Project Overview
The objective of the Bath Zero Emissions Motorcycle, New Motocross bikes division, was to design an electric off- road bikes to participate in the ACU motocross competition. As part of the new motocross bikes subsystem, this part of the project will be looking into the detailed cooling system design and bespoke passenger accommodation as well as their feasibility. These includes technical design calculations, detailed radiator and seat design, and cooling components selection.
The objective of the Bath Zero Emissions Motorcycle, New Motocross bikes division, was to design an electric off- road bikes to participate in the ACU motocross competition. As part of the new motocross bikes subsystem, this part of the project will be looking into the detailed cooling system design and bespoke passenger accommodation as well as their feasibility. These includes technical design calculations, detailed radiator and seat design, and cooling components selection.
My Contributions
I worked alongside a team of five members, each with distinct roles, to develop an off-road electric bike. My specific responsibilities were centered around the design of the cooling system and seat for this bespoke bike. I successfully computed the quantity of heat discharged by the motor and devised a cooling system that can effectively sustain the operating temperature of the motor. Additionally, I proposed a manufacturing procedure and costing plan that adhered to the product design specifications. To validate the efficacy of our design, I conducted Finite Element Analysis (FEA) on the bespoke seat and FEA thermal analysis on the radiator using Inventor Nastran.
I worked alongside a team of five members, each with distinct roles, to develop an off-road electric bike. My specific responsibilities were centered around the design of the cooling system and seat for this bespoke bike. I successfully computed the quantity of heat discharged by the motor and devised a cooling system that can effectively sustain the operating temperature of the motor. Additionally, I proposed a manufacturing procedure and costing plan that adhered to the product design specifications. To validate the efficacy of our design, I conducted Finite Element Analysis (FEA) on the bespoke seat and FEA thermal analysis on the radiator using Inventor Nastran.
Business model development
Engineering design
Cooling system design
Autodesk Inventor
FEA analysis
Product design and development
Heat exchanger design
Heat transfer calculation
The Project Timeline
Click to reveal details about the process
01
Technical feasibility and concept generation
This segment of the project focused on examining the technical feasibility of creating a customized cooling system and seat design. This involved assessing the technical difficulties and issues, creating design specifications, and generating concepts.
02
Business plan development
This stage involves evaluating and refining the ideas that were generated during the brainstorming session. This is where the team selects the most promising ideas and begins to develop them into design concepts.
03
Concept design research and development
Develop a detailed plans and specifications for the chosen solution. This stage includes proposing a detailed final design, technical research studies and suggesting future improvements.
Passive liquid Cooling System
A single loop passive cooling liquid cooling system was proposed for the motor and controller cooling. A total of 2.035kW of heat dissipated from the components was estimated, which would be transferred into the cooling loop with 63.8 °C of coolant temperature at the inlet of the radiator. The bespoke radiator was designed to be able to maintain the operating temperature of 60 °C of the motor at 45 °C ambient temperature. A coolant pump was chosen to mitigate pressure drops along the system and maintain coolant flow at of 9 l/m. The radiator was suggested to be installed in the front of the frame where maximum airflow intake is possible.
A single loop passive cooling liquid cooling system was proposed for the motor and controller cooling. A total of 2.035kW of heat dissipated from the components was estimated, which would be transferred into the cooling loop with 63.8 °C of coolant temperature at the inlet of the radiator. The bespoke radiator was designed to be able to maintain the operating temperature of 60 °C of the motor at 45 °C ambient temperature. A coolant pump was chosen to mitigate pressure drops along the system and maintain coolant flow at of 9 l/m. The radiator was suggested to be installed in the front of the frame where maximum airflow intake is possible.
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Bespoke radiator design
The bespoke radiator was designed to be able to maintain the operating temperature of 60 °C of the motor at 45 °C ambient temperature. A coolant pump was chosen to mitigate pressure drops along the system and maintain coolant flow at of 9 l/m. The radiator was suggested to be installed in the front of the frame where maximum airflow intake is possible.
The bespoke radiator was designed to be able to maintain the operating temperature of 60 °C of the motor at 45 °C ambient temperature. A coolant pump was chosen to mitigate pressure drops along the system and maintain coolant flow at of 9 l/m. The radiator was suggested to be installed in the front of the frame where maximum airflow intake is possible.
Bespoke seat design
Purchasing a suitable off-the-shelf seat module was initially considered to reduce complexity of the project. However, it was later discovered that there was limited data on the geometry of the proposed seat and therefore is unable to register the position of the mounting points to the frame. For this reason, a custom-made seat was put forward to alleviate the problem. The design was generated by studying 58 different off-road bike models in the market, to assist in the overall geometry and functional sitting area. The seat module will be divided into 2 parts, the seat base plate and seat foam. Both components will define the overall ergonomics, seat height and firmness.
Purchasing a suitable off-the-shelf seat module was initially considered to reduce complexity of the project. However, it was later discovered that there was limited data on the geometry of the proposed seat and therefore is unable to register the position of the mounting points to the frame. For this reason, a custom-made seat was put forward to alleviate the problem. The design was generated by studying 58 different off-road bike models in the market, to assist in the overall geometry and functional sitting area. The seat module will be divided into 2 parts, the seat base plate and seat foam. Both components will define the overall ergonomics, seat height and firmness.
The firmness of the seat foam was also a key factor for safety and comfort. Injuries such as tailbone injuries could be caused by excessively soft foam, especially in off-road conditions where jumps frequently occur. Therefore, the foam has to act as a cushion for these occasions. Rigid polyurethane foam for additional firmness was suggested. The foam can be freely trimmed for more ergonomic customisation. Other ergonomic features include the addition of humps or steps to prevent the rider from sliding backwards during instant acceleration
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