Riding Into New Territories

Ricardo Motorcycle Conference 7.0

RicardoFeature heading Quarterly Review Q2 2013 Riding into new

A focus on the latest in technology, markets innovation and sustainability BMW launches into the maxi- scooter sector with powertrains Riding into new engineered by Ricardo territories RQ extract: Q2 2013

Interview Jerome Guillen, Tesla Motors Military economy Helping the US forces use less fuel Climate change action Ricardo-AEA helps draw up Kenya’s low-carbon development pathway BMW maxi-scooter BMW maxi-scooter

MotoRCyCLes AND PeRsoNAL tRANsPoRtAtIoN Riding into new territories

BMW Motorrad is renowned for its touring bikes and, more recently, its sports bikes too. Yet with the new C600 Sport and C650 GT maxi scooters, with a powertrain engineered by Ricardo, the Munich-based premium motorcycle maker is entering a completely new sector of the market. Jesse Crosse talks to Ricardo’s Paul Etheridge about how this ambitious programme was completed – in record time

Personal private mobility is a phrase For premium motorcycle Premium product – at a which began to appear frequently in manufacturer BMW Motorrad this cost-competitive price the late 1990s: it neatly sums up the presents both an opportunity and a For BMW this further new sector value that human beings place on challenge. In the last few years the – urban mobility, which includes independence, regardless of which German company has been especially scooters, required yet another new socio-economic group they belong successful in the touring bike market approach to product development. to. Urban mobility, in its turn, has now and produces a number of ‘best in The new ‘maxi’ scooter is available in become a clearly identified sector in class’ products based on its iconic both C600 Sport and C650 GT models, the motorcycle business at a time boxer twin engine. though both share the same engine when individual use of cars in many BMW has also looked to expand capacity of 650 cm3. The new scooter urban areas is being discouraged by moving into new sectors. By does not compete with the multitude or is becoming more difficult due to launching the S1000RR in 2009 it of smaller 125-400 cm3 machines congestion. successfully went head-to-head with available: in fact, BMW has chosen a Providing competitive options for established Japanese sports bike level of the market currently occupied two-wheeled personal mobility is thus manufacturers in a highly specialized by only four or five competitors. becoming an ever more important market sector. In 2011 the six- Maxi scooters are especially popular area of the market for motorcycle cylinder K1600, a range-topping in Europe, with Spain and Italy in manufacturers, with the need for touring bike, further established particular representing the strongest affordable transport growing at a BMW in a sector which it already markets. Despite the premium nature rapidly accelerating rate. dominated. of the products (a maxi scooter

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MotoRCyCLes AND PeRsoNAL tRANsPoRtAtIoN Riding into new territories

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the BMw C600 and C650 engine and transmission in numbers: “we shouldn’t underestimate the challenge of putting type: 2-cylinder 4-stroke liquid-cooled engine, 4 valves per cylinder Bore x stroke: 79 mm x 66 mm such a big engine in a scooter. we worked very closely with Capacity: 647 cm3 Rated power: 44 kw at 7500 rev/min BMw and the vehicle engineering partner in the concept Max. torque: 66 Nm at 6000 rev/min definition phase to make sure the package was right – it’s Compression ratio: 11.6:1 emission control: Closed-loop 3-way catalytic converter, exhaust very tight.” Paul Etheridge, chief engineer for Ricardo standard eu-3 Maximum speed: 175 km/h Fuel consumption at constant 90 km/h: 4.4 litres per 100 km Fuel consumption at constant 120 km/h: 5.6 litres per 100 km Fuel type: Premium grade fuel, unleaded 95 (RoN) Alternator: three-phase generator, 588 w Battery: 12 V / 12 Ah, maintenance-free Clutch: Centrifugal Gearbox: CVt Final drive: Chain drive in oil bath

costs in the region of €10,000) the and readily available transmission industrialization of the engine, market is ferociously cost competitive components. transmission, swing-arm, final – so it was imperative that while In reality, this set of objectives drive and exhaust system. It was incorporating all the brand image required a complete overhaul of the a decision for BMW to outsource a and quality attributes expected of a existing driveline concept, taking in significant amount of engineering BMW, the new scooters would still be everything from the engine through support for this product, due to affordable. to the back wheel. The most popular internal capacity limitations. Ricardo has already completed transmission type used in scooters Ricardo supported the powertrain two other successful engine projects is the step-less automatic CVT. design, an external scooter specialist for BMW Motorrad: the four-cylinder The original concept incorporated was involved in vehicle design K1300 upgrade between 2006 and a bespoke CVT module, which support, a new engine control unit 2008 was followed by design support Ricardo would need to replace with a (ECU) was developed, and the BMW of the six-cylinder K1600 power train commercially available alternative – a industrialization and quality team between 2006 and 2010 (see RQ Q2 major task. worked together with the nominated 2009 and RQ Q2 2011 respectively). In engine manufacturer. Clearly, BMW 2009 Ricardo was appointed to review Detailed engineering itself was the most important member an existing powertrain concept for the of the project team, closely managing Below: Parallel twin proposal engine is inclined at new scooter, an area of considerable This first stage consisted of a short the whole process to ensure that 70 degrees forward previous Ricardo experience thanks study, completed in just three the finished result stayed true to its to allow a low step- through platform, to work on earlier scooter projects months. During that time Ricardo originally product brief and also met while a 270-degree in the European and Asian markets. also supported the development of the exacting brand, technical, quality crankshaft was chosen The task was to keep the price entry a detailed engineering proposal for and cost requirements of the company. for both smoothness and a distinctive sound. point competitive, yet also to simplify the main programme including the The project was challenging for a transmission is by CVt. the design using certain well proven complete design, development and number of reasons, the first being

the challenging time schedule for Complete powertrain large number of supplier visits the introduction of a new market design with designers, manufacturing sector product. Secondly, despite Although they may look simple, engineers and test engineers so that we the relatively high cost of scooters at scooters are complex machines and were in control of the overall process, this level, the final product still had are if anything even more complex frequently reviewing manufacturing to remain price-competitive within than a conventional motorcycle. Some aspects with component suppliers and the segment. In practical terms there premium machines like the BMW have BMW quality specialists, and the hand- were also geographical and cultural ABS, there are a significant number of over of documentation,” explains Paul differences to overcome as the bodywork components and the driveline Etheridge, Ricardo’s chief engineer on project was split between Germany, is both complicated and compact. the project. UK, Czech Republic, Italy and Asia. The Ricardo’s final brief was to support The powerful 647 cc engine produces engineers were also up against tough the design of a complete powertrain 44 kW [60 hp] and 66 Nm [48 lb ft] competition technically from two very compatible with BMW’s worldwide torque. It is a twin-cylinder, four-stroke, distinct and established competitors sourcing strategy, incorporating locally double overhead camshaft water- in this sector – for example the sourced materials whilst employing cooled design. The cylinders are heavily Yamaha TMax in the sport segment techniques meeting BMWs exacting inclined towards the front at 70°, a and the Suzuki Burgman in the manufacturing and quality standards. typical feature in scooters where a low comfort sector. “During this programme we made a step-through platform is needed. “We

12 RQ • Q2 • 2013 RQ • Q2 • 2013 13 BMW maxi-scooter BMW maxi-scooter the BMw C600 and C650 engine and transmission in numbers: “we shouldn’t underestimate the challenge of putting type: 2-cylinder 4-stroke liquid-cooled engine, 4 valves per cylinder Bore x stroke: 79 mm x 66 mm such a big engine in a scooter. we worked very closely with Capacity: 647 cm3 Rated power: 44 kw at 7500 rev/min BMw and the vehicle engineering partner in the concept Max. torque: 66 Nm at 6000 rev/min definition phase to make sure the package was right – it’s Compression ratio: 11.6:1 emission control: Closed-loop 3-way catalytic converter, exhaust very tight.” Paul Etheridge, chief engineer for Ricardo standard eu-3 Maximum speed: 175 km/h Fuel consumption at constant 90 km/h: 4.4 litres per 100 km Fuel consumption at constant 120 km/h: 5.6 litres per 100 km Fuel type: Premium grade fuel, unleaded 95 (RoN) Alternator: three-phase generator, 588 w Battery: 12 V / 12 Ah, maintenance-free Clutch: Centrifugal Gearbox: CVt Final drive: Chain drive in oil bath

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the BMw Motorrad perspective thomas Ringholz, project leader, powertrain, BMw Motorrad

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How competitive is the maxi scooter Please outline some of the benefits that using market and how difficult is it to engineer a an experienced powertrain developer like product from scratch capable of being truly Ricardo brought to the project? competitive? Ricardo was already familiar with multi- the urban mobility segment is a new and cultural programs, and their experience important one for BMw Motorrad. Most with Asian suppliers helped to save time important is to define and set targets at an to fulfil the time schedule. For Asia more early stage for a successful entry in a new design/drawing effort and design/drawing segment, especially for powertrain behaviour loops were needed in comparison to in the vehicle, so that the result will be europe. Ricardo always provided this need competitive overall and also be able to beat satisfactorily. BMw and Ricardo specialists the competition in magazine road tests. complemented each other in a good way, and they developed a very efficient test How challenging was it developing scooter programme. compared to a motorcycle? After investigating and understanding the the early project gateway was passed based “It was decided to use a chain because it is efficient, quiet scooter specific product requirements (i.e. solely on analysis and simulation results. How for package and transmission) in addition valuable was this approach to BMw Motorrad and presents fewer manufacturing challenges than gears” to the definition of specific test programs, and would you do it again? it was developed in the same way and with BMw has good experience with this, and we Paul Etheridge, chief engineer for Ricardo same standards as our motorcycles. now use analysis based frontloading on all projects. though overall control was retained by BMw Motorrad, a significant proportion of the the press reviews were very good. How shouldn’t underestimate the challenge gives the same firing interval as you enclosing the final drive chain. Swing cylinder power unit would then be project was outsourced to partners. How satisfied are you with the end result given of putting such a big engine in a scooter,” would find on a 90° V-twin and we arm length is critical to provide good too wide. So scooter drive trains are unusual was this for BMw Motorrad and what that this project was a first for BMw Motorrad says Etheridge. “We worked very closely settled on that crank angle for two stability for the rider and in order typically arranged sequentially, one were the benefits? on several levels? with BMW and the vehicle engineering reasons. The first was to provide better to achieve this at the same time as component after the other. The drive is Development with the support of external Press and market responses to our new partner in the concept definition phase inherent vibration levels for a smoother locating the engine in the correct place transmitted from the crankshaft to the partners is usual for BMw Motorrad for many C600 and C650 scooters are very promising. to make sure the package was right – it’s ride. The second was to give the engine in the chassis, the transmission is CVT (mounted behind the engine) by a years now. In this case it was new because we we will observe the urban mobility market very tight.” a distinctive sound, a crucial aspect of angled up at the rear to provide space central primary drive chain designed to decided to use partners for powertrain and to define the future needs. It will be a Crankshaft balance is a crucial aspect the BMW brand and something our client for the swing arm and final drive. This last the life of the power train. vehicle, for simultaneous development. there challenging target to get and keep BMw there of the design. The engine is a parallel had specifically asked for.” arrangement of the drivetrain also “It was decided to use a chain were advantages for our internal capacity as a key player. twin, which in itself gives a number of provides robustness and refinement because it is efficient, quiet and planning. the programme needed a high options in relation to crankshaft angle. Driveline and keeps unsprung weight to a presents fewer manufacturing amount of flexibility in workforce capacity for “Those choices influence balance and Scooters in this class usually have minimum for good handling. challenges than gears,” explains design as well as for engine build and testing. sound as well as the manufacturing double sided swing arm for the rear An ideal configuration would be Etheridge. The drive sprocket on the this was provided well by our partners. process. In this engine BMW chose a suspension – but for the BMW a single to mount the CVT directly on the CVT end incorporates a torsional 270° crank,” explains Etheridge. “That sided swing arm was selected, also end of the crankshaft, but the twin damper to protect the chain from the

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peak impulses of the engine, a crucial parts, Ricardo was able to improve do that to shorten the normal new train, too, reporting that “the two sophisticated aspect of the design. powertrain efficiency and cut the bill product development process.” scooters accelerate briskly and cruise analysis and New focus on motorcycles and personal simulation The layout of a scooter final drive, of materials for the powertrain from at high speed…like motorcycles.” techniques meant transportation from the output end of the CVT to the the original concept layout without Positive reviews North America’s Cycle World, testing that there was no rear wheel, varies considerably from compromising quality: a major The C600 Sport and C650 GT are now in the range in Madrid, was equally need to build costly prototypes to prove manufacturer to manufacturer. First of achievement. production and receiving good reviews. enthusiastic, describing the comfort that the engine could all there has to be a simple reduction The usual BMW development “The engine and transmission work and convenience of the new model deliver the planned gearbox. This cannot be placed process involves building a first well together, not always a given with as “all very scooter-like but with a lot power and torque outputs immediately after the engine because prototype to prove that the design can this kind of CVT drivetrain,” said the more punch from the engine bay…. the torque multiplication would be too achieve the planned power and torque UK Daily Telegraph, adding “on many That’s an important point: The GT (and high for the CVT to withstand. Beyond outputs, but on this occasion things scooters there’s a small delay between the 2-in. shorter overall, 25-lb. lighter that is the transmission system to the were different, as Paul Etheridge opening the throttle and the drive Sport) is not a gutless grocery-getter.” rear wheel. One production solution explains: “This is one of the first BMW being taken up, making low-speed The new C600 Sport and C650 GT xxxxxx uses no primary drive at all and has Motorrad products which has gone riding awkward, but on the BMWs it’s clearly represent another success for two final drive chains instead, but it through the early project gateways immediate, smooth and predictable, Ricardo and its client, BMW. It is an could be argued that this cancels out based solely on analysis and simulation and when you give it a handful the achievement of which both companies any efficiency gained. Another solution results. I think that is a real plus point acceleration is strong: 0-60 mph takes are rightly proud. Together with its is to use a gear train along the length for Ricardo’s process, which involves less than 6 seconds.” partners, BMW has succeeded in of the swing arm; an elegant solution front-loading with analysis using our Motor Cycle News also gave producing a premium product at the but one which, again, lacks efficiency extensive CAE software tools to reduce the engine the thumbs up, calling right price and, perhaps even more due to the number of gears, carries the number of design and development it “powerful for a scooter, with a importantly, delivering the kind of an NVH risk and has a significant cost iterations and associated prototype very motorbike-like throaty roar.” performance and brand attributes that penalty compared to alternatives. costs. We had to prove that we could Ridermagazine.com liked the power its customers demand. A shaft drive was ruled out on the grounds of cost, and disadvantages due to the relatively short swing arm length of the scooter, so finally BMW decided on a fully enclosed, conventional chain drive. It was further decided to the motorcycle sector is a complex one, and understanding it run the chain in an oil bath, and which requires in-depth product engineering and industry knowledge, as is expected to last much longer than a ”this is one of the first BMw Motorrad products which Paul Etheridge, recently appointed head of the Ricardo’s German normal chain final drive. The CVT itself based Centre of excellence in Motorcycle engineering explains needs servicing every 20,000 km, the has gone through the early project gateways based usual interval for such a device. It’s absolutely crucial to understand the solely on analysis and simulation results. I think that is a market and technology context of motorcycle Powerful sound real plus point for Ricardo’s process” and other two-wheeler projects, and to The original engine concept remained empathise with the product’s customers. substantially unchanged and the 270° Paul Etheridge, chief engineer for Ricardo one of the key factors that makes our Centre crankshaft, bore and stroke of 79 mm of excellence so successful in serving x 66 mm (bore size shared with BMW’s premium, technology-led brands such as K1200 motorcycle), balancer shaft BMw (and others) as well as the more volume layout and double overhead camshaft and value-driven manufacturers in emerging were all carried forward throughout the Asian markets is that our team lives and project. breathes the product. However, Ricardo carried out a good we are all very keen motorcyclists, and deal of detailed work to make the we understand not only what influences almost any complexity of motorcycle or design production ready. The usual the customer, but also the underlying personal transportation project, from the refinement and analysis of the engine’s technologies and the imperatives of each most technologically advanced products for gas flow and the mechanics of the market. In my own case, I have been working luxury and sports brands to the most value- valve train were achieved using WAVE on motorcycle projects at Ricardo for nearly driven for emerging markets. In addition, and VALDYN respectively to optimize 30 years – almost as long as I have held a based at our Motorcycle Centre of excellence combustion efficiency and valve train motorcycle licence. we have added significant new development dynamics. Then Ricardo’s design team Ricardo has a unique track record of resources including, for example, the recent performed some detailed engineering successfully delivering motorcycle engineering commissioning of our brand new motorcycle to integrate certain BMW standard projects dating back to the 1920s, and in chassis dynamometer facility. parts into the engine. A considerable the past 25 years we have developed our From concept design to production amount of analysis was also done on motorcycle engineering activities around implementation, and while meeting the the driveline, again using VALDYN. a specialist team equipped with dedicated technology transfer and engineering needs of In addition, Ricardo worked closely facilities. In my opinion none of our competitors our global clients, our aim is always to create with the primary chain supplier, which can provide such a proven, specialized and a fantastic product that customers will want also performed its own independent diverse whole motorcycle engineering service. to buy. that’s where our extensive experience analysis to ensure the absolute working with our colleagues across the and enthusiasm for motorcycles really pays robustness of the final component. global Ricardo organization, we can deliver dividends for Ricardo clients worldwide. By streamlining and basing the engine around globally produced components and BMW standard

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16 RQ • Q2 • 2013 RQ • Q2 • 2013 17 Ricardo UK Ltd Shoreham Technical Centre (Head Office) Shoreham-by-Sea West Sussex BN43 5FG UK T: +44 (0)1273 455611 E: [email protected]

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