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Design and Analysis of a Human Powered Vehicle's Design and Analysis of a Human Powered Vehicle’s Frame and Seat Assistance Mechanism by Bradley S. Helm A Report Submitted to the Faculty of the Milwaukee School of Engineering in Partial Fulfillment of the Requirements for the Degree of Master of Science in Engineering Milwaukee, Wisconsin February 2017 2 ABSTRACT The objective of this project was to complete the redesign and analysis of a human powered vehicle (HPV) called the Heliocycle, which is an existing tricycle (also referred to as trike). The Heliocycle was a Senior Design Project that was completed at the Milwaukee School of Engineering (MSOE) by Bradley Helm, Kelly Bauserman, Michael Caelwaerts, and Nicholas Weis from September 2014 through May 2015. Since the Heliocycle’s debut in May 2015, it has been showcased and ridden, gaining exposure and feedback. In addition, a company (Omnium Cycles, LLC) was formed around the Heliocycle, and the Heliocycle received a provisional patent. This redesign was completed to improve the original design, based on knowledge gained through fabricating the initial prototype and feedback gathered during showcases. A brief market analysis determined a need for this trike and defined the target audience who would be most likely to buy and use this product. In order to complete this project, a five-stage design process was followed. Throughout these stages, this project involved engineering design and analysis, which included the selection of materials, mechanics of materials, and finite element analysis, as well as some minor business aspects. The analysis was completed to confirm the design would be safe and withstand the stated maximum load established during the design. There was communication with the potential fabrication team (FT) to ensure that the design is feasible to build. After the completion of this project, Omnium Cycles may build and test the second prototype of the Heliocycle. Note: the fabrication of the redesign was out of scope for this project. 3 ACKNOWLEDGMENTS There was assistance from others in order to complete this graduate capstone project. From the Milwaukee School of Engineering, several academic faculty members provided assistance. Assistance was provided by Dr. Subha K. Kumpaty in general project advising, Dr. Nebojsa Sebastijanovic in finite element analysis, Professor Gene A. Wright in business, and Professor Gary Shimek in literary and technical expertise. A special thank you is extended to Adam Fronek for his assistance in the areas of design and fabrication advising. 4 TABLE OF CONTENTS List of Figures ..................................................................................................................... 7 List of Tables .................................................................................................................... 10 Nomenclature .................................................................................................................... 11 Symbols ........................................................................................................................ 11 Abbreviations ................................................................................................................ 12 Glossary ............................................................................................................................ 13 Introduction ....................................................................................................................... 17 Description of the Project ............................................................................................. 17 Justification of the Project ............................................................................................ 18 Original Vision.......................................................................................................... 18 Future Sights ............................................................................................................. 19 Background Research ....................................................................................................... 20 Existing or Similar Technology .................................................................................... 20 Recumbent Design .................................................................................................... 20 Power Assistance ...................................................................................................... 22 Braking ...................................................................................................................... 25 Heliocycle ................................................................................................................. 28 Potential Market ............................................................................................................ 31 Market Description ................................................................................................... 31 Customer Description ............................................................................................... 32 5 What They Want ....................................................................................................... 32 How They Buy .......................................................................................................... 32 Best Ways to Communicate with Customers............................................................ 33 Literature Review ......................................................................................................... 33 Patents and Prior Art ................................................................................................. 33 Codes and Standards ................................................................................................. 34 Bicycles and FEA ..................................................................................................... 34 Bicycles and MS/Paraplegia ..................................................................................... 35 Mechanics of Tricycles ............................................................................................. 36 Product Specifications ...................................................................................................... 38 Design Objectives ......................................................................................................... 38 Design Constraints ........................................................................................................ 40 Methods............................................................................................................................. 42 Results and Discussion ..................................................................................................... 46 Idea Generation ............................................................................................................. 46 Redesign Model Development ...................................................................................... 55 Engineering Analysis .................................................................................................... 64 Factor of Safety Determination ................................................................................. 65 Gear Stress Analysis – Component Properties ......................................................... 66 Gear Stress Analysis – Bending Stress ..................................................................... 68 Gear Stress Analysis – Contact Stress (Pitting Resistance) ...................................... 73 6 Finite Element Analysis of Frame – Preliminary ..................................................... 76 Finite Element Analysis of Frame – Lowered Position Setup .................................. 78 Finite Element Analysis of Frame – Raised Position Setup ..................................... 82 Finite Element Analysis of Frame – Convergence Study ......................................... 86 Finite Element Analysis of Frame – Results............................................................. 89 Finite Element Analysis of Frame – Summary ......................................................... 95 Conclusions and Recommendations ................................................................................. 97 References ......................................................................................................................... 99 Appendix A: Codes and Standards Descriptions ............................................................ 103 Appendix B: MATLAB Code for Gear Stress Analysis ................................................. 108 7 LIST OF FIGURES Figure 1: Example of a Recumbent Bicycle ..................................................................... 20 Figure 2: Example of a Recumbent Tricycle .................................................................... 21 Figure 3: Center of Gravity of a Tadpole Tricycle ........................................................... 21 Figure 4: Center of Gravity of a Delta Tricycle ................................................................ 22 Figure 5: Example of a Hydraulically Powered Recumbent Tricycle .............................. 23 Figure 6: Example of a Pneumatically Powered Bicycle.................................................. 24 Figure 7: Example of an Electrically Powered Bicycle .................................................... 24 Figure 8: Example of a Rim Brake ..................................................................................
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