Difference between revisions of "Group 11 - Beginner Dirt Bike"

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[[Image:Bike Website Edit.jpg|300 px|Wikipedia Encyclopedia]]  
 
[[Image:Bike Website Edit.jpg|300 px|Wikipedia Encyclopedia]]  
  
[[Group 11 - Gate 1]]
 
  
[[Group 11 - Gate 2]]
 
  
==Gate 3: Coordination Review==
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== Introduction ==
===Component Summary===
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Group 11 was tasked this semester to reverse engineer our product, the beginner dirt bike, as instructed for the class MAE 277. The process of reverse engineering for this product consisted of our group having the dis-assemble, analyze and the reassemble our product.  Along the way of completing the dis-assembly, and reassembly, the group was required to submit information about our process to the instructor in the form of gates. These gates are documented below for you to read and review.
Part Numbers were found using the online product owners manual. The are specific to our brand of dirt bike. In parts that are assemblies, part numbers are for the main product of the assembly.
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 +
Our group faced many challenges, but was able to complete all work in a satisfactory way. One such problem was coordinating between members. But we were able to develop a system that allowed us to communicate effectively between group members and stay in touch with weekly meetings. Another challenge was the overall size of our product. With our product consisting of over fifteen separate assemblies, we thought we would be overwhelmed by the amount of work we would have to do. Luckily we were paired with another group, [[Group 17 - Beginner Dirt Bike|Group 17]] to work together in reverse engineering the beginner dirt bike.
  
The complexity rating is a rating of 1 to 5. 1 being the easiest to manufacture, while 5 is the most difficult. Our ratings are based on the groups assumptions of the number of steps it takes to assemble each part.
 
  
  
 +
== Executive Summary ==
  
Photos will be uploaded when the website picture uploading capabilities resume. Till then we are sorry for any inconvenience.  
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Listed here on this page are all of the submissions that our course required us to produce for this assignment. Each gate consisted of several tasks that our group needed to complete by the due date. Here is the overall summery of what each gate consisted of:
  
Thank You.
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'''Gate 1: Request for Proposal:'''
 +
Gate one consisted of our introduction to our group and our product. The deliverables for this gate were the work proposal, the management proposal, and our initial product assessment.
  
{| border="1" cellspacing="3" cellpadding="3" align="center"
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'''Gate 2: Preliminary Design Review:'''This Gate consisted of out information that we had gathered after dissecting our product. The deliverables for this gate were a correction of our gate one, based on issues or fault. Also to provide a guide to dissecting out product, the dirt bike.
! width="400" |Part and Quantity
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! width="400" |Part Number
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! width="400" |Function
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! width="400" |Materials
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! width="400" |Forces
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! width="400" |Manufacturing Process
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! width="400" |Shape
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! width="100" |Part Complexity
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! width="400" |Photo
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|-
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'''Gate 3: Coordination Review:'''
|align="center"|Engine Cover (2)
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This Gate consisted of doing analysis on our product. We had to do analysis of a specific system within our product, as well as think about design changes that would improve the function of the bike. We also had to document all of the parts that our product consisted of.  
|align="center"|DR70-118
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|align="center"|Functional/cosmetic: This part is a combination. It is used to cover and protect the engine from the rider and debris. It also hides the less attractive parts of the engine
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|align="center"|Metal, probably aluminum because of its light weight
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|align="center"|No forces exerted
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|align="center"|Die Casting because of its fine surface finish and the residual risers
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|align="center"|Rounded edges and hollowness of part lends itself to die casting
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|align="center"|1
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|align="center"|[[Image:Engine_Cover.jpg|250 px]]
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|-
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|-
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|align="center"|Gas Tank (1)
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|align="center"|DR70-147
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|align="center"|Functional: storage place on dirt bike to hold fuel
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|align="center"|Main tank is plastic because it is light weight and will not react with the fuel. The hose is rubber to allow it to move
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|align="center"|The force from the fuel weight would be 5 lbs or less. The forces exerted on the frame would be in equilibrium
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|align="center"|Plastic blow molding because it is a hollow plastic container. Drilling would then be done for holes.
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|align="center"|Seams along the edges lend to blow molding. The shape allows for maximum storage in the space allotted.
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|align="center"|2
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|align="center"|[[Image:Gas_Tank.jpg‎|200 px]]
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|-
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|-
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|align="center"|Handle Bars (1)
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|align="center"|DR70-136
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|align="center"|Functional: Allows rider to steer the bike. Also gives rider something to hold onto while riding
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|align="center"|Main frame is metal, probably aluminum because it is light weight. Handles are rubber for a better grip.
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|align="center"|Only forces exerted would be those exerted by rider.
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|align="center"|For main ‘U’ tubing is heated then bent into shape. Then horizontal bar is welded into place
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|align="center"|Shape lends itself to comfort of use. Also shape leans itself to ease of production
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|align="center"|3
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|align="center"|[[Image:Handle Bars.jpg|250 px]]
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|-
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|-
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|align="center"|Engine Block (1)
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|align="center"|DR70-117                           
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|align="center"|Functional: Takes the fuel provided and turns into in to forward motion, by the use of chemical combustion
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|align="center"|Metal is used, probably aluminum for its strength and durability. Some parts might require steel for even more strength.
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|align="center"|The only major forces are those within the engine. These forces would be the result of the fuel combusting and moving within the engine. These forces are equal to the power that drives the bike.
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|align="center"|This part is an assembly of many different processes. There would be die casting for the main part. Drilling would be done for several connecting holes. Several parts have been welded on as well
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|align="center"|The shape lends itself to many different processes because it is so complex. No single process could create the engine block as a whole. The side gears and rotating parts would need to be separately made then assembled
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|align="center"|5
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|align="center"|[[Image:Engine_block11.jpg|300 px]]
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|-
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|-
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|align="center"|Front Fender (1)
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|align="center"|DR70-137
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|align="center"|Functional: Protects rider from debris. Color of part is cosmetic to give bike an overall color scheme
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|align="center"|Plastic is used to be light weight.
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|align="center"|The only forces acting would be if something where to hit this part. The force would then depend on the object and the speed of the bike
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|align="center"|Injection Molding because of its symmetrical look and risers on underside of part
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|align="center"|The part is formed to follow the contour of the wheel to proved extra protection for the rider
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|align="center"|1
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|align="center"|[[Image:Front_Fender11.jpg|100 px]]
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|-
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|-
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|align="center"|Frame Cover (1)
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|align="center"|DR70-100
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|align="center"|Functional/cosmetic: Provide comfortable riding while protecting rider from engine and the engine from debris. Color is cosmetic.
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|align="center"|Mostly plastic with seat being foam padding with  fake leather covering
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|align="center"|Only forces would be the weight of the rider. This should be 165 lbs or less.
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|align="center"|Plastic molding, probably injection molding
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|align="center"|Several parts were formed separately then connected together through screws.
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|align="center"|3
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|align="center"|[[Image:Frame_cover11.jpg|100 px]]
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|-
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|-
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|align="center"|Kick Stand/Foot Pegs (1)
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|align="center"|DR70-090
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|align="center"|Functional: place for rider to place feet when moving  and Holds  up bike when stationary
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|align="center"|Metal, probably aluminum because it is light and strong.
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|align="center"|Forces would be a portion of the rider’s weight. The kick stand would support the bike weight -132 lb
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|align="center"|Die casting for foot pedals, bending for main bar. Welding and other forms of metal casting for side parts
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|align="center"|This part is an assembly of other smaller parts. The parts need to be able to move separately causing them to be manufactured separately.
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|align="center"|4
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|align="center"|[[Image:Kick_stand11.jpg|100 px]]
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|-
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|-
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|align="center"|Electrical Cables (1)
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|align="center"|DR70-129
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|align="center"|Functional: Transfers electricity to spark plug to start engine
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|align="center"|Wiring is metal, probably copper. Outside is rubber. Connectors are plastic.
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|align="center"|No forces would be applied.
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|align="center"|Metal wiring, most likely copper, is cold drawn into desired shape. Rubber housing is wrapped around as an insulator. Plastic ends are plastic injection molded
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|align="center"|The shape of this part is determined by two specifications. First is what is needed by the bike for the electrical supply. The other is how the different components are assembled together
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|align="center"|3
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|align="center"|[[Image:Electrical_cables11.jpg|100 px]]
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|-
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|-
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|align="center"|Rear Shock (1)
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|align="center"|DR70-116
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|align="center"|Functional: absorbs forces caused by movement over uneven terrain
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|align="center"|Metal spring; probably steel for strength and resistance. This is coated in rubber housing.
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|align="center"|Forces applied would depend on the weight of the rider and the motion of the bike
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|align="center"|Metal is twisted in a spiral to create spring. Spring is then coated in rubber to protect it. Ends are milled and drilled to create space to for attachment
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|align="center"|Shape is defined by the requirements of the shock. A shock designed to absorb 100 lb of force compared to 200 lb of force would be very different, in size and thickness of spring
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|align="center"|4
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|align="center"|[[Image:Rear_shock11.jpg|100 px]]
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|-
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|-
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|align="center"|Muffler System (1)
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|align="center"|DR70-124
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|align="center"|Functional: Takes exhaust from engine and releases it at the rear of the bike. Helps to minimize noise from the engine.
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|align="center"|Whole part is metal, most likely steel. Steel would be used because of its high strength and cheap cost
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|align="center"|The only forces applied would be the air flowing through the system. On straight parts, this would result in very little force. Where the tubing turns, the forces would depend on the pressure, temperature, and velocity of the exhaust
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|align="center"|The main system was manufactured by heating steel tubing and then bending it. The outer pans where metal extrusions and then bending. These parts were then welded together.
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|align="center"|The shape is needed to do the purpose. The turns are needed to slow the velocity of the air. The length of the part is also needed to make sure the exhaust is directed far enough from the engine and the rider.
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|align="center"|3
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|align="center"|[[Image:Muffler_system11.jpg|100 px]]
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|-
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|-
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|align="center"|Gear Shift (1)
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|align="center"|DR70-125
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|align="center"|Functional: Allows rider to shift gears while riding bike
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|align="center"|Mostly metal, probably aluminum because of its light weight
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|align="center"|The only force would be those applied when the rider shifts gears. Thus the force would only be the a percentage of the rider strength
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|align="center"|Several parts created, the welded together. This can be seen because of welding marks near joints. The two end pieces are just metal tubing, while the middle is bent metal.
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|align="center"|The shape is dictated by two things. The first is to allow enough torque to change gears, with little force needed from the rider. Also the shape is designed for comfort of the rider, with there being no sharp edges.
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|align="center"|2
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|align="center"|[[Image:Gear_shift11.jpg|100 px]]
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|-
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|-
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|align="center"|Steering Shaft Assembly (1)
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|align="center"|DR70-197
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|align="center"|Functional: Attaches to the handle bars and the front wheel assembly to allow rider to steer. Also holds the front forks, front shock absorbers.
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|align="center"|Metal, most likely steel composite because it is lighter than other steel part, but strength is needed for this part.
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|align="center"|Force would be created as the rider turns the handlebars. Depending on terrain there could be resistance to this motion. Also since this secures the shocks, it would get force from that.
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|align="center"|Parts are created then assembled. The two bases are die-cast, because of left over risers. Several parts are then drilled, and threaded. Parts are then assembled by nuts or screwed together.
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|align="center"|Shape is needed for several reasons. First is that the parts are rounded, because die casting straight edges is difficult. Also this is a part that the rider could hit, and straight edges could cause injury.
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|align="center"|4
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|align="center"|[[Image:Steering_Shaft11.jpg|100 px]]
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|-
+
|-
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|align="center"|Chain (1)
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|align="center"|DR70-046
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|align="center"|Functional: used to connect the engine to the rear wheel, and transfer energy between the two.
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|align="center"|Metal, most likely steel for its strength and resistance to wear because of friction
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|align="center"|There would be a friction force between the chain and the gears. There would also be a tension force between the chain links.
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|align="center"|Individual chain links pinned together with the correct spacing needed for the gears used to create a flexible belt.
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|align="center"|Shape and size is determined by several factors. One is the spacing between the engine and the wheel. The spacing of the links is determined by the gears that are being used.
+
|align="center"|4
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|align="center"|[[Image:Chain11.jpg|100 px]]
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|-
+
|-
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|align="center"|Rear Frame (1)
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|align="center"|DR70-107
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|align="center"|Functional: connects back tire to the rest of the bike.
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|align="center"|Metal, most likely aluminum , because of its light weight. 
+
|align="center"|There would be two forces applied to it. The first would be horizontal, in keeping the wheel vertical. The other would be a portion of the bike’s and rider’s weight.
+
|align="center"|Square metal tubing is heated and bent into the needed shape. The cross bar is welded onto these parts. Holes and slots are then drilled into the part.
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|align="center"|Specific Shape is needed because of the forces applied to it. Must be able to distribute weight and not break.
+
|align="center"|4
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|align="center"|[[Image:Rear_frame11.jpg|100 px]]
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|-
+
|-
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|align="center"|Front Shocks (2)
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|align="center"|DR70-114
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|align="center"|Functional: Absorbs vibration from the front wheel to provide a smooth ride for the rider.
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|align="center"|Metal tubing with a metal piston. The air chamber inside the tubing is pressurized.
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|align="center"|Forces caused by vibration and sudden changes in height. Shocks absorb forces because of weight from bike and rider.
+
|align="center"|Two cylindrical tubes connect to each other with the smaller one being underneath the larger one. This allows for the smaller tube to fit inside the larger tube where forces are eliminated with the use of an air pocket.
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|align="center"|Cross sectional area and dimensions of the air chamber depend on the desired force to negate.
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|align="center"|4
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|align="center"|[[Image:Front_Shocks11.jpg|100 px]]
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|-
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|-
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|align="center"|Front Brake Cable (1)
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|align="center"|DR70-366
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|align="center"|Functional: Connects the hand brake to the wheel
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|align="center"|Rubber housing covering a metal cable, steel for strength so that it doesn't brake
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|align="center"|Forces caused by rider when the rider engages the brake
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|align="center"|Steel cold pressed into wire of desired shape. Rubber covering to prevent friction
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|align="center"|Shape can change and is formed to connect the hand brake with the wheel brake without the cable affecting other components
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|align="center"|2
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|align="center"|[[Image:Front_Brake_Cable11.jpg|100 px]]
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|-
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|-
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|align="center"|Frame (1)
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|align="center"|DR70-100
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|align="center"|Functional: Holds components of bike together
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|align="center"|Metal steel mixture so that it is light but has steel for strength
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|align="center"|Forces are the weight of the bike and the rider along with the vibrations that were not absorbed by the shocks
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|align="center"|Metal tubing heated then bent to create shape of bike along with some welding to connect joints
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|align="center"|Shape is formed to connect all components of the bike while still creating a comfortable riding position
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|align="center"|2
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|align="center"|[[Image:Frame11.jpg|100 px]]
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|-
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|-
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|align="center"|Rear Sprocket (1)
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|align="center"|DR70-381
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|align="center"|Functional: Connects chain to the rear wheel
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|align="center"|Metal/steel for strength
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|align="center"|Force of engine driving the chain which transfers force to drive the wheel
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|align="center"|Pressed into correct shape
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|align="center"|Shape has multiple pegs evenly spaced to fit into the links on the chain
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|align="center"|2
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|align="center"|[[Image:Rear_Sprocket11.jpg|100 px]]
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|-
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|-
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|align="center"|Brake Pedal (1)
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|align="center"|DR70-406
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|align="center"|Functional: Transfers force of rider to the rear brake
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|align="center"|Metal, aluminum for less weight
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|align="center"|Force of rider when rider engages the rear brake
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|align="center"|Metal tubes bent and welded. Foot peg is molded
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|align="center"|Shape has pointed edges to eliminate the rider's foot from slipping off the brake
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|align="center"|2
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|align="center"|[[Image:Brake_Pedal11.jpg|100 px]]
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|-
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|-
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|align="center"|Rear Brake (1)
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|align="center"|DR70-402
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|align="center"|Functional: Presses shoes against brake drum creating friction to stop the bike
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|align="center"|Metal, steel for strength
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|align="center"|Frictional forces needed to slow bike
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|align="center"|Die-casting
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|align="center"|Circle shape with two "half moon" shaped shoes
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|align="center"|4
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|align="center"|[[Image:Rear_Brake11.jpg|100 px]]
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|-
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|-
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|align="center"|Number Plate (1)
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|align="center"|DR70-143
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|align="center"|Cosemetic: Provides a smooth surface for a racing number to be placed
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|align="center"|Plastic
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|align="center"|Force of air resistance when bike is in motion
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|align="center"|Molded to create correct shape
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|align="center"|Square shape with rounded edges
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|align="center"|1
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|align="center"|[[Image:Number_plate11.jpg|100 px]]
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|-
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|-
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|align="center"|Front Axel (1)
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|align="center"|DR70-159
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|align="center"|Functional: Connects the front wheel to the front forks while still allowing the wheel to freely rotate
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|align="center"|Metal, steel for strength
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|align="center"|Force that the weight of the rider and bike exert on the front wheel
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|align="center"|Extruded and then threaded
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|align="center"|Long cylinder which fits directly in the center of the front wheel
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|align="center"|1
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|align="center"|[[Image:Front_Axel11.jpg|100 px]]
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|-
+
|+<b><u>Dirt Bike Parts List</u></b>
+
|}
+
<br>
+
  
===Design Revisions===
+
'''Gate 4: Critical Design Review:'''This Gate consisted of our documentation of reassembling the dirt bike. We also had questions that needed to be answered about the difference between dis-assembly and reassembly.
====First Revision====
+
Braking system from drum brakes to disk brakes.
+
  
''Reason''
+
== Gate One ==
  
Drum brakes are more inefficient than disk brakes because they trap heat within themselves and lose their efficiency as they heat up.  This is because the trapped heat causes the pads to expand which makes them not rub against the drum around them using its whole surface area, losing braking power.  Disk brakes allow for free flow of air around them and continually cool off as they are used, so they maintain their stopping ability with a minimal if any loss in efficiency.  Disk brakes are also easier to replace and maintain.
 
  
====Second Revision====
+
Please see this page for our completed
Cable lines converted to hydraulic line system.
+
[[Group 11 - Gate 1|Gate 1]]
  
''Reason''
 
  
Cable lines rub against their protective coating on the majority of the cable itself.  This friction greatly reduces the amount of braking force that could be applied if there was no friction.  Hydraulic lines have almost no friction and the fluid used in the lines cannot be compressed, so there is virtually no loss in power.
+
'''Deliverables'''
  
====Third Revision====
+
-Work Proposal
All bolts in standard sizes.
+
  
''Reason''
+
-Management Proposal
  
Disassembly was more complicated than it needs to be because of the time spent searching for tools because half of the dirt bike is assembled in standard and the other half in metric.  Also if the company used all the same size or close to the same size bolts in most places the assembly cost would go down because ordering bolts in bulk in abundant sizes would be cheaper and each part on the assembly line could use the same tool to attach their part of the dirt bike.
+
-Initial Product Assessment
  
===Solid Modeled Assembly===
 
  
Our solid modeling assembly was that of the steering column. Please follow the link to a picture of the exploded view. When picture uploading resumes on this website, we will post this picture and more up on our web.
 
  
Thank you.
+
== Gate Two ==
  
[http://i59.photobucket.com/albums/g298/roseofblue/exploded_view.jpg]
 
  
===Engineering Analysis===
+
Please see this page for our completed
====First Revision====
+
[[Group 11 - Gate 2| Gate 2]]
Braking system from drum brakes to disk brakes.
+
  
''Assumptions''
 
  
-Weight of overall dirt bike is the same for both braking types
+
'''Deliverables'''
-Speed, and stopping force applied are the same in both cases initially
+
-Coefficient of friction is the same for all brake pads and shoes
+
+
'''Governing Equations'''
+
  
P=F/A
+
-Causes for Corrective Action
  
A= ((Pi)*r^2*w)/2
+
-Product Dissection Plan
  
F=m*((Vf-Vo)/t)
 
  
'''Calculations'''
+
== Gate Three ==
  
F=209.5 N with m=70.3kg and Vo=8.94 m/s Vf=0 m/s  at 3 seconds
 
  
Disk:
+
Please see this page for our completed
 +
[[Group 11 - gate 3|Gate 3]]
  
A=2e-4m (cold)
 
  
A=2.8e-4m (heated)
+
'''Deliverables'''
  
Pcold<=Pheated because of expansion
+
-Component Summary
From heating
+
+
P=748214.2857 N/m
+
  
 +
-Design Revisions
  
Drum:
+
-Solid Modeled Assembly
  
A=2e-4m (cold)
+
-Engineering Analysis
  
A=2.8e-4m (heated)
 
  
Pcold>Pheated because of deformation due to expansion from heating
+
== Gate Four ==
  
P=561160.7143 N/m
 
  
 +
Please see this page for our completed
 +
[[Group 11 - gate 4|Gate 4]]
  
'''Discussion:'''
 
  
Drum brakes are more inefficient than disk brakes because they trap heat within themselves and lose their efficiency as they heat up.  This is because the trapped heat causes the pads to expand which makes them not rub against the drum around them using its whole surface area, losing braking power. Disk brakes allow for free flow of air around them and continually cool off as they are used, so they maintain their stopping ability with a minimal if any loss in efficiency. Disk brakes are also easier to replace and maintain.
+
 
 +
'''Deliverables'''
 +
 
 +
-Product Reassembly Plan
 +
 
 +
 
 +
 
 +
== Sources ==
 +
 
 +
These sources were used throughout the whole reverse engineering process. They are:
 +
 
 +
1. [http://www.bajamotorsportsonline.com/product_info.php?cPath=3&products_id=92| Beginner Dirt Bike home page]
 +
 
 +
2.[http://www.bajamotorsportsonline.com/productfiles/DR70/PARTS%20CATALOG%20-%20DR70%20Hensim%20Dirt%20Runner%2070cc%20Dirt%20Bike%20(VIN%20PREFIX%20LUAH).pdf| Beginner Dirt Bike Parts Catalog]

Latest revision as of 13:32, 16 December 2009

Contents

Wikipedia Encyclopedia


Introduction

Group 11 was tasked this semester to reverse engineer our product, the beginner dirt bike, as instructed for the class MAE 277. The process of reverse engineering for this product consisted of our group having the dis-assemble, analyze and the reassemble our product. Along the way of completing the dis-assembly, and reassembly, the group was required to submit information about our process to the instructor in the form of gates. These gates are documented below for you to read and review.

Our group faced many challenges, but was able to complete all work in a satisfactory way. One such problem was coordinating between members. But we were able to develop a system that allowed us to communicate effectively between group members and stay in touch with weekly meetings. Another challenge was the overall size of our product. With our product consisting of over fifteen separate assemblies, we thought we would be overwhelmed by the amount of work we would have to do. Luckily we were paired with another group, Group 17 to work together in reverse engineering the beginner dirt bike.


Executive Summary

Listed here on this page are all of the submissions that our course required us to produce for this assignment. Each gate consisted of several tasks that our group needed to complete by the due date. Here is the overall summery of what each gate consisted of:

Gate 1: Request for Proposal: Gate one consisted of our introduction to our group and our product. The deliverables for this gate were the work proposal, the management proposal, and our initial product assessment.

Gate 2: Preliminary Design Review:This Gate consisted of out information that we had gathered after dissecting our product. The deliverables for this gate were a correction of our gate one, based on issues or fault. Also to provide a guide to dissecting out product, the dirt bike.

Gate 3: Coordination Review: This Gate consisted of doing analysis on our product. We had to do analysis of a specific system within our product, as well as think about design changes that would improve the function of the bike. We also had to document all of the parts that our product consisted of.

Gate 4: Critical Design Review:This Gate consisted of our documentation of reassembling the dirt bike. We also had questions that needed to be answered about the difference between dis-assembly and reassembly.

Gate One

Please see this page for our completed Gate 1


Deliverables

-Work Proposal

-Management Proposal

-Initial Product Assessment


Gate Two

Please see this page for our completed Gate 2


Deliverables

-Causes for Corrective Action

-Product Dissection Plan


Gate Three

Please see this page for our completed Gate 3


Deliverables

-Component Summary

-Design Revisions

-Solid Modeled Assembly

-Engineering Analysis


Gate Four

Please see this page for our completed Gate 4


Deliverables

-Product Reassembly Plan


Sources

These sources were used throughout the whole reverse engineering process. They are:

1. Beginner Dirt Bike home page

2.Beginner Dirt Bike Parts Catalog