Design and Fabrication of Safety System

for two-wheeler side stand

Automobile Project
MEC-340
Submitted in partial fulfillment of the
Requirement for the award of the Degree of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
Mohemmed Aadil Khurshid
Tripuraneni Akhil
Mamidi Harish
Vyas Krishankant

Under the Guidance of

Mr. Manish Kumar Tated
UID:19483

DEPARTMENT OF MECHANICAL ENGINEERING

LOVELY PROFESSIONAL UNIVERSITY
PHAGWARA, PUNJAB (INDIA)-144402
2016
 Lovely Professional University, Jalandhar, Punjab

CERTIFICATE

I hereby certify that the work which is being presented in the Automobile Project entitled
“Design & Fabrication of Safety System for Two-Wheeler Side Stand” in partial
fulfillment of the requirement for the award of degree of Bachelor Of Technology and
submitted in Department of Mechanical Engineering, Lovely Professional University, Punjab
is an authentic record of our own work carried out during period of project completion under
the supervision of Mr. Manish Kumar Tated, Assistant Professor, Department of
Mechanical Engineering, Lovely Professional University, Punjab.

The matter presented in this report has not been submitted by us anywhere for the award of any
other degree or to any other institute.
.

Date: (Mohemmed Aadil Khurshid)

(Tripuraneni Akhil)
(Mamidi Harish)
(Vyas Krishnakant)

This is to certify that the above statement made by the candidates is correct to best of my
knowledge.

Date: (Mr. Manish Kumar Tated)

Project Mentor
 Acknowledgement
This project was a welcome and challenging experience for us as it took a great deal of hard work
and dedication for its successful completion. It’s our pleasure to take this opportunity to thank all
those who helped us directly or indirectly in preparation of this report.

We (Md. Aadil Khurshid, Tripuraneni Akhil, Harish, Mranal Vyas) students of Lovely
Professional University, in our acknowledgement, we would like to thank all the people who have
helped us in making this project a success. My first and foremost acknowledgement goes to my
mentor Mr. Manish Kumar Tated for the assistance and guidance that he provided throughout the
session. I am ever grateful to him for that.

We are also thankful to our university which has assigned us this project. This has immensely
improved our technical knowledge. We are thankful to university for providing us various
resources like lab, tools for the timely completion of this project.

Date: [Md. Aadil Khurshid (11302187)]

[Tripuraneni Akhil]
[Harish]
[Mranal Vyas]

Lovely Professional University

 Abstract

The report explains about sprocket side stand retrieval system which is concerned with the
releasing of the side-stand of two-wheeler automatically by using the mechanical engage. This
system is designed in order to ensure the safety of the person riding the vehicle. As it is being
observed that the accidents happening on the road concerned with two-wheelers has increased.
These all accidents mainly happen just because of little ignorance rather than some major fault.
One of these causes is not lifting the side-stand or forgetting to lift it in a hurry. Thus, in order to
eliminate this cause of road accident with two-wheelers this system is fabricated.

This system is cheap and reliable. In this system, small (external) sprocket is connected over the
chain of the two wheelers. While the vehicle is in moving condition the side-stand is automatically
released. Due to the rotation of the sprocket the lifting of the side stand takes place driven by the
chain in mesh with the sprocket. This system is purely mechanically powered and does not require
any other power source. Thus, it does affect the performance of the engine and also does not add
extra weight.
 CONTENTS
Page No
1. Introduction
1.1 Introduction to automobile 1
1.2 Sources of Accidents
1.3 Types of existing side stand 2
1.4 Existing Methods
1.4.1 Modern ECU
1.4.2 Mechanical Project
1.5 Drawbacks of Existing Methods 3
1.6 Proposed Method
2. Construction & Components
2.1 Construction 4
2.1.1 Components & Its Design
2.1.2 Axle
2.1.3 Sprocket Pinion
2.1.4 Lifting Lever 6
2.1.5 Pushing Lever 7
3. Specification of Components
3.1 Specification of Sprocket 9
3.2 Specification of Axle
3.3 Specification of Lifting Lever 10
3.4 Specification of Pushing Lever
3.5 Specification of Spring 11
4. Assembly & Arrangement
4.1 Assembly of Components 12
4.1.1 Inciter Assembly
4.1.1.1 Arrangement of Inciter Assembly
4.1.2 Retriever Assembly 13
4.1.2.1 Arrangement of Retriever Assembly 13
5. Power
5.1 Power Source for Inciter Assembly 15
5.2 Power Source for Retriever Assembly
6. Working
6.1 Working Principle 16
6.1.1 Resting Condition
6.1.2 Riding Condition 17
6.2 Side View 18
6.3 Advantages
6.4 Applications
7. Conclusion 19
8. Cost Analysis 20
9. References 21
List of Tables

Table1.1 Data of accidents with two-wheelers 2

Table3.1 Specification of Sprocket 9
Table3.2 Specification of Axle 9
Table3.3 Specification of lifting lever 10
Table3.4 Specification of pushing lever 10
Table3.5 Specification of Spring 11
List of Figures
Fig 2.1 Axle with Keyway 5
Fig 2.2 Sprocket with Bearing 5
Fig 2.3 Sprocket with nomenclature 6
Fig 2.4 Lifting Lever 7
Fig 2.5 Pushing Lever 8
Fig 4.1 Inciter Assembly 12
Fig 4.2 Retriever Assembly 13
Fig 6.1 Resting Condition 16
Fig 6.2 Riding Condition 17
Fig 6.3 Side view of Sprocket Side Stand Retrieval System 19
 Chapter-1
INTRODUCTION

1.1 INTRODUCTION TO THE AUTO MOBILE

The present world is the world of automation. Every system is being automated in order to
reduce human effort. Automobile is such an automation. It reduces human effort which is
required in walking from one place to another or travelling long distances. It has become an
important part of our life and has become our secondary legs. But as we know every mechanical
system requires certain things to be taken care of. It also requires care and presence of mind
while using it. Generally used automobile is the two-wheeler i.e. bikes, motorcycles, etc. Being
a two-wheeler, it cannot stand without being supported with some component to keep it in the
same position.
To enable this motorcycles are generally provided with stand for providing support when they
are not in use. The stand usually comprises of a bar or rod which is pivotally attached to the
lower portion of the motorcycle frame and is movable to a laterally downward direction in
extending position so that the motorcycle can be tilted against and rest upon the bar. When the
motorcycle is in use, the bar is swung upwardly and along the frame so that it will not interfere
with the movement of the motorcycle. Often the cyclist neglects to lift the stand to its raised
position and when a banked turn is made the stand strikes the road creating disturbance in the
stability of the two-wheeler thus causing serious consequences to both the cyclist and the
motorcycle and even causing risk of life.

1.2 SOURCE FOR ACCIDENTS

While the two-wheelers are concerned, accidents occur due to riding the vehicle in high speed,
ignores to use helmets, does not maintains the speed limit and forgets to lift the side stand while
riding the vehicles. These are the major source for accidents. Forgetting to lift the side stand
causes huge accidents in rural areas partly in urban areas too, because all the other source of
accident has preventive measure, but accident due to side stand do not have proper preventive
measure. If you see the accident status 36% of the accidents occur due to this problem.

1
 Table 1.1 Data of accidents with two-wheelers

S.NO DURING THE REASON FOR THE ACCIDENT %OF

YEAR ACCIDENTS

1. 2002-2008 Forgetting to lift side-stand 36%

2. 2002-2008 Does not maintain speed limit 38%

3. 2002-2008 Does not obey traffic rules 22%

4. 2002-2008 Other problems 04%

1.3 TYPES OF EXISTING SIDE-STAND

i) Manual Stand Manually Operated
ii) Stand with indicators Indicate position of side stand
iii) Stand with springs Retraction caused by spring

1.4 EXISTING METHODS

To prevent accidents occurring due this side-stand many ECU (Electronic Control Unit) and
mechanical project have been undertaken.

1.4.1 MODERN ECU:

In order to reduce accidents due to carelessness in lifting the side-stand, many advance
measures have been introduced like ECU, the modern ECU contains a 32 bit and 40 MHz
processor. It will be fast as pc’s microprocessor. The ECU decides timing and functioning of
engine and its parts. This play its role in dashboard, this indicates the gear shifting, side stand,
to wear helmet in digital display like, Hero Honda’s Karizma ZMR. But the people ignore this
those indicators and safety rules so, for safe guard many mechanical projects have been found
to retrieve the side stand automatically.

1.4.2. MECHANICAL PROJECT

In existing mechanical project, many ideas had been found to lift the side-stand automatically.
i) One small flat rod is kept attached and pivoted between the gear actuator lever and
the side stand of the bike. when the gear is actuated the side, stand get lifted
automatically.

2
 ii) Small stepper motor is connected between the side stand and the engine, when
engine is started the stepper motor gains the source of power and retrieve side-stand
automatically.

These are some methods to retrieve side stand automatically when the vehicle moves but it is
not implemented in practical use due to its drawback.

1.5 DRAWBACK OF EXISTING METHODS

ECU methods are implemented only in costlier bikes but it does not implement in normal
domestic bikes due to their cost.
When we come across those mechanical projects we could note some drawbacks like wear out
of gears, making injuries in legs while actuating gears. Major drawback is it cannot use in all
type of two-wheelers. So, in order to solve this, we thought and designed “SPROCKET-SIDE
STAND RETRIEVE SYSTEM” this system can be attached in all type of two-wheelers
(mopeds, geared, non-geared, hand geared bikes).

1.6 PROPOSED METHOD

Based on the working principle of two-wheeler (i.e. the power is generated in the engine and
it transmits power to the pinion and makes it to rotate. The pinion transmits power to the rear
wheel pinion and makes the vehicle to move). This is the basic principle followed in all type
of two-wheelers, based on this “sprocket-side stand retrieve system” is designed because this
system works by getting power from chain drive. This sprocket system consists of four
components, which is assembled as two set up which would be explained briefly in construction
and working part of this paper.

3
 Chapter-2
CONSTRUCTION AND COMPONENTS

2.1 CONSTRUCTION

The whole construction of this system is simple and efficient. The arrangement and position of
components makes the system to function. Each and every component has its own property and
responsibility. The power obtained from the chain drive is transmitted to the appropriate
component without power loss. The systematic design of system is made in order to consume
only very low amount of power initially for few seconds to retrieve the stand. Then the power
consumption does not occur after retrieving the stand. Construction of the proposed “sprocket
side stand retrieve system” consists of four major components. They are:

2.1.1COMPONENTS & ITS DESIGN:

 Axle
 Sprocket pinion
 Lifting lever
 Pushing lever
2.1.2 AXLE:
Axle is the metallic rod made up of mild steel. It connects the lifting lever and sprocket
centrally. The axle is welded centrally to the sprocket. The axle is hold by a holder. The
holder is welded with the frame. The holder is used to prevent vibration and to provide
support to the axle. The holder has small metallic tube and a rectangular metal plate.

Fig 2.1 Axle with key way

The metal plate is welded perpendicular to the tube. The diameter of tube is slightly greater
than the axle diameter about 2 to 4mm. This is for allowing the axle to rotate freely without
friction with the tube.

4
The other end of the metal plate is welded at the frame. The whole metallic members of holder
is of mild steel. The one end of axle is welded with sprocket and other end with lifting lever
and thus the power is transmitted from sprocket to lifting lever.
2.1.3 SPROCKET PINION:
Sprocket is the major component of this system because it is power transmitting device. It gets
power from the chain drive and makes this system to work. It is the device which transmits the
linear motion of meshing chain drive into rotary motion by means of the tooth found on it.
The sprocket with ball bearings is said to be FREE WHEEL.

Fig 2.2 Sprocket with bearing

Since it is a free wheel it allows the toothed part to rotate free from central portion in a direction.
Hence this type of sprocket is used as the rear power transmission device in by cycle that makes
the wheel to rotate and also allows toothed area to rotate in anticlockwise when pedaled
anticlockwise direction. This action of sprocket allows attached lifting lever to adjust freely
automatically or manually when it does not engage with pushing lever properly.

Fig 2.3 Sprocket with nomenclature

5
Since the sprocket transmit the power from chain drive, it should have the capability to
withstand the heavy loads of engine. So, to withstand those impacts on toothed area, it is made
of high carbon steel. The ball bearings are made up of high chromium steel. Hence all these
material gives
 Heavy duty
 Smooth running
 Tempered
 Long life

Hence the sprocket is considered as heart of this system

2.1.3 LIFTING LEVER

Lifting lever is the third major component of the system. The lifting lever is the rectangular rod
made of ms-rod, which consists of two lifting leaves which is mounted with the edge of axle.
The lifting leaves should be parallel to the sprocket pinion. The lifting lever is composed of
two metal rods, where both are welded at either side of the axle. The free ends of the lifting
leaves are tapered well. The ends are machined well for tapered shape for smooth engaging
with pushing lever.

Fig 2.4 Lifting lever

6
This smooth engagement leads proper retrieving of side-stand. This tapered surface makes the
lifting lever as capable to withstand engine impact. When stand is moved vertical in position,
the pushing lever engages with lifting leaves. This may not possible in all time, since the angle
of lifting lever may be any degree. So, due to effect of free wheel and tapered surface of the
lifting lever can adjust itself.

2.1.5 PUSHING LEVER

Pushing lever is the component pivoted centrally to the side stand. The pushing lever is metallic
rectangular plate, whose bottom end is bended in shape of C and top end is welded with a small
piece of rectangular rod. This small piece of rod is used for getting lifted by the lifting lever.
Since this rod engages (or) lays over tapered edge of lifting lever, thus the retrieving occurs
smoothly.

Fig 2.5 Pushing lever

The pushing lever is made of mild steel flat rod with the length according to the distance of
side stand arrangement. Its top end is made tapered so as to engage with lifting lever. The
bottom end of the lever is made as C-clamp, which holds the side stand as shown in fig2.5

These are four major components using in this system and other small components like Nuts
and bolts, hooks etc., are used in this system. specification and dimension of the component is
described in chapter 3.

7
 Chapter-3
SPECIFICATION OF COMPONENTS

3.1 SPECIFICATION OF SPROCKET

Table 3.1 Specification of sprocket
MATERIAL High Carbon Steel

PITCH 12.7mm

WIDTH 30mm

TEETH 16

BALLS High carbon high chromium steel balls

3.2 SPECIFICATION OF AXLE

Table 3.2 Specification of axle
MATERIAL Mild Steel

SHAPE Cylindrical rod

LENGTH 50mm

DIAMETER 13mm

INNER DIAMETER OF SUPPORTING 15 mm

AXLE
OUTER DIAMETER OF SUPPORTING 17mm
AXLE
LENGTH 30mm

THICKNESS 3mm

8
3.3 SPECIFICATION OF LIFTING LEVER
Table 3.3 Specification of lifting lever
PARAMETERS SPECIFICATIONS

LENGTH OF LEVER 95mm

THICKNESS 10mm

TAPERED ANGLE 45deg

CHAMFERED ANGLE 20deg

POSITION Parallel to Sprocket

WELDED LENGTH 13mm

MATERIAL USED Mild Steel

3.4 SPECIFICATION OF PUSHING LEVER

Table 3.4 Specifications of Pushing Lever
PARAMETERS SPECIFICATIONS

MATERIAL Mild Steel

LENGTH OF LEVER 180mm

THICKNESS 3mm

DIAMETER OF HOLE 8mm

LENGTH 30mm

THICKNESS 10mm

DIAMETER OF CLAMP 28mm

DIAMETER OF STAND 25mm

PIVOTED ANGLE 55deg

BOLT DIAMETER 8mm

9
3.5 SPECIFICATION OF SPRING
Table 3.5 Specification of spring
NO. OF COIL 32

DIAMETER OF COIL 2mm

DIAMETER OF WIRE 15mm

INNER DIAMETER OF COIL 12mm

MEAN COIL DIAMETER 13.5mm

TYPE Closed coil helical spring

EXTENSION LENGTH 17mm*2=34mm

MATERIAL Stainless Steel

10
 Chapter-4
ASSEMBLY AND ARRANGEMENT

4. 1. ASSEMBLY OF COMPONENTS
For the functioning of system, the above four components are arranged in two assembly which
is described below,
 Inciter assembly
 Retriever assembly

4.1.1 INCITER ASSEMBLY:

Inciter assembly consists of axle, sprocket and lifting lever. The Sprocket is mounted on the
center of the axle and the lifting lever is welded at the front side of axle as shown in fig 4.1

Fig 4.1 Inciter assembly

This inciter assembly is main assembly because it receives the power from the chain and incites
the retriever assembly to retrieve the side stand because this inciter assembly is kept under the
chain as such that the sprocket attached centrally with the axle get engage with chain drive.

4.1.1.1 ARRANGEMENT OF INCITER ASSEMBLY

This set up is arranged in the bike as such that this inciter assembly is hold by the small hollow
shaft with rod welded at the center which is welded to the bottom side of the bike. As the inciter
assemblies’ sprocket get engage with chain drive. When sprocket rotates, the axle along with
lifting lever rotates.

11
4.1.2 RETRIEVER ASSEMBLY:
Retriever assembly consists of pushing lever and side stand. The pushing lever is centrally
pivoted with the side stand as the pushing levers tapered end is at the top side and clamp is at
the bottom as shown in fig 4.2

Fig 4.2 retriever assembly

Side stand of the bike is drilled at the center as to pivot the pushing lever as shown in figure
4.2. Pushing lever is also drilled at the center as such the both components kept together and
bolted as such that C shaped clamp is at the bottom and flat rod is kept at the top side.

4.1.2.1 ARRANGEMENT OF RETRIEVER ASSEMBLY

This retriever assembly is arranged as such the arrangement of side stand in the bike. The
pushing lever is arranged as such the flat rod is kept at the top as to mesh of lifting lever. C
clamp end is kept at the bottom as to push the side stand by receiving the power from inciter
assembly.

12
 Chapter-5
POWER SOURCE

This chapter deals with the power source of the working component and how each component
and assembly of component works is explained below with flow chart.

Engine

Chain

Sprocket

Axle

Lifting lever

Pushing lever

Side stand

Flow chart 5.1 Power source of component

13
5.1 POWER SOURCE OF INCITER ASSEMBLY
Inciter assembly gets the power from the linear chain motion i.e. (as engine transmit power to
the rear wheel through chain drive since the setup is kept at the bottom and sprocket get engage
with chain so, when chain rotates in anti-clockwise direction the sprocket engaged rotates in
clockwise direction) as sprocket rotates the axle rotates as the result lifting lever rotates in
clockwise direction.

5.2 POWER SOURCE OF RETRIEVER ASSEMBLY

As the retriever assembly’s pushing lever get engage with lifting lever. It gets power from the
rotation lifting lever and transmits to the clamp and retrieve the side stand automatically.

Rotary motion

Linear motion

Rotary motion

Lifting

Pushing

Retrieving

Flow chart 5.2 Action flow

14
 Chapter-6
DETAILS OF PROJECT

6.1 WORKING PRINCIPLE

Sprocket side stand retrieve system retrieves the side stand automatically if the rider forgets to
lift the side stand while moving the bike. It works based on the working principle of the two-
wheelers. every bike transmit power from engine’s pinion to the rear wheel i.e. rotary motion
of the pinion makes the linear motion of the chain. that linear motion of the chain is absorbed
by rear wheel’s sprocket and converted into rotary motion. That rotary motion of the rear wheel
makes the bikes to move. Based on this Sprocket side stand retrieve system is designed.
If Sprocket is kept between the chain drive, it makes the sprocket to rotate so, using the
sprocket as the major component this system works. It gains the power from the chain and
make specially designed component (lifting lever) to rotate. This rotation incites engaged
pushing lever to push the side stand to retrieve.
When chain rotates anti-clockwise direction the inciter assembly’s sprocket absorbs the power
and rotates in clockwise direction. The working of “Sprocket-Side Stand Retrieve System is
explained below in both (resting & riding condition of two-wheeler)

6.1.1 RESTING CONDITION:

When two-wheeler is in resting condition i.e. when rider actuates the side stand of the vehicle
to ground, the pushing lever that is pivoted at the center of the side stand gets engage with the
inciter assemblies lifting lever. During this condition the inciter assembly is at rest and retriever
assembly (pushing lever’s tapered end get engage with tapered end of lifting Lever).

Fig 6.1 Resting condition

15
Pushing lever’s length can be changed according to type of bikes and distance calculated
between the side stand and chain drive. Closed coil helical spring which gets pulled, the coil
of spring get tensed during stand resting in ground. This is the condition of system during
resting stage.

6.1.2 RIDING CONDITION:

When two-wheeler is started, Engine’s pinion transmits power to the rear wheel by the chain
drive. The inciter assembly which is kept at the center of the chain drive gets rotates as the
sprocket gets engage with chain drive. so, when the sprocket rotates the lifting lever mounted
with axle rotates. hence the lifting lever lifts engaged the pushing lever and therefore the
pushing lever pushes the side stand by clamping it with the C shaped clamp stand holder and
hence the spring tensed in the side stand get compressed quickly as a result side stand get
retrieves .

Fig 6.2 Riding condition

16
The working of “Sprocket-Side Stand Retrieve System is explained below in the flowchart 6.1

Sprocket Meshing

Down bottom Line of Chain

Rightward Linear Motion

Clockwise Rotation of Sprocket

Lifting lever rotates

Pushing lever pushes

C-clamp forces

Side Stand Retrieves

Flow chart 6.1 Working positions

17
6.2 SIDE VIEW

Fig 6.3 Side View of Sprocket side stand retrieve system

6.3 Advantages
 It’s less costly
 This system is does not affect the engine efficiency.
 It does not affect the structure of a vehicle.
 It can easily be fitted in the two-wheelers.
 It does not add extra weight to the vehicle.
 Electrical power not required.

6.4 Applications
This method reduces the side stand accidents in two wheelers. This method also used for with
gear and without gear of two wheelers.

18
 Chapter-7
CONCLUSION

“Sprocket side-stand retrieval system” will definitely serve as a better safety system for the
two-wheelers. The setup is compact and it does not affect the performance and efficiency of
the vehicle because the power is obtained from chain drive and does not require any extra
source. Definitely this system can be used in all type of two-wheelers for retrieving the side
stand automatically. It will serve as a major system to control accidents due to rider failing to
retrieve the side-stand or getting forgotten to lift it due to situations and protect the rider from
getting into some fatal situations. These systems can be implemented in all types of bikes by
doing small variation in size.
The cost of this system very less as it does not require much of the components except a
sprocket and the length of the chain need to be increased a bit. Thus, the overall cost of the
vehicle is also not affected drastically.
This system is completely noise free if proper lubrication is done. It does not affect the
aesthetics of the vehicle as the sprocket remains hidden. Also, it does add much to the dead
weight of the vehicle being light in weight because of less components. It has no disadvantages
at all and can be added later also in the two-wheelers without putting much effort and can also
be easily removed depending on riders’ choice.
Thus, in all this system is very cheap, reliable, requires little maintenance and above all, it
releases the thought of lifting the side-stand every time people are going to ride it. Hence,
“Sprocket Sid-Stand Retrieval System” is best and can prove to be life-saving.

19
 Chapter-8
COST ANALYSIS

COST OF THE MODEL & FABRICATION

MATERIAL COST
SPROCKET 2 NOS 250*2 =500
LARGER SPROCKET 1NOS 800
WHEEL CHAIN 400
SIDE STAND WITH BOLT&SPRING 350
MS RODS FABRICATION (FRAME, 1200
LIFTING&PUSHING LEVER)
PEDAL 150
TOTAL 3400

20
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