Low Rider Motorcycle Fuel Tank - Research Proposal Example

Low Rider Motorcycle Fuel Tank Proposal Table of Contents Overview 4 Aims & Objectives 5 Proposed Work Process 6 Research Methodology 6 **** Engineering Recent Related Projects 7 Note to potential sponsors 8 Technical Requirements 9 Overall Design Considerations 9 Bike in Development 9 Compatibility 10 Hub Centre Steering 10 Tank Capacity 11 Sender Unit 12 Nozzle 12 Fuel Gage 13 Legal 13 Health & Safety 14 Appendix A 15 Sponsorship 15 Sponsor 1 15 Sponsor 2 16 Further Potential Sponsors 16 Appendix B 17 Project Finance 17 Appendix C 18 Project Plan 18 Schedule 18 Contingencies 19 Bibliography 20 Overview Motorcycles have been around since the beginning of motorised transport as an alternative means of transportation. The concept of a two wheeled vehicle has been developed, like the car to cater to differing needs form learner, commuting, touring, cruisers to the out and out sports machine. Much interest in motorcycles over the past few years have meant the various unconventional ideas have been explored and put into development utilising new technology and materials alike. The motorcycle under development has hub centre steering and is currently a project undertaken by ***** Engineering. Recently, there has been an upsurge in the popularity of motorbikes and especially in motor bike racing (Great Tiding for Motorbike Racing, 2007). This motorbike is not a racing bike, it is a low-level riding cruiser bike. However, this article shows that the environment for motorcycles is good for producing new ideas into the mix. This research proposal is concerned in finding a method for designing a complex fuel reservoir for a concept motorcycle under development by the **** Engineering. The work need extensive research into fuel tank technology of various vehicle types as this is not a conventional motorcycle and neither is the fuel tank. The fuel tank has to also double up as the seat, also a structural load bearing member of the chassis. Fuel tank technologies which have similarities to this are aircrafts, Motor sport (F1), Jetski and mopeds. Although Satellite, rocket, speed boat and scooter technologies are also proposed to be explored and similarities in application and technological application are also proposed to be considered. Aims & Objectives At present the prototype which is up and running has a fuel capacity of under a gallon as fundamentally the bike was initially stuck together roughly to test the concept and has yet to be refined. The Concept found to work rather well is now under further development and this project is involved in providing a design for a fuel tank which also doubles up as a seat and provides the vehicle a range of about two hundred miles before filling up again. Research must be undertaken from various fields in fuel tank technology as this is not a conventional motorcycle fuel tank. Some areas of fuel tank design with similarity would be aircrafts, formula one racing cars, mopeds, scooters and at a long shot jetski's. The fuel tank should fit in the space now governed by the seat, should also provide seating for the rider and a range of about 200 miles. The main purposes of the project are: To develop a method for design in this context To develop the use of 2D and 3D CAD for use in this context To propose a design for the fuel tank of the experimental 'low-ride' motor cycle Proposed Work Process The proposed list of processes involved in this work is as follows: Investigate parameters involved in designing complex fuel tanks Investigate financial aspects Project planning Determine prevalent regulations Investigate Health & Safety concerns Research Existing products Gain product area knowledge Carry out a literature search of engineering practices Investigate existing engineering design *** Engineering are aware of the problems concerned with the development of this type of fuel tank and fully support any investigation which is deemed a pre-requisite to progress the development of the project. *** Engineering is fully committed to the successful outcome of this project. Research Methodology In order to find which is the best approach to use for this exercise, as mentioned , fuel tank technology shall be researched, similarities between technologies and the client themselves shall also be consulted. **** Engineering Recent Related Projects Recently, **** Engineering have been investigating the latest trend in Sport bikes, which offer the latest motor technologies. The idea was to build a "test" sports bike based on a similar concept to the one currently being produced by Kawasaki (Herald, 2005). This offers high horsepower, but with smaller displacements. The rev range is in the mid to upper end of the rev range. In the Kawasaki version the suspension responds swiftly to the terrain allowing easy handling of the machine. **** Engineering has produced the test version in a similar mould as the Kawasaki version, excepting the budget available was not on the same level as the Japanese giant. The similarity exists in that sports bikes need to be small, light, but powerful. They similarity here is in the seating arrangement. The Kawasaki version has appropriately been named as a "Naked Bike" It is intended to be a combination of a cruise bike and a roadster. The difference in concept in regard to low rider bikes is that sports bikes need to have a high seating arrangement, which is not always comfortable for the rider, but is appropriate for the sports bike field. The intention of **** Engineering is to design a low rider bike, with the same power and lightweight handling as a sports bike. The size of the bike will also need to be taken into account. With this in mind, and given the weight of the fuel, it is an appropriate project for the design of a "Low Rider" seat which also incorporates the fuel, thus saving space and weight in the process. This should assist with the horsepower the machine can provide. Another aspect to the fuel tank, in addition to the "Low Ride" feature is the method used to fill the tank when required. **** Engineering have been looking at a solution for the possibility of having a tailored fitting for the fuel tank in order to provide ease of use, given that the fuel tank also functions as the motorbike seat. Recent patents on this have been investigated in order to see what would be required. One such example is U.S. Patent Number 4811763. This patent is for a generic idea for all kinds of motor vehicles. Some of the ideas in the patent influenced the method used by **** Engineering when investigating this aspect. The end product should be usable on the final version of the fuel tank proposed. Note to potential sponsors The work requires further funding from interested parties. The funding will provide for the additional research and technology capability in order to engineer, and possibly market the product once it is complete. The benefits to the potential sponsor are numerous, including a possible partnership and a shareholding with the design company. The product will also lead to future related research into similar new designs and technologies for other 'Low Ride' vehicles. Possible sponsors should have related knowledge in this area of engineering, and be willing to commit to the project from both a financial, and a technical point of view where this is required. Another factor is that the cost of the fuel tank will be partly government subsidised; This will come from government initiatives. An application has also been made to Camelot, the owners of the lottery fund. Various other initiatives are under investigation. The costings mentioned in this project are the costs after the subsidies and other grants which have been taken into account. The list of potential sponsors as of the cut-off date 'date' is provided in Appendix A. Technical Requirements Overall Design Considerations The tank should be design both to accommodate the seating arrangement, and ensure that it has no sharp edges and fulfil health and safety requirements. All fuel tanks must meet health and safety concerns, for both the rider and benefit of the general public, who will be out there when the machine is finally on the road. There are also regulatory concerns with regard to this, and these will be discussed in the remainder of this report. The fuel tank must be able to withstand atmospheric pressures caused by either gasoline vapours expanding or vacuum caused by fluid displacement as the tank empties. This applies to ALL fuel tanks without exception. Third party suppliers ALWAYS say, "test, pressurize and seal." This is an important concept to be considered and a testing process for this MUST be built into the project schedule. Bike in Development The bike in development is of a feet forward style motorcycle with hub centre steering, which provides stability in long distance riding. The concept is of a two wheeled car and is mainly focused at medium to long distance applications. A sketch of the proposed completed bike design is illustrated below: Fig 1: Compatibility The fuel tank needs to be compatible with 2004 upwards fuel injection based systems. It also needs to be considered how the tank will fit onto the small (hand welded) frame, and the level of comfort available for the rider. It may be that some adjustments to the frame will need to be made in order for the new fuel tank to fit correctly. Hub Centre Steering The steering mechanism will need to be taken into account, as part of the fuel tank design. This is a form of front end steering and suspension system for motorcycles and is an alternative to telescopic forks. The difference being that it has a swing arm similar to the one at the rear wheel, extending from the front of the frame or engine to the middle of the front wheel. Hub centre steering separates the three main functions of telescopic forks namely being suspension, braking and steering. The swing arm is pivoted on bearings which allow the wheel to pivot eliminating friction, a common enemy of the telescopic fork, especially under braking. Braking forces are the redirected along the swing arm away from the vertical and are put to use to counterbalance weight shift. Also the swing arm allows the steering geometry to remain constant under braking or acceleration and variable road conditions. The downside of hub centre steering has been steering sensitivity. The use of complex linkages and the additional material used in the front swing arm can sometimes give a slack or vague feel to the bike. Tank Capacity A "trade-off" may need to be considered for the tank, in that the capacity will be offset by the size available for the seat. In this regard, however, the fact that it is also being used as a seat indicates that the tank should be adequate size as the seat and fuel tank live together as one unit on the machine. The fuel tank will need to be designed so that it can be placed in a number of positions and any resulting air trapped in the tank will not affect that capacity available when refuelling. As briefly mentioned in the introduction, the current capacity for this tank is around 5 gallons and should have a cruising range of about 150 - 200 miles. The capacity will need to be verified during the design process. The best and simplest way to do this is to fill up the tank and empty the contents into calibrated jugs, and measuring containers to measure the actual volume of the liquid. The tank can be tested independently of the bike. Any liquid can be used for this measurement process. Sender Unit The fuel tank will need to have a "Sender Unit" designed to be built into the tank to measure capacity of the fuel, which is read by the fuel gage. This technique has been around for a number of years. Through the constant supply of a constant current to the fuel gage, a measurement is obtained regarding the state of the fuel. The needle on a fuel gage works by the application of higher or lower voltage to the device, causing the needle to be raised or lowered. The lower the resistance, the higher the needle will point on the display. Therefore, we deduce that the needle is controlled by the application of lower voltage to the device for a higher measurement of fuel, and a higher voltage to the device for a lower amount of fuel. If the float is at the top of the tank, then less resistance is sent to the fuel gage, hence the needle shows 'Full'. In contrast when the float is at the bottom of the tank the resistance is higher and the needle moves to the lower readings. The trick is to calculate the exact resistance required in order to accurately calculate the amount of fuel in the tank. This could be designed as part of the overall design, or one could be purchased if necessary. Nozzle The nozzle for the tank will need to be accessible, given that it also forms the basis of the rider's seat, and conforms to standard nozzle sizes. Fuel Gage The fuel gage should be considered with regards to where it is going to be sighted. This should be visible at all times, even when riding. Therefore the position of the fuel gage should be given careful consideration. Legal With regard to current regulations (nationally and internationally) governing the design of fuel tanks the following will need to be considered. The points below are only mentioned here as a sample of the requirements for a legal fuel tank which conforms to the regulations for motor cycles. For a full list, reference will need to be made to the appropriate government legislation governing fuel tanks. The tank will need to be drop tested on its corners at about 30 feet, filled with water and cannot leak. The tank will need to meet a rollover test which states that the complete system i.e. the tank and all its associated parts, must be turned through an angles of 150 degrees in any direction about an axis from its normal position. The tank must not leak more than one ounce in minute or five ounces in five minutes. A flame test will need to be carried out on the tank. The process is that a tank should be fully filled with fuel, and must release its contents prior to reaching an internal pressure of 50 psi. There is also a predetermined speed at which the tank will need to fill up per minute. This information is covered by the appropriate government paper. Health & Safety ***** Engineering has safety policies in place which is strictly adhered to, as is necessary. It is a requirement for anyone working in the engineering environment and working with corrosive materials such as petroleum products, should be covered by the appropriate legislation. The safety policy is frequently reviewed, in order to meet government legislation. An employer has responsibility under the Health and Safety at Work Act to ensure that all reasonable steps are made to ensure the safety of staff. Risk assessments should be carried out and appropriate safety training in line with company procedure and legislative guidance on the matter. In addition, the legal concerns stated in this report with regard to the minimum requirements for the design of fuel tanks are also stated in this report, along with measures to test the tank to conform to safety requirements. Appendix A Sponsorship We are now considering sponsorship proposals from various individuals and organisations. This section of the proposal only provides details for potential interested parties. For more information about the benefits of becoming a sponsor for the project, please see the section entitled "Note to potential sponsors." Sponsor 1 'name' has been involved both with Engineering and motorcycles taking mainly hands on approach to the subjects since the early 1990's. His increasing interest for the subjects have lead him to progress from a B-Tec in Engineering in 1991 to graduating from Westminster university in 1997 his Undergraduate project entitled 'To design an innovative motorcycle chassis incorporating: The use of CFRP and suggestions towards an alternative steering and suspension system ' lead to extensive research being carried out into to mechanisms which make motorcycles function, Designing a chassis around an existing 750cc engine which had to be modelled into 3D data and involved the use of CAD programs and finally the analysis of stress of the proposed design and the interpretation of the results. The project was one of personal interest and received much support from sources of information which were approached on the subject. Britten Motorcycles a pioneer in the field of carbon fibre framed motorcycles, were very encouraging with their advice and criticisms and were happy to help with advice and concerns related to the project. Industrias Guerra in Ponte Vedra Spain were also very helpful in drawing up the final design by allowing 'name' access to their Pro Engineer CAD software and with advice with respect to structures. The project was supervised by Cathy Grundy a Product Design lecturer at Westminster University. Since graduation 'name' has had various job roles using engineering design from specialised machinery concepts being made into a real machine at Queen City Container a project undertaken during a summer holiday whilst undertaking his bachelor degree to automotive stress analysis for a consultancy based in Basildon UK. Sponsor 2 'David Smith New Concepts' is a new small business (Est 2006) in the development of new and unusual designs in motorbike developments. They have an increasing market for bikes which do not fit the standard designs for some countries in the Middle East and in some parts of Europe. They are looking for designs which are marketable and are also something they can feature in motorbike magazines. The owner has been involved in the process of bike design since early 2000 and has worked for various companies including Kawasaki and Honda in the UK. Numerous qualifications, and experience in the motor cycle industry. These days he concentrates mainly on running the business venture. Further Potential Sponsors There have been enquires from other various interested parties around this project. This document will be updated to reflect this as and when they arise. Interest has been shown in the project from as far as Canada, and far Eastern Europe, in addition to additional interest in the UK and the US. Appendix B Project Finance The following list is the finances required for the project. The benefit of the system is in the potential sales and the overall marketability of the project, therefore these costs should easily be recoverable over a period of one to two years. VAT has already been included in the costing: Item Unit Cost (Totals) Work Required Research & Investigation 1,000.00 Design Phase 1,000.00 Build Prototype 1,500.00 Testing 1,000.00 Build Final Version 3,000.00 Final Testing 1,000.00 Administration 500.00 Sub Total 9,000.00 Materials Sheet Metal 1,000.00 Purchase of Sender 250.00 Fuel Gage 50.00 Standard Nozzle 50.00 Fuel for Testing 50.00 Sub Total 1,400.00 Overall Total 10,400.00 Appendix C Project Plan Schedule The following project plan has been proposed. The dates are left to be filled in when required. The ideal cycle is 14 weeks. Taken into account contingencies this could be increased up to 20 weeks. This is a draft plan and is not finalised. The final plan will take account of contingencies stated in the following section of the report. Fig 2. Project Plan Contingencies During the project events may occur which is beyond our control and therefore contingency plans will need to be provided. This will require some investigation as to what the contingencies will involve. However, at the moment the contingency plans should at least cover: Parts: Any required parts will need to be ordered in line for the appropriate stage of the project. We need to be prepared in the event that the parts are not available, or will take longer to arrive than originally expected. Therefore it is proposed that more than one supplier of parts should be available, along with potential websites where parts can be obtained from. Testing: Given that there are testing phases, we need to be prepared for the tests to fail and a continuing cycle will need to be provided in the existing project plan. The existing project plan is an ideal, logical situation, approaching a 14 week cycle. However, this is subject to be increased for up to 20 weeks and should be flexible. Staff Absence: The existing schedule takes account of possible staff absences. If the team is down by one or two members other employees should be able to continue the work. For specialised work, some of this may need to be put on hold or instructions left with telephone support in order to progress the process. Government Legislation: Prior to releasing the bike on to roads legally, it will need to be inspected to ensure that it conforms to the minimum requirements. Modifications may be forthcoming as a result of these. Therefore the design should be presented to the authorities in the early stages along with our proposals. We will also need to prepare the necessary paperwork for this to take place. Bibliography Articles A 'Naked' Bike with Real Power Kawasaki's Z750S Offers the Best of Two Bikes. 2005. Daily Herald (Arlington Heights, IL), September 12, 1. http://www.questia.com/PM.qsta=o&d=5010983601. US Patent Office. "Arrangement for filling fuel tanks of motor vehicles, especially of motorcycles." Patent Number 4811763. Great Tiding for Motorbike Racing. 2007.Manila Bulletin, December 25, NA. http://www.questia.com/PM.qsta=o&d=5024590873. Internet ebay member om3874. "BUYING HARLEY FXR GAS/FUEL TANKS." Reviews & Guides. 2007 Ebay. http://reviews.ebay.com/BUYING-HARLEY-FXR-GAS-FUEL-TANKS_W0QQugidZ10000000003205913. Envirowise. "Practical Environment Advice for Business." Environmental Legislation. http://http://www.transferflow.com/fuel_tank_regulations.html. Health and Safety website. "DISPENSING PETROL AS A FUEL HEALTH AND SAFETY GUIDANCE FOR EMPLOYEES." Health and Safety Home Pages. http://http://www.healthandsafety.co.uk/petrol.htm. Read More