Front and Rear Swing Arm Design of an Electric Racing Motorcycle | Teses (TCC) Engenharia Mecânica

Front and Rear Swing Arm Design of an Electric Racing

Motorcycle

João Diogo da Cal Ramos

Thesis to obtain the Master of Science Degree in

Mechanical Engineering

Supervisor: Prof. Luís Alberto Gonçalves de Sousa

Examination Committee

Chairperson: Prof. João Orlando Marques Gameiro Folgado

Supervisor: Prof. Luís Alberto Gonçalves de Sousa

Member of the Committee: João Manuel Pereira Dias

November 2016

Pré-visualização parcial do texto

Baixe Front and Rear Swing Arm Design of an Electric Racing Motorcycle e outras Teses (TCC) em PDF para Engenharia Mecânica, somente na Docsity!

Front and Rear Swing Arm Design of an Electric Racing

Motorcycle

João Diogo da Cal Ramos

Thesis to obtain the Master of Science Degree in

Mechanical Engineering

Supervisor: Prof. Luís Alberto Gonçalves de Sousa

Examination Committee

Chairperson: Prof. João Orlando Marques Gameiro Folgado

Supervisor: Prof. Luís Alberto Gonçalves de Sousa

Member of the Committee: João Manuel Pereira Dias

November 2016

Acknowledgments

The author would like to express his most sincere gratitude to his supervisor, Prof. Luis Sousa. This was not the shortest of rides, but his knowledge, patience and friendship were always there when needed. It was an honour and a privileged to work with him.

To all TLMoto team members. It was a pleasure to learn and work so much with great future engineers on this passionate topic.

To my family. My father and my mother. This is as much my success as it is yours.

To all my professors, family and friends, thank you.

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Resumo

A indústria motociclista lida atualmente com os novos desafios impostos pelo design de veículos elétricos. As soluções mais vanguardistas são por vezes testadas primeiro no mundo da competição. Este estudo pretende examinar o design inicial e consequente processo iterativo de melhoramento dos braço oscilante traseiro e frontal, de acordo com as regras impostas pela competição MotoStudent. Todas as partes desenhadas foram concebidas para serem fabricadas na liga de alumínio 7075-T6 e maquinadas em CNC. O Método Clássico de Cossalter é de medição da rigidez de braços oscilantes foi complementado com um novo estudo de condições sob carga vertical extrema (3580 N no perpendiculares ao eixo da roda). FEA foi usada no processo de simulação iterativo de diferentes modelos sob condições de carga vertical, torsional e laterais. Os modelos finais do braço oscilante traseiro e frontal respeitam o coeficiente de segurança 𝑛𝑝𝑟𝑜𝑗 = 1. 82 e os intervalos de rigidez de Cossalter (𝐾𝑙𝑎𝑡𝑒𝑟𝑎𝑙 = 0.8- 1.6 kN/mm and 𝐾𝑡𝑜𝑟𝑠𝑖𝑜𝑛𝑎𝑙 = 1-2 kNm/°). O peso final atingido em ambos foi, 4,86 kg and 2, kg, respetivamente. No entanto, a complexidade final de ambas as partes devido a pormenores internos e numerosas soldaduras torna a maquinação por CNC inviável. Um novo Sistema de direção frontal foi proposto para a consequente utilização do braço oscilante frontal.

Palavras-chave: Design estrutural, mota, braço oscilante, veículos elétricos, FEA, CAD, CNC

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Acknowledgments ........................................................................................................................ v

Resumo ........................................................................................................................................vii

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Figure 13 (left) Original Moto Guzzi pivoted rea spring. Long springs are actuated by a

1. Introduction Abstract .........................................................................................................................................ix
- 1.1 Motivation and Context
- 1.2 The Competition
- 1.3 Aims and Objectives
- 1.4 The Modern Competition Electric Motorcycle
  - 1.4.1 Electric motor
  - 1.4.2 Battery Pack
  - 1.4.3 Frame
  - 1.4.4 Swing arm
2 Theoretical Overview
- 2.1 Structural Criteria Selection
- 2.2 Simplified Motion of a Motorcycle
  - 2.2.1 Centre of Gravity
  - 2.2.2 Motorcycle Loads and Limit Situations
- 2.3 Squat and Dive
  - 2.3.1 Rear Suspension Balance
  - 2.3.2 Squat Ratio and Squat Angle
3 Swing Arm Design and testing
- 3.1 Finite Element Analysis Observations
- 3.2 Material Selection
- 3.3 Initial Geometry of the Rear Swing Arm
- 3.4 Test Procedures
- 3.5 Rear Swing Arm First Iteration (HM1) xii
- 3.6 Model HMF
- 3.7 Model LM1
- 3.8 Model LMF
- 3.9 Final Rear Swing Arm Model
- 3.9 Frontal Swing arm design
- 3.11 Model FSS2
4 Manufacturing
- 4.1 Designing to Manufacture
- 4.2 Interior Corners
- 4.3 Weld location and sizing
5 Conclusions and future developments
- 5.1 Conclusions
- 5.2 Future Developments
References
Annex
Annex
Annex
Annex
Annex
Table 1 Material characteristics relative to material, loads and stress analysis for nsx List of Tables
Table 2 Fail impact for nsy
Table 3 Main differences in behaviour due to Centre of Gravity shift
Table 4 General specs of an Aprilia RS250
Table 5 Dynamic changes due to shift in CG
Table 6 Initial assumed approximate hg
Table 7 Variation in R – rear suspension
Table 8 Variation in R - front suspension
Table 9 Percentage variation of Maximum Stress in relation to previous mesh dimension
Table 10 Percentage variation of Minimum Stress in relation to previous mesh dimension
Table 11 Simulation time per mesh size in seconds
Table 12 Percentage variation of Minimum Safety Factor
Table 13 Percentage variation of Maximum Safety Factor
Table 14 Comparison between Aluminium 7075-T6 and Steel AISI 4340...................................
Table 15 General Properties of an Aluminium 7075-T6..............................................................
Table 16 Comparison between HE and LE
Table 17 Lateral Loading Results (HM1)......................................................................................
Table 18 Vertical Results (HM1)
Table 19 Torsional Results (HM1)
Table 20 Lateral Results (HMF)
Table 21 Vertical Results (HMF)
Table 22 Torsional Results (HMF)................................................................................................
Table 23 Results Comparison (Models HM1 and HMF)
Table 24 Lateral Results (LM1)
Table 25 Torsional Results (LM1)
Table 26 Vertical Results (LM1)...................................................................................................
Table 27 Lateral Results (LMF)
Table 28 Torsional Results (LMF)
Table 29 Vertical Results (LMF)
Table 30 Results Comparison (LM1 and LMF)
Table 31 Lateral Results (LMF)
Table 32 Torsional Results (LMF) xv
Table 33 Vertical Results (LMF)
Table 34 Lateral Results (FSS1)....................................................................................................
Table 35 Torsional Results (FSS1)
Table 36 Vertical Results (FSS1)
Table 37 Lateral Results (FSS2)....................................................................................................
Table 38 Torsional Results (FSS2)
Table 39 Vertical Results (FSS2)
Table 40 Results Comparison (FSS1 and FSS2).
Table 41 Raw material blocks and plates VS final machined part weight (Rear Swing arm)
Table 42 Raw material blocks and plates VS final machined part weight (Front Swing arm).....
Table 43 Increase in weight VS increase in interior corner radius
Table 44 SolidWorks general weld sizing prediction under vertical loading of 1790 N
Table 45 Chain Standards and Motor size...................................................................................
Figure 1: Graphic description of horizontal and vertical static tests List of Figures
Figure 2: Moto3.e the EM prototype constructed by MEF Technologies (2013)
Figure 3 Converted BMW S1000RR constructed at MIT
parts; (c) Motorcycle with electric powertrain. [21] Figure 4 (a) BMW S1000RR initial structure; (b) Critical structural assembly without powertrain
Figure 5 Heizmann PMS 150 Air-Cooled CAD model
Figure 6 Cost per Unit Energy [$/kWh] related to Cost per Unit Power [$/kW] [10]
Figure 7 Efficiency related to lifetime at 80% DoD – Cycles [10]
Figure 8 Power Density [W/kg] related to Energy Density [Wh/kg] [10]
Figure 9 Motorcycle types
Figure 10 Mission R (Mission Motors Company) uses a truss frame (yellow strut)
Figure 11 R1 Yamaha Twin-Spar frame example [11]
Figure 12 The BMW boxer frame with engine as central structural member.
swing arm. triangulated fork; (right) 3Fasi, presented in 2014, by Energyca Ego, has a conventional superbike
Figure 14 Schemes of rear suspension with swing arms [14]
Figure 15 Schemes of rear suspension with swing arm and four-bar linkage. [14]
Figure 16 Schemes of rear suspensions with four-bar and six-bar linkage. [14]
Figure 17 Lateral deflection in telescopic fork systems.
Figure 18 Hard braking leads to extreme compression of the fork.
Figure 19 Schemes of front suspension with pushed and pulled wishbones.
Figure 20 Schemes of four-bar linkage suspension.....................................................................
Figure 21 Schemes of four-bar linkage front suspension with prismatic pairs.
system (both different takes on four-linkage applications) Figure 22 (left) BMW H2R with telelever system; (right) Vyrus 986 M2 with a frontal swing arm
Figure 23 Cossalter’s Approach for torsional and lateral swing arm testing
Figure 24 Motorcycle weight distribution...................................................................................
Figure 25 Balance of forces and moment on rear wheel and swing arm
Figure 26 Squat - Load transfer lines...........................................................................................
Figure 28 Rear Suspension Rocker xviii
mesh (Element size (5;1)[mm]) Figure 29 Swing arm link a) Geometry; b) Non adaptative mesh (Elem. size =5mm); c) Adaptative
Figure 30 Corner mesh deformation (Von Mises local Stress)
Figure 31 General behaviour of metal alloys
Figure 32 Single chain rear example
Figure 33 Dual chain rear example..............................................................................................
Figure 34 HE - high motor assembly Figure 35 D2 - low motor assembly
Figure 36 Cantilever Beam example (base is fixed to rigid wall)
Figure 37 Swing arm fixtures, considering a fully recoiled rear suspension
Figure 38 a) Cossalter's vertical test; b) Extreme conditions vertical test
Figure 39 Cossalter's lateral test
Figure 40 Cossalter's torsional test
Figure 41 Perspective view of HE
Figure 42 Main Dimensions and geometry limits of HE
Figure 43 Main dimensions and geometry of HM1
Figure 45 Von Mises Stress propagation in HM1 Figure 44 Von Mises Stress propagation in Model 1.0 Error! Bookmark not defined.
Figure 46 Design improvements on Model 1.1
Figure 47 Local Stress concentration (rear suspension mount)
Figure 48 Deformed shape of HMF (Deformation scale 21.5)
Figure 49 Perspective view of LM
Figure 50 Main dimensions and geometry limits of LM..............................................................
Figure 51 Main dimensions and geometry of LM1
Figure 52 Design improvements on LMF
Figure 53 Von Mises Stress propagation in LMF
Figure 54 Deformed shape of LMF (Deformation scale 21.5
Figure 55 Final rear swing arm model
Figure 56 Von Mises Stress propagation in Final Model
Figure 57 Deformed shape of Final Model (Deformation scale 21.5)
Figure 58 Main dimensions and geometry of FSS1
Figure 59 Proposed front wheel external steering system
Figure 60 Main dimensions and geometry of steering system
Figure 61 Main dimensions and geometry of FSS2
Figure 62 Von Mises Stress propagation in FSS2 with single side suspension............................
Figure 63 Von Mises Stress propagation in Final FDS2 with dual suspension xix
Figure 64 Deformed shape of FSS2 with single side suspension (Deformation scale 21.5)
Figure 65 Deformed shape of FDS2 with dual suspension (Deformation scale 21.5)
Figure 66 Rear (left) and Front (right) swing arms with respective composing parts
Figure 67 Interior corners and deep pockets machining
Figure 68 Rear Swing Arm interior pockets.................................................................................
Figure 69 Edged weld formulation (SolidWorks 2014)
Figure 70 Edge weld main dimensions
Figure 71 Simplification of half of frontal swing arm
Figure 72 Von Mises Stress propagation in simplified model
Figure 72: Final design of the battery and motor structural frame.
Figure 73: Two DC electric motors connected by a steel shaft with a 16T sprocket
Figure 74 (a) battery module assembly; (b) frame fabricated using waterjet
Figure 75 Example of Altrax PWM Controller 24-48V 300A
Figure 76 General Cd distribution for different vehicles.............................................................
Figure 78 Chain Standard dimensioning

Front and Rear Swing Arm Design of an Electric Racing Motorcycle, Teses (TCC) de Engenharia Mecânica

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Pré-visualização parcial do texto

Baixe Front and Rear Swing Arm Design of an Electric Racing Motorcycle e outras Teses (TCC) em PDF para Engenharia Mecânica, somente na Docsity!

Front and Rear Swing Arm Design of an Electric Racing

Motorcycle

João Diogo da Cal Ramos

Thesis to obtain the Master of Science Degree in

Mechanical Engineering

Supervisor: Prof. Luís Alberto Gonçalves de Sousa

Examination Committee

Chairperson: Prof. João Orlando Marques Gameiro Folgado

Supervisor: Prof. Luís Alberto Gonçalves de Sousa

Member of the Committee: João Manuel Pereira Dias

November 2016

Acknowledgments

Resumo

xi

Contents

xiv

xvii