International Hellenic University School of Economics, Business Administration and Legal Studies MSc in Strategic Product Design Dissertation Thesis 31/1/2017 Motorcycle Design Defining a new typology and form for the electric motorcycle of the 21st century. Maioglou Dimitrios Student Name: Dimitrios Maioglou SID: 1106140007 Supervisor: Prof. Georgios Liamadis I hereby declare that the work submitted is mine and that where I have made use of another’s work, I have attributed the source(s) according to the Regulations set in the Student’s Handbook. January 2017 Thessaloniki - Greece 1 Abstract The following paper is a Thesis, written for the MSc in Strategic Product Design. The purpose of this project is to research the engineering and design identity of the electric motorcycle of the 21st century. As part of the project, a research has been conducted, regarding the history of motorcycles and engineering that shaped their current visual form. Following, in this paper, there has been presented the current technology in electric motorcycles with production models and brands that are investing in electric vehicles. The main goal of this paper, is to present a design proposal for an electric motorcycle. Based on the engineering research on electric motors for electric vehicles, a reader will find a full description of the parts that assembly an electric motorcycle, the important points that need to be addressed while designing a concept for an electric motorcycle and the trade-offs that must be resolved regarding the geometry, ergonomics and performance. At the final chapters, our concept electric motorcycle takes form with sketches and different variations. A final concept is being developed further and presented through Adobe Photoshop renders. For completing this project, I would like to thank my supervisor, Professor Georgios Liamadis, as he trusted me with a project that exceeded the available time frame and guided me through this process with his experience in Automotive Design. I would also like to thank Mr. Errikos Ampatzoglou, for his tutoring in vehicle design sketching and rendering and his professional experience and advise in a concept design follow through pipe line. 2 Table of Contents 1 Introduction ....................................................................................................................... 5 2 Project Target .................................................................................................................... 6 3 Target Group ..................................................................................................................... 7 4 Motorcycle History ............................................................................................................ 9 4.1 Types of Motorcycles .............................................................................................. 10 5 Current Trends & Aesthetics ........................................................................................... 18 6 Electric Motorcycles ........................................................................................................ 21 6.1 History of Electric Motorcycles................................................................................ 22 6.2 Existing Production Models ..................................................................................... 25 6.2.1 Zero Motorcycles ............................................................................................. 25 6.2.2 Victory Motorcycles - Empulse® TT ................................................................. 25 6.2.3 Energica Motor Company S.p.A. ...................................................................... 26 6.2.4 Lightning Motorcycle Corp .............................................................................. 27 6.2.5 Alta Motors ...................................................................................................... 28 6.2.6 Mission Motorcycles ........................................................................................ 28 6.2.7 KTM-Freeride E ................................................................................................ 30 6.2.8 BMW-Motorrad ............................................................................................... 30 6.2.9 Yamaha-PES2/PED2 ......................................................................................... 31 6.2.10 Harley-Davidson-LiveWire™ ............................................................................ 32 6.2.11 Johammer ........................................................................................................ 33 6.2.12 Saietta Group ................................................................................................... 34 6.2.13 LITO Green Motion .......................................................................................... 34 7 Electric Motorcycle Technology & Mechanics ................................................................ 36 7.1 Drive Systems .......................................................................................................... 36 7.2 Electric Motors ........................................................................................................ 37 7.3 Converters & Controllers ......................................................................................... 38 7.4 Batteries .................................................................................................................. 39 8 Modeling & Design .......................................................................................................... 40 8.1 Selection of Drive System, Motor & Batteries......................................................... 40 8.2 Geometry ................................................................................................................. 41 8.2.1 Trail .................................................................................................................. 41 8.2.2 Rake or castor angle (steering axis inclination) ............................................... 41 8.2.3 Wheelbase ....................................................................................................... 42 8.2.4 Wheel diameter ............................................................................................... 42 3 8.2.5 Weight (mass) and its position ........................................................................ 42 8.2.6 Center of gravity .............................................................................................. 43 8.2.7 Sprung and Unsprung Mass ............................................................................. 43 8.3 Ergonomics & Dimensions ....................................................................................... 44 8.4 Design Trade Offs .................................................................................................... 47 8.5 Chassis ..................................................................................................................... 48 8.6 suspension ............................................................................................................... 51 8.6.1 Front System- Hub Center Steering ................................................................. 51 8.7 Rear System ............................................................................................................. 54 9 Conceptualization & final design ..................................................................................... 55 9.1 Concept Sketches .................................................................................................... 55 9.2 Variations of Selected Sketch .................................................................................. 60 9.3 Final Render ............................................................................................................. 64 10 Conclusions .................................................................................................................. 65 11 References ................................................................................................................... 66 4 1 INTRODUCTION Motorcycle Design is a little bit more complex process than Automotive Design. This is since a motorcycle, is all in one, the engine, the body, the exterior and the interior of a car, altogether combined into a single space. Thus, a motorcycle designer needs to obtain technical knowledge of motorcycle engineering to deliver a concept from an idea. Moreover, motorcyclists, is a peculiar target group, with a technical knowledge higher than any other vehicle buyer. They need to know their motorcycle function, have a clear image of its parts and understand of their role. Most motorcyclists love engineering and they buy a motorcycle not from necessity but for passion. When a motorcyclist is choosing his next motorcycle, he is considering details that are a lot more different from those when looking to buy a car. It is not irrelevant the fact that when a potential car buyer is looking a car, in which he is interested, firstly steps back to have a full image of the body and the shape but in the case of a potential motorcycle buyer, firstly he steps more close to see the details of the engine and the frame quality and then tends to have a more complete view. In the new upcoming age of electric vehicles, motorcycles are tested as an archetype. Their shape has been always related to their engine and their form had the