Project 2 - Electric Scooter

Task1-

Market analysis for electric scooter

Report Attribute	Details
The market size value in 2022	USD 22.28 billion
The revenue forecast in 2030	USD 40.6 billion
Growth rate	CAGR of 7.8% from 2022 to 2030
Quantitative units	Revenue in USD million and CAGR from 2022 to 2030
Regional scope	North America; Europe; Asia Pacific; Latin America; MEA
Country	U.S.; Canada; U.K.; Germany; France; China; Japan; India; Mexico; Brazil
Key companies profiled	Yadea Technology Group Co., Ltd.; Jiangsu Xinri E-vehicle Co. Ltd.; Hero Electric; Gogoro Inc.; Vmoto Limited; BMW Motorrad International; Mahindra GenZe; Terra Motors Corporation

Source-https://www.grandviewresearch.com/industry-analysis/electric-scooters-market

State-of-the-art products-

• Unagi Model1

• Segway Ninebot Kickscooter Max

• GoTrax GLX V2

• Apollo City
• Hero Vida V1

• TVS iQube electric

• Ola S1(India)

Key players in the market-

• Yadea Technology Group Co., Ltd.
• Jiangsu Xinri E-vehicle Co. Ltd.
• Hero Electric
• Gogoro Inc.
• Vmoto Limited
• BMW Motorrad International
• Mahindra GenZe
• Terra Motors Corporation

Industry trends of electric scooters

• Sleek design
• Clear display
• Dual motors which is good for hills
• Very affordable
• Light system availability
• Strong braking
• Comfortable ride
• Turn signals added
• Apps let the user customize the performance of the scooter
• Portable
• Great KM range

Task 2

Product Development Roadmap

	Q1 1980-2000	Q2 2009	Q3 2012	Q4 2022
Body	Variable reluctance electric motor scooter Bike body used for racing	Battery operated scooter Skateboard cycle type design	Electric scooter with charging capability	Solar-efficient electric scooter Charging electric scooter Portable scooter with inbuilt navigation system
Battery	Nickel-cadmium battery Lead acid battery	A123 systems Li-ion nano phosphate cells	Li-ion battery
Wheel electric motor	Brushed DC motor		Brushless DC motor
Handlebar system	Brakes Accelerator	Brakes Accelerator Speed setting	Brakes Accelerator Speed setting Turn signal	Brakes Accelerator Speed setting Turn signal Navigation system

Resource requirements

#	Requirements
Customer Requirements	Affordable Good Km range Battery life Power nodes Performance of the electric motor should be good Less charge time Features Ride ergonomics Display Riding modes Bluetooth connectivity Charging ports Boot space Navigation
Functional Requirements	To provide good communication range in both high-speed and slow speed scooters A navigation system with built in GPS to get turn by turn notification Good build quality Reliability
Performance Requirements	Speed 61mph Range 0-30 Miles per hour Hill speed 7-20 mph Hill time 6.5s-35s Braking Max 40 ft
Design Requirements	Motor wattage 250 watt Drive system Lightweight Number of motors Two Battery 4 Bldc Hub motor

Mission statements-

Mission Statement
Product Description	Plug-in electric vehicles with two wheels Rechargeable batteries supply the power which drives one or more electric motor Step through frame
Benefits Statement	User friendly Portable powered personal transport Improves the body balance Improves lifestyle by saving money and make the users journey easier No pollution More sustainable Lower running costs Cheaper purchase cost Easy storage Simple transport
Business Objectives	To obtain stellar products and services within a tight timeframe Obtain these services at a reasonable cost which represents the best possible value to their customers and shareholders
Core Market	U.S. Canada The U.K. Germany France China Japan India Mexico Brazil
Stakeholders	● Manufacturing and supply chain partners ● Retailers and stores ● Existing and new customers

Task 3

Work breakdown structure of the electric scooter

The integrated architecture of electric scooter

• The architecture used in the electric scooter design is integrated
• The electrical scooter has a seamless integration of the various futuristic technologies
• It has an electric motor and a battery instead of a fuel tank and combustion engine
• The motor is self-started and can easily control by the about current
• It has the following integrated architecture of the electrical vehicles
• Plug-in electrical vehicle
• Hybrid electrical vehicle
• Battery electrical vehicle
• Powertrains integrated with the Electrical scooter is
• Electric motor
• Battery pack
• Invertor
• DC-DC converter
• On-board charger
• It has an integrated power module

The solidworks file chosen for designing the electric scooter is attached

A 3D rendering of the electric scooter

2D engineering drawings of the electric scooter

Task4

(A)

Failure Mode Effect analysis (FMEA) of the electric scooter

Component	Failure mode	Failure effect	SEV	Potential cause	OCC	Existing detection method	DET	RPN
Electric hub	Fails to rotate Motor overheat	Scooter fails to operate using electric hub	7- Major Scooter performance severely affected	Short circuit	3-Low occurance of failure	Present of smoke	3-High probability of detection	63
Battery	Not enough power supply	System fails to operate	5- Moderate Effect on the product performance	Exceed lifespan on a single charge	4- relatively low occurance rate	Motor not running	2-low chance of detection	40
Chasis	Breaking	Chasis system fails to operate Fail to hold the other part	4-Low Moderate Effect on the product performance	Fracture	2- Remote occurance	Crack in the frame	8-Remote chance of detection	64
Handle	Fails to steer properly	Shock the absorber	5-Moderate Effect in the product performance hence the product requires repair	Wrong installation	5-Moderate probability of failure	Steer to wrong direction	1-Almost certain detection	25
Brake	Fail to decelerate the scooter	The scooter fails to stop	8-Extreme Accident might occur	Wear brake pads	3-Low occurrence probability	Scooter takes time to stop	3-High probability of detection	78
Wheel/Tire	Fail to move fluently Rim punctured	Scooter cannot move	5- Moderate The product requires repair	Punctured	6- Moderately high due to unavoidable obstacle	Need a lot of energy to move	2-high chance of detection	60

(B)

Fault Tree Analysis

Task 5

(A)DFMA

Ten areas of the potential design improvements that are compliant with design for manufacture and assembly would be-

1. Minimize the total number of parts
2. Weld the bracket with the chassis
3. Use the fillet to avoid the sharp corner
4. Avoid the excessively tight tolerances
5. To absorb vibration from main body
6. Support the weight of the car
7. To utilize the characteristics of the process
8. Reduce the number of process stages
9. Designing of the process
10. Improve battery efficiency

DFMA key elements

• Process selection

Parts	Process
Main frame	Cutting and welding
Front fork	Cutting and welding
Absorber
Swing arm	Cutting,drilling and welding
Tyre shaft	Cutting
Handle bar	Cutting and bending

• To reduce the number of process stages
  • Elimination of finishing process of some parts
  • Welding the rocker will reduce the weight of the scooter
• Eliminate unnecessary process
• Design of the process
• Use standard spring coil for machining
• Design for robust
  • Handlebar and front fork connection
  • Design to hold the front frame
  • Connection of the seat and main frame
• Connections parts by parts
• Material of parts

Costing of components

Bill of materials of mechanical parts and component

No.	Name of parts	Quantity	Types of material	Cost(INR)
1.	Swing arm	1	Mild steel	876
2.	Handle bar	1	Mild steel	525
3.	Floor deck	1	Mild steel	350
4.	Seat	1	Fabric	876
5.	Front shock absorber	1	Mild steel	900
6.	Real shock absorber	1	Mild steel	900
7.	Rim	1	Aluminium	340
8.	Brakes lever	1	Plastic	525
9.	Bearing swing arm	1	Mild steel	87
10.	Bolts	26	Mild steel	80
11.	Nuts	26	Mild steel	80
12.	Washer	1	Mild steel	87
13.	Handle bar	1	Steel	80
14.	Tyre bearing	1	Mild steel	550
Total cost on mechanical components				6526 ₹

Bill of materials of electrical parts and component

No.	Name of parts	Quantity	Type of materials	Cost(INR)
1.	Speed Controller	1	Electrical parts	1400
2	Battery	4	Electrical parts	5000
3	Battery Charge port	1	Electrical parts	660
4	Horn	1	Electrical parts	200
5	Front light and signal	1	Electrical parts	350
6	Wire	1	Electrical parts	300
7	Power switch	1	Electrical parts	500
8	Throttle set	1	Electrical parts	613
9	Charger	1	Electrical parts	800
10	Connector	1	Electrical parts	250
The total cost of the electrical components				10,073₹

The outcome of DFA

• It reduces the assembly time
• Simplifies the assembly process
• Shorten the product design time
• Reduces the total material costs
• Reduces the labor content
• Improves the quality by reducing the defects

(B)

Environmental impact

1. Natural resource degradation
2. Emission and waste generation
3. Reduced amount of biodiversity due to the deforestation
4. Air pollution from factory emissions affects the environment
5. Waste generation during the production of the electric scooter
6. Air pollution due to transportation emissions by the transport vehicles
7. Maintenance and cleaning materials
8. Electricity consumed during operating the electric scooter
9. Waste generation during the recovery process
10. Incineration basically generates air pollution and toxic Ash

Materials

• It has the highest environmental impact due to the large variety of materials which is needed to build the electric scooters

Production

• The production of materials causes pollution of the air, water, and land
• Factory emissions, water discharge, and waste generation are the main cause of it

Distribution

• Transportation needed to transfer the materials from one place to another causes huge air pollution
• The packaging creates lots of waste which is harmful to the environment such as plastic waste

Use

• The use is very High
  • The amount of electricity needed to operate the electric scooter is 250 watts
• Example

Recovery

• The recovery is very high due to the large amount of waste which will be slow to degrade and might leak toxins into the soil or air
• Example
• Large plastic enclosures
• The circuit boards containing beryllium
• Electricity too causes pollution
  • Coal-fired electricity plants
• Example

DFES guidelines for the electric scooter

Life Cycle Stage	Design for environment and sustainability guidelines
Materials	● Sustainability of resources ● Healthy inputs and outputs	● Specify renewable/recyclable/recycled material ● Specify renewable forms of energy ● Specify non-hazardous materials ● For safe handling of toxic material, including labels and instructions
Production	● Minimal use of resources in production	● Employ as few manufacturing steps as possible ● Specify materials that do not require surface treatment or coating ● Minimize the number of components and raw material consumption
Distribution	● Minimal use of resources in the distribution	● Use folding, nesting,and disassembly to minimize packaging ● Use recyclable/reusable/lightweight material in packaging
Use	● Efficiency of resources during use ● Appropriate durability	● Implement default power off for systems that are not in use ● Implement feedback or controls for how many Resources are used ● Design to ensure long product life, facilitate repair and upgrades
Recovery	● Disassembly, separation, and purification	● To ensure joints and fasteners/incompatible materials are easily accessible ● Specify the joints and fasteners that can be separated by hand or common tools

Ways to reduce the environmental impact caused by the electric scooter in each life cycle stage-

Materials	Reduce the use of raw and non-toxic material Choose renewable raw materials instead of rare materials Improve the energy efficiency of the harvesting process Intensify the use of recovered and recycled materials
Production	Mention the process materials that can be completely recovered and recycled Eliminate toxic materials in the process Select the processes with high energy efficiency Reduce production scrap and wastes
Distribution	Use the most energy-efficient shipping method Reduce emissions during transportation Eliminate toxic and dangerous packaging materials or remove packaging
Use	Extend the product life span Enable clean and efficient service operations
Recovery	Facilitate product disassembly to separate materials Enable the recovery and remanufacturing of components Facilitate material recycling

(C)

Prototype technologies used in manufacturing electric scooters -

Subtractive prototyping technologies

CNC machining

• Types of CNC machining used are
  • Laser Cutter
  • Plasma cutter
  • Electric discharge machines(EDM)
• CNC Cutting
• CNC turning
• Machining materials
• Alluminium alloys
• Brass alloys
• Bronze alloys
• Copper
• Stainless steel
• Mild low-carbon steel
• Titanium alloys
• Zinc alloys
• Plastic
• ABS
• Polycarbonate
• Garolite G10

Sheet metal fabrication

• Laser cutting

• High-power laser beam to cut the materials
• High precision and repeatability
• Quick production turnaround

• Plasma cutting

• An accelerated jet of hot plasma cut through electrically conductive materials
• All-around sheet metal fabrication tool
• Easy to operate and high-speed cutting

Additive prototyping technologies

3D printing

• A manufacturing process where the materials are joined together via later by layer process
• Types of 3D printing
  • FDM
  • Polyjet
  • SLS, DMLS
• Material Extrusion
• Material Jetting
• Powder Bed Fusion
• Vat Photopolymerisation

The 3D printing used by most manufacturing companies is-

• Selective Laser Sintering(SLS)

• A powder bed fusion 3D printing process using a high power laser to fuse small particles of plastic powders into a mass that has desired 3D shape
• Benefits
• Parts can be made by various materials including plastic, metal,ceramic, or glass powder
• Does not require a support structure

• Direct Metal Laser Sintering (DMLS)

• Allow multiple parts to be combined during the printing process
• Can create complex and strong metal parts
• Small build size and expensive process

The reason why the Manufacturing company uses 3D printing technologies such as SLS and DMLS instead of conventional manufacturing technologies to produce electric scooter parts

• The SLS and DMLS operate by adding layers of material altogether to make an object while traditional manufacturing technologies are subtractive removing parts of a block of material in to create the desired shape of the product
• Creating complex geometries is easier with the DMLS technology but it is difficult with the traditional method to create highly complex parts which would cost much more
• Functional difference of the SLS and DMLS includes the possibility to print full moving assemblies but for the conventional firm, each part must be manufactured for the assembly separately and then they can be assembled later on
• Equipment required in SLS and DMLS is more and it is the mostly automated manner where less labor is required but for conventional Technology different skilled laborers are required to operate each individual machine that is being used
• Business applications customization by creating many more personalized products is possible with the DMLS technology compared to the conventional Technology

Why 3D printing is superior compared to other technologies-

• Advantages
  • Enables manufacturing agility
    • A wide range of products can be produced using 3D printing
    • Even if the market shift the manufacturer can modify their design quickly with no retooling time
    • Multiple SKU's can be produced in a single 3D printing machine
  • Reduced costs and risks
    • It eliminates tooling cost making it economical for low volume production runs
    • Greater flexibility
    • A single factory can support more amount of customers
  • Greater control over the quality
    • In 3D printing, automation quality can be controlled directly
  • Reduce tariff risk
    • The manufacturing companies can tax optimize by opening the manufacturing sites in the same region because multiple 3d printing machines will help to open more side stations
  • Faster customer response
    • With 3-D printing less time is required to produce the product hence faster customer response initiated in a few moments of time

(D)

I have chosen the following factors to make it harder for people to do reverse engineering of my designed electric scooter -

Patent

• It is an exclusive right that is granted to an invention
• This intellectual property will give me the legal right to exclude others from making selling or using the invention for a limited period of time in exchange for enabling disclosure of the invention
• Using patent protection I can prevent from doing reverse engineering

Trademark

• It will help my customers to recognize my products in the marketplace and distinguish my product from the competitors
• If my product will be protected by the trademark the other person cannot reverse engineer it simply by duplicating the product

Source-
https://www.grandviewresearch.com/industry-analysis/electric-scooters-market

https://www.tomsguide.com/best-picks/best-electric-scooters

https://www.embitel.com/wp-content/uploads/Single-ECU-Architecture.jpg

https://www.researchgate.net/publication/320065052_Ergonomic_study_and_static_analysis_for_new_design_of_electric_scooter

https://www.iezway.com/design-and-development-of-electric-scooter/

https://www.slideshare.net/ShafeequrRehman6/concept-testing-product-architecture-and-design-of-modular-system

https://evnerds.com/design/electric-motorcycle-design/electric-scooters-modular-design-by-electric-dutchman/

https://e-vehicleinfo.com/electric-vehicle-architecture-ev-powertrain-components/

https://www.productplan.com/glossary/product-architecture/

https://www.sciencedirect.com/science/article/abs/pii/S0957417417300714

http://inside.mines.edu/fs_home/cskokan/courses/failure/analysis.html

https://www.smartdraw.com/fault-tree/

https://iopscience.iop.org/article/10.1088/1748-9326/ab2da8

https://futurist.law.umich.edu/the-environmental-impacts-of-e-scooters/

https://hackaday.com/2021/09/15/3d-printed-scooter-zips-around/