1. The TEAMMATE A Mechanical Regenerative Braking Design Project Winter 2013 Team Eight 1

2. The Team John El-Tawil Colin MacKenzie Michael Matthews Alan Robinson Dr. Marek Kujath Supervisor 2

3. Outline Introduction Design Testing Design Requirements Budget Summary & Recommendations 3

4. Scope Design/build a mechanical regenerative braking system Capture energy dissipated during braking of a bicycle Lower input energy to accelerate from stop Improve rider efficiency IntroDesignTesting Design Requirements Budget Summary 4

5. The Design 5 IntroDesignTesting Design Requirements Budget Summary

6. The Spring System uses a spiral torsional spring Issue: Input is CW Output is CCW Solution: Charge outside Release inside 6 Figure 1 – Spiral Torsional Spring IntroDesignTesting Design Requirements Budget Summary

7. How the Spring will Work 1. 3. 2. 4. 7 Figure 2 – Spring Dynamics IntroDesignTesting Design Requirements Budget Summary

8. Custom Axle 8 Figure 4 - Custom Hub (Shimano, 2013) IntroDesignTesting Design Requirements Budget Summary Figure 3 – Standard Hub

9. Custom Axle 9 IntroDesignTesting Design Requirements Budget Summary Figure 5 – Custom Axle

10. 10 The System IntroDesignTesting Design Requirements Budget Summary Figure 6 – The System

11. Input Shaft 11 IntroDesignTesting Design Requirements Budget Summary Figure 7 – The Input Shaft

12. 12 The System IntroDesignTesting Design Requirements Budget Summary Figure 8 – The System

13. Output Shaft 13 IntroDesignTesting Design Requirements Budget Summary Figure 9 – The Output Shaft

14. Manual Control / Operation 14 IntroDesignTesting Design Requirements Budget Summary Figure 10 – The Manual Control Triggers

15. Testing Friction losses from system Weight losses from the system Energy gained from the spring 15 IntroDesignTesting Design Requirements Budget Summary Figure 11 – Testing

16. Test # 1: Friction Losses Energy could be lost in the system from bearing friction A speed test was run 5 times with chains attached and detached Final speeds were averaged and compared to determine if there were losses in energy 16 IntroDesignTesting Design Requirements Budget Summary

17. Friction Losses Chained RunsFinal SpeedElapsed Time (s) 117.85.3 220.24.8 317.85.3 415.45.5 517.75.2 Mean17.785.22 17 Not Chained RunsFinal Speed (km/h)Elapsed Time (s) 117.75.3 216.75.4 319.95.1 417.65.2 519.65.0 Mean18.35.2 Table 1 – Average speed with system not chained Table 2 – Average speed with system chained

18. Friction Losses 18 IntroDesignTesting Design Requirements Budget Summary

19. Test # 2: Weight Losses 19 IntroDesignTesting Design Requirements Budget Summary

20. Weight Losses With System RunDistance Travelled (m)Time (s) 124.319.58 219.887.46 323.388.65 423.388.84 524.169.39 Mean23.028.78 20 Without System RunDistance Travelled (m)Time (s) 121.937.84 220.667.33 320.667.45 418.816.54 523.388.01 Mean21.097.43 Table 3 – Distance and time for acceleration with system Table 4 – Distance and time for acceleration without system

21. Weight Losses 21

22. Test # 3: Energy Gained 22 IntroDesignTesting Design Requirements Budget Summary

23. Testing Results 23 IntroDesignTesting Design Requirements Budget Summary

24. Testing Summary 24 IntroDesignTesting Design Requirements Budget Summary

25. Key Design Requirements 25 IntroDesignTesting Design Requirements Budget Summary RequirementStatusDetails Must not reduce functionality  Cannot reverse Improved Rider Efficiency +16.1 J per charge Propel rider and bike mass of 100 kg  88.8 kg Assist in acceleration Balance Manually controlled engage and disengage Fatigue 100 charge cycles

26. Budget 26 SuppliesSupplierAcquiredProjected Cost Actual CostDifferential Mounting System BicycleCanadian TireY $ 345.00 $ 344.92 $ 0.08 Back RackCyclesmithY $ 70.00 $ 46.00 $ 24.00 Containment BoxHome DepotY $ 110.00 $ 160.80-$ 50.80 HingesHome DepotY $ 20.00 $ 3.59 $ 16.41 BoltsFastenal/Home DepotY $ 20.00 $ 68.99-$ 48.99 AluminumMetals 'r' UsY $ 200.00 $ 48.88 $ 151.12 Mechanical Transmission System SprocketsCyclesmithY $ 215.00 $ 58.98 $ 156.02 Bicycle ChainsCanadian TireY $ 80.00 $ 87.39-$ 7.39 Mounting Shafts/SteelMetals 'r' UsY $ 40.00 $ 66.76-$ 26.76 DerailleurCyclesmithY $ 50.00 $ 156.57-$ 106.57 BearingsPrincess AutoY $ 100.00 $ 166.68-$ 66.68 Disc Brake AxleIdeal BikesY $ 70.00 $ - $ 70.00 Energy Storage System Spiral Torsional SpringJohn Evans and Sons INC.Y $ 100.00 $ - $ 100.00 PinsDalhousie Machine ShopY $ 40.00 $ 5.61 $ 34.39 Disc Brake AssemblyCyclesmithY $ 150.00 $ 68.99 $ 81.01 Manual Control System Gear ShiftersIdeal BikesY $ 60.00 $ 28.75 $ 31.25 Dual Pulling Brake LeverIdeal BikesY $ 70.00 $ 46.99 $ 23.01 Locking Brake LeverIdeal BikesY $ 70.00 $ - $ 70.00 Shifter CablesCanadian TireY $ 10.00 $ 9.18 $ 0.82 Miscellaneous Wheel BuildingIdeal BikesY $ - $ 113.84-$ 113.84 HandleHome DepotY $ - $ 1.15-$ 1.15 ToolsCyclesmithY $ - $ 19.17-$ 19.17 Wheel StandIdeal BikesY $ - $ 287.49-$ 287.49 TOTAL $ 1,820.00 $ 1,790.73 $ 29.27 REMAINING $ 29.27 IntroDesignTesting Design Requirements Budget Summary

27. Future Recommendations 1. Custom torsional spring 2. Reduce weight 3. Add output tensioner 27 4. Different bicycle 5. Custom back rack 6. Better bearings IntroDesignTesting Design Requirements Budget Summary

28. Acknowledgements Angus Albert, Mark Dr. Marek Kujath Dr. Ted Hubbard, Dr. Clifton Johnston Ideal Bikes Cyclesmith Master Auto Supermileage Team Dr. Robert Bauer 28 IntroDesignTesting Design Requirements Budget Summary

29. Questions? 29 Website: http://poisson.me.dal.ca/~dp_12_08/http://poisson.me.dal.ca/~dp_12_08/ Twitter: @MechTeamEight

30. Key Ring Intro Design Requirements DesignTestingBudget Summary 30 Key Ring

31. Maximum Torque Required to Accelerate a Bicycle Basic ParameterValueChosen Provided by Manufacturer Total Mass of Bicycle and Rider 100 kg Initial Velocity0.0 m/s Final Velocity 15 km/hr (= 4.2 m/s) Distance10 metres Frontal Area of Average Rider Diameter of Bicycle Wheel.800 m 31

32. 32

33. Safety Factor of Bicycle Chain Basic ParameterValueChosen Provided by Manufacturer Maximum System Torque 44.0 Nm (= 33 ft-lb) Maximum Allowable Force in Low Quality ANSI 40 Chain (Standard Bicycle Chain) 940 lb Minimum Sprocket Diameter (12 Teeth) 1.5 in 33

34. Safety Factor of Bicycle Sprockets Basic ParameterValueChosen Provided by Manufacturer ** Minimum # of Sprocket Teeth 12 Sprocket MaterialSteel 1045 Shear Area of Sprocket Tooth Force in Chain Minimum Chain Wrap Angle 34

35. Safety Factor of Disc Brake Basic ParameterValueChosen Provided by Manufacturer Maximum System Torque 44.0 Nm (= 33 ft-lb) Maximum Pinching Force of Disc Brake 1200 lbf Radius of Disc Brake80 mm.67 35

36. Safety Factor of Spiral Torsional Spring Basic ParameterValueChosen Provided by Manufacturer ** Maximum System Torque44.0 Nm (= 33 ft-lb) Maximum Spring Angle of Deflection Spring Rate ‘K’ 36

37. Safety Factor of Shafts Subjected To Torsion Basic ParameterValueChosen Provided by Manufacturer ** Maximum System Torque44.0 Nm (= 33 ft-lb) Shaft Diameter1.5 in= 38.1 mm Shaft MaterialSteel 316 (Stainless) 37

38. Safety Factor of Shafts Subjected to Shear Basic ParameterValueChosenProvided by Manufacturer Maximum System Torque44.0 Nm (= 33 ft-lb) Shaft Diameter.75 in= 19.05 mm Shaft MaterialSteel 316 (Stainless) 38

39. Test # 4: Energy Storage System Efficiency 39 IntroDesignTesting Design Requirements Budget Summary