IRJET- Design and Analysis of Plug-in Hybrid Motorcycle Chassis

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 02 | Feb 2020 www.irjet.net p-ISSN: 2395-0072
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 170
DESIGN AND ANALYSIS OF PLUG-IN HYBRID MOTORCYCLE CHASSIS
K. BHANU KIRAN1, C. RAHUL2, MAHESH. CH3, P. DINESH GUPTA4
1Professor Dr.P.Issac Prasad, Dept. of Mechanical Engineering, K L Deemed to be University, Andhra Pradesh, India
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Abstract - Plug-in hybrid electric motorcycle (PHEM) is an
alternative to promote sustainability lower emissions.
However, the PHEM overall system packaging is affected by
restricted area in an exceedingly motorcycle chassis. In this
paper, a chassis applying the concept of a half-duplex cradle
(double cradle) is analysed to apply in PHEM. The chassis
3dimensional (3D) modelling is built with CAD software. The
PHEM power-train components and drive-train mechanisms
are replaced with the same size and material blocks into the
3D modelling to ensure the chassis provides enough space.
Besides that, a human dummy model is built into the 3D
modelling to ensure the rider’s posture and comfort. The
chassis 3D model then undergo to the analysis in ansys. The
analysis predicts the stress distribution, displacement and
strain. The data are used to identify the critical point, thus
suggesting the chassis design is applicable or need to
redesign/ modify to meet the require strength. Critical points
mean highest stress which might cause the chassis to fail. This
point happens at the joints at triple tree and bracket rear
absorbent for a motorcycle chassis. As a conclusion, this
analysis predicts the stress distribution and guideline to
develop a safe prototype chassis.
Key Words: PHEM chassis, Half-Duplex cradle,
computational analysis.
1. INTRODUCTION
A plug-in hybrid electric motorcycle (PHEM) is equips with
two or more energy source, typically a gasoline internal
combustion engine is coupled with an electric motor to
propel the PHEM. The electric system in PHEM operates at
high efficiency, allow diversification of energy resources,
zero local emission and work silently [1,2]. However, PHEM
require more components and complex drive-train
mechanism as compare to conventional internal combustion
engine motorcycle [3,4]. These cause the design of PHEM
overall system packaging is challenging as constraint by
limited space in a motorcycle chassis [5].
For instant, there are several motorcycle chassis design
available with varies features and applications. These
include Cruiser, Sport Bike, Touring, Standard, Dual-Sport,
Scooters and Off- Road type [6]. The chassis is the central
frame of the motorcycle which upholds the components and
loads. These include the weight of each component and the
forces manifest during acceleration, deceleration and
cornering [7]. The chassis design must be able to withstand
above loads besides consideration for the rider safety, fuel
efficiency and aerodynamics [8-10].
Half-duplex cradle framed one is type of sport motorcycle,
which originally meant for high speeds and deeper turns
purpose. Its built from scratch to have compact appearance.
The main features in present frame include widened frame,
raked fork, Clubman handlebar and feet backward riding
posture. Figure 1 illustrates the features in Half-duplex
cradle type motorcycle.
FIG-1: A Half duplex cradle chassis is modelled in
solidworks.
2. LITERATURE SURVEY
A hybrid electric vehicle (HEV) consistoftwoormorepower
source namely, internal combustion engine and an electric
motor to improve its fuel efficiency and the reduction of
harmful emissions. A plug-in hybrid vehicle (PHEVs) is an
HEV with the ability to recharge its energy storage system
with the supply of electricity from the electric utility grid.
The terminology between PHEV and HEV can be classified
further into charge-sustaining mode, charge-deleting mode,
all-electric range (AER), electrified Miles, PHEVxx, SOC,
degree of hybridization and utility factor .
The hybrid electric motorcycle are introduced as
motorcycles are the major mode oftransportationespecially
in South Asia and Asia region. Motorcyles are favoured due
to limited space, short daily trip distances, population
density, easy operation and maintenance. The number of
motorcycles has increased by 0.35 million per year for
domestic sales and 1 million for export into South Asia
market. The development of hybrid electric motorcycles are
driven by the ‘go green’ technological push, economic sense
as well as to reduce harmful exhaust emissions
In the design of plug-in hybrid electric motorcycle (PHEM),
the chassis plays a significant role as it supports the
powertrain components,drivetrainpartsandrider.Achassis
is essentially the skeleton of a motorcycle.Itmustbestraight
to provide a secure mounting for the steering apart from
proper wheel alignment. The frame must be structurally

sound to support the weight of the rider, the engine and the
other components attached to it.
One of the chassis design types of the sport motorcycles is
the Half-duplex cradle or feet backward type. This type of
chassis is characterized by the footrests being backward
from the seat, short forks. The handlebars may be lower as
compared to the seat which is often positioned relatively
high. The riding position is as such that the legs of the rider
are folded backward.
3. PROBLEM STATEMENT
The arrangement of a plug-in hybrid electric motorcycle
(PHEM) components in a constrained space of a motorcycle
frame is becoming a challenging task. Therefore, the design
of the chassis is important to ensure enoughspaceisgiven to
mount all the peripherals well.
The chassis design should also provide enough strength to
support the powertrain components, rider and remaining
forms of weight contributions. Plug-in hybrid electric
motorcycle (PHEM) are heavy when compared to
conventional motorcycles. Therefore, it is essential that the
chassis could withstand the before mentioned contributing
loads other than providing required support.
Hence, the combination of the above-discussed aspects as
well as other factors such as aerodynamics, economics and
comfort are commendable in the design of such chassis.
4. MOTORCYCLE CHASSIS DESIGN
In chassis design, the most important thing that must be
constraint is about the reference geometry on that chassis.
The importance of reference chassis geometry is to produce
new chassis in fully characteristic in design such as
aerodynamically stability, manoeuvrability and safety
consideration. Figure 2 shows the main parameter of
reference motorcycle chassis geometry.
FIG-2: Main parameters of motorcycle chassis geometry
The rake angle of the front fork indicates the angle between
the steering axis and the ground plane. A smaller rake angle
of the front suspension rods results in a greater stabilizing
effect on the front suspension system. The rake angle (angle
of steering axis) exists within the limit 24° to 30° to the
ground. Steering axis and ground interaction point is the
point of contact with the ground is indicated as wheel axis
contact perpendicular to the base of a stationary bike at a
point of their contacting. Trail is the distance between the
steering axis and ground contacting point and the point of
wheel contact. The trail has a important effect on the
stability and handling of a motorcycle. The wheelbase is the
distance between the rotation axis of the wheels in a
straight-line drive. Centre of gravity is determined by
vertical and horizontal position.
The driving attributescanbe mainlyeffectedbymodification
of the basic parameters. Therefore, if to alter the driving
stability of an already fabricatedmotorcycle,itmusthavethe
following parameters. Position can be adjusted the centre of
gravity. This can be accomplished by altering of a riding
positioning, which is, however, bounded by positioning of
control and support components of the motorcycle. Still,
these changes are not always easy to guideproperlybecause
it is impossible to encrypt all the variety of co-rider’s
weights. Further parameters of chassisare: wheel base,trail,
rake or steering axis angle.
5. SPECIFICATIONS
Wheel base = 1350mm = 53.149 inches.
FIG-3: Wheelbase of the motorcycle
Total weight = 140 kgs =308.647 lbs.
Load on front wheel (LF)calculated from the CG value got
from the solid works software.
Load on rear wheel (LR) calculated from the CG value got
from the solid works software.
FIG-4: Centre of gravity(CG) point which was obtained
from Solidworks.

Behind the front wheel = 727.05 mm = 28.624 inches.
Above the ground = 395.52mm = 15.571 inches.
6. THORETICALLY CALCULATED VALUES FOR CG
FIG-5: wheel base shown from above the ground with an
angle.
FIG-6: The CG point distance shown from the ground
Behind the front wheel = 726.948 mm = 28.62 inches.
Above the ground = 360.17 mm = 14.18 inches.
From solving the above-mentioned figure 5 sequentially we
can get the final theoretical CG value from the figure 6.
7. RESULTS
7.1 Static structural analysis
FIG-7: shows the result for von Mises Stress of maximum
of 749.69 Mpa.
FIG-8: shows the result for strain maximum value of
0.0037642 mm/mm.
FIG-9: shows the result for displacement
The analysis result for displacement (figure-9)showhighest
displacement is at the frame where the rider sits and the
frame supporting the weight of engine, electric motor,
controller, batteries and drive-train mechanism. The
maximum displacement is 4.57mm, thus providing
insignificant undesirable effect on neither chassis nor rider.
7.2 Vibrational Analysis
FIG-10: shows the result for equivalent stress of
maximum 4.0525e5 Mpa.
FIG-11: shows the result for deformation.

FIG-12: shows the result for vibrational displacement.
7.3 Impact Analysis
FIG-13: shows the result for equivalent stress of
maximum 0.10484 Mpa.
FIG-14: shows the result for equivalent elastic strain.
FIG-15: shows the result for total deformation.
REFERENCES:
[1] Chau K T and Wong Y S 2002 Overview of power
management in hybrid electric vehicles Energy Conversion
and Management 43 1953–68
[2] Amjab S, Neelakrishnan S and Rudramoorthy R 2010
Review of design considerations and technological
challenges for booming development and preparation of
plug-in hybrid electric vehicles Renewable and Sustainable
Energy Reviews 14 1104-10
[3] Sheu K B and Hsu T H 2006. Design and implementation
of a novel hybrid-electric-motorcycle transmission Applied
Energy 83 959-74
[4] Wu X, Cao B, Li X, Xu J and Ren X 2011 Component sizing
optimization of plug-in hybrid electric vehicles Applied
Energy 88 799-04
[5] Bayindir K C, Gozukucuk M A and Teke A 2011 A
comprehensive overview of hybrid electric vehicle:
Powertrain configuration, powertrain control techniques
and electronic control units Energy Conversion and
Management 52 1305-13
[6] Teoh E R and Campbell M 2010 Role of motorcycle type
in fatal motorcycle crashed Journal of Safety Research 41
507-12
[7] Mat M H and Ghani A R 2012 Design and analysis of„
Eco‟ car chassis Procedia Engineering 41 1756-60
[8] Kamal M, Rahman M M and Rahman A G A 2012 J Mech
Eng Sci 3 291
[9] Robertson S A and Minter A 1996 A study of some
anthropometric characteristics of motorcycleridersApplied
Ergonomics 27 223-29
[10] Kamal M, Rahman M M and Rahman A G A 2013 Inter J
Automot Mech Eng 7: 912

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