on the core part of calculating and designing the transmission system of a single gear electric
go kart. All the mathematical formulae were either approach based or from the design data book. Almost every
calculation was covered and also how to select motor was discussed. The chain drive system was explained in detail
and all the forces and torque required were calculated with some assumptions. The analysis was done on the
OPTIMUM LAP software for speed v/s time and the sprocket analysis was done on the online tool BLOCKLAYER
and finally the sprockets were designed on the SOLIDWORKS software.

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 IARJSET ISSN (Online) 2393-8021
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International Advanced Research Journal in Science, Engineering and Technology

Vol. 8, Issue 5, May 2021

DOI: 10.17148/IARJSET.2021.85114

VII. FUTURE SCOPE

As electric vehicles are the future the calculation will get more complex as the differential system for the electric
vehicles will improve. Batteries can be charged using solar cells and the battery storage systems will be improved in the
near future. The basic calculations were covered in this paper but it will change as the motors will become more
powerful with higher torque.

REFERENCES

1) Srivastava, Jay Prakash, et al. "Case Study on Different Go Kart Engine Transmission Systems." IOP Conference Series:
Materials Science and Engineering. Vol. 981. No. 4. IOP Publishing, 2020 .
2) Kudari, Gurunath C., et al. "Design of Transmission System for Go-Kart Vehicle." Int. J. Eng. Tech 4 (2018): 926-31.
3) Gupta, S. P., et al. "Transmission in Go-Kart." Invertis Journal of Science & Technology 12.2 (2019): 47-49.
4) Bopaiah, Karan. "Design and Analysis of Go-Kart using Finite Element Method."
5) Krishnamoorthi, Sangeetha, et al. "Design and analysis of electric Go-Kart." Materials Today: Proceedings (2020).
6) Heisler, Heinz. Advanced vehicle technology. Elsevier, 2002.
7) Nilawar, Abhinay, et al. "Design of Go-Kart." Maharashtra, India, IJFEAT, ISSN (2016): 2321-8134.
8) Lingaiah, Karnati. Machine design databook. McGraw-Hill Education, 2003.

BIOGRAPHY

I am a final year Mechanical Engineering student , headed the transmission department of our college’s
team Electro Infinity which builds electric go kart for national level competitions such as N.E.K.C.
Our team won the best innovation award 2020 at the N.E.K.C. 2020 Bhopal and I had written this paper
to share my work on the transmission system of electric vehicles.

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