4. USPS project tasks/accomplishments
● Upgraded LFP battery pack (increased capacity 60%, peak
discharge 30%, replaced liquid heating with electric)
● Replaced damaged MCU (motor control), DC/DC,
transmission
● Upgraded suspension (add stiffeners and tunable air springs)
● Added operator display / instrumentation
● Returned working vehicle to USPS for test
● Complete design/repair/upgrade/test program executed in
under 3 months
● Managed team of 0 – 5 international engineers/technicians
5. LFP Battery Upgrade
● Selected specific cell
from battery partner
(Performance analysis,
system design)
● Designed cell pkgs,
arrangement,
distribution in vehicle
● Machined retaining
plastic
● Converted to electric
heat elements (from
liquid heat system)
6. ● Installed thermal insulation
● Each (of 3) box contains LMU (Local
Management Unit), reporting to BMS
● Thermal probes, HV polarized locking
connectors
● Flexible terminal connections (nickel
plated copper)
● BMS (not shown) inside power
distribution box
7. ● Managed 95% volume increase
(Old vs. New battery packages)
● Increased Front Box cavity, relocated
components/wiring/hose arrangements
● Accomodated existing RWD
driveline arrangement
8. ● Replaced damaged MCU (motor control), DC/DC, updated
distribution box (integrated BMS, contactors, HV disconnects)
● Cleaned wiring nest, particularly HV paths. Corrected conductor
color + sizing. Eliminated noise-related errors on CANbus.
Before After
12. ● Upgraded charging to J1772 compliant Level 1, 2
● Installed fuel-fired cabin heater (for driver comfort)
● Eliminated multiple fluid thermal circuits
● Cleaned CAN code, system architecture; added data
logging + diagnostics (user and service level)
● Increased vehicle range (110%), power (loaded top speed,
extended hill climb), utility (rider comfort, display, J1772)
● Documented results, wrote manual for management, client,
& service personnel
Additional Accomplishments
13. 2) ZTR: Zero-Turn Radius Mower
Convert ICE / Hydraulic system to BLDC electric
14. ZTR : Zero-Turn Radius Riding Mower
● Executed system design, fabrication and integration of replacement electric drive
and mow for hydraulic and belt-driven ZTR riding lawn mower. Performed proof-of-
concept performance test, evaluation and customer demonstration.
15. ● Performed CAD & shop fabrication of Drive Gearmotor: integrating BLDC
motor with gearbox from OTS centrifugal clutch (2-stroke garden tool)
16. ● Designed & fabricated
an integrated BLDC
motor/ control package
for drop-in replacement
of belt-driven deck
blades
17. 3) Electric Roto -Tiller conversion Project
Prototype 1:
Proof-of-Concept
Prototype 2: field test
and power evaluation
20. 4) Miscellaneous Projects
● Jackelope: Electric Off-Road Dirt Bike
● Submersible Drive for Boat
● Electric Trailers for Bike
● Industrial Applications: pump, air compressor, floor
scrubber, utility vehicle . . .
21. “Jackelope”
Evolution of Production “Jackal”
● Jackal
● Jackelope
● Reduced weight 25%
● Upgraded PM brush to BLDC drive
● Upgraded PbA to LFP batteries
● Added CVT transmission (wheel)
● Increased ground clearance
● Increased range over 80%
● Increased rear suspension travel 50%
● Increased top speed 42mph to 55mph
● Performed all Design and Fabrication duties
(except for fillet braze of frame tubing)
22. Trim-Tab Boat Drive
● Dual motor system w/ joystick control,
differential power to steer boat, shown
compared to single large motor
● CAD design, fabrication, assembly, test
of submersible motor/controller system
23. Electric Power-Assist Trailers for Bike
Multiple Prototypes
● Long Range
● Utility (suspension, cargo capacity)
● Commuter (short, light, suspension)
● Performed all design/fab of non-COTS parts
24. More Miscellaneous . . .
Design, Fabrication & Integration of BLDC motor/controller solutions:
● Spa pump
● Floor scrubber
● Air compressor
● Utility vehicle
(Not Shown): paint sprayers,
weed whips, leaf blowers,
door openers, pool cover
openers, exhaust fans . . .
