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| | [http://gicl.cs.drexel.edu/wiki-data/index.php?title=Group_22_Beginner_Cruiser:_Request_for_Proposal Request for Proposal] | | [http://gicl.cs.drexel.edu/wiki-data/index.php?title=Group_22_Beginner_Cruiser:_Request_for_Proposal Request for Proposal] |
| | | | |
| − | ==Gate 2: PRELIMINARY PRODUCT REVIEW== | + | ==Gate 2: Preliminary Product Review== |
| | | | |
| | The following link will direct you to Group 22's Product Dissection Plan which inludes: | | The following link will direct you to Group 22's Product Dissection Plan which inludes: |
| Line 26: |
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| | :''*For Front end Dissassembly see [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle Group 21]'' | | :''*For Front end Dissassembly see [http://gicl.cs.drexel.edu/wiki/Group_21_-_Beginner_Cruiser_Motorcycle Group 21]'' |
| | | | |
| − | ==COORDINATION REVIEW== | + | ==Gate 3: Coordination Review== |
| − | ===Component Summary===
| + | The following link will direct you to Group 22's Coordination Review which includes: |
| − | ====Component Summary Chart====
| + | :*Component Summary |
| − | {| class="wikitable" border="1"
| + | ::*Component Summary Chart |
| − | |-
| + | ::*Detailed Component Summary |
| − | ! Component Name
| + | :*Design Revision |
| − | ! Sub Part Name
| + | :*Solid Model |
| − | ! Number Of Parts
| + | :*Engineering Analysis |
| − | ! Materials
| + | |
| − | ! Manufacturing Process
| + | |
| − | |-
| + | |
| − | |colspan="2" align="center"| Back Fender
| + | |
| − | | align="center"| 1
| + | |
| − | | Aluminum
| + | |
| − | | Die Casting, Bending
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Fender Bracket
| + | |
| − | |align="center"| 2
| + | |
| − | | Steel
| + | |
| − | | Die Casting, Trimming
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Back Wheel Axel
| + | |
| − | |align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | |rowspan="2" align="center"|Back Wheel Assembly
| + | |
| − | | Central Hub
| + | |
| − | |align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | align="center"|Tire
| + | |
| − | |align="center"| 1
| + | |
| − | | Rubber
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Drive Gear
| + | |
| − | | align="center"|1
| + | |
| − | | Steel
| + | |
| − | | Hot Forming
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"|Brake System Bracket
| + | |
| − | | align="center"|2
| + | |
| − | | Steel
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Brake Shoes
| + | |
| − | |align="center"| 2
| + | |
| − | | Steel
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"|Drum Break
| + | |
| − | |align="center"|1
| + | |
| − | |Steel
| + | |
| − | |Injection Molding
| + | |
| − | |-
| + | |
| − | |
| + | |
| − | | 10mm bolts
| + | |
| − | | align="center"| 4
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Fuel Line
| + | |
| − | | align="center"| 1
| + | |
| − | | Plastic
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Vapor Line
| + | |
| − | | align="center"| 1
| + | |
| − | | Plastic
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Wing Nut
| + | |
| − | | align="center"|3
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | rowspan="2" align="center" | Plastic Air Filter
| + | |
| − | | Cover
| + | |
| − | | align="center"|1
| + | |
| − | | Plastic
| + | |
| − | | Injection Modeling
| + | |
| − | |-
| + | |
| − | | 12mm Nuts
| + | |
| − | | align="center"|1
| + | |
| − | | Plastic
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | COLSPAN="2" align="center"| Gasket
| + | |
| − | | align="center"| 2
| + | |
| − | | Plastic
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Springs
| + | |
| − | | align="center"| 2
| + | |
| − | | Stainless Steel
| + | |
| − | | Hot Rolled Forming
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Connecting Rod
| + | |
| − | | align="center"| 1
| + | |
| − | | Aluminum
| + | |
| − | | Drilling, Die Casting
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Phillips Head Screw
| + | |
| − | | align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Carburetor
| + | |
| − | | align="center"| 1
| + | |
| − | | Zinc
| + | |
| − | | Die Casting, Taping
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Heat Shield
| + | |
| − | | align="center"| 1
| + | |
| − | | Aluminum
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | rowspan="4" align="center"| Hand Brake Assembly
| + | |
| − | | align="center"| Hand Brake
| + | |
| − | |align="center"| 3
| + | |
| − | |Aluminum
| + | |
| − | |Die Casting
| + | |
| − | |-
| + | |
| − | | align="center"| 9mm Screws
| + | |
| − | | align="center"| 2
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | align="center"| 9mm Nut
| + | |
| − | | align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | align="center"| 9mm Washer
| + | |
| − | | align="center"| 2
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | align="center" rowspan="3"| Kickstand Assembly
| + | |
| − | |Kickstand
| + | |
| − | |align="center"|1
| + | |
| − | |Steel
| + | |
| − | |Injection Modeling
| + | |
| − | |-
| + | |
| − | |10 mm Bolt
| + | |
| − | |align="center"|5
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | |10 mm Nut
| + | |
| − | |align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | rowspan="3" align="center"| Engine to Frame Assembly
| + | |
| − | | 12 mm Screw
| + | |
| − | | align="center"| 8
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | 12 mm Bolt
| + | |
| − | | align="center"| 4
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | 12 mm Nut
| + | |
| − | | align="center"| 4
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center" | Chain
| + | |
| − | | align="center"| 2
| + | |
| − | | Carbon Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | rowspan="4" align="center"| Pull Start Assembly
| + | |
| − | |8 mm Screw
| + | |
| − | | align="center"| 3
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | 8 mm Washer
| + | |
| − | | align="center"| 3
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | Large Coil Spring
| + | |
| − | | align="center"| 1
| + | |
| − | | Stainless Steel
| + | |
| − | | Hot Rolled Forming
| + | |
| − | |-
| + | |
| − | | Small Spring
| + | |
| − | | align="center"| 2
| + | |
| − | | Stainless Steel
| + | |
| − | | Hot Rolled Forming
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Clutch
| + | |
| − | | align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center"| Fuel Tank
| + | |
| − | | align="center"| 1
| + | |
| − | | Aluminum
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | rowspan="2" align="center"| Magneto Assembly
| + | |
| − | |12 mm bolts
| + | |
| − | | align="center"| 2
| + | |
| − | |Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | Grounding Wire
| + | |
| − | | align="center"| 1
| + | |
| − | | Copper
| + | |
| − | |
| + | |
| − | |-
| + | |
| − | | align="center" |Exhaust
| + | |
| − | |12 mm bolts
| + | |
| − | | align="center" |2
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | align="center" |Spark Plug
| + | |
| − | | Metal Casing
| + | |
| − | | align="center"| 1
| + | |
| − | | Nickel
| + | |
| − | | Die Casting, Cold Forming
| + | |
| − | |-
| + | |
| − | | rowspan="3" align="center" | Fly Wheel
| + | |
| − | | Fly Wheel
| + | |
| − | | align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | 19mm Nut
| + | |
| − | | align="center"| 1
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | Plastic Cover
| + | |
| − | | align="center" | 1
| + | |
| − | | Plastic
| + | |
| − | | Injection Molding
| + | |
| − | |-
| + | |
| − | | rowspan="2" align="center"| Motor Head Assembly
| + | |
| − | | Motor Head
| + | |
| − | | align="center"| 1
| + | |
| − | | Cast Iron
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | 10mm screws
| + | |
| − | | align="center"| 4
| + | |
| − | | Steel
| + | |
| − | | Die Casting
| + | |
| − | |-
| + | |
| − | | colspan="2" align="center" | Push Rods
| + | |
| − | | align="center"| 2
| + | |
| − | | Steel
| + | |
| − | | Injection Molding
| + | |
| − | |}
| + | |
| − | | + | |
| − | '''Reasons for Materials Used:'''<br/>
| + | |
| − | : Aluminum was used because it is cheap and fairly strong and doesn’t need to withstand any heavy collisions. Also, Aluminum was used because it is not that great of a conductor of heat, and is used as the material for the heat shield.<br/>
| + | |
| − | | + | |
| − | : The plastic was used where liquid was involved and where the parts needed to move a little bit. The plastic allows some sway and movement with the parts, and is strong enough to handle some wear and tear. The plastic is also used because it is a cheap alternative to other types of materials, and it can be replaced easily with little or no cost. <br/>
| + | |
| − | | + | |
| − | : Stainless steel was used in the springs as most springs are made of stainless steel according to www.indspring.com/material.html. Stainless steel was used because it is a very strong type of metal, and is very resistive to wear and tear, and will last a long time. <br/>
| + | |
| − | : Zinc was used in the carburetor as most carburetors use zinc according to www.alibaba.com/product-gs/.../JAWA350_6V_Carburetor.html.
| + | |
| − | | + | |
| − | ====Detailed Component Summary====
| + | |
| − | '''Seat'''
| + | |
| − | :The seat is manufactured first by welding a metal frame together. Then foam is placed on the frame and is held on by a leather seat cover which is stretched over the top of the frame and stapled underneath. Bolts then go through the frame on the bottom to be attached to the bike. ( ½ inch wrench used twice, and ¾ inch wrench used once.)
| + | |
| − | :* Material is foam used for the comfort of the rider. It is covered by leather to protect the foam and add comfort. The metal frame gives the seat its shape and support.
| + | |
| − | :* Since it is placed on the top-most part of the bike the only force constraints on it is itself. If there is a rider then there is a constraint right on top with a force of about 1962 N (200lbs * 9.81)
| + | |
| − | :* The material affects the manufacturing, because the different materials add steps to the creation. It could be simplified by just making the seat out of plastic. However, the stability and comfort of the seat is lower greatly.
| + | |
| − | :* The shape is pretty complex. The foam and leather has to bend around the metal frame, which can cause complications if the foam and leather doesn’t lay right.
| + | |
| − | :* The shape is specific to the comfort of the rider when he or she sits.
| + | |
| − | :* The seat was manufactured for comfort and stability.
| + | |
| − | :* The seat has a form and a function. The form is important because it is on the outside of the bike, so it has to mesh with the rest of the bike and look good to the eye. The function of the seat is comfort for the rider.
| + | |
| − | :* The component is semi complex due to the different materials and shape.
| + | |
| − | '''Back Fender'''
| + | |
| − | : The back fender was manufactured by a machine stamping out the shape of it from a flat piece of sheet metal. The machine trims and bends the sheet metal into its desired shape. Finally holes are drilled on the sides where bolts will go. The fender is then primed and coated with its paint finish. (9mm socket wrench was used four times)
| + | |
| − | :* The material used for the fender is a thin metal. The reason it is thin is to cut down on weight. Also the fender is to give the wheel extra protection as well as give the bike a more appealing looks.
| + | |
| − | :* No force is applied to the fender except its own weight which probably weighs 2 pounds.
| + | |
| − | :* The material makes the manufacturing process very simple as it is a simple thin metal plate formed into a shape.
| + | |
| − | :* The shape calls for the metal to be formed into its curved shape.
| + | |
| − | :* The manufacturing of thin metal was to cut down on weight and the shape was for appeal.
| + | |
| − | :* The shape of the fender was to give the wheel the best protection, so the fender has a curve that goes with the wheel.
| + | |
| − | :* The fender has function and form. The function is the protection of the wheel, and the form is how it appeals to people.
| + | |
| − | :* The manufacturing was not too complex because the part is not important to the function of the bike.
| + | |
| − | :* The complexity of the part is minimal, and is one of the simplest parts on the bike.
| + | |
| − | '''Fender Bracket (x2)'''
| + | |
| − | : The fender brackets were very simply punched out of thick sheet metal by machine. Both brackets are exactly the same, so we know it was made by a machine.
| + | |
| − | :* The material of the brackets is thick metal. The brackets hold the fender to the frame of the bike, so the thickness gives it strength and support.
| + | |
| − | :* The brackets share the weight of the fender, which we assumed weighs around 2 pounds so the force on each bracket is 9.81 Newton.
| + | |
| − | :* The manufacturing of the brackets is very simple as the metal is just trimmed and punched with holes. No bending or painting of the part.
| + | |
| − | :* The shape doesn’t affect the manufacturing process.
| + | |
| − | :* The manufacturing of the thick metal was to hold the fender to the frame. The thickness gives it stronger support.
| + | |
| − | :* The component only has a function. Since it is hidden underneath the fender it has no point to look good.
| + | |
| − | :* The manufacturing is very simple since its one step and is a small part.
| + | |
| − | :* The complexity is extremely minimal.
| + | |
| − | '''Back Wheel Axel'''
| + | |
| − | : The axel is manufactured by steel being molded into a rod. At one end there is a cap that is 12mm. It is in the shape of a nut so a wrench can be used to tighten and loosen it. The other end is threaded. (One 9mm socket wrench, and a 12mm wrench is used each once.)
| + | |
| − | :* The material of the axel is thick heavy steel. The axel is made very thick to hold up half the weight of the bike.
| + | |
| − | :* If we assume the bike as a whole weighs 200 pounds then force acting on the back axel is about 981 Newton.
| + | |
| − | :* The manufacturing of the axel is multiple steps and not very simple. The molding into a rod is simple, but the molding of the cap on the end is additional work. There is an extra step of the axel having to be threaded to hold the nut on the other side.
| + | |
| − | :* The shape is very important. The axel has to fit the wheel and all the washers that go on it. If the size is off the bike’s efficiency will be lowered or not work at all.
| + | |
| − | :* The manufacturing of the axel is to hold the wheel to the frame of the bike. It also has to be able to hold up the weight of the bike and the rider, so it has to withstand heavy stress.
| + | |
| − | :* The component only has a function and that is to hold the wheel onto the frame, and to make the wheel rotate around it.
| + | |
| − | :* The manufacturing is semi complex, as there is more than one complex step to make it. Also precision is important in making this part.
| + | |
| − | :* The complexity of the part is fairly simple, as it is only one solid mass.
| + | |
| − | '''Back Wheel'''
| + | |
| − | :The back wheel is made of different parts. There is the central hub which was molded from metal. The wheel bearings are made of plastic and go around the hole in the center of the wheel hub. These are molded to fit perfectly around the axle. The plastic lowers the friction and heat transfer of the axel on the wheel. The third part that makes this component is the rubber tire. Molded and fitted around the wheel hub the tire is then inflated with air.
| + | |
| − | :* There were a total of three different materials noticeable on this component. The metal central wheel hub, the plastic bearings, and the rubber tire. The hub is made of metal because it needs to be sturdy and hold the weight of the bike and rider. The plastic bearings help reduce friction on the axle and lowers heat transfer from the axel to the wheel. The tire is rubber because rubber on pavement has a high friction coefficient which will prevent the tire from slipping when rotating.
| + | |
| − | :* The forces that are applied to the tire are the normal force of the entire bike and the force of the ground reacting to the weight of the bike. If the bike is in motion then there is a friction force acting on the tire. If we assume the bike as a whole weighs 200 pounds then force acting on the wheel is about 981 Newton as the weight is distributed on both tires. That means the ground has a force of 981 Newton pushing on the tire as well. If the bike was moving with a velocity of 8.94 m/s (20 miles/hr) and the coefficient friction of rubber on pavement is 0.67 the friction force would be 657.27 Newton.
| + | |
| − | :* With the three different types of material on the component, there has to be separate manufacturing processes for the three different parts. They are then brought together and put together in a very precise why. The wheel bearings are fitted in to the hubs hole. The tire is then placed inside the hub glued and inflated. When inflated the tire is locked inside the hub.
| + | |
| − | :* The shape for all three is a circular. All parts have to mold from its material and is made precise by machines.
| + | |
| − | :* All three manufacturing parts were chosen to be from a mold, because the shapes cannot be carved out. The tire is made from rubber, and has to be molded. Any other process to rubber would damage the material weakening it. The plastic cannot be cut due to risk of cracking. Also the metal hub is too thick to engrave to shape.
| + | |
| − | :* All components are made in a cylindrical shape for the wheels ability to rotate and make a smooth rotation over the ground. Making the ride of the bike more enjoyable for the rider.
| + | |
| − | :* The tire has a function to support the bike’s weight and give the bike its motion from rotation. The wheel is visible to the consumer so the hub and tire has to look appealing to the rest of the bike.
| + | |
| − | :* The component is very complex. The precision of each piece on the other is important for the motion and efficiency. The three different materials make it difficult for the pieces to fit together.
| + | |
| − | '''Drive Gear'''
| + | |
| − | :The component is easy manufactured as it is a flat piece of metal. Molded or possible stamped out in circular shape with pegs spaced for a chain link. (9mm wrench used four times)
| + | |
| − | :* One material is used for this component. Polished metal is used as the chain will make contact against the gear. Therefore the gear has to be sturdy enough to hold up against the tension.
| + | |
| − | :* The only force that is acting on the gear is the force of the chain turning it.
| + | |
| − | :* The material doesn’t really affect the manufacturing of the component. Metal is the easiest to cut into the shape needed.
| + | |
| − | :* The shape is a semi-complex but it can all be cut out of flat metal using a machine.
| + | |
| − | :* The manufacturing process of this component is chosen because it is the easiest and cheapest way to form the metal.
| + | |
| − | :* The shape of the gear is circular to fit around the axel and turn the wheel. The teeth on the gear match up with the chain which is powered by the engine.
| + | |
| − | :* The part is purely functional as it plays an important role in transferring the engines power into rotational force. | + | |
| − | :* The component is fairly simple as it is just a flat piece of metal. | + | |
| − | '''B.S.(Brake System) Bracket 1'''
| + | |
| − | : This component is a thick flat piece of metal with a slight bend in it and 2 bolt holes. It was punched out and stamped into this shape. It was then primed and painted black. (10mm socket wrench was used twice to remove) | + | |
| − | :* One material was used. It was chosen for it strength and ability to be formed. | + | |
| − | :* The component is used to hold the drum brake into the wheel hub. The only force that is applied on the bracket is its own weight which is about a pound (9.81 N) also a horizontal force holding the drum into the wheel which is negligible. | + | |
| − | :* The material of the part is helpful in the manufacturing process as it is easy to shape and cut. | + | |
| − | :* The shape of the bracket requires be cutting, punching with 2 bolt holes and bending slightly. All which can be done by a programmed machine. | + | |
| − | :* The process was chosen so that the piece could be bolted onto the frame and drum of the bike. The slight bend is to help line up the positioning of the component in the hub.
| + | |
| − | :* The component is purely functional to hold the drum brake into the wheel hub.
| + | |
| − | :* The component is very simple, as it is one solid piece.
| + | |
| − | '''B.S. Bracket 2'''
| + | |
| − | :The component is a steel bracket. It was molded into a complex shape to hold the brake line and attach to the drum brake.
| + | |
| − | :* One material is used. The bracket is made of steel so that it’s durable and wont brake.
| + | |
| − | :* The only force is a tension force from the break line which can be assumed to be 20 Newton.
| + | |
| − | :* The material steel is a smart choice for this manufacturing process as steel is easy to shape but still durable.
| + | |
| − | :* The shape is very complex. There are 3 bolt holes cut into it and it has a fold. The shape has to be molded and then the holes punched into the component.
| + | |
| − | :* The manufacturing of the component is so that the brake line can be held inside of the bracket. Also the bracket has to rotate to trigger the braking component.
| + | |
| − | :* The end of the bracket has an indent so the brake line can fit in it. A bolt is then inserted through it to hold the brake line securely. The other hole is so a pin can be placed and fastens the bracket to the drum.
| + | |
| − | :* The component is purely functional, to transfer the force of the tension into rotary motion, which triggers the braking components.
| + | |
| − | :* The manufacturing process where given so that the part could be easily made but still has durability to hold the other components.
| + | |
| − | :* The component is semi-complex as the part has two jobs, to hold the line and triggering the braking component. However, it’s all one solid piece.
| + | |
| − | '''Brake Shoes (x2)'''
| + | |
| − | : The shoes are manufactured using steel in a mold. The brake pad is then wrapped against the flat side of the mold and fastened on using an adhesive.
| + | |
| − | :* There are two materials. The steel mold is to hold the pad onto the drum as well as act as a backup break if the pad wears out. The second material is the pad which gives the brake shoe its main resistance and stopping power.
| + | |
| − | :* There is a friction force acting on the hub and brake pad. If the coefficient of the brake pad is around .57 then the friction force is 11.4 Newton per pad.
| + | |
| − | :* The two materials affect the manufacturing process by making an adhesive step for the pad to be attached to the steel mold.
| + | |
| − | :* The shape of the steel is molded into its crescent shape. The pad is then wrapped around the long side.
| + | |
| − | :* The steel mold is heavy and thick, making it very difficult for a machine to do anything to it, so the part had to mold. The pad was trimmed from a sheet and pasted onto the mold. The pad has to be a part of the manufacturing because its material gives the brake its deceleration power.
| + | |
| − | :* The parts are hidden inside the wheel drum so the component is purely functional and its function is to stop the wheel from spinning.
| + | |
| − | :* The component is complex in that its different materials have to fitted together and then attached through adhesives.
| + | |
| − | '''Drum Brake'''
| + | |
| − | : The Drum is manufactured by using a mold and pouring steel into it and letting it cool.
| + | |
| − | :* Steel is the only material used.
| + | |
| − | :* There are no forces acting on the drum other then holding up its own weight since it rests on the wheel.
| + | |
| − | :* The shape is a mold which is circular with some infirmities. There are some bolt holes for the B.S. Bracket 1 and 2 to attach to. As well as places for the shoes to attach.
| + | |
| − | :* The manufacturing choice was made so that the part is one solid part. It was too thick to be cut but had to be shaped when it was soft.
| + | |
| − | :* The manufacturing choice was so that the components can be held within the brake.
| + | |
| − | :* The component is purely functional as it holds and works the braking components within the wheel.
| + | |
| − | :* The component is complex in the sense of all the working parts that fit within the mold and the precision of each part has to place on it.
| + | |
| − | '''Hand Brake'''
| + | |
| − | : The Hand Brake is made of 3 aluminum pieces held together using two 9mm steel screws, two 9mm washers and one 9mm steel nut. The screws, nut and hand brake itself are all manufactured through die casting.
| + | |
| − | :* Aluminum was selected for the handbrake because is light weight and easily formed into the shape used for the handbrake. Steel is used for the screws because the screws need to be sturdy and less fragile. Steel meets these requirements better than other metals.
| + | |
| − | :* Only the force of the rider’s hand squeezing the handbrake is applied to the components. This force depends on the rider’s strength and how quickly they are trying to stop.
| + | |
| − | :* The material does not really affect this manufacturing choice.
| + | |
| − | :* Due to the unique shape of the hand brake essentially requires a die cast manufacturing process.
| + | |
| − | :* The handbrake was shaped to comfortably fit to the grasp of any rider.
| + | |
| − | :* The component is functional.
| + | |
| − | :* The component is not that complex due to the fact that there are only three main pieces held together with screws, nuts and washers.
| + | |
| − | '''Kick Stand'''
| + | |
| − | : The Kickstand is made of steel and attached to the frame with five 10mm bolts and one 10 mm nut. The Kickstand itself is made through injection molding.
| + | |
| − | :* The kickstand was made of steel due to its need to be strong enough to help support the weight of the bike when it is at rest.
| + | |
| − | :* The forces applied to the kickstand include the weight of the bike, and the friction applied between the kickstand and the floor.
| + | |
| − | :* The material selected has little to do with the manufacturing process since metal is one of the easiest to shape and cut.
| + | |
| − | :* The unique shape of the kickstand is easiest formed using injection molding.
| + | |
| − | :* The shape of the kickstand is used to support the bike while being small enough to not impede the speed of the bike while it is in motion.
| + | |
| − | :* The component is completely functional
| + | |
| − | :* The component is not very complex because it essentially is made of one piece of metal.
| + | |
| − | '''Chain (x2)'''
| + | |
| − | : Both chains are made of carbon steel and formed through die casting.
| + | |
| − | :* There is only on material used in this component.
| + | |
| − | :* The forces applied to the chain include the force of the gears and the force required to cause wheel rotation.
| + | |
| − | :* The material chosen affects the manufacturing choice because metals are easily shaped through a casting process.
| + | |
| − | :* The shape of the chain is made simplest through die casting.
| + | |
| − | :* The chain is designed to fit with the gears.
| + | |
| − | :* The component is completely functional since cosmetics are not necessary for the location of this component.
| + | |
| − | :* The component is fairly complex considering that every link in the chain is designed to be removed or added to a chain depending on its length requirements.
| + | |
| − | '''Pull Start'''
| + | |
| − | : The pull start is comprised of a large coiled spring and a small spring and held to the frame using three 8mm screws and three 8 mm washers.
| + | |
| − | :* The forces applied to the pull start include the force of the spring and the fore of the rider pulling the pull start itself.
| + | |
| − | :* The material does not really have an effect on the manufacturing process because steel is easily cut and shaped.
| + | |
| − | :* The shape of the coil springs is best formed through hot rolled forming.
| + | |
| − | :* Hot rolled forming was also used due to the thinness of the steel being used.
| + | |
| − | :* The component is completely functional because the cosmetics are not necessary for the interior of a pull start.
| + | |
| − | :* The components complexity is found when one analyzes the location of the large spring. Designing and stabilizing the spring in the position to maximize its force is fairly complex.
| + | |
| − | '''Clutch'''
| + | |
| − | : The clutch is comprised of steel and formed through die casting.
| + | |
| − | :* The clutch is an intricate part of the bike. Therefore steel is chosen for sturdiness and its endurance since it holds the gears and chain.
| + | |
| − | :* The material selected has little to do with the manufacturing process since metal is one of the easiest to shape and cut.
| + | |
| − | :* The unique shape of the clutch is most easily formed through die casting.
| + | |
| − | :* The clutch is designed to fit on the engine while supporting the weight of the gears and the chain.
| + | |
| − | :* The component is more functional then cosmetic.
| + | |
| − | :* The clutch itself is not fairly complex since it is one strong sheet of metal.
| + | |
| − | '''Fuel Tank'''
| + | |
| − | : The fuel tank is made of aluminum and formed using Injection molding.
| + | |
| − | :* There is only one material used for this component.
| + | |
| − | :* The material selected does not affect manufacturing process since metal is one of the easiest to shape and cut.
| + | |
| − | :* The shape of the fuel tank is easily formed through die casting.
| + | |
| − | :* The shape of the fuel tank is designed to hold a predetermined amount of gasoline safely.
| + | |
| − | :* The component is both functional and cosmetic since it holds the gasoline required to fuel the bike while still being completely visible.
| + | |
| − | :* The fuel tank is not complex.
| + | |
| − | '''Heat Shield'''
| + | |
| − | : The heat shield is made of aluminum. Die casting is used to manufacture the component.
| + | |
| − | :* There are no real forces applied to the component.
| + | |
| − | :* The manufacturing process is not affected by the material since metal is among one of the easiest materials to shape and cut.
| + | |
| − | :* The shape needed for the heat shield is easily formed through die casting.
| + | |
| − | :* The shape of the heat shield is designed to cover all heat exhausted by the engine that is not directed through the exhaust pipe.
| + | |
| − | :* The component is functional simply because cosmetics are not required for its location.
| + | |
| − | :* The component is not complex due to the fact that it is simply a sheet of metal.
| + | |
| − | '''Fuel Line and Vapor Line'''
| + | |
| − | : The fuel line and vapor line are both made of plastic and formed through Injection molding.
| + | |
| − | :* The forces applied to either line can be found within the lines themselves by the substance flowing through them. This force is essentially negligible.
| + | |
| − | :* Plastic can be is easily shaped into a hollow tube using injection molding.
| + | |
| − | :* The shape of a hollow tube is commonly used for lines required to transport substances from one section to another.
| + | |
| − | :* The component is both functional and cosmetic since it is visible without disassembling the bike.
| + | |
| − | :* The component is not complex.
| + | |
| − | '''Throttle Assembly'''
| + | |
| − | : The throttle assembly is comprised of one main solid piece, a connecting rod, one Philips head screw and two springs. The throttle itself is made up of steel and formed through die casting. This piece is connected to the connecting rods by two springs. The one screw is used to control the amount of gasoline used to flow into the engine.
| + | |
| − | :* The springs are made of stainless steel for the materials strength and stiffness. The connecting rods are made of aluminum and manufactured through drilling, and die casting. Both the screw and the main throttle piece are made of steel for its endurance and sturdiness.
| + | |
| − | :* The metals used have no real affect on the manufacturing process chosen.
| + | |
| − | :* The shaped of the springs is most easily formed through hot rolled forming. The connecting rod, screw, and throttle are design through die casting because it is the simplest way to form the shapes required for each of these parts.
| + | |
| − | :* The component is entirely functional and is not visible when the bike is assembled.
| + | |
| − | :* The component is fairly complex considering that it is comprised of several pieces and the position of the springs.
| + | |
| − | '''Carburetor'''
| + | |
| − | : The carburetor is made of zinc according to www.alibaba.com/product-gs/.../JAWA350_6V_Carburetor.html.
| + | |
| − | :* The material chosen does not affect the manufacturing process
| + | |
| − | :* The shape of the carburetor is most easily formed through a combination of die casting and taping.
| + | |
| − | :* The shape of the carburetor is designed to fit on the engine while functioning at a high efficiency.
| + | |
| − | :* The component is functional.
| + | |
| − | :* The component is complex.
| + | |
| − | '''Magneto'''
| + | |
| − | : The magneto is an electromagnet and it therefore comprised of an iron armature, two copper wire coils, an electronic control unit, a strong magnet and a rubber casing. It is connected to the engine with two 12 mm steel bolts formed through die casting.
| + | |
| − | :* The magneto experiences an electromagnetic force from its parts.
| + | |
| − | :* The material does not affect the manufacturing process.
| + | |
| − | :* The shape of the magneto is typical for an electromagnet of its size and has no effect on the overall manufacturing process.
| + | |
| − | :* The component is functional. Although the rubber casing can be considered cosmetic the entire magneto is not easily visible while the bike is assembled and the rubber is used more as an insulator than for aesthetics.
| + | |
| − | :* The component is a fairly complex elector magnet.
| + | |
| − | '''Spark Plug'''
| + | |
| − | : The spark plug’s metal casing is made of nickel and manufactured through die casting and cold forming.
| + | |
| − | :* The material does not affect the manufacturing process since metal is among the easiest materials to shape and cut.
| + | |
| − | :* The shape of the casing is unique and is manufactured easiest through die casting or cold forming.
| + | |
| − | :* The component is functional.
| + | |
| − | :* The spark plug casing is a fairly simple component. The spark plug itself is a complex component.
| + | |
| − | '''Fly Wheel'''
| + | |
| − | :* The flywheel assembly is comprised of a steel flywheel and a plastic cover which are held together using a 19mm steel nut.
| + | |
| − | :* Plastic was used for its lightweight while steel was used on the flywheel due to its strength and sturdiness.
| + | |
| − | :* The flywheel feels the force of crankshaft as it turns.
| + | |
| − | :* Plastic is most easily manipulated through injection molding and may sometimes be too fragile for other manufacturing processes. Die casting is commonly used to shape metals including steel.
| + | |
| − | :* The grooves of the flywheel cover are easily created through injection modeling. The shape of the flywheel itself has no affect on the manufacturing process decision.
| + | |
| − | :* The grooves of the cover are designed to regulate airflow.
| + | |
| − | :* The component is functional. None of these parts have any bearing on the aesthetic appeal of the bike while it is assemble.
| + | |
| − | :* This component is fairly complex.
| + | |
| − | | + | |
| − | ===Design Revision===
| + | |
| − | *One design revision would be to change the position of the exhaust. Currently, the exhaust it is positioned to blow hot air on to the seat. If you were to ride the bike for a long time the seat would get very hot and you could potentially burn yourself on the seat and the metal surrounding the seat. We would move the exhaust by placing the exhaust exit near the back of the bike close to the wheels, such as in a Harley Davidson bike. If we were to fix it on the current bike we would put a funnel where the exhaust exits and run the funnel to the back of the bike by the wheel. By changing the exhaust you make it more comfortable and safer to ride for a long period of time. Making these changes would not increase the price very much. The material added to the bike would not add to the weight enough to affect the speed or gas mileage of the bike. We are surprised that they still have the exhaust blowing on the seat as it is very uncomfortable. | + | |
| − | | + | |
| − | *A second design revision we would consider for the road bike would be the steering ability of the Baja Mini Bike. During our initial testing of the bike, we found that the turning capabilities of the bike were nothing to be desired. There is a bar on the front wheel which inhibits the bike from turning sharply. Because of the bikes inability to turn effectively, a rider could potentially crash when trying to maneuver the bike in tight spaces. The only way we can fix this problem is if we were to remove the turning stopper already in place on the road bike. Another fix for this problem would be decreasing the size of the bar, giving the bike better turning abilities rather than giving the bike full rotation. In doing so, this would increase the functionality of the bike, as well as making a safer ride for the owner. This design change would cost the company very little or money at all, and wouldn’t be hard to complete. It would be a very easy change for the company to make in their design, and would yield more satisfied customers.
| + | |
| − | | + | |
| − | ===Solid Model Assembly===
| + | |
| − | [[Image:Rimanddrumbrake1.jpg|frame|Rim and Drum brake]]
| + | |
| − | [[Image:Rimanddrumbrake3.jpg|frame| Rim and Drum Brake]]
| + | |
| − | [[Image:Rimanddrumbrake2.jpg|thumb|300px|Rim and Drum brake]]
| + | |
| − | [[Image:Rimanddrumbrake4.jpg|thumb|left|300px|Rim and Drum brake]]
| + | |
| − | | + | |
| − | <br style="clear:both" />
| + | |
| − | | + | |
| − | ===Engineering Analysis===
| + | |
| − | ===='''Problem Statement:'''====
| + | |
| − | Using Engineering analysis identified in class:<br/>
| + | |
| − | :: The brake cable has snapped. How much force was needed to snap the brake cable?
| + | |
| − | | + | |
| − | ===='''Diagram:'''====
| + | |
| − | Simplified version of the brake handle:
| + | |
| − | [[Image:brakediagramgroup22.jpg]]
| + | |
| − | | + | |
| − | ===='''Assumptions'''====
| + | |
| − | *The cable is a static problem.
| + | |
| − | *The cable is made of steel (most brake cables are made from steel).
| + | |
| − | *The tensile strength of the steel assuming it is type: AISI 1060 0.6% carbon is 2200X106 N/m2 (http://en.wikipedia.org/wiki/Tensile_strength).
| + | |
| − | *The radius of the wire is .25 cm.
| + | |
| − | *No friction on cable.
| + | |
| − | *No outside forces acting on the cable.
| + | |
| − | *No gravitational force on the cable.
| + | |
| − | *No fatigue on the cable.
| + | |
| − | *The force from hand acts at a single point in only the Y direction.
| + | |
| − | *The brake cable doesn’t slip when the brake is applied.
| + | |
| − | ===='''Governing Equations'''====
| + | |
| − | Static Problem: Moment (at pin) = 0 = Force*distance
| + | |
| − | Tension (needed to snap wire) = Tensile strength * area
| + | |
| − | | + | |
| − | ===='''Calculations'''====
| + | |
| − | 0=-F(.13) +.05(T)<br/>
| + | |
| − | TS= 2200000000 N/m2<br/>
| + | |
| − | T= TS *A<br/>
| + | |
| − | A= .0025 m2*π<br/>
| + | |
| − | A=.000019635 m2<br/>
| + | |
| − | T= 2200000000 N/m2*.000019635m2<br/>
| + | |
| − | T= 43197 N<br/>
| + | |
| − | F= .05T/.13<br/>
| + | |
| − | F= (.05*43197)/.13<br/>
| + | |
| − | F= 16614 N<br/>
| + | |
| | | | |
| − | ===='''Solution Check'''====
| + | [http://gicl.cs.drexel.edu/wiki/Group_22_-_Beginner_Cruiser_Motorcycle:_Coordination_Review Coordination Review] |
| − | : The units check out for force, and the answer seems reasonable for the strength of steel and the way the handle is oriented. The moments were correctly configured and the math checks out. The force to break the cable is more than a human can apply so it shouldn’t break from forces of the rider. | + | |
| | | | |
| − | ===='''Interpretation and Discussion:'''====
| |
| − | : The answer will vary depending upon how much fatigue the wire has experienced. As the cable experiences more fatigue, the smaller the force it would take to break the cable. Friction would also cause fatigue on the wire. On the real mini bike the steel may be different than the one I assumed, and therefore would have a different strength. There is no way to find out as it is not listed on any web sites and I don’t know how to tell different types of steel apart from sight. If the radius of the cable was changed, this would change the outcome. The greater the radius, the more force you would need to snap the cable. The cable is not a static problem in real life so the outcome would be different. The gravitational and other outside forces would have an effect on the fatigue and the force on the cable. The force on the brake in real life wouldn’t act as a single force but would be spread out all over the brake. If the tensile strength were stronger you would need a greater force to snap the cable. The force required is very high, too high for the rider to snap it. I expected that because steel is very strong and a human cannot break it by themselves. The only way the cable could snap from the riders force would be if it wore down from friction or fatigue. Also, when the break is pulled, there is some give on the cable from the hand brake, which would change the force to snap to cable. The distance from the pin would also change the answer. The farther away the force is applied the greater tension is applied. The force also would be spread out over the brake not as I assumed. This would change the force applied to the brake and where it acts. It would act as a function over the hand brake not as a single force. This would change the force applied and the force applied to the cable. Also, the hand brake on the bike would most likely deform or break if that much pressure was applied. The pin connecting the cable to the hand brake would also break before the cable was to fail if this much pressure was applied.
| |
| | ==Critical Project Review== | | ==Critical Project Review== |
| | ===Reassembly Plan=== | | ===Reassembly Plan=== |
| − | '''Rear End Reassembly:''' | + | ===='''Rear End Reassembly:'''==== |
| | :'''Kick Stand:''' | | :'''Kick Stand:''' |
| | :: Using needle nose pliers to aid in fastening the Kick Stand to the frame. Secure the kick stand to the frame using a 10mm socket wrench. | | :: Using needle nose pliers to aid in fastening the Kick Stand to the frame. Secure the kick stand to the frame using a 10mm socket wrench. |
| Line 564: |
Line 46: |
| | | | |
| | :'''Seat:''' | | :'''Seat:''' |
| − | [[Image:seat2.jpg|thumb|left|Bottom of the seat frame]]
| + | |
| | :: Place the seat back on to its position on the frame. Screw in the two 1/4inch nuts and the middle 3/4inch nut using their respective wrenches. | | :: Place the seat back on to its position on the frame. Screw in the two 1/4inch nuts and the middle 3/4inch nut using their respective wrenches. |
| − | [[Image:seat1.jpg|thumb|right|Seat Attached to frame]] | + | {|align="center" |
| | + | |[[Image:seat1.jpg|thumb|right|Seat Attached to frame]] |
| | + | |[[Image:seat2.jpg|thumb|left|Bottom of the seat frame]] |
| | + | |} |
| | <br style="clear:both" /> | | <br style="clear:both" /> |
| | | | |
| | | | |
| | :'''Rear Fender:''' | | :'''Rear Fender:''' |
| − | [[Image:backfender3.jpg|thumb|left|Metal bracket: Inside of the Back fender]]
| + | |
| | :: Place the fender in its designated location under the seat on the bike. There are 4 9mm nuts that need to be tightened using a 9mm socket wrench and two bolts two either side on the interior of the fender. A metal bracket must be placed on the interior of the fender between the bolts and the fender itself. | | :: Place the fender in its designated location under the seat on the bike. There are 4 9mm nuts that need to be tightened using a 9mm socket wrench and two bolts two either side on the interior of the fender. A metal bracket must be placed on the interior of the fender between the bolts and the fender itself. |
| − | [[Image:backfender2.jpg|thumb|Back fender attached to frame]] | + | {|align="center" |
| | + | |[[Image:backfender3.jpg|thumb|left|Metal bracket: Inside of the Back fender]] |
| | + | |[[Image:backfender2.jpg|thumb|Back fender attached to frame]] |
| | + | |} |
| | <br style="clear:both" /> | | <br style="clear:both" /> |
| | | | |
| Line 602: |
Line 90: |
| | | | |
| | ===='''Engine:'''==== | | ===='''Engine:'''==== |
| − | :'''Piston cover and Motor Head:''' Place the push rods into their designated springs. Using a 12mm socket wrench, secure the piston cover. The motor head must be aligned with the push rods so that they push each the rocker arms found in the motor head.. Using a 10mm socket wrench, secure the motor head. | + | :'''Piston cover and Motor Head:''' |
| | + | :: Place the push rods into their designated springs. Using a 12mm socket wrench, secure the piston cover. The motor head must be aligned with the push rods so that they push each the rocker arms found in the motor head.. Using a 10mm socket wrench, secure the motor head. |
| | {|align="center" | | {|align="center" |
| | |[[Image:34.5d.JPG|thumb|Push Rods]] | | |[[Image:34.5d.JPG|thumb|Push Rods]] |
| Line 609: |
Line 98: |
| | |} | | |} |
| | | | |
| − | :'''Train Covers:''' Firmly secure the train cover to the engine using a 10mm socket wrench on 6 screws. The Valve Train Cover must be secured using an 8mm socket wrench on a set of 4 bolts. | + | :'''Train Covers:''' |
| | + | ::Firmly secure the train cover to the engine using a 10mm socket wrench on 6 screws. The Valve Train Cover must be secured using an 8mm socket wrench on a set of 4 bolts. |
| | [[Image:28d.JPG|thumb|center|Train Cover]] | | [[Image:28d.JPG|thumb|center|Train Cover]] |
| | | | |
| | | | |
| − | :'''Spark Plug and Magneto:''' Place the spark plug back in its designated location. Place a spacer between the magneto to assure that it is not too close to the flywheel or the flywheel magnet. Using a 12mm wrench on 2 bolts secure the two the flywheel making sure to leave the grounding wire exposed. Place the rubber plug back onto the spark plug. | + | :'''Spark Plug and Magneto:''' |
| | + | :: Place the spark plug back in its designated location. Place a spacer between the magneto to assure that it is not too close to the flywheel or the flywheel magnet. Using a 12mm wrench on 2 bolts secure the two the flywheel making sure to leave the grounding wire exposed. Place the rubber plug back onto the spark plug. |
| | {|align="center" | | {|align="center" |
| | |[[Image:41d.JPG|thumb|200px|Spark Plug]] | | |[[Image:41d.JPG|thumb|200px|Spark Plug]] |
| Line 621: |
Line 112: |
| | |} | | |} |
| | | | |
| − | :'''Carburetor, Gasket and Governor Assembly:''' Using needle nose pliers insert the springs into the assembly. The governor arm must be place on the plastic axle. Fit the carburetor onto the two designated bolts on the engine block. Slide gasket into place at the end of the carburetor. | + | :'''Carburetor, Gasket and Governor Assembly:''' |
| | + | :: Using needle nose pliers insert the springs into the assembly. The governor arm must be place on the plastic axle. Fit the carburetor onto the two designated bolts on the engine block. Slide gasket into place at the end of the carburetor. |
| | {|align="center" | | {|align="center" |
| | |[[Image:50d.JPG|thumb|Carburetor]] | | |[[Image:50d.JPG|thumb|Carburetor]] |
| Line 629: |
Line 121: |
| | |} | | |} |
| | | | |
| − | :'''Throttle:''' Using needle nose pliers on two springs place them onto the connecting rod. Insert the screw which is used as a regulator. Place another gasket between the throttle and the air intake. | + | :'''Throttle:''' |
| | + | :: Using needle nose pliers on two springs place them onto the connecting rod. Insert the screw which is used as a regulator. Place another gasket between the throttle and the air intake. |
| | {|align="center" | | {|align="center" |
| | |[[Image:48d.JPG|thumb|Throttle]] | | |[[Image:48d.JPG|thumb|Throttle]] |
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| | |} | | |} |
| | | | |
| − | :'''Exhaust:''' Attach the exhaust and the muffler using a 12mm socket wrench on two bolts. | + | :'''Exhaust:''' |
| | + | ::Attach the exhaust and the muffler using a 12mm socket wrench on two bolts. |
| | {|align="center" | | {|align="center" |
| | |[[Image:26d.JPG|thumb|Exhaust]] | | |[[Image:26d.JPG|thumb|Exhaust]] |
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| | |} | | |} |
| | | | |
| − | :'''Air Filter and Cover:''' Place the air intake on top of the carburetor now attached to the engine block. Using a 12mm wrench, secure the two 12mm nuts to the engine block. Place the plastic air filter cover over the air filter. Secure the cover by placing two wing nuts on the underside of the cover and one wing nut on the top of the cover. | + | :'''Air Filter and Cover:''' |
| | + | :: Place the air intake on top of the carburetor now attached to the engine block. Using a 12mm wrench, secure the two 12mm nuts to the engine block. Place the plastic air filter cover over the air filter. Secure the cover by placing two wing nuts on the underside of the cover and one wing nut on the top of the cover. |
| | {|align="center" | | {|align="center" |
| | |[[Image:13d.JPG|thumb|Air Filter and Cover]] | | |[[Image:13d.JPG|thumb|Air Filter and Cover]] |
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| | |} | | |} |
| | | | |
| − | :'''Heat plate:''' Line the three designated holes up with the heat shield. Using a 10mm socket wrench, secure the heat shield to the engine block. | + | :'''Heat plate:''' |
| | + | :: Line the three designated holes up with the heat shield. Using a 10mm socket wrench, secure the heat shield to the engine block. |
| | {|align="center" | | {|align="center" |
| | |[[Image:Group22heatsheild.jpg|thumb|Heatshield]] | | |[[Image:Group22heatsheild.jpg|thumb|Heatshield]] |
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| | | | |
| | | | |
| − | :'''Flywheel Cover:''' Attach the fly wheel cover by aligning the 4 holes on the engine block with the 4 holes on the flywheel cover. Using a 10mm socket wrench, secure the bolts into the holes. | + | :'''Flywheel Cover:''' |
| | + | :: Attach the fly wheel cover by aligning the 4 holes on the engine block with the 4 holes on the flywheel cover. Using a 10mm socket wrench, secure the bolts into the holes. |
| | {|align="center" | | {|align="center" |
| | |[[Image:Group22Flywheelcover.jpg|thumb|Fly Wheel Cover]] | | |[[Image:Group22Flywheelcover.jpg|thumb|Fly Wheel Cover]] |
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| | |} | | |} |
| | | | |
| − | :'''Pull Start Assembly:''' Securely coil the long spring around the inner wheel of the assembly. The spring should fall within a groove designated for it. The pull rope must then wrap around this wheel. The rope must be wound around the inner wheel of the main housing. Pull the rope to tighten the spring. This allows the spring to reach a maximum tension. Rewind the rope around the main housing so it retracts when it is pulled. Once the pull start is reassembled attach the assembly to the flywheel cover using three 8mm bolts and an 8mm socket wrench. | + | :'''Pull Start Assembly:''' |
| | + | :: Securely coil the long spring around the inner wheel of the assembly. The spring should fall within a groove designated for it. The pull rope must then wrap around this wheel. The rope must be wound around the inner wheel of the main housing. Pull the rope to tighten the spring. This allows the spring to reach a maximum tension. Rewind the rope around the main housing so it retracts when it is pulled. Once the pull start is reassembled attach the assembly to the flywheel cover using three 8mm bolts and an 8mm socket wrench. |
| | {|align="center" | | {|align="center" |
| | |[[Image:largespring22.jpg|thumb|Long Spring]] | | |[[Image:largespring22.jpg|thumb|Long Spring]] |
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| | |} | | |} |
| | | | |
| − | :'''Fuel Tank:''' Secure the fuel tank using a 10mm socket wrench. Two nuts on the back of the fuel tank and one nut near the front. | + | :'''Fuel Tank:''' |
| | + | :: Secure the fuel tank using a 10mm socket wrench. Two nuts on the back of the fuel tank and one nut near the front. |
| | {|align="center" | | {|align="center" |
| | |[[Image:18d.JPG|thumb|Fuel Tank]] | | |[[Image:18d.JPG|thumb|Fuel Tank]] |
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| | |} | | |} |
| | | | |
| − | :'''Clutch and Bracket Plate:''' The bracket plate must be perfectly aligned with the engine block during its portion of the assembly. Secure the bracket using four 12mm bolts and a 12mm socket wrench. Once this is secured slide the clutch onto the drive shaft. During the process make sure the key and groove of the clutch line up. Secure the 12mm nut and washer onto the end of the drive shaft using the 12mm socket wrench. | + | :'''Clutch and Bracket Plate:''' |
| | + | :: The bracket plate must be perfectly aligned with the engine block during its portion of the assembly. Secure the bracket using four 12mm bolts and a 12mm socket wrench. Once this is secured slide the clutch onto the drive shaft. During the process make sure the key and groove of the clutch line up. Secure the 12mm nut and washer onto the end of the drive shaft using the 12mm socket wrench. |
| | {|align="center" | | {|align="center" |
| | |[[Image:2d.JPG|thumb|Clutch]] | | |[[Image:2d.JPG|thumb|Clutch]] |
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| | |} | | |} |
| | | | |
| − | :'''Small chain:''' Place the smaller train on to the clutch and the inner gear on the clutch bracket plate. | + | :'''Small chain:''' |
| | + | :: Place the smaller train on to the clutch and the inner gear on the clutch bracket plate. |
| | [[Image:1d.JPG|thumb|center|Clutch, Bracket Plate and chains attached to engine block]] | | [[Image:1d.JPG|thumb|center|Clutch, Bracket Plate and chains attached to engine block]] |
| | | | |
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| | :* The difference in assembly and disassembly can be found in the speed of both processes. Although the exact times were not documented, it took us approximately 4 days to fully disassemble the bike. Reassembly only took two group meetings. All the same tools were used for both processes. The only difference was the use of tape instead of sip ties. | | :* The difference in assembly and disassembly can be found in the speed of both processes. Although the exact times were not documented, it took us approximately 4 days to fully disassemble the bike. Reassembly only took two group meetings. All the same tools were used for both processes. The only difference was the use of tape instead of sip ties. |
| | :* It is necessary to consider that the pull start was incredibly difficult to reassemble. It should not be taken apart unless there is a problem with the mechanism. Upon reassembly, it should also be taken into consideration that the idle position for the throttle should not be too high. By not taking this into consideration the bike upon start may take off by itself. | | :* It is necessary to consider that the pull start was incredibly difficult to reassemble. It should not be taken apart unless there is a problem with the mechanism. Upon reassembly, it should also be taken into consideration that the idle position for the throttle should not be too high. By not taking this into consideration the bike upon start may take off by itself. |
| − | [http://www.example.com link title]
| |
Group 22 and Group 21 are going to disassemble a beginner Cruiser Motorcycle. Our group (Group 22) will disassemble the back half of the motorcycle while Group 21 will disassemble the front half of the motorcycle. Both groups will work simultaneously on the engine ensuring that it is done carefully and that it only needs to be reassembled once.
The following link will direct you to Group 22's Product Dissection Plan which inludes:
The following link will direct you to Group 22's Coordination Review which includes:
