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The Omnibike

Allan Regis
Allan Regis

The document provides details of a design project to develop a new product called the Omnibike for Rhoadescar International. The Omnibike is intended to be a fitness bike that incorporates carbon fiber, allows for upper body exercise, and can fold or disassemble to fit in a sedan. The document discusses the competition, various design considerations including materials selection between carbon fiber and aluminum, methods for incorporating carbon fiber construction, the final frame and powertrain designs, and major contributions from team members.

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Design Review Lloyd Ambrose Willie Carter Andrew Marione bike Allan Regis Daniel Tepper Chufei Yu (High-fidelity prototype)
Rhoadescar International Leading International Quadricycle Manufacturer Headquarters: Hendersonville, TN Founded: 1991 Key people David Rhoades (Founder, President 1992 2009) Bill Pomakoy (Co-owner, President, and CEO) Phyllis Shelton (Co-owner)
Design Project Description Develop new product called The Omnibike. Fitness bike based on GoBoy: Comfort Ride Key Design Criteria: Incorporate carbon fiber into design Add an upper body exercise to augment fitness benefits Design such that product can be folded or disassembled to fit in the back of an average sedan Mom Certified; an older woman should be able to intuitively understand what our product is, and how it works
Needs Wants Exciting aesthetic quality Intuitive, no lean steering system Multi-gear drive train Lightweight design Simple repair and replacement 4 Wheels Carbon Fiber Upper-Body Workout Fold/Disassemble 20 wide comfort seat Capable of seating 300lb riders
The Competition No product exactly like the Omnibike exists Individual design elements are used in design of Quadricycles, Tricycles, Bicycles, and other vehicles. Focus Elements: Frame Design and Material Selection (Carbon Fiber) Upper Body Movement Folding/Disassembly
The CompetitionFrame Design Pacific 2rider Very-Eco Quadricycle Specialized Big Hit Custom Bicycle by Svetlyo Kostov Da Vinci Tandem Bicycle
Folding Not Quadricycles, but Bicycles. Two main styles of folding: Fold in half at center hinge 際際滷 through sockets into a single plane Goal is to get bike to a compact shape in a single plane Pacific Cycles If Pacific Cycles Carry Me
The CompetitionUpper Body Exercise Seen in exercise bicycles and more commonly in tricycles for handicapped athletes. Wheel with handles rotates chain that drives either front or rear wheel. Varibike Pacific Cycles Handy
High Modulus of Elasticity High electrical and thermal conductivity Low coef. of thermal expansion Low failure strain High Strength Low Density Anisotropic Carbon Fiber Properties
General Comparison Taken from Aluminum: Properties and Physical Metallurgy, John Hatch and Carbon Fiber Composites, Deborah Chung Aluminum: Density: 2600 kg/m3 Modulus of Elasticity: 62 GPa Poissons Ratio: 0.33 Ultimate Tensile Strength: 115 MPa Carbon Fiber: Density: 1600 kg/m3 Modulus of Elasticity: 70 GPa Poissons Ratio: 0.1 Ultimate Tensile Strength: 600 MPa Steel: Density: 7850 kg/m3 Modulus of Elasticity: 190 GPa Poissons Ratio: .27 Ultimate Tensile Strength: 276 MPa
- PAN - most common, less expensive - 610K TOW PITCH donated by Oak Ridge Natl Labs, fiber strands Future Challenges: moving from fiber to prepreg 610K TOW is hard to mold PAN (polyacrylonitrile) vs PITCH (petroleum pitch)
The experimental 610K TOW carbon fiber is exactly thatexperimental. How can a group of undergraduate college students think of a way to use unimpregnanted carbon fiber to build a sturdy, four-wheeled bicycle?? Our Problem
The bladder and mold method Carbon fiber sheets are placed over an inflatable latex bladder, which is inflated in high pressure mold Disadvantage: Requres carbon fiber to be pre-prepared in uniform sheets, + expensive tooling and resources Possible Methods of Carbon Fiber Manufacturing
The plug and bag method 1. Create a plug out of Styrofoam 2. Wrap the plug with carbon fiber and epoxy (prepared in sheets or otherwise) 3. Vacuum-bag to create a more compressed carbon fiber structure 4. Melt the Styrofoam with acetone once carbon fiber is dry Disadvantages: Carbon fiber tubes would be incredibly ununiform in strength failure could result in catastrophic injury for the end user
Manufacturing Option 3The Uhing With the help of my peers and the CEO of a bicycle manufacturing company known as Slipstream Bicycle, LLC, we considered constructing a uhing apparatus, which uses small devices called uhings that move up and down a shaft at a constant rate as it rotates. By threading carbon fiber strands through a plate mounted on top of a uhing as is goes up and down the shaft, we can wrap a plastic mold with the carbon fiber at an angle, and in a uniform manner. Carbon Fiber Spools Uhing Devices Plastic Mold Small GearmotorsRubber Belt Oak Ridge National Laboratory has offered to allow our team to utilize their state of the art 3D printers to print plastic molds of our pieces. Once the components are wrapped with carbon fiber, they will be sent back to Oak Ridge and baked in an over to cure the impregnated carbon fiber and melt out the plastic mold. Finally, the parts will be sent to Rhoadescars mill to be cut in the appropriate shapes and dimensions.
However In the end, the team decided that purchasing prefabricated carbon fiber tubes was the wisest decision. We decided that it would not have been ethical for us to design a device not knowing if it was safe to ride or not, and that trying to reinvent the wheel would have taken too much time away from our core objectives. Ultimately this proved to be a very wise decision for us.
Omnibike Initial Concept Design my initial design was WAY too unbelievable. We all quickly realized the constraints of modern manufacturing
Final Frame Design Final CAD dimensions done by Daniel Tepper, once we knew what parts we had, and what their dimensions were
Dissasembly The tubes of the bicycle would interlock and be kept in place via store-bought push pins. When the bike is to be disassembled, the pins would be removed, the tubes would slide in (to allow for easy removal of chains), and then the tubes can easily be slid out.
Powertrain Considerations How might we achieve gear switching with rear-wheel drive, while still allowing the bicycle to disassemble?? My proposed solution was a jack-axle setup, in which the cassette of the bicycle sits on the back wheels. The jack axles main job would be to allow the chain (or carbon belt) to be easily removed for disassembly, then easily put back onto the bike to ride again. A more advanced version of our bike could make use of a second cassette, which would provide a much larger range of gear ratios for the bicycle. (Powertrain notes included separate in portfolio) Cassette (In Use) Cassette (Not In Use; no derailleur on bike) Overrunning Clutch Gear
Power Train Plans What is an overrunning clutch? http://www.youtube.com/watch?v=QjR7dimpSJA&t=0m37s http://www.youtube.com/watch?v=OqV_VHz5BKo Similar technology can be used in a freewheeling system for bicycles Allows for drive only in one direction
Front Wheel Drive/Hand Crank Drive? Could we make the powertrain happen through the front wheels? Nope! We cant run an axle through the front wheels. To better address this concern, we looked at front-wheel drive cars. But quickly realized that any attempt to make the bike front-wheel drive would drastically increase the cost of manufacturing & assembly Could we make the powertrain connect to the hand crank? Integrating the steering into a hand crank for exercise proved too difficult Having steering handlebars AND the hand crank would be impractical (cuz you know, humans only have two arms n stuff)
Upper Body Exercise Store-bought dual hydraulic piston system w/ handles Resistance can be adjusted to users preference Again, an excellent idea that avoids reinventing the wheel
Steel vs. Aluminum? We chose to fabricate our works-like-prototype of the bike using steel tubes instead of aluminum. This is because we only had one experienced welder on our student team (Daniel), and he didnt feel comfortable trying to weld aluminum due to its high conductivity and low melting point.
Finally Finished!
Major Team Contributions Me! Established the initial conceptual framework for the bikes main systems, namely the powertrain and disassembly method; assembled the jack axle Handled all communication & Report deliveries to Rhoadescar, LLC executives Helped think of cheap and reliable ways to manufacture the bike Worked closely w/ Walter Webber, CEO of Slipstream Bicycle, to flush out the details of the uhing manufacturing method When we realized that making our own carbon fiber wouldnt work, I found the cheapest pre-made tubes I could find (They were on clearance!!) Designed all 3D-printed components Andrew Marione Led the research for carbon fiber manufacturing methods, specifically the plug-and-bag method & the bladder-mold method Machined most of the parts Came up w/ the idea for the pre-fabricated hydraulic hand exercise
Major Team Contributions Daniel Tepper The designated team leader; was very good at keeping us on task and making sure we were prepared for deadlines Made many quick manufacturing decisions towards the end of the project that helped us save a lot of time Handled all part orders Did ALL the welding Led the efforts to research & compile data about general carbon fiber material properties, PAN vs. PITCH, comparison to aluminum/steel, etc. Made revised CAD designs for final design Lloyd Ambrose (my partner in crime!!) Machined parts w/ Andrew Excellent at 2D visualization. Provided nice bike renders for our presentations to Rhoadescar, and came up w/ the logo The wheel inside the O used to spin, but now it wont do it anymore and idk why bike
Major Team Contributions Chufei Yu Handled all the driving! :D Did majority of competition benchmarking in Nashville area by visiting local bike shops Willie Carter Did most of the online benchmarking research Did extensive research into the steering conditions for cars, specifically the Ackerman Condition and caster angles (typically observed in cars) Although we found significant inefficiencies in the current Go Boy models steering geometry, we decided that it would be outside of our time frame to change it.
Needs & Wants, Revisited Exciting aesthetic quality Intuitive, no lean steering system Multi-gear drive train Lightweight design Simple repair and replacement 4 Wheels Carbon Fiber Upper-Body Workout Fold/Disassemble 20 wide comfort seat Capable of seating 300lb riders
Things to Consider Moving Forward Abandon the idea of making partially carbon fiber bicycles; go all aluminum instead. Not only were the materials expensive, but the dislocations of materials throughout the bike create discrete stress points (not to mention that drilling carbon fiber is bad.) Explore possibility of adding shocks to the bicycles More product documentation! Statics Charts? Failure Analysis w/ ANSYS or Creo Simulate? Complete parts list? Do more research into the Rhoadescar steering linkage; review Ackerman conditions to see if any power is being lost through turns Consider carbon fiber belt-driven system for easier & cleaner chain removal? Stands to support bike sections during disassembly? Better ways to keep brake cables out of the way during disassembly

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The Omnibike

  • 1. Design Review Lloyd Ambrose Willie Carter Andrew Marione bike Allan Regis Daniel Tepper Chufei Yu (High-fidelity prototype)
  • 2. Rhoadescar International Leading International Quadricycle Manufacturer Headquarters: Hendersonville, TN Founded: 1991 Key people David Rhoades (Founder, President 1992 2009) Bill Pomakoy (Co-owner, President, and CEO) Phyllis Shelton (Co-owner)
  • 3. Design Project Description Develop new product called The Omnibike. Fitness bike based on GoBoy: Comfort Ride Key Design Criteria: Incorporate carbon fiber into design Add an upper body exercise to augment fitness benefits Design such that product can be folded or disassembled to fit in the back of an average sedan Mom Certified; an older woman should be able to intuitively understand what our product is, and how it works
  • 4. Needs Wants Exciting aesthetic quality Intuitive, no lean steering system Multi-gear drive train Lightweight design Simple repair and replacement 4 Wheels Carbon Fiber Upper-Body Workout Fold/Disassemble 20 wide comfort seat Capable of seating 300lb riders
  • 5. The Competition No product exactly like the Omnibike exists Individual design elements are used in design of Quadricycles, Tricycles, Bicycles, and other vehicles. Focus Elements: Frame Design and Material Selection (Carbon Fiber) Upper Body Movement Folding/Disassembly
  • 6. The CompetitionFrame Design Pacific 2rider Very-Eco Quadricycle Specialized Big Hit Custom Bicycle by Svetlyo Kostov Da Vinci Tandem Bicycle
  • 7. Folding Not Quadricycles, but Bicycles. Two main styles of folding: Fold in half at center hinge 際際滷 through sockets into a single plane Goal is to get bike to a compact shape in a single plane Pacific Cycles If Pacific Cycles Carry Me
  • 8. The CompetitionUpper Body Exercise Seen in exercise bicycles and more commonly in tricycles for handicapped athletes. Wheel with handles rotates chain that drives either front or rear wheel. Varibike Pacific Cycles Handy
  • 9. High Modulus of Elasticity High electrical and thermal conductivity Low coef. of thermal expansion Low failure strain High Strength Low Density Anisotropic Carbon Fiber Properties
  • 10. General Comparison Taken from Aluminum: Properties and Physical Metallurgy, John Hatch and Carbon Fiber Composites, Deborah Chung Aluminum: Density: 2600 kg/m3 Modulus of Elasticity: 62 GPa Poissons Ratio: 0.33 Ultimate Tensile Strength: 115 MPa Carbon Fiber: Density: 1600 kg/m3 Modulus of Elasticity: 70 GPa Poissons Ratio: 0.1 Ultimate Tensile Strength: 600 MPa Steel: Density: 7850 kg/m3 Modulus of Elasticity: 190 GPa Poissons Ratio: .27 Ultimate Tensile Strength: 276 MPa
  • 11. - PAN - most common, less expensive - 610K TOW PITCH donated by Oak Ridge Natl Labs, fiber strands Future Challenges: moving from fiber to prepreg 610K TOW is hard to mold PAN (polyacrylonitrile) vs PITCH (petroleum pitch)
  • 12. The experimental 610K TOW carbon fiber is exactly thatexperimental. How can a group of undergraduate college students think of a way to use unimpregnanted carbon fiber to build a sturdy, four-wheeled bicycle?? Our Problem
  • 13. The bladder and mold method Carbon fiber sheets are placed over an inflatable latex bladder, which is inflated in high pressure mold Disadvantage: Requres carbon fiber to be pre-prepared in uniform sheets, + expensive tooling and resources Possible Methods of Carbon Fiber Manufacturing
  • 14. The plug and bag method 1. Create a plug out of Styrofoam 2. Wrap the plug with carbon fiber and epoxy (prepared in sheets or otherwise) 3. Vacuum-bag to create a more compressed carbon fiber structure 4. Melt the Styrofoam with acetone once carbon fiber is dry Disadvantages: Carbon fiber tubes would be incredibly ununiform in strength failure could result in catastrophic injury for the end user
  • 15. Manufacturing Option 3The Uhing With the help of my peers and the CEO of a bicycle manufacturing company known as Slipstream Bicycle, LLC, we considered constructing a uhing apparatus, which uses small devices called uhings that move up and down a shaft at a constant rate as it rotates. By threading carbon fiber strands through a plate mounted on top of a uhing as is goes up and down the shaft, we can wrap a plastic mold with the carbon fiber at an angle, and in a uniform manner. Carbon Fiber Spools Uhing Devices Plastic Mold Small GearmotorsRubber Belt Oak Ridge National Laboratory has offered to allow our team to utilize their state of the art 3D printers to print plastic molds of our pieces. Once the components are wrapped with carbon fiber, they will be sent back to Oak Ridge and baked in an over to cure the impregnated carbon fiber and melt out the plastic mold. Finally, the parts will be sent to Rhoadescars mill to be cut in the appropriate shapes and dimensions.
  • 16. However In the end, the team decided that purchasing prefabricated carbon fiber tubes was the wisest decision. We decided that it would not have been ethical for us to design a device not knowing if it was safe to ride or not, and that trying to reinvent the wheel would have taken too much time away from our core objectives. Ultimately this proved to be a very wise decision for us.
  • 17. Omnibike Initial Concept Design my initial design was WAY too unbelievable. We all quickly realized the constraints of modern manufacturing
  • 18. Final Frame Design Final CAD dimensions done by Daniel Tepper, once we knew what parts we had, and what their dimensions were
  • 19. Dissasembly The tubes of the bicycle would interlock and be kept in place via store-bought push pins. When the bike is to be disassembled, the pins would be removed, the tubes would slide in (to allow for easy removal of chains), and then the tubes can easily be slid out.
  • 20. Powertrain Considerations How might we achieve gear switching with rear-wheel drive, while still allowing the bicycle to disassemble?? My proposed solution was a jack-axle setup, in which the cassette of the bicycle sits on the back wheels. The jack axles main job would be to allow the chain (or carbon belt) to be easily removed for disassembly, then easily put back onto the bike to ride again. A more advanced version of our bike could make use of a second cassette, which would provide a much larger range of gear ratios for the bicycle. (Powertrain notes included separate in portfolio) Cassette (In Use) Cassette (Not In Use; no derailleur on bike) Overrunning Clutch Gear
  • 21. Power Train Plans What is an overrunning clutch? http://www.youtube.com/watch?v=QjR7dimpSJA&t=0m37s http://www.youtube.com/watch?v=OqV_VHz5BKo Similar technology can be used in a freewheeling system for bicycles Allows for drive only in one direction
  • 22. Front Wheel Drive/Hand Crank Drive? Could we make the powertrain happen through the front wheels? Nope! We cant run an axle through the front wheels. To better address this concern, we looked at front-wheel drive cars. But quickly realized that any attempt to make the bike front-wheel drive would drastically increase the cost of manufacturing & assembly Could we make the powertrain connect to the hand crank? Integrating the steering into a hand crank for exercise proved too difficult Having steering handlebars AND the hand crank would be impractical (cuz you know, humans only have two arms n stuff)
  • 23. Upper Body Exercise Store-bought dual hydraulic piston system w/ handles Resistance can be adjusted to users preference Again, an excellent idea that avoids reinventing the wheel
  • 24. Steel vs. Aluminum? We chose to fabricate our works-like-prototype of the bike using steel tubes instead of aluminum. This is because we only had one experienced welder on our student team (Daniel), and he didnt feel comfortable trying to weld aluminum due to its high conductivity and low melting point.
  • 26. Major Team Contributions Me! Established the initial conceptual framework for the bikes main systems, namely the powertrain and disassembly method; assembled the jack axle Handled all communication & Report deliveries to Rhoadescar, LLC executives Helped think of cheap and reliable ways to manufacture the bike Worked closely w/ Walter Webber, CEO of Slipstream Bicycle, to flush out the details of the uhing manufacturing method When we realized that making our own carbon fiber wouldnt work, I found the cheapest pre-made tubes I could find (They were on clearance!!) Designed all 3D-printed components Andrew Marione Led the research for carbon fiber manufacturing methods, specifically the plug-and-bag method & the bladder-mold method Machined most of the parts Came up w/ the idea for the pre-fabricated hydraulic hand exercise
  • 27. Major Team Contributions Daniel Tepper The designated team leader; was very good at keeping us on task and making sure we were prepared for deadlines Made many quick manufacturing decisions towards the end of the project that helped us save a lot of time Handled all part orders Did ALL the welding Led the efforts to research & compile data about general carbon fiber material properties, PAN vs. PITCH, comparison to aluminum/steel, etc. Made revised CAD designs for final design Lloyd Ambrose (my partner in crime!!) Machined parts w/ Andrew Excellent at 2D visualization. Provided nice bike renders for our presentations to Rhoadescar, and came up w/ the logo The wheel inside the O used to spin, but now it wont do it anymore and idk why bike
  • 28. Major Team Contributions Chufei Yu Handled all the driving! :D Did majority of competition benchmarking in Nashville area by visiting local bike shops Willie Carter Did most of the online benchmarking research Did extensive research into the steering conditions for cars, specifically the Ackerman Condition and caster angles (typically observed in cars) Although we found significant inefficiencies in the current Go Boy models steering geometry, we decided that it would be outside of our time frame to change it.
  • 29. Needs & Wants, Revisited Exciting aesthetic quality Intuitive, no lean steering system Multi-gear drive train Lightweight design Simple repair and replacement 4 Wheels Carbon Fiber Upper-Body Workout Fold/Disassemble 20 wide comfort seat Capable of seating 300lb riders
  • 30. Things to Consider Moving Forward Abandon the idea of making partially carbon fiber bicycles; go all aluminum instead. Not only were the materials expensive, but the dislocations of materials throughout the bike create discrete stress points (not to mention that drilling carbon fiber is bad.) Explore possibility of adding shocks to the bicycles More product documentation! Statics Charts? Failure Analysis w/ ANSYS or Creo Simulate? Complete parts list? Do more research into the Rhoadescar steering linkage; review Ackerman conditions to see if any power is being lost through turns Consider carbon fiber belt-driven system for easier & cleaner chain removal? Stands to support bike sections during disassembly? Better ways to keep brake cables out of the way during disassembly
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