Long-term planned project
I have been accompanying the Benched project as an inventor and developer since its inception in June 2016. Currently, I have completed the fourth generation of prototypes. Many improvements form the basis of the fifth generation of prototypes. This is to be successfully translated into small batches of professional production, crowdfunding funding, marketing by experienced sales and marketing staff.
Marketing staff, will market the product. Technically, success is guaranteed. Cash flow is to be provided by targeted marketing and sales activities, as well as business leadership.
Crowdfunding will be used to finance the initial phase.
The whole project development
Pre-prototype E-bike
- test of wiring and technical parameters of the engine
- testing the engine for mechanical stress on the road and in the field
I focused the prototype solely on testing the electric motor. The first tests were carried out on a women’s bicycle. I mounted the motor on the front wheel. I was completely satisfied with the traction and performance, even though the front wheel was smaller than the rear (see photo). The motorized ladies bike was especially liked by Alenka, my girlfriend.
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Prototype 0 – motorised wheelchair
- Wheelchair with motors on both wheels (dimension 24 inches)
- Separate control of each motor
- Use of small front wheels for motorised travel
The idea for the original project was born in July 2016. I installed an electric motor in both rear wheels of the wheelchair. Each electric motor was equipped with a controller with a rotary handle, like adding gas on a motorcycle.
I found the following deficiencies, which I corrected in subsequent projects:
- The small front wheels of the wheelchair posed a high risk of falling when driving on uneven terrain.
- When traveling straight across a sloped sidewalk, the wheelchair was constantly turning in the direction of the sloped surface and could not maintain a straight course.
- Driving at speeds in excess of 15 km/h caused the front wheels to vibrate, making the wheelchair unstable. There was a risk of damage to the front wheels.
The solution of the zero project proved to be very unsatisfactory. I started working on a new concept for a stable tricycle.
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Prototype 1 – tricycle
- Detachable towing motor unit
- Stable tricycle concept
- Harley-style high-angle front wheel
- External protection against rider injury
- Classic mechanical brake on the front wheel
I tested the first prototype of a stable tricycle, optimal for a comfortable and safe ride over large obstacles in the terrain in January 2017. The front wheel with an integrated electric motor was placed on a fork with a Harley-style slope to prevent the rider’s feet from coming into contact with the bike. The front wheel was also equipped with a conventional brake with opposing rubber feet. The design already provided external protection for the rider.
Despite the great advances, serious problems had to be solved:
- The towing unit had to be attached/detached using mounting tools for the time being.
- Problematic cornering due to the high fork angle and the placement of the heavy battery directly on the handlebars.
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Prototype 2 – tricycle
- Quick couplers to attach and detach the drive to the wheelchair
- Improved steering with control rods
- Battery mounting on the power unit frame
- Stabilization against engine torque on front wheel fork
On this second prototype I worked with a renowned manufacturer of design frames for the production of racing downhill bikes. I wanted to make a design frame out of the special lightweight and strong tubing used to make custom downhill racing bikes. The frame was not yet collapsible and was only adapted for one wheelchair. This was the first design piece. Here I used more modern electric components with a black and white display to read the parameters while riding. I fitted a two-piston hydraulic disc brake for added safety.
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Prototype 3 – tricycle
- first design prototype
- hydraulic two-piston brake on the front wheel
- folding handlebars
On this prototype I collaborated with a manufacturer of design frames for downhill racing bikes. I gave him my finished frame for the 2nd prototype, which we based it on. We explained what I expected from the frame. It was a new design made from new special lightweight and strong tubing used to make custom downhill racing bikes. The frame was not yet collapsible and had been modified to accommodate only one wheelchair. This was the first design sketch. Apart from the design, the frames were not very different from each other structurally. I also used the more modern electric motor controls with a black and white display to read the parameters. A front hydraulic two-piston disc brake was used for greater stopping power.
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Prototype 4 – tricycle
- hydraulic four-piston brake on the front wheel
- battery mounted on the frame by a design bracket
- new handlebar stems for maximum travel angles
- steering bars hidden under the battery holder
- folding frame arms for minimal folding
- stands on the frame arms
- Front wheel lock for easy handling
- increased motor power from 750 W to 2,000 W
With this fourth prototype of the trike, I achieved maximum travel angles by innovating the steering. The wheelchair unit now has excellent accessibility even in tight spaces. The motor power has been increased from 750 W to 2,000 W. I used a color display with multiple functions. The design of this model unit is foldable, both the frame arms and the handlebars. The frame arms have stands at the ends, to stand the frame itself or to more easily attach the unit to a wheelchair. I made the quick couplers stronger and used a hydraulic four-piston disc brake for increased motor performance. The battery is mounted on a bracket that is a design feature of the frame and protects the control rods. The steering has an anti-spin lock on the front wheel, to better manipulate the frame to connect the unit to the wheelchair. Still, this frame is designed for one size wheelchair.
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Prototype 5 – tricycle
- adjustment mechanism to adjust the width of the arms to connect different sizes of wheelchairs (universal frame)
- reinforcement of the motor attachment to the front fork
- new type of stronger quick couplers
- additional components for riding in traffic (lighting, turn signals, rear view mirrors, …………)
- two types of packaging for the power unit
- travel bags for the drive frame
On the fifth prototype, there will already be frame adjustment elements for all kinds of wheelchairs. The fifth prototype will already be fully functional and will be destined directly for sale.
