Finite Element Based Structural Design and Stress Deformation Analysis of a Rotary Electric Bike Parking System for Urban Space Optimization

Abstract

Rapid urbanization in India has led to a severe shortage of bike parking infrastructure, with vehicle-to-citizen ratios approaching 1:3 in major cities. This paper presents the finite element based structural design and stress-deformation analysis of a rotary electric bike parking system capable of accommodating 6–8 motorcycles within the footprint normally required for 2 vehicles. The system employs a motorized rotary mechanism where bike-holding pallets mounted on a rotating rim are brought to ground level for parking or retrieval. 3D solid models of all structural components—bike holding pallet (C-section frame), pallet side structure, supporting shaft, and outer frame—were developed in SolidWorks 2017 and analyzed using ANSYS 2023 R1. Both L-section (75×75×5 mm) and C-section (100×50×10 mm) pallet frame configurations were evaluated; the optimised C-section was selected as the safe design with ?_max = 2.527×10? Pa against ?_all = 1.66×10? Pa (FOS = 1.5). Analytical calculations using truss theory, Macaulay\'s method, and Euler\'s buckling load theory corroborated FEA results for all components. A 5.5 kW crane-duty motor was selected for actuation. All components satisfied design safety criteria, confirming structural integrity for real-world implementation at malls, offices, and residential complexes.

Introduction

The study addresses the growing parking crisis in India caused by rapid urbanization, population growth, and increasing vehicle ownership. Limited parking infrastructure leads to traffic congestion, illegal parking, accidents, and wasted time searching for parking spaces. Traditional parking systems are classified into on-street parking and off-street parking, but both face limitations in densely populated urban areas.

To overcome these challenges, the project proposes a Rotary Bike Parking System, an automated multi-level parking solution designed specifically for two-wheelers. Unlike conventional multi-level parking structures, the rotary system uses a rotating wheel-like mechanism with multiple bike-holding slots. Bikes are parked on pallets attached around the circumference of the wheel, and a motor-driven rotation brings the required bike to ground level for retrieval. This design significantly reduces land usage while improving parking efficiency.

The system offers several advantages, including:

• Parking 6–8 bikes in the space normally required for 2 bikes.
• Reduced time spent searching for parking spaces.
• Lower accident risk and improved safety.
• Suitability for small, medium, and large parking areas.
• Potential integration of EV charging facilities.
• Fully automated operation with minimal maintenance.

The project scope includes designing and analyzing the mechanical structure using SolidWorks 2017 and ANSYS 2023 R1. Key components such as the bike-holding pallet, side structure, supporting shaft, plummer block, outer frame, chain-sprocket transmission, and motor were designed using Mild Steel (IS 2062) with a Factor of Safety (FOS) of 1.5.

A detailed literature review examined various automated parking technologies such as lift mechanisms, puzzle parking, Geneva mechanisms, traction lifts, and rotary systems. The review highlighted the advantages and limitations of existing systems and identified the need for a bike-specific rotary parking solution supported by structural analysis.

Finite Element Analysis (FEA) and analytical calculations were conducted to evaluate the structural safety of the design. The original L-section pallet frame was found unsafe due to excessive stress, while an optimized C-section frame (100 × 50 × 10 mm) with six members proved structurally safe and material-efficient. The pallet side structure, supporting shaft, and outer frame were also analyzed and found capable of withstanding operational loads.

The motor selection was based on the total system load and required movement speed, resulting in the selection of a 7.5 HP crane-duty motor suitable for frequent start-stop operations.

Conclusion

The major enablers or drivers for smart parking essentially are the problems of urban liability, transportation mobility, and environmental sustainability. Some of the underlying benefits could be lowering operation costs while building value for the customer to drive occupancy, revenues, and facility value. To solve all the bike parking issues, a rotary bike parking system has been designed by considering the actual size, dimensions, and weight of the bikes. The following specific conclusions are drawn: The rotary bike parking system accommodates 6–8 motorcycles within the footprint of 2 conventional parking bays, delivering a 3–4× improvement in space utilization, making it highly suitable for malls, offices, cinema halls, and residential complexes. It has been understood that the L-section frame (75×75×5 mm) will not be suitable for pallet design as it may lead to failure when subjected to critical loading (?_max = 1.69×10? Pa ? ?_all = 1.66×10? Pa). Hence C-section Frame (100×50×10 mm) is utilized and with dimensions considered the above design is safe (?_max = 2.527×10? Pa <

References

[1] Prasad Pashte, Vaibhav Narkhede, Shubham Nade; \"Design and Analysis of Rotary Automated Car Parking System\" International Journal for Scientific Research and Development, Volume 3, Issue 04, 2016. [2] Chetan S. Jiotode, Mahfooz Ansari, Nilay V. Chindhalore; \"Multilevel Car Parking System Using Geneva Mechanism\" International Journal for Research in Applied Science and Engineering Technology, Volume 6, Issue 3, March 2018. [3] Maharshi Gandhi, Niyati Vala, Amir Vahora, Shetty N.; \"Design of Automatic Parking System for Two Wheeler\" International Journal of Advance Engineering and Research and Development, Volume 4, Issue 3, March 2017. [4] Prashanth Kumar, Dr. H.R. Vitala, Praveen M.P; \"Concept Design and Proto Build of Roto Parker for Two Wheeler\" International Journal of Innovation Science, Engineering and Technology, Volume 1, Issue 5, July 2014. [5] Rahul J. Kolekar; \"Design and Development of Lift for an Automatic Car Parking System\" International Journal on Applied Research in Mechanical Engineering (IJTARME), Volume 3, Issue 2, 2014. [6] Sonila Sonker; \"Planning & Designing of a Multi-Level Vehicle Parking at Aakash Ganga Complex, SupelaBhilai (Chhattisgarh)\" Imperial Journal of Interdisciplinary Research (IJIR), Vol-3, Issue-1, 2017. [7] V.B. Bhandhari; \"Machine Design Book, Chapter 3 – Manufacturing Considerations in Design, Chapter 10 – Shaft, Keys and Couplings.\" [8] Sanders McDonald; \"Cars, Parking and Sustainability\", The Transportation Research Forum, 2012. [9] R.S. Khurmi; \"Strength of Material Book, Chapter 13 – Bending Moment and Shear Force.\" [10] Pashte P, Narkhede V, Nade S, More S, Maske Y. 2016. Design and Analysis of Rotary Automated Car Parking System. International Journal for Scientific Research & Development, 4(4): 2321-0613. [11] Gandhi M, Vala N, Vahora A, Shetty N. 2017. Design of Automatic Parking System for Two-Wheeler. International Journal of Advance Engineering and Research Development, 4(3): 2348-4470. [12] Choudhary S, Padole K, Shete A, Bhilkar L. 2018. Design and Fabrication of Multilevel Car Parking System using Geneva Mechanism. International Journal for Research in Applied Science & Engineering Technology, 6(3): 2321-9653. [13] Prashanthkumar T J, Vitala H, Praveen M P. 2014. Concept design and proto build of Roto parker for two wheeler. International Journal of Innovative Science, Engineering & Technology, 1(5): 2348-7968. [14] Kolekar R, Gawade S. 2014. Design and Development of Lift for an Automatic Car Parking System. International Journal on Theoretical and Applied Research in Mechanical Engineering, 3(2): 2319-3182. [15] Shinde V, Chaurasia B, Gadhe K. 2018. Automatic Multilevel Car Parking System. International Research Journal of Engineering and Technology, 5(5): 2395-0056. [16] Jog Y, Sajeev A, Vidwans S, Mallick C. 2015. Understanding Smart and Automated Parking Technology. International Journal of u- and e-Service, Science and Technology, 8(2): 251-262. [17] Vigneshwaran S, Murali G, P R Shobana Swarna Ratna, Balakumaran G. 2020. Design and Development of Sensor Based Multilevel Parking System. IOP Conf. Series: Materials Science and Engineering, 993. [18] Javed M, Abhish M S. 2019. Study of Smart Parking System. Journal of Emerging Technologies and Innovative Research, 6(6): 2349-5162. [19] Waghmare A, Nirwan T, Rahate G, Shahu A. 2016. Introduction to Multistage Car Parking System. International Journal of Mechanical Engineering, 4(4): 2321-6441. [20] Dahane R, Pajgade P S. 2016. Design of Multi-Level Car Parking. International Journal of Innovative and Emerging Research in Engineering, 3(1).

Copyright

Copyright © 2026 Mr. Vishant Devendra Bargat, Asst. Prof. Vaibhav H. Bankar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.