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1. wheeiMel Wheel moment of inertia calculator The wheel moments of inertia are used in the calculation of the squat and dive characteristics and the sag etc under braking and acceleration This calculator is really three in one It can calculate for three different methods of physical measurements This theme is covered in more detail in the section on measuring the motorcycle Wheel Moment of Inertia calculator The period is the time for the wheel to traverse the slope length starting with the wheel stationary Slope length m Wheel weight Kgf Total period secs Slope angle deg Slope length E Moment of Inettia Kam 2 Slope angle M Close Emp Update project Calculate QUICK HELF This calculator determines the polar moment of inertia of the wheels and tyres by any one of the 3 methods described In the User s Manual 1 Let the wheel swing like a pendulum and measure the time for several complete swings say 20 for example 2 Let the wheel roll down an incline of about 10 to 15 degrees and measure the time to traverse a known distance starting from stationary 3 Fis a small pulley to the wheel and use a known weight on the end of thin cable to accelerate the wheel Measure the time period to complete 2 or 3 complete revolutions starting from stationary The results are expressed in Kg m 2 Wheel Moment of Inertia calculator Front Rear wheel weight Ko Numbercycles
2. 0 intervals The tables are initially filled with 10 1200 500 example data 20 2400 1200 To smooth out measurement errors and 30 3600 2100 fill in between data points the data is 40 4300 3700 converted to a smoothed 2 order curve 50 6000 4500 In cases where a spring has basically 2 or 3 distinct rates rather than a smooth oe cea oe transition it is best to un tick the Use 0 6400 F700 smooth curve tickbox this will then use 80 4600 4600 the spring data as entered 2 Lakiala Ur The Use custom spring tickbox 100 12000 14000 toggles between using the custom spring or fixed rate data Pot Plot spring Pot Plot bump stop Save spring Save bump stop Load spring Load bump stop Make sure that the spring properties are entered to cover the maximum possible compression range The displacement value for the final data point must be at least the maximum shock displacement plus the preload In the specification of the bump stop the Stroke before contact data is the amount of shock stroke before initial contact with the bump stop 13 Custom spring and bump stop data can be saved separately to hard disk for later use This makes it very easy to quickly calculate the effects of changing springs and or bump rubbers in any design at Plot spring Eat Plot bump stop These buttons plot the custom spring obump stop characteristics Both the smoothed and the entered curves are plotted and the equations of th
3. 32 Energy Results plots x Spring wheel forces Wheel rate Motion ratio Shock displacement SA angle SA pivot forces Rocker pivot forces Energy Tabular data T H Stored energy s vertical wheel movement Ref Lr eee Energy Joules hm 0 10 l ail 40 50 ol 40 100 110 120 Vertical P E mrm Static loaded sag 26 mm bet Refresh m Save and print options Ea Units converter To LL ene on eee ae LL y This shows the energy stored in the spring at varying displacements This energy is an important parameter when considering suspension in impact situations such as a motoX bike landing after a high jump Of most interest is the value at the maximum compression point 33 Front forks Front forks The data entry fields accept the data for one fork leg but the graphs show the combined results of the complete fork As with the rear suspension there is the option to enter data for a custom or multi rate spring O x E Front fork characteristics Seok fort fork daa Single fork leg Fork and wheel loads Ys fork movement Loading Required data Soring rate in forks Mmm 3500 oes Wheel force ame Forks both legs Wax fork movement mm Fork spring preload ee rm S000 Top out spring rate Ee Mmm Top out spring contact ee mrm 2500 Extended air volume o mil Inner fork tube diameter Ee mm 2000 Extended gas pressure Ea bar Rake angle deg 1500
4. 4 Horizontal os y erlical Resultant wee ink force 0 10 20 30 40 AO BO r0 ol gg 100 110 120 Yertical wheel movement mm Static loaded sag 26 mm F IgIrE Et Refresh Lj Save and print options i Units converter In many designs using a rocker and link system the forces at the rocker pivot can be substantial As with the previous plot these curves show the total and its horizontal and vertical components Also shown is the force in the link tension is shown as negative and compression as positive If specified the effects of a bump stop rubber will be shown in these plots N B Remember that this does not include the effects of damping forces which may easily double these values in some cases 31 Swing arm angle Ei Results plots Soring wheel forces Wheel rate Motion ratio Shock displacement 54 angle SA pivot forces Rocker pivot forces Energy Tabular data Swingarm angle Ys vertical wheel movement Ref Angle deg T 10 e0 30 40 AO BO Fall ol 40 100 110 120 Vertical wheel movement mn E Toggle s axis base bet Refresh m Save and print options Ea Units converter This shows the angle of the swing arm to the horizontal over the range of wheel movement The swing arm angle is defined as the angle between the horizontal and the line drawn through the swing arm pivot and the rear wheel axle A negative value occurs when the swing arm slopes downward toward the rear
5. Software User s Manual Version 1 15 Tony Foale Designs 2006 2007 Last revision 25 03 2007 Contents Introduction Principal selection screen Button features Miscellaneous data Rear suspension Quick start Swing arm data Shock and spring data Miscellaneous Rocker and link Goal seeking Results screens Tabular view Wheel loads Shock compression Motion ratio Wheel rate Swing arm pivot forces Rocker pivot forces Swing arm angle Stored energy Front forks Anti squat Attitude calculation Spring calculator Centre of Gravity height Rake and trail calculator Moment of inertia calculator Whole bike trim Current data Master data Plotting Saving and loading data Parametric Calculated results 11 13 14 15 17 24 24 25 2 2 28 29 30 31 32 33 35 37 38 39 40 41 43 45 46 47 49 49 51 Measuring the motorcycle Special notes Extension shocks Multi language features 52 57 57 57 Introduction During the past 3 decades there has been a proliferation of different rear suspension designs Prior to this with a few notable exceptions like the Vincent most motorcycles used the traditional double shock system with the shocks mounted approximately vertical towards the wheel end of the swing arm This gave almost linear effective wheel rates and the available wheel movement was limited to about 10 or 20 more than the shock stroke Double springs or progressivel
6. 1240 16 1352 76 1466 25 1580 61 1695 67 1812 04 1929 11 2047 11 2166 03 2200 09 2406 70 2528 47 2651 21 ZT de 2099 62 3025 32 3152 02 seh f4 3405 50 3030 29 3672 65 d Static loaded sag 26 mm ae Print data Ea Units converter All calculated values are available in this table The data is shown at increments of 1 mm of vertical wheel movement ranging from zero up to the maximum permitted by the maximum shock stroke Vertical and horizontal scroll bars allow access to the whole table The full table can be printed and or saved in various formats Viz ERD For use with the internal multi plotter and WinEP Windows Engineering Plotter XLS For use with MS excel and compatible programmes SLK General purpose spreadsheet format Loads with excel and many other spreadsheets TXT TAB delimited file Can be imported into spread sheets and other software 25 Spring and wheel loads Geen plots Spring wheel forces Wheel rate Motion ratio Shock displacement SA angle SA pivot forces Rocker pivot forces Energy Tabular data i Spring and wheel forces ys vertical wheel movement Ret AFCE 4 4000 agag r000 BOOU 5000 4000 S000 2 O00 1000 0 10 ei 30 40 BO BO fall ol 40 100 110 120 Eqn 0 00195x 3 0 0209x 2 29 4 16 Vertical wheel movement mm Static loaded sag 26 mm e Equation bE Toggle origin be Togg
7. 1400 1400 Tyre load Kg 100 100 Tyre radius mm 300 300 eth mm U 9 36 th mm U 23 13 Pivot height mm ari 393 02 OA rrr FOO AOU sb mr 14 14 rb mrn 91 Sl mal rrr 134 129 08 ral mrn FBS 559 34 Est length mm 20a 0 Mas stroke rrr rU r Spring rate Mmm 140 140 Custom spring ref 456 Preload mm p p Custom springs front and rear and bump stop rubbers rear only The custom springs and bump stops are all stored together in one file allowing this to be scrolled as a list for easy selection Haster data list Ioj x Description l Fil on i Project data aii ort sto P Springs stops Project name Springs and bump stops file C Rear springs Bump stops Suspension type jal springsbumpstops T Delete selected item DOue CICR OR G TOY fo JOGO that spriadg of stag E i Fork springs 6 1200 3 2100 12 3200 15 4500 16 6000 717700 24 9600 371170 301400 0 0 12168 24336 36504 48672 60040 721008 841248 961528 108 1766 120 2008 0 0 1168 24336 36504 48 672 6040 72 1008 821248 92 1528 1021762 112 2008 5 321 testi true 0 0 101400 20 2800 30 4200 40 5600 50 7000 60 8400 709800 8011200 9012600 100 1 400 5 469 test false O10 101400 20 2800 30 4200 40 5600 50 7000 60 8400 70 9800 80 11200 90 12600 100 1 400 S 4BC Dual rate 40 100 false O10 10 400 20 800 301200 401600 50 2000 60 2400 70 3400 80 4400 90 5400 100 640C See Progressive 0 5x 2 100x true 0 0 101050 20 2200 30 3450 40 4840 50 625
8. 20 fo Total period secs Swing radius mm Moment of Inertia Rg 2 x Close Emp Update project Calculate 41 42 Wheel Moment of Inertia calculator R Pulley radius 43 VW hole bike trim 4 oo Whole bike trim This feature brings the front and rear suspensions into a complete motorcycle for analysis Various loading conditions can be tested and the steady state trim calculated The initial data is loaded from the Misc data window on the opening screen and the rear suspension and front Suspension windows any changed data in the squat and attitude screens is ignored Clicking the Show data button shows all the data in use and lets you change some as described in the next section The data entry method for the rear suspension shows the rear wheel off under the ground level if there is some tolerance or error in the dimensional data In the whole bike analysis the fixed coordinates SA pivot height and frame mtg of shock and rocker etc are adjusted to place the wheel on the ground These coordinates will remain changed when you return to the rear Suspension screen The whole bike graphic is drawn br 5 selectable conditions in order to help visualize the attitude change the CG position and a line showing pitch angle is superimposed over the same for the reference position which is wheels just on ground with both suspension fully extended The fourth case Acceleration with no anti squat effe
9. The four setup parameters are Rear ride height fork sliders position chain link addition or subtraction and fork clamp offset On first entry this window is loaded with default data which must be adjusted to the dimensions of the bike being analyzed The basic physical parameters of the motorcycle are entered into the data fields lightly shaded in yellow This data defines the static loaded condition of the machine All data entry boxes have fly out hint messages to describe each parameter although in most cases their meaning is obvious from their location on the graphic Additionally there is a small help window available by clicking the Help button Rear ride height changes as measured vertically above the rear axle and adjustment to the fork sliders position can be entered into the bright yellow fields A positive value at the rear represents an increased ride height setting A positive value at the forks represents the fork sliders being raised in their clamps Therefore positive values for either value lead to a pitched forward change of attitude There are addition bright yellow fields for the addition or removal of chain links and also for changes to fork clamp offset On clicking the Calculate button various parameters are shown to the ight Both the base values and the values with the ride height changes made are displayed The following illustration shows the effects of adding 2 links to the chain Stat
10. E Kat Rocker and link system x coord pivot i F796 mm Spring rate in forks 14 Mirm Rear wheel weight 24 Kot Y coord pivot E02 21 mm Max fork movement 120 mm Front wheel Mol Kgm2 wing arm Pivot height Fr DE E LUT Fork spring preload jo mrm Rear wheel Mal Eg me s Length 04 mm a ane Load on front tyre 125 Kaf sh anh EF fian mrm Top out spring rate O Mmm Load on rear byre 125 Kat Vh eri Link length 225 mm Top out spring contact E mm Y coord of CG 650 mm a Suspension unit Rocker orientation i Extended air volume ml Front tyre radius 300 mm Ere es eee ee a ahaor aaga mt Inner fork tube diameter mm Rear tyre radius 300 mm HC jo A Extended gas pressure har le jo au Custom spring ref m Chain sprockets Y coord fred end Rake angle 25 deq Static length Fork offset e mm Maximum stroke Wheel base 450 Spring rate 1 mm Spring preload 2 A ride height ref 325 mm Top out spring rate Y R ride height ref F50 rir Top out contact 1 Ph URE ake Case notes mann Pitch 0 625 inch Mmm coord J 100 0 mm un Y coord 400 43 mm No sprocket teeth Front js Rear E iE Refresh data Update project E Save project E Load project Trail 00 2 mm Custom spring ref wit balance F A 50 0 50 0 Bump stop ret 46 amp d Master data Master data The purpose of this is fully described in a following section on saving data and is not repeated here Ss
11. The ve button enables printing of the data entered into the grid but also blank data entry sheets one each for the three different classes of rear suspension system These sheets are useful for manual entry of measured data when actually measuring in the workshop Master data list ia Eg Case notes ee Ee oa File name CADocuments and Settings dministratorhay Documents Susp Honda CBREOD unit pro link Scaled from Honda drawings C Springs stops Project name Unit prolink Rear springs C Bump stops Suspension type Floating rocker and link Get project file Fork springs able OICR OR G COD fe foe fal case Parameter Base case Case 2 Case sd Case4d Case5 Caseb Case Case Case 9 Case 10 Unit prolink Honda CBE Rake Offset Wheel base Rear tyre load Front tyre load Rear wheel weight Front wheel weight Rear wheel Mal Front wheel Mal Rear tyre radius Front tyre radius srh th og fog Pivot height OA ib Yb sal ral Ext length Maz stroke Spring rate Preload Top out rate Top out contact Custom spring ret Bump stop ref 47 A Flotting ar a Multi plots Plotting This opens a selection screen for choosing up to ten saved results files for comparative plotting The files must first be saved from the tabular values on the results pages in ERD format see following section on saving data Comparison
12. bike on a Front 50 0 A horizontal surface and again vith one wheel lifted onto a block The higher this black the Ped poo s better the accuracy IT IS VERY IMPORTANT THAT THE WEIGHT DATA IS TAKEN WITH THE VWHEELS FREE TO ROTATE THE BRAKES MUST NOT BE APPLIED CG position Front lifted Data required CG height 603 1 C Rear lifted pas E iaNee CG from rear axle r25 0 H Calculate Wheelbase xl 40 Enter data into any three of the four data entry boxes click on Calculate and it will calculate the fourth For example if you know the required rake and trail values and wheel size then it will calculate the parameter Rake and trail calculator required offset necessary to give those values his is to calculate the missing value in a set of four given the other three The castorrake angle must be entered in degrees from the vertical not radians J The linear dimensions can be in any units as long as all three use the same e g all in mm or all in inches etc To use just enter values for the three known parameters and then press the calculate button The missing value will then be entered by the computer IF you enter all four parameters then an error message will be displayed Be sure to leave one entry bos completely empty A zero is not the same as empty There are two trail values real and ground The real trail is not available as input 7 ai bo T g MW angie 06g i
13. front values are optional The Spring preload 3 m Extended length relationship between shock Top out spring rate jo Memm Distance between mounting eves when extended compression VS wheel Top out contact E mm Maximum stroke displacement and the motion ratio Difference between extended and compressed lengths will be calculated without these E Custom spring bump stop Spring preload data If you dont know the spring Miscellaneous Difference between the spring s free and installed lengths rate it is suggested that you use a Weight on rear wheel 125 kgf Top out spring rate value such as 100 N mm and then Bear wheel weiht 22 Kat The rate of the top out spring if fitted the results based on forces will be i O Tonsil contael shown in proportion to that value ee jas n The distance between full rebound and top out contact and can easily be extrapolated Up Calculate and Plot H Custam Opens a window to enter data for multirate or down Ec 21O Mrr l pS i ee eee A springs and bump rubbers Custom spring and bump stop setup Description Description Reference Reference Use custom spring Use bump stop Both variable rate spring and bump stop data can be entered in force displacement Fiked spring rate Mmm 120 Stroke before contact rom 65 tables which accept 11 data points 10 points plus 1 for zero It is not necessary to use equally spaced displacement Use smoothed curve yw Use smoothed curve w
14. of a Kawasaki Uni trak has three mounting points on the frame e Swing arm pivot e Top mounting of shock e Rocker pivot 53 The sketch shows the significance of the co ordinates required by the software These dimensions should be measured with the motorcycle supported such that both front and rear suspensions are extended and with the tyres just touching the road surface The other components such as swing arm shock rocker and link are regarded as free pieces and their dimensions are entered without regard to their co ordinates when fitted to a motorcycle Therefore unless all entered dimensions are compatible the rear tyre will not appear to be on the ground This immediately signals an error in the data If the error in tyre position is small say less than 2 mm this probably O _ Adjust wheel height indicates that the error is just measurement tolerances in which case the use of the pii naian button as explained earlier is the simplest way to bring everything into line The static height of the rear tyre is shown numerically on the lower part of the animation control area when the image is shown at full droop Components Swing arm Yb is negative when B is underneath as shown Using the Uni trak example from above this sketch shows how the swing arm is measured as a separate component to get the data for entry into the programme In those cases with a rocker system and where the shock also mounts on the
15. plots Fa jch a 2a 7eRp Graph title basecase ERD ase bazecaze ERD gt My Documents basecase EAD Tats taste 5 ionD at basecaseZ2 EAD i SuspensionData Paseeace 2 EAD 1 Select dive and folder where your ERD files are stored fe Kinematichesults hasera EEL 2 Click on the filers that you wish to plot the selected files maxinium of 7 SlopeT ests deelen ad 10 permitted and descriptions Will appear In the list below HondaPLink ERD 3 You can remove files from the selected list below by selecting the file Hond SRL aneL cia er ERD and clicking on the clear button ee eee ea ee e 4 Enter the Graph title in the box above that you wish to appear at the HondaPLink Shorter EAD top of each plot 5 Click on the plot button HondaPLinkShorters ame shock ERD HondaFroLinkN ew ERD The plott d 7 n HondaProLinkOld ERC Grae a e a HondaR CHT ERD 1 Select from the axis and asis lists the parameters that you wish to low damping erd plot and the appropriate graphs will be drawn Tee Other parameters can be selected from the list and plotted e j 1 to 10 files can be selected for comparison plots Too many lines on the MA 5c erd plot can make it hard to read hence the limit of 10 MyOLERD So R eR Clear selected file from list Fat Flot graphs prol ERAD proe EAD Clear all files frora list x Cancel 77 C MM HondaPLink Suspension Kinematic Analysis HondaPLinkLonger Suspension Kinematic Analysis Hon
16. this feature becomes more evident The next example shows what can happen when we allow changes to the rocker pivot position as below d AIA AJOLA Static wheel height 6 mm Goal seeking LA Save an Click and mark range f Shock mounting f Link mounting f Rocker pivot C Rocker to shock C Rocker to link As shown below the original maximum value of the normalized wheel rate was 5 2514 In this case we only want to increase the rate at the end of the wheel travel so only the last value of the goal rate was changed to 25 We can see that the achieved characteristic is very close to that requested To get that change the X coordinate of the rocker pivot changed from 158 to 175 and the Y coordinate from 602 to 605 Link length changed from 225 to 231 3 to maintain the starting wheel position Ei Specily goal Wheel force goal setup Dizplacement mm Page rate Goal rate 1 0000 1 1462 1 1462 1 3147 1 3147 36 1 5115 1 5115 4B 000s 17445 1 7445 Te Fn 2 0236 2 3622 2 3622 ao Fi 27774 C Ese 3 9287 Import from file lt Clear changes Goal search wal ce UGE Selected fist Use this data x Cancel fe Welete selected oF m fee Eaneellimpant ames Base values loj x Normalized wheel rate ys displacement Wheel displacement mm Goal values Achieved values 20 Original system fully extended Modified design fully extend
17. tyre The rear sag value is that for a point vertically above the rear axle The front sag is that of the forks themselves A sag value of zero indicates that the suspension has topped out Whole bike attitude Front Rear sag Front Rear tyre load Rake Trail Pitch angle Wheelbase Mult plots Fork and rear sag s acceleration G oag mim ee eae ce f Braking f Acceleration b Add data to plot ist Save data Lj Copy print options Units converter The Save data button will allow an ERD file to be saved which can be viewed and compared in the multi plotting feature or the programme WinEP 45 Current data Current data All of the current project data can be seen in one place by clicking on the Current data also Show data from within the whole bike screen button Where some data is show in green and some in yellow Throughout this software data in green is read only and not changable on that screen Yellow is changable Some data on this screen is made read only because it needs to be checked for integrity by the appropriate parts screen For example changing some rear suspension dimensions can only be done on the rear suspension screen because it is very easy to change data elsewhere which might lead to an impossible system Current case data O x Project name Startup default Miscellaneous Rear suspension type Rocker and link Front fork single leg i 15 P
18. we have to make a few measurements There are several methods that could be used to do this but this software employs a measurement philosophy that reflects the physical reality and tends to show up measurement errors and mis typing of the input data Measurement reference With any vehicle set up measurements it is necessary to have a reference base Some people recommend the Static loaded position but this cannot be considered as a fixed reference because it will vary depending on rider weight and fuel load just to mention 2 variables This software is based around the reference being with the suspension fully extended at both ends of the bike with the tyres just touching the ground The calculated output data are considered as being relative to this initial reference position The mounting points on the main frame are regarded as fixed and are entered as X and Y co ordinates The ground is taken as the origin for the Y co ordinate and the vertical line through the swing arm pivot is taken as the X origin Points to the rear of the pivot are positive and those to the front are negative The other suspension components such as the shock link and rocker are considered as separate pieces and are input as such without regard to their final co ordinates which are calculated internally se ae X coord of shock mount Height of SA gt lt X coord of rocker pivot Y coord of rocker pivot Ground level The example above
19. wheels with the lateral weight offset of the sprocket and cush drive assembly It is possible to make a simple incline from wooden board thick enough not to bend under the weight of the wheel but 2 metres length at an incline of 10 degrees is about the minimum necessary to achieve sufficient timing accuracy 3 metres at 15 degrees would give approximately equal transit times but with greater directional stability Mark out a defined distance along the slope Hold the wheel at the higher mark and start timing at the moment of freeing the wheel stop the clock as it passes the second mark Repeat this several times and average the times This method is very sensitive to timing errors and is the hardest to get good timing because unless a long incline is available the time intervals are quite short 1 5 seconds and up Slope length olope angle Pulley and weight Probably the most accurate method of the three but requires a little more preparation A small pulley about 100 mm diameter is ideal needs to be made that can be attached to the wheel concentric with its spin axis Some thin cord or flexible cable is wound around the pulley and the free end attached to a known weight 2 kg for example Using this method the wheel can be supported with its own axle which must be mounted sufficiently high to allow the weight to fall the equivalent of 2 or more wheel revolutions Using a pulley of 100 mm diameter the weight will fall just o
20. 0 6027800 70 9460 86801120C 90 1305C 100 150C 51 Saving calculated results These can be saved by clicking on the Ty Save data buttons which are accessible at the bottom of the tabular data page on the rear suspension results window and also the plotting window of the whole bike trim feature Save As Ea o z B Save jni EinematicH esulta Pe Al c l Ef 2 basecase 1 ERD 2 goal erd i e ba asecased2 EAD e goals erd L iz basecase 3 ERD iz goald erd T le bagecases ERD le goalS erd D lz deleteme erd ie goalb erd ot l goall erd lz goal erd g Sk i ima q I 10 Save as type Internal plotting amp WwinEP ERD Cancel gt Internal plotting amp WinEP ERC 1 Excel spreadsheet format lt L5 General spreadsheet format F SLK 12 4 606 1002 Sieg RATS a E E eee me 136 42 1 fa 26 12 A693 10341110 320206 201199 08679 21149 179761 12 2604 10658682 230499 2110 35 111742 228750 186399 13 There is a choice of file formats available allowing the data to be imported into spread sheets or other external analysis programmes when thought necessary The default file extension is erd which is the required format for the internal multi plotting feature as well as WinEP ERD files This is the file format for the freeware programme WinEP Windows Engineering Plotter Which is included on the distribution CD for the suspension software WinEP
21. 1000 Ea Units converter Save fork data 00 Load fork data Save graph data T 0 10 e0 30 40 BO BO rd 60 gn 100 110 120 Fork movement mm H Save options The only data that is additional to that entered for the rear are the three parameters related to the compression of air in the forks The significance of which follows e Extended air volume This is the air volume above the oil in a fork leg in the fully extended position The spring must also be in place It is usual to set the oil level purely as a linear measurement but the calculation of the free air volume is not straight forward from that data Allowance must be made not only for the tube diameter but also for the volume of some spring coils Probably the easiest and most accurate way to measure this is with the aid of a fork cap that has been drilled Then fill the fork completely with oil Suck some oil out into a bottle and then remove the cap Suck out more oil until the desired level is reached The volume of oil that has been sucked out will be the free air volume It is important to make this measurement as carefully as possible because in some cases a small error can have a large effect on the results of the fork force calculation at or near full compression e Inner fork tube diameter This is the external diameter of the inner fork tube e Extended gas pressure Some forks are pressurized with air or nitrogen This parameter is relative to atmospheric press
22. a single parameter from each of the selected files 48 Graph plotting x Suspension kinematics 100 120 140 ou WheelDsp mm Scaling and offset Bs Plot refresh Lj Save and print options Ea Units converter On the plotting window above the area to the left shows that the wheel displacement has been chosen for the X axis and the wheel spring rate for the Y axis The 3 graphs show this parameter pair for the 3 files selected from the previous screen This multi file plotting feature is extremely useful and is also very fast and easy to use 49 Saving and loading data There are two types of data that can be saved in the software Parametric project data Calculated results The parametric data refers to the physical parameters of the motorcycle For example rocker dimensions wheel size spring rates etc This data has been centralized under the Master data option The calculated results are the characteristics of the systems being analyzed such as wheel rate forces motion ratio etc Parametric project data The data is stored in the concept of a project A project represents all the parametric data for a particular motorcycle layout consisting of front fork rear Suspension and rake wheelbase data including any custom springs or bump stop rubbers used Up to 10 different configurations of a basic project can be stored in one project file This is useful for example if you analyze the sam
23. allows comparison between different layouts and bike models on an equal footing In this example the Goal rate was entered manually to request a design with a total of 25 progression not a lot for a rocker system but quite high for this simple design which achieved 16 When the goal is entered click on the Goal search button and the achieved values will be plotted H Specify goal IOl Wheel force goal setup Displacement mm Base rate 1 0000 Normalized wheel rate ys displacement jo aooo i fe Delete selected fect Use this data M Cancel Wheel displacement mm ames Hace values Goal values ae m 7 eas Eaneelimparnt Achieved values You can now either Cancel or elect to use the new layout The new dimensions will be transferred back to the data entry screen automatically The following picture shows how the frame to shock mounting has been moved forward to give the closest fit possible to our requirement The shock movement will also be adjusted to keep the original maximum wheel displacement Spring rate and spring preload will be automatically adjusted also to maintain the same initial wheel rate and wheel preload these parameters may need further manual adjustment to get the overall effect desired Original position Modified position E Static wheel height 22 mm Rocker systems 19 It is when we consider the rocker systems that the real power of
24. case the rocker is flipped both horizontally and vertically The user is encouraged to play with this control to get familiar with its effect 17 _E Goal seeking Within certain physical and kinematic limits this feature will automatically adjust the selected dimensions to attempt to achieve a specified suspension characteristic The desired characteristic can either be entered manually or be cloned from another bike For example if the progressive characteristics of a certain model motorcycle are deemed superior to those of a second bike then this feature will largely automate the process of calculating the modifications needed to apply those characteristics to the second machine The dimensions which can be physically adjusted depend on which class of suspension design is under consideration For example with the simple shock on swing arm designs we can either change the frame shock mounting or the swing arm to shock mounting or both Whereas with a rocker system we have 5 possibilities plus combinations This software only allows one set of dimensions to be changed at a time Experiments during the development showed that multi parameter searches were extremely slow and user control was lost Simple shock on swing arm The following graphic shows how to select the dimensional limits of the parameter which we wish to alter to achieve a set characteristic In this case the chosen variable is the frame to shock mounting coordinates The
25. cker pivot Static wheel height 26 mm C Rocker to shock C Rocker to link Goal seeking A Save an LALA ANOLA ANA AO Modified design fully extended Modified design fully compressed This design has a greater margin before reaching an over centre condition Original system fully extended We can see that even though the normalized wheel rate range was a bit greater than in the previous example there is a greater margin before the lock condition The plot of the wheel rate also shows how the rate increases at a slower rate as full bump position is approached 22 Graph plotting Suspension kinematics Wheellsp mm Scaling and offset st Flotrefresh L Save and print options Ea Units converter Important note When marking the range within which you allow the specified dimension to be modified do not follow the temptation to make the range too large without considering if such dimensions are physically possible It is very easy to specify a range in which a lock may occur or perhaps cause the shock to go over centre In most cases the software will simply ignore these rogue dimensions and eliminate them from the results of a goal search However it is possible that occasionally a combination of dimensions will cause an error message to be displayed Cloning a design In addition to entering the desired wheel rate values by hand we can clone the characteristics from another model as f
26. ct is only included for reference it does not represent a realistic case but shows just what effect the anti squat has when compared with the real case The attitude calculations assume a perfectly smooth road and are for low speed acceleration and braking At higher speeds the attitude is affected by the aerodynamic drag value and general aerodynamic properties of the machine which are not usually known Warnings are given if the setup being analyzed cannot withstand the specified acceleration braking level without looping There are additional warnings to let you Know when the shock forks have reached the maximum bump level of their travel Whole bike trim OW x Loading Conditio Rear sag 0 mm Rake 21 0 deg Pee eect Show Data Fork sag 107 5 mm Trail 76 8 mmn f Static load Braking Calculate Front tyre load 243 7 Kof Pitch change 4 0 deg D n Rear tyre load 5 3 Kgf CG height 605 0 mm Acceleration with anti squat fet Plot Load Distribution 9747r 253 fee Wheelbase 1408 mm Deceleration in Gs fi lt Q Lee 44 Plots are available showing various parameters plotted against braking and acceleration G The maximum value of G plotted is the limit at which looping will occur unless the rider reduces the braking or acceleration In general this limit will be slightly different for the braking and acceleration cases The looping limit is reached when all load has been transferred off one
27. ct the correct class to describe any design that you wish to analyze the programme uses different internal calculation algorithms for each class However it is relatively unimportant which example is chosen from within a particular class as the details can be changed through entered data on the following screen Data entry Dimensional data is entered numerically in the appropriate boxes Mini fly out context help screens are activated by pressing the buttons Use these to get information about particular aspects of data entry Full descriptions of all features on this screen are show in the detailed sections of this manual Data entry screen Rocker and link system E Project name Startup default a Rocker and link 4 coordinates 774 576 mm T set to static loaded height F Full droo Full bum aning arm coord pivot fi og mm z Pivot height a0 m Sth l Y coord pivot E02 mm Length DA 500 mm ar p mm mh Jed mm DF 5 mm YE E2 mm EF 140 mm we Alternative data Ea ps a Suspension unit ee Rocker orientation fi ock compression mm 0 Tyre above ground mm o coord fied end an Gd T coord fired end mm Shock on S Static length mm Maximum stroke mm TEE Spring rate 120 Mmm Spring preload Top out spring rate N rrr uf Top out contact i Q Chain sprockets ic ih mm Fitch 0 625 inch ii Custom spring bump sto
28. daPLinkS harter Suspension Kinematic Analysis The window will initially open into the default file save directory You can navigate to other directories if you saved the files elsewhere Default is My Documents SuspensionData KinematicResults The second column will display a list of saved files Click on those which you wish to compare up to a maximum of 10 and they will appear in the plotting list across the bottom There are buttons to remove files from this list or clear it altogether Click on the Plot graphs button when you have listed the files of interest 3 in this example The plotting window shown next has 3 areas On the left are 2 lists of the parameters which can be plotted The top one selects the parameter for the X axis usually the Wheel displacement or Shock compression The lower one selects the Y axis The graphs will change dynamically as you select different plotting parameters Along the bottom of the window are some buttons with fairly obvious significance except perhaps for the Scaling and offset Occasionally it is useful to be able to scale or offset the data before plotting For example if you wanted to see the wheel force curves for different strength springs normally you would have to change the data and rerun the analysis With the scaling you could simple scale the plot in the proportion as the rate of the various springs The main area on this window is the plotting area which graphs
29. e basic setup with different ride height settings The parameters for all the settings can be kept together in one file There are times when you will only be working on say the rear suspension and will not specify any front fork parameters in such cases a set of default data will be saved for the forks The reverse is true when you are only working with the front a simple default rear layout will be saved Master data window There are buttons to save a project on each the front and rear suspension windows and the initial selection screen If the data to be saved was originally entered by choosing the front suspension option or that for the rear suspension from the main menu then a new file new project will be created after prompting for a filename and some notes to help with later selection However if the project was originally loaded from an existing project file from the Master data centre then you will have the option to save as anew project or add the current layout to the existing project up to a maximum of 10 cases per project file When saving to a project file you will be prompted to write some case notes to describe each case Make a good job of that because it ll be a big help when you come back to load a design a few weeks or months later Choose a column in which you want to save the current project data and double click in that column If the column is not empty then you will be asked if you wish to overwrite the existin
30. e number of turns to be entered should be counted from tip to tip All good quality suspension springs are flattened and ground on ther ends This has the effect of making the ends of 4 spring less compliant than the centre section Expenmenatal results show that an average value for the number of active coils can be found by deducting 1 75 turns from the total number This value is usually quite close for front fork springs but will probably need reducing for springs with few tums az typified by mono shock rear springs This calculator uses 1 75 tums end coll factor by default but this can be changed by the user as necessary 39 D Ch height Centre of Gravity height The CG height is an important parameter needed for the analysis of motorcycle setup There are various ways to measure this but most need facilities outside of those readily available The simplest is to weigh each end of the machine when level and when lifted onto a block at one end This calculator will then calculate the CG position You can toggle the calculator depending on whether you raise the front or rear of the motorcycle Itis usually easier for the rider to raise the front end A help window is built into the screen and warnings are given if input data is not mutually compatible Mei ES CoG calculator Thi calculates the CoG location of a motorcycle Weight distribution tis required that the weight on front and rear wheels be measured with the
31. e smoothed characteristics are shown Soring force vs displacment Bump stop characteristics 20000 14000 12000 JZU 10000 z p g a00 10000 LT Lm gg00 EF jae Ww Ww 4000 S000 2000 j O j z0 40 BO ol 100 j 5 10 lS z0 Spring displ mm Spring displ mm ae Entered values Smoothed values Entered values Smoothed values Equation of smoothed line 1 1582 87x x lines Equation of smoothed line 25 00 2 200s x Close The sample spring data shown above is for a dual rate spring and the differences between the actual and smoothed curve can be clearly seen In this example it would be best to un tick the Use smooth curve tickbox to use the spring data exactly as entered On the other hand the smoothed example data fits the sample bump stop data perfectly and the blue curve is hidden behind the red Bump rubbers are invariably smoothly progressive and are not designed to have 2 or 3 specific rates but in practice some bump rubbers are difficult to match with a simple mathematical curve In those cases where the smoothed and entered curves differ significantly it is best to untick the Use smoothed curve tickbox 14 Miscellaneous Chain sprockets The weight and tyre radius data should initially be o Wa entered in the Misc data panel on the opening screen but can also be changed here s coord 100 mm l The shaft drive information is used in the M
32. ed Modified design fully compressed Note that more wheel displ would cause a locked movement Word of warning Although we have achieved the wheel rate range that we sought we have created a design that is very close to a lock condition as explained in the Kinematics booklet at full compression as we can see from the above graphics We can also see how the characteristics have changed by comparing the real wheel rates not the normalized values of the two designs in the following plot Note how the rate of the modified design increases rapidly toward full compression as the lock state is approached Graph plotting Suspension kinematics WheelDsp mm Scaling and offset Plot refresh Lj Save and print options 2 Units converter 21 This does not mean that all layouts which give nearly a 25 1 wheel rate range will tend to this potential lock problem Even higher ranges can be achieved with other design options The above example was chosen to illustrate that whilst a goal searching feature can be extremely useful the resulting design and characteristics must be scrutinized carefully to make sure that it satisfies all requirements The next example starts with the same basic design but instead of goal searching on relocating the rocker pivot the search was done for moving the link to swing arm dimensions As follows E aa e n a E Click and mark range C Shock mounting f Link mounting C Ro
33. eight will be inserted in the calculations i z Rear tyre radius Rake angle 5 deg The loads on the tyres are the weights supported by each wheel Fork offset E mm under loaded conditions i e with the rider on board Wheelbase 1450 mm Fork offset is the offset between the steering axis and the wheel l axle Itis used to calculate trail Y R ride height ref 830 mm l l Click on the Update project button when all the data has been entered correctly Trail 100 2 mm Wh balance F A 1 50 0750 0 M Close Em Update project F H Rear suspension Quick start Chose a starting design similar to that to be analyzed from the following initial selection screen If you have already selected or loaded a design and wish to return to that project the click on the Current proj button There are three basic classes from which any other suspension designs can be input Simple types Suspension unit connected directly Rocker and link rod Link connected to swing arm Floating rocker and link Link connected to frame _ Suspension analysis simple types Rocker and link rod shock connected directly to 5A Link connected to swingarm These classes are shown in the three on screen columns Floating rocker and link tf Link connected to frame Load project J Save project EE Curent proj r Master data Help Main menu Ww x It is important to sele
34. ent They can be described as 1 Swinging pendulum 2 Rolling down an incline 3 Pulley and weight These methods will be described in detail Swinging pendulum 55 The previous photos show how the wheel needs to be mounted off centre such that it can swing from side to side about an axis defined by the supporting bar In cases where there is no convenient symmetrical supporting locations rear wheels and single disc fronts the wheel can be supported by the bar just under the rim section The distance between the swing axis and the axle centre needs to be measured The wheel should be slightly displaced to one side and allowed to swing back and forth like a pendulum Measure the time required to complete a number of complete cycles 20 for example to reduce the effect of timing errors A swing amplitude of 5 degrees is quite sufficient This method has the advantage that only the minimum of equipment is needed to do the measurements Apart from a watch weighing scales and a ruler or vernier calipers a bar strong enough to support the wheel without excessive flex 10 mm diameter is usually sufficient and some means of supporting the bar horizontally is all that s necessary Rolling down an incline In this case the longer the slope the better and an incline angle of greater than 15 degrees is preferable If the incline is too flat the wheel will not accelerate quickly and will often tend to run to one side particularly rear
35. eters under static braking and accelerating conditions Shows load transfer and warns of wheelie or stoppie limits Lists all the input physical parameters used in the current project Some of which can be changed from this screen whilst using the Whole bike analysis feature Centre for management of saved project data Up to ten cases can be saved in the same project file A plotting module which graphs up to ten examples of a selected parameter This is very useful for comparing the results of different set ups Updates to this and other software will be announced on our web site so visit from E time to time We welcome feedback and suggestions about this programme and they Send email can be sent by email Full details of each feature Misc data Miscellaneous data Miscellaneous data Front wheel weight 10 Eat Rear wheel weight 13 kgf Front wheel Mal kg m Rear wheel Mol Kg me This is the source of data values used in various parts of the programme but not specifically tied to the front forks nor rear Load on front tyre 125 kgf suspension Load on rear pre 125 Kal Where appropriate all data is taken from the reference attitude of Y coord of CG 650 mim the motorcycle That is both suspensions fully extended with the tyres just touching the ground Front tyre radius 300 mm If you do not have the values for the wheel moments of inertia ram use the value 1 then default values based on wheel w
36. g data You can activate the Master data window for loading projects from buttons on the main menus and front fork window Click here to select a project file to open Simply double click on the column which contains an the desired case to load and the data for that case will be entered into the system Data display The data display can be toggled between the project data and a list of custom springs and 9 Project data bump stops Springs stops shows a full list of front and rear custom springs as well as any 2 pririgsy stops bump stops They are colour coded and grouped to help identification as shown below f Rear springs Bump stop rubbers are pre fixed with a B fork springs with F and rear springs with S f Bump stops The remaining options show those components separately Double click on any item to load Fork springs it into the current project 50 E Master data list Oe Q Froject data File name JCSMy Documents SuspensionL atash anual dat s 2 prings stops Project name Test case for manual Case notes Similar toa base case Fixed rate spring and shorter link f Rear springs Bump stops Suspension type Racker and link gt Get project file H i Fork springs double cick OR G COD fe foe ial case Paene ome peee cme ene 2 Cave Eres tees Cove tave7 Covet eaves Ca 10 x a case for manual a ia Simular to a Rake deg 25 25 Trail mm 95 ob 4 Wheel base mm
37. heel rate Motion ratio Shock displ SA angle SA pivot forces Rocker pivot forces Energy Tabular data Multi plots Actual wheel rate vs vertical wheel movement Ref Wheel rate Nimm 0 10 ei cjl 4u BU BU fall ol a 100 110 120 Vertical wheel movement mm Da Toggle Y as be Toggle s axis base bet Refresh H Save and print options Ea Units converter The effective wheel spring rate is the vertical rate as seen by the wheel and is usually lower in value than the rate of the spring itself At any point in the movement range the wheel rate is defined as the extra vertical force at the tyre road interface needed to produce a small unit vertical displacement of the wheel This software calculates this in steps of 1 0 mm of wheel movement This curve will also show the effects of specifying a bump stop although that was not done in this example which is highly progressive just by the nature of the geometric layout The rate at full bump is over 5 times that at full rebound Compare this graph with that of the shock compression The compression graph can be very misleading to a casual glance it looks almost linear in this example but as we can see it is far from that T Teasle Yas This button toggles the display between showing the actual wheel rate as in the graphic above and showing the same data as a percentage of the starting wheel rate The percentage display is useful as a comparison with other
38. ic attitude calculation Base case ee Front rear 50 00 750 00 Front load 1250 Rear load E CG height e500 Wheel base 14500 SA angle 8 0 Rake angle 25 0 Trail 100 2 Changed case Z Front rear 50 54 7 49 46 Front load 126 3 Rear load 123 7 CG height 651 0 Wheelbase 1465 7 SA angle 8 0 Rake angle 24 9 Trail 93 6 Make this the new base case Calculate 38 Spring calcs Spring calculator This utility is to help calculate the spring rate when only the dimensional data is known It makes these calculations for the two most common spring materials spring steel and titanium The calculation of spring rates is dependent on the accuracy of the allowance for the end coils and so any calculation should only be regarded as an approximation Where possible it is always preferable to measure the rate physically Coil spring calculator Units Material Outside diameter Comm H Spring steel i ara C inches lbf C Titanium Bam e diameter Outside diameter Wire diameter Humber of turns Spring rate Mmm End coil factor 1 75 turns Calculate x Close Enter data into any three of the upper four data entry boxes and the programme will calculate the missing value This allows you to calculate the spring rate but also to work backwards from the spring rate to calculate one of the other parameters Note that spring design is 4 specialist task and this is only meant as a rough guide Th
39. ile name chosen S helps to identify the design being saved for example Yam_R1_3mm_preload An option to enter some additional notes to help identify the suspension configuration is also available See the Save project separate chapter on saving projects i Oded I rete LR sample examples of project name and Project name Pro_link_config_6 notes The filename defaults to the project name although that can be changed This test was with an additional 5 mm ride height after clicking the save button Hotes M Cancel This button opens a window to select this user manual in PDF format or to choose from a range of tutorial videos It is highly recommended that you watch at least the basic tutorials before using the programme Each one is only a few minutes long and it will speed the learning process greatly Help 10 Data entry screen The full window is shown in the Quick Start section above The following will look in detail at specific features of this screen Animation and layout graphic al Rocker and link ii A coordinates 429 123 mm i lo iale mamen megh Full droop Full bump coord pivot h a mm oN gt 4 pi 602 E eraa altel AoT Shock compression mm 0 DE 75 mm Tyre above ground mm 0 DF 75 mm EF 140 mm Link length 225 mm Rocker orientation i Shock on 5A Q Chain sprockets C Fitch 10 625 inch coord 100 mm coord 390 mm No
40. ions of the swing Pivot height 370 mm a fa arm the normal shown to Length 04 500 mm iy YD Whee ie avaiable ah i 42 arle e omer IS avalaDbie atter s n b clicking the Alternative m Pivot height data button ae Alternative data B The standard method is B is underneath when rb is negative much easier if you wish to Ground level enter different length swing o arms without changing other dimensions For example to see the effect O swing arm pivot location on suspension of chain adjustment A wheel axle location B mounting point for shock or link displays fly out help screen Alternative method Alternative DA data entry Spring or link mounting SA pivot O OA m OE m Iil x Cancel sometimes it is more convenient to measure a swing arm as shown above Access to this screen is by clicking the Alternative data button 12 Shock data Suspension unit amp coord fired end g mm Y coord fixed end 336 mm Static length 200 mm Suspension unit The fly out help screen shows the A Y coord fixed end S significance of the various shock Coordinates of the mounting of the fixed end of unit Kaximum stroke jn ae Y isthe height above ground level parameters nee EE T A 6 I referenced to a vertical line through the S pivot The spring rate and preload ale postive when behind the pivot and negative in
41. is an excellent and flexible plotter for XY data which allows the concurrent plotting of data from several files This is particularly useful for overlaying the results of different suspension set ups for comparison purposes Scaling and zooming are easily accomplished This can be done with Excel but it is much more tedious A PDF user s manual for WinEP is included in the Docs folder After saving data to an ERD file it is only necessary to double click on the required ERD file to open it into WinEP The opening screen shows a list of output parameters which can be plotted Select those required and select plot Consult the WinEP PDF manual for more advanced features WinEP can be used to analyze data from other sources also It is only necessary to create an ERD file in the format described in the manual WinEP is freeware and is now included in the install package as a service to users purely on an As ls basis and does not form part of the paid for content no responsibility is accepted for any incorrect functioning It is being distributed with the permission of the authors at the University of Michigan The latest version should always be available at www trucksim com winep winep zip The in built graphing module for comparing the results from different configurations largely supersedes the need for WinEP in this application However it is included as a useful tool 52 Measuring the motorcycle Before we can analyze anything
42. is designed to make that job easy It is only necessary to enter some dimensional data to automatically get detailed information about any suspension design and setup configuration It becomes a rapid exercise to investigate many different permutations of any design Indispensable for anyone involved in Designing or modifying a motorcycle Setting up sport or racing motorcycles Achieving improved comfort and handling Students Anyone wanting to better understand the workings of suspension systems and motorcycle setup Virtually all designs of current rear suspension systems can be analyzed by inputting appropriate data The BMW paralever and similar designs are not presently supported However designs are continually evolving and if you find it impossible to specify any particular layout with the existing programme then please send an email info tonyfoale com describing the design We will try and update the software to accommodate all systems that we regard of interest This software is currently limited to analyzing telescopic forks at the front This does not prevent the overall analysis of a machine fitted with an alternative front end The rear suspension anti squat and attitude calculations will still apply Foot note Alternative front ends For anyone interested in analyzing alternative front ends we have some stand alone software which may be of interest This will calculate numerous parameters such as anti dive rake and trai
43. iscellaneous Y coord 400 uut calculation of the anti squat characteristics Weight on rear wheel 125 Kaf No sprocket teeth Use the zoom button to expand or minimize the l R fis Chain sprockets panel Sometimes it is useful veer Will ete Be Agi to minimize this window to avoid interference with Tyre radius 300 mm Rear 43 the graphic of the suspension system The panel Shaft Drive 7 can also be dragged to another part of the screen T C Adjust wheel height Calculate and Plot E Save project ES Load project Adjust attitud O Aust atitude This button adjusts the pitch attitude by rotating the whole bike about the front axle to bring the rear tyre back to road level For example if you change some configuration data such as shock length then the rear wheel will not be at the correct height unless the attitude of the bike is corrected Clicking this button will adjust data such as swing arm pivot height and the co ordinates of shock and rocker mountings It is also useful to correct for measurement tolerances in the input data These tolerances may indicate a small error up to 5mm or so in the rear tyre height In such cases adjusting attitude will ensure mutually compatible dimensions m Save and print options Print save to file or copy the graphic to the clipboard Conversion between metric and imperial units Lay Units converter Rocker and link E Rocker and link amp coord pivot fise
44. l ia Kg me Y coord CG 650 mm Max rear wheel movement 127 7 mm Mas fork movement 120 mm Rake angle 25 deg Rear wheel rolling radius S00 tarp Wheelbase 1450 mm x Close Recalculate Part Flot The Plot button opens the following screen which plots the anti squat percentage over the specified range of wheel movement The calculated values of anti squat percentage are dependent on the accuracy of the entered CG height As an option it is possible to toggle between displaying the results as a percentage or as the anti squat angle This angle is not dependent on the CG height value In either case there are two lines plotted one shows the anti squat performance with the front Suspension extended and the other shows it with the front suspension compressed Therefore these two lines define the full range of possible anti squat values Under hard acceleration the front will be at least near to the full extension condition The legend box can be dragged out of the way of the curves where necessary by using standard Windows dragging methods 36 Squat characteristics Copy graph to clipboard Front extended Front compressed ffi Pt Ay o ER Pi aa a 37 4 it oO Attitude Attitude calculation The purpose of this function is to quickly analyze the effects on the attitude of changes to up to four setup parameters Attitude changes are compared to the base setup
45. l to the software itself this makes it very easy to add more translations and enables users to make their own translation files if required The base software remains the same regardless of the language in use As few or as many language files as required can be present in a single installation of the software and switching between languages can be done with the programme running If no language files are present then the programme will display all text in English If one language file is present then the translations in that file will be loaded without user action When two or more language files exist in the same directory as the software then a drop down list will be displayed as follows in the lower right hand side of the opening screen English Espa ol Rakertrail Wheel Mol Anyone interested in creating a translation for a particular language should send an email to info tonyfoale com and we ll provide all the information necessary 58 At time of writing a partially complete Spanish translation file exists in addition to the default English These are available at no cost by emailing to info tonyfoale com Currently we have no plans on translating this users manual into other languages but that may change if sales volume to a particular country warrant the work involved
46. l variation etc etc of all known systems supported by arms and or links It does not handle any with sliding elements For example it will analyze the new BMW _ duolever but not the older telelever which has sliding members Email info tonyfoale com for further information Principal selection screen From the opening screen select the required action according to the function of each button The lower row of buttons access various aspects of motorcycle setup in a separated manner For example you can look at different front Ork setups without reference to the rear suspension etc On the other hand the upper row gives views of the whole bike data and characteristics x WHOLE BIK ANALYSIS fe Licence management INDIVIDUAL ANALYSIS pring calcs Accesses data that is common to all modules throughout the programme This is the first data that needs to be entered or confirmed for each analysis project Selection screen for the type of rear suspension There are three main classes of suspension configuration available which cover almost all current designs The BMW paralever and similar Rear suspen systems are not covered Analyses the front fork characteristics Top out springs can be specified when appropriate as well as oil levels and gas pressures to show the effect on suspension action of the internal volume Syaral fae change with movement C Allows f
47. le amp axis base These curves show the actual forces experienced by the wheel and shock spring over the range of wheel movement In actual use there will be additional forces due to damping but these vary with shock velocity and so cannot be calculated in a static analysis such as this These curves and that of the actual wheel rate are probably the most important in any suspension analysis If specified the effects of a bump stop rubber will be shown in these plots The vertical heavy black line is the static sag position in this case it is 26 mm In other words under initial static loading the sag at the wheel will be 26 mm The origin of the X axis can be toggled to be either at the fully extended position or at the static sag position by using the l button The above graph shows the origin at the default full rebound position When the origin is at the ride height positive wheel movement values indicate compression from the static position and negative values show the sag The wheel load graph as shown later illustrates the origin when set to the ride height Other features shown on this graph are Equation of a 3 order polynomial fit to the wheel load graph Points can be marked with XY coordinates by pressing and releasing the LHS mouse button without moving the mouse as shown on the blue curve Lines can be drawn by dragging with the mouse and holding the LHS button on release the slope of the line will be sho
48. ng points on the swing arm Xc and Ye The fly out help screen not shown explains the significance of the additional swing arm co ordinates Rocker orientation 4 There are 4 possible orientations of the rocker It can be flipped horizontally and or vertically The user can use the spin control to toggle through to the desired configuration Rocker orientation The following illustrations which appear when the spin control is used show the four alternative orientations for this particular design The correct orientation is 1 as can be seen by reference to the graphics on the previous page Some orientations lead to impossible physical layouts To avoid the inherent problems of trying to draw impossible layouts the illustrations only show the wheel swing arm rocker and link An incorrect orientation is physically equivalent to an assembly error on the bike Click the of Select this orientation button to select the correct layout Orientation 1 Orientation 2 af Select this orientation af Select this orientation ea Orientation 3 Orientation 4 v select this onentation y Select this onentation A al Rocker and link coord pivot h58 mm Y coord pivot e02 mrm DE 75 mm DF 75 mm EF 140 mm Link length 225 mm Rocker orientation E l l Shock on SA Here we see the effect of choosing an incorrect orientation of the system above Orientation 3 instead of 1 In this
49. nt mrm Static loaded sag 26 mm b Equation if igir be Toggle es axis base bet Refresh A Save and print options i Units converter The motion ratio is also called leverage ratio velocity ratio and mechanical advantage As plotted it shows the shock velocity in terms of the vertical wheel velocity In this example we can see that at full rebound the motion ratio is around 0 46 which means that the wheel is moving upward at a rate of over double the compression rate of the shock Hence the leverage between the wheel and shock is 2 17 so the wheel rate is softer than the shock rate At full compression this ratio is just above 0 8 which represents a lower leverage of 1 25 and hence a stiffer suspension rate This example is of a progressive suspension geometry A completely fixed single rate design would be represented by a constant motion ratio over the full range of suspension movement It is usual that this ratio is always less than 1 0 that is the shock moves slower than the wheel The total movement of the shock is less than that of the wheel This is not a physical requirement but no current designs are known where the motion ratio is greater than 1 0 The red curve shows the same curve but normalized such that the starting value is equal to 1 0 and other values have been increased proportionally This gives a curve which is useful for comparison with other designs 28 Wheel rate Ej Results plots Springwheel forces W
50. ollows e Enter the data or load it from file for the bike to be cloned e Click the Calculate and plot button and select the Wheel rate page e Click the Save and print options button and select Save eqn to file The data from the bike to be cloned will be put in a file with any others that you may have already saved to be cloned Now load the data for the design which you wish to modify as above and select the parameter to do the goal search with from the goal search panel as in the examples above From the goal search screen e Click on the Import from file button e Select the required design from the list e Click on the Use selected button 23 Mie x Ratetest O preload 2 07267 LONNIFE MOISES 325 da Unspecified 7 837E 7 0 0001 8 0 00248 32 5 133 The data from the donor will be loaded into the Goal rate table and then you can proceed with the goal search as in the previous examples When using a donor design it is quite likely that the range of wheel displacement will be different from the receiving design In that case the software will automatically impose the donor range of wheel rate values onto the receiving design 24 Results screens Calculate and Plot There are several pre defined screens with graphs plotted of various sets of calculated data contains the calculated data in tabular form which can be exported in eXcel spread sheet as well as other f
51. or a very rapid assessment of the squat anti squat characteristics and the effects of changing sprocket sizes and swing arm angle etc Anti guat oo Attitude Spring calcs sia LG height Aake trall J wheel Mol it Curent data Ox Master data RU Plotting Visit web site The effects of changing rear ride height and or fork slider positions are calculated After a change the new weight distribution rake trail CG position swing arm angle and wheelbase are shown This is a very rapid way to see the global effects of attitude changes regardless of how those changes were made Calculates the spring rate from dimensional data of a spring This is useful to get an estimate of the spring rate for those with no facilities to measure the rate directly Suitable for linearly wound springs it will in most cases provide reasonable accuracy for the starting rate only of progressive springs A built in help window gives instructions for use Shows one way to measure CG height and does the necessary calculations Evaluates the missing parameter in a set of four relating to steering geometry Rake angle wheel size offset and trail are the 4 parameters Enter any three of them and the fourth will be calculated Calculator for the moments of inertia of wheels and tyres There are three different methods included Complete attitude analysis of the whole bike Calculates steady state attitude or trim param
52. ormats for additional analysis or charting All of these results screens can be printed separately The results screens display automatically after clicking on the button and are selected by the following page tabs spring wheel forces wheel rate Motion ratio Shock displacement SA angle SA pivot forces Rocker pivot forces Energ Tabular data Tabular view Wheel displ Shock displ Wheel load Prvot load total Pivot load vert Pivot load honz Rocker load total 0 4642 0 9301 1 3978 1 5673 2 3306 eoll 3 2065 3 7634 4 2420 4 rzad 5204r 5 6000 6 1749 6 6625 r 1526 r Bddd 5 1361 0 6337 3 1312 9 630 10 1322 10 6357 11 1412 11 6467 12 15682 360 000 415 700 471 612 BAr Fao nod O s 640 633 697 406 fod 396 817 605 069 035 926 687 904 562 1042 660 1100 985 1153 536 1218 316 1277 326 1336 566 1396 039 1455 746 1515 689 1575 869 1636 267 1696 945 1757 045 1815 9858 166 703 193 322 220 160 247 301 zrg rda 302 507 330 578 356 966 307 679 416 708 446 069 dro 63 505 792 536 161 066 874 597 935 629 349 661 120 693 251 r25 4 fog 61 r 91 860 025 462 ood 490 Odo coe 926 675 690 27 6 66 907 59 1017 98 1128 92 1240 73 1353 41 1466 97 1581 43 1696 79 1813 05 1530 24 2045 35 2167 40 feof ad 2405 34 2530 26 2653 15 off Oe 2901 50 302r ra 3154 67 3202 60 3411 56 3541 57 One screen Rocker loa 90 36 307 53 1017 55 1128 43
53. p coord 100 Miscellaneous Y coord 40U Weight on rear wheel 145 Raf Mo sprocket teeth _ Front jis Rear E Shaft Drive D Rear wheel weight 22 Kg Tyre radius 300 i E Calculate and Plot Ets m project E Load project Fo Adjust wheel height f Goal seeking d Copy print options a Units converter Numbered features on this screen are 4 Calculate and plot button Click on this when data entry is complete to calculate and plot the results Custom spring button This opens a window to specify variable rate springs and or bump rubbers 9 Animate The slider bar allows continuous animation of the suspension system graphic between full rebound and full bump The i button toggles between full rebound and full bump 4 Pictorial representation of the suspension design as defined by the entered data The illustration may disappear when returning from another screen the screen saver or Suspend mode in which case clicking on the area of the graphic will cause it to be redisplayed Results screens Ei Results plots opring wheel forces Wheel rate Motion ratio Shock displacement S4 angle SA pivot forces Rocker pivot forces Energy Tabular data 5 x s Spring and wheel forces Ys vertical wheel movement Ref OFCE 4 a00 r000 BOUU s5000 4000 3000 e00 1000 0 10 Fall 120 ee Paar acres mm fe Toggle axis base be Refresh d Save and print o
54. ptions fa Unita converter The results are plotted on eight separate graphs each showing different characteristics of the suspension system being analyzed Spring wheel load as illustrated above the forces at the wheel contact patch and on the shock spring These plots include the effects of variable rate spring and bump rubbers if specified Actual wheel rate the effective vertical spring rate as seen at the wheel plotted against wheel movement Motion ratio the leverage ratio between shock and wheel Shock compression this shows the relationship between the shock and wheel movements Swing arm angle the angle to the horizontal of the swing arm throughout the range of wheel movement Swing arm pivot forces the horizontal vertical and resultant forces at the swing arm pivot point Rocker pivot forces the horizontal vertical and resultant forces at the rocker pivot as well as the link force Energy the energy stored in the compressed spring The results are also available in tabular form and can be printed or saved in various formats allowing additional analysis or graphing possibilities There are buttons on each plot page as follows e Shows a polynomial equation of the data Also plots a graph under the data graph to Ey Eauation iad show degree of fit kE Toggle origin Toggles the origin of the X axis between full rebound position and static ride height l Toggle axis base Toggles be
55. rim Y coord pivot e02 mm DE m mm OF mm EF fao mm Link length 225 H mm Rocker orientation fi E Shock on SA P Rocker Shock end D a Pivot D H 15 The fly out help window shows the meaning of the various rocker dimensions The software does some error checking to try and ensure that the dimensions are physically compatible For example EF must be less than or equal to DE DF E and F may both be on the same side of the pivot D this is controlled by the length EF When the cursor hovers over the data entry window it is possible to drag that window to another part of the screen for those cases where it would otherwise obscure the graphic IMPORTANT NOTE The letters E and F refer to the mounting points for the shock and link respectively regardless of the orientation of the rocker These letters DO NOT signify left nor right E Rocker and link amp coord pivot ise mm Y coord pivot oz mm DE ES mm OF eS mm EF fao mm Link lenath 225 H nm Rocker orientation fi Shock on S e E feo ae bide w mm This is an example similar to that shown above but with the shock mounted on the swing arm Often called a Fully floating system The Shock on SA tickbox defines whether the shock is mounted on the chassis or fixed to the swing arm If this is ticked then additional data entry boxes are displayed to define the shock mounti
56. selected limits might be determined by packaging constraints for example re above ground mm 2 Click and mark shock mounting f On frame WA oe C On swing arm x Cancel From the pop up panel select the parameter to modify in this example it is On frame Then with a normal click and drag procedure mark the limits as shown and click on the OK button when done Static wheel height 22 mm m Save an This will then pass on to a screen for entering the desired characteristic which will show the unmodified characteristic as well as the achieved characteristic The closeness of fit least squared error between the desired characteristic and that achieved will depend on how realistic the requested requirement was and the sensitivity to the modified parameter For example asking for a 2 1 wheel rate progression with a simple twin shock layout is not generally realistic Depending on wheel movement etc 1 1 to 1 2 is the maximum obtainable In the case shown below the required degree of progressiveness is beyond that which the simple layout can provide and so the achieved result only goes part way to satisfy the unrealistic requirement This example was chosen for illustrative purposes to show that not all requirements can be physically achieved 18 On entry to this screen we see a table and graph of the unmodified layout the characteristic chosen for comparison is the normalized value of the wheel rate this
57. setups and designs because it is independent of the rate of the suspension spring The actual wheel rate display will change according to the specified spring rate 29 Swing arm pivot forces Results plots el Spring wheel forces Wheel rate Motion ratio Shock displacement S4 angle 5A pivot forces Rocker pivot forces Energy Tabular data ue SA pivot forces Ys yYertical wheel movement Ref Force My ame Horizontal ce oe Ye rtical He sultant 0 10 zal 30 40 AO BO Fall ol 40 100 110 120 ertical wheel movernent mm bet Refresh m Save and print options Ea Units converter The advent of modern suspension systems with high leverage has resulted in higher loading in the swing arm pivot bearings Due account must be taken of this in the selection of the bearings and the structural properties of the swing arm and frame supporting points These graphs show the total or resultant force together with the horizontal and vertical components If specified the effects of a bump stop rubber will be shown in these plots N B Remember that this does not include the effects of damping forces which may easily double these values in some cases 30 Rocker pivot forces Results plots Sporing wheel forces Wheel rate Motion ratio Shock displacement S4 angle SA pivot forces Rocker pivot forces Energ T abular data ae 7 r Rocker pivot forces YS vertical wheel movement Ref OFCE
58. sprocket teeth Front 15 Graphic Rear 43 Shaft Drive C Adjust attitude i Goal seeking Lj Copy print options a Units converter Size gt Help N B At times the image may disappear a mouse click in this part of the screen will redraw it The layout graphic image serves a double purpose Firstly it gives a visual check on the accuracy of the dimensional data that has been entered If a mistake has been made during data specification then it will be quite obvious as the graphic representation will differ from that expected When any data item is changed then so too will it s representation Set to static loaded height F Set to static loaded heig Secondly the image can be animated over the range of movement defined by the maximum stroke of the shock The i button will toggle between full rebound and full bump positions The slider control allows a gradual animation over the same range Itis possible to specify a suspension design that becomes dimensionally incompatible over the full range of shock movement and the animation feature is very useful to see the cause of the problem A typical cause might be that the length of a rocker is too small for the shock displacement specified Full droop Full bump JE Shock compression mm 0 Tyre above ground mm 1 11 Swing arm data There are two possible l Swing arm methods for entering the owing arm E is shock or link mounting dimens
59. swing arm there will be an additional point on the swing arm to specify The fly out help screens show how this is done The following sketch shows the Alternative method of measuring In some cases this may be the easiest way to measure but requires additional measurements if you wish to try the suspension calculations with the wheel position altered for chain adjustment 54 Rocker D pivot CF dlink The rocker from the same example Also measured as a separate component The shock and link are characterized by their length only which is self evident and not shown here Moments of Inertia of the wheels and tyres These values are used in the calculation of the squat and sag values under acceleration and braking conditions The accuracy of the Mol values do not have a large effect on the squat and sag values they are just a refinement to the calculations not a major part In many cases the Mol values will not be available if you do not have this information use the value 1 which loads default values into the calculations based on typical wheels according to their weight These default values will normally be sufficient lt is not difficult to measure the actual moments of inertia and there is a three in one Mol calculator built into the software There are many different ways of doing these measurements depending on the facilities available but these calculators do the hard work for three simple methods of measurem
60. tween wheel movement and shock compression as X axis Redraws graphs cleaning any user added lines or marks EA Save and print options Print save to file or copy graph to clipboard Ea Units converter Conversion between metric and imperial units The best way to learn to use the programme is to play around Enter various data and see what happens The following section explains each feature in detail and there is a separate publication which explains the theory and practice of Suspension systems in general Detailed description The following explains all the features of the software on a window by window basis Hear suspen Rear suspension As shown in the Quick start section above this can used to select a starting type from a range of pre defined designs The three columns of speed buttons like that shown to the left define three basic classes of Suspension design The three rows just predefine three separate examples within each class Within a particular class the specific design is defined by manually entered data The examples are just starting points the notes are displayed to help chose the correct file This feature is very helpful when you want to The Load button retrieves previously saved designs from the hard disk When a file is selected k find a file some weeks after it was first saved Load project Project data can be saved to a file for later retrieval It is suggested that the f
61. ure and entered as bar One bar is approx 100 kpascal or 14 5 psi 34 Pressurizing forks has several effects viz Pre load similar to adding pre load to the spring Seal pressurization aids sealing but increases friction Reduces cavitation in the oil Increases progressive rate tendencies near full compression 35 Anti t M Anti squat On first entry this window is loaded with some default data which must be adjusted to the dimensions of the bike being analyzed If you have previously entered data into the rear suspension module and plotted the results then the parameters of that case will be the default The graphic is kept simple and does not show details of the type of suspension system in use because that has no effect on the anti squat properties The graphic can be exercised over the specified range of wheel movement the main purpose for this is to visually see the proximity of the chain run to the swing arm pivot Click the recalculate button to refresh the graphic after changing some data Squat calculation Swing arm length 500 par TU orau Bull pump Graphic E 4 P Swing_arm pivot height 390 mm il size Mo teeth rear sprocket 43 Ho teeth front sprocket i 5 Chain pitch inches 0 625 inch coord sprocket centre 100 mm Y coord sprocket centre H10 mm Load on front wheel ER Kg Load on rear wheel 25 Kg Rear wheel weight 3 Kg Front wheel Mal ia Kg m2 Rear wheel Ma
62. ver 0 3 metres for each revolution The pulley should be a light as possible so that it contributes a minimum to the Mol of the wheel although in most cases it will be a simple matter to calculate its own Mol and subtract from the overall value but this is usually not necessary 56 Layout of pulley and wheel R Fulley radius Possible pulley design Diameter nominal dia of card 57 Special notes Extension shocks Shocks that are arranged to extend rather than compress when loaded Some Harley Davison models use these To model these in this software it is necessary to specify the Maximum stroke as a negative value as shown below In the software it is only the simple shock on swing arm designs that accept a negative Maximum stroke value Suspension unit coord fired end Y coord fed end Static length b lasimum stroke Spring rate 120 Nmm Spring preload f mm Top out spring rate E Mrmr O Top out contact mm 2 Custom spring bump stop Miscellaneous ttit Rear sprung weight 100 Kg Tyre radius 300 mmn Calculate and Plot Rake and trail Multi lingual features From version 4 10 the software structure incorporates features to allow translation into any number of languages Although it has not been tested with alternative character sets such as those used in various Asian languages The translation files are in text format and are externa
63. wn this is shown on the red curve Clicking the Refresh button will redraw the curves with any marks and lines cleaned off As you move the mouse over the graph cross hairs will be displayed with the XY values The tetimamcmmaememcnm button toggles between using the wheel motion or shock compression as the values for the X axis The line equation will automatically change to reflect the new axis 26 Shock displacement Results plots lel Soring wheel forces Wheel rate Motion ratio Shock displacement SA angle SA pivot forces Rocker pivot forces Energy Tabular data Help Shock displacement s vertical wheel movement Ret shock displ mm y yy T S T Lme oes a mae een mr Static loaded sag 26 mm ke Toggle origin bet Refresh m Save and print options i Units converter This plot shows the relationship between the shock compression and vertical wheel movement In this example nearly 130 mm of total vertical wneel movement causes almost 80 mm of shock compression 2 Motion ratio Spring iwheel forces Wheelrate Motion ratio Shack displacement 54 angle SA pivot forces Rocker pivot forces Energy Tabular data F ShockAyheel motion ratio Ys vertical wheel movement Ref Motion ratio i lt lt O T I y i Cll D rrrrrri lt C writs CC n l 0 10 20 30 40 BO BO fall oo 90 100 110 120 Eqn 5 85E 8x 3 1 92E 6x 2 0 00182x 0 463 Vertical wheel moyveme
64. y wound springs were sometimes employed to give a progressive rate at the wheel The modern era was initiated when the Yamaha cantilever revived the Vincent system and employed just one Suspension unit monoshock although the original Vincent system used two shocks along side each other Initially the Yamaha version was designed for moto cross to extend wheel movement and this led to a wide variety of alternative rear suspension systems by several manufacturers These quickly spread into most other forms of motorcycling including racing and road use Many of these new designs also incorporated movement geometries that gave varying degrees of progression Whilst these progressive systems offer a much wider range of set up options they have also been the source of much confusion Most people find it more difficult to understand the precise behaviour of the suspension action It is usually necessary to go through awkward step by step physical measurement and tedious geometric plotting to get an idea of the characteristics Along with improvements in rear suspension as well as engine and tyre technology there has been an increased need to setup the overall configuration of sports and competition motorcycles to levels of refinement not seen in the past Unfortunately the methods and tools to do this have not been generally accessible outside of the confines of the design departments of the motorcycle manufacturers This software

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