Design, Analysis and Build Motorcycle Transmission Drive Extension Device

SA Conference Proceeding: Industrial Revolution 4.0 Vol.1, Issue 01 (2020) 133-140 International Innovation Technology Exhibition & Conferences 2019 (Itec’19), September 24th - 25th 2019 Copyright © 2020 Kolej Kemahiran Tinggi MARA (KKTM) Kemaman E-ISBN: 978-967-17985-0-8

1Aznizam A., 2Noorhelinahani A.B.

1,2 Universiti Kuala Lumpur Malaysian Spanish Institute Branch Campus

ABSTRACT

In many developing countries, motorcycle has popularly becoming the mass medium of transportation. It's growth usage has increased rapidly as to solve the common needs and various applications. One of the potential applications is to design a device to link with drive system for the purpose of additional machinery attachment. This will make motorcyle as mobile drive system useful for remote area where fix machinery is hard to transport. Transmission drive extension proposed is attached to the motorcycle drive system consist of front sprocket, rear sprocket and drive chain. The front sprocket is attached to the engines transmission output shaft and it rotates at the same time. The power transfer through drive chain links to the rear sprocket attached to the rear wheel. The extension is designed by using Triz Method, while stress analysis is gathered from Finite Element Analysis (FEA).The simulation runs by applying 1332 N force on the teeth with 2000 rpm from motorcycle engine. The torque from engine speed is measured by using motorcycle engine dyno. Eventually, it'll be reviewed with some design's modification. The parts is acquired from commercial of the shelves or fabricated before the assembling process of components. Results has provenly shown the important function of power transmission device and it's measurement of output speeds from the extension shaft. An application of this extension can be vary such as mobile power source for water pump for irrigation and shredder machine for plastics or organic waste from farm

INTRODUCTION Motorcycle is defined as a motor vehicle equipped with a seat or saddle designed to travel with no more than three wheels in contact with the ground [1]. In today’s automobile world, passenger cars and motorcycles are about 90% of the total vehicles registered in Malaysia [3] with more than 12.9 million private motorcycle was registered in Year 2017[4]. Motorcycles are popular choice for private transportation because of its ability to commute fast, fuel-efficiency and low cost although safety become major concern for riders [5]. Furthermore, motorcycle with performance improvement and more functions also can be available for adventure riding and other applications [6]. For example, in Zambia, basic health care delivery used motorcycle to send health care workers, essential medicines, and supplies to villagers who live in remote areas [7]. Motorcycle used as taxi is one of urban transport system in many developing countries and become dominant modes to provide temporary solution for mobility demand [8],[9]. In other application, Western New England University with an investment firm developed motorcycle fast food delivery system to ensure the food hot and become soggy while being delivered up to 110 minutes [10]. For the case of two and three wheelers like scooters, bikes and rickshaws there is chain drive used as a final drive [2]. Sprocket The

Aznizam, A. and Noorhelinahani, A.B.

two wheeled drive motorcycle was design used to compensate the problem in climbing high inclination roads, driving along muddy roads, desert roads, farm land and mountains [6] as shown in Figure . Slip-On Sprocket was designed to increase motorcycle torque by up to 30% for better hill ascension [11]. The higher power of motorcycle is useful for farmers at rural area that requires them to carry heavy payloads especially during harvesting season[12]. Sprocket performance: Motorcycle torque , chain tensioner, variable drive, etc..

Innovation directions of change in product innovation can able to enhance motorcycle applications for rural area user or alternative source of rotary machinery source. Therefore, our objective is to provide Mechanical device G-rog waste machine is a functional machine to solve Solid Waste Management and Animal Feeding by helping local authority for waste management or our Farmers. About one third of all our garbage is organic material like leaves, grass clippings and garden waste. In Malaysia, local authority used to collect all this organic materials and transport it to landfill for dispose it. Therefore, waste minimization is vital to reduce pollution to our environment. However, this garden waste may be used to create compost or mulch, which can be used as a soil conditioner, adding valuable nutrients and building humus. The creation of compost requires a balance between, nitrogen, carbon, moisture and oxygen. Garden waste that need to be recycled requires machine. On other view, the small scaled farmer also in need to have portable machine to help them to produce animal’s food and also fertilizer. G-rog waste machine allows the raw materials such as garden leaves, grass clipping and garden waste to be recycled or produce on-site. At the same time, this machine can be used to produce animal food. Transmission extension work as a device to transmit power from motorcycle engine to the machine component such disk mill, shredder machine, water pump and other rotary machines through sprocket and chain. The functionality of the device to help the problem associated with this activity. The device will attached with the motorcycle swing-arm and connect with chain through use sprocket and shaft. As we know the swing-arm or swinging arm also known as swing fork or pivoted fork work as a main component of the rear suspension of most modern that used to hold the rear axle firmly, while pivoting vertically, to allow the suspension to absorb bumps in the road.

PROBLEM STATEMENT

In designing any power transmission, we must ensure that it is to know what that best to minimize the characteristic of vibration. Power transmission device was attach with motorcycles swing arm that at the below motorcycles. Most of the motorcycles will having a vibration within the engine and chain. Previous version of power transmission, the idea of this design is to transmit the power from motorcycles engine to the machine. But there have some issues of the vibration on the chain, when we throttle to rev up the rotational engine the chain will move directly and it’s create a instability within the device. The device it attach with swing-arm and therefor the nut and bolt will fall off from it attachment. Other that, basically machine will operate under electric power engine or petrol engine such sugar cane machine to operate it. But there have issues with weight on the base machine to attach. Load up the electric power engine will create issues of stability, over weight and modified the attachment with the base. Lastly, previous version of power transmission is very harmful and dangerous

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when operating the machine. It is not well protected to the user when operate the machine. The sprocket is to expose and also the chain without a protected cover up. When it operating, it can cause a serious injury like the fingers will stuck to the sprocket and chain, the cloth will stuck to chain and pulls up. In response of this problem, the study are proposed to design modular shape of power transmission assembly that can be custom to meet with safety and easy to handle. The adjustment are made to the benchmark model selected in term of overall dimension. Therefore, the modification on the power transmission design are allow it to be fabricate in UniKL MSI facility using modular design technique. Transmission is a unit to transfer power (torque) from one location to another. From drive motor, peddles, engine, windmill, turbine to driven that is conveyor belt, back wheels, generator rock crusher, dryer and etc. it is helps used to span larger distances or need flexible x-mission elements. Gear drives have a higher torque capability but not flexible or cheap. These products include shaft couplings, chains and sprockets, belts and sheaves, and drive components. A mechanism for the transmission of mechanical power, usually with a transformation of the forces, torques, speeds, and in some cases, the nature of the motion.

Quality Function Deployment (QFD) is a quality instrument that deciphers the Voice of the Customer (VoC) into new items that really fulfil their requirements. In this paper, QFD will be explored so as to see how it functions, to feature its qualities and shortcomings and to talk about its pragmatic applications. The initial segment of the paper will introduce a diagram of QFD and clarify the procedure. QFD will be characterized and clarified by methods for a model and various advantages and execution issues will be uncovered (D.J. Delgado & E.M. Aspinwall, 2003). QFD is utilized to make an interpretation of client necessities to designing determinations. It is a connection between clients - structure engineers - contenders - fabricating. It gives a knowledge into the entire structure and assembling task from idea to make and it can significantly enhance the effectiveness as generation issues are settled right off the bat in the plan stage. QFD is a technique for organized item arranging and improvement that empowers an advancement group to determine plainly the customer’s needs and needs, and afterward to assess each proposed item or administration ability efficiently as far as its effect on meeting those needs (Cohen, 1995).

TRIZ is a premier troublesome innovation for advancement that can be utilized completely through numerous businesses and orders. Highlights of TRIZ can be proficiently utilized by an extensive variety of individuals from youngsters to grown-ups. The beginning of TRIZ is gotten from exact information, licenses. In critical thinking, TRIZ logically analyzes the issue as an innovative state and relates a fasten of procedures to make arrangement substitutes. Inconsistencies, or clashes, portray the most difficult kind of issue amid item improvement. As a rule an ideal enhancement can cause crumbling in another region. However, TRIZ is really the main innovation based methodical technique that overwhelms the “mental dormancy” and produces an extensive scope of arrangement ideas [x]. Alongside the general public improvement, the development works and procedures have turned out to be increasingly complicated, which puts tons of development associations from shake out. Thusly, assets and endeavors on development researchers ought to be introduced to confront this test.

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METHODOLOGY

Understanding the requirement and needs in design

The main purpose of this research is to improvise and do some modification on the design already have in the project. Essentially there is only one type prototyping in the previous design. These design have been some issued detected when conducted through by testing on the machine. there have many aspect need to be considered and re-design the actual power transmission. Therefore, the product understanding table are crucial in making comparison because from here we can determine the specification of each selected product and at the same time can determine the strength and weaknesses of every aspect on the Power transmission device.

TRIZ

TRIZ consists of the initials of the original named “Theoria Resheneyva isobretatelskehuh Zadazc” in Russian translated into English as ‘theory of Inventive Problem Solving and used acronym”. It is useful analysing and inventive tool in product design and development to create or optimise the uncertainty or imprecision in previous design process. Creative problem Solving Method suitable to be use in second stage after Quality Function Development (QFD) in design and analysis as it become a crucial most efficient methods to producing conceptual design. Based on previous product design, we found that varies of sizing of Power Transmission Device are needed. Although there is tested and running, it is doubtful adhere the safety and also the efficiency of the motorcycle fuel. Therefore specific Power Transmission Device size are require to redesign and need to analysis the best option from previous design.

Conceptual Design A Conceptual Design B

Figure 1: Conceptual Design

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Table 1: specific Power Transmission Device size Selecting a task Choosing the Data collection Researchi Finding intellectual Finding practical concept of research ng for solutions application opinion

Levels A B C D E F

Using an existing task Using concept of an Using existing data Using Using prepared design Producing current design existing research existing 1 solutions

Choosing one of many task Choosing one of the Collecting data from Choosing Choosing one of the Producing altered version of research concepts the many sources one of many design an existing design 2 among several many concept opinions

Changing the original task Changing the Changing the collected Changing Changing the existing Producing new design research concept in data in accordance with the current solution 3 according with the the new task solution new task

Finding a new task Finding the concept Collecting new data Finding a Developing new design Using a new way of design of new research according to a new task new 4 solution

Find a new problem Find a new problem Collect new data Finding Developing new Changing system that is according to new out the structural concepts applied the new concept 5 problem new concept (in Principle)

Figure 2: Conceptual Design

RESULTS AND DISCUSSION

Motorcycle Transmission Attachment with Motorcycle Attachment with Motorcycle Side Device Extension (Isometric View) View Figure 3: Motorcycle Transmission

This project has its own reliability. In this particular project, it can engage and disengaged the shaft and also can be disarmed the device from the motorcycles swing- arm. So that the task are not quite easy to handle in one system of mechanism. There have

Aznizam, A. and Noorhelinahani, A.B.

need two different shaft that connect each other while operating. Because two of the shaft are operating in a different ways, one of the shaft is receiving the power while the other is transmit from the power to the machine.

CONCLUSION

In conclusion, using a CAD software can improvised the design before going through fabrication process. It can help to eliminate the problem faces when designing and obtain the result. Reverse engineering process is a process by obtaining the real situation result but it can resulting waste a lot of time and energy. Recommendation was always through the CAD software before entering the next process flow. By the time, the Power Transmission Device been through using Solidwork as the main CAD software design and analysis.This project managed to create a new upgrading model power transmission device from the previous design with modular techniques consist of two major part which is connected between two different shafts. The main parameter in designing Power Transmission device is to ensure the position that can fit to swing-arm motorcycles that can hold a long time when operating work. Each side of the housing clamp the swing-arm in 20 millimeter wide using 4 of bolt and nut. The design had been down to 5% from the original design using 2 bolt and nut. Thus it make the device become longer that expected to minimize the scale.

The new shaft allow some preventing injury to user when operating. It shown from the previous design that had no stopper and may cause highly injuries 75% occur during operate. Thus, the new design where allowable the user safer and easy to handle by reduce 45% injuries. This is the main reason why this kind of approach is made designing new Power Transmission Device. However, the main goal to achieve better design of Power Transmission Device was still a massive one solid structure that require more time to improvise the design. Our part can be replaced and buy in hardware shop thus does not have issues in replacing the parts. The only those that can most issues was the user using different motorcycles when to work but most commonly user using Honda EX5 Dream motorcycle as a work machine. Thus, this project actually have achieve this kind of the situations.

ACKNOWLEDGEMENTS

This sub-section is not compulsory but most research reports convey appreciation to those who have been involved in the study. I would like to express my special thanks of gratitude to my supervisor as well as our dean who gave me the golden opportunity to do this wonderful project, which also helped me in doing a lot of Research and I came to know about so many new things. I am really thankful to them. Secondly I would also like to thank my parents and friends who helped me a lot in finishing this project within the limited time. I am making this project not only for marks but also increase my knowledge.

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