the teammate a mechanical regenerative braking design project winter 2013 team eight 1
TRANSCRIPT
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The TEAMMATEA Mechanical Regenerative Braking Design Project
Winter 2013Team Eight
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The Team• John El-Tawil• Colin MacKenzie• Michael Matthews• Alan Robinson
• Dr. Marek Kujath
Supervisor
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Outline
• Introduction
• Design
• Testing
• Design Requirements
• Budget
• Summary & Recommendations3
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Scope
• Design/build a mechanical regenerative braking system
• Capture energy dissipated during braking of a bicycle
• Lower input energy to accelerate from stop
• Improve rider efficiency
Intro Design Testing Design Requirements Budget Summary
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The Design
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Intro Design Testing Design Requirements Budget Summary
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The Spring• System uses a spiral
torsional spring
• Issue: Input is CW Output is
CCW
• Solution: Charge outside Release
inside
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Figure 1 – Spiral Torsional Spring
Intro Design Testing Design Requirements Budget Summary
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How the Spring will Work
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3.
2.
4.
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Figure 2 – Spring Dynamics
Intro Design Testing Design Requirements Budget Summary
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Custom Axle
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Figure 4 - Custom Hub
(Shimano, 2013)
Intro Design Testing Design Requirements Budget Summary
Figure 3 – Standard Hub
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Custom Axle
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Intro Design Testing Design Requirements Budget Summary
Figure 5 – Custom Axle
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The System
Intro Design Testing Design Requirements Budget Summary
Figure 6 – The System
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Input Shaft
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Intro Design Testing Design Requirements Budget Summary
Figure 7 – The Input Shaft
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The System
Intro Design Testing Design Requirements Budget Summary
Figure 8 – The System
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Output Shaft
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Intro Design Testing Design Requirements Budget Summary
Figure 9 – The Output Shaft
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Manual Control / Operation
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Intro Design Testing Design Requirements Budget Summary
Figure 10 – The Manual Control Triggers
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Testing
• Friction losses from system
• Weight losses from the system
• Energy gained from the spring
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Intro Design Testing Design Requirements Budget Summary
Figure 11 – Testing
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Test # 1: Friction Losses• Energy could be lost in the system from bearing
friction
• A speed test was run 5 times with chains attached
and detached
• Final speeds were averaged and compared to determine if there were losses in energy
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Intro Design Testing Design Requirements Budget Summary
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Friction Losses
ChainedRuns Final Speed Elapsed Time (s)
1 17.8 5.3
2 20.2 4.8
3 17.8 5.3
4 15.4 5.5
5 17.7 5.2
Mean 17.78 5.22 17
Not ChainedRuns Final Speed (km/h) Elapsed Time (s)
1 17.7 5.3
2 16.7 5.4
3 19.9 5.1
4 17.6 5.2
5 19.6 5.0
Mean 18.3 5.2
Table 1 – Average speed with system not chained
Table 2 – Average speed with system chained
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Friction Losses
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• Assuming no losses from friction, the final velocities should be the same
= 97.2%
• Losses were minimal with system engaged
• Therefore friction losses neglected in energy balance
Intro Design Testing Design Requirements Budget Summary
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Test # 2: Weight Losses• Energy lost due to added weight of the system (8.98 kg)
• Accelerating a mass requires energy
• The difference in accelerating the bicycle with and without the system will show the energy taken to accelerate just the system from rest.
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Intro Design Testing Design Requirements Budget Summary
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Weight LossesWith System
Run Distance Travelled (m) Time (s)1 24.31 9.58
2 19.88 7.46
3 23.38 8.65
4 23.38 8.84
5 24.16 9.39
Mean 23.02 8.78
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Without SystemRun Distance Travelled (m) Time (s)
1 21.93 7.84
2 20.66 7.33
3 20.66 7.45
4 18.81 6.54
5 23.38 8.01
Mean 21.09 7.43
Table 3 – Distance and time for acceleration with system
Table 4 – Distance and time for acceleration without system
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Weight Losses
• extra needed to accelerate the system mass after each stop
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Test # 3: Energy Gained • Spring ‘’ obtained through testing using torque sensor ratchet
()
• Rotational angle for a max charge, 270 degrees
• Spring’s K and max lower than ideal
• Limits system benefits
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Intro Design Testing Design Requirements Budget Summary
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Testing Results
• Rider uses 16.1 J less than they would without the system per acceleration
• The total savings will increase based frequency of use
• 34 KJ saved per semester for one team member.23
Intro Design Testing Design Requirements Budget Summary
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Testing Summary• Showed overall net gain in energy while using the
“TeamMate”
• Energy gain is very low, but can be improved with two simple design improvements:• Reduce system weight (cast iron and steel not required)• Custom torsional spring (higher K and greater
• The output chain can slip in high torque situations24
Intro Design Testing Design Requirements Budget Summary
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Key Design Requirements
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Intro Design Testing Design Requirements Budget Summary
Requirement Status Details
Must not reduce functionality
Cannot reverse
Improved Rider Efficiency +16.1 J per charge
Propel rider and bike mass of 100 kg
88.8 kg
Assist in acceleration Balance Manually controlled engage and disengage
Fatigue 100 charge cycles
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Budget
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Supplies Supplier Acquired Projected Cost Actual Cost Differential
Mounting System Bicycle Canadian Tire Y $ 345.00 $ 344.92 $ 0.08
Back Rack Cyclesmith Y $ 70.00 $ 46.00 $ 24.00
Containment Box Home Depot Y $ 110.00 $ 160.80 -$ 50.80
Hinges Home Depot Y $ 20.00 $ 3.59 $ 16.41
Bolts Fastenal/Home Depot Y $ 20.00 $ 68.99 -$ 48.99
Aluminum Metals 'r' Us Y $ 200.00 $ 48.88 $ 151.12
Mechanical Transmission System
Sprockets Cyclesmith Y $ 215.00 $ 58.98 $ 156.02
Bicycle Chains Canadian Tire Y $ 80.00 $ 87.39 -$ 7.39
Mounting Shafts/Steel Metals 'r' Us Y $ 40.00 $ 66.76 -$ 26.76
Derailleur Cyclesmith Y $ 50.00 $ 156.57 -$ 106.57
Bearings Princess Auto Y $ 100.00 $ 166.68 -$ 66.68
Disc Brake Axle Ideal Bikes Y $ 70.00 $ - $ 70.00
Energy Storage System
Spiral Torsional Spring John Evans and Sons INC. Y $ 100.00 $ - $ 100.00
Pins Dalhousie Machine Shop Y $ 40.00 $ 5.61 $ 34.39
Disc Brake Assembly Cyclesmith Y $ 150.00 $ 68.99 $ 81.01
Manual Control System
Gear Shifters Ideal Bikes Y $ 60.00 $ 28.75 $ 31.25
Dual Pulling Brake Lever Ideal Bikes Y $ 70.00 $ 46.99 $ 23.01
Locking Brake Lever Ideal Bikes Y $ 70.00 $ - $ 70.00
Shifter Cables Canadian Tire Y $ 10.00 $ 9.18 $ 0.82
Miscellaneous
Wheel Building Ideal Bikes Y $ - $ 113.84 -$ 113.84
Handle Home Depot Y $ - $ 1.15 -$ 1.15
Tools Cyclesmith Y $ - $ 19.17 -$ 19.17
Wheel Stand Ideal Bikes Y $ - $ 287.49 -$ 287.49
TOTAL $ 1,820.00 $ 1,790.73 $ 29.27
REMAINING $ 29.27
Intro Design Testing Design Requirements Budget Summary
Mounting
Mech System
Storage System
Manual Control
Misc.
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Future Recommendations
1. Custom torsional spring
2. Reduce weight
3. Add output tensioner
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4. Different bicycle
5. Custom back rack
6. Better bearings
Intro Design Testing Design Requirements Budget Summary
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Acknowledgements• Angus• Albert, Mark• Dr. Marek Kujath • Dr. Ted Hubbard, Dr. Clifton Johnston• Ideal Bikes• Cyclesmith• Master Auto• Supermileage Team • Dr. Robert Bauer 28
Intro Design Testing Design Requirements Budget Summary
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Questions?29
Website: http://poisson.me.dal.ca/~dp_12_08/Twitter: @MechTeamEight
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Key Ring
IntroDesign
Requirements
Design Testing Budget Summary
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Key Ring
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Maximum Torque Required to Accelerate a Bicycle
Basic Parameter Value ChosenProvided by
Manufacturer Total Mass of
Bicycle and Rider100 kg
Initial Velocity 0.0 m/s Final Velocity 15 km/hr (= 4.2
m/s)
Distance 10 metres Frontal Area of Average Rider
5.5 ft x 2 ft
= 11
(=1.022 )
Diameter of Bicycle Wheel
.800 m
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Assume is based on air resistance at and
(1.022 )
NOTE: 5.63 N was increased to 10 N to compensate for relative wind velocity and neglected mechanical losses in bicycle.
(9)(10)
= 44.0 Nm (11)
NOTE: It was later determined through testing that the maximum torque required was approximately 35.0 Nm but to maintain a conservative approach, all following calculations are based on 44.0 Nm.
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Safety Factor of Bicycle ChainBasic Parameter Value Chosen
Provided by Manufacturer
Maximum System Torque
44.0 Nm (= 33 ft-lb)
Maximum Allowable Force in Low Quality
ANSI 40 Chain (Standard Bicycle
Chain)
940 lb
Minimum Sprocket Diameter (12 Teeth)
1.5 in
S.F. = = 1.78
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Safety Factor of Bicycle SprocketsBasic Parameter Value Chosen
Provided by Manufacturer **
Minimum # of Sprocket Teeth
12
Sprocket Material Steel 1045 Shear Area of Sprocket
Tooth 2.0 x
Force in Chain
Minimum Chain Wrap Angle
120
S.F = 34
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Safety Factor of Disc BrakeBasic Parameter Value Chosen
Provided by Manufacturer
Maximum System Torque
44.0 Nm (= 33 ft-lb)
Maximum Pinching Force of Disc Brake
1200 lbf
Radius of Disc Brake 80 mm of Steel Rotor on Brake
Pad.67
Safety Factor
35
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Safety Factor of Spiral Torsional Spring
Basic Parameter Value ChosenProvided by
Manufacturer **Maximum System Torque 44.0 Nm (= 33 ft-lb) Maximum Spring Angle of
Deflection240
Spring Rate ‘K’ 4.2312
Safety Factor
36
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Safety Factor of Shafts Subjected To Torsion
Basic Parameter Value ChosenProvided by Manufacturer
**Maximum System Torque 44.0 Nm (= 33 ft-lb)
Shaft Diameter 1.5 in= 38.1 mm
Shaft Material Steel 316 (Stainless)
Safety Factor
37
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Safety Factor of Shafts Subjected to Shear
Basic Parameter Value Chosen Provided by Manufacturer Maximum System Torque 44.0 Nm (= 33 ft-lb)
Shaft Diameter .75 in= 19.05 mm
Shaft Material Steel 316 (Stainless)
Safety Factor
38
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Test # 4: Energy Storage System Efficiency
• Compare input and output speeds on the stand
• With and without torque resistance
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Intro Design
Testing
Design Requirements
Budget
Summar
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