ChargeCart Dynamics
75 kg
Load capacity
1 hour / 5 km
Operating target
5 km/h
Target speed
< 3 min
Easy Install / Remove
Traditional handcarts are useful for transporting materials over short distances, but carrying heavier loads can require significant physical effort, especially on inclined surfaces.
The challenge was to create an electric assistance system that remained compact, detachable and easy to operate while still fitting a standard handcart.
Protection
IP 54
Motor
BLDC
Rated Power
100 W
Transmission
Chain drive
Operational Features
Battery & Status Display
Shows speed, battery level and basic system information.
Easy Throttle Control
Handlebar-mounted throttle allows simple and direct speed control.
Emergency Stop
Dedicated emergency-stop function for immediate system shutdown.
Easy Charging
Accessible charging port allows the battery to be recharged without complicated setup.
Overload Protection
Circuit protection helps protect the electrical system during abnormal load conditions.
Temperature Monitoring
A temperature sensor monitors the system and can provide warning feedback.
User Feedback
Display and buzzer provide visual and audible information during operation.
Safety by Design
Safety was considered from the beginning of the concept.
The design includes emergency stop, overload/circuit protection, temperature monitoring and a DFMEA-based risk assessment.
SolidWorks · MATLAB/ Simulink · Microsoft Excel · MicrosoftaWord · Microsoft PowerPoint · Microsoft Project · Arduino IDE · Google Trends
D-FMEA · RPN · Product Life Cycle · HMI · Gantt Planning · Motor Sizing · Battery Sizing · Drive Calculations · Material Selection · Cost Analysis · Production Planning · System Flowchart
My Contributions
Product Concept Development
Developed the overall concept for a detachable motorization system that upgrades a conventional handcart without permanent modification.
3D CAD Development
Worked on the complete 3D model of the handcart motorization system and its mechanical integration.
Motor & Energy Storage Dimensioning
Contributed to the selection and dimensioning of the motor, transmission and battery system based on the required load and operating conditions.
Technical Drawings
Prepared the technical drawings for the main assembly, including key dimensions and component relationships.
System Logic
Contributed to the program flowchart describing the operational sequence, system checks and safety responses.
Engineering Documentation
Supported the development of the project from initial concept through detailed engineering documentation.
Project Outcome
A complete engineering concept was created around one simple idea: upgrade the existing handcart instead of replacing it.
The result combined mechanical design, electric drive integration, user interaction, safety analysis and production preparation in one detachable system.
TECHNICAL DRAWINGS AND BOM
≤ 10°
INCLINE
Voltage
24 V
Motor Speed
1500 rpm
HOW IT WORKS ?
Throttle
↓
Controller
↓
BLDC Motor
↓
Chain Drive
↓
Rear Axle
↓
Assisted Motion