MEC 531 Mechanical Engineering Design 1 Project Report

MEC 531
MECHANICAL ENGINEERING DESIGN 1
PROJECT NAME : KOUGAR SCOOTER (E-SCOOTER)

LECTURER:
DR.NOOR FAZLI ADULL MANAN
STUDENTS:
AMIRUL ‘ARIFF BIN ABDUL MANAF
(2015154373)
AZZAMUDUDDIN BIN AZIZUDDIN
(2015125709)
LUQMAN HAKIEM BIN SULAIMAN
(2015182365)
MUHAMMAD HARIZ BIN RAHAMAT
(2015115263)
WAN MUHAMAD HASLAH BIN JAMALUDIN
(2015116497)
MARKS:
BACHELOR OF ENGINEERING (HONS) MECHANICAL

SEMESTER 5
EM220-2A
TABLE CONTENT
NO CONTENT PAGE
Acknowledgement 1
Abstract 2
1.0 Introduction 3
PHASE 1: CONCEPTUAL DESIGN
2.1 Background of study 7
2.1.3 Problem statement 15
2.1.4 Objective 16
2.1.5 Scope of project 17
2.1.6 Significant of project 19
2.2 Gather information 21
2.2.1 Article and journal 21
2.2.3 Survey form and analysis 24
2.2.4 Interview 31
2.2.5 Benchmarking 32
2.3 Concept generation 36
2.3.1 Functional decomposition 37
2.3.2 Morphological chart 39
2.3.3 Conceptual design 44
2.4 Concept evaluation 51
2.4.1 Pugh chart 51
2.4.2 Decision matrix 52
PHASE 2 EMBODIMENT DESIGN
3.1 Product architecture 57
3.1.1 Design for human factor 70
3.1.2 Creating user friendly design 74
3.2 Configuration design 75
3.2.1 Modelling 76
3.2.2 Simulation 79
3.2.3 Analysis of calculation 84
3.2.4 Material selection 95
3.3 Parametric design 98
3.3.1 Failure Mode And Effect Analysis (FMEA) 99
3.3.2 Design For Assembly (DFA) 101
3.3.3 Design For Manufacture (DFM) 102
3.3.4 Design for robust 104
3.4 Final dimension 105
PHASE 3: DETAILED DESIGN
4.1 Introduction 108
4.2 Objective 109
4.3 Detail drawing 110
4.3.1 Details Engineering drawing 111
4.3.2 Details Engineering drawing 118
4.4 Bill of material of electric scooter 131
4.5 Full Assembly 134
4.6 Bill of material (BOM) 135
4.6.1 Costing 138
4.6.2 Total costing and overhead 141
4.7 Final specification 142
4.8 Brochure of Kougar-Scooter 147
5.0 Conclusion 148
6.0 Gantt chart 149
7.0 References 150
LIST OF FIGURE
LIST OF FIGURE PAGES

Figure 2.1.1.1: Hub motor 9
Figure 2.1.1.2: Hub motor 10
Figure 2.1.1.3:Chain Motor 10
Figure 2.1.1.4 10
Figure 2.2.3(A) and (B):The sample of survey form 25
Figure 2.2.3(C) : Gender 26
Figure 2.2.3(D): Number of University Student 26
Figure 2.2.3(E) : Residency Status 27
Figure 2.2.3(E): Percentage of frequent mode of transportation 27
Figure 2.2.3(F): Electric scooter are relevant to you as a university student 28
Figure 2.2.3(G): Reasonable Price For Electric Scooter 29
Figure 2.2.3(H): The main problem with electric scooter 29
Figure 2.2.3(I): Desired characteristic 30
Figure 2.3.3.1: Design concept 1 (Scooter-Rama) 45
Figure 2.3.3.2: Design concept 2 (Piz-Scooter) 46
Figure 2.3.3.3: Design concept 3 (Kougar -Scooter) 47
Figure 2.3.3.4: Design concept 4 (Cool scooter) 51
Figure2.3.3.5: Design concept 5 (Foldable scooter) 49
Figure 2.3.3.6: Design concept 6 (V-Scooter) 50
Figure 2.4.2.1: Selection of concept design 53
Figure 3.1 : The basic geometry of bicycles and motorcycles showing the 62
rake and trail
Figure 3.2: Graphical representation of steering 5 motion 63
Figure 3.3:Graphical representation of steering 5 motion 64
Figure 3.4- Front fork assembly view 75
Figure 3.5: Main frame assembly 76
Figure 3.6: Swing Arm Assembly 77
Figure 3.7 Von Misses Stress on Front Fork 78
Figure 3.8:Boundary Condition 78
Figure 3.9 Von Misses Stress on Main Frame 80
Figure 3.10:Boundary Condition 81
Figure 3..11 Von Misses Stress on Swing Arm 82
Figure 3.4.1 :Final Dimension 104
Figure 3.4.2: Final Dimension 104
Figure 3.4.3: Final Dimension 105
Figure 4.7.1: Final Specification 1 142
Figure 4.7.5 144
LIST OF TABLE
LIST OF TABLE PAGES

Table 2.2.5: Additional parts for standard existing electric scooter. 32
Table 2.2.51: Details differences between commercial with own-made 33
electric scooter.
Table 2.2.5.2: Advantages of standard electric scooter. 34
Table 2.2.5.3: Disadvantages of electric scooter 35
Table 2.3.2 Morphological Chart 39
Table 2.3.3.1: List of Part of Design concept 1 (Scooter-Rama) 45
Table 2.3.3.2: List of Part of Design concept 2 (Piz-Scooter) 46
Table 2.3.3.3: List of Part of Design concept 3 (Kougar Scooter) 47
Table 2.3.3.4: List of Part of Design concept 4 (Cool scooter) 48
Table 2.3.3.5: List of Part of Design concept 5 (Foldable scooter) 49
Table 2.3.3.6: List of Part of Design concept 6 (V-Scooter) 50
Table 2.4.1 Pugh Chart 51
Table 2.4.2: Decision Matrix 52
Table 3.1 :Electric Scooter Dimension Parameter 58
Table 3.2.2.1:Properties of material 78
Table 3.2.2.2:Properties of material 79
Table 3.2.2.3: Properties of Material 80
Table3.2.4: Properties of Steel 95
Table 3.2.5: ASTM A36 Mild (low carbon) steel properties 96
Table 3.3.1: Failure Mode and Effect Analysis (FMEA) 99
Table 3.3.3: Process Selection 102
Table 4.6.1 :Bill of material of mechanical part 136
Table 4.6.2 :Bill of material of electrical l part 137
Table 4.6.3:Total costing of mechanical part 138
Table 4..6.4 : Total Costing Electrical Part 139
Table 4.6.5 : Total Costing Electrical Part 140
Table 4.7.1: Hub Motor Specification 144
Table 4. 7.2: Specification of electric Scooter 144
Table 6.1 :Gantt Chart 148
ACKNOWLEGEMENT
We would like to express our deepest appreciation to numerous individuals who have
contributed to the success of our report. First of all, we thank our lecturer of this subject,
Dr.Noor Fazli Adull Manan for his unrelenting guidance from the beginning of the semester to
the completion of this report.
We thank our classmates who have also been great friends to exchange opinions and share
ideas for improvements to complete this design report...Last but not least, we also thank our
own families for moral and financial support which make this report successful.
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ABSTRACT
Electric scooters are plug-in electric vehicles with two wheels that can be recharged from any
external source of electricity, and the electricity is stored in a rechargeable battery, which
provides power to one or more electric motors to attain movement. Electric scooter, as
differentiated from scooters, do not have a step-through frame. The electricity generated from
an external source helps in acceleration of the motorcycle. The speed of this cycle is limited
(45km/h). The electricity is stored using a battery and the locomotion and movement of the
vehicle is hence propelled using an electric hub motor The electric scooter are not using an
engine, becomes an effective way of road transport as it causes no pollution. It is eco-
friendly and it definitely reduces human effort. In this project report, work concerning
product design and manufacturing process making of an electric scooter is described, which
was the outcome of a collaborative project for new product development. The ﬁnal product
was satisfactory, and was designed according to the aesthetic principle of golden section
proportion, and subsequently outer housings were produced with carbon fiber. Not only the
product appearance was created, but an electric scooter was also built using various
traditional modeling and engineering techniques.
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1.0 INTRODUCTION
Concern about global warming and urban air pollution have become central issues in
transport policy decision-making, and as a result much research in recent years has focused on
the development of vehicles which are environmentally friendly. Air quality in cities is
currently significantly lower than in rural areas and this has been shown to be directly link to
the level of vehicle emissions from private cars. The haze episodes in Southeast Asia in 1983,
1984, 1991, 1994, and 1997 imposed threats to the environmental management of Malaysia
and increased awareness of the environmenti. Due to the fact that urban transport policy, the
design is to reduce or discourage the use of private cars, there has been an increase in the sale
of non-polluting vehicles such as electric scooter. However, although the number of electric
scooter users has increased, safety and comfort issues need to be addressed if the number of
users is to increase to a level at which a significant effect on environmental pollution can be
achieved. Researchers have studied and improved many aspects of the electric scooter. In this
study, we used computer simulation to model the aerodynamic effect of the existing safety and
comfort features and we present a new design which integrates these features in an optimally-
effective aerodynamic shape. As student of mechanical engineering part 5, we were given a
task to develop a new single seated electric scooter. In this task, students need to design a
scooter from a raw material, build their own design concerning several factors and fabricate
the scooter by the end of part 6. For this semester, students focus are more on the gather
information and generate concept scooter. Followed by having a drawing and prepare to
fabricate in next semester. The process will teach students about how the work flow of building
a product from scratch until the end product. Each step is a self-learning process for a
mechanical student a complexity of every task is different from one to another. In the designing
of electrical scooter, there are three phases of the engineering design process involved. There
are conceptual design, embodiment design and detail design.
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Conceptual design
Define Gather Concept Evaluation of

problem information generation concept
Parametric Configuration Product

Detail design
design design architecture
Embodiment design
In phase 1, the conceptual design, there are 4 processes. These 4 processes are problem
definition, gather information, concept generation and lastly evaluation of generated concept.
In the process of defining problem, the electric scooter had gathered and brainstorming process
has been done. The general problem regarding electrical scooter has been voiced out. There are
problem statements in designing the electrical scooter, objectives of the team wanted to be
achieved, scope of the project and lastly the significant of the design has been determined.
Next, for the gather information process, there is a lot of readings have been done by each of
the team members including books, articles and also journals. Survey also has been conducted
with the supplier of electrical scooter. In the concept generation and evaluation process, a few
designs of electrical scooter has been made by the design engineers and then will be compared
by using Pugh method and weighted decision matrix in order to choose the best suspension for
our car.
In phase 2, the embodiment design phase, there are three process involved. The
processes are product architecture, configuration design and parametric design. In the product
architecture, the design for human factor by using information from ergonomic and
anthropometric data to integrate with physical arrangement has been considered. Next, in the
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configuration design process, the suspension modeling, simulations, details analysis of
calculations, materials selections is shown. In the last step, the parametric design process, it
includes the DFA, DFM, design for robust, FMEA, and final dimension for our suspension.
Last phase in designing our suspension is the phase 3 which is detail design where in
the phase there are details drawing, bill of materials, costing and final specifications for
electrical scooter.
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PHASE 1:
CONCEPTUAL
DESIGN
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2.1 BACKGROUND OF STUDY
Electric scooter is a vehicle empowered by electric motor in order to move. It is also

known as e-scooter. For the power source of the electric motor, certain country used different
power, because it is depends on the Law of the country. Basically, rechargeable batteries that
used for the e-scooter is 40 to 65km/h. The invention of the electric scooter is as a proof that
the engineering field keep advancing, the invention of the electric scooter make it replacing
the old scooter in the market. Although the electric scooters are using electric motor, it still
called as scooter rather than motorcycle. This is because it identity as scooter is still fixed
which is most of it part are belong to scooter. So, it not included in transportation law which
require the certification and operation as on good motor vehicle. It is not need to have license
to ride the electric scooter.
The electric scooter is not a fully motorized vehicle, it’s just semi motorized scooter,
which is still have brake and frame design and so on. This electric scooter use NiMH which is
a common power supply used on the electric scooter. This kind of the battery is rechargeable
and a lighter and denser capacity batteries which is make it the designing of an electric scooter
more handful and easier. The electric scooter is not like a motorcycle in many concept, either
it design or it power supply. Besides that, the electric motor is also used lower power
compared to motorcycle which is the scooter. There is some type of electric scooter that
commonly used by all the people in term of weight and frame material type. Weight of the
scooter also plays an important role in the speed of the scooter. The weight of the scooter
depends on the purpose of the scooter been used, it is to either for competition so there is
few of common weight that been used for the scooter. On the older scooter, the weight of
the scooter is about 50 or 60 kg, this kind of weight was back older day before the technology
of the scooter still not growing. Now, the weight of the scooter was improved, the weights of
the scooter have been reduced about to 35 and 45 kg. The improvement of the weight of the
scooter is for the purpose of scooter handling and speed of the scooter.
Next is frame or chassis of the scooter, there is few of material that is popular to
develop the scooter frame, it purpose is to make the scooter lighter and strong frame. The
type of materials that commonly used to develop scooter frame are Carbon fibre, Steel, and
Titanium. Most popular material used in develop scooter frame is carbon fibre, the term of
carbon fiber describe this material have various different composites that include different
polymers, carbon and graphite that are link by an epoxy-resin matrix which is sometimes
containing metals or ceramics. This carbon fibre is one the advanced composites which offer
great possibilities for light weight and high-performances in many way, this is because layer
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of composite can be insert only where it needed to be placed. Fibre also called whiskers of
material used to stabilize dynamic forces due to different degrees and direction on different
part of the scooter frame.
Steel which also commonly used to develop the scooter frame. Steel is the material
which used for many scooter frames. Lots of scooter designers have used their many years of
experience in refining the design of steel scooter. Steels offers a comfortable ride and frame
made up from steel can act as a spring to store energy when the rider causes the frame to flex
at different parts. The stored energy by the steel can be released and converted to forward
motion. Steel frame can be repaired with low cost and when there is damaged, steel scooter
can show or reveal frame stress injuries before the frame break. Steel scooter frame break
slowly compared to aluminium frame which break suddenly when there is failure on the
frame. Most of the high quality scooter frames are made of steel tubing which has been
alloyed with chromium and molybdenum, sometimes also alloyed with manganese and
molybdenum. 3 beside than Carbon fibre and Steel frame, Titanium also one of the popular
materials used to develop scooter frame. The characteristic of the Titanium as scooter frame
is almost similar to steel but it have more advantages than both carbon fibre and steel.
Titanium is lighter than the carbon fibre and steel, also the strength to overcome the stress
by force or impact is higher than steel and fatigue life of the titanium is more than steel. Even
though titanium wins all aspect for develop the scooter frame, but the cost to develop frame
from titanium is higher than steel and carbon fibre.
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2.1.1 Types of electric Scooter
Generally, electric scooter can be broadly classified into main parts which are the types
of motor which generated by using hub motor and chain motor system .These types of motor
were having different way to use and installation for the motor in electric scooter. Firstly, hub
motor are electric motor that are housed inside the hub of either the front or rear wheel. The
figure below shows one of the types of hub motor that sell in market. In general a front hub
motor pulls you and it creates an all wheel drive. The Hub motor also commonly use by electric
bike. The clearly difference between electric scooter and electric bike which is the electric bike
have a pedal to ride the bike meanwhile for electric scooter only use a throttle to control the
speed of the scooter.
Figure 2.1.1.1: Hub motor
Electric scooter of using hub motor creates an all wheel drive the scooter because the motor
drives front wheel or rear wheel. The system of hub motor in electric scooter were easy to
install or remove from the scooter wheel because there no gear system to deal with chain. Hub
motor can provide for a more balanced scooter weight distribution if the battery mounted in
the middle or back part of the scooter. There are few design of electric scooter that using a hub
motor (rear hub motor and front motor) refer figure 2.1.1.1
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BATTERY
REAR HUB
MOTOR
Figure 2.1.1.2: Hub motor
The other type of electric scooter by using the chain motor. Chain motor were install with
connected with chain ,sprocket and gear to move the scooter. The chain were having different
mechanism between the hub motor and chain motor because the hub motor were not using any
gear meanwhile for chain motor have a gear refer figure 2.1.1.2 and figure 2.1.1.3
Figure 2.1.1.3:Chain Motor
Chain motor also provide different power of motor with come out different on speed on torque
and speed of scooter. Figure 2.1.1(D) shows the installation of electric scooter for chain motor.
Normally for electric scooter the chain motor were install and connected at the rear tire of
scooter. Meanwhile for the hub motor in can install either on front or rear.
Chain
Motor
Chain
Figure 2.1.1.4
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2.1.2 HISTORY
Scooter-like traits began to develop in motorcycle designs around the 1900s. In 1894,
Hildebrand & Wolfmüller produced the first motorcycle that was available for purchase. Their
motorcycle had a step-through frame, with its fuel tank mounted on the down tube, its parallel
two-cylinder engine mounted low on the frame, and its cylinders mounted in line with the
frame. It was water-cooled and had a radiator built into the top of the rear fender. It became the
first mass-produced and publicly sold powered two-wheel vehicle, and among the first powered
mainly by its engine rather than foot pedals. Maximum speed was 40 km/h. The rear wheel was
driven directly by rods from the pistons in a manner similar to the drive wheels of steam
locomotives. Only a few hundred such bikes were built, and the high price and technical
difficulties made the venture a financial failure for both Wolfmüller and his financial backer,
Hildebrand.
1) First generation
The Motoped entered production in 1915, and is believed to be the first motor scooterii. They
were followed that year by the Autoped, whose engine was engaged by pushing the handlebar
column forward and whose brake was engaged by pulling the column back iii. Autopeds were
made in Long Island, New York from 1915 to 1921, and were also made under licenced by
Krupp in Germany from 1919 to 1922. The number of scooter manufacturers and designs
increased after World War I. The Skootamota, the Kenilworth, and the Reynolds Runabout
debuted in 1919, with Gloucestershire Aircraft Company following with its Unibus in 1920.
The Skootamota was noted for being practical, popular, and economical, the Kenilworth for its
electric lights, and the Reynolds Runabout for its advanced specifications, including front
suspension, a two-speed gearbox, leg shields, and a seat sprung with leaf springs and coil
springs. The Unibus also had a two-speed gearbox, but it is more notable for its full bodywork,
similar to that which would appear of second- and third-generation scooters. The reputation of
first-generation scooters was damaged by a glut of unstable machines with flexible frames, and
more substantial examples like the Reynolds Runabout and the Unibus were too expensive to
be competitive. The first generation had ended by the mid-1920s.
2) Second Generation
E. Foster Salsbury and Austin Elmore developed the Salsbury Motor Glide, which was a
division of Northrop Aircraftiv, a scooter with a seat above an enclosed drivetrain, and began
production in 1936 in California. In 1938, Salsbury introduced a more powerful scooter with a
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continuously variable transmission (CVT). This was the first use of a CVT on a scooter. It was
such a success that Salsbury attempted to license the design to several European manufacturers
including Piaggio. The Motor Glide set the standards for all later models. It inspired production
of motor scooters by Powell, Moto-scoot, Cushman, Rock-Ola, and others. The Cushman
Company produced motor scooters from 1936 to 1965. Cushman was an engine manufacturer
that started making scooters after Salsbury found their offer to supply engines to be
unacceptable. Cushman and Salsbury competed against each other, with both companies
advertising the economy of their scooters. Cushman claimed an efficiency of 2.0 L/100 km at
48 km/h. Cushman introduced a centrifugal clutch to their scooters in 1940. The Cushman Auto
Glide Model 53 was designed to be dropped by parachute with Army Airborne troops, and was
eventually called the "Cushman Airborne". Cushman scooters were also used around military
bases for messenger servicev. Salsbury continued manufacturing scooters until 1948, while
Cushman continued until 1965. Small numbers of the 165 cc Harley-Davidson Topper scooters
were produced from 1960 to 1965 using the engine from their line of light motorcycles based
on the DKW RT 125. It had a fiberglass body, a continuously variable transmission, and a pull-
cord starting mechanism.
3) Early Postwar Japanese Scooters
After World War II, wartime aircraft manufacturers were forbidden from making aircraft, and
had to find other products to make in order to stay in business. Fuji Sangyo, a part of the former
Nakajima Aircraft Company, began production of the Fuji Rabbit S-1 scooter in June 1946.
Inspired by Powell scooters used by American servicemen, the S1 was designed to use surplus
military parts, including the tailwheel of a Nakajima bomber, re-purposed as the front wheel of
the S1. Later that year, Mitsubishi introduced the C10, the first of its line of Silver Pigeon
scootersvi. This was inspired by a Salsbury Motor Glide that had been brought to Japan by a
Japanese man who had lived in the United States. Production of the Mitsubishi Silver Pigeon
and the Fuji Rabbit continued through several series until the 1960s. Some series of the Fuji
Rabbit were developed to a high level of technological content; the S-601 Rabbit Superflow
had an automatic transmission with a torque converter, an electric starter, and pneumatic
suspension. Mitsubishi ended scooter production with the C140 Silver Pigeon, while Fuji
continued production of the Rabbit until the last of the S-211 series was built in June 1968.
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4) Kick Scooters
Kick scooters have been handmade in industrial urban areas in Europe and the U.S. for at least
100 years, often as play items made for children to roam the streetsvii. One common homemade
version is made by attaching roller skate wheel sets to a board with some kind of handle, usually
an old box. One can lean to turn, or by a second board connected by a crude pivot. The
construction was all wood, with 75–100 mm wheels with steel ball bearings. An additional
advantage of this construction was loud noise, just like from a "real" vehicle. An alternative
construction consists of one steel clamp–on roller skate divided into front and rear parts and
attached to a wood beam.
5) The Early History of Electric Motorcycles.
On 19 September 1895, a patent application for an "electrical bicycle" was filed by Ogden
Bolton Jr. of Canton Ohio. On 8 November of the same year, another patent application for an
"electric bicycle" was filed by Hosea W. Libbey of Boston. At the Stanley Cycle Show in 1896
in London, England, bicycle manufacturer Humber exhibited an electric tandem bicycle.
Powered by a bank of storage batteries, the motor was placed in front of the rear wheel. Speed
control was by a resistance placed across the handlebars. This electric bicycle was mainly
intended for racetrack useviii. The October 1911 issue of Popular Mechanics mentioned the
introduction of an electric motorcycle. It claimed to have a range of 121 km to 100 miles 160
km per charge. The motorcycle had a three-speed controller, with speeds of 6.4 km, 24 km and
56 km per hour. In 1919, Ransomes, Sims & Jefferies made a prototype electric motorcycle in
which the batteries were fitted under the seat of the sidecar. Even though the vehicle was
registered for road use, it never went past the trial stageix. In 1936, the Limelette brothers
founded an electric motorcycle company called Socovel in Brussels. They continued
production during the German occupation with their permission. Due to fuel rationing, they
found some degree of success. But after the war, they switched to conventional models. The
electric models remained available until 1948x. During the World War II, compelled by fuel
rationing in the United States, Merle Williams of Long Beach, California invented a two-
wheeled electric motorcycle that towed a single wheeled trailer. Due to the popularity of the
vehicle, Williams started making more such vehicles in his garage. In 1946, it led to the
formation of the Marketeer Company (ParCar Corp.). In 1967, Karl Kordesch, working for
Union Carbide, made a fuel cell/Nickel–cadmium battery hybrid electric motorcycle. It was
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later replaced with a hydrazine fuel cell, giving it a range of 320 km per gallon and a top speed
of 40 km/h. In the same year, a prototype electric motorcycle called the Papoose, was built by
the Indian Motorcycle Company under the direction of Floyd Clymer. In 1974, Auranthic
Corp., a small manufacturer in California, produced a small motorcycle called the Charger. It
had a 48 km/h and 80 km range on a full charge. In the early 1970s, Mike Corbin built a street-
legal commuter electric motorcycle called the Corbin Electric. Later in 1974, Corbin, riding a
motorcycle called the Quick Silver, set the electric motorcycle speed world record at 266.165
km/h). The motorcycle used a 24 volt electric starter motor from a Douglas A-4B fighter plane.
In 1975, Corbin built a battery-powered prototype street motorcycle called the City Bike. This
motorcycle used a battery manufactured by Yardney Electric. In June 1975, the first Annual
Alternative Vehicle Regatta was held at Mt. Washington, New Hampshire. The event was
created and promoted by Charles McArthur, an environmentalist. On June 17, Corbin's
motorcycle completed the 13 km uphill course in 26 minutes. In 1988, Ed Rannberg, who
founded Eyeball Engineering, tested his electric drag motorcycle in Bonneville. In 1992, the
January issue of Cycle World carried an article about Ed Rannberg's bike called the
KawaSHOCKI. It could complete 400 m in 11–12 seconds. In 1995, Electric Motorbike Inc.
was founded by Scott Cronk and Rick Whisman in Santa Rosa, California. In 1996, EMB
Lectra was built by Electric Motorbike Inc., which used a variable reluctance motor. It had a
top speed of about 72 km/h and a range of 56 km. About a 100 of these were built. In 1996, the
first mass-produced electric scooter, Peugeot Scoot'Elec, was released. It used Nickel-
Cadmium batteries and a range of 40 km. On 26 August 2000, Killacycle established a drag
racing record of completing a quarter mile (400 m) in 9.450 seconds on the Woodburn track in
Oregon. Killacycle used lead acid batteries at a speed of 244.73 km/h. Later, Killacycle using
A123 Systems Li-ion nano-phosphate cells set a new quarter mile record of 7.824 seconds
breaking the 8 seconds barrier at 270 km/h in Phoenix, Arizona at the All Harley Drag Racing
Association (AHDRA) 2007, on 10 November 2007. On 4–5 April 2009, Zero Motorcycles
hosted the "24 Hours of Electricross" event in San Jose. It is considered the first all-electric
off-road endurance racexi.
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2.1.3 PROBLEM STATEMENT
Project electric scooter was chosen in this engineering design project. The initial problem
for designing this project which is to design the product that wasn’t similar to the current
market.
a) What does the client desired?

-Lightweight
-A scooter could ride easily to reduce transit time
-Easy to use
b) What does client really want?

-A product which safe to use
-Affordable
c) What are the real causes of what the client presents as problem?
-The existing product its hard to store and expansive.
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2.1.4 OBJECTIVE
a. To fulfil the requirement of MEC 531: Product Design
b. To apply and utilize all existing knowledge acquired throughout the degree
programme in designing and manufacture a desirable product
c. To evaluate the students ability in generating new ideas in solving existing
problems
d. To instil the right notion in the word of “teamwork” by providing essential
background of the real working environment.
e. To produce the “scooter” according to the design process as what was taught.
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2.1.5 SCOPE OF PROJECT
PROJECT OBJECTIVE
To construct a high-quality, custom electric scooter within fourteen weeks at cost not
to exceed RM1000.
DELIVERABLES
 An electric scooter that can commute single rider.
 Empowered by 36V battery
 Included safety feature such as alert light
 Able to move 3 to 5 km in a single fully charge battery
MILESTONES
1. Blue print approved by the end of semester 5
2. Basic material and component are ready by week 2 of semester 6
3. Structure of scooter is ready by week 5
4. Component is assemble by week 10
5. Adjustment and imprecision before week 12
6. Scooter is ready in week 13
7. Presentation should be done in week 14
TECHNICAL REQUIREMENTS
1. Electric scooter must meet design blueprint
2. Electric motor should be powerful enough to carry the weight of the rider and the weight
of scooter itself
3. Electric component should be insulated to avoid any short circuit
4. The structure strength should bear the force taken
5. High efficiency in transferring power from motor to tyre
6. Seats must able to hold any size of riders
7. Low vibration on rider
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LIMITS AND EXCLUSIONS
1. The electric scooter must minimize adjustment from blue print during fabricating
2. Owner responsible for safety
3. Rider weight shall not exceed 120 kg
4. Scooter is not foldable but the seat is adjustable
5. Technicians must assist the fabricating process
6. Lectures should advise into having better product
7. Site work limited to Monday through Friday, 8:00 A.M. to 6:00 P.M.
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2.1.6 SIGNIFICANT OF PROJECT
An electric scooter, is a vehicle which uses one or more electric motors for propulsion.
Depending on the scooter, motion may be provided by wheels or propellers driven by rotary
motors or by linear motors.
At the beginning of the 21st century, increased concern over the environmental impact
of the petroleum-based transportation infrastructure, along with the spectre of peak oil, led to
renewed interest in an electric transportation infrastructure. Electric scooter has the potential
of significantly reducing city pollution by having zero tail pipe emissions. Vehicle greenhouse
gas savings depend on how the electricity is generated. With the energy mix using an electric
scooter would result in a 30% reduction in carbon dioxide emissions. Electric scooters are
commonly powered by on-board battery packs, and as such are battery electric vehicles.
Electric scooter are expected to cause a revolution in the auto industry given advantages in city
pollution, less dependence on foreign oil imports, and expected rise in gasoline prices.
In an electric scooter, a battery or other energy storage device is used to store the electricity
that powers the motor. Batteries must be replenished by plugging in the vehicle to a power
source. Electric scooters are considered zero-emission vehicles because their motors produce
no exhaust or emissions. These electric scooters are commonly used for neighbourhood
commuting, light hauling, and delivery. Their use is limited to areas with 55km/h speed limits
or for off-road service on college campus or at airports or resort areas. An important goal for
electric vehicles is overcoming the disparity between their costs of development, production,
and operation, with respect to those of equivalent internal combustion engine vehicles.
Electric scooter produce no pollution at the tailpipe, but their use increases demand for
electricity generation. Generating electricity and producing liquid fuels for vehicles are
different categories of the energy economy, with different inefficiencies and environmental
harms, but both emit carbon dioxide into the environment that must be accounted for in a "well
to wheel" comparison. The major potential benefit of electric scooter is to allow diverse
renewable electricity sources to fuel scooter.
Great effort is taken to keep the mass of an electric vehicle as low as possible, in order to
improve the electric scooter range and endurance. Despite these efforts, the high density and
weight of the electric batteries usually results in being heavier than a similar equivalent gasoline
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vehicle leading to less interior space, worse handling characteristics, and longer braking
distances.
Proponents of electric scooter usually tout an increased efficiency as the primary

advantage of an electric vehicle as compared to one powered by an internal combustion engine.
The energy efficiency comparison is difficult to make because the two vehicles operate on
different principles. Vehicles powered by internal combustion engines operate by converting
energy stored in fossil fuels to mechanical energy through the use of a heat engine. Heat engines
operate with very low efficiencies because heat cannot be converted directly into mechanical
energy. Electric vehicles convert stored electric potential into mechanical energy. Electricity
can be converted into mechanical energy at very high efficiencies. A quick analysis will show
electric vehicles are significantly more efficient. The electricity used for electric scooter may
be created by converting fossil fuels to electricity using a heat engine (with a similar efficiency
as an automotive engine), converting nuclear energy to electricity using a heat engine, or
through dams, windmills, or solar energy. Each of these conversion processes operate with less
than 100% efficiency and those involving heat engines operate at relatively low efficiencies.
The greater efficiency of electric scooters is primarily because most energy in a

gasoline-powered vehicle is released as waste heat. With an engine getting only 20% thermal
efficiency, a gasoline-powered vehicle using 96 kW·h/100 km of energy is only using
19.2 kW·h/100 km for motion.
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2.2 GATHER INFORMATION
2.2.1 ARTICLE AND JOURNAL
1) Alternate mode of transport

One problem many public transport commuters face is the last-mile –the distance
between the station and their home or workplacexii. In many cases, walking is not a
convenient solution, as our local weather and lack of easy pedestrian access does not
make foot power conducive. Some have turned to a folding bicycle as a solution, with
such personal vehicles now allowed on the mass transit systems in Kuala Lumpur. The
e scooter can move in a range of 15 and 30 km, respectively, with a maximum governed
speed of 25 km/hxiii.
2) Portability
Not all, but most electric scooters are portable. If there is a problem with the motor or
chain or tire, the electric scooter can be carried back to the garage where you can fix
these issues. Designed to be a last mile solution for commuters, or a quick and easy run-
about for short trips close to home or workxiv. Made from aluminium, with the battery
pack located inside the frame spar, its folding design also makes it easy to store at home
or workxv. Weighing in at 13.9 kg to 15.2 kg, this e-scooter will fit into the boot of a
sedan. For hatchbacks, the rear seat will have to be folded down. Unfolding is a simple
two-step operation, with folding being the reverse. Folded up, the scooter has a footprint
of 48 by 40 cm. Switching on the scooter is with a push-button and transponder key,
which also switches on the front LED headlight and brake/tail light.
3) Time
In busy cities, time is the issue and these sleek vehicles can help you save a lot of time
on the roadxvi. They're portable and can access anywhere, so, you will have no trouble
taking a short cut through the subway, a shopping mall or a park. You just need to
recharge the batteries for a given amount of time, and that's it. Your scooter will save
your precious time otherwise spent in heavy traffic, gas stations and parking lots.
Electric Scooters reduces the journey time, especially if it’s a short distance. It doesn’t
matter where you live and how many rush hours you embrace, but if you’re on a scooter,
in a way, you would fly. The traffic flow won’t affect you as such, and you won’t deal
with familiar traffic jam conditions as well. The greatest advantages is you don’t need
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to ponder a lot regarding parking if you’re on a scooter. You can easily place it on the
side of the road/street and lock itxvii. Already, with the rising population of
automobiles, it’s tough to find a parking place, particularly if you’re residing in a dense
urban area. In fact, some places don’t even allow you to park the vehicle until you don’t
pay them any heavy amount of money. Therefore, in these conditions, I would say, a
scooter is a lucky thing from the seventh heaven.
4) Safety
Mr Sam Koh, 23, worked at PassionGadgets, a shop that sells e-scooters and unicycles,
for more than two years and was popular among its customersxviii. But in a tragic
accident, he died on Sunday from serious head injuries after falling from his e-scooter
early Saturday morning. After the fall, he went into a coma and never regained
consciousness. Mr Koh fell and landed on his back. He just wore a cap, but didn't wear
a helmet.
The panel recently recommended that all PMDs such as e-scooters, hoverboards,
unicycles and motorised wheelchairs, be allowed on footpaths and cycling and shared
paths - but with a speed limit of 15kmh on footpaths and 25kmh on cycling and shared
paths.
Riding the e scooter is easy, with power controlled by a twist grip on the right handlebar.
Braking is with levers on the left and right, activating a V-brake in front, and a cable-
operated disc brake at the back. The tyres are proper pneumatic items, and there is no
suspensionxix.
5) Eco-friendly
In recent years we have seen a worrying rise in the PM10 index, which measures the
concentration of fine particles caused by air pollutionxx. Fine particles are microscopic
particles consisting of heavy metals. They are suspended in the air are inhaled and can
cause various respiratory disorders, as well as being the cause of serious diseases. A
viable alternative to the petrol engine car and scooter is without doubt the electric
scooterxxi.
 Emissions
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The electric scooter does not produce any form of emissions that are harmful to the
environment and to people; it does not require petrol and diesel and runs on a lithium-
ion battery, which can be charged from 0 to 100% with about 1 k/Wh. With the electric
not only do you save, you also contribute to the well-being of the environment.
Charging time is approximately three hours, using household current.
 ·Noise pollution
Because they don’t have traditional petrol-powered car and scooter engines, electric
scooters emit much less noise. Just think: wouldn't it be nice to live in the city that was
less chaotic and polluted?
 Less waste
Not only zero emissions and less noise: the electric scooter also requires less
maintenance than traditional car or scooter engines because it doesn’t have valves,
cylinders or carburettor and doesn't need oil changes. This means that the electric
scooter is a 100% ecological means of transport: less maintenance means less wear and
tear on its components, fewer replacements and interventions and servicing and
therefore less hazardous waste to dispose of.
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2.2.3 SURVEY FORM AND ANALYSIS
Survey form were use to collect more information about what the cusmtomer needs on
scooter. This survey has been made and the survey was condudted to the fellow students and
50 students were cooperatively answered the survey.The figure bellows shows the example of
the survey form which is divided into three section.
(A)
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(B)
Figure 2.2.3(A) and (B):The sample of survey form
After conducting the survey among the student at UiTM. The analysis were made to
collect the important to improvise and gather additional information from customer. Refer on
the analysis below shows that the survey form were so helpful in terms of gather information.
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Male Female
40%
60%
Figure 2.2.3(C) : Gender
Figure above shows the pie chart of gender from Faculty of Mechanical Engineering. It was
found that 60% of the respondents are female, while the balance of 40% are male.
Yes
100%
Yes No Others
Figure 2.2.3(D): Number of Univerisity Student
Figure above shows the number of the University student in UiTM with various faculty who
responses in this survey which 100 %.
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College Non-resident
30%
70%
Figure 2.2.3(E) : Residency Status
Figure above shows the frequency of residency in UiTM.It was found that 70% of the
respondents living in college and only 30% who are non resident.
16%
Walk
40% 8%
Car
1%
Bicyle
35% Motorcyle
Bus
Figure 2.2.3(E): Percentage of frequent mode of transportation
The figure above shows the frequency of student usage frequent mode of transportation. It
was found that 40% of the respondent preferred take a bus to go anywhere ,while 35% uses
motorcycle,16% of respondents were walking,8% of the respondent use a car and only 1%
respondent use bicycle.
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7%
8%
42%
43%
Less than 100 100 Between 200

300 between 500 More than 500
Figure 2.2.3(F): Spend main transportation per month
Figure above shows that the percentage of respondent spend on main transportation per
month.It was found that 43% of the respondent spend only RM 100-RM 200,followed by
42% of the respondent spend less than RM 100,8% of the respondents spend RM 300-RM
500 and only 7% respondents spend more than RM 500 for transportation per month.
11% 20%
26%
43%
Strongly Agree Agree Disagree Strongly Diasgree
Figure 2.2.3(F): Electric scooter are relevant to you as a university student
Figure above shows the respond from respondent about electric scooter relevant to the
university student. It was found that 43% of the respondent were agree on electric scooter.
Next, 26% of the respondent were disagree, follow by 20% of the respondent strongly agree
and only 11% strongly disagree.
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3%
17%
36%
44%
RM500-1000 RM 1000-RM 1500

RM1500-RM2000 >RM2000
Figure 2.2.3(G): Reasonable Price For Electric Scooter
Figure above shows the reasonable prices for electric scooter that respondent response. It
was found that 44% of the respondent think the price between RM 1000-RM 1500 were
reasonable price. Follow by,36% of the respondent preferred RM 500-RM 1000,17% of the
student preferred RM 1500-RM2000 and only 3 % preferred more than RM 2000 were
reasonable price for scooter
63
53
26 33
19
6
Figure 2.2.3(H): The main problem with electric scooter
Figure above shows the main problem with electric scooter that selected by a respondent. It
was found that 63% said, there are getting enough information about electric scooter. Follow
by, 53% of the respondent said the price of the cooter too expansive. Next, It was found that
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33% of the respondent think the electric scooter was not safe.26% of the respondent thinks
how important about the maintenance issues,19% of the respondent think there are not
relevant for usage and 6% of the respondents were don’t know the electric scooter existence.
200
150
100
50
0 Series1
Figure 2.2.3(I): :Desired characteristic
The figure above shows the desired characteristic by respondent of electric scooter. The
respondent have given 2 choice out of 7 selection. It was found that 200% were select as light
weight it the most priority aspect for the electric scooter and follow by 97 % of respondent
think the the scooter need to sold with low price.Next,55 % of the respondent choose aesthetic
value of the electric scooter were important.,30% of respondent choose an ergonomic
aspect,31% of the respondent choose high performance of electric scooter, 5% of the
respondent respond as stability of electric scooter and 3% of respondent respond that the
electric scooter were easily to store
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2.2.4 INTERVIEW
The interview session were handle on 2 May 2017 with the supplier of AZ EASY Trading at
Klang.The objective of the interview to gain knowledge about the parts needed in electric
scooter and also to get the info for actual cost on each part in the electric scooter that sell AZ
EASY TRADING.
Supplier: AZ EASY TRADING
Address: No.169A Jalan Ah choo Pandamaran ,4200 Port klang,Selangor Darul Ehsan.
Hp:012-2099303
From this session, there are things learned and taken into account:
 The ways of installation on electrical part
 The types of electric motor that suitable to achieve 55km/hr with certain specification.
 The battery usage information for certain types of power motor.
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2.2.5 BENCHMARKING
COMPETITIVE PRODUCTS AND BENCHMARKING
a) Parts involved
Table below shows some part of requirement of standard electric scooter existed by industries
against some part of improvements added by own group, in order to innovate new product
that meets the objectives shown earlier.
Standard industry’s electric scooter Self-made electric scooter improvements

Saddle adjustment Side mirrors
Engine cover Horn
Connectors & plugs Front light
Speed adjust/controller Rear light
Brake caliper Signal lights
Wire for brake Forth & back seat adjustments
Shock absorber spring Basket (storage)
Rims
Shock absorber fork
Seat beam support
Engine
Chain
Motor
Fuse/circuit breaker
Battery
Battery charger port
Power switch
Floor deck/chassis
Tyre
Seat
Hand brakes
Gear set
Table 2.2.5: Additional parts for standard existing electric scooter.
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b) Details involved
Table below explained on the details comparison between commercial electric scooter with one
own-made. Some of the task may have in common while mostly its differ. That’s the
improvement had been pour into research and development to achieved the objectives required.
Types Standard commercial electric Own-made electric

Task scooters’ scooters
Images
Top Speed 55km/hr 45km/h

Safety Front and Rear Lights Sidemirrors, signals, front & rear
light, horn, fillet edges, speedometer
Power usage 1600 Watt 360watt
Acceleration 36 km/m^2 36 km/m^2
voltage 48 volt 48volts (ac)
Driving All terrain Easy urban environment
mode
Range 20 km 30km
Battery 250 cycle Up to 6 hours
lifetime
Features Heavy, versatile, expensive, Lightweight, versatile, affordable,
moderately safe safer, convenient, ergonomic
Weight Up to 120 kg 120kg maximum
support
Product 53 kg 45kg
Weight
Table 2.2.5.1: Details differences between commercial with own-made electric scooter.
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ADVANTAGES OF STANDARD ELECTRIC SCOOTER
Table below shows the advantages with justifications of existed standard industries electric
scooter as compared to nowadays fuels consumptions vehicles.
Task Descriptions
Economical With the rising prices of fuel and increases
in the concern of global warming and the
environment, electric scooters and
motorbikes are becoming in demand
Noise Extremely quiet performance leads no sound
pollution.
Environment Very environmentally friendly, no emissions
at source. There’s no fuel consumptions
which there’s no exhaust fumes generated.
Privacy Very covenant to recharge, it can be done at
home!
Maintenance Small amount of parts lead to lower
maintenance, which equals lower
maintenance costs as compared to petrol
vehicle.
Convenient electric scooters and motorcycles can be
ridden indoors, means safe energy & time.
Table 2.5.2: Advantages of standard electric scooter.
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DISADVANTAGES OF STANDARD ELECTRIC SCOOTER
Table below shows the disadvantages with justifications of existed standard industries
electric scooter as compared to nowadays fuels consumptions vehicles.
Task Descriptions
Lifetime Electric vehicles tend to have a shorter
range before needing to be recharged, but
again, this is changing due to improvements
in battery power.
Power Recharging your vehicle takes longer that
filling your tank up with petrol, but this can
be done overnight on a trickle charge.
Speed The top speed of electric scooters and
motorcycles tend to be lower than their
petrol counterparts.
Recharge stations To recharge an electric vehicle, you need to
be near a power outlet, you will need a very
long lead if you live on the top floor of an
apartment building!
Side effects On very cold days, battery power can reduce
by up to 20%.
Noise The near to silent operation of an electric
scooter or motorbike can dangerous for both
yourself and pedestrians.
Table 2.2.5.3: Disadvantages of electric scooter.
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2.3 CONCEPT GENERATION
Power scooters have 2 wheels powered by an electric motor which is fixed at the rear end of
the scooter. A power scooter is rear wheel drive get the power from the engine by an electric
hub motor. This scooter provides all the controls for driving it by the driver. It is provided with
simple platform for standing and drives it comfortably. Some people think that power scooter
is difficult to operate, so they are less worried about to purchase it. Once a person gets the feel
for it, the control console makes it simple. Power scooters are also equipped with advanced
brake systems, so stopping is simple, safe and comfortable. Now days, small scooter becomes
popular especially during recreation time, relaxing and for human exercise. Most of the power
scooters are operated by engine or motor or just using our leg to move scooter like playing
skate board. The problem in most of the scooter is that they are not flexible though it is very
small.
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2.3.1 FUNCTIONAL DECOMPOSITION
Functional decomposition is a term that engineers use to describe a set of steps in which they
break down the overall function of a device, system, or process into its smaller parts. This is
usually accomplished through thoughtful analysis and team discussions of project information
and the result is a chart that describes the problem and or solutions in increasing detail. In this
project the functional decomposition is important to detail every component and function.
Large or complex functionalities are more easily understood when broken down into pieces
using functional decomposition.
Power Source
Supply Transmit Activate Regulate

Store
Electricity Electricity Electricity Electricity
Electricity
(On/Off) (Speed/Direction)
Drive System
Convert
Electricity Change Transmit Rotate Voltage
To Torque Torque Torque wheel controller
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2.3.1.1 PHYSICAL AND FUNCTIONAL DECOMPOSITION
Electric Motor Scooter

4. Material 5. Mechanical
1. Electric Component 2.Frame 3. Suspension
Selection component
Speed controller Optimize

Handle bars Wheels Reduce cost
(ID box) motion
Economize
Power switch Grips Tires Easy avaibility
value
Battery charger Simple

Throttle Brakes Aesthetic value
port replacement
Battery
Cables Pads Easy movement
(rechargable)
ECU Kill switch Cables
Starter Seat Monoshock
Wiring Foam
Circuit breaker Fabric
Electric hub
Headlight
motor
Throttle (control
Bulb
speed)
Wiring
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2.3.2 MORPHOLOGICAL CHART
The morphological chart is a design tool that helped satisfy each design criteria from the
functional decomposition. The choices that were elected for the design process are highlighted
in the chart below. The results were further examined for the best performance and the
maximum compliance with requirement. The morphological chart below summarizes the team
thoughts for the best combination of below task/characteristics:
Task Solution
Frame Portable Portable Fixed Semi portable
Type of Soldering Welding Mechanical Adhesive glue Rivet

joint fastener
Type of Double seat Single seat Bucket seat Single seat Small Cafe Racer
seat (fixed) (fixed) (adjustable) Seat
Type of 12V 350W 24V 250W 24V 250W 24V 400W

Electrical belt drive chain drive chain drive
electric
Hub Motor
motor
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Task Solution
Socket plug/ Two pin plug Three pin plug Adapter Adapter USB
cord (Battery
charger)
Power source Gasoline Engine Turbo Engine Electric Motors Stirling engines Human powered
Mechanism Gears Belts Chains Linkages Hybrids
Front light Double round Single round Rectangular Eclipse
Type of Lead Acid Lithium Ion Nickel cadmium Lithium Ion Lithium Ion
(Li-ion) (NiCd) Polymer
battery
(rechargeable
)
Type of Leaf Springs Torsion bar Coil spring Shock Absober front fork shock
spring/ absorbe
absorber
Type of Regular Regular Regular swing

swingarm, twin swingarm, arm, mono-
swing arm
shock monoshock shock
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Task Solution
Back light Led backlight Mentol Tail light
(For safety)
Signal light Round shape Pointing shape NO SIGNAL

LIGHT
Side mirror Round shape Wide NO SIDE

MIRROR
Type of Disc brake Drum brake Emergency brake Anti-lock brakes side pull caliper
braking brake
system
Others Reverse powe Brakes Blocks under Drag and weight NONE
stopping wheels on the floor
alternative
Handle bar Zero drag Low drag H-Bar Moto Bar
Type of tire Wide (rubber) Round (rubber) Chain thread Wood
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Task Solution
Type of Fork Telescopic fork trailing link fork Earles fork Girder fork
Design of A B C D
Girder forks
Steering All three fixed Two front rotate One front rotate One front rotate
tires Two rear fixed Two rear fixed One rear fixed
Transmission Direct Belting Chain Differential Electric hub

of power to transmission motor
wheel
Material Aluminium Mild steel Carbon Fiber Composite

selection for material
the main
body frame (
swing arm,
body frame&
fork)
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Task Solution
Storage Front Behind Behind the front On the base NO BASKET
basket cover
placement
Horn Single Doube NO HORN
motorcycle Cruiser Riding Sport Riding Standard Riding

ride body Posture Posture Posture
posture
Table 2.3.2 MORPHOLOGICAL CHART
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2.3.3 CONCEPTUAL DESIGN
The idea behind the design was to create an entirely new electric scooter that would corporate
with light weight as well as most ergonomic scooter design. The team wanted to stick with
the principle that the establishment and wanted the electric scooter to fulfill those
requirements. After the preliminary research was conducted by each of the members, it can
be concluded that it would be it would be ideally to redesign an electric scooter to help the
people or student to move easily with the scooter.
Based on the research that has been conducted, the team has sketched a number of different
mechanisms that would satisfy the problem statement. Refer to figure Below for initial design
sketches
2.3.4 BRAINSTORMING -SKECTHES
Design concept 1 Design concept 2
Design concept 4
Design concept 3
Design concept 5
Design concept 6
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Design Concepts:
Figure 2.3.3.1: Design concept 1 (Scooter-Rama)

No. Part Choice Reason
1 Frame Semi portable Can decide between seat or stand
2 Type of joint Fastener/Welding Stronger
3 Type of seat Adjustable Can be stand or seat
4 Type of electric motor 24V 250W belt drive More torque on wheel
5 Socket plug/ cord (Battery charger) Adapter Control amount current flow into battery
6 Type of tire Round (rubber) Efficient used and contact between road
7 Front light Single round Night use
8 Type of battery (rechargeable) Lithium Ion Last much longer
(Li-ion)
9 Type of spring/ absorber Shock Absober Dissipate energy between wheel
(rear) (impact) and frame
10 Back light NONE -
(For safety)
11 Signal light NONE -
12 Side mirror Wide Easy to look vehicle behind the wheel
13 Type of braking system Disc brake Reliable
14 Handle bar Zero drag Easy to control
15 Type of Fork Girder fork Low cost and simplicity
16 Design of girder forks Type C Easy to manufacture
17 Steering One front rotate Not carry heavy things
One rear fixed
18 Transmission Belting High efficiency
19 Storage basket placement Front Suitable to bring small items
20 Power source Electric motor Environment friendly
21 Mechanism Chain Transmit power to the wheel
22 Motorcycle ride body posture Standard riding posture Relaxing
23 Material selection for the main body Aluminum Light weight
frame ( swing arm, body frame& fork)
Table 2.3.3.1: List of Part of Design concept 1 (Scooter-Rama)
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Figure 2.3.3.2: Design concept 2 (Piz-Scooter)
1 Frame Fixed Stronger
7 Front light Rectangular Night use
(Li-ion)
(rear and front) (impact) and frame
(For safety)
12 Side mirror NONE -
One rear fixed
19 Storage basket placement behind Suitable to bring small items
20 Power source Gasoline Last much longer
23 Material selection for the main body Mild steel Stronger

frame ( swing arm, body frame&
fork)
Table 2.3.3.2: List of Part of Design concept 2 (Piz-Scooter)
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Figure 2.3.3.3: Design concept 3 (Kougar -Scooter)
7 Front light round Night use
(Li-ion)
11 Signal light Round shape Direction go and aesthetic value
One rear fixed
19 Storage basket placement Behind Suitable to bring small items
23 Material selection for the main body Mild steel Stronger

fork)
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Figure 2.3.3.4: Design concept 4 (Cool scooter)
3 Type of seat Single seat (fixed) Can withstand higher load
(Li-ion)
(For safety)
One rear fixed
19 Storage basket placement NONE -
23 Material selection for the main body Aluminum Light weight

fork)
Table 2.3.3.4: List of Part of Design concept 4 (Cool scooter)
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Figure2.3.3.5: Design concept 5 (Foldable scooter)
1 Frame Portable Can be foldable
(Li-ion)
9 Type of spring/ absorber NONE -
(For safety)
One rear fixed
23 Material selection for the main body ALuminum Stronger

fork)
Table 2.3.3.5: List of Part of Design concept 5 (Foldable scooter)
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Figure 2.3.3.6: Design concept 6 (V-Scooter)
1 Frame Portable Can be foldable
4 Type of electric motor 48V 350W Hub Ease the manufacturing process
Motor
5 Socket plug/ cord (Battery charger) Adapter (3pin) Control amount current flow into battery
7 Front light Eclipse Night use
8 Type of battery (rechargeable) Lead acid Can store more battery capacity
9 Type of spring/ absorber Shock absober Absorb impact from wheel
10 Back light Mentol Notify other vehicle at back
(For safety)
11 Signal light Round shape Notify changing direction of movement
13 Type of braking system Drum brake Reliable
15 Type of Fork Telescopic fork Absorb shock by fork
One rear fixed
18 Transmission Electric hub motor Simplicity
20 Power source Electric motor Environmental friendly
21 Mechanism Hybrid Electric hub motor (built in mechanism)
22 Motorcycle ride body posture Standard riding posture ergonomic
23 Material selection for the main body Mild steel Stronger part joint
fork)
Table 2.3.3.6: List of Part of Design concept 6 (V-Scooter)
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2.4 CONCEPT EVALUATION
2.4.1 PUGH CHART
The goal of this project was to develop a product become more ideal with others product in the
market. There are four different design of electric scooter which are nine criteria that
considered to compared this project and others design in the market. The team has created a
total of 4 concepts design in order to finalize the design of the project.
The concepts were created based on university student or public people. The team then chose
the top 4 design in order to compare them using the Pugh chart below. The Pugh chart
comparison was depending on the criteria below where all 14 criteria included. The chart below
will display the most creative designs in order of having most positive signs. The winning
designs later moved to be compared in the decision matrix in order to choose the final design
ELECTRIC SCOOTER Scooter- Piz-Scooter Kougar Cool scooter Foldable V-Scooter

Rama Scooter scooter
SKETCH
CRITERIA WEIGH DESIGN 1 DESIGN 2 DESING 3 DESIGN 4 DESIGN 5 DESIGN 6

T
RELIABILITY 1 - + + + - +
EASY TO USE 2 - 0 - + 0 +
SAFETY 2 0 0 + - 0 +
DURABILITY 1 0 + 0 - + 0
AESTHETICS 2 + 0 + + + 0
ENVIRONMEN 1 + + + - + +
T
ERGONOMIC 2 + + + - - +
(HUMAN
FACTOR)
EXCIMENT 2 + - + - + -
LOW COST 2 0 0 - 0 - +
LIGHT WEIGHT 1 + - 0 - + 0
STRENGTH 1 - 0 + + - +
MINIMUM 1 + 0 - - + 0
PARTS
REPARIBILITY 2 0 + 0 0 + 0
EASE OF 1 0 0 - 0 0 +
ASSEMBLY
+ 7 5 11 6 10 11
0 8 11 4 3 3 6
- 4 2 6 9 6 2
NET 3 3 5 -3 4 9
Table 2.4.1 Pugh Chart
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2.4.2 DECISION MATRIX
After considering the three designs from the Pugh chart. The team used decision matrix
(Table) with the same criteria that has been used in the Pugh chart. The criteria weight has to
be sum of 100% therefore, the team weighted the most importance to less importance for
each criterion. After weighting the criteria, the team considered a raw weight out for each
criterion. Then the teams used the weight criteria and multiplied it with the raw weight to get
the final weight of each concepts. Finally, by sum up the final weight the team gets the total
weight for each concept, and ranked each concept from the highest total weight. The final
design that the team will design is Kougar Scooter-Scooter.
CONCEPTS
Scooter-Rama Piz-Scooter Kougar-Scooter Foldable scooter V-Scooter

SELECTION WEIGHT RATING WEIGHT RATING WEIGHT RATING WEIGHT RATING WEIGHT RATING WEIGHT
CRITERIA SCORE SCORE SCORE SCORE SCORE
RELIABILITY 5% 2 0.1 3 0.15 3 0.15 2 0.1 2 0.1
EASY TO USE 5% 2 0.1 1 0.05 3 0.15 2 0.1 3 0.15
SAFETY 10% 3 0.3 1 0.1 2 0.2 1 0.1 4 0.4
DURABILITY 5% 2 0.1 2 0.1 2 0.1 1 0.05 4 0.2
AESTHETICS 10% 3 0.3 2 0.1 3 0.3 3 0.3 3 0.3
ENVIRONMENT 5% 4 0.2 4 0.2 4 0.2 2 0.1 3 0.15
ERGONOMIC 10% 2 0.2 2 0.2 3 0.3 1 0.1 4 0.4
(HUMAN
FACTOR)
EXCIMENT 5% 3 0.15 1 0.15 2 0.1 2 0.1 2 0.1
LOW COST 10% 1 0.1 2 0.2 2 0.2 2 0.2 2 0.2
LIGHT WEIGHT 5% 2 0.1 2 0.2 2 0.1 2 0.1 2 0.1
STRENGTH 10% 1 0.1 3 0.3 3 0.3 1 0.1 3 0.3
MINIMUM 5% 1 0.05 1 0.05 2 0.1 1 0.05 2 0.1
PARTS
REPARIBILITY 5% 1 0.05 1 0.05 2 0.05 2 0.1 2 0.1
EASE OF 10% 1 0.1 2 0.2 2 0.2 2 0.2 3 0.3
ASSEMBLY
TOTAL SCORE 1.95 2.03 2.45 1.70 2.90
RANK
CONTINUE? NO NO NO NO YES
Table 2.4.2: Decision Matrix
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Figure 2.4.2.1: Selection of concept design
Figure show a design that have been chosen among all of the options that we have considered,
we have chosen this option as the final product design because of a few important factors.
1) Easy to manufacture
The components and parts of this design is mostly readily available in hardware stores,
especially the electrical motor, material used (Rod steel). Since the used of electric hub motor,
the scooter assemble is simplified because no additional chain drive is needed to attach to the
sprocket. Minimal part (electrical component) make this scooter is easy to fabricate and less
cost and time is need to assemble the whole part.
2) Low cost
Contributed by the easily available parts and the simple arrangement, this design thus has
relatively low cost as compared to other choices which may need costly custom made parts.
This cost reduction is due to compact and selection of very best material to maintain its
performance at high with low cost.
3) Reliability and durability
Due to the simple design, the structure is considered to be much more durable and strong to
withstand rough road and make it much more long lasting. All of the main part and component
is joint using a strong joiner.
53 | P a g e
4) Aesthetic value
The shape of the electric scooter look futuristic as well as is attract young people to buy.
5) Easy to use
It is easy to use since only one push start button is need to start the motor and the electric
scooter can be run by pulling the throttle using speed controller
6) Environment friendly
Since electric scooter is using battery, it is green technology which not producing carbon
through ekzos. The battery just need to be recharging after using.
7) Ergonomic (human factor)
The seat position of this electric scooter is very suitable for normal human to use as well as
the seat can be adjust into desired position
8) Light weight
Due to minimum part of producing this scooter, the electric scooter weight can be reduce in
order to get the maximum performance. With light weight of the scooter, the impact (between
frame and absorber) also can be reduce
9) Strength
The design selected is based on the design shape of the main frame of the scooter. Because to
sustain for a long use, the frame is design to withstand any load and stress for a long period of
time
10) Minimum parts
To reduce cost and ease the assembly process
11) Safety
Safe to be use even rainy day. The cover motor were fully water resistant to avoid any
damage
12) Reparability
Most of the component of the electric motor can be maintained because the main purpose of
design this scooter is to make sure that this scooter can be maintained to use for a long time
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PHASE 2-
EMBODIMENT DESIGN
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3 INTRODUCTION
Design phase 2 is the continuation which complements the design phase 1. Embodiment
design is the stage where the selected design concept is invested with physical form.
Embodiment design phase contained the detailed analysis and calculations. There are three
stages of embodiment design phase which must be considered:
Product Configuration Parametric

architecture design design
56 | P a g e
3.1 PRODUCT ARCHITECTURE
Product architecture is about arrangement of the physical elements to carry out its
required function and the relationship among the component in the product and the function
of product performs. There are two type of product architecture which is:
1. Integral architecture
 Use only one or few chunks and the component perform multiple function.
Every changes made to any component tend to propagate to other physical
element. Weight, space or cost always adopted when there is a constraint.
2. Modular architecture
 Chunks implement only one or a few function. Accomplish overall function
through combination of block building.
Advantages of product architecture:

 Easier to evolve overtime
 To adapts to needs of different customers
In the table below, there are 87 parameters that we have put into equation
before designing the electric scooter. By having all the data below, we divide into 3
major parts for calculation. There are steering length design, steering handle angle,
rake and trail calculation. Focusing one by one part, we end up having the complete
calculation before putting into effort on designing full dimensions for our electric
scooter.
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Electric scooter dimension parameters
*Anthropometric data adapted from D. Mohammad, B.M. Demos, A.R. Ismail, D.I.
Daruis, (2010). Development of A Malaysian Anthropometric Database
Parameter Symbol Acquisition Value unit

Sitting Shoulder Height L19 Data 51.584 cm
Shoulder-Elbow Length L26 Data 34.051 cm
Forearm hand length L25 Data 42.153 cm
Palm length L31 Data 9.752 cm
Elbow to grip length L31-25 L25 - L31 32.401 cm
Shoulder grip length L35 Data 65.103 cm
Shoulder breadth L8 Data 43.897 cm
Thigh clearance L28 Data 19.662 cm
Thigh-palm clearance C28 Suitability 5 cm
Total thigh clearance CEy L28 + C28 24.662 cm
Elbow to body clearance CEz Suitability 0 cm
Maximum steer angle ‫ﺏ‬ Suitability 45 degrees
sin (‫)ﺏ‬ 0.70711
cos (‫)ﺏ‬ 0.70711
Rake angle θR Suitability 25 degrees
sin (θR) 0.42262
cos (θR) 0.90631
tan (θR) 0.46631
-1
sin (CEz/L26) 0
-1
cos (sin (CEz/L26)) 1
Elbow to grip length in Calculation of non-linear
(L31-25)x 31.32 cm
x-axis system of equations
Elbow to grip length in L19 - L26 cos (sin-1
(L31-25)y -7.129 cm
y-axis (CEz/L26)) - CEy
Elbow to grip length in
(L31-25)z Y cos (‫ )ﺏ‬- CEz - L8/2 -4.2708 cm
z-axis
Half of steering grip Calculation of non-linear
Y 25 cm
length system of equations
Half of steering grip
(S‫)ﺏ‬x Y sin(‫ )ﺏ‬cos(θR) 16.0214 Cm
length in x-axis
(S‫)ﺏ‬y Y sin(‫ )ﺏ‬sin(θR) 7.47091 cm
length in y-axis
58 | P a g e
(S‫)ﺏ‬z Y cos(‫)ﺏ‬ 17.6777 cm
length in z-axis
Sitting shoulder height L19 Data 51.584 cm
Buttock popliteal length L22 Data 44.86 cm
Hip angle θ22 Suitability 10 degrees
x-axis (L22)x L22 cos (θ22) 44.1785 cm
y-axis (L22)y L22 sin (θ22) 7.78986 cm
z-axis (L22)z Approximation 0 cm
Popliteal height L20 Data 42.48 cm
Knee angle w.r.t thigh θ20 Suitability 10 degrees
Knee angle w.r.t y-axis (θ20)y θ20 + θ22 20 degrees
Popliteal height in x axis (L20)x L20 sin (θ20)y 14.529 cm
Popliteal height in y axis (L20)y L20 cos (θ20)y 39.9181 cm
Foot length L33 Data 22.568 cm
Foot angle w.r.t calf θ33 Suitability 0 degrees
Foot angle w.r.t x-axis (θ33)x θ33 + θ22 + θ20 20 degrees
x-axis (L33)x L33 cos(θ33)x 21.207 cm
y-axis (L33)y L33 sin(θ33)x 7.71871 cm
z-axis Approximation 0 cm
Steering center to
LA X + Y sin(‫ )ﺏ‬cos(θR) 47.3414 cm
buttock length in x-axis
Steering center to
LB CEy + (S‫)ﺏ‬y 32.1329 cm
buttock length in y-axis
Fork offset Of Suitability 5 cm
Fork offset effect on
tyre center displacement (Of)x Of / cos(θR) 5.51689 cm
in x axis
Fork offset effect on
tyre center displacement (Of)y Of sin(θR) 2.11309 cm
in y axis
y-component of Steering
(LST)y (L20)y + LB + (L33)y 79.7698 cm
center to tyre center
x-component of Steering
(LST)x (LST)y tan (θR) + (Of)x 42.7141 cm
center to tyre center
Clearance between foot LA + (LST)x - ((L33)x -
(CFT)x 39.1991 cm
and tyre center in x-axis (L20)x + (L22)x)
Clearance between foot (LST)y + DT/2 - LB - (L22)y

(CFT)y 13.2101 Cm
and tyre center in y-axis - (L20)y - (L33)y
Diameter of tyre DT Suitability 42 Cm
59 | P a g e
Buttock to foot in x-axis (LB-F)x (L33)x - (L20)x + (L22)x 50.8564 cm
Buttock to foot in y-axis 55.4267 cm
Tyre center to buttock
(LTB)x (LST)x + LA 90.0555 cm
length in x-axis
Tyre center to buttock
(LTB)y (LST)y - LB + tB/2 48.8869 cm
length in y-axis
Steering throat length Sth Suitability 27.5 cm
x-axis (Sth)x 11.622 cm
y-axis (Sth)y 24.9235 cm
z-axis (Sth)z cm
Fork length Lf Suitability 34.5 cm
x-axis (Lf)x 14.5803 cm
y-axis (Lf)y 31.2676 cm
z-axis (Lf)z
Tyre center to center of
(LT-
steering throat length in (Lf)x + (Of)x + (Sth)x/2 25.9082 cm
ThC)x
x-axis
Tyre center to center of
(LT-
steering throat length in (Lf)y - (Of)y + (Sth)y/2 41.6163 cm
ThC)y
y-axis
Buttock to center of (LB-
(LTB)x - (LT-ThC)x 64.1473 cm
steering throat in x-axis ThC)x
Buttock to center of (LB-

(LTB)y - (LT-ThC)y 7.27059 cm
steering throat in y-axis ThC)y
Seat base to swing arm

SSB-SA Suitability 20 cm
link
Length of rear shock
SSh Suitability 13 cm
absorber
Seat base to shock base
(SSB-Sh)x 7 cm
in x-axis
Seat base to shock base
(SSB-Sh)y 20 cm
in y-axis
Rear tyre to swing arm
CRt-SA Suitability 15 cm
link clearance
Swing arm link to rear
SRt-SA DT/2 + CRt-SA 36 cm
tyre center
Shock base to swing
θSh-SA Suitability 45 degrees
arm angle
cos(θSh-SA) 0.70711
sin(θSh-SA) 0.70711
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Swing arm shock
SSAe 28.2843 cm
extension length
Swing arm shock
extension length in x- (SSAe)x SSAe cos(θSh-SA) 20 cm
axis
Swing arm shock
extension length in y- (SSAe)y SSAe sin(θSh-SA) 20 cm
axis
Swing arm shock
extension to tyre center (SSAe-T)x Suitability 0 cm
offset in x-axis
Swing arm shock base (OSh-
16 cm
offset in x-axis SA)x
Swing arm shock base (OSh-

0 cm
offset in y-axis SA)y
Thickness of base tB 2.5 cm

Swing arm shock base
to swing arm link length (SSA-Sh)x Suitability 0 cm
in x-axis
Swing arm shock base
Suitability, = (SSB-Sh)y +
to swing arm link length (SSA-Sh)y 21.25 cm
tB/2
in y-axis
Foot base to buttock
(LFB-B)y (LTB)y - tB/2 47.6369 cm
length in y-axis
Foot base to center of (LFB-
(LT-ThC)y - tB/2 40.3663 cm
steering throat in y-axis ThC)y
Steering neck angle θSN Suitability 10 degrees

Steering neck length in
(SSN)y Suitability, = (LFB-ThC)y 40.3663 cm
y-axis
Steering neck length in
(SSN)x (SSN)y tan(θSN) 7.11766 cm
x-axis
Steering neck width tSN Suitability 5 cm
Steering neck base
(SSNb)x tSN / cos(θSN) 5.07713 cm
length in x-axis
Clearance between foot
(LB-ThC)x - (LB-F)x - (SSN)x -
and steering neck in x- 3.63466 cm
(SSNb)x/2
axis
Table 3.1 :Electric Scooter Dimension Parameter
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Rake and Trail Calculation
Rake angle is the angle between the steering head and an imaginary vertical line drawn from
the front tyre's point of contact with the groundxxii. It is known that generally the rake angle is
inversely proportional to the handling responsiveness. Standard rake angles for motorcycles
in the market range from 24 to 35 degrees depending on the design.
The rake angle value has a direct consequence to the trail value, which is the horizontal
length between the two lines measured at ground levelxxiii. The standard values for
motorbikes range from 5cm to 11cm.
Taking considerations of aesthetics, control, safety and availability of parts, the trail is
calculated with a 5cm fork offset to be 4.28cm. This is slightly below the minimum standard
of trail for motorbikes in the market, but for this electric scooter application with maximum
speed far below conventional motorbikes, the value is assumed to be acceptablexxiv.
Figure 3.1 : The basic geometry of bicycles and motorcycles showing the rake and trailxxv.
2.56343y\sqrt{-0.5y^2+31.03986637y+517.266}+2y^2-32.181y-2514.6= 0
0 = 1X2 + 2.563425528 XY +2.5Y2 + -63.22094325 Y + -3031.869873
X2 = -0.5 Y2 + 31.03986637 Y + 517.2655078
X = ± (-0.5 Y2 + 31.03986637 Y + 517.2655078) 0.5
0 = 2.563425528 XY + 2 Y2 + 32.18107688 Y + -2514.604365
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Steering handle angle
The ergonomic aspect of the handle part of the steering bar for the hand is crucial since it is
the main controlling feature of the scooterxxvi. It is set to have an angle of 20 degrees at zero
steering angle which is found to be the most suitable natural angle for the palm, as found by
Young , Lin , Chang & McGorry (2013).
Derivation of Equations of Position for Steering and Arm
Figure 3.2: Graphical representations of steering motion in 5 different orientations
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Plane orientation Steering motion equation and parameters
z – RN Let;
Distance from grip to grip: 2G
Distance from one grip to the center: G
Equation of circle
z2 + RN2 = G2
Location of grip at steering angle, ‫ ﺏ‬in z-axis

direction, (S‫)ﺏ‬z:
(S‫)ﺏ‬z = G cos(‫)ﺏ‬
Location of grip at steering angle, ‫ ﺏ‬in RN-axis

direction, (S‫)ﺏ‬RN:
(S‫)ﺏ‬RN = G sin(‫)ﺏ‬
Rθ – RN Location of grip at steering angle, ‫ ﺏ‬in Rθ-axis

direction, (S‫)ﺏ‬Rθ:
(S‫)ﺏ‬Rθ = 0
x–y Equation of straight line

y = tan(θR) + 0
Location of grip at steering angle, ‫ ﺏ‬in x-axis

direction, (S‫)ﺏ‬x:
(S‫)ﺏ‬x = (S‫)ﺏ‬RN cos(θR)
= G sin(‫ )ﺏ‬cos(θR)
Location of grip at steering angle, ‫ ﺏ‬in y-axis

direction, (S‫)ﺏ‬y:
(S‫)ﺏ‬y = (S‫)ﺏ‬RN sin(θR)
= G sin(‫ )ﺏ‬sin(θR)
x–z Equation of ellipse:

2
G2 sin2 (90 − θR ) − z 2
x =
sin2 (90 − θR )
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Steering angle as viewed from the x-z plane, ‫ﺕ‬:
(S‫) ﺏ‬x
‫ = ﺕ‬tan-1
(S‫) ﺏ‬z
-1
sin(‫)ﺏ‬cos(θR )
= tan
cos(‫)ﺏ‬
= tan-1[tan(‫ )ﺏ‬cos(θR)]
z–y Equation of ellipse:

2
G2 sin2 (θR ) − z 2
x =
sin2 (θR )
Steering angle as viewed from the z-y plane, ‫ﺙ‬:

(S‫) ﺏ‬y
‫ = ﺙ‬tan-1
(S‫) ﺏ‬z
-1
sin(‫)ﺏ‬sin(θR )
= tan
cos(‫)ﺏ‬
= tan [tan(‫ )ﺏ‬sin(θR)]
-1
Figure 3.3: Graphical representations of steering motion in 5 different orientation
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Steering Length Design
For the steering length design, two boundary conditions are set so that the equation of
position can be completed and solved. Both boundary conditions are set during the maximum
angle of steer.
The extended arm is set to attain its maximum reach with the elbow joint straight while
keeping the torso straight at neutral position without the need to turn the bodyxxvii. This is so
that the rider can maintain the freedom of their torso for balancing and other handling
purposes during a maximum steer angle.
On the other hand, the contracted arm is set to attain its minimum reach with the shoulder
joint in parallel with the torso at neutral position as to avoid muscle strain between the neck
and shoulder. Two clearances are put into consideration for the contracted arm. The first one
is the clearance between the hand holding the handle and the thigh, which was set to 5cm.
The second one is the clearance between the elbow and the torso. Relative to the shoulder,
this clearance was set to 0cm to minimise the steering bar lengthxxviii. This was also due to the
consideration that the shoulder and hip, where the elbow is most likely to face interference,
already have a difference of 3cm on each side according to the anthropometric data in
referencexxix.
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Let distance from one grip to the center, G = Y
L352 = [X ＋ 2Y sin (‫ )ﺏ‬cos (θR)] 2 ＋ [L19－ 2Y sin (‫ )ﺏ‬sin (θR) －CEy] 2 ＋ [Y cos (‫ )ﺏ‬－
L8/2] 2 [Eq. 1A]
[X ＋ 2Y sin (‫ )ﺏ‬cos (θR)] 2 = X2 ＋ 4XY sin (‫ )ﺏ‬cos (θR) ＋4Y2 sin2 (‫ )ﺏ‬cos2 (θR)[L19－
2Y sin (‫ )ﺏ‬sin (θR) －CEy] 2 = [(L19 - CEy) － 2Y sin (‫ )ﺏ‬sin (θR)] 2
= (L19 - CEy) 2 － 4(L19 - CEy) Y sin (‫ )ﺏ‬sin (θR) 4Y2 sin2 (‫)ﺏ‬
sin2 (θR)
[Y cos (‫ )ﺏ‬－L8/2]2 = Y2 cos2 (‫ )ﺏ‬- L8Y cos (‫ )ﺏ‬+ L82/4
L352 = X2 ＋ 4XY sin (‫ )ﺏ‬cos (θR) ＋4Y2 sin2 (‫ )ﺏ‬cos2 (θR) + (L19 - CEy) 2 － 4(L19 - CEy) Y
sin (‫ )ﺏ‬sin (θR) ＋4Y2 sin2 (‫ )ﺏ‬sin2 (θR) + Y2 cos2 (‫ )ﺏ‬- L8Y cos (‫ )ﺏ‬+ L82/4
= X2 ＋ 4XY sin (‫ )ﺏ‬cos (θR) ＋4Y2 sin2 (‫ )ﺏ‬cos2 (θR) ＋ 4Y2 sin2 (‫ )ﺏ‬sin2 (θR) + Y2 cos2 (‫)ﺏ‬
－ 4(L19 - CEy) Y sin (‫ )ﺏ‬sin (θR) - L8Y cos (‫ )ﺏ‬+ L82/4 + (L19 - CEy) 2
= X2 ＋ 4XY sin (‫ )ﺏ‬cos (θR) + Y2 [4 sin2 (‫ )ﺏ‬cos2 (θR) + 4 sin2 (‫ )ﺏ‬sin2 (θR) + cos2 (‫ ])ﺏ‬+ Y
[－4(L19 - CEy) sin (‫ )ﺏ‬sin (θR) － L8Y cos (‫ ])ﺏ‬+ L82/4 + (L19 - CEy) 2
0 = X2 ＋ 4XY sin (‫ )ﺏ‬cos (θR) + Y2 [4 sin2 (‫ )ﺏ‬cos2 (θR) + 4 sin2 (‫ )ﺏ‬sin2 (θR) + cos2 (‫ ])ﺏ‬+
Y [－4(L19 - CEy) sin (‫ )ﺏ‬sin (θR) － L8 cos (‫ ])ﺏ‬+ L82/4 + (L19 - CEy) 2 －L352 [Eq. 1B]
Coefficient of the terms from Equation 1A

X2 : 1
XY : 4 sin (‫ )ﺏ‬cos (θR)
Y2 : 4 sin2 (‫ )ﺏ‬cos2 (θR) + 4 sin2 (‫ )ﺏ‬sin2 (θR) + cos2 (‫)ﺏ‬
Y : －4(L19 - CEy) sin (‫ )ﺏ‬sin (θR) － L8 cos (‫)ﺏ‬
1 : L82/4 + (L19 - CEy) 2 － L352
L31-252 = X2 ＋ [L19 - L26 cos (sin-1 (CEz/L26)) - CEy] 2 ＋ [Y cos (‫ )ﺏ‬- CEz - L8/2] 2 [Eq. 2A]
= X2 ＋ [L19 - L26 cos (sin-1 (CEz/L26)) - CEy] 2 ＋ [Y cos (‫ )ﺏ‬- (CEz + L8/2)] 2
= X2 ＋ [L19 - L26 cos (sin-1 (CEz/L26)) - CEy] 2 ＋ Y2 cos2 (‫ )ﺏ‬－ 2Y cos (‫( )ﺏ‬CEz +
L8/2) + (CEz + L8/2)2
X2 = – Y2 cos2 (‫ )ﺏ‬+ 2Y cos (‫( )ﺏ‬CEz + L8/2) + L31-252 – [L19 - L26 cos (sin-1 (CEz/L26)) -
CEy] 2– (CEz + L8/2)2[Eq. 2B]
Coefficient of the terms from Equation 2B

Y2 : – cos2 (‫)ﺏ‬
Y : 2 cos (‫( )ﺏ‬CEz + L8/2)
1 : L31-252 – [L19 - L26 cos (sin-1 (CEz/L26)) - CEy] 2– (CEz + L8/2)2
∴ X = ± [– Y2 cos2 (‫ )ﺏ‬+ 2Y cos (‫( )ﺏ‬CEz + L8/2) + L31-252 – [L19 - L26 cos (sin-1 (CEz/L26)) -
CEy] 2– (CEz + L8/2)2] 0.5
67
Arrangement for non-linear system of equations
Equation no. Coefficients Value Insert Eqn 2A into 1A

2
1A X 1 3A X2 0
XY 2.563425528 XY 2.56343
Y2 2.5 Y2 2
Y -63.22094325 Y -32.1811
1 -3031.869873 1 -2514.6
2A Y2 -0.5
Y 31.03986637
1 517.2655078
Eqn 1A 1X2 + 2.56343XY + 2.5Y2 - 63.221Y - 3031.9 = 0

Eqn 2A X2 = -0.5Y2 + 31.0399Y + 517.266
X = (-0.5Y2 + 31.0399Y + 517.266)0.5
Eqn 3A 2.56343XY + 2Y2 - 32.181Y - 2514.6 = 0
Insert 2A
into 3A 2.56343Y(-0.5Y2 + 31.0399Y + 517.266) 0.5 + 2Y2 - 32.181Y - 2514.6 = 0
Solving unknowns Y = 25.4

X = 40.35
The distance from one grip end to the center of steering is approximated to be 25cm.
Therefore, the distance between the two grips is 50cm.
68
3.1.1 DESIGN FOR HUMAN FACTOR
Electric scooter is combination of few main components on the main frame. To
complete the electric scooter, the measurement must be precise and fulfil the required
calculation. The electric scooter must provide a comfortable ride for the rider as well as the
safety when the scooter accelerates, braking and cornering. To fulfil its main function, the
scooter must be able to commute from one place to another without having problem. Thus, the
decision to design an electric scooter should be influenced by the user of the scooter itself.
In building electric scooter, there are three main components have been designed by our group
which are:
a) Swing arm
b) Front fork
c) Main frame
A) ERGONOMIC
Ergonomics is the study of designing equipment and devices that fit the human body,
its movements, and its cognitive abilities. Ergonomics (or human factors) is the scientific
discipline concerned with the understanding of interactions among humans and other
elements of a system, and the profession that applies theory, principles, data and methods
to design in order to optimize human well-being and overall system performance. By
reducing the sharp edge for each component at our suspension, we think this factor is also
contributed to this aspect, ergonomics.
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Description for design on human factor
1. Swing arm
A swing arm, originally known as a swing fork or pivoted fork, is the
main component of the rear suspension of the electric scooter. It is used to hold
the rear axle firmly, while pivoting vertically, to allow the suspension to absorb
bumps in the road. The strength of the arm must be higher. This is because to
ensure that the force acting on the arm will not break the arm. In our process in
designing the swing arm geometry, there is minimum dimension for the wheel
base also the track. To decide the suitable dimension for the wheel base and
track width used in our electric scooter, we considering that a rider is seated on
the scooter. It is easier to estimate the wheel base after that designing the arm
geometry.
2. Front Fork
A fork connects a motorcycle's front wheel and axle to its frame,
typically via a pair of triple clamps. It typically incorporates the front suspension
and front brake, and allows the front wheel to rotate about the steering axis so
that the bike may be steered. Handlebars attach to the top clamp. The fork and
its attachment points on the frame establish the critical geometric parameters of
rake and trail, which play a major role in defining how a motorcycle handles
and dives during braking. Team has put a lot of effort to establish the front fork
system that enables to absorb more bounce and jounce. It is important that the
front fork system has the ability to absorb the bounce and jounce to give the
driver comfort for riding the car.
3. Main Frame
A main frame is a motorcycle's core structure. It supports the engine,
provides the hinge points for both front and rear suspension, and supports the
rider and any pillion or luggage. Also attached to the frame are the fuel tank and
battery. At the front of the frame is found the head tube that holds the pivoting
front fork, while at the rear there is a pivot point for the swing arm. Some
motorcycles include the engine as a load-bearing stressed member, while some
others bikes do not use a single frame, but instead have a front and a rear sub-
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frame attached to the engine. For the driver comfort and safety, the team has
design the main frame based on calculation generated by the team.
The designed electric scooter has a standard ergonomic design used for
commercial motorcycle which is single seated vehicle. The design is simple since the
purpose of the electric scooter is clearly made that to provide comfort and safety ride.
The geometry and location of all parts are put at where they should be so that they can
perform their function wherever if need.
To make sure that the electric scooter is perform well, some kinematic analysis
such as static and dynamic loading, rolling, anti-dive, and anti-squat and steer analysis
had been conducted. The dimensions to the each component also have been design in
CATIA V5 R20 to get the accurate reading. Accurate reading is important in the
assembly process and also in the further fabrication process.
B) ANTHROPOMETRIC
The branch of ergonomics that deals with human variability in size, shape and
strength is called anthropometry. Anthropometry refers to the measurement of humans.
Anthropometry has been considered as the very basic core of ergonomics in an attempt
to resolve the dilemma of ‘fitting people to machine’. Bridger and Chou & Hsiao
believed anthropometry is a research area in ergonomics dealing with the measurement
of human body dimensions and certain physical characteristics. Anthropometric data
can be used in ergonomics to specify the physical dimensions of workspaces,
workstations, and equipment as well as applied to product design. As mentioned in the
abstract section, the objective of this study was to develop an anthropometric database
for Malaysian population. The aim was to assist the designer and engineers in
incorporating anthropometric features in their design process.
Anthropometry is defined as the the measurement of the size and proportions of

the human body (Dictionary.com LLC). Due to the known target market of university
students in Malaysia, it is very relevant to use specific anthropometric data of
Malaysians so that better comfort and safety can be implemented into the design xxx. The
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main source of this anthropometric data was obtained from Darliana Mohamad, Baba
Md Deros, Ahmad Rasdan Ismail, Dian Darina Indah Daruis (2010).
Anthropometric refers to the measurement of the human individualxxxi. An early

tool of physical anthropology, it has been used for identification, for the purposes of
understanding human physical variation, in pale anthropology and in various attempts
to correlate physical with racial and psychological traits. Why this anthropometry is
very important in the design? This is because to give comfort to the driver in riding the
car by enhancement of the electric scooter.
The human anthropometry is differ from one another, thus it is basically

important to produce electric scooter that can serve different type of anthropometry.
Basically we need to ensure that the electric scooter is capable to overcome some
criteria such as:
1. Different type of load of human as they have different mass from another.
2. Have the universal measurement for rider to ride and serve different type
of size of human as long as it has not exceed the limit size of requirement
of rider as designated.
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3.1.2 CREATING USER FRIENDLY DESIGN
1. Good display.
2. Controller easy to handle.
3. Simplify task.
4. Fit the product to the user’s physical attributes and knowledge from
ergonomics and anthropometric data.
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3.2 CONFIGURATION DESIGN
Configuration Design is done in order to establish the shape and general dimensions of
the components (special purpose parts, standard parts, standard assemblies or modules).
Configuration Design depends on:

1. Available materials and production methods.
2. Spatial constraints.
3. Product architecture.
Configuration Design is divided into several sections:

1. Modeling
2. Simulation
3. Analysis calculation
4. Material selection
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3.2.1 Modelling
For the modelling in design project, we choose the electric scooter that includes
the parts such as swing arm, front fork and main frame. This model of electric scooter
has divided by three sections which are front, middle and rear.The reason of choosing
these 3 parts of the scooter because of the front fork, frame and swing arm are the
crucial part. These crucial part are connection of weight og the rider and contact surface
of road.In order to avoid any catastrophic failure electric scooter.So these part were
important to analysis and simulation .
3.2.1.1 Front Fork
Figure 3.4- Front fork assembly view

The fork and its attachment points on the frame establish the critical geometric
parameters of rake and trail, which play a major role in defining how a motorcycle handles and
dives during braking. A motorcycle fork connects a motorcycle's front wheel and axle to its
frame, typically via a pair of triple clamps. It typically incorporates the front suspension and
front brake, and allows the front wheel to rotate about the steering axis so that the bike may be
steered. Handlebars attach to the top clamp.
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3.2.1.2 Main Frame
Figure 3.5: Main frame assembly
A motorcycle frame is a motorcycle's core structure. It supports the engine,

provides the hinge points for both front and rear suspension, and supports the rider
and any pillion or luggage. Also attached to the frame and battery. At the front of
the frame is found the head tube that holds the pivoting front fork, while at the rear
there is a pivot point for the swing-arm. Some motorcycles include the engine as a
load-bearing stressed member. While some others bikes do not use a single frame,
but instead have a front and a rear sub-frame attached to the engine.
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3.2.1.3 Swing Arm
Figure 3.6: Swing Arm Assembly
Originally motorcycles had no rear suspension, as their frames were little more
than stronger versions of the classic diamond frame of a bicycle. Many types of
suspension were tried, including Indian's leaf spring suspended swing-arm, and
Matchless's cantilevered coiled-spring swing-arm. Immediately prior to and after
World War II, the plunger suspension, in which the axle moved up and down two
vertical posts, became commonplace. In the latter, the movement in each direction
was against coiled springs.
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3.2.2 SIMULATION
Simulation is the imitation or representation, as of a potential situation or in
experimental testing. Simulation generally representing certain key characteristics or
behavior of a certain selected physical part of the system or the abstract of the system.
All parts needs to simulate in order to know the parts achieved the specification. The
finite element tools by CATIA software was done in analyzing the stress for arm and
spring coil. The simulation involve of force exerted on the all the parts that supported
the loads with normal loads and consider the safety factor. The analysis involves stress,
deformation, and yield-strength also strain deformation on several design parts.
3.2.2.1 Front Fork
The front fork which were assumed to hold 200kg acting on the fork.The fork
is the part of scooter that holdt he front wheel. In this case ,the von misses stress shows
the analysis of the front fork when the force acting on tithe maximum stress on fork
with the value of 4.17×107 Pa and compare to value of yield strength on material of
mild steel shows that the front were safe to use.The maximum von misses stress can be
refer on the red mark at figure 2.4.
Table 3.2.2.1:Properties of material
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Figure 3.7 Von Misses Stress on Front Fork
3.2.2.2 Main Frame

The main frame where the most important on scooter which it has supported
load from a rider.The maximum load acting on the seat which is 200kg.The main frame
also use a mild steel to being fabricate and anlaysis. As refer on table below shows the
properties of material on mild steel.
Table 3.2.2.2:Properties of material
Figure 3.8:Boundary Condition
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The figure 2.5 shows the main frame of scooter where the placing of load
applied and the clamp. The yellow colour shows the load applied meanwhile for the
blue line shows for the clamping part. The result of load applied and the clamped ,it
can be refer on the figure of 2.6.The Figure 2.6 shows the von misses stress of main
frame with resulted that the maximum stress which is 3.66×107 Pa .By comparing the
result of maximum stress and yield stress shows the maximum stress are below than
yield stress.It is shows that the main frame are safe to use.The part where the stress
have high value shows with red-yellow colour on figure 2.6.This is because the force
were concentrated on that area.
Figure 3.9 Von Misses Stress on Main Frame
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3.2.2.3 Swing Arm
Swingarm is literally a main component of the scooter which allows for the fitment of
the rear axle of the bike and the rear suspension to be set up as well as allows for the vertical
movement of the rear tyre which helps manage the undulations on the road.The material
applied on the swing arm use a mild steel with the properties material refer on table 2.2.2.3.
Table 3.2.2.3: Properties of Material
Figure 3.10: Boundary Condition

The figure 2.7 shows where the load and clamped were placing. Refer on
figure 2.7 shows that the yellow line(arrow) where the load is applied meanwhile for
the blue colour as clamp place. The analysis result can be on von misses stress figure
2.8.The maximum stress acting on swing arm which is 1.28× 108 Pa. By comparing
the yield strength and maximum stress after applied load shows that the value of
maximum stress were lower than yield strength. It can consider that the analysis of
swing arm achieve to used.
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Figure 3.11 Von Misses Stress on Swing Arm
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3.2.3 ANALYSIS OF CALCULATION
A) Overall Force Distribution
To calculate the force distribution to the rear and front tyres, a maximum load of 200kg is used.
The location of centre of gravity is assumed to be at the seat centre.
W = mg
= 200kg * 9.81m/s2
= 1962N
Distance from centre of gravity to rear tyre, P = 360mm

Distance from centre of gravity to front tyre, Q = 1100.6mm
For static case analysis, the summation of moments at all points and forces in all directions
equals to zero. To calculate the force exerted on front tyre, NF;
∑ 𝑀𝑅 = 0
NF*(P+Q) – W*(P) = 0
NF = W*P/ (P+Q)
= 1962*360/ (360+1100.6)
= 483.58N
To calculate force exerted on rear tyre, NR;
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∑ 𝐹𝑌 = 0
NF + NR – W = 0
NR = W – NF
= 1962 – 483.58
= 1478.42N
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B) Steering Fork Forces
Fork offset, Of = 50mm

Steering throat length, Sth = 275mm
Length of fork, Lf = 345mm
Rake angle, θR = 25⁰
∑ 𝑀𝑏 = 0
Fa(Sth) – NF sin(θR)(Lf) = 0
Fa = NF sin(θR)(Lf)/Sth
= 483.58 sin(25⁰)(345)/275
= 210.56N
∑ 𝐹𝑅𝑁 = 0
Fa – Fb + NF cos(θR) = 0
Fb = Fa + NF sin(θR)
= 210.56 + 483.58 sin(25⁰)
= 395.62N
∑ 𝐹𝑅θ = 0
Fc – NF sin(θR) = 0
Fc = NF cos(θR)
= 483.58 cos(25⁰)
= 446.77
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a)Front tyre axle diameter
To calculate the minimum size of the front tyre axle diameter, Maximum Shear Stress Theory
is used with the maximum force NF acting in double shear.
To calculate shear force acting on the rear tyre axle;
∑𝐹 = 0
NF – 2VF = 0
VF = NF/2
= 483.58 /2
= 241.79N
Yield strength of A36 steel, Sy = 250MPa

Maximum shear stress according MSST, τmax with factor of safety, n of 10;
τmax = Sy/2n
= 250*106/2*10
= 12.5MPa
To relate with area of the cylindrical shaped axle and minimum diameter required;
τmax = VR/A
= 4VR/ πd2
d = (4VR/ πτmax)0.5
= (4*241.79/π*12.5*106)0.5
= 4.963mm
The minimum diameter for the bolt connection on each shock absorber is 4.963mm. However,
the standard specification of the found front tyre axle has a connection diameter of 10mm.
Hence, according to the maximum loading, the connection is safe.
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C) Swing Arm Forces
Swing arm link to rear tyre centre length, SRt-SA = 360mm

Swing arm shock extension length in y-axis, (SSAe)y = 200mm
To calculate the total force acting on the shock absorbers;
∑ 𝑀𝑆𝐴 = 0
NR(SRt-SA) – FSh(SSAe)y = 0
FSh = NR(SRt-SA)/(SSAe)y
= 1478.42(360)/(200)
= 2661.156N
Since the two forces NR and FSh act only in the vertical and horizontal directions respectively,
the remaining force FSA is a summation of both forces in their respective opposite directions.
FSA = (NR2 + FSh2)0.5

= (1478.422 + 2661.1562)0.5
= 3044.253N
Angle of FSA;
θ = tan-1(NR/FSh)
= tan-1(1478.42/2661.156)
= 32.28 ⁰
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a) Rear tyre axle diameter
To calculate the minimum size of the rear tyre axle diameter, Maximum Shear Stress Theory
is used with the maximum force NR acting in double shear.
To calculate shear force acting on the rear tyre axle;
∑𝐹 = 0
NR – 2VR = 0
VR = NR/2
= 1478.42/2
= 739.21N

τmax = Sy/2n
= 250*106/2*10
= 12.5MPa
τmax = VR/A
= 4VR/ πd2
d = (4VR/ πτmax)0.5
= (4*739.21/π*12.5*106)0.5
= 8.677mm
the standard specification of the found rear tyre axle pre-assembled with hub motor has a
connection diameter of 14mm. Hence, according to the maximum loading, the connection is
safe.
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b) Rear support connector bolt diameter and thickness
To calculate the minimum size of the rear support connection bolts, Maximum Shear Stress
Theory is used with the maximum force FRS for each of the rear supports, equivalent to half of
the force acting on the rear tyre, NR. This force is acts in single shear.
To calculate shear force on the bolt;
∑𝐹 = 0
FRS – VRS = 0
VRS = FRS
= NR/2
= 1478.42/2
= 739.21N
Minimum yield strength of bolt from Property Class 4.8, Sy = 340MPa

Maximum shear stress according MSST, τmax with factor of safety, n of 1.5;
τmax = Sy/2n
= 340*106/2*1.5
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= 113.33MPa
To relate with area of the cylindrical shaped bolt and minimum diameter required;
τmax = VRS/A
= 4VRS/πd2
d = (4VRS/πτmax)0.5
= (4*739.21/π*113.33*106)0.5
= 2.882mm
The minimum diameter for the bolt connection on each shock absorber is 3mm. The connection
is safe using M3 x 10mm Property Class 4.8.
To calculate the minimum thickness of the rear support, t,

maximum bearing stress is calculated at the axle connection.
For aluminium, the yield strength, Sy = 95Mpa with factor of

safety, n of 3
Diameter rear tyre axle, dR = 14mm
Sy/n = FRS/t*dR
t = nFRS/Sy*dR
= (3)739.21/95*106*0.014
= 1.667mm
A suitable thickness of the rear support is 2mm
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c) Swing arm axle diameter
To calculate the minimum size of the swing arm connector axle, Maximum Shear Stress Theory
is used with the maximum force FSA acting in double shear.
To calculate shear force acting on the swing arm axle;
∑𝐹 = 0
FSA – 2VSA = 0
VSA = FSA/2
= 3044.253/2
= 1522.123N

τmax = Sy/2n
= 250*106/2*5
= 25MPa
τmax = VSA/A
= 4VSA/πd2
d = (4VSA/πτmax)0.5
= (4*1522.1233/π*25*106)0.5
= 8.805mm
A suitable diameter of the swing arm axle is 10mm.
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d) Shock absorber bolt diameter
To calculate the minimum size of the shock absorber connection bolts, Maximum Shear Stress
Theory is also used with the maximum force FSh acting in double shear. For the use of two
shock absorbers, the force FSh will be divided by two for each shock absorber.
To calculate shear force acting on the shock absorber bolt;
∑𝐹 = 0
FSh/2 – 2VSh = 0
VSh = FSh/4
= 2661.156/4
= 665.289N
Minimum yield strength of bolt from Property Class 4.6, Sy = 240MPa

τmax = Sy/2n
= 240*106/2*5
= 24MPa
τmax = VSh/A
= 4VSh/πd2
d = (4VSh/πτmax)0.5
= (4*665.289/π*24*106)0.5
= 5.941mm
the standard specification for the found shock absorbers has a connection diameter of 10mm.
Hence, according to the maximum loading, the connection is safe using M10 x 30mm Property
Class 4.6.
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TRAIL CALCULATION
Trail is defined as the distance between the contact points of the front tyre with the imaginary
line extended from the steering axis.
𝑅𝑓 sin 𝜃𝑅 − 𝑂𝑓
𝑇𝑟𝑎𝑖𝑙, 𝑇 =
cos 𝜃𝑅
Where;
Radius of front tyre, Rf = 210mm

Rake angle, θR = 25⁰
Fork offset, Of = 50mm
The trail is calculated to be 42.8mm
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3.2.4 MATERIAL SELECTION
Material selection is a step in the process of designing any physical object. In the
context of product design, the main goal of material selection is to minimize cost while
meeting product performance goals. Systematic selection of the best material for a given
application begins with properties and costs of candidate materials. A few types of steel
have been brought into consideration and finally selecting the best material properties to
be use in the fabrication process of the electric scooter chassis
There are few types of steel will select to use in electric scooter chassis.
The types of the steel are:
1. Carbon Steels:
 Can be further categorized into 3 groups depending on their carbon content
which are low carbon steel, medium carbon steel and high carbon steel.
 The carbon steel is the cheapest among other types of steel.
 It has a good properties of high stiffness, easy to machine and joint
 However, it has poor resistance to corrosion.
2. Stainless Steel:
 It is not normally used to manufacture tools.
 With over 11% chromium, steel is about 200 times more resistant to corrosion
than mild steel.
 High strength properties.
 High aesthetical appeal compare to carbon steel.
 Stainless Steel generally costs larger than compare to Carbon Steel and Alloy
Steel.
3. Alloy Steel:
 It has greater strength, hardness, hot hardness, wear resistance, hardenability, or
toughness compared to carbon steel.
 However, they may require heat treatment in order to achieve such properties.
 If compared based of the cost of the steel, the alloy steel are at the average cost
when compared to the carbon steel and stainless steel.
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Referring to the general properties of steel in table
Table3.2.4: Properties of Steel

For the whole construction of the chassis on electric scooter, only one type of the materials for
all of the part in the chassis is chosen. This is because the materials that are to be used for all
of the part in chassis are exactly the same. The materials must be the best in properties of
strength, cost, green product and formability. From the comparison of each of these properties,
the selected material for fabricating the the frame is mild steel. Specifically the ASTM A36
Mild (low carbon) steel. By referring the table on ASTM Mild (low –carbon steel) shows the
minimum properties on material.
Table 3.2.5: ASTM A36 Mild (low carbon) steel properties
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Mild steel is selected by various reasons and mainly by its certain purpose of the
chassis electrical scooter. Mild steel have been chosen to fabricate the chassis of as its hold
the high strength properties to withstand force and light weight.
In addition, selecting mild steel gives benefits to the team project. The mild steel is
readily available compare to other material such as alloy steel. Thus, the project may be
progress smoothly or undisturbed by material problem. Moreover, mild steel is considerably
cheap compare to other material such as stainless steel or alloy steel. The stainless steels or
alloy steel may give more advantages such as lower in weight and anti-corrosion, but the high
value of the material may interrupt the project budget and thus the total cost become higher.
The cost must be controlled to be in lower range as long as it can achieve the quality of the
desired product.
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3.3 PARAMETRIC DESIGN
Parametric design in one important part in relative to the phase of embodiment design.
The attributes that was identified in configuration design will become variables to be used in
parametric design as to set the dimensions ad tolerances in order to maximize quality and
performance and minimize cost. The objectives of the parametric design is to set values for the
design considering both performance and manufacturability.
Design variables:
Attribute of a part.
The value is under designer control.
Below is the list of established method in order to maximize performance and quality of a
design:
FMEA
Maximize
performance Robust
DFA and quality of design
a design
DFM
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3.3.1 Failure Mode and Effect Analysis (FMEA)
A failure modes and effects analysis (FMEA) is a procedure for analysis of potential failure
modes within a system for classification by severity or determination of the effects of failures
on the system. It is widely used in manufacturing industries in various phases of the product
life cycle and now is increasingly finding use in the service industries. Failure modes are any
errors or defects in a process, design or item especially those that affect the customers and can
be potential or actual. Effects analysis refers to studying the consequences of those failures.
FMEA is designed to assist the engineer to improve the quality and reliability of design.
Properly used FMEA will provide engineers with a lot of benefits such as:
 Improve product/process reliability and quality.

 Increase customer satisfaction.
 Early identification and elimination of potential failure modes.
 Prioritize deficiencies.
 Emphasize problem prevention.
 Minimize late changes and associated cost.
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Part Function Failure Failure Failure effect on Failure
Identification mode cause detection
Component System
method
or
functional
assembly
Electric Hub Provide Fails to Short Motor over- Scooter fails Present of
desired rotate circuit heat to operate smoke
mechanical using electric
movement hub
Battery Source of Not Exceed Electric System fails Motor not

energy for enough life span component to operate running
electric scooter power on a single fail to
supply charge function
Chassis Combines all Breaking Fracture Fail to hold System fails Crack on
the component other part to operate the frame
Handle Steering the Fails to Wrong Front fork Shock Steer to

direction of steer installation absorber wrong
scooter properly direction
Brake Decelerate the Fail to Wear None Scooter fail Scooter

scooter decelerate brake pads to stop take times
the scooter to stop
Tire Contact Fail to Punctured Rim Scooter Need a lot

between move cannot move of energy
scooter and fluently to move
road surface
Table 3.3.1: Failure Mode and Effect Analysis (FMEA)
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3.3.2 DESIGN FOR ASSEMBLY (DFA)
In design for assembly, the team has put the effort in choosing the best components in
order to minimize the assembly process. The concern about design for ease of assembly
involves these principles:
1. Handling
2. Insertion and fastening
In part count, the electric scooter has been chosen with less number of parts. The team
manages to minimize the number of part to ensure the assembly process is easier and not time
consuming. The lesser the total number of part in the electric scooter, the easier and faster the
assembly and disassembly process. For example, front fork and handle bar is weld to be quite
like a T-shaped to establish as 1 part to minimize the number of part counts of the whole
systems.
Insertion and fastening of the suspension part can be minimized based on the total
number of part. The lesser number of parts, the less of the insertion and fastening process will
be based on the type of fastener used. Thus, the lesser number of fastener can be used and the
easier the process of assemble and disassembly would be. For example, the electric scooter is
assembled using bolt and nut as it is easier to dismantle for maintenance or packing for
distribution purpose.
The outcome of DFA:
 Shorten product design time

 Reduce assembly time
 Simplify assembly process
 Reduce total material cost
 Improves quality and reduce defects
 Reduce labor content
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3.3.3 DESIGN FOR MANUFACTURE (DFM)
Design for manufacture, (DFM) is the way of thinking that can be applied to reduce
manufacturing cost and improve quality. DFM is the design for ease of manufacture of the
collection of parts or product. At a complex level, DFM take several fundamental problems in
combining each of parts. Design for manufacturability (DFM) is the general engineering art of
designing products in such a way that they are easy to manufacture. The basic idea exists in
almost all engineering disciplines, but of course the details differ widely depending on the
manufacturing technology. There are several guidelines that we use to our product as shown
below:
• The numbers of parts were reduced by combining

Minimize total it using screw and welding process.
number of parts • Example: Weld the bracket with the chassis.
• This will increase safety when we assembly the

Use fillet to avoid car.
sharp corner
• The reason is because if the parts were tight too

Avoid excessively tight close the movement of suspension will be not
smooth and to prevent the part from touching
tolerances each other.
• Functions of suspension:
Design part to be • I. Absorb vibration from main body.
multifunctional • II. Support weight of the car.
• III. To counter the cornering force of the car.
Utilize the special • DFM 3 keys element:

• Process selection
characteristics of the • Reducing the number of process stages
process • Designing of the process
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DFM keys element:
1. 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
Table 3.3.3
2) REDUCING THE NUMBER OF PROCESS STAGES

Eliminate unnecessary process
 Elimination of finishing process

Some of parts do not have to use finishing process.
 Combining processes
Welding the rocker rather than using bolt will reduce weight of the car.
3) DESIGN OF THE PROCESSES
 Design for machining

Use standard spring coil.
For the absorber, our department decided to use the already available part in market
which is part shock absorber from second-hand electric scooter.
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3.3.4 DESIGN FOR ROBUST
Robust Design method, also called the Taguchi Method, pioneered by Dr. Genichi
Taguchi, greatly improves engineering productivity. Robustness is the property of systems that
enables them to survive unforeseen or unusual circumstances. In the design there are some
parameters that cannot be controlled which are called as uncontrollable parameter. This
parameter will causes the design to be failure if it is totally out of control, therefore the
controllable parameter should be ensure to be balanced enough to reduce it effects:
In design the electric scooter, the uncontrollable parameter had been identified and so
does the way to increase its efficiency. They are,
1) Connection parts by parts
 Connections of the handle bar and front fork are the vital role in the whole of the electric
scooter.
 The connection is design up to hold the force from main frame with the help of the
absorber and meanwhile, it easy to assemble and dismantle.
 The connection of the seat and main frame also apply the same concept as it gives more
benefits.
2) Material of parts
 Suitable material must be applied to the parts to increase of its efficiency.
 For front fork, the hard material is chosen to withstand the force due to turning and the
bouncing.
 As for the brake, strong material has been chosen to give beneficial to the electric
scooter and at the same time lightweight material to reduce the load to the electric
scooter.
 For rock, the material chosen is ductile to withstand the distribution load.
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3.4 Final Dimension
Figure 3.4.1
Figure 3.4.2
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Figure 3.4.3
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PHASE 3
DETAILED
DESIGN
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4.1 INTRODUCTION
The third phase which is the final phase in mechanical engineering design is the detail
design phase. At this phase, most of the essential process in designing the product is already
completed. It is about 85% of product process is complete and before fabrication process to be
started.
In the phase 3, the finalization of process of the design for the electric scooter has
been done. This process is a very important process as it determined the suitability for the all
parts in electric scooter.
In completing this phase, the first task that has to be completed is the detail design in
detail engineering drawing. Using layout view it shows about specification in size and suitable
with production for costumer order. 3 main section of design drawing it is component,
subassembly and assembly.
This phase will consist of:
i. Detailed engineering drawing,

ii. Verification testing of prototype
iii. Bill of materials
iv. Cost estimation
v. Product specification.
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4.2 OBJECTIVE
a) To show the detail drawing for each component, subassembly and assembly.
b) To shows the bill of material of design
c) To estimate the cost of products’ design
d) To discuss the final specification
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4.3 DETAIL DRAWING
Each of scoter parts and components were design by using CATIA V5R20
software.
Show:
 Component
 Subassembly
 Assembly
There are part that electric scooter had decided to fabricate and buy from the supplier. For the part
that will be fabricated,
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4.3.1Details Engineering Drawing
The component being fabricate
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4.3.2Details Engineering Drawing
The component from supplier
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4.4Bill of Material of Electric Scooter
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4.5 Full Assembly
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4.6 BILL OF MATERIAL (BOM)
A bill of materials (BOM) is a list of the raw materials, sub-assemblies, intermediate
assemblies, sub-components, components, parts and the quantities of each part needed in
manufacturing an end product. It is basically a list of the overall assembly design of a product. In
BOM, it shows the list of quantity, number of part and source of the part, which is either the part is
design, built or order. Once the design of the system is completed, the BOM list is passed on to the
layout engineer as well as component engineer who will procure the components required for the
design
Sufficient amount of material per unit were considered, to bypass any waste of material
outstanding. Type and material properties used for this product also crucial in cost planning as it will
decide life expectancy indirectly efficiency. Referring to Bill of material on table below, it is estimate
the combination of all materials combine worth around RM 1929. The bill of materials and costing
were created to provide capital costs during the progress of making the product, and expected
lifecycle for specific elements used in the making of Electric Scooter.
Table below shows bill of material which separated into two types which is mechanical and
electrical.
Mechanical part of bill material:
BILL OF MATERIAL
No. Name of parts Quantity Types of materials Manufacturer/ vendor
1. Swing Arm 1 Mild steel Self-made/ Workshop UiTM
2. Handle bar 1 Mild steel Self-made/ Workshop UiTM
3. Floor deck 1 Mild steel Self-made/ Workshop UiTM
4. Seat 1 Fabric Self-made/ Workshop UiTM
5. Front Shock absorber 2 AZ EASY TRADING
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6. Rear shock absorber 2 AZ EASY TRADING
7. Rim 2 Aluminum AZ EASY TRADING
8. Brakes lever 2 Plastic AZ EASY TRADING
9. Bearing Swing Arm 1 AZ EASY TRADING
10. Frame middle 1 Mild steel Self-made/ Workshop UiTM
Bolts 26
BNT Sdn.Bhd
11.
Nuts 26
BNT Sdn.Bhd
12.
Washer 20
BNT Sdn.Bhd
13.
14. Handle bar 1 Self-made/ Workshop UiTM
15. Tyre bearing 4 AZ EASY TRADING
Table 4.6.1 :Bill of material of mechanical part
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Electrical Part:
BILL OF MATERIAL
No. Name of parts Quantity Types of materials Manufacturer/ vendor
1. Speed controller 1 Electrical parts AZ EASY TRADING
Electrical parts
2. Battery 4 AZ EASY TRADING
Electrical parts
3. Battery Change Port 1 AZ EASY TRADING
Electrical parts
4. Horn 1 AZ EASY TRADING
Electrical parts
5. Front Light and Signal 1 AZ EASY TRADING
Electrical parts
6. Wire 1 AZ EASY TRADING
Electrical parts
7. Power Switch 1 AZ EASY TRADING
Electrical parts
8. Throttle Set 1 AZ EASY TRADING
Electrical parts
9. Charger 1 AZ EASY TRADING
Electrical parts
10. Connector 4 AZ EASY TRADING
Table 4.6.2 :Bill of material of electricall part
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4.6.1 COSTING
The following section performs the overall cost in order to produce a single seater car
suspension. The costing includes the components cost, machining cost and other cost which may
involve. However, the table below shows estimation for costing of our project because the fabrication
of our project will be done in the next semester.There are main part that already bought to study
and to get the exact dimension of the part (refer appendix).Table below shows the costing of of
electrical part and manufacture part.
BILL OF MATERIAL OF MECHANICAL PART AND COMPONENT
No. Name of Quantity Types of Manufacturer/ Cost/ unit Total (RM)

parts materials vendor (RM)
1. Swing Arm 1 Mild steel Self-made/ 50

Workshop UiTM
2. Handle bar 1 Mild steel Self-made/ 30

Workshop UiTM
3. Floor deck 1 Mild steel Self-made/ 20

Workshop UiTM
4. Seat 1 Fabric Self-made/ 20

Workshop UiTM
5. Front Shock 2 AZ EASY TRADING 50

absorber
6. Rear shock 2 AZ EASY TRADING 50

absorber
7. Rim 1 Aluminium AZ EASY TRADING 50
8. Brakes lever 1 plastic AZ EASY TRADING 20
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9. Bearing 1 AZ EASY TRADING 30
Swing Arm
Bolts 26
BNT Sdn.Bhd 5
10.
Nuts 26
BNT Sdn.Bhd 5
11.
Washer 20
BNT Sdn.Bhd 5
12.
Self-made/
13. Handle bar 1 40
Workshop UiTM
AZ EASY
14. Tyre bearing 1 30
TRADING
TOTAL 355
Table 4.6.3:Total costing of mechanical part
BILL OF MATERIAL OF ELECTRICAL PART AND COMPONENT
No. Name of Quantity Types of Manufacturer/ Cost/ unit Total (RM)

parts materials vendor (RM)
1. Speed 1 Electrical AZ EASY TRADING 80

controller parts
Electrical
2. Battery 4 AZ EASY TRADING 250
parts
Electrical
3. Battery 1 AZ EASY TRADING 38
parts
Change Port
Electrical
4. Horn 1 AZ EASY TRADING 10
parts
Electrical
5. Front Light 1 AZ EASY TRADING 20
parts
and Signal
Electrical
6. Wire 1 AZ EASY TRADING 20
parts
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Electrical
7. Power 1 AZ EASY TRADING 25
parts
Switch
Electrical
8. Throttle Set 1 AZ EASY TRADING 35
parts
Electrical
9. Charger 1 AZ EASY TRADING 45
parts
Electrical
10. Connector 1 AZ EASY TRADING 15
parts
TOTAL 1574
Table 4.6.4 : Total Costing Electrical Part
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4.6.2TOTAL COSTING AND OVERHEAD
In the world of manufacturing, as competition becomes more intense and customers demand
more services. It is important that management not only control its overhead but also understand
how it is assigned to products and ultimately reported on the company's financial statements.
Manufacturing overhead can be divided into 2 categories which are manufacturing overhead and
nonmanufacturing cost. For the manufacturing overhead, it includes factory overhead, factory burden
and manufacturing support costs. How these costs are assigned to products has an impact on the
measurement of an individual product's profitability. In our design, fabrication has not been
conducted yet, hence all the overhead cost is the estimated cost only.
On financial statements, each product must include the costs of the following:
1. Direct material
2. Direct labor
3. Manufacturing (or factory) overhead
Component Rate (RM) Usage Total (RM)

Electricity 39.3 sen/kwh 1 hour in 5 days 14.00
Equipment 69.00/5kg 2.5 kg 34.50
(electrodes@fille
r metal)
TOTAL RM 48.50
Rate of electrical used = (P/1000) x H x D x R

P=power watt
H= hours
D= days
R= rate
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4.7 Final Specification
Figure 4.7.1: Final Specification 1
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The figure above shows from 4 different angle for electric scooter. As it can been seen from figure
4.5.1 the designing of the steering were follow on ergonomic design which easy for the rider to
control the steering with less force use.
Absorber
Figure 4.7.5
Next, inside of the frame there have 2 absorber were apply on that electric scooter to give the
rider more comfortable during riding on the road
Table 4.5.2 and 4.5.1 shows the specification of the electric scooter. The motor which is
using hub motor were use 48 Volt and the power is 350 Where the speed of the electrical
scooter is 45km/hr
Specification of the electric Kougar scooter:
Table 4.7.1: Hub Motor Specification
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Table 4.5.1 is the specification of hub motor that provided from supplier (AZ EASY
TRADING)
Table 4. 7.2: Specification of electric Scooter
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4.8 Brochure of Kougar-Scooter
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5.0 Conclusion
Due to the many problems of congestion, pollution and urban mobility, new modes of
transportation (electric scooter) transportation devices, increasingly seem to be an alternative
to widespread automobile use. The ergonomic evaluation also demonstrated that power scooter
is easy to use in normal use situations, including situations involving obstacles, for a broad
cross section of users. The devices also compare favorably with other types of vehicles,
particularly in terms of stability, where they seem superior to other vehicles such as bicycles
and mopeds. However, electric scooter is designed for a broader segment of the population and
is meant to meet a wider variety of mobility requirements in urban transfers to alternative forms
of mobility and use for short distances. The performance studies carried out in a closed
environment also demonstrated that power scooter is easy to use in normal use situations as
well as to get around obstacles. The survey results clearly show that a large majority of test
participants found all scooter movements easy to perform. However, this electric scooter is
targeted more for young people and seems primarily intended for recreational purposes. The
evaluation results suggest that electric power scooter use is appropriate in closed environments,
such as major industrial complexes, hospitals, shopping centers and airports. The reliability
and safety of this electric scooter when used in urban communities; Social acceptance of power
scooters help to reduce traffic problem. In future we can use flexible sitting arrangement also
we can use advance braking and suspension system. This scooter can be modified according to
once interest.
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6.0 GANTT CHART
Months March April May June
Weeks 1 2 3 4 1 2 3 4 1 2 3 4 1 2
Assign Team
Identify Problems
Gather Information
Concept generation
Concept evaluation
Product architecture
Configuration design
Parametric design
Details drawing
Bill of materials
Costing
Final specifications
Table 6.1 :Gantt Chart

We have 14 weeks to cover all the task so that the report can be completed before due date.
Having a Gantt chart helps to put every working in order. With a very good disciplines from
every members of the group, the Gantt chart was followed exactly as planned from the
beginning of the semester. Some task took a lot more time to cover and some are quit lenient.
Having a good team work between team members is the key to complete the task each and
every week, and finally the whole report
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7.0 REFERENCE
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MEC 531 Mechanical Engineering Design 1 Project Report

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MEC 531

MECHANICAL ENGINEERING DESIGN 1

PROJECT NAME : KOUGAR SCOOTER (E-SCOOTER)

BACHELOR OF ENGINEERING (HONS) MECHANICAL

LIST OF FIGURE PAGES

LIST OF TABLE PAGES

Define Gather Concept Evaluation of

Parametric Configuration Product

Electric scooter is a vehicle empowered by electric motor in order to move. It is also

Figure 2.1.1.1: Hub motor

Figure 2.1.1.3:Chain Motor

3) Early Postwar Japanese Scooters

5) The Early History of Electric Motorcycles.

a) What does the client desired?

b) What does client really want?

Proponents of electric scooter usually tout an increased efficiency as the primary

The greater efficiency of electric scooters is primarily because most energy in a

2.2.1 ARTICLE AND JOURNAL

1) Alternate mode of transport

Figure 2.2.3(A) and (B):The sample of survey form

Figure 2.2.3(C) : Gender

Figure 2.2.3(D): Number of Univerisity Student

Figure 2.2.3(E) : Residency Status

Figure 2.2.3(E): Percentage of frequent mode of transportation

Less than 100 100 Between 200

Figure 2.2.3(F): Spend main transportation per month

Strongly Agree Agree Disagree Strongly Diasgree

Figure 2.2.3(F): Electric scooter are relevant to you as a university student

RM500-1000 RM 1000-RM 1500

Figure 2.2.3(G): Reasonable Price For Electric Scooter

Figure 2.2.3(H): The main problem with electric scooter

Figure 2.2.3(I): :Desired characteristic

Supplier: AZ EASY TRADING

 The ways of installation on electrical part

 The battery usage information for certain types of power motor.

COMPETITIVE PRODUCTS AND BENCHMARKING

Standard industry’s electric scooter Self-made electric scooter improvements

Types Standard commercial electric Own-made electric

Top Speed 55km/hr 45km/h

Supply Transmit Activate Regulate

Electric Motor Scooter

Speed controller Optimize

Battery charger Simple

ECU Kill switch Cables

Starter Seat Monoshock

Circuit breaker Fabric

Type of Soldering Welding Mechanical Adhesive glue Rivet

Type of 12V 350W 24V 250W 24V 250W 24V 400W

Mechanism Gears Belts Chains Linkages Hybrids

Front light Double round Single round Rectangular Eclipse

Type of Regular Regular Regular swing

Signal light Round shape Pointing shape NO SIGNAL

Side mirror Round shape Wide NO SIDE

Type of tire Wide (rubber) Round (rubber) Chain thread Wood

Transmission Direct Belting Chain Differential Electric hub

Material Aluminium Mild steel Carbon Fiber Composite

Horn Single Doube NO HORN

motorcycle Cruiser Riding Sport Riding Standard Riding

Table 2.3.2 MORPHOLOGICAL CHART

2.3.4 BRAINSTORMING -SKECTHES

Design concept 1 Design concept 2

Figure 2.3.3.1: Design concept 1 (Scooter-Rama)

21 Mechanism Chain Transmit power to the wheel