project report on Electrical Scooter all PDF

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ABSTRACTElectric scooters are plug-in electric vehicles with two wheels that can be recharged from any external source of electricity, and the electricity is stored in a rechargeable battery, which provides power to one or more electric motors to attain movement. Electric scooter, as differentiated ...

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DESIGN OF ELECTRIC SCOOTER

DESIGN OF ELECTRIC SCOOTER

ABSTRACT Electric scooters are plug-in electric vehicles with two wheels that can be recharged from any external source of electricity, and the electricity is stored in a rechargeable battery, which provides power to one or more electric motors to attain movement. Electric scooter, as differentiated from scooters, do not have a step-through frame. The electricity generated from an external source helps in acceleration of the motorcycle. The speed of this cycle is limited (45km/h). The electricity is stored using a battery and the locomotion and movement of the vehicle is hence propelled using an electric hub motor The electric scooter are not using an engine, becomes an effective way of road transport as it causes no pollution. It is ecofriendly and it definitely reduces human effort. In this project report, work concerning product design and manufacturing process making of an electric scooter is described, which was the outcome of a collaborative project for new product development. The final product was satisfactory, and was designed according to the aesthetic principle of golden section proportion, and subsequently outer housings were produced with carbon fiber. Not only the product appearance was created, but an electric scooter was also built using various traditional modeling and engineering techniques.

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DESIGN OF ELECTRIC SCOOTER INTRODUCTION

Concern about global warming and urban air pollution have become central issues in transport policy decision-making, and as a result much research in recent years has focused on the development of vehicles which are environmentally friendly. Air quality in cities is currently significantly lower than in rural areas and this has been shown to be directly link to the level of vehicle emissions from private cars. The haze episodes in Southeast Asia in 1983, 1984, 1991, 1994, and 1997 imposed threats to the environmental management of Malaysia and increased awareness of the environmenti. Due to the fact that urban transport policy, the design is to reduce or discourage the use of private cars, there has been an increase in the sale of non-polluting vehicles such as electric scooter. However, although the number of electric scooter users has increased, safety and comfort issues need to be addressed if the number of users is to increase to a level at which a significant effect on environmental pollution can be achieved. Researchers have studied and improved many aspects of the electric scooter. In this study, we used computer simulation to model the aerodynamic effect of the existing safety and comfort features and we present a new design which integrates these features in an optimally- effective aerodynamic shape. As student of mechanical engineering part 5, we were given a task to develop a new single seated electric scooter. In this task, students need to design a scooter from a raw material, build their own design concerning several factors and fabricate the scooter by the end of part 6. For this semester, students focus are more on the gather information and generate concept scooter. Followed by having a drawing and prepare to fabricate in next semester. The process will teach students about how the work flow of building a product from scratch until the end product. Each step is a self-learning process for a mechanical student a complexity of every task is different from one to another. In the designing of electrical scooter, there are three phases of the engineering design process involved. There are conceptual design, embodiment design and detail design.

DESIGN OF ELECTRIC SCOOTER

Conceptual design

Define problem

Detail design

Gather information

Parametric design

Concept generation

Configuration design

Evaluation of concept

Product architecture

Embodiment design

In phase 1, the conceptual design, there are 4 processes. These 4 processes are problem definition, gather information, concept generation and lastly evaluation of generated concept. In the process of defining problem, the electric scooter had gathered and brainstorming process has been done. The general problem regarding electrical scooter has been voiced out. There are problem statements in designing the electrical scooter, objectives of the team wanted to be achieved, scope of the project and lastly the significant of the design has been determined. Next, for the gather information process, there is a lot of readings have been done by each of the team members including books, articles and also journals. Survey also has been conducted with the supplier of electrical scooter. In the concept generation and evaluation process, a few designs of electrical scooter has been made by the design engineers and then will be compared by using Pugh method and weighted decision matrix in order to choose the best suspension for our car.

In phase 2, the embodiment design phase, there are three process involved. The processes are product architecture, configuration design and parametric design. In the product architecture, the design for human factor by using information from ergonomic and anthropometric data to integrate with physical arrangement has been considered. Next, in the

DESIGN OF ELECTRIC SCOOTER configuration design process, the suspension modeling, simulations, details analysis of calculations, materials selections is shown. In the last step, the parametric design process, it includes the DFA, DFM, design for robust, FMEA, and final dimension for our suspension.

Last phase in designing our suspension is the phase 3 which is detail design where in the phase there are details drawing, bill of materials, costing and final specifications for electrical scooter.

DESIGN OF ELECTRIC SCOOTER

BACKGROUND OF STUDY Electric scooter is a vehicle empowered by electric motor in order to move. It is also known as e-scooter. For the power source of the electric motor, certain country used different power, because it is depends on the Law of the country. Basically, rechargeable batteries that used for the e-scooter is 40 to 65km/h. The invention of the electric scooter is as a proof that the engineering field keep advancing, the invention of the electric scooter make it replacing the old scooter in the market. Although the electric scooters are using electric motor, it still called as scooter rather than motorcycle. This is because it identity as scooter is still fixed which is most of it part are belong to scooter. So, it not included in transportation law which require the certification and operation as on good motor vehicle. It is not need to have license to ride the electric scooter. The electric scooter is not a fully motorized vehicle, it’s just semi motorized scooter, which is still have brake and frame design and so on. This electric scooter use NiMH which is a common power supply used on the electric scooter. This kind of the battery is rechargeable and a lighter and denser capacity batteries which is make it the designing of an electric scooter more handful and easier. The electric scooter is not like a motorcycle in many concept, either it design or it power supply. Besides that, the electric motor is also used lower power compared to motorcycle which is the scooter. There is some type of electric scooter that commonly used by all the people in term of weight and frame material type. Weight of the scooter also plays an important role in the speed of the scooter. The weight of the scooter depends on the purpose of the scooter been used, it is to either for competition so there is few of common weight that been used for the scooter. On the older scooter, the weight of the scooter is about 50 or 60 kg, this kind of weight was back older day before the technology of the scooter still not growing. Now, the weight of the scooter was improved, the weights of the scooter have been reduced about to 35 and 45 kg. The improvement of the weight of the scooter is for the purpose of scooter handling and speed of the scooter. Next is frame or chassis of the scooter, there is few of material that is popular to develop the scooter frame, it purpose is to make the scooter lighter and strong frame. The type of materials that commonly used to develop scooter frame are Carbon fibre, Steel, and Titanium. Most popular material used in develop scooter frame is carbon fibre, the term of carbon fiber describe this material have various different composites that include different

DESIGN OF ELECTRIC SCOOTER polymers, carbon and graphite that are link by an epoxy-resin matrix which is sometimes containing metals or ceramics. This carbon fibre is one the advanced composites which offer great possibilities for light weight and high-performances in many way, this is because layer

DESIGN OF ELECTRIC SCOOTER of composite can be insert only where it needed to be placed. Fibre also called whiskers of material used to stabilize dynamic forces due to different degrees and direction on different part of the scooter frame. Steel which also commonly used to develop the scooter frame. Steel is the material which used for many scooter frames. Lots of scooter designers have used their many years of experience in refining the design of steel scooter. Steels offers a comfortable ride and frame made up from steel can act as a spring to store energy when the rider causes the frame to flex at different parts. The stored energy by the steel can be released and converted to forward motion. Steel frame can be repaired with low cost and when there is damaged, steel scooter can show or reveal frame stress injuries before the frame break. Steel scooter frame break slowly compared to aluminium frame which break suddenly when there is failure on the frame. Most of the high quality scooter frames are made of steel tubing which has been alloyed with chromium and molybdenum, sometimes also alloyed with manganese and molybdenum. 3 beside than Carbon fibre and Steel frame, Titanium also one of the popular materials used to develop scooter frame. The characteristic of the Titanium as scooter frame is almost similar to steel but it have more advantages than both carbon fibre and steel. Titanium is lighter than the carbon fibre and steel, also the strength to overcome the stress by force or impact is higher than steel and fatigue life of the titanium is more than steel. Even though titanium wins all aspect for develop the scooter frame, but the cost to develop frame from titanium is higher than steel and carbon fibre.

DESIGN OF ELECTRIC SCOOTER 2.1.1 Types of electric Scooter Generally, electric scooter can be broadly classified into main parts which are the types of motor which generated by using hub motor and chain motor system .These types of motor were having different way to use and installation for the motor in electric scooter. Firstly, hub motor are electric motor that are housed inside the hub of either the front or rear wheel. The figure below shows one of the types of hub motor that sell in market. In general a front hub motor pulls you and it creates an all wheel drive. The Hub motor also commonly use by electric bike. The clearly difference between electric scooter and electric bike which is the electric bike have a pedal to ride the bike meanwhile for electric scooter only use a throttle to control the speed of the scooter.

Hub motor Electric scooter of using hub motor creates an all wheel drive the scooter because the motor drives front wheel or rear wheel. The system of hub motor in electric scooter were easy to install or remove from the scooter wheel because there no gear system to deal with chain. Hub motor can provide for a more balanced scooter weight distribution if the battery mounted in the middle or back part of the scooter. There are few design of electric scooter that using a hub motor (rear hub motor and front motor) refer figure 2.1.1.1

DESIGN OF ELECTRIC SCOOTER BATTERY

REAR HUB MOTOR

Hub motor The other type of electric scooter by using the chain motor. Chain motor were install with connected with chain ,sprocket and gear to move the scooter. The chain were having different mechanism between the hub motor and chain motor because the hub motor were not using any gear meanwhile for chain motor have a gear refer figure 2.1.1.2 and figure 2.1.1.3

Chain Motor Chain motor also provide different power of motor with come out different on speed on torque and speed of scooter. Figure 2.1.1(D) shows the installation of electric scooter for chain motor. Normally for electric scooter the chain motor were install and connected at the rear tire of scooter. Meanwhile for the hub motor in can install either on front or rear.

Chain Motor Chain

DESIGN OF ELECTRIC SCOOTER 2.1.2 PROBLEM STATEMENT Project electric scooter was chosen in this engineering design project. The initial problem for designing this project which is to design the product that wasn’t similar to the current market.

a) What does the client desired? -Lightweight -A scooter could ride easily to reduce transit time -Easy to use

b) What does client really want? -A product which safe to use -Affordable

c) What are the real causes of what the client presents as problem? -The existing product its hard to store and expansive.

DESIGN OF ELECTRIC SCOOTER Alternate mode of transport One problem many public transport commuters face is the last-mile –the distance between the station and their home or workplacexii. In many cases, walking is not a convenient solution, as our local weather and lack of easy pedestrian access does not make foot power conducive. Some have turned to a folding bicycle as a solution, with such personal vehicles now allowed on the mass transit systems in Kuala Lumpur. The e scooter can move in a range of 15 and 30 km, respectively, with a maximum governed speed of 25 km/hxiii. 1) Portability Not all, but most electric scooters are portable. If there is a problem with the motor or chain or tire, the electric scooter can be carried back to the garage where you can fix these issues. Designed to be a last mile solution for commuters, or a quick and easy run- about for short trips close to home or workxiv. Made from aluminium, with the battery pack located inside the frame spar, its folding design also makes it easy to store at home or workxv. Weighing in at 13.9 kg to 15.2 kg, this e-scooter will fit into the boot of a sedan. For hatchbacks, the rear seat will have to be folded down. Unfolding is a simple two-step operation, with folding being the reverse. Folded up, the scooter has a footprint of 48 by 40 cm. Switching on the scooter is with a pushbutton and transponder key, which also switches on the front LED headlight and brake/tail light. 2) Time In busy cities, time is the issue and these sleek vehicles can help you save a lot of time on the roadxvi. They're portable and can access anywhere, so, you will have no trouble taking a short cut through the subway, a shopping mall or a park. You just need to recharge the batteries for a given amount of time, and that's it. Your scooter will save your precious time otherwise spent in heavy traffic, gas stations and parking lots. Electric Scooters reduces the journey time, especially if it’s a short distance. It doesn’t matter where you live and how many rush hours you embrace, but if you’re on a scooter, in a way, you would fly. The traffic flow won’t affect you as such, and you won’t deal with familiar traffic jam conditions as well. The greatest advantages is you don’t need

DESIGN OF ELECTRIC SCOOTER to ponder a lot regarding parking if you’re on a scooter. You can easily place it on the side of the road/street and lock itxvii. Already, with the rising population of automobiles, it’s tough to find a parking place, particularly if you’re residing in a dense urban area. In fact, some places don’t even allow you to park the vehicle until you don’t pay them any heavy amount of money. Therefore, in these conditions, I would say, a scooter is a lucky thing from the seventh heaven.

3) Safety Mr Sam Koh, 23, worked at PassionGadgets, a shop that sells e-scooters and unicycles, for more than two years and was popular among its customersxviii. But in a tragic accident, he died on Sunday from serious head injuries after falling from his escooter early Saturday morning. After the fall, he went into a coma and never regained consciousness. Mr Koh fell and landed on his back. He just wore a cap, but didn't wear a helmet. The panel recently recommended that all PMDs such as e-scooters, hoverboards, unicycles and motorised wheelchairs, be allowed on footpaths and cycling and shared paths - but with a speed limit of 15kmh on footpaths and 25kmh on cycling and shared paths. Riding the e scooter is easy, with power controlled by a twist grip on the right handlebar. Braking is with levers on the left and right, activating a V-brake in front, and a cable- operated disc brake at the back. The tyres are proper pneumatic items, and there is no suspensionxix.

4) Eco-friendly In recent years we have seen a worrying rise in the PM10 index, which measures the concentration of fine particles caused by air pollutionxx. Fine particles are microscopic particles consisting of heavy metals. They are suspended in the air are inhaled and can cause various respiratory disorders, as well as being the cause of serious diseases. A viable alternative to the petrol engine car and scooter is without doubt the electric scooterxxi. 

Emissions

DESIGN OF ELECTRIC SCOOTER The electric scooter does not produce any form of emissions that are harmful to the environment and to people; it does not require petrol and diesel and runs on a lithiumion battery, which can be charged from 0 to 100% with about 1 k/Wh. With the electric not only do you save, you also contribute to the well-being of the environment. Charging time is approximately three hours, using household current. 

·Noise pollution Because they don’t have traditional petrol-powered car and scooter engines, electric scooters emit much less noise. Just think: wouldn't it be nice to live in the city that was less chaotic and polluted?

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Less waste Not only zero emissions and less noise: the electric scooter also requires less maintenance than traditional car or scooter engines because it doesn’t have valves, cylinders or carburettor and doesn't need oil changes. This means that the electric scooter is a 100% ecological means of transport: less maintenance means less wear and tear on its components, fewer replacements and interventions and servicing and therefore less hazardous waste to dispose of.

DESIGN OF ELECTRIC SCOOTER 2.2.1 MORPHOLOGICAL CHART The morphological chart is a design tool that helped satisfy each design criteria from the functional decomposition. The choices that were elected for the design process are highlighted in the chart below. The results were further examined for the best performance and the maximum compliance with requirement. The morphological chart below summarizes the team thoughts for the best combination of below task/characteristics: Task

Solution

Frame

Portable

Portable

Fixed

Semi portable

Type of

Soldering

Welding

Mechanical

Adhesive glue

Rivet

Small Cafe Racer Seat

fastener

joint

Type of seat

Double seat (fixed)

Single seat (fixed)

Bucket seat

Single seat (adjustable)

Type of

12V 350W Electrical Hub Motor

24V 250W belt drive

24V 250W chain drive

24V 400W chain drive

electric motor

DESIGN OF ELECTRIC SCOOTER Task Socket plug/

Solution Two pin plug

Three pin p...