TCNJ Electric Transport Vehicle Senior Project 1 Design

1. TCNJ Electric Transport VehicleSenior Project 1 Design Brian Broderick Phillip Cap Brian Migliore Kevin Weld Advisors: Professor Sepahpour Dr. Asper Student Advisor: Matthew Rawson

2. PROJECT OVERVIEW Create a zero-emissions vehicle with the ability to transport elderly and handicapped around paths on TCNJ campus • Solar-electric • Cruising Speed: 15 mph • Passenger Capacity: 8 • Utility • Wheelchair accessibility • Cargo storage • Weight • Curb Weight – 1500 lbs • Total Weight – 3100 lbs • Dimensions • Length = 124” • Width = 44” • Run Time: Continuous 2 hours

3. TCNJ electric transport vehicle

4. Agenda • Frame and Braking – Phillip Cap • Steering and Suspension – Kevin Weld • Drivetrain and Electrical – Brian Migliore • Anthropometrics, Ramp, and Canopy – Brian Broderick

5. Frame and Brake Design Phillip Cap

6. Current Frame Design

7. Frame Design • Support weight of passengers and components • Allow space for subsystems • Able to operate on all the paths within the TCNJ campus • Comply with ADA regulations Design Constraints

8. Potential Designs 3-Wheeled Drive Vehicle with Trailer • High stress on rear wheel 4-Wheeled Drive Vehicle with Trailer • Trailer adds: • Weight • Complexity 4-Wheeled Integrated Vehicle • Reduces weight and complexity • Ladder frame style design

9. Beam Selection

10. Material Selection

11. Beam Optimization Initial Hand Calculations • Preliminary beam section dimensions • 2” x 1.5” x 1/8” Stress Analysis in SolidWorks • Varied section dimensions • Reinforced critical locations

12. Stress Analysis

13. Brake Design Design Considerations • Safety of passengers and pedestrians • Reliable • Adequate stopping power • Easy to maintain

14. Brake Selection

15. Steering and Suspension Kevin Weld

16. Suspension Design Design Constraints • Minimize ride height • Comfortable range of oscillation frequency • Variable load

17. Potential designs Independent Suspension • MacPherson Strut • Torsion Bar • Transverse Leaf Spring Solid Axle Suspension • Coil over Shock • Longitudinal Leaf Spring

18. Decision matrix

19. Weight distribution

20. Leaf spring options

21. Front axle design

22. Integrated front suspension

23. Steering Design Design Constraints • 10 ft steering radius • Avoid skipping • Ackermann steering angle

24. Potential designs Six Bar Linkage Rack and Pinion

25. Steering axis orientation Steering Axis Inclination – 15 degrees Caster Angle – 5 degrees

26. Integrated Steering Design Sprockets – mechanical advantage: 1.875

27. Drivetrain Design Brian Migliore

28. Drivetrain components Single Motor • Brushed DC Series Wound • High Torque Battery Powered • Zero-Emissions Green Vehicle • Lead-Acid Charging • On Board Charger • Solar Panels on Canopy Motor Controller • Intuitive and perceptive • Anyone should be able to operate this vehicle Rear-Wheel Drive • Direct Drive • Large Differential Reduction • Strong Rear Axle

29. Power Flow Chart

30. Motor Considerations • Drivetrain Parameters • Cruising Speed of 15 mph • Time to Top Speed = 3 seconds • Total Torque Needed = 512 ft-lbs • Total Power Needed = 4 kW • 16.5 Inch Diameter Tire • DD Motor Systems – ES-63-49 • 19 Tooth Female Spline • Peak Power • 65 ft-lbs • 1,625 RPM • 20.1 HP • 500 Amps/Armature • S2 – 30 Min • 12 ft-lbs • 2,650 RPM • 6.05 HP • 115 Amps/Armature

31. Battery Design Considerations Desired Qualities • 48 Volts • Deep Cycle • Industry Standard Li-Ion Battery Performance • Greater Cycle Life / Discharge Rate • Li-Ion Battery use will save • 51.5% Reduction in Weight • 31.1% Reduction in Volume • Cost 2.5 times Lead-Acid

32. Battery Choice Trojan T-105 (Lead-Acid) • 6 Volt Deep Cycle Battery • 225 Ah @ 20Hr Rate • 62 lbs per Battery Trojan T-105 Performance Curves

33. Controller Considerations Design Parameters • Programmable – Depending on batteries this will help prevent any damage to power source • Possible to use an electronic reverse for DC series wound motor

34. Controller Choice Curtis Model 1268 - 5502 • 48 Volts, 500 Amp Max Power Rating • Industry name, effective, safe, and tested design • Speed sensor allows closed loop control for regulating speed of vehicle • Acceleration and braking of throttle can be programmed • Electronic Reverse is included • Diagnostic tools and codes to alert of any issues

35. Charging Considerations Design Parameters • Programmable to display errors and/or warnings during charging • Charge at certain voltages and current • Prevents over-voltage • Prevents over-heating of batteries • Small and portable enough to fit on-board vehicle • Eagle Performance Model i4818 • 48 Volt Charger • LED Charge Indicator • Auto Off/Auto On Trickle Charge • 9.75” x 8.38” x 8.25”

36. Differential Considerations Decision Matrix Titan HD Axle – Model #600185G02 • 14.76 : 1 Differential Gear Reduction • Includes 7” Rear Brake Drums • 4 on 4 Brake Stud Alignment • 19 Tooth Male Spline

37. Rear Axle Assembly

38. Anthropometrics, ramp Design, and Solar Canopy Brian Broderick

39. Anthropometric Design Design Goals • Minimize loading/unloading times • Meet ADA standards for wheelchair accessibility • Maximize Passenger Capacity • Maximize Comfort

40. Potential Designs • Conventional Golf Cart Mid-Chassis Wheelchair Accessible Golf Cart

41. Proposed Design 8 Passengers 7 Passengers Including 1 Wheelchair Patron ADA Designated Areas shown in Red

42. Decision Matrix

43. Seat Spacing 95th Percentile Dimensions

44. Alternative Seating designs EZ GO TXT Complete Seat Springfield Low Back Folding Seat

45. finalized Design Custom Wooden Seats • Wood Rib Design • 3” Foam • Vinyl Fabric Bottom Seat Assembly Back Support

46. Decision Matrix

47. Ramp Design Design Constraints • Minimize obstruction of pathways • ADA Standards • Provides additional restraint 24” 24” 4” 2” 2”

48. Potential Designs Side Folding, Bi-Fold ramp 24” 24” 4” 2” 2” Tri-Folding, Rear Ramp

49. Proposed Design Rear-loading Bi-fold Ramp 24” 24” 4” 2” 2”

50. Canopy Design Design Considerations • Provide shelter • ADA Compliance • Solar Panel Incorporation • Lightweight 24” 24” 4” 2” 2”