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Small Electric Car
- 1. B2 Final Electric Car Madison Burnham, Miguel Gonzalez, Nick Miller, Jordan Bartow, Lauren Cugliotta
- 2. Fabrication Process • Total Time • Body • Brackets • Axle • Motor Gouge • Set Screw • Assembly
- 6. After Testing Without a Motor • Velcro • Lock Nuts
- 8. Remaining Testing Steps • Find correct duty cycle • Test on track
- 9. Changes from Original Design • No weight holder • Motor Gouge • Breadboard lays flat • Firebolt • Longer time line • Budget Increase
- 10. Budget Item Price ($) Novak Terra Claw Motor 6 FireBolt Motor 4 Gears 15.98 Wheels & Replacement Gears 23.8 Brackets 1.25 Threaded Rod 1.14 Nuts 0.14 U bracket 0.5 Bolts 0.04 Wood (Body) 1 Additional Nuts 0.12 Velcro 2 Washers 0.04 Total $56.01 Remaining Goal Budget ($16.01) Remaining Actual Budget $43.99
- 11. Where we could have saved time • Original Breadboard • CAD Drawings • Gear Size • Meshing of Gears • Motor Gauge • Wheels Locking • Bent Axle
- 12. How we could have saved money • TerraClaw $6 • Wrong Gears $15.98 • Wood • Axle • Velcro • Bracket
Editor's Notes
- Total Time= 4 shop days Body= cut from a square into the pentagon shape Brackets=cut into four 2 inch pieces, drilled two holes through each bracket and the body, drilled one hole on the side of each bracket for the axle Axle=Cut rod into one 7 inch piece and one 11 inch piece, Back rod was grinded in the middle to allow for a set screw Motor Gouge= Drilled down 0.35 inches with the end mill. Metal was added underneath to strength the now 0.11 inch wood Set Screw= A set screw was placed into both gears so they are steady on the axle and motor Assembly=The wheels, washer, nuts, and gears were all assembled onto the axles. The breadboard and battery were attached with Velcro. The motor was placed in the U bracket.
- One side of Velcro was placed under the motor to raise it up. This is because the motor gear was too tight on the gear on the axle The nuts were locked using a second nut because they originally were tightening themselves and rubbing the bracket causing the wheels to lock.
- No wooden pegs are needed to hold the weight because the heads of the bolts on the front brackets and the U bracket for the motor keep the weight from sliding forward or to the side and the forward slant of the car keeps the weight from sliding backwards The motor had to be placed into a gauge in the body in order to have the gears mesh The breadboard was originally planned to be placed on wooden pegs so the gear could fit under it. Instead, the breadboard now hangs off the board and is attached with Velcro At first, we planned on using the TerraClaw motor but after repeating the motor test we did in the first semester with the TerraClaw and Firebolt, the Firebolt ended up being faster. We planned on finishing the fabrication process on April 15Th but instead finished on April 19th Budget increased due to unforeseen errors, like wrong size gears and needing a few extra bolts.
- The original breadboard caught on fire so another one had to be built. The CAD drawings did not account for the wood used for the body to be 0.44 inches instead of 0.5 inches exactly. It also did not account for the brackets to be less than 2 inches due to sanding. The time spent in the shop took longer because we had to recalculate the dimensions and placements of the cuts. Next time, we should consider imperfections in the materials. The wrong size gears were ordered so the fabrication process had to be paused until the new ones came in The gears did not mesh at first because the motor gauge was not deep enough so this too slowed down the fabrication process until we could get more shop time to mill down the gauge even more The Motor gauge was then so deep that the remaining body material was too thing to support the weight of the motor and the tension from the nuts and bolts on the u bracket. This halted the fabrication process momentarily until a solution was thought of The wheels were locking when the car was in motion. This was fixed by double nutting which require to take both axles off and reassemble it with twice the amount of nuts When tightening the nuts to ensure they were locked in place, the force of the tightening bent the axle. The axle then had to be removed and restraightened and then reassembled.
- So far, we have not had to use the TerraClaw motor. This could have saved us $6. $15.98 was spent on gears we could not use We have extra wood, axle, Velcro, and bracket. Although we could only buy these items by the foot, another hardware store may have sold them in smaller sizes