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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.)

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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

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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

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Summary

Chaitanya Gadre

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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

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APPENDIX SLIDES

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Hydraulic CircuitManifold

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Hydraulic CircuitManifold

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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

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Cost AnalysisSingle Vehicle Prototype

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Cost AnalysisSingle Vehicle Prototype

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Cost AnalysisA Batch of 500 Vehicles

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Cost AnalysisA Batch of 500 Vehicles

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Lesson Learned