Charles Van Hook Portfolio

Project overview

Motivated by the need for convenient campus transportation and a personal interest in electric mobility devices, this project focused on designing and building a functional electric skateboard. It served as a practical application of engineering skills using available and repurposed components, shared as a project with brothers.

Timeline

3 Months (March-June 2022)

Team

Solo project (self-directed)

Role

Lead Engineer

Components

Firmware Development

RF Technology

Awards

Most Dangerous Thing I've Made - My Mother

STATUS

Complete

Tools

Fusion 360

KiCad

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Design Process

The design evolved from an initial concept with independent suspension to a more robust setup using all-metal trucks, custom-machined on a CNC, to ensure reliable turning. Brushless motors were mounted to drive wheels repurposed from old robots. The skateboard deck housed a custom-built battery pack and associated electronics.

3D Render/CAD

Software / Electronics

A custom battery pack was assembled using cells salvaged from old laptops, managed by a custom Battery Management System (BMS) board featuring a heatsink for thermal control. Brushless motors were driven by electronic speed controllers (ESCs). A custom control board, implemented intelligent speed control differentiating between front and back motors, offered six distinct speed modes, and included a reversing capability, controlled via a wireless remote.

Electronics

SOFTWARE

Challenges

The initial design challenge was achieving effective turning, which led to abandoning the suspension idea in favor of custom CNC-milled trucks. Sourcing and integrating repurposed components (wheels, battery cells) presented compatibility and reliability hurdles. Designing a safe and efficient custom BMS for the salvaged battery cells was crucial for performance and longevity. Implementing the sophisticated multi-mode speed control software required careful programming and tuning.

MEDIA

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