The goal of this project was to gain experience in CNC manufacturing and further develop my CAD skills. This project was also a way to learn more about electronics, and creating safe and protected power systems.
Current Designed Specs:
32 mph top speed
42 Nm torque at the wheels
44 volt system
Up to 7.5 kW continuous
Dual Motor Setup
Super Flexible Deck
Current Designed Specs:
32 mph top speed
42 Nm torque at the wheels
44 volt system
Up to 7.5 kW continuous
Dual Motor Setup
Super Flexible Deck
Design
I used SolidWorks 2019 as my primary CAD software, and use Fusion 360 for my primary CAM software. Since I was able to utilize professional CNC laser cutters and press breaks during my time at Edro Corporation, I was challenged to almost everything from sheet metal. This included the trucks, motor mounts, and battery box. I got extensive practice with the SolidWorks sheet metal tool, which came very useful at Edro later in the summer as I was tasked to design sheet metal parts.
Manufacturing
Manufacturing was very easy as everything was designed with CNC laser cutting and bending in mind. Since correct tolerancing was implemented, and locating tabs were used, everything fit together were it was supposed to go. Once everything was laser cut, we then sent it through a deburring machine, went to the CNC press break for bending, then it was welded together. I was very fortunate to have these professional machines available to me, I learn a lot and utilized them to create something was was very easy to manufacture and assemble
Electronics
With this project I wanted to do more than just buy a battery pack. I took it a step further and bought 2, 6 cell 12 Ah Lipo (Lithium Polymer) batteries wired in series, to create a 12s1p battery. Putting the batteries in series doubles the voltage to ~44V nominal.
I then wired the battery into a BMS (battery management system). The BMS protects the VESC (motor controllers) from overcurrent and overvoltage, as well as allows me to comfortably charge the whole pack via one standard barrel connector.
Lastly, I used two VESC 6 (vedder electronic speed controller) motor controllers. They are open source speed controllers purpose built for these applications.
I then wired the battery into a BMS (battery management system). The BMS protects the VESC (motor controllers) from overcurrent and overvoltage, as well as allows me to comfortably charge the whole pack via one standard barrel connector.
Lastly, I used two VESC 6 (vedder electronic speed controller) motor controllers. They are open source speed controllers purpose built for these applications.