Part of a "ribbon" design for the battery compartment. This triangular ribbon structure wraps around 2 mirrored "caps" made of ABS plastic to form a 3D triangular shell in which the batteries, microcontroller, and associated wires are housed.
The ebike being worked on, currently without any battery box at all.
The completed ribbon portion of the design. 2 of our batteries are also included at the top of the frame.
2 of the MDF wood molds used to vacuum-form the cap sections of the compartment.
Large whiteboard of sketches, calculations, and circuit diagrams from the brainstorming phase of development.
Mixing wood filler to round out the second MDF mold.
Vacuum forming over one of the MDF molds to create one side of the compartment.
Cutting one of the MDF molds down to size on a bandsaw.
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Ebike Battery Compartment Redesign
My team and I were tasked with redesigning the battery and microcontroller housing for an ebike from our Electric Vehicle Team (EVT). The previous design had the rather heavy compartment mounted on a frame above the back tire, which was in need of changing since this position was unstable for both the components and the rider, as it caused the center of gravity to be much higher than on a regular bike. We are currently working on fitting the battery box into the triangular space in the frame, where it will be much safer and provide a more stable ride.
