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There are two tests going to be used in my part of the project (structural part). The first test is to measure the deflection of the motor’s mount where in the requirement the deflection must be less than 0.1 in. The second one is to determine the deflection of the basic mount that hold the battery and the electric panel.

 

Method/Approach:

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Test 1

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The first method test is to measure the deflection of the motor’s mount. A dial indicator and hanging scale will be used to do this test. First, the hanging scale will be attached to the mount surface from back as well as the dial indicator. Next, the mount will be subjected to loads, and the deflection will be recorded. The dial indicator values will also be recorded before and after each test, to insure that no permanent deformation has occurred.

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Test 2

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Test 2 will test the overall deflection of the battery’s mount. This test will require a dial indicator, steel blocks, and a hanging scale. First, the dial indicator will be placed below the mount. Then, the mount will be subjected to 30-pound load, and the deflection will be recorded with the dial indicator values.

 

Test Procedure:

 

Motor’s mount test

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Time: 2 hour

Place: Thermodynamics Lab

procedure

1. Place the electric motor on the mount and tight it to make it fixed on place.

2. Put the belt on the sheave of the motor and tension it.

3. Start pedaling the bike at variable speeds (110rpm).

4. Start looking for any vibrations or misalignment.

5. Attach the hanging scale from inside the mount, so it can be ready to pull.

6. Attach the dial indicator on the mount and set the dial to zero.

7. Pull and Apply up to 50 pounds.

 

   8. Record this value, release the tension and repeat two more times to find an average.

 

The main safety concern here is breaking the mount while applying pounds of force, and if the belt tensioned so hard to get cut.

 

 

 

 

 

 

Battery and electronics’ panel mount Test:

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Time: 1 hour

Place: Thermodynamics Lab

1. Below the mount, place the dial indicator pointing straight up

2. Adjust the dial indicator, and set the dial to zero.

3. Apply up to 30 pounds of force on the mount

4. Measure the deflection on the dial indicator.

5. Remove the force and record the final value of the dial indicator, to ensure that no permanent deformation has occurred.

6. Repeat this process two more times and find an average value.

 

*Experimental Data for test 1:

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*Experimental Data for test 2:

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