Group 6 Design Report 3

EML 4501 – Mechanical System Design

Design Report 3

Design Group 6:

Jose Cortes

Laura DeTardo

Matthew DeVries

Jonathan Franco

Massimiliano Giffuni

Matthew Vitarelli

Table of Content

Executive Summary………………………………………… 1

Introduction…………………………………………………. 2

Operation and Use…………………………………………... 3-13 Safety Precautions…………………………………………... 14

Material and Fabrication……………………………………. 15-20

Fabrication Processes……………………………………….. 21-22 Assembly Process

Assembly Steps………………………………………….. 23-59

Handling and Insertion Times…………………………… 60-62 Performance Analysis………………………………………. 63-68

Mechanical Analysis

Frame Loading Analysis………………………………… 69-76 Chain Drive……………………………………………… 77-78

Brake Assembly………………………………………… 78-80

Thermal Analysis…………………………………………… 81-82 Electrical and Control Analysis……………………………... 83

Parts Lists

Standard Parts List………………………………………. 84-85 Custom Parts List………………………………………... 86-87

Cost Analysis……………………………………………….. 88-91

Appendix A: SolidWorks Drawings………………………... 92-161 Appendix B: Cost Analysis…………………………………. 162-183

Appendix C: Insertion and Handling Charts………………... 184-186

Executive Summary

This design report outlines our seamlessly constructed high-end electric scooter. The

design process required countless hours of brainstorming, analyzing, and perfecting the design,

as well as a vast wealth of engineering knowledge. Our product, the Electric Slide, is a

lightweight electric scooter with excellent performance capabilities that is designed and built

with the ability to fold and collapse into itself, making it a compact and convenient product for

the average consumer. The Electric Slide targets the young teenage consumers seeking a fun

mode of transport, college students that need a compact vehicle to get to classes on time, and

adults that go to work everyday. The specs of our design are unrivaled, but what sets our scooter

apart from the competitors is the way it can fold and fit inside a carry-on suitcase. The Electric

Slide places no limitations on the user in terms of specs and storage, and using an electric battery

appeals to the “green” market of the 21st century.

Throughout the design process, the important unique aspects of the Electric Slide were

given heavy consideration. When compared to other electric scooters on the market such as the

well-known Razor E300, the Electric Slide is half the weight and can produce twice the torque,

while achieving up to 45 minutes of continuous run time at a similar maximum speed. When

discussing performance and weight, the Electric Slide already has a huge advantage over the

competition. Additionally, our revolutionary scooter is one of a kind with its folding mechanism

that allows the scooter to be folded into a compact configuration for easy transport. The folding

mechanism is simple to use – it can be folded and unfolded without tools in seconds! In its

folded configuration the Electric Slide fits comfortably in the standard carry-on suitcase

dimensions of 24” x 12” x 9”. As stated above, it is environmentally friendly; not only is it

electric but its structure is made out of magnesium alloy and it is powered by a 6S Li-Po battery.

Magnesium is known to be a fully recyclable metal and Li-Po batteries can be thrown away if

discharged properly. Overall, the Electric Slide can adapt to any lifestyle with a high torque

that’s rated to move any individual of any weight at maximum speed, and better stall torque to

move uphill. Although our company is based in the flat state of Florida, the Electric Slide can

adapt to many different environments and will prove to be the ultimate scooter for you.

Designed as a high-end scooter with many great features the Electric Slide has a

manufacturing cost of $992.13 and a sales price of $1,979.99. With 100,000 scooters in

production this can potentially generate $98,7860,000 in profits.

Group 6 pg. 1

Introduction

This design report reviews the Electric Slide scooter and its individual parts. Included are

an explanation of the operation and use for the scooter, a list of safety precautions, materials and

fabrication processes, the assembly process, a detailed analysis of multiple systems of the

machine and a cost analysis for the scooter.

The operations goes over how the scooter should be operated and how to fold and unfold

the scooter. The list of safety precautions provides an overview of the design process with

respect to hazards we wanted to avoid when constructing this scooter.

The material and fabrication specifies the materials of the individual components and

highlights the fabrication processes for the custom-made parts. There are small descriptions

explaining how those processes are done.

The assembly process contains diagrams with written instructions along with a chart of

the handling and insertion times to give an estimate of the overall time to manufacture the

complete scooter.

A comprehensive analysis was implemented to evaluate the mechanical, thermal, and

electrical components of the scooter. The performance analysis covers stall torque of the motor,

top speed, and battery life.

The cost analysis reviews the prices of the individual off-the-shelf parts, as well as how

the prices of the custom parts were estimated.

Group 6 pg. 2

Operation and Use

The Overall Scooter

The scooter is put into motion through a three step process. First, the throttle is

twisted which sends an electrical signal through the throttle cable into the controller. The

controller then uses power from the batteries to send a signal to the motor. Finally, the

motor converts the electrical signal from the controller into mechanical power, through

the rotation of its shaft and sprocket, which powers the drive train. To stop, the brake

handle is compressed which pulls the brake cable. When the brake cable is pulled

forward it in turn compresses the brake caliper creating friction against the brake drum

slowing down the wheels. To support the weight of a rider, the scooter’s design disperses

the load over the deck and frame so there is no concentrated load on a single element of

the scooter’s frame. [Design Report 2]

Scooter Collapsing Process

Step 1

Simultaneously rotate both folding deck locator in the directions of the arrows as shown.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 3

Step 2

Flip the folding deck onto the rear deck plate.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 4

Step 3

Firmly press down the button connector at location 1, and simultaneously slide the top

telescoping tube into the second tub. Then repeat this process for locations 2-4.

𝛼 = 360° 𝛽 = 360°

Step 4

Place the thumb of the right hand at location 1, and the thumb of the left hand at same

location on the other arc. Wrap the index and middle fingers of right hand around the

underside of the lock rod at location 2, and same fingers of other hand on other side of

rod. Pull the rod in the direction of the red arrow. When the rod is raised to its highest

point, follow the direction of the orange arrow, and lower the rod into location 3.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 5

Step 5

Using both hands, simultaneously press down the button connectors at location 1, and

slide the front section in the direction of the red arrow. Use both hands to then

simultaneously press the button connectors at location 2. Slide the front section and align

the hole with location 2, locking it into place with the button connectors.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 6

Step 6

Similarly to the previous step, press down the button connectors of the rear frame

assembly at location 1. Slide back and align the holes with the buttons at location two,

locking the rear assembly into place.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 7

Step 7

Push down the button connectors denoted by the orange arrows and pull out the handle

bar assemblies in the direction of the blue arrows. Place both handlebar assemblies on the

deck of the scooter.

𝛼 = 360° 𝛽 = 360°

The scooter is now fully collapsed.

Group 6 pg. 8

Scooter Unfolding Process

Step 1

Press down the handlebar button connectors and insert the handlebar in the top

telescoping tube, aligning the holes and locking into place with the button connectors.

𝛼 = 360° 𝛽 = 360°

Step 2 Using both hands, simultaneously press the button connectors at location 1 and slide the

front section in the direction of the arrow. Press down the button connectors

simultaneously at location 2, and lock the front section into place, aligning the front

section holes with the button connectors.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 9

Step 3 Use both hands to simultaneously press down the button connectors at location 1 and

slide the rear section in the direction of the arrow. Press the button connectors at location

2 simultaneously, and slide the rear section, locking it into place with the button

connectors at location 2.

𝛼 = 360° 𝛽 = 360°

Step 4

Place the thumb of the right hand at location 1, and thumb of left hand at same location of

other arc. Place the index and middle fingers of right hand at underside of location 2, and

the same fingers of other hand on the other side of rod. Pull the rod in the direction of the

red arrow. When the rod is raised to its highest point, follow the direction of the orange

arrow, and lower the rod into location 3.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 10

Step 5

Holding tube 4 with the dominant hand, pull in the direction of arrow, locking the button

connector in place in rod 3. Continue pulling the remaining three tubes until all the tubes

are locked into place with respect to the fork.

𝛼 = 360° 𝛽 = 0°

Step 6

Flip the folding deck in the direction of the arrow and onto the frame rails.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 11

Step 7

Simultaneously rotate both of the folding deck locators in the direction of the arrows and

rest them over the deck.

𝛼 = 360° 𝛽 = 360°

The scooter is now ready to ride!

Group 6 pg. 12

Table 1: Folding Handling and Insertion Times

Total Folding Time: 49.45 seconds

Table 2: Unfolding Handling and Insertion Times

Total Unfolding Time: 58.35 seconds

Handling Insertion

Step Alpha Beta Alpha +

Beta

# of

Occurrences

Handling

Time

Step

Time

Source # of

Occurrences

Insertion

Time

Step

Time

Source

1 360 360 720 2 1.95 3.9 (3,0) 2 1.5 3 (0,0)

2 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

3 360 0 360 4 1.5 6 (1,0) 4 1.5 6 (0,0)

4 360 360 720 1 5.6 5.6 (8,3) 1 2.5 2.5 (0,1)

5 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)

6 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)

7 360 360 720 2 3 6 (8,3) 2 1.5 3 (0,0)

Total Time: 29.45 20

Handling Insertion

Step Alpha Beta Alpha +

Beta

# of

Occurrences

Handling

Time

Step

Time

Source # of

Occurrences

Insertion

Time

Step

Time

Source

1 360 360 720 2 1.95 3.9 (3,0) 2 5 10 (3,1)

2 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)

3 360 360 720 1 3 3 (9,1) 1 2 2 (3,0)

4 360 360 720 1 5.6 5.6 (8,3) 1 2.5 2.5 (0,1)

5 360 0 360 4 1.5 6 (1,0) 4 2.5 10 (2,0)

6 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

7 360 360 720 2 1.95 3.9 (3,0) 2 1.5 3 (0,0)

Total Time: 27.35 31

Group 6 pg. 13

Safety Precautions

Using our previous knowledge from the Razor E300 scooter, we came to the conclusion

that the On/Off throttle (bang-bang controller) was not as safe for younger riders as a

proportional throttle. By using a proportional controller the user can control the

acceleration of the scooter when in use, as high accelerations can potentially result in

injury if maneuverability of the scooter is lost.

It should be noted that the Lithium Polymer battery used in this scooter should not be

drained below 3 volts or it could cause permanent damage to the battery. By the inclusion

of a low voltage cutoff indicator the user is able to know when it is suggested to turn off the

scooter due to safety precautions.

We felt that it was important to use as many eco-friendly materials as possible when

designing this scooter. With that in mind, Lithium Polymer batteries can be disposed of in

the trash with no harm to the environment when discharged properly. All parts made of

magnesium alloy and polypropylene can be melted down and reused.

When reviewing our original design concept, it was noted that a space on the deck could be

dangerous as it was large enough for a foot to slide through and become stuck under the

scooter while in operation. To fix this issue, we added an additional deck plate to ensure

there would be no holes. The deck plates folds by the use of a hinge, that way we can fold

and unfold the scooter within the required dimensions. To keep the front deck plate from

bouncing during operation, a set of metal strips rotate to hold the plate to the frame.

Rider comfort is always very important. By using the ergonomics of the design and the

damping capacity of the magnesium alloy used in the structural frame of the scooter, the

rider can have a safer and more pleasant ride. As magnesium alloy absorbs bumps and

shocks better than aluminum or steel, the user feels the vibrations less on the hands and

body. The grip of the scooter could potentially cause injury on the rider or pain if the user

is not accustomed to it. Too many vibrations could result in extreme discomfort in the

hands or other parts of the body. The air-filled inner tire tubes also help improve the rider’s

comfort and vibration absorptions of the road.

The folding mechanism assembly is designed in a way that prevents the folding mechanism

from being free while it is unfolded into its riding mode. The lock rod stays in place by the

inclusion of the clips which keep the rod from rotating and the spring which applies a

downward force. This downward force prevents the lock rod from moving up and

potentially causing danger to the rider if the handle assembly moved by folding.

The two side guards around the rear axle mechanisms prevent the user or anyone else from

reaching into the rotating mechanisms which can cause serious injury. Side guards protect

the motor assembly as well.

The battery box works as a protective barrier to the battery and the other electrical

components. Water could create some shock to the user and the battery box is made of a

plastic that prevents this from happening. Also, it protects the battery from bumps or other

environment hazards that could cause the electrical components to explode or ignite.

The grips of the handle bar are made out of silicone rubber material. This rubber material

allows for the user to form a good grip with the scooter, thus preventing any slippage that

could result from bumps or harsh turns.

Aside from preventing dirt from getting accumulated inside the frame rail sets, the frame

end caps also hide the sharp edges of the rails that resulted from the manufacturing process.

Group 6 pg. 14

Material and Fabrication

Frame:

End Caps - Polypropylene

Polypropylene (PP) is a highly versatile plastic with a fairly low density and low cost. PP

can be used in many molding and extrusion processes. It is flexible and impact resistant

so that it can withstand any rocks or debris it may come in contact with when operating

the scooter so that nothing gets inside the frame of the scooter. An added benefit is that

polypropylene can be dyed without degrading the integrity of the material.

[Source: http://composite.about.com/od/Plastics/a/What-Is-Polypropylene.htm]

Fabrication Process: Plastic Injection Molding

Button Clips – Steel

Steel is used because it provides structural integrity to the part without adding a large

amount of additional weight. The zinc-plating on the exterior provides good corrosion

resistance for a part that will be exposed to the elements.

Tubes- Magnesium Alloy

These parts are manufactured using a magnesium alloy. This metal was chosen for its

high strength to weight ratio and ease of machinability. Magnesium is the lightest

structural metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its

material properties give it a high damping ratio so that it reduces the vibrations

transferred to the hands and feet of the rider. In addition, magnesium has good fatigue

and dent resistance which allows the scooter parts to last longer without wearing out.

[Sources: http://www.azom.com/article.aspx?ArticleID=10415;

http://www.wellcharter.com/Magnesium/Mag_Adv.htm]

Fabrication Process: Extrusion and welding

Deck Plates- Magnesium Alloy









Fabrication Process: Extrusion

Folding Mechanism:

Arc – Magnesium Alloy

This part is manufactured using a magnesium alloy. This metal was chosen for its high

strength to weight ratio and ease of machinability. Magnesium is the lightest structural

metal, it is 76% lighter than steel and 20 times stronger than thermoplastics. Its material

properties give it a high damping ratio so that it reduces the vibrations transferred to the

Group 6 pg. 15

hands and feet of the rider. In addition, magnesium has good fatigue and dent resistance

which allows the scooter parts to last longer without wearing out.



Fabrication Process: Die Casting and welding to attach to frame

Folding Spring – Steel

Steel was used for the spring for its ability to withstand repetitive motions without

breaking. It is also pliable when in wire form so it aids in the ability to form coils without

unwinding.

Fabrication Process: CNC Machine

Handlebars:

Grips – Silicon Rubber

Silicone was used for the grips for its anti-slip properties, this keeps the riders hands from

coming of the handlebars when operating the scooter. Silicone also has a high resistance

to tearing so that the grips will not wear out during the life of the scooter.

Fabrication Process: Liquid Injection Molding

Brake Lever – Polypropylene



so that it can withstand continual use while operating the scooter. An added benefit is that




Throttle – Polypropylene



so that it can withstand continual use while operating the scooter. An added benefit is that




Drive Train:

Motor Mount – Magnesium Alloy



metal, it is 76% lighter than steel and 20 times stronger than thermoplastics. Its material


Group 6 pg. 16


which allows the scooter parts to last longer without wearing out.



Fabrication Process: Die Casting and welding

Motor- Steel

The motor is made of steel. The motor creates a large amount of heat and needs to consist

of a material that will not warp or deform under those temperatures. Steel creates a rigid

component that can withstand the weight of the internal components without cracking or

breaking from the temperature. The motor must also resist the vibrations of its rotating

components inside, and the rigidity of the steel provides this feature.

[Source: Design Report 2]

Chain – Steel

The chain is comprised of steel so that it can withstand the friction generated from

moving over the two sprockets and the tensioner, as well as the friction created between

its own components when in motion. Steel creates a rigid part that can be easily

reproduced through a stamping process and will not fail under the forces generated when

operating the scooter.


Chain Tensioner – Magnesium Alloy









Fabrication Process: Die Casting

Chain Tensioner Spring – Steel

Steel was used for the spring for its ability to withstand repetitive motions without

breaking. It is also pliable when in wire form so it aids in the ability to form coils without

unwinding.

Fabrication Process: CNC Machine

Clutch – Magnesium Alloy




Group 6 pg. 17







Sprocket – Magnesium Alloy










Wheels:

Tires – Synthetic Rubber Compound

The tire’s rubber material and pattern allow the tire to have a good grip with the surface it

is rotating about at both wet and dry conditions, in order to create the traction necessary.

The material of the tire is able to withstand both cold and hot temperatures while still

performing its function without cracking. The material of the tire helps in the longevity of

the tire since it can withstand thousands of revolutions and usage without breaking. The

tire material must be able to withstand deformations from the terrain and combined

weight of the rider and the scooter.


Inner Tubes – Butyl Rubber

The inner tubes of the tire are manufactured from Butyl Rubber. This material has good

damping properties to help cut down on the vibrations generated while riding that could

transfer to the rest of the scooter. The material properties allow the tube to within stand

high pressure and have the ability to elastically deform without bursting. This material is

resistant to weathering when exposed to the environment. It also has quick curing times

to allow for lower manufacturing times.

[Source: http://www.exxonmobilchemical.com/Chem-English/brands/butyl-rubber-

exxon-butyl-rubber.aspx?ln=productsservices]

Group 6 pg. 18

Rims - Polypropylene



so that it can withstand any bumps endured while riding the scooter. An added benefit is

that polypropylene can be dyed without degrading the integrity of the material.



Hubs – Magnesium Alloy






and dent resistance which allows the scooter parts to last longer without wearing out. The

magnesium hub can then form a tight seal with the bearings to prevent them from sliding

out.




Battery Box – Polypropylene



so that it can withstand any bumps endured while riding the scooter. An added benefit is

that polypropylene can be dyed without degrading the integrity of the material.



Brake:

Brake Caliper – Magnesium Alloy



metal, its 76% lighter than steel and 20 times stronger than thermoplastics. Its material



which allows the scooter parts to last longer without wearing out. The magnesium hub

can then form a tight seal with the bearings to prevent them from sliding out.




Group 6 pg. 19

Brake Casing – Magnesium Alloy











Brake Latch – Magnesium Alloy









http://www.wellcharter.com/Magnesium/Mag_Adv.htm


Brake Drum – Magnesium Alloy











Washers/Spacers/Screws – Steel

Steel is used for this part to allow for a rigid component that can be easily replicated

through stamping and extrusion processes. Steel provides structural integrity without

adding a large amount of additional weight


Group 6 pg. 20

Fabrication Processes

Magnesium Alloy-

The material properties of magnesium makes it one of the easiest materials to manufacture. It

has the ability to be machined, molded, stamped, and extruded with a high production rate.

To prevent corrosion, magnesium is usually coated with paint.

Die Cast- During the casting process, molten magnesium is drawn into the chamber and

through the nozzle into the mold. The molds, or dies, are composed of two halves that are

clamped together while the metal is being injected. Once cooled, the molds are separated

and ejector pins push the pieces out molds. One advantage to using magnesium in place

of aluminum during the die casting is its quick solidity rate. To clean up any rough edges

or polish the finish, the die casted part would be taken to a grinding wheel.

Hot Die Casting Process

Cold Die Casting Process

[Source: http://en.wikipedia.org/wiki/Die_casting]

Extrusion-During the hot extrusion process, a large block of the metal is heated past is

recrystallization temperature. It is then pressed through a die that has been cut into the

desired shape.

[Source: http://en.wikipedia.org/wiki/Extrusion#Hot_extrusion]

TIG Welding- A tungsten rod is introduced inside a cloud of welding gas, which is typically

argon, to provide a current to ignite the gas. This heat creates a small area where the metal parts

begin to melt. To create the weld, a filler rod it pulled along the area to fix the two pieces

together. [Source: http://www.millerwelds.com/resources/tech_tips/TIG_tips/]

Tension Springs- Tension springs like the one used in the folding mechanism are manufactured

by CNC machines when ordered in large quantities. Steel wire cords, which vary in size, are fed

to the CNC machine that coils the wire into the required shape. Rollers of the CNC machines

force the steel wire through the coiling point where it gets the coiling done by a tool at the end

called the mandrel. Springs can be custom made into many different requirements and the

number of coils will be the dependent on the amount of wire that is fed through the coiling

machine. After they are coiled, springs get their ends shaped depending on the application in this

case hook ends. The spring is then tested and relieved of any bending stress that was

accumulated due to the coiling.

[Source: http://www.diamondwire.com/about-springs/spring-manufacturing-process.html]

Group 6 pg. 21

Torsional Springs- Torsion springs are manufactured by CNC machines when ordered in large

quantities. Steel wire cords, which vary in size, are fed to the CNC machine that coils the wire

into the required shape. Rollers of the CNC machines force the steel wire through the coiling

point where it gets the coiling done by a tool at the end called the mandrel. Springs can be

custom made into many different requirements and the number of coils will be the dependent on

the amount of wire that is fed through the coiling machine. After they are coiled, springs get their

ends shaped depending on the application. Torsional spring resist rotational forces and their ends

are shaped very specifically to their application.

[Source: http://www.diamondwire.com/about-springs/spring-manufacturing-process.html;

http://www.acewirespring.com/torsion-springs.html]

Plastic Injection Molding- Pellets of the desired plastic is added to the hopper of the machine,

they are feed into the extruder using a screw mechanism and heated along the way. The plastic is

injected into the molds and left to solidify. Once cooled, the molds are separated and ejector pins

push the part out of the mold (with any excess plastic removed later).

When manufacturing the wheels, the wheel hubs will be inserted into the molds before the

injection process to mate both parts.

[Source: Dr. Ifju, Lecture 18 10/15/2014]

Liquid Injection Molding - The desired liquid and its hardening catalyst are held in separate

tanks until production. The liquid and catalyst are then pumped through a measuring unit to

ensure the proper ratio. Once measured the components are combined in mixers and then

pumped into the molds.

[Source: http://www.thomasnet.com/articles/plastics-rubber/liquid-injection-molding]

Group 6 pg. 22

Assembly Process

Front Section Assembly

Step 1

Align the front frame section so that the folding mechanism arc is upwards and towards

the left hand side.

𝛼 = 360° 𝛽 = 360°

Step 2

Pick up the female revolving axis arm with the dominant hand and insert it into the lower

circular hole on the front frame section via the hole cut in the angle piece.

𝛼 = 360° 𝛽 = 0°

Step 3

Grab the fork holder and place in the arbor press.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 23

Step 4

Pick up the fork guide and insert it into the press with the smaller hole aligned with the

hole in the holder arm. Use the arbor press to press fit the fork guide to the holder arm.

𝛼 = 360° 𝛽 = 0°

Step 5

Flip the holder arm and place it back in the press.

𝛼 = 360° 𝛽 = 360°

Step 6

Pick up second fork guide and align the smaller hole with the other hole in the holder

arm. Use the arbor press to create a press fit between the fork guide and the holder arm.

𝛼 = 360° 𝛽 = 0°

Step 7

Pick up fork holder arm and locate with respect to the front frame section as shown in

following picture.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 24

Step 8

Pick up lock rod with the dominant hand and begin to insert it into the notch in the front

frame section and the holder arm.

𝛼 = 360° 𝛽 = 360°

Step 9

Using tweezers, pick up the folding mechanism spring and locate the spring such that the

top hook is concentric with the lock rod.

𝛼 = 180° 𝛽 = 180° Step 10

Push lock rod through spring hook and out other end of the fork holder arm and the front

section frame.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 25

Step 11

Pick up the lock rod spacer with the dominant hand and insert it around the lock rod.

Repeat for the other side of the lock rod.

𝛼 = 180° 𝛽 = 0°

Step 12

Pick up the rod clip with the dominant hand and using force insert it onto the notch in the

lock rod. Repeat for the opposite side.

𝛼 = 180° 𝛽 = 0°

Step 13

Pick up the revolving axis spacer with the dominant hand and insert it around the female

revolving axis arm.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 26

Step 14

Align the fork holder arm with respect to the circular hole and the revolving axis arm and

insert the female revolving axis arm up to the notch in the end.

𝛼 = 360° 𝛽 = 0°

Step 15

Pick up the rod clip with the dominant hand and insert it on the notch at the end of the

female revolving axis arm.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 27

Step 16

Pick up the male revolving axis arm with the non-dominant hand and insert it into the

circular hole in the front frame section via the hole in the angled section.

𝛼 = 360° 𝛽 = 0°

Step 17

Using tweezers, pick up and locate the second spacer between the front frame section and

fork holder arm with respect to the male revolving axis arm and insert arm through

spacer.

𝛼 = 180° 𝛽 = 0°

Step 18

Using tweezers, ensure that the male end is inserted through the bottom hook of the

spring. Use Allen wrenches to fasten male and female revolving axis arms together.

𝛼 = 360° 𝛽 = 0°

Step 19

Pick up the rod clip with the dominant hand and insert it onto the notch at the end of the

male revolving axis arm.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 28

Fork Assembly

Step 20

Pick up the fork with the shaft end pointed upwards.

𝛼 = 180° 𝛽 = 360° Step 21

Pick up front tire axle ring and insert it around the fork shaft and slide it down until it

rests on the shelf on the shaft of the fork.

𝛼 = 360° 𝛽 = 0°

Step 22

Pick up the bearing washer and locate it above the front tire axle ring on the shaft.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 29

Step 23

Insert the front fork assembly upwards into the fork holder arm and hold in place.

𝛼 = 360° 𝛽 = 0°

Step 24

Pick up and insert the second bearing washer onto the fork shaft.

𝛼 = 180° 𝛽 = 0°

Step 25

Pick up and insert the fork bar lower nut around the fork shaft. Screw on until it is

securely tightened.

𝛼 = 360° 𝛽 = 0°

Step 26

Pick up and locate the fork bar washer above the lower nut.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 30

Step 27

Pick up and insert the fork bar upper nut around the fork shaft and screw on until it is

securely tightened.

𝛼 = 360° 𝛽 = 0°

Front Axle Assembly

Step 28

Pick up front wheel hub and lay flat.

𝛼 = 180° 𝛽 = 0°

Step 29

Pick up bearing with dominant hand and align with hole in the wheel hub. Use a soft

hammer to press fit the bearing into the hole.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 31

Step 30

Pick up the inner rod bearing with the dominant hand and insert into the wheel hub.

𝛼 = 180° 𝛽 = 0°

Step 31

Pick up the second bearing the dominant hand and using a soft hammer, press fit onto

open end of the wheel hub.

𝛼 = 180° 𝛽 = 0°

Step 32

Pick up the tire tube and stretch around the hub, aligning the valve with the

corresponding hole in the hub.

𝛼 = 180° 𝛽 = 360°

Group 6 pg. 32

Step 33

Align the front wheel assembly with the axel holes in the front fork.

𝛼 = 180° 𝛽 = 0°

Step 34

Pick up the female socket drive post with the non-dominant hand and insert through the

holes in the fork and the front wheel assembly.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 33

Step 35

Pick up the male socket drive post with the dominant hand and insert through holes on

the other side of the front fork and front wheel assembly. Use two Allen keys to tighten

the socket posts.

𝛼 = 360° 𝛽 = 0°

Handlebar Assembly

Step 36

Pick up telescoping tube 1 with the non-dominant hand and position the end with only

one hole towards the dominant hand.

𝛼 = 360° 𝛽 = 0°

Step 37

Pick up the button connector with the dominant hand and align such that the button end is

away from the tube. Simultaneously compress the button connector while inserting it into

the tube, aligning the button and the hole. Repeat previous two steps for telescoping tubes

2-4.

𝛼 = 360° 𝛽 = 360°

Step 38

Pick up tube 1 with the non-dominant hand and tube 2 with the dominant hand. Compress

the button connector on tube 2 and slide it into tube 1 through the side with the button. If

assembling for riding, allow button connector to be inserted into one of the holes on the

top of tube 1. If assembling for travel, avoid the holes on top of tube 1 and slide tube 2

into tube 1 until tube 2 hits the connector within tube 1. Repeat this process with tubes 3

and 4 (3 into 2 and then 4 into 3).

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 34

Step 39

Pick up a single handlebar with the non-dominant hand and align so the hole in the bar is

towards the left and facing the holder.

𝛼 = 360° 𝛽 = 360° Step 40

Pick up a button connector with the dominant hand. Compress and insert the button

connector, same as before, through the hole-end of the handlebar, allowing the button to

be housed in the hole.

𝛼 = 360° 𝛽 = 360° Step 41

Pick up throttle twist holder with the dominant hand and slide onto the handle bar from

left to right.

𝛼 = 360° 𝛽 = 360° Step 42

Pick up the throttle twist with the dominant hand and slide onto handle bare from left to

right and onto twist holder.

𝛼 = 360° 𝛽 = 360°

Step 43

Pick up the motor side grip with the dominant hand and slide onto the handle bar.

𝛼 = 360° 𝛽 = 0°

Step 44

Once the grip is in place and all other components are aligned, use a screwdriver to screw

the throttle twist holder in place.

Group 6 pg. 35

Step 45

Grab second handlebar with non-dominant hand and a button connector with the

dominant hand. Compress and insert the connector into the handlebar such that the button

is housed in hole. Align the button and hole on the right hand side facing the holder.

𝛼 = 360° 𝛽 = 360° Step 46

Pick up the hand brake with the dominant hand and slide onto the handlebar such that the

brake is pointed to the left.

𝛼 = 360° 𝛽 = 360° Step 47

Pick up brake side grip and slide onto the handlebar behind the brake.

𝛼 = 360° 𝛽 = 0°

Step 48

Once the brake and grip are in place and aligned properly, use a screwdriver to tighten

the brake in place.

Rear Axle Assembly

Step 49

Grab rear frame section and align with the deck down and the battery support rails further

away.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 36

Step 50

Pick up the motor the dominant hand and align the motor holes with holes in the rear

frame section as shown.

𝛼 = 360° 𝛽 = 360°

Step 51

Grab a motor mount screw with the non-dominant hand and insert through first the hole

in the frame section and then the corresponding motor hole.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 37

Step 52

Grab a motor mount nut and use wrenches to tighten onto the screw. Repeat last two

steps for the other motor hole.

𝛼 = 180° 𝛽 = 0°

Step 53

Pick up rear wheel hub and lay it flat.

𝛼 = 180° 𝛽 = 0°

Step 54

Pick up bearing with the dominant hand and press fit it into the rear wheel hub using a

soft hammer.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 38

Step 55

Pick up inner bearing rod with the dominant hand and insert it on other side of the rear

wheel hub.

𝛼 = 180° 𝛽 = 0°

Step 56

Pick up second bearing and press fit it onto open end of the hub using a soft hammer.

𝛼 = 180° 𝛽 = 0°

Step 57

Stretch the tube and tire around the rear wheel hub, aligning the valve with hole in the

hub.

𝛼 = 180° 𝛽 = 360°

Group 6 pg. 39

Step 58

Pick up the clutch with the dominant hand and screw onto one side of the hub.

𝛼 = 360° 𝛽 = 0°

Step 59

Pick up the brake drum with the dominant hand and screw onto other side of the hub with

the hollow end facing the tire.

𝛼 = 360° 𝛽 = 0°

Step 60

Pick up the rear axle with the dominant hand and through the hub.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 40

Step 61

Pick up the brake assembly with the dominant hand and slide over the brake drum.

𝛼 = 360° 𝛽 = 0°

Step 62

Pick up a washer and slide onto axle behind the brake assembly.

𝛼 = 180° 𝛽 = 0°

Step 63

Pick up the small spacer with the dominant hand and slide onto the clutch side of the

axle.

𝛼 = 180° 𝛽 = 0°

Step 64

Pick up the cut washer with the dominant hand and slide on the axle behind the spacer.

𝛼 = 180° 𝛽 = 0°

Group 6 pg. 41

Step 65

Pick up the chain with both hands and engage the links on one end to the clutch sprocket

and on the other end to the motor sprocket.

𝛼 = 180° 𝛽 = 0°

Step 66

Pick up the rear axle assembly and insert it on the rear wheel supports, aligning the clutch

sprocket with the motor sprocket.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 42

Step 67

Pick up the medium sized washer with the dominant hand and slide onto the axle.

𝛼 = 180° 𝛽 = 0°

Step 68

Pick up the split washer and slide onto the axle behind the medium sized washer.

𝛼 = 180° 𝛽 = 0°

Step 69

Pick up the rear axle nut and screw it on behind the split washer. Repeat the past three

steps for other side of the axle.

𝛼 = 360° 𝛽 = 0°

Step 70

Grab the chain tensioner spring and insert it around the chain tensioner and force spring

arm around the tensioner arm.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 43

Step 71

Pick up the tensioner and align the tensioner hole with the hole on the inside of the right

side rear wheel support.

𝛼 = 360° 𝛽 = 0°

Step 72

Pick up the tensioner screw with the dominant hand and insert through first the tensioner

and then the rear wheel support. While inserting screw make sure to align the spring

through small hole in rear wheel support.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 44

Step 73

Pick up the tensioner nut with the dominant hand and, using a wrench, tighten to the rear

wheel support.

𝛼 = 180° 𝛽 = 0°

Battery Box Assembly

Step 74

Align the battery tub with the base downwards and the rectangular on/off switch hole on

the front left hand side.

𝛼 = 360° 𝛽 = 360° Step 75

Pick up the battery with the dominant hand and center it on the right hand side of the tub,

ensuring the base is down and connectors toward the left.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 45

Step 76

Pick up the on/off switch with the dominant hand. Using force, pop on the switch to the

rectangular hole in front left side of the tub such that the red switch is facing outwards

with the “ON” lettering on the top.

𝛼 = 360° 𝛽 = 360°

Step 77

Grab the reset button with the non-dominant hand and insert it from the inside of the tub

through the circular hole above and to the left of the on/off switch.

𝛼 = 360° 𝛽 = 0°

Step 78

Pick up the reset button nut in the dominant hand and screw onto the reset button from

the outside of the battery tub.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 46

Step 79

Grab the charger port with the non-dominant hand near the wires and the charger port cap

with the dominant hand. Push the end of the cover over the ridge of the charger port.

𝛼 = 360° 𝛽 = 0°

Step 80

Feed the wires from the charger port through the remaining hole next to the reset button

through the outside of the battery tub and insert the port into the hole.

𝛼 = 360° 𝛽 = 0°

Step 81

Pick up the charger port nut with the dominant hand and feed it over the wires of the

charger port and screw it onto the charger port, securing it to the battery tub.

𝛼 = 180° 𝛽 = 0°

Step 82

Pick up the processor with the dominant hand and align it with the screw hole to the left

of the battery box.

𝛼 = 360° 𝛽 = 180°

Group 6 pg. 47

Step 83

Grab one of the processor screws and align with the screw hole of the processor. Use a

screwdriver to tighten processor to battery tub. Repeat this step for the other processor

screw.

𝛼 = 360° 𝛽 = 0°

Step 84

Pick up the battery box and slide it into the battery impact cage, aligning the hole on the

top.

𝛼 = 360° 𝛽 = 180°

Group 6 pg. 48

Step 85

Pick up the entire battery box assembly and slide onto the support rails of the rear frame

assembly such that the battery is towards the wheel.

𝛼 = 360° 𝛽 = 360°

Step 86

Run the motor wire from the motor through the notch at the rear of the battery tub into

the tub.

𝛼 = 360° 𝛽 = 0°

Step 87

Hold the battery wire with the non-dominant hand and pick up the wire clip with the

dominant hand and insert the clip over the metal tabs

𝛼 = 360° 𝛽 = 180° Step 88

Holding the brake line in the dominant hand, feed the line from the brake assembly

through the hole in the back of the tub.

𝛼 = 360° 𝛽 = 0°

Step 89

Following the wiring diagram, attach the three wires to the On/Off switch.

𝛼 = 360° 𝛽 = 360° Step 90

Following the wiring diagram, attach the two wires to the charger port.

𝛼 = 360° 𝛽 = 360° Step 91

Following the wiring diagram, attach the five wires to the processor.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 49

Step 92

Run brake and throttle cables through the largest hole of the battery tub cover.

𝛼 = 360° 𝛽 = 0°

Step 93

Pick up the battery tub cover and place on top of the battery box assembly such that the

large hole is towards the on/off switch side. Align the holes of the cover with the holes of

the cage, frame and tub.

𝛼 = 180° 𝛽 = 360°

Step 94

Pick up one of the battery box screws and screw down cover to the support rail and tub.

Repeat for the three other holes.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 50

Step 95

Run the brake line up the handlebars and insert the rounded tip into the slot on the

underside of the brake handle.

𝛼 = 360° 𝛽 = 180°

Step 96

Feed the brake line into the channel on the front of the brake handle and through the

metal screw attached to the hand brake.

𝛼 = 360° 𝛽 = 0°

Step 97

Grab the metal screw with the dominant hand and tighten to secure the brake line.

𝛼 = 360° 𝛽 = 0°

Group 6 pg. 51

Folding Deck Assembly

Step 98

Pick up one plastic hinge with the non-dominant hand and align with the holes on the top

of the folding deck with hinge side downwards.

𝛼 = 360° 𝛽 = 180° Step 99

Pick up one of the hinge screws and secure the hinge to the deck top. Repeat for the other

hole in the hinge and then repeat past two steps for the second hinge.

𝛼 = 360° 𝛽 = 0°

Step 100

Align the remaining holes on the other side of the hinge with holes on the rear frame

assembly deck.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 52

Step 101

Pick up a hinge screw and secure the hinge to the rear frame assembly. Repeat for the

three remaining hinge holes. Then fold up the deck top.

𝛼 = 360° 𝛽 = 0°

Step 102

Pick up a silicon deck damper and adhere lengthwise to the underside of the folding deck

in between the hinge holes. Repeat for the other side of the deck.

𝛼 = 360° 𝛽 = 180°

Group 6 pg. 53

Frame Assembly

Step 103

Pick up the left frame rail and align such that the front is towards the left and holes are on

the closest side. The front is indicated by the letter “F” on the tip of the rail.

𝛼 = 360° 𝛽 = 360° Step 104

Using the long tweezers apparatus, install the frame rail button connectors in the order

shown. The connector orientation flips 180 Degrees about the button on the connector for

locations 3 and 4. Repeat last two steps for right frame rail.

𝛼 = 360° 𝛽 = 360°

Step 105

Pick up the front section assembly with the non-dominant hand. With the dominant hand,

pick up the left frame rail and insert the front end of the rail through the square hole on

the left side of the front section assembly, ensuring the button connectors are facing

outward to line up with the holes in the front assembly. Repeat for the right frame rail.

Then using one hand on each frame rail, compress the first button connectors and slide

the frame rails into the front frame section, locking it into place with the button

connectors.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 54

Step 106

Pick up the rear frame section and align it with the frame rails. Slide the rear section onto

the frame rails, up to the closest set of button connectors. Then using one hand on each

frame rail, compress the first button connectors and slide the rear frame section onto the

frame rails.

𝛼 = 360° 𝛽 = 360°

Deck Locator Assembly

Step 107

Pick up the deck locator with the non-dominant hand and the deck locator silicon pad

with the dominant hand. Adhere the silicon pad to the underside the non-hole ledge.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 55

Step 108

Pick up the deck locator spacer with the dominant hand and align with the top hole in the

front deck assembly.

𝛼 = 180° 𝛽 = 0°

Step 109

Pick up the deck locator assembly and align the hole with the hole in the front deck

assembly with the silicon pad downwards.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 56

Step 110

Pick up the deck locator screw with the dominant hand and insert it into the hole of the

deck locator. Using a screwdriver, tighten down the locator such that it is not loose yet

still able to spin about the hole. Repeat past four steps for the deck locator on the other

side of the front deck assembly.

𝛼 = 360° 𝛽 = 0°

Chain Guard Assembly

Step 111

Grab the chain side guard and locate the screw holes with the holes on the right rear

wheel support.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 57

Step 112

Pick up one of the chain guard screws with the dominant hand and insert into the hole on

the chain guard. Securely tighten the screw with a screwdriver and repeat for the other

screw hole on the guard. Repeat last two steps for the brake side guard on the other side

of the scooter.

𝛼 = 360° 𝛽 = 0°

Final Scooter Assembly

Step 113

Pick up the handlebar assembly and align the telescoping tubes with the fork. Press the

bottom button connector and slide the handlebar assembly into the fork.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 58

Step 114

Pick up a frame end cap and align it with the hole in the frame rail. Using a slight

amount, locate the cap inside the frame rail in an interference fit. Repeat this for the three

remaining frame rail hole locations.

𝛼 = 360° 𝛽 = 360°

Group 6 pg. 59

Table 3: Handling and Insertion Times

Handling Insertion

Step Alpha Beta Alpha + Beta

# of Occurrences

Handling Time

Step Time

Source # of Occurrences

Insertion Time

Step Time

Source

1 360 360 720 1 1.95 1.95 (3,0) - - - -

2 360 0 360 1 1.5 1.5 (1,0) 1 4 4 (0,1)

3 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

4 360 0 360 1 1.5 1.5 (1,0) 1 3.5 3.5 (9,3)

5 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

6 360 0 360 1 1.5 1.5 (1,0) 1 3.5 3.5 (9,3)

7 360 360 720 1 1.95 1.95 (3,0) 1 5.5 5.5 (0,6)

8 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)

9 180 180 360 1 4.75 4.75 (5,2) 1 6.5 6.5 (2,2)

10 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (2,0)

11 180 0 180 2 1.43 2.86 (0,1) 2 1.5 3 (0,0)

12 180 0 180 2 1.69 3.38 (0,3) 2 5 10 (3,1)

13 180 0 180 1 1.43 1.43 (0,1) 1 4 4 (1,0)

14 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)

15 180 0 180 1 1.69 1.69 (0,3) 1 5 5 (3,1)

16 360 0 360 1 1.5 1.5 (1,0) 1 4 4 (1,0)

17 180 0 180 1 6.85 6.85 (4,1) 1 4.5 4.5 (4,0)

18 360 0 360 1 5.6 5.6 (8,3) 1 10 10 (5,8)

19 180 0 180 1 1.69 1.69 (0,3) 1 5 5 (3,1)

20 360 0 360 1 1.5 1.5 (1,0) - - - -

21 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)

22 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)

23 360 0 360 1 3 3 (9,1) 1 5.5 5.5 (0,6)

24 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)

25 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)

26 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)

27 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)

28 180 0 180 1 1.13 1.13 (0,0) - - - -

29 360 0 360 1 1.5 1.5 (1,0) 1 7 7 (3,5)

30 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)

31 180 0 180 1 1.13 1.13 (0,0) 1 7 7 (3,5)

32 180 360 540 1 1.8 1.8 (2,0) 1 8.5 8.5 (4,4)

33 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)

34 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (0,6)

35 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)

36 360 0 360 4 1.5 6 (1,0) - - - -

Group 6 pg. 60

37 360 360 720 4 1.95 7.8 (3,0) 4 4.5 18 (4,0)

38 360 360 720 3 1.95 5.85 (3,0) 3 4.5 13.5 (4,0)

39 360 360 720 1 1.95 1.95 (3,0) - - - -

40 360 360 720 1 1.95 1.95 (3,0) 1 4.5 4.5 (4,0)

41 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

42 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

43 360 0 360 1 1.5 1.5 (1,0) 1 2 2 (3,0)

44 - - - - - - - 1 6 6 (3,8)

45 360 360 720 1 1.95 1.95 (3,0) 1 4.5 4.5 (4,0)

46 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

47 360 0 360 1 1.5 1.5 (1,0) 1 2 2 (3,0)

48 - - - - - - - 1 6 6 (3,8)

49 360 360 720 1 1.95 1.95 (3,0) - - - -

50 360 360 720 1 1.95 1.95 (3,0) 2 8 16 (1,6)

51 360 0 360 2 1.5 3 (1,0) 2 8 16 (1,6)

52 180 0 180 2 1.13 2.26 (0,0) 2 12 24 (5,9)

53 180 0 180 1 1.13 1.13 (0,0) - - - -

54 180 0 180 1 1.13 1.13 (0,0) 1 5 5 (3,1)

55 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)

56 180 0 180 1 1.13 1.13 (0,0) 1 5 5 (3,1)

57 180 360 540 1 1.8 1.8 (2,0) 1 6 6 (3,4)

58 360 0 360 1 1.5 1.5 (1,0) 1 8 8 (3,9)

59 360 0 360 1 1.5 1.5 (1,0) 1 8 8 (3,9)

60 180 0 180 1 1.13 1.13 (0,0) 1 5.5 5.5 (0,6)

61 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (0,6)

62 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)

63 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)

64 180 0 180 1 1.13 1.13 (0,0) 1 1.5 1.5 (0,0)

65 180 0 180 1 4.1 4.1 (8,0) 1 9 9 (1,8)

66 360 360 720 1 3 3 (9,1) 1 1.5 1.5 (0,0)

67 180 0 180 2 1.13 2.26 (0,0) 2 1.5 3 (0,0)

68 180 0 180 2 1.13 2.26 (0,0) 2 1.5 3 (0,0)

69 360 0 360 2 1.5 3 (1,0) 2 6 12 (3,8)

70 360 360 720 1 1.95 1.95 (3,0) 1 5 5 (3,1)

71 360 360 720 1 1.95 1.95 (3,0) 1 9.5 9.5 (2,6)

72 360 0 360 1 1.5 1.5 (1,0) 1 9.5 9.5 (2,6)

73 180 0 180 1 1.13 1.13 (0,0) 1 8 8 (3,9)

74 360 360 720 1 1.95 1.95 (3,0) - - - -

75 360 360 720 1 1.95 1.95 (3,0) 1 1.5 1.5 (0,0)

76 360 360 720 1 1.95 1.95 (3,0) 1 5 5 (3,1)

77 360 0 360 1 1.5 1.5 (1,0) 1 5.5 5.5 (0,5)

Group 6 pg. 61

78 360 0 360 1 1.5 1.5 (1,0) 1 6 6 (3,8)

79 360 0 360 1 1.5 1.5 (1,0) 1 2 2 (3,0)

80 360 0 360 1 1.5 1.5 (1,0) 1 1.5 1.5 (0,0)

81 180 0 180 1 1.13 1.13 (0,0) 1 6 6 (3,8)

82 360 180 540 1 1.8 1.8 (2,0) 1 2.5 2.5 (0,2)

83 360 0 360 2 1.5 3 (1,0) 2 6 12 (3,8)

84 360 180 540 1 3 3 (9,1) 1 2.5 2.5 (0,2)

85 360 360 720 1 1.95 1.95 (3,0) 1 2.5 2.5 (0,1)

86 360 0 360 1 1.5 1.5 (1,0) 1 9 9 (9,8)

87 360 180 540 1 1.8 1.8 (2,0) 1 2 2 (3,0)

88 360 0 360 1 1.5 1.5 (1,0) 1 9 9 (9,8)

89 360 360 720 3 1.95 5.85 (3,0) 3 9 27 (9,8)

90 360 360 720 2 1.95 3.9 (3,0) 2 9 18 (9,8)

91 360 360 720 5 1.95 9.75 (3,0) 5 9 45 (9,8)

92 360 0 360 2 1.5 3 (1,0) 2 1.5 3 (0,0)

93 180 360 540 1 1.8 1.8 (2,0) 1 2.5 2.5 (0,2)

94 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)

95 360 180 540 1 1.8 1.8 (2,0) 1 9 9 (9,8)

96 360 0 360 1 1.5 1.5 (1,0) 1 9 9 (9,8)

97 360 0 360 1 1.8 1.8 (1,1) 1 6 6 (3,8)

98 360 180 540 2 1.8 3.6 (2,0) 2 2.5 5 (0,2)

99 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)

100 360 360 720 1 1.95 1.95 (3,0) 1 6.5 6.5 (0,8)

101 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)

102 360 180 540 2 1.8 3.6 (2,0) 2 5 10 (3,1)

103 360 360 720 2 1.95 3.9 (3,0) - - - -

104 360 360 720 8 1.95 15.6 (3,0) 8 6 48 (5,0)

105 360 360 720 2 3 6 (9,1) 2 2 4 (3,0)

106 360 360 720 1 3 3 (9,3) 1 5 5 (3,1)

107 360 360 720 2 1.95 3.9 (3,0) 2 5 10 (3,1)

108 180 0 180 2 2.18 4.36 (0,4) 2 1.5 3 (0,0)

109 360 360 720 2 1.95 3.9 (3,0) 2 1.5 3 (0,0)

110 360 0 360 2 1.5 3 (1,0) 2 6 12 (3,8)

111 360 360 720 2 1.95 3.9 (3,0) 2 5.5 11 (0,6)

112 360 0 360 4 1.5 6 (1,0) 4 6 24 (3,8)

113 360 360 720 1 1.95 1.95 (3,0) 1 2 2 (3,0)

114 360 180 540 4 1.8 7.2 (2,0) 4 2 8 (3,0)

Total Times: 296.55 789

Total Assembly Time: 1085.55 sec = 18.09 mins

Group 6 pg. 62

Performance Analysis

The Electric Slide scooter boasts some of the highest performance ratings to any

scooter on the market. Despite being lightweight, this scooter has the strength and torque

to operate under any urban conditions. The Electric Slide scooter was designed using the

E-300 Razor scooter as a base jumping-off point and so is designed to be better in every

physical category. This analysis will break down the calculations for the velocity, torque,

battery life, and turning radius and compare them to the E-300 Razor to outline

performance improvements.

Motor: Torque

The Electric Slide was designed to be faster and more powerful than the E-300

while only being half the weight. To do this, the design called for a much more powerful

motor. The motor is a 24 V electric motor rated for 750 W and 2600 RPM so that our

scooter can double the torque of the E-300 while not sacrificing speed.

According to the stall torque calculations provided by Dr. Ifju, the E-300 provides

an estimated stall torque of 11.43 Nm, providing a stall force of 90 N. The goal of our

design is to double this stall force, meaning our motor must provide at least 180 N of

force on the ground.

To calculate the rated torque for the motor we use the relation,

T P

n

where T is the torque, P is the power in watts, and n is the number of revolutions per

minute of the motor sprocket. Using a conversion factor to change the units to Nm, we

calculate the rated torque of our motor to be,

750

2600

30

2.75Nm

However, when we calculate the motor torque, we must take the battery into

consideration. Our battery is a Lithium Polymer 22.2 V battery pack with a 22 Ah

capacity. Because our motor’s rated power and RPM is at 24 V and our battery supplies

22.2 V, our motor’s power and torque will be lower than rated. The drop in torque that

the motor will experience is proportional to the drop in voltage. Therefore we can

calculate a more accurate torque output based on our battery.

2.7 52 2.2

2 4

2.5 5 Nm

Group 6 pg. 63

The torque now on the rear tire will be the calculated motor torque multiplied by

the gear ratio. Our motor sprocket has 11 teeth and our drive train sprocket has 30 teeth.

So our rear wheel torque will be,

2.5530

11

6.95Nm

Based on the stall torque calculations released by Dr. Ifju, the stall torque is a

little over two times the rated torque and in the calculations a factor of 2.3 was used. So

the stall torque of the tire for our motor and battery will be 6.95*2.3 = 15.98 Nm. Finally,

the stall force the tire provides can be calculated by

Fs t al lTs t al l

r

where r is the radius of the rear tire in meters. Our rear tire is 6 inches in diameter, or a

0.0762 meter radius. Therefore the stall force of our tire is

15.98

0.0762209.75 Nm

The E-300 Razor scooter provides 90 N of force on the ground. Our design

provides almost 210 N of force, more than 230% of the E-300 stall force. This increased

force also allows us to handle steeper terrain. To get an idea of the kind of slope our

scooter torque could handle, we can relate the slope of the incline the scooter would stall

at with riders of varying weight. Using a free-body diagram of the rear wheel, can make

the relation,

Fs t a l lW gs i n() where F is the force required prevent our scooter of a combined rider and scooter weight,

W, on a incline of slope,

, from rolling down the incline. We know our maximum stall

force is 209.75 Nm, so the incline a rider of given weight would stall at can be calculated

by arranging the equation like below. The data for a range of rider weights is also shown

on the next page.

si n1209.75

W9.81

Group 6 pg. 64

Fig. 1: The graph shows the incline slopes that a rider between 100 lb – 220 lb could climb before stalling.

The equations used assume a relatively smooth, uniform surface.

The graph shows that with our given motor, someone weighing as much as 220 lbs could

climb an incline of up to 11 degrees before stalling. This means our scooter could be used

by riders in a wide range of areas, including areas with hills or steep inclines.

Motor: Speed

The second rating of performance is the scooter speed. Despite the design

requirement of the Electric Slide scooter to be half the weight of the E-300 Razor, we

needed a motor that could provide at least double the stall force without sacrificing speed.

The E-300 has a top speed of 15 mph. The speed of the scooter is dependant on the RPM

of the motor, the gear ratio of the drive train, and the size of the tire. The calculations in

this section will show that our design is faster than E-300 Razor scooter based on the

motor and battery chosen for our design.

As mentioned in the previous section, our battery is 22.2 V, less than the voltage

used for the rated power and RPM: 24 V. Just like the torque, the difference in RPM

between the motor at a lower voltage and the rated voltage is proportional to the

difference in voltage. Therefore, we can find the RPM our motor will run at with our

battery by multiplying it by the voltage ratio,

2600r a t e d22.2

24

2405RPM

Group 6 pg. 65

As the rotational motion is transmitted from the motor to the rear axle, the RPM

will be reduced by the gear ratio. Knowing that, the rotational speed of the back tire can

be calculated.

2 4 0 51 1

3 0

8 8 1.8 3 RPM

Then, using 6 inches as tire diameter, 881.83 RPM as the rotational speed, and

multiplying by a conversion factor to convert from inches per minute to miles per hour

(9.47x10-4), we find that the velocity of the scooter to be

8 8 1.8 369.4 71 04 1 5.7 4 mph

Therefore, our motor, battery, and sprocket combination produces a scooter with a

speed 105% of the E-300 Razor, meeting our velocity specifications.

Battery Life

Another important performance factor is the battery life. The E-300 had an

effective battery life of 40 minutes. Our design must be as good or better than the E-300’s

battery performance. Our motor is much more powerful than the E-300’s motor and

therefore also draws more current, requiring a much more efficient battery in order to

provide the voltage for an adequate amount of time without being too large or heavy. Our

battery, a lithium polymer battery, provides 22.2 V with a 22 Ah capacity. In order to

calculate the battery life, we must find the current usage of our motor. Since power is a

function of current and voltage, the current of the motor can be determined by the

equation,

I P

V

The power of our motor with reduced battery voltage can be found by using the

power-voltage-resistance relation,

P V 2

R

Using this relation, assuming a minimal change in resistance for the motor we can

calculate the new motor power knowing the actual voltage provided by the battery is

92.5% of the rated voltage.

Pa c t u a lV a c t u a l

2

R

0.9 2 5Vr a t e d

2

R 0.8 5 6

V r a t e d

2

R 0.8 5 6Pr a t e d

Group 6 pg. 66

So the power of our motor coupled with our battery is,

Pa c t u a l0.856Pr a t e d0.856750641.72 W

Now using this calculated power with the battery’s voltage into the current

equation above, we find the motor’s current usage to be,

I P

V

6 4 1.7 2

2 2.22 8.9 1 A

Finally, if we divide the battery capacity by the current usage of the motor, we

find the battery life at that current. In this case, with our motor, and a capacity of 22 Ah,

our battery will have an effective life of

2 2

2 8.9 10.7 6 hrs

45 mins

Therefore, with our given power and electric needs, the Electric Slide scooter will

have an effective battery life of 45 minutes, a battery life 14% longer than the life of the

E-300 Razor scooter.

Turning Radius

The final performance factor is the turning radius, which dictates the rider’s

ability to make turns at varying speeds. A theoretical turning radius can be determined

from the equation below, where the angle is defined as the maximum angle of turning

allowed by the scooter, measured with respect to the straight forward position.

Turning Radius =Scooter Wheelbase

1

sin(angle)

The wheelbase of the scooter was determined to be 2.597 feet and a safe turning

radius of 50 degrees. These measurements result in the following calculation:

Scooter Turning Radius =

2.597

sin(50) 3.39 (ft)

If a turning circle were desired, the turning ratio could be multiplied by two to

obtain a turning circle of diameter 6.78 feet. The turning radius for the Electric Slide

scooter is for a safe turning angle: 50. Since there is no limiting mechanism, the scooter

could turn sharper at slower speeds.

Group 6 pg. 67

Summary

Overall, using the E-300 Razor scooter as a launching point, our scooter shows an

improvement in every performance category, including over twice the E-300’s stall force.

The Electric Slide’s performance calculations, along with its strong, lightweight, and

compactable design show that this scooter will have a large desirability among other

products. The table below summarizes the performance specifications of the Electric

Slide and E-300 Razor scooter.

Table 4: Electric Slide and E-300 Razor performance specifications.

Electric Slide E-300 Razor Performance

Comparison

Stall Force (N) 209.75 90 233%

Speed (mph) 15.75 15 105%

Battery Life (mins) 45.66 40 114%

Wheelbase (ft) 2.60 2.50 104%

Group 6 pg. 68

Mechanical Analysis

Frame Loading Analysis

To ensure there would not be any failure in the structural elements of the design, a finite element

analysis was run using SolidWorks to determine the maxium deflection and von Mises stresses

on the base of the frame. A fine mesh (76,549 nodes) of the element was generated and a

simulation was run using normal loading conditions, having a 220 lb person standing on the

deck. Under these loading conditions the maximum deflection reached 0.0099 inches at the

center of the scooters deck and a von Mises stress of 3,410 psi (location is denoted with a red

circle). Using the equation below, it was determined that our frame has a factor of safety of 4.46

for a normal loading condition.

𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 𝜎𝑦𝑖𝑒𝑙𝑑

𝜎𝑑𝑒𝑠𝑖𝑔𝑛=

15,200 𝑝𝑠𝑖

3,410 𝑝𝑠𝑖= 4.46

Group 6 pg. 69

A second simulation was run for an extreme condition with a rider of 500 lbs. This produced

resuts of a maximum deflection of 0.022 inches and a maximum von Mises stresses of 7,700 psi.

These maximums were located in the same positions of the scooter`s frame as for the original

loading condition. Using the equation below, this loading conditions gives a factor of safety of

1.97.



15,200 𝑝𝑠𝑖

7,700 𝑝𝑠𝑖= 1.97

Group 6 pg. 70

Handlebars Loading Analysis

A loading analysis was simulated to determine whether the handle bars would buckle if 50

pounds of force were applied to the edges. A fine mesh (63,424 nodes) was generated and a

simulation was run to mimic an extreme case where force was only applied to the far ends of the

handlebar grips. Under this loading condition, the maximum deflection is 0.065 in and maximum

von Mises stress of 7,794 psi giving a factor of safety of 2.



15,200 𝑝𝑠𝑖

7,794 𝑝𝑠𝑖= 1.95

Group 6 pg. 71

A loading analysis was simulated to determine whether the handle bars would buckle if 50

pounds of force were applied if someone were to pull back or push against the handlebars. A fine

mesh (63,316 nodes) was generated and a simulation was run to determine the maximum

deflection and von Mises stress. Under this loading condition, the maximum deflection is 0.31 in

and maximum von Mises stress of 8,098 psi giving a factor of safety of 2.



15,200 𝑝𝑠𝑖

8,098 𝑝𝑠𝑖= 1.88

Group 6 pg. 72

Fork Loading Analysis

A loading analysis was done to simulate a 220 pound rider placing all of their weight directly on

the fork of the scooter. A fine mesh (55, 258 nodes) was generated and a simulation was run to

determine the maximum deflection and von Mises stress. Under these loading conditions, it was

found that the maximum deflection was 0.0015 in and the von Mises stress was 4,188 psi giving

us a factor of safety of 3.6.



15,200 𝑝𝑠𝑖

4,188 𝑝𝑠𝑖= 3.6

Group 6 pg. 73

Group 6 pg. 74

Another simulation was run for the front fork to analysis what would happen during a front

impact of 100 pounds. A fine mesh (50,746 nodes) was generated and a simulation was run to

determine the maximum deflection and von Mises stress. Under these loading conditions, the

maximum deflection was found to be 0.0024 in and the maximum von Mises stress was 5,200 psi

giving a factor of safety of 3.



15,200 𝑝𝑠𝑖

5,200 𝑝𝑠𝑖= 2.9

Group 6 pg. 75

Group 6 pg. 76

Chain Drive Assembly

In order for the scooter to be driven, electrical power from the battery must be converted

into mechanical power. This manipulation of energy takes place inside of the electric motor of

the scooter. Magnets are installed inside the housing of the motor in order to create a magnetic

field. Coils placed inside the motor carry an electric current from the battery source with a

component called the commutator attached to the end of these coils. The purpose of the

commutator is that it continuously reverses the electric current in the coils. Electric power is fed

into the commutator through objects called brushes, which come in “brush” with the

commutator. The alternating electric field created in the coils is then continually propelled to

rotate in the presence of the static magnetic field from the batteries. Figure 2 shows a simple

schematic of how this all works.

Fig. 2 – Simplified diagram of how an electric motor functions. Notice how the commutator allows for the current

from the battery to continually be reversed in the coil.

The motion created by the rotating coils is then used to rotate the driveshaft. At the end of

the drive shaft is a toothed gear called a sprocket. The sprocket is designed to have its teeth on

the outer edge to correlate with the spacing of the links of a roller chain. The sprocket on the

motor is quite small with only ten teeth. One end of the roller chain is wrapped around the motor

sprocket while the other end is attached to the wheel sprocket. The chain is comprised of two

distinct pieces, an inner and outer link. There are 32 of each, alternating and connect at their

respective ends by small pins. The chain used in this scooter assembly was a standard #25 roller

chain.

The sprocket that is connected the wheel is a much larger sprocket than the one of the

motor, containing 30 teeth. Holes are placed in this sprocket to allow it to be attached to the

clutch and wheel mount. As torque from the motor is created, the motor sprocket uniformly pulls

on the links of the chain. This rotation is translated across the whole length of the chain back to

the larger sprocket. The larger sprocket is consequently made to rotate as well spinning the tire in

the desired direction. This is what allows for propulsion of the tire and the scooter to be driven.

An additional part is added to this assembly to increase the overall effectiveness. The

chain tensioner is a piece that, as the name implies, creates tension on the underside of the roller

chain. A spring runs from a small hole in the frame to the chain tensioner. This forces the

Group 6 pg. 77

spinning roller of the tensioner to press against the bottom of the chain near the wheel sprocket.

This keeps the chain tight so that no links will slip off either of the sprocket teeth. [Design

Report 2]

Brake Assembly

During the operation of the scooter it is important for the rider to have an efficient and

safe means of stopping. The brake assembly works in tandem with the brake cable and the brake

drum on the rear axle to stop the scooter. The brake cable is connected to a latch, which is fixed

to the frame of the brakes, or the brake casing. The latch is also connected to a flexible metal

strip that can bend significantly without plastic deformation. A ceramic pad is screwed to the

metal strip and the other side of the metal strip is fixed to the brake casing. As the brake cable is

pulled it rotates the latch, which then contracts the brake caliper. The brake caliper contracts

until it contacts the brake drum attached to the rear axle. The brake caliper turns the rotational

energy of the rear axle into thermal energy through friction and the rear axle comes to a stop.

The brake cable is attached to the latch by a screw with a hole near the head. The screw

passes through a hole in the latch arm and, when tightened, pins the cable against the latch arm.

When the brake cable is pulled, it will pull on the end of the latch arm. Since the latch arm is

fixed at its vertex, this will cause a torque equal to the linear force applied by the brake cable

multiplied by the length of the latch arm. This rotational force will cause both arms to rotate in

the direction of the cable. This movement is diagramed in Fig. 3.

Fig. 3 – The brake cable provides a linear force on the latch arm (shown in red) that causes a rotational force (shown

in green) about the center of the latch. This will cause the other arm to rotate and pull on the end of the brake

caliper.

Group 6 pg. 78

The other arm of the latch will then rotate in the same direction as the force of the brake

cable, pulling on the end of the brake caliper. Since the brake caliper is attached to the brake

casing at the other end, the brake caliper will contract into a smaller diameter until it contacts the

brake drum.

Fig. 4 – The photo shows the motion of the latch and the caliper when the upper latch arm is pulled to the left. The

other latch arm rotates and pulls the brake caliper in creating a smaller diameter.

The brake caliper will cause a frictional force on the brake drum and will absorb the

rotational motion as heat. The brake drum is attached to the rear axle and the friction applied to

the brake drum will also stop the rotation of the rear axle, stopping the motion of the scooter.

However, once the brake cable is released, the brake caliper must return to its original

position to release the brakes. Since the brake cable can only act by pulling on the latch, the latch

will not automatically rotate back to reset the brake caliper once the brake cable is released.

Therefore, to return the latch and the brake caliper back to their original positions, a torsional

spring is hooked onto the latch arm and rests against the brake casing. The torsional spring acts

against the brake cable. As the brake cable rotates the latch arm (counter-clockwise at this view)

the torsional spring is compressed and creates an opposing force to rotate the latch back

(clockwise) to the original position. When the brake cable is pulled it overpowers the torsional

spring but when it is released the torsional spring acts to reverse the motion. Fig. 5 shows the

unobstructed view of the torsional spring and the rotation force it provides on the latch.

Group 6 pg. 79

Fig. 5 – The torsional spring has one coil, the diameter of which is concentric with the hole on in the latch

vertex. One arm rests against the wall of the brake casing, the other hooks around the latch arm to pull it in the

direction shown in blue.

Once the brake cable is released, the force of the torsional spring will pull the latch arm

to rotate in the direction shown in blue in Fig. 5. The torsional spring will return the latch to its

original position and the latch arm will allow the brake caliper to unbend back to its original

position, thereby releasing the brakes. In conclusion, using the brake cable and the torsional

spring to control the rotation of the latch, the brake cable can control the contraction of the brake

caliper and by relation, the frictional force applied to the brakes. [Source: Design Report 2]

Group 6 pg. 80

Thermal Analysis

During an analysis of our motor it is also important to estimate the losses that

occur. The most significant loss that occurs in the motor is loss due to heat. The

calculations performed in this analysis are for a motor operating freely under no load.

As mentioned before, the main loss in power is going to be through heat loss. The

other losses are small and can be ignored for this estimation. Using an energy balance of

the power of the motor, with the sum of the powers equaling zero, we can find the heat

loss in relation to the input and output power of the motor.

P 0 Pin Pout Ploss

Ploss Pin Pout

Then we can also relate the input and output for the motors to the motor

efficiency. We define the motor efficiency as the ratio of power gained as the power input

into the system. With that definition we can relate the power lost to the performance

efficiency.

Pout

Pin

Pin Pout

Ploss Pout

Pout

Ploss Pout

1

1

The efficiency was determined from a data set of standard average motor

efficiencies for motors of certain sizes. The data was fit with a linear regression line and

the line equation used to determine the efficiency for a motor at the same power usage at

which our motor runs. The fitted curve is shown in the graph below.

Group 6 pg. 81

Fig. 6 – The curve fit for the data uses a logarithmic approximation. The initial increase in motor sizes

results in a large jump in power efficiency.

Our motor runs at about 640 watts, or 0.86 horsepower. From the logarithmic fit,

our motor has an efficiency of about 77.7%. This efficiency represents the performance

of motor under no load. When a load is applied the motor efficiency will become lower

and the heat losses greater. Finally, plugging in the efficiency and using 640 watts as the

power out, we can estimate the thermal power loss.

Ploss 6401

.7771

180.26

Therefore, about 180 watts are lost due to heat during operation of the motor. The

heat loss accounts for approximately 22% of the power put into the system.

Group 6 pg. 82

Electrical and Control Analysis

The Charging Process

When the scooter is plugged in, the charging cord converts the 120 volts from the wall into the

22.2 volts of the battery. The charge travels through the charging port and into the controller

which than routes the charge into the batteries for storage. [Source: Design Report 2]

Operating the Scooter

To operate the scooter, the ON/OFF switch is moved to the ON position to close the circuit.

Once the circuit is closed, the throttle is twisted which sends a signal to the controller that pulls

power from the battery and sends it to the motor with uses the voltage to spin and rotate the

motor. This throttle is a proportional control, which means that speed the motor rotates is

proportionally dependent on the amount that the throttle is twisted. Due to the use of a LiPo

battery a low voltage indicator was added to the electrical circuit to alert the user when the

battery reaches 3V.

Group 6 pg. 83

Standard Parts List

Table 5: Off the Shelf Parts

Part Name Source Part Number

Quantity Weight Total

750W Motor Electric Parts

1 6.5 6.5

6S LiPo Battery 1 5.6 5.6

Tension Spring MC 9044K203 1 0.00145 0.00145

Fork Guide Old Sc 2 0.0254 0.0508

Bearing Washer Old Sc 2 0.01 0.02

Axle Ring Old Sc 1 0.03 0.03

Fork Bar Lower Nut Old Sc 1 0.0353 0.0353

Fork Bar Washer Old Sc 1 0.00372 0.00372

Fork Bar Top Nut Old Sc 1 0.02 0.02

Wheel Ball Bearing Old Sc 4 0.0272 0.1088

Socket Drive Post Set MC 97851A204 1 0.06 0.06

Button Connector Handle MC 92988A510 6 0.01 0.06

Motor Twist Holder Electric Parts

1 0.14 0.14

Motor Twist Electric Parts

1 0.02 0.02

Right Grip Electric Parts

1 0.0795 0.0795

Left Grip Electric Parts

1 0.13 0.13

Brake Handle Electric Parts

1 0.3 0.3

Button Connector Rails MC 92988A530 8 0.0158 0.1264

End Nut MC 93827A245 2 0.0452 0.0904

Thin Washer MC 93286A029 1 0.00145 0.00145

Rear Axle MC 23595T16 1 0.06 0.06

Medium Rear Washer MC 93286A031 2 0.00266 0.00532

Split Luck Washer MC 92147A030 2 0.00507 0.01014

Tensioner Nut MC 90591A151 1 0.00115 0.00115

Motor Mount Screw MC 91280A421 2 0.0273 0.0546

Motor Mount Nut MC 90591A154 2 0.00657 0.01314

Processor Old Sc 1 0.157 0.157

Low Voltage Processor Quadcopter 1 0.05 0.05

ON/OFF Button Electric Parts

1 0.00821 0.00821

Reset Button Electric Parts

1 0.02 0.02

Reset Button Nut MC 93827A245 1 0.0011 0.0011

Battery Plug Electric Parts

1 0.01 0.01

Group 6 pg. 84

Battery Plug Cap Electric Parts

1 0.00418 0.00418

Battery Plug Nut MC 93827A241 1 0.00187 0.00187

Processor Screw MC 92005A220 2 0.00339 0.00678

Battery Box Screw MC 92005A222 8 0.00372 0.02976

Deck Hinge MC 1637A713 2 0.00392 0.00784

Deck Hinge Screw MC 91420A112 8 0.000515 0.00412

Brake Locator Screw MC 94792A424 1 0.002 0.002

Folding Deck Locator Screw MC 91735A013 2 0.00271 0.00542

Old Sc: Part used from Razor E300 scooter MC: McMaster Carr Electric Parts: Electric Scooter Parts.com Quadcopter: Quadcopter.com

Group 6 pg. 85

Custom Parts List

Table 6: Custom Parts List

Part Name Quantity Weight Total

Frame Rail 2 0.69 1.38

Frame Front Section 2 0.11 0.22

Frame Rear Section 2 0.53 1.06

Deck Plate 2 0.67 1.34

Arc 2 0.05 0.1

Revolving Axis Arm Male 1 0.006 0.006

Revolving Axis Arm Female 1 0.004 0.004

Clip 4 0.000044 0.000176

Lock Rod 1 0.01 0.01

Lock Rod Spacer 2 0.00011 0.00022

Fork Holer Arm 1 0.12 0.12

Fork 1 0.19 0.19

Front Bearing Rod 1 0.00403 0.00403

Front Wheel Rim 1 0.27 0.27

Tube 2 0.06 0.12

Tire 2 0.0775 0.155

Telescoping Tube 1 1 0.08 0.08




Handle Bar Single 2 0.0584 0.1168

Front Wheel Hub 1 0.076 0.076

Frame Front Wing 1 0.165 0.165

End Caps 4 0.00817 0.03268

Rear Wheel Hub 1 0.22 0.22

Rear Wheel Hub 1 0.0369 0.0369

Brake Drum 1 0.08 0.08

Rear Bearing Rod 1 0.0455 0.0455

Brake Casing 1 0.03 0.03

Brake Latch 1 0.0151 0.0151

Case Pin 1 0.000948 0.000948

Brake Caliper 1 0.0296 0.0296

Latch Washer 1 0.000529 0.000529

Latch Nut 1 0.00163 0.00163

Brake Torsional Spring 1 0.00116 0.00116

Small Spacer 1 0.00196 0.00196

Washer with Cut 1 0.00637 0.00637

Rear Wheel Support Left 1 0.118 0.118

Rear Wheel Support Right 1 0.116 0.116

Group 6 pg. 86

Motor Mount 1 0.17 0.17

Chain Tensioner 1 0.02 0.02

Chain Tensioner Spring 1 0.00573 0.00573

Chain 1 0.09 0.09

Tensioner Screw 1 0.00354 0.00354

L-Channel 2 0.12 0.24

Battery Tub 1 0.5 0.5

Battery Box Impact Cage 1 0.12 0.12

Battery Tub Cover 1 0.159 0.159

Silicone Deck Padding 2 0.03 0.06

Brake Locator 1 0.00451 0.00451

Brake Locator Washer 2 0.000947 0.001894

Chain Side Guard 1 0.118 0.118

Brake Side Guard 1 0.0862 0.0862

Folding Deck Locator 2 0.0052 0.0104

Folding Deck Locator Silicone

Pad

2 0.00143 0.00286

Folding Deck Spacer 2 0.00044 0.00088

Clutch/Sprocket 1 0.36 0.36

Group 6 pg. 87

Cost Analysis

When solving for the overall manufacturing costs and sales price of the scooter several

steps and assumptions were taken. The total manufacturing cost of the scooter come from the

direct labor and the indirect labors that it takes to make one complete scooter assembly. The

direct labor costs come directly from manufactured custom parts, commercial off the shelf parts,

and direct labor cost of the assembly. It is important to note that all calculations were based from

an order quantity of 100,000 scooters.

The scooter was designed with many custom parts made out of different materials and

processes. For example, the custom parts of the wheels are composed of magnesium alloy hubs,

polypropylene rims, butyl rubber inner tubes, and rubber tires. Using customparts.net we were

able to find a cost estimate per part for die casting of the hub and plastic injection molding for

the rims. Using an external manufacturer we calculated the cost of the inner tube and the tires

from an alibaba.com supplier from China that makes custom orders. Other parts like the bearings

and the inner bearing rods of the wheels were off the shelf parts from McMaster Carr. When

dealing with certain custom parts like the rear wheel hub that has threaded features an extra

machining cost was added for the addition of holes and threads.

To calculate for the structural rails and the handle bars an overall weight was taken. By

using the cost of magnesium alloy per unit weight for extrusion applications we found the

manufacturer that would provide pre-cut lengths for all the structural components of the frame.

All buttons pins used for the handle bars and rails were off the shelf parts from McMasters.

The motor was an off the shelf part from electricscooterparts.com. To mount the motor to the

assembly we used custom parts and off the shelf parts. The motor mount was calculated as a

magnesium die casted part from customparts.net. Nuts and washers were calculated as off the

shelf parts from McMaster Carr.

Since we scaled down many parts from the Razor E300 we used those prices as

references. In the scooter design the brake assembly, clutch, and brake drum assembly were all

used. The price of the E300 was used as a references point but this was assumed to be 200%

more expensive due to its smaller size and magnesium components. Other parts like the brake

casing and the brake drum were calculated from customparts.net as die casted parts using

magnesium alloy.

Some of the major components that were off the shelf parts are the front axle (Socket

Drive Post), the Tattu 6S Lipo battery, controller, reset buttons, ON/OFF switch, charger port,

charger, grips for the handle bar, throttle, brake lever, an brake cable among others. These were

all used as a reference price at times. Some of our springs were custom made, but we used

similar McMaster Carr springs as a reference price as well as other parts such as spacers and

rods.

Overall when dealing with custom parts we used plastic injection molding estimators

(side guards, battery box, wheel rims), die casting for magnesium alloy (brake casing, motor

mount, folding mechanism parts), and extrusion applications. An extra uncertainty cost was

added for polished coatings of certain parts and extra machining costs. Tables 7 and 8 show the

list of prices of all prices used in the scooter. Appendix B shows the estimators from

customparts.nets that were used as well as some off the shelf part as guidance for the steps and

processes that were taken to perform a cost analysis.

Group 6 pg. 88

Knowing the total assembly time, commercial off the shelf parts price, and manufactured

parts price the total direct cost of making one scooter can then be solved for as seen below:

𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡

= (𝐴𝑠𝑠𝑒𝑚𝑏𝑙𝑦 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) + (𝐶𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑂𝑓𝑓 𝑡ℎ𝑒 𝑆ℎ𝑒𝑙𝑓 𝑃𝑎𝑟𝑡𝑠)+ (𝑀𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑒𝑑 𝑃𝑎𝑟𝑡𝑠)

Where, the assembly direct cost is assumed to be $50 per hour. The Commercial of the

shelf parts are 50% of the catalogue price due to the large quantity of 100,000 units. Finally, the

manufactured parts are the full cost of producing the custom parts.

To get the total cost of making one scooter we add the total direct cost and the indirect

cost. Where the indirect cost is the total direct cost times a constant K, which in this case is

assumed to be 0.5. 𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 = 𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡

𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 = (𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) × 𝐾

Because we want to make money as an electric scooter company we get the sales price to

be twice of the total direct cost in order to break even and have a good profit, as seen in the

relation below. 𝑆𝑎𝑙𝑒𝑠 𝑃𝑟𝑖𝑐𝑒 = (𝑇𝑜𝑡𝑎𝑙 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) × 2

Commercial Off The Shelf

Parts $549.84

Assembly Direct Cost $15.08

Manufactured Custom Parts $96.50

Total Direct Cost $661.42

Indirect Cost $330.71

Total Cost (Indirect plus

Direct) $992.13

Sales Price $1,984.27

Assembly

Time 18.1 min

K constant

for indirect

cost

0.5

Group 6 pg. 89

Table 7: Off the Shelf Parts Prices

Part Part # Quantity Cost/part Price

Motor XYD-6B 1 $139.95 $69.98

Battery SKU-2162 1 $570.00 $285.00

Socket Drive Post 97851A204 1 $21.50 $10.75

Rod Clip 51055K413 1 $0.23 $0.12

Sproket 2737T236 1 $17.55 $8.78

Wheel Nut Axle 91982A300 2 $3.63 $3.63

Charger for Battery iCharger208B 1 $126.99 $63.50

Inner Bearing Rod 6391K212 2 $0.84 $0.84

Grips Elec Scoot 2 $3.95 $3.95

Chain Elec Scoot 1 $5.76 $2.88

Case Pin 90145A418 1 $0.95 $0.47

Latch Nut 91841A155 1 $0.08 $0.04

Latch Pin 95648A530 1 $0.30 $0.15

Latch Washer 96659A102 1 $0.03 $0.02

Medium Washer Wheel 91455A140 2 $0.09 0.0897

Wheel Thin Washer 91455A440 1 $0.11 0.0549

Wheel Washer with Cut 91455A180 1 $0.12 0.06035

Wheel Split Washer 91190A560 2 $0.08 $0.08

Silicone Rubber Deck 5787T33 2 $4.37 $8.74

Torsional Spring 9271K631 2 $5.81 $5.81

Brake Lever Elec Scoot 1 $15.95 $7.98

Brake Cable Elec Scoot 1 $2.95 $1.48

On/Off Elec Scoot 1 $5.95 $2.98

Reset Elec Scoot 1 $7.95 $3.98

Speed Controller Elec Scoot 1 $35.95 $17.98

Throttle Elec Scoot 1 $21.95 $10.98

Charger Port Elec Scoot 1 $7.95 $3.98

Wheel Small Spacer 2868T38 1 $0.36 $0.18

Low Voltage Cut-Off Quadcopter 1 $25.99 $13.00

Front Fork Bearing Elec Scoot 1 $11.95 $5.98

Button Pins 94282A290 14 $0.74 $5.15

Group 6 pg. 90

Tensioner Screw 92327A279 1 $2.31 $1.16

Motor Mount Spacer 2868T38 1 $0.36 $0.18

Folding Spring 9654K286 1 $0.63 $0.31

End Caps 9474K42 4 $0.25 $0.51

Wheel Bearing 6383k160 4 $4.57 $9.14

Table 8: Custom Parts Prices

Part Amount Cost/part Price

Custom Brake Caliper 1 $1.77 $1.77

Custom Brake Casing 1 $1.37 $1.37

Custom Brake Latch 1 $1.13 $1.13

Custom Clutch 1 $14.95 $14.95

Alibaba Magnesium 6.21 $9.09 $56.45

Custom Motor Mount Top 1 $1.70 $1.70

Custom Chain Tensioner New 1 $0.09 $0.09

Custom Arc 2 $1.33 $2.66

Custom Brake Drum 1 $0.90 $0.90

Alibaba Inner Tube 2 $1.25 $2.50

Nashbar Tire 2 $2.50 $5.00

Custom Black Battery Box 1 $1.81 $1.81

Custom Lid for Battery Box 1 $1.17 $1.17

Custom Chain Side Guard 1 $0.92 $0.92

Custom Front Rim Wheel 1 $1.61 $1.61

Custom Rear Wheel Rim 1 $1.61 $1.61

Custom Brake Side Guard 1 $0.84 $0.84

Group 6 pg. 91

APPENDIX A

SOLIDWORKS DRAWINGS

Group 6 pg. 92

31.09 ±0.24 37.09 ±0.29

47.

53 ±

0.38

4

0.42

±0.

32

16.

24 ±

0.12

Scooter AssemblyUnfolded

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Dimensions in inches

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Group 6 pg. 93

22.84 ±0.18

11.

64 ±

0.09

8.06 ±0.06

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Group 6 pg. 94

A2

A1

1

A3

242

Part/Assembly Number

Part/Assembly Name QTY

1 Frame Rail 2

2 Button Connector 8

3 End Cap 4

A1 Front Section Assembly 1

A2 Handlebars Assembly 1

A3 Rear Section Assembly 1

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Group 6 pg. 95

13

A4

14

15

6

7

8

54

17

16

9

10

12 11

18

19

20

21Part/Assembly

NumberPart/Assembly

Name QTYA4 Wheel Assembly 14 Front Section 15 Lock Rod 16 Tension Spring 17 Lock Rod Spacer 28 Clip 4

9 Deck Locator Washer 2

10 Deck Locator Silicon Pad 2

11 Deck Locator Screw 2

12 Deck Locator 213 Socket Female 114 Socket Male 115 Fork 116 Fork Guide 217 Fork Holder Arm 118 Bearing Washer 219 Fork Bar Lower Nut 120 Fork Bar Washer 121 Fork Bar Top Nut 1

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Group 6 pg. 96

2

22

23

24

25

2627

28

29

30

31

Part Number Part Name QTY2 Button Connector 622 Telescoping Tube 1 123 Telescoping Tube 2 124 Telescoping Tube 3 125 Telescoping Tube 4 126 Motor Side Grip 127 Motor Twist 128 Motor Twist Holder 129 Handle Bar 230 Brake 131 Brake Side Grip 1

Handlebar ExplodedAssembly


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Group 6 pg. 97

32

33

36 3837 40 41 A5

42

43

44

45

46474849A6

39

34

35

Rear Assembly


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Group 6 pg. 98

Part/Assembly Number

Part/Assembly Name QTY

A5 Rear Axle Assembly 1A6 Battery Tub

Assembly 1

32 Rear Section 133 Chain Link

Assembly 134 Deck Hinge 235 Deck Hinge Screw 836 Chain Tensioner 137 Chain Tensioner

Nut 1

38 Chain Tensioner Spring 1

39 Chain Tensioner Screw 1

40 Deck 141 Folding Deck

Locator Silicon Pad 2

42 Brake Locator 143 Brake Locator Nut 144 Brake Locator

Screw 145 Brake Side Guard 146 Chain Side Guard 147 Motor Mount Nut 148 Motor Mount 149 Motor Mount

Screw 1

Rear AssemblyExploded

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Group 6 pg. 99

53 54 55 56

Part Number Part Name QTY53 Front Wheel Rim 154 Front Wheel Hub

Assembly 1

55 Tube 156 Tire 1

Front Wheel AssemblyExploded


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Group 6 pg. 100

50 51 52 50

Part Number Part Name QTY50 Wheel Ball Bearing 251 Front Wheel Hub 152 Front Bearing Rod 1

Wheel Front Hub Assembly Exploded


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Group 6 pg. 101

6060

61

69

68

A8

67

65

66

A7

64

63

62

61

Part Number Part Name QTY60 End Nut 261 Split Lock Washer 2

62 Medium Rear Washer 1

63 Washer with Cut 164 Small Spacer 165 Rear Axle 1A7 Clutch 166 Rear Wheel

Assembly 1

67 Brake Drum 168 Thin Washer 1A8 Brake Assembly 169 Medium Washer 1

Rear Axle Exploded


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Group 6 pg. 102

88

8990

91

92

93 95 96 97

98

99 100

94

Part Number Part Name QTY88 Battery Cover Screws 489 Tub Cover 190 Processor Screws 291 Processor 192 Battery 193 Battery Tub 194 ON/OFF Switch 195 Reset Button 196 Reset Button Nut 197 Charger Port Nut 198 Charger Port 199 Charger Port Cap 1100 Battery Impact Cage 1

Battery Box Assembly


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DRAWING BY:Jose Andre Cortes

Group 6 pg. 103

78

86 79

85

80

80

81

82

83

84

87

85

Part Number Part Name QTY78 Clutch Big Side 179 Clutch Spring 180 Ball Bearing 281 Clutch Washer 4 182 Clutch Washer 3 183 Clutch Washer 2 184 Clutch Washer 1 185 Test Rocker 286 Sprocket 187 Clutch Small Side 1

New Clutch Explode


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Group 6 pg. 104

75

74 71

7772

76

70

73

Part Number PartName QTY70 Brake Casing 171 Brake Latch 172 Case Pin 173 Brake Caliper 174 Latch Washer 175 Latch Nut 176 Brake Torsional

Spring 177 Latch Pin 1

Brake AssemblyExploded


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Group 6 pg. 105

2.0

0 ±0

.02

0.09 ±0.01

22.

75 ±

0.18

2.00 ±0.02 10.00 ±0.08 14.00 ±0.11 20.75 ±0.16

0.38 ±0.01

Frame Rail Single


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Group 6 pg. 106

0.1

0 ±0

.01

0.3

5 ±0

.01

2.00 ±0.02

1.0

0 ±0

.01

0.8

1 ±0

.01

0.7

4 ±0

.01

1.81 ±0.02 1.74 ±0.01

0.09 ±0.01 0.91 ±0.01 1.00 ±0.01

Frame End Cap


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Group 6 pg. 107

R2.30 ±0.02

R2.01 ±0.00

3.00 ±0.03

1.87

±0.01

135° ±1°

0.60 ±0.01 0.27 ±0.01

R0.17 ±0.01 0.2

9 ±0

.01

0.2

0 ±0

.01

0.26 ±0.01

R0.33 ±0.01

R0.28 ±0.01

0.26

±0.01

0.66

±0.01

1.23

±0.01

0.60

±0.01

R1.47 ±0.01

0.4

8 ±0

.01

0.75 ±0.01

R0.39 ±0.01

0.2

0 ±0

.01

Arc


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Group 6 pg. 108

0.1

0 ±0

.01

45.

83° ±

1°

2.44

±0.02

0.60 ±0.01

0.36 ±0.01

2.9

8 ±0

.00

1.23 ±0.01 2.93 ±0.02 4.77 ±0.04 6.47 ±0.05 7.70 ±0.06

0.7

4 ±0

.01

0.1

8 ±0.0

1

#10-24 Threaded Holes .

Frame Front Wing


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Group 6 pg. 109

0.

30 ±

0.01

0.22

±0.

01

0.

13 ±

0.01

0

.62

±0.0

1 0

.64

±0.0

1 1

.54

±0.0

1 1

.61

±0.0

1 2

.51

±0.0

2 2

.53

±0.0

2 3

.15

±0.0

3

Lock Rod


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Group 6 pg. 110

0.

39 ±

0.01

0.30

±0.

01

0.0

6 ±0

.01

Lock Rod Spacer


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Group 6 pg. 111

0.2

8 ±0

.01

0.22 ±0.01

R0.11 ±0.01

0.0

2 ±0

.01

Rod Clip


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Group 6 pg. 112

0.

25 ±

0.01

0.19

±0.

01

0.0

6 ±0

.01

Fold Deck Spacer


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Group 6 pg. 113

1.91±0.02

0.47±0.01

0.95±0.01

0.58±0.01

3.05±0.03

1.84±0.02 1.21±0.01

1.84±0.02 1.21±0.01

0.20±0.01 0.20±0.01 0.41±0.01

R0.05±0.01

Note: All filletshave radius 0.05 in

Deck UnfoldedLocation Metal

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Group 6 pg. 114

1.1

4 ±0

.01 1.40 ±0.01

0.

91 ±

0.01

1.14

±0.

01

1.

25 ±

0.01

0.3

8 ±0.0

1

0.81 ±0.01

86.22° ±1°

0.3

8 ±0.0

1

0.5

0 ±0

.01

5.5

6 ±0

.04

6.1

0 ±0

.05

6.0

0 ±0

.05

10.

15 ±

0.08

0.10 ±0.01

Fork


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Group 6 pg. 115

1.

74 ±

0.01

1.21

±0.

01

0.06 ±0.01

0.1

6 ±0

.01

0.3

1 ±0

.01

0.7

7 ±0

.01

R0.21 ±0.01

Fork Guide


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Group 6 pg. 116

0.08 ±0.01 1.18 ±0.01 1.25 ±0.01

0.61 ±0.01

0.18 ±0.01

0.25 ±0.01

0.4

0 ±0

.01

1.6

5 ±0

.01

2.5

0 ±0

.02

3.0

2 ±0

.02

3.9

7 ±0

.03

1.50 ±0.01

2.32 ±0.02

0.30 ±0.01

1.32 ±0.01 0.08 ±0.01

Fork Holder Arm


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Group 6 pg. 117

0.2

9 ±0

.01

0.4

6 ±0

.01

0.2

5 ±0

.01

1.

97 ±

0.02

1.

16 ±

0.01

1.4

1 ±0

.01

1.

85 ±

0.02

Fork Bar Lower Nut


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Group 6 pg. 118

0.0

7 ±0

.01

1.

41 ±

0.01

1.16

±0.

01

Fork Bar Washer


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Group 6 pg. 119

0.3

6 ±0

.01

1.41 ±0.01 1.

16 ±

0.01

Fork Bar Top Nut


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Group 6 pg. 120

0.

91 ±

0.01

0.81

±0.

01

0.3

0 ±0

.01

10.

00 ±

0.08

0.38 ±0.01

Telescoping Tube 1


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Group 6 pg. 121

0.

81 ±

0.01

0.71

±0.

01

0.3

0 ±0

.01

8.7

3 ±0

.07

9.0

3 ±0

.07

0.05 ±0.01

0.38 ±0.01

Telescoping Tube 2


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Group 6 pg. 122

0.

71 ±

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0.

61 ±

0.01

0.38 ±0.01

0.05 ±0.01

0.3

0 ±0

.01

8.7

3 ±0

.07

9.0

3 ±0

.07

Telescoping Tube 3


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Group 6 pg. 123

4.00 ±0.03

0.38 ±0.01

0.3

0 ±0

.01

8.5

5 ±0

.07

0.05 ±0.01

0.

96 ±

0.01

0.86

±0.

01

Telescoping Tube 4


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Group 6 pg. 124

0.

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0.76

±0.

01

0.5

0 ±0

.01

7.5

0 ±0

.06

0.38 ±0.01

Handlebar Single


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Group 6 pg. 125

1.96±.02 A

12.00±.10

2.19±.02 1.09±.01

2.00±.02

1.15±.01 .96±.01

DETAIL ASCALE 2 : 3

Rear SectionSingle


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Group 6 pg. 126

7.6

9 ±0

.06

14.22 ±0.12

0.12 ±0.01

0.2

1 ±0

.01

1.3

3 ±0

.01

6.3

6 ±0

.05

7.4

8 ±0

.06

#5-44 Threaded Holes...

0.1

0 ±0

.01

Frame Rear Deck


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Group 6 pg. 127

Chain Link Assembly


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32 chain links


Group 6 pg. 128

R0.40 ±0.01

0.

47 ±

0.01

0.32

±0.

01

0.33 ±0.01 1.95 ±0.02 2.17 ±0.02

0.4

4 ±0

.01

0.30 ±0.01

100° ±1°

R0.31 ±0.01

0.

50 ±

0.01

R0.20 ±0.01

0.

35 ±

0.01

0.

82 ±

0.01

0.2

2 ±0

.01

0.3

3 ±0

.01

0.3

5 ±0

.01

0.1

2 ±0

.01

0.1

7 ±0

.01

0.2

3 ±0

.01

0.2

4 ±0

.01

0.6

7 ±0

.01

0.7

2 ±0

.01

0.7

4 ±0

.01

0.8

0 ±0

.01

147.49° ±1°

Chain Tensioner


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1


Jonathan FrancoDRAWING BY:

Group 6 pg. 129

0.3

0 ±0

.01

0.1

5 ±0.0

1

0.1

5 ±0

.01

0.8

6 ±0

.01

1.85 ±0.02 1.97 ±0.02

0.31 ±0.01

Brake Locator


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 130

0.0

5 ±0

.01

0.1

5 ±0

.01

0.3

0 ±0

.01

R1.50 ±

0.01 5.52 ±0.04

R2.00 ±0.02

1.2

6 ±0

.01

6.50 ±0.05 6.38 ±0.05

6.61 ±0.05 6.83 ±0.05 7.51 ±0.06 8.42 ±0.07 8.52 ±0.07

1.6

1 ±0

.01

0.3

5 ±0

.01

1.1

1 ±0

.01

2.0

9 ±0

.02

0.10 ±0.01

Brade Side Guard


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 131

0.9

0 ±0

.01

1.0

0 ±0

.01

1.0

5 ±0

.01

R1.50 ±0.01

5.52 ±0.04 R2.00 ±0.02

1.2

6 ±0

.01

6.50 ±0.05 1

.26

±0.0

1 1

.61

±0.0

1 2

.31

±0.0

2

6.61 ±0.05

7.51 ±0.06

8.52 ±0.07 8.42 ±0.07

0.10 ±0.01

0.

18 ±

0.01

0.3

5 ±0

.01

6.83 ±0.05

chain side guard


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 132

0.3

7 ±0

.01

0.7

6 ±0

.01

2.0

0 ±0

.02

2.2

5 ±0

.02 R2.00 ±0.02 0

.25

±0.0

1 0.28 ±0.01

0.43 ±0.01 0.25 ±0.01

2.25 ±0.02 2.50 ±0.02 4.50 ±0.04 4.75 ±0.04

516 - 18 Threaded Holes .

4.75 ±0.04

0.7

5 ±0

.01

Motor Mount


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 133

2.00±.02

.18±.01 X 2Internally

Threaded#8

4.50±.04

.35±.01

.32±.01

1.68±.01 1.00±.01

.50±.01

62.04°

.10±.01

.10±.01

.30±.01

.40±.01

1.90±.01

Rear Wheel Support Left


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1


DRAWING BY:Jose Andre Cortes

Group 6 pg. 134

4.50±.04

2.08±.02

1.00±.01

.32±.01

.35±.01 .32±.01

.35±.01

R.19±.01

R.10±.01

R.10±.01

.70±.01

2.51±.02

62.04°

.50±.01

Internally Threaded#8

.40±.01

1.80±.01 2.00±.02

Rear WheelSupport Right


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 135

6.48±.00

1.07±.01

.67±.01 5.41±.04

5.82±.05

ExternallyThreaded

.47±.01 .38±.01

Rear Axle


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 136

0.0

5 ±0

.01

1.0

5 ±0

.01

1.1

0 ±0

.01

5.

00 ±

0.04

3.70

±0.

03

3.

00 ±

0.02

1.

46 ±

0.01

1.00

±0.

01

0.09 ±0.01

0.55 ±0.01

R0.

78 ±

0.01

0.

32 ±

0.01

R0.50 ±0.01

Rim Wheel Frame


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 137

0.4

8 ±0

.01

0.6

8 ±0

.01

1.1

5 ±0

.01

1.

46 ±

0.01

1.04

±0.

01

0.

86 ±

0.01

0.09 ±0.01

Front Wheel Hub


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 138

0.2

5 ±0

.01

1.8

8 ±0

.01

2.0

8 ±0

.02

3.7

7 ±0

.03

4.0

2 ±0

.03 Externally threaded 0.35 inches

1-8 threads

Externally threaded 0.42 inches1-8 threads

2.

20 ±

0.02

0.97

±0.

01

0.

86 ±

0.01

0.83

±0.

01

0.20 ±0.01

Rear-Wheel Hub


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 139

0.3

8 ±0

.01

2.

21 ±

0.02

2.12

±0.

02

0.

93 ±

0.01

1.

06 ±

0.01

1.03

±0.

01

0.23 ±0.01

1-8 Threaded Hole

Brake Drum


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 140

0.5

4 ±0

.01

0.1

8 ±0

.01

4.4

7 ±0

.04

4.8

3 ±0

.04

5.0

1 ±0

.04

0.90 ±0.01 0.71 ±0.01 0.20 ±0.01

0.1

0 ±0

.01

Battery Tub Cover


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 141

0.45 ±0.01 0.65 ±0.01

1.76 ±0.01

0.33 ±0.01

1.47 ±0.01

5.38 ±0.05 10.28 ±0.08 11.75 ±0.09

0.1

2 ±0

.01

0.8

2 ±0

.01

1.7

0 ±0

.01

2.8

0 ±0

.02

3.1

1 ±0

.03

0.3

9 ±0.0

1

0.6

2 ±0.0

1

0.

33 ±

0.01

0.17

±0.

01

0.

18 ±

0.01

0.20 ±0.01

0.85 ±0.01 0.90 ±0.01 4.96 ±0.04 10.08 ±0.08 10.85 ±0.09

0.7

3 ±0

.01

0.9

0 ±0

.01

2.0

7 ±0

.02

3.4

0 ±0

.03

#10-32 Threaded Holes.

0.4

4 ±0

.01 1.77 ±0.01

0.3

9 ±0

.01

Battery Tub


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 142

0.1

8 ±0

.01

0.6

1 ±0

.01

0.7

6 ±0

.01

0.9

6 ±0

.01

1.1

0 ±0

.01

2.5

0 ±0

.02

0.09 ±0.01 0.29 ±0.01 0.92 ±0.01 1.16 ±0.01 1.41 ±0.01 6.14 ±0.05

0.18 ±0.01

0.1

0 ±0

.01

0.20 ±0.01

Battery Box Impact Cage


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 143

1.

38 ±

0.01

R0.47 ±0.01

R0.48 ±0.01

0.2

4 ±0

.01

0.2

1 ±0

.01

0.10 ±0.01 0.09 ±0.01

0.0

3 ±0

.01

0.1

1 ±0

.01

0.1

8 ±0

.01

0.2

2 ±0

.01

0.2

9 ±0

.01

0.4

2 ±0

.01

0.09 ±0.01 0.16 ±0.01 0.62 ±0.01 0.73 ±0.01

R0.60 ±0.01

R0.53 ±0.01

R0.06 ±0.01 1-8 Threaded Hole

Clutch Big Side


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Part scaled down to 70%of original scooter

Group 6 pg. 144

R0.83 ±0.01

R0.80 ±0.01

0.0

3 ±0.0

1

0.1

1 ±0

.01

0.15 ±0.01

Clutch Spring for Assembly N


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 145

0.

12 ±

0.01

Clutch Ball Bearing


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 146

1.

73 ±

0.02

1.54

±0.

01

0.0

1 ±0

.01

Clutch Washer 1


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 147

1.

73 ±

0.02

1.54

±0.

01

0.0

1 ±0

.01

Clutch Washer2 N


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 148

1.

73 ±

0.02

1.54

±0.

01

0.0

2 ±0

.01

Clutch Washer3 N


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 149

1.

73 ±

0.02

1.54

±0.

01

0.0

2 ±0

.01

Clutch Washer4 N


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 150

R0.

09 ±

0.01

0.11 ±0.01

0.05

±0.01

0.17 ±0.01 160.80° ±1° 125° ±1°

0.16 ±0.01 0.27 ±0.01 0.30 ±0.01

0.0

9 ±0

.01

0.2

1 ±0

.01

0.1

3 ±0

.01

Clutch Rocker


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 151

R1.14 ±0.01

1.

48 ±

0.01

1.

41 ±

0.01

1.

32 ±

0.01

1.41 ±0.01 INTERNAL THREAD

Standard 30-tooth#25 Sprocket

1.41 ±0.01

0.1

5 ±0

.01

0.2

6 ±0

.01

0.4

1 ±0

.01

Clutch Center


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1



Group 6 pg. 152

1.

97 ±

0.02

1.73

±0.

02

1.

49 ±

0.01

0

.03

±0.0

1 0

.14

±0.0

1

Clutch Small Side


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 153

R1.38 ±0.01

2.

37 ±

0.02

2.18

±0.

02

1.

61 ±

0.01

1.32

±0.

01

1.

16 ±

0.01

0.82

±0.

01

0.

28 ±

0.01

R0.23 ±0.01

0.15 ±0.01

R0.64 ±0.01

R0.28 ±0.01

R0.79 ±0.01

0.1

0 ±0

.01

0.1

8 ±0

.01

0.2

2 ±0

.01

0.7

1 ±0

.01

0.1

5 ±0

.01

0.4

3 ±0

.01

0.5

1 ±0

.01

0.5

3 ±0

.01

0.6

7 ±0

.01

Externally Threaded

Brake Casing


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 154

0.2

8 ±0.0

1

0.11 ±0.01

R0.11 ±0.01

0.89 ±0.01

0.1

2 ±0

.01

1.2

8 ±0

.01 0.25 ±0.01

R0.06 ±0.01

R0.25 ±0.01

107° ±1°

79.51° ±1°

R0.20 ±0.01

0.0

7 ±0

.01

Brake Latch


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 155

0.4

2 ±0

.01

0.10 ±0.01

Case Pin


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 156

0.97 ±0.01

0.20 ±0.01

R0.05 ±0.01

R1.29 ±0.01

R1.25 ±0.01

R1.14 ±0.01

0.3

3 ±0

.01

Brake Caliper


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 157

0.0

3 ±0

.01

0.

34 ±

0.01

0.18

±0.

01

Latch Washer


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 158

0.0

3 ±0

.01

0.3

7 ±0

.01

0.4

0 ±0

.01

0.

17 ±

0.01

0.10

±0.

01

Latch Pin


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 159

0.1

4 ±0

.01

0.

16 ±

0.01

0.27 ±0.01

Latch Nut


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 160

0.30 ±0.01

R0.02 ±0.01

0.44 ±0.01 0.14 ±0.01 125.50° ±1°

0.1

0 ±0

.01

0.1

8 ±0

.01

Torsional Spring


REVDWG. NO.

ASIZE

TITLE:

COMMENTS:

5 4 3 2 1




Group 6 pg. 161

APPENDIX B

COST ANALYSIS REFERENCES

Group 6 pg. 162

Front Wheel Rim

-Plastic Injection molding using polypropylene

Group 6 pg. 163

Rear Wheel Rim

-Plastic injection molding using polypropylene

Group 6 pg. 164

Front Wheel Hub

-Die casting using magnesium alloy for a similar shaped part from the website

-Total price was divided by 100,000 to find the cost of price per unit

-Reference part

Group 6 pg. 165

Rear Wheel Hub



-Reference Part

Group 6 pg. 166

Motor

http://www.electricscooterparts.com/motors24volt.html

Battery

http://www.getfpv.com/tattu-22000mah-6s-25c-lipo-battery.html

Group 6 pg. 167

Brake Casing

-Die casting using magnesium alloy

Group 6 pg. 168

Latch Nut



-Reference Part

http://www.custompartnet.com/partcost-216

Group 6 pg. 169

Brake Caliper


Group 6 pg. 170

Sprocket-30

-Reference price for sprocket used in scooter

-Part was downloaded to SW and modified.

-http://www.mcmaster.com/#roller-chain-sprockets/=uubssr

Group 6 pg. 171

ARC (JUST ONE)


-Overall there are two arcs in assembly

Group 6 pg. 172

Chain

-Price per link from electricscooterparts.com

-A total of 32 links were used in scooter assembly.

Group 6 pg. 173

Motor Mount Top


Group 6 pg. 174

Chain Tensioner



-Reference Part

Group 6 pg. 175

Motor Mount Spacer

-Off the shelf part from McMaster Carr.

-Reference part.

Group 6 pg. 176

Brake Drum


Group 6 pg. 177

Charger

-Reference part from hobbyking.com

Grip Price

--Off the shelf part from electricscooterparts.com.

Group 6 pg. 178

Low Voltage Cutoff for Lipo Battery

-Off the shelf part from http://www.quadrocopter.com/LipoSaver_p_1315.html

-Reference part

Group 6 pg. 179

Black Battery Box

--Plastic Injection molding using polypropylene

Group 6 pg. 180

Battery Tub Cover


Group 6 pg. 181

Chain Side Guard


Group 6 pg. 182

Brake Side Guard


Group 6 pg. 183

APPENDIX C

INSERTION AND HANDLING CHARTS

Group 6 pg. 184

Group 6 pg. 185

Group 6 pg. 186

Group 6 Design Report 3

Documents

Transcript of Group 6 Design Report 3