ECO-SWAP battery ecosystem

The Problem

Extensive primary and secondary research identified a need for greater sustainable transport infrastructure in the outer suburbs of Brisbane. As unfortunately limited public transport infrastructure has led to workers resorting to less sustainable transport means. Further, the high-cost barrier to entry and range anxiety attributed to electric cars led to survey respondents feeling that adoption is not a viable option. Additionally, range anxiety was identified as the biggest contributor to a lack of adoption of electric vehicles. My solution is the Eco-swap battery ecosystem.

Conceptualising the problem

The initial hypothesis was to investigate how to improve commuter transport sustainability for CBD commuters. Although through secondary research investigation it became clear that the problem was not in the inner city, as 76% of CBD commuters were already utilizing more sustainable public transport means. This highlighted a key area of design intervention for outer city commuters where only 20% utilize public transport. This lack of utilization was primarily attributed to lacking public transport infrastructure in those areas. Meaning that while those underdeveloped areas are slowly upgraded, commuters are having to report experiencing extended transport times or having to use nonsustainable transport means. Additionally, the study of the factors which limit electric vehicle adoption found that ‘Range anxiety and ‘Price’ Were the biggest limiting factors.

Research process

An integrated qualitative research process was conducted which was comprised of three industry expert Interviews, three commuter Interviews, three industry expert surveys, four design feedback surveys from riders, and 26 commuter surveys. The industry experts were professionals from the automotive or manufacturing field and provided unique insights into the key design and technical needs for a successful sustainable vehicle. Further, the commuter Interviews and surveys provided key insights into the patterns and beliefs of Brisbane commuters.

Research analysis

The Interview data was then analysed using the thematic analysis method to draw out key themes within the transcripts. For this process, a more interactive method was chosen for its benefit to the visualisation of the issue. First key codes were drawn out of the transcripts and written into socket notes. Then these codes were grouped into key themes which were labeled on the wall. Finally, it become clear that further themes were present, thus more themes were created under the larger themes. This process allowed for the large data set to be easily interpreted. In addition, the surveys were analysed using the inbuilt tools within google forms, creating easy-to-interpret graphs out of the data received. This process informed the required design details of the design concepts.

Post research concept ideation

Concept ideation informed by primary and secondary research process. Final concepts created were centred around the proposition of recycled motorbike components, implementation of solar technology, and battery swap technology. These concepts’ directions bled into the final design solutions, embodying all directions.

ECO-SWAP station

Eco-swap system sequence of use

The Eco swap station is designed to fit into the urban landscape, including greenery, recycled wood, and re-purposed shipping containers. In addition, the stations include angled Solar panels and a gutter that collects rainwater to be stored in the included water tank. This water would automatically feed the included greenery and could offer filtered water for Eco-swap users. The swap systems are designed to swap a Eco-swap motorbike battery within minutes, charging the discharged battery providing an autonomous and swift charging system. The system is fitted with three large displays which guide the user through the sequence of use. Further, an automatic door ensures the user does not interfere with the sequence. A percentage of energy supplied would be offsetted by the included solar panels. Although the systems would be connected to the grid, and as sustainable energy infrastructure is developed, sustainable power would easily be able to be routed to these systems. During expert interviews, it was established that often getting sustainable power to consumers can be difficult. Meaning that these locations could be offered as centralised sustainable hubs where routed energy could easily be tracked and provided to transport users, reducing their carbon output.

ECO-swap motorbike

The Eco-swap motorbike is aesthetically designed to stand out as an organic neo-retro futuristic motorbike. The design is inspired by the ‘Cafe-racer’ trend, as well as modern technology trend of organic shapes that end in hard edges. Further, the hexagonal hub-like rims, is inspired by ‘Syd Meads’ vehicle concepts with a modern twist. Overall, the aesthetics were positioned to make the vehicle stand out among similar product offerings in the market.

The eco swap motorbike is designed to be a technologically advanced electric motorbike offering, comprised of features to support a commuter on their journey. Such as two large storage compartments, presenting the benefit of the limited space required for an electric drivetrain. Additionally, the motorbike has been anthropometrically designed to suit a six-foot male rider (Various adjustments could be made to suit smaller or larger riders), and the motorbikes aerodynamics has been optimised to benefit user comfort while riding while benefiting motorbike efficiency. A key aero feature is the lack of mirrors, opting for the use of cameras mounted to the fairing which displays the rear view of the bike on left and right dash displays. Further, the motorbike offers large rear indicators and taillight to benefit rider safety. To benefit the user experience customisable control layout was included which uses tactile buttons whose location and function can be adjusted based on the rider’s needs. During user design, testing riders identified a key pain point around the perceived risks of silent electric motorbikes. This design would include speakers which play exhaust sounds at the required decibel. All functionality would be controlled through a connected app.

An emphasis on sustainability

The sustainability of the design was considered in far more depth than simply the powers source. Sustainability-sourced recycled materials would be implemented where possible to make up the plastic, rubber, leather, and aluminum used. Additionally, the design utilised aluminum unpainted fairings to benefit recycling and remanufacturing at the end of its useful life. In context, the design would lack any use of nonrecycled painted products, further benefiting ease of recycling. In context, industry expert Interviews identified the benefit to sustainability of localised production of components and limiting off the shelf components. Thus, small scale manufacturing locations would be established in or nearby major cities to limit travel, distance of comments for assembly/manufacturing and off the shelf parts would be limited where possible.

Manufacturing

The motorbike design theorises the near future potential of Aluminium 3D printing, incorporating this method into the frame, swing-arm, and kick stand. Although if at the time of production these processes were not viable the components could easily be replaced with CNC counterparts. Some key companies would be purchased from suppliers as it would likely not be economically viable to produce in-house, such as the tires and brake assembly. The swap station would start off with the 2nd hand-shipping container structure and use additive/subtractive fabrication to fit the inner and outer components. Then the swap station internals, solar panels, water tank, guttering, circulatory, would be manufactured at the same locations as the motorbikes and assembled with the containers. The finished containers could then be packed and transported easily as a standard container to the required location. The benefit of opting for the use of shipping containers is transport should be very convenient to arrange due to suppliers frequent transport of containers of that footprint.

Business model

Research process survey respondents identified price as a key limiting factor for electric vehicle adoption. Thus, this business model would incorporate the concept of battery rental. Where a buyer of the eco swap motorbike will be offered the option to purchase the motorbike without a battery. Then they would rent the battery off Eco-swap fort a monthly fee. This model would reduce the upfront costs incurred when buying an electric vehicle. In addition, if a higher capacity battery or new battery technology (Such as solid-state batteries) become available the customer can upgrade their plan paying a high price per month to swap to the new battery. This model would be of benefit for not only the customer but also for Eco-swap, as the model would ensure a regular income stream. Additionally Eco-swap motorbike riders would have access to the swap stations, but as popularity increases motorbike organisations can opt to use the eco swap battery system within their vehicles. Allowing their customers to also utilise the Eco-swap system, but for a higher price per kilowatt. Further, to benefit the sustainable manufacturing goals of the organisation, Eco-swap will offer a buy back scheme where they will buy back older eco-swap motorbikes disassemble them and repurposes the materials into future models.

Gravity sketch

Gravity sketch visualisation was implemented into this project at various key stages. Initially, gravity sketch was used to rough sketch motorbike components and forms over an existing motorbike model. This stage helped flesh out possible components and features, as well as conceptualise form. Next the final CAD design visualisation was also completed in Gravity sketch. Specifically, the complete surface modelling tools assisted in creating them complex organic form of the vehicle. In addition, the scale model mannequins in gravity sketch were used to test anthropometric measurements right in 3D. This technique was very effective as human models of different scales were able to be tested and the model adapted based on the results. This project conveyed the power of virtual reality 3D modelling tools such as Gravity sketch.

Model making

Rough model making

BATTERY SWAP PROCEDURE ROUGH PROTOTYPING

A serious of rough models were used to test battery swap functionality. Designing how the battery would be replaced from the vehicle, trying to optimise user experience. The result is a system that is unhindered by human interaction, operating autonomously in a matter of minutes.

FINAL MODEL MAKING PROCESS

For the final model making various forms of 3D printing was used. ‘Powder printing’ was used to print large components, ‘FDM printing’ to print smaller components and wheels, and ‘SLA resin printing’ was utilized to print the more detailed sections such as the handlebar assembly. This multi-process assembly allowed for more learning than would otherwise be available for use of one process.

ECO SWAP MOROBIKE FINAL PROTOTYPE