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1
2015 – 2016 Chainless Challenge
Sponsored by NFPA
Hosted by Parker-Hannifin Corp.
ME 470 Final Presentation
05/03/2016
Chaitanya Gadre, Arjun Krishna Kumar, Wai Hong Lee, Vi Vi Phung, Relwin Jay Singh, Chee Kang Yew
Advisor: Bruce Flachsbart
T.A: Conrad Smith
Simple Light Efficient (S.L.E.)
2
Motivations• Primary transportation: walking
• Biking requires 1/3 energy
• Bicycle + hydraulic fluid = energy storage
Chaitanya Gadre
3Chaitanya Gadre
Rules and Regulations• Competition Event
- Sprint• 200m straight course
- Efficiency• No pedaling
- Time Trial• 7.2 mile race
• General Rules- Chainless bike- Fluid Power
Course at the Great Park
Slalom
STARTFINISH
ParkingTent
Chaitanya Gadre 4
Our Objective
• No Chain
• Bicycle as lightweight as possible
• Reduce number of parts
Wai Hong Lee 5
System Layout1. Front Gear Train
2. Rear Gear Train
3. Hydraulic Pump
4. Reservoir
5. Accumulator
6. Hydraulic Motor
7. User Interface
8. Manifold
9. Circuit Box
Power Transmission
System
Hydraulic System
Controls System 1 2
7
3
45
6
8 9
Wai Hong Lee 6
Front Gear Train
• 2 mounting brackets, 8 tabs, 5 gears, 1 pump, and 1 gear hub
• 8-speed transmission
• Overall Gear Ratio: 1:4.22 – 1:12.92
• Speed Range: 350 rpm – 1050 rpm (Pedaling at 80 rpm)
Gear 1 (Crank)
Gear 2
Gear 3
Shimano Nexus 8-Speed Gear Hub (SG-8R36)
PGP-505Pump
Gear 4
Gear 5(Pump)
Mounting Tab
Mounting Bracket
Wai Hong Lee 7
Modified Front Gear Train
• FEA Solver: ABAQUS
• Factor of Safety: 1.6• Total weight reduction: 10.9 lb (46% reduction)
• Before: 23.8 lb• After: 12.9 lb
• Reinforcement plate added
Wai Hong Lee 8
Rear Gear Train• Rear Gear Train ratio: 5:1 to 8.33:1
• Overall Gear ratio: 1:0.5 to 1:2.58
• Rear wheel max RPM: 207 (Pedaling at 80 rpm)
• Theoretical max speed: 16.6 Mph
Relwin Jay Singh 9
Hydraulic CircuitManifold
Charging Valve
Discharging Valve
Regenerative Braking Valve
Pressure Gauge Needle Valve
Pressure Release
Valve
Relwin Jay Singh 10
Hydraulic CircuitDirect Drive Mode
(default)
Pedals
Pump
Accumulator
Rear Wheel
Manifold
Reservoir
Motor
C D R
Relwin Jay Singh 11
Hydraulic CircuitCharging Mode
Pedals
Pump
Accumulator
Rear Wheel
Manifold
Reservoir
Motor
D RC D R
Relwin Jay Singh 12
Hydraulic CircuitDischarging Mode
Pedals
Pump
Accumulator
Rear Wheel
Manifold
Reservoir
Motor
C D RC D R
Relwin Jay Singh 13
Hydraulic CircuitRegenerative Braking
Pedals
Pump
Accumulator
Rear Wheel
Manifold
Reservoir
Motor
C D RC D R
Relwin Jay Singh 14
Hydraulic CircuitCoasting Mode
(passive)
Pedals
Pump
Accumulator
Rear Wheel
Manifold
Reservoir
Motor
C D RC D R
15Chee Kang Yew
Hydraulic CircuitPump
• Pump: Parker-Hannifin PGP505-5
Specification Weight Factor
Rating Weighted RatingF11-5 PGP505-04 PGP505-05 F11-5 PGP505-04 PGP505-05
Displacement 3 5 2 5 15 6 15
Weight 4 2 4 3 8 16 12Size 4 2 4 3 8 16 12RPM 4 2 3 3 8 12 12
Input Torque 5 1 2 2 5 10 10
Efficiency 3 2 1 1 6 3 3TOTAL 56 66 67
Limited space for pump
16Chee Kang Yew
Hydraulic CircuitMotor• Motor: Parker-Hannifin F11-05• Simulink simulation • To compare the displacement and
velocity of the gear motor and piston motor• Estimated efficiency • Gear motor : 84%• Piston motor: 92%
17Chee Kang Yew
Hydraulic CircuitSimulink Plots
18Chee Kang Yew
Hydraulic CircuitReservoir• Whey Protein Container (2 Gallons)• Material: Plastic• Pros:• Lightweight• Low cost• Can be easily replaced
• Cons:• Thin wall
Reservoir with Fittings Attached
19Arjun Krishna Kumar
Hydraulic CircuitAccumulator
2014 – 2015
• Manufacturer : Parker Hannifin• Min: 1000 psi • Max: S: 3000 psi L: 4000 psi• Combined Weight: 44 lbs• Capacity: 1.25 gallons
2015 – 2016
• Manufacturer : Steelhead Composites• Min: 1000 psi • Max: 3000 psi • Weight: 8.7 lbs• Capacity: 1.34 gallons
20Arjun Krishna Kumar
Control System and User InterfacePCB and Simple Circuit
PCB
• Input Voltage: 12V DC• Lumex LCD Display Screen • ATMEGA 328P Microcontroller• Modes : Direct Drive, Charging,
Discharging, and Regenerative Braking
Simple Circuit
• Input Voltage: 12V DC• SPST and SPDT switches• Speedometer• Modes: Direct Drive, Discharging and
Regenerative Braking
SPST SPDT
Speedometer
21Arjun Krishna Kumar
Outdoor Testing• Bike Weight: 130 lbs• Mode Tested:
• Direct Drive• Pre-charge: 750psi, Charged to: 1500
psi• Regenerative Braking
Categories ResultsMaximum Speed 8.6 mphDistance Travelled 1.1 mi
Time Travelled 10 min 9 secsTime Brake 4 secs
22Vi Vi Phung
S.L.E. Performance
Event Time Place
Sprint 1 min 43 secs 6th
Efficiency N/A N/A
Time Trial 1 hr 3 mins 3rd
Maximum Speed 10.6 mph
23Vi Vi Phung
Results and Awards• 5th Place Overall
• 3rd Paper and Presentation $300• 3rd Time Trial $300• 3rd Cost Analysis $150
• Total Winnings $1750• $1450 to UIUC• $300 to Team Members
24Vi Vi Phung
Project BudgetPart Estimated Cost ($) Actual Cost ($)
Vehicle Components 200.40 180.40
Power Transmission Components 1236.39 872.67
Hydraulic Components 2400.75 325.99
Electronic Components 77.41 60.16
Machining Cost 800.00 800.00
Shipping Crate 85.95 85.95
TOTAL $4800.90 $2325.17
• Total Donated Parts: $2075.00
• Total Reused Parts: $400.73
• Comparison to Previous Year’s:
• Estimated Spending: 30% Lower
• Actual Spending: 37% Lower
25
Recommendations• Start building the bike early
• Test and debug early
• Get in touch with professionals
• Higher overall gear ratio
• Modify pump and motor
Chaitanya Gadre
26
Summary
Chaitanya Gadre
27
Acknowledgements• National Fluid Power Association• Parker Hannifin• Sandy Harper• Shell• Hydraforce
• David Ruxton
• Steelhead Composites• Mickey Salva
• HTE Technologies• Ryan Edwardson
• Neutral Cycle• Matt Crosby
• UIUC ECE Department• Jackson Lenz, Mark Smart
• MechSE Machine Shop• UIUC 2014–2015 Chainless Team• Prof. Bruce Flaschbart, Conrad Smith, and UIUC MechSE Faculty
28
APPENDIX SLIDES
29
Hydraulic CircuitManifold
30
Hydraulic CircuitManifold
31
Hydraulic CircuitAccumulator
• A lower pre-charge pressure allows
for more fluid to enter the
accumulator
• Higher amount of energy is stored
in the accumulator with a lower
pre-charge pressure
32
Cost AnalysisSingle Vehicle Prototype
33
Cost AnalysisSingle Vehicle Prototype
34
Cost AnalysisA Batch of 500 Vehicles
35
Cost AnalysisA Batch of 500 Vehicles
36
Lesson Learned