Design of an Energy-Efficient Bicycle

[Pages:92]College of Engineering Department of Mechanical Engineering

Spring 2016-2017

Senior Design Project Report

Design of an Energy-Efficient Bicycle

In partial fulfillment of the requirements for the

Degree of Bachelor of Science in Mechanical Engineering

Team Members

Student Name 1 Ahmed Mohammed

Student ID 201200501

2 Faisal Aldosari

201200888

3 Abdullaziz Alshamrani

201203368

4 Abdulaziz Alghamdi

201102875

5 Muhanad Alyami

201200665

Project Advisors:

Advisor Name: Dr. Muhammad Asad Co-Advisor Name: Dr. Nader Sawalhi

Abstract

A gear mechanism has been designed in this project. The mechanism is attached to an ordinary bicycle. The prime objective is to reduce the pedaling force in tough inclement. A small motor, generator, battery, and solar panel are also used to acquire the objective. Generally, during downhill cycling, the speed of bicycles increase and the riders apply brakes to decelerate their bicycles. This application of brake converts excessively available mechanical energy into friction; which is a waste of energy. In addition, brake and friction mechanisms cause excessive wear of brake shoes resulting in frequent shoes (brake pads) replacement. Rather than applying brakes and through a clutch mechanism, cycle wheel is engaged with a dynamo/generator that will convert excessively available kinetic energy into electrical energy from the wheel rotation. This electrical energy can be stored and onwards can be utilized either for lighting or can be used during uphill cycling when the installed motor produces torque to, where more human effort is required to get the required speed in uphill cycling. Additionally, by utilizing a solar panel to recharge the battery connected to the motor. We achieved an environmentally friendly system that will influence big companies to use and improve this idea. The aim of this project is to have an energy-efficient bicycle that can reduce the required pedaling force in different elevations, and increase brake's life.

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Acknowledgment

Firstly, we would like to express our sincere gratitude to our advisor Dr. Muhammad Asad for the continued support of our project. Also, we wish to express our sincere thanks to our coadvisor Dr. Nader Sawalhi for sharing expertise, and valuable guidance and encouragement extended to us. We place on record, our sincere thank you to Dr. Faramarz Djavanroodi, chair of the Mechanical Engineering Department at PMU, for the continued encouragement. We are also grateful to thank Dr. Mohammed Morsey, assistance professor, Department of Electrical Engineering at PMU. We take this opportunity to express gratitude to all of the Department faculty members for their help and support. We also thank our parents for the unceasing encouragement, support, and attention. We are also grateful to thank our colleague Sadiq AlAmeer for his assistance in SolidWorks. Lastly, we would like to appreciate Al-Nader international workshop for the place, installation, welding, and fabrication.

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List of Acronyms (Symbols) Used in the Report

Symbol

Definition

Radius of Crank

Distance from Pedal To Center of Crank

Radius of Rear Multi-Gears

Radius of Tire

W

Mass of The Rider

T

Tension

Torque

Torque on Crank

Torque on Rear Wheel

f

Friction Force

I

Moment of Inertia

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Table of Contents

Abstract ........................................................................................................................................... 2 Acknowledgment ............................................................................................................................ 3 List of Acronyms (Symbols) Used in the Report............................................................................ 4 Table of Contents ............................................................................................................................ 5 List of Figures ................................................................................................................................. 7 List of Tables .................................................................................................................................. 9 Chapter 1: Introduction ................................................................................................................. 10

1.1 Project Definition: ............................................................................................................... 10 1.2 Project Objectives:............................................................................................................... 10 1.3 Project Specifications: ......................................................................................................... 11 1.4 Applications:........................................................................................................................ 12 Chapter 2: Literature Review........................................................................................................ 13 2.1 Project Background and History of Bicycles: ..................................................................... 13 2.2 Previous Work: .................................................................................................................... 15 2.3 Comparative Study: ............................................................................................................. 20 2.4 Parts: .................................................................................................................................... 20

2.4.1 Gear Mechanism of Bicycles:....................................................................................... 21 2.4.2 Clutch: .......................................................................................................................... 22 2.4.3 DC Motor:..................................................................................................................... 24 2.4.4 Generator: ..................................................................................................................... 25 Chapter 3: System Design............................................................................................................. 26 3.1 Design Constraints:.............................................................................................................. 26 3.2 Design Methodology: .......................................................................................................... 26 3.3 Product Subsystems and Components:................................................................................ 27 3.4 Implementation:................................................................................................................... 28 3.4.1 Sprocket Ratio: ............................................................................................................. 31 3.4.2 Torque Calculations:..................................................................................................... 31 Chapter 4: System Testing and Analysis ...................................................................................... 36 4.1 Motor: .................................................................................................................................. 36 4.1.1 Bicycle Motor Simulation: ........................................................................................... 38 4.2 Power Generation: ............................................................................................................... 44

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4.3 Overall Results, Analysis and Discussion: .......................................................................... 45 Chapter 5: Project Management.................................................................................................... 48

5.1 Project Plan:......................................................................................................................... 48 5.1.1 Gantt Chart: .................................................................................................................. 50

5.2 Contribution of Team Members: ......................................................................................... 51 5.3 Project Execution Monitoring: ............................................................................................ 52 5.4 Challenges and Decision Making: ....................................................................................... 53

5.4.1 Problems with Team Members:.................................................................................... 53 5.4.2 Challenges of Project Parts:.......................................................................................... 54 5.4.3 Problems with Equipment: ........................................................................................... 54 5.5 Project Bill of Materials and Budget: .................................................................................. 54 Chapter 6: Project Analysis .......................................................................................................... 56 6.1 Life-long Learning:.............................................................................................................. 56 6.1.1 Project Analysis:........................................................................................................... 56 6.1.2 Equipment's Specifications: ......................................................................................... 56 6.1.3 Installation: ................................................................................................................... 57 6.1.4 Problem Solving: .......................................................................................................... 57 6.1.5 Teamwork:.................................................................................................................... 57 6.1.6 Engineering Sense: ....................................................................................................... 57 6.2 Impact of Engineering Solutions: ........................................................................................ 58 6.3 Contemporary Issues Addressed: ........................................................................................ 58 Chapter 7: Conclusion and Future Recommendations.................................................................. 60 7.1 Conclusions: ........................................................................................................................ 60 7.2 Future Recommendations: ................................................................................................... 60 References:.................................................................................................................................... 61 Appendix A ................................................................................................................................... 64 Appendix B ................................................................................................................................... 73 Appendix C ................................................................................................................................... 84

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List of Figures

Figure 2.1: Caprotti bicycle sketch........................................................................14 Figure 2.2: Karl Drais design................................................................................14 Figure 2.3: McCall design...................................................................................15 Figure 2.4: Eug?ne Meyer high front wheel bicycle.....................................................15 Figure 2.5: A free body diagram for the bicycle...........................................................16 Figure 2.6: A free body diagram for the bicycle with a motor..........................................17 Figure 2.7: A motor connected to the chain wheel.......................................................18 Figure 2.8: An electric assisted bicycle...................................................................18 Figure 2.9: The motor connected the hub by a chain....................................................19 Figure 2.10: The final fabrication of the motor in the bicycle..........................................19 Figure 2.11: Chainless bicycle................................................................................20 Figure 2.12: Gear mechanism of bicycles..................................................................21 Figure 2.13: Clutch description...............................................................................23 Figure 2.14: Clutch pushing lever mechanism in motorcycle .........................................24 Figure 2.15: DC motor connected to a gear................................................................25 Figure 3.1: The components of the project...............................................................27 Figure 3.2: Side view of prototype showing the motor.................................................29 Figure 3.3: Components of the prototype.................................................................29 Figure 3.4: The designed gear mechanism attached to the motor......................................30 Figure 3.5: Torque developed on crank...................................................................32 Figure 3.6: Torque developed on rear wheel.............................................................32 Figure 3.7: Motor.............................................................................................34 Figure 3.8: The Motor fabricated with a gear.............................................................34 Figure 3.9: Electrical connection drawing................................................................35 Figure 4.1: A Multimeter................................................................................................36 Figure 4.2: Testing setup....................................................................................37 Figure 4.3: Parallel connection diagram..................................................................37 Figure 4.4: Graphical power, efficiency, torque, and load data........................................39

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Figure 4.5: Graphical power, efficiency, torque, and load data........................................40 Figure 4.6: Bicycle simulation at speed of 20.1 km/h...................................................41 Figure 4.7: Speed vs. distance traveled graph.............................................................41 Figure 4.8: Bicycle simulation at speed of 5 km/h and 5% inclined surface.........................42 Figure 4.9: Speed vs. distance traveled at 5% inclined surface........................................42 Figure 4.10: Bicycle simulation at speed of 10 km/h and 10% inclined surface.....................43 Figure 4.11: Speed vs. distance traveled at 10% inclined surface.....................................43 Figure 4.12: Solar panel.....................................................................................44 Figure 4.13: Workshop......................................................................................45 Figure 4.14: Generator.......................................................................................45 Figure 4.15: First test........................................................................................46 Figure 4.16: Batteries connected in parallel..............................................................46 Figure 4.17: Thick Wires...........................................................................................................47 Figure 4.18: Final installed system............................................................................47

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