ELECTRIC SCOOTER
The Overview
Demand for alternative solutions to fossil fuels has seen a significant uptrend in recent years. Interestingly, an online release by Forbes estimates that up to 46% of all traffic is caused by vehicles operating on less than 3 miles. The need for more efficient transportation - especially within an urban environment – is paramount.
Perhaps the solution to both these problems is electric scooters. Despite the global pandemic impediment, electric scooters are expected to hit a $16 billion market capitalization by 2025 in the USA alone. Towards different markets, both food and e-commerce delivery services are expected to grow at an annual compound rate of 20% and 14% respectively, whilst ride-hailing services are to compound at an annual rate of 18.45%
A 4 person team led by myself arrived at a core objective: To develop an electric scooter that could capitalize on these market trends, as well as future trends yet to be seen.
Prototype Generation
Through concept and prototype generation finalised through CAD modelling, a unique fastening system chassis able to implement various “modules” such as seats for hailing services and extra compartments for delivery services was developed. This fastening system would allow other companies to design their own modules for the scooter; allowing for endless possibilities and customization, and a larger market capitalization.
The design proposed features a robust electric scooter, providing more vital chassis integrity as well as larger suspension systems to accommodate for heavier loads expected from the target market.
The designed assembly consists of 31 parts. The base was designed with a cavity for battery and control system placement. Due to the many parts, the overall skillset of the team significantly improved towards CAD modeling, especially with having to design and come up with the more delicate features such as break handles and headlights.
Design for Manufacturing and Assembly
From the beginning of the design process, the team pushed forwards for an incentive to ensure that the design of the scooter would accommodate for efficient and simple manufacturing processes as the product is very much akin to what a start-up company would initially begin with as a prototype.
From this initial design with a healthy Design Efficiency of 12.63, we were able to ingeniously eliminate further processes that could in turn be combined together, resulting in further decreased assembly times and thereby an increased Design Efficiency of 14.26
Life Cycle Assessment
LCA analysis has involved the determination of the unit processes associated with the cradle-to-grave operation of the electric scooter product, with the inclusion of the product flows.
These unit processes include the production and transport of materials, production and supply of scooter components, scooter assembly and transportation, scooter use and the disposal of the various components at the end of the products’ lifecycle.
The collation of the unit processes has formed the complete - although simplified - product system of the electric scooter below.
Environmental Analysis
From observation, the steel processing required for scooter production has a less significant impact on the environment in comparison to aluminium, for all environmental factors. Despite this, aluminium has been selected as the appropriate material to use for the scooter.
For the proposed design, use of aluminium substantially reduces the mass of the scooter. Using steel will fix the frame mass to approximately 110 kg which is highly unfeasible, restricting the practicality of the product. Furthermore, with the additional mass using steel, the power required to provide scooter motion would be significantly large and unrealistic.
This in effect would have an adverse environmental impact not accounted for in the environmental analysis. As a result, aluminium is the chosen material for the scooter frame and wheel cores.
