Rear Derailleur

2016

DESIGN PROJECT By: Jessica Byrne (C14303401), Stephen Scallan (C12453912), Niamh Fahy (C13490928), Ryan Palmer (C13363561), Oliver Hughes (C14722449), Benjamin Campbell (C1444963)

DUE: 9TH DECEMBER 2016 |

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Declaration

To the best of our knowledge and belief, this report is our own work, all source have been properly

acknowledged, and the report contains no plagiarism. The report contains 8417 words, 37 figures and 8

tables.

Name: ____________________ Date: _____________________

Name: ____________________ Date: _____________________

Name: ____________________ Date: _____________________

Name: ____________________ Date: _____________________

Name: ____________________ Date: _____________________

Name: ____________________ Date: _____________________

Abstract

This is a report conducted by six students as part of a 12-week design project. This report is done on a

Shimano rear derailleur. This report covers the history, parts list, tolerances, parameters, the design

specifications, standards, manufacturing process, cost, sustainability a risk analysis and a user manual.

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Table of Contents Declaration ................................................................................................................................................... 1

Abstract ........................................................................................................................................................ 1

Table of Tables ............................................................................................................................................. 3

Table of Figures............................................................................................................................................ 4

Introduction ................................................................................................................................................... 5

History of Bicycle Rear Derailleur ................................................................................................................. 5

Standards ..................................................................................................................................................... 8

Test method .............................................................................................................................................. 8

General ..................................................................................................................................................... 8

Requirements ........................................................................................................................................... 8

Testing ...................................................................................................................................................... 8

Testing components .................................................................................................................................. 9

Safety factor .............................................................................................................................................. 9

Product Design Specifications ...................................................................................................................... 9

Performance ............................................................................................................................................. 9

Maintenance ............................................................................................................................................. 9

Finish ........................................................................................................................................................ 9

Materials ................................................................................................................................................... 9

Weight ...................................................................................................................................................... 9

Aesthetics ................................................................................................................................................. 9

Product life ................................................................................................................................................ 9

Customer .................................................................................................................................................. 9

Life in service ............................................................................................................................................ 9

Safety ....................................................................................................................................................... 9

Environment ............................................................................................................................................ 10

Shelf Life ................................................................................................................................................. 10

Packaging ............................................................................................................................................... 10

Ergonomics ............................................................................................................................................. 10

Competition ............................................................................................................................................. 10

Marketing ................................................................................................................................................ 10

Manufacturing Facilities .......................................................................................................................... 10

Parts List .................................................................................................................................................... 11

Tolerances .................................................................................................................................................. 12

Tolerance discussion .............................................................................................................................. 12

Fitments .................................................................................................................................................. 20

Chain width standards ............................................................................................................................. 21

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Parameters ................................................................................................................................................. 22

Sketches .................................................................................................................................................... 24

Block diagram ............................................................................................................................................. 26

Manufacturing Process ............................................................................................................................... 29

Costing and sustainability ........................................................................................................................... 30

Costing ................................................................................................................................................... 30

Sustainability ........................................................................................................................................... 30

Environmental Impact ............................................................................................................................. 31

(calculated using CML impact assessment methodology) ....................................................................... 31

Component Environmental Impact .......................................................................................................... 32

Calculations ................................................................................................................................................ 33

Assumptions made at beginning of calculations ...................................................................................... 33

Aim of Calculation ................................................................................................................................... 33

Calculations for Average Human ............................................................................................................. 33

Calculations for Athlete (Bradley Wiggins): ............................................................................................. 35

Comparison 0.649Nm vs 3.767Nm ......................................................................................................... 36

Spring Force ........................................................................................................................................... 36

Risk Analysis .............................................................................................................................................. 37

User manual ............................................................................................................................................... 38

Bibliography ................................................................................................................................................ 39

Table of Tables

Table 1 Job Description ................................................................................................................................ 5

Table 2 Parts List ........................................................................................................................................ 11

Table 3 metal injection moulding tolerances ............................................................................................... 12

Table 4 Tolerances ..................................................................................................................................... 18

Table 5 description of parts in sketch .......................................................................................................... 25

Table 6 description of parts in block diagram .............................................................................................. 29

Table 7 Component Environmental Impact ................................................................................................. 32

Table 8 Metals in consideration for choice of spring ................................................................................... 36

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Table of Figures

Figure 1 Parallelogram Derailleur ................................................................................................................. 6

Figure 2 simplex cable shifter derailleur ........................................................................................................ 6

Figure 3 Campagnolo the Gran Sport ........................................................................................................... 7

Figure 4 Suntour Cyclone ............................................................................................................................. 7

Figure 5 manufacturers of derailleurs ........................................................................................................... 8

Figure 6 Parts ............................................................................................................................................. 11

Figure 7 Tolerances .................................................................................................................................... 12

Figure 8 Pressing Tolerances ..................................................................................................................... 13

Figure 9 plastic injection moulding tolerances ............................................................................................. 13

Figure 10 injection moulding Tolerances .................................................................................................... 14

Figure 11 Pulley Movement and tolerance .................................................................................................. 14

Figure 12 Axle fitment and tolerance .......................................................................................................... 15

Figure 13 Bicycle chain allowance .............................................................................................................. 15

Figure 14 Overall Size ................................................................................................................................ 16

Figure 15 maximum dimensions ................................................................................................................. 16

Figure 16 Fitments between rivet and front bracket 1 ................................................................................. 17

Figure 17 Fitments between rivet and front bracket 2 ................................................................................. 17

Figure 18 Tolerances .................................................................................................................................. 18

Figure 19 part facts ..................................................................................................................................... 19

Figure 20 Key Fitments............................................................................................................................... 20

Figure 21 retaining rings ............................................................................................................................. 20

Figure 22 axial fitments............................................................................................................................... 21

Figure 23 chain length ................................................................................................................................ 22

Figure 24 Sketch 1 ..................................................................................................................................... 24

Figure 25 Sketch 2 ..................................................................................................................................... 25

Figure 27 pully wheel mould ....................................................................................................................... 29

Figure 28 Manufacturing and Use Regions ................................................................................................. 30

Figure 29 Sustainable Design diagram ....................................................................................................... 31

Figure 30 Environmental Impact Assessment ............................................................................................. 31

Figure 31 Component Environmental Impact .............................................................................................. 32

Figure 32 Bike chain with rear derailleur ..................................................................................................... 33

Figure 33 90 Degrees from Cog to Chain ................................................................................................... 34

Figure 34 Bracket bolting ............................................................................................................................ 38

Figure 35 Connecting Gear Cable .............................................................................................................. 38

Figure 36 Top Adjustment Screw ................................................................................................................ 38

Figure 37 Lower Adjustment Screw ............................................................................................................ 38

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Introduction This is a report that discusses the rear derailleur on a bicycle. A rear derailleur works by moving the chain between rear sprockets and taking up chain slack caused by moving to a smaller sprocket at the rear or a smaller chaining by the front derailleur. The table (1) below shows the topics cover in this report and who done each of the topics.

Job Description Name

Introduction/ Abstract Jessica

History Stephen

Standards Ryan

Product Design Specifications Oliver

Parts List Stephen

Tolerances Stephen

Parameters Ben

Sketch’s Niamh

Function Block Diagram Ryan

Manufacturing Process Jessica

Costing Jessica

Sustainability Jessica

Calculations Oliver & Ryan

Risk Analysis Niamh

User Manual Niamh

CAD Design (Solidworks) Everyone

Solidworks Assembly Jessica

Presentation Formatting Niamh

Report Formatting Jessica Table 1 Job Description

History of Bicycle Rear Derailleur Derailleur gears are a variable-ratio transmission system commonly used on bicycles consisting of a chain, multiple Sprockets of different sizes, and a mechanism to move the chain from one sprocket to another. They are referred to as gears in the bike world, these bicycle gears are technically Sprockets since they drive or are driven by a chain, and are not driven by one another.

Modern front and rear derailleurs typically consist of a moveable chain-guide that is operated remotely by a Bowden Cable attached to a shifter mounted on the handlebars. When a rider operates the lever while pedalling, the change in cable tension moves the chain-guide from side to side, "derailing" the chain onto different sprockets.

Derailleur is a French word, there were many designed during the 19th century but the most prominent is the Protean two speed Derailleur which was on the Whippet safety bicycle.

Pail de Vivie was a French tourist, writer and cycling promoter who wrote under a different name Velocio he invented a two-speed rear derailleur in 1905 which was used on his trips in the alps passes

Some of the early designs used rods to move the chain between the various gears,

Other early designs were the Champion Gear which somewhat resembled the modern-day Derailleurs systems, the technical of this system was that it was chain stay mounted paddles and single lever chain tensioner mounted on the downtube.

These systems also with the rod systems that I mentioned before were superseded by the Parallelogram Derailleur which is what out derailleur system is based on.

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Figure 1 Parallelogram Derailleur

Then in 1937, the derailleur system was introduced to the pinnacle of cycling sport, the Tour De France. As in the modern world they were easily able to change between the multiple gears without having to remove the wheel to change the gear that is being driven.

This was necessary regularly in stages as the terrain changed. It wasn’t till the following year that derailleur became common when simplex introduced a cable shifter derailleur.

Figure 2 simplex cable shifter derailleur

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Then in 1949 Campagnolo introduced the Gran Sport which was simply a more refined version of the previous derailleurs. It didn’t sell well as a cable operated Parallelogram rear derailleur

Figure 3 Campagnolo the Gran Sport

When 1964 came around the next significant derailleur evolution was by Suntour.

They had invented a slant parallelogram rear derailleur, which crucially let the jockey pulley maintain a somewhat constant distance from the varied sized sprockets which helps the shifting become easier. Crucially once the patents expired; other manufactures could get in and adopt the design. This has led to the current trend of Slant Parallelogram rear derailleurs being used in all forms of cycling.

Figure 4 Suntour Cyclone

Before the 1990s many manufacturers made derailleurs including Simplex, Huret, Galli, Mavic, Gipiemme, Zeus, Suntour, and Shimano. But the successful introduction and promotion of indexed shifting by Shimano in 1985 required a compatible system of shift levers, derailleur, sprockets, chainrings, chain, shift cable, and shift housing.

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Figure 5 manufacturers of derailleurs

Today Campagnolo, Shimano, and SRAM are the three main manufacturers of derailleurs, with Italian manufacturer Campagnolo only making road cycling derailleurs and Shimano making both road and offroad. American manufacturer SRAM has been an important third, specializing in derailleurs for mountain bikes, and in 2006 they introduced a drivetrain system for road bicycles.

Standards

Test method Secure the Rear Derailleur in a fixture that will hold the Rear derailleur firmly but will allow the individual components to movie freely and without deforming any components. Applying a certain force on the inside of the arm and on the top arm. This will allow both springs to operate and will prove whether all the components can move in sync with each other. This will also show the failure rate.

General Each component has their own stress and failure rate and are all different to each other. For this reason, the test procedure requires all components assembled and for the tolerances and tightening to be of the finally selling produced.

Requirements For the test procedure, all individual components need to be inspected so that there are no flaws in any component that will throw off the results. These flaws include visible cracking, notches out of the material or even excess material that may cause friction.

Testing The results from the tests will show if the Rear Derailleur is strong enough to carry out its procedure. If not, then the tests will show where and how the failure happened and then a solution can be found. The testing will also show the maximum force that the springs can with stand and the distance the component can movie the chain from left to right meaning the number of gears that can be attached to the bike. The materials for each component will wear differently especially on a different type on material, meaning a maintains may have to be applied or a different design or material will need to be picked. Therefore, the test is very valuable.

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Testing components Test each component separately will show how each component will deform or fail. This can be useful for starting off, as try with different materials, thickness and shapes will give different results allow the best material, shape and thickness to be chosen.

Safety factor Once the Rear Derailleur fails at speed, series injury’s or fatalities may take place. Because of this a high safety factor is needed to pervert this. A safety factor is the failing force or angle, minus a certain percentage for the force or angle, meaning the component will never reach its failure rate.

Product Design Specifications The Rear Derailleur constantly keeps tension on the chain so that the cogs can’t slip as they rotate. It also guides the chain from gear to gear. The produced Design specification (PDS) for a rear derailleur is as follows:

Performance To withstand a heavy impacted without altering the shape or its safety features. To constantly keep the chain under tension and in line. To have a long-life span so it can last as long as the bike.

Maintenance The maintenance is minimal on the rear derailleur. The springs and joints need to the greased every few weeks to prevent rusting and corrosion. This will allow the component to run smoothly and flawlessly. The cable may need to be adjusted to re a line the chain or to adjust the tension on the chain. This can be achieved be adjusting the plastic connecter that holds the braided hose in place and allows the cable to fix to the rear derailleur.

Finish The Rear derailleur housing needs to have a tough finish to withstand the impacts of the crashes. The housing needs to be corrosion resistance so that it minimises the possibility of damaging the springs, cable and chain.

Materials The materials would need to be light weight so it's easy to install and won’t disrupt the balance of the seat. The materials would also need to be durable due to the high impact loads. The battery pack or power source will need a water proof protecting material so it can't fail.

Weight The total weight of the rear derailleur is 314 grams

Aesthetics The housing needs to the aesthetical pleasing yet functional, strong and small.

Product life The life of the product should match that of the bike, unless involved in a serious collision. Then buying a new rear derailleur or new parts for the damage derailleur can be sourced easy enough by contacting a bike dealer or the company that produce the rear derailleur its self.

Customer The main costumer for this produced would be bike manufactures and bike parts provider.

Life in service Between the chain stretching and the components wearing, adjusting the rear derailleur will take place every so often mainly when it’s not selecting gear as easy. Besides this the rear derailleur is a heavy-duty component that should last the length of the bike or even long.

Safety The rear derailleur needs to be heavy duty due to the speed the bike can achieve. Once the bike is at the top speed and the rear derailleur fails the back wheel may lock causing the bike to get out of control. The

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rear derailleur housing needs to be safe and secure to prevent the spring force from catching fingers or skin when adjusting or replacing the component or complements.

Environment All the components must be able to with stand cold temperatures, for Ireland that would be 1 or 2 degrees but in Canada that would be -19 degrees. In sunnier countries, the components would need to with stand temperatures of up to 47 degrees. The housing must be able to with stand moisture, splashes, grit and salt.

Shelf Life The shelf life for the component would be infinite. As the component is being fitted it will be connected to the cable and adjusted, so as long as it doesn't get damaged on the shelf, it will fit with ease.

Packaging The product, once its assembled would be packed into its purchase box, made from cardboard, along with the instructions on how to recalibrate, the warranty and information on the product. Then that box would be stacked with the rest of the boxes and placed in a reinforced packaging box made from cardboard. That box would then be loaded onto a pallet along with other boxes and shrink wrapped together and placed in the delivery truck.

Ergonomics The rear derailleur must be easily attached to a various range of bikes easily. The rear derailleur should be able to be fitted by one person in 10 minutes. The rear derailleur must not protrude from the bike’s frame as to have a negative effect on the cyclist. . It must also be easy to store, so the packaging can't be an unusual shape and there can't be pieces that need to be check week, it needs to be durable.

Competition There’s many competitors for this component but it mainly comes down to price and brand name. The more the name is known the more likely that company will be selected for the product.

Marketing This product was designed for a range of bikes, so the marketing would be worldwide in the bicycle industry.

Manufacturing Facilities The main facilities that would be needed to produce this product in large quantities would be, a Manufacturing Facility to produce the parts needed for the rear derailleur, an Assembly facility to assemble the rear derailleur and a packaging / distribution facility to package and transport the good.

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Parts List

Figure 6 Parts

Number Shimano Part No.

Product Specifications Planned materials

One Y54W11000 B-axis cap Plastic

Two Y52130010 E-ring (φ6mm) Low quality Steel

Three Y54Y24120 B-tension spring Stainless Steel

Three Y5UU14000 B-tension spring (for the SS type / Seitsume bracket type)

Stainless Steel

Three Y53X12000 B-tension spring (for the SS type / bracket type)

Stainless Steel

Four Y53X98020 Bracket (with axis) Seitsume Aluminium alloy

Five Y54M98030 Set bolt (M5 × 11.5) and nut Stainless Steel

Five Y53X98030 Set bolt (M5 × 14.5) and nut Stainless Steel

Six Y52198230 Stroke adjustment bolt (M4 × 14.5) and plate Stainless Steel and Plastic

Seven Y54Y98060 Wire fixing bolt unit Stainless Steel

Eight Y54N98030 Outer casing adjustment bolt unit Stainless Steel and Plastic

Nine Y54Y21000 P axis cap Plastics

Ten Y54Y24110 P tension springs (for the SS type) Stainless Steel

Ten Y52228000 P tension springs (for GS type) Stainless Steel

Eleven Y54Y98020 Right plate (with axis) for the SS type Aluminium Alloy

Twelve Y52472020 4-524 72020 DM pulley bolt unit Stainless Steel

Thirteen Y56398030 Pulley unit Aluminium Alloy

14 Y53922010 Left plate (for the SS type) Aluminium Alloy

14 Y54L09000 Left plate (GS type) Aluminium Alloy

Fifteen Y5UU13000 B-tension spring (SS type / for direct mounting type)

Stainless Steel

Fifteen Y54Y24100 B-tension spring (GS type / for direct mounting type)

Stainless Steel

Sixteen Y54Z98080 Bracket axis (with spacers) for with straight Stainless Steel

17 Y54P98060 Bracket (with axis) for direct mounting type Aluminium Alloy

Eighteen Y56398100 Pulley set (10 pairs) Plastic Table 2 Parts List

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Tolerances Tolerances are critical to the assemble ability of products but excessively tights tolerances will make the products excessively expensive. In this document, I will indicate the most critical tolerances on the component using the below drawing and perform analysis on some of the parts regarding my suggested tolerances. Due to Shimano still producing a variety of the below derailleur we are unable to have exact tolerances for the Tourney RD-TY18-GS (Medium Cage)

Engineering tolerance is the permissible limit or limits of variation in: a physical dimension, a measured value or physical property of a material manufactured object, system, or service.

Tolerance discussion

Figure 7 Tolerances

The three parts above are what I have refenced to do with the below tolerances of

1. Metal Injection moulding

2. Sheet Metal tolerences

3. Plastic Injection moulding tolerances

1. So for the axles which there are two main ones the injection metal mounding would be between the typical and the best possible, around .1mm. This is down to there not being enough allowable space in the axle housing.

For the rest of the variables it would come in as between the typical and best possible

The metal injection moulding isn’t relevant to the pulley wheels as the they are made of plastic.

For the side of the cage I would say that it would come in much closer to typical because as long as it is flat on either face there is enough allowable bolt shaft left to take in some possible poor tolerances.

Table 3 metal injection moulding tolerances

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2. For the Axles only the injection mounlding is relavent. The pulleys are also not relavent to this kind of manufacture because they are made form a plastic

material. The sheet metal tolerance are very much to do with the cage sides because this it the most likely way they were manufactured, But again as long as the tolerance stay belows the bolt shaft length there shouldn’t be an issue.

Figure 8 Pressing Tolerances

3. Then for the plastic injection moulding is only relavent to the pulley wheels, We used polypropylene we found that +/- .125mm because our pulley is 8.72mm As with the cage designs aslong as added material in the design doesn’t do above the bolt length there should be no issue

Figure 9 plastic injection moulding tolerances

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Figure 10 injection moulding Tolerances

The materials used for our derailleur will generally be cheap due to the mass production of rear derailleurs for this reason there is no fine tolerances in the derailleurs construction.

Pulley Movement and tolerance

Figure 11 Pulley Movement and tolerance

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Fig. (11) is to show the distance that is set between each of the pulley wheels, this one of the most important relationships the derailleur has with the bicycle. Without the maintaining this distance correctly for the entire bike this is fitted to, then this is a problem. Although from the above photo it can be seen that shimano has made aditions to the pulley wheel, of the solid metal bearing and two metal caps, which allow little to no tolerance of movment +/- 1mm movement between the pulley wheels

Axle fitment and tolerance

Figure 12 Axle fitment and tolerance

Here is show the tolerance between the axial housing and axial do to the material they are made of and the relatively low forces they are under I feel there would be no negative tolerance. But as can see there is nearly a +.5 mm all around the axle. This is also a press fitment.

Bicycle chain allowance

Figure 13 Bicycle chain allowance

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As I have researched tolerances are as simply as the size of a part, for this I have measured between the two cage walls to find the maximum chain width that can be put into this derailleur. Coming in at 8.72mm this means that our derailleur can take a five-speed chain of 7.8mm with an allowable tolerance of +/- .47MM.

Overall Size

Figure 14 Overall Size

From this you are given several figures, but dX is the one that tells us the max height of the derailleur.

Figure 15 maximum dimensions

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The above dY shows the greatest width of the derailleur.

The derailleur can extend further in both directions but only when under severe load.

The following Fig. () are showing the Tolerance/Fitments between the No thread rivet and the front bracket of the Parallelogram linkage

Figure 16 Fitments between rivet and front bracket 1

Figure 17 Fitments between rivet and front bracket 2

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The below Fig. () shows the tolerance

Figure 18 Tolerances

Table 4 Tolerances

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The Solidworks over all part facts

Figure 19 part facts

The above Fig. (19) was taken from a Solidworks, it is some many dimensions of the derailleur.

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Fitments

Figure 20 Key Fitments

In the above Fig. (20) we have some of the key Fitments shown as this is the contact point between derailleur and bike chain. Using 2 small pulley bolts, the two sides of the medium length cage are held together using 2 bolts that have been manufactures into left plate of the cage. This is seen as interference fit, this is down to the use of the two materials inter fearing which each other i.e. the thread. This is also an element of friction going on between both metal materials keeping the fit together.

Figure 21 retaining rings

Above in Fig. (21) is a small step on from Fig. (20) but what can be see here is main working of the derailleur away from the chain. The two highlighted retaining rings are the key to the entire derailleur. They attach the cage to the parallelogram linkage which provides the horizontal motions to the derailleur. Then with the lower retaining ring the entire derailleur is attached via the B knuckle bracket with axle to the bike. Both retaining rings are held on using an interference fit (friction/press fit). They are literally pushed into place and their small diameter keeps a strong fiction fit around the axle which has a manufactured indent.

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Figure 22 axial fitments

Chain width standards Fig. (22) is showing the axial tolerance and fitment which is a press fit and the tolerance is around the 1mm so it would be seen as a fine tolerance

Standards for Metric fits

ISO-R286 and ANSI B4.14831

Here are the external widths for the derailleur chains that you will likely find on transport bikes. Manufacturing tolerances can be one tenth of a millimetre.

5 speed: 7.8mm

6 speed: 7.8mm

7 speed: 7.3mm

8 speed: 7.1mm

9 speed: 6.8mm

At ten-speed, things get complicated because different manufacturers used different external widths, but they’re all thinner than 6.8mm.

Nine-speed chains are generally more expensive than eight-speed ones. Ten-speed chains are more expensive again.

Eight-speed chains are backwards compatible (they work with five-speed, six-speed, seven-speed and eight-speed cassettes).

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Parameters Parameters are numerical or other measurable factors that defines a system or sets the conditions of its operation. Parameters can also refer to a limit or boundary which defines the scope of a particular process or activity.

Introduction

A bicycle rear derailleur allows gear changes. It moves the chain up and down the cassette, which is a set of increasing diameter gear sprockets, on the rear wheel of the bicycle.

Bicycle derailleurs look like a complicated mechanism at first sight, but this is just a false impression. The basic principle behind them is quite simple. They rely on the mechanism of a mobile parallelogram.

The travel of the whole bike derailleur is limited by two adjustment screws which act as maximum and minimum stops.

Key Parameters

Parallelogram Mechanism

Modern rear derailleurs are built as a parallelogram which has one end attached to the frame, while the other one has a mobile arm that guides and tensions the chain. The parallelogram is actioned thanks to a lever and a cable, which are in turn actioned by the shifters. The shifters are operated by the cyclist and are positioned on the handle bars of the bicycle. Also, the derailleur is responsible for keeping the mobile arm parallel with the sprockets so that it aligns perfectly with them.

Stops

The stops are adjustable screws to keep the derailleur within the minimum and maximum gear sprockets. The stops can be adjusted depending on how many different number of gear sprockets are on the bicycle’s cassette. If there were no stops on a derailleur, nothing would be preventing the chain from falling off and onto the ground or falling onto the spokes. For this reason, it is very important that the stops are measured perfectly in the manufacturing of the rear derailleur.

Cage

The derailleur cage is a swinging link, with two pulleys. As the chain moves between different size sprockets, the amount of chain required changes.

If a smaller diameter gear is selected on the cassette, there will be a shorter chain length required. The derailleur cage’s movement picks up this slack.

Figure 23 chain length

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Tensioner Spring

The tensioner spring moves the cage to provide gear changes and to keep the chain in tension. If the spring wears over a long period of time, it may cause the chain to start ‘skipping’. This is when the chain slips off the teeth while cycling because there is not enough tension on the chain.

Chain Capacity

Chain capacity is the amount of potential slack chain the rear derailleur cage can handle. It is the measurement of how well it can keep a chain in sufficient tension. Since it’s expressed as a number of teeth, it’s derived by the following equation:

Chain capacity = (biggest cog teeth – smallest cog teeth) + (biggest chainring teeth – smallest chainring teeth)

Because it’s based on the number of teeth of the entire drivetrain, the effective chain capacity varies from bike to bike. Drivetrain manufacturers therefore have to cater for these variations

Different Cage Sizes

The manufacturer Shimano, who manufactures the rear derailleur we used for the project has three different sized derailleurs. They are SS (short-cage), GS (medium-cage) and SGS (long-cage) derailleurs. The derailleur we used has a GS medium cage size.

The SS derailleurs have a maximum chain capacity of 33 teeth or less. These are usually built for road bikes. Some down hill mountain bikes also use a short-cage derailleur.

The GS derailleurs have a higher maximum chain capactiy of 37T to 39T or less. This is usually the longest cage offered for road bike rear derailleurs, but also the default “short” option offered for their mountain bike counterparts.

The SGS has the longest cage and this is exclusively the domain of mountain bikes or any unit marketed for touring bikes. A typical unit sees chain capacity well into the 43-44T range.

Indexed gears

‘Indexing’ is a system where the shifter clicks into preset positions corresponding with individual gears. This allows for a smoother and more efficient gear change than the older system which relied on friction alone.

Indexed rear derailleurs have a different action than friction ones. However, indexed derailleurs are compatible with friction shifters. Certain types of shifter have both index and friction modes.

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Sketches

Figure 24 Sketch 1

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Table to Accompany Isometric Sketches

Identifying number Name Number Required

1 B- Axle Cap 1

2 Stop Ring 2

3 B-Tension Spring 1

4 Adapter w/Mounting Shaft 1

5 Adapter Screw & Nut 1

6 Stroke Adjusting Screws & Plate 1

7 Cable Fixing Bolt Unit 1

8 Cable Adjusting Bolt Unit 1

9 P-Axle Cap 1

10 P-Tension Spring 1

11 Outer Plate w/Mounting Shaft 1

12 Pulley Bolt 2

13 Pulley Unit 2

14 Inner Plate 1

15 Casing 1 Table 5 description of parts in sketch

Figure 25 Sketch 2

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Block diagram Below is a chart that describes how a rear derailleur works.

The Gear Selector is

rotated to the required

gear.

Adjusting the

gear selector

cable.

Displaying

the gear that

is chosen.

The gear selector cable travels through a braided

hose until it reaches a notch in the frame of the bike

which is located underneath the frame.

The cable is now bear and as it reaches the bottom

bracket there is a plastic guide that guides the cable

to the second notch.

As the cable reaches the second notch, which is located

at the back of the bike where the seat stay and chain

stay meat, the cable is fed back through a braided hose.

The cable is then fixed to the barrel adjuster which is

connected to the outer hinge of the rear derailleur.

As the hinge moves diagonally up and down from

the cable being adjusted, the inner and out plate that

hold the plastic cogs are moved in parallel with the

hinge.

The barrel adjuster,

adjusts the distance of the

derailleur from the

sprocket cluster (rear

gears), to allow smoother

gear changing.

Braided hoses are used

so the cable stays under

tension and protected

from the elements and

from being snagged.

As the cable moves,

the hinge adjusts

causing a spring to

compresses or release.

The hinge puts the

chain under enough

tension to prevent the

chain from slipping and

to away maximum

power transfer to the

rear wheel. This allows

the hinge to stay in the

desired location. The

plastic cogs have inner

steal sleeves to

prevent the plastic cog

from wearing. The

plastic cogs allow the

chain to rotate

smoothly and freely.

The inner and out

plates prevent the

chain from disengaging

these plastic cogs.

The chain

converts the

movement from

the chain rings to

the sprocket

cluster (rear

gears). To allow

the chain to move

up and down the

sprocket cluster

the rear derailleur

is needed.

The cogs are used for

guiding the chain to the

right gear.

Once the right gear has

been engaged then. The

possess is over until a

new gear is required.

27 | P a g e

below is a block diagram of how a rear derailleur works.

28 | P a g e

29 | P a g e

Number Description

1 Gear Selector, rotates forward and back

2 Gear selected shown on plastic display and the tension in the cable coming from the gear selector is changed.

3 Cable in Braided hose travels down the front of the bike to the underneath of the frame.

4 Cable travels through a guide on the bottom of the crank.

5 Cable becomes bare from the guide under the crank to the braded hose at the rear of the bike.

6 The braided hose at the rear of the frame is connected to the rear derailleur.

7 The rear derailleur is connected to the rear of the frame that holds the chain in place and under tension.

8 The chain travels through the rear derailleur, the back gearing and the front gearing, linking the three components together.

9 Front gearing.

10 This is a diagram the shows the chain, rear derailleur, front gears and rear gears all in position and linked together.

Table 6 description of parts in block diagram

Manufacturing Process There are two main types of manufacturing processes required to make a rear derailleur these are; Injection Moulding and Stamping.

Injection moulding is a manufacturing process for producing parts by injecting material into a mould. For manufacturing a derailleur both metal injection moulding and plastic injection moulding are used. Fig. (27) shows the mould used for producing the pully wheels.

Stamping (pressing) is the process of placing flat sheet metal into a stamping press where a tool and die surface forms the metal into shape.

Figure 26 pully wheel mould

30 | P a g e

Fig. (28) below shows that the derailleur is Manufacturing in Asia and the bulk of the derailleurs made are sold in the USA. This is due to a lot of bicycle companies are American.

Manufacturing Region

Use Region

Figure 27 Manufacturing and Use Regions

Costing and sustainability The costing and sustainability have effects on the price, human opinion, and the environment. Over the past couple of years’ people have become more concerned about how products they us effect the environment. With a lot of laws and regulation about how products affect the environment. Both these factors increase the costing and therefore the price of a product.

Costing How a product is made, the quality of materials used in production, the efficiency of a manufacturing plant all have an influence of the costing. Material prices are as followed aluminium alloy (€1.89 per kg) polypropylene (€1.62 per kg), stainless steel (€5.23)[8], as it can be seen the steel is much more expensive per kg compared to both the aluminium alloy and polypropylene. The reason behind this is that the components that are made of steel are much more critical to the overall derailleur because it these fail it will have a greater effect on the derailleur.

Sustainability Product lifecycle sustainability is an approach to managing the stages of a product's existence so that any negative impact on the environment is minimized. Environmental Impact Assessment is the process that anticipated the effects on the environment of a product is measured.

Carbon-dioxide and other gasses which result from the burning of fossil fuels accumulate in the atmosphere which in turn increases the earth’s average temperature. Carbon footprint acts as a proxy for the larger impact factor referred to as Global Warming Potential.

Sulfur dioxide, nitrous oxides other acidic emissions to air cause an increase in the acidity of rainwater, which in turn acidifies lakes and soil this is called Air Acidification. These acids can make the land and water toxic for plants and aquatic life.

Total Energy Consumed is the measure of the non-renewable energy sources associated with the part’s lifecycle.

When an overabundance of nutrients is added to a water ecosystem, eutrophication occurs which causes an overabundance of algae to bloom, which results in the death of both plant and animal life. This is called Water Eutrophication.

31 | P a g e

Figure 28 Sustainable Design diagram

Fig. (29) shows the important areas of product lifecycle sustainability. These areas need to be carefully

looked at when an environmental impact assessment is carried out.

Environmental Impact

(calculated using CML impact assessment methodology)

Figure 29 Environmental Impact Assessment

32 | P a g e

Fig. (30), show the Four Areas of Environmental Impacts of one product. As it can be seen the majority of the negative environmental impact is caused due to the choose of the materials used on the sustainable design diagram Fig. (29) this is the raw material extraction and processing. The manufacturing of the product causes the second amount of negative impact on the environment again in the sustainable design diagram Fig. (29) this is the part manufacturing and part assembly stages are causing this. There is no negative environmental impact caused by the use of the derailed. Both transportation and end of life respectably have a very small amount of negative impact on the environment compared to the manufacturing and materials.

Component Environmental Impact Component Carbon Water Air Energy

Bracket 0.278 6.4E-5 1.9E-3 3.4

Outer plate 0.253 5.8E-5 1.8E-3 3.1

Inner plate 0.198 4.5E-5 1.4E-3 2.4

Front Bracket 0.153 3.5E-5 1.1E-3 1.9

Pulley Wheel 2 0.102 2.3E-5 7.1E-4 1.2

Big Spring 0.093 2.1E-5 6.5E-4 1.1

Back Bracket main body

0.074 1.7E-5 5.1E-4 0.902

Small Spring 0.028 1.3E-5 1.7E-4 0.339

LBracket 0.027 6.1E-6 1.9E-4 0.326

Inner Spring 0.021 9.1E-6 1.2E-4 0.246

Table 7 Component Environmental Impact

Figure 30 Component Environmental Impact

it can be seen from the table. (7) and Fig. (31) above that the components that are red are the most unsustainable, the grey components are the more sustainable. The green components are products the company buys rather than manufactures due to the availability of these products such as the rivets and springs. The Carbon footprint, Air Acidification, Water Eutrophication and the Total Energy Consumed are all considered when determining the sustainability of the different components

33 | P a g e

Calculations

Assumptions made at beginning of calculations 1. No friction on the bearings

2. The terrain at which the bike was speeding across does not slow it down in any way i.e. Flat smooth surface

3. No environmental elements in which a bike would encounter whilst speeding

4. Bike was in a vacuum

5. A gearing ratio was excluded

Aim of Calculation Aim of calculations is to find out how much force and torque is required in a chain on a bike to move the rear derailleur and its bike with it. A material will then be determined for the multiple springs in a selected rear derailleur.

Figure 31 Bike chain with rear derailleur

Prior calculations, a bike ratio must be known.

A selected bike with rear derailleur has wheel size 26 inches which is approximately 0.7m in diameter. Bike chains depend on the speed at which a bike is designed for example a racer bike is designed to go at a faster speed than a normal road bike therefore it has a thinner chain and wider gap between the sprockets in a chain [1]. It’s also to allow correlation between the gears, the chain and the wheel size of a bike as miscorrelation can cause a chain to wear faster. This shows that a mountain bike has a thicker chain and less gaps between the sprockets in its chain typically. A selected bike with a selected rear derailleur has a gear of speed of 7 [2].

Calculations for Average Human

An assumption was made based off a reference [3], that a normal human being i.e. not an athlete, could make a bike move from 0 – 22 Mph in 20 seconds, with all assumptions stated at the start of this section.

22 Mph = 35.4 Km/Hr

This was the speed a selected rear derailleur would have to move at. A speed equation was then brought

into account: 𝑎 =𝑢𝑡+𝑣

𝑡

34 | P a g e

It was assumed that:

U = 0 𝑚/𝑠

T = 20 seconds

V = 35. 4 Km/Hr = 9.80 𝑚/𝑠

From this it can be calculated that the acceleration is 0.49150 𝒎/𝒔−𝟐

It is known that the force of an object is equal to its mass multiplied by its acceleration. A known weight of a bike and an average human was found.

Weight of bike: 16.9 kg [2]

Weight of average human (Global): 62kg [4]

Total weight= 78.9kg

Using formula 𝐹 = 𝑚×𝑎 with a equal to 0.49150 𝑚/𝑠−2

F = 38.779N

In order to find a torque required for a specific chain, the diameter of a derailleur’s cog teeth must be known in order to know specific chain size.

The diameter of a cog tooth on a specific derailleur is 32.55mm.

Torque can be found by multiplying a radius by a force by sine of an angle:

T = 𝑟𝐹𝑆𝑖𝑛∅

Figure 32 90 Degrees from Cog to Chain

The angle at which a chain meets a cog tooth on a derailleur is 90° as shown in Fig. (33).

Sin (90) = 1

35 | P a g e

F = 38.779

r = 16.275mm

Torque required to move cog tooth in derailleur is equal to 0.6495Nm.

Based off this figure, the right chain size can be determined.

Calculations for Athlete (Bradley Wiggins): An assumption was made off the basis of athlete Bradley Wiggins, famous athletic cyclist ref [5], to make a comparison between a normal human and an athletic cyclist. The same method approach was used.

In cycling, however, there is a maximum bike weight that the Union Cycliste Internationale (UCI) which are the union in charge of competitive bike racing, allow competitive cyclist to race with. This weight in kilograms is 6.8kg [6]. For this comparison, this very fact was ignored as it would be unfair to an average human.

Bradley Wiggins weighs 76kg [5]

76 + 16.9 = 92.6kg

Total weight = 92.6kg

80.5 Km/Hr [7] = 22.36 m/s

This was the speed a selected rear derailleur would have to move at. A speed equation was then brought

into account: 𝑎 =𝑣−𝑢

𝑡

It was assumed that:

U = 0 𝑚/𝑠

T = 20 seconds

V = 22.36 m/s

acceleration = 2.5 𝒎/𝒔−𝟐

Using formula 𝐹 = 𝑚×𝑎 with a equal to 2.5 𝑚/𝑠−2

F = 231.5N

Repeating the same method that was found to acquire a torque from an average human, a torque for Bradley Wiggins was acquired.

Although there is a change of bike weight, the same rear derailleur was used in calculations.

Therefore;

Diameter of cog teeth is 32.55mm

Torque can be found by multiplying a radius by a force by sine of an angle:

T = 𝑟𝐹𝑆𝑖𝑛∅

Sin (90) = 1

F = 231.5N

r = 16.275mm

T = 3.767Nm

36 | P a g e

Comparison 0.649Nm vs 3.767Nm This means that a chain that could last longer and maybe was made of a stronger material would be needed for Bradley Wiggins compared to an average human. For an average human, not a lot of torque is needed. This would suggest that a typical 7 speed chain would be needed compared to chain that is closer to 9 or 8 speed for an athlete.

Spring Force The diameter of the rear derailleur as stated prior to this calculation is 32.55mm. Upon further investigation on the teeth of a selected rear derailleur, it was found that from a Solidworks CAD model to be 10.77mm. 7mm was taken away from this to obtain a tooth height.

10.77 – 7 = 3.37mm = 0.037m

From prior calculations, it was seen that the max load on a bike from an average human was equal to 78.9kg. With both figures, a torque and spring force can be acquired for a spring in a selected rear derailleur.

A known metal must be determined for a selected spring before calculating the spring force. The software known as CES Edu pack 2016 [8], was used to find a material. Table. (8) shows the comparison between the different materials to determine a suitable metal. Price per kg, young’s modulus, shearing modulus, Poisson’s ratio, elongation, hardness Vickers and tensile strength are the criteria that was used to choose a suitable material for a selected spring.

After careful consideration, stainless steel was chosen mostly due to its elongation and tensile strength. Although low alloy steel is the cheapest metal in consideration, it lacks the elongation needed for a spring. Mass manufacturing was also taken into consideration. Stainless steel springs are very common compared to low alloy steel springs which are none existent. It is also easier to mould the stainless steel compared to a low alloy steel material. With a material selected the calculations were finalised.

𝑇 = 𝑟𝐹𝑆𝑖𝑛∅

r = 0.01685m

F = 774.009

∅ = 90

T = 13.042Nm

A spring constant would then have to be found to know displacement. This was done with calculations from spring calculator [9]. By knowing an outer diameter, wire diameter, number of coils and the selected material a selected spring is, a spring constant can be found.

Table 8 Metals in consideration for choice of spring

Cast Al-Alloy Low Alloy Steel Stainless Steel

Price per Kg (€/Kg) 1.89 – 2.176 0.5 – 0.544 5.23 – 5.425

Young’s Modulus (GPa) 72 - 89 205 - 217 189 - 210

Shear Modulus (GPa) 25 – 34 77 - 85 74 - 84

Poisson’s Ratio 0.32 – 0.36 0.285 – 0.295 0.265 – 0.275

Elongation (%Strain) 0.4 - 10 3 - 38 5 – 70

Hardness = Vickers (HV) 60 -150 140 - 693 120 - 570

Tensile Strength (MPa) 65 - 386 550 – 1.76𝑒3 480 – 2.24𝑒3

37 | P a g e

From a Solidworks CAD model, these parameters can be found

Wire Diameter :1.6mm Number of coils :10.5

Outer Diameter :12mm Material : Stainless Steel 17-7ASTM A313

With all this information, the spring constant for a selected spring is found to be 1.255N/mm [10]

Risk Analysis This section, Risk Analysis, outlines the risks and failures that are associated with the rear gear derailleur. It discusses potential ways in which the derailleur could fail as well as evaluating these risks and the actions taken to combat them.

It will make use of Failure Mode and Effects Analysis (FMEA) system, which has two types; design and process. Design type is undertaken before the part is produced and highlights its function, while process type is analysing the assembly process of the product after its completion. [11] [12]

The failure most associated with the derailleur is actually its attachment to the bike frame. The derailleur is attached by a bracket, known as the derailleur hanger. This hanger can snap but is more likely to bend. The effect of the hanger snapping is that the derailleur is only partially attached, only through the chain, and gears cannot be changed. The cause of this failure is due to the fact most derailleur hangers are made from stamped aluminium [13] [14]. Stamped aluminium is relatively fragile [15]. However, this material is chosen purposely so that the bracket will bend/bracket rather than the frame of the bike breaking. A new bracket cost under €20 [16] [17] and therefore can be sacrificed to preserve the more expensive frame. The cause of this failure can occur from simply heavy duty use such as long haul journeys, rugged terrain and mountain biking. However, it can also occur from having the wrong gear combination for the type of terrain, but this is rare. With these heavy uses mentioned the occurrence of this failure can be as little as every six months.

A resulting risk of this failure is the fact that if the bracket bends by snagging on the cogs, it can bend in such a way that the spokes become damaged. A much more severe outcome, is if the entire derailleur interacts with the wheel. This can occur from the bracket snapping, or bending far too much, as well as the limiting screw being incorrectly set. If the lower limiting screw is set incorrectly, set too loose, it allows the derailleur to travel too far inwards –past the cogs and towards the wheel. This could entirely destroy the derailleur, cable, housing and the wheel itself. More so, the human injury it could cause is quite dire; a locked back wheel or the entanglement of the derailleur and chain could cause huge damage. If traveling at any speed and suddenly stopping, the cyclist may be thrown from the bike. This then leads in to the aspects of, if the cyclist is wearing a helmet and the surrounding environment for which they will be falling on. The most severe case would result in death, from either a head or neck injury. Paralysis could also occur. However, it is rare for this to occur, with the more likely outcome being the derailleur partially interacting with the wheel, but still allowing for the bike to move until the cyclist can slowly stop –resulting in little injury. The precautions in place are, that if the derailleur hanger breaks, the metal snaps so that the derailleur hangs on the chain but does not interact with the wheel. The position of the derailleur also makes it unlikely for interaction with the wheel as well as the gear cable attaching to the derailleur.

The other failures can occur from ordinary metal fatigue and everyday cumulative damage. Such as the wearing of the sprockets, which results in unsmooth gear change. These can be easily replaced when worn too low. The other obvious failure that could occur, is if the bike itself was in a crash, where there is a side impact which could smash and bend the derailleur.

38 | P a g e

User manual Tools required:

Torque wrench Bike Stand, as rear wheel will need to be elevated

Philips head Screw driver

1. Attach the rear derailleur to the bikes derailleur hanger.

Before tightening the bracket spindle, make sure to not to cause deformation of the hanger/dropout tab due to the B-tension screw.

2. Tighten the bracket spindle bolt through the bracket, frame and bracket nut just enough so that the derailleur will stay on.

3. Using the torque wrench tighten the bolt until it makes a click, setting a value between 3-4 Nm.

4. Starting from the shifters feed the gear cable down to the derailleur, but hold off on securing the derailleur to the cable.

5. Using the Philips head screw driver turn the high/top adjustment screw to line the pulley just below the smallest sprocket. When this screw is turned clockwise the pulley will move inwards to the wheel spokes, and anticlockwise, outwards from the wheel spokes.

6. To connect the gear cable, pull slack and feed it through the groove of the rear derailleur, give tension to the cable by pulling

with a pliers.

7. With the cable connect, shift the derailleur to just below the largest sprocket by turning the low/bottom adjustment screw. When this screw is turned clockwise the pulley will move outwards from the wheel spokes, and anticlockwise, towards the wheel spokes.

8. To use the B tension adjustment screw, place the chain on the largest sprocket and smallest chain ring, and turn the crank arm clockwise. Adjust the guide pulley so that is as close as possible to the sprocket, but not touching. Then, place the chain on the smallest sprocket and repeat the steps, making sure the pulley and sprocket do not touch and the chain has correct tension.

Note

• Wash and lubricate the derailleurs moving parts if shifting gears does not feel smooth.

• Replace the derailleur if adjustment is impossible due to the links being too loose.

• The Derailleur should be periodically cleaned and all moving parts lubricated.

Figure 33 Bracket bolting

Figure 34 Connecting Gear Cable

Figure 35 Top Adjustment Screw

Figure 36 Lower Adjustment Screw

39 | P a g e

Bibliography

[1] http://hub.chainreactioncycles.com/buying-guides/components/chains- buying-guide/ [2] http://www.halfords.ie/cycling/bikes/mountain-bikes/apollo- gradient-mens- mountain-bike [3] http://www.bikeforums.net/fifty-plus- 50/312802-acceleration- rate-bikes.html [4] http://download.springer.com/static/pdf/469/art%253A10.1186%252F1471-2458- 12-439.pdf?originUrl=http%3A%2F%2Fbmcpublichealth.biomedcentral.com%2Farticle%2F10.1186%2F1471-2458-12-439&token2=exp=1479465023~acl=%2Fstatic%2Fpdf%2F469%2Fart%25253A10. 1186%25252F1471-2458- 12-439.pdf*~hmac=0d5bcfa704e14e5cb84b1304e2ab54a8f0770d d1b86e1173b618338f4b9dfc40 [5] http://www.procyclingstats.com/rider/Bradley_Wiggins [6] http://road\.cc/content/tech-news/173097- could-uci- scrap-68kg- weight-limit- 2016 [7] https://answers.yahoo.com/question/index?qid=20121018132406AA1JUuf [8] CES Edu Pack 2016 (2016) Rustat, 62 Clifton Road, Cambridge CB1 7EG United Kingdom: Granta Design Limited [9] http://www.tribology-abc.com/calculators/t14_4.htm [10] http://www.acxesspring.com/spring-constant-calculator.html [11] K. Delaney, Failure Mode and Effects Analysis (FMEA), Engineering Drawing and Design PowerPoint, (2016) [12] www.leansixsigmasource.com [13] www.hangerbike.com [14] www.downtheroad.org [15] www.thebiketube.com [16] www.amazon.co.uk [17] www.evanscycles.com [18] Mountain-Bicycle- Safety Requirements and the test methods, I.S. EN14766 – 2006: (EN) National Standards Authority of Ireland, DIT Library – Database. [19] http://www.sutherlandsbicycle.com/7th_Edition.html [20] http://bicycles.stackexchange.com/questions/7264/how-to-calculate-the-capacity-of-a-rear-derailleur [21] http://www.sheldonbrown.com/chainline.html [22] http://www.parktool.com/blog/repair-help/torque-specifications-and-concepts [23] http://cyclingfortransport.com/bike/components/gears/derailleur-gears/ [24] https://en.wikipedia.org/wiki/Engineering_tolerance [25] https://www.amazon.co.uk/Shimano-Rapidfire- Mountain-Cycling- Shifter/dp/B00AYCNHRW [26] https://www.amazon.com/SRAM-Road- Mountain-Shift- Cable/dp/B005547P8Q [27] http://www.parktool.com/blog/repair-help/cutting- and-sizing- cable-housing [28] http://www.robertsdonovan.com/?p=500 [29] https://www.universalcycles.com/shopping/product_details.php?id=6695 [30] http://mmba.org/forum/viewtopic.php?f=11&t=131570&start=0 [31] http://handsonbike.blogspot.ie/2011/11/part-6- cheap-bikes- vs-premium- bikes.html [32] http://www.ebay.co.uk/itm/EK-Chains- 530-DRZ2- Series-Drag- Bike-Chain- Chrome-140- Links- /310967170992 [33] https://es.aliexpress.com/promotion/promotion_freewheel-bike- promotion.html [34] http://justyna.typepad.com/bike_chicago/2008/05/how-to- use-your.html [35] http://www.abcl.org.in/gear/index.html [36] http://www.yescoloring.com/college-alphabet- coloring.html

A A

B B

C C

D D

E E

F F

8

8

7

7

6

6

5

5

4

4

3

3

2

2

1

1

Jessica

DWG NO.

SCALE:1:2 SHEET 1 OF 1

A3Rear DerailleurSOLIDWORKS Educational Product. For Instructional Use Only

A A

B B

C C

D D

E E

F F

8

8

7

7

6

6

5

5

4

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DWG NO.

SCALE:1:5 SHEET 1 OF 1

A3Exploded ViewSOLIDWORKS Educational Product. For Instructional Use Only

7

5

5.20

60°

10.39

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2

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3.50

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8.50

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Wire Fixing nut

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SOLIDWORKS Educational Product. For Instructional Use Only

12

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SOLIDWORKS Educational Product. For Instructional Use Only

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7

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4

4

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3

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DWG NO.

SCALE:2:1 SHEET 3 OF 4

A3Springs & RiviotsSOLIDWORKS Educational Product. For Instructional Use Only

16

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A3Front PlateSOLIDWORKS Educational Product. For Instructional Use Only

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SECTION B-BSCALE 4 : 1

A A

B B

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D D

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F F

8

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6

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A3Pully CogSOLIDWORKS Educational Product. For Instructional Use Only

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A3DrawingsSOLIDWORKS Educational Product. For Instructional Use Only

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A3SOLIDWORKS Educational Product. For Instructional Use Only

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5

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SCALE:2:1 SHEET 3 OF 4

A3BracketSOLIDWORKS Educational Product. For Instructional Use Only

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SCALE:1:1 SHEET 4 OF 4

A3Left PlateSOLIDWORKS Educational Product. For Instructional Use Only