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ASME Human Powered Vehicle ASME Human Powered Vehicle Benjamin Knaus Philip Basmadjian Nick Supat Mechanical Engineering Department California Polytechnic State University San Luis Obispo 2010 ASME Human Powered Vehicle i Statement of Disclaimer Since this project is a result of a class assignment, it has been graded and accepted as fulfillment of the course requirements. Acceptance does not imply technical accuracy or reliability. Any use of information in this report is done at the risk of the user. These risks may include catastrophic failure of the device or infringement of patent or copyright laws. California Polytechnic State University San Luis Obispo and its staff cannot be held liable for any use or misuse of the project. ASME Human Powered Vehicle ii Table of Contents Statement of Disclaimer ............................................................................................................... i Table of Contents ........................................................................................................................ ii List of Tables .............................................................................................................................. iv List of Figures .............................................................................................................................. v Chapter 1: Introduction ...............................................................................................................1 Chapter 2: Background ................................................................................................................2 Chapter 3: Design Development ..................................................................................................4 Chapter 4: Description of the Final Design .................................................................................10 4.1 – General Overview .........................................................................................................10 4.2 – Clearance ......................................................................................................................11 4.3 – Single Track Theory .......................................................................................................11 4.4 – Steering Assembly .........................................................................................................13 4.5 – Fairing Integration .........................................................................................................17 4.6 – Frame Design ................................................................................................................17 4.7 – Seat ...............................................................................................................................19 4.8 – Ergonomics ...................................................................................................................19 4.9 – Cadence and Gearing ....................................................................................................21 Chapter 5: Product Realization ..................................................................................................23 5.1: Manufacturing Processes ................................................................................................23 5.2 – Prototype Alterations ....................................................................................................29 5.3 – Manufacturing Recommendations ................................................................................31 Chapter 6: Design Verification (Testing) ....................................................................................33 6.1 Review of Design Verification Plan ...................................................................................33 6.2 Design Verification Results ...............................................................................................34 6.3 Serviceability ...................................................................................................................51 Chapter 7: Conclusions and Recommendations .........................................................................53 Appendices ...............................................................................................................................56 Appendix A: QFD, Pugh Matrix ...............................................................................................56 Appendix B: Drawing Packet ..................................................................................................57 ASME Human Powered Vehicle iii Appendix C: List of Vendors, Contact Information, Pricing .....................................................80 Appendix D: Vendor Supplied Component Specifications and Data Sheets ............................81 Appendix E: Detailed Support Analysis...................................................................................83 Appendix F: Gantt Chart ........................................................................................................89 ASME Human Powered Vehicle iv List of Tables Table 1: Speed and Gearing Spreadsheet ..................................................................................21 Table 2: Top Speed Test Results ................................................................................................34 Table 3: Vehicle Weight Test Results .........................................................................................35 Table 4: Turning Radius Test Results .........................................................................................36 Table 5: Vehicle Acceleration Test Results .................................................................................37 Table 6: Vehicle Braking Test Results .........................................................................................39 Table 7: Rider Weight Capacity Test Results ..............................................................................46 Table 8: Rider Height Capacity Test Results ...............................................................................46 Table 9: Quality Function Deployment (QFD) ............................................................................56 Table 10: Pugh Matrix ..............................................................................................................57 Table 11: Parts Cost...................................................................................................................73 Table 12: Hardware Cost ...........................................................................................................73 Table 13: Services Cost ..............................................................................................................73 Table 14: Patterson Model Parameters Definition .....................................................................83 Table 15: Bike Paramaters .........................................................................................................85 Table 16: Gantt Chart ................................................................................................................89 ASME Human Powered Vehicle v List of Figures Figure 1: Semi-prone concept sketch...........................................................................................4 Figure 2: Twist chain concept sketch ...........................................................................................5 Figure 3: Pivoting boom concept sketch ......................................................................................5 Figure 4: Initial u-joint concept sketch .........................................................................................7 Figure 5: Square tube, monocoque with crank behind u-joint ....................................................8 Figure 6: Current round tube frame design .................................................................................9 Figure 7: Rider in our recumbent bicycle ...................................................................................10 Figure 8: Single track diagram as applied to our model .............................................................12 Figure 9: Patterson model output plots comparing our bike and prefvious HPV bikes ...............13 Figure 10: U-joint apparatus exploded view ..............................................................................14 Figure 11: U-joint mounted on the frame with chain routing ....................................................14 Figure 12: U-joint and bottom bracket assemblies ....................................................................15 Figure 13: Detailed view of the u-joint as it is assembled on the bike ........................................15 Figure 14: Close up of u-joint apparatus ....................................................................................16 Figure 15: View of the front steering linkage system .................................................................17 Figure 16: Master assembly exploded view ...............................................................................18 Figure 17: Our finished bike frame and fork ..............................................................................18 Figure 18: Bike fit for recumbent ...............................................................................................20 Figure 19: Bike fit for triathletes ................................................................................................20
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