E17: Applications and Implications
This weeks assignment is to propose a final project that integrates the range of units covered:
- What will it do?
- Who's done what beforehand?
- What materials and components will be required?
- Where will they come from?
- How much will it cost?
- What parts and systems will be made?
- What processes will be used?
- What tasks need to be completed?
- What questions need to be answered?
- What is the schedule?
- How will it be evaluated?
How to MAKE it
What will it do?
For my final project I have been working towards a motorized vehicle. I started with the idea of an eBike but because of time, I decided to scale it down. Finally, I ended up with the idea of a motorized fabKickBoard.
Who's done what beforehand?
There are some nice projects about motorized kickBoards but most of them just use 2-wheeler versions. The K2 Kickboard has two wheels in the front and one wheel in the back end. Also, I have not found a DIY-project that nicely integrates all electronic parts in a seamless way. Quite often, components are provisional put on top or below the board.Here are some examples:
What materials and components will be required?
To fabricate the board I will need:- Board: Bamboo, peel ply, polyester resin
- Handle: ABS or flexible fillament
- Axle: Steel
- Motor mount: Aluminium
- Battery mount: ABS
- Electronics case: ABS
- ESC: TURNIGY K-Force 120A-HV OPTO V2 5-12S Brushless ESC
- Motor: Alien 6374 Outrunner brushless motor 170KV 3200W
- Batteries: LG Lithium Ion INR18650 HG2 3000mAh Akku.
In a configuration of 6S2P, they will deliver 22,2 V, continious current of 40A and energy of 133,2 W/h. - Control Unit (CU): a modified satshakit
Where will they come from?
All materials are available in our stock or have been ordered already.How much will it cost?
Hardware:
| Article | Price |
|---|---|
| K2 Kick Board (used) | 25.00€ |
| ESC | 117.83€ |
| Motor (65.00GBP) | 80.00€ |
| Batteries | 106.80€ |
| Timing Belt, Sprocket, Bearings | 20.00€ |
| Aluminium (sheet of 40x40cm) | 40.00€ |
| Bamboo, Composites, etc. | 20.00€ |
| ABS, Nuts, Bolts, Conumables | 15.00€ |
Electronics:
| Article | Price |
|---|---|
| Control Unit (a modified satshakit cnc) | 9.00€ |
| ADCInputBoard | 5.50€ |
What parts and systems will be made & what processes will be used?
As part of the project I will:- create the 3D design of the board, mechanics (e.g. motor mount, rear swinging fork, control device, etc.), the mold for vacuum forming
- Mill the mechanics
- 3D print the HMI/Handle (and assecoires)
- create the customized board with cable duct (Vacuum forming, Composites)
- create PCBs to control the ESC, to measure the speed, for the HMI (speed, cruise control, etc.) , to transfer analysis data (to a PC), etc. Boards are connected by wire.
What tasks need to be completed & what is the schedule?
Name |
Begin date |
End date |
Resources |
|
Electronics
|
25.05.16
|
07.06.16
| |
|
Create ADCInputBoard
|
25.05.16
|
26.05.16
| |
|
Add button(s) control to CU
|
06.06.16
|
07.06.16
| |
|
Create control unit (CU) - a modified satshakit
|
01.06.16
|
03.06.16
| |
|
Programming
|
27.05.16
|
05.06.16
| |
|
Arm & control the motor (rpm)
|
27.05.16
|
27.05.16
| |
|
Read button data and transfer it to control unit
|
04.06.16
|
04.06.16
| |
|
Read ADC (rpm) & transfer data to control unit
|
04.06.16
|
04.06.16
| |
|
Process RPM and button data to control the motor
|
04.06.16
|
04.06.16
| |
|
Integration & Testing
|
05.06.16
|
05.06.16
| |
|
3D Design
|
05.06.16
|
07.06.16
| |
|
3D Design of mechanical components (axle, rear swinging fork, motor mount)
|
05.06.16
|
07.06.16
| |
|
3D Design of housing for the CU
|
06.06.16
|
06.06.16
| |
|
3D Design of housing for the ESC
|
06.06.16
|
06.06.16
| |
|
3D Design of the handle
|
06.06.16
|
06.06.16
| |
|
3D Design akku pack
|
06.06.16
|
06.06.16
| |
|
3D Print
|
07.06.16
|
07.06.16
| |
|
3D Print handle (w. embedded buttons)
|
07.06.16
|
07.06.16
| |
|
3D Print housing of the CU
|
07.06.16
|
07.06.16
| |
|
3D Print housing of ESC
|
07.06.16
|
07.06.16
| |
|
Manufacturing
|
03.06.16
|
10.06.16
| |
|
Mill the mechanical components
|
05.06.16
|
06.06.16
| |
|
Create battery pack
|
03.06.16
|
06.06.16
| |
|
Assemble all components
|
10.06.16
|
10.06.16
| |
|
Documentaion
|
30.05.16
|
12.06.16
| |
|
Text (Fab Academy Profile)
|
01.06.16
|
12.06.16
| |
|
Final poster
|
10.06.16
|
10.06.16
| |
|
Make Video snippets
|
30.05.16
|
09.06.16
| |
|
Video (10MB, 30-40sec.)
|
10.06.16
|
10.06.16
|
What questions need to be answered?
- Time, Time, Time ... will there be enough time ;)?
How will it be evaluated?
The success of the project can be defined by:- MUST: hardware components are assembled and function so that the board can be driven by user-controlled input
- May-Be: by user input, cruise cotrol can be activated (measure speed & control motor)
- EXTRA: track position and performance data
- EXTRA: transfer analysis data to a PC and run analysis (for improvements of motor control)