DESIGN AND FABRICATION OF HYDRAULIC

POWERED BICYCLE
A PROJECT SUBMITTED

IN PARTIAL FULFILLMENT OF REQUIREMENT FOR THE DEGREE OF

BACHELOR OF TECHNOLOGY

IN MECHANICAL ENGINEERING

BY

NALLAM SIVA NARASIMHA SAI, (2020BMEC077)

MANNAM SRAVYA, (2020BMEC095)

PITTU VISHNU VARDHAN REDDY, (2020BMEC101)

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY SRINAGAR

JAMMU AND KASHMIR, INDIA -190006

JUNE 2024

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 DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY SRINAGAR,

SRINAGAR, J&K, 190006, INDIA

CERTIFICATE

This is to certify that the Project Report entitled, “Design and Fabrication of Hydraulic powered
bicycle” submitted by Nallam Siva Narasimha Sai, Mannam Sravya, Pittu Vishnu Vardhan Reddy
to the Department of Mechanical Engineering, National Institute of Technology Srinagar, J&K,
India, is a record of bonafide project work carried out by them under my supervision and guidance
and is worthy of consideration for the award of the degree of Bachelor of Technology in
Mechanical Engineering of the Institute.

Supervisor Head of the Department

Dr. Dinesh Kumar Rajendran Prof. Adnan Qayoum

Assistant Professor

Department of Mechanical Engineering

Date of Viva Voice: 20 June 2024

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DECLARATION

We certify that:

a. The work contained in this report is original and has been done by us under the

guidance of our supervisor.

b. The work has not been submitted to any other Institute for any degree or diploma.

c. We have followed the guidelines provided by the Institute in preparing the report.

d. We have conformed to the norms and guidelines given in the Ethical Code of

Conduct of the Institute.

e. Whenever we have used materials (data, theoretical analysis, figures, and text)

from other sources, we have given due credit to them by citing them in the text of

the report and giving their details in the references. Further, we have taken

permission from the copyright owners of the sources, whenever necessary.

NALLAM SIVA NARASIMHA SAI

MANNAM SRAVYA

PITTU VISHNU VARDHAN REDDY

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ACKNOWLEDGEMENT

We would like to express our gratitude to our project supervisor Dr. Dinesh Kumar Rajendran,
Assistant Professor, Department of Mechanical Engineering, NIT Srinagar for their priceless
consolation, recommendations and support from an early phase of this research and providing us
unprecedented experiences throughout the work. Above all, their priceless and meticulous
supervision at each and every phase of work inspired us in multitudinous ways. And also, we are
thanking all the teachers, professors, Head of Department of Mechanical Engineering and Project
Coordinator for helping and guiding us through whole year of graduation.
We specially acknowledge our project supervisor for their advice, supervision and the
indispensable contribution as and when presupposed amid this research. Their involvement with
originality has triggered and nourished our scholarly development that will help us for a long time
to come.
We want to convey our sincere thanks to all our friends for their consistent support during our
graduate studies and aiding us to achieve the objectives of our project.

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ABSTRACT

This project presents the design and implementation of a hydraulic-powered bicycle that utilizes a
hydraulic mechanism in combination with a rack and pinion system. The primary objective of this
study is to explore the feasibility and efficiency of using hydraulic power to enhance the
performance and functionality of bicycles. The hydraulic system comprises a series of hydraulic
pipes, pistons, and a rack and pinion mechanism to convert linear motion into rotational motion,
thereby driving the bicycle’s wheels. The hydraulic mechanism offers several advantages over
traditional mechanical systems, including smoother power transmission, reduced maintenance,
and the ability to easily integrate with existing bicycle components. The rack and pinion system,
in particular, provides precise control over the movement of the bicycle, allowing for efficient
power transfer and improved handling. Experimental results demonstrate that the hydraulic-
powered bicycle achieves a significant improvement in performance, with increased torque and
smoother acceleration compared to conventional bicycles. Additionally, the system’s modular
design allows for easy customization and scalability, making it suitable for various applications,
from urban commuting to off-road cycling.

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TABLE OF CONTENTS:
CERTIFICATE II
DECLARATION III
ACKNOWLEDGEMENT IV
ABSTRACT V
TABLE OF CONTENTS VI
LIST OF TABLES IX
LIST OF ABBREVIATION AND SYMBOLS X
LIST OF FIGURES XI
CHAPTER 1 1
INTRODUCTION AND BACKGROUND 1
1.1 Origin of Bicycles and Their History 2
1.2 Evolution of Bicycles 2
1.2.1 1493: The Earliest Bicycle Sketch 3
1.2.2 1817 To 1819: The Draisine 3
1.2.3 1860s: The Boneshaker Era – Now with Pedals 3
1.2.4 1930’s: Taking It Up a Gear 4
1.2.5 21st Century: Existing Model Bicycles 4
1.3 HYDRAULICS 5
1.3.1 History of Hydraulics 5
1.3.2 Science Behind Hydraulics – Pascal Law 6
1.3.3 Blaise Pascal – Father of Hydraulics 8
1.3.4 Pros and Cons of Hydraulics 8
1.3.5 Market Leading Innovations with Hydraulics 9
CHAPTER 2 11
LITERATURE REVIEW 11
2.1 Review on Bicycle and Hydraulics 11
2.1.1 Scope of Hydraulics 11
2.1.2 Study and Review on Bicycle 12
2.2 Research Gap 14
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 2.3 Problem Identified 15
2.4 Solution 16
2.5 Objective 16
CHAPTER 3 17
METHODOLGY AND WORKDONE 17
3.1 System Design 17
3.2 Method Study 17
3.2.1 Theoretical Design 18
3.2.2 Execution 19
3.3 Raw Material Selection 19
3.4 Main components of Mechanism 19
3.4.1 Hydraulic Pipes 19
3.4.2 U-Pipe 20
3.4.3 Rack and Pinion 21
3.4.4 Pistons 22
3.4.5 Crank 23
3.4.6 Connecting Rod 24
3.4.7 Freewheel 25
3.5 Design Views 26
CHAPTER 4 27
PROTOTYPING 27
4.1 Theoretical Study and Assumptions 28
4.2 Calculations 29
4.3 System Testing and Analysis 32
CHAPTER 5 33
RESULTS AND DISUCSSIONS 33
6.1 Challenges and Decision Making 35
6.2 Limitations of the old existing method 35
6.3 Advantages of Hydraulic Mechanism in the Bicycle 35

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CHAPTER 6 36
CONCLUSION AND FUTURE DIRECTIONS 36
6.1 CONCLUSION 36
6.2 FUTURE DIRECTIONS 37
6.3 MARKET POTENTIAL OF OUR BICYCLE 37
CHAPTER 7 38
REFERENCES 38

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LIST OF TABLES
Table -1: Advantages and Disadvantages of Chain Transmission Mechanism
Table 2 Advantages and Disadvantages of Gear Transmission Mechanism
Table 3 Advantages and Disadvantages of Hydraulic Transmission Mechanism
Table 4 Dimensional specifications of some parts

Table 5 Future Recommendations for our model

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LIST OF ABBREVIATIONS AND SYMBOLS

SI – International System of units

mm- milli meter
m- meter
N – Newton
ω – Angular velocity
rpm -rotation per minute
Kmph- Kilometre per hour
USD – United States Dollar
CAGR – Compounded Annual Growth Rate

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LIST OF FIGURES
Fig 1.1 Leonardo da Vinci imagined cycle

Fig 1.2 Draisine cycle

Fig 1.3 Boneshaker bicycle

Fig 1.4 Person riding in the Olympics event

Fig 1.5 Example for the hydraulics

Fig 2.1 Gear Mechanism

Fig 2.2 String Type Transmission Mechanism

Fig 3.1 3D drawings of Hydraulic pipes

Fig 3.2 Fabricated images of Hydraulic pipes

Fig 3.3 3D diagram of Hydraulic U pipe

Fig 3.4 Fabricated Hydraulic U-pipe

Fig 3.5 3D diagram of Rack and Pinion

Fig 3.6 Fabricated images of Rack and Pinion

Fig 3.7 3D diagram of Primary and Secondary piston

Fig 3.8.10 Fabricated parts of pistons

Fig 3.9 3D diagram of Crank

Fig 3.10 3D diagram of Connecting Rod

Fig 3.11 Fabricated part of Freewheel along with shaft

Fig 3.12 Isometric View of Hydraulic Mechanism

Fig 3.13 Exploded view of Hydraulic images

Fig 4.1 Side view of the Fabricated parts

Fig 4.2 Top View of the Fabricated parts

Fig 4.3 Single slider crank mechanism

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Fig 5.1 Analysis of Connecting Rod

Fig 5.2 Analysis of Crank

Fig 5.3 Analysis of Rack and Pinion

Fig 6.1 Isometric View of Hydraulic powered Bicycle

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 CHAPTER 1
INTRODUCTION AND BACKGROUND

The bicycle, often hailed as one of the most enduring and elegant inventions in the history of
human transportation, has undergone a remarkable journey of transformation since its inception in
the early 19th century. From its humble beginnings as a rudimentary wooden contraption to its
current status as a sophisticated amalgamation of materials, engineering, and design, the bicycle
has evolved in countless ways. This report embarks on a comprehensive exploration of this
evolution, with a specific focus on hydraulic mechanism,

In an era characterized by rapid technological advancement and an ever-increasing emphasis on

sustainable transportation, understanding the state of the art in bicycle design and technology is
essential. This report seeks to provide insight into the development of the hydraulic mechanism to
the bicycle replacing the old chain and crank mechanism, offering a lens through which we can
appreciate how far this mode of transport has come and where it may be headed.

Additionally, we are dealing with the mechanism CAD images and also the 3d images parts are
included in this report. This report also includes how the mechanism works and also includes the
principles that we are used in the developing the mechanism.

As we are delighted to say that we included the calculations of the mechanism and also the
formulae which we had gone through during the process of calculations. In the calculation, we are
dealing with the speed of bicycle, when we fit this mechanism to our normal bicycle and some
constant values were taken from the norms of the recent bicycles.

This hydraulic mechanism to the bicycle has several advantages and also some disadvantages too.
We are very pleased to include the advantages and uses and also in what way it was different from
the old mechanism and how it was helpful to the mankind and also the future generation too.
Besides, every invention has some disadvantages too, we didn’t hesitate to include those and also,
we included that what can be added to our mechanism in future in order to develop our mechanism
further.

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 As we embark on this journey of exploration, we will not only witness the recent developments
in bicycle technology but also uncover the underlying principles that allow bicycles to be efficient,
safe, and enjoyable means of transportation and recreation. This knowledge not only appeals to
the curiosity of enthusiasts but also holds significance for engineers, urban planners, and
policymakers looking to foster sustainable and accessible modes of transportation. Join us as we
navigate the fascinating world of the bicycle’s evolution, from its historical roots to the cutting-
edge innovations of today.

1.1 Origin of Bicycles and their history

Historians disagree about the invention of the bicycle, and many dates are challenged. It is most
likely that no individual qualifies as the inventor and that the bicycle evolved through the efforts
of many. Although Leonardo da Vinci was credited with having sketched a bicycle in 1492 in
his Codex Atlanticus, the drawing was discovered to be a forgery added in the 1960s. Another
presumed bicycle ancestor, the vélocifère, or célérifère, of the 1790s was a fast horse-
drawn Coach that is not considered to be a predecessor of the bicycle.

A sketch from around 1500 AD is attributed to Gian Giacomo Caprotti, a pupil of Leonardo da
Vinci, but it was identified as a premeditated hoax by Hans-Erhard Lessing in 1998, a statement
that is now widely recognized. The validity of the bicycle sketch, however, is vehemently
supported by supporters of Prof. Augusto Marinoni, a lexicographer and philologist who was
entrusted with the transcription of Leonardo’s Codex Atlanticus by the Commissione Vinciana of
Rome.

A later, similarly unsubstantiated claim is that in 1792, the “Comte de Sivrac” invented a célérifère,
demonstrated in the Palais-Royal in France. This device had two wheels on a wooden frame with
no steering, controlled only by leaning.

1.2 Evolution of Bicycles:

The cycle has been evolved into several ways and had different timelines; these timelines has been
discussed as shown below:

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1.2.1 1493: the Earliest Bicycle Sketch:

Legend credits Leonardo da Vinci with a bicycle-like design, discovered during the 1970s
restoration of the Codex Atlanticus. However, since 1998, physicist Hans-Erhard Lessing
has disputed its authenticity, arguing that the bicycle originated in 19th-century Germany.

Fig 1.1 Leonardo da Vinci imagined cycle

1.2.2 1817 to 1819: the Draisine:

In 1817, during an oat shortage, Baron Karl Von Drais of Germany created the
“laufmaschine” or “running machine,” a 22 kg wooden vehicle without pedals. It covered
13 miles in under an hour on its first journey. Von Drais patented it in 1818, leading to the
production of similar devices, known as “dandy horses,” across Europe.

Fig 1.2 Draisine cycle

1.2.3 1860s: the Boneshaker Era – now with pedals:

Historians credit Pierre and Ernest Michaux, a father-son team in Paris, with inventing the
modern bicycle. Around 1867, they created a two-wheeled velocipede with pedals and
cranks linked to the front wheel. Pierre Lallement, an employee who claimed to have
developed the prototype in 1863, brought the design to the United States.

Fig 1.3 Boneshaker bicycle

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1.2.4 1930’s: Taking it Up a Gear:

The derailleur was developed in France in the early 20th century but was introduced in the
Tour de France for the first time in 1937. Before that, riders were forced to use a two-speed
bicycle and would have to get off to switch gears. Derailleurs did not become common
road racing equipment until 1938 when Simplex introduced a cable-shifted derailleur

Fig 1.4 Person riding in the Olympics event

1.2.5 21st Century: Existing model bicycles:

Space-age materials like titanium and carbon fibre have transformed bike construction,
producing remarkably lighter and stronger bicycles than the early iron and wooden models.
This innovation in materials, combined with evolving bike styles, allows riders to choose
specialized designs tailored to their preferred riding style when visiting a bike shop.

Fig 1.5 New era bikes

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1.3 HYDRAULICS
Hydraulic systems are used in many different types of applications nowadays, ranging from large
machinery and integrated steel applications to minor assembly processes. By using Pascal’s law
and hydraulics, an operator may do substantial tasks like as lifting heavy loads, turning a shaft,
drilling precise holes, and more with a minimal investment in mechanical linkage.

1.3.1 History of Hydraulics:

People have been using hydropower for daily needs for ages. It is among the oldest and most
popular ways to use energy. In order to fulfil the demands of the modern world, the engineers of
the past established the foundation for modern hydraulic systems.

Although the original inventor of hydraulic systems is unknown, several of history’s greatest
thinkers, including Blaise Pascal, Joseph Bramah, Leonardo da Vinci, and Galileo Galilei, are
credited with helping to develop the technology. During the industrial revolution, hydraulics
emerged as a useful field with a wide range of practical uses.

The 20th century also marked the start of new and diverse applications for hydraulics. These days,
a lot of people use hydraulic systems due to their versatility and ease of use with a variety of
actuator types. A further benefit of a hydraulic system is its high-power density. Apart from
automotive and industrial applications, hydraulic systems are ubiquitous: most sophisticated
machinery where one can spot hydraulic systems includes machines such as airplanes, space
shuttles and construction equipment.

A hydraulic press usually consists of two connected cylinders that are pressurised with an oil-
based hydraulic fluid. Two pistons on the sides of these cylinders are in constant contact with the
fluid. The pressure within the fluid is transferred by applying a certain force to the smaller section
of the piston. According to Pascal's law, the pressure will be the same as the pressure the fluid in
the other piston exerts.

Hydraulic power is produced by moving hydraulic fluid through the hydraulic system. The fluid
is directed towards the cylinder through the valve, where hydraulic energy converts it back into

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mechanical energy. The valves help control the fluid's flow and allow for the release of pressure
as necessary.

The first hydraulic press was created at the start of the industrial revolution by a British mechanic
by the name of Joseph Bramah. His hydraulic press, patented in 1795 and commonly referred to
as the Bramah press, was developed on the basis of the idea that pressure applied to a small area
converts to a bigger force in the area that is larger on the other side of the cylinder. This idea is
realised in a hydraulic system by the hydraulic fluid that transfers energy from one point to another.
Because the hydraulic fluid is almost incompressible, it can transmit power instantly.

1.3.2 Science Behind Hydraulics – Pascal Law:

The Pascal’s Principle is the name of the science underlying hydraulics. The foundation of fluid
mechanics, known as Pascal’s law or Pascal’s principle, was discovered in 1653 and published by
Blaise Pascal in 1663. It states that energy will be transferred evenly in all directions if the
hydraulic fluid’s pressure changes at any point. The fluid will spread evenly and remain
undiminished when pressure is applied. Everywhere inside the container will experience the same
fluid pressure.

Pascal’s principle states that pressure is equal to force divided by the area of action. When a piston
is subjected to pressure, the second piston in the system experiences an equivalent increase in
pressure. When the area multiplies by ten the initial area, the force is ten times higher on the second
piston even though the pressure is the same all the way through the cylinder. This effect is
produced by the hydraulic press using Pascal’s principle. Pascal also found that the pressure in a
fluid at rest is constant throughout; that is, the pressure at a given location would be constant across
all planes running through it.

Pascal found that when the pressure inside an enclosed fluid change, the fluid's pressure is
transferred to all of its points as well as the walls of the container it is contained in, without
decreasing. The reason for this is that the fluids are almost incompressible, therefore when pressure
is applied, it travels un all directions vertically to the container's walls.

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In this example case, a small force F1 applied to a small piston of area A1 causes an increase in
the pressure in the fluid. According to Pascal’s principle, this increase is transmitted to a larger
piston of area A2 by exerting a force F2 on this piston.

The pressure is the applied force over a surface as;

P=F/A >> F is the used force and A is the surface area.

Fig 3.1 Example for the hydraulics

There are two pistons on either side of the container, and the container is filled with incompressible
fluid like oil. The pressure applied will be transferred equally and undiminished to all parts of the
system.

For the first piston, a force F1 applied over a surface area A1. The pressure P1 is then: P1=F1/A1

The pressure P2 in the second cylinder with a force of F2 and surface area A2 will be: P2=F2/A2

When you apply pressure(P1) in the first piston, it will be equally transmitted through the confined
incompressible fluid.

P1=P2

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The hydraulic system allows the lifting of a heavy load with a small force. This equation shows
that the force F2 is greater than the force F1 by a factor equal to the ratio of the areas of the two
pistons. Note that the pressures in both pistons are essentially the same and as their areas are
different, so are the forces, resulting in the ratio between their magnitudes equal to the ratio
between their areas.

1.3.3 Blaise Pascal – Father of Hydraulics:

Blaise Pascal (1623 – 1662) was a French mathematician, physicist, inventor, philosopher, and
writer. Throughout his life, he made a substantial contribution to science. Fluid dynamics and
pressure are two of the physical domains where Pascal made significant contributions. The unit of
pressure (SI) and Pascal's rule bear his name in recognition of his contributions to science. Pascal's
most significant mathematical contribution was the development of probability theory.

One of his most famous statements is known as the Pascal principle which refers that –

“The pressure exerted on a fluid that is not compressible and in equilibrium in a vessel with non-
deformable walls is transmitted with equal intensity in all directions and at all points of the fluid.”

1.3.4 Pros and Cons of Hydraulics:

Power transmission networks known as hydraulic systems use mechanical energy to create
pressure, which then flows back into mechanical motion. Usually, an internal combustion engine
or an electric motor produces the first mechanical energy in the form of a rotating movement.
Hydraulic oil creates the pressure and flow gearbox, and the resultant movement can be linear or
rotating.

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The hydraulic system benefits are:

• Self-lubricating hydraulic systems;

• Good power to weight ratio;
• Relatively minimal components
• The ability to detach the actuation from hydraulic power generation due to the simple and
flexible transfer of hydraulic energy
• The hydraulic systems can be operated manually or with the use of contemporary
electronics

The hydraulic system limitations are:

• The cleanness of transmission fluids

• The temperature dependant characteristics of fluids
• Long-distance power transmission causes power losses in the system
• The components and hydraulic fluids require maintenance
• Maintenance at regular intervals

1.3.5 Market Leading Innovations with Hydraulics:

Hydraulic technology has advanced astronomically since the 1800s. The primary benefits of
hydraulic systems include their capacity to multiply force-transmission in a wide range of
industrial applications, their adaptable and customisable qualities, and their easy and powerful
energy transfer. The operation and control of machine tools, agriculture, construction, and mining
equipment, as well as the automotive and aviation industries, all successfully use hydraulic
systems. We can categorically state that fluid power can effectively compete with mechanical and
electrical technologies. Systems with hydraulic power can produce forces ranging from thousands
of tonnes to a few kilogrammes.

As technology development is evolving rapidly in the modern world and the variety of hydraulic-
power systems are getting more specific and customized to many industries, there are still many
possibilities to develop hydraulic use further. One of the main participants in hydraulic energy
transmission technologies, hydraulic power systems are utilised extensively in the mining,
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forestry, aerospace, and even space technology industries. The brakes, steering, and transmissions
of automobiles all make extensive use of hydraulic power systems. The fundamentals of hydraulic-
power technology are also used in industrial automation and mass production
Hydraulic systems will continue to be important as the space race develops. The hydraulic sector
is starting to take greater initiative. Customers' requirements are shifting, becoming more detailed
and complex in their expectations.

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 CHAPTER 2

LITERATURE REVIEW
Since our project deals with bicycles, hydraulic mechanism and also rack and pinion mechanism.
So, we intended to research on these three topics for further information and our research
summarization on these three topics will be as follows:

2.1 Review on Bicycle and Hydraulics:

2.1.1 Scope of Hydraulics

The uses of hydraulic power enable the administrator to complete large tasks (lifting heavy loads,
turning a pole, boring exactness openings, etc.) with the least amount of effort by utilising Pascal's
Law, which states that: "Weight connected to any piece of a bound liquid transmits to each other
part with no misfortune. The weight demonstrations with break even with constrain on every single
equivalent range of the limiting dividers and opposite to the walls." Because pressure driven liquid
is nearly incompressible, hydraulic frameworks are found in a vast array of applications and
scenarios, from small gathering apparatus or security entryways to heaping rigs, theme park rides,
supersonic aircraft, and the bascules on London's Tower Bridge.
Oil-based products reach the planet annually in excess of 700 million lady (2.65 billion litres!),
according to the National Maritime and Environmental Organisation (NOAA). Approximately
50% of this volume comes from illegal and dubious transfers. Doors, a manufacturer of hoses,
states that hydraulics is committed to 98 million lady (370 million litres). That illustrates the annual
amount of oil spilled by water-powered equipment. These are incredible figures, especially in light
of the NOAA's claim that even a single litre of oil can contaminate up to a million litres of water.
What is the annual pressure-driven oil consumption of each of your machines? If more than one
machine is under your supervision, the primary method you can be certain is whether you measure
and record all best offs. It's close difficult to control or oversee anything, however, so those
estimations likely don't occur.[6]

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2.1.2 Study and Review on Bicycle

A bicycle is a two-wheeled vehicle propelled by the rider and steerable with the use of a handle.
It is among the most affordable and environmentally friendly forms of transportation available
worldwide. Different bicycle forms have existed in the past, influencing the evolution of the
current design. Research to improve the comfort and economy of cycling is still ongoing. This
review paper describes the specifics of several bicycle designs throughout history. Data on various
components of a typical safety bicycle are also provided. The exhibit includes details of the free
wheel mechanism that gives the drive wheel one direction of motion. This review paper provides
an overview of recent advancements in various techniques for pedal power transmission to the
rotation of the wheels and the major advantages and disadvantages of these transmission methods
reported in the literature. It covers how the energy efficiency of the bicycle is calculated
considering the case of a chain driven safety bicycle. It is intended to help readers to obtain a
comprehensive review on design developments in bicycle.
In field tests, relevant variables are measured while a cyclist or a group of cyclists is riding. The
variables that can be measured include the cyclist's power exerted, oxygen consumption, velocity,
and/or power. From the measured variables, mathematical models can be used to infer the
aerodynamic drag. Debraux et al. (2011) provided a thorough review of these methods along with
methodologies to assess the cyclist frontal area.
There were several mechanisms that can be suitable to ride the bicycle, such as
➢ Chain Mechanism
Chain drive is used to transmit mechanical power from one place to another. It often conveys
power to the wheels of bicycles. The drive chain or transmission chain also known as roller chain
is passed over a sprocket gear, with the teeth of the gear meshing with the holes of the chain links.
The gear turning results pulls the chain putting mechanical force in to the system.

ADVANTAGES DISADVANTAGES

Transmission system is compact Frequent maintenance is required

Can easily adapt the multigear system Chance to disengage from the sprocket gear is
higher

Chain gear mechanism is cheap Slack and backlash are more

Table -1: Advantages and Disadvantages of Chain Transmission Mechanism

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 ➢ Gear Mechanism
The power from the pedal gear is transmitted to the wheel using intermediate gear mechanisms.
The gear mechanism chosen for transmission is simple spur gear.

Fig 2.1 Gear Mechanism

ADVANTAGES DISADVANTAGES

Less noise on riding Slack and backlash are more

Easy maintenance and lubrication Size of the intermittent gear is large. So the
system is not compact

Table 2 Advantages and Disadvantages of Gear Transmission Mechanism

➢ Hydraulic Transmission Mechanism:

In hydraulic bicycles, power to the pedals is transmitted by means of a liquid through the tubes
from a hydraulic pump and to hydraulic motor and vice versa. Hydraulic bicycles are chainless.

ADVANTAGES DISADVANTAGES

Continuously variable gearing Heavier

No slack or backlash occurs The overall losses are higher compared to

open chain

Mechanism is clean and operates silently Fluid leak

Table 3 Advantages and Disadvantages of Hydraulic Transmission Mechanism

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 ➢ String Type Transmission Mechanism

In string type transmission mechanism, the forward momentum is obtained when triangular
swinging mechanism pulls on the rope and rotates a drum on the wheel. The freewheel mechanisms
is provided on either side of the rear wheel which is connected by polyethylene rope to the
swinging arm. When one unit on the right is driving the bicycle forward, the other is being returned
to its starting position and vice-versa.

Fig 2.2 String Type Transmission Mechanism

2.2 Research Gap

The research gap in the power transmission of bicycles revolves around several critical areas.
There is a lack of comprehensive studies comparing the efficiency and durability of alternative
power transmission systems, such as belt drives and shaft drives, against traditional chain drives.
Innovations in materials used for power transmission components are underexplored, particularly
in developing lightweight, durable materials that minimize energy loss. The impact of different
power transmission systems on rider comfort, maintenance needs, and overall lifecycle costs
remains inadequately studied. Additionally, the environmental implications of manufacturing and
disposing of various power transmission components are not well understood. Addressing these
gaps can lead to advancements in bicycle performance, user experience, and sustainability.

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2.3 Problem Identified:

In the existing model of bicycles, we had identified several problems that had been faced
by all ages of people while riding the bicycles. Some of the problems that we had identified
from our research are:

The main problems with existing bicycle models were:

1. High Maintenance: Early bicycle designs often required frequent repairs and upkeep.
The materials used and the mechanical complexity of the early models meant that riders
had to spend a considerable amount of time and resources on maintenance.

2. Less Speed: These bicycles were not optimized for speed. The design and construction
materials limited how fast they could go, making them less efficient for transportation and
recreational purposes.

3. Health Issues: Riders often experienced health problems such as knee sprains and
muscle cramps. The ergonomics of the early bicycles were not well understood, leading to
physical strain and injuries.

4. Fatigue: Due to their inefficient design, riding these bicycles was physically demanding,
leading to rapid fatigue. This made them impractical for extended use or for covering long
distances.

5. Unsuitability for Long Distances: The combination of low speed, high physical
exertion, and potential for injury made these bicycles unsuitable for long-distance travel.
Riders were limited to shorter journeys, reducing the practical utility of the bicycles for
daily commutes or travel.

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2.4 Solution:

Since, we had encountered the problems faced with the old models. In order to overcome the
problems, we had come up with the solution like using hydraulic mechanism instead of chain and
crank mechanism. The cycles we are presenting are based entirely on hydraulic technology,
eliminating the traditional mechanical systems of chains and gears. These hydraulic bicycles
achieve velocities similar to traditional models but offer significant advantages such as smoother
and more efficient power transfer, low maintenance, enhanced rider comfort, and reduced physical
strain. The enclosed hydraulic system extends lifespan and reliability while opening new avenues
for future innovations, such as regenerative braking and automatic gear shifting, thus marking a
significant advancement in bicycle design.

2.5 Objective:

The design and simulation of the hydraulic-powered cycle involve creating a conceptual model
and using software to predict performance, efficiency, and potential issues. Fabrication and
analysis of the prototype include constructing the physical model based on the design
specifications and performing rigorous evaluations to identify any practical challenges and areas
for improvement. Testing of the product encompasses real-world trials to assess the bicycle's
functionality, durability, and efficiency under various conditions, ensuring it meets safety
standards and performance expectations. This process validates the design, identifies any
necessary adjustments, and provides insights into the practical applications and potential market
readiness of the hydraulic-powered cycle.

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 CHAPTER 3
METHODOLGY AND WORK DONE

3.1 System Design:

Since we had encountered the problems faced with the existing model of bicycle, we as a team
come up with solution of replacing old mechanism of chain and sprocket with the hydraulic
mechanism along with rack and pinion mechanism. The mechanism that we had developed is the
combination of hydraulic mechanism and also rack and pinion. Here, hydraulics were used to
transmit the force and power applied on pedal to the other side of pedal with minor losses and also
rack and pinion mechanism connects to the wheel shaft, used for both force transmission and also
conversion of motion i.e. linear to rotatory which helps in the motion of the rear wheel. The
mechanism is simpler and easy to understand, design, and prototype making

3.2 Method study:

In Initial stage of project, we had gone through the journals in order to understand about the
hydraulics more deeply and also understood the governing forces on the cycle and also how chain
and sprocket mechanism is playing role in the cycle motion and understood the basic concepts of
cycle.in order to conversion of motion we had studied journals on rack and pinion mechanism in
order to get more knowledge on their technical terms and formulae. After this we had finalised,
the parts required for the design and fabrication.

Parts Required:
Crank
Hydraulic pipes
Pistons
Rack and pinion
U pipe
Hydraulic fluid
Connecting rods
Shaft
Freewheel

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3.2.1 Theoretical Design:
In the Second part of plan, we had made a rough 2D model by taking certain assumptions and also
taking into the account of existing cycle frame and designed the 3d model with the Solid works
Software and came to the conclusion of dimensions and their tolerance, and the dimensions of
some parts are follows as:

PARTS DIMENSIONS (mm)

S.NO

1 Crank Rotational Diameter 60 mm

2 Length of primary cylinder 100 mm

3 Length of Secondary cylinder 280 mm

4 Inner diameter of U pipe 30 mm

5 Length of connecting rod 55 mm

6 Length of straight U pipe (excluding 250 mm

curvature)

7 Rack length 440 mm

8 Pinion Pitch Circle Diameter 27 mm

9 Pinion Module 2.5 mm

Table 4 Dimensional specifications of some parts

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3.2.2 Execution:

In the third stage of the project, we executed the whole theory in designing and fabricating the
Hydraulic mechanism. At this stage, we had faced several problems in fabricating the components
but at last we had overcome all the obstacles that came in between those. Now, we implemented
our idea and thoughts in making prototype. We took measurements accordingly, which would be
feasible to do necessary operations to make it work. Initially, we started the fabrication with the
hydraulic step pipes and U pipe. After that we slowly fabricated the other parts like Rack and
pinion, pistons, and some other assembly parts required for mechanism. Especially, the parts like
rack and pinion were made cautiously in order to get proper mating and required gear ratio.

3.3 Raw Material Selection:

The selection of material is very issue for the making of any machine or mechanism. The selected
material should fulfill the basic requirement of the design. There are lots of material, are available
for the fabrication purpose like mild steel, stainless steel, cast iron, aluminium alloys, etc. There
are lot of considerations in selection of raw material process like cost, availability, their properties,
etc. hence we selected the best suitable material for chassis, mechanism as mild steel.

For fabrication of Hydraulic pipes and U pipe, mild steel is used. Because, in order to make the
complete whole system light weight. The rack and pinion too, were fabricated with stainless steel,
as it needs to strong, non-corrosive and good life. Sixty-eight fluid is used as a hydraulic fluid as
it can useful in extreme conditions without any failure. Rubbers were used on the piston head in
order to reduce the shock vibration and less noisy.

3.4 Main components of Mechanism:

3.4.1 Hydraulic pipes:

Hydraulic pipes in a hydraulic mechanism bicycle play a crucial role in the power transmission in
the bicycle. They are typically made of durable materials like reinforced rubber or braided stainless
steel. Pumping hydraulic fluid through the hydraulic system generates hydraulic power. Through
the valve, the fluid is directed towards the cylinder, where hydraulic energy transforms it back into
mechanical energy. The valves help control the fluid's flow and allow for the release of pressure
as necessary.

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The hydraulic fluid in a hydraulic system, which transfers energy from one place to another,
realises the principle of Pascal's law. The hydraulic fluid can carry power instantly since it is
almost incompressible.

Fig 3.1 3D drawings of hydraulic pipes Fig 3.2 Fabricated images of Hydraulic pipes

3.4.2 U pipe:

The U-pipe helps in routing hydraulic fluid efficiently within the system1.It allows for smooth and
continuous flow of hydraulic fluid2.The U-shape design minimizes the risk of fluid leakage1.It
helps in maintaining consistent pressure throughout the hydraulic system2.The U-pipe is designed
to withstand high pressure and temperature1.It ensures that the hydraulic fluid reaches all
necessary components2.The U-pipe’s design helps in reducing the overall weight of the bicycle1.It
contributes to the durability and longevity of the hydraulic system2.The U-pipe is crucial for the
efficient operation of the hydraulic mechanism1.It plays a vital role in the overall performance and
reliability of the bicycle.

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 Fig 3.3 3D diagram of U pipe Fig 3.4 Fabricated Hydraulic U-pipe

3.4.3 Rack and Pinion:

To translate rotating motion into linear motion, gear racks are used. A gear rack works using a
pinion, a tiny cylindrical gear that meshes with the gear rack, and has straight teeth cut into one
surface of a square or round segment of rod. In general, the term "rack and pinion" refers to both
the gear and the pinion. Gears can be used in a variety of ways. For instance, a gear and gear rack
are used to rotate a parallel shaft, as seen in the photo.

Fig 3.5 3D drawing rack &pinion

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 Fig 3.6 3D diagram of pinion

3.4.4 Pistons:

Pistons are integral components in hydraulic systems, functioning as the primary agents for
converting fluid power into mechanical motion. In a hydraulic cylinder, a piston moves within a
cylindrical chamber, driven by pressurized hydraulic fluid. When fluid enters one side of the
cylinder, it pushes the piston, creating linear motion that can be used to lift, push, or pull loads.
This motion is utilized in a wide range of applications, including construction machinery,
automotive brakes, industrial machinery, and aircraft control systems, providing precise control,
high power density, and efficiency in converting hydraulic energy into mechanical work.

Fig 3.7 3D diagram of primary piston and secondary piston

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 Fig 3.8 Fabricated parts of Pistons

3.4.5 Crank:

A crank is an arm attached at a right angle to a rotating shaft by which circular motion is imparted
to or received from the shaft. It can be used to change circular motion into reciprocating motion
or vice versa when paired with a connecting rod. The arm could be a separate arm or disc attached
to the shaft, or it could be a bent section of the shaft. A rod, also referred to as a connecting rod, is
pivotally attached to the end of the crank.

Fig 3.9 3D diagram of Crank

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3.4.6 Connecting rod:

The component of a piston engine that joins the piston and crankshaft is known as a connecting
rod, or "con rod." The connecting rod, in conjunction with the crank, transforms the piston's
reciprocating motion into the crankshaft's rotation. The connecting rod is necessary in order to
transfer the piston's compressive and tensile forces. Its most prevalent form permits spinning on
the shaft end and pivoting on the piston end of an internal combustion engine. A mechanic linkage,
which was employed in water mills to transform the spinning motion of the water wheel into
reciprocating motion, was the ancestor of the connecting rod. Steam and internal combustion
engines are the two applications for connecting rods that occur most frequently.

Fig 3.10 3D diagram of Connecting rod

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3.4.7 Freewheel:

A freewheel is a mechanism in bicycles that allows the rear wheel to rotate independently of the
pedals when the cyclist is not pedalling. It consists of a ratcheting mechanism that engages when
the cyclist pedals forward, transferring power to the wheel, but disengages when the pedalling
stops, enabling the wheel to spin freely. This allows the rider to coast without the pedals moving,
providing a smoother and more efficient riding experience, especially when descending or taking
a break from pedalling. The freewheel is crucial for modern cycling, enhancing
comfort and control.

Fig 3.11 Freewheel with the shaft

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3.5 DESIGN IMAGES:

Fig 3.12 Isometric View of Hydraulic Mechanism

Fig 3.13 Exploded view of Mechanism

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 CHAPTER 4

PROTOTYPING AND TESTING

The basic working mechanism depends on the fluid’s principle like Pascal principle and continuity
equation. Our bicycle's hydraulic system operates on the Pascal principle, whereby force applied
to the crank pedal is transferred to the primary cylinder piston through the use of a connecting rod
and crank (which is connected to the piston of the primary cylinder and crank). Pressurised fluid
moves from primary cylinder to secondary cylinder as a result of the primary cylinder fluid's piston
compressing the fluid in primary cylinders. The secondary cylinder's piston, which is attached to
the rack and travels linearly to the U pipe cylinder, is forced by the pressurised fluid. The pinion
that rotates in tandem with the rack transforms the linear motion of the rack into rotational motion.
The pinion, which is attached to the wheel shaft and free wheel, is what starts the wheel moving.
With the fluid inside the U pipe, the U pipe transfers the force to the other side of the rack. The
fluid in the secondary cylinder is pushed and compressed by the force applied by the rack on the
opposite side. The primary cylinder on the opposite side receives the pressurised fluid, and it then
travels to the pedal on that side. This means that the force a person applies to the pedal initially
drives the entire mechanism, allowing us to eventually acquire roughly the same force on the other
side of the piston. This makes riding a bicycle easier for the rider because they can exert less force
on the other side of the piston, even though doing so requires more effort. It also allows them to
ride for longer periods of time without getting tired or experiencing pain when cycling long
distances.

Fig 4.1 Side view of the Fabricated parts

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 Fig 4.2 Top view of mechanism

5.1 Theoretical Study and Assumptions:

The Assumptions which we made in order to calculate the velocity of the wheel and also force on
the mechanism:

• Considered Weight applied by the Healthy Human on the cycle: 200 N.

• Assuming the crank, connecting rod and piston in the mechanism as a Single slider Crank
Mechanism.
• By Trail and Error method, we had assumed ratio of diameter of primary cylinder to the
diameter of secondary cylinder as 5:3
• Assumed the person is riding the bicycle with constant cadence of 80 rpm.
• For, Suitability we had assumed Gear ratio between rack and pinion is 2.
• Module of pinion is assumed as 2.5mm.
• By taking into consideration of normal available wheels, we assumed that radius of wheel
is 0.36 m.
• Lengths of primary, secondary and U pipe were assumed on the basis on normal cycle i.e.
consideration of distance between the pedal to the centre of the rear wheel.
• Assumed the losses such as frictional losses, bend losses etc. were negligible and did not
consider the air drag and friction on the wheels.
• Assumed the person is riding in the proper roads without any damage.

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4.2 Calculations:
Length of Secondary cylinder = 273.75mm

Diameter of Secondary cylinder = 34.5mm

Length of primary Cylinder = 98.25mm

Diameter of primary cylinder = 54.5mm

Torque on the crank= radius of crank * weight applied by human on the cycle

= 0.165*200

= 33N-m

Velocity of piston (Vp):

Vp= wr (SinΘ + (Sin 2Θ)/2n)

Fig 4.3 Single slider crank mechanism

w = angular velocity at the pedal

r = length of crank

n=l/r

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The Cadence Speed (N) is 80 rpm

Therefore,

Angular Velocity= 2*pi*N/60

= 2*pi* 80/60

= 8.37 rad/s
Vp = 0.36m/s
By applying the continuity equation:
A1 V1 = A2 V2

A1= Area of the primary cylinder

A2= Area of the Secondary Cylinder
V1= Velocity of the primary piston
V2= Velocity of the secondary piston
D1=Diameter of the Primary cylinder
D2= Diameter of the Secondary cylinder
D1/D2= 5/3

A1 / A2 = V2 / V1

(D1/D2)2= V2 / V1

(5/3)2 = V2/ 0.36

V2= 0.89m/s

Therefore, rack velocity = 0.89m/s

Since, we assumed Gear ratio=2

Therefore, pinion velocity = 0.89m/s(app)

Since Wheel is connected with pinion with same Center it will have same Angular velocity

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Angular velocity of pinion= 0.89/radius of pinion

= 0.89/ 0.027

= 32.96 rad/s

Velocity of Wheel = Angular velocity of pinion * Radius of Wheel

= 32.96 * 0.36
= 11.8 m/s

Velocity of Wheel = 11.8* 18/5 = 42.5 Kmph

Force calculation on Pistons:

Force on Big piston (F1):

T = F1 * r [ SinΘ + Sin 2Θ/2√(𝑛2 − 𝑠𝑖𝑛2 Θ) ]

33= F1 * 0.04 [ 0.866+0.240]

F1 = 825/1.11 = 743.2 N

By using Pascal Law,

F1/ A1= F2/ A2

D1/D2= 5/3

Force on second piston (F2):

A1 / A2 = F1/F2

(D1/D2)2 = F1/F2

(5/3)2 = 743.2/F2

F2 = 270 N

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4.3 System Testing and Analysis:
The team had a plan to simulate the testing for the machine after the fabrication. This is to ensure
having the right measurement and dimension for each component. The testing procedure are
available as shown in photos below:

Fig 5.4 Testing of the product

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 CHAPTER 5

RESULTS AND DISCUSSIONS

The design of hydraulic mechanism along with rack and pinion is as easy as the basic machine
design knowledge is applied to design to the parts like hydraulic pipes, rack, pinion and crank etc.
and also used single slider crank mechanism for the calculation of forces and velocity of wheel
when we apply the force on the pedal. The cost of the new product development was bit high but
it can be done at minimal cost when it was done in mass production. But we tried to lower the cost
of the product by selecting the easily available and local materials.

After gone through towards the calculation, we can understand that the force what we are applying
on the pedal, is available on the other side of pedal which makes the rider to apply the less force
while riding on the other side. Besides, with the help of single slider crank mechanism concept,
we had calculated the force on the primary cylinder piston and also with the help of the pascal law
we calculated the force on another piston. The force applied on the rack is similar to the force
applied on the secondary cylinder piston as both rack and piston are connected

Besides we had done analysis of the design of the hydraulic mechanism parts along with the Rack
and pinion in the ANSYS software and the results which had been acquired for different parts had
been shown below:

Fig 5.1 Analysis of Connecting Rod

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 Fig 5.2 Analysis of Crank

Fig 5.3 Analysis of Rack and Pinion

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5.1 Challenges and Decision Making
During the project execution, the team faced number of challenges that required the team quick
response to meet the project deadline. Challenges included the following:
1. Finding proper fabrication shop.
2. Design problems.
3. Arranging the spare parts.
4. Execution of the motion of crank and pistons.

5.2 Limitations of the old existing method:

The bicycle with the chain and sprocket mechanism had certain limitations:

1. Requires regular lubrication, tension adjustments, and cleaning

2. Not optimized for maximum speed.

3. Causes knee sprains and muscle cramps due to poor ergonomic

4. Leads to significant rider fatigue.

5.3 Advantages of Hydraulic mechanism in the bicycle:

1. The requirement maintenance of the cycle would be low and it reduce the maintenance
cost.
2. The riders will be not affected with the health problems like knee sprains and cramps which
arose while using normal chain and sprocket mechanism cycle
3. The riders can ride the hydraulics mechanism bicycle for long distance as the effort
required to put up is less
4. The riders cannot feel fatigue, even though they ride for long distance and longtime
5. The bicycle is suitable for all ages as it requires less effort
6. There would be no chain breakage situations as instead of chain Rack and pinion.

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 CHAPTER 6
CONCLUSION AND FUTURE DIRECTIONS

6.1 CONCLUSION
Now coming to conclusion of our project, our mechanism has solved the problems that we have
stated in the previous chapters. This also leads to sustainability and make us take a step towards
GO GREEN initiative. This makes that every person to use bicycle for long distance without any
knee sprains, cramps, and also rider cannot feel fatigue as he put his efforts less as compared to
the normal traditional cycles. This also led to innovation in hydraulics in field of vehicles and we
might feel that this would be the first step that leads to grater innovation in the field of mechanical
using hydraulics.

Fig 6.1 Isometric view of Comple Hydraulic powered bicycle

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6.2 Future directions:
Since, our project completely uses the mechanical concepts and mechanical parts. But, in future
there were several ways that our project can evolve and shows the new path for the human
development. We as a team noticed some of the future directions to our project from our side.
These future directions can be clearly stated in the given below table:

S.NO PARTS/FINDER RECOMMENDATION

1 Hydraulic pipe (Step Cylinder) We can replace step cylinder with straight
cylinder without any steps, would work in the
same way as the present model works

2 Hydraulic pipes We can replace the pipe with the hydraulic

wire

3 Rack and pinion We can replace Rack and pinion with worm
and worm wheel as both work in the same way
and that purpose of usage were same too

Table 5 Future Recommendations for our model

6.3 Market potential of our bicycle:

The bicycle market size in India was valued at USD 1.5 billion in 2019. The market is expected to
reach USD 2.97 billion by 2023, growing at a CAGR of 5.65% from 2023 to 2028 .In global
market, the no of cycles that are being sold are getting increased Continuously. India is one of the
largest producers and exporters of bicycles in the world, with an annual production of around 15
million units and an export of around 1.5 million units. We need to target the people living in hilly
areas and knee problems. Our plan is to attain a 10-20% Indian market share in 5 years and focus
on increasing exports to European and American markets with new facelift models and
new technologies.

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 CHAPTER 7

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