| OBJECTIVE | Collectively design and prototype an electric scooter that can be folded for easy transport |
| MATERIALS/TOOLS | AluminumHub motorKelly motor controllersScooter wheelsWater Jet |
| TIMELINE | October 2014- December 2014 |
| TEAM SIZE | 5 |
| Progression |
Our team decided to work on a designing an electric scooter that was not only functional but could be folded for easy transport. It was a challenge deciding the best way to do this. Our initial design involved a triangular base that could be folded into a box. Unfortunately, while this would allow us to make the scooter very small, it did not factor in the sizes of the motor controllers and batteries we would need.
(Paper prototype of the original design)
Instead, we focused on a more rectangular design. This consisted of two 10"x11" boxes made of aluminum that would be connected by sets of hinges in the center. The spaces in the boxes closest to the hinges would be reserved compartments that would encase the batteries and motor controllers.
(Base of final design - dimensions test on SolidWorks. Initially we thought about using wood, but it actuality it would have been made out of aluminum)
We went on to make a real-scale styrofoam prototype of the final design before we moved on to steering, to ensure we had the right dimensions.
(Cardboard and styrofoam prototype of final design and components)
Our steering mechanism was built around a steering fork from an old scooter we already had. Our design was to have a hole we could insert the fork into at the surface of our scooter's base, and then water jet pieces that could be welded onto the fork and then bolted onto the base. Unfortunately, after waterjetting the pieces, we realized that it would be too difficult to use the fork at all because it was made of aluminum, and not steel as we had thought.
(Aluminum fork we were unable to use)
On the electric side of the project, we were able to use the Kelly Controller to control one of the hub motors with a throttle. Below is the triumphant moment of getting the motor to spin.
The foldable scooter was not actually made, but in working with it, I got a lot of experience with Solidworks, waterjetting, prototyping, using motor controllers, and generally working in a team on a project of this complexity.