Final Report 4th Year Cycling PRINT

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Final Project Report

Tandem Cycling

A 4th Year, Carleton UniversityIndustrial Design Projectby William McDonald

April 4 2012

This report describes the process used in the

development of a tandem cycle designed to

provide an accessible cycling experience for

users with special needs as well as their

caregivers. The project was completed by

William McDonald as his major fourth year thesisproject at Carleton Universitys School of

Industrial Design. The design process used in

the development of the product included:

identifying a problem or need, research,

conceptual development, testing, concept

refinement, computer modeling, technical

drawings and specifications, and the

construction of a final appearance model.


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Index

Introduction ........................................................................2

Inspiration.......................................................................3

Research.........................................................................4

Conceptual Development..................................................6

Testing............................................................................7

Concept Refinement..........................................................9

Final Concept....................................................................11

Final Model........................................................................17

Conclusion....................................................................19


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INTRODUCTION1.0

2

Quality of life is the degree to which a person enjoys

the important possibilities of his or her life.

Generally, there are 3 main factors that affect ones

quality of life: being, belonging, and becoming. Being

active and becoming involved in sports can help any

individual grow in each of these domains, but

especially those with disabilities. Allowing people with

disabilities to participate in sport to the best of their

abilities while providing stimulation with new

experiences can increase their quality of life

dramatically.

This became the focus of the Paralympic group of sixCarleton University Industrial Design students

completing their major thesis projects. The goal was to

expand recreational sport opportunities to those with

disabilities. The group was called as AccessSport.

Adaptive Tandem Cycling

For his focus, William McDonald looked at cycling. The

project focused on how to provide users with

moderate to profound disability with a cycling

experience, while also benefiting the lives of theircaregivers.

Cycling is extremely popular and current trends show

that it is growing significantly in both recreational and

utilitarian use. The tandem cycle is aimed at disabled

users who do not have the ability to independently

cycle. There is a wide variety of disabilities that could

contribute to this level of disability; including spina

bifida, cerebral palsy, muscular dystrophy, spinal cord

injuries, sight impairment, mentally disabilities, seniors

with limited mobility and more. It is also aimed at able

bodied users who would like to participate in an

activity with a specially abled individual, and may also

like the option to use cycling as transportation. The

tandem cycle will offer function as a mode of

transportation and use as a detachable wheelchair.

This enables the users to travel by cycling, reach theirdestination, and use the cycle as a wheelchair to enter

buildings such as museums, restaurants, cinemas, etc.

The following report will describe the steps taken to

develop the final product as well as the features of the

Tandem Cycle.


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INSPIRATION2.0

3

Inspiration for the project came from a discussion with

Mike and Larry McCloskey. Mike was a Canadian

Olympic cyclist. He has multiple sclerosis, and uses awheelchair. Currently, it is too difficult for Mike to use a

traditional handcycle. There seemed to be an

opportunity to develop something that could give a

user a cycling experience, even if the participation

was more passive and assisted by a caregiver.

After further discussions and interviews with caregivers

of special abled youth and adults it was evident an

opportunity existed to assist the caregivers and

improve their quality of life as well. As a result,

inspiration was taken from the functionality of bicycle

child carriers and strollers, as well as cargo bicycles.

The project has developed to offer a fun cycling

experience while providing functionality, utility, and

transportation.

burley bicycle trailer kids at Easter Seals Camp

Examples of custom devices used in marathons and triathlons

Exploration, and social interaction during cycling


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RESEARCH3.0After identifying the opportunities interviews were

conducted with various people including a physiotherapist,

a wheelchair manufacturer, an Easter Seals Camp councilorand two wheelchair users.

The next phase involved creating an in depth research

report which included information on the user, disabilities,

ergonomics, wheelchair equipment, market trends, cycling

environments, wheelchair environments, task analysis,

economics of the users, wheelchair and bicycle technology,

a competitive analysis, and measures of success.

From the research report important needs and

specifications were identified to be used in a design brief:

4

User needs:

-be useful for both users for recreational and utilitarian use

-provide an efficient means of tandem cycling for one

disabled and one able user

-provide an enjoyable experience and sense of participation

for both users

-provide a detaching wheelchair for use indoors

-allow the disabled user to sit in a dignified, comfortable

way when cycling and -indoors

-have some adjustability (foot rests, hand holds, and back

rest angle)

-be easy and quick to attach/detach the wheelchair

-be safe and appropriate for a city cycling environment

-be appropriately sized for indoor use

-be affordable as a secondary wheelchair (similar in cost to

sport wheelchairs and hand cycles, $1500- $3,000)

-be easy to maintain and repair at local bicycle shops

-have options to add accessories to increase functionality

(cargo carrying, electronic assisted bicycle)

Technical specifications

-the wheelchair should be no larger than 0.7m wide, 1.25m

long

-the chair should attach to a variety of existing bicycle

models (custom fork fitting is okay)

-be as light weight as possible

-make use of traditional bicycle materials and manufacturing

methods to reduce cost where appropriate

Percentage of Cyclists in Toronto, 2009

RecreationalCyclists

NonCyclists

UtilitarianCyclists


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Two products identified in the competitive analysis

Inspiration for functionality came from several strollers,

bicycle child carriers and cargo bicycles.

5

Vanraam OPair Cycle

Onya Front-End Loader

Fuseproject cargo bike

TriobikeChariot Sidecar

Quest Draisin Plus


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Using the research and deign brief conceptual development

was done to come up with a variety of solutions. Sketching

and small models were used to communicate the various

ideas. Three concepts were chosen and presented for

discussion. All three concepts satisfied the needs outlined in

the design brief, including having a detachable wheelchair and

situating the disabled user in front of the bicycle. This was so

that they can feel the wind, have good visibility, be monitored

by the caregiver and participate in a dignified way. All three

concepts also incorporated a bicycle and wheelchair that

could be used individually when detached from the system.

1. Concept one used a specially designed bicycle frame for

attaching the wheelchair portion to the front. This meant that

the design could be simpler, however the user had to

purchase both the chair portion as well as the bicycle.

2. Concept two used a specially design attachment system

to connect the redesigned wheelchair to a variety of existing

bicycles.

3. Concept three involved using a tilting tricycle to give the

disabled user a new sensation of tilting while cornering.

After discussion with group members and instructors in was

decided concept 2 had the most potential. There were more

marketing opportunities, the product could save cost if it

attached to a variety of bicycles, and there was more

opportunity do develop intellectual property.

CONCEPTUAL DEVELOPMENT4.0

6

Scale models


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The next phase in the product development was to test the

concept at full scale. The purpose of the testing was both to

test the mechanism and functionality of how attachmentwas made to the bicycle as well as the ergonomics and task

analysis. Ethics clearance for testing was given by the

Carleton University Research Ethics Board.

An important innovation that was discovered was the ability

to put bearings inside a standard bicycle fork. By doing this

a rod could be inserted into the inner fork and attached to

the wheelchair. The rod would provide an important

supporting structure while still allowing the forks to pivot

and steer. Testing of this concept revealed it wassuccessful.

Rod end bearings were chosen to be used for the

articulation points because their design permitted for easy

adjustments. They would eventually be chosen to be used in

the final product for this reason.

TESTING5.0

7

Testing seat size, height, and handle placement

Building the testing rig

Rod connects to chair system

Bearings pressed into standard1 1/8 threadless fork


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Testing attachment and steering system

Testing functionality of

wheelchair indoors

Public display of project

The testing phase was extremely helpful in finding important

dimensions for both the ergonomics as well as the

mechanisms and areas needing improved strength. The

results of the testing were displayed publicly at Carleton to

generate discussion about the project and possible next

steps.


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The next step was to refine the concept using what was

learned during testing. All the details of the product needed

to be resolved, manufacturing processes and materialsneeded to be specified, and a final concept developed.

The first step was to take what was learned

during testing to create a use cycle

storyboard of how the product would be

used.

CONCEPT REFINEMENT6.0

9


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A major decision was made to use water-jet cut aluminum

sheet metal for the basis of the structure for the bicycle

attachment system. This would allow for easy assembly and

adjustment of various spacer parts located between two

sheet metal parts.

Sketching was used to quickly explore different aesthetics

of the product. Finding forms that worked well with the

wheelchair as well as the bicycle was important.

The full scale drawing, testing model, and sketches were

used to generate a CAD model of the final design. It should

be noted that more time was spent developing the bicycleattachment system due to time constraints because it was

the most innovative part of the product. Further

development of the seat and folding caster system needs to

be done.

To better understand what materials and processes would

be appropriate for the product a full scale drawing was

created. This full scale drawing was helpful when trying to

visualize the location of the different components.

When choosing materials and processes several factors

needed to be considered.

-The product would likely be low run (at least in the

beginning) so minimizing tooling cost was considered.

-The product needed to be installed and tuned by bicyclemechanics, so only basic hand tools could be used.

-The final cost of the product needed to be minimized, so

reducing materials and assembly time was considered.

-The product needed to be lightweight in order to be used

efficiently during cycling.

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Full scale drawing Solidworks modelingSketching


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The final concept was developed in CAD using Solidworks.

The concept features are:

-innovative bicycle attachment system compatible with a

wide variety of bicycle

-easily adjusted and maintained using simple tools

-24 wheels with disk brakes

-adjustable and removable handlebars

-lightweight aluminum used throughout the product

-folding casters

-adjustable back rest

-adjustable foot rest

-compatible with a wide variety of wheelchair accessories

including head support, lateral support, harnesses, etc.

The final CAD model was rendered and used to create a

presentation board as part of a final deliverable as well as to

be used in a public exhibition.

FINAL CONCEPT7.0

11

Mountain bikes Road bikes Electric bikes

Steering


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12

Cycle together Detach

ExploreEnjoy


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The innovative bicycle attachment system:

13

CNC aluminum

water jet cut aluminum


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5 4 3 2 16

D

C

B

A

D

A

B

C

236 5 4 1

82.7

41.0

27.5

39.

6

CHECKED:

Will McDonald0.01

N/A

TS

Stephen Field

Tandem Cycle Wheelchair Assembly DECIMALTOLERANCES:

1DATE:

CLIENT:

TITLE:

ANGLEDRAWN:

DWG. #: SCALE:

MATERIAL:

01/01/10

01 not toscale

SHEET 1 OF 1

OTTAWA, CANADA

CARLETON SCHOOL OF INDUSTRIAL DESIGN

B 11x17

Technical Drawings were created using CAD. These

drawings were used throughout the final model

building phase to mill, cut and specify components and

fasteners.

14


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15

1

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

4

3

2

1

1

2

2

2

1

1

1

2

1

7

1

1

1

1

1

46

2

4

2

4

PART NAME QTY. MATERIAL

PARTS LIST

NO.

ASSEMBLY NOTES:

- water jet cut pieces

1/4-20 Socket Head Cap Screw 2Blk OxideSteel

Blk OxideSteel

Blk OxideSteel

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Steel

Stn Steel

PolybutyleneTerephthalate

Steel

Steel

Steering linkage

1/4-28 Steel Ball Joint Rod End

Axle Receiver

Main Axle

Center Pivot Bracket

1/2-20 Steel Ball Joint Rod End

1/2-13 Socket Head Cap Screw

Receiver Rod Cap

Receiver Rod

Frame Clamp Knob

Main Bracket

Receiver Rod Clamp

Spacer

Cross Bridge Bracket

Pivot Rod Bracket

Fork Support Axle

Fork Support Pivot Bracket

Fork Locking Knob

1/4-20 Low Head Socket Cap Screw

- CNC aluminum pieces

5 4 3 2 1

CHECKED:

Will McDonaldN/A

N/A

TYPE

TS

Stephen Field

Connection System Sub AssemblyDECIMAL

TOLERANCES:

1DATE:

CLIENT:

TITLE:

ANGLEDRAWN:

DWG. #: SCALE:

6

D

C

B

A

D

A

B

C

236 5 4 1

MATERIAL:

01/01/10

02 Do not scale

SHEET 1 OF 1

OTTAWA, CANADA


B 11x17

15

14

13

12

11

10

9

16

17

18

19

20

3

2

4

5

6

7

8


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16

5 4 3 2 16

D

C

B

A

D

A

B

C

236 5 4 1

CHECKED:

Will McDonald0.01

N/A

TS

Stephen Field

Tandem Cycle Wheelchair AssemblyDECIMAL

TOLERANCES:

1DATE:

CLIENT:

TITLE:

ANGLEDRAWN:

DWG. #: SCALE:

UNITS: Inches

01/01/10

03 not to scale

SHEET 1 OF 1

OTTAWA, CANADA


B 11x17

6.25

3.5

6

7.1

3

19.77

1.44

19.53

12.60

0.82

20.

92

7.

22

14.

95

4.

217

6.

098

9.

657

19.3

15


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A final full scale appearance model of the bicycle attachment

system was created. The goal of the model was to show

proportion and materials as well as being a presentation tool.

Full scale was chosen because many of the components that

could be purchased would be difficult to model in scale.

Wheels, bearings, fasteners and a bicycle were easily

obtained to be used with a full scale model. The model was

also designed to have some functionality and enough strength

to demonstrate the steering and bicycle attachment feature.

The main sheet metal parts were water-jet cut at Hydrotech

Cutting Inc in Ottawa. The parts designed to be CNC milled

were made from high density renshape and cut using a

bandsaw and shaped by hand. Other components were made

using a milling machine, lathe, and FDM 3D printing.

FINAL MODEL8.0

17

Assembling the model Test fitting

Shaping the renshape

Finished components ready for assembly


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18


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The project was a huge undertaking. There is still a lot of

development that can be done to refine the product before

it is ready to be brought to market. Overall however, the

project was very successful and a great learning experience.

All aspects of the design process were utilized in order to

create the product.

The tandem cycle is an exciting and innovative concept with

a tremendous opportunity to change the lives of people with

limited mobility as well as the people who take care of them.

With the Tandem Cycle they will be able to get exercise and

fresh air together, explore cities and parks, and visit

museums and restaurants and other indoor destinations.

Dependency on vehicles is reduced, new experiences are

enjoyed and health is increased.

CONCLUSION9.0

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Documents

Final Report 4th Year Cycling PRINT