Design and Development of a Foldable Motorized Micro-Haulage Vehicle

Abstract: This thesis describes the process of designing and developing a foldable motorized micro-haulage vehicle, which follows the user, for urban transportation. The project is made in collaboration with Volvo Car Corporation. The transportation industry stands as a significant contributor to greenhouse emissions. As a result, many efforts are being made to lower these emissions and reach sustainability goals, hence why many transportation companies are shifting to electric options. At the same time, urban spaces in cities are becoming more congested which have environmental and social consequences. In response to congestion, infrastructural changes are being made, such as limiting personal traffic within certain areas and dedicated pedestrian-bike paths. With these goals and changes in mind, new or alternative modes of transport are required for a more sustainable future. Through the use of the established product development process by Ulrich and Eppinger, a conceptual vehicle was developed. The goal for the vehicle was to encourage walking and aid users in personal haulage activities. While at the same time keeping the vehicle low weight, foldable, sturdy and within size requirements. Additionally, packaging of an electric powertrain should be incorporated, and additive manufacturing (AM) should be explored to reduce the number of parts in the vehicle. The final version of the product was made entirely in CAD to visualize the product concept digitally. Topology optimization was performed on the main critical part of the vehicle, the skeleton, which through the use of AM could reduce the number of parts simultaneously. The optimization yielded a weight reduction of 88% while complying with stiffness requirements.