Unleashing the Power: In-Wheel Motors & All-Terrain Tires of the Outisan e-Wagon

Welcome to the world of the revolutionary Outisan e-Wagon, where we’ve reimagined the concept of utility wagons and goes beyond the ordinary. What sets it apart? Three essentials: the motor, power battery, and electronic control system. Together, they bring new features to life, providing users with uphill power assist, downhill speed control, and adaptability to different terrains. Today, let’s dive into the remarkable in-wheel motors and all terrain tires developed by Outisan.

Roadmap of Motor Development

Technical path of motor

Developing the core component of our e-Wagon, the in-wheel motors, was a journey of intensive discussions, prototyping, and validation. We began by exploring the advantages and disadvantages of direct drive and gear motors, considering technical feasibility and user experience. Direct drive motors use magnetic force within a copper winding coil, offering quieter operation, easier maintenance, and long-lasting performance, though larger and heavier. On the other hand, gear motors employ a set of planetary gears to transfer motor force to the wheels. Geared motors excel in low-speed, high-torque applications with higher battery efficiency. But it came with a trade-off—potential noise and the need for additional driving systems, which would increase the product’s weight and complexity.

While delving into the pros and cons of these motor types, we couldn’t overlook the importance of structural and industrial design. We had to make critical choices between in-wheel, mid-drive, or rear axle configurations. At the moment, we already had six alternatives to think of. But our quest didn’t end there. We continued diving into crucial details, evaluating brushed versus brushless motors for lifespan and energy efficiency, carefully selecting control sensors for the ideal performance-to-cost ratio, and fine-tuning technical key metrics to enhance overall motor performance.

The result? Our e-Wagon is now equipped with two extraordinary in-wheel motors, offering exceptional power transmission with minimal mechanical losses. Its all-in-one design also helps to achieve IP66 waterproof grade, making the e-Wagon more confident when dealing with the unpredictable weather.

The story behind the in-wheel motor

In October 2022, a pivotal moment marked the birth of our in-wheel motors. We embarked on a journey, investing in molds to bring our vision to life. Initially, each motor was a powerhouse, delivering an average output of 250W, with the potential to reach an impressive 450W at its peak.

Through meticulous assembly and rigorous field testing, we discovered an opportunity to fine-tune our creation. We realized that torque output, not power output, was the key to unlocking the e-Wagon’s true potential. Torque determines uphill carrying capacity, while power affects flat ground speed. In designing our in-wheel motors, we initially drew inspiration from e-scooter industry standards. However, we realized a crucial distinction: the Outisan e-Wagon isn’t meant for riding; it’s designed for walking alongside. It’s a low-speed, high-torque vehicle. Dual in-wheel motors generating 500W could propel it to 30km/h, surpassing its original purpose. Additionally, our updated folding mechanism raised the loading capacity from 180lbs to 200lbs, necessitating increased torque.

Recognizing this, we made quick adjustments to match its purpose. By enhancing the motor’s design, we amplified its peak torque from 30NM to an impressive 55NM, while scaling back the rated power output to 150W. These modifications meant that our e-Wagon could now conquer 15-degree inclines, laden with up to 200lbs of gear, all while strolling at a comfortable walking pace. No more struggles or sweat; just a delightful journey where you can savor every moment.

But remember, the motor alone isn’t the sole hero here. Its best buddy, the mighty all-terrain tire, plays an equally crucial role. Together, they conquer rough terrains, traverse challenging paths, and ensure a smooth and exhilarating ride.

Ideation of All-Terrain Tires

Take the challenge

You won’t believe the crazy things we discovered during our market research escapades. Turns out, people use their utility wagons in various locations and for different purposes, and it got us scratching our heads. It presents a challenge in defining the key target audience for the brand new e-Wagon. Here are some examples we observed:

• Families lugging wagons to transport heavy outdoor gear to their campsite from the parking lot.
• Fishing fanatics bringing their entire tackle box to their favorite spots.
• Festival-goers grooving with their wagons in parks or farms.
• Sports parents supporting their mini-athletes with trusty wagons carrying all the gears.
• Event and wedding photographers wheeling around props and capturing those picture-perfect moments.
• Homeowners viewing wagons as their ultimate gardening assistant, hauling soil, seeds, tools and even firewood with ease.
• Beachgoers carrying everything needed for a day of sun, from BBQ stoves to food and beverages.

Wagons, the ultimate multitaskers. They’re there for shopping sprees, events of all kinds, and even for helping new students move into their dorms!

But here’s the hilarious part: each adventure calls for a different set of wheels. Wide and large hollow tires for rugged trails and grass, flat and inflatable ones for sandy beaches, and sleek and quiet rubber wheels for smooth pavements. It’s like a comedy show of tire preferences. So, we faced a delightful dilemma: do we create a universal tire that satisfies most needs or cater to specific needs with interchangeable wheels? After some lively banter and friendly debates, our team agreed to take on the challenge and develop an all-terrain tire that adapts to every wagon endeavor.

Further analysis of the specs

Let’s put on our technical hats and dive into the fascinating world of tire design. After meticulous user research and feedback, we set out to establish key requirements for our all-terrain tires. Here’s what we discovered:

1. Durability: Our tires needed to withstand the test of time, ensuring long-lasting performance for our customers. We sought materials and techniques that could withstand wear and tear, allowing the tires to endure adventurous journeys.
2. Trafficability across terrains: We focused on enhancing traction on various surfaces, from mountain trails to grassy fields and paved roads. Additionally, we examined the unique challenge of soft sands and discovered that increasing the tire’s contact area with the ground helped prevent sinking.
3. Traction for inclines and wet surfaces: Uphill power assist and downhill speed control were essential features of the Outisan e-Wagon. To ensure optimal performance, we aimed to design tires that provided excellent grip on slopes and maintained traction even in slightly wet conditions.
4. Noise, Vibration, and Harshness (NVH): In urban environments like shopping malls, museums, and parking lots, reducing NVH became a priority. While soft rubber wheels offered potential solutions, we had to carefully balance this aspect with our durability requirement.
5. Easy maintenance: Like automobiles, wagon wheels can accumulate debris such as rocks, mud, and grass in their tread pattern. We strived for a design that facilitated effortless cleaning, allowing customers to easily rinse off unwanted elements with a water hose.

With these requirements in mind, we started drawing up our tire game plan. We envisioned large-sized, top-notch synthetic rubber wheels with a cleverly designed tread pattern that could check off most of our boxes. But hey, life’s not that simple! We encountered trade-offs and conflicting demands during the design process. For instance, increasing tire size for improved traction also meant increased weight. Deeper tread patterns enhanced grip but posed cleaning difficulties. And let’s not forget about inflatable tires, known for their prowess on soft sands, but prone to punctures from sharp objects. Balancing these factors required continuous iterations, rapid prototyping, and extensive field testing.

Through rounds of testing, we made an enlightening discovery: soft sands would be our Achilles’ heel. Due to the e-Wagon’s weight distribution, the front part would sink into soft sands, while the powerful motors would inadvertently create a hole, hindering smooth movement, but it performs well on packed sands. So, we made the tough decision to focus on other terrains where the e-Wagon shines brilliantly. Rest assured, our driving system is optimized to tackle a wide range of surfaces with finesse, ensuring a remarkable experience for our users.

Take on Adventure with a Smile

The pursuit of perfection led us to dedicate extensive time and effort to developing the in-wheel motor and all-terrain tire for the e-Wagon, resulting in a true masterpiece of utility wagon driving system. Our goal was to achieve the perfect balance, not only in meeting most of the requirements but also in preserving the essence of our artisanal industrial design.

With meticulous precision, we crafted a unique tread pattern that offers exceptional traction while ensuring easy removal of small particles. The final design boasts a dynamic combination of high-density synthetic rubber tires at the front, serving as our reliable drive wheels, and lightweight PU foaming material tires at the back, acting as efficient follower wheels. This configuration not only reduces weight but also minimizes maintenance needs.

By harnessing the immense power of our in-wheel motors in harmony with these specially designed all-terrain tires, we have created a high-performance drive system that stands the test of time. The Outisan e-Wagon emerges as the ultimate outdoor companion, effortlessly lifting the weight off your shoulders. It’s also time to redefine what a utility wagon can achieve, blending craftsmanship, innovation, and reliability into one remarkable package. Unleash the true potential of your outdoor escapades with a wagon that dares to go where others can only dream. Because at Outisan, we believe in wheels that go the extra mile, making your wagon experience simply wheely-awesome!