Electric Motorcycle Design Project SR. Design Project Fall 2008-Spring 2009 Justin Cole Chad Dickman Todd Sanderson Kris Williams

Outline The project Components Where we stand Budget Sample Calculations Data Tables Graphs Timeline What’s Next? Conclusion

The project Convert gasoline motorcycle to electric Emissions Energy crisis Ideal for short commutes. Create publicity for the school. Outreach Open house

Components Batteries Charger 4-12VDC sealed lead acid Designed for electric vehicles. electricmotorsport.com Charger Soneil 48 V 5 amp thunderstruck-ev.com

Components (continued) Motor Briggs and Stratton Etek-R 8 hp continuous 15 hp peak Controller Sevcon Milipack Regenerative 48VDC Wiring, fuses, throttle electricmotorsport.com

Where we stand Motor kit & Batteries Purchased and received electricmotorsport.com Purchased motorcycle Lemon and Barrett’s Still need parts Chain Sprockets Charger Miscellaneous

48 volt System Budget Breakdown Table of budget breakdown Item Price Supplier Bike $250.00 Lemon and Barrett’s Kit(which includes the following): $1,075.00 electricmotorsport.com motor controller throttle contactor fuses wiring Charger $175.00 thunderstruck-ev.com 4 Batteries @ $70 $280.00 Chain $100.00 Gears $200.00 General Costs $300.00 subtotal $2,380.00 Taxes $142.80   Total $2,522.80 Table of budget breakdown

Sample Calculations Aerodynamic Drag Force (Fd): Cd= Coefficient of drag of the vehicle A= Frontal area of the vehicle in square feet V= The vehicle’s speed in mph Rolling Resistance (Fr): Cr= Rolling resistance factor W= Vehicle weight in lbs Force due to Acceleration (Fa): Ci= Unit conversion factor W= Vehicle weight in lbs a= Acceleration in mph/second Force due to Climbing Hills (Fh): Φ= Angle of incline

Sample Calculation (continued) Total Force on the Vehicle (FT): All four forces added together The Horsepower needed (hp): FT= Total Force in lbs V= Speed expressed in mph Torque needed from the Motor (T): hp= Horsepower RPM= Revolutions per minute Conversion from hp to Watts (W): Current needed to Power in Amps(A): V= Volts from the battery W= Power need to run in Watts

Sample Calculations (continued) Time in hours the Vehicle can run (Time): Ah= Amp-hours from the battery A= Current Total Distance in Miles Vehicle can Drive (D): mph= Speed in mph Time= Time in hours vehicle can run Battery Charging Time (Tc): Ah= Amp-hours from the battery Amp= Amps from the battery charger

Acceleration Resistance Data Tables Speed Force mph Aerodynamic Rolling Resistance Wind Resistance Acceleration Resistance Hill Climb Total 5 0.128 7.320 69.365 14.63 91.446 10 0.512 91.830 15 1.151 92.469 20 2.046 93.364 25 3.197 94.515 30 4.604 95.922 35 6.266 97.584 40 8.184 99.502 Table of various resistive forces with a constant acceleration of 3 mph/sec and a 3% grade.

Data Table (continued) Speed Acceleration Force Total Power Torque Current Time Distance RPM mph mph/sec lbs HP W ft*lbs Amps Hrs min Miles 2830.6 40 1 30.57 3.26 2433.40 6.05 50.70 0.69 41.42 27.62 2 53.69 5.73 4273.93 10.63 89.04 0.39 23.58 15.72 3 76.81 8.19 6114.46 15.20 127.38 0.27 16.49 10.99 4 99.93 10.66 7954.99 19.78 165.73 0.21 12.67 8.45 5 123.06 13.13 9795.52 24.35 204.07 0.17 10.29 6.86 Table of Distance and other parameters with varying accelerations

Data Tables (continued) Speed Grade of Incline Force Total Power Torque Current Distance MPH % lbs HP W ft*lbs Amps Miles 40 1 20.38 2.17 1622.59 4.03 33.80 41.42 2 25.26 2.69 2010.91 5.00 41.89 33.42 3 30.14 3.21 2399.00 5.96 49.98 28.01 4 35.01 3.73 2786.74 6.93 58.06 24.11 5 39.87 4.25 3174.01 7.89 66.13 21.17 6 44.73 4.77 3560.71 8.85 74.18 18.87 7 49.58 5.29 3946.72 9.81 82.22 17.03 Table of Distance and other parameters with varying inclines

Data Tables (continued) Accelerating at 4 mph/sec Accelerating to 40 mph Total KWh from the batteries KW needed for accelerating at 4mph/sec Accelerating Time in Hours (30 stop and go's) KWh used when accelerating at 4 mph/sec for a total of 5 min worth of accelerating Distance traveled accelerating 0 to 5 1.00674668 0.599 0.01 0.05 5 to 10 1.801 0.02 0.10 10 to 15 3.014 0.03 0.16 15 to 20 4.246 0.04 0.21 20 to 25 5.505 0.06 0.26 25 to 30 6.798 0.07 0.31 30 to 35 8.134 0.08 0.36 35 to 40 9.518 0.42 Total KWh used accelerating Remaining KWh Hours of constant speed Distance traveled in miles after Accelerating at 40 mph Distance traveled accelerating (miles) Total Distance traveled in miles 0.41 0.59 0.44 17.56 1.88 19.43 Table of distance with a period of acceleration followed by a period of constant speed.

Graphs

Graphs (continued)

Previous Designs Very similar Verified project calculations Motor Batteries Type of bike Verified project calculations Made in home garage. Proves feasibility Total project costs less than $3000 Picture of bike that uses the same motor and type of batteries as this project.

Current Timeline Electric Bike Conversion Gantt Chart Timeline October   November January February March April May 1 2 3 4 Research Budget Calculations Design of Bike Specs Design of Bike Layout Writing Sponsorship Proposal Presenting to Companies Purchasing the Bike Buy Batteries Build Batt. Trays Buy Electric Motor Kit Drive train Assembly Motor Mount Electric Assembly Testing Demo

What’s Next? Bike preparations Layout of components Bike Design Assembly Wiring Testing Demonstrations

Conclusions The design is feasible Some minor funding is still needed The project is coming along pretty well according to the plan. The preliminary research and calculations are complete. The bike is ready to begin laying out the components.