Structural and Safety Design of a Low-Cost Electric Three-Wheeler for Dense Urban Traffic Using a Multidisciplinary FEA Approach

This paper presents the structural and safety design of a low-cost electric three-wheeler intended for use in the densely populated urban environment of Dhaka, Bangladesh. The goal of this project was to improve currently available informally manufactured or unregulated motorised vehicles, which often have unsafe structural features, such as a high centre of gravity and inadequate braking systems. The vehicle is designed to accommodate five people (one driver and four passengers), reach a maximum speed of 30 km/h, and be manufactured locally at an estimated cost of 1200–1400 EUR. The vertical centre of gravity was determined to be 0,642 m above ground level, resulting in a static stability factor of 1,09. Structural performance was evaluated using ANSYS Mechanical under combined static loading conditions and a simulated frontal impact at 30 km/h. The redesigned tubular frame reduced maximum upward deflection by 15,6% and increased energy absorption during frontal collision by 37,3% compared to previous designs. Braking performance analysis showed that the vehicle can stop within 10 metres from 25 km/h, while rotor temperatures maintained a 108 °C margin below the fade threshold for brake fade during repeated emergency braking. The results demonstrate that substantial improvements in structural safety and thermal performance can be achieved in low-cost electric three-wheelers using locally available manufacturing resources.