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This project was developed over a six-week industrial internship in response to a client brief from Qukzy Tech Solutions, seeking a compact, modular street-cleaning vehicle tailored to the realities of Indian urban environments. The brief emphasized the need for a cost-efficient, easy-to-maintain, and adaptable system that could operate effectively in narrow lanes, uneven roads, and mixed-traffic conditions—while being manufacturable within local supply chains.
The initial phase centered around market research and requirement analysis, employing the
5W1H framework (What, Why, When, Where, Who, How)
to map the functional expectations of existing municipal sweepers.
Over ten models were reviewed and categorized by cleaning mechanism—mechanical, regenerative air, and vacuum-based systems—as well as by vehicle class.
Comparative matrices were created to assess efficiency, coverage, and maintainability. This groundwork revealed a significant gap in mid- to small-scale sweepers that could balance performance and accessibility without the high operational costs of imported machines.
Following the research phase, the project moved into conceptual exploration. Early design sketches experimented with an “all-in-one” multifunctional vehicle combining garbage collection, sewage suction, and road cleaning capabilities. While ambitious, detailed analysis showed that such integration would create excessive weight, operational complexity, and cost barriers.
Through iterative reviews with mentors and the client, the direction evolved toward a dual-module configuration—a focused street sweeper with a dedicated steam-cleaning unit for sidewalks and dividers. This decision marked a shift from theoretical ambition to practical engineering, reflecting real-world feasibility and modular efficiency.
The Tata Super Ace chassis was selected as the base vehicle, offering an optimal combination of size, payload (≈1000 kg), and compatibility with modular fitments. The vehicle bed served as a foundation for a removable rear module, housing all major systems: twin 65 L vacuum tanks, a steam generator, battery packs, and water reservoirs. Internal zoning followed a strict logic of weight distribution and service accessibility, with heavier components placed low and centrally to maintain stability. Vacuum intake ducts and rotary brushes were positioned near the wheelbase for maximum debris collection, while insulated channels routed steam lines for divider and sidewalk cleaning. A control board behind the driver’s cabin enabled intuitive operation of each subsystem, giving operators flexibility to activate vacuum, brush, or steam functions individually or simultaneously.
To ensure operational efficiency, an energy and weight analysis was conducted. The complete system required approximately 43.6 kWh for six hours of continuous use. The final module weighed around 577 kg—well within safe limits for the Super Ace platform—with further optimization possible via light composite housings. All major components were sourced locally to reduce cost and simplify maintenance, aligning the project with sustainable and scalable design practices.
From a design perspective, the project embraced industrial honesty and clarity of function. Instead of concealing the machinery, the form openly expressed its mechanical character—robust, balanced, and purposeful. Structural safety, angular surfacing, and exposed fastenings reinforced its engineered aesthetic, while color and finish recommendations—such as matte municipal green or high-visibility orange with black trim—added both visual order and safety value. The modular rear assembly can be detached for servicing or upgraded independently, promoting product longevity and adaptability for different urban requirements.
Beyond its technical merit, the project demonstrates how design thinking and engineering pragmatism can converge to solve real civic problems. It embodies a philosophy of modular innovation—creating a system that can evolve through interchangeable components rather than single-use specialization. The result is not just a vehicle, but a scalable model for urban sanitation that merges functionality, affordability, and sustainability into one cohesive product.
Key Learnings & Skills Gained:
Constraint-Driven Design: Developed a structured understanding of balancing payload, space, and power requirements within project limits.
Integration: Strengthened system-level design skills to ensure cohesive operation between vacuum, steam, brush, and battery components.
Modularity: Applied modular thinking to create flexible systems that can be detached, serviced, or upgraded independently.
Optimization: Gained insight into energy and weight management to achieve efficient six-hour runtime performance.
Collaboration: Enhanced teamwork and documentation abilities through weekly reports, layouts, and concept drawings under NDA protocols.
Feasibility: Learned to align client expectations with practical engineering outcomes, balancing performance, manufacturability, and cost.
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