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Dirtbike Frame

Students on Project: Olivia Griffin, Hannah Tripoli, Colin DeRidder

ManuFacturing

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Side view: Frame on jig

Jig

  • Used to constrain tubes, nodes, and brackets during welding

  • Design using PLA, Al 6061, optical table

  • All jig parts manufactured in house

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Tubes

  • Outsourced to VR3 for bending and coping

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Nodes and Headtube

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Welding

  • ​Frame will be tacked by students on jig

  • Then sponsor ConnWeld in Princton, WV will complete welding​​

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Frame Brackets

Design

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Near Finalized Frame Design

General Notes​

  • Full outer protection of powertrain and controls components

  • Coaxial motor and swingarm pivot

  • Sufficient wheel clearance at max suspension compression

  • 9.5" seat width

  • 11.5" maximum bike width

  • Clearance for top loading battery packs

  • 85° turn radius

  • Chain clearance

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Mounting - Controls/Powertrain

  • High Voltage Juntion Box (HVJB)

  • Motor Controller

  • Dirtbike Control Unit (DBCU)

  • Auxiliary Battery Pack

  • Pump

  • E-stop

  • LED Board

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Mounting - Chassis

  • Front suspension

  • Rear suspension

  • All stock bearings and hardware

  • Motor mounting plates

  • Mounting for swingarm​​

Planning

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Preliminary Frame + Main Components

​General Notes

  • Frame will consist of 4 major components

    • Tubes​

    • Nodes​

    • Brackets

    • ​Jig

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Requirements

  • Bike needs to be reasonably sized​

    • Seat maximum width 15in​

    • At least 10in ground clearance

    • Clearance for full front and rear suspension travel

  • Protection and Internal Components

    • Needs to house all powertrain and controls components​

    • Needs to protect all powertrain and controls components in the event of a crash or fall

    • Battery packs need to be swappable through top or side of frame

    • The motor should be coaxial with the swingarm pivot point

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Major Considerations

  • Frame Type

    • Twin Spar ​

    • Trellis

  • Manufacturing Method​

    • Cast​

    • Tube

  • Battery Swap Method​

    • Top Loading

    • Side Loading

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