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Electric Go Kart

Jan. 2016 - Jun. 2016

Over 6 months, my team has designed and built an electric go kart that is safe, has a long lasting battery, and is inexpensive. 

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  • Created timeline for the whole work-scope and each member specific tasks. 

  • Innovated solutions to unexpected problems in the project including cost saving, systems’ design, welding of each component, and breaking systems coordination problems.

  • Designed the chassis completely, and used ANSYS Workbench to analyze the FEA of it, choose two different size of square tubing instead of the traditional round tubing to cut cost, reduce weight and enhance the loading capacity, reducing the mass of chassis by 70lb.

  • Assembled the whole chassis using welding techniques.

  • Optimized drivetrain and power system to deliver 19 horsepower from the electric motor, which is very comparable to traditional gasoline operated racing karts (15-26 horsepower).

  • Achieved successful outcome: a safe, automatic, long-lasting electric, inexpensive go-kart with a max speed of 35mph.

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The final prototype remained almost unchanged from the original design with only three minor exceptions, the first one being the location of the controls. Both the throttle and brake pedals were converted to hand controls in order to ensure that the project met the presentation deadlines. The second modification was necessary in order to improve the ergonomics. After the chassis was completed, it soon became apparent that there was not enough legroom for an average size driver to sit comfortably in the kart. Therefore, the foot plate was moved farther forward in order to better accommodate the driver. As a result, the seating position of the kart was much more comfortable and less cramped than a traditional go kart. Finally, to insure that the drivers feet were well protected, an additional bumper extension was added. After the first test drive it became apparent that the kart had a strong tendency to understeer. Adding additional weight helped to reduce the tendency but ultimately the decision was made to narrow the width of the rear wheel base. As a result, the kart handled in a neutral manner and was capable of quick turns. The handling adjustments helped meet one of the original client needs in that it greatly improved the fun factor of the kart. The top speed of the kart was originally geared for 25 MPH, however, the sprocket size on the motor was increased to help achieve a higher top speed. The final prototype is currently capable of 35 MPH. This is a 40% increase in top speed over what was initially planned. The client, being the Go Kart Team, was very pleased with the final prototype. Everything worked as expected and in many cases exceeded the client's needs.


In short, the project was considered by everyone involved to be a complete success. With that being said, however, the design and build process was not without its speed bumps. Early on in the design stage, the team had a lot of difficulty getting started with the solidworks drafting. This delay was attributed to the fact that we simply didn't possess the parts that we needed to finalize a design concept. Throughout the building stage, technical difficulties with the controller, potentiometer, and many other aspects put the project about two and a half weeks behind schedule. Fortunately, the team was able to make up some lost time by using the CNC plasma cutter to make almost all of the mounting surfaces on the kart. This saved about two weeks of manual labor. In the end, the team was able to deliver a working prototype to the client on time and under budget.

Electric Go Kart

Electric Go Kart
Prototype Testing

Prototype Testing

00:08
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Racing

Racing

00:18
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©2018 by Xiangyu Gao

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