Background
This bike was created when I was working for Boyce Technologies. The product was transferred to another company, and was an amazing project to work on.
The Challenge
The main challenge of this bike was to create a cargo bike which was a 3 wheeler. Two in the front 1 in the back. Definitely difficult considering the configuration to include proper turning.
My Role
My job was to completely overhaul the old design of the bike to allow for proper Ackerman steering. This allowed the trike to feel a bit more like a bike rather than an ATV. I also added a speed reduction gearbox to allow for easier turning.
Process
16 times. That’s how many times so far I have taken this bike apart and put it back together. It’s been a rough process filled with blood, sweat, and tears. Boyce Technologies does not really do a lot of simulation, and so far I have been working on the guess and check process. I have, however, thrown in some of my own simulations from time to time. For instance, I used FEA to determine that the main driveshaft was bending under load. As well, I used FEA to find sources of “slop” in the steering. I was able to reduce the slop of the steering system from about 25 degrees, all the way down to about 2.5 degrees. Getting rid of the slop may prove to be impossible with the current system, so all of these changes may be swapped out.
To add, it is a bit nice to have a whole factory in the first floor of the building where we can rapidly generate new designs.
Along with the physical labor has also come testing, which I have done rigorously. I’ve slammed many a curb with this trike, and of course all in the name of science.
Final Outcomes
This has been an excellent project to work on. It is currently a work in progress, however I believe in time, Amazon will want to purchase the final product. This trike will go in conjunction with other projects that I am working on, including a cover for a cart (for whole foods), and perhaps to other clients. I’ve learned a lot from this project so far, and I think that’s what counts.
