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Kylie Apelquist
Janna Al Nabhani
Xingyu Wang
Harvish Mehta
EDSGN 100 Section 9
Team Number 4
Submitted to Wallace Catanach
12/16/2013
Alcoa Project: BikeLion
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Table of Contents
Team Member Information...2
Abstract….3
Introduction….3
Executive Summary…..4
Mission Statement…5
Customer Needs Analysis….5
Needs vs Metrics Diagram….6
External Research
Benchmarking…7
Location…..10
Aluminum Recycling Process….10
Aluminum Properties….12
Various Forms of Campus Transportation….13
Concept Generation….14
Possible Concept Designs….15
Concept Selection……16
Concept Scoring…..17
CAD Model….18
Final Model….20
Maintenance Requirements….21
Final Design Description…..21
Conclusion…..22
References…23
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Team Member Information
Kylie Apelquist Janna Al Nabhani
[email protected] [email protected]
Xingyu Wang Harvish Mehta
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Abstract
Our group’s goal is to design and apply the intrinsic properties of aluminum to
improve the efficiency of energy and to increase the sustainability of the campus,
all while promoting the use of aluminum. Therefore, BikeLion is a bike renting
service, in which we turn down the energy consumption by making more of an
individualized and energy efficient way of travel. This is to be accomplished by
following the aluminum recycling process and making an all-purpose aluminum
bike to promote the use of clean energy and the re-use of aluminum.
Introduction
Aluminum is the most abundant metal found on Earth. However, it is not
found free in nature. Since aluminum is durable and sustainable metal about two-
thirds of the aluminum ever produced is still in use today. Recycling aluminum is
beneficial because making products with recycled aluminum uses 95% less energy
than products made with new aluminum. Recycling one aluminum can saves
enough energy to keep a 100-watt bulb burning for almost four hours or keep a
TV running for three hours.1
Alcoa is the world’s leading producer of primary and fabricated aluminum.
Alcoa was founded in 1888 and has now branched out into over 200 locations in
various countries. It has been the industry leader for aluminum for 125 years.
Alcoa has many products that are beneficial in industries of aerospace,
automotive, construction, electronics, and packaging. Its many sources of sales
come from the products that are made of aluminum. Some examples of products
that Alcoa makes are pieces of airplanes and cars, aluminum bottles, and
aluminum die-casting technology. The first product that Alcoa ever made was a
tea kettle.2
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Executive Summary
The Alcoa Agency has a need for improvement of the efficiency and sustainability of products used on campus by using products that are made of recyclable aluminum. Today, over 70% of the aluminum ever produced remains in use, because the increase in the efficiency of energy usage is of extreme importance. The objective of this project is to design a product that can increase the efficiency and sustainability of the campus and is also recyclable and environmentally friendly. The bike is needs to be lightweight but durable, so the weight of the aluminum frame should be about 15 lbs. The bike will have an adjustable seat to fit the needs of both short and tall people. The handle bars and the tires (solid rubber) of the bike will be made of rubber for grip of the road for the tires and the hands for the handle bars. The chain will be made of steel in order for durability.
Aluminum can provide solutions to meet these critical needs; its strength and light weight allow aircraft and ground vehicles to save fuel while providing us with the performance that is needed. Knowing this, our conceptual basis from the customer needs was defined by recyclability and sustainability, paired with promotion and efficiency. Concept scoring was done after the needs-matrix chart was, and five concepts were selected for scoring. For example the bike will have solid rubber tires, and the bike frame will be made of aluminum with the frames of the front and back wheel. The bike will be light, sturdy, and for the most part effective.
There are risks that can arise with the creation of this problem. One risk is
customers can abuse the system and take the bikes for an extended period of time, which does not allow others to use it. Also customers may steal the bike completely or break the bike. This risk will be minimized by designing a bike that looks different from other bikes that students may have on campus. Also each student or professor will have the bike for not cost for up to 30 minutes and then money will be charged from the ID card of the customer if the bike is not returned in 30 minutes. Finally the violator will have to pay for the bike itself through Bursar Tuition Bill if the bike is stolen or damaged. BikeLion is effective way to use aluminum and this project will hopefully be implemented by March 1, 2017.
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Mission Statement
Our mission for this project is to design a product that is made of
lightweight aluminum that can be used all across Penn State’s campus and
eventually other college campuses. The bike will be accessible to all students and
staff of the university and have a safe design to keep the customers safe. To keep
the bike sustainable and energy efficient, the bikes will go through a recycling
process in order to keep the bikes in the best condition without using new
aluminum to create a new bike.
Customer Needs Analysis
Our customer needs were based off of two surveys that we created. We asked
simple questions about recycling, aluminum, transportation around campus, and
thoughts on bikes. We found that most customers wanted a bike rental system on
campus, but they wanted the bikes to be safe and inexpensive. They would also
want a bike that could be recyclable and made of recyclable material.
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Needs vs. Metrics Diagram
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External Research
Benchmarking
Our group researched bicycle rental systems in the U.S. and other
countries. We found there were three similar design ideas to our concept. They
are located in Washington DC, Paris, and Hangzhou. The one most similar to our
bike is the Vélib bike in Paris, France. This bike design and BikeLion have a similar
build and cost. Below is the research we found on each of the three bicycles.
Capital Bikeshare3- www.capitalbikeshare.com
Location: Washington D.C., Arlington, Alexandria and Montgomery County. Operator: Alta Bicycle Share, Inc. Bikeshare Equipment Manufacturer: Public Bike System Company (or Bixi.)
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Vélib'4- http://en.velib.paris.fr
Location: Paris Operator: JCDecaux Equipment Manufacturer: Cyclocity Inc.
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Hangzhou5
Location: Hangzhou Operator: Hangzhou Public Transport Bicycle Service Development Co. Equipment Manufacturer: Tianjin Flying Pigeon Bicycle Manufacture&Research Co.
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Location6
Location for the bike rental stations is very important for the convenience
of the staff and the students who use it. We decided on have 21 stations on
campus. We essentially placed a station where there would be a majority of
students. The diagram below shows how we placed the stations. There are bluish-
purplish dots on the graph that represent the location of the stations.
Aluminum Recycling Process7
Through research we found how the aluminum is producing and recycled in
order for the use. To make aluminum bauxite is mined and then the alumina it
creates is refined which will be smelted down. Then the smelted down aluminum
would be casted and sheets of aluminum would be produced. After the aluminum
products were made, the consumer would purchase these products and use
them. Once the products were useless and done, they would be recycled and
shredding down again and decoated of the labels. Then it would be remelted
down and the process would start over. This process can be seen in the first
picture below. However, through our research we found that by starting our
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products with recycled aluminum and not virgin aluminum about 95% of energy
would be saved. So our process which can be seen in the second picture just
starts with the aluminum recycling process.
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Aluminum Properties8
Light Weight
o Aluminum is a very light metal with a specific weight of a 2.7 g/cm³,
about a third that of steel.
o Its strength can be adapted to the application required by modifying
the composition of its alloys.
Corrosion Resistance
o Aluminum naturally generates a protective oxide coating and is
highly corrosion resistant.
o It develops a thin film of aluminum oxide which then stops any
further corrosion.
Electrical and Thermal Conductivity
o Aluminum is an excellent heat and electricity conductor and in
relation to its weight is almost twice as good a conductor as copper.
Because of this many electrical lines have been switched to Al.
Reflectivity
o Aluminum is a good reflector of visible light as well as heat, and that
together with its low weight makes it an ideal material for reflectors
in, for example, light fittings or rescue blankets.
Ductility
o Aluminum is ductile and has a low melting point and density.
o In a molten condition, it can be processed in a number of ways. Its
ductility allows products of aluminum to be basically formed close to
the end of the product’s design.
Recyclability
o Aluminum is 100 percent recyclable with no downgrading of its
qualities.
o The re-melting of aluminum requires little energy; only about 5
percent of the energy required to produce the primary metal initially
is needed in the recycling process.
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Various Forms of Campus Transportations
When choosing a form of transportation that was used widely across
campus, we found the four most popular forms of transportation are walking,
riding a bike, riding the bus, or skateboarding. We compared riding a bike and car
and which would get more use. Through the surveys, we found bike would be
more popular if it was available. We also found that bikes are more energy
efficient when being made and used. The first graph shows that bikes do not
produce carbon dioxide emissions like cars do.9 The second graph shows many
more bikes are being produced compared to cars.10
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Concept Generation
These graphs show the how our concept will work through the problems needed
to be met be our consumers. We also made a concept generation on the
functionality of use of the BikeLion rental system (shown by the second graph).
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Possible Concept Designs
These are the three concepts our group came up with that could be possible
designs. We took the concepts and made a concept selection matrix in order to
see what design would fit the needs of our customers the best.
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Concept Selection
Our group used the concept selection matrix we created below in order to see
what concept was the best. After going through the selection criteria, which is the
customer needs, we decided that the best possible design was concept A. This
was moved on in order to make a CAD model and our final project.
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Concept Scoring
Our group also created a concept scoring matrix to put the concepts on a
weighted scale to double check to make sure concept A was the best idea for this
project. From the weighted scale we found that it still was the best concept,
which we then made a CAD model.
Concepts A B C Selection
Criteria Weight Rating Weighted
Score Rating Weighted
Score Rating Weighted
Score Widely Used 10% 4 0.4 4 0.4 4 0.4 Energy
Efficient 5% 4 0.2 4 0.2 4 0.2
Light Weight 5% 3 0.15 2 0.1 3 0.15 Recyclable 15% 4 0.6 2 0.3 3 0.45 Durable 15% 5 0.75 3 0.45 3 0.45 Environment
Friendly 5% 4 0.2 2 0.1 3 0.15
High
Performance 5% 4 0.2 2 0.1 3 0.15
Made by
Aluminum 20% 4 0.8 3 0.6 3 0.6
Little Energy
Produced 5% 2 0.1 2 0.1 2 0.1
Safe 10% 4 0.4 3 0.3 4 0.4
Low Cost 5% 2 0.1 3 0.15 3 0.15
Alternative
Designs 0% 1 0 1 0 1 0
Total
Score 3.9 2.8 3.2
Rank 1 3 2 Continue develop no No
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CAD Model of Bike and Station11
This is the CAD model of our bicycle and an individual station.
This is a CAD model of our bike that will we be creating.
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This is a CAD model of our bike station with the card swipe to unlock the bike
from the station.
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Final Model
These two pictures are of our bicycle that we created. The design and the station
match the CAD models of the two things. We also put our logo on our bike station
to show the name of our product.
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Maintenance Requirements
There will be some maintenance with our product. First if the bikes were to
break, we would either have to fix them on campus if it was a minor problem or
we would have send it away and be remelted down and built for a new bike. The
stations would also need maintenance to make sure the locks and the card reader
work properly in order for the customers to get full advantage of the product.
Final Design Description
There was no budget for our product. However, we tried to make the
amount of money students or staff members pay for the bike rental as
inexpensive as possible. Also, we tried to make the bikes and stations as
inexpensive as possible while keeping the bike safe and comfortable for the
customers. Our final design of the bike had an aluminum bike frame and pedals
with a steel chain, rubber tires that were inflated, rubber handle bars, and rubber
seat with foam inside. The stations final design has a lock right below the handles
of the bike where the handles connect with the bike frame. Each station will have
a card swipe on the right side in order for the IDs to unlock the locks.
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Conclusion
Our group successfully designed an aluminum bicycle that meets the needs
of the customers of Alcoa. BikeLion will be a rental system for all students and
professors with a valid Penn State ID card. There will be 21 bike stations located
throughout campus with 15 bikes at each station. The bike will also be recyclable
and be able to go through the aluminum recycling process. Our bikes and stations
will be made of already recycled aluminum rather than virgin aluminum because
then it will save 95% of energy and it will cost less to make.
Our aluminum bicycle would be a product that Alcoa would want to create
and sale because it is a great idea and energy efficient since it will save energy in
production of the bikes and keep people from using harmful forms of
transportation. Hopefully with this design, colleges and universities will
implement our bike rental system onto their campuses to not only help the
environment, but to give their students and staff a form of transportation.
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References
1. Facts About Aluminum Recycling. http://earth911.com/recycling/facts-
about-aluminum-recycling/
2. Alcoa. http://www.alcoa.com
3. Capital Bikeshare. www.capitalbikeshare.com
4. Vélib. http://en.velib.paris.fr
5. Hangzhou Public Bike.
http://www.travelchinaguide.com/cityguides/zhejiang/hangzhou/public-
bicycle.htm
6. Campusmaps.psu.edu. http://www.campusmaps.psu.edu/explore/
7. Novelis. The Recycling Process. http://www.novelis.com/en-us/Pages/The-
Recycling-Process.aspx
8. LennTech. Aluminum-Al.
http://www.lenntech.com/periodic/elements/al.htm
9. FuturePundit. Energy Production and Usage Graph.
http://www.futurepundit.com/archives/007812.html
10. Mission Local. ½ Prius, ½ Bike- Electric Bike.
http://missionlocal.org/2009/12/half-prius-bike-electric-bikes/
11. Grab CAD. http://grabcad.com/library/velo-1
