CONCEPTUAL AXIOMATIC DESIGN ON ERGONOMIC ELECTRIC SCOOTER
OOI YONG MIN
Bachelor of Engineering with Honour’s (Mechanical and Manufacturing Engineering)
2010
UNIVERSITI MALAYSIA SARAWAK
R13a
BORANG PENGESAHAN STATUS TESIS
Judul: Conceptual Axiomatic Design On Ergonomic Electric Scooter SESI PENGAJIAN: 2009/2010
Saya OOI YONG MIN
(HURUF BESAR)
Mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.
4. Pusat khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
5. ** Sila tandakan ( √ ) di kotak yang berkenaan
SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/
badan di mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap:
2B-8-3A, Halaman Bukit Gambir Dr. Syed Tarmizi Syed Shazali Nama Penyelia
11700 Gelugor, Pulau Pinang.
Tarikh: Tarikh:
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.
** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT dan TERHAD.
APPROVAL SHEET
Final Year Project attached here:
Title : Conceptual Axiomatic Design on Ergonomic Electric Scooter Name : Ooi Yong Min
Matric No. : 17090
is hereby read and approved by:
Dr. Syed Tarmizi Syed Shazali Date
Project Supervisor
CONCEPTUAL AXIOMATISED DESIGN ON ERGONOMIC ELECTRIC SCOOTER
OOI YONG MIN
Bachelor of Engineering with Honour’s (Mechanical and Manufacturing Engineering)
2010
UNIVERSITI MALAYSIA SARAWAK
R13a
BORANG PENGESAHAN STATUS TESIS
Judul: Conceptual Axiomatised Design On Ergonomic Electric Scooter SESI PENGAJIAN: 2009/2010
Saya OOI YONG MIN
(HURUF BESAR)
Mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.
4. Pusat khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
5. ** Sila tandakan ( √ ) di kotak yang berkenaan
SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/
badan di mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap:
2B-8-3A, Halaman Bukit Gambir Dr. Syed Tarmizi Syed Shazali Nama Penyelia
11700 Gelugor, Pulau Pinang.
Tarikh: Tarikh:
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.
** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT dan TERHAD.
APPROVAL SHEET
Final Year Project attached here:
Title : Conceptual Axiomatised Design on Ergonomic Electric Scooter Name : Ooi Yong Min
Matric No. : 17090
is hereby read and approved by:
Dr. Syed Tarmizi Syed Shazali Date
Project Supervisor
i
CONCEPTUAL AXIOMATISED DESIGN ON ERGONOMIC ELECTRIC SCOOTER
OOI YONG MIN
Thesis is submitted to
Faculty of Engineering, University Malaysia Sarawak In Partial Fulfillment of the Requirements For the Degree of Bachelor of Engineering
With Honours (Mechanical and Manufacturing Engineering) 2010
ii
To my beloved family and friends
iii
ACKNOWLEDGEMENT
I would like to take this opportunity to express my appreciation to my supervisor, Dr. Syed Tarmizi Syed Shazali, Head of Department for Mechanical and Manufacturing Engineering, Universiti Malaysia Sarawak for his advices, encouragement, guidance, critics, motivations and helps until the completion of the project. Without his continuous support, this thesis would not been the same as presented here.
Very special thanks for those who helped me and gave me their support throughout the duration of this project especially to my project partner Yap Jee Siang, my friends Chin Hon Woi, Tai Theam Meng, and technicians at the mechanical workshop.
Finally, I am also thankful to my parents who always give me their endless support while doing this project.
iv
ABSTRACT
The conceptual design of Ergonomic Electric Scooter is developed based on axiomatised design parameters. Axiomatised design parameters are all of the possible area of designs, systems, components and parts that can exist in a concept design.
Axiomatised design parameters are obtained based on benchmarking from existing products, designs, systems, components, and etc. in nowadays markets and technologies. After the axiomatised design parameters are obtained, market survey is needed to obtain the most preferred functional requirements by customers and users.
Based on the functional requirements listed, the highest weight functional requirements will be set as the concept selection priority based on the axiomatised design parameters. Mutually exclusive design parameters will be analysed based on priority. Elimination of impossible design parameters will be carried out and the finalised design parameters will serve as the base reference when conceptual design and detailed design are carried out in the design phase. Once the detailed designs are obtained, a prototype will be fabricated in order to evaluate the design performance and functionality based on the objectives and aims of this project.
v
ABSTRAK
Konsep rekacipta untuk Skuter Ergonomik Electrik adalah dibangunkan berdasarkan parameter rekacipta aksiomatik. Parameter rekacipta aksiomatik adalah seluruh kawasan rekacipta, sistem, komponen dan bahagian-bahagian yang berkemungkinan yang boleh wujud dalam konsep rekacipta. Parameter rekacipta aksiomatik adalah diperolehi berdasarkan pembandingan daripada produk, rekacipta, sistem, komponen, dan lain-lain yang telah wujud di dalam pasaran dan teknologi kini. Setelah parameter rekacipta aksiomatik diperolehi, kajian pasaran adalah diperlukan untuk mendapatkan keperluan fungsi yang paling banyak dipilih oleh pelanggan dan pengguna. Berdasarkan keperluan fungsi yang disenaraikan, kuantiti mengikut berat bagi keperluan fungsi yang tertinggi akan ditetapkan sebagai keutamaan pemilihan konsep berdasarkan parameter rekacipta aksiomatik. Parameter rekacipta yang eksklusif antara satu sama lain akan dianalisis berdasarkan keutamaan.
Penghapusan parameter rekacipta yang tidak berkemungkinan akan dilakukan dan parameter rekacipta terakhir akan menjadi dasar rujukan ketika konsep rekacipta dan rekacipta terperinci dilakukan pada tahap perekaciptaan. Setelah rekacipta terperinci diperolehi, prototaip akan dibuat untuk menilai prestasi dan fungsi rekacipta sekiranya sesuai dengan tujuan dan matlamat projek ini.
vi
TABLE OF CONTENTS
CONTENT PAGE
TITLE i
DEDICATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
ABSTRAK v
TABLE OF CONTENTS vi
LIST OF FIGURES ix
LIST OF TABLES xii
Chapter 1 INTRODUCTION 1.0 Introduction
1.1 Background of Study
1 2
1.2 Objectives 3
1.3 Problem Statements 3
1.4 Summary 3
Chapter 2 LITERATURE REVIEW
2.0 Introduction 4
2.1 Scope of Users 5
2.2 Types of Scooters in Market 6
vii
2.2.1 Piaggio MP3 250 7
2.3.2 Brammo Enertia Powercycle 11
2.3.3 Segway i2 16
2.3 Scooter Systems Design 18
2.3.1 Frame Materials 18
2.3.2 Suspension System 22
2.3.3 Braking System 25
2.3.4 Tyres 27
2.3.5 Steering System 29
2.3.6 Ergonomics 30
2. 4 Summary 32
Chapter 3 METHODOLOGY
3.0 Introduction 33
3.1 Flow Chart 34
3.2 Axiomatised Design Parameters 35
3.2.1 Ergonomics Axiomatised Design Parameters 37 3.2.2 Electric Axiomatised Design Parameters 40 3.2.3 Scooter Axiomatised Design Parameters 42
3.3 Data Collection 50
3.4 Summary 51
Chapter 4 RESULTS AND ANALYSIS
4.0 Introduction 52
4.1 Market Survey Statistical Data 53
viii
4.2 Concept Selection 57
4.3 Concept Design from Axiomatised Design Parameters 60
4.4 Detailed Drawing from Concept Design 67
4.5 Stress Analysis 69
4.6 Fabrication 83
4.61 Fabrication of Scooter Chassis 83
4.62 Installation of Drive Train System 86
4.7 Testing on Ergonomic Electric Scooter 89
4.8 Summary 91
Chapter 5 DISCUSSIONS AND CONCLUSION
5.0 Introduction 92
5.1 Discussions 93
5.2 Problems and Limitations 96
5.3 Recommendations 98
5.4 Conclusion 99
5.5 Summary 100
REFERENCES 101
APPENDIX 103
ix
LIST OF FIGURES
Figure Page
2.1 Piaggio MP3 250 (Piaggio USA, 2009) 7
2.2 Specification of Piaggio MP3 250 (Piaggio USA, 2009)
8
2.3 Leaning feature of front wheel of Piaggio MP3 250 (Piaggio USA, 2009)
9
2.4 Brammo Enertia Powercycle (Brammo Enertia, 2009)
11
2.5 Specification of Brammo Enertia Powercycle (Brammo Enertia, 2009)
12
2.6 Specification of Brammo Enertia Powercycle (Brammo Enertia, 2009)
13
2.7 Well-to-wheel efficiency bar chart of various vehicles compare with Brammo Enertia (Brammo Enertia, 2009)
14
2.8 Segway i2 (Segway, 2009) 16
2.9 Coaxial steering front suspension (Wikipedia, 2009) 23 2.10 Swingarm of BMW Paralever (Wikipedia, 2009) 24
2.11 Drum brake (Orthwein, 2004) 25
2.12 Disc brake (Orthwein, 2004) 26
2.13 Sentinel (Xtreme Green Products, 2009) 28
x
2.14 Piaggio MP3 500 (Piaggio USA, 2009) 28
2.15 Hans-Ulrich Reimers rear wheel steering bicycle (Wannee, 2005)
29
2.16 Duane Flatmo on his rear wheel steering bicycle (Wannee, 2005)
29
3.1 The flow chart of the Project 34
3.2 Axiomatised design parameters of Ergonomic Electric Scooter
35
3.3 Categorisation of Ergonomic Electric Scooter 36 3.4 Categorisation of Ergonomics axiomatised design
parameters
37
3.5 A typical adjustable car seat design 38
3.6 Categorisation of Electric axiomatised design parameters
40
3.7 Categorisation of Scooter axiomatised design parameters
42
3.8 Relationship between mass, volume and density 48
4.1 Bar chart of 1st question feedback 53
4.2 Bar chart of 2nd question feedback 54
4.3 Bar chart of 3rd question feedback 54
4.4 Bar chart of 4th question feedback 55
4.5 Bar chart of 5th question feedback 55
4.6 Bar chart of 6th question feedback 56
4.7 Finalised Ergonomics axiomatised design parameters 60 4.8 Finalised Electric axiomatised design parameters 61
xi
4.9 Finalised Scooter axiomatised design parameters 63
4.10 Basic sketching based on concept design 65
4.11 Auxiliary front view of Ergonomic Electric Scooter 67
4.12 Side view of Ergonomic Electric Scooter 68
4.13 Free body diagram of scooter 70
4.14 Free body diagram of seat connector 71
4.15 Free body diagram of front body chassis 72
4.16 Free body diagram of foot paddle 74
4.17 Free body diagram of rear body chassis 75
4.18 Equivalent stress distribution on seat connector 78 4.19 Equivalent stress distribution on front body chassis 79 4.20 Equivalent stress distribution on foot paddle 80 4.21 Equivalent stress distribution on rear body chassis 81 4.22 Front auxiliary view of finished scooter chassis 85 4.23 Rear auxiliary view of finished scooter chassis 85
4.24 Drive train system 86
4.25 Front auxiliary view of Ergonomic Electric Scooter 88 4.26 Rear auxiliary view of Ergonomic Electric Scooter 88
xii
LIST OF TABLES
Table Page
2.1 Physical properties of steel, aluminium, titanium, and carbon fibre (Smith and Hashemi, 2006)
19
2.2 Frame manufacturability of steel, aluminium, titanium and carbon fibre
21
4.1 Maximum equivalent load and respective reacting forces on each part of the system
77
4.2 Physical properties of steel 77
4.3 Bill of materials for scooter chassis fabrication (Part 1)
83
4.4 Bill of materials for scooter chassis fabrication (Part 2)
84
4.5 Bill of materials for drive train system 87
CHAPTER 1
INTRODUCTION
CHAPTER 1 INTRODUCTION
1
CHAPTER 1
INTRODUCTION
1.0 Introduction
In this thesis, the author has developed a project in designing an ergonomic electric scooter which is suitable to be used by students inside the UNIMAS. In this introduction, the author will discuss about the background of electric scooter, the objective of this project and the problem statements with respect to the development of the project.
CHAPTER 1 INTRODUCTION
2 1.1 Background of Project
Electric vehicles have become the second alternative of transportation around the world after the fuel gas combustion vehicles. People are started to taking concern about the mean of transportation as the depleting fossil fuel and petroleum resources around the world have started to get the attention from everyone. The American Petroleum Institute estimated in 2004 that the total world reserves were estimated to be 1.25 trillion barrels and daily consumption was about 85 million barrels, hence computed that the estimated oil depletion year will be in 2057 (Energy Information Administration / International Energy Outlook, 2006). Besides, the emission of exhaust gases from fossil fuel combustion around the world has also causing the issue of global warming and greenhouse effect to become more and more severe.
Hence, in order to face these global issues, people around the world have started to develop electric vehicles, such as electric scooters.
In nowadays market, there are many kinds of electric scooters available from many varieties, from two-wheeled to three- wheeled, from light-and-compact to heavy-duty, and etc. in order to meet the demand from people. In this project, the design of the electric scooter will be focused mainly for the use of students inside the campus of UNIMAS. Transportation for students inside a campus is relatively important in order for students to arrive in lecture hall punctually. Hence, for the ease of students, electric scooter can be introduced inside university campus other than the university buses. Among the reasons that electric scooter is suitable for in-campus use are: simplicity, green machine, affordability, and safety.
CHAPTER 1 INTRODUCTION
3 1.2 Objectives of the Project
The aim of the project is to develop a conceptual design of an electric scooter with a few characteristics:
A brand new design which is not yet developed by anyone or not yet available in market.
An ergonomic design for a greater comfort and a correct posture of riding.
User friendly as the scooter is relatively easy to manage and handle.
1.3 Problem Statements
The main problem in this project is to develop a complete scale of electric scooter from skeleton design, suspension system, joints, exterior shapes and covers, wiring of electric components, and the methodology used in fabrication. Besides, stress analysis, weight distribution, reliability, safety factor and electricity distribution are also the measures needed to be developed in this project in order to design a safe and reliable electric scooter.
1.4 Summary
This chapter is basically defined the reasons this project is carried out.
Besides, in order to carry out this project, objectives have been defined in order to make this project has a direction to achieve without deviating from its primary purpose. Problem statements have been defined so that more attention can be given in the particular scopes in order to succeed this project.
CHAPTER 2
LITERATURE REVIEW
CHAPTER 2 LITERATURE REVIEW
4
CHAPTER 2
LITERATURE REVIEW
2.0 Introduction
In this literature review, the author will make some reviews onto scope of users of the ergonomics electric scooter design, together with a few scooters from various companies to make comparison. Besides, the author will also review scooters in sub-sections, which will include the frame materials, suspension system, braking system, tyres, steering system, and the term ergonomics.