RISD HUMAN POWERED VEHICLE ´09

Project Book

2009-06-30T12:12:00.000-07:00

Link to Book

Videos

2009-06-22T23:22:00.000-07:00

Thanks to Hemi for directing, starring in, and editing these videos.

An overview of the vehicle:

RISD Human Powered Vehicle 2009 from Mike Eng on Vimeo.

And the "making of":

RISD Human Powered Vehicle 2009 - The Making of from Mike Eng on Vimeo.

FOR MORE PICTURES...

2009-06-09T13:30:00.001-07:00

In case you want to see more pictures than shown on the blog just click on the picture below and you will be guided to our picasa web album. Enjoy some unpublished material!

SOME MORE DETAILS

2009-06-09T13:26:00.001-07:00

THE PRESENTATION

2009-06-09T10:15:00.000-07:00

Tuesday 19th of May, 1.30pm. The time has come to present the bike to our critic and the public.

THE FINAL ASSEMBLY

2009-06-09T09:47:00.000-07:00

Only a few hours before the final presentation we could finally assemble the whole bike.

THE FINAL COAT

2009-06-09T09:18:00.000-07:00

After having achieved a rigid enough body it was time to put on the final layer of carbon fibre. The difficiculty was to produce a nearly seemless coat.

ASSEMBLING THE DRIVE TRAIN

2009-05-23T21:57:00.000-07:00

Assembling the drivetrain inside of the frame was definitely one of the most tense moments - taking all of our custom machined components and putting them to the ultimate test. We tested the fit of the components together and made sure nothing was rubbing on the inside of the frame. Though the assembly operation required a Leatherman, allen wrenches, and several improvised hooks, we were able to put everything together fine. The fit of the parts erred on the side of too tight. Only a couple of points inside the frame had to be sanded away to allow the chain to clear.

FIRST ROUGH ASSEMLBY

2009-05-16T20:47:00.000-07:00

Having the frame, the front fork and the spoked wheels we could roughly assemble the parts and get a gasp of how the actual bike will look. A very exciting moment!

THE FRONT FORK

2009-05-16T18:01:00.000-07:00

A lot of discussions took place about the design of the front fork, but no it´s finally done.

THE SEAT

2009-05-16T17:22:00.000-07:00

Krisa spent a lot of time working on the seat and it´s starting to pay off. Completly made out of carbon fibre, it will be an important touchpoint between the rider and the bike. Especially with our concept with the crank before the saddle it is important that the seat offers enough back support.

SANDING, LAYING, SANDING, LAYING....

2009-05-16T16:24:00.000-07:00

To get enough stiffness and stability in the frame we have to lay layer over layer and do in between lots and lots of sanding.

Components, components, components

2009-05-15T09:25:00.000-07:00

Mike's setup for the crown - it is cut off-center in order to achieve a press fit with the crown race.

Hemi, the lathe master.

Nick, the machinist machine.

Nick's setup with a custom jig in order to drill accurately into the airfoil tubing for the fork.

Adrian cleaning components in our clean room before setting them in the carbon fiber. Not pictured - the rest of the team standing around in haz-mat suits.

DRYING PROCESS

2009-05-10T09:37:00.000-07:00

For a faster drying process we built a very rough but functioning case with a heating lamp around the modell.

LAYING CARBON FIBRE

2009-05-10T09:18:00.000-07:00

After long time of preparation we finally have all the parts together and can start laying the carbon fibre. In a first round we secured all our hardpoints around the drive train by setting up the machined parts and laying the carbon fibre around these points.

SETTING UP THE JIG

2009-05-10T09:03:00.000-07:00

Having finished the machinig and the pink foam modell we started setting up the jig. All the collected informations from the prototype and the real size drawing are coming together now.

PINK FOAM MODELL

2009-05-10T08:57:00.000-07:00

Parallel to the machining we started working on the pink foam model, which will be the base for the laying of the carbon fibre.

The first rough cut and the stencil.

The final shape.

The intermediate hub will be placed in here.

SOME IMPRESSIONS OF THE HARD WORKING STUDENTS

2009-05-04T12:37:00.001-07:00

NEW DESIGN

2009-05-04T12:21:00.000-07:00

After locating the new position of the transfer hub, we had to come up with a new design. Biggest change is the drastic shortening of the rear fork and enlongment of the actual body. Further on, based on the new location of the transfer hub we had to relocate the saddle and integrated him into the body.

COLLIDING DRIVE CHAIN

2009-05-04T12:02:00.000-07:00

Having set up the drive chain, we took advantage of the fact that we have the first time actual 3 dimensional hard points. A quick seat testing showed that the position of the drive chain is colliding with pedaling. This means that we have to rearrange the components which consequently had a huge impact on the design of the bike.

Drive Train Assembled

2009-05-03T08:37:00.000-07:00

We finished fixing the drive train to the jig on Saturday night, and we have the final (we hope) coordinates for the components.

The design has changed according to this. Some stuff had to be changed/removed, and other needs to be redesigned to fit the new layout.

We plan to have the pink foam for the body on today and
continue working on the other parts (brake, front fork, seat). It's quickly coming to the final stretch.

Components Update

2009-04-23T20:17:00.000-07:00

Another generation of the drive components. We designed them to be functional yet as simple as possible so that we can machine them all by next Tuesday and then get on to other things in this wild ride. We've got some good progress already - someone on our team served up a cafeteria tray of a few of the components the other day.

Bottom Bracket

Just like before, we are still designing the drive to go inside of a hollow frame. So on this here bottom bracket, we are centering the chainring on the spindle. Note the flat areas on the spindle to key with the spider and thereby prevent slippage.

A guide to the parts:

Red = outer plates
Green = frame inserts (embedded in carbon fiber frame)
Yellow = bearings
Gray = spindle
Purple = spider
Black = chainring

Transfer Gear

We are using an internally-geared 3-speed hub as a transmission. It will have two chains - one input and one output, similar to the chains on a tandem. Here is a system for adjusting the dropout angle so that we can tension both chains with one adjustment.

Red = adjustable plates

Green = frame inserts (embedded in carbon fiber frame)

Gray = input cog / 3-speed hub.

Black = output cog

Rear Hub

The rear hub is designed so that the rider can remove the wheel from the side - without messing with the chain. The rear axle fits into the hub, and the axle rotates with the wheel.

Orange - hub

Gray = axle

Red = outer plates

Green = frame inserts (embedded in carbon fiber frame)

Yellow = bearings

Purple = spider

Black = output cog

Here's a closeup on the spider, which is basically a modified split collar. It's going to be a small but action-packed machining job.

Front Hub

We've yet to detail it fully, but we're going to be modifying an existing Shimano Nexave roller brake. The brake engages with the hub from the side, so it will be fairly simple to modify it to fit on a one-sided fork. Here's an exploded view drawing from Shimano.

Bottom Bracket Assembly

2009-04-19T23:38:00.001-07:00

In order to enclose the drivetrain inside the frame, we are machining some custom components. Here is the bottom bracket assembly:

And an exploded view:

Note that the spider is actually a split collar which clamps onto the center of the spindle with a bolt.

Nick is currently having fun turning the spindle on the lathe - and he is eagerly looking forward (really!) to tackling that spider.

OVERALL DESIGN DECISION

2009-04-19T12:58:00.000-07:00

During our work on our specific parts we realize that there is an outstanding decision about the overall design, which hold us back from ordering parts and getting hard data for the bike. Both versions had their pros and cons.
V1:

V2:

After a discussion in the group we chose Variant 1. As a consequence we have the following hard points for our bike:

one sided fork in the front and the back.
20"wheel
intermediate hub
foldable handlebars as part of the locking system
collapsible saddle
integrated lighting in the frame
a body out of carbon fibre

TIME TO GET CONCRETE

2009-04-19T12:33:00.000-07:00

With all the won information it is now time to get precise informations and a clear concept for every part of the bike. To be more effective we split the group and assigned one part of the bike to members:

Storage: Krisa
Locking/Foldable Handlebar: Adrian
Over all design: Erik
Chain wheel: Mike
Visibility: Ashley
Seat fixation: Hemi
Seat shape: Hemi/ Nick
Handle bars: Harry

IMPROVED PROTOTYPE

2009-04-19T12:15:00.000-07:00

With our modified prototype we went out again and did some more testings. The results were confirming us: Smaller wheels will offer a more compact package, with acceptable loss of comfort. It also opens up a niche in the bike segments: Compact Crank Forward.

EVALUATION OF THE TEST RIDES

2009-04-19T11:53:00.000-07:00

Based on our test rides we found out some valuable informations:

The bike as it is now is too big. -->As a consequence of that we will put on 20" wheels and test it with smaller wheels

The seat doesn´t have to have a big back-rest to garanty enough support for efficient pedaling --> Find out the minimum solution for the back rest

The handling is very unpractical. -->New handlebars and a better relation to the body has to be found.

The frame has to much flex. --> After finding the right relation between the crank and the seat, we´ll fix and support the frame.

TESTS

2009-04-19T11:42:00.000-07:00

Under perfect conditions we were able to do some first test rides

RIDABLE PROTOTYPE

2009-04-19T11:34:00.000-07:00

As a result of the feedback, the rest of the team built this modular ridable protoype. It will help us to find out valuable informations about the seat, hard points for the final bike and most important information about the handling of the bike.

DAILY USER SCENARIO

2009-04-19T11:12:00.000-07:00

The "identity-group" also developed two user-scenarios to get an idea of the daily challenges the bike has to face.

1. Gabriel Smith, 20 years old, Anthropology Student, Nice Weather Commuter

2. Michael Stange, 37 years old, Social Worker, Everyday-Commuter
Short summary:
Distance: ca. 2Miles
Mostly in city, a lot of signals, where has to wait
Mostly flat path, only one tunnel underneath the tracks.
Has to carry food and drinks, a laptop and some documents

IDENTITY OF THE BIKE

2009-04-19T10:38:00.000-07:00

To get a clearer idea of the identity the group was asking themselves: What is our Innovation? What separates us from the rest of the market? After analyzing our progress so far, we came up with a list of specific problems we´re trying to tackle:

small people can not blance on a normal bike
it is hard to get on a diamond frame bike
no convincing locking solutions
uncomfortable seating position on a upright bike
people don´t know how to change the wheels
dirty pants from the chain
no working lights
diamond framed bikes need a lot of space for storage

Based on that we had the idea for a marketing campaign that would focus on this problems and how we solved them. For example showing dirty fingers and tell that this is history, because we solved the problem.

EVALUATION OF THE PRESENTATION

2009-03-27T19:45:00.000-07:00

In a discussion after the presentation we evaluated the results of the presentation and came up with a plan for our next steps:

The team will split up into two work- groups within the next days.
Group 1 will built an ridable and easy to modify prototype.
Group 2 will work out a more precise identity for the bike, including personas and their daily user-experiences, possible logos, slogans and advertisement.

THE PRESENTATION

2009-03-27T19:04:00.000-07:00

Good process up till now, but more work has to be done in the future. The crit has been hard but fair and constructive. Unclear or unsolved points have been clearly pointed out, discussed and ideas how to solve them were given to us:

-The idea of our typical commuter is not very clear yet -> Create a more specific picture of a persona and his daily commuting experience.

-The concept is not very tangible yet. -> Clarify the strengths and the weaknesses and create a clear vision with details (seat, seating-position, gears, suspension...)

-The existing prototype is too two dimensional and not very useful -> Build a ridable and easy to modify prototype, because the riding experience will be the key to a successful bike. Test as much as possible under real conditions.

-The design is not very exciting yet -> Have a look back at themore exciting sketches. Build also 3-dimensional protoypes, whenever it is possible.

PREPARATION FOR THE PRESENTATION

2009-03-27T18:41:00.000-07:00

For the concept presentation we tried to make our concept more tangible and tried to find a slogan for our bike. A first representation was found in:
Simple...
visual impression
experience
and maintentance.

Further on we produced an explanatory modell of the chain drive, a real-scale model and real-scale drawing of our the latest and best concept.

PROGRESS!

2009-03-10T17:31:00.000-07:00

Based on our ergonomic mock-up more important decision could be made today. After long testing, with following photo-analysis, the team could establish valuable measurements for the vehicle. Further on, after a long discussion, the wheel size was defined to 26". Based on this freshly won knowledge first real-size sketches were produced. They will build the foundation for more concret concepts.

determination of the seating position

real-size drawing with the established fixed points

FIRST BIG STEP

2009-03-08T10:14:00.000-07:00

Based on our research, the needs of our user group and a discussion about the best seating-position we established our first two DEFINITIVE criteria:

1. Crank-forward seating position

We chose this position because it combines the best aspects of a recumbent bike and the classic upright seating postion:

- good visibility (seeing and beeing seen)

- relaxed ergonomic position

- safety aspects (feet easy on the ground)

- efficient pedaling

2. hidden technique

PRESENTATION OF 3 CONCEPTS

2009-03-08T10:11:00.000-07:00

Based on our research in the refined fields everyone came up with 3 concepts.

pics soon...

USER GROUP

2009-03-08T10:09:00.000-07:00

In a discussion after the demos we established our user group:

COLLEGE STUDENTS

WORKSHOP DEMOS

2009-03-08T09:40:00.000-07:00

Preparing for long days and short nights in the workshop at the end of the semester, we got some demos in brazing and vacuuming of carbon-fibre

Brazing in the metal-shop

Vacuuming carbon-fiber

REFINEMENT OF RESEARCH

2009-03-08T09:28:00.000-07:00

After a broad research on the whole spectrum of bikes, it was time for a refinement of the research. Therefore we focused on, what seemed to be the most important aspects of commuting and assigned them to each one of us:

- Infrastructure: Mike

- Transforming: Erik

- Visibility: Harry

- Safety: Krisa

- Simplicity: Hemi

- Storage: Ashlee:

- Security/ Lock: Nick

- Foldability: Adrian

FIRST RESEARCH RESULTS

2009-03-08T09:20:00.000-07:00

Mutual updating about the individual research is an efficient way of covering the huge field of bikes. Here some results:

pics soon

RESEARCH

2009-03-08T08:46:00.000-07:00

Beside our own research, we collectively got some lectures about bike anatomy and structure. Further on we had a valuable interview with everyday commuter Lane Myer and a field trip to Providence Bike.

Interview with Lane Myer

Field trip to Providence Bike

POSSIBlE CRITERIA FOR A COMMUTER BIKE

2009-03-08T08:29:00.000-07:00

Before we got started we established possible criteria and therewith fields of research for more efficiency:

storage, personalization, speed, security, weather, number of passengers, emergency, simplicity/ user-friendly, modularity, cost, freshness, visibility, infrastructure, accessories, ergonomics, parking, gender, health, fitness, positive feedback, seductive wow factor.

THE MISSION

2009-03-03T08:31:00.000-08:00

Commuting to work with oil

Commuting to work by bicycle reduces traffic, alleviates parking, saves resources, does not pollute, and keeps you healthy. In recognition of these facts, more and more people are pedaling to work and communities are developing or expanding their infrastructures for human powered traffic.

The goal of this course is to design and fabricate a unique human powered vehicle that will answer the specific needs of a person commuting to work. After extensive research the class will establish the criteria necessary for a successful vehicle and develop several concept models. With additional research in ergonomics, materials, structure, and mechanics, those concept vehicle constructed within the alloted time and materials budget.

There´s also a special emphasis on team dynamics as students work together on Research, Design, Fabrication, and Documentation

THE TEAM

2009-03-03T08:25:00.000-08:00

from left to right: Nick, Ashlee, Hemi, Harry, Michael (teacher), Adrian, Krisa, Erik, not on the photo: Mike