Jon La Follette September 30, 2009 Period 5

Project Lead The Way – Introduction to Engineering Design

“Birth of the V-Rod”

While viewing the video “Birth of the V-Rod”, comment on each stage of the V-Rod’s development
as it relates to the design process.

What was the reason Harley-Davidson began to develop the V-Rod?

(Identification of the real problem).
Harley Davidson was losing sales because the younger generation wants the faster Japanese bikes.

What research did Harley-Davidson do regarding previous designs, patents, desired qualities, etc.?
(Research)
They first looked at the Harley racing team and at dragsters. They saw the VR 1000 engine in the bikes; it
was a liquid cooled engine and was able to run at higher RPM. Harley also looked at competitor bikes.

What possible solutions did Harley-Davidson consider once their research was completed?
(Possible solutions)
They first had the basic idea of putting a VR 1000 engine in a Harley frame. To get a better engine, they
decided to work with Porsche. Aluminum was used for the frame, and the frame was constructed using
hydroform technology to reduce the number of welds from 17 to 7. They also changed the frame from the
classing one-rail design on top to a two-rail design to improve the strength of the frame. To fit in a gas
tank, a plastic gas tank was molded and placed in the back of the bike; it was able to hold 4 gallons that
way. To cool the engine at idle, two small fans were strategically placed inside the bike. To help with air
intake, the radiator’s air intake had two vortex generators. They were small fins that drew in air as air
passed through it. The exhaust had two pipes next to each other, but to have the necessary 12L of air in
the exhaust, part of the exhaust was joined on the inside to form a chamber or air. With Porsche, a V-
Twin engine was created for the bike.

What process was used to evaluate the possible solutions and decide on a final choice?
A compromise was formed between the engineering and design team. The bike had to look good, but it
also had to be able to perform the way they wanted. Still, it was Willie Davidson who said the final yes or
no to the bike.

Discuss what technologies were used to create the 3-D models and the working drawings?
A CAD (computer-aided design) program was used to create 3D models. The Cad program allowed them
to create the parts on the computer and also put them together on the computer.

Describe the types of models that were created in the developmental stage?
A clay model of the engine was made. A model of the whole bike was made of clay, fiberglass, and metal.
The clay allowed to changes to easily be made and/or undone.
What problems developed during the mock-up and prototype stage?
The exhaust had to meet California standards for sound and emissions which required at least 12L of air
in the exhaust. There were too many welds in the original two-rail design which weakened the frame. The
gas tank couldn’t be mounted where it originally went, and a metal one could only hold 1 gallon of gas.
They had to put a radiator on the bike in a place that would both look good and cool the engine. In the
original design, the front tire was preventing air to get to the air intake. After that problem was solved, air
would just go into the radiator and then right back out.

Discuss the types of tests were performed to evaluate the final design before production.
The radiator was tested in a wind tunnel. The mock-up was given a test ride. The engine was given the
Düsseldorf test. It was simulated to drive for 500 hours in various terrains. Each engine would break and
then get remodeled. The engine that passed it was named the Revolution Engine. The bike was also tested
to see how it would handle at idle. It was first ridden to get the temperature of the engine up. Then it was
placed in a room enclosed on all four sides in a desert area. After some time, it was ridden for an hour and
placed in the same room. The prototype was given a real-life test on various terrains including a bump
course. The riders then gave their feedback. The sound was tested in an anechoic chamber. The anechoic
chamber eliminated echoes. The bike was given a hog wash which battered the bike with high pressure
water. A reverb chamber was used to send out various wavelengths at the bike to test for electrical
interference. Finally, each individual part was pounded, shaken, and battered until they broke. That tested
for weaknesses within the bike.

Discuss whether or not the final V-Rod design was a success for the Harley-Davidson company.
The final V-Rod design was a success for the Harley-Davidson company. The final design of the V-Rod
passed the Düsseldorf test. It was rumored that if a vehicle passed that test would survive the real world.
The bike also passed the other tests that pushed the bike to the limit. The final bike did of course look
good enough for Willie’s approval and preformed like how it was envisioned it would. When Harley
presented the V-Rod to the dealers, the dealers were impressed and liked it.