Engineering Design Concept

Author: Majed Fazeli

British Middle-East Center for studies & Research UK Aerospace Engineering , Sheffield1 University [email protected] http:// bmcsr.com Concept 1

The first concept is and gps system on a bicycle, this is shown below in the drawn model. As you can see from the side view and the top view that the navigation system attaches to the bike by two grips griping onto the bike. This is done by pushing the navigation system into place, because the grips are made out of plastic they are easy to push into place and therefore a light force is only required.

The handles bars are made out of rubber, the reason for this is so that when held the hand will not slip. The handlebar is made out of stainless steel; the reason for this is because it’s a very cheap metal. Also the case of the navigation system is kept plastic because it’s needed to be light.

The navigation system provides the street names as well as the buildings names. From the diagram below you can see the layout of the screen and what it provides. Also the screen is a touch screen that is the reason why it has no buttons. The navigation system also works on solar so its power source is solar therefore it does not need any external power source.

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Concept 2

This concept is similar to a stand used for navigation systems, like the stands that are used in cars; however this stand is designed for a bicycle. As you can see from the drawing provided below in concept two we can see that where the navigation system sits there are four grips which will hold the navigation into place and stop it from vibrating in its place.

These grips can be adjusted to different sizes depending on the size of the navigation system. These grips can be vertically adjusted or horizontally, again this depends on the size of the navigation system. The way the stand will be attached to the bike is different from the first concept, this product has to be screwed by two screws onto the bike, and this is shown below in the drawings.

The materials of the product are not one material as they separate into two and theses are stainless steel and plastic. The bit that is screwed onto the bike is made from steel, because it has to withstand the force of the screws being tightened on the bike. The grips however are made out of plastic the reason for this is light weight and because they are adjustable.

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Concept 3

This concept is also a grip used for the navigation system to be attached to the bike, however it’s different from the first previous ideas as this is a more complex idea. As you can see from the concept drawing provided below we can see that the navigation system will have to be screwed onto the product then the product will be screwed onto the bike, however this will only work on navigation systems that provide that option to be screwed onto the product.

The product has and adjustable tube that extract or detract its self, doing so the tube will slide into the cylinder provided (as shown in the drawing). This will require additional produces such as oil to be placed onto the tube to be lubricated for it to extract.

The materials are stainless steel for the tube. For the cylinder it’s plastic. In order to keep the product safe rubber was added to the product this is located between the cylinder and the tube and that is done so when the navigation extracts it hits the rubber and therefore will not be damaged.

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Evaluation

To evaluate the first concept was not difficult to draw but only the 3D view was because it required your imaginations in order to draw it, but the side and the top view were easy to draw because all that was required was the measurements and therefore I could start. However the measurements had to be adjusted later on because the first attempt was that it was measured in centimetres and therefore after it had to be converted to millimetres. In order to start on the drawings an overall research had to be done to get an understanding of these designs and the standards they are drawn in.

The second concept was the drawn the same day as the first concept and therefore a lot of mistakes accrued while drawing this concept because I did not have the measurements for the product, as well as I drew the 3D view to large and therefore the concept had to be changed into a smaller size and therefore it was accomplished. This concept was similar to some the stands used in the market but this stands out because it’s adjustable. If I was to carry out this task again I would draw the 2nd concept on a separate day with the measurements ready so I can draw it accurately.

The third concept was the navigation system that can be adjusted by extracting and detracting. The concept shown above is not the original as before this was drawn a different concept was being thought of but then after my research I realised that this concept is more reliable as the concept that was going to be chosen was too similar to the pervious concepts. However this concept is the most complex because if its requirement for a third party product (oil). If I could re-attempt this task I would chose a much simpler sample of the same product.

With the help of the equipment, it become possible to design the cad drawings above, as well as being able to create a more realistic 3D model using the help of the lecturers, as well as the feedback from collies I was able to accomplish these drawings with the minimum supervision of the lecturer and with a bit of difficulties that is was able to overcome with my drawing techniques.

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There are many types of matrix selection methods and they all differ from each other, as you can see above there three different types, the one on the left is a Pugh method. This method uses positive or negative codes to determine the score. The one on the right is the comparison method. This method compares what is available or unavailable for every choose by marking what applies. The method used in the middle is the standard method used in most circumstances and therefore it’s used is that the products are compared by scoring them and those scores are then calculated to determine the best option.

Previous approaches to methods selection have resulted in a very close call, however most methods focus on the strengths and weaknesses and their cost of the products. However the reason for using matrix selection methods is because the goal of the matrix selection is to produce the product in the quickest time, a successful product that meets specifications with the fewest resources, while minimizing risks. We must focus on factors of success, such as how effectively the method introduces usability improvements into the product. The method used below is the matrix selection method. First it was understood that there is 5 ideas for the project. However, in order to carry out the project there had to be one final idea for the project. Below is the list of the five ideas:

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1. Design a new aircraft wing. To design a new aircraft wing I will be using wood and the reason for this is that it is easy to cut. However, there have not been any wing designs for the past 50 years.

2. GPS system on a bike. To design this system, a lot of research is required to look at how systems can take such vibrations on a bike. Also what is needed to carry out this task is navigation system used for only bikes.

3. Design a car that can fly. To design this aircraft I will be using similar software’s to the ones listed above, but for this idea, I will be combining an Audi R8 with the military aircraft F16 to design a car capable of flying.

4. Make an aircraft aerodynamic. To carry out this design I will be using the structure of the blackbird SR-71 to make it more aerodynamic and therefore when finished designing it I will then make the new aircraft out of wood.

5. Design a new aircraft seat. To do this I will only be using 3D computer systems to design a new aircraft seat, the seat will have all the relaxation features such as entertainment and massaging.

6. Design an aircraft targeting system. I will first have to do research about the history of aircraft targeting system; I will then design a new system that focuses on the eyes and therefore were ever the eyes look the targeting system aims. I will also be using 3D software’s to illustrate how the system works.

For quality improvement activities, a decision matrix can be useful in selecting a project, in evaluating alternative solutions to problems, and in designing preparations. A decision matrix is a chart like the one shown below that allows an individual to systematically identify, analyse, and rate the strength of relationships between sets of information. The matrix is especially useful for looking at large numbers of decision factors and assessing each factor’s relative importance.

The advantage of this approach to decision making is that subjective opinions about one alternative versus another can be made more objective. Another advantage of this method is that sensitivity studies can be performed. An example of this might be to see how much your opinion would have to change in order for a lower ranked alternative to out rank a competing alternative. In order to determine what idea will be used the matric selection has to be used. As you can see below the data shows which idea is more appropriate to carryout and therefore the scores shows that.

As you can see the criteria that were used are the cost, the time taken to carry out the project and the manufacturing process. After the score where put in the total is then calculated by determining the wining idea by seeing which has the lowest score. Because I have decided the lower the number the better the outcome becomes, so the total od each idea is compared by the lowest number wins and therefore this is shown clearly in the table below:

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Matrix table Cost Time Manufacture Total

Make a new 6 6 4 16 aircraft wing

Design a car 5 9 10 24 that can fly

GPS system 3 6 6 15 on a bike

Make an aircraft more 5 8 9 22 aerodynamic

Design a 4 7 6 17 new aircraft seat

Aircraft targeting system 4 7 9 20

1 = Good 10 = Bad So for the total, the lower the number the more suitable the idea is to be carried out as a project.

The reason why I have chosen my finale idea to be the gps system on a bike is because after doing my matrix selection it had the highest score and therefore over all it stood out to be the most appropriate idea to carry out. As well as if we look at the cost of this concept its 3 which if compared to the other ideas it’s less which men scarring out this concept is going to be cheaper than the other ideas. Also For the time it consumes to have the product ready is 6 which compared to the other ideas is the lowest which makes it the best in that category. The manufacturing process the reason why it has scored a 6 is because it requires to separate sectors one to manufacture the GPS system and the other to manufacture the Bike. And therefore as you can see from the table above that idea scored the lowest which make it the wining idea.

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To evaluate choosing a method from the matrix selection methods was difficult as it required us to research into each method and to see which method is right for your selection and best for you. Therefore I looked at many different types and in the end decided to use the one above because of its simplicity as well as the information it provides. If I was to carry out this task again, I would write down on paper the names of different types of methods as I research them so later on I would know the name of each on when it comes to doing the actual task.

The table below is a compliance check of the chosen design solutions against the product design specification:

Customers design Does it meet the design How does it meet the design specifications specifications? specification?

This criterion has been achieved by a minimum of 3 year but after the production took place the life span was increased to 5 Life span Yes years of constant use.

From the fixed parameter we kept the size fixed for all parts of the bike and therefore it has met the customer’s needs. Size Yes

The product can withstand its limitations as they are to be able to for e.g. withstands Limitations Yes high speeds such as 80 mph.

The material required to produce the product have changed, and therefore do no meet the requirements of the customer. Material required No

The power source is solar. Therefore it has met the requirements of the customer (this is the power source of the navigation Power source Yes system).

What was required was that the bike had to be easy to maintain such as replacing the

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change of the bike or on of the wheels and therefore it has been made easy to access and replace. Maintenance Yes

The cost is fixed parameter therefore it has not change. What was discussed with the costumer about the cost has stayed the same Cost Yes which is £200.

The performance of the bike as well as the system have meet the requirements as they produce more then what is required at the Performance Yes same cost.

The appearance of the bike however has changed as to what was shown to the customer in the interview; this is because of the navigation system on the bike.

Appearance No

To evaluate doing this task required us to look back as the customer requirements and therefore compare them to the design specifications. I had to check if they meet the requirements so I had to both of them side by side and compare and therefore made a list and ticked the ones that meet the requirement and crossed the ones that didn’t and therefore came up with the table above. If I was to do this again I would record the data on pc the first time instead of writing on paper first.

Design Brief This design brief is a written explanation which is then given to a designer. This outlines the aims, objectives and milestones of a design project. Below are the questions gained from the meeting with the customer.

1. What is the purpose of the product?

2. What are the products limits?

3. How does it operate?

4. What materials are required to manufacture the product?

5. What is the size of the product?

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6. What is the cost of the product?

7. Who long would the product last for?

8. Does it already exist?

9. What does the product operate on?

10. Why is it needed?

11. Who will use it?

12. What is the safety factors associated with this product?

13. What are the general maintenance procedures?

The design that was chosen is to make traveling with a bicycle much easier and the way that is done is by having a bike with a built in navigation system. So the idea is to design a bicycle with navigation system.

Here's what is going to be included in order for the designer to understand the design:

 The Goal

 The Idea

 The Problem

 The customer

 The Approach

 Challenges and unknowns

The goal

The goal of the product is to design a bicycle that will have a built in system that will navigate you though places around the world.

The idea

The idea of designing a bicycle with built in navigation system, is to make life easier for people to travel using bicycles and never get lost again.

The problem

In order to accomplish the design we need to tackle the problem and therefore this covers what the problem is and who has the problem or who is the customer.

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 Bikes don’t have navigation systems.

 Bikers find them self’s lost most of the times in the mountains.

 It cost more to buy a separate navigation system.

 The battery on a navigation system runs out.

 Navigation systems only support certain countries.

The costumer

This idea will appeal to bikers at ages of 15+, male and female. It is used for the general public not only in the United Kingdom but all over the world if the product sale was successful within the United Kingdom.

The approach

The way this product operates is when the rider of the bike activates the navigation system. When the navigation system is activated, it first uses the current location of the bike and lets the rider know where he is. It does this thought the satellite figures it gains. As well as this the altitude is also given. If the rider is in a city the traffic details are also given. This is how the idea is implemented.

Challenges and unknowns

 Where would the Position of the navigation system be on the bicycle?

 What is the size of the navigation system?

 Would the navigation system affect the bicycles performance?

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Design parameters

The customer was asked a number of questions to determine the design parameters. Below is a brainstorm showing the fixed design parameters. These parameters are fixed and therefore cannot be changed. These parameters were requested by the customer.

Max speed = 80 mph Height = 1.1 m

Cost = £200

Weight = 16.5 kg Fixed Design parameters Power source = solar

Length = 2 m

Width = 3 inches Life span = 5 years

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Design specifications

I will be using the BS 7373-1:2001 layout for the design specification, this is because it gives guidance on the layout and preparation of specifications, and describes systems for their management. It applies to specifications used within industry, commerce and the public sector. The guidance is applicable to the specification of all types of product. Performance 1.1 To be able to ride at any ground (Mountain, roads, sand etc.).

1.2 The bicycle must have a height of ≤ 435 mm. (See BS EN 14781:2005)

1.3 Must allow the rider to have easy access to the bicycles equipment, such as gears and breaks.

1.4 Must be easy to operate, (The bicycle & The navigation). The age groups are expected to be ranged from teenagers to adults.

1.5 The bicycle should be strong enough to withstand a weight of about 100 kg. (See Product limits)

1.6 The navigation must be easy to access.

1.7 When the system is used it must be able to find locations within 6 seconds.

1.8 The bike chain must not come off at any circumstances.

Environment

2.1 Normal use: The navigation system will be fitted on to a mountain bicycle in the workshop (not by the customer).

2.2 Resistance to weather Conditions: the navigation will be exposed to different weather conditions and therefore must be able to withstand these conditions at hot or cold temperatures.

2.3 Temperatures: the system must be able to operate at temperatures of -10°C to 60°C.

2.4 Corrosion resistance: The bicycle should be resistant to corrosion from salt water or any other liquids (Weather Conditions).

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2.5 Abuse: The bicycle wheels must be able to withstand damage from the ground. Also it must have shock observers.

2.6 Dust and dirt: if dust or dirt gets on the chain it must not affect the bike and must be easy to clean the chain from dirt as well.

Life in service

A minimum of 3 years is required, but, if used the bike constantly then 2 years would be required.

Maintenance

The general public tends to go towards maintenance-free products. To keep within the targeted production cost and equal the competitors’ maintenance policy at this end of the market, the design should comply with the following:

4.1 The bicycle must be completely maintenance free with the exception of light lubrication if required.

4.2 Where screws, bolts and washers are used, British standards must be complied with (see ‘Standards and specifications’).

4.3 If any parts that do require lubrication then this should be accessible within one minute or less, this should not require special tools or equipment.

4.4 If any part of the bicycle requires removing then it can be done by the customer if it’s simple maintenance.

Target product cost

Our objective at NAVBIKES is to produce an operative navigation system on a bicycle that will fall into the lower price range. The average retail cost of present bicycles with navigation systems is £400. Therefore our product target cost for manufacture should be between £150 and £250 per completed and packaged bike.

Competition

6.1 Muddyfox is a company that manufactures and sells bikes and the company has been around for over 25 years. But does not have navigation systems that come with the

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bicycles. (For further details see market research document).

6.2 Releigh for over 120 years, this company has been creating market-leading bikes in Nottingham in the United Kingdom. However their bikes do not support navigation systems. (For further details see market research document).

6.3 Accell Group NV is a Dutch holding company. This company owns several European bicycle manufacturers. Besides bikes, it also involved in the production of fitness equipment. Accell is one of the largest producers of bicycles and bicycle parts in the world. (For further details see market research document).

6.4 Derby Cycle is one of the largest bicycle manufacturers in Germany. And with its five brands, Focus, Kalkhoff, Raleigh, Univega and Rixe, it is one of the leading manufacturers in Europe. (For further details see market research document).

Packaging The following points should be considered for the packaging of the device. (See Size & Materials)

7.1 Weight must be kept to a minimum.

7.2 The company’s logo must clearly be shown on the package.

7.3 The packaging must be waterproof.

7.4 The cost of the packaging must be kept to a minimum.

7.5 The package must be substantially attractive to the customer.

7.6 The size of the packaging must be kept to a minimum.

7.7 Instructions on how to use the navigation system should be supplied with the package.

7.8 The packaging of the bike must be easy to remove.

7.9 The packaging should prevent corrosion.

Testing

8.1 The Bike will be tested in a special lab for fracture in the material of the bike.

8.2 The bike will be tested to withstand weights of 100 kg acting upon it.

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8.3 The navigation system will be tested to see the signal strength.

8.4 The navigation will be put on a vibrating surface to see it performance under rough grounds.

8.5 The navigation will be tested on different weather conditions to see if it can withstand these conditions.

8.6 The bike will be tested on rough grounds to test for movability.

Market constraints

The navigation system as well as the bike will be marketed on a trial basis within the UK and, if successful, will be marketed worldwide.

Shipping

10.1 The package of every bike will be stored for transport in a box.

10.2 Transport will be by sea then road or rail within the overseas market. (World Wide).

10.3 A fork lift will be used to carry the boxes to the place of deportation.

10.4 Transport will be by road or rail within the home market. (United Kingdom).

Quantity

Market analysis indicates that a large percentage of the public suffer from getting lost with bikes. Those of the public that do have navigation on their bike, they complain about battery life or the device not working in certain weather conditions. Therefore, it would be reasonable to expect the market to grow over the next year, considering the rise of bike purchases.

Product life span

The material used for the paddles is aluminium and therefore aluminium has a life span of about 250,000 cycles, which means you can stress it at its maximum load Bering (that’s before it actually cracks) 250,000 times, then the metal starts fatiguing (but not necessarily broken yet). This factor depends on how hard you are on the bike. However the estimated life span of the Bike is set to be 5 years by the manufacturer.

Materials

13.1 The materials should resist constant forces of about 100 kg.

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13.2 The chosen material must withstand specific weather conditions.

13.3 The materials chosen must not corrode in any way, because the product will be constantly wet due to weather conditions.

13.4 The materials must be lightweights within the designated limitations of the weight of the bike. (See weight for more details).

13.5 The materials should not be toxic to the individuals that use the bike.

13.6 The material must with stand specific weights. (See design parameters for more details).

Size

14.1 The height of the bike should be no more than 1.1 meters.

14.2 The length of the bike must not be more than 2 meters.

14.3 The width of the bike should not be more than 3 inches.

Weight

15.1 The total weight of the bike should be no more than 16.5 kg with the navigation attached.

15.2 The weight of the bike must be kept to a minimum of 15.9 kg.

Appearance Navigation system

The bike will look similar to the bike shown above but will have a navigation system attached to it. The navigation system will be at the front of the bike, between the break handles and therefore will have its solar panels also next to it. As shown above were the arrow is pointing.

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Safety

The Pedal Bicycles Safety Regulations 2010 which I'll shorten to PBSR are there to ensure that new bicycles that are manufactured are sold in a safe condition. When first passed, in 1983, the major requirement of PBSR was to ensure that every new bicycle that was sold conformed to the British Standard for bicycles: BS6102 part 1. In 2005 this standard was superseded by a suite of European standards developed from BS6102, but with a lot of extra tests and requirements that differed according to the type of bicycle.

The PBSR 2010 requirements are listed below:

17.1 Any hand-operated brakes arranged left-hand rear, right-hand front

17.2 A bell

17.3 The bike must have white or yellow reflectors on both sides of each wheel.

17.4 A white wide-angle front reflector, or a front lamp

17.5 A red wide-angle rear reflector

17.6 Yellow reflectors front and rear on each pedal

Standards and Specifications

BS 14872 Accessories for bicycles. BS 4190 Bolts and screws, ISO metric black hexagon. BS 3692 Screws and bolts. BS 6105 Screws and bolts, stainless steel, corrosion resistant. BS 5750 Design, manufacture and installation. BS 5760 Reliability of systems, equipment and components. BS 6102 Specification for safety requirements for bicycles. BS 14764 City and trekking bicycles. Safety requirements and test methods.

Task V (P1.4) The table below shows that the bike is designed to the specified requirements and the needs of the customer.

Design Specification Criteria Meets The Customer Requirements

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The cost of the Bike £250 ✔

Navigation system operates on solar panel ✔

Width of the bike is 3 inches ✔

Height of the bike is 1.1 meters ✔

Length of the bike is 2 meters ✔

Weight of the bike is 16.5 kg ✔

Withstands a weight of 100 kg ✔

Design specification categories

Below are is a brainstorm of the categories used to write up the design specifications. I have chosen 18 categories to do the project design specifications.

Standards and specifications Quantity Environment Weight Life in servers

Shipping Performance

Categories Product life span cover in a PDS Maintenance

Target product cost Market Constraints

Materials Competition Packaging Appearance Testing Size

Safety

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Design process

Below is the design process used to determine the final product. I will now briefly explain the

Customer requirements/ideas

Analysis with the client’s needs

Provide samples of similar product

Develop a prototype

Changes according to client’s feedback

Final product

functions of these departments.

The customer requirements are determined by having an interview with the customer and therefore when this done we can then find out the customer requirements.

Analysis with the client’s needs is when we look at the need of the customer and from that we determine the fixed parameters of the product.

Research about similar products and therefore from that provide samples of the product to show an idea of how the product will look like.

The development department deals with making a prototype of the product required by the customer and therefore this department develops the prototype according to the feedback from the client, and therefore after that is achieved the final product is manufactured.

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Project Plan

As you can see this is the project plan used to plan out the time required to complete the product required by the customer.

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Market research

Mountain biking in the UK has been around for over 25 years, and it all began with Muddy Fox. The sport started in the Californian foothills in the late 70’s, and the idea of throwing yourself full-speed down massive hills hit a chord with a couple of British enthusiasts. They came home awe-struck and decided to go forth and spread the gospel: Muddy Fox was born! Throughout the 80’s and 90’s Muddy Fox was the bike to have. It was always ahead of the pack and usually the brand leading the way to bring new ideas to the sport. Occasionally the designs were a little too advanced, as a testament to their ingenuity some of them are starting to crop today. The Muddy Fox Race Team has always played a large part in the testing and developing of new products and at its peak boasted a string of elite riders including Gee, Dan and Rachel Atherton and Dan Stanbridge to name a few. Muddyfox is owned by Universal Cycles Plc, and all the bikes are designed and developed at our headquarters in Essex, England. http://www.muddyfox.com/aboutus_home.html

Raleigh's history started in 1887, in Raleigh Street, Nottingham. Frank Bowden, a prosperous 38-year-old, bought a bicycle made by Messrs. Woodhead, Angois and Ellis, because his doctor had told him to ride a bicycle for his health. Bowden was impressed by his bicycle and went to Raleigh Street to find the makers. Woodhead, Angois and Ellis were making three bikes a week. Bowden made them an offer and bought the business. Production rose and three years later he needed a bigger workshop, which he found in a four-storey building in Russell Street. He changed the company's name to Raleigh Cycles to commemorate the original address.

In six years Bowden created a business which became the biggest bicycle manufacturing company in the world and occupied seven and a half acres in Faraday Road, Lenton, Nottingham.

Sir Frank Bowden died in 1921 and his son Sir Harold Bowden, 2nd Baronet took over as chairman and chief executive, guiding the company through the next 17 years of expansion.

In 1939 Raleigh opened a bicycle factory at 6 Hanover Quay, Dublin, Ireland and commenced bicycle production there. The Raleigh (Ireland) business expanded and moved to 8-11 Hanover Quay, Dublin in 1943. The plant produced complete bicycles and Sturmey- Archer hubs, and remained in production until 1976, when the factory burned down. Models

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Copyright © 2012, British Middle-East Center for Studies & Research, All rights reserved. 22 produced there latterly were the Chopper and Triumph 20. The head badges changed in the late 1960s, possibly after the passing of the Trade Descriptions Act in the UK. Dublin-made machines no longer had "Nottingham England" on the Heron or Triumph head badge, the panel being left blank instead.

In 1899 Raleigh started to build motorcycles and in 1903 introduced the Raleighette, a belt- driven three-wheel motorcycle with the driver in the back and a wicker seat for the passenger between the two front wheels. Financial losses meant production lasted only until 1908.

In 1930 the company acquired the rights to the Ivy Karryall, a motorcycle fitted with a cabin for cargo and a hood for the driver. Raleigh's version was called the Light Delivery Van and had a chain drive. A two-passenger version was followed by Raleigh's first three-wheel car, the Safety Seven. It was a four-seat convertible with shaft drive and a maximum of 55 mph (89 km/h). A saloon version was planned, but Raleigh shut its motor department to concentrate on bicycles again. Chief designer T. L. Williams took the equipment and remaining parts and moved to Tamworth, where his company produced three-wheelers for 65 years. The leftover parts from Raleigh carried an "R", so Williams chose a matching name: Reliant. http://en.wikipedia.org/wiki/Raleigh_Bicycle_Company

The Accell Group has several production facilities in the Netherlands, Germany, France, Hungary and Finland. Besides these locations several parts are produced in East Asia. The production locations in the Netherlands are located in Heerenveen (Batavus and Koga Miyata) and Apeldoorn (Sparta). In Germany the production locations are in Sennfeld (Winora and Staiger). In the Hungarian Tószeg it owns a factory where mainly Hercules, but also Sparta bikes are being made. Fitness equipment is made in Finland. Accell also owns factories in Andrézieux-Bouthéon and Dijon, France.

Besides supplying bicycles to independent vendors, the Accell Group owns Seattle Bike Supply, an American company which focuses on the design and building of BMX bikes, Loekie a Dutch brand of kids bikes, the German Bike Partswhich supplies bike parts to specialised trade and Tunturi, a Finnish produces of fitness equipement and bicycles, Bremshey a German producer of fitness equipment and Juncker Bike Parts, which supplies parts and accessories to the Dutch bicycle shops. http://en.wikipedia.org/wiki/Accell

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Derby Cycle is innovation leader and trendsetter in the bicycle industry. Development, design and production of the products are made in atest productions facilities in Cloppenburg and Quakenbrueck under highest measures of quality. We permanently work in research and development to improve the product ergonomics and technical details.

In our final assembly all branded bikes are pre-assembled for 98 %. This reduces the assembly effort for the specialized trade and extends the margin. Currently we produce approx. 2,500 bikes per day and are able to deliver 500,000 units per year. Derby Cycle Owens Top brand names within the industry suach as Focus, Kalkhoff and Rixe. Derby Cycle uses only components from well-known manufacturers, which have been proved themselves over the years and which bear up against the hardest quality demands. Our internal testing laboratory is unique in the bike industry. Optimized frame geometries out of light aluminium or carbon as well as sophisticated suspension systems belong to the standard of Derby Cycle. Also environmentally compliant shock-resistant sealings of varnishs and decals for long-lasting optical pleasure and joy with the bikes are considered by the company. http://derby-cycle.de/en/produktion.html

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The research into four different types of computer aided design systems has required us to look all the different software used in the engineering industry. These software’s each serve a specific purpose, for e.g. there are software’s such as stress and strain analysis, mould flow analysis, cad software’s and 3d max animation software, all are available in this industry and performing to their standards.

ANSYS

ANSYS develops markets and supports engineering simulation software used to foresee how product designs will behave and how manufacturing processes will operate in real-world environments. The software continues to advance simulation solutions by, first, developing or acquiring the very best technology; then integrating it into a unified and customizable simulation platform that allows engineers to efficiently perform complex simulations involving the interaction of multiple physics; and, finally, providing system services to manage simulation processes and data, all so engineers and product developers can spend more time designing and improving products and less time using software and searching for data.

The ANSYS suite spans the entire range of physics, so customers can confidently assess how their designs will behave in a real-world environment; this software helps to ensure product success at the same time. This software not only delivers efficiency, it drives innovation. The technology reduces or eliminates physical constraints, enabling simulated tests that might otherwise not be possible. It fosters what-if thinking so engineers can readily explore design alternatives for an optimal solution. This process is called Simulation-Driven Product Development which comes with the software.

This company extends its functionality by partnering with independent software vendors, including computer-aided design (CAD) and product lifecycle management (PLM) developers as well as niche organizations that range from physics (such as audibility) to optimization to materials data. The reason for this is to ensure that the software can get the most accurate solution in the fastest amount of time. The collaboration helps customers in all industries navigate the rapidly changing high-performance computing (HPC) landscape. This image of the chair is an example of the work capability of Ansys.

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ANSYS was listed on the NASDAQ stock exchange in 1996. In late 2011, Investor's Business Daily ranked ANSYS as one of only six technology businesses worldwide to receive the highest possible score on its SmartSelect Composite Ratings. ANSYS has been recognized as a strong performer by a number of other sources as well. The organization invests 15% of its revenues each year into research to continually refine the software. (ANSYS, 2012)

VISI Flow (VERO Software)

Vero Software is a company that creates and distributes CAD / CAM / CAE software for aiding the design and manufacturing process in specific sectors of the industry with a knowledge driven focus on Mould & Die. The specific sectors include the design and manufacture of plastic injection moulds, sheet metal stamping dies, progressive dies, 2D > 5- axis milling, electrode production, multi-axis laser cutting, Wire EDM and others. These widespread product types are in turn to be found in a multitude of manufacturing industry sectors such as automotive, electronic, medical, white goods and aerospace.

VISI is acknowledged as one of the world's leading PC based CAD / CAM solutions for the Mould & Die industries. It offers a unique combination of applications, fully integrated wireframe, surface and solid modelling, comprehensive 2D, 3D and 5 axis machining strategies with dedicated high speed routines. Industry specific applications for plastic injection tool design including material flow analysis and progressive die design with step-by- step unfolding provide the toolmaker with unsurpassed levels of productivity.

VISI Flow provides a user friendly interface with short model preparation and calculation times. Initially introduced to the injection simulation market over 25 years ago, VISI Flow combines the powerful versatility of VISI Modelling with the undisputed result accuracy of Finite Element Analysis. VISI Flow provides the complete solution for part/mould designers and plastic injection moulding technicians; from filling analysis, to warpage calculations and thermal optimisation analysis.

VISI Flow can work directly with Para solid, IGES, CATIA v4 & v5, Pro-E, UG, STEP, Solid Works, Solid Edge, ACIS, DXF, DWG, STL and VDA files. The extensive range of translators ensures that users can work with data from almost any supplier. Very large files can be handled with ease and companies working with complex designs will benefit from the ease with which their customer's CAD data can be manipulated. Below are examples of VISI Flow. (Flow, 2012)

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Solidworks

Solidworks is a 3D mechanical CAD (computer-aided design) program that runs on Microsoft Windows and is being developed by Dassault Systèmes Solidworks Corp., a subsidiary of Dassault Systèmes, S. A. (Vélizy, France). Solidworks is currently used by over 1.3 million engineers and designers at more than 130,000 companies worldwide. FY2009 revenue for Solidworks was 366 million dollars.

Building a model in Solidworks usually starts with a 2D sketch (although 3D sketches are available for power users). The sketch consists of geometry such as points, lines, arcs, conics (except the hyperbola), and splines. Dimensions are added to the sketch to define the size and location of the geometry. Relations are used to define attributes such as tangency, parallelism, perpendicularity, and concentricity. The parametric nature of Solidworks means that the dimensions and relations drive the geometry, not the other way around. The dimensions in the sketch can be controlled independently, or by relationships to other parameters inside or outside of the sketch.

In an assembly, the analogies to sketch relations are mates. Just as sketch relations define conditions such as tangency, parallelism, and concentricity with respect to sketch geometry, assembly mates define equivalent relations with respect to the individual parts or components, allowing the easy construction of assemblies. Solidworks also includes additional advanced mating features such as gear and cam follower mates, which allow modelled gear assemblies to accurately reproduce the rotational movement of an actual gear train. (Solidworks, 2012)

Finally, drawings can be created either from parts or assemblies. Views are automatically generated from the solid model, and notes, dimensions and tolerances can then be easily added to the drawing as needed. The drawing module includes most paper sizes and standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC). Solid works also includes:

 Solidworks Simulation is a design validation tool that shows engineers how their designs will behave as physical objects.  Solidworks Motion is a virtual prototyping tool that provides motion simulation capabilities to ensure designs function properly.  Solidworks Flow Simulation is a tool that tests internal and external fluid-flow simulation and thermal analysis so designers can conduct tests on virtual prototypes.  Solidworks Simulation Premium is a Finite Element Analysis (FEA) design validation tool that can handle some multiphysics simulations as well as nonlinear materials.  Solidworks Sustainability is a product that

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measures the environmental impact of designs while they are modelled in Solidworks.

This is an example of Car designed in Solidworks:

Autodesk 3D Max

Autodesk 3ds Max, formerly 3D Studio Max, is 3D computer graphics software for making 3D animations, models, and images. It was developed and produced by Autodesk Media and Entertainment. It has modelling capabilities, flexible plugin architecture and can be used on the Microsoft Windows platform. It is frequently used by video game developers, TV commercial studios and architectural visualization studios. It is also used for movie effects and movie pre-visualization. In addition to its modelling and animation tools, the latest version of 3ds Max also features shaders (such as ambient occlusion and subsurface scattering), dynamic simulation, particle systems, radiosity, normal map creation and rendering, global illumination, a customizable user interface, and its own scripting language.

Autodesk, Inc. is a leader in 3D design, engineering and entertainment software. Customers across the manufacturing, architecture, building, construction, and media and entertainment industries including the last 16 Academy Award winners for Best Visual Effects use Autodesk software to design, visualize, and simulate their ideas before they’re ever built or created. From blockbuster visual effects and buildings that create their own energy to electric cars and the batteries that power them, the work of our 3D software customers is everywhere. (Autodesk, 2012)

Autodesk 3ds Max provides a comprehensive, integrated 3D modelling, animation, rendering, and compositing solution for game developers, visual effects artists, and motion graphics artists along with other creative professionals working in the media design industry.

 Powerful 3D modelling: With an extensive polygon modelling and texture mapping toolset, you can create compelling characters, props, and environments more quickly and effectively.  Advanced character rigging and animation: The fully integrated Character Animation Toolkit (CAT) provides an out-of-the-box advanced rigging and animation system.  Accelerated rendering options: Create highly realistic or stylized looks at faster speeds with unlimited batch mental ray rendering, interactive GPU hardware rendering with Quicksilver, and the NVIDIA iray renderer.  Extensible pipeline support: Customize, extend, and integrate 3ds Max into existing pipelines with support for C++ and .NET.  Adobe software interoperability: If you’re a creative professional in the media design industry that uses Adobe After Effects or Adobe Photoshop software, you can enjoy a level of interoperability that sets a higher standard for 2D/3D data exchange.

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To evaluate the four different types of CAD system can all be used for different types of needs however for this particular project there can only be one. Doing this task took the longest period of time as it required looking into four different types of CAD systems and to look at their functionality and purpose in the engineering industry. If I was to do this task again I would take a day on each system and research it instead of taking one day for two systems.

From the research that I have carried out to look at four different types of computer design systems, I have chosen Solidworks to be the system that will be using. There are many reasons for this as I will go through but one of the main reasons is that Solidworks is the only software at the place of study as well as the fact that I already have gained knowledge of the system and am familiar with some of its functionality. Solid works has the following features which makes it above the other products:

Freeze feature

You can freeze features to exclude them from rebuilds of the model. This feature is new as it is only provided with the new version of solid works (2012). The freeze bar controls the point at which a part’s Feature Manager Design tree rebuilds. Features above the freeze bar are frozen, you cannot edit them, and they are excluded from rebuilds of the model. Freezing a portion of a model can be useful if you work with complex models with many features. Freezing the features helps to reduce rebuild time and prevent unintentional changes to the model.

Exploded Views of Multibody Parts

This feature allows you to create exploded views of Multibody parts.

Collapsed Exploded

The process is similar to creating exploded views in assemblies. So therefore the feature allows you to create:  Creating an Exploded View you can create exploded views of Multibody parts.  Auto-spacing Bodies you can evenly space exploded groups of bodies.

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 Collapsing an Exploded View you can toggle between the exploded and collapsed views

Hole Wizard - Placement of Holes

You can precisely define the position of the first point in a Hole Wizard sketch. Previously, the first point was placed wherever you clicked when selecting the face where you wanted to drill the hole.

When you activate the Positions tab, the first sketch point and a shaded preview of the hole follow the pointer until you click to place the hole. As you move the pointer about the screen, you can take advantage of sketch snaps and inference lines to place the point precisely.

Templates for Split Parts

In the Split and Save Bodies Property Managers, you can select an alternate part template to override the default template from Tools > Options > System Options > File Locations. The selected template is applied to all the new part files you create during that Split or Save Bodies operation.

Previously, you could set a system option to prompt you for an alternate template whenever you created a part. Then you had to repeatedly specify that template (once for each body that you saved).

Reference Planes

Reference planes defined from the top plane are no longer rotated 180º from the top plane, and now behave the same as reference planes defined from the front or right planes. This change eliminates unexpected rotation of the model when viewing normal to the reference plane. It also eliminates flipping of copied sketches when you paste them onto the reference plane. For e.g., suppose you create Plane1 at an offset from Top Plane. Then you copy a sketch from Top Plane and paste it onto Plane1.

In SolidWorks 2012, the copy of the Previously, the copy of the sketch flipped sketch is oriented as expected. 180º.

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To evaluate choosing one CAD system was easy because I compared all the four types and because I wasn’t doing an animation not the stress and strain analysis nor any other type of analysis software all I required was a simple software that I could make my 3D model in and that turned out to be solid works as well as because I had access to it in the place of study. If I was to choose a CAD system again I would ask someone that works in the CAD systems Field and therefore they could compare because of their experience and tell me which is more suitable for me.

This is a 2 view diagram of the This is a 4 view diagram of the handle bars of the bike where navigation systems, with the the grips attached to. grips attached to the back of the navigation system.

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This a realistic image of the This a realistic image of the handlebar produced on solid navigation system produced on works, as well as the materials solid works, as well as the mentioned in the drawings also materials mentioned in the have been applied. drawings also have been applied.

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These two drawing represent the product and they show the dimensions. The top vie is the navigation system and the bottom view is the handlebar for the bike. These are drawn to BS 8888

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To evaluate I have used Solidworks to produce these cad drawings which are shown above. I face some difficulties such as scaling and object using Solidworks features, to overcome this problem I looked at some tutorials on the internet and therefore found many solutions and I was able to scale the handlebar down. Also another difficulty was using the mate feature in Solidworks assemble to assemble the parts together, I did not know how to use this feature but I searched the Solidworks data and therefore it explained to me how to use the feature and showed me a step by step instructions. If I was to carry out the drawings again I would start my sketch and finish all the drawing on sketch then extrude base the sketch.

As explained before the reason why I have chosen to use Solidworks is because it’s CAD software I have used before and I am familiar with its functionality. Therefore I have used it to design my product and the reason for this was because this software was very easy to use and friendly.

Solidworks has many advantages as these include being able to move, copy and rotate the product in a 3D format. So if you have an active plane selected, the move, copy and rotate actions work the same as in 2D sketches.

In order to design the product I had to start from the drawing that I created in order to create the 3D model therefore the measurements that I had, had to be accurate because a slight error in the measurements would stop the procedure because all the parts must fit. Therefore what was used was the smart dimension tool in solid works which is used to calculate the length as well as angles of lines and circles as well as it gives the option to modify those lengths. Also when the 3D model was being created I had to keep going back to the drawing and compare to the actual 3D model that I was making to see if it was the same and double checking the size of every part before it was assembled. If anything occurred I would use the help tool provide by Solidworks which helps you get thought difficulties and helps correct errors. The following list is what some of the help that was provide by Solidworks which helped in certain circumstances:

 Solidworks Configuration Support  Categories  Assembly Visualisation Support  Establishing the Baseline  Dashboard with Key  Specify Transportation Type

As I was making the 3d model I wrote down every tool that I used so later on I could use it in my evaluation as well it helped me to remember the names of the tools that I used and there functions which was very important. I have explained some of the features which makes the

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Copyright © 2012, British Middle-East Center for Studies & Research, All rights reserved. 34 product unique when compared to the other 3D software’s but I haven’t mentioned all the features that it contains, these features below are also found in other CAD systems but Solidworks lays them out in an easy way and they stands out because of the windows layout used by the developers of Solidworks as well as the option given to customize the layout of windows. So these features include:

 Sketch, Spline, Point, Plane, Swept Boss/Bass, 3D sketch, Extrude cut, Revolved Boss/Bass, Smart dimension, Revolved Cut, Fillet, Chamfer, Draft, Scale, Hole Wizard, Smart Dimension, Extrude boss/bass, Line, Rectangle, Circle, Centre point Arc, Tangent Arc, Three point Arc, Sketch Fillet and Centre line.

These features are from the Solidworks database and therefore are all included in the software. Every single tool served its purpose and did it correctly without any struggle; consequently these tools guided me to finish the product. However I did not need the need to use any add-ons to complete the model for e.g. when the model was required to look realistic and to be rendered the softer had its own materials to be applied to the model as well as having its own render options and therefore there was no need for any third party software’s.

The software was never confusing to use but the only problem with it was the help tool that keep on popping up and the error tool which I did not know how to switch off as well as the keyboard short-cuts were a little bit hard to get used to, to solve this solid work allows the user to edit the short-cut key positions and therefore allowed me to change them to what i was comfortable with, but the overall experience was adequate. I have managed to finish my design before time that was given to finish the final product and that is due to my knowledge that I had on solid works before starting the project.

Conclusion

To conclude the whole purpose of the assignment was to concentrate on the CAD systems and the design of your concept. The research shows that Solidworks is mostly used not only in engineering industries but also in universities and colleges. Again this is because solid is widely known for its performance as well as its simplicity.

Also Autodesk 3D max is also another CAD system that is widely used in animation and in game creation as well as advertisement, but these systems all have one thing in common and that is the ability to create models in 3D but it’s the procedure of doing so that separates them and ranks them. However in order to create my concept I used Solidworks and therefore created three parts of the concept as well as the whole idea. Doing all of these tasks required me to seek help from the lecturers.

To Start the assignment the first thing that was required doing was the matrix selection table which was used to determine which concept was best to carryout and which was not a good idea, therefore using that information I decided to do the GPS system on the bicycle. Doing

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Copyright © 2012, British Middle-East Center for Studies & Research, All rights reserved. 35 this on the CAD system which in my case was Solidworks, made me go through a lot of steps to achieve the final concept of the finished 3D model.

The design specifications specified exactly what was used for the product and what was needed as well as specifying the specs. However the design brief is a written in this assignment was an explanation in which is then given to a designer. This outlines the aims, objectives and milestones of a design project. All the tasks attempted in this assignment were to meet the customers’ requirements and how a process takes place when a new product is needed in the engineering industry and what steps the design team go thought to achieve what we have achieved here.

Evaluation

The overall experience of the assignment was interesting; because I found out new knowledge about CAD systems that I did not know before I started this assignment. As well as the challenges that I faced while researching into all the four types of 3D CAD software, it was not very easy to find the different types of CAD/CAM software. From this research i realized how much of competition of CAD/CAM software between many companies and which ones are mostly used for engineering companies.

However what was interesting during the research was realising the difference between each system and it features and what make each system stand out above its competitors. In this assignment there are only four types of CAD systems mentioned however there are many other types of 3D software out their but the ones mentioned above are the most know and are the ones that I came across. Before doing this research I did not know that there were so many different CAD systems for different industries.

One major difficulty was to learn how to use this software and for that reason, I had to take out some teaching books on Solidworks. I used Solidworks 2011 and if I had Solidworks 2012, it would have made a difference on the outcome of the project, as I know that Solidworks 2012 has more features and provides more accessibility to the software. The reason why I could not use Solidworks 2012 was because of the cost.

Choosing which software to use was difficult because I both systems were similar but after looking at tables (Matrix selection) that compared both software, it was clear that solid works was the preferred option. One feature that I liked about solid works was to be able to edit the dimension of the 3D model during any time; however this option is not possible in any other CAD system but only available in Solidworks, so this feature is really help full and saves you a lot of time from starting from scratch again. So Solidworks experience was fascinating as it taught me the right and easy way to make my 3D model and I will never forget the experience.

Time Management

Creating a project plan is the first thing you should do when undertaking any kind of project. Often project planning is ignored in favour of getting on with the work. However, many

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Copyright © 2012, British Middle-East Center for Studies & Research, All rights reserved. 36 people fail to realise the value of a project plan in saving time, money and many problems. As you can see below this a table showing how I managed my time throughout the assignment. The purpose of this is to plan your project and know what is supposed to be done by the end of every month. Therefore doing this will keep you up to date with project and as a result you will not fall behind. Therefore as well as saving time it also prevent errors, because you’re not doing something that is already done and you’re not wasting time because the longer time acquired the more cost of staff which will in result cost the company. In the table the dates are included and facing every date is the accomplishments achieved or should be completed by that date, this is all shown below in the time management table.

Date Accomplishment

October - December I have Started to write my customer requirements as well as had an interview with the customer and wrote down all the requirements in order to start on the design specifications.

December 02-15 I have written the report for my design requirements, to say what the ideas were and what must the requirements be. Also I have finished the project plan of how long the project will take to finish, therefore I have made a table for the time management to see what I’ll be doing every month and to keep up with deadline for this project.

December 15-31 I have finished the project plan and have finished writing the customer requirements as well as started on design specification.

January 1-15 I have finished the design specifications and therefore included the fixed parameters. I have also started to look at different types of matrix selection methods.

January 15-31 I have researched into different types of methods for matrix selection methods and therefore decided to use the most appropriate for this project.

February 1-15 I have started to look at different types of 3D CAD system.

February 15-28 Part of my research I have found four types of CAD systems, and therefore compared them with each other to see which is the most suited for my design.

March 1-15 I have Chosen to Solidworks from the four CAD systems which are ANSIS, Solidworks, Autodesk 3D Max and VISI Flow.

March 15-31 I have started to use Solidworks, in order to finish the design I

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first have to learn to use the software and become more familiar with the interface of the software.

April 1-15 I have started to model the parts for my final product. These include the frame and the handle which holds the navigation system as well as the hands of the bike which the navigation system sits on.

April 15-30 I have finished making all the parts and therefore they are ready to be assembled.

May 1-15 I have finished the practical work for my project and all I have left is the overall Conclusion and Evaluation for my design to be done.

May 15-24 The project has finished and therefore is ready to be handed in. Therefore the project took a time of 181 days to complete and therefore that was with the help of managing my time correctly and finishing everything to date.

The data above this then put into a timeline using Microsoft project, therefore as you can see below every step depends on the one before it, if one task is not completed the next task cannot start until all tasks have followed one another to be completed. So the diagram below as you can see is the project plan used to plan out the time required to complete the product which was required by the customer and achieved. The duration of the project therefore was 181 days to achieve. The table provided show this evidence.

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Bibliography ANSYS. (2012, 05 01). ANSYS Products. Retrieved 05 01, 2012, from http://www.ansys.com: http://www.ansys.com/Products

Autodesk. (2012, 05 04). Autodesk 3ds Max Products. Retrieved 05 04, 2012, from http://usa.autodesk.com: http://usa.autodesk.com/3ds-max/features/

Flow, V. (2012, 05 05). VISI Flow. Retrieved 05 05, 2012, from http://www.vero-software.com: http://www.vero-software.com/products.php?page_id=1&sub_id=5

Solidworks. (2012, 05 12). SOLIDWORKS PRODUCTS. Retrieved 05 12, 2012, from http://www.solidworks.com: http://www.solidworks.com/sw/3d-cad-design-software.htm

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