Level 2 Technological modelling Part 2 Case studies

Angle grinder- modelling

Kick-bike case study 1 Starting point

priming phase

User requirements

Observations

Concept presentation

Refined concept

Case study 2 - Avanti

Benchmarking A significant amount of time is spent analysing what makes a bike fast. Every area of the bikes on test is scrutinised and compared “The genesis of any good design project is to take what exists already and improve on it. This is what benchmarking involves.” By taking current leading frame designs such as their very own Chrono and testing them in the purpose built wind tunnel in San Diego, California, with the same rider and componentry under exactly the same conditions, a database of information is created to analyse.

Concept “It is during the concept phase that we start to see what the final bike may look like. However, there is still a great deal of work still to be done.”

Data Armed with a wealth of data the ADT (Avanti Design Technology) team analysed the results, learning where improvements could be made, to give direction to the project. One area that stood out was the front brake and its impact on the overall aerodynamics of the bike. Development for an integrated front brake begins in line with the rest of the bike..

Submodelling Before a full bike can be built, each section of a bike is broken down into its individual components and assessed on a separate basis whilst still considering the overall design: -Seat tube / top tube attachment Head Tube Fork Bottom bracket Seat stay attachment

Complete bike modelling Once the ADT team are happy with the individual elements of the bike it is time to put them all together and create a whole structure to analyse. This is still all in the pre- prototype phase of development. The models being tested are hugely complicated and some take up to eight hours to solve. Approximately 800 hours of aero engineering is spent developing the aerodynamics of the entire structure. Models are built and then tested at angles from minus 20 degrees, through zero, and back to 20 degrees. These angles most represent the wind angle in the real world. An aerodynamic feature that works extremely well at 0 degrees may be appalling at 20 degrees.

Testing aerodynamics “All these factors must be calculated and the very finest of lines trodden to achieve the perfect balance of aerodynamics at the most wind angles.”

Final prototypes Once the team are happy with the modelling, prototypes are commissioned. All the best modelling in the world can’t compete with the raw data and aesthetic appreciation that comes from a built prototype. “It is during this stage that minor tweaks are made to the bike. No area is beyond scrutiny in the pursuit of perfection. “

Wind tunnel The most anticipated stage of development is the validation. This is where all the hours of design are put through its paces. Off to the A2 wind tunnel in North Carolina, USA for the final testing phase.

Technology

Final outcome

Fore/Aft Adjustable Seat Clamp By allowing a large degree of adjustment at the saddle the rider is able to custom tune their fit. Positioning on the bike is vital for both comfort and power transfer. Integrated Seat Clamp The Chrono Evo II’s integrated seat clamp has been specifically engineered to hold the seat post rigid and to sit flush with the top tube for optimum aerodynamics. Integrated Handlebar Stem The Chrono Evo II’s handlebar stem sits flush with the top tube. This allows for optimum wind flow around the head tube area and down the bike. Integrated Front Brake Housing the brake inside a streamlined fork structure hugely reduces the turbulent effects of the brake. Controlling the flow around the fork and front brake is crucial for overall performance.

Material CFD Developed Tube Shapes Each tube has been developed using CFD (Computational Fluid Dynamics) technology. Mathematical modelling is used in conjunction with wind tunnel testing to achieve the tube shapes that offer the most aerodynamic efficiencies. CR5 Carbon Material This is our highest grade of carbon combined with modular monocoque construction method offering high stiffness for maximum drive efficiency.

Hydration Dual Water Bottle Cage Mounts As any endurance athlete knows, hydration is key, and the ability to pick up water and place it into a standard bottle cage during longer events is a feature not to be overlooked.

Case study 3 - Base impact jersey

Sketches and Idea generation

Material exploration

Material prototype

Details

Prototype

Activity Look at the different stages of modelling for the “ReadyToPresent” device for theBigBlueButton web conferencing client Identify the types of modelling What were the "should" and "could" decisions? Anticipate different stakeholder feedback

Identify different forms of modelling (functional to prototype). Why was the modelling selected? What information was required from the modelling at different stages of practice? What were the "should" and "could" decisions?. What modelling was used with different stakeholders? How did the modelling and feedback from stakeholders provide valid/reliable evidence? How did the modelling mange risk (reduce the potential of malfunction or increase the level of success of the tech outcomes? Did the modelling identify type, severity and probability of risk during the development stages? “ReadyToPresent” device for theBigBlueButton web conferencing client

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17