ELECTRIC CARGO MOTORCYCLE: FINAL YEAR PROJECT SUMMARY€¦ · · 2013-11-24ELECTRIC CARGO...

ELECTRIC CARGO MOTORCYCLE: FINAL YEAR PROJECT SUMMARY Robert Cuzner, Josh Gallo, Neyland Butt June, 2012

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

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

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

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.”

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

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

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

Identification of User Needs

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

Research User

Needs Matrix

QFD – House of Quality

Concept Generation

Concept Selection C

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Concept Development - Ergonomics

CATIA V5 CAD Model – 5th, 50th, 95th Percentile Males @ 750mm seat height

Field of view for 50th percentile male

Concept Development – Steering Linkage

Concept Development – User Interface

Android Tablet display: Vehicle information, GPS, base station info, troubleshooting

Wireless data provider

Wheel speed + battery state data

Forward Camera (accident disputes, rider behavior)

Flat screen display (for advertising)

Real time tracking

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

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

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


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


Road Irregularities •  Gutters/speed humps/potholes/dips

•  Large stress on chassis •  Very uncomfortable •  Can be dangerous

•  Currently refining Simulink model •  Corresponds spring and damping co-

efficient, sprung and unsprung weight

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


Range Simulation •  ΣForces

•  Driving Patterns

•  Battery Indicator

•  Specify Battery Power

Battery Power & Level

Drag & Thrust

Hill Resistance

Roll Resistance


Vibration •  Weave, Wobble, Capsize

•  Dangerous

•  Eigen Value Plot – Stability

•  Natural Frequency

•  Speed Self-Stability

•  Time Constant of Roll


Evaluation & Testing •  Mathematical

•  Steady Turning •  U-turn •  Slalom •  Lane Change •  Obstacle Avoidance

•  Computer •  ADAMS Simulation •  Solidworks FEA & Fatigue

•  Practical •  Chassis Jig •  Apply Real Loads •  Measure Deflection &

Strain

Chassis Jig

FEA – 300N Load @ Seat

Rear Suspension Mount Front Suspension Mount

Swingarm Mount

Fixed Geometry

300N Load


Conclusion

•  Manufactured & Evaluated Rolling Chassis

Interest

•  Range Simulator & Useful Tools http://www.electricmotion.org/ •  JBike6 http://ruina.tam.cornell.edu/research/topics/bicycle_mechanics/JBike6_web_folder/index.htm •  Motorcycle Dynamics Author: Vittore Cossalter

Thank you for listening

ELECTRIC CARGO MOTORCYCLE: FINAL YEAR PROJECT SUMMARY€¦ · · 2013-11-24ELECTRIC CARGO...

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