Electric Motorcycle Technology

This assignment delves into the fascinating world of electric motorcycle technology. It explores various aspects, including different types of batteries used in these vehicles, the workings of electric motors specifically designed for motorcycles, and the evolving landscape of charging systems. Understanding these key components is crucial for comprehending the advancements and potential of electric motorcycles as a sustainable transportation solution.

Mechanical Engineering

Table of Contents
1. Introduction...........................................................................................................................1
1.1 Background......................................................................................................................1
1.2 Aim...................................................................................................................................2
1.3 Objective..........................................................................................................................2
2. Literature Review..................................................................................................................2
2.1 Sustainability...................................................................................................................2
2.2 Sustainability Values.......................................................................................................2
2.3 Sustainability Audit........................................................................................................3
2.4 Recommendations for Reducing Energy Emissions....................................................3
3. Product Exploration...............................................................................................................3
3.1 Manufacture of product.................................................................................................4
3.1.1 Wheel........................................................................................................................4
3.1.2 Manufacture of Engine............................................................................................7
3.1.3 Manufacturing of Battery.......................................................................................7
3.2 Sourcing Materials..........................................................................................................7
4. Problem Definition................................................................................................................8
4.1 Low Mileage.....................................................................................................................8
4.2 Dirty Engine Oil..............................................................................................................8
4.3 Carburetor.......................................................................................................................8
4.4 Poor Performance...........................................................................................................8
4.4.1 Air Filter...................................................................................................................9
4.4.2 Quality of the Fuel...................................................................................................9
4.4.3 Chain Slack...............................................................................................................9
4.4.4 Lack of Warmup......................................................................................................9
4.4.5 Poor Brakes..............................................................................................................9
4.4.6 Disc Brakes...............................................................................................................9
4.4.7 Drum Brakes............................................................................................................9
4.4.8 Fail of Electric Starter.............................................................................................9
5. Design for Function and Sustainability...............................................................................10
5.1 Bike Engine....................................................................................................................10
5.1.1 Engine Constructional Features...........................................................................11

5.2 Wheel..............................................................................................................................15
5.2.1 Wheel Fixing...........................................................................................................16
5.2.2 Wheel Nut Torque.................................................................................................16
5.2.3 Types of Wheels.....................................................................................................16
5.2.4 Wheel Brake and Suspension Parts.....................................................................17
5.2.5 Dust.........................................................................................................................18
5.2.6 ABS..........................................................................................................................19
5.2.7 Speedometer...........................................................................................................20
5.2.8 Tires........................................................................................................................20
5.2.9 Brakes.....................................................................................................................20
5.2.10 Transmission Part..................................................................................................21
5.2.11 Clutch......................................................................................................................21
5.2.12 Gear.........................................................................................................................22
5.2.13 Fuse.........................................................................................................................22
5.3 Motorcycle Battery.......................................................................................................22
5.3.1 Lead Acid Motorcycle Battery.............................................................................22
5.3.2 Components............................................................................................................23
5.3.3 Design of the Battery.............................................................................................24
5.3.4 Spark Plugs.............................................................................................................25
6. Identification of Current Good Practice in Motorbike........................................................27
7. Identification of Current Bad Practice in Motorbike..........................................................27
8. Justification for Component Choices..................................................................................28
9. Granta CES Edupack Software Analysis............................................................................29
9.1 Eco Audit Tool...............................................................................................................29
9.2 Advantages and Disadvantages of Motorbike............................................................40
9.2.1 Advantages of Motorbike......................................................................................40
9.2.2 Disadvantage..........................................................................................................40
10. Sustainability Audit.............................................................................................................40
10.1 Old Method................................................................................................................40
10.2 New Method...............................................................................................................40
10.3 Comparison of Old System and New System..........................................................41
11. Conclusion...........................................................................................................................41

References......................................................................................................................................43

Table of figures
Figure 1 bike engine......................................................................................................................11
Figure 2 cylinder............................................................................................................................12
Figure 3 piston rings......................................................................................................................13
Figure 4 crank shaft.......................................................................................................................14
Figure 5 Engine bearings...............................................................................................................14
Figure 6 cam shaft.........................................................................................................................15
Figure 7 Wheel..............................................................................................................................16
Figure 8 steel wheel.......................................................................................................................17
Figure 9 wheel break and suspension part.....................................................................................18
Figure 10 Dust...............................................................................................................................19
Figure 11 ABS...............................................................................................................................20
Figure 12 Lead acid battery...........................................................................................................22
Figure 13 spark plugs.....................................................................................................................26
Figure 14 Relative contribution of life phases...............................................................................31
Figure 15 energy analysis..............................................................................................................32
Figure 16 CO2 footprint analysis..................................................................................................34
Figure 17 cost analysis...................................................................................................................36
Abbreviations
ABS - Anti-Lock Braking System (ABS)
CVT - Continuously Variable Transmission (CVT)

1. Introduction
The software CES Edu pack is used for teaching resources which is a major support
education material in engineering for designing and architect ruing development. In this report
two wheeler is investigated, which is one of the basic need in daily life. The sourcing of
materials and parts of bike, design for function and sustainability and its life time usage will be
studied. The numerical analysis is done by Granta design CES Edupack software. The bike
engines have two stroke engines which are used for producing the required amount of
performance, during the process. There are various spare parts which are used for the function of
two stroke bike engines. The carburetor type engine has air tight crank case which is used for
partially compressing the air fuel mixture. When the piston travels down, the crank case is
partially compressed and the mixture is drawn into the case. The piston uncovers the exhaust and
intakes portion as the piston nears the bottom of the stroke. The exhaust is escaped reducing the
pressure in the cylinder. The incoming mixture is deflected upward, by the baffle on the piston.
This action takes place when the pressure in the combustion chamber is lower than the pressure
in the crank case near port opening, for combustion. When the piston moves up, it compresses
the mixture which is above and draws it into the crank case. The number of active motorbikes
who follow the principles of motorcyclist licenses are less and the motorcyclist who doesn’t have
the license are more. The motorcyclists without license are not allowed to ride. The information
of motorcyclist is available in the demographic information is the drawback of this measure.
Some other issues are some of the owners fail to license their vehicles to avoid excise duty
(Jones, 2013).
1.1 Background
The challenges faced for the sustainability of motorcycle are based on the development of
technologies, methods and challenges faced by the people. Now-a-days, the production and
consumption of motorcycles have increased and it creates great impact on the society.
Sustainability has high awareness and it describes the quality of the product. Many transport
industries, face intense pressure from society to fulfil their requirements. Hence, the management
of those organization creates some additional challenges for the employees to produce the
product with more sustainability features. Motorcycles are potentially more sustainable than the
other transports which requires less space, few resources and with less pollution. It improves the
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sustainability of the motor cycles. The sustainability analysis of the motorcycle deals with
sourcing materials, design of a function, manufacturing of the product, life time of the product,
maintenance of the product and its disposal.
1.2 Aim
The main aim of this report is to analyze the sustainability audit of the motorcycle with
its following components:
1) Motorcycle Engine
2) Motorcycle Wheel
3) Motorcycle Battery
1.3 Objective
The objective of this report is to select a product to study its three main components. The
selected product considered in this report is motorbike. Analysis using Granta CES Edupack
software will be done for analyzing environment sustainability of motorbike. Current good and
bad practices of motorbike will be identified. Among 6 life phases, any three life phases will be
studied. Justifications for the components will be provided. Graph will be plotted using the
software that depicts the analysis of the considered components. Cost analysis will be estimated.
The overall analysis about the motorbike will be determined.
2. Literature Review
2.1 Sustainability
Sustainability can be defined as the requirement of the system or product to maintain the
resources based on the quality. It is based on the accomplishment of the objectives and its
impacts. In a project, it mainly focuses on the design, engineering and sustainability. It is also
used to evaluate the climate changes and developments in the project.
2.2 Sustainability Values
Sustainability values are based on quality engineering. These values give additional
definitions for quality engineering. In engineering work, this value is separated into five parts. In
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quality engineering, it is used to identify the cost, maintains sustainability, also it refers to the
documents and functions in the background. To achieve the targets it has speculation phase.
Based on the real judgments and quality, the analysis phase provides alternative solutions. The
details are developed in the development phase and it is the last implementation phase
("Sustainable Motorcycle", 2018).
2.3 Sustainability Audit
Sustainability audit is one of the tools which is used to measure the best practices of the
organization. It is mainly designed to check the key areas of the organization. This audit function
mainly investigates the sustainability of the organization (Coyne, 2018). The categories of
sustainability are extensive and most of the organizations contrast with the advantages of
sustainability.
2.4 Recommendations for Reducing Energy Emissions
Industries produce raw materials every day and it emits energy both in direct and indirect
ways. The energy emission can be controlled by the reduction of carbon gas which is effective
for modern practices, organizations and individuals (Humphries, 2016). Different types of sound
ventures can be used to reduce carbon emission. It will secure people from harmful carbon
emission that is caused due to the vehicles, trucks and power plants.
3. Product Exploration
Some of the renowned manufacturers of motorbike are listed below:
1) Royal Enfield
2) Hero motor corp.
3) Bajaj
4) KTM
5) Hartley Davidson
6) Triumph
7) TVS
8) Honda
9) Yamaha
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10) Suzuki
11) Vespa
12) Kawasaki
13) Ducati
14) BMW
15) UM motorcycles
16) SWM
17) Okinawa
18) Lohia
19) Hyosung
20) DSK benelli
21) Tork
22) Palatino
23) Indus
Each manufacturing company offers different prices for its bikes, according their model,
quality, and performance.
3.1 Manufacture of product
3.1.1 Wheel
Composite Materials
The composite material is also known as the material composed in more than two or two
component combined on a macroscopic scale, by chemical bonds and mechanical bonds. The
using composite materials are given below:
1) Fibers
2) Sheets
3) Particle materials
4) Embedded materials.
5) Design of using alloy wheel
Chemical Materials
a) Aluminum alloy 87 to 100
b) Copper0.25
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c) Manganese 0.35
d) Silicon 6.5 to 7.5
e) Iron 0.6%
f) Zinc 0.35
g) Magnesium alloy uses manganese 0.6 and copper 0.05, calcium 0.04, silicon 0.1iron
0.005, magnesium 85 to 100.
Specification of the Problem
The aluminum alloy is designed by collecting the data from the reverse engineering
process, using the existing system module. This model is designed by using the ultimate variable
as two different alloy material. The alloy wheel is designed with different loads. The goal of
maximum outer diameter fits the accessory areas of bolt.
Carbon Fiber Materials
1) Fiber is designed with 5 to 10μM diameter.
2) The composite materials mostly uses carbon atoms. The carbon fiber produces thermal
decomposition of rayon precursor material. The polyetherimide polyether, etherketone
polyphenylene sulfide and polyetherimide are used to make thermoplastic.
Specification of Alloy Wheel
1. Diameter of wheel Rim 43.18mm
2. Perimeter of wheel Rim 2711.704 mm
3. weight of Existing Alloy
Wheel
1.98 kg
Motorbike Design
The motorbike is designed fuel of drained to vertically positioned and hard to horizontal
surface. The wheel of rear and front is placed in the transmission neutral. The center and side
stands must be designed in folded up form. These stands support to double act the air cylinder.
This cylinder is fixed at the opposite stand.
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The vertical position works like a compressed air, to the cylinder. The bike is vertically
positioned, to start at zero velocity and to be free from fall. The falling over is produced under
the influence of gravity. The hand bar switches must be designed with clearance from the fuel
tank.
The foot is operated using the gear and brake. This design should not damage the frame
stationary fall.
The steel frame brackets designed is not attached to the other. The steel bolts and aluminum
frames, aluminum threads are also not attached to the steel frame.
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3.1.2 Manufacture of Engine
Materials
1) Two stroke and four stroke
2) Cylinder heads
3) Four stroke valve control
4) The range of capacity uses engine of 50cc to 650cc.
3.1.3 Manufacturing of Battery
1) Battery is designed using SL 12V.9AH.
2) The battery is designed using 9LB and recharge lithium ion batteries.
3) Fuel type is used for the prototype battery.
3.2 Sourcing Materials
Electrical Parts
a) Battery
b) Spark plug
c) Fuse
d) Light
e) Horn
Transmission Parts
1) Gears
2) Clutch
3) Drive system
Accessories
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a) Speedometer
b) Turn Signal indicator
c) Shock Absorber
d) Fuel indicator
4. Problem Definition
Most of the motorbikes have problems in their machines. The most common problems
faced by the people includes, Mileage problem, performance issues, brakes, electric starter,
engine, battery and vibration of the bike (Yuan, Ohmori & Lv, 2012).
4.1 Low Mileage
It is one of the common problem faced by many people. The main reasons for this
problem will be explained in this section. If the tire has low pressure, it will reduce the efficiency
of the fuel. Air is required by the tires to maintain proper shape. If air is low in the wheels, it will
create rolling resistance and becomes hard to ride. Hence, mileage is necessary to be decreased.
To avoid this problem, it is important to check the pressure of the tires ("Common Bike
Problems & Solutions: Mileage, Performance, Brakes & Electric Start", 2018).
4.2 Dirty Engine Oil
The efficiency of the motorbike is also reduced by dirty engine oil. The dirty engine oil is
thick and it resists the movement of the engine. The most dirty engine oil makes the gear shift
lever too hard and it creates more noise during the shifts. The oil should be changed, if the gauge
oil is black in color. It is really important to use good oil for the engine, for proper maintenance
(Lewis & Gagg, 2010).
4.3 Carburetor
It is also important to check the carburetor. The engine has two screws to adjust the ratio
of air and fuel usage. If it has more air and less fuel, the efficiency will increase and performance
will be decreased.
4.4 Poor Performance
Poor performance is another common problem in motorbikes, due to its machines. The
main reasons for the poor performance of the motorbike are listed below:
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4.4.1 Air Filter
It is more important to clean the air filter every time. Based on the riding conditions, the
air filter gets dirty, for every 1000Kms. It gets dirty when the ride is around dusty areas. To
avoid poor performance, the air filter must be cleaned periodically (Jones, 2013).
4.4.2 Quality of the Fuel
It is another factor for poor performance. If the fuel quality is poor, it will lead to poor
performance. To deliver better performance, different mixes can be used with different pumps.
4.4.3 Chain Slack
A slacking chain will lead to poor performance and it reduces the acceleration. If the
chain makes more noise from its cover, then it should be greased and tightened.
4.4.4 Lack of Warmup
Warmup is more important for the engine before it is started. It should be done every
time to reach the optimum temperature level to ensure better performance.
4.4.5 Poor Brakes
It is the primary element in motorbikes, for life security. Good quality brakes avoid break
issues.
4.4.6 Disc Brakes
If the disc break has poor performance, first it is necessary to check the fluid levels of the
break i.e., whether it is filled to its top level or not. Next, the air bleeding must be checked,
because the air gets into the tube which is placed between the calipers and pump. Hence, it can
reduce the breaking force. Air bleeding also improves the sharpness and bleed of the breaks.
4.4.7 Drum Brakes
If the drum break in the rear of the bike has poor braking, then the pedal or break lever
must be checked. If it has too loose, tighten the bolts. Hence, the wheels will rotate freely and
maximum pressure can be applied. The performance of the drum brakes are also affected by the
dirty brake pads (Yan, Yi, Zhu & Fu, n.d.).
4.4.8 Fail of Electric Starter
If the electric starter fails to start, then check the following signs.
4.4.8.1 Relay of the Starter
This starter relay is one of the part of electric system which is used to provide current for
the starter. If it is failed, we can hear a noise from the starter when the start button is pressed. It
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also happens due to low battery ("Six Common Motorcycle Problems and Solutions - BikeBD",
2018).
4.4.8.2 Battery Level
The efficiency of the bike is also reduced by low batter level, when it run out of acid. The
battery’s acid level should be checked after a long time of starting the bike. The battery is
charged when the bike is used for a ride. Hence, it is should be filled to avoid further troubles.
4.4.8.3 Halting Problem of the Engine
This problem has many reasons, but the most common reason is insufficient fuel flow to
the engine. Another reason for this problem is poor quality of fuel. Then, the condition of the
spark plug must also be checked i.e., whether it gets enough sparks to run the engine or not.
4.4.8.4 Strong Vibration
All bikes should have minimum vibration. If it has more vibration level, it will affect the
riding capabilities when it is riding at high speed. Thus, it is recommended to check the
functioning of all the body parts of the bike. The seat bolts, shock absorbers and suspensions
should be checked to avoid strong vibrations.
5. Design for Function and Sustainability
The motorbike is mainly based on this three systems, namely:
a) Engine
b) Wheel
c) Battery
5.1 Bike Engine
The bike engine converts heat energy into mechanical energy. The fuel combustion such
as petrol or diesel generates the heat energy, which is supplied to a working substance at high
temperature. The heat energy is converted into useful work by the expansion of the substance in
the suitable machines. Heat engines can be classified into two types they are External
combustion and internal combustion. In two wheelers we are using internal combustion. In the
internal combustion the combustion the combustion takes place inside the engine. The internal
combustion can be classified into horizontal or vertical, stationary or mobile, low medium or
high speed.
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Figure 1 bike engine
5.1.1 Engine Constructional Features
5.1.1.1 Cylinder
The basic and supporting portion of the engine power unit is cylinder. The major function
of the cylinder is to provide the space where the piston can be operated to mix the fuel and the air
which is dependence on the spark ignition and the compression ignition it allows to expand and
generate the power. By using the high grade of cast iron the cylinder is made, which supports
with the strength and resistance with less weight, chromium, nickel and some of the materials
which are added for the quality of the material. The starting movement of the engine is done by
the piston of the engine, which begins the movement and starts to transmit the power, to the
crankshaft as the result of pressure in the energy that is generated in fuel combustion. To permit
the direct attachment of the connecting rod and to perform the free action, the piston is closed in
the one end and open in the other end. The cast iron and the cast steel and the aluminum alloy
are the materials for the pistons. The current trend uses only aluminum alloy piston for the high
power diesel engine.
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Figure 2 cylinder
5.1.1.2 Piston Rings
Piston rings are made of cast iron on the account of their ability to retain bearing qualities
and elasticity. The retain compression is the primary function of the piston rings at the same time
to reduce the cylinder wall and piston wall contact area to a minimum. The other important
functions of the piston rings are the cylinder lubrication, control of lubricating oil, and
transmission of heat away from the piston and also from the cylinder walls. Depending on their
function and the location on the piston rings are classed and compressed as rings, and oil rings.
Near the piston head the compression rings are always at plain one piece and placed in the
grooves. Above the piston pin or in a groove near the piston skirt oil rings are grooved or slotted
and they are located. Controlling the distribution of the lubricating oil to the cylinder and the
piston is the main function, in order to prevent the unwanted consumption of oil.
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Figure 3 piston rings
5.1.1.3 Piston pin
The piston pin connects the connecting rod of the piston, which is made of hardened alloy
steel with the precision finish. Three various methods are used for connecting the piston to the
connecting rod. Connecting rod connect the piston and the crankshaft. One of the end which
connects the piston is called small end and the other end is called big end. The big end contains
two halves of bearing bolted together.
5.1.1.4 Crankshaft
Crankshaft is connected to the piston through the connecting rod which converts the
linear motion into rotational motion. The main bearing, housed in the crankcase is supported by
the crankshaft. Crankshaft supports counter weights and the flywheel blotted and smooth running
of the engine.
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Figure 4 crank shaft
5.1.1.5 Engine bearings
Anti-friction bearing supports the crankshaft and the cam shaft. At the high speed, heavy
load and high temperature these bearing are strong enough. In the above characteristics normally
cadmium, silver or copper is coated on steel back. In the current manufacturing, ball bearing in
place of main bearings of the thin shell type is used.
Figure 5 Engine bearings
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5.1.1.6 Valves
The valves are mounted either on the head of the cylinder or on the cylinder block. The
valves allow the air to enter the cylinder or to exhaust gases to outflow from the cylinder.
5.1.1.7 Camshaft
Camshaft operates the valves by action. It has separate cams for the inlet and outflow
valve. By the pressure of the spring the valve is lifted by the cam and soon it closes the valve.
From the crankshaft, the cam gets drive through the gear or the sprocket and the chain system,
which rotates at the half speed of the camshaft. Flywheel is made up of cast iron and its primary
function which is used to maintain the uniform engine speed. Regarding to the number of
cylinders and the types and size of the engine the flywheel size varies, which helps in the
balancing rotating masses.
Figure 6 cam shaft
5.2 Wheel
The wheel is mounted on brake on the front and rear, to measure the rotational speed in
each wheel delivered. The back wheel receives transmission motion from the transmission
system.
1) The manufacture wheel is strong enough to perform the above function.
2) The wheel is balanced both dynamically as well as statically.
3) It manufactures lightest possible unsprang weight.
4) The wheel design has the possibility to mount the wheel easily or it can remove it.
5) The wheel should not weaken and should not weathering age.
6) Wheel allows the tire to be removed and refitted.
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Figure 7 Wheel
5.2.1 Wheel Fixing
The wheel nuts and studs are attached to the wheel, to connect the hub. The wheel studs
press the axle flange or hub Wheel studs, which usually have right hand thread. The wheel is
designed with left hand thread, is marked with a symbol L. The wheel in metric threads is
marked with metric or M.
5.2.2 Wheel Nut Torque
The torque is used to fix the wheel, for all vehicles. The torque is lead to hub distortion or
wheel, causing run out and vibration. Low torque allow the wheels to come off and wheels’ nuts
to work loose. The nuts should be tightened in a diagonal pattern.
5.2.3 Types of Wheels
a) Spoke Wheels
The spoke wheels is a wire wheels. It uses older sports vehicles. The spoke wheel cannot
fit the tubeless tires.
b) Steel Wheel
Steel wheels is called as Disc wheel. This wheels’ design is very popular and is very
strong and cheap to produce. The disc brake’s design helps to dissipate the generated
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heat. These breaks are generally used on heavy load in the front discs, on the road. The
disc brakes still have positive effect in wet conditions, because of the holes.
Figure 8 steel wheel
The disc brakes are damaged usually in four ways, as follows:
(1) Scarring
(2) Cracking
(3) Excessive result or warping.
The damage of disc brakes is easy to remove and is low cost when compared to other breaks.
c) Alloy Wheel
The alloy wheels is light in weight and is attractive. But, these wheels are difficult to
clean.
Divided Rims
The rims is must never be separated while the tire is inflated
Split Rims
It is where the tire is held in place, by a large circle and it cannot remove the tire, unless
the user is properly trained.
5.2.4 Wheel Brake and Suspension Parts
The motorcycle wheel are generally made of steel rims with spokes of aluminum. India is
using most common wheel called alloy wheels. These wheels are produced by heat forging from
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magnesium alloys ZK60 and MA-14. The tubeless tires are conventional tube tires with fast
catching up. The motorcycle front brake is used to push the piston into cylinder, which forces the
fluid out and through the tube. The tube is connected to caliper. The squeeze lever force is
applied proportionally to the force applied on the front well. The suspension system works on the
collection of springs and shock absorbers that help to keep the wheels in contact on road.
Figure 9 wheel break and suspension part
5.2.5 Dust
The brake dust is occupied in the wheel, the calipers and the other components of the
braking system consist mostly of disc material. The breaking force applies the friction between
the breaker pad and the disc wears both the pad and disc away. The dust immediately clears if it
cannot clean, then the performance of breaks will be damaged.
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Figure 10 Dust
5.2.6 ABS
Anti-lock braking system (ABS) in the motorcycle is used for wheel locking, from the
braking situations. This Anti-lock brake system is also used in the motorcycle as wheel speed
sensor, to adjust the pressure of the brake fluid for avoiding fall down. The ABS helps the
motorcycle to maintain stability by decreasing the stopping distance. ABS uses main parts of the
Valve and pump system. The two systems that use pressure modulation system are, inlet in
solenoid and outlet valves and plumb, motor and accumulator. The valves contain different
number of model, for modeling additional number of break channels. The input EUC is based on
the coils that operate the in-and outlet valves. The ABS system is alternatively seeing failure to
brake hard enough, which can result in rider failing to avoid crash.
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Figure 11 ABS
5.2.7 Speedometer
1) The speedometer cable is also powered by the drive shaft turns.
2) Speedometer engine when turns over, the driveshaft turns to make the wheels spin round.
3) The speedometer around the same speed inside the cup and magnet rotates continually in
the same direction (that is counter clockwise).
4) Spinning magnet creates eddy currents in the speed cup. The eddy currents create speed
using cup route counter clockwise direction. The magnet and speed cup are should not be
joined together in any way, due to the presence of air in between them.
5) The hair spring tightens restraining the speed cup. So it can turn only a little way.
5.2.8 Tires
Motorcycle’s tires are manufactured using pneumatic tires. The importance of using tire
is the contact patch. The tire is covered at small area. The dirt bike tires have knobby deep treads
for maximum grip on loose dirt and mud or gravel. The tires are made by harder rubber
compound.
5.2.9 Brakes
1) The motorcycle have generally two independent brakes. One is set in the front wheel and
another one is set on the rear. Both the brakes can be applied at the same time, using only
one control.
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2) The front brakes are generally have high effective when compared to the rear brakes. The
motorcycle wheel is short compared to center of mass height. This result is known as
brake dive. The brakes manufacturing in either based on drum or disc.
5.2.10 Transmission Part
1) Drive System
The drive system generally use three basic ways to transmit engine power to the rear
wheel of a motorbike. The drive system consists of chain shaft or belt. The drive system uses the
shaft for transmission. The output shaft is connected to the sprocket i.e., attached to the
motorbike’s rear wheel, by metal chain. Transmission turns the smaller front sprocket, which
transmits power to the chain, to larger rear sprocket. This type of system must be adjusted,
lubricated and its chain must be stretched. The sprockets wear require periodic replacements.
2) Friction Drive System
The friction drive is another transmission used in motorbikes. The friction drive
transmission type is Continuously Variable Transmission (CVT). The CVT variation of gear
ratio has disc connected, for rotation of engine. The engine rotates is connected across the face of
second disc, in the rear wheel. The changing radius contacts between the two disc surfaces and
has different gears. The friction drive uses material made of advanced belt. Today, the belts are
operating much like the metal chains and are made in cogged rubber. The shaft final drives
sometimes use the friction drive system. This shaft system transmits power to the rear wheel.
The popularly used shaft drives the system, because this system is convenient and don’t require
much maintenance, like the chain based system. The shaft drives sometime cause unwanted
motion and are heavier.
5.2.11 Clutch
The clutch is used in motorbike for smooth shift. The function of clutch is used to
transmit the torque from engine to derivation of speed between different gears without causing
damage to the teeth of gears.
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5.2.12 Gear
The gears is using to increase or decrease the speed of rotation. It can be used for rotation
of reverse direction. The gear is rotational to transmit different axis. The gears are round shape
and the edge of the gear have teeth.
Types of Gears
The gear contains various types such as super gears, bevel gears, helical gears, worm
gears and gear racket. The common and easy to produce shaft is cylindrical gears.
5.2.13 Fuse
The fuse using motorbike’s inverse time current characteristics and it is used for overload
protection. It is the cheapest form of protection that is available. The fuse needs no maintenance.
It helps the minimum time of operation that can be made with much smaller circuit breakers.
5.3 Motorcycle Battery
An electrical storage device, which is used in the motorcycles to store the electrical
energy is called as motorcycle battery. Here, reversible chemical reaction takes place between
the lead and acid of the battery to store electrical energy. The battery acid or battery electrolyte is
a mixture of distilled water and sulfuric acid. It is used as a conductor between the lead and acid
of the batter to form the electrical charge.
5.3.1 Lead Acid Motorcycle Battery
Figure 12 Lead acid battery
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Lead acid motorcycle battery is a first type of wet cell battery, which is also called as
conventional or flooded cell batteries ("Different Kinds of Motorbike Battery - Motorcycle
Battery Types", 2018). This type of batteries contain plastic stoppers row at the top. Usually, it
has higher and lower acid levels with opaque or white lower casting. The reference number of
this batteries usually starts with YB, Y, C or G, GB or CB. These batteries store the electrolytes
in an acid and give off the hydrogen gas. But, it is important to check these batteries periodically
and it should be topped up with distilled water.
5.3.2 Components
The basic components of the batteries are listed below:
Battery Casing
It is used to enclose and seal the body of the battery. It is made up of layers and it is
manufactured by various materials like polyethylene, polymer and terephthalate layer. Also this
casing layers are manufactured with carbonized plastic ("What Materials Are Used to Make a
Battery? – Battery Education", 2018).
Battery Chemistry
It is a fact that, the battery device converts the chemical energy into electrical energy.
Chemical energy is the base for this conversion. Here, the lead acid is used as a chemical. These
lead acid batteries are portable, light weight and they are used in many places.
1. Electrolyte of the Battery
This electrolyte solution is mainly used for the electron flow between the two electrodes.
This electrolyte is a chemical compound which is dissolved in the solvent for form a solution. It
is used as a conducting medium in the battery cell.
2. Hardware’s of the Battery
The battery requires specialized hardware to create a smart battery. The common
hardware of the smart battery are Connector, Fuse, cell pack, fuel gauge IC, thermistor, pc
board, sense resistor, discharge and charge FET and EEPROM.
23

5.3.3 Design of the Battery
This motorcycle battery with 12 volt is made up of six cells with plastic case. Each cell
contains negative and positive plates, which are immersed in the electrolyte such as dilute
sulfuric acid. Each cell has 2.1 volts when it is charged fully. These cells are connected together
to produce 12.6 volte battery. Electrochemical reaction takes place between the cells to convert
the chemical energy into electrical energy. Each cell contains plate which is made up of lead
calcium. An active material, such as a paste is used to create a bond between the plates. Sponge
lead is used for the negative plates and lead dioxide is used for the positive plates. This active
material carryout the chemical reaction with sulfuric acid when the electric load is placed in the
terminals of the battery.
Working
The battery will discharge when the sulphuric acid is depleted in the electrolyte. Thus, the
electrolyte resembles water. At the same time, the sulphate is coated in the plates to reduce the
amount of surface area in which the chemical reaction takes place. Then, charging takes place in
the reverse order and the sulphate goes back to the acid. The electrolyte contains the charged
ions of the hydrogen and sulphate ("Yuasa Batteries -", 2018). In which, the hydrogen ions have
positive charges and the sulphate ions contains negative charge. When the load is placed in the
sulphate ions, it moves to the negative plates to give their negative charge. To form the lead
sulphate, the remaining sulphate ions combines with the active materials on the plate. But, it
reduces the electrolyte strength and the sulphates in the plate act like an electrical insulator.
Hence, the excess electrons move from negative end and back to the positive terminal, through
electrical device.
The positive plates accept the electrons which are back from the negative end. To form
the water, the oxygen in the active material reacts with hydrogen. To form the lead sulphate, lead
reacts with the sulfuric acid. The current flow is created by the ions which moves around the
electrolyte. But the cell is discharged and the ions count decreases because the sulphate is coated.
The chemical reaction takes place between the pores of the active material, which is bonded with
the plates.
Self-Discharge of the Battery
24

If the battery is not used, they discharge all by themselves. It is a bad feature of this
battery. This self-discharge rate increases at high temperature and decreases at cold temperature.
Each device keeps alive memory with 20 milliamps. It requires half amp hour of battery with 80
degree. It is combined with the self-discharge rate. Hence, the battery will be discharge 50
percentage in two weeks if it is not used or un-attended.
Charging of Battery
Charging process of the battery is based on the reverse electrochemical reaction. In this
process, the electrical energy is converted into chemical energy. The battery will not store
electricity, but it stores chemical energy to produce electricity ("Charging Information for Lead
Acid Batteries – Battery University", 2018). The current flow of the battery is reversed by the
charger to provide high voltage than the battery. This charger creates excess electrons at the
negative plates to attract the positive ions of hydrogen. When the charge current is more than the
absorption rate, it leads to overcharging. Hence the battery will overheat and the electrolyte will
bubble. Also it wastes some charging current and it increases the amp hours.
Lead acid batteries are charged in three stages such as constant current charge, float
charge and topping charge. Constant current charge stage is used for bulk charges and it requires
half of the overall charging time. Float charge stage is used to compensate the loss of self-
discharge. Topping charge is used to lower the charge current and it provides more saturation. In
the first stage, 70 percent of the battery is charged within 5 to 8 hours. The remaining 30
percentage is filled in the topping charge stage and requires 7 to 10 hours. At the third stage, the
battery is maintained at full charge.
5.3.4 Spark Plugs
Spark plugs are used to boost the mobility and engine power of the motorcycle. The
performance, quality and reliability of the motor cycle is based on the spark plugs. Hence, the
design and functionality of the spark plug is more important. This sparkplugs determines the
performance and safe function of the engine. The main features of the spark plugs are listed
below:
a) Reliable cold starting
b) Smooth operation.
c) Dependable performance for the overall service.
25

d) Wide range of applications with several brands.
e) Factory set electrode which suits all engine types.
f) Easy and quick replacement.
Figure 13 spark plugs
The heat range number denotes the thermal capacity of the spark plug. If the heat range is higher,
the resistance will be higher and reduces auto ignition ("Moving motorcycles: Spark plugs from
Bosch", 2018). The heat number is measured by the extensive applications and current ionic
process is used for the measurement. The heat range is more important to achieve the minimum
temperature and it avoids carbon fouling. To avoid auto ignition the maximum temperature
should not be exceeded. The low heat range number that is 8 to 2 indicates the cold spark plugs.
The high number that is 7 to 10 indicates the hot spark plugs
Tasks of spark plugs
26

The air fuel mixture is ignited by spark plug in the combustion chamber of the gasoline
engine by using electric spark.
1) It should be reliable with right moment.
2) It must function over the entire service without any misfiring.
3) It should not be overheat even it is used in a long operation with high load.
6. Identification of Current Good Practice in Motorbike
a) For each revolution of the crank shaft, two stroke engine gives one working stroke. The
power developed from the engine speed and the cylinder volume is double than the four
stroke engine. Only one stroke is given for every two revolutions of the crank shaft.
b) The turning moments on the crank shaft is more uniform due to one working stroke for
each revolution of the crankshaft. Moreover, the two stroke engine needs lighter
flywheel.
c) The engine must have simple construction and the maintenance must be much simpler
than the valve mechanism.
d) The frictional resistance of the suction and the exhaust is saved to overcome the power
required, which results in fuel economy.
e) The mechanical efficiency is higher responding to the absence of cam, camshaft.
f) It produces less oscillation.
g) The two stroke engine is compact and less space is required when compared to the four
stroke engine.
h) The engine has less weight and has the same power and speed especially when the
crankcase compression is used.
i) As the engine is in the compact size, the requirements of the spare parts are reduced.
j) If the valve has less type, the two stroke engine can be easily reversed.
7. Identification of Current Bad Practice in Motorbike
1) In two stroke engine, the foraging is not efficient. In the poor thermal efficiency the
dilution of the charges takes place.
2) The lubricating oil is mixed with the fuel. The two stroke spark ignition does not consist
of separate lubrication system.
27

3) The parts of the two stroke engine are subjected to comfort in assembling and
dismantling.
4) The fuel is passed directly to the exhaust in spark ignition two stroke engine. Due to this,
the consumption per horse power is comparatively high.
5) The two stroke engine gets heated up due to the excessive heat produced with the heavy
loads. On the other hand, running with the engine is not much smooth at the same time.
6) As higher amount of heat is generated, it consumes more lubricating oil.
7) In the upward stroke, the ports are opened and the actual compression is started after the
both inlet and the exhaust are closed.
8) The efficiency of the engine is directly proportional to the compression ratio.
9) The efficiency of the two stroke engine is lower than the four stroke engine of the same
size.
8. Justification for Component Choices
There are several spare parts to assemble the motorbike and also different types of fuel
consumption engines are available. To run the motorbike, its components and the spare parts
must be suitable for a comfortable and smooth ride. Each component differ from each other such
that, the spares must be fixed on the correct place. The excess amount of heat is produced during
the process, to compensate the lubricant oil, as shown below:
Motorbike Parts Quantity
Engine 1
Battery 1
Wheels 2
Head light 1
Seat 1 or 2
Fuel tank 1
Exhauster 1
Speedometer 1
28

Each component provides different process of approach and where the output is to run the motor
bike successfully. Cost and aesthetics are designed by the designers. In the modern world, the
motorbikes became fuel efficient and best for economical transportation. Physical conditions like
environmental situation affected the usage of motorbikes. If the environment is pleasant, the
usage of motorbike will be increased rapidly.
9. Granta CES Edupack Software Analysis
9.1 Eco Audit Tool
There are six relative constructive life phases, but, this report selects the following life
phases:
1) Sourcing of Material
2) Product Manufacturer
3) Lifetime Usage
The sources that are considered in motorbike are:
1) Engine
2) Wheel
3) Battery
The eco Audit Tool performance are mentioned below. The level1 Database used in this
product performance are:
a) Product name: Motorbike
b) Country of manufacture: Worldwide
c) Country of use: Worldwide
d) Product life (years): 7 years
The below screenshot indicates the Eco audit tool chart, for motorbike.
29

The relative constructive life of phases graph is shown in the below graph.
30

Figure 14 Relative contribution of life phases
Phase Energy
(MJ)
Energy
(%)
CO2 footprint
(kg)
CO2 footprint
(%)
Cost
(USD)
Cost
(%)
Material 2.29e+05 0.3 1.69e+04 0.3 3.68e+03 4.75
Manufacture 8.06e+07 97.2 6.04e+06 97.4 1.93e+04 25
Transport 0 0.0 0 0.0 0 0
Use 2.05e+06 2.5 1.46e+05 2.3 5.44e+04 70.2
Disposal 1.41e+03 0.0 98.9 0.0 45.3 0.0585
Total (for first life) 8.29e+07 100 6.21e+06 100 7.75e+04 100
End of life potential -1.08e+03 -148
31

Energy Analysis
Figure 15 energy analysis
Energy
(MJ/year)
Equivalent annual environmental burden (averaged over 7 year product
life):
1.18e+07
Sourcing of Materials
Component Material
Recycled
content*
(%)
Part
mass
(kg)
Qty.
Total mass
processed**
(kg)
Energy
(MJ) %
engine
Cast iron, nodular
graphite, EN GJS 350
22
Virgin (0%) 7.1e+03 1 7.1e+03 2.3e+05 99.5
battery Li-Ion battery (for
scooters) Virgin (0%) 0.71 1 0.71 2.3e+02 0.1
wheel
Magnesium,
commercial purity,
ASTM 9980A
Virgin (0%) 1.5 2 3.1 1e+03 0.4
Total 4 7.1e+03 2.3e+05 100
Manufacture
32

Component Process % Removed Amount processed Energy
(MJ) %
engine Vaporization - 7.1e+03 kg 8.1e+07 100.0
engine Coarse machining - 0 kg 0 0.0
wheel Casting - 3.1 kg 36 0.0
Total 8.1e+07 100
Life Time Usage
Static mode
Energy input and output type Fossil fuel to mechanical, internal combustion
Country of use World
Power rating
(hp) 15
Usage (hours per day) 12
Usage (days per year) 1.8e+02
Product life (years) 7
Relative contribution of static and mobile modes
Mode Energy
(MJ) %
Static 2.1e+06 100.0
Mobile 0
Total 2.1e+06 100
Disposal
Component End of life option % recovered Energy
(MJ) %
engine Landfill 100.0 1.4e+03 99.8
battery Reuse 100.0 0.14 0.0
wheel Recycle 100.0 2.2 0.2
Total 1.4e+03 100
CO2 Footprint Analysis
33

Figure 16 CO2 footprint analysis
CO2
(kg/year)
Equivalent annual environmental burden (averaged over 7 year product
life):
8.87e+05
Detailed breakdown of Individual Life Phases
Sourcing of Materials
Componen
t Material
Recycled
content*
(%)
Part
mass
(kg)
Qty.
Total mass
processed**
(kg)
CO2
footprint
(kg)
%
Engine
Cast iron, nodular
graphite, EN GJS 350
22
Virgin (0%) 7.1e+03 1 7.1e+03 1.7e+04 99.1
Battery Li-Ion battery (for
scooters) Virgin (0%) 0.71 1 0.71 17 0.1
Wheel
Magnesium,
commercial purity,
ASTM 9980A
Virgin (0%) 1.5 2 3.1 1.4e+02 0.8
Total 4 7.1e+03 1.7e+04 100
Product Manufacture
Component Process % Removed Amount processed CO2 footprint
(kg) %
Engine Vaporization - 7.1e+03 kg 6e+06 100.0
Engine Coarse machining - 0 kg 0 0.0
34

Wheel Casting - 3.1 kg 2.7 0.0
Total 6e+06 100
Lifetime Usage
Static Mode
Energy input and output type Fossil fuel to mechanical, internal combustion
Country of use World
Power rating
(hp) 15
Usage (hours per day) 12
Usage (days per year) 1.8e+02
Product life (years) 7
Relative contribution of static and mobile modes
Mode CO2 footprint
(kg) %
Static 1.5e+05 100.0
Mobile 0
Total 1.5e+05 100
Disposal
Component End of life option % recovered CO2 footprint
(kg) %
engine Landfill 100.0 99 99.8
battery Reuse 100.0 0.0099 0.0
wheel Recycle 100.0 0.15 0.2
Total 99 100
Cost Analysis
35

Figure 17 cost analysis
Sourcing of materials
Componen
t Material
Recycled
content*
(%)
Part
mass
(kg)
Qty.
Total mass
processed**
(kg)
Cost
(USD) %
engine
Cast iron, nodular
graphite, EN GJS 350
22
Virgin (0%) 7.1e+03 1 7.1e+03 3.5e+03 96.5
battery Li-Ion battery (for
scooters) Virgin (0%) 0.71 1 0.71 1.2e+02 3.3
wheel
Magnesium,
commercial purity,
ASTM 9980A
Virgin (0%) 1.5 2 3.1 8.6 0.2
Total 4 7.1e+03 3.7e+03 100
Product Manufacture
Component Process Length
(m)
%
Removed
Amount
processed
Cost
(USD) %
engine Vaporization - - 7.1e+03 kg 1.9e+04 100.0
engine Coarse
machining - - 0 kg 0 0.0
wheel Casting - - 3.1 kg 7.8 0.0
Total 1.9e+0
4 100
Life time usage
36

Static mode
Energy input and output type Fossil fuel to mechanical, internal combustion
Country of use World
Fuel rate Domestic
Power rating
(hp) 15
Usage (hours per day) 12
Usage (days per year) 1.8e+02
Product life (years) 7
Relative contribution of static and mobile mode
Mode Cost
(USD) %
Static 5.4e+04 100.0
Mobile 0
Total 5.4e+04 100
Disposal
Component End of life option % recovered Cost
(USD) %
engine Landfill 100.0 45 99.9
battery Reuse 100.0 0.0046 0.0
wheel Recycle 100.0 0.02 0.0
Total 45 100
Bubble chart for the given product
The bubble chart indicates the properties of the given metal and alloys of the product
used. The below chart indicates the performance of the given mechanical properties and general
properties of the metals. The given chart indicates the performance of the yield strength vs.
density of the given metal and alloys used in this product.
37

Yield strength (elastic limit) (MPa)
10 100 1000
Density (kg/m^3)
2000
5000
10000
20000
Young’s modulus vs. density of the given chart indicates the performance of the given product.
The bubble chart indicates the difference between metals and alloys, to determine performance.
Young's modulus (GPa)
10 20 50 100 200 500
Density (kg/m^3)
2000
5000
10000
20000
The below chart indicates the performance of gasoline (petrol) vs. specific heat capacity of the
motorbike.
38

Petrol (gasoline)
Unacceptable Limited use Acceptable Excellent
Specific heat capacity (J/kg.°C)
200
400
600
800
1000 Wrought magnesiumalloys
Cast magnesium alloys
Age-hardening wrought Al-alloys
Cast Al-alloys
Non age-hardening wrought Al-alloys
The difference between young’s modulus and price performance of the given metals and alloys
used in this product.
Young's modulus (GPa)
10 20 50 100 200 500
Price (USD/kg)
1
10
100
1000
10000
100000
Cast iron, gray Metals and alloys
Nickel-based superalloys
Tungsten alloys
Silver
Gold
Tin
Wrought magnesiumalloys
Lead alloys
Commercially pure lead
39

9.2 Advantages and Disadvantages of Motorbike
9.2.1 Advantages of Motorbike
The advantages are:
1) The motorbikes utilize less fuel when compared with other vehicles, especially
on longer journeys. The small size of gas tank in the motorbike reduces cost and
fill up at the pumps.
2) The motorbike needs less maintenance and fewer repairs.
3) The motorbike is small in size when compared to other vehicle, which makes it
easy to cross traffic roads, as it occupies less road space.
4) It is easy to park motorbikes.
5) The registration and taxes for motorbike is less when compared to other
vehicles. The government discounts on registering motorbikes.
9.2.2 Disadvantage
The disadvantages are:
1) When compared to driving a car, there are maximum personal risks involved to
ride a motorbike.
2) Only two people can travel at a time.
3) Some of the bike models cannot be recommended for long distance travel.
4) Seating position is not comfortable in some bikes.
10. Sustainability Audit
10.1 Old Method
The motorbike is designed using one dimensional method. The bike’s engine designing is
a very hard task. The bike cooling system is replaced in every two years. It provides average
mileage, it has poor impression on its looks and it had poor performing engine design.
Maintenance and reliability was high and fuel efficiency was low.
10.2 New Method
The new design of the motorbike is designed using CSE Granta, in three dimensional.
The design of bike engine is easy to access. The cooling system of bike has life time usage. It
40

offers good mileage and good design looks when compared to the old one. Moreover, it has
better performance and reliability. The fuel system is good.
10.3 Comparison of Old System and New System
11. Conclusion
Motorbike is the selected product of this report, where its three main components like
wheel, engine and battery are studied. Analysis and performance of the motorbike using Edupack
software tool designed the susceptibility of the motorbike’s performance. Among six life phases,
this report discusses about, Sourcing of materials, Product manufacture and lifetime usage of the
product. A clear study about the motorbike and the analysis function using the Edupack software
is completed. Each spare parts required in the motorbike are explained. Current good and bad
41
Old System New System
Bike engine is hard. Bike engine is easy to use.
Bike manuals replaces the
coolant in every two years.
Bike manuals can be used for
life-long.
Average mileage and low
price.
Good mileage and high cost.
Design and Looks: 7/10
Engine and Performance:
8/10
Comfort and Ergonomics:
6/10
Maintenance and
Reliability: 6/10
Fuel Efficiency: 8/10
Total Score: 35/50
Design and Looks: 7/10
Engine and Performance:
8/10
Comfort and Ergonomics:
7/10
Maintenance and
Reliability: 8/10
Fuel Efficiency: 8/10
Total Score: 38/50

practices of motorbike are identified. The graph is plotted using the software, which depicts the
analysis of the considered components. Cost analysis is estimated. Necessary recommendations
for the manufacturers are provided. The overall analysis determines that, the motorbike is a
sustainable product.
42

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