EMG Electric Golf Buggy Components

EMG is proudly Australian and purchase as many parts and services that are available in Australia;

  • EMG buggies are made from aircraft quality Australian Ullrich Aluminium Newcastle.
  • The buggies are manufactured, designed and assembled in Newcastle, not made overseas.
  • Injection moulded wheels and plastic components are manufactured in Newcastle
  • Powder coating, laser cut parts, nuts and bolts, stickers are all sourced in Newcastle, NSW
  • Hand grips, switches, wiring, battery terminals are sourced within Australia
  • Drive assemblies and electronic control units are imported and modified prior to assembly by EMG.

EMG has total confidence in our suppliers of consumable parts as they have worked with us for over 5 years of development and most offer warranty on their products.

Golf Buggy Engineering

You have probably heard through friends or other golf buggy owners, the do’s and dont’s of owning a golf buggy.

EMG golf buggies have seen and heard and tested it all, we know what makes an electric golf buggy tick, so to help you make it through every game we have built a buggy stronger, more reliable and practical than anyone else.

We are not here to make a quick buck, we are here to design and manufacturer a golf buggy that will last and satisfy our customers for many years, so the following information is of our quality golf buggies and components v the rest of the buggies supplied throughout Australia and the rest of the world.

1. Golf Buggy Frame Material

EMG chooses to use aircraft quality Australian Made Ullrich Aluminium Newcastle.

  • Aluminium has excellent strength qualities.
  • Overall, weight is kept to a minimum.
  • Aluminium does not rust therefore if sand or water enters any of the structural components no deterioration will occur, guaranteeing product longevity.

2. Golf Buggy Frame Strength

To achieve the strength needed for our golf buggy the Chassis of our buggy has to be able to complete all courses day in day out and not break through fatigue like so many other poorly designed but fancy looking electric golf buggies.

EMG assessed the best aluminium material type and strength, then looked into how much bracing you need throughout our structure, so we could compliment our world class tig welding.

The EMG chassis is a product of extensive testing that is carried out both on and off the golf course.
Examples of our off course testing;

  • repetitive motions such as moving up and down stairs simulating steps and gutters
  • Rough surfaces found in and around golf courses.

The EMG Australian designed and constructed frame has the fundamental principals of load bearing directions in mind.

Extreme loads that a motorised golf buggy experiences, is when the user pulls backward and down on the top t-handle lifting the front wheel off the ground.

The lower frame or “chassis” that is contact with the axle housing, has to tolerate the weight of several items at once, the golf bag (up to 20 kilograms) battery (10 kilograms) and motor/gearbox assembly.

The EMG design ensures that all loading pressures from this common movement are evenly distributed throughout the entire chassis via structural plates that embrace the axle housing, sump and main frame, rather than the handle being welded to the axle housing alone.

Most manufacturers have assistance bracing from the handle to the chassis, due to undersized tubing they need extra help to stop the handle from folding under weight from the bag and the pressure from turning the buggy from left to right and to get over objects such as gutters etc and they also spoil the look of a golf buggy.

Other manufacturers choose not to brace at all, which inevitably leads to the axle housing fracturing away from the chassis.

3. Golf Buggy Welding

The welding of any component is very important whether it is a golf buggy, lawn mower or competition racing car.

The method that EMG uses is “TIG” welding, a world class form of welding used on competition vehicles, including Formula 1, V8 supercars WRC rally cars all over the world.

Many factors work together with “TIG” welding as it is a precise temperature controlled process.

Aluminium has to be at the right temperature before the filler rod can be added ensuring that penetration of both components has taken place.

Once the welding process is completed on components our buggies, no further preparation of the welds is needed (ie grinding smooth for a finished look hence lose of material and strength) before being sent off to the final phases of production.

Other welding processes are suited mostly to fast production of components, this is usually achieved using “MIG” welding, which is a good welding process, but can often have inconsistent penetration, therefore is not suited to intricate component welding that is found in our golf buggies.

Imported buggies are a classic example of fast production welding and inferior metals are used, the result is an old cliché “you get what you pay for.”

4. Golf Buggy Drive Assembly

A to C explains the difference between 3 types of gearbox available and why EMG chose a worm – helical combination, taking the strength of a worm and efficiency of the helical.

A. EMG Unique Gearbox

EMG is aware of the benefits and failures of both worm drive and helical configured gearboxes.

Our solution has been to take advantage of the strong points of the worm and helical.

EMG opted for a worm – helical combination, taking the strength of a worm and efficiency of the helical. The EMG gearbox has only a pinion gear and main gear, this lends itself directly to be able to achieve the maximum diameter main gear with a massive 4mm tooth depth.

This depth is only comparable to those found in your motor vehicle.

EMG is extremely confident with the design and a 2 year warranty is provided.

B. Helical Gearbox

The helical configured gearbox primarily used in motor vehicles. This gearbox when configured correctly has only 1 tooth in mesh and is very efficient with minimal drag.

The problem that manufacturers of motorised golf buggies have is restrictive size gearbox housings.

Configurations using up to 4 gears to acquire final drive ratios have to be used which in turn eliminates all efficiencies due to the fact 4 teeth are in mesh.

Manufactures are forced to use small diameter plastic gears with delicate .08 of millimetre fine-pitch

C. Worm Drive Gearbox

The worm drive, designed primarily for use in heavy engineering, was initially conceived in the 1800’s. The main problem associated with this gearbox is drag or friction.

A worm drive gearbox has 3 teeth in mesh at any one time, which in turn causes excessive drag, therefore the motor has to work harder to compensate.

A motor working harder than necessary causes increased strain on the battery, which in turn leads directly to much shorter battery life and less power to make that final tee off.

5. Golf Buggy Wheels

EMG 5 spoke injection rear wheel with rubber overlay, designed for strength and durability for rough courses. The spokes are a + design to give extra strength from forward and sideways motions and bumps that occur on fairways and paths in between.

The wheels are produced from a 2 part process. Bearing hub area (Wheel Centre) and spokes are moulded in the same process for strength. Once this procedure is complete the wheels are put through a process which is manual.

The injection moulding operator puts each individual injected carcaus into the machine for the rubber to be injected to the outside. This leaves no consumable plastic or rubber sleeves to replace, or possibility of delamination like a worn out car tyre.

Superior Quality, with a 2 year warranty that is not matched by any other manufacturer. Wheels are produced by; Deeps Engineering, Salmander Bay, Newcastle NSW

6. Wheel Bearings & Drive Axle

Rear or drive axles are a common problem on Golf Buggies for failures, as this is where all the load and shock from surfaces is absorbed.

All imports have a 12mm axle which connects to the main gear of the gearbox via a 4mm roll pin. Over time on rough surfaces the hole in which the rollpin is situated starts to wear and can result in the axle snapping through the roll pin hole.

They also machine a 3-4 mm groove at the end of the shaft for the mechanism for the removable wheels, now the axle is reduced to 8mm and with a steel quick release inserts inside the rear wheel it causes 2 problems;

  • Shear points for axle
  • Squeeky metal on metal sound

From common sense and customer experience EMG know that this set up and design creates a shear point as the quick release wheel that runs on the shaft is steel on steel.

We have tried and tested 12mm axles and after a couple of games the end of the axles bend where the wheels locate. At EMG we use 15mm bright bar material for our axle.(Never Broken 1).

The drive bearings are Needle roller clutch bearings that connect through a hexagon drivenut that drives the wheels when the motor is turned to on. This setup works the same as a differential in a car, turn left to right each bearing will disengage to make maneuverability easy.

From previous reading you would have read that we use an imported gearbox/motor assembly.
It has a 12mm hole through the main gear. We have an alignment jig that we place the gears into on a lathe, to re-drill them out to 15mm so that we can insert the 15mm axle.

Wheel bearings are an important factor for longevity of a motorised golf buggy. EMG’s rear wheels are supplied with needle roller clutch bearings in each wheel, that helps turning mobility.

When the buggy is not turned on it can free-wheel forward and backwards with ease. How this system works is once the motor is engaged via the On/Off switch the needle roller bearings engage onto the axle, giving you drive through both wheels for traction up steep hills and slippery surfaces.

If you need to turn the buggy left to right the clutch bearings will disengage for optimum turning ability.

Bearings in the front wheel of the EMG buggies have spacers between the bearings to ensure that no matter how much torque is applied, the mounting bolt and bearings will never operate outside there torque parameters.

7. Golf Buggy Batteries

EMG use a standard 24amp/hr full deep cycle battery. The 24amp/hr battery supplied is for the golfer that plays 1-2 days a month playing 9- 18 holes.(6 months Warranty)

EMG have an optional upgrade to a 24 – 28amp/h Sonnenschein Gel battery at a small additional cost.

Sonnenschein are the world leaders in Gel battery technology and it also helps our buggy travel further than your standard 18 holes on hilly courses.(12 months Warranty)

Testing has brought about results such as on very hilly golf courses the EMG had ample battery power still in reserve, which allows the buggy to continue well past 18 holes.

8. Golf Buggy Umbrella Holder

“The only buggy on the market in which you can leave your umbrella attached at all times”

This simple ingenious idea came about when the team at EMG received a request. Customers told EMG that they were experiencing difficulties when having to continually bend over or duck down under the umbrella mounted to their golf buggy, even though an extra hand-or umbrella holder, had been used.

We spoke with a few of our local customers about the umbrella height situation, we then came up with a quiet simple solution.

Without to much engineering, we mounted the extra hand on the highest point of the handle, offset to the side so it is not right in front of your face.

The best positive to utilising this position is that if its a raining/overcast/type of day, which we all encounter from time to time on the golf course, you can simply fold down your brollie, leave it in the extra hand umbrella holder and adjust the extra hand down the side of your bag.

Then if it rains again, all you have to do is re-adjust the umbrella holder into the most upright position and open your brollie into the open position, then you are covered for the next shower.

(No pulling out of your bag and re inserting into your umbrella holder, its ready to go every rain shower) Most manufactures have the umbrella holder clamped half way down the top handle, which in turn means you lose up to 6 inches from the top of the handle.

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