Group 11 - Gate 1

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Group 11 - Beginner Dirt Bike

Contents

Work Proposal

Overview

Our group will be discussing how we plan to accomplish the semester long reverse engineering project. We will first discuss the schedule of how we will complete each task. We will then discuss our dissection plan, talking about the tools we will need, the part by part plan and the challenges we believe we will face in the dissection. Lastly, we will discuss each group member and what they bring to the project, as well as their self-admitted faults.

Schedule

Wikipedia Encyclopedia

For scheduling purposes, each column represents a week starting with a Monday. If a task is due on that Monday, the task will incorporate that week in the planning schedule. It is for this reason that some tasks look like they overlap. In reality, the first task ends that week, while the second task begins on that week.

Tasks are broken down first by the specific project gate. Then the main tasks are split into the subtasks necessary to achieve the deliverables necessary for that gate.

Dissection Plan

  1. Tools Needed
    • Crescent wrench- needed to disassemble body
    • Socket wrench and socket set – needed to unfasten parts
    • Alan wrench set – needed to unfasten parts
    • Phillips and slotted screwdriver – needed to unfasten parts
    • Mirror – needed to see into hard to see spots
    • Needle-nose pliers/pliers – needed to take apart specific parts
    • Rubber mallet – needed to dislodge a part that is stuck without doing considerable damage to the part
    • Magnet wand – needed if small parts are dropped into hard to reach spots
    • Cleaning cloths and solvent – needed for cleaning parts that will be solid modeled and reassembled
    • Containers and funnel – needed so that product can be emptied of liquids such as oil or gas to prep for dissection.
    • parts needed to be replaced in order for reassembly such as gaskets
  2. Time
    • We have scheduled that dissection will take two to two and a half weeks. We scheduled this much time because we have a very large product. This will cause us to have many different parts that will need to be dissected. In addition, we are not able to take the product out of the lab, which restricts the amount of time per week we have to accomplish the dissection.
  3. Step by step plan (order in which parts will be dissected)
    • seat
    • brakes
    • shocks
    • exhaust
    • clutch
    • Ignition
    • Air Filter
    • Transmission
    • Engine
  4. Potential challenges
    • A major challenge will be that we are sharing this product with another group. Thus coordinating with them will be very difficult.
    • Organizing our schedules so that the majority of the group can be present for the dissection
    • Since we have such a large product, one problem will be keeping to the schedule for the dissection with the time available to us.
    • With having such a large product, a problem will be keeping all of the parts organized and cataloged.

Personal Assessment

Name Strengths Shortcomings
Dan Arnold
  • Proficient in CAD
  • Desire to learn about automotive parts
  • Great problem solving skills
  • Completes tasks in a timely manner
  • Has good math and science skills
  • Lacks technical knowledge on automotive systems
  • Terrible reading and writing skills
Nichaela Bald
  • Past leadership experience
  • Has some mechanical skills
  • Organized and responsible
  • Good speaker and presenter
  • Has AutoCAD Inventor Skills
  • Patient and works well under stress
  • Proficient writer
  • Not much free time between classes and school work
  • Lives off campus, thus meeting with group is harder
  • Sometimes procrastinates
  • Usually takes on to much work


Mike Baldino
  • Good at disassembling and reassembling items
  • Good at dealing with small engines
  • Able to weld
  • Good at wiring items
  • Organized and responsible
  • Team Player
  • Knows AutoCAD Inventor
  • Not much spare time
  • Lives off campus, thus meeting with group is harder
  • No previous web programming knowledge
Zack Ball
  • Strong understanding of how the product works
  • Technical skill dealing with tools needed
  • Experience dealing with engines
  • Some experience dealing with brakes, suspension and drive chain
  • Has never owned or used product
  • Never [[Link title]]completely disassembled an engine or dirt bike before
  • No web programming skills
  • Not much spare time
  • Lives off campus, thus meeting with group is harder
  • No previous web programming knowledge
Greg Barnhard
  • Mechanically inclined.
  • Works well under stress.
  • Analytical thinker.
  • Previous maintenance experience in the aviation field.
  • Able to think outside the box when needed.
  • Able to multitask
  • Usually level headed
  • Sometimes overlooks certain details.
  • Occasionally get impatient.
  • Short attention span towards monotonous speakers.
Team Strengths and Shortcomings


Management Proposal

Group Roles

Group Leader

  • Nichaela Bald
    • Organize group meetings
    • Keep tasks on schedule
    • Supervise other roles to verify work completed

Communication Liaison

  • Nichaela Bald
    • Contact person for teacher and teaching assistants to group
    • Keep group communicating through email, phone and Google Calendar
    • Main contact person between group and second group working on product

Wiki Page Development

  • Zack Ball
    • Keep group Wiki page up to date with information
    • Primary people for taking photography and Video during project
    • Uploading photography and video in a timely manner to Wiki page
    • Uploading completed task deliverables to Wiki before due date

Part Solid Modeling

  • Dan Arnold, Greg Barnhard (Assistant), Nichaela Bald (Assistant), and Mike Baldino (Assistant)
    • Create solid modeling of desired parts using AutoCAD Inventor
    • Sending files to Zack to be placed on the Wiki Page

Disassembly Leader

  • Greg Barnhard
    • Being present for majority of disassembly
    • Keeping track of how the product is disassembled
    • Keeping track of parts after then are disassembled

Reassembly leader

  • Greg Barnhard
    • Being present for majority of reassembly
    • Keeping track of how the product is reassembled
    • Making sure that product is reassembled correctly


Meetings

When?

  • Meetings will be held every Friday afternoon from 1 PM to 2 PM.

Where?

  • Meetings will be held in the Capen Library. We will use either a table on the First or Ground floor depending on availability.

Why?

  • We will meet weekly to discuss what we have accomplished over the week. We will be checking our progress of the immediate tasks to the timeline to see what needs to be completed over the coming week. We will also discuss any problems or difficulties we are facing with our assigned tasks and brainstorm how to best solve them.


Initial Product Assesment

What is the intended use of this product?

  • Our product is designed for riders from skill levels ranging from beginner to intermediate. With the size and weight constraints of this bike, the user is most likely under the age of 15 years old and 155 pounds.
  • The use of this product is mainly for recreational use but has the possibility of being brought into professional competitions. The product’s function is simply a means of transportation over off road terrain. In a professional competition, the function of this product is for the rider to have the fastest means of transportation.

How do you think the product works?

  • This product works using chemical and mechanical energy. The engine utilizes the combustibility of gasoline to convert fuel into forward motion. The engine consists of pistons, fuel injectors, and spark plugs, which work together to create power that then travels to the transmission. This power is in the form of torque causing the gears to rotate and drive a chain connected to the back wheel. Gears in the transmission allow different efficiencies for different needs. Lower gears provide more power for greater acceleration, primarily at low speeds, while higher gears utilize the engines power in a different manner allowing the bike to travel faster under the same amount of RPMs, Rotations per Minute. After the fuel undergoes the combustion process in the engine, the by-product is channeled through the exhaust system and directed away from the rider. The forms of energy that the fuel creates are rotational force to the wheels, heat through friction in the engine, and the exhaust.

Is the product currently functioning?

  • After testing our product, we found that it ran very well. We reached max speed while utilizing each of the different gear. We tested both brakes and they both worked as expected. The suspension absorbed the impacts while the muffler controlled the noise level of the engine. As a first analysis, our product worked perfectly and we were unable to observe any problems.

How complex is the product? Be specific about your definition of complexity.

  • Complex can be defined as being “composed of many interconnected parts” . Based on this definition our product is a very complex system. It is complex because of the many different individual components working together to accomplish one final goal.
  • To simplify our product we broke down the components into three categories each having the ability to be broken down further into less complex workings; suspension, engine, and brakes. Each category can be broken down to the point that it is a single piece. The suspension consists of front and back shock absorbs to allow for a more comfortable experience for the rider. The front suspension is a telescopic fork while the back is a mono shock. The engine consists of a four-stroke process in which a piston moves up and down rotating a crankshaft. That then leads to the transmission, which provides power to the wheels. The brakes utilize a drum brake system with the front brake control being on the right handle while the back brake control is under the right foot.
  • Each of the three components is complex when every part has to work together correctly, however the parts individually are not as complex when analyzed separately.

What materials are used in the product?

  • Our product consists of four main materials that are clearly visible; metal, cloth/foam, rubber, and plastic. The engine components are metal to allow for the extreme heats they endure. The rims and frame are also metal to allow for a rigid body. The seat is created from foam that is covered in cloth. This allows for comfortable accommodations for the rider. The tires are rubber to hold the air pressure inside them while also conforming to the terrain creating a softer ride. The fender and motor covering are plastic to create a firm yet somewhat flexible body and to protect the rider from the extremely hot engine components.
  • Materials that might not be visible would be the specific insulators and conductors used in any of the inside wiring. In addition, there could be a different type of metal used for gears or other parts inside the body that are not used on the outside. The metal on the outside would need to be a lightweight, non-corrosive metal that could stand up to the wear and tear. Inside the body, gears might need to be made of a stronger metal that could stand up to the stress and pressures needed.

If you had to use the product, would you be happy with it?

  • If we were to use this product, we would be unhappy with the size constraints. This product is designed for a younger market and would not be able to fit our needs. However, the product is offered in different sizes, which could possibly accommodate our size requirements. This specific bike would not be comfortable for us to use, but a larger bike with the same components would. For the cliental this product was designed for, this product is easy to use and maintain. The only regular maintenance required is changing the oil, refilling the gas tank, and keeping proper air pressure in the tires, all of which are easy to do. Specific issues that may arise with continued use, such as broken parts, can be resolved by contacting the company that made it. They will provide the part you need along with instructions for installation.

What other alternatives to your product are there? How do the alternatives compare?

  • The only alternatives to this product are different sizes within the same product line, along with bikes that have different quality parts from the same or different company. With a larger, higher quality bike, the cost would most likely increase; while on the other hand, a smaller, lower quality bike would be less expensive. The only advantages or disadvantages would be different levels of performance. With a higher quality bike, the user could expect a more comfortable ride along with greater speed and control. With a lower quality bike the opposite would most likely occur.