Electric Motorcycle Design Project

SR. Design Project Fall 2008-Spring 2009

Justin ColeChad Dickman

Todd SandersonKris Williams

Outline• The project• Components• Where we stand• Budget• Sample Calculations• Data Tables• Graphs• Timeline• What’s Next?• Conclusion

The project

• Convert gasoline motorcycle to electric– Emissions – Energy crisis– Ideal for short

commutes.

• Create publicity for the school.– Outreach– Open house

Components

• Batteries– 4-12VDC sealed lead

acid– Designed for electric

vehicles.– electricmotorsport.com

• Charger– Soneil 48 V 5 amp – thunderstruck-ev.com

Components (continued)

• Motor– Briggs and Stratton Etek-R

• 8 hp continuous• 15 hp peak

• Controller– Sevcon Milipack– Regenerative– 48VDC

• Wiring, fuses, throttle• electricmotorsport.com

Where we stand

• Motor kit & Batteries Purchased and received – electricmotorsport.com

• Purchased motorcycle– Lemon and Barrett’s

• Still need parts– Chain– Sprockets– Charger– Miscellaneous

Budget48 volt System Budget Breakdown

Item Price SupplierBike $250.00 Lemon and Barrett’sKit(which includes the following): $1,075.00 electricmotorsport.com

motorcontroller

throttlecontactor

fuseswiring

Charger $175.00 thunderstruck-ev.com4 Batteries @ $70 $280.00 electricmotorsport.comChain $100.00 electricmotorsport.comGears $200.00 electricmotorsport.comGeneral Costs $300.00 subtotal $2,380.00 Taxes $142.80  Total $2,522.80

Table of budget breakdown

Sample CalculationsAerodynamic Drag Force (Fd):

Cd= Coefficient of drag of the vehicle

A= Frontal area of the vehicle in square feetV= The vehicle’s speed in mph

Rolling Resistance (Fr):

Cr= Rolling resistance factor

W= Vehicle weight in lbs

Force due to Acceleration (Fa):Ci= Unit conversion factorW= Vehicle weight in lbsa= Acceleration in mph/second

Force due to Climbing Hills (Fh):

W= Vehicle weight in lbsΦ= Angle of incline

Fd

Cd A V2

391

Fr Cr W

Fa Ci W a

Fh W sin ( )

Sample Calculation (continued)Total Force on the Vehicle (FT):

All four forces added together

The Horsepower needed (hp):FT= Total Force in lbs

V= Speed expressed in mph

Torque needed from the Motor (T):hp= HorsepowerRPM= Revolutions per minute

FT Fd Fr Fa Fh

hpFT V

375

T5252hp

RPM

Conversion from hp to Watts (W):

Whp 1000

1.34

Current needed to Power in Amps(A):V= Volts from the batteryW= Power need to run in Watts

AW

V

Sample Calculations (continued)Time in hours the Vehicle can run (Time):

Ah= Amp-hours from the batteryA= Current

Total Distance in Miles Vehicle can Drive (D):mph= Speed in mphTime= Time in hours vehicle can run

Battery Charging Time (Tc):

Ah= Amp-hours from the batteryAmp= Amps from the battery charger

TimeAh

A

Dmph

Time

TcAh

Amp

Data TablesSpeed Force

mph AerodynamicRolling

ResistanceWind

ResistanceAcceleration Resistance

Hill Climb Total

5 0.128 7.320 0 69.365 14.63 91.446

10 0.512 7.320 0 69.365 14.63 91.830

15 1.151 7.320 0 69.365 14.63 92.469

20 2.046 7.320 0 69.365 14.63 93.364

25 3.197 7.320 0 69.365 14.63 94.515

30 4.604 7.320 0 69.365 14.63 95.922

35 6.266 7.320 0 69.365 14.63 97.584

40 8.184 7.320 0 69.365 14.63 99.502

Table of various resistive forces with a constant acceleration of 3 mph/sec and a 3% grade.

Data Table (continued)Speed Acceleration Force Total Power Torque Current Time Distance

RPM mph mph/sec lbs HP W ft*lbs Amps Hrs min Miles

2830.6 40 1 30.57 3.26 2433.40 6.05 50.70 0.69 41.42 27.62

2830.6 40 2 53.69 5.73 4273.93 10.63 89.04 0.39 23.58 15.72

2830.6 40 3 76.81 8.19 6114.46 15.20 127.38 0.27 16.49 10.99

2830.6 40 4 99.93 10.66 7954.99 19.78 165.73 0.21 12.67 8.45

2830.6 40 5 123.06 13.13 9795.52 24.35 204.07 0.17 10.29 6.86

Table of Distance and other parameters with varying accelerations

Data Tables (continued)Speed

Grade of Incline

Force Total Power Torque Current Distance

MPH % lbs HP W ft*lbs Amps Miles

40 1 20.38 2.17 1622.59 4.03 33.80 41.42

40 2 25.26 2.69 2010.91 5.00 41.89 33.42

40 3 30.14 3.21 2399.00 5.96 49.98 28.01

40 4 35.01 3.73 2786.74 6.93 58.06 24.11

40 5 39.87 4.25 3174.01 7.89 66.13 21.17

40 6 44.73 4.77 3560.71 8.85 74.18 18.87

40 7 49.58 5.29 3946.72 9.81 82.22 17.03

Table of Distance and other parameters with varying inclines

Data Tables (continued)

Table of distance with a period of acceleration followed by a period of constant speed.

Accelerating at 4 mph/sec

Accelerating to 40 mph

Total KWh from the batteries

KW needed for

accelerating at 4mph/sec

Accelerating Time in Hours (30 stop and

go's)

KWh used when accelerating at 4

mph/sec for a total of 5 min worth of

accelerating

Distance traveled

accelerating

0 to 5

1.00674668

0.599 0.01 0.01 0.05

5 to 10 1.801 0.01 0.02 0.10

10 to 15 3.014 0.01 0.03 0.16

15 to 20 4.246 0.01 0.04 0.21

20 to 25 5.505 0.01 0.06 0.26

25 to 30 6.798 0.01 0.07 0.31

30 to 35 8.134 0.01 0.08 0.36

35 to 40 9.518 0.01 0.10 0.42

Total KWh used

accelerating

Remaining KWh

Hours of constant

speed

Distance traveled in miles

after Accelerating at

40 mph

Distance traveled accelerating

(miles)

Total Distance

traveled in miles

0.41 0.59 0.44 17.56 1.88 19.43

Graphs

Graphs (continued)

Previous Designs

• Very similar – Motor– Batteries– Type of bike

• Verified project calculations

• Made in home garage.• Proves feasibility• Total project costs less

than $3000Picture of bike that uses the same motor and

type of batteries as this project.

Current Timeline Electric Bike Conversion Gantt Chart Timeline

October   November   January     February   March     April       May

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1

Research    

  Budget    

  Calculations  

 Design of

Bike Specs        

  Design of Bike Layout  

  Writing Sponsorship Proposal  

  Presenting to Companies  

  Purchasing the Bike  

  Buy Batteries  

  Build Batt. Trays  

  Buy Electric Motor Kit  

  Drive train Assembly  

  Motor Mount  

  Electric Assembly  

  Testing

                                              Demo

What’s Next?

• Bike preparations• Layout of components• Bike Design• Assembly • Wiring• Testing• Demonstrations

Conclusions

• The design is feasible• Some minor funding is still needed• The project is coming along pretty well

according to the plan.• The preliminary research and calculations are

complete.• The bike is ready to begin laying out the

components.