Low Speed Motorcycle Stabilization Device

Project Number: MQP KZS 1102

Low Speed Motorcycle Stabilization Device A MQP Proposal

Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE in partial fulfillment of the requirements for the

Degree of Bachelor of Science in Mechanical Engineering

by ___________________________________

Adam Sears

___________________________________ Alexander Segala

___________________________________ Jessica White

Date: 04/25/2012

Approved:

Prof. Kenneth Stafford, Major Advisor

Prof. Torbjorn Berstrom, Co-Advisor

Contents

Abstract......................................................................................................................................................... 5 Acknowledgements....................................................................................................................................... 6 Executive Summary....................................................................................................................................... 7 1. Introduction .......................................................................................................................................... 9

1.1 Objective ..................................................................................................................................... 10 2 Design Criteria..................................................................................................................................... 11

2.1 Assessment of Customer Needs ................................................................................................. 11 2.2 State of the Art............................................................................................................................ 12 2.3 Analysis ....................................................................................................................................... 22

2.3.1 Stability ............................................................................................................................... 22 2.3.2 Tadpole and Delta ............................................................................................................... 23 2.3.3 Design Decision ................................................................................................................... 27 3 Linkage ................................................................................................................................................ 28 3.1 Design Criteria............................................................................................................................. 28 3.2 Preliminary Designs..................................................................................................................... 29 3.2.1 Bell Crank ............................................................................................................................ 29 3.2.2 Expanding Leading Arm....................................................................................................... 30 3.2.3 Expanding Trailing Arm ....................................................................................................... 31 3.3 Final Linkage Design .................................................................................................................... 32 3.3.1 Testing and Analysis ........................................................................................................... 34 4 Fluid Power ......................................................................................................................................... 39 4.1.1 Air to Hydraulic Converter ................................................................................................. 42 4.1.2 Deployment Cylinder .......................................................................................................... 44 4.1.3 Secondary Cylinder ............................................................................................................. 45 4.1.4 Testing and Analysis ........................................................................................................... 47 5 Controls System .................................................................................................................................. 49 5.1 Design Criteria............................................................................................................................. 49 5.2 Proof of Concept ......................................................................................................................... 49 5.3 Microcontroller Selection ........................................................................................................... 52

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5.4 Controller Input........................................................................................................................... 54 5.5 Controller Outputs ...................................................................................................................... 56

5.5.1 Air-Hydro Converter........................................................................................................... 56 5.5.2 Deployment Solenoid.......................................................................................................... 56 5.5.3 Secondary Solenoid............................................................................................................. 56 5.6 Programming .............................................................................................................................. 57 5.6.1 mph_sense Function............................................................................................................ 58 5.6.2 print2screen Function.......................................................................................................... 59 5.6.3 Testing and Analysis ........................................................................................................... 60 6 Frame .................................................................................................................................................. 61 6.1 Design Criteria............................................................................................................................. 61 6.2 Final Design ................................................................................................................................. 62 7 Manufacturing .................................................................................................................................... 63 8 Conclusions and Future Work ............................................................................................................. 67 9 Bibliography ........................................................................................................................................ 69 Authorship .................................................................................................................................................. 70 Appendix ..................................................................................................................................................... 73

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Table of Figures

Figure 1: Customer, Howard Sears, on the Existing Motorcycle ............................................................... 10 Figure 2: Sportster Trike Conversion.......................................................................................................... 13 Figure 3: Motorcycle Outfitted with Sidecar .............................................................................................. 14 Figure 4: BRP Spyder ................................................................................................................................. 15 Figure 5: Piaggio MP3 ................................................................................................................................ 16 Figure 6: Tilting Motor Works Prototype ................................................................................................... 17 Figure 7: Ghost Wheels Unlocked at Speed (Left) Locked in Stationary Position (Right) ........................ 18 Figure 8: Motorcycle outfitted with Retract-a-Trike extended at rest (Left) in motion (Right) ................. 20 Figure 9: Motorcycle outfitted with LegUp extended at rest (Left) retracted at rest (Right)...................... 21 Figure 10: Location of the CG on the existing motorcycle........................................................................ 23 Figure 11: Free-body diagrams for Delta and Tadpole Configurations (Three Wheeled Vehicle Dynamics) .................................................................................................................................................................... 24 Figure 12: Rollover stability to Lateral Acceleration ................................................................................. 26 Figure 13: Rollover Velocity as a function of track width.......................................................................... 26 Figure 14: Sketch of Bell Crank Design ..................................................................................................... 30 Figure 15: Sketch of Expanding Leading Arm Design ............................................................................... 31 Figure 16: Sketch of Expanding Trailing Arm Design .................................................................................. 32 Figure 17: Coupler Curve of Expanding Trailing Arm............................................................................... 33 Figure 18: Model of Final Linkage ............................................................................................................. 34 Figure 19: Point of Highest Stress in the Lower Link ................................................................................ 34 Figure 20: Free Body Diagram of the Linkage ........................................................................................... 35 Figure 21: Diagram for pivot bolt in double shear..................................................................................... 37 Figure 22: FEA Results............................................................................................................................... 38 Figure 23: Actuator Design Matrix ............................................................................................................. 39 Figure 24: Deployment Cylinder Schematic............................................................................................... 40 Figure 25: Secondary Cylinder Schematic.................................................................................................. 41 Figure 26: Solid Model of Air to Hydraulic Convertor .............................................................................. 42 Figure 27: Installed Deployment Cylinder.................................................................................................. 44 Figure 28: Installed Secondary Cylinder .................................................................................................... 45 Figure 29: Internal Configuration of Secondary Cylinder .......................................................................... 46 Figure 30: Proof of Concept Model Using VEX Components ................................................................... 50 Figure 31: Flow Chart of Test Program ...................................................................................................... 51 Figure 32: Vex PIC v0.5 Microcontroller, Arduino UNO, and chipKIT Uno32 (not to scale) .................. 52 Figure 33: Microcontroller Options ............................................................................................................ 52 Figure 34: chipKIT Basic I/O Shield .......................................................................................................... 54 Figure 35: Speed Input Test of the Speedometer ........................................................................................ 55 Figure 36: Flow Chart for Final Program .................................................................................................. 58 Figure 37: Oscilloscope Readings and Display for Different Conditions.................................................. 60 Figure 38: Final Frame Model with Linkage Attached............................................................................... 62

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Figure 39: Secondary Cylinder Body before drilling and reaming ............................................................. 64 Figure 40: Esprit generated 4-axis tool paths.............................................................................................. 64 Figure 41: Esprit simulation of Deployment Cylinder Body ...................................................................... 65 Figure 42: Tool Path for Surface finishing ................................................................................................. 65 Figure 43: Simulated Deployment Cap Surfacing ...................................................................................... 66 Figure 44: Assembled Prototype................................................................................................................. 66 Figure 45: Final Integrated System Prototype ............................................................................................ 67

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