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Electric Motorcycle Design Project SR. Design Project Fall 2008-Spring 2009 Justin Cole Chad Dickman Todd Sanderson Kris Williams

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

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The project Convert gasoline motorcycle to electric – Emissions – Energy crisis – Ideal for short commutes. Create publicity for the school. – Outreach – Open house

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Components Batteries – 4-12VDC sealed lead acid – Designed for electric vehicles. – electricmotorsport.com Charger – Soneil 48 V 5 amp – thunderstruck-ev.com

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Components (continued) Motor – Briggs and Stratton Etek-R 8 hp continuous 15 hp peak Controller – Sevcon Milipack – Regenerative – 48VDC Wiring, fuses, throttle electricmotorsport.com

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Where we stand Motor kit & Batteries Purchased and received – electricmotorsport.com Purchased motorcycle – Lemon and Barrett’s Still need parts – Chain – Sprockets – Charger – Miscellaneous

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Budget 48 volt System Budget Breakdown ItemPriceSupplier Bike$ Lemon and Barrett’s Kit(which includes the following): $1, electricmotorsport.com motor controller throttle contactor fuses wiring Charger$175.00thunderstruck-ev.com 4 $70$280.00electricmotorsport.com Chain$100.00electricmotorsport.com Gears$200.00electricmotorsport.com General Costs$ subtotal$2, Taxes$ Total$2, Table of budget breakdown

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Sample Calculations Aerodynamic Drag Force (F d ): C d =Coefficient of drag of the vehicle A=Frontal area of the vehicle in square feet V=The vehicle’s speed in mph Rolling Resistance (F r ): C r =Rolling resistance factor W=Vehicle weight in lbs Force due to Acceleration (Fa): Ci=Unit conversion factor W=Vehicle weight in lbs a=Acceleration in mph/second Force due to Climbing Hills (F h ): W=Vehicle weight in lbs Φ=Angle of incline

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Sample Calculation (continued) Total Force on the Vehicle (F T ): All four forces added together The Horsepower needed (hp): F T =Total Force in lbs V=Speed expressed in mph Torque needed from the Motor (T): hp=Horsepower RPM=Revolutions per minute Conversion from hp to Watts (W): Current needed to Power in Amps(A): V=Volts from the battery W=Power need to run in Watts

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Sample Calculations (continued) Time in hours the Vehicle can run (Time): Ah=Amp-hours from the battery A=Current Total Distance in Miles Vehicle can Drive (D): mph=Speed in mph Time=Time in hours vehicle can run Battery Charging Time (T c ): Ah=Amp-hours from the battery Amp=Amps from the battery charger

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Data Tables SpeedForce mphAerodynamic Rolling Resistance Wind Resistance Acceleration Resistance Hill ClimbTotal Table of various resistive forces with a constant acceleration of 3 mph/sec and a 3% grade.

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Data Table (continued) SpeedAccelerationForce TotalPowerTorqueCurrentTimeDistance RPMmphmph/seclbsHPWft*lbsAmpsHrsminMiles Table of Distance and other parameters with varying accelerations

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Data Tables (continued) Speed Grade of Incline Force TotalPowerTorqueCurrentDistance MPH%lbsHPWft*lbsAmpsMiles Table of Distance and other parameters with varying inclines

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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 to to to to to to to 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

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Graphs

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Graphs (continued)

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Previous Designs Very similar – Motor – Batteries – Type of bike Verified project calculations Made in home garage. Proves feasibility Total project costs less than $3000 Picture of bike that uses the same motor and type of batteries as this project.

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Current Timeline Electric Bike Conversion Gantt Chart Timeline October November January February March April May 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

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What’s Next? Bike preparations Layout of components Bike Design Assembly Wiring Testing Demonstrations

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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.

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