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R.I.T. 175th Anniversary Chopper Senior Design Team (Project Number 05912) : 

R.I.T. 175th Anniversary Chopper Senior Design Team (Project Number 05912)

Diverse Team Members: 

Diverse Team Members Advisors Dr. James Taylor (ISE Associate Professor) John Bonzo (Brinkman Lab Facilities Manager) Mechanical Engineering Jonathan Howard Alexandra (Alli) Collier Lee Gagne Industrial Engineering Jeremy Rank John Johnson Anthony Rounding Electrical Engineering Curtis Vana Industrial Design Scott Janis Devin Connolly Tim Houck


Agenda Needs Assessment Concept Development Feasibility Assessment Specifications Analysis and Synthesis

175th Anniversary Chopper Project Description / Desired Outcomes: 

175th Anniversary Chopper Project Description / Desired Outcomes Convert stock 883 Harley-Davidson Sportster into custom chopper prototype Create customization kit for aftermarket sales Conversion components must be bolt on No significant modifications can be made to the frame


Rochester Institute of Technology Senior Design Team Santa Cruz Harley-Davidson Primary stakeholder for conversion kit Conversion Kit Customers Approximately 500 Sportsters are manufactured daily Stakeholders

Needs Assessment: 

Needs Assessment Team researched chopper motorcycles Talk with Mike James and Bob Davis of Santa Cruz Harley-Davidson

Needs Assessment: 

Team developed a list of order qualifiers: Rear end of the bike shall change Front end of the bike shall change Sheet metal on the bike shall change Electronics on the bike shall change Ride height shall change Paint on the bike shall change Seat on the bike shall change Custom parts must be bolt on Bike must be operable Needs Assessment

Concept Development: 

System changes to meet order qualifiers: Fuel Tank Handlebars / Controls Ride Height Wheel Design Tire Drive System Concept Development Wheel Hubs Headlight Electrical Exhaust Seat Conversion Kit

Feasibility Analysis: 

Methods Used Pros & Cons Pugh’s Method Weighted Concept Evaluation Expert input / discussion Feasibility Analysis

Electronics Specifications : 

Electronics Specifications Increase Lighting Hurt Motorcycle Accident Study ½ of all motorcycle accidents involve a motor vehicle (automobile) violating the motorcycle right-of-way Failure to recognize and detect motorcycles in traffic was the predominating cause of motorcycle accident Freedman and Ketron Lighting Study Found that the adding lights to the motorcycles rear and sides improved conspicuity

Electronics Specifications: 

Electronics Specifications Accent Lighting System General Layout System Schematic Cost Analysis

Triple Clamp Specifications: 

Triple Clamp Specifications Design Constraints Safety Machinability 7 Degree Rake Angle Forks Steering stem Mid-Glide front end Handlebars Style

Top Triple Clamp Analysis: 

Top Triple Clamp Analysis Top Triple Clamp with 7G Horizontal Impact Loading Top Triple Clamp with 3G Vertical Impact Loading Max Stress 29,000 psi Max Stress 9,300 psi

Lower Triple Clamp Analysis: 

Lower Triple Clamp Analysis Lower Triple Clamp with 7G Horizontal Impact Loading Lower Triple Clamp with 3G Vertical Impact Loading Max Stress 9,000 psi Max Stress 37,000 psi

Front Wheel Specifications: 

Front Wheel Specifications Design Constraints Safety Manufacturability Style New Front End Design Rear Wheel

Front Wheel Concepts: 

Front Wheel Concepts Preliminary Design Issues Manufacturability Safety

Front Wheel Analysis: 

Front Wheel Analysis Impact Load Torsion Test 6 G Load Max Stress 8,123 psi 3,500 lb Load Max Stress 20,071 psi

Front Hub Analysis: 

Front Hub Analysis Impact Load Torsion Test 6 G Load Max Stress 2,264 psi 3,500 lb Load Max Stress 8,100 psi

Kit Contents Custom Parts Designed and Manufactured: 

Kit Contents Custom Parts Designed and Manufactured Front Wheel Front Hub Front Axle Rear Wheel Rear Hub Rear Axle Triple Clamps Top and Bottom Steering Stem Shaft Steering Stops Modified Purchased Front Sprocket Modified Purchased Rear Sprocket Tank Mounts Seat Mounts Seat Pan Ignition / Key Casing Converted To Hydraulic Clutch Exhaust Paint Scheme and Implementation Gas Tank Rear Fender Oil Cover Electronics Cover Frame Engraved Designs On The Air Intake and Engine Casing Cutting Fender Struts and Remanufacturing Chrome Covers Brake Light LED Lighting System

Kit Contents Aftermarket Parts Purchased and Implemented: 

11inch Eye-To-Eye Shocks Inverted Forks Handlebars Front and Rear Tires Chain Air Intake Filter Chrome Engine Covers Single Rider Seat Chrome Swing Arm Headlight Slave Cylinder Kit Contents Aftermarket Parts Purchased and Implemented

Lessons Learned: 

Lessons Learned Always have a predetermined contingency In the feasibility analysis, we only decided upon the optimal solution Fender attachment Critical path – reconstructing the critical path to make difficult tasks non-sequential



Shoulder Moment Reduction: 

Shoulder Moment Reduction Original design M (shoulder) = (18.62N*.170m) + (10.78N*.480m) M (shoulder) = 8.34 Nm New Design M (shoulder) = (18.62N*.120m) + (10.78N*.340m) M (shoulder) = 5.89 Nm Moment Reduction – 29% Back


Algorithm Back General outline of lighting control algorithm Comparator state check Increment Toggle Output

Lighting Control System: 

Lighting Control System Back Power conditioning circuit Signal conditioning circuit Processing

Cost Analysis: 

Cost Analysis Pugh’s Method Comparison Back

Digital Control Unit: 

Digital Control Unit Device Comparison Algorithm Back

Rear Wheel and Hub: 

Rear Wheel and Hub Back

Handlebar Control Concepts: 

Clean up controls – sleeker look Hide control cables within handlebar Change handlebar shape / geometry Biomechanics Use twist-grip clutch Suicide Shift Custom foot controls Handlebar Control Concepts Back

Ride Height Concepts: 

Lower ride height – rear end Shorten shocks Rigid Hard-tail design Redesign rear suspension geometry Ride Height Concepts Back

Wheel Design Concepts: 

Three claw design 3-dimensional 2-dimensional Solid Wheel Design Spoke Appearance Incorporate tiger image into design Fabricate wheels in-house (Brinkman Lab) Outsource wheel fabrication Wheel Design Concepts Back

Tire Concepts: 

Increase rear tire width Size Range – 180mm – 220mm Change front tire to match new rear tire Find similar front & rear tire pattern Tire Concepts Back

Drive System Concepts: 

Switch from belt to chain drive Switch to narrower belt Use current belt Drive extension / spacer to accommodate new rear tire Widen swing arm Replace existing drive covers Chrome Powder coat Aftermarket color Drive System Concepts Back

Conversion Kit Concepts: 

Fabricate all components of kit Purchase all components (aftermarket) Combination of purchase / fabrication Final Kit delivery All components – 1 set Documentation “Bolt on” components Conversion Kit Concepts Back

Wheel Hub Concepts: 

Design hubs to fit custom wheel Purchase aftermarket hubs Requires wheel design to conform Wheel Hub Concepts Back

Headlight Concepts: 

In-house custom fabrication Purchase aftermarket headlight Remove headlight from design Reuse stock headlight Headlight Concepts Back

Exhaust Concepts: 

Left exit exhaust Converging exhaust pipes (two into one) Shortened straight pipes Street sweeper pipes Purchase aftermarket pipes Fabricate exhaust in-house Exhaust Concepts Back

Seat Concepts: 

Replace stock two-up seat Single seat Fabricate in-house Purchase aftermarket Redesigned two-up seat Fabricate in-house Purchase aftermarket Sissy bar Fabricate in-house Purchase aftermarket Incorporate Logo into seat design RIT 175th anniversary Sponsor Logo Seat Concepts Back

Electrical Feasibility: 

Pugh’s Method Electrical Feasibility Back

Electrical Concepts: 

Integrate rear lights into rear fender Develop proximity sensors Develop variable intensity lighting Accent lighting for engine Custom turn signals Ignition Access code Toggle switch Electrical Concepts Back

Electrical Feasibility: 

Variable intensity lighting Pro: Safety (increase visibility) Aesthetically pleasing Con: Not visible during the daytime Proximity sensor system Pro: Safety (visibility) Con: Cost Time required to implement Resources (people) Electrical Feasibility Back

Fuel Tank Feasibility: 

Custom designed tank Cons: Team lacks expertise in metalworking Cost to outsource fabrication of in-house design ~ $2000 per tank Pros: Radical one of a kind Does not compromise the Industrial Designer’s design Commercially available tank Cons: Compromises the Industrial Designer’s design Not a radical design Pros: Cost: ~$600 per tank Fuel Tank Feasibility Back

Fuel Tank Feasibility: 

Weighted concepts Fuel Tank Feasibility Back

Fuel Tank Feasibility: 

Pugh’s method Fuel Tank Feasibility Back

Handlebars Feasibility: 

Custom built handlebars Cons: No member of the team has experience designing handlebars Pros: Conceal controls Change look of bike from dirt bike to a chopper Purchase handlebars Cons: Cost: ~ $3000 per set Pros: Built by manufacturers with experience Conceal controls Changes look of bike from dirt bike to chopper Handlebars Feasibility Back

Ride Height Feasibility: 

Remove shocks Cons: Turns bike into rigid, decreasing the ride ability of the bike Pros: Gives bike a sleeker look by removing the shocks Shorten shocks Cons: May result in possible problems with concerning clearance, ground clearance and handling Cost of new shocks $281 per set Pros: Gives the bike a squatter stance As compared to the rigid, the bike is easier to ride (comfort) Ride Height Feasibility Back

Wheel Design Feasibility: 

3D design Cons: Requires adding material to the wheel blank Safety concerns (excess weight) Machinability Pros: Radical custom look 2D design Cons: Not as custom Pros: Machinable Safer Wheel Design Feasibility Back

Tire Feasibility : 

Tire Feasibility Width over 190mm Cons: Rear wheel in excess of 190mm will result in a redesign of the XL swing arm Pros: Will give bike the massive back wheel look of a chopper Width equal to or less then 190mm Cons: Rear wheel may appear to be stock Pros: 190mm is a proven good look on an XL No swing arm of drive redesign is needed Back

Drive System Design Feasibility: 

Drive System Design Feasibility Pugh’s method Back

Exhaust Design Feasibility: 

Exhaust Design Feasibility Right hand exhaust Cons: Looks like the majority of bikes on the market Pros: XL 883C is built with and for right hand exhaust Proper flow of exhaust Left hand exhaust Cons: Proper flow of exhaust may be difficult to obtain on XL XL 883C is not built for left hand exhaust Pros: Left hand exhaust is not norm, creating custom and radical look Back

Fuel Tank Concepts: 

Fuel Tank Concepts Custom designed tank Incorporate RIT Tiger into tank Custom fabricate Custom paint Commercially available tank Back

Fuel Tank: 

Feasibility Methods Used Pros and Cons Pugh’s Method Weighted Concept Evaluation Specifications Purchase aftermarket tank Fuel Tank

Handlebars / Controls: 

Feasibility Methods Used Pros and Cons Specifications Have custom handlebars with integrated controls manufactured Handlebars / Controls

Ride Height: 

Feasibility Methods Used Pros and Cons Specifications Lower ride height by 1” Ride Height

Wheel Design: 

Feasibility Methods Used Pros and Cons Specifications 2-dimensional design In-house fabrication Wheel Design


Feasibility Methods Used Pros and Cons Specifications 190mm rear tire Purchase front tire with matching tread pattern Tires

Drive System Design: 

Feasibility Methods Used Pugh’s Method Specifications Chain drive Drive System Design

Electrical Design: 

Feasibility Methods Used Pro & Con Pugh’s Method Specifications Accent lighting - safety Blinking frequency dependant on RPM Electrical Design

Exhaust Design: 

Feasibility Methods Used Pros and Cons Specifications Right Exit Exhaust Exhaust Design

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