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PERSONAL TRANSPORT: GROUND, WATER, AIR
Motorcycle design. Personal transport
Directory / Personal transport: land, water, air Designing motorcycles is no less exciting than building any other vehicles. In addition, a motorcycle, which is, in fact, a naked concept of a self-propelled mechanism, requires more design sophistication, inventive gift and instinct of a good mechanic. I propose to the reader's court my ideas for the design of home-made motorcycles. I can say that I have some experience in this kind of work: at the Motosam-90 competition, my self-made - the eighth in a row - motorcycle was presented, a photograph of which the readers of the magazine could see in a report from the show in MK No. 2 for 1991 year. In the photographs that are presented on these pages, there are three more motorcycles of my design. About one of them - the last and most successful - I want to tell the readers. In thirteen years I have designed and built twelve two-wheeled machines. All of them differed significantly from each other. Moreover, two motorcycles were designed with partial use of the monocoque scheme, and three were completely frameless, with a monocoque bearing body. It is this design solution that I prefer today: it seems to me the most reliable and profitable in terms of strength, weight culture and ergonomics. I hope that my design experience can be useful for those who are going to make a motorcycle. So, what is a regular frame motorcycle? Simplifying the answer, we can say that this is a frame, a fuel tank, tool boxes, an air filter housing with an intake silencer, an exhaust silencer, a rear fender with a tail light bracket and numbers, a saddle base, a trunk, as well as a kilogram of all kinds of bolts, nuts, bushings , studs, washers and rubber bands, with the help of which all of the above is connected into a single structure. If you sum up the masses of these components and assemblies, you get a very impressive value. In addition, all this put together forms a far from aesthetically looking "skeleton", which has many secret places where absolutely indelible dirt will inevitably accumulate - you can get rid of it only by completely disassembling the motorcycle. A year or two passes - and tool boxes begin to rattle, cracks creep along the rear wing, the number falls off along with the bracket ... And if the motorcyclist, God forbid, gets into at least a minor accident or even simply falls? In these cases, the frame bends, dents appear on the tank and tool boxes. Huge lower mufflers deliver even more trouble, clinging to corners even on smooth asphalt and significantly reducing patency on bad roads. All these shortcomings are deprived of a two-wheeled vehicle designed according to the "monocoque" design scheme. Such a motorcycle is a monoblock welded box-shaped structure that performs the functions of all the above parts and assemblies. Interestingly, the spatial box structure is significantly more rigid and durable than the classic frame (including duplex frames). The use of the monocoque scheme in the design of the motorcycle not only reduces the weight of the two-wheeled vehicle, but also brings the center of gravity of the motorcycle closer to the ground. This happens due to the fact that in this design the tool box and battery compartment are located in the lower part of the body, and a lightweight air filter with an intake silencer is in the upper part, where the fuel tank cap is located on classic motorcycles. The air intake is made above the steering column - in this area the cleanest, dust-free air. An exhaust silencer can also be located inside the monocoque, however, reliable thermal insulation from the fuel and the seat cushion must be ensured.
Pictures 1 and 2 show my enduro bike and its monocoque body with rear suspension and engine protection frame. The mass of the monocoque is only 23 kilograms, and the useful volume of such a hull is about 56 liters, of which 41 liters fall on fuel tanks (more than that of the Zhiguli!), The remaining volume of the hull is also fully used. At the same time, the motorcycle does not look bulky. On the contrary, it has relatively small dimensions - in particular, the base of the car is only 1350 mm (less than any Izhevsk motorcycle). I must say that making a monocoque body is no more difficult than welding a good frame and equipping it with all attachments. It is only necessary to strictly adhere to the previously developed technology so that all the parts fit well and it would be convenient to weld them. When drawing the design of the body, take care to ensure a comfortable fit for the rider - this is especially important for enduro motorcycles - as well as the safety of the rider's movements, ease of movement in a sitting position, in a rack and in a quickdraw. After choosing the optimal, in the opinion of the designer, layout solution, you should draw the entire motorcycle in full size - depict a side, top, front and rear view, and also draw the most characteristic sections. The more detailed the drawing documentation, the easier it will be for further work on the manufacture of a two-wheeled vehicle. It is most rational to place the engine directly on the axis of the pendulum. In this case, the reaction from the tension of the drive chain closes directly to the pendulum. And it is far from small - sometimes it reaches the tensile strength of the chain, that is, almost two tons! It is necessary to fasten the powerful and not too well-balanced engine "Izh-Planet" (as well as all cross-country motors) with the help of silent blocks or rubber cushions. It is only necessary to take into account that the chain not only pulls the engine back, but also turns it in a horizontal plane due to the asymmetrical arrangement of the chain. In the work on creating a monocoque case, it is very convenient to use the method of volumetric prototyping. In this case, the layout of the case is assembled from cardboard blanks, which are connected using strips of paper and glue. In the process of making a layout, as a rule, changes occur in the design of the hull, since not everything can be foreseen in flat drawing projections. Simultaneously with the layout of the case, it is desirable to work out the technological map of its assembly - this will ensure the convenience of welding. In this case, it is necessary to take into account the possible warping of metal blanks when welding the body with uneven heating. Keep in mind that the parts on which the swingarm and steering column are attached are welded last. If necessary, they should be adjusted to the body so that on the finished motorcycle the planes of the wheels coincide with the plane of symmetry of the monocoque body. The finished three-dimensional layout is cut at the gluing points, and the cardboard patterns of the monocoque elements are numbered: it is these patterns that will be used to cut blanks from a steel sheet of the appropriate thickness - from 1,2 to 1,5 mm. The easiest way to do this is with a chisel on a massive anvil. Welding should be carried out in strict accordance with the technological map. To make the seams look neat and strong, the edges of the parts to be welded should be slightly bent, as shown in Figure 3. To ensure sufficient strength of the monocoque body, it is advisable to introduce additional amplifiers, flanging, and stiffeners into its design. For example, the steering column on my motorcycle and the transverse stiffening beam, to which the bracket of the only rear suspension shock absorber is welded, are additionally connected with a 25x40 mm rectangular steel pipe. In addition, inside this pipe it is convenient to place electrical wiring and motorcycle control cables. The design of the intake silencer significantly affects the engine power and its torque characteristics. The larger its volume, the easier the engine “breathes”, respectively, the less air pulsation in the filter, and hence the less noise. Experts recommend setting the muffler volume to at least 20 engine displacements. The path from the air filter to the carburetor should be smooth, excluding turbulence in the air flow, which significantly reduces engine power. After welding, the monocoque body is checked for leaks - first with water and then with pure gasoline. In the absence of leakage, the welds are coated from the inside with liquid epoxy glue - it will fill the small pores, bind pieces of slag and metal drops - this is especially important for the intake silencer. Rear suspension - pendulum type, with cantilever wheel mounting. Wheel travel - about 260 mm. The pendulum hinge is on ball bearings with gland seals. Chain tension - using an eccentric. The disc brake is mechanically driven. The front suspension is based on the fork from the CZ-516 motocross motorcycle. Wheel - under the tire in 21 inches, a drive of brake pads of a disk brake - hydraulic. The padded saddle pad is glued directly to the monocoque body, while the faux leather cover is flush-mounted with screws. I would like to warn readers who do not have sufficient experience in the design of motor vehicles that the creation of home-made two-wheeled vehicles is a very complicated matter. In this article, I tried to talk about my work and those ideas that I consider promising for amateur motorcycle construction. However, I would categorically advise novice motor builders not to take up the creation of a powerful machine based on this material. Maybe it's better to start with simpler motorcycles. After all, I went to the monocoque, creating more la dozen intermediate structures ... Author: A.Garagashyan
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