ELECTRIC CARGO MOTORCYCLE: FINAL YEAR PROJECT SUMMARY
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1 ELECTRIC CARGO MOTORCYCLE: FINAL YEAR PROJECT SUMMARY Robert Cuzner, Josh Gallo, Neyland Butt June, 2012
2 Final Year Engineering Project Overview Section 1: Robert Cuzner Industrial Design / Mechanical Engineering The Product Design Process n The Need n Solution Statement n Market Research n Conceptualization n Concept Selection n Concept Development Section 2: Josh Gallo Mechanical Engineering Vehicle Dynamics n Handling n Road Irregularities n Braking Characteristics Section 3: Neyland Butt Mechanical Engineering n Range Simulation n Evaluation and Testing
3 The Need û Increasing congestion û Lack of parking û High fuel prices û Negative environmental impacts ü Motorcycles take up ¼ of a cars road space ü High energy efficiency ü Minimal parking requirements û Poor ability to carry cargo û Poor weather protection for riders
4 The Need Australian volume manufacturing in decline e.g. Ford, Holden, Toyota Strong engineering + manufacturing skills in Australia Opportunities for Intellectual Property generation and niche market manufacturing
5 Solution Design Statement Design a two wheeled, electrically powered vehicle that has the ability to carry large amounts of cargo, and protect the rider from the elements.
6 Target Markets / Market Size Service / Delivery Industries: Food delivery services Goods Australia Post Florists Increasing trend toward online buying of products Services Mobile Technicians First Aid General Public: Car replacement vehicle Ability to carry goods i.e. Shopping, laptop, books Protection from bad weather Environmentally friendly solution Market Size (units per year): Australia 3360 International 60,000 Total 63,360
7 Research Methodology Online Questionnaire: Motorcycle / scooter forums Quantitative and qualitative questions 76 responses Semi Structured Interviews 3 Local Domino s stores One manager and two delivery riders interviewed
8 Competitor Benchmarking Erider Thunderbolt: Poor turning circle Poor handling due to chassis flex High seat height Cargo space too small Auto Moto 3 Wheeler: Poor manoeuvrability Too wide to filter traffic Very slow (40km/h top speed) Excellent storage space and weather protection
9 Identification of User Needs Research User Needs Matrix QFD House of Quality Product Design Specification - Core Needs: Cargo capacity 375L Weather protection for rider Neutral riding position Adjustable seat height 100km range 0 50km/h acceleration < 7sec. Max. charge time < 8hrs Full Australian Design Regulation Compliance Small turning circle High manoeuvrability + many more
10 Concept Generation
11 Concept Generation
12 Concept Generation
13 Concept Generation
14 Concept Generation
15 Concept Generation
16 Concept Selection Concept Selection Matrix
17 Concept Development - Ergonomics CATIA V5 CAD Model 5 th, 50 th, 95 th Percentile 750mm seat height Field of view for 50 th percentile male
18 Concept Development Steering Linkage
19 Concept Development User Interface Real time tracking Wireless data provider Forward Camera (accident disputes, rider behavior) Flat screen display (for advertising) Android Tablet display: Vehicle information, GPS, base station info, troubleshooting Wheel speed + battery state data
20 Concept Development Possible Motor Selection Option 1: Kelly Controls 72V, 7kW Hub Motor (Similar to current Thunderbolt Motor) Option 2: Kelly Controls 72V, 7kW Car Hub Motor with 13in Car Rim + Scooter Tyre To be used with matching Kelly Controls Controller
21 Concept Development / Future Development Current Iteration: ü Cargo + battery capacity more than adequate û Overall height too large û Curvature of rear body counterproductive to purpose of seat height adjustment Future Development: Reduce body height and sacrifice some cargo space
22 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis What we want to do achieve Expect the delivery drivers to push to this design to it s limits Primary goal is to design a manufacturable chassis Requires full dynamic analysis Evaluate required handling and manoeuvrability Both requirements by VASS engineers Apply tests Thunderbolt components may change
23 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis Turning Motorcycle dynamics are very difficult to predict 11 d.o.f model to obtain high accuracy Large lateral forces cause twisting and bending on rear chassis Large steering torque = bad handling perception Biggest contributors Lateral forces Reaction forces Twisting torque All linked by geometry and weight distribution Need to find a happy medium
24 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis Road Irregularities Gutters/speed humps/potholes/dips Large stress on chassis Very uncomfortable Can be dangerous Currently refining Simulink model Corresponds spring and damping coefficient, sprung and unsprung weight
25 Heavy Braking/Acceleration Ideally try to obtain even load distributions Large forces that can cause fatigue failures All related to geometry Requires large compromises Need to be able to apply these models to tests to find a happy medium
26 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis Hill Resistance Roll Resistance Drag & Thrust Range Simulation ΣForces Driving Patterns Battery Indicator Specify Battery Power Battery Power & Level
27 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis Vibration Weave, Wobble, Capsize Dangerous Eigen Value Plot Stability Natural Frequency Speed Self-Stability Time Constant of Roll
28 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis Evaluation & Testing Mathematical Steady Turning U-turn Slalom Lane Change Obstacle Avoidance Chassis Jig Rear Suspension Mount Front Suspension Mount Computer ADAMS Simulation Solidworks FEA & Fatigue Swingarm Mount 300N Load Practical Chassis Jig Apply Real Loads Measure Deflection & Strain Fixed Geometry FEA 300N Seat
29 Design & Evaluation of a Commercial Electric Delivery Scooter Chassis Conclusion Manufactured & Evaluated Rolling Chassis Interest Range Simulator & Useful Tools JBike6 bicycle_mechanics/jbike6_web_folder/index.htm Motorcycle Dynamics Author: Vittore Cossalter
30 Thank you for listening
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