e-Wagon Structure: A Journey of Continuous Improvement

Creating the world’s first electric utility wagon is like trying to invent a hoverboard – challenging but oh-so-rewarding. We decided to blaze a new trail, crafting an e-Wagon that breaks free from the shackles of generic camping gear. We put our hearts and souls into developing a product that truly rocks its users’ world. Now, let’s dive headfirst into the structural design of the e-Wagon, seen through the eyes of its users.

Folding Mechanism

The e-Wagon’s folding mechanism has undergone multiple upgrades, driven by a shared commitment to creating the best user experience possible. The initial design featured two X-shaped supporting bars on each side, forming a rhombus in the middle of the wagon’s body. But, alas, it lacked the smoothness and sturdiness we craved during those folding and unfolding moments.

Undeterred, our team put on their thinking caps and brewed up some fresh ideas. We introduced an additional vertical supporting bar, transforming that rhombus into a robust triangle. This new design brought notable improvements, including enhanced shock absorption and a higher loading capacity.

But the story didn’t end there. The team delved further into the design’s potential risks, particularly the concern that a strong impact at relatively high speeds could unintentionally separate the supporting blocks from the horizontal bar at the wagon’s bottom. To address this challenge, we took a leap of faith and revamped the folding mechanism entirely. The result? An incredibly sturdy diamond-shaped design, featuring a pair of press-to-unlock folding parts crafted from durable zinc alloy.

Exploring uncharted territory is no easy feat, but our dedication to perfection keeps us going. Like a soft fire that yields sweet malt, each iteration brings them closer to refining the e-Wagon’s folding mechanism for an exceptional user experience in daily life.

Battery Pack Sliding Mechanism

Right from the get-go, we recognized the importance of a removable battery pack for convenient charging. But we faced a challenge: how do we ensure a secure connection that won’t bail during those bumpy rides?

After brainstorming like mad scientists, we arrived at a clever design – an extended component that links the sliding framework with the wagon, giving the battery pack some serious stability. With this design, the terminal block of battery pack fit snugly into the connector as it slides in, while the extended component keeps the upper part steady as a rock. The beauty of this solution is that users can effortlessly slide the battery pack in or out, even without looking. When it’s time to juice it up at home, simply press the unlocking button and pull the pack handle to slide it out. Convenience and ease are at the forefront of the design.

Control System with Sensors

The e-Wagon’s control system, positioned beneath the battery pack, plays a crucial role in bringing the innovative FlowStride technology to life. This technology allows the e-Wagon to effortlessly follow the user’s movements and adapt to different terrains.

Within the control system’s outer shell, we’ve got 2 rounded PCBs, 4 sensors, 7 wire terminals, and even stop blocks to prevent any fall of the handle system. The key challenge lay in effectively organizing these components within limited space without any interference. Imagine a tightrope walker doing acrobatics! We called upon the powers of 3D printing technology, testing countless designs without breaking the bank or our sanity. Through rigorous field testing, we successfully found the optimal configuration. With the production of actual mold parts, further rounds of field and aging testing will continue, aiming to make the e-Wagon a robust and dependable companion for outdoor adventures.

Extendable Tailgate

Inspired by the mighty pickup trucks ruling America’s roads, we couldn’t resist the allure of their monstrous cargo-hauling abilities. So, we borrowed a page from their book and gave the e-Wagon an extendable tailgate that’s ready to take on any oversized load. From humongous tents to fishing rods as long as a whale, this tailgate can handle it all.

However, ensuring proper weight distribution presents a challenge. It is not advisable to place small yet heavy objects solely on the tailgate, as they may exceed the supporting limit of the iron wires safeguarding the backend table. To address this concern, we’ve incorporated high-quality steel wires that connect the tailgate to the body frame. Plus, we’ve assembled iron connectors on both sides of the tailgate rotator, providing reinforcements up to 55 lbs.

Designing a fastener to keep that tailgate locked up tight presented us with yet another challenge. When ascending uphill, objects inside the wagon tend to shift towards the tailgate, intensifying the impact it experiences. While a highly stable locking mechanism could have been implemented, such a solution would not align with user intuition as it would prove difficult to open. After numerous rounds of 3D printing and rigorous validation, we cracked the code: incorporating two buckles. These buckles allow users to effortlessly pull back the locking blocks by their thumbs, releasing the tailgate to accommodate additional cargo.

Backend Table

Ah, the backend table, your trusty companion for all your gadget and beverage needs. During the development of the table, the team encountered two primary challenges. Firstly, the backend table only connects to the wagon through its top part, resembling a pair of ears. As a result, any items placed on the table create significant tension due to the long force arm generated. Secondly, there was a need to strike a delicate balance between thickness and weight. Too thick, and the table becomes a heavyweight champ. Too thin, and it’s as useless as a rubber sword.

To overcome these challenges, our dedicated product wizards embarked on an odyssey to optimize the table’s structure, functionality, and aesthetic appeal. We explored bolts, springs, and levers, turning the design lab into our very own magical playground. After countless rounds of wizardry, we stumbled upon the perfect solution – an additional piece of iron net that connects to the middle part of the table. This ingenious addition provides extra support, reminiscent of a car hood with its support lever, improving both functionality and visual appeal.

Conclusion

Now that you’ve experienced the thrilling journey through the e-Wagon’s structural design, it’s clear that we’ve left no stone unturned. Every element has been meticulously crafted to make your adventure extraordinary.

We’re not just about creating a product; we’re about creating magic on wheels. The e-Wagon’s structural design is a testament to our relentless pursuit of delivering an exceptional utility wagon that exceeds your wildest expectations. So, buckle up, embrace the excitement, and let the e-Wagon redefine outdoor experiences for all. Trust us, it’s going to be one heck of a ride!