Brian Broderick Phillip Cap Brian Migliore Kevin Weld TCNJ ELECTRIC TRANSPORT VEHICLE SENIOR PROJECT 1 DESIGN Advisors: Professor Sepahpour Dr. Asper Student Advisor: Matthew Rawson

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 2

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

FRAME AND BRAKE DESIGN Phillip Cap

CURRENT FRAME DESIGN 6

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 7

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 8

BEAM SELECTION Beam EvaluationI-BeamSquare TubingRectangular Tubing Bending Resistance 978 Torsional Resistance 578 Availability 577 Cost 678 Strength to Weight Ratio 867 Total

MATERIAL SELECTION Material EvaluationAluminum 6061-T6AISI 1018 SteelASTM A36 SteelASTM A513 Steel Strength 5778 Weldability 4887 Corrosion Resistance 8666 Fatigue Resistance 5778 Weight 8666 Cost 5677 Availability 5668 Total

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 11

STRESS ANALYSIS 12

BRAKE DESIGN Design Considerations Safety of passengers and pedestrians Reliable Adequate stopping power Easy to maintain 13

BRAKE SELECTION Brake EvaluationMechanical DiscHydraulic DiscHydraulic Drum Stopping Power 487 Installation 757 Reliability 588 Cost 967 Total

STEERING AND SUSPENSION Kevin Weld

SUSPENSION DESIGN Design Constraints Minimize ride height Comfortable range of oscillation frequency Variable load 16

POTENTIAL DESIGNS Independent Suspension MacPherson Strut Torsion Bar Transverse Leaf Spring Solid Axle Suspension Coil over Shock Longitudinal Leaf Spring 17

DECISION MATRIX Suspension EvaluationLeaf SpringDouble A-Arm Torsion Bar None Cost Manufacturability Size 6588 Utility Total

WEIGHT DISTRIBUTION All weights in lbs WV (weight of vehicle) W1 (driver and passenger) W2 (front bench passengers) W3 (rear bench passengers) W4 (far rear passengers) Front spring design load Rear spring design load

LEAF SPRING OPTIONS Spring DescriptionSource/Part No. Max Capacity (provided by manufacturer) (lb) Deflection at 1000 lb load (in) Ride Height (in) Maximum Natural Frequency (Hz) 20" Double Eye Leaf Spring (3 leaves) #US-1007 Eastern Marine/ " Double Eye Trailer Leaf Spring (4 leaves) #US Eastern Marine/ /4" Double Eye Trailer Leaf Spring (3 leaves) #US Eastern Marine/ /8" Double Eye Leaf Spring (3 leaves) #US-1014 Eastern Marine/ " Double Eye Trailer Leaf Spring (2 leaves) #US Eastern Marine/

FRONT AXLE DESIGN Outside Box Size (in)Wall Thickness (in)Stress (psi) Factor of Safety

INTEGRATED FRONT SUSPENSION 22

STEERING DESIGN Design Constraints 10 ft steering radius Avoid skipping Ackermann steering angle 23

POTENTIAL DESIGNS Six Bar Linkage Rack and Pinion 24

STEERING AXIS ORIENTATION Steering Axis Inclination – 15 degrees Caster Angle – 5 degrees 25

INTEGRATED STEERING DESIGN Sprockets – mechanical advantage:

DRIVETRAIN DESIGN Brian Migliore

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 28 Motor Controller Intuitive and perceptive Anyone should be able to operate this vehicle Rear-Wheel Drive Direct Drive Large Differential Reduction Strong Rear Axle

POWER FLOW CHART 29

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 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 30

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 31

BATTERY CHOICE Trojan T-105 (Lead-Acid) 6 Volt Deep Cycle Battery Hr Rate 62 lbs per Battery Trojan T-105 Performance Curves 32

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 33

CONTROLLER CHOICE Curtis Model 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 34

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 i Volt Charger LED Charge Indicator Auto Off/Auto On Trickle Charge 9.75” x 8.38” x 8.25” 35

DIFFERENTIAL CONSIDERATIONS Decision Matrix Titan HD Axle – Model #600185G : 1 Differential Gear Reduction Includes 7” Rear Brake Drums 4 on 4 Brake Stud Alignment 19 Tooth Male Spline 36 Weight:20%30% 10% 100% OptionWeightStrength Gear Ratio CostMaintenanceScore EZ-GO 2 Person Axle Titan HD Axle

REAR AXLE ASSEMBLY 37

ANTHROPOMETRICS, RAMP DESIGN, AND SOLAR CANOPY Brian Broderick

ANTHROPOMETRIC DESIGN Design Goals Minimize loading/unloading times Meet ADA standards for wheelchair accessibility Maximize Passenger Capacity Maximize Comfort 39

POTENTIAL DESIGNS Conventional Golf Cart Mid-Chassis Wheelchair Accessible Golf Cart 40

PROPOSED DESIGN 8 Passengers 7 Passengers Including 1 Wheelchair Patron 41 ADA Designated Areas shown in Red

DECISION MATRIX Anthropometric Evaluation Traditional Golf Cart -Limo Mid-Chassis Wheelchair Rear Wheelchair Cost 764 Manufacturability 764 Wheelchair Accessible 010 Accessibility 678 Capacity 759 Total

SEAT SPACING th Percentile Dimensions

ALTERNATIVE SEATING DESIGNS EZ GO TXT Complete Seat Springfield Low Back Folding Seat 44

FINALIZED DESIGN Custom Wooden Seats Wood Rib Design 3” Foam Vinyl Fabric Bottom Seat AssemblyBack Support 45

DECISION MATRIX Front and Middle Seats Seat Evaluation EZ GO TXT Complete Set Custom Made Seats Springfield Low Back Folding Seat Cost 578 Manufacturability 8410 Comfort 796 Fit 5101 Total Rear Seats Seat Evaluation EZ GO TXT Complete Set Custom Made Seats Springfield Low Back Folding Seat Cost 358 Manufacturability 105 Folding Capability 0010 Fit 7109 Total

RAMP DESIGN 24” 4” 2” Design Constraints Minimize obstruction of pathways ADA Standards Provides additional restraint 47

POTENTIAL DESIGNS 24” 4” 2” Side Folding, Bi-Fold ramp Tri-Folding, Rear Ramp 48

PROPOSED DESIGN 24” 4” 2” Rear-loading Bi-fold Ramp 49

CANOPY DESIGN 24” 4” 2” Design Considerations Provide shelter ADA Compliance Solar Panel Incorporation Lightweight 50

ALTERNATIVE DESIGNS 24” 4” 2” Pre-Made Stretch Plastics Top Custom Split Level Aluminum Top 51

FINALIZED DESIGN 24” 4” 2” Custom Flat Aluminum Top 52

TOTAL BUDGET 53 SubsystemCost Frame $ Suspension $ Drivetrain $5, Steering $ Braking $ Seating $ Canopy $ Ramp $ ADA/Misc $ Total$10,481.01

GANTT CHART 54

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TCNJ ELECTRIC TRANSPORT VEHICLE (ETV) SENIOR PROJECT 1 DESIGN 56 Comments or Questions? Brian Broderick - Manager, Anthropometrics, Ramp, Canopy Phillip Cap - Frame, Braking Brian Migliore - Drivetrain, Electrical Kevin Weld - Suspension, Steering Advisors: Professor Sepahpour Dr. Asper Student Advisor: Matthew Rawson