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

1. R.I.T. 175th 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. 175th 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. Stakeholders • 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

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

7. Needs Assessment • 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

8. Concept Development • Wheel Hubs • Headlight • Electrical • Exhaust • Seat • Conversion Kit • System changes to meet order qualifiers: • Fuel Tank • Handlebars / Controls • Ride Height • Wheel Design • Tire • Drive System

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

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. User Interface 12VDC Battery Digital Control Unit RPM signal LED Driver Accent Lighting( LEDs) Electronics Specifications 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 Max Stress 29,000 psi Top Triple Clamp with 3G Vertical Impact Loading Max Stress 9,300 psi

14. Lower Triple Clamp Analysis Lower Triple Clamp with 7G Horizontal Impact Loading Max Stress 37,000 psi Lower Triple Clamp with 3G Vertical Impact Loading Max Stress 9,000 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 6 G Load Max Stress 8,123 psi • Impact Load • Torsion Test 3,500 lb Load Max Stress 20,071 psi

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

19. Kit ContentsCustom Parts Designed and Manufactured • 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 • 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

20. Kit ContentsAftermarket Parts Purchased and Implemented • 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

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

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

26. Final Parts Final Parts UA7805C UA7805C PIC12F675 PIC12F675 PVDZ172N PVDZ172N PCB Terminals PCB Terminals Project Enclosure Project Enclosure Manufacturer Manufacturer Texas Instruments Texas Instruments Microchip Microchip International Rectifier International Rectifier Radio Shack Radio Shack Radio Shack Radio Shack Function Function Voltage Regulator Voltage Regulator Signal Processor Signal Processor Solid State Relay Solid State Relay Terminals Terminals Enclosure Enclosure Quantity Quantity 2 2 2 2 2 2 8 (2 sets of 4) 8 (2 sets of 4) 2 2 Price per Price per .52 .52 2.15 2.15 8.50 8.50 2.29 2.29 3.99 3.99 Price for 2 sets Price for 2 sets 1.04 1.04 4.3 4.3 17 17 4.58 4.58 7.98 7.98 Total Project Price Total Project Price $34.90 $34.90 Cost Analysis Pugh’s Method Comparison Back

27. Digital Control Unit Device Comparison Algorithm Back

28. Rear Wheel and Hub Back

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

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

31. Wheel Design Concepts • 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 Back

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

33. Drive System Concepts • 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 Back

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

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

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

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

38. Seat Concepts • 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 175th anniversary • Sponsor Logo Back

39. Electrical Feasibility • Pugh’s Method Back

40. Electrical Concepts • 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 Back

41. Electrical Feasibility • 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) Back

42. Fuel Tank Feasibility • 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 Back

43. Fuel Tank Feasibility • Weighted concepts Back

44. Fuel Tank Feasibility • Pugh’s method Back

45. Handlebars Feasibility • 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 Back

46. Ride Height Feasibility • 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) Back

47. Wheel Design Feasibility • 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 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