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Pedaling and Braking Forces and Their Effect on Suspension Performance

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Pedaling and Braking Forces and Their Effect on Suspension Performance Pedaling and Braking Forces and Their Effect on Suspension Performance by: Kathleen Kramer Nik Goodell Cesar Giron Mechanical Engineering Department California Polytechnic State University San Luis Obispo March 17, 2012 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 at San Luis Obispo and its staff cannot be held liable for any use or misuse of the project. Table of Contents Table of Contents Table of Contents ........................................................................................................................................... i Table of Figures ............................................................................................................................................ v Abstract ......................................................................................................................................................... 1 1. Project Introduction .................................................................................................................................. 1 1.1 Sponsor ............................................................................................................................................... 1 1.2 Objectives ........................................................................................................................................... 1 2. Background ............................................................................................................................................... 3 2.1 Suspension Independence ................................................................................................................... 3 2.1.1 Single Pivot .................................................................................................................................. 3 2.1.2 Four Bar Linkage ......................................................................................................................... 4 2.2 Suspension Dynamics ......................................................................................................................... 5 2.3 Potentiometers ..................................................................................................................................... 7 2.4 Inductive Proximity Sensors ............................................................................................................... 8 2.5 Frequency to Voltage Converter ....................................................................................................... 10 2.6 Power Meters .................................................................................................................................... 10 2.7 ANT Wireless ................................................................................................................................... 12 2.8 Strain Gauges .................................................................................................................................... 13 2.8.1 Theory ........................................................................................................................................ 13 2.8.2 Full Wheatstone Bridge ............................................................................................................. 13 2.9 DAQ - Collection Systems ................................................................................................................ 14 3. System Design ........................................................................................................................................ 16 3.1 Specifications .................................................................................................................................... 16 3.2 Brake Strain Bridge ........................................................................................................................... 16 3.2.1 Theory ........................................................................................................................................ 16 3.2.2 Solid Works Analysis................................................................................................................. 17 3.2.3 Wheatstone bridge design .......................................................................................................... 18 3.2.4 Strain Gauge Selection ............................................................................................................... 18 3.3 String Potentiometer ......................................................................................................................... 19 3.4 Crank Strain Bridge .......................................................................................................................... 20 3.4.1 Theory ........................................................................................................................................ 20 3.4.2 Strain Bridge Design .................................................................................................................. 22 3.4.3 Finite Element Analysis of the Crank Spider ............................................................................. 22 i Table of Contents 3.4.4 Strain Gauge Selection ............................................................................................................... 23 3.5 Crank Bridge Amplifier .................................................................................................................... 23 3.6 Logomatic V2 Data Collection Board .............................................................................................. 25 3.7 Inductive Proximity Sensors ............................................................................................................. 25 3.8 Frequency to Voltage Converter ....................................................................................................... 26 3.9 Circuit Design ................................................................................................................................... 26 3.10 Swoop Data Collection Board......................................................................................................... 27 3.11 Materials and Design ...................................................................................................................... 28 3.12 Sampling Rate ................................................................................................................................. 30 3.13 Modifications to Data Collection System for Initial Braking vs. Suspension Testing ................... 32 4. Fabrication and Setup ............................................................................................................................. 33 4.1 Brake Strain Bridge ........................................................................................................................... 33 4.1.1 Gauge installation ...................................................................................................................... 33 4.1.2 M-Coat F Protective Coating ..................................................................................................... 34 4.1.3 Wiring to the Swoop Board ....................................................................................................... 34 4.2 String Potentiometer ......................................................................................................................... 35 4.2.1 Mounting Plate ........................................................................................................................... 35 4.2.2 Pulley mount .............................................................................................................................. 35 4.2.3 Cable End Clamp ....................................................................................................................... 36 4.3 Crank Strain Bridge .......................................................................................................................... 37 4.3.1 Gauge installation ...................................................................................................................... 37 4.3.2 M-Coat F Protective Coating ..................................................................................................... 37 4.3.3 Wiring to the Bridge Amplifier .................................................................................................. 39 4.4 Logomatic V2 Data Collection Board .............................................................................................. 39 4.5 Inductive Proximity Sensors ............................................................................................................. 41 4.5.1 Design ........................................................................................................................................ 41 4.5.2 Setup .......................................................................................................................................... 42 4.6 Frequency to Voltage Converter ......................................................................................................
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