Introduction: Conversion of a Hoverboard to a Segway
My motivations in making this project were that long wanted a Segway, but because of its high price (about 4,000 to 9,000 euros), I decided to turn a hoverboard, which has a price much lower (between 150 and 300 euros), a Segway vehicle type.
One of the disadvantages that I have encountered is that no one has made this transformation (or I have not found any) and i had to start from scratch without any reference as how to do it.
My goals when I pose this project were: see if it was possible to transform a Hoverboard into a Segway vehicle, and if so, how can a kit be created to adapt it.
In this project I will expose the possible ways to make this conversion using the best possible parts of the original Hoverboard.
By using materials such as iron and aluminum, and different graphic tools I will try to show the steps to follow to reach the final objective.
P.S. This project was done in Spanish so if you do not understand something, tell me to solve any doubt.
Step 1: Introduction
Hoverboard is an electric vehicle with a concept very similar to that of a Segway. So why Hoverboard has a better acceptance on the part of the public than the Segway? Of course, the answer is obvious: the price, but it is much more than that.
Segway Personal Transporter was invented by Dean Kamen in 2001. Initially, it began to be a utility machine for the workers and it was improved and modified to perform various tasks. Although it is a very useful and powerful machine, it is also very heavy and clumsy, which also favors a Hoverboard. The price that was initially presented was $ 4000.
The Hoverboard was launched in China in 2015. This device does not receive a universal name since it can be recognized as a self-balanced wheel board or Hoverboard among others. These names are attributed to companies that distribute them more than the manufacturer itself. The majority of the hoverboard costs between € 150 and € 300.
Step 2: Design
- Maneuverability similar to the Segway
- Economic manufacturing kit
- Lighter than the original
- Reuse the maximum possible hoverboard pieces
- Design aesthetically similar to a Segway
3D sketches and designs
In this section I will show the sketches and designs that I have made until finding a definitive model. To begin I will show the different sketches with which I have an idea of how to make the pieces and an approximation of their final design.
Step 3: Construction and Assembly
The construction and assembly of this project is subdivided into the following sections:
- Casing and floor
- Final assembly
Step 4: Chassis
Initially, the idea was to make the structure with structural aluminum profiles, but because I do not have the necessary tool to weld aluminum and screwed it would not be sufficiently rigid, I decided to make the structure with steel profiles.
Once all cut and welded iron as shown in the drawings and photographs, should make the subject of the wheel.
To held the wheel-motor in the chassis, four steel pieces have been necessary, two of which have been modified to be able to mount the wheel on to the chassis.
These pieces were initially the ones that held the wheel over the Hoverboard. It was necessary to replicate the helding of the wheel, so it was necessary to buy two extra pieces and modify them to finish the helding.
To these modified clamps I've welded four screws to each one to hold the motor. Immediately I've welded the clamp in the chassis. The finished work is shown in the last photography.
There's a video of the chassis construction process that I've made.
P.S. The welds were not perfect, but it was the first time that I welded.
Step 5: Direction
This section is subdivided into two more sections to be better explained:
- Handlebar and steering column
Handlebar and steering column
To build the steering column I used a steel antenna mast, because it has two different diameters (to connect several masts). I soldered some washers that would make a stop so that it wouldn't escape from the support. This antenna mast was cut and welded at a 90 ° angle as shown in the photographs.
The support of the steering column is a printed block with a 3D printer. This support is formed by two separate blocks for being assembled or disassembled if it's necessary. When I created this support I had to weld a steel plate to hold it.
To subject a handlebar to the steering column I designed a clamp similar to a bicycle clamp, and I printed it in 3D. Once printed it I made a hole to fix it in the direction column and painted it black. To cover the top hole of the tube, I designed a cap with a clamping mechanism so it didn't come out. This mechanism is like a "spider" that when spinning a screww , the clamp expands against the tube, making it impossible to get out of the tube. Once all fixed in the place, the result it's shown in the last photography.
To replicate the driving movement of a Segway I have to re-adapt the hoverboard's steering system.
The direction of a Segway is very simple. To move forward or back you only have to tilt the Segway, and to rotate it is only necessary to move the handlebars to the side you want to rotate. The movement of a hoverboard is even easier, to go forward or backwards you just have to tilt your feet. In order to make the turn you have to lean forward the foot opposite that of the turn.
Example: To turn to the right, you must lean forward on the left foot.
To replicate the movement of the feet using the handlebar it is necessary to weld a support that holds two rods. These connecting rods press two levers that are connected to the board of the gyroscopes. All the components were 3D printed.
The last photography shows a 3D model of the mechanism. Also there is a video that shows how the mechanism works.
Step 6: Casing and Floor
The casing and the floor are the easiest section. To carry out the casing, you only have to cut a plate of ecoglass with the necessary shapes. To make the floor is the same but with a non-slip metallic sheet, like "damero aluminio " or "chapa palillo" (in spanish).
All these pieces have been screwed with metal drill screws.
Step 7: Final Assembly
First we'll screw the wheels in the chassis using the pieces that hadn't been modified in the section of the chassis.
Next you have to mount the steering column and the support that holds it into the chassis. The clamp, the handlebar, the tube cover and the bicycle fists must also be installed. Inside the tube, a female is attached with a two-component adhesive that will help the screw to hold the clamp onto the tube. Then a 3D printed box must be installed in the chassis. That box accommodate the battery charger connector, the ON-OFF pushbutton, and the battery and balance indicators. All of these indicators and pushbuttons came installed in the original hoverboard.
Once the connection box is installed, the mechanism must be mounted against the chassis.
To be able to safely use it, the original hoverboard had phototransistors. These create a beam of infrared light that when someone is above the device, is interrupted and allows to use it. This sensor serves to detect that there is someone on top. If the light barrier is not interrupted, the hoverboard doesn't work. This way if the pilot falls the device stops and it does not continue moving forward.
Before screwing the plates of the gyroscopes to the mechanism, phototransistors must be unwelded to be able to relocate them outside.
The motherboard, battery and connections are then installed. In this step I had to extend several cables because the one that went to the plate on the right in the original hoverboard had to go left and vice versa. This is because in order to be able to rotate with the handlebar, the plates must be changed sideways to imitate the movement that would be done with the feet. Once the electrical installation is completed, screw the "chapa palillo" into the chassis.
The phototransistors must be cut in half to be relocated. The half phototransistors must be placed inside boxes printed in 3D so that they do not affect the infrared rays of the sun.
Once all this is done, it is only necessary to put on the casing.
Step 8: Finished Project
Here the construction process ends. I hope you liked it!!!
If you have any questions, do not hesitate to put it in the comments.
Attached video of the device working.