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Above picture is not a product of Ur-cycle company, just for illustration purpose only.

ME2101 Design Process Assignment


by

Chan Wah Hsing Lin Shao Dun

A0066122R A0066078X

Leong Kang Siang A0066104R

TABLE OF CONTENTS

BACKGROUND/RECOGNITION OF NEEDS

IDENTIFICATION OF CONSTRAINTS IMPOSED

SPECIFICATION AND REQUIREMENTS

FEASIBILITY STUDY

IDEA GENERATION AND DEVELOPMENT

DETAIL DESIGN

PRODUCTION OF DESIGN

DISTRIBUTION, SALE, USAGE

OBSOLESCENCE

CONCLUSION

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REFERENCE / APPENDIX

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BACKGROUND / RECOGNITION OF NEEDS

Carbon dioxide and other greenhouse gases emitted by automobiles and other human activities have been cited as major contributors to the global climate change [1] (Figure 1) base on tremendous scientific studies in the past few decades. [2] The rise of environmentalism has led to recognition that promotion of public transportation systems is one of the key aspects for sustainable and eco-friendly social development. However, despite the fact that public transportation systems are the most efficient mode of transportation by many metrics, they do not provide door-to-door flexibility or the short travel time of personal transportation modes (such as bicycles).

Figure 1

Figure 2

Ur-Cycle, a newly established company, aims to redesign the bicycles for urban use. In view of future rising cost in fossil fuel [3] (Figure 2) and increase pollution to atmosphere due to fossil fuel utilization, the company foresees a better designed bicycles has enormous potential. The company is planning to develop a new innovative bicycle that attempts to persuade car drivers to stop using their cars but to ride the bicycle for everyday transportation. Apparently, bicycle as daily transportation tool has many benefits, such as: Promote an efficient and clean way of transportation which has zero greenhouse gas emission. Reconcile the economic development in cities with the quality of life and environmental protection. Minimize the environmental impact. Reduce the fossil energy use and the economical / social cost.

With above explanations, a redesigned, innovative bicycle is essential for developing a lifestyle less dependent on cars so as to attain a green life style.

IDENTIFICATION OF CONSTRAINTS IMPOSED

After conduct a market survey (see Appendix B) of 50 candidates who driving car, here is the list of the concerns if change the transportation method to bicycle. Length of trip and travel time Absence of bicycle lanes Lack of secure bicycle parking Learn curve needed for riding bicycle ( instability feeling) Cycling is not comfortable in Singapore climate condition

Apart of car drivers concerns, safety regulation of motorized bicycle (complying with LTA law) [4] also need to put into consideration: The construction of a motorized bicycle must be similar to that of a conventional pedal bicycle; It must be powered by an electric source i.e. not petrol driven; Its motor's maximum power output must not exceed 200 watts; The electric motor can only cut in when the rider starts to pedal; and The electric motor must cut off when the bicycle reaches a speed of 25 km/hr or when the rider stops pedaling. This speed is comparable to the average speed of a moderately fit adult pedaling a conventional bicycle on level ground; The rider of the motorized bicycle must be at least 16 years old; The rider must wear a suitable protective bicycle helmet securely.

Other constrains as follow: The main target of this bicycle is workers. It is necessary to think about the profile and the habits of this group of people. The bicycle is an eco-product and this feature should be visible to end users. The maintenance and the starting of the electric bicycle should be fast and easy, reducing the necessity of tools. The bicycle must have lights to see and to be seen in the darkness. The bicycle will contain as much standard parts as possible. The price of the bicycle should not exceed S$400-S$700. The autonomy of the battery should be more than 50 kilometer. The bicycle should give to the user the possibility to choose the engine help level. The bicycle should be compact, light weight, foldable, easily to change shape for transport and ease storage.

SPECIFICATION AND REQUIREMENTS

Specifications Product Weights <=15kg Product able to withstand <=120kg of load Product dimension <= 1000mm X 800mm X 1100mm Traveling speed <= 25km/hr (if motorized bicycle are selected) Motors maximum power <= 300 watts (if motorized bicycle are selected)

Requirements Aesthetically pleasing Easy to use Comfortable Environmental friendly Economical Affordable (S$500~$800)

With the specifications, requirements and constraints identified. We proposed the design and construction of an Electric Scooter. The purpose-build electronic scooter is similar in operation to the conventional type currently available. However, many improvement and design concepts will be integrated into our design.
FEASIBILITY STUDY

After a long discussion with the design team, we had identified some factors that will decide the success or failure of our product. They are being generalized into 2 main standpoints: 1) Economical standpoint: Affordability: From the market surveys we gathered, majority of the people recommended the price range of S$500~S$800. Hence the sale price of our product must fall within this range, so as to attract people from buying it. Cost of product: In order to achieve maximum profits from our product, we need to keep the cost of the product as low as possible. And hence we are required to source for the cheapest manufacturer that could meet our quality standard. 2) Technical standpoint: Strength of the material selected: The strength of the material being selected must have a safety factor of 2 with respect to our design calculations, so as to avoid any unnecessary accident involving customers as it might tarnished the reputation of the company

Accessibility of spare parts: Spare parts of the bicycle must be easily be accessible so that repair work for our product can run smoothly without having the customer from waiting unhappily. Hence adequate spare parts must be stock earlier on to avoid such incident from happening.

IDEA GENERATION AND DEVELOPMENT

After comparing the advantages and disadvantage of existing bicycle designs (see Appendix A), we have a brainstorming sessions to generate some concepts, we shortlist our best 3 ideas that meet our specifications, requirements and constraints. They are: 1) Storage Bicycle: A bicycle that is able to store bigger stuff like briefcase, Laptop, luggage and etc. The 4x Clips that are being mounted at bicycle frame helps to do the tricks. It is most likely to be popular with office workers, as laptop and briefcase is an essential part of their daily working life. 2) Trolley Bike: A tricycle that is foldable to become a trolley. The 2 rear wheel of the tricycle helps the user to feels more balance and carry heavier load such as groceries, brief case. This product will definitely be welcome by housewives. 3) Foldable Scooter: A two wheeled foldable electric scooter that can enable user to effortlessly ride to anywhere, any place without having to get tired and sweaty. The additional foldable function allows it to be easily stored or hand carry to any places. *Please refer to Appendix C1~5 for sketches for the 3 designs. Product selections criteria:
Possible points 10 10 10 10 10 10 60 Storage Bike 5 5 10 8 6 3 37 2 Trolley Bike 8 7 8 6 4 3 36 3 Foldable Scooter 10 8 8 3 10 10 49 1

Ranking Criteria Innovativeness Appearance Easy to use Cost Speed Comfort Total score Ranking

Selection: Based on the product selection criteria, Foldable Bike emerged as a successful product in our idea generation. Our team decided to work further to realize product design of Foldable Bike.

DETAIL DESIGN INNOVATIONS OF REDESIGNED BICYCLE:

Parallel-Hybrid powered. Ez clip on foldable structure. Maintenance-free Twheel.

PARALLEL-HYBRID POWERED

A typically available lithium ion cell with an energy density of 201 Wh/kg [5] but a fuel cell has twice or more energy density than Li-Ion [6] [7] , which means it is suitable for of bicycle power source for larger range autonomy . Here is a block diagram of ParallelHybrid powered bicycle. (Figure 1) The main power source is a Solid Oxide Fuel Cell using natural gas which is easily available. Power management system will determine the distribution of power and the power usage scheme: When the bicycle is riding on low slope roads, electric motor will draw power from fuel cell only, extra power from fuel cell will charge the Li-Ion battery. When the bicycle is riding on uphill condition, both Li-Ion battery and fuel cell will be used to drive the motor. When the bicycle is riding on downhill condition, fuel cell can be throttled to minimum power condition and the electric motor now become a generator to charge the Li-Ion battery.

Li-Ion Battery Power Management and Motor Control Unit Fuel Cell

Vehicle Accessories

Motor / Power generator

Battery Level Display

Speed / Brake Control

Figure 1

Rider Inputs / Feedbacks

Detection of slope can be easily achieved by low cost MEMS type Triple Axis Accelerometer [8]; power management unit can be build base on Microprocessor PIC16F8XX series.

Here is an illustration of operation of Solid Oxide Fuel Cell [9] [10].

EZ CLIP ON FOLDABLE STRUCTURE

Here is an innovative simple mechanism to make the bicycle foldable. (Figure 2) This mechanism just uses one simple part to connect two tubular shafts together, the connector can engage to the fix part which mounts on a sheetmetal base plate. When it need to fold the bicycle (See Appendix X), just rotate the connector 90and move it upwards, until the two tubular shaft joins exposed, then the bicycle can be folded so that it can be easily carried onto MRT or bus or stored in convenience places.

Figure 2

MAINTENANCE-FREE TWHEEL

To ensure the bicycle is maintenancefree, Michelin Twheel is installed, which is a non-pneumatic mobility concept, will increase product reliability because it is maintenance-free, punctureproof, easy to mount and dismount and provides a longer service life than radial tires. [11] [12].
Figure 3

DETAILED OVERALL DESIGN

Please refer to Appendix C3~C5 for the sketch of detailed overall design of bicycle.
PRODUCTION OF DESIGN

Main structures are made by Sheetmetal, easy for mass production, low cost for manufacturing. To ensure the cost of the product is viable before it is launched to the market, we have taken the following steps in cost reduction: To source for cheaper raw materials. Improvise on existing motor design so as to reduce cost in R&D for new motor. Accurate sale forecast where mass production can take place accordingly. Use of tubular bar instead of solid material where appropriate. To shear and shape unwanted/obsolete areas after prototype, reduce materials, hence cost saving. To use recyclable materials where appropriate.

DISTRIBUTION, SALE, USAGE

Distribution of product can be easily achieved by following points: 24 hours convenience stores like 7-11 and cheers for easy accessibility to all buyers Supermarkets like Sheng Shiong and NTUC Fairprice are also another avenue. Sale of the product is as shown below: Estimated cost of production is $700.00 per piece Estimated selling price of device is $850.00 per piece Estimated profit is $150.00 for every device sold Advertising and Marketing can be classified under internal strategy and external strategy:

For internal strategy, the best way is to let our employees to test our product for a period not more than 1 month. Upon completion of 1 month, they could purchase it at a discount of 10%. Reason being for this is mainly because if even an employee purchase the product for his personal use, other buyers would have more confident in our product. For external strategy, we would propose collaboration with the National Environmental Agency. The purpose of this is to develop a bicycle culture and to educate the people about the environments crisis and save our environment for our future generations.

OBSOLESCENCE

Most of the electric bicycle can be classified as zero-emission vehicles because they emit no combustion products. Hence our electric bicycle will have significantly lower environmental impact than those automobiles and most importantly it is generally seen as environmentally desirable in an urban environment. Sheet metal and Aluminum tubes can be recycled; it can be scraped and used to manufacture other products. The amount of wastage at the end of useful life is minimal.

CONCLUSION

Our Electric Bicycle is generally small in size; it doesnt pose a threat to the space especially in a small country like Singapore, and buyers would not have to worry about the issue of parking problem. In addition to that, our electric bicycle has higher speed than normal bicycle as it is being powered by motor and this greatly minimize the effort of buyers. As for the pricing of our electric bicycle, our cost is much more cheaper as compared to the cars and most importantly, we dont used fuel which is not environmental-friendly. Lastly, we can conclude that our electric bicycle is compact, higher speed, minimum effort to run the bicycle, environmental friendly, abundant of energy (electricity) and lower cost. Based on the above advantages of an electric bicycle, I strongly recommend the production of the design not only for the benefits of the company, but also for the general well being and convenience of the people.

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REFERENCE
[1] Global Climate Change. (n.d.). Retrieved 2 18, 2010, from http://www.globalchange.gov/: http://www.globalchange.gov/images/cir/pdf/Global.pdf [2] The Discovery of Global Warming. (n.d.). Retrieved 2 21, 2010, from http://www.aip.org: http://www.aip.org/history/climate/summary.htm [3] Energy and Emissions Data. (n.d.). Retrieved 2 20, 2010, from http://www.env-ne.org/: http://www.env-ne.org/Publications-and-Data/Energy-and-Emissions-Data [4] LTA News release. (n.d.). Retrieved 2 26, 2010, from http://app.lta.gov.sg: http://app.lta.gov.sg/corp_press_content.asp?start=3dg0xkd0ist3c311hbqq6t2t7z3m0f47uxed640rf7zvcala6 4 [5] Power-to-weight ratio. (n.d.). Retrieved from Wikipedia: http://en.wikipedia.org/wiki/Power-toweight_ratio [6] Fuel Cell Power Source with Twice the Energy Density of Lithium Batteries. (n.d.). Retrieved 2 27, 2010, from http://news.softpedia.com/: http://news.softpedia.com/news/Fuel-Cell-Power-Source-withTwice-the-Energy-Density-of-Lithium-Batteries-6787.shtml [7] The utilization of regenerative fuel cell. (n.d.). Retrieved 2 27, 2010, from https://www.llnl.gov/: https://www.llnl.gov/str/Mitlit.html [8] Triple Axis Accelerometer Breakout - ADXL335. (n.d.). Retrieved 2 18, 2010, from http://www.sparkfun.com: http://www.sparkfun.com/commerce/product_info.php?products_id=9269 [9] How a SOFC Works. (n.d.). Retrieved 2 27, 2010, from Bloom Energy: http://www.bloomenergy.com/products/solid-oxide-fuel-cell-animation/ [10] Solid Oxide Fuel Cells. (n.d.). Retrieved 2 27, 2010, from Bloom Energy: http://www.bloomenergy.com/products/solid-oxide-fuel-cell/ [11] The TWEEL - radical new wheel technology. (n.d.). Retrieved 2 27, 2010, from http://www.gizmag.com/: http://www.gizmag.com/go/3603/ [12] News. (n.d.). Retrieved 2 27, 2010, from http://www.michelin.com/: http://www.michelin.com/corporate/actualites/en/actu_affich.jsp?id=17448&lang=EN&codeRubrique=4& actu=true

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APPENDIX A: COMPARISION OF CURRENT DESIGNS

Existing Designs
Normal Bicycle

Advantages Environmental friendly Very affordable Light in weight Can weave in and out traffic Durable Environmental friendly Compact (for storage purpose) Portable Can weave in and out traffic Affordable More balance Able to carry heavier load Environmental friendly Easy to ride

Disadvantages: Get tired and sweaty after long duration of riding Uncomfortable seat Not foldable Uncomfortable seat Get tired and sweaty after long duration of riding Require skill during unfolding Bulky Require more strength to ride Get tired and sweaty after long duration of riding Not foldable

Foldable bicycle

Tricycle

Quadricycle

Huge and bulky in size Allow more than 1 people to Slow speed ride Get tired and sweaty Balanced after long duration of Very useful for tour places riding Not foldable

Small size Electric Scooter/ bicycle

Effortless riding Environmental friendly Faster speed compare to normal bicycle Affordable

More accident prone due to effortless riding Require electric power to run the scooter Not foldable Short autonomy distance

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APPENDIX B: UR-CYCLE SURVEY FORM


Dear Sir/Madam, The purpose of this survey is to understudy Singaporean response to the concept of giving up cars and take up bicycle for their daily transportation. Please kindly take a few minutes to read through these questions and place a tick on the relevant box. Your cooperation would be deeply appreciated. Please be assured that your feedback will be kept strictly confidential and used for academic research purposes only.

tick where applicable / others: please specify.


1 What is your age group? 10 20 2 Gender: Male 3 Female 21 40 41 60 61 and above

Occupation: Admin/HR Professional Services Manufacturing Student Others

What is the max. amount of money that you are willing to pay for a multi-functional bicycle? $50-$250 $251-$500 $501-$800 $801 to $1000 >$1001

Please indicate the following factors that would significantly encourage you to travel by bicycle Ability to maintain appropriate professional appearance Clearly designated bicycle lanes

Length of trip and travel time Secure and sheltered bicycle storage facilities in Singapore Others: 6 What prevents you from giving up cars and take up bicycle for daily transportation? Weather Cars are more comfortable than bicycle Destination are too far away Cars are more safe and stable as compared to bicycle No bicycle Boulevards All of the above Others:

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APPENDIX C-1: STORAGE BIKE CONCEPT - CHAN

APPENDIX C-2: TROLLEY BIKE CONCEPT - LEONG

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APPENDIX C-3: FOLDABLE SCOOTER CONCEPT - LIN

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APPENDIX C-4: FOLDABLE SCOOTER CONCEPT - LIN

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APPENDIX C-5: FOLDABLE SCOOTER CONCEPT

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