Manufacturing Processes • Design for Manufacture • Mockups and Prototyping
Outrider USA is a 4x4 electric powersports vehicle manufacturer based in western North Carolina. Their current model, The Coyote, features a control variant known as the tri-pin designed to be driven by people with spinal and muscular conditions. After working at Outrider for a month, I noticed an area of opportunity to bring in customers who have limited reach in their arms and legs due to their short stature. An alternative set of controls needed to be compatible with the Coyote’s control hardware.
OutriderUSA Assembly Floor
Insight
The throttle and brake controls mounted on handlebars, needed to be modified to be within reach when the vehicle was doing tight maneuvers. When turning, the outer handlebar became out of the rider's reach. Similarly, a person of average stature would be able to put their legs over the steering and suspension components, but with shorter legs the rider's feet were directly over them. As a result, a new footpan needed to be designed to preserve rider comfort and safety.
A. Reaching control surfaces like brake handles is impossible in tight maneuvering for people with shortened limbs.
B. Hydraulic brakes lend themselves to adjustable travel for the brake handle.
C. Footpans bent and ready for welding.
Exploration
The early stages of exploration took the form of using scrap materials and experimentation in between my work on the assembly line. While working on the assembly line, I learned why manufacturing decisions regarding bend angles and welding techniques were made. First, I began looking at the existing parts’ digital drawings and models to see where modifications could be made in a cost effective way.
Extended brake levers would add leverage to cable brakes for weaker hand strength. The cost of modifying existing brakes would surpass the cost of installing hydraulic brakes negating the advantage of this concept.
Modifying an existing footpan created a pinch point on the electrical readout cable.
The new mounting point moves the footpan closer to the rider vertically and horizontally.
Making an aluminum pan and a steel mount to the vehicle allows a clamp to squeeze the aluminum around the steel mount for easy and secure attachment.
Solution
The Limited Reach package is a set of controls to allow riders of short stature to safely and comfortably control the Coyote vehicle with minimal adaptive parts needed. The set includes an adjustable height footpan and inboard handlebars. The Limited Reach foot pan adjustable from 3”-7”. Both pieces attach to preexisting hardware which allows for ease of installation in final assembly. The design avoids electrical cables in order to prevent pinch points. Quality control is not inhibited due to its simple part subassembly.
Maintaining a single bend the limited reach handlebars move the hand controls closer to the rider, while having a similar manufacturing cost similar to the standard handlebars.
Original Handlebar
Limited Reach Handlebar
Credits: Tommy Ausherman, and Blake Wilson