1.

Introduction
This project aims to design and fabricate an electric-powered trolley cart capable of transporting
heavy loads (500–1000 kg) within industrial and workshop environments. The primary goals are
to improve workplace efficiency, reduce manual handling effort, and promote operator safety
while maintaining a low cost of production.

2. Objectives
 Capacity: Carry loads between 500 kg and 1000 kg.
 Mobility: Enable smooth and controlled electric movement in forward and reverse directions.
 Safety: Include mechanical and regenerative braking systems.
 Usability: Offer a simple, intuitive manual throttle interface.
 Efficiency: Achieve a minimum range of 25–30 km per charge.
 Affordability: Keep the manufacturing cost under ₹80,000.
 Durability: Build a rugged and corrosion-resistant steel chassis.

3. Design Specifications
Category Specification
Load Capacity 500 – 1000 kg
Platform Size 1200–1400 mm × 800–1000 mm
Overall Dimensions ~2000 × 1000 × 1100 mm
Top Speed 3–5 km/h (adjustable)
Battery Type LFP (Lithium Iron Phosphate)
Range per Charge 25–30 km
Charging Time ≤ 4 hours
Drive System Rear-wheel or differential DC drive
Brake System Mechanical + Regenerative
Tyres Solid Rubber, Non-marking
Control Interface Manual throttle + emergency cutoff
Chassis Material Mild Steel / Alloy Steel with powder coating
Additional Features Foldable side barriers, LED lighting, horn,
charger
 CHASSIS
The electric trolley utilizes a ladder frame chassis, chosen for its structural simplicity,
strength, and cost-effectiveness. This type of frame consists of two longitudinal members
connected by multiple lateral cross members, forming a robust and rigid platform capable
of withstanding heavy loads ranging from 500 to 1000 kg. Its open and modular design
allows for easy mounting of drivetrain components, battery enclosures, and body panels,
while ensuring uniform weight distribution and stability during operation. The ladder
frame’s proven performance in utility vehicles and industrial carts makes it an ideal
choice for workshop and warehouse environments, where durability and ease of
maintenance are critical.
4. System Architecture
a. Mechanical System
• Chassis: Fabricated from powder-coated mild steel for durability.
• Platform: 1200–1400 mm long, supports large tools or equipment.
• Wheels: Two drive wheels and two caster wheels for maneuverability.
• Axle: Rear axle with differential(OPTIONAL) for smooth turning under load.

b. Electrical System
• Motor: 1 × 17000 INR-rated DC motor (high torque, reliable).
• Battery Pack: LFP battery with ~30 km range and <4 hours charge time.
• Motor Controller: 6000 INR-rated controller for direction and speed.
• Braking: Mechanical system plus optional regenerative braking.
• Lighting & Indicators: Headlight and horn for low-light operation.
• User Interface: Throttle with emergency cutoff and battery level display.

PMSM (Permanent Magnet

Criteria DC Motor
Synchronous Motor)
Cost Lower initial cost Higher initial cost
Simple (basic controller, Complex (requires precise control and
Control Simplicity
open-loop OK) sensor feedback)
Torque
High starting torque High torque density, smooth torque
Characteristics
Efficiency Moderate (70–85%) High (85–95%)
Higher (brushes and
Maintenance Low (no brushes, less wear)
commutator wear)
Moderate; brushes degrade
Durability High; long-lasting with proper cooling
over time
Cooling Air cooling generally Often needs enhanced cooling (fan or
Requirement sufficient liquid)
Complexity of Easier; less demanding Complex; needs advanced
Integration electronics inverter/controller
Regenerative Difficult to implement
Easily integrated and highly efficient
Braking effectively
Bulkier for same power
Weight & Size More compact and lightweight
output
Low-cost, low-speed High-efficiency, precision-controlled
Best Suited For
applications EVs
Use in Current Chosen for simplicity and Optional upgrade for higher
Design affordability performance and efficiency
5. Cost Breakdown
Component Cost (INR)
Base Frame 4,500
Platform Sheet 2,500
Side Barriers 4,000
Fasteners 500
DC Motor 17,000
Mounts & Couplings 3,000
Drive & Caster Wheels 7,000
Axle with Differential 3,500
Battery Pack (LFP) 18,000
Battery Enclosure 1,200
Motor Controller 6,000
Manual Throttle 900
Emergency Cutoff 450
Wiring Harness & Connectors 1,000
Mechanical Brakes (x2) 2,400
Regenerative Braking Circuit 0
Headlight / Indicator 600
Horn / Buzzer 250
Handlebar / Control Panel Mount 500
Battery Level Indicator 800
Onboard Charger 2,500
Paint / Coating 1,500
Total Estimated Cost ₹78,100

6. Benchmarking
Model Capacity Speed Battery Range Price
Smith 1000 kg 5 km/h LFP 30 km ₹1.8–2.3
ETWSB Lakh
Presto Truck 600 kg 4.5 km/h VRLA/LFP 20–25 km ₹1.2–1.6
Lakh
BharatBenz 750 kg 5 km/h LFP 30 km ₹2.2–2.6
E-Trolley Lakh
This Project 1000 kg 5 km/h LFP 30 km ₹78,100
Key Advantage: Comparable functionality at nearly ⅓ the cost of market alternatives.

7. Use Cases
 Mechanical workshops: Move gearboxes, engines, tool sets.
 EV production floors: Carry battery modules, panels.
 Warehouses: Transport stock between shelves and loading areas.
 Assembly lines: Streamline heavy part movement with minimal manpower.
8. Conclusion
This electric trolley design is a cost-effective, reliable, and safe alternative to existing commercial
products. With efficient power usage, customizable dimensions, and simplified controls, it is ideal
for industrial and workshop settings. Its low production cost and practical design make it scalable
for institutional or commercial use.