1. 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

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 2

3. TCNJ ELECTRIC TRANSPORT VEHICLE 3

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

5. FRAME AND BRAKE DESIGN Phillip Cap

6. CURRENT FRAME DESIGN 6

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 7

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 8

9. BEAM SELECTION Beam EvaluationI-BeamSquare TubingRectangular Tubing Bending Resistance 978 Torsional Resistance 578 Availability 577 Cost 678 Strength to Weight Ratio 867 Total 3334 38 9

10. 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 404647 50 10

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 11

12. STRESS ANALYSIS 12

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

14. BRAKE SELECTION Brake EvaluationMechanical DiscHydraulic DiscHydraulic Drum Stopping Power 487 Installation 757 Reliability 588 Cost 967 Total 2527 29 14

15. STEERING AND SUSPENSION Kevin Weld

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

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

18. DECISION MATRIX Suspension EvaluationLeaf SpringDouble A-Arm Torsion Bar None Cost 85710 Manufacturability 75710 Size 6588 Utility 81070 Total29 252928 18

19. 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 1500200000521329 1500400000621329 150040020000704346 1500400 00787363 1500400 2000839411 1500400 0891459 1500400 200898552 1500400 904646 19

20. 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/5266002 15000.5652.9357.60 20" Double Eye Trailer Leaf Spring (4 leaves) #US- 1008 Eastern Marine/5266001 10000.7942.2066.41 25-1/4" Double Eye Trailer Leaf Spring (3 leaves) #US- 1035 Eastern Marine/5266091 15001.1371.8635.36 23-1/8" Double Eye Leaf Spring (3 leaves) #US-1014 Eastern Marine/5266065 12500.8742.1266.11 26" Double Eye Trailer Leaf Spring (2 leaves) #US- 1013 Eastern Marine/5266008 10001.3452.9054.92 20

21. FRONT AXLE DESIGN Outside Box Size (in)Wall Thickness (in)Stress (psi) Factor of Safety 1.75 0.083153233.00 1.75 0.12113044.07 2 0.065143173.21 20.083115223.99 21

22. INTEGRATED FRONT SUSPENSION 22

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

24. POTENTIAL DESIGNS Six Bar Linkage Rack and Pinion 24

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

26. INTEGRATED STEERING DESIGN Sprockets – mechanical advantage: 1.875 26

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 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

29. POWER FLOW CHART 29

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 30

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 31

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 32

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 33

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 34

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” 35

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 36 Weight:20%30% 10% 100% OptionWeightStrength Gear Ratio CostMaintenanceScore EZ-GO 2 Person Axle705070802060 Titan HD Axle5090 402070

37. REAR AXLE ASSEMBLY 37

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 39

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

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

42. 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 273435 42

43. SEAT SPACING 43 95 th Percentile Dimensions

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

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

46. 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 253025 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 20 37 46

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

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

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

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

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

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

53. TOTAL BUDGET 53 SubsystemCost Frame $531.55 Suspension $795.50 Drivetrain $5,609.77 Steering $332.42 Braking $735.84 Seating $723.19 Canopy $802.08 Ramp $424.13 ADA/Misc $526.53 Total$10,481.01

54. GANTT CHART 54

55. TCNJ ELECTRIC TRANSPORT VEHICLE 55

56. 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