Building a Motorized Electric Skateboard: A Step-by-Step Guide for Mechanical Engineering Students.

The motorized electric skateboard is a modern update to the traditional skateboard, designed for enhancing mobility and convenience. It is equipped with an electric motor, enabling the rider to control both acceleration and braking effortlessly through a handheld remote. Capable of carrying upto100kg, this skateboard is perfect for commuting or leisure rides. With a range up to 7km , it provides a smooth and efficient ride even on uneven surfaces, combining technology and practicality for an exciting and eco-friendly transportation solution.

1. Presentation on   Modelling, Designing and Fabrication of Electric Motorized Skate-Board XXX     In partial fulfillment of the requirements of the degree of   Bachelor of Technology in Mechanical Engineering   (2018)   Under the Guidance of   XXX Assistant Professor Mechanical Department   DEPARTMENT OF MECHANICAL ENGINEERING SIKKIM MANIPAL INSTITUTE OF TECHNOLOGY MAJHITAR, RANGPO, EAST SIKKIM-737132

2. INTRODUCTION Board sports, including snowboarding, skateboarding and surfing have been around for many years and are considered popular recreational activities. The application of these boards is partially restricted as they can only be ridden under particular environmental conditions and certain circumstances. An electric skate-board is an upgraded skateboard, with an attached motor, capable of accelerating and braking the skate-board through a hand held throttle and brake. Fig no. 1: Electric Skate-Board

3. Literature Review The main reason to pursue this project was to evaluate the performance and make it cost effective. Due to its unavailability in India the price is 6 times higher so the idea is to develop a suitable design to manufacture the board, with price under Rs20000 Fig No. 2: Price in different website

4. PROJECT AIM Design an Electric Skate-board. Fabricate the designed model. Analyze the performance of Electric Skate-board w.r.t. load and distance. Analyze battery performance. Suggest improvements.

5. DESIGN REQUIREMENTS Criteria Target Requirements Dimensions and Weight The dimensions of the board are 90cm long, 25cm to 30cm width, 1.5cm thickness. It will consist of a metallic frame. Total weight of board including all components to be < 15kg Performance Requirements It should be able to travel on bitumen, dirt, gravel, grass. Able to accelerate to reach a speed of 8-10km/hr. Able to travel up a 10° incline from standstill. Have a minimum run time of 20mins or 2km. (will vary depending on terrain and rider weight) Reliability and Maintenance Electrical components sealed from water, snow, mud and the elements. Be durable enough to withstand moderate impacts. Ergonomic Design Have a maximum capacity to allow riders of up to 100kg. Be adjustable for different sized riders Turn via rider weight transfer. Have a maximum battery charge time from completely discharged to fully charged of 8-12 hrs. Safety Foot straps for grip. Manual breaking system. Price Total cost of components including manufacturing to be < Rs20,000. Table no. 1: Design Requirement.

6. DIFFERENT COMPONENTS OF AN ELECTRIC SKATE-BOARD DECK FRAME TRUCK AND SUSPENSION AXLE WHEELS MOTOR ESC MOTOR MOUNT THROTTLE BRAKE LEVER FOOT STRAPS BATTERY Fig No. 3:Different components of electric skate-board.

7. DIFFERENT COMPONENTS OF AN ELECTRIC SKATE-BOARD MOTOR MOUNT THROTTLE BRAKE LEVER Fig No. 4: Different components of electric skate-board.

8. DECK MODELLING IN CREO PARAMETRIC4.0 Fig No. 5: Image showing rendered drawing of deck in Solid Works. Primarily we sketched the different components of the board in chart paper, than we modelled the components in CREO Parametric 4.0. All dimension in cm

9. DECK MODEL ANALYSIS IN ANSYS Fig No. 6: Equivalent Stress Analysis of deck . . E quivalent stress of the board was simulated in ANSYS. Figure no. 6 shows stress on different parts of the board, when a force of 1000N is applied at top surface of the board and has a support at both ends.

10. DECK MODEL ANALYSIS IN ANSYS Fig No. 7: Displacement Magnitude Analysis of deck . . Displacement magnitude of the board was simulated in ANSYS. Fig no.7 shows displacement magnitude on different part of the board, when a force of 1000N is applied at top surface of the board and has a support at both ends.

11. DECK MODEL ANALYSIS IN ANSYS Fig No. 8: Fatigue Life Analysis of deck . . Fatigue experienced on the board was simulated in ANSYS. Fig no.8 shows Fatigue life on different parts of the board, when a force of 1000N is applied at top surface of the board and has a support at both ends.

12. TRUCK MODELLING IN CREO PARAMETRIC4.0 Fig No. 9: Image showing rendered drawing of deck in Solid Works . . Different truck components were modelled in CREO in 3-dimensional view. The 2-dimensional sketch was achieved from solid works e-drawing. All dimension in cm All dimension in cm

13. TRUCK MODEL ANALYSIS IN ANSYS Fig No. 10: Equivalent Stress Analysis of Truck . . E quivalent stress of the truck was simulated in ANSYS. Figure no. 10 shows stress on different parts of the truck, when a force of 1000N is applied at top surface of the truck and has a support at both ends.

14. TRUCK MODEL ANALYSIS IN ANSYS Fig No. 11: Displacement Magnitude Analysis of Truck . . Displacement magnitude of the truck was simulated in ANSYS. Fig no.11 shows displacement magnitude on different part of the truck, when a force of 1000N is applied at top surface of the truck and has a support at both ends.

15. TRUCK MODEL ANALYSIS IN ANSYS Fig No. 12: Fatigue Life Analysis of truck . . Fatigue experienced on the truck was simulated in ANSYS. Fig no.12 shows Fatigue life on different parts of the truck, when a force of 1000N is applied at top surface of the truck and has a support at both ends.

16. Part Name Description Parts Included (no.) Deck Deck with 15° Risers (includes truck bolt kit) 2 pieces wooden ply 2 pair nut and bolt Baseplate/Frame Mild steel material for more support. Welded metallic frame. Springs Coil springs for damping and suspension. 4 Springs Foot straps Pair of foots straps for secure connection of rider to deck 1 Foot straps (Pair) 2 Bolt , 4Nut Motor 24 volts 350 watt 9 tooth 1/8" bicycle chain sprocket   1 ESC 24V 350watt ESC   1 Trucks Flat plate(MS)   12 Bolts   2 Washer   2 Nuts 2 Spring   2 Charger For charging battery   1 Throttle For acceleration mechanism   1 Battery Battery12V,7 Amp   2 Axle Shaft and wheel assembly Axle and shaft   2 Wheels   4 Bolt   4 Motor Mount 1 PART PROCUREMENT Table no. 2: Part Procurement

17. FABRICATION DECK: Two pieces of ply wood was fixed by adhesive for making the deck, this process is also termed as lamination of wood. Fig 13 shows different views of deck. Fig no. 13 shows the different views of the deck and Fig no. 14 shows the fabricated deck. Fig No. 13: Image showing rendered drawing of deck in Solid Works .. . Fig No. 14: Final Fabricated Deck . All dimension in cm

18. FABRICATION FRAME: We used mild steel bar and got it welded as shown in the figure to achieve the design. Fig No. 15: Fatigue Life Analysis of truck . . Fig No. 16: Fatigue Life Analysis of truck . . All dimension in cm

19. FABRICATION TRUCK: We used mild steel bar and got it welded as shown in the figure to achieve the design. Fig No. 17: Image showing rendered drawing of truck in Solid Works . . . Fig No. 18: Image showing rendered drawing of truck in Solid Works . Fig No. 19: Final Fabricated Truck.

20. FABRICATION MOTOR MOUNT: We used mild steel bars and got it welded to the axle shaft and a wooden piece to hold the motor to the bar. Fig No. 20: Motor mounted on motor mount . . . Fig No. 21: Foot Straps attached to deck . FOOT STRAPS: We used several pieces of cloth and foam, stitched together to achieve the required foot straps.

21. MOTOR AND ESC SPECIFICATION MOTOR: We used 24V,350watt DC gear motor. Lead acid battery of 12V(2 units) will be used to run the motor. Fig No. 22: Motor Specifications .

22. MOTOR AND ESC SPECIFICATION Fig No. 23: ESC Specifications . ELECTRONIC SPEED CONTROLLER: An electronic speed controller (ESC) is an electrical circuit capable of varying an electric motors speed .

23. FINAL BOARD ASSEMBLY Fig No. 24: Final prototype board . Once all the parts were procured and fabricated, the final assembled prototype looks like.

24. OBSERVATION AND CALCULATION OBSERVATION: Two different types of observations were taken under two different conditions. First condition was idle condition and secondly on load condition. Condition 1: Idle condition with no friction, vibration, constant acceleration, battery fully charged. Table no.7 shows reading for first condition. Sr no. Speed(km/hr)(rated) Time(hr) 1 18 0.42 Condition 2: On load condition of 1100N including with the board weight. Table no.8 shows reading for first condition. Sr no. Speed(km/hr) Time(minutes) 1 15to16 0.33 2 15to17 0.36

25. OBSERVATION AND CALCULATION CALCULATION: Condition 1: Distance travelled = (observed speed x time) = 7.56km Condition 2: Distance travelled = (observed speed x time) = 4.65km Overall Efficiency = [(7.56-4.65)/7.5]x 100 = 38%

26. RESULTS AND DISCUSSION Distance travelled by board on idle condition was 7.56km whereas distance travelled on load condition was only 4.56km, resulting in overall efficiency of 38%. Overall the dimension and weight requirements where mostly met, with the exception of the total weight of the board. The board was designed to be as light as possible whilst still providing adequate strength and functionality. The prototype board was 15.8kg. The total price of the board is under Rs20000

27. CONCLUSIONS The board has overall dimensions of 70cm long, 21cm wide and 15cm high and a total weight of 15.8kg. The total cost of the prototype board was under Rs 20000

28. SCOPE FOR FUTURE WORK All the parts should be manufactured using aluminium alloy to decrease its weight. Wireless throttle and regenerative braking system can be incorporated. Disc brake can be incorporated. Deck should be made using glass fibre, carbon fibre to decrease its weight. Ratchet Foot Binding can be used.