Introduction: KASHUP-wheels a Hybrid Segway

Picture of KASHUP-wheels a Hybrid Segway

It is an electric powered personal vehicle one type of RMP-robot mobility platform.

Highlights:

1. Comes with throttle for speed variation.

2. Led lights making it attractive

3. Tubeless tires –no need of air filling.

4. Operating time more than 2 hours with <40 kg load.

5. 2 Dead man switch.

6. Gryo sensors for left right movements.

7. Simple logics operations using Arduino.

8. 2*250=500 watts electric Dc motors makes it more powerful.

9. Dual H-bridge motor deriver circuit with 15 Amps peak per channel.

10. Powerful 12 V 12 amps battery.

Step 1: Find the Following Components.

Picture of Find the Following Components.

1. Gyroscope :Accelerometer MPU6050

2. Dual H-bridge 15 A motor driver circuit.

3. Aurdino board

4. PMDC motors 250W each

5. 12 V 12 Ah dry battery

6. Wheels 40 c.m.

7. Handle bar and platform

8. Switches etc.

9. led.

10. Electric throttle.

11. Wires

12. Material for frame structure.

Step 2: The Metallic Frame Structure

Picture of The Metallic Frame Structure

The frame structure of segway is made as simples as possible. It has been designed keeping in mind that it has to withstand the weight of motors, battery and the major weight of rider. We have used ms rods from the junkyard with X-section area 16 cm. They are hollow square tubes having less weight and high strength thus best suitable for this purpose. Previously our choice was wood for making the frame, as it might create problems in watery surrounding in rainy season we changed our way using ms. Also it was easy to weld rather than crafting from wood. The figure shows the frame structure in cad. The original is not exactly similar because of some small adjustments but the overall structure is quite similar.There is an extra support wheel at rear for extra support.

The measurement in the structure was taken on the basis of position of motors and tyres. As shown in figure frame includes middle area for motor area or on which the rider use to stand and two wheels support rectangular structures.

Step 3: Motor Foundation

Picture of Motor Foundation

The two dc motors are fixed upside down above the frame. For the proper foundation it is supported on an ms plate 11 cm. above the frame base with four LN screw. The arrangement is such that motor sets can directly removed from the frame as the rods are concertized with each other. Thus the entire frame can be dismantled in various small parts.

The motors are geared motors having gears away from the motor shaft center, making misbalance in the center of gravity for motor. They are placed such that motor shaft comes out at the mid of breadth of frame.

The shaft is made from a single allumilium rod connecting motors shaft at one end and supported with bearing of 0.8 cm at other end. The bearing offers free movement to the shaft it is mounted in ms 0.8 cm thick plate welded at the frame end.

Step 4: Electrical Design

Picture of Electrical Design

The heart of the Segway is its controller we have used arduino for its simplicity. As shown in the circuit the motor‟s high current is handled by current controlling mosfets. The motor driver can handle max of 10 amps peak in single channel. MPU6050 is used to sense the handle movements, its send data to arduino. Arduino understands it and commands the motor driver with inbuilt programmed logics and algorithm to run the motors. PWM is used to control the speed of motors, for this and for rider convenience electric throttle is used, it is attached in the handle. Throttle provides necessary acceleration for achieving speed. Arduino converts the throttle data into PWM and this output is given to motor controller

Step 5: The Codes

Here you can find the arduino codes.

Or mail it to me at itfakash18@gmail.com I would send you the codes

#include const int MPU = 0x68; // I2C address of the MPU-6050 int16_t AcX, AcY, AcZ, Tmp, GyX, GyY, GyZ; int sensorValue = 0; //6050 value int throttle = 0; // throttle value int valt = 0; int r; int vall=0; int valr=0; void setup() { Serial.begin(9600); Wire.begin(); Wire.beginTransmission(MPU); Wire.write(0x6B); // PWR_MGMT_1 register Wire.write(0); // set to zero wakes up the MPU-6050 Wire.endTransmission(true); pinMode(7, INPUT); pinMode(4, OUTPUT); digitalWrite(4, HIGH); //motor pins pinMode(5, OUTPUT); //mot right +v pinMode(6, OUTPUT); //mot right -V pinMode(9, OUTPUT); //mot left -v pinMode(10, OUTPUT); //mot right +v //motor pins } void loop() { throttle = analogRead(A0) ; r = digitalRead(12); Wire.beginTransmission(MPU); Wire.write(0x3B); // starting with register 0x3B (ACCEL_XOUT_H) Wire.endTransmission(false); Wire.requestFrom(MPU, 14, true); // request a total of 14 registers AcX = Wire.read() << 8 | Wire.read(); // 0x3B (ACCEL_XOUT_H) & 0x3C (ACCEL_XOUT_L) AcY = Wire.read() << 8 | Wire.read(); // 0x3D (ACCEL_YOUT_H) & 0x3E (ACCEL_YOUT_L) Tmp = Wire.read() << 8 | Wire.read(); // 0x41 (TEMP_OUT_H) & 0x42 (TEMP_OUT_L) Serial.print("AcX = "); Serial.print(AcX); Serial.print(" | AcY = "); Serial.print(AcY); Serial.print(" | Tmp = "); Serial.print(Tmp / 340.00 + 36.53); Serial.print("pin="); Serial.print(r);//equation for temperature in C Serial.print(" throttel value = "); Serial.println(throttle); sensorValue = AcX; if (throttle<170) { valr = map(AcY, -1800, -4000, 0, 255); vall = map(AcY, 1800, 4500, 0, 255); if ( AcY < -1800) { analogWrite(5, LOW ); analogWrite(6, 1.25* +3 valr); analogWrite(9, LOW); analogWrite(10, LOW); } else if (AcY > 1800) { analogWrite(5, LOW ); analogWrite(6, LOW); analogWrite(9, LOW); analogWrite(10, vall); } else { analogWrite(5, LOW ); analogWrite(6, LOW); analogWrite(9, LOW); analogWrite(10, LOW); } } else { if (throttle > 165) { valt = map(throttle, 165, 535, 0, 255); analogWrite(5, LOW ); analogWrite(6, 1.25*valt); analogWrite(9, LOW); analogWrite(10, valt); } } delay(300); }

Step 6: Finishing

Picture of Finishing

Finish it with final touch up by paint, lightning with led or any addition as you like

Just look at the final figure you will get an idea.

1. Electric throttle.

2. Arduino powered switch.

3. Battery powered switch.

4. Tubeless tyres.

5. PMDC motors.

6. MPU 6050 Gyro+accel.

7. Support wheel.

8. Indicator LED

9. Neon lights led.

10. Handle bar.

11. Platform.

Step 7: Video Link

https://youtu.be/1W0yD_TvlpQ

Comments

MVVSTEM2015 (author)2017-02-03

Can you share where we can order the

- motors

- grip shifters - those are awesome!

- wheels / tires

?

Thanks,

Mike

Motors are easily available on ebay ,search for 350 watt DIY e bike kits. Wheels from junk-yard. frame shafts etc you have to design as per requirement.

achow60 (author)2016-07-18

What is the Specification on the item #10- the electric throttle? Is this a simple variable resistor? Any substitute for that?

PATEL AKASH R (author)achow602016-07-19

Ya its similar to potentiometer it uses hall effect sensor to vary resistant you can get it from old electric bike.
You can make using 10k potentiometer and some spring mechanism.

Jerin VG (author)2016-06-03

can u please share the motor driver name

PATEL AKASH R (author)Jerin VG2016-06-05

you can use any h bridge high current motor driver I have used robotikits 12 amps motor driver.

Jerin VG (author)PATEL AKASH R2016-06-06

thankz

Saiyam (author)2016-05-22

Good one!?
Any idea of the total cost, especially the motors?

PATEL AKASH R (author)Saiyam2016-05-22

Over all expenses 28K. including major cost of 2* 250 watt motor costing 15K

ennalta (author)PATEL AKASH R2016-05-24

Which would be just under $400US.

PATEL AKASH R (author)ennalta2016-05-24

Yes under 400usd as I have to pay more for motor, not easily available in India

sekitori (author)2016-05-24

Please add a better video. Can you estimate top speed and maybe max range ?

PATEL AKASH R (author)sekitori2016-05-24

As yours wish I have uploaded new video .speed depends upon load and not still measured

BayuB4 (author)2016-05-24

Please semd the code to bayucorporation@gmail.com
thanks sir:)

PATEL AKASH R (author)BayuB42016-05-24

I have finally added the codes above please have it from there

curiosity36 (author)2016-05-23

Nice project. Congratulations. It appears the handle is fixed to the platform. How do you initiate a turn? Where does the MPU6050 come into play?

Thanks

no the handle is not fix it is attached to the frame via universal bearing and springs mpu6050 is at the edge of handle bar for making turns

Thank you. Wishing you continued good luck with your projects.

ИгорьМ6 (author)2016-05-24

video bad quolity

PumpMD (author)2016-05-23

Great Project! I would love to have the code to set up for my own unit. Could you send it to rchapman@tdmgo.com?

PATEL AKASH R (author)PumpMD2016-05-23

I have added the codes above

dandano (author)2016-05-22

please send me the codes to

lumanaux@yahoo.fr

PATEL AKASH R (author)dandano2016-05-22

yup! I would soon add codes here too.

mustafacey (author)2016-05-22

Please send me codes. mustafaceylan83@hotmail.com

PATEL AKASH R (author)mustafacey2016-05-22

ya sure

EToft (author)2016-05-22

what is max weight capacity? do you have video of it in use?

PATEL AKASH R (author)EToft2016-05-22

don't know but it handles my 50 kg weight. I would soon upload the video

hgautam1 (author)2016-05-22

Hey please send me the codes to
hmngtm@gmail.com

It would be really appreciated

hgautam1 (author)hgautam12016-05-22

And will you please tell me that, have you used the PID setup in your codes and if yes, then how you managed to get those PID tuning because I am tackling with it for a long time to make it more stable...

PATEL AKASH R (author)hgautam12016-05-22

ya shure I am mailing you the codes .

hgautam1 (author)PATEL AKASH R2016-05-22

And could you send me the link of this h-bridge I mean from where u have bought this.... And about PID tuning also...

PATEL AKASH R (author)hgautam12016-05-22

it here
https://www.flipkart.com/rotobotix-high-current-dc-motor-driver-15a/p/itme7qpwjahphngw?pid=ETYE7QPWQAENMGMU&lid=LSTETYE7QPWQAENMGMUEVLH4T

I have not used PID filters just simple logics

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