Engineering and Technology Journal e-ISSN: 2456-3358

Volume 09 Issue 03 March-2024, Page No.-3565-3582

DOI: 10.47191/etj/v9i03.02, I.F. – 8.227
© 2024, ETJ

Optimum Design of Electric Scooter for Longer Operating Time

W.A. Akpan1, I.I. Nyaudo2, O.W. Obot3
1, 2
Mechanical Engineering Department, Federal University of Technology Ikot Abasi, Nigeria
3
Department of Mechanical and Aerospace Engineering, University of Uyo, Nigeria

ABSTRACT: Electric scoter has come to stay as a mobility device with various uses in sporting, transportation and leisure. Electric
vehicles are proven to be one of the promising solutions to the global environmental problem caused by emission of greenhouse
gases from fossil fuels, thus there is need to produce new designs to meet immediate demand. This research work was focused on
computer aided design of electric scooter to enhance longer operating time for the ‘scot-man’ The electric scooter produced was
successfully tested and satisfactory performance obtained.
KEYWORDS: Electric, scooter, operating time, transportation.

1.0 INTRODUCTION One of them was a company called Myway which started as
The wooden kick scooter, with skate wheels, dates back to a garage project in 2009. The gains of electric scooters and
sometime in the late 19:th century, about the same time particularly stand-up scooters over the gas-powered mopeds
motorized bikes were also arriving on the scene[1]. are plentiful and evermore people realize this daily.
To answer the question "who invented the electric scooter" is Portability, lightweight, zero emissions, easy to use and
not as straightforward as one would think.A quick search handle, perfect last-mile solution, and extremely low cost per
online of who invented it, sometimes answers the name of mile are some of the benefits of the modern electric scooter.
Arthur Hugo Cecil Gibson, an inventor who developed the Figure 2 shows the modern electric scooter.
Autoped in 1913 and patented it in 1916.
It is similar to e-scooters with collapsing stem, and
handlebars for better storage.Many thought it was merely a
toy for the rich elite but it found use by delivery men, postal
workers, and NYC traffic officers amongst others.
The exact date, place and the name of the inventor is
unknown .What is known as fact is that on 1st December 1895
Ogden Bolton Jr was granted his first patent for a battery-
powered bicycle. It was seen as a modification to the existing
electric bicycle.
Figure 1 shows a wooden-kick scooter.
Figure. 2: Modern Electric Scooter [1]

Electric vehicles have gained more attention because of the

rising fuel cost and battery development technology.
BLDC(Brushless Direct Current) electric motors are being
encountered more frequently in electric vehicles due to their
high efficiency and robustness.. By using the computational
ability and simulation of modern computers and CAE
(Computer-Aided Engineering) software, the dynamic
responses, dynamic stress distribution and modal tests can be
calculated and performed. The existing literature about
ePTWs(electric Powered Two wheelers) is presented. One of
Figure 1: Wooden-kick Scooter [1] the first analyses of ePTWs and its usage is presented in [1].In
this paper, a broad introduction of the Chinese market,
Various electric scooter prototypes saw the light of day. regulatory distinctions of PTWs in China, and industry
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 “Optimum Design of Electric Scooter for Longer Operating Time”
development is given. A more usage centered analysis of varies over time. In the traditional motor design method, 80%
eBikes in Chinese cities is presented by [2], where a survey of the area is larger than 80% of the total working area of the
among bike, eBike and liquefied petroleum gas (LPG) scooter motor.
users was conducted. A general overview of the market 1.1 System Description
situation, especially in China, is given by[3] Alongside the The electric scooter comprises of several electrical,
market analysis, technological developments and employed mechanical and electronic components which are assembled
technique relevant in this sector are presented , with together to construct a complete model of the system. The
classifications globally.In order to evaluate the global ePTW electric scooter consists of :
market.[4] presented a market analysis and clarified the i. Battery
differences between the markets in Asia, North America, and The battery is an electrical device that converts
Europe. The given forecast estimates China and India as the chemical energy into electricity. Without battery,
largest markets for low-powered ePTWs in 2018, expectng electric scooter will not work. Batteries are divided
12.4 million units to be sold in China and 1.1 million units to into two types which are rechargeable batteries and
be sold in India. One of the first studies about PTW usage in disposable batteries (which cannot be charged. Its
European cities is presented by [5] where the development of advantage is it can deliver high electrical current for
PTW usage in the city of Paris, France is analyzed. Findings starting an engine. However, it runs down quickly
indicate a rise in travelled passenger-kilometers by 36% and need to be charge about 1 hour and 20 minutes.
between 2000 and 2007, adding to a share in road traffic of For this electric scooter, two batteries will be used
up to 17%. Surveying PTW users, the prevailing reason for and connected in series to produce larger input
using PTWs was commuting (>90%), making it the most supply which is equal to 24V.The battery used in
relevant trip purpose. Another approach to understand usage this study is shown in figure 1.Figure 1. SLA
of PTWs especially in western countries is presented by [6].. Rechargeable Battery (GPP1272)
By analyzing registered addresses, trip distances were ii. Motor driver
estimated, revealing that Scooters travelled significantly MD30C is designed to drive medium to high power
shorter distances than other PTW types. The influence of brushed DC Motor with current capacity up to 80A
national and regional policies on the adoption of electric peak and 30A continuously. AC /DC Rectifier
vehicles is analyzed by [7 Therefore, a program to promote Adapter
and subsidize low-powered ePTWs was commenced in 1998, It converts the AC source into DC to charge the
spending NT$ 1.8 billion, which included tax reductions for battery. Adapter for battery power equipment may
manufacturers of ePTWs, subsidies for charging facilities, described as chargers.
and rebates for buyers up to 50% of the retail price. However, iv. Indicating Unit
there were neither bans nor other restrictions on gasoline- It includes speed output unit and plugged in charger.
powered PTWs.. It basically contain a monitor type display where the
The main aim of this review paper is to present the idea of condition of the vehicle shown on the display.
harnessingvarious energy and use it in today’s existence of v. Driver controller unit
human life. For human being travelling has become vital. Table 1 shows the trend in the development of
This is quite a challenging task, as the performance of the electric scooter.
battery in terms of usable capacity and internal resistance,

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 “Optimum Design of Electric Scooter for Longer Operating Time”
Table 1: Trend in the development of electric scooter

1.2 Usage of Electric Scooter in this study were commuting trips. Comparing these shares,
It is used in commuting and leisure activities. Shopping and a prevalence of these trips is apparent.
running errands seems to be underrepresented with just 8%
and 6% respectively, though.. After all, the Mid survey, a 2.0 MATERIALS AND METHOD
quinquennial nationwide representative survey of traffic 2.1 The Materials used include: Stainless steel, Iron
behaviour in Germany with several additional regional Pan, High Carbon Chromium Steel, Lithium-ion Battery,
studies, and the evaluation for Munich [8] in particular, was Hover board Motor, Rubber,Square inch rectangular mild
chosen. Although, the data from this study refers to mobility steel Pipe, Electric Speed controller, Arduino Mega 2560
patterns of persons, while our data refers to mobility data of Micro-controller and Hover boar
vehicles, yet it is the most useful dataset available at this time 2.2 Design Using Cad Software
and therefore is incorporated. Business trips only account for The design of the electric scooter was carried out using the
5% of all trips while pickup/drop-off accounts for 7%. Solidworks 2023 software on a DELL Latitude E5430 non-
Comparing our results with these shares, leisure trips are pro PC. The process involves creating a concept for the
close to these numbers with 31%. The largest share of trips electric scooter and making decisions about the size, shape
and features of the vehicle, design calculations and detailed
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part design [9]. The design also considered the materials that 4,5,6,7,8,9,10,1 and 11 show the various views of the
will be used in the construction of the scooter [10]. Figure 3 components.
shows the basic design of electric scooter, while Figures

Figure 3: Model of an Electric Scooter

Figure 4: Orthographic view

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Figure.5: Detailed drawing of the fasteners

Figure 6: Detailed drawing of the bearing

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Figure.7: Detailed drawing of the Tyre

Figure.8: Detailed drawing of the frame

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Figure.9: Detailed drawing of the handle (stem)

Figure. 10: Detailed drawing of the block bearing

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Figure. 11: Detailed drawing of the axles

2.3 Design Criteria disc brake at the back of the tyres are proper
Working through the design of an electric scooter, there are a pneumatic item items, and there is no suspension but
few things that needs to be fully understood first, like the with a speed limit of 15kmh on footpaths and 25kmh
basic components of the scooter, what kind of power source on cycling and shared paths.
to be used, the kind of motor, the amount of load it would 4. Eco-friendly: A viable alternative to the petrol
carry, the distance it would cover etc.Those things are the engine car and scooter is without doubt the electric
foundations of the design of this work and need to be decided scooter, as it does not produce any form of emission
first, and then we can move on to other details, like the that are harmful to the environment and to the
dimension of each component and choosing the right wheels. people, and it requires less maintenance than
In this chapter we are going to go through some basic design traditional cars or scooter engines as itdoes not have
criteria to get an overall idea about the design of the scooter. valves, cylinders or carburetor and doesn’t need oil
Some factors which we took into consideration while changes.
designing the electric scooter are; 5. Availability of Materials: Materials used in the
1. Portability: Not all, but most electric scooters are construction of this scooter were locally sourced for
portable. It is designed to be a last mile solution to easy production and replaceability incase a part gets
commuters, or a quick and easy run about for short damaged.
trips close to home or work. 6. Load carrying factor: The electric scooter was
2. Time: In busy cities, time is the issue and these sleek designed to carry just one person at a time with
vehicles can help you save a lot of time on the road, maximum load of 100kg.
hence we selected materials that can enhance the
2.4 Design Calculations
speed of the scooter.
The major designs were on the mechanical component of
3. Safety: Riding the scooter is easy, with power
the electric scooter, to determine the strength of the
controlled by a twist grip on the right handlebar.
material to be used and the various forces acting on the
Braking is with the levers on the left and the right,
scooter.Figure 12 presents the overall force analysis.
activating a v-brake in front, and a cable operated

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Figure 12: Overall Force Distribution

To calculate the force distribution to the rear and Substituting into Equation 2
front tyres, a maximum load of 200kg was used. NF = W*P/ (P+Q) = 1962*360/ (360+1100.6) =
From Equation 1, 483.58N
W = mg Equation 1 The force exerted on rear tyre,
m NR; 84 ∑ 𝐹𝑌 = 0 NF + NR – W = 0
m=200 kg, g  9.81 Equation 3
s2
Substituting into Equation 3
hence
NR = W – NF = 1962 – 483.58 = 1478.42N 85
W = 1962N
In terms of dimensions, P = 360mm and Q =
Torque = r*F (sinƟ) Equation 4
1100.6mm
Where r=0.9m
Ɵ= 120°
For static case analysis, the summation of moments
F= 980.67 N
at all points and forces in all directions equals to
where r is the length of the scooter, thus
zero.
T= 0.90*980*sin 120
The force exerted on front tyre, NF; ∑ 𝑀𝑅 = 0
= 512.45Nm
NF*(P+Q) – W*(P) = 0 Equation 2

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Figure 13 shows the steering fork forces

Figure 13:Steering Fork Forces

Fork offset, Of = 50mm Steering throat length, Sth ∑ 𝐹𝑅𝑁 = 0, Fa – Fb + NF cos(θR) = 0

= 275mm Length of fork, Lf = 345mm Rake angle, Equation 6
θR = 25⁰ Substituting into Equation 6
∑ 𝑀𝑏 = 0, Fa(Sth) – NF sin(θR)(Lf) = 0 Fb = Fa + NF sin (θR)
Equation 5 = 210.56 + 483.58 sin(25⁰) = 395.62N
Substituting into the above Equation ∑ 𝐹𝑅θ = 0, Fc – NF sin(θR) = 0
Fa = NF sin(θR)(Lf)/Sth = 483.58 sin(25⁰)(345)/275 Equation 7
= 210.56N Substituting, we have
Fc = NF cos(θR) = 483.58 cos(25⁰) = 446.77

Figure 13:Front tyre axle diameter

The minimum size of the front tyre axle diameter, τmax = Sy/2n Equation 9
Maximum Shear Stress Theory is used with the Substituting into Equation 9
maximum force NF acting in double shear. = 250*106 /2*10 = 12.5MPa
To calculate shear force acting on the rear tyre axle; To relate with area of the cylindrical shaped axle and
∑ 𝐹 = 0, NF – 2VF = 0 Equation 8 minimum diameter required;
Substituting τmax = VR/A = 4VR/ πd2 d Equation 10
VF = NF/2 = 483.58 /2 giving 241.79N Making Substitution
= (4VR/ πτmax) 0.5
Yield strength of A36 steel, Sy = 250MPa = (4*241.79/π*12.5*106 ) 0.5 = 4.963mm
Maximum shear stress according MSST, τmax with
factor of safety, n of 10;

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The minimum diameter for the bolt connection on
each shock absorber is 4.963mm. According to the
maximum loading, the connection is safe.

Figure 14 presents the front tyre diameter.

Figure 14: Rear tyre axle diameter

To calculate the minimum size of the rear tyre axle diameter, To relate with area of the cylindrical shaped
Maximum Shear Stress Theory is used with the maximum axle and minimum diameter required;
force NR acting in double shear. The shear force acting on the τmax = VR/A = 4VR/ πd2 d
rear tyre axle, is given as: Equation 10
∑ 𝐹 = 0, NR – 2VR = 0 VR = NR/2 Putting values
Equation 11 = (4VR/ πτmax) 0.5
Substituting = (4*739.21/π*12.5*106 ) 0.5 = 8.677mm
= 1478.42/2 = 739.21N The minimum diameter for the bolt connection
Yield strength of A36 steel, Sy = 250MPa on each shock absorber is given as :8.6777mm.
Maximum shear stress according MSST, τmax However, the standard specification of the
with factor of safety, n of 10; found rear tyre axle pre-assembled with hub
τmax = Sy/2n Equation 9 motor has a connection diameter of 14mm.
Making substitution, Hence, according to the maximum loading, the
= 250*106 /2*10 = 12.5MPa connection is safe. Figure 15 shows rear support
connector bolt diameter and thickness.

Figure 15: Rear support connector bolt diameter and thickness

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To calculate the minimum size of the rear support connection τmax = Sy/2n
bolts, Maximum Shear Stress Theory is used with the
maximum force FRS for each of the rear supports, equivalent Equation 9
to half of the force acting on the rear tyre, NR. It is a single Substituting values
shear force. = 340*106 /2*1.5 90 = 113.33MPa
To calculate shear force on the bolt; ∑ 𝐹 = 0 To relate with area of the cylindrical shaped bolt and
FRS – VRS = 0 Equation 12 minimum diameter required;
Making substitution τmax = VRS/A = 4VRS/πd2 d
VRS = FRS = NR/2 = 1478.42/2 Equation 10
= 739.21N Minimum yield strength of bolt Substituting
from Property Class 4.8, Sy = 340MPa = (4VRS/πτmax) 0.5
Maximum shear stress according MSST, τmax = (4*739.21/π*113.33*106 ) 0.5 = 2.882mm
with factor of safety, n of 1.5; The minimum diameter for the bolt connection
on each shock absorber is 3mm. Figure 16 the
swing axel diameter.

Figure 16: 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.

Figure 17: Shear force acting on swing

To calculate shear force acting on the swing VSA = FSA/2 = 3044.253/2 = 1522.123N
arm axle; Yield strength of A36 steel, Sy = 250MPa
∑ 𝐹 = 0 FSA – 2VSA = 0 Equation 13 Maximum shear stress according MSST, τmax
Substituting, with factor of safety, n of 5;
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τmax = Sy/2n Equation 9 = (4VSA/πτmax) 0.5
= 250*106 /2*5 = 25MPa = (4*1522.1233/π*25*106 ) 0.5 = 8.805mm
To relate with area of the cylindrical shaped A suitable diameter of the swing arm axle is
axle and minimum diameter required; 10mm.
τmax = VSA/A = 4VSA/πd2 d
Equation 10

Figure 18 is the shock absorber bolt diameter

Figure 18: Shock absorber bolt diameter

To calculate the minimum size of the shock absorber = 240*106 /2*5 = 24MPa
connection bolts, Maximum Shear Stress Theory is also used To relate with area of the cylindrical shaped axle and
with the maximum force FSh acting in double shear. For the minimum diameter required;
use of two shock absorbers, the force FSh will be divided by τmax = VSh/A = 4VSh/πd2 d Equation 10
two for each shock absorber. To calculate shear force acting = (4VSh/πτmax) 0.5
on the shock absorber bolt: = (4*665.289/π*24*106 ) 0.5 = 5.941mm
∑ 𝐹 = 0 FSh/2 – 2VSh = 0 Equation 13 The minimum diameter for the bolt connection on
Substituting each shock absorber is 5.941mm.
VSh = FSh/4 = 2661.156/4 = 665.289N However, the standard specification for the found
Minimum yield strength of bolt from Property Class shock absorbers has a connection diameter of 10mm.
4.6, Sy = 240MPa Hence, according to the maximum loading, the
Maximum shear stress according MSST, τmax with connection is safe using M10 x 30mm Property Class
factor of safety, n of 5; 4.6.
τmax = Sy/2n Equation 9

Figure 19 is the trail calculations

Figure 19: Trail Calculations

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Trail is defined as the distance between the contact points of The trail is calculated to be 42.8mm from Equation
the front tyre with the imaginary line extended from the 14
steering axis.
𝑇𝑟𝑎𝑖𝑙, 𝑇 = 𝑅𝑓 sin 𝜃𝑅 − 𝑂𝑓cos𝜃𝑅 2.5 Materials Selection
Equation 14 Following the results from the analysis based on
where; computations, the appropriate materials for the machine
Radius of front tyre, Rf = 210mm components design were selected. Table 2 shows the
Rake angle, θR = 25⁰ calculated values and properties of the materials.
Fork offset, Of = 50mm

Table 2: Materials Selection

Mechanical Components
Component Material Tensile Ultimate Yield Selection Criteria
Modulus Tensile Strength σy
(Young’s Stress, σu (Mpa)
Modulus of (MPa)
Elasticity, E)
(GPa)
Deck Aluminium 69 110 95 1.Light weight
Composite 2.Durable and
Panel robost
3. Rigid
4. Cost effective
Frame Mild steel 200 400 250 1. High tensile
square pipe strength
2. High impact
strength
3. Good ductility
and
weldability
Stem Iron Pipe 210 262 130 It can easily be shaped
and formed
Bolt, nuts wahers Stainless Steel 193 515 205 1. Corrosion
resistance
2. High tensile
strength
3. Temperature
resistance
4. Very durable
Electrical Components
Component Materials Specification Selection
Battery Lithium ion 1.charge faster
2. Last longer
3. high power density

Suspension Pneumatic tires Special features: 8x 1, ¼ 1. Better shock

Aluminium alloy hub absorption then
material type: suspension
Aluminium alloy hub. 2. Large damping
Item weight: 0.4kg effect
Item diameter: 8inch
Motor BLDC Motor (Brushless Capacity: 350W 1. \High efficiency
Direct Current) Max load bearing 2. High dynamic
capacity: 100kg response
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3. High speedranges
4. Long operating
life
Brake Electric Brake 1. Fast response
time
2. Precise tension
control
Micro controller Arduino UNO Board Length:68,6mm 1. Very adaptable
Width: 53,4mm 2. 2. It’s cheap.
3. There is a lot of
documentation
about it, so the
sensors would be
easily
incorporated.

Figure 20 shows the exploded view of the electric scooter.

Figure: 20 Material selection drawing

2.6 Production Process the middle to get U shape. Cut out one side in the
I. Frame Construct: The frame was made of square shape of a motor. On one side we drilled 8mm hole
inch rectangular pipe (steel) and iron pan welded and on the other cut out frame for motor shaft. The
together to provide the scooter with qualities such as hole and cut out must be in level with the frame and
light weight, durability and strength to support the the motor shaft.
weight of the rider. The frame was constructed II. Battery Installation: After the frame is constructed,
using welding and bonding technique, take one the next step is to install the battery. The battery is
rectangular pipe, cut it in half then connect them in typically located under the footrest or in the stem of
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 “Optimum Design of Electric Scooter for Longer Operating Time”
the electric scooter. The battery type used here is the
lithium ion battery. Figure 21 is the lithium battery
and Figure 22 the hover board motor used.

Figure 21:Lithium-ion Battery

III. Motor Installation:Once the battery is installedthe wheel up. The motor used is thehoverboard motor
motor will be mounted onto the frame. The motoris with the following specifications
typically located in the rear wheel up or in thefront

Figure 22: Hover board Motor

IV. Wiring: Wiring of the electric scooter is a critical installed to ensure the safety and performance of the
component of the manufacturing process. The scooter. Figures 23 a and 23 b indicate the electric
wiring connects the battery, motor and other speed controller and the micro-controller employe
components of the scooter. The wiring was properly

Figure 23 (a):Electric Speed Controller Figure 23 (b): Micro-Controller

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V. Assembly: Once all the components are installed, VI. Quality Assurance and Testing: The scooter will
the electric scooter is assembled. This includes be tested for safety, durability and overall
attaching the handle bars, wheel and brakes. The performance. Any issues or defects will be
scooter will then be tested to ensure that all the addressed before the scooter is released for sale
components are functioning properly.

3.0 RESULTS AND DISCUSSION

3.1 Result
The electric scooter designed and produced had the listed features in Table 2
Table 2: Operational Test
1. Duration of the battery 1hr
2. Maximum speed 15km/hr
3. Performance Relatively well
4. Battery charge cycle 2000 charge cycle

Figure 23 (a):Electric Scooter (Current Progress) Figure 23 (b): Fixing of Electrical Components

3.2 Discussion 1. Weinert. J.X.; Ogden J.; Spenrling G,; and Burke, A
With the increase in demand for more eco-friendly vehicles, (2008).The Future of Electric Two-Wheelers and
the design and production of electric vehicles holds greater Eectric Vehicle in China. Energy Policy, 36(7)
benefits for the university community and country at large. 2544-2555,
Also with the increase in the price of transportation as a result https:doi.org/10.1016/j.enpol.2008.03.008
of the increase in the price of fuel, electric scooter can serve 2. Cherry, C. R., and Cervero, R. (2007). Use
as a perfect alternative to commuters. characteristics and mode choice behavior ofelectric
The electric scooter produced here has added other features bike users in China. Transport Policy, 14(3), 247–
and will undoubtedly form some contributions to its 257.https://doi.org/10.1016/j.tranpol.2007.02.005
development. 3. Fu, J. (2013). The Role of Electric Two-Wheelers in
Sustainable Urban Transport inChina: Market
4.0 CONCLUSION analysis, trends, issues, policy options. Sustainable
The use of electric scooters as an alternative means of Development,United Nations, 1–17.
transportation will help to reduce the cost of transportation in 4. Hurst, D., and Gartner, J. (2012). Executive
urban areas and reduce the over reliance on cars and Summary: Electric Motorcycles and
motorcycles.The electric scooter can carry a maximum load ScootersElectric Power Two-Wheelers: Market
of 100kg efficiently.The electric scooter is a more eco- Drivers and Barriers, Technology Issues,
friendly means of transportation as it produces little or no KeyIndustry Players, and Global Demand Forecasts.
form of pollution.Further works be carried out to develop an Retrieved
electric scooter that has a longer battery life, greater speed fromhttps://www.navigantresearch.com/wp-
and efficiency content/uploads/2012/12/EMOT-12 Executive-
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