R I T 175 th Anniversary Chopper Senior

R. I. T. 175 th Anniversary Chopper Senior Design Team (Project Number 05912)

Diverse Team Members • • • Advisors – Dr. James Taylor (ISE Associate Professor) – John Bonzo (Brinkman Lab Facilities Manager) Mechanical Engineering – Jonathan Howard – Alexandra (Alli) Collier – Lee Gagne Industrial Engineering – Jeremy Rank – Johnson – Anthony Rounding Electrical Engineering – Curtis Vana Industrial Design – Scott Janis – Devin Connolly – Tim Houck

Agenda • • • Needs Assessment Concept Development Feasibility Assessment Specifications Analysis and Synthesis

175 th Anniversary Chopper Project Description / Desired Outcomes • Convert stock 883 Harley-Davidson Sportster into custom chopper prototype • Create customization kit for aftermarket sales – Conversion components must be bolt on – No significant modifications can be made to the frame

Stakeholders • Rochester Institute of Technology • Senior Design Team • Santa Cruz Harley-Davidson – Primary stakeholder for conversion kit • Conversion Kit Customers – Approximately 500 Sportsters are manufactured daily

Needs Assessment • Team researched chopper motorcycles • Talk with Mike James and Bob Davis of Santa Cruz Harley-Davidson

Needs Assessment • Team developed a list of order qualifiers: – – – – – Rear end of the bike shall change Front end of the bike shall change Sheet metal on the bike shall change Electronics on the bike shall change Ride height shall change Paint on the bike shall change Seat on the bike shall change Custom parts must be bolt on Bike must be operable

Concept Development • System changes to meet order qualifiers: – – – Fuel Tank Handlebars / Controls Ride Height Wheel Design Tire Drive System – – – Wheel Hubs Headlight Electrical Exhaust Seat Conversion Kit

Feasibility Analysis – Methods Used • Pros & Cons • Pugh’s Method • Weighted Concept Evaluation • Expert input / discussion

Electronics Specifications • Increase Lighting – Hurt Motorcycle Accident Study • ½ of all motorcycle accidents involve a motor vehicle (automobile) violating the motorcycle right-of-way • Failure to recognize and detect motorcycles in traffic was the predominating cause of motorcycle accident – Freedman and Ketron Lighting Study • Found that the adding lights to the motorcycles rear and sides improved conspicuity

Electronics Specifications Accent Lighting System General Layout User Interface RPM signal Digital Control Unit LED Driver Accent Lighting( LEDs) • System Schematic • Cost Analysis 12 VDC Battery

Triple Clamp Specifications • Design Constraints – – – – Safety Machinability 7 Degree Rake Angle Forks Steering stem Mid-Glide front end Handlebars Style

Top Triple Clamp Analysis Top Triple Clamp with 7 G Horizontal Impact Loading Max Stress 29, 000 psi Top Triple Clamp with 3 G Vertical Impact Loading Max Stress 9, 300 psi

Lower Triple Clamp Analysis Lower Triple Clamp with 7 G Horizontal Impact Loading Max Stress 37, 000 psi Lower Triple Clamp with 3 G Vertical Impact Loading Max Stress 9, 000 psi

Front Wheel Specifications • Design Constraints – – Safety Manufacturability Style New Front End Design Rear Wheel

Front Wheel Concepts • Preliminary Design Issues – Manufacturability – Safety

Front Wheel Analysis • Impact Load • Torsion Test 3, 500 lb Load Max Stress 20, 071 psi 6 G Load Max Stress 8, 123 psi

Front Hub Analysis • Impact Load • Torsion Test 3, 500 lb Load Max Stress 8, 100 psi 6 G Load Max Stress 2, 264 psi

Kit Contents Custom Parts Designed and Manufactured • • • • Front Wheel Front Hub Front Axle Rear Wheel Rear Hub Rear Axle Triple Clamps – Top and Bottom Steering Stem Shaft Steering Stops Modified Purchased Front Sprocket Modified Purchased Rear Sprocket Tank Mounts Seat Pan • • Ignition / Key Casing Converted To Hydraulic Clutch Exhaust Paint Scheme and Implementation – Gas Tank – Rear Fender – Oil Cover – Electronics Cover – Frame Engraved Designs On The Air Intake and Engine Casing Cutting Fender Struts and Remanufacturing Chrome Covers Brake Light LED Lighting System

Kit Contents Aftermarket Parts Purchased and Implemented • • • 11 inch Eye-To-Eye Shocks Inverted Forks Handlebars Front and Rear Tires Chain Air Intake Filter Chrome Engine Covers Single Rider Seat Chrome Swing Arm Headlight Slave Cylinder

Lessons Learned • Always have a predetermined contingency – In the feasibility analysis, we only decided upon the optimal solution • Fender attachment • Critical path – reconstructing the critical path to make difficult tasks non-sequential

Questions

Shoulder Moment Reduction • Original design M (shoulder) = (18. 62 N*. 170 m) + (10. 78 N*. 480 m) M (shoulder) = 8. 34 Nm • New Design M (shoulder) = (18. 62 N*. 120 m) + (10. 78 N*. 340 m) M (shoulder) = 5. 89 Nm • Moment Reduction – 29% Back

Algorithm Begin Check State of Comparator Interrupt Flag Peak Check Is Peak? Increment Counter Have 45 peaks been counted? Toggle Output Reset Counter General outline of lighting control algorithm • Comparator state check • Increment • Toggle Output Back

Lighting Control System • Power conditioning circuit • Signal conditioning circuit • Processing Back

Cost Analysis Final Parts UA 7805 C PIC 12 F 67 PIC 12 F 6 5 75 PVDZ 172 N PCB Terminals Manufactu Manufact rerurer Texas Instruments Microchip International Rectifier Radio Shack Function Voltage Regulator Signal Processor Solid. State Solid Relay Terminals Enclosure Quantity 22 2 22 8 (2 sets of of 8 (2 4) 4) 2 Price perper . 52 2. 15 8. 50 2. 29 3. 99 Price for 2 2 sets 1. 04 4. 3 17 17 4. 58 7. 98 Total Project Price Project Enclosure Pugh’s Method Comparison 2 $34. 90 Back

Digital Control Unit Device Comparison Algorithm Back

Rear Wheel and Hub Back

Handlebar Control Concepts – Clean up controls – sleeker look – Hide control cables within handlebar – Change handlebar shape / geometry • Biomechanics – Use twist-grip clutch – Suicide Shift – Custom foot controls Back

Ride Height Concepts – – Lower ride height – rear end Shorten shocks Rigid Hard-tail design Redesign rear suspension geometry Back

Wheel Design Concepts – Three claw design • 3 -dimensional • 2 -dimensional – Solid Wheel Design • Spoke Appearance – Incorporate tiger image into design – Fabricate wheels in-house (Brinkman Lab) – Outsource wheel fabrication Back

Tire Concepts – Increase rear tire width • Size Range – 180 mm – 220 mm – Change front tire to match new rear tire – Find similar front & rear tire pattern Back

Drive System Concepts – Switch from belt to chain drive – Switch to narrower belt – Use current belt • Drive extension / spacer to accommodate new rear tire • Widen swing arm – Replace existing drive covers • Chrome • Powder coat • Aftermarket color Back

Conversion Kit Concepts – – Fabricate all components of kit Purchase all components (aftermarket) Combination of purchase / fabrication Final Kit delivery • All components – 1 set • Documentation – “Bolt on” components Back

Wheel Hub Concepts – Design hubs to fit custom wheel – Purchase aftermarket hubs • Requires wheel design to conform Back

Headlight Concepts – – In-house custom fabrication Purchase aftermarket headlight Remove headlight from design Reuse stock headlight Back

Exhaust Concepts – – – Left exit exhaust Converging exhaust pipes (two into one) Shortened straight pipes Street sweeper pipes Purchase aftermarket pipes Fabricate exhaust in-house Back

Seat Concepts – Replace stock two-up seat – Single seat • Fabricate in-house • Purchase aftermarket – Redesigned two-up seat • Fabricate in-house • Purchase aftermarket – Sissy bar • Fabricate in-house • Purchase aftermarket – Incorporate Logo into seat design • RIT 175 th anniversary • Sponsor Logo Back

Electrical Feasibility – Pugh’s Method Back

Electrical Concepts – – – Integrate rear lights into rear fender Develop proximity sensors Develop variable intensity lighting Accent lighting for engine Custom turn signals Ignition • Access code • Toggle switch Back

Electrical Feasibility – Variable intensity lighting • Pro: – Safety (increase visibility) – Aesthetically pleasing • Con: – Not visible during the daytime – Proximity sensor system • Pro: – Safety (visibility) • Con: – Cost – Time required to implement – Resources (people) Back

Fuel Tank Feasibility • Custom designed tank • Cons: • Team lacks expertise in metalworking • Cost to outsource fabrication of in-house design ~ $2000 per tank • Pros: • Radical one of a kind • Does not compromise the Industrial Designer’s design • Commercially available tank • Cons: • Compromises the Industrial Designer’s design • Not a radical design • Pros: • Cost: ~$600 per tank Back

Fuel Tank Feasibility • Weighted concepts Back

Fuel Tank Feasibility • Pugh’s method Back

Handlebars Feasibility • Custom built handlebars • Cons: • No member of the team has experience designing handlebars • Pros: • Conceal controls • Change look of bike from dirt bike to a chopper • Purchase handlebars • Cons: • Cost: ~ $3000 per set • Pros: • Built by manufacturers with experience • Conceal controls • Changes look of bike from dirt bike to chopper Back

Ride Height Feasibility • Remove shocks • Cons: • Turns bike into rigid, decreasing the ride ability of the bike • Pros: • Gives bike a sleeker look by removing the shocks • Shorten shocks • Cons: • May result in possible problems with concerning clearance, ground clearance and handling • Cost of new shocks $281 per set • Pros: • Gives the bike a squatter stance • As compared to the rigid, the bike is easier to ride (comfort) Back

Wheel Design Feasibility – 3 D design • Cons: – Requires adding material to the wheel blank – Safety concerns (excess weight) – Machinability • Pros: – Radical custom look – 2 D design • Cons: – Not as custom • Pros: – Machinable – Safer Back

Tire Feasibility – Width over 190 mm • Cons: – Rear wheel in excess of 190 mm will result in a redesign of the XL swing arm • Pros: – Will give bike the massive back wheel look of a chopper – Width equal to or less then 190 mm • Cons: – Rear wheel may appear to be stock • Pros: – 190 mm is a proven good look on an XL – No swing arm of drive redesign is needed Back

Drive System Design Feasibility – Pugh’s method Back

Exhaust Design Feasibility – Right hand exhaust • Cons: – Looks like the majority of bikes on the market • Pros: – XL 883 C is built with and for right hand exhaust – Proper flow of exhaust – Left hand exhaust • Cons: – Proper flow of exhaust may be difficult to obtain on XL – XL 883 C is not built for left hand exhaust • Pros: – Left hand exhaust is not norm, creating custom and radical look Back

Fuel Tank Concepts • Custom designed tank – Incorporate RIT Tiger into tank • Custom fabricate • Custom paint • Commercially available tank Back

Fuel Tank – Feasibility Methods Used • Pros and Cons • Pugh’s Method • Weighted Concept Evaluation – Specifications • Purchase aftermarket tank

Handlebars / Controls – Feasibility Methods Used • Pros and Cons – Specifications • Have custom handlebars with integrated controls manufactured

Ride Height – Feasibility Methods Used • Pros and Cons – Specifications • Lower ride height by 1”

Wheel Design – Feasibility Methods Used • Pros and Cons – Specifications • 2 -dimensional design • In-house fabrication

Tires – Feasibility Methods Used • Pros and Cons – Specifications • 190 mm rear tire • Purchase front tire with matching tread pattern

Drive System Design – Feasibility Methods Used • Pugh’s Method – Specifications • Chain drive

Electrical Design – Feasibility Methods Used • Pro & Con • Pugh’s Method – Specifications • Accent lighting - safety • Blinking frequency dependant on RPM

Exhaust Design – Feasibility Methods Used • Pros and Cons – Specifications • Right Exit Exhaust