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Content
About VELO CHIC Product Requirements Concept Development Design Finalization Material & Process Bill of Material CAD Documentation Final Design 5 15 19 51 73 78 91 117 133
About
VELO CHIC
Project Goal
The goal of this project is to get more people to start cycling for urban transport.
Problem S tatement
Bicycles are one of the key elements for entering a sustainable future. However, compared to other advanced countries, the American bicycle culture is small. In 2009, only 4% of daily trips were made on bicycles in America. Because of the huge car culture and the commuting pattern, bicycles have been perceived as a method of exercise rather than a form of transportation that can help people get where they need to go.
Hypothesis
In the U.S., if a design can renew womens perception of bicycling and improve their cycling experience, then,In the U.S., People will be more likely to use bicycles for transportation and the American bicycle culture will expand.
Target User
Non-bicyclists Female users Living and Working in Metropolitan areas Living alone Living in a small studio
User Persona
Nancy Habitation: Metropolitan Area Age: 38 years old Occupation: Office Manager Working Location: Metropolitan Area Annual Income: $ 40,600 Personality: Punctual, Neat and Tidy Likes: Freedom, Healthy Food, DVDs, Dislikes: Complicated Mechanisms, Wasting time, Energy Consumption Education: Bachelors Degree in Financial Management Living Situation: lives alone in downtown area, Dreams: Saving money to travel around the world in her retirement. Vehicle: a member of Zip Car
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Task No.
Scenario
Task
Jenny prepares a lunch box for herself and put it and her work suit into two bicycle panniers.
Jenny gets her folding bike out Jenny attaches Jenny put her of her walking bicycle clothing on bike lights (front closet and unfolds and rear) and two and gets the other it. She spends things she needs panniers to her 6~7 minutes on bike. into her backpack. unfolding her bicycle. Unfolding my bicycle is tiring Bicycle clothing is and complicated. Can I have a not stylish. Can I have more stylish more efficient way way to transport to storage my bicycle or Can I everything I need use my bicycle as to work? a decoration in my apartment?
Jenny walks her bike out of her Jenny lifts up her room and uses bicycle to get over the elevator to the stair in front transport her bike her building. and herself down to the 1st floor.
Jenny tries to ride uphill but at the middle of hill, she starts to walk her bike to get over the hill.
Task Analysis
Consideration
Can I put on my work suit and ride to work without getting dirty?
Can I have a bicycle that comes with bike lights (front and rear) and storage space for my belongings?
Can I have a bicy- Is there a way that can help me to cle that is easy to bring in and out of move my bicycle elevator and wont up or down stair take to much without spending a lot of energy? space?
Jenny
rents a small studio in downtown, San Francisco. Her office is 5 miles away from her studio and she needs to dress formally for her job. For cost saving and weight losing, she starts to ride her bike (Dahon 20 folding bicycle) to work and runs some errands. After couple of days bicycle riding, she thinks that riding bicycle is inconvenient and makes her tired.
Paint - Points
Bicycle clothing is not stylish. Work suit is taking space of my limited storage space.
Its hard to bring my bike in or out of a small elevator especially when I share the elevator with other people.
Electric power assist system Integrated storage space Detachable storage space Flexible storage space Skirt guard Chain guard chain-less transmission system
Functionality
small size bicycle small wheel (16) a folding bicycle can be folded without bending or can be folded with one hand simple mechanic
small size bicycle small wheel (16) a folding bicycle can be folded in a short time
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Task No.
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Task No.
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Scenario
After work
Scenario
Home!!
Task
Jenny stops her bicycle in front of her office building and walk her bike into her office.
Jenny detaches the front and rear bike lights and put them into her backpack.
Jenny detaches the bicycle panniers and put them on her table
Jenny starts to fold her bike to make it smaller find a corner to lean on.
Jenny brings her work suit with her to the rest room and redress herself.
Jenny put her backpack and panniers under her working table and start to work
On the way home, Jenny ride to supermarket to buy some food for her dinner.
Task
Jenny parks and locks her bike in front of the supermarket with a sign pole.
Jenny detaches her panniers and bicycle lights and carries them into the supermarket.
After Jenny gets the food she needs, she put the grocery bags into her panniers
Jenny put everything back to her bike and unlocks her bike.
Jenny lift up her bicycles with the heavy groceries Jenny uses elevator to go up stair to get over the stair in front of her building
Jenny leans her bike on the wall next to her apartment door and opens the door.
Consideration
Can I put on my Can I have a Can I have a more Can I have a storwork suit and ride age space that is more efficient way clean way to to work directly integrated in my storage my dirty to storage my without getting clothes? bicycle? bicycle? dirty? Folding my bicycle is tiring and complicated. Sometimes, I just keep it unfold. Bicycle clothing is not stylish. Work suit is taking space of my limited storage space.
Can I have more storage space on my bike? will it increase my bicycle size? Consideration
Paint - Points
I dont want to I want to walk do this every time my bicycle into when I need to supermarket but it park my bicycle doesnt help at all. outside.
Is there a way that Can I have a bicyFor the green cle that is easy to future, can I use I dont want to do can help me to I need a kickstand What if my bicycle move my bicycle bring in and out of my bicycle to this every time I to park my bike all can also become up or down stair elevator and wont carry the groceries need to park my the time. a shopping cart? bicycle outside. without spending take to much I buy rather than space? grocery bag? a lot of energy?
Functionality Integrated bicycle lock Integrated bicycle lights Integrated storage space Detachable storage space
Small size bicycle Small wheel (16) A folding bicycle can be folded without bending or can be folded with one hand Simple mechanic Kick stand
Electric power assist system Integrated storage space Detachable storage space Flexible storage space Skirt guard Guard Chain-less transmission system
Paint - Points
Detaching bike lights and panniers is laborious and inconvenient and its heavy to carry them around.
Its hard to bring my bike in or out of a small elevator especially when I share the elevator with other people.
What if there is nothing I can lean my bike on? I need to hold my bike with one hand and open the door with the other hand.
flexible storage space Functionality Trolley bicycle bicycle lock Can be used as a shopping cart integrated bicycle lights integrated storage space detachable storage space a storage space with better ventilation system.
small size bicycle small wheel (16) a folding bicycle can be folded in a short time
kickstand
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Task No.
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Scenario
Home!!
Task
Jenny folds her bicycle and put it back to the walking closet
Consideration
Can I have a bicycle that comes with bike lights (front and rear) and storage space for my belongings?
Can I have a more efficient way to storage my bicycle or Can I use my bicycle as a decoration in my apartment? Folding my bicycle is tiring and complicated. Sometimes, I just keep it unfolded and treat it like a decoration.
Paint - Points
I live in a small studio with a small entrance. Its not easy to bring my bicycle in and out especially I put something close to entrance.
Product Requirements
Functionality small size bicycle small wheel (16) Integrated bicycle lights integrated storage space detachable storage space
small size bicycle small wheel (16) a folding bicycle can be folded without bending or can be folded with one hand simple mechanic stylish design
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Scope This document defines the requirements for the product system and serves as a basis for concept development and design. Definition The product requirements are defined by the following conditional words: MUST: Necessary or essential Should: Recommended but not required. Indicates product goal May: Expresses possibility Will: Use to indicate a statement of fact Adding the word not to any one of these definitions means the opposite of the statement above.
Physical Requirements
General Requirements The bicycle must be collapsible to storage at home. The bicycle must be easy to transport after user fold it up. Product size The overall height of this bicycle must not exceed 38 inches. Minimum product width will be affected by the type of electric power assist technology used. The overall length of this bicycle must not exceed 60 inches with two 20 inches wheels. Product weight The product weight must not be less than 14.99 pounds for safety concerns defined by UCI regulation.
Performance Requirements
Electric power assist 1. The electric power assist must be able to help user to ride up a 30% grade or 20 degrees hill for 3 miles without human power input. 2. The weight of the electric power assist must be less than 20 pounds 3. The power of the electric motor must be less than 750 watts. 4. The power of the electric motor must not be less than 250 watts. 5. The maximum speed on a paved level surface must be less than 20 mph while ridding downhill. 6. The maximum speed on a paved level surface must be more than 15 mph while ridding uphill. Storage space 1. The storage space of the product must be able to accommodate 2 grocery bags,17x 24 x 7 inches. Safety system 1. The front and rear light must be able to emit a white light and illuminate the highway, sidewalk or bikeway and be visible from a distance of 300 feet in front and from the sides of the bicycle. 2. A red reflector on the rear must be visible from a distance of 500 feet to the rear when directly in front of lawful upper beams of headlamps on a motor vehicle. 3. The product should have a white or yellow reflector on each pedal, shoe, or ankle visible from the front and rear of the bicycle from a distance of 200 feet. 4. The product should have a white or yellow reflector on each side of the front center of the bicycle, and a white or red reflector on each side of the rear center of the bicycle, except that bicycles that are equipped with reflectorized tires on the front and the rear need not be equipped with these side reflectors.
Functional Requirements
The product must be able to provide the user with an electric power assist while riding uphill. The product must be able to provide the user with a storage space for their belongings or groceries. The product must be able to provide the user with a safety system that can make them visible during the daytime and nighttime. Bicycles must have functioning front and rear lights when ridden after dark. As some generator or dynamodriven lamps only operate while moving, Rear reflectors may be required. Bicycles may have a warning bell for use when approaching pedestrians and other cyclists. The product should be able to be used as a shopping cart for users groceries in supermarkets.
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Concept Development
Design Phase - Bicycle, Storage, Mechanism
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Concept Development
Stage 1
Bicycle - Ideation Sketches
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Concept Development
Stage 1
Bicycle - Mock-ups
User Feedbacks
Stage 1
Users like the simple folding and home No extra charger design would be betstorage idea. It could be developed ter. more. The storage space on the bicycle should Users want to use their own bag while be detachable. bicycling. Some of the storage ideas are too bulky Users like the folding pedal idea (crank for users. or crankless). It could be developed more. Bicycle frame should carry the weight of users bags for them. The storage space should not turn with the handlebar.
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Concept Development
Stage 2
Bicycle - Concept Sketches Folding Pedal Mechanism Layout Frame Design
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Concept Development
Stage 2
Bicycle - Full Size Mock-ups Ergonomics
User Feedbacks
Stage 2
Need to design the hinge. The lowest seat height should be 24 Users like both crank or crankless deinches. sign, so I need to make a choice be This design should adopt the handlebar tween them. design of a cruiser bicycle. Need to build mockups to test crankless The center of hollow sprocket should design. move 0.5 to 1 inch to the front. 27
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Concept Development
Stage 3
Bicycle - Concept Sketches Hollow Sprocket Design Folding Pedal Revision 29
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User Feedbacks
Stage 3
Users like the crank and folding Pedal design and they should be used on the final design. Folding handlebar idea is interesting but it looks a little bulky. Users can accept the reasons that crankless wont work in reality.
Testing Results
Stage 3
Crankless design will hit some taller barriers while riding. While test walking the mockup, it hit the curb several times Crankless design created some safety concerns, so I will change back to the design with crank and hollow sprocket.
Concept Development
Stage 3
Bicycle - Mock-ups Crankless Design Testing Handle Bar
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Concept Development
Stage 4
Storage on Bicycle Concept Sketches 33
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Concept Development
Stage 4
Storage on Bicycle Storage Mock-ups
User Feedbacks
Stage 4
Users would like their storage on the front. There are some possibilities that I can combine some of the storage ideas together. Users like the expandable storage ideas. The rotatable storage space is a bit bulky.
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Concept Development
Stage 5
Storage Design Revision Concept Sketches
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Concept Development
Stage 5
Bicycle Styling Thumbnail Sketches
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Concept Development
Stage 5
Bicycle Styling with Storage idea Refine Sketches
User Feedbacks
Stage 5
Rear storage looks like pizza delivery bicycle. Front Storage looks bulky. The frame design need to be smoother.
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Concept Development
Stage 6
Concept Development
Stage 6
Storage Design Revision - Sketches
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Concept Development
Fusion
Bicycle Design Revision - Sketches
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Concept Development
Fusion
Bicycle Design Revision - Mock-ups
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Final Concept
Feedback
After folding, the position of handlebar is too high to control. The mechanism of folding handlebar doesnt look very strong. How to lock the folding handlebar after folding it. Need to redesign basket styling. Current basket design is not good for aerodynamics. Need to Improve the overall mechanism.
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Design Finalization
Implementation Phase - Storage, Mechanism
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Handlebar Revision
Concept Sketches
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Handlebar Revision
Concept Sketches
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Rim Design
Styling Sketches
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Appearance Revision
Refine Detail Design
Mechanism Revision
Detail Mechanism Exploded View
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Mechanism Revision
The Head part (Light, Handlebar, Stem)
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Mechanism Revision
Head Tube, Battery Housing
Mechanism Revision
Front Wheel, Front Fork
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Mechanism Revision
Back Frame, Drive System
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Mechanism Revision
Rear Wheel
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Criteria
Manufacturing Process
Verton composites compounds can be successfully molded on most injection compression molding machines. Since the unique properties available from Verton composites result from the length of the fibers and the reinforcing framework they form, attrition during processing is detrimental to part performance. Because of the length of Verton composite pellets (approximately 12 mm), bridging may be a problem in machines with small (less than 30 mm) feed throats. A free flow screw tip is highly recommended to obtain the full spectrum of properties.Furthermore it is important that the tool steels for cavity and core are hardened to 50-54 Rc.
Design Considerations
Uniform wall thickness (0.1~0.25) Add ribs Wall transition design - preferred design approximately 3:1 ratio Increase section properties (Use Ibeams, ribbed U-sections, hollow sections) No sharp corners (less stress concentrations) All part walls should have 2 -3 degree draft per side.
Material
LNP Verton Compound RV00CE (Long Glass Fiber Composite) LNP VERTON* RV00CE is a compound based on Nylon 66 resin containing Long Glass. Added features of this material include: Easy Molding. Features: Lightweight, Hight impact strength and stiffness, Good surface quality Application: Automotive (Structure, Body Panels, Bumper), Furniture
Body Panels
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Criteria
Design Considerations
Uniform wall thickness Add ribs (obtain maximum strength) Avoid sharp corner Draft (1 degree)
Material
Magnesium Alloy Products made with Magnesium are lightweight, strong, environmentally, recyclable, and beneficial in conserving energy
Bicycle Frame
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Bill of Materials
Front Wheel Section
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80
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11
12
13 14
Item No.
1 2 3 4
Description
Headlight Cover Headlight Glass Cover LED Headlight Headlight Adapter Stem Screw Quick Release Grip Handlebar Cap Handlebar Grip Handlebar Top Handlebar Clamp Top Clamp Cap Top Head Panel Stem Bolt Cap Stem Bolt Stem Upper Head Panel Bottom Clamp Cap Bottom Handlebar Clamp Screw Nut Q.K. Screw Stem (front part) Lower Head Panel
Material
Verton Composite (SABIC) Glass N/A PVC N/A Magnesium ABS Rubber Magnesium Magnesium ABS Verton Composite (SABIC) ABS N/A Magnesium Verton Composite (SABIC) ABS Magnesium N/A N/A Magnesium Verton Composite (SABIC)
Mfg.
Injection Compression Molding Blow Molding OutSourcing Injection Molding OutSourcing Die Casting Injection Molding Injection Molding Die Casting Die Casting Injection Molding Injection Compression Molding Injection Molding OutSourcing Extrusion & Welding Injection Compression Molding Injection Molding Die Casting OutSourcing OutSourcing Die Casting Injection Compression Molding
Unit
1 1 1 1 4 2 2 2 2 1 2 1 1 1 1 2 2 1 4 4 1 2
Price (USD)
2 0.20 4.85 0.8 0.04 3 0.3 0.5 5 4 0.3 3 0.1 0.05 10 6 0.3 4 0.2 0.05 5 6
6 3 5 19 20 18
15 16
5 6 7 8 9 10 11 12 13 14 15
21 1 2 4
17 22
16 17 18 19 20 21 22
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82
32 31
23 24 25 26
Item No.
23 24 25 26 27
Description
Lock Nut Adjustable Race Upper Head-Tube Race Front Frame Lower Head-Tube Race Fork Bearing in Cage (Lower) Front Right Body Panel Bearing in Cage (Upper) Wahser
Material
N/A N/A Magnesium Magnesium Magnesium Magnesium N/A Verton Composite (SABIC) N/A N/A
Mfg.
Outsourcing Outsourcing Die Casting Die Casting Die Casting Die Casting Outsourcing Injection Compression Molding Outsourcing Outsourcing
Unit
1 1 1 1 1 1 1 2 1 1
30
Price (USD)
0.01 0.05 1 40 1 26 0.1 6 0.1 0.05
29
28 29 30
28
31
27
32
83
84
33
34 35 47 36 37 46 38 39 40 41 42 45 44 43
Item No.
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Description
Front Cover Cover Screw Front Fender Front Rim Front Axle Disc Adapter Screw Brake Clip Axle Nut Brake Disc Screw Screw Front Left Hub Front Right Hub Front Tire Screw
Material
ABS N/A Verton Composite (SABIC) Magnesium N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Mfg.
Injection Molding Outsourcing Injection Compression Molding Die Casting Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing Outsourcing
Unit
2 8 1 1 1 1 2 1 2 1 3 3 1 1 1 4
Price (USD)
2 0.4 8 25 0.5 3 0.1 1 0.1 10 0.15 0.15 5 5 3.7 0.2
48
85
86
58 56 55 52 51 69 53 54 57 59
60
61
Item No.
48 49 50 51 52 53 54 55 56 57 58 59 60 61
Description
Right Spur Gear (Drive Shaft) Pedal Crank Screw Rear Body Panel Left Spur Gear (Motor) Rear Left Hub Motor Housing Cover Front Left Body Panel Hinge Grip Hinge Pin Hinge Connecting Pin Seat Clamp Seat Post Rear Right Hub Screw (Seat Clamp) Rear Cover Cover Screw Kickstand Rear Frame Screw Motor Ball Bearing Screw (Spur Gear)
Material
N/A N/A Magnesium N/A Verton Composite (SABIC) N/A Magnesium Magnesium Verton Composite (SABIC) Magnesium N/A N/A Magnesium N/A Magnesium N/A ABS N/A Magnesium Magnesium N/A N/A N/A N/A
Mfg.
Outsourcing Outsourcing Die Casting Outsourcing Injection Compression Molding Outsourcing Die Casting Die Casting Injection Compression Molding Die Casting Outsourcing Outsourcing Die Casting Outsourcing Die Casting Outsourcing Injection Molding Outsourcing Die Casting Die Casting Outsourcing Outsourcing Outsourcing Outsourcing
Unit
1 2 2 4 2 1 1 1 1 1 1 1 1 1 1 1 2 8 1 1 1 1 1 6
Price (USD)
1.5 10 30 0.2 30 1.5 5 8 6 5 0.1 0.2 2 7.6 5 0.05 2 0.4 5 60 0.2 70 1.7 0.35
63
62
48
50 70 49
68
62 63 64 65
67 71 66
65 64
66 67 68 69 70 71
87
88
72
73
74 75
Item No.
72 73 74
Description
Saddle Front (Inner) Basket Rear Basket Rear Fender Shaft Drive System Rear Rim Rear Tire Rear Axle Rear Disc Brake Rear Hub
Material
N/A Verton Composite (SABIC) Verton Composite (SABIC) Verton Composite (SABIC) N/A Magnesium N/A N/A N/A N/A
Mfg.
Outsourcing Injection Compression Molding Injection Compression Molding Injection Compression Molding Outsourcing Die Casting Outsourcing Outsourcing Outsourcing Outsourcing
Unit
1 1 1 1 1 1 1 1 1 1
Price (USD)
1.5 2.6 2.8 8 50 25 3.7 0.5 10 5
76
75 76 77
77 81 80 78 79
78 79 80 81
89
90
CAD Documentation
91
92
0.20 0.19
0.44 4.14
B B
0.40
5.91 21.43
1.79
C C
2.39
14.68
5.15
0.33
E
0.88 0.82
R1.75
1.84
1 2 3 4 5 6 7
Back Axle Cover 001 Third Angle Inch Verton Composite Nov.,27th, 2011
93
94
3.76
1.72
0.98
1.66
3.17
0.30
5.89
C C C C
4.91
1.54
R1.83
9.57
R1.91
1.16
7.19
4.90
Rear Body Panel 001 Third Angle Inch Verton Composite Nov.,27th, 2011
10.04
1 2 3 4 5 6 7
95
96
3.85
4.86
3.57
0.97
3.30
R0.39
14.69 12.70
5.08
D
14.68
18.25
E
0.90
Front Body Panel 001 Third Angle Inch Verton Composite Nov.,27th, 2011
3.10 16.49
0.41
0.50
97
98
11.69
A A A
18.06 3.32 4.33
5.72
3.02
2.64
R0.13
3.47
C
3.04
6.25
6.16
11.86
D
2.45
1.81
1.72
11.69
2.90
0.95
9.27
2.21
Title
Front Basket
0.42
3.60
Front Fender 001 Third Angle Inch Verton Composite Nov.,27th, 2011
18.00
99
100
3.72
A A A
R0.54
2.30
1.49
0.76
0.72
1.71
C C C
1.35
0.12
5.34 R0.39
D D D
R0.04 R1.84
R0.10
D
5.14 1.52
2.28 17.34
Right Gear Barrel 001 Third Angle Inch Magnesium Nov.,27th, 2011
R0.10
1 2 3 4 5 6 7
Material Date
101
102
2.07
B B
R0.08
1.49
0.77
0.73
0.14
R0.04 3.47
C C
R0.04
D
R0.08
D D
3.53
E
Title Drawing Nr. Projection Left Gear Barrel 001 Third Angle Inch Magnesium Nov.,27th, 2011
R0.10
1 2 3 4 5 6 7
103
104
1.10
3.19
9.85
6.04
1.13
163.40
0.80
1.00
0.87 1.10
1.26
3.19
151.90
1.40
0.94
Headlight Adapter 001 Third Angle Inch Verton Composite Nov.,27th, 2011
0.05
3
105
106
1.25
0.51
1.41
2.29
2.57
3.53
1.62
C
1.70
R0.14
D D D
1.03
9.22
1.66 1.74 1.73
Headlight Cover 001 Third Angle Inch Verton Composite Nov.,27th, 2011
107
108
R0.58
9.43
A A
9.30
2.17 0.38
4.18
5.51
1.33
2.89
1.49
1.65
R1.04
10.39
0.72
7.55
5.72
1.04
5.31
Lower Head Panel 001 Third Angle Inch Verton Composite Nov.,27th, 2011
1.05
Rear Basket 001 Third Angle Inch Verton Composite Nov.,27th, 2011
9.52 12.06
1.94 2.70
2.08
1 2 3 4 5 6 7
109
110
0.36
0.64
R0.04
0.64
11.23
7.29
6.1 4
0.14
3.94
0.74
0.47
0.41
6.
Title Quick Release 001 Third Angle Inch Magnesium Nov.,27th, 2011
39
1.59 3.20
Title Drawing Nr. Projection
E
9.17 1.84
0.06
3.40
Rear Fender 001 Third Angle Inch Verton Composite Nov.,27th, 2011
20.37
111
112
5.86 5.00
6.43
R0.89
3.57
R0.70
R0.84
1.43
1.35
R0.45
17.48
1.75
0.70
0.51
0.40
113
114
5.47
3.62
3.39
2.28
1.82
1.70
12.89
1.79
1.12
Top Head Panel 001 Third Angle Inch Vertom Composite Nov.,27th, 2011
13.20
Upper Head Panel 001 Third Angle Inch Verton Composite Nov.,27th, 2011
1.50
Projection
0.75
115
116
Final Design
117
118
Folding Handlebar
119
120
Folding Hinge
121
122
KickStand
123
124
Storage
125
126
127
128
Motor Switch
129
130
131
132
133
134
RESUME
Education Bachelor Degree Mechanical Engineering, National Taipei University of Technology Master Degree Industrial Design, Academy of Art University Area of interest Skills Product and Furniture 3D Modeling Alias, Autocad, Rhino 3D Rendering Alias Showcase, Hypershot Hand Sketch Graphic Photoshop, Illustrator, Indesign Notable Achievement Employment History Wood 2 Night Light was selected into 2009 AAU spring show Project TAG WATCH was selected as a semifinalist of competition of Get Kids Moving 2008 Shan Horng, Kaohsiung County, Taiwan CAD Drafter, 2005 2006
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