Table of Content

TABLE OF CONTENT
TITLE PAGE
NO
ABSTRACT………………………………………………………………. iii
ACKNOWLEDGEMENT ……………………………………………… iv
LIST OF FIGURES …………………………………………………….. vii
LIST OF TABLES ……………………………………………………… viii
ABBREVIATIONS……………………………………………………… ix
NOTATIONS……………………………………………………………..
Chapter 1 INTRODUCTION
1.1 General……………………………….. ……………………… 1
1.2 Types of Analysis ...……………………….………..………… 2
1.3 Literature Review…..………………………..……………....... 4
1.4 History of Motorcycle frame and pannier. ....………………… 5
1.4.1 Types of frame ………………………………………………..
1.5 Types of Pannier ……………………………………………… 6
1.6 Scope of Work……………………………………………….... 6
1.7 Objective ……………………………………………………...
1.8 Methodology………. ………………………………………… 7
1.9 Organization of Thesis ……..………………………………… 7
Chapter 2 GEOMETRICAL SPECIFICATION OF MOTORCYCLE

WITH PANNIER
2.1 Introduction…………………………………………………… 8
2.2 Geometry of Motorcycle Frame.…………………………….… 8
2.3 CAD Model of Pannier Assembly……………………………. 11

LIST OF FIGURES
FIGURE PAGE
TITLE
NO. NO.
1.1 Himalayan motorcycle with pannier assembly…………………. 9
1.2 Single cradle frame……………………………………………... 10
1.3 Double cradle frame……………………………………………. 10
1.4 Tubular backbone frame……………………………………….. 13
1.5 Monocoque frames…………………………………………….. 14
1.6 Honda CBR650 made of aluminum (Twin spar frame)……… 16
1.7 Omega frame of motorcycle…………………………………… 17
1.8 Perimeter frame (CBR600R)…………………………………… 19
1.9 Himalayan bike frames…………………………………………. 19
1.10 Olden days animal pannier…………………………………… 20
1.11 21
Motorcycle pannier assembly…………………………………...
1.12 Methodology Chart……………………………………………... 22
LIST OF TABLES
TABLE TITLE PAGE
NO. NO.
2.1 Specifications of himilayan motocycle board................................ 15
2.2 Material properties of pannier rail assembly…………………….. 18
2.3 Pannier rail assembly dimensions……………………………….. 20
3.1 Description of material…………………………………………... 21
3.2 Material properties with reference to components………………. 25

ABBREVIATIONS
FRF Frequency Response function
DFMA Design For Manufacturing and Assembly

PSD Power Spectrum Density
CHAPTER-1
INTRODUCTION
1.1 GENERAL
A motorbike has as characterizing attributes which are its high firmness, high capacity to-
weight proportion, flexural oppos
Dr. Bhaskar Rao. L
Faculty
Advisor
Project Gear Levers of heavy commercial vehicles are subjected to range of
Abstract forces (shifting and selecting) by the driver depending on their travel.
Unfortunately this suffers from inevitable variations due to different
driving styles and individual driver interpretation of a given gearshift.
Gearshift quality has traditionally been determined by subjective
assessment conducted by test drivers. Shift quality discussions are one
of the central topics during the development phase of transmissions.
The specification sheets set out characteristic values related to the shift
quality. So our aim is to design and manufacture a modular test rig to
test the endurance strength of gear lever for designated number of
cycles and analyze gear lever free play and driver effort for executing a
gear shift.
The various approaches for conducting this endurance test include
complete automation of Force Application, Closed loop Load
Accelerators, Simulator Setups. We will be performing the test of
PUSH-PULL Actuators which are well within our manufacturing,
Economical, Feasibility Constraints. Moreover, the project demands
reduction in test set up lead time through modular design of rig thereby
allowing reduction in fatigue of test workers. Since, the test rig has to
replicate realistic conditions thus it is important to design the actuator
and gear lever mounting structures so as to avoid deflection and
vibration of columns.
We will prepare the modular setup Initially And then use the load cell
and other sensors to control the Travel of the Gear lever. The pressure
regulators and valves for the actuators will be synced with the required
Travel distance to apply the designated load for stipulated time period.
Further, load bearing columns and channels have to be designed to
minimize deflection and vibrations in the setup. Since, gear levers are
generally mounted at an angle to the plane of the engine and gearbox,
thus provision for angular adjustment also has to be provided to
accommodate gear lever positioning. Provisions also have to be made
for CSO cable routing for efficient force transmission from gear lever
to gearbox.
Safety has become a priority in modern vehicles be it
commercial or passenger vehicles. Here comes the role of RUPD and
FUPD. These are rear under-run protection device and front under-run
protection device which offer protection against under running of
vehicles during rear or frontal impact thus affecting engine as well as
the steering system and preventing loss of life. The aim of the project
is to design a test rig for testing the durability of RUPD and FUPD by
replicating realistic conditions during the test.
List codes BED Bolts Size M16x100 - IS: 2269-1967-4D
and ASSEMBLY Threads M16x1.5 - IS: 4218-1967
standards Lock Nuts Size M16 - IS: 1367-1961-4D
that Threads M16x1.5 - IS: 4218-1967
significantly Washers Size Machined Washer 17 IS: 2016-
affect your 4D
project. ACTUATOR COLUMN Material BSK46 ( ARAI code 123 )
SUPPORT Threads M16x1.5 - IS: 4218-1967
COLUMN Threads M16x1.5 - IS: 4218-1967
ASSEMBLY
Cable Material MS
Mounting Bolts M16x100 - IS: 2269-1967-4D
Brackets
CSO Gear Lever Material MS
FIXTURES Mounting Bolts M16x100 - IS: 2269-1967-4D
Automotive IS 14272
RUPD requirement
standard
A) Economical:
List at least
Many of the advanced technological options and equipments cannot be used
two
due to the cost curtailment of company.
significant
realistic  Servo Pneumatics: Cost and maintenance of servo motor is very high
design and specialized encoder required in integrating the system with the test
constraints setup.
that are  Robotic Arm: The precision obtained by employing an armed robot
applied to will be very high but the setup and maintenance cost will be very
your project. much.
 CSO Cables: the complete modular arrangement of the test setup
depends on the routing of cables so that efficiency is maintained and it
does not experience any unrealistic loads during test.
B) Manufacturing:
 Realistic Conditions differ for each truck (the loading conditions and
the overall length) and hence each component cannot be manufactured
every time which will attribute to the increased cost.
 Availability of the size of test rig in the company premises (CTL lab)
determines the new manufacturing involved as the already available
test rig reduces the cost.
C) Sustainability:
 All the components, Equipments and fixtures are mounted on the same
test rig so that closed loop structure is formed to nullify the reaction
forces experienced by different members.
 The Gear lever and its mounting are designed such that it can
withstand lakhs of cycles for the straight shift gates and cross shift
gates..
 Electric Actuators which are cheap and offer high precision cannot be
used due to the AL standards which state that Durability/ Endurance
test cannot be performed with Electric actuators.
Briefly CSO
1) COST OF MODULARITY: use of studs instead of lead screw mechanism
explain two
for cso cable mounting.
significant
trade-offs
2) EASE OF USE VS POSITION ACCURACY: use of push pull actuators
considered
instead of rack and pinion assembly for gear shift and select force application.
in your
design,
including RUPD
options 1) LOAD BEARING CAPACITY OF ROLLER VS LEAD SCREW:
Forces of 16 ton is applied during impact which makes use of rollers for linear
considered
motion difficult. Thus, lead screw is used.
and the
solution
2) TEST RIG SIZE CONSTRAINT: Use of horizontal actuator requires
chosen
large component of forces to be balanced thus significantly increasing the size
of the test rig. Hence, vertical mounting of actuator is provided.
Describe the
1) Use of Solidworks and CATIA for designing of components and assembly.
computing
aspects, if
2) Use of National instruments Lab View for programming microcontrollers to
any, of your
map the path of gear lever.
project.
Specifically
identifying
hardware-
software
trade-offs,
interfaces,
and/or
interactions
===//==
===//==
1. Titikshya Biswal, Lokavarapu Bhaskara Rao, “Analysis of the magnetic field for MR damper
working in shear mode”, International Journal of Structural Engineering, Vol. 7, No. 1,
(2016), pp. 48-62.
2. Vipin. V. Gopal, Lokavarapu Bhaskara Rao, “Design and analysis of gasket cutting machine”,
Mediterranean Journal of Modeling and Simulation, Vol. 5, No. 1, (2016), pp. 046–058.
=====//
=====//

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TABLE OF CONTENT

LIST OF FIGURES …………………………………………………….. vii

LIST OF TABLES ……………………………………………………… viii

1.1 General……………………………….. ……………………… 1

1.2 Types of Analysis ...……………………….………..………… 2

1.3 Literature Review…..………………………..……………....... 4

1.4 History of Motorcycle frame and pannier. ....………………… 5

1.4.1 Types of frame ………………………………………………..

1.5 Types of Pannier ……………………………………………… 6

1.6 Scope of Work……………………………………………….... 6

1.7 Objective ……………………………………………………...

1.8 Methodology………. ………………………………………… 7

1.9 Organization of Thesis ……..………………………………… 7

Chapter 2 GEOMETRICAL SPECIFICATION OF MOTORCYCLE

2.3 CAD Model of Pannier Assembly……………………………. 11

1.2 Single cradle frame……………………………………………... 10

1.3 Double cradle frame……………………………………………. 10

1.4 Tubular backbone frame……………………………………….. 13

1.5 Monocoque frames…………………………………………….. 14

1.6 Honda CBR650 made of aluminum (Twin spar frame)……… 16

1.7 Omega frame of motorcycle…………………………………… 17

1.8 Perimeter frame (CBR600R)…………………………………… 19

1.9 Himalayan bike frames…………………………………………. 19

1.10 Olden days animal pannier…………………………………… 20

TABLE TITLE PAGE

2.1 Specifications of himilayan motocycle board................................ 15

2.2 Material properties of pannier rail assembly…………………….. 18

2.3 Pannier rail assembly dimensions……………………………….. 20

3.1 Description of material…………………………………………... 21

3.2 Material properties with reference to components………………. 25

FRF Frequency Response function

DFMA Design For Manufacturing and Assembly

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