After we examined the fit of the motor mount a little closer, we realized we needed to tweak it a little to get it to fit perfectly. A few welds on the frame were interfering with the mount fitting flush. To solve this problem we ground a chamfer onto the edges that didn’t fit. It worked out quite nicely
-Anthony
I check the fit of our newly fabricated motor mount. It fits pretty well and I am pretty excited about it. We will need to modify it a little to make it fit perfectly.
Sorry for the long absence. Last semester was really rough and we had a hard time trying to fit in any updates. I will work on filling you guys in with the design steps from the previous months. This semester look forward to the installation of our designed kits. We will upload videos and photos of our builds. Thanks for sticking with us.
–Anthony
I went down to Largo today to spend some time with my dad at his workplace. We manufactured the motor mount, a motor washer and our shaft brace. The manufacturing videos can be seen on our youtube channel. A big thanks goes out to Infinity Manufactured Industries for manufacturing our parts.
-Anthony
I made the drive from Orlando to Largo to visit my dad today at work to get our parts manufactured. Here are some videos of our parts being made
-Anthony
Here is the shaft brace being cut using a high pressure water jet cutter. It was then deburred and welded.
Our motor mount was manufactured using a high precision laser cutter. The holes were then reamed to make sure they were within tolerance. The edges were also ground down.
We are mounting the motor controller to a heat buffer. This buffer is made from a 5/8 in thick aluminum plate. The plate was too long and needed to be trimmed a little. Watch how this saw just eats through the plate like its nothing.
In order to install the motor mount we had to drill 5 3/8 inch holes. It was pretty difficult considering we were drilling through steel and the compartments were pretty tight. It took a lot longer than we though and in hindsight we would have designed the mount with 1/4 inch holes. We had to drill several holes and gradually increase the bit size to get our desired hole size. It was also helpful that we designed slot holes in the motor mount because the drill walked on us and our holes weren’t exact.
-Anthony
We needed to create a more exact design for our motor mount. We ended up taking foam display board a cutting out a shape that fit our cart more precisely. I then took that foam cutout and dimensioned it. I input the dimensions into Pro/E and ran a new FEA. Here is our new design.
We also chose to go with a 1/4 inch hot roll steel. This saves money because steel is cheaper than aluminum. We are also able to go thinner in material thickness without sacrificing any strength.
We finally have word on our budget for the project. We have $3,000 thanks to Progress Energy!
-Anthony
Back in November, we removed the driven clutch from the golf cart. When we opened it up, we discovered that the internal components were heavily worn. To make sure the golf cart would perform well and last the remainder of the year, we decided to replace these components. The pieces that we replaced include three clutch ramp shoes and the clutch cam. After some initial trouble reassembling clutch, we finally got everything back together.
Jason
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On The Green Hybrid Cart Team 