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.

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

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

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

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.

#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); }

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Step 6: 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