1. R.I.T. 175 th Anniversary Chopper Senior Design Team (Project Number 05912)

2. Diverse Team Members Advisors –Dr. James Taylor (ISE Associate Professor) –John Bonzo (Brinkman Lab Facilities Manager) Mechanical Engineering –Jonathan Howard –Alexandra (Alli) Collier –Lee Gagne Industrial Engineering –Jeremy Rank –John Johnson –Anthony Rounding Electrical Engineering –Curtis Vana Industrial Design –Scott Janis –Devin Connolly –Tim Houck

3. Agenda Needs Assessment Concept Development Feasibility Assessment Specifications Analysis and Synthesis

4. 175 th Anniversary Chopper Project Description / Desired Outcomes Convert stock 883 Harley-Davidson Sportster into custom chopper prototype Create customization kit for aftermarket sales –Conversion components must be bolt on –No significant modifications can be made to the frame

5. Rochester Institute of Technology Senior Design Team Santa Cruz Harley-Davidson –Primary stakeholder for conversion kit Conversion Kit Customers –Approximately 500 Sportsters are manufactured daily Stakeholders

6. Needs Assessment Team researched chopper motorcycles Talk with Mike James and Bob Davis of Santa Cruz Harley-Davidson

7. Team developed a list of order qualifiers: –Rear end of the bike shall change –Front end of the bike shall change –Sheet metal on the bike shall change –Electronics on the bike shall change –Ride height shall change –Paint on the bike shall change –Seat on the bike shall change –Custom parts must be bolt on –Bike must be operable Needs Assessment

8. System changes to meet order qualifiers: –Fuel TankFuel Tank –Handlebars / ControlsHandlebars / Controls –Ride HeightRide Height –Wheel DesignWheel Design –TireTire –Drive SystemDrive System Concept Development –Wheel HubsWheel Hubs –HeadlightHeadlight –ElectricalElectrical –ExhaustExhaust –SeatSeat –Conversion KitConversion Kit

9. –Methods Used Pros & Cons Pugh’s Method Weighted Concept Evaluation Expert input / discussion Feasibility Analysis

10. Electronics Specifications Increase Lighting –Hurt Motorcycle Accident Study ½ of all motorcycle accidents involve a motor vehicle (automobile) violating the motorcycle right-of-way Failure to recognize and detect motorcycles in traffic was the predominating cause of motorcycle accident –Freedman and Ketron Lighting Study Found that the adding lights to the motorcycles rear and sides improved conspicuity

11. Electronics Specifications Digital Control Unit RPM signal User Interface 12VDC Battery LED Driver Accent Lighting( LEDs) Accent Lighting System General Layout System Schematic Cost Analysis

12. Triple Clamp Specifications Design Constraints –Safety –Machinability –7 Degree Rake Angle –Forks –Steering stem –Mid-Glide front end –Handlebars –Style

13. Top Triple Clamp Analysis Top Triple Clamp with 7G Horizontal Impact Loading Top Triple Clamp with 3G Vertical Impact Loading Max Stress 29,000 psi Max Stress 9,300 psi

14. Lower Triple Clamp Analysis Lower Triple Clamp with 7G Horizontal Impact Loading Lower Triple Clamp with 3G Vertical Impact Loading Max Stress 9,000 psi Max Stress 37,000 psi

15. Front Wheel Specifications Design Constraints –Safety –Manufacturability –Style –New Front End Design Rear Wheel

16. Front Wheel Concepts Preliminary Design Issues –Manufacturability –Safety

17. Front Wheel Analysis Impact Load Torsion Test 6 G Load Max Stress 8,123 psi 3,500 lb Load Max Stress 20,071 psi

18. Front Hub Analysis Impact Load Torsion Test 6 G Load Max Stress 2,264 psi 3,500 lb Load Max Stress 8,100 psi

19. Kit Contents Custom Parts Designed and Manufactured Front Wheel Front Hub Front Axle Rear Wheel Rear Hub Rear Axle Triple Clamps –Top and Bottom Steering Stem Shaft Steering Stops Modified Purchased Front Sprocket Modified Purchased Rear Sprocket Tank Mounts Seat Mounts Seat Pan Ignition / Key Casing Converted To Hydraulic Clutch Exhaust Paint Scheme and Implementation –Gas Tank –Rear Fender –Oil Cover –Electronics Cover –Frame Engraved Designs On The Air Intake and Engine Casing Cutting Fender Struts and Remanufacturing Chrome Covers Brake Light LED Lighting System

20. 11inch Eye-To-Eye Shocks Inverted Forks Handlebars Front and Rear Tires Chain Air Intake Filter Chrome Engine Covers Single Rider Seat Chrome Swing Arm Headlight Slave Cylinder Kit Contents Aftermarket Parts Purchased and Implemented

21. Lessons Learned Always have a predetermined contingency –In the feasibility analysis, we only decided upon the optimal solution Fender attachment Critical path – reconstructing the critical path to make difficult tasks non-sequential

22. Questions

23. Shoulder Moment Reduction Original design M (shoulder) = (18.62N*.170m) + (10.78N*.480m) M (shoulder) = 8.34 Nm New Design M (shoulder) = (18.62N*.120m) + (10.78N*.340m) M (shoulder) = 5.89 Nm Moment Reduction – 29% Back

24. Algorithm Back Check State of Comparator Interrupt Flag Peak Check Is Peak? Increment Counter Have 45 peaks been counted? Toggle Output Begin Reset Counter General outline of lighting control algorithm Comparator state check Increment Toggle Output

25. Lighting Control System Back Power conditioning circuit Signal conditioning circuit Processing

26. Cost Analysis Pugh’s Method Comparison Back Final PartsUA7805CPIC12F67 5 PVDZ172NPCB Terminals Project Enclosure Manufactu rer Texas Instruments MicrochipInternational Rectifier Radio Shack FunctionVoltage Regulator Signal Processor Solid State Relay TerminalsEnclosure Quantity2228 (2 sets of 4) 2 Price per.522.158.502.293.99 Price for 2 sets 1.044.3174.587.98 Total Project Price $34.90 Final Parts UA7805CPIC12F6 75 PVDZ172NPCB Terminals Project Enclosure Manufact urer Texas Instruments MicrochipInternational Rectifier Radio Shack FunctionVoltage Regulator Signal Processor Solid State Relay TerminalsEnclosure Quantity2228 (2 sets of 4) 2 Price per.522.158.502.293.99 Price for 2 sets 1.044.3174.587.98 Total Project Price $34.90

27. Digital Control Unit Device Comparison Algorithm Back

28. Rear Wheel and Hub Back

29. –Clean up controls – sleeker look –Hide control cables within handlebar –Change handlebar shape / geometry Biomechanics –Use twist-grip clutch –Suicide Shift –Custom foot controls Handlebar Control Concepts Back

30. –Lower ride height – rear end –Shorten shocks –Rigid Hard-tail design –Redesign rear suspension geometry Ride Height Concepts Back

31. –Three claw design 3-dimensional 2-dimensional –Solid Wheel Design Spoke Appearance –Incorporate tiger image into design –Fabricate wheels in-house (Brinkman Lab) –Outsource wheel fabrication Wheel Design Concepts Back

32. –Increase rear tire width Size Range – 180mm – 220mm –Change front tire to match new rear tire –Find similar front & rear tire pattern Tire Concepts Back

33. –Switch from belt to chain drive –Switch to narrower belt –Use current belt Drive extension / spacer to accommodate new rear tire Widen swing arm –Replace existing drive covers Chrome Powder coat Aftermarket color Drive System Concepts Back

34. –Fabricate all components of kit –Purchase all components (aftermarket) –Combination of purchase / fabrication –Final Kit delivery All components – 1 set Documentation –“Bolt on” components Conversion Kit Concepts Back

35. –Design hubs to fit custom wheel –Purchase aftermarket hubs Requires wheel design to conform Wheel Hub Concepts Back

36. –In-house custom fabrication –Purchase aftermarket headlight –Remove headlight from design –Reuse stock headlight Headlight Concepts Back

37. –Left exit exhaust –Converging exhaust pipes (two into one) –Shortened straight pipes –Street sweeper pipes –Purchase aftermarket pipes –Fabricate exhaust in-house Exhaust Concepts Back

38. –Replace stock two-up seat –Single seat Fabricate in-house Purchase aftermarket –Redesigned two-up seat Fabricate in-house Purchase aftermarket –Sissy bar Fabricate in-house Purchase aftermarket –Incorporate Logo into seat design RIT 175 th anniversary Sponsor Logo Seat Concepts Back

39. –Pugh’s Method Electrical Feasibility Back

40. –Integrate rear lights into rear fender –Develop proximity sensors –Develop variable intensity lighting –Accent lighting for engine –Custom turn signals –Ignition Access code Toggle switch Electrical Concepts Back

41. –Variable intensity lighting Pro: –Safety (increase visibility) –Aesthetically pleasing Con: –Not visible during the daytime –Proximity sensor system Pro: –Safety (visibility) Con: –Cost –Time required to implement –Resources (people) Electrical Feasibility Back

42. Custom designed tank Cons: Team lacks expertise in metalworking Cost to outsource fabrication of in-house design ~ $2000 per tank Pros: Radical one of a kind Does not compromise the Industrial Designer’s design Commercially available tank Cons: Compromises the Industrial Designer’s design Not a radical design Pros: Cost: ~$600 per tank Fuel Tank Feasibility Back

43. Weighted concepts Fuel Tank Feasibility Back

44. Pugh’s method Fuel Tank Feasibility Back

45. Custom built handlebars Cons: No member of the team has experience designing handlebars Pros: Conceal controls Change look of bike from dirt bike to a chopper Purchase handlebars Cons: Cost: ~ $3000 per set Pros: Built by manufacturers with experience Conceal controls Changes look of bike from dirt bike to chopper Handlebars Feasibility Back

46. Remove shocks Cons: Turns bike into rigid, decreasing the ride ability of the bike Pros: Gives bike a sleeker look by removing the shocks Shorten shocks Cons: May result in possible problems with concerning clearance, ground clearance and handling Cost of new shocks $281 per set Pros: Gives the bike a squatter stance As compared to the rigid, the bike is easier to ride (comfort) Ride Height Feasibility Back

47. –3D design Cons: –Requires adding material to the wheel blank –Safety concerns (excess weight) –Machinability Pros: –Radical custom look –2D design Cons: –Not as custom Pros: –Machinable –Safer Wheel Design Feasibility Back

48. Tire Feasibility –Width over 190mm Cons: –Rear wheel in excess of 190mm will result in a redesign of the XL swing arm Pros: –Will give bike the massive back wheel look of a chopper –Width equal to or less then 190mm Cons: –Rear wheel may appear to be stock Pros: –190mm is a proven good look on an XL –No swing arm of drive redesign is needed Back

49. Drive System Design Feasibility –Pugh’s method Back

50. Exhaust Design Feasibility –Right hand exhaust Cons: –Looks like the majority of bikes on the market Pros: –XL 883C is built with and for right hand exhaust –Proper flow of exhaust –Left hand exhaust Cons: –Proper flow of exhaust may be difficult to obtain on XL –XL 883C is not built for left hand exhaust Pros: –Left hand exhaust is not norm, creating custom and radical look Back

51. Fuel Tank Concepts Custom designed tank –Incorporate RIT Tiger into tank Custom fabricate Custom paint Commercially available tank Back

52. –Feasibility Methods Used Pros and Cons Pugh’s Method Weighted Concept Evaluation –Specifications Purchase aftermarket tank Fuel Tank

53. –Feasibility Methods Used Pros and Cons –Specifications Have custom handlebars with integrated controls manufactured Handlebars / Controls

54. –Feasibility Methods Used Pros and Cons –Specifications Lower ride height by 1” Ride Height

55. –Feasibility Methods Used Pros and Cons –Specifications 2-dimensional design In-house fabrication Wheel Design

56. –Feasibility Methods Used Pros and Cons –Specifications 190mm rear tire Purchase front tire with matching tread pattern Tires

57. –Feasibility Methods Used Pugh’s Method –Specifications Chain drive Drive System Design

58. –Feasibility Methods Used Pro & Con Pugh’s Method –Specifications Accent lighting - safety Blinking frequency dependant on RPM Electrical Design

59. –Feasibility Methods Used Pros and Cons –Specifications Right Exit Exhaust Exhaust Design