“Comfiest Seat Ever”

…is what Ada said when she sat on it :)

Here it is, the first full size prototype of the wheelchair seat:

I realise that it looks just a slightly scrappy ;) but that’s fine; this is just a tool for collecting measurements for the actual mountain wheelchair.

I can then take photographs and measurements and use them in the 3D environment to make sure the mountain wheelchair concept drawings have the correct dimensions:

The next step is to tweak the design to suit and then, carrying on with the pvc pipe, continue building a life-size model of the wheelchair.

Just a dream?

So the other day I estimated that the wheelchair would need to be driven by six 3,000 watt motors. At a constant gradient of 40 degrees, to do the 18 mile round trip, the 4QD calculator suggested the motor would have a constant draw of approximately 65 Ampheres.

I have in my shed a very large 12v 120AH leisure battery which I use to power an electric outboard motor on a canoe. The 120AH rating means that with a 6 Amp draw, the battery provided 12v for 20 hours.

With the 65 amp draw of the 3000w motor, this battery would last 1.8 hours (120 ÷ 65). Let’s say it took 5 hours to reach the top, then you would need 3 of these batteries.

Of course, this is only for 12 volts. For 48 volts we’d need to multiply this number by 4. 4 x 3 = 12.

That’s 12 very heavy caravan batteries. At a guess, I’d say my 120AH battery weighs about 30kg. So overall, that’s a weight of 360kg just for the batteries.

But… Because I want to use 6 motors, does that mean I have to multiply this number by 6? If it does, then it would mean that the batteries weighed over 2 tonnes!!!

And of course, if you’re dragging a two tonne battery up the mountain then the power requirements of the motors increase and then so do the battery requirements. Perhaps then it isn’t possible, and this is why it appears something like this doesn’t already exist.

How about looking at other battery solutions?

I came across a 1.2v 500ah battery which weighs 15.9kg dry. To make a 48v battery, you would need 40 of these. 40*15.9. That’s 636kg for one motor and that’s without the battery fluid. You’d then need to multiply this by 6 which is nearly 4 tonnes and that’s before adding battery fluid.

It was starting to look like a bit of a pipe dream so I got out my map and actually measured the distance to the top of Snowdon rather than relying on secondary information. The distance to the top of Snowdon (On the Llanberis Path) is just over 7km, so a 14km round trip, which is far less than the 18 miles that I’d been using up until now. The internet lied!!!

I’ve also made a very basic estimation of the Llanberis path’s gradient. I had originally been using a value of 30 but keeping in mind that I’m sat at my desk and not out in the field, I’ve estimated it to be more like 10 degrees.

So if I took these new values, slowed down both the the acceleration and top speed, and gave the calculator what could be an unrealistic weight of 200kg, the current draw comes down to 20 Amperes. This would mean that 4 of the caravan batteries (120kg in total) in my shed would be able to get us to the top.

The problem now is that I don’t really know if I then need to multiply this by 6, so that each motor has the same battery pack.

I think the answer isn’t going to be as simple as this.

With 6 motors, individually they won’t need to draw as much power from the motors because they’ll be sharing the load. Imagine trying to push a car by yourself. Then imagine how much easier it would be if you had five more people to help.

Using this analogy, I suppose the same amount of force is required to push a car no matter how many people are pushing. Perhaps it’s the same for the motors? It doesn’t matter how many motors you use, the amount of current drawn will be the same.

I don’t know enough about electricity to be able to say if this is the case, and I imagine it’s not as linear as this, but it does at least sound logical. If this is case then it would mean that 120kg battery (or thereabouts) might get the wheelchair to the top of Snowdon. 120kg still sounds like a lot, but really it’s just four caravan batteries and this to me sounds doable. It is at least far more doable than a 3 tonne battery.

Moving forward, it’s clear that I don’t have the required underpinning knowledge to make these kinds of calculations and I think it’s therefore time to ask for some expert advice.

I think I might also have to stop feeding Ada! Or as mum suggested, ask Elon Musk for help.

Motor/Wheel Choice and Wheelchair Measurements

Over the weekend Ada and I went into Colwyn Bay KTM and Honda to look at quad bike wheels and see what inspiration could be drawn. Originally I had in my mind that the wheelchair was going to use fat, chunky quad bike wheels to provide better grip on the wet rocks, however, for some time I’ve been thinking that a thinner 12″ wheel would probably do the job. Low-and-behold as we walked into KTM I was instantly drawn to this 12″ wheel on the back of a pit bike.

It somehow seems smaller in the photos but I think it’s ideal. Without measuring the steps at the top of Snowdon and doing a lot more testing I won’t know for certain if 12″ is the right size but they do help to keep the overall weight down, will mean the wheelchair is more likely to fit through narrow gates and stair cases, and will look less menacing to mountain walkers.

12″ wheels with 3000w motors built into the hubs are also readily available:

However, I am more drawn to the 13″ wheel which is capable of producing 225Nm torque, whereas the 12″ only 182Nm. Another useful feature of the 13″ wheel is that the wheel rim easily detaches from the hub. At £400 each (and I think we’ll need six), the motors are probably going to be the most expensive part of this build. If a rim gets damaged, it means that you can just replace the rim without having to replace the whole motor. It also means you can easily change the tyres so that you could have a set of both off-road and road going tyres.

These 13″ wheels take a 130/60-13 tyre such as this Maxxis M6024:

Combined, the wheel and tyre would have an outside diameter of 19″ and a width of 5″.

This means that if the wheels were touching each other, the shortest possible length of a 6 wheeled vehicle is nearly 60″. This size needs to be increased though to allow the rocker bogie mechanism to work. I don’t yet know if a 19″ wheel will be suitable to get up the steps at the top of Snowdon but thinking about the overall size of the wheelchair, I certainly don’t want to go any bigger than this if possible. Generally speaking though, a rocker bogie mechanism is capable of overcoming obstacles which are twice the wheel height. For a 19″ wheel that’s 38″, or three and a half feet. Imagine seeing a wheelchair drive over a 3 1/2 foot tall obstacle!!!

Taking the measurements of these wheels and combining them with the measurements of Ada’s current wheelchair, the following is a scale drawing of what the finished wheelchair might look like.

Although this is a very rough concept and room needs to be made for the differential and batteries, and at the moment the positioning of Ada’s feet will dictate the maximum size of obstacle it can overcome, it does at least give some sense of scale and is a better representation than the current working prototype.

This page was last updated on April 18th, 2018 by .
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