One Man Controlled Electric Goods Carrier

One Man Controlled Electric Goods Carrier

Dr. FEBINA BEEVI P

Associate Professor

Dept of Electrical and Electronics Engineering

MEA Engineering College Perinthalmanna, India

Mr. ARUN SAYI T

Dept of Electrical and Electronics Engineering

MEA Engineering College Perinthalmanna, India

Mr. RIYAS .P

Assistant Professor

Dept of Electrical and Electronics Engineering

MEA Engineering College Perinthalmanna, India

Mr. ABIN DAS

Dept of Electrical and Electronics Engineering

MEA Engineering College Perinthalmanna, India

Mr. ABOOBACKER SIDDEEQUE PT

Dept of Electrical and Electronics Engineering

MEA Engineering College Perinthalmanna, India

Mr. AGNAN.M

Dept of Electrical and Electronics Engineering

MEA Engineering College Perinthalmanna, India

AbstractThe paper emphasizes the design and development of a miniature form of one man controlled goods carrier to be used in confined spaces like warehouses, small lanes and dense urban areas. The light weight and small footprints of the vehicle make it a suitable option for space-restricted areas. The carrier features a Brushless DC (BLDC) motor that is highly efficient, compact in design, and has low maintenance, and so is perfect for small-scale transport operations. The main aim is to develop a lightweight, electrically driven, affordable vehicle that can transport small weights and can be transported by an individual in congested or tight spaces.The vehicle will have a small chassis, minimized to ensure stability and weight distribu- tion, with the BLDC motor driving enough torque to transport goods short distances. The design is aimed towards simplicity in control, efficiency in energy consumption, and providing a seamless operation in confined places, thus a suitable option for companies that have frequent, low-cost, and efficient transfers of commodities. The system proposed would help reduce labor and improve productivity where large vehicles are impractical or impossible to apply. Objective is to create a functional prototype to showcase the viability of the idea, emphasizing the functionality and efficiency of employing BLDC motor-driven material carriers in limited spaces.

Index TermsElectric goods carrier, BLDC motor, Field- Oriented Control (FOC), Lithium Iron (Li-ion) battery.

1. INTRODUCTION

   The traditional large-scale freight carriers fail to find handy applications at confined sites like the limited warehouse aisle widths, metropolitan lane widths with overfilled lane widths, and small-sized industrial locations [1]. Growing demand for companies that have become green and favor energy- saving technology has driven demand for electric power-driven

   solutions that are environmentally friendly and operationally effective [2].

   The One-Man-Controlled Electric Goods Carrier contra- dicts this by the design of a compact, easy-to-maneuver vehicle for transporting light to medium loads in crowded areas. The proposed carrier has a Brushless DC motor, compact in size, and very efficient, with low maintenance [3]. The motor of this type is very well adapted to continuous running in the limited space of operation and, therefore, is very desirable.

   Electric vehicles (EVs) are the top priority due to their reduced carbon emissions, energy efficiency, and lower main- tenance requirements. The employment of Brushless DC (BLDC) motors in electric transportation solutions has also improved their efficiency since BLDC motors provide greater torque, better speed control, and less wear and tear com- pared to conventional DC motors [4]. Besides this, improved technology in batteries like Lithium Iron batteries has helped to improve the dependability and life expectancy of electric transport vehicles, and so they are being used in a more effective manner for commercial and industrial use.

2. PROBLEM STATEMENT

   The growing need for effective, space-efficient, and eco- friendly material handling systems is a daunting challenge in present-day industrial and urban logistics [5]. Urbanization and growth in the distribution network and warehouses lead to space shortages that necessitate material transportation systems functioning in harmony in confined spaces [6]. Tra- ditional freight carriers, whose primary source of power is through the utilization of internal combustion engines (ICEs), are not appropriate in most uses since they possess a heavy

   frame, high fuel consumption, and contaminate the environ- ment. The emissions, noise pollution, and the higher cost of operation make them not appropriate in thin aisles, small stor- age, and city logistics services. To address all these problems, electrically operated material handling movers become more viable choices by dint of being emissions-reducing, cheaper to run, and easier to move around [7].

   The current electric counterparts fall short in fulfilling the requisite conditions of miniaturization, economy, and power saving. Most standard electric carriers and forklifts are not yet light enough for space-restricted applications or affordable enough for small and medium-sized enterprises to implement on a wide scale. Hand-operated material handling remains the norm in budget-constrained situations, which contributes to increased labor cost, decreased productivity, and higher on- the-job injury potential. Lacking an ideal transport solution, businesses are still beset by inefficiencies that take away from operational sustainability and competitiveness [8].

   Brushless DC (BLDC) motors are a technological advance in electric vehicle use because of their reliability, efficiency, and minimal maintenance needs [6]. BLDC motors, as op- posed to conventional DC motors, mechanically avoid brush wear and tear, which translates into longer life and better energy efficiency. Their ability to produce high torque and power output places them particularly in high demand for ma- terial handling jobs in limited space, where proximity control and prolonged use are a necessity. Additionally, technology advances in batteries, particularly the lithium-ion (Li-ion) battery, provide more operating time, lower charging time, and more power-to-weight ratio, which match the capabilities of small-sized electric goods carriers [7].

   Material choice is a critical consideration in the de- sign of vehicle performance and durability. The applications of high strength-to-weight, low-strength but affordable and deformation-resistant steel are extensive in industrial transport equipment. Light yet strong frame production, apart from pro- viding energy efficiency gain, also possesses benefits regard- ing portability and single-operator operation in tight spaces [8]. In addition, ergonomic aspects such as simple control, weight balance, and improved steering and braking continue to play significant roles in mitigating fatigue on the operator and work-related accidents, hence increasing productivity and safety [9].

   Despite all these advancements, there is still a significant lack of availability of a small electric goods carrier with single- person control that is ideal for congested warehouses, in- city urban supply networks, and small industrial applications. To fill this lacuna, the present study suggests launching an inexpensive, miniaturized, and power-efficient transportation system. By adopting a high-power BLDC motor, lithium- ion battery pack, and advanced motor driver in an ultrathin, ergonomic-shaped casing, the system developed herein is to transform material handling productivity, minimize costs of operation, and assis in mitigating environmental degrada- tion. This paper aims to provide a sustainable alternative to traditional material transportation systems, driving future- generation logistics solutions [5].

3. PROPOSED METHOD

   This journal is to create a lightweight, single-driver elec- tric goods carrier for small industrial and urban settings. Giant carriers cannot perform efficiently in narrow aisles, small factories, and busy areas, and therefore an inexpensive, lightweight, and quick substitute is in order.

   High-efficiency Brush less DC (BLDC) power driven, the carrier provides energy efficiency, low maintenance and high torque and therefore is best suited for transporting light to medium loads short distances. Ergonomic and stable in design, the carrier enhances maneuverability and ease of handling through smooth and easy operation.

   The project aims to develop a functional prototype to showcase the viability of energy-efficient and electric-powered goods carriers as a cost-effective and sustainable option. By integrating green design and control systems with efficiency, this innovation will increase productivity, lower running costs, and improve sustainable logistics in space-restricted areas.

4. DESIGN AND ARCHITECTURE

   Fig. 1. Circuit diagram

   1. Device Components and Specifications

      • BLDC Motor: 48V, 250W, 750 RPM, 3.18 Nm torque, high efficiency (80-90), with low maintenance and long operation life.

      • Lithium-Ion Battery:12V, 10Ah, high energy density, fast charging, and long cycle life, ensuring power supply reliability.

      • FOC Motor Controller: High speed and torque reg- ulation optimisation, ensuring smooth acceleration and energy optimisation.

      • DC-DC Buck Converter:48V to 12V DC/DC conver- sion, efficiency 85-95, ensuring power stability delivery to auxiliary systems.

      • Chassis and Load Platform:Lightweight, structurally reinforced, with stability design, optimized weight dis- tribution, and future load addition.

   2. BLDC Shunt Motor

      The 48V, 750W Brushless DC (BLDC) shunt motor was particularly built for material handling and mobility use that is reliable and efficient. It featured a permanent magnet rotor in fixed windings, with no brushes or commutator, thereby reducing friction, minimal maintenance, and no sparks [10].

      It was 400 RPM rated and gave high torque and pre- cise speed control, thus used in electric forklifts, automated transporters, and industrial automation [11]. BLDC motors gave increased efficiency (8595 pct), better thermal perfor- mance, and longer operating life compared to the traditional brushed motors [12]. Its compact size (4 kg) gave increased portability, while electronic commutation gave precise speed regulation, thus facilitating cost-saving and environmentally friendly transport applications [13].

      Fig. 2. BLDC motor

   3. Field-Oriented Control (FOC)

      Field-Oriented Control (FOC) or Vector Control is an advanced method of motor control widely used in electric vehicles for achieving precise torque and speed control [14]. As compared to trapezoidal or six-step commutation, FOC translates three-phase stator currents to direct and quadrature axis components using Clarke and Park transformations so that torque and magnetic flux may be controlled independently [15].

      FOC optimizes motor efficiency, acceleration, and low- speed torque, reducing torque ripples and noise to result in smoother and quieter operation [16]. It maximizes battery efficiency and range, and hence is appropriate for electric bicycles and other mobility systems [17]. Due to its high energy efficiency and precision, FOC-based controllers are used massively in modern electric vehicle systems [18].

      Fig. 3. FOC Circuit diagram

   4. DC TO DC BUCK CONVERTER

      The DC-DC buck converter or step-down chopper effec- tively transformed high voltage (48V80V) DC into a stable 12V DC output at 10A, providing guaranteed power regulation to low-voltage systems [19]. Employing pulse-width modu- lation (PWM) and inductive energy storage, it attained high efficiency, negligible power loss, and accurate voltage control [20].

      In contrast to traditional linear regulators, the buck con- verter improved energy efficiency and was perfectly suited for battery-operated applications, electric vehicles, and industrial automation [21]. Its compact design with a reliable provision of a constant low-voltage supply and excellent thermal control made it a vital element in up-to-date power electronics [22].

      Fig. 4. DC TO DC BUCK CONVERTER

   5. Lithium-ION

   The lithium iron 12V, 10Ah battery was a compact, lightweight, high-energy-density, and long-life energy stor- age device [23]. It was a high-performing and efficient bat- tery compared to traditional lead-acid batteries, with faster recharge, enhanced thermal stability, and lower self-discharge rates, and hence appropriate for electric vehicles, backup power supply systems, and industrial uses [24]. Through its satisfactory discharge efficiency and improved cycle life, it provided consistent power output as well as low maintenance costs, factors that led to higher system performance and sustainability [25].

   Fig. 5. Lithium-ION Battery

5. RESULT

   Successfully development of the One-Man Controlled Elec- tric Goods Carrier validates its effectiveness, reliability, and applicability to confined-space material handling. The Field- Oriented Control (FOC) BLDC motor provides smooth ac- celeration, accurate torque control, and power consumption optimization, and the lithium-ion battery offers high energy efficiency and long runtime.

6. CONCLUSION

The electric goods carrier proposed is an efficient, sus- tainable, and space-effective solution for use in areas where space is limited. With a high-efficiency BLDC motor and lightweight structure, it offers high efficiency, low mainte- nance, and durability, which makes it suitable for industrial applications With easy-to-use, single-operator controls, it saves labor costs and facilitates smooth, reliable transportation. As an environmentally friendly option, it reduces fossil fuel usage, ensuring sustainable and economical logistics. This project effectively provides an efficient, energy-saving, and maintenance-free transport system for small industries.

Fig. 6. Goods Carrier

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