Professional Documents
Culture Documents
BICYCLE HELMET
GROUP 4
• Project development
• Background study
• Risks related to helmet use
• Objective
• Data Collection
• Statistical Analysis
• Conceptual Design
• Material Selection
• Design Evaluation and Analysis
• Manufacturing process (in general)
• Conclusion
PROJECT DEVELOPMENT
BACKGROUND STUDY
[1] Diane Hales. An invitation to health 2009 – 2010 Ed. US. Cangage Learning (2009)
BACKGROUND STUDY
• Bicycle helmet
Head gear intended for cycling protection.
Developed to reduce impact to the skull during a crash.
Able to prevent head and brain injury
• Suggested improvement
Different material selection for lighter weight
Redesigning air circulation / ventilation system
Changing the outer shell design for better aerodynamic
result
Improved helmet fitting
RISKS TO HELMET USE (MSD)
• Inappropriate helmet will cause muscle spasm, especially at
trigger points. The muscles of the neck such as the
suboccipitals and the cervical paraspinals may be affected.
NO COMFORT!
RISKS TO HELMET USE (COGNITIVE)
HOT!
MIGRAIN! LOSING
CONCENTRATION!
PROBLEM STATEMENT
• Extra load of helmet may affect the cyclist
performance and lead to MSD (discomfort and
hyperextension to neck)
• Poor helmet fitting lead to neck pain
• Back pain by overuse injury due to cycling
posture which is adapted decrease drag
coefficient
• Poor ventilation during cycling
• Helmet usage affect cyclist hearing (design)
OBJECTIVE OF PROJECT
• Sample selection
31 male students (total student batch 2010 = 287 pax)
• Activity selection
Cycling for race activity
DATA COLLECTION
• Measurement method
Measurement point : anthropometry point as agreed by group
members
Tool used : Tailoring tape, Vernier caliper, Ruler
Reference : National Institute of Bioscience and Human Technology Japan, NIBH Technical Report
DATA COLLECTION
• Design consideration
Product weight
Product fit to user
Ventilation and humidity
Aerodynamics
User coverage
Manufacturability.
CONCEPTUAL DESIGN
• Concept 1
Redesigned contour of outer
shell - improved aerodynamics
effect.
Ventilation slot - improved air
flow and internal humidity
during cycling.
Reduced product weight
Strap – same with benchmark
design
CONCEPTUAL DESIGN
• Concept 2
Contour of outer shell
• added with new structure
• re-designed for improved
aerodynamics effect
Ventilation slot – Improved air
flow and internal humidity during
cycling
Reduced product weight
Adjustable head grip and strap
Internal reinforcement
• maximise venting
• minimise bulk
• Comply to safety standards.
DESIGN SELECTION (VIA PUGH MATRIX)
CONCEPTUAL DESIGN
OUTER SHELL
• Aerodynamic contour
• Ventilation slot to INNER SHELL (FOAM LINER)
release internal heat and
improve humidity
• Main protection component
• Optimal cooling • Absorb impact
• Keep the foam in place • Minimum 20mm distance for
• Curve – sliding effect 300g impact protection
during impact instead of
direct hitting
INTERNAL REINFORCEMENT
• Maximise venting and
ADJUSTABLE minimise bulk
STRAP • Comply to safety
• Provide standards
external
support to neck
area ADJUSTABLE HEAD GRIP
• Adjustable for • Improved fitting for varying head size
varying head
size
CONCEPTUAL DESIGN
(a) (b)
Picture: Cross sectional view of cycle helmet concept (a) Frontal (b) Sideways
MATERIAL SELECTION
COMPONENT MATERIAL SELECTION REQUIREMENT
Outer shell • Enhanced surface features – sliding effect during impact
• Able to mould for ventilation slot
• Thin and light
• Absorbs impact fairly
Inner shell / Foam • Able to absorb most energy / unit volume instead of
liner bouncing back to the user head.
• Redistributes a localised external force over a larger area,
reducing the local stress on the skull.
• F = ma = 9kN
(Max tolerable deceleration, a = 300g)
To prevent F>9kN, plateau stress = 0.9 MPa
Strap • Able to be adjustable
(buckle and strap) • Fair shear strength (for sliding strap to tighten or loosen the
helmet grip)
Internal reinforcement • Able to absorb shock and does not bounce back to the head
• Provide additional strength to inner shell
MATERIAL SELECTION
Example of inner foam material selection based on Cambridge Engineering Selector (CES)
MATERIAL SELECTION
COMPONENT MATERIAL OPTION MATERIAL SELECTION
Outer shell • ABS • Polycarbonate
• PVC Nitrile-Nitrex High heat resistance
• Fiberglass Able to mould vent slot
• Lexan
• PET
• Polycarbonate
Inner shell • Ultra low density balsa (0.09- • Expended Polystyrene (EPS)
0.11Mg/m3) Cheaper
• Cork (low density) Lighter weight
• Polystyrene foam closed cell Durable at high and low
( = 0.05Mg/m3) temperature
No oxidation or corrosion
MATERIAL SELECTION
COMPONENT MATERIAL OPTION MATERIAL SELECTION
• Product weight
Mass analysis = 190.5 g (benchmark weight ~ 200-400 g)
Weight reduction contributed by material selection (low
density EPS) for inner foam
Incorporate ventilation slot
• Helmet fitting
Adjustable strap
Head grip
DESIGN EVALUATION & ANALYSIS
• Aerodynamics
20-25% of drag is due to the equipment (bike, helmet)
Additional structure at frontal area
Smooth curved contour
DESIGN EVALUATION AND ANALYSIS
• Ventilation
Critical in hot weather for cooling, and cold weather to carry the
moisture away
Improved humidity
Interior channel : takes up most air through front vents
Exit channel : air released through side or top vent
Air channels can be left in fitting foam around the edges of a
helmet to encourage air flow.
air out
air in
DESIGN EVALUATION AND ANALYSIS
• Von Mises stress simulated analysis
(front impact)
Impact energy
absorption w/out
helmet
• Inner shell
Granules of EPS place in mould
Expended in steam
Pressured into cooler foam
Can be made in layers for varying impact density
(depends on less impact or hard impact area)
• Internal reinforcement
Placed inside the mould during inner shell expansion phase
• Straps
Weaved and cut to final desired shape.
Strap installed to the helmet assembly.
Buckle of the strap is made from plastic injection moulding and is later
added to strap.
CONCLUSION
• Cyclists are exposed to various risks during
cycling activity (MSD, cognitive effect)