The document summarizes the design and construction of a single-rider human powered vehicle for a competition. It discusses the objectives to design and build a recumbent bike that can win races for speed and endurance. Key aspects summarized include the frame design using bamboo for its strength and lightweight properties, a chain drive system with a wide gear range, aerodynamic fairing construction using composite sandwich materials, and a total project budget of $4,060.

1. Single Rider Human Powered Vehicle Senior Project 1 Presentation

2. Design and construct, respective of constraints, a single-rider recumbent fully faired human powered vehicle. Compete and win the 2010 ASME East Human Powered Vehicle Challenge. Objective

3. Matthew Wright Team Manager/Seating Position/SteeringJames VanBiervlietFrameDante MucaroDrivetrain/Frame IntegrationsRich NelsonFairing Advisor: Dr. Lisa GregaCo-Advisors: Dr. Norman Asper Dr. Manish PaliwalTeam Members

4. 2010 ASME East Human Powered Vehicle Challenge“to provide an opportunity for engineering students to demonstrate application of sound engineering design principles toward the development of efficient, sustainable, and practical human-powered vehicles” May 7-9, 2010Central Connecticut State University

5. 2010 ASME East Human Powered Vehicle ChallengeDesign EventSubmission of design report and presentationDrag EventDouble elimination tournament.6-.8 km trackEndurance Event2 ½ hoursMultiple Drivers

6. Design ConstraintsGoalsRoll Bar LoadingTop: 600 lbSide: 300 lbTurning Radius: 25 ftBraking Distance (15 mph-0 mph): 20 ftIncorporate Shoulder HarnessTop Speed in Drag Competition: 50 mphEndurance Average Speed: 30 mph

7. Project ManagementMatthew Wright

8. Ensure that the project team completes the task at handDevelop the plan with the team and manages the team’s performance of tasksMake sure the project is delivered in budget, on schedule, and is practical Project Management

9. Google CalendarCoordinate schedules for meetingsInform team members of project deadlinesProject Management

10. DropboxOnline file storage serviceAll team members and advisorsProject websitetcnjhumanpowered.blogspot.comEnable public to be informed and track progress of the projectProject Management

11. Project Management

12. Rider Position & Steering SystemMatthew Wright

13. Be secured safely within the vehicleComfortableProvide power to the crankRider Position

14. Rider Position

15. Rider Position

16. Above Seat Steering vs. Under Seat Steering (rps.info)Steering System

17. Above seat steering system chosenHead tube too far away from rider for standard straight bicycle handlebarsSolid bent handlebars (Tiller steering)Universal Joint with steering column to handlebarsEnables easy entrance and exit of vehicleSteering System

18. Steering System

19. Frame James VanBiervliet

20. Withstand a 600 lb top load at a 12 degree angle towards rear of vehicleSupport 300 lb loading directly to the side of the vehicleAll team membersmust fit insideFrame - Constraintshttp://www.wind-water.nl/rec_build_n.html

21. Original designs included one under seat support and two converging supports on the side of the seatPedals were located behind the front wheel Frame - Designhttp://bikemart.com

22. Frame - DesignFrame Length: 75 inchesTotal width: 20 inchesGround clearance: 5 inches

23. Second frame design incorporated a tub like styleProvides anchor points for fairingUsed a pedal set above the front wheel to reduce overall length lengthFrame - Design

24. Frame - DesignFrame Length: 60 inchesGround clearance: 6.4 inchesMaximum width: 20 inches

25. Ultimately chose the second designKept length to a minimumProvided better support for the fairingGave driver the most leg roomFrame - Design

26. Needs to be strong and durableSince the goal is speed, lightweight materials are essentialWanted a material that would minimize cost without sacrificing safetyFrame - Material Selection

27. Two materials were considered4130 Normalized Steel (Chromolly)Bamboo Poles4130 Steel was found to be used for frame construction by retailers Bamboo was found to be used by independent manufacturersFrame – Material Selectionwww.bmeres.com

28. 4130 Steel properties are widely available but little can be found about Bamboo’s properties so tests were done to verify.Frame – Material Selection

29. Frame – Material Selectionhttp://bambus.rwth-aachen.de/http://www.tropicaltikis.com/

30. Frame – Material Selection Side Loading4130 SteelBamboo

31. Frame – Material Selection Bamboo4130 SteelBamboo

32. Frame – Material Selectionhttp://www.engineersedge.com/Bamboo was ultimately chosen based on the significant difference in cost and weight.

33. Drivetrain& Frame Integrations Dante Mucaro

34. Drivetrain RequirementsHigh range of gears for acceleration runs and endurance testingDurableEasily servicedUtilize standard bicycle drivetrain components for cost2 wheel layoutMinimize weight

35. Wheel Choices2 wheeled vehicleFront or rear drive wheel:Image Sourced: http://www.rose-hulman.edu/hpv/Image Sourced: http://img.alibaba.com/photo/10798856/Recumbent_Bike.jpg

36. Wheel selection Rear drive wheel system selectedWheel selection:Maximize acceleration and overall speed20” front wheelCompactLightweight26” drive wheelMaximize developmentAdaptable hubs

37. Drivetrain System SelectionRequirements:Wide gear rangeDurableInexpensiveAdaptableEasily servicedThree optionsChain driveShaft driveBelt drive

38. Option 1: Chain DriveCranksetcrank arms chainringsbottom bracketCassetteDerailleurCassetteChainImage Sourced: http://en.wikipedia.org/wiki/File:Derailleur_Bicycle_Drivetrain.svg

39. Option 2: Shaft DriveBevel gear replaces chainringsDriveshaft replaces chainRear bevel gearHub GearsScreen Capture Source: http://www.dynamicbicycles.com/

40. Option 3: Belt DriveSingle front gearSingle rear gearToothed belt replaces chainGearing through hubImage Source: http://paketabike.files.wordpress.com/2009/08/wac_corp_beltdrive2.jpg

41. Decision: Chain DriveGearing:Top speed and accelerationMany available gearsHigh speed: High front-to-rear ratioQuick start: Low front-to-rear ratioAcceleration: Proper gear ratio spacing

42. Sprocket optionsStandard road bike drivetrainTen speed cassetteTwo speed cranksetModify to achieve proper gear spacing while getting a higher top gear ratioUse two speed crankIntegrate second chain system with a high to low sprocket for higher overall ratios pedal-to-crank20 overall speeds

43. Layout

44. Selected SprocketsFront crank chainring: 55TDrive chainring: 40TDriven chainrings: 34/50TCassette: 11-28T11, 12, 13, 14, 15, 17, 19, 22, 25, 28

45. Gear rangesHighest overall gear ratio:55T-40T translated to 50T-11T43.5mph at a pedaling rate of 90RPM42.542ft of development/ revolutionDrive ratio: 6.25:1Lowest overall gear ratio:55T-40T translated to 34T-28T11.6mph at a pedaling rate of 90RPM11.365ft of development/ revolutionDrive ratio: 1.67:1

46. Braking System15-0 mph braking distance:<20ftStopping more mass than in typical bicycle applicationOptionsRim BrakesDisc BrakesHydraulic DiscMechanical DiscStrong consideration to DH brakes

47. Brake SelectionMechanical disc brakesAdvantages:Provide greater stopping power than most competitively priced rim brakesMuch less expensive than hydraulic disc brakesNo risk of boiling in high heat applicationsCan be adapted well to a 26” wheel hubDisadvantages:Front 20” wheel must be custom built with a disc brake compatible hub

48. Front Crank Arm DesignAdjustable for different ridersWithstand both torsional and axial cyclic loading with minimal deflectionHouse bottom bracket for cranksetHouse headset for steering systemIntegrate into bamboo frameLightweight

49. Front Crank Adjustable Arm

50. Goals for Senior Project IIConstruct adjustable crank armDetermine ideal method to mount drive and driven sprockets beneath rider seatObtain all necessary drivetrain componentsConstruct custom front wheelConstruct chain guides for 55-40T chain extensionDevelop lightweight kickstand to be integrated into fairing/ tub frame assembly

51. Aerodynamic FairingRich Nelson

52. RulesRequire frontal fairing, tail box, or full fairingPurpose:To Reduce aero dynamic dragWhen riding over 18 mph, drag accounts for over 80% of the forces acting to slow an unfaired bike. 1GoalsReduce Aerodynamic DragFully Encompass Frame and RiderStiffLightMinimize CostAerodynamic FairingGross, Albert C., Chester R. Kyle, and Douglas J. Malewiki. Aerodynamics of human-powered land vehicles. Rep. Professional Engineering, 2004.

53. Composite Sandwich ConstructionHigh stiffness-to-weight ratio compared to standard coreless composite laminate 2Acts similarly to an I-beamAerodynamic FairingVinson, Jack R. Behavior of sandwich structures of isotropic and composite materials. Lancaster, Pa: Technomic Pub. Co., 1999.

54. Common composite Sandwich materialsLight Core materialStructural FoamBalsa WoodHoneycomb CoreCore Mat Laminate BulkerHigh Strength Composite SkinsFiberglassCarbon FiberKevlarAerodynamic FairingComposite SkinsCore Material

55. Aerodynamic Fairing – Materials Testing

56. Construction of Samples12”x3.5” with positive camberVacuum Bag ConstructionCreates strong bond between core and skinRemoves excess resinPresses samples onto the formAerodynamic Fairing – Materials Testing

57. Vacuum Bag LayupAerodynamic Fairing – Materials Testing

58. Samples in Vacuum BagAerodynamic Fairing – Materials TestingUntrimmed Completed Samples

59. Wetted out with epoxy resin.Samples Tested as simply supported beamsInformation RecordedMaximum DeflectionMaximum Load SupportedWeight of SamplesAerodynamic Fairing – Materials Testing

60. Aerodynamic Fairing – Materials Testing

61. Aerodynamic Fairing – Materials Testing

62. Aerodynamic Fairing – Materials Testing

63. ConclusionsCore¼” Diviney Cell Foam (2x1/8” for tight contoured areas)$50 more expensive Than 1/8” Foam for the whole fairingHeld the most weight in all cases22-30% Heavier than 1/8” Foam but 60-77% StrongerCompositeFiberglassheld 10-20% less weight than Carbon Fiber~4lb heavier for whole fairing.Able to Deflect 40%-60% more than Carbon Before Breaking2-3 time less expensive then Carbon FiberAerodynamic Fairing – Materials Testing

64. RequirementsStreamlined to reduce dragFully enclose frameAllow for rider’s full range of motionAerodynamic Fairing - Design

65. 2-D Sketch of Fairing DesignAerodynamic Fairing - Design

66. 3-D Model Made from 2-D SketchAerodynamic Fairing - Design

67. Aerodynamic Fairing - DesignDesigns will be tested using

68. Computational Fluid Dynamics

69. Wind Tunnel Testing

70. Used to analyze

71. Aerodynamic Drag