Electric Marine Propulsion: Optimization for Low Volume Manufacturing

Abstract

This project explores the development of an electric outboard motor that could be manufactured by a small startup as a marketable replacement for internal combus- tion outboard motor of approximately 25 HP. This has been accomplished through the design, optimization, and construction of an electric system to power a launch boat commonly used by the coaches of competitive high school and university crew teams. The design aimed to maximize manufacturability and value without sacri- ficing power, durability, structural integrity, attractiveness or safety. This thesis focusses on the mid-section of the motor, ultimately developing components and a manufacturing schedule such that the motor could be constructed by a single em- ployee in the span of one week. Analysis of the assembly is used to explore produc- tion costs, providing insight into marketability, benefits, drawbacks, and barriers that must be overcome in order to see such a system successfully brought to the marketplace.