About: Principal Consultant cum Trainer for Lean Management.
He graduated from a Technical College majoring in Mechanical Engineering and is also a Certified Kaizen Specialist and a hands on TPM Lean Facilitato...
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This is my Green & Lean HPV, (Human powered vehicle)
It is made from a combination of parts available at home right from used computer chair to a kid's outgrown bicycle.
The goal of this project is to promote Green Living in Malaysia to create the awareness of Global Warming caused by excessive noxious emissions and how we can do our part to help the Environment from further depleting through Cycling as one of our mode of Commute.
This HPV is designed with only 3 gearing system (initially and upgraded accordingly) for leisure Cruising, Hill climbing and Down-hill riding. Gear ratios were specially selected for a most efficient use of our Human Power, roughly 1/8 of an Horsepower.
Average speed attained with a cadence of 70 is 28km/hr distributing your weight evenly on a sponged seat ergonomically position for a relaxed ride relieving pressure points on sensitive parts.
Apart from this it can also be used for muscles toning up & burning of Waste cholesterol as you pedal.
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Step 1: Lighting
Lighting is supplied through a Solar Charger attached on the front fairing. It charges 2 AA rechargeable alkaline batteries during the day. A six hour exposure to the sun will supply lighting to a 0.5Watt high Intensity LED front light and a rear LED light for 10hrs continuous use.
Step 2: Brakes
Brakes are Front: Hydraulic disc on Suspension Front Fork and Rear: Simple Y pull for simplicity.
Step 3: Steering
Steering is positioned at an ergonomic location turning like a normal bike without a Tiller effect swaying the handlebars. This is accomplished using timing gears and linking them using chain with a chain tensioner.
Step 4: The Frame
Design of the frame is from a 20” Mountain bicycle frame extended using a 11/2” diameter pipe and reinforced with ¾” pipes between chain-stay to form a triangle structure extending to the rear to take vertical and side twisting load when taking a sharp turn.The 3/4" tube between the bottom Triangle is for a Rider's weight exceeding 100kg and can be omitted if Rider is below 100kg.
Step 5: A 20” Front Wheel Combined With 2 Sets of 26” Wheel
A 20” front wheel combined with 2 sets of 26” wheel for the rear is decided to have a low front and a 7” ground clearance from seat creating a low Crank position for ease of going up & down.
Step 6: Only 1 Front Derailer
Only 1 Front Derailer is used for gear shifting on the front triple Chain ring with standard 24,36 & 44 teeth driving a standard 18 teeth Freewheel cog. A Rear Derailer is used midway to act as a Chain Tensioner.
The Rear Axle is linked to the left Rear Wheel through a 1:1 Final Drive set up using 2 standard 18T Freewheel cogs. Another 18 teeth Freewheel is used on the Rear drive wheel. No Derailer is fitted to ease tire removal during puncture. Rear brake is only on the Right rear wheel to evenise wear & tear of driving & stopping on opposite tires.
Step 7: How to Build the Drive Shaft
Take a look at a good quality Steel rear wheel hub.
Get 2 units of those and cut it at somewhere in the middle.
Get a a thick tube /pipe of similar diameter with the Outer diameter of the hub.
Mine was about 5/8" diameter and 12" in length.
Weld this tube extending the middle of 2 precut hubs .Ensure that it is cylindrical as possible.
(Note: Ensure that the threaded portion of the hub is used to screw in a Freewheel later).
Next Extend the Inner threaded shaft with similar diameter steel rod leaving 3/4" extending the outer hub race.
Put back all the bearings and tighten the hub cone to only move freely!
You have now extended a Hub cone assembly without affecting the fit & function.
Step 8: Seat Position
Seat Position is premeasured and decided during frame length development to cater for a kid and an adult. It is made adjustable within this range.
A Givi 45 liters trunk box is fitted at the rear for luggage. A space of 12” from the back seat to the box is reserve for placement of batteries to convert it to a EV (Electrical Vehicle) should there be a need!
Step 10: Finally My Completed HPV, Timmy Green!
Finally my Completed HPV, Timmy Green! A green human powered Vehicle with a low Center of gravity capable of 45km/hr on a level terrain.
Design & build by a Malaysian for Malaysia! Malaysia Bolih!
Im planning to cycle from Kedah to Johor covering 800kms from North to South in 10days to promote Green if I can get enough Sponsers.
My goal is to create awareness of Global Warming in Malaysia and to be the 1st Malaysian to cycle a homemade Recumbent promoting Green Living through Cycling as one of our commute to reduce Carbon Footprints!.
Step 11: Timothy Wooi, 20C,Taman Bahagia,06000,Jitra, Kedah, Malaysia. Emai: Timothywooi2@gmail.com Hp (Malaysia) 019 4514007
Timothy Wooi a Certified hands on TPM Lean Facilitator / Kaizen Specialist with 28 years of working experience is also a DIY handyman who loves outdoor activities & adopt Green living. He builds most of his stuff by recycling idle resources to eliminate waste and help conserve the environment He develops Tim’s Waterfuel, a HHO generator that suppliments gasoline usage in automobiles whilst producing cleaner emission towards a greener environment.