INNOVATIVE HOVERBOARD CAD DESIGN AND ......Through the market study [3–7], it was found that the...

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INNOVATIVE HOVERBOARD CAD DESIGN AND DEVELOPMENT FO R GREEN

URBAN MOBILITY

ALFREDO LIVERANI, DANIELA FRANCIA, GIANNI CALIGIANA & SIMONE CANTARELLI

Alma Mater Studiorum University of Bologna, Department of Industrial Engineering, Viale Risorgimento, Bologna, Italy

ABSTRACT

After the application of innovative design methodologies used to define an optimized technical specification, the present

paper aims to manage the transition from conceptual design to construction project of an innovative means of urban

transport, meeting the needs of 'Renewable energy’ requirements, which then decline into an hoverboard. Hoverboard

can be considered, as described by Frizziero L. in “Conceptual design of an innovative electric transportation means

with QFD, Benchmarking, TOP-FLOP Analysis” [1], Far East Journal of Electronics and Communications, a good

solution for green mobility in urban traffic. The methodologies used in the precedent manuscripts were Quality

Function Deployment (QFD), to identify quality requirements of the new green product, BENCH MARKING, to

perform competition analysis, TOP-FLOP analysis in order to better improve the BENCH MARKING implementation,

and finally TRIZ, for identifying the best way to generate innovation [1].

KEYWORDS: QFD, Bench Marking, Top-Flop Analysis, Renewable Energy, Green Energy & TRIZ & CAD

Received: Nov 30, 2018; Accepted: Dec 20, 2018; Published: May 22, 2019; Paper Id.: IJMPERDJUN2019111

1. INTRODUCTION

With this article, we intend to manage the transition from conceptual design to a construction project of an

innovative means of urban transport, after a strict and deepen analysis performed with QFD, Benchmarking,

Top-Flop Analysis and TRIZ [1]. In particular, this work referring to the setting of the project of an

innovative means of transportation, green, sustainable, based on renewable energy, to move in the centre of

medium and large cities, intends to explain how the construction project could be developed through CAD

application.

Hover board can be considered, as described by Frizziero L. in “Conceptual design of an innovative

electric transportation means with QFD, Benchmarking, TOP-FLOP Analysis” [1], Far East Journal of Electronics

and Communications, a good solution for green mobility in urban traffic. In fact, these innovative means was

indicated by a poll developed among a large group of citizens od medium size cities as the best one for moving, in

future, inside the urban environment. The hover board was considered the best green vehicle among bus, taxi,

bicycle, car, bike, etc. It is green because it presents zero emissions, no pollution, no noise and it can enter Traffic

Limited Areas. It can be easily transported by the user, it can enter close spaces, it can be used by young and old

people, also ones without driving licence.

The presented discussion presents the natural evolution of design process after the implementation

of a series of cutting-edge methods, in series of logical use, in order to make decisions both strategic and

technical.

Original A

rticle International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN(P): 2249–6890; ISSN(E): 2249–8001 Vol. 9, Issue 3, Jun 2019, 1033–1050 © TJPRC Pvt. Ltd.

1034 Alfredo Liverani, Daniela Francia, Gianni Caligiana & Simone Cantarelli

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11

Among the inputs of the methods, we had an analysis of customer requirements, competitive analysis,

innovation analysis, a series of technological objectives (or performances) as the result of the work-in-progress.

In particular, it was initially used the method Quality Function Deployment (QFD), then the method of analysis of

competition by Bench Marking for detecting the quantitative requirements that will give us the possibility to realize an

innovative product, empowered by a Top-Flop Analysis [6] to determine the number of requirements of the best product on

the market, that normally limit to overcome to embody innovation in a new project, and finally TRIZ method to identify

innovation requirements.

As for the QFD, the input values were the customer requirements, obtained through the method of "Six

Questions"; then applying a QFD matrix interrelationship, there were obtained the outputs of the above-mentioned

method, which represented the classification of all the various urban transport, ranked according to user

preferences.

The application of the method of analysis of competition, innovation-oriented, through the use of Bench Marking

was applied after the QFD [2, 3].

The inputs used were the quantitative specifications, i.e. the performances, of all the hoverboard models of all

brands on the market. The output, however, was a comparison chart that contained all performance values for each model.

Other inputs were the table data, other outputs, the values (or the value ranges) for each performance, so as to achieve a

technical specification with the quantitative targets to achieve an innovative product [4, 5].

2. WHY APPLYING RENEWABLE GREEN ENERGY INNOVATION TO NEW CITY TRANSPORTATION MEANS? [1]

Our way of life is closely related, among other things, to the mode of travel that we use to make our activities (work,

leisure, study, etc.). We think we are right in car use, maybe even when there is no a real need. The car, which we much

appreciate, owns in fact some positive sides (especially the autonomy), but, especially in urban trips, they are often

overtaken by other important and negative elements suffered personally by the driver (lost time in the queue, difficulty and

parking costs, etc.).

Nevertheless, there are also many negative effects suffered by the rest of the citizens, who may move

without using the car. They suffer from the problems generated by traffic, even without having the benefit of making

any movement in the car. These people suffer from the so-called "external costs", i.e. those negative effects

generated by those who use the road transport system but which are experienced by all other citizens, even by those

who do not own a car.

Nowadays, traffic is an integral part of urban life affects our habits, it takes time away from social relationships

and emotions, it causes stress, it is harmful to health. Every day many people die in road accidents (including many

pedestrians) and many more are injured. The social cost of road accidents is around 24 billion euro. The pollution deriving

from car reaps thousands of victims every year. In almost all big cities, the PM10 limits imposed by the Directive on air

quality are not met.

In addition to the social and environmental damage, we must also remember the economic costs related to the

ownership and maintenance of private vehicles: on average each household spends on the car about 5000 € per year in

Innovative Hoverboard Cad Design and Development for Green Urban Mobility 1035


Europe. In addition, the economic value of time lost in traffic is estimated figures on the order of billions of euro at

national level.

The alternatives to cars are often unattractive. Public transport and bicycle mobility do not always have the

attention they deserve by administrators, not only because of lack of resources but, very often, the appropriate specialist

skills. In the absence of valid alternatives, the car remains the preferred means by many Europeans, despite many, in equal

travel times, would be willing to use public transport. But today the share of journeys by public transport is lower than

would be desirable, mainly because of poor ride comfort, optimal odd coincidences and connections and infrequent. With

regards the bike, it could be a real means of transport in the city for short distances (about half of all car trips in fact is less

than 5 km), but it fails to establish itself mainly because of the lack of safety conditions on the road, with the exception of

countries like the Netherlands and Denmark [2].

Everything described above makes us to understand the need to develop an innovative means of transport,

which overcomes the problems associated with traffic, pollution, lack of comfort, and being able to shorten transport

times. Basically it is needed to understand what means of transport will be the ones of the future for a future

mobility.

So, the present work developed a decision making process, based on QFD, Bench Marking and TRIZ, in order to

identify the guidelines to design the ideal city transportation means [2] [6–13].

3. DEVELOPMENT OF THE PROJECT

The present report concerns the description of the development of an innovative solution for the production of a new

hoverboard.

The purpose of the study is to go to design a new hoverboard that can play a leading role in the market, going to

improve what are the main characteristics of competitors.These characteristics have been identified through a market study

that has been done on 16 categories:

• Speed

• Battery life

• Charging time

• Maximum driver weight

• Hoverboard weight

• Length

• Width

• Height

• Maximum motor power

• Nr. of engines

• Led lighting



• Led display

• Maximum climb angle

• Bluetooth music

• Driving mode

• Price

Through the market study [3–7], it was found that the best hoverboard currently on the market stands out in 7 of

these categories, so we tried to design something that would overcome the latter in at least 8 categories.

3D modeling has been carried out using the PTC Creo Parametric 3.0® software, which allows us not only to

design each part of our model in the smallest details, but also to define many parameters that will then be useful in the

subsequent production phases, such as materials with the relative characteristics, thus allowing to have a first behavioural

study already in the planning phase.

3.1 Main Actions

The activities carried out were essentially:

• Study of the problem;

• Maximum sizing;

• Particular sizing;

• Rendering.

The results of the study were excellent. This training allowed us to expand knowledge of the software, in

particular on the use of particular commands such as Blend that is used to transform a circular section into another

shape, and also gave us a little glimpse of the reasoning that must be done when you want to go and design

something innovative.

3.2 Work Steps

The work was set in the following four steps [8–14]:

Step 1

This phase was conceptual. In the first instance, the merits and defects of the competitors taken into

consideration in the market study were assessed, so as to be able to identify the strengths and the points where they

could improve.

The points that were immediately identified as improvable are the duration, the recharge time and the size that

could be reduced in some cases. On the other hand, the cost, weight and transportable weight have been abandoned

regardless, since no cost and mechanical analyzes will be carried out.

At this point ideas were developed to try and improve the remaining sectors.



The first idea was to rely on a geometry common to other hoverboards, at least as shapes and then go to

modify them, in order to obtain the necessary spaces and at the same time be able to reduce the overall

dimensions.

The second solution was thought to be more extreme and its development would have resulted in a much more

extensive conceptual study, therefore it was discarded.

Step 2

Once the conceptualization phase of the project has been completed, the development and preliminary modeling has been

concluded. We started from a geometry very similar to that of most of the hoverboards on the market, i.e. with circular and

conical shapes. Going forward with the evaluation of the necessary internal space, it was realized that the circular shape led

to some critical issues, which made the rest of the design particularly complex. Therefore, we have moved to a trapezoidal

shape that instead manages to fully solve the problems of encumbrance of the batteries, which are larger than those

normally mounted, since it aims to increase the duration.

Step 3

In the third phase, the object was definitively modeled, solving some constructive and assembly problems. In

addition, a study was carried out on some peculiar parts of hoverboards such as engines and the central hub, looking

for details used by competitors, construction specifications. All this was used to design the central joint (similar in

operation to that of the main competitors) and to carry out a mild electro-mechanical analysis of the type of engines

mounted on these devices.

Step 4

In the fourth and last phase attention was paid to the details, so the final details were added, such as the LED lighting both

on the front and on the back and the displays with information on the batteries, the driving mode and the music being

listened to.

The addition of these details has proved to be very important if we are going to contextualize the problem,

because in an urban environment it is important that the user is always clearly visible and that he can see the obstacles in

front of him, moreover the displays with the information it is of vital importance as it allows the user to always know the

state of charge of the batteries for example.

4. ANALYTIC DESCRIPTION OF THE STEPS

4.1 Step 1: Market and Conceptual Study

The market study developed in the precedent papers [1] was intended to provide the basis for the feasibility study of the

project, and to follow, to give cues for the realization of the project.

In fact, inside it we can find a variety of data, because in the bench marking analysis [1] are collected different

hoverboards, both as forms and technical features, such as speed, battery life and engine powers. This diversity has allowed

to space and not focus on a particular solution.

As a result, the first draft of the project was born, which had as main purpose to improve or equalize the best

dimensions of the competitors.



Therefore, in this first phase the overall dimensions are defined, establishing that the finished product would have

mounted 180 mm wheels, it would have been 544 mm long and wide in the part of the 100 mm platform. In this way the

finished product would have had the best dimensions of the competitors, excluding the Segway One S1 being built with

unconventional shapes [14–18].

4.2 Step 2: 3D Model Development

For the 3D modeling, as already mentioned, we used the software of PTC, Creo 3.0 which is a parametric 3D modeler that

has its strength in combining parametric and direct modeling as well as having many other features, such as the possibility

of draw 2D tables, or perform simulations or renderings of finished products.

Moreover, as far as the 3D sector is concerned, it offers a vast series of commands that allow practically every

shape or geometry required, from the simplest to the most complex. The possibility then to modify the parameters allows

to customize each single part of the piece going to insert details that can be useful in later stages as the materials used,

tolerances that must be respected, (both dimensional and in the phase of coupling of the pieces) in order to make the design

more complete, thus managing the project variables better.

Coming to the actual project, the modeling was based in the first instance on the same forms used by the main

competitors (figure 1). In fact, in the first draft of the project, circular shapes and cones were used above all.

Subsequently, however, we realized that this geometry led to some critical issues. In this way it was not possible

to mount batteries larger than normal with loss of running time, moreover the control electronics would not have found an

adequate space within which to stay.

Figure 1: First Hoverboard CAD Shape Model.

Moreover, in a subsequent analysis, this type of shape would have created even more problems when the frame

was inserted that has the purpose of supporting all the loads and providing a mounting base for the remaining

parts.Therefore, the circular base shapes were abandoned to use trapezoidal-shaped prisms, which, although aesthetically

less attractive, provide a series of remarkable advantages.



In fact, with this new shape the battery finds an adequate space in which to be placed, the frame can be developed

in a way that ensures both the support and fixing functions, and we also obtain the necessary space to install the electronics

control and other options such as screens, LED lights and Bluetooth systems (Figure 2).

Figure 2: Hoverboard CAD Model of Half Structure.

4.3 Step 3: Final Modeling

Once the basic dimensions, the shapes and the dimensions of the components to be included in our hoverboard have

been defined, we have gone on to give a definitive form to the various parts. In this phase a rough frame was then

designed, which has not been verified on a structural level, but it should cover the supporting role of the whole model

structure.

The aim to be pursued in designing it was to give the hoverboard an ideally supporting structure, a housing for the

batteries and the hub for the wheels.

Also in this phase the study on the functioning of electric motors, which are entirely made inside the wheels, has

been studied in depth, which will have to be waterproofed and sealed to prevent tampering, while the cables carrying the

current in the windings are passed into a through hole inside the frame, while for simplicity only the magnets have been

designed inside the rims, going instead to neglect the windings of the stator.

Finally, in this phase it was studied how to make the central joint, particularly vital for the operation of the

hoverboard as a rotation of the two platforms too large would risk to make the balance of the driver unstable, while

rotation of the platforms too small would lead to have a narrow range of action with problems in the control of the

vehicle.

4.4 Step 4: Insertion Details

At this stage they were finished, so the last details completed. Two touchscreen screens have been added to the outer part

of the hoverboard to check all the functions, as well as the battery status, the mode of use and the music being listened to

via the Bluetooth device. LED lights have been added to the front and rear to make the driver visible to other people and



allow him to see obstacles in front of him. The rubber mats were then added to facilitate the adherence of the feet on the

platform and all the screws, in PVC on the fairings and in steel on the wheels.

Finally, various renderings of the vehicle were made in order to give a graphic idea of the finished project. In this

part, we opted for rather flashy colors in order to immediately hit a possible buyer, like the one shown in the photo below

where a gold color is used that makes the hoverboard of sure impact.

Figure 3: Entire Hoverboard CAD Model.

5. SINGLE PARTS ANALYSIS

In this section we will talk about the main parts that make up the project and will also explain some choices made in the

design phase in order to make clear the use of certain forms or certain ideas that have been brought forward.

5.1 Frame

The chassis has been designed to support the weight of the driver and to accommodate the wheels by means of a hub.

Specifically in making it happen some measures have been taken (Figure 4).

In the right part (in the picture) there is the housing with the fixing holes for the central joint, in this way the joint

and the two frames are integral, thus allowing the joint to work with maximum precision. With this constructive solution it

is therefore possible to tilt the two platforms independently, thus allowing to control the hoverboard.

In the central part there are three rectangular shapes. The horizontal one has the purpose of housing the battery,

which as already mentioned is larger than those of the main competitors, so as to ensure a longer life compared to current

standards, while the other two on the oblique sides of the trapeze serve to do not interfere with the electronics of the LED

lighting system which must then be inserted. In the upper part, two slots have been made for each side in order to house

and block the lid with plastic screws, equipped with a rubber mat. Moreover, in the picture you can see small holes made

on the oblique part and inside the cylindrical part. These holes are designed to block the front and rear covers that are

mounted interlocking, not having to bear loads.

On the cylindrical part, in the upper part of the frame, a rectangular plan hole has been obtained which will house



the touchscreen which will give the information to the driver, and finally on the left side there is the hollow hub inside

which is a groove has been created to feed the motor power and control cables inside the wheels.

Figure 4: Hoverboard CAD Frame.

5.2 Central Joint

The central hub is the heart of the project. In fact, in its optimal functioning, it resides the ease of use of the hoverboard

(Figure 5).

The development of this particular was done using as a starting point the central junction of the competitors.

Specifically it is composed of a central hollow shaft, in order to allow the passage of the cables, on which a pin has been

obtained that acts as a limit switch, two bushes within which the shaft rotates and two elastic rings that have the function of

avoiding the translation.

The operation of this part is purely mechanical. In fact, the inner shaft is free to rotate only for an angle portion,

which is defined by the limit pin which moves inside two slots, formed in the bushings. In this way it is possible to rotate

the footrests freely and this by means of the control electronics allows the hoverboard to move forward and backward or to

go left or right.

Finally, the joint is connected to the two frames by positioning it in the designated slots and then making it

integral by means of four head screws with M2 hexagonal groove for the frame.



Figure 5: Hoverboard CAD Central Joint.

5.3 Carter

The carter (Figure 5) was designed to protect the internal structure and the electronics from adverse weather conditions and

support the front and rear leds and the screens on the cylindrical parts.

They have been designed divided into two halves, front and back, so that they can be assembled without problems

to the frame. The fixing is made by interlocking by means of 3 rungs on each side on the front and back and 2 rungs on

each side on the base of the cylinder. Furthermore, in the upper part there are two slots with a non-threaded cylindrical hole

where the PVC screws will be inserted on one side and the hoverboard platform on the opposite side. On the left side (in

the picture) you can then notice the cylindrical hole within which the central joint passes, which has no support functions

but only isolates the interior from the outside.

Figure 6: Hoverboard CAD Carter.



5.4 Wheels

A particular that has been the object of a slightly longer study has been the wheel. In fact, its peculiarity is that inside it is

obtained the engine that moves the wheel itself.

Initially it was thought to increase the speed of the hoverboard going to insert a motor with more power, but with

much smaller size, then discovering that the real rock (and that's why you are back to the choice of the engine inside the

wheel ) is the delivered torque that is too low for the loads expected to be transported.

Therefore, as already mentioned, the commercial solution has been proposed, assuming that it is possible to

increase the developable power while maintaining the high torque so as to improve the maximum speed ranges

achievable.

In the proposed design the windings of the motor stator were not included, but only the magnets fixed on the

external part of the casing while the closure of the rim by means of the cover is obtained by means of 4 screws which are

screwed onto the side part of the rim itself.

Figure 7: Hoverboard CAD Wheel Developed.

5.5 Upper Cover

The upper cover is of particular importance. In fact, it aims to prevent liquids from entering the hoverboard, protecting the

structure from atmospheric agents and ensuring a stable base for the driver's foot (Figure 6).

The shape of the hoverboard follows the plan of the hoverboard itself, going to resume (as seen in the right part of

the photo above) the covering of the central joint. The adherence, as already mentioned, is guaranteed by a rubber mat that

aims to keep the driver who uses our vehicle as tight as possible.

The fixing to the frame is made by four perforated and threaded projections in which the four PVC screws are

screwed.



Figure 8: Hoverboard CAD Upper Cover.

6. FIRST RENDERING PROPOSAL

Some renderings were also made in order to better present the finished project.

More or less daring versions have been made to intercept the tastes of potential buyers as much as possible. Below

are some examples (Figure 7–9).

Figure 9: Hoverboard First Rendering.

A first render was made by coloring the footrests and the outer wheel rims with shiny blue, the inner wheel rims

and the rest of the glossy red fairing.



Figure 10: Hoverboard Second Rendering.

A second render was made in a much more conspicuous way, going to color the whole hoverboard in gold,

keeping the black of the carpets, the screens and the wheels as the only contrast.

Figure 11: Hoverboard Third Rendering.

The third and final render was made by coloring the metallic red fairings and covers, while keeping the tires and

the carpets black and making the fixing screws in white.

7. CONCLUSIONS

In conclusion, the project to create a new hoverboard having the characteristics of the leader can be said to have been

successfully achieved, as the minimum target that had been placed was 7 categories, and this margin was largely

exceeded.



In order they were definitely improved:

• Speed: by increasing the engine power, the maximum speed that can be reached can be increased;

• Battery Life: the technology of Li-Ion (Li-Ion) batteries is improved by increasing capacity while maintaining the

weight of the batteries;

• Recharge Time: as above, the technology also allows to increase the charging current, thus lowering the recharge

time;

• Maximum Driver Weight: on this point it is not possible to make considerations as a constructive study on the

frame should be carried out;

• Hoverboard weight: Even on this point it is not possible to give a judgment as it is not possible to predict the

weight of the components

• Length, Width, Height: On this point it is necessary to make a clarification. The dimensions are in line with those

of the competitors excluding the Segway One which is constructively different from the others;

• Maximum Power: the reasoning is similar to that for speed and therefore, it is reasonable to think that in order to

reach a higher speed a greater power of the engines is needed;

• Engines: If the Segway One is always excluded, our project has two engines as well as the other competitors;

• Led lighting: It has been planned both front and rear;

• Display: There are two screens with the main information concerning the batteries, the way of use and the music

via bluetooth;

• Ascent: There are no data that allow you to compare the maximum degrees of ascent of the hoverboard;

• Music via Bluetooth: It is provided, and you can therefore listen to music via Bluetooth;

• How to use: This is also provided in order to limit the maximum speed and consequently make it easier to

use;

• Price: It is not possible to give information about it.

12 of the 16 points in the market study have been reached and / or exceeded, and it is therefore possible to say

that, if implemented, this Hoverboard could be the top of the category compared to current competitors.

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AUTHORS PROFILE

Alfredo Liverani is Full Professor in Design and Methods of Industrial Engineering at the University of Bologna,

Italy. In 2000, he got PhD degree discussing a final thesis titled “A Virtual Reality system for engineering design”. The

main research activities concern Computer Graphics, CAE and Methods for Industrial Engineering, Virtual Reality,

Augmented Reality, Live and Constructive Simulation. From October 2002 he is in the current position at University of

Bologna.

Daniela Francia graduated in Mechanical Engineering at the University of Bologna in 2004; in 2008 she got a

PhD degree discussing a final thesis titled "Modeling and simulation of mechanical systems with a high number of degrees

of freedom by means of non-conventional methods and CAD systems ". Since 2005, she teaches Computer Aided Design

and Industrial Technical Drawing. In 2010 she became Assistant Professor at the Faculty of Engineering, University of

Bologna, in the field of Design and Methods of Industrial Engineering.

Giampiero Donnici is a Mechanical Enineering involved in Design and Method of Industrial Engineering. For

many years he worked in big Mechanics and Automation Companies. Now he is PhD Student at Alma Mater Studiorum

University of Bologna



Simone Cantarelli is a student of the Master Degree Course in Mechanical Engineering at the Alma Mater

Studiorum University of Bologna.

INNOVATIVE HOVERBOARD CAD DESIGN AND ......Through the market study [3–7], it was found that the...

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