Folding electric scooter
The aim of this project was to design afolding electric commuter scooter capable of carrying a small amount of cargo in order to replace a car for commuting. Power requirements had to be calculated, FEA analysis was carried out on the frame to ensure it could handle the load and it had to be aesthetically pleasing.

Initially some rough sketches were produced to get a general look for the scooter

Some rough prototypes were made to investigate the folding mechanism
Then it went into the research phase where I had to look into average commute distances and times as well as the average weight of the user plus their cargo so I could chose an appropriate motor and battery combination to ensure it was suitable for most people's commute
Next a more detailed design was drawn up in Solidworks and the frame was tested using finite element analysands to ensure it could cope with all the forces involved while keeping the weight down. The rear subframe took many iterative prototypes to get right - it was designed to be made from a single piece of formed sheet metal to ensure it could be produced easily. 
The scooter had a removable battery that could be charged at your desk in work. It had dual motors which lowered the cost vs one large motor and offered some redundancy so if one failed the scooter would still work. It has a small screen showing speed, range and other stats and front and real lights. The frame is made aluminium sheet metal and the frame rails are carbon fibre tubes to keep the weight down.
Cargo can be stowed under the seat or on the foot plate to make it suitable for city courier duties as well as commuting. The range was in the region of 20m depending on load.
Folding electric scooter
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Folding electric scooter

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Published:

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