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Hydrogen-Electric Motorcycle HHyyddrrooggeenn--EElleeccttrriicc MMoottoorrccyyccllee Final Project Report Designers: Dave Berkey, Josh Bitterman, Darren LeBlanc Michelle Lehman, Kevin McGarvey Sponsor: Electrion, Inc., Messiah College Collaboratory Advisor: Dr. Don Pratt May 13, 2002 2 Abstract “The number of vehicles on our roads and the number of miles driven by those vehicles are growing at an accelerating rate, resulting in increased national petroleum consumption and air pollution.” (Sutula, 2) In response to these problematic trends, new vehicles are being introduced to achieve better fuel efficiency while producing fewer harmful emissions. In view of this need, this project has worked in collaboration with Electrion Inc. to develop a personal transportation device using hydrogen, a zero- emissions fuel. The main focus of our team lied in the mechanical and electrical aspects of a small motorcycle, or scooter, rather than the implementation of the hydrogen fuel. With a prototype of the scooter provided for us by our industry contact, Dr. Joseph Kejha, we have made improvements to his design in order to solve several performance-limiting problems. The bulk of our work falls into three main areas of design: the body, the steering, and the electrical system. The body design, or chassis design, was accomplished using finite element analysis software, in which we were able to assess our material choice and analyze our frame design in order to construct the most efficient body. Our steering system will simply improve upon the present steering column and its actuation mechanism. The electrical aspect of this project incorporates the design of a system integrating Lithium Polymer batteries with the electric motor and overall control system. 3 Table of Contents Abstract 2 Table of Contents 3 Acknowledgments 4 1. INTRODUCTION 5 1.1 Description 5 1.2 Literature Review 5 1.3 Solution 10 2. DESIGN PROCESS 10 2.1 Chassis 10 2.2 Steering 11 2.3 Electrical System 13 3. IMPLEMENTATION 14 3.1 Construction 14 3.2 Operation 15 4. SCHEDULE 15 5. BUDGET 16 6. CONCLUSIONS 16 7. RECOMMENDATIONS FOR FUTURE WORK 16 References and Bibliography 18 Appendices 20 Appendix A – Designs 20 Appendix B – Structural Analysis 22 Appendix C – Specifications and Gantt Chart 23 4 Acknowledgements Our team would like to thank Dr. Joseph Kejha for giving us the opportunity to collaborate with him on this project, while allowing us much individual design freedom. We would like to thank Messiah College professor Dr. Tim VanDyke, and former Messiah College student, Shane Kinsley, for all of their assistance in learning and understanding finite element analysis and I-DEAS. Lastly, we would like to thank our team advisor, Dr. Don Pratt, for his input and guidance throughout the life of this project. 5 1. INTRODUCTION 1.1 Description The problem presented to us by our industry contact, Dr. Joseph Kejha, was to find a way to improve upon the basic idea for a hydrogen-powered scooter prototype he had already created. The main areas which needed improvement included the chassis, the fairings, the steering system, the suspension system (or lack thereof), and the electrical system. The foremost problem with the chassis design was that the sole central shaft was experiencing torsion with the onset of the scooter’s motion. The effects of wind resistance on the chassis only intensified this problem. Our goal was to eliminate this problem, while maintaining an extremely lightweight frame. We also intended to design fairings which would provide a protective plastic shield for the scooter as well as improve aerodynamics and aesthetic appeal. The problem to solve with the steering system was to find a way to provide ease of use for the rider as well as good maneuverability for the scooter itself, while improving upon the less-than perfect actuation mechanism that was in place. As for suspension, the scooter originally had no shocks; therefore, we intended to design and implement an effective suspension system. The electrical system of the prototype presented to us also needed some improvements. A high energy and power density electric system was desired by our industry contact. Our original objectives were to create a recumbent scooter that would satisfy the following specifications: 1) to have a dry weight of 100 lbs. or less; 2) to accelerate from 0 to 60mph in 10 seconds or fewer; 3) to cost less than $3500 for production; 4) to maintain stability for a rider up to 230 lbs.; 5) to have a stress safety factor for the frame of at least 2.0. As the project progressed throughout the year, though, we realized that due to the magnitude of the work before us, we would have to set aside some objectives in order to focus on the other, more important design aspects. Therefore, our intentions for this project became threefold: first, to design a frame for production that would be both lightweight and durable; second, to implement a method of steering that would improve maneuverability and ease of use; and third, to create a method to control the voltage both charging the batteries and driving the motor. The body design, or chassis design, was accomplished using finite element analysis software, in which we were able to assess our material choice and analyze our frame design in order to construct the most efficient body. Our steering system will simply improve upon the present steering column and its actuation mechanism. The electrical aspect of this project incorporates the design of a system integrating Lithium Polymer batteries with the electric motor and overall control system. 1.2 Literature Review Hydrogen Fuel For quite some time scientists have been researching different methods to power automobiles so that they are not only more economically efficient but also environmentally cleaner. The more popular methods that have been pursued include 6 deriving power from electricity, natural gas, hydrogen, nitrogen, and numerous hybrids using two or more of the aforementioned means. Many different manufacturers currently have electric vehicles available and gas- electric hybrids that use a small generator to charge the battery. These electric vehicles have a relatively short range and require long charging time between uses. A few manufacturers have been experimenting with hydrogen to power assorted vehicles. Currently there are two main methods of implementing hydrogen power for transportation functions: first, using a hydrogen fuel cell to create electricity to run a motor, and second, converting a gasoline engine to simply run on hydrogen instead. The first of these methods, the hydrogen fuel cell, is desirable in that it is truly a zero emissions vehicle, pure water being the only byproduct. The problems involved with using a hydrogen fuel cell are the immense cost of the cell itself, and the complications of efficiently transferring power to the wheels. Until more efficient and less expensive methods of using hydrogen fuel cells are developed, some manufacturers have decided to begin experimenting with hydrogen internal combustion engines. The benefits of this method include reasonably simple implementation, results that closely rival that of gasoline and diesel engines, and far better emissions than both gasoline and diesel (although it is not a zero emissions vehicle). Automobile manufacturers such as Mazda, Ford, and BMW are pioneering leading edge technology involving hydrogen internal combustion engines. Each of these three manufacturers has been working on and testing adapted versions of some of their own automobiles that run on hydrogen. BMW’s solution to the problem is to make simply convert their standard eight-cylinder engine to run on hydrogen and to store the hydrogen in the trunk in two large tanks. They claim that their hydrogen versions can perform very similarly to the gasoline counterparts, with only slight drops in horsepower and torque. Frame In recent years, there has been a revolution in the development and use of new materials for building bicycle frames. It wasn't that long ago that frames were made out of cast iron or even wood. Today, bicycles are made out of exotic materials such as titanium, aluminum, and carbon fiber. Bicycle frames in the 1990s are lighter and stronger than ever before. When a bicycle maker chooses a material to make a bike frame, he or she usually considers the following properties of the material: elasticity, yield strength, and ultimate strength. Materials Steel: Steel has good ultimate strength, with a much lower yield strength. This is good, since it means that a steel frame will bend well before it breaks, lessening the chance of a disastrous crash. Steel also has good elasticity. This combination of properties has made steel a longtime favorite of frame builders. Steel's only drawback is its relatively high weight. "Steel has been around a long time. It's probably the most researched, well known, and the most used material in just about every industry. It's the 7 most tunable, in the sense that if you want to tune a frame the way someone tunes a piano, you have a really great selection of tubes that you can select from." (Paolo Salvagione, modern frame maker) Steel is also generally the most affordable of the materials listed here. Aluminum: Aluminum has recently become a choice material for frames, because of its very light weight. However, aluminum has a yield strength very close to its ultimate strength. Therefore, it is quite brittle, and prone to breaking. This has many dangerous consequences for the rider of an aluminum bike, so frame makers have responded by over-building aluminum bikes with very large tubes and thick welds, to lessen the chance of frame breakage. "Aluminum is an interesting material. You can't really let it flex, because the more it gets to bend the quicker it reaches the end of its life.
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