Scooter Presentation
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Designed and analyzed a folding electric scooter as a senior class design project. I was the primary designer for both the mechanical and electrical systems. The scooter had specific weight and power requirements that needed to be met. The scooter's manufacturability and total cost had to be in line with comparable on-the-market scooters.
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Scooter Presentation
- 1. The Minnow
- 6. FOLDING HANDLEBARS Tabs for correct handlebar orientation
- 7. FOLDING HANDLEBAR STEM Thumbscrew Wedge shape to avoid over rotating
- 8. FOLDING REARWHEEL Pivot lock Pull both pivot locks outward to disengage pins
- 9. FOLDING REARWHEEL Split electronics housing to allow wheel collapse
- 10. SPRING LOADED DECK PLATE Spring • Spring keeps deck plate secure while the scooter is being carried • Hinge is wedge shaped to prevent deck plate from being over rotated
- 11. INTERNAL WIRING
- 12. Materials and fabrication • Frame Chassis Materials: 6061-T6 Aluminum Fabrication: AbrasiveWater Jetting, Bending,Welding Neck & Collar Material: 356 & 6061-T6 Aluminum Fabrication: Cutting,Grooving, Casting,Welding • Handlebar fork Material: 6061-T6 Aluminum Fabrication: Cutting, Bending, Milling, Drilling,Turning,Welding
- 13. Materials and fabrication • Upper Connector Material: 356 Aluminum Fabrication:Casting • Pivot Joint Material: 356 Aluminum Fabrication: Casting, Drilling • Deck Plate Material: 6061-T6 Aluminum Fabrication: AbrasiveWater Jetting
- 14. Materials and fabrication • Wheel Guard Material: ABS Plastic Fabrication: Plastic Injection Molding • Rear Pivot Locks Material: ASTMA36Cast Carbon Steel Fabrication: Casting • Electronics Housing Material: ABS Plastic Fabrication: Plastic Injection Molding
- 15. ASSEMBLY COST
- 16. Performance Performance Metric Value Stall Force (per motor) 33 lbf Operation Force (per motor) 14.7 lbf Acceleration 3.89 ft/s^2 AccelerationTime 5.65 seconds Runtime 56.3 min • All calculations done using a • Scooter mass of 23 𝑙𝑏𝑚 • Rider mass of 220 𝑙𝑏𝑚 • Motor specifications were from the manufacturer. • Two brushless hub motors were used in the design of the Minnow.
- 17. Maximum Grade • Raz0r e-300 (on-the-market competitor) can handle: • Incline of 2.88 degrees • Grade of 3.2% • The Minnow can handle: • Incline of 14.32 degrees • Grade of 15.9% 𝐹 = 0 𝑠𝑖𝑛 𝜃 + 𝜇𝑐𝑜𝑠 𝜃 = 2𝐹 𝑚𝑔
- 18. Brake Performance Performance Metric Value Brake Force 325.9 lbf BrakeTime 0.51 seconds Brake Acceleration -43.12 ft/s^2 Braking Distance 5.61 ft • The Minnow uses a 3.15 inch band brake • Actuation force calculated from 60% of the average max grip strength of a 18-29 year old.
- 19. Finite Element Analysis • All parts underwent Finite Element Analysis (FEA) in SolidWorks as they were designed. • Each part is designed to have a minimum factor of safety of 3.
- 20. Thermal Analysis • Motor Analysis • Temperature increase of 0.6 °𝐹 in the motor during acceleration from zero to max speed of 22 𝑓𝑡 𝑠 • Brake Analysis • Temperature increase of 47.5 °𝐹 • Assumes worst cases: • No heat is transferred while braking • Force applied instantaneously
- 22. COST Cost Category Cost Direct Costs - Manufactured Parts $102.50 Commercial (off the shelf) $315.03 Assembly (direct labor) $9.16 Total Direct Costs $426.69 Indirect Costs $213.35 Total $640.04 Sales Price $1,299.00