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Final PresentationCleveland State University
Advisor: Bogdan KozulApril 16, 2020
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Meet the Team!
Angela Rodriguez, Sarah Smith, Naik Yusufi, Jake Landry, Ellen Rea
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Final Bike
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Design Objectives:
• Improve Frame Design
– Reduce weight
– Simplify component mounting
• Improve Hydraulic Circuit
– Safe/ user friendly operation
– Add charging versatility
– Reduce friction energy loss
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Vehicle Frame: Carbon Fiber
Maximum Deflection: 3mm
Maximum Stress: 70 MPa
Conservative Simplification:
Considerations:
• Weight
• Deflection
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Vehicle Frame: MountsTank/ Component Bracket:
● 6061 T6 Aluminum
● Lower seat bracket sees highest load (500lb)
● Maximum Stress: 15 MPa
● Maximum Deflection: 0.008mm
FEA:
Motor Mount
Accumulator Mount
Upper Seat Bracket
Lower Seat Bracket:
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Steering Mechanism
Ackerman Steering Condition
(Steering Dynamics):
Trapezoidal Steering Linkage
(Steering Dynamics):
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Vehicle Frame: CAD
Tank Integration
Seat Mounting
Steering Mechanism
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Hydraulic Circuit:
Pump
(Bent Ais)Ball Valve 1 Check Valve 1
Pressure
Gauge
Motor
(Bent Axis)Tank
Ball
Valve 2
Check
Valve 2
Flow Control
Valve
Pump
(Bent Axis)
Tank
Check
Valve 3
Solenoid Valve
3-Way Manual
Ball Valve
Manual Ball
Valve
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Pedaling Drive:
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Accumulator Drive:
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Charge By Pedaling:
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Check Valve 1
Pressure
GaugeAccumulator
Motor
(Bent Axis)
Flow Control
Valve
Tank
Regenerative Braking:
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Component Selection
(Parker)
Piston Pump:● High speed and efficiency
● Fixed displacement
Bladder Accumulator● High Efficiency
● Requires Recharging
(Steelhead Composites)
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Component SelectionSolenoid Valve:
• Safety
• Regen Braking
• Normally Open
• Reduce Pressure DropElectrical Schematic:
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Vehicle Build: Frame and Steering
Building Carbon Tubing
Frame
Putting Spokes on the Wheels
Welding the Kingpins
Aluminum Frame Support
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Waterjetting Aluminum for
MountsRear Axle/ Disc
Brake MountCutting Handlebars to Size
Vehicle Build: Components
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Vehicle Build: Tank and Hydraulics
Fabricating the Tank Working out the Hydraulics Bi-directional Valve Mount
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Testing
• Rear Wheel Gearing
• Accumulator Precharge
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Power Output
● Increased gear ratio:
○ Torque
○ Required Motor Flow
● Increased precharge:
○ Energy
○ Accumulator Pressure
○ Oil Volume
Weighted Average PressureUsable Volume
Stored Energy in
Accumulator (NFPA):
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Speed
● Increased gear ratio:
○ Acceleration
○ Flow Rate
● Increased Precharge:
○ Volume and
Pressure balance
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Gear Ratio and Precharge
Gear Ratio: 3.75
Precharge: 1000 psi Speed Endurance
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Final Vehicle
• Top Speed: 27mph
• Curb Weight: 171 lb
• Full Throttle Efficiency: 8%
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• Carbon Fiber Tadpole Recumbent Frame
• Custom Fabrication:
– Tank/ Seat Bracket
– Trapezoidal Steering Linkage
• Modified Hydraulic Circuit
– Solenoid Valve
• Testing for Gear Ratio and Precharge
Summary
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Resources
• Jazar, R. N. (2017). Vehicle dynamics: theory and application. New York: Springer.
• Norton, R. L. (2020). Design of machinery: an introduction to the synthesis and analysis of mechanisms and machines.
New York, NY: McGraw-Hill Education.
• Joseph, A. (2013, March 26). Hydraulic Pump Noise Reduction. Retrieved December 13, 2019, from
https://www.designworldonline.com/hydraulic-pump-noise-reduction/.
• Cosford, J. (2014, February 28). Accumulators add functionality to hydraulic circuits. Retrieved December 13, 2019,
from https://www.hydraulicspneumatics.com/technologies/accumulators/article/21883813/accumulators-add-
functionality-to-hydraulic-circuits.