DESIGN AND FABRICATION OFMECHANICALLY OPERATED SIDE STAND REMOVER

R. NARAYANAN (Reg.no:21008114067) Mr.K.Thiruselvam M.E. M.RAJESH (Reg.no:21008114086)K. SANTHOSH KUMAR(Reg.no:21008114091)D. SRIRAMKRISHNA (Reg.no:21008114104)C. SATHYA KUMAR (Reg.no:21008114306)

Submitted by Guided by

This project concentrates on to completely reduce the possibility of driving two wheelers without releasing the side stand.

This may suitable for all kind of two wheelers which are driven in gear system with low cost with simple lever arrangement considering as a four bar link.

Since it is cost effective it can be implemented in two wheelers which has first gear shifting in front side.

ABSTRACT

SIDE STAND

• A side stand is a single leg that simply flips out to one side, usually the non-drive side, and the bike then leans against it. Side stands can be mounted to the chain stays right behind the bottom bracket or to a chain and seat stay near the rear hub. Side stands mounted right behind the bottom bracket can be bolted on, either clamping the chain stays or to the bracket between them, or welded into place as an integral part of the frame.

TYPES OF EXISTING SIDE STAND

• Manual stand – operated manually

• Stands with indicators – indicates the position of stand to the driver

• Side stand releasing using motor

• Side stand releasing using hydraulic actuators

CHARACTERISTICS OF SIDE STAND

Motorcycle side stand support the entire weight of the vehicle when it is parked.

They are provided with a spring that pulls it back into position to ensure extra safety. Motorcycle side stand is generally made of strong and extremely durable materials. Two wheeler side stands are generally associated with following features: • Simple to use.

• Some two wheelers have sensitive side stands and needs to be positioned down before leaning the vehicle on them.

• Side stands should be used on flat or level surfaces.

• Most two wheelers do not start until the side stands are in up position.

• Includes a rubber bump for better parking.

  

DESIGN OF THE PROJECT

DESIGN CONSIDERATIONS:

• The extension spring which is used to release the side stand should be properly selected in order to make it with the capability of withstand the load.

• Weight of the materials which are used must me limited. So the weight of the vehicle also be maintained.

• The type of gear shifting whether forward or backward also taken into account

• The end of the lever is designed in such a way that there is no slippage when the lever hits the stand.

• Motorcycle Side stand is generally made of strong and extremely durable materials.

• The most commonly used materials for making motorcycle side stands are

• Steel • Aluminum  • The Side stand is made of Fabricated Steel Sheet Metal Parts, Pipe and Machined Pins. The MIG (CO2) welding process is used.

MATERIALS USED FOR SIDE STAND

The spring used here is tension helical spring. Its specifications are given below:  

•Spring length L = 126mm•Spring diameter D = 44mm•Coil diameter d = 14mm•Thickness t = 2.5mm•No of turns n = 14turns

SPRING SPECIFICATIONS

The mechanical properties of the mild steel used are as follows:  Young’s modulus E = 2.1 * 105 Mpa Density = 7.8 Kg/m3 Yield strength Syt = 250 Mpa Ultimate tensile strength Sut = 410 Mpa Carbon content = 0.2 to 2.1%

Design of spring:From PSG design data book, q = (E*d) / (8 * C3 * n) C = D/d Substituting the known values: C = 44/14 = 3.14 Hence, the value of tension force q is calculated as q = (2.1*105 *14) / (8 * 3.143 * 14)  q = 847.89 N/mmFrom PSG design data book, q = P/yassume that the maximum deflection of the spring as 3 mm ( i.e y=3mm)Substituting the known values in above formula,  847.89 = P/3  P = 847.89*3 = 2543N

DESIGN CALCULATIONS

•Thus the spring force, during working condition of the stand, is calculated. In order to retract the stand to it’s rest position, a force which is greater than this spring force must be applied. The force created during the shifting of gear is used, through suitable linkages, to retract the stand. The L-clamp with given dimensions are welded with the gear shifting lever. Thus, the stand is removed automatically before driving,even if the driver forgets to remove it.

•The dimensions of the L- clamp which is welded with the foot lever are measured as follows: Length of the L clamp = 195 mm Breadth of the L clamp = 50 mm Thickness of the L clamp = 13 mm

Design of foot lever:

Dimension of shaft : Let d = diameter of the shaft P= load acting on the lever = 800 N L= length of the lever = 400 mm τ = allowale shear stress = 410 N/mm2

The twisting moment on the shaft, T = P * L = 800 * 400 = 320*103 N-mm From PSG Design data book, T = (π * τ * d3) / 16 320*103 = (π * 410 * d3) / 16 d = 15.8 = 20 mm The diameter of the boss d2 = 1.6 * d = 1.6 * 20 = 32 mmThe thickness of the bosst2 = 0.3 * d = 0.3 * 20 = 6 mm Length of the boss l2 = 1.25 * d = 1.25 * 20 = 25 mm

Dimension of key: From PSG Design data book, the standard dimensions of the key for a 20 mm diameter shaft are, Width of the key w = 6 mmThichness of the key = 6 mm The twisting moment in key may be given as T = l1 * w * τ * d / 2 800 * 103 = l1 * 6 * 410 * 20 / 2 l1 = 32.5 = 35 mm

It may be taken equal to the length of the boss l2 = l1 = 35 mm

Dimension of rectangular arm: Let t = thickness of arm in mm B= width of arm in mm = 3* t

 Let the distance of the arm from the center of the shaft = 150 mmBending moment at the arm is M = 800 * (400-150) = 200 * 103 N-mm Section modulus of the arm is Z = B2 * t / 2 = 1.5 * t3 mm3

 The tensile bending stress is given by σt = M / Z 210 = 200 * 103 / (1.5 * t3 ) t = 8.6 mm = 10 mmtherefore, B = 3 * 10 = 30 mm

The width of the arm is tapered while the thickness is kept constant throughout. The width of the arm on the foot plate side is B1 = B / 2 = 30 / 2 = 15 mm

AUTOCAD DIAGRAM

PART DIAGRAMS

ASSEMBLED DRAWING

CONSTRUCTION

• The gear shifting pedal is provided with small lever which is projected downwards. This lever can either be welded or bolted at the gear pedal.The lever is tilted in some angle so that it has maximum ground clearance.

• The other lever which is projected from the lever connected to the gear pedal can be welded to have fixed angle .The fixed angle must be positioned in such a way that it should have maximum ground clearance and minimal distance from the stand.

• The main design aspect considered is when force is applied longitudinally to gear pedal, there is maximum displacement achieved to lever which is projected towards the side stand.

• The plate with minimum thickness upto 2mm can be welded along the side stand to avoid slippage since the stand is round in design.

WORKING

• When the two wheeler is in standing condition, the spring in the side stand is subjected to maximum elongation. While the driver starting the motor cycle, there may be a possibility of forget to release the side stand.

• This can be rectified by releasing the side stand when the driver tends to shift the first gear. During gear shifting the force required to shift the gear is transmitted through the lever which is welded to the gear pedal.

• This force makes the lever to experience maximum linear displacement which makes the lever to hit the side stand. This in turn makes the spring to compress in the side stand which tends to release the side stand.

• To avoid slippage, a thin plate of minimum thickness is welded to the side stand for better releasing of the stand.

CHAPTER -5

COMPONENT IMAGES

PARTS PRICE

Gear shifting pedal Rs.500

Low carbon steel rod Rs.100

Labour charges Rs.300

Total Rs.900

COST ESTIMATION AND COMPARISON

ADVANTAGES

DISADVANTAGES OF EXISTING SIDE-STANDS

• Accident prone

• Maximum Fatigue

• Only indicate the position

ADVANTAGES

• Customer safety

• Can form as a ‘Standard Feature’

• Marginal increase in cost

• Improved sales : To face competition.

• Low maintenance: Can be repaired locally

CONCLUSION

• This project concentrates on to reduce completely the possibility of driving two wheeler without releasing the side stand.

• Since it is cost effective, it can be implemented in two wheelers, which has first gear shifting in front side.

• The difficulties in using existing side stands can be overcome using this type of stands.

• Thus the side-stand remover is designed and components where manufactured by suitable finishing processes. All the components were assembled successfully.

Thank you