Chapter 1

Introduction

The thrill of the open road has called to millions of riders since the introduction of the
motorcycle over a century ago. Motorcycles offer an open and free riding experience, as the
operator can lean and swerve through turns of old country roads. One short coming of the
motorcycle is the discriminating nature of riding in regards to the physical ability of the
operator. Many handicapped riders are forced from their bikes forever. However, new systems
and applications of technology are re-opening the world of riding to people whose disabilities
have kept them off of their beloved motorcycles.
1.1 Background
In the case of this project, the customer was determined to be capable of controlling the
motorcycle at high speeds, but due to extensive nerve damage incapable of moving his feet
from the pegs to the ground when the bike must come to a stop. This made riding an
unmodified motorcycle impossible for him. The system designed during this project has been
created to aid the rider when he needs it, while providing an uninhibited riding experience
whenever possible.
The basis of the design consists of two smart outriggers extending one from each side
of the motorcycle. An on board microprocessor actively monitors vehicle speed through use of
the OEM gear tooth sensor located in the transmission. As the speed drops below the top
threshold set by the loaded program, the hydraulic deployment cylinder extends and locks the
system into its operating position. The secondary cylinder then provides a small amount of
force to cause the wheel to lower and follow the road. As speed further reduces, the secondary
cylinder becomes increasingly damped, providing more resistance to movement. Once the
motorcycle’s speed travels past the lower threshold, the secondary cylinder becomes fully
rigid and retains the bike in the upright position. Each out rigger is fully independent of the
other allowing the bike toremain upright even in the case of uneven roads. As the rider
increases speed from a stop, the system first becomes decreasingly damped, and finally
retracts fully up and out of the way, allowing the operator to return to normal motorcycle
riding.

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1.2 Problem Statement

Background:
In INDIA there were about 15 lakh accidents from which 1.5 lakh people are killed
from which 63% are motor cycle users.And in monsoon its graph is at hype. To overcome
such problem, we invented a new mechanism which installed in replace of the center stand and
reduce accident casualty for 2- wheeler riders.

● It is a new Idea not is in market as a product nor as a developing prototype.

● Life saving ideas are best ideas because life is priceless.

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 Chapter 2
Literature Review

This section represents new definitions of product design and development with
respect to sustainable design parameters, life cycle design and ecology design. This section
also gives ideas about the related studies done in the similar field of milling machine and
explores new fields to work on.

2.1 Review of literature

The group researched existing designs that might meet the objective, shown in Table
2.1. There were many trike solutions already available on the market including: the Delta
trike, a vehicle similar to a motorcycle with two wheels in the back and one in the front; the
Tadpole trike, similar to the Delta but with two wheels in the front and one in the back; and
the Sidecar option, a motorcycle with a buggy attachment used for stability.

After considering the option that the customer the customer may be capable of
controlling a motorcycle at speed the group research alternative designs. The designs
researched for this case included: the Ghost Wheels option, an arrangement allowing two extra
wheels in the back of the motorcycle to remain in contact with the ground at all times that can
be locked in an upright position at a stop; the Retract-a-Trike mechanism that allows a set of
“training wheels” to be deployed for stability under 18mph; and the Leg Up design, similar to
the Retract-a-Trike but the wheels are much smaller. All of the research for these designs is
described in detail in this document.

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 Table 2.1: Background of literation review

Existing Designs Description

Delta Trike (Figure 2.1) Two Rear Wheels, One Front Wheel
Sidecar (Figure 2.2) Buggy Attachment
Tadpole Trike (Figure 2.3) Two Front Wheels, One Rear Wheel
Leaning Tadpole (Figure 2.4) 45 degree of lean angle
Trike Alternatives (Figure 2.5 ) Attractive feature to many riders
Ghost Wheels (Figure 2.6) Three Rear Wheels Always in Contact
Retract-a-Trike (Figure 2.7) Deployable Training Wheels
Leg up (Figure 2.8) Deployable Small Wheels for Partial Stability

Figure 2.1 Delta Trike- Sportster Trike Conversion

The delta trike is a three wheeled motorcycle consisting of two wheels on the rear axle
The delta trike is a three wheeled motorcycle consisting of two wheels on the rear axle
(1F2R). This is the most common configuration and models have been commercially available
for many years. One of the reasons for its common use is its simplicity and ease of
manufacture. Most units start with a complete motorcycle and modify the stock swing arm to
accept a solid rear axle. The trike then retains the original motorcycle front end which is gives
the rider the perception of riding a motorcycle.

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 While delta configuration trikes give the rider a sense of stability, it was discovered
that this configuration can quickly become unstable. During 1980’s, Three wheeled ATVs
became popular in the off road community. A TIME Magazine article from Jan 1988 stated:
Costing an average of $2,000, they can cruise up to 50 m.p.h. and negotiate some of the
toughest terrain around, from sand dunes and rock-strewn hills to marshy lowlands. They are
also exceedingly dangerous. Nearly 7,000 people are injured in ATV accidents each month,
and an estimated 900 people have been killed over the past five years (TIME, 1988).
In 1987 the Consumer Product Safety Commission filed a lawsuit against the five major ATV
distributors, declaring ATVs an ‘Imminently hazardous consumer product’. The lawsuit was
settled in the spring of 1988 and a ten year ban was imposed.

Figure 2.2: Sidecar - Motorcycle Outfitted with Sidecar

Sidecars have been in use for approximately the last one hundred years. This is a
common design used to improve the low speed stability of motorcycles. A sidecar is an
additional component that is simply bolted to an existing motorcycle. While this design
benefits from improved stability during slow speed maneuvering, it suffers from a substantial
amount of flaws as well. The sidecar assembly adds a significant amount of weight and drag to
the vehicle that is massively off from the center of gravity. This makes the bike much more
susceptible to changes in handling characteristics due to road crown, and direction of turning.
As speed increases, drag of the sidecar increases and the operator must composite for this by
steering away from the sidecar. Another issue with this design is the difference in turning from

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one direction to the other. Turning into the sidecar can cause the inner wheel to lift, if this lift
is extreme enough,the vehicle can flip over. Turning away from the sidecar in extreme cases
can drive the nose of the sidecar into the ground, commonly resulting in the rollover of the
vehicle. Sidecars also exert additional loads on the stock motorcycle frame that were never
considered in the initial design. Overall, while the sidecar system improves low speed
stability, high speed stability requires not only an experienced rider, but is generally reduced
in comparison to other designs.

Figure 2.3: Tadpole Trike - BRP Spyder

The tadpole trike is a three wheeled vehicle configured so that the most forward axle
has two wheels. This design has increased in popularity over the years and recently has
become commercially available in the form of the BRP Spyder. Most custom units, like the
delta configuration, start as a complete motorcycle. The front end of the motorcycle is
completely removed and the frame is modified and extended to allow for mounting locations
for a double wishbone suspension. The tadpole configuration is heralded as the most stable
trike configuration. Its wide stance in the front makes it stable while braking and cornering.
The main drawback to this design is the sensation of driving a motorcycle is lost. Many have
compared it to driving a snowmobile on pavement.

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 Figure 2.4: Leaning Tadpole - Piaggio MP3

In recent years there’s been an effort to combine the stability gained by a tadpole trike
configuration, while retaining the motorcycle feel. Until the recent emergence of the Piaggio
MP3, leaning tadpole trikes had been limited to one-off customs. Piaggio took the concept and
created a line of three-wheeled scooters that use a unique front suspension consisting of
trailing arms and a parallelogram linkage. At slow speeds or while stopped, the linkage can be
locked into place allowing the trike to remain upright with no rider input. Other companies
like Tilting Motor Works are working to produce kits to convert a motorcycle to a tilting
tadpole configuration trike. Their design allows for 45 degrees of lean angle and has an initial
price point of $8,000 - $10,000 installed.

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 Figure 2.5: Trike Alternatives - Tilting Motor Works Prototype

Within the motorcycle trike conversion industry, there is a separate group of solutions.
These are commonly referred to as trike alternatives. These systems are designed to be added
to the existing motorcycle without major frame modification. These designs act as an aide to
the rider at slow speeds, but do not limit the vehicles movement at higher speeds. This is an
attractive feature to many riders looking for the traditional motorcycle experience. Another
promising aspect of this method is that it avoids many risks, by leaving the stock vehicle
design to that of the OEM Company. Trike alternatives are commonly lower in cost when
compared to that of full trike conversions. These designs offer a great opportunity for riders
that may only need minor assistance controlling their bikes.

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Ghost Wheels
Ghost Wheels is a system currently built and sold by the company Trike Alternatives
LLC. This arrangement uses two wheels that are constantly in contact with the ground. The
wheels hang out from each side of the motorcycle and pivot allowing normal leaning of the
vehicle. This can be seen in the pictures below.

Figure 2.6: Ghost Wheels- Unlocked at Speed (Left) Locked in Stationary Position

The pivoting action of the trailing wheels can be locked by a control located on the
handlebars. The control panel is composed of two switches. A toggle switch that allows the
rider to select either lock or unlocked operation; and a momentary switch that unlocks the
system to allow for leveling of the vehicle. This control allows the rider to lock the motorcycle
in an upright position as traffic, a streetlight or stop sign approaches. Once the bike is up to
speed again, the rider can release the locking mechanism and return to standard motorcycle
operation again. The Ghost Wheels system does have an integrated safety feature that
prohibits locking the wheels at speeds above approximately 18mph. This keeps the rider from
accidentally locking
The wheels while leaning through a turn and then not being able to level the vehicle
leaving the turn. The Ghost Wheels system is made possible through the use of hydraulics.
The pivoting arms are controlled by double acting hydraulic cylinders. These cylinders are
controlled through the use of solenoid valves. Each cylinder has a single valve connecting the
two ports of the cylinder to each other. When the system is locked, the valves are closed not
allowing any fluid flow from one side of the cylinder to the other. When the system is
unlocked the, the valve is opened allowing fluid flow and the free, albeit slightly dampened,
movement of the piston and thus trailing arm and wheel (Trike Alternatives LLC, 2011).

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Retract-a-Trike
Retract-a-Trike is another offering developed and sold by Trike Alternative LLC. The
system operates through the extension and retraction of out rigger like wheels. When the
wheels are down the vehicle is fully supporting its own weight with a rider onboard.
Retracting the wheels returns the vehicle to the standard motorcycle arrangement and riding
feel. These two conditions can be seen below.

Figure 2.7 : Motorcycle outfitted with Retract-a-Trike extended at rest (Left) in motion

Similar to the Ghost Wheels system, the extension and retraction is controlled by a
handlebar mounted switch. There is also safety feature which keeps the wheels from extending
at speeds above 18 miles per hour regardless of switch activation. This attribute exists to keep
from accidentally extending the wheels while the motorcycle is leaning through a turn and
potentially causing the rider to lose control of the vehicle. The Retract-a-Trike system offers
support and assistance when needed, and quickly retracts out of the way when not needed.
The Retract-a-Trike system is actuated through the use of hydraulics. The system includes a
small onboard 12-volt hydraulic pump and reservoir. When the rider activates the switch, the
pump turns on and a single valve directs the force to the extending port of the two cylinders,
one on each side, used to drive the out-riggers. When the switch is returned to the upright
position, a similar chain of events occurs causing the wheels to retract (Trike Alternatives
LLC, 2011).

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LegUp
LegUp is a new market offering to the trike alternative sector produced by Chopper
Designs. At first glance it is similar to the Retract-a-trike system offered by Trike Alternatives
21 LLC, but under closer examination the LegUp system is strikingly different. The LegUp
design involves two small wheels, one hanging out from each side of the bike. The wheels are
purposely design to be subtle in appearance. This can be seen in the pictures below.

Figure 2.8: Motorcycle outfitted with LegUp extended at rest (Left) retracted at rest

The LegUp system is operated by a handlebar switch. There is a built in safety feature
that prohibits extension above 10mph to remove the risk of incidental deployment. When the
wheels are extended, they are not intended to carry the entire weight of the bike. Chopper
Designs states that the rider should still step down to stabilize the motorcycle at every stop.
Along with standard manual mode, the system can also operate automatically through use of
the integral computer controller. In this mode, the wheels automatically extend as the bike
slows to approximately 7mph. As the vehicle then accelerates, the wheels are retracted as the
bike reaches roughly 10mph.
The LegUp system operates through the use of electric linear actuators. When the
computer or manual control signals to deploy the wheels, a small high torque linear actuator
moves the wheels into place. The wheels are also spring loaded. This helps the wheels
accommodate small differences in terrain changes as wheel as allow the bike to still slightly
lean even though the wheels are down (Chopper Design, 2011).

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2.2. Objective
The objectiveof the project is a one of the most important thing in project. The scope
as a guidelines to achieve the objective which the scope made their line to fix to make sure
over scope not involve with other scope. The objective totally makes sure followed the line of
the project what the project need to achieve.
Below is aobjective of this project:
● The main cause is to reduce the percentage of motorcycle accident.
● Making driver and pillion rider safe.
● Support the drive to get the balance control.

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 Chapter 3
Material Selection
____________________________________________________________________________
Material section is a main step in designing process to select the appropriate materials
for each element of the machine so that they can sustain all the forces and at the same time
they have least possible cost.

3.1 Relation of Materials Selection to Design

AISI 1018 mild/low carbon steel has excellent weldability, produces a uniform and
harder case and it is considered the best steel for carburized parts. AISI 1018 mild/low carbon
steel offers a good balance of toughness, strength and ductility. AISI 1018 hot rolled steel has
significant mechanical properties, improved machining characteristics and has a high Brinell
hardness measure.Specific manufacturing controls are used for surface preparation, chemical
composition, rolling and heating processes. All these processes develop a supreme quality
product that is suited to fabrication processes such as welding, forging, drilling, machining,
cold drawing and heat treating.

3.2 Chemical Composition

Element Content
Carbon, C 0.14 - 0.20 %
Iron, Fe 98.81 - 99.26 % (as remainder)
Manganese, Mn 0.60 - 0.90 %
Phosphorous, P ≤ 0.040 %
Sulfur, S ≤ 0.050 %

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3.3 Mechanical Properties

Mechanical Properties Metric Imperial

Hardness, Brinell 126 126
Hardness, Knoop (Converted from Brinell hardness) 145 145
Hardness, Rockwell B (Converted from Brinell hardness) 71 71
Hardness, Vickers (Converted from Brinell hardness) 131 131
Tensile Strength, Ultimate 440 MPa 63800 psi
Tensile Strength, Yield 370 MPa 53700 psi
Elongation at Break (In 50 mm) 15.0 % 15.0 %
Reduction of Area 40.0 % 40.0 %
Modulus of Elasticity (Typical for steel) 205 GPa 29700 ksi
Bulk Modulus (Typical for steel) 140 GPa 20300 ksi
Poissons Ratio (Typical For Steel) 0.290 0.290
Machinability (Based on AISI 1212 steel. as 100% machinability) 70 % 70 %
Shear Modulus (Typical for steel) 80.0 GPa 11600 ksi

3.4 Weldability

AISI 1018 mild/low carbon steel can be instantly welded by all the conventional
welding processes. Welding is not recommended for AISI 1018 mild/low carbon steel when it
is carbonitrided and carburized.

Low carbon welding electrodes are used in the welding procedure. Post-heating and
pre-heating are not necessary, although pre-heating can be performed for sections over 50 mm.
Post-weld stress-relieving also has benefits, like the pre-heating process.

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 Chapter 4
Layout Selection

4.1 solid modeling

The entire model has been designed with the help of designing software solid works.

Figure 4.1 :Side framePortable stage assembly

Figure 4.2 Portable stage assembly drafting

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Figure 4.3 Portable stage assembly Figure 4.4 Portable stage assembly

Figure 4.5 Locking frame with each other Figure 4,6portable stage assembly

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 Chapter 5
Result and discussion
_________________________________________________________________
5.1 working

Stability is a requirement critical for safe operation of a vehicle. Cases were made for
the importance for lateral and rollover stability. An emphasis was put on the rollover scenario
due to the increased difficulty to correct via driver input, and potentially catastrophic result. It
was decided that each configuration would be analyzed for rollover stability.

In order to analyze rollover stability, we needed to know the vehicles weight and
location of its center of gravity (CG). The weight was determined using corner weighting
scales. With individual weights of both the front and rear contact patches, we could easily
determine the lateral position of the CG. In order to find the vertical position of the CG, we
recorded the weights at both wheels on level ground. Another set of weights was recorded
with one wheel raised a known distance. Using trigonometry, the height of the CG could be
determined. A spreadsheet of this analysis can be found in the appendix.

Location of the CG on the existing motorcycle

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5.2 Project Flow Chart

From the flow chart, this project started with the objective of the project. The objective of the
project must follow the title. The objective must fulfill the title Then follow up with design
review about folding table and then study a lot of investigation about folding table. This is
including study about several of stage, type of stage, types of material which suitable to make
a stage. These tasks have been done through study on internet, books and others resources.
After all information had been collected and gathered, the project continued with the design
process. All the knowledge and lessons had been applied to make a suitable design for the
project. After several design sketched, design consideration have been made and one of the
design have been chosen by using Pugh’s concept selection. The solid modeling and
engineering drawing by using solid works software the fabrication process progress use
drawing as a reference. The process consist fabrication to all parts that have been designed by
the dimension using various type of manufacturing process. The manufacturing process
includes welding, drilling, bending, cutting and etc. During the fabrication process, if there
have error occur, such as fabrication error, so the process need to modification the process
need to go back to the previous step and the process flow again, until no error occur the
process can been continued smoothly until the final product finished. Then, the draft report
need to be submitted to the supervisor for double checking if there had an error.

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LITERATURE SURVEY

PROBLEM
DEFINATION

OBJEECTIVE

DESIGN OF PHYSICAL
MODEL

MATERIAL SELECTION
AND MEASUREMENTS

OPTIMIZATION

FABRICATION

CONFIRMATION TEST

CONCLUSION

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5.3 Cost Estimation
Raw Material Cost And Finished Product Cost:-

It includes the material in the form of the Material supplied by the “ Steel authority
of India limited” as the round bars Channels, angles, square rods , plates along with the strip
material form.Some of the items are cheaply available in the market and the comparative cost
of their manufacturing is more as compared to the market cost, hence we have purchased it
directly from market. We have to search for the suitable available material as per the
requirement of designed safe values.

Table 5.1 Cost of Project

Sr no Part name Mat Qty Prize

1 Splendor Bike STD 1 NO 15000

2 Linear Actuator STD 2 NO 3000

3 Aurdino Uno STD 1 NO 1400
4 LCD STD 1 NO 125
5 Accelerometer Sensor STD 1 NO 475
6 Power Supply STD 2 NOS 300
7 Switch STD 1 NO 20
8 MS Plate 5 MM MS 1 M2 450
9 Bush MS 2 NOS 400
10 Nut Bolts MS 10 NOS 50
11 Color SPRAY 1 CAN 180
12 Miscellinous - - 200

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 Chapter 6
Conclusion

The ability to deploy the system when needed and retract it out of place while at high
speeds was inspired by the Retract-a-Trike design discussed above. Using the motivation of
the Leg-Up design the group decided to create a fully automated system to retract and deploy
the outriggers based on the speed of the bike. The new design is unique in its ability to be
progressively damping and become increasingly rigid as the motorcycle speed decreases. The
team plans to continue work on the project in order to realize a fully functioning system for
the customer. Once the group has addressed the issues previously discussed in the bench
testing processes, road and conditional testing will be conducted to ensure the safety of the
customer while using the product. From there the team can begin to consider optimization of
the system to guarantee quality functionality throughout the lifetime of its use.

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 Chapter 7
Features scope

 No screws or tools – quick and easy set up

 Painted plywood deck – helps against moisture/damp ingress
 Locating lugs and securing locks – lock down the deck
 Wipe clean oil painted frame – low maintenance
 Durable staging system
 Slim line trolley – fits through single/double width doorways dependent upon frame
size
 One trolley stores and transports up to 3m2 of staging
 Compact/space saving
 Range of accessories available include steps, guardrails, skirting –
 complete solution
 Fully powder coated trolleys – offers a harder, more durable finish

Specifications
 Dance floor specification:
 20mm black plywood deck
 30mm mild steel box section x 2mm wall thickness
 Bended locks
 Mild steel locating lugs
 All MS construction storage trolley

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 REFERENCE

1) Outlawing a Three-Wheeler, Time, January 11, 1988, p. 59.

2) "Standards for All Terrain Vehicles and Ban of Three-Wheeled All Terrain Vehicles;
Proposed Rule". Consumer Product Safety Commission (Federal Register). 2006-08-
10. http://www.cpsc.gov/businfo/frnotices/fr06/066703.html.
3) J.Y. Wong, Theory of Ground Vehicles, Wiley, 2008.
4) J.C. Huston, B.J. Graves, and D.B. Johnson, Three Vehicle Dynamics, SAE Technical
Paper 820139, 1982, pp. 45-58.
5) Linkages Student Edition (Version 10.1.7.3) [Software]. (2012). Norton Associates
Engineering
6) EasyC Pro (Version 3.1.3.8) [Software] (2011). Intelitek, Inc.
7) Solidworks Education Edition (SP4.0) [Software]. (2011). DassaultSystèmes
8) ESPRIT 2012 (Build 19.0.3.1325) [Software]. (2012). DP Technology Corp.
9) Electrical Diagnostic Manual, 07 Sportster® Models. Harley Davidson Motor Group.
2007
10) Photos
11) Delta Trike - http://www.her-motorcycle.com/harley-sportster-2006-lehman-trike.html
12) Sidecar - http://www.hdforums.com/forum/hacked-conversions-and-trailering/289306-
new-liberty-sidecar.html
13) BRP Spyder - http://www.insideline.com/brp/can-am-
spyder/2007/photos/2007_brp_can-am-spyder_actf34_fd_3.html
14) Piaggio MP3 - http://motorcycleinfo.org/wp-
content/uploads/2010/04/mp3piaggio250.jpg
15) Leaning Tadpole – www.tiltingmotorworks.com
16) Trike Alternatives - http://trikealternatives.com/photos/
17) VEX Controller – http://www.vexrobotics.com/276-2170.html
18) Arduino Uno – http://arduino.cc/en/Main/arduinoBoardUno
19) chipKIT Uno32 –http://www.digilentinc.com/Products/Detail.cfm?
NavPath=2,892,893&Prod=CHIPKIT-UNO32

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