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Electric Vehicle

In summer 2013, I was lucky to get the privilege of going to Massachusetts Institute of Technnology (MIT) for summer school. My university, Singapore University of Technology and Design (SUTD), has a partnership with MIT for this program. 30 students were selected. The activities that we signed up for were ceramics making, sketching, entrepreneurship seminars, and many more. The main project was to build an electric vehicle (gokart) within 10 weeks. I documented the entire experience of building the gokart in this page. Check out the videos first! Then, read the individual posts if you are interested. Enjoy! :)

Gokart Reflection

Lord Charles has ordered us to do a reflection. He has given us some pointers to follow so here we are answering it! Assessment of your machine’s performance. Consider the differences between your design calculations and the actual performance. This is an interesting one. There were many things we had...

Batt Mobile Complete!

Here’s a teaser of our gokart. IT WORKS. Evidently a last minute hack to make it work. Look at that mess of wires! Okay so we fired up our vehicles today but it didn’t start. Andrew was wondering why didn’t it start. And then he realised that we didn’t power...

Solder, solder, solder, solder.

The controllers (with rings) The controllers (no rings) Our controller came with the ring terminals. However, we decided that they wouldnt be too glam when we put it our our kart. Therefore, we decided to swap all of them out into the bullet connectors. They look awesome. Connecting the wires...

$0.0033 left.

We milked every penny! We are left with one third of a cent. wow

Rolling test completed!

Batt Mobile all set and ready to roll Us and the kart Woohoo! We got 10/10. Soldered hall effect sensor That concludes our journey with the Mechanical Component of this EV summer program. Time for electronics! Can’t wait to get the car moving!

Chassis completed!

And so… We began our assembly after dinner, at about… 8pm? Andrew fixing the front wheel. Tightening the bolts The front wheel was slightly problematic as the holes were somehow misaligned. They weren’t misaligned the first time we put them in. We think it was largely due to the fact...

Towel Seat

So… Our wheels are finally complete! We drilled the washer and the sprocket onto the wheel with the inner ring of the plastic wheel. Charles used 6 screws for Chibikart. 6 screws sounds legit, but we thought we would just go 12 for extra safety :D Loctite-ed bolt. I think...

Naming the Kart

We have decided. After much deliberation. To name our kart the BATT MOBILE. BATT MOBILE!

Loctite

The red stuff is Loctite. And so we’ve finally started loctiting our stuff. All our wheels are now liberally blessed with loctite, and soon our entire cart will be loctited. Mwahaha. The brake lever in the photo now works as well. Woohoo. That said, we’re having a huge problem with...

All waterjet parts are in, assembly begins!

Drilling Milling the messed up waterjet parts Precisiong drilling. It's quite a thin strip of plastic we have to drill into. Drilling again Drilling the tiny holes on the wheel Alright, relatively short blog post here. So we bought our sprockets from McMaster but the 6 holes that come with...

Wood has evolved to Metal!

A significant portion of our parts were waterjetted from sheet aluminium today! I’ve never used a waterjet before so that was utterly awesome. Charles and Justin, awesome dudes who helped us waterjet it and brought the metal sheets to the archi lab and back to IDC. The sign is very...

Protoyping with Wood and MDF

Prototyping has finally begun and was actually slated to be finished last week. Our table Cold Saw. Why is it called this anyway? However the moment we began building we quickly realized that some of the joints we wanted to have in our CAD model weren’t possible (or just required...

Give me a Brake!

As it turns out, Charles has told us that can-braking is something “he should never have allowed” – I suppose that means it’s allowed though. Heheh. Can braking is the act of braking your vehicle by stopping your outrunner motor. This has a major benefit – convenience and cost. But...

Our CADs

Bare Chassis Chassis with Electronics and Steering Chassis with Seat Front Wheel Rear Wheel 3D Printed Steerer? EV Car V3

Milestone 2 Calculations

I did up a neat excel sheet which allowed me to calculate some simple approximated values from a few given parameters: Since the power output of the motor is roughly equal to the approximated power loss due to air drag of the kart at 35kmh, and given that the motor...

Milestone 2

So given that we’re going to use two motors driving two rear wheels, we’ve done some calculations and we’ve realized that the kv of the motors we’ve been browsing are too damn high. The problem was that with the gear ratio given and the max speed that we’d be travelling...

Choices. Choices.

And so our instructor Charles told us that a differential would be too ambitious a project in such a short timespan. Somehow or another he was extremely convincing, so we agreed to not be so ambitious. So here are some of things that we’ve decided on: Four Wheels Around a...

Preliminary Brainstorming and Sketches

Based on the briefings and the 2.007 blogs that we’ve seen, there are a few variables that we could explore: Differential? Gear box? How many wheels? How many motors? Big or small wheels? How is steering done?

Differential Disassembly

We found a cheap differential and we thought we’d disassemble it, just to learn more about them so we could decide better if we wanted to construct/buy one (the one we could order was almost the exact same thing from Surplus Center). It was an extremely simple design, but at...