|Personal Electric Vehicle Technology
Composite Electric Longboard Project
This is a "Design Team" curriculum
* Design Team courses are for students interested in working on new projects where the curriculum has not been completely defined. This means there could be many challenges along the way, and depending on the class's chosen direction or methodology, the completion of the project is not guaranteed. The learning and project involvement is more of the intent rather than the end product. This course concept is definitely not for everyone, but for some folks it's a great experience.
As electric cars become more and more a part of our society, we'll begin to see the rise of other PEVs such as Segway type vehicles, single person "cars", eBikes, and scooters. As our understanding, safety protocols and trust in this technology increases, so will the volume of alternative transportation mechanisms. While the size will vary, all vehicles large and small have a core system of battery, drive electronics and motors common to all. Sensors, AI, machine vision, balance and more become layered on top of this system. We would like to show students how to implement this core technology and have the ability to design systems of their own. With all our years manufacturing snowboards and longboards, the electric longboard seemed the perfect application of this technology.
Wikipedia - Personal transporter
Another important facet of the electric vehicle concept is the structure itself. While it is common to convert older gas powered vehicles to electric power, when given the opportunity to design from the ground up, more modern engineering and material science principles are needed to reduce weight and increase efficiencies. The obvious choice is composite materials (carbon fiber, Kevlar, boron, fiberglass) which we have over a decade experience in aerospace training and manufacturing. Students will learn about all the basic methods and materials used, along with their strengths and weaknesses, which each will use to fabricate the vehicle body. While this will still have the classic longboard aesthetic (Canadian Maple wood laminate), internally this is an advanced composite structure unlike any typical design. This process will include hand layup, mold preparation and vacuum bagging. Besides the vehicle body itself, there will be another layup to create the enclosure for all the drive electronics.
To complete the full cycle of the manufacturing training experience, students will learn how 3D design programs (CAD), such as Fusion 360 and CATIA are used to create the actual product as well as the mold used for forming and the toolpaths (CAM) created to machine the finished pieces. They will have the opportunity to help load and operate the CNC milling machines used to perform this process. After a final hand sanding and finishing, they will then assemble the vehicle and test.
As with all our advanced technology courses we're proactively preparing students for the future demand for technical expertise, be it anything from development to maintenance and repair.
- Battery Technology
- C rating
- Voltage and Current needs
- Failure points
- Basic electronic components
- Capacitors, resistors, inductors, motors, diodes, transistors
- Types of motors
- Brushless DC motors
- Cable making
- Structural components
- Composite technology
- Composite fabrication
- Layup methods
- Vacuum bagging
- Resin types
- Resin preparation
- Composite Structural interface preparation
- Mold preparation
- Release agents
- Polymer types (focusing on durability)
- UHMW, delrin
- 3D design software (Fusion 360, CATIA)
- Overview of 3D design areas
- Mold making
- Solid modeling, surface design, assembly
- CAM software
- Creating toolpaths for CNC
- Machining parts on CNC
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- Call The BTC (425-640-1840) and give them the number of the class you wish to register for
Contact Damian Cianci at firstname.lastname@example.org if you have any questions.
The Business Training Center of Edmonds Community College has been "off-campus" in the heart of the community providing practical industry focused education since 1998.