Authored By: Art Gostick Student Number:: Prepared For Prof Neil Walker

PREPARED FOR PROF NEIL WALKER
Authored by: Art Gostick
Student Number: 9500734

Bike Trailer Proposal MECH1912
Contents
1.0 Introduction 3
2.0 Design Requirements 3
3.0 Proposed Design Concepts 5
3.1 Wheels 5
3.2 Trailer Frame 6
3.2.1Horizontal Support Members 6
3.2.2 Vertical Side Wall Columns 6
3.2.3 Trailer Attachment Device 6
3.3 Analysis Plan 7
4.0 Alternative Design Concepts 7
4.1 Alternate Design 1 7
4.2 Alternate Design 2 7
5.0 Project Plan 8
6.0 REFERENCES 9
Appendix A A1
List of tables
Table 1- Compliance Matrix..........................................................................................................3
List of Figures
Figure 1 Project Plan Gantt Chart................................................................................................8
Figure 2 Kids Bike Trailer [4]......................................................................................................A1
Figure 3 Proposed Design Concept...........................................................................................A2
Figure 4 Proposed Design Tongue Weight Analysis..................................................................A2
Figure 5 Proposed Design Tongue Weight Calculations...........................................................A3
1
Figure 6 Universal Mounting Bracket.........................................................................................A3
Figure 7 Rod End Ball Joint [5]..................................................................................................A4
Figure 8 Alternate Design 1 Seat Post Clamp...........................................................................A4
Figure 9 Alternate Design 1 Trailer U-Joint................................................................................A5
Figure 10 Alternate Design 2 Trailer Frame...............................................................................A6
Figure 11 Alternate Design 2 Tongue Weight Analysis..............................................................A7
Figure 12 Alternate Design 2 Tongue Weight Calculation.........................................................A7
2
1.0 Introduction
This project is to design a prototype cargo trailer to be towed behind a bicycle. It is to be

designed for bicycle intensive urban markets. This trailer will provide transport of goods
with a foot print of 3 feet by 4 feet and up to 200 lbs. This project is for course MECH1912
Mechanical Systems Design and is a simulation of a work project.
2.0 Design Requirements
The design requirements for the bike trailer are specified in Table 1.
Table 1- Compliance Matrix
Requirement Requirement Statement of Compliance

Number
1. The trailer must be able to attach The trailer will be attached at the rear
safely to a typical adult bicycle. bike axle. The attachment arm will
Attachment can be to the seat use a ball-joint type of connection
post, frame, rear axle, or any other that will allow proper freedom of
feasible location. travel when towing the trailer.
2. The trailer should be large enough The cargo area of the trailer will leave
to transport a box with a footprint 1 in. clearance for a cargo box of 3
measuring 3 ft by 4 ft. ft. by 4 ft.
3

Number
3. The trailer should be strong The trailer will be constructed of

enough to transport 200 lb. cargo. aluminum hollow square tubing.
Dynamic loads due to road
The welds will be of significant
conditions and maneuvering are
strength and be able to meet
set at 0.5 g in the sideways
strength / safety requirements. Each
direction (hard cornering), 0.5 g in
wheel will be capable of supporting
the forward and reverse direction
300 lbs. in the event of an uneven
(sudden braking/low-impact
road surface to avoid failure.
collisions), and 1.5 g in the vertical
direction (bumpy roads.) The trailer will be subject to a full
stress/strain analysis after the 3D
modeling is complete.
4. A design factor (i.e., minimum The trailer will be designed to safely

allowable safety factor against transport 300 lbs. of cargo in addition
yielding or proof load) of 1.5 is to its own weight.
required
5. The trailer should be as light as The trailer will be constructed of

possible, consistent with structural aluminum hollow square tubing to
adequacy and general robustness keep the weight as low as possible.
and suitability. Maximum allowable The smallest size that will meet all
trailer weight is tentatively set at the design requirements will be used.
about 100 lbs. (45 kg). Final size to be determined after 3D
model stress analysis.
6. The trailer should be constructed The trailer will be constructed of

from commercially available aluminum hollow square tubing of
structural members such as ANSI standard size. The smallest size that
rectangular or square tube, angle will meet all the design requirements
iron, channel, etc. Steel or will be used. Final size to be
aluminum plate may be used determined after 3D model stress
where necessary. analysis.
7. Standard, commercially-available Any parts that can be sourced from

parts should be used wherever an economical outside source that
possible. (E.g., wheels, bearings, will meet the design requirements will
fasteners, etc.) be used. All others will be fabricated.
4

Number
8. The trailer should be reasonably The trailer frame will be designed

aerodynamic and low-profile. with 6 of clearance from the ground
to clear any curbs and will be
designed as aerodynamically as
possible.
9. The trailer must be attractive, low The entire trailer frame will be
maintenance and corrosion- powder coated to ensure maximum
resistant. corrosion resistance while having an
appealing appearance. Bearings will
be of the sealed type so no further
lubrication will be required.
3.0 Proposed Design Concepts
The design concept is similar to the trailers used to transport children (Figure 2). This
follows some of those same principles but it increases the trailers cargo area and load
capabilities. This trailers main function will be to transport cargo with a maximum foot
print of 3 ft. by 4 ft. weighing 200 lbs. The weight of the trailer is not to exceed 100lbs with
a safety factor of 1.5. See Figure 3 for proposed design concept.
3.1 Wheels
The wheels will be standard tube filled bicycle tires able to absorb light impact and
capable of withstanding a minimum of 300 lbs. This will be enough to support the weight
of the trailer and 200lbs of cargo. The wheels will be attached to a straight axle that will
attach under the trailer.
5
3.2 Trailer Frame
The proposed design (Figure 3) is well balanced (Figure 4) with approximately 8% (Figure
5) of the trailer weight being tongue weight. Ideal tongue weight is 10% [1].
3.2.1Horizontal Support Members
The horizontal support members will be fabricated out of aluminum 6061-T6 hollow square
tubing to maximize strength and reduce weight. This material was chosen due to its
excellent joining characteristics and good acceptance of applied coatings. It combines
relatively high strength with good workability, and high resistance to corrosion [2]. It is
also widely available. The size of these members will be determined after the stress/strain
analysis is performed at a later date. The smallest possible size will be used as determined
by this analysis.
3.2.2 Vertical Side Wall Columns
The vertical side wall columns will be fabricated from 6061-T6 aluminum hollow square
tubing to maximize strength and minimize weight. The vertical support column will be
welded to the horizontal support members. The size of these columns will be determined
at a later date.
3.2.3 Trailer Attachment Device
The trailer attachment apparatus will be a custom designed mounting bracket (Figure 6).
The bottom clamp attaches to the lower rail and using the pivoting upper mounting
bracket and the elongated slot attaches to the upper rail that goes to the seat post. This
design should allow utilization with almost every brand of bicycle. The bracket will have a
rod-end ball joint (Figure 7) where the trailer arm will attach. The trailer arm will be held in
place with a hitch pin for quickly connecting and disconnecting.
3.3 Analysis Plan
The main structural beams of the frame will be analyzed for maximum bending loads [3].
All welds and bolted joints will be tested for bending and shear stress failure in Inventor
using the 3D model.
4.0 Alternative Design Concepts
4.1 Alternate Design 1
The first concept was to attach the trailer to the seat post (Figure 8) and using a u-joint at
the trailer (Figure 9) to allow for range of motion when turning. This initial design allowed
for no movement at the seat post creating a long moment arm which would put significant
stress on the attachment clamp when cornering.
4.2 Alternate Design 2
The second concept (Figure 10) was designed to attach and pivot at the rear axle of the
bicycle and have a u-joint that would allow the trailer to pivot side to side when cornering.
This design had the trailer wheels at the rear of the trailer. This design does not balance
6
the load (Figure 11). This design would cause the u-joint to have to support 30% (Figure
12) of the cargo weight. Optimum weight at the u-joint would be 10% [1].
7
5.0 Project Plan
Figure 1 Project Plan Gantt Chart
6.0 REFERENCES
[1 W. Nichols, "AutoZone Reference Library," Chilton, 1998. [Online]. Available:
8
] www.procare.com. [Accessed 29 January 2012].
[2 "MatWeb Material Property Data," [Online]. Available: http://www.matweb.com.

] [Accessed 1 February 2012].
[3 R. Budynas and J. K. Nisbett, Shigley's Mechanical Engineering Design, New York:

] McGraw Hill, 2011.
[4 "Bicycle Trailers," [Online]. Available: www.bicycletrailers.com. [Accessed 30 January

] 2012].
[5 "Accent Bearings," 12 October 2007. [Online]. Available: www.accentbearing.com.

] [Accessed 1 February 2012].
9
Appendix A
Figure 2 Kids Bike Trailer [4]
A1
Figure 3 Proposed Design Concept
Figure 4 Proposed Design Tongue Weight Analysis
A2
Figure 5 Proposed Design Tongue Weight Calculations
Cargo
U-joint Wheel
Figure 6 Universal Mounting Bracket
A3
Figure 7 Rod End Ball Joint [5]
Figure 8 Alternate Design 1 Seat Post Clamp
A4
Figure 9 Alternate Design 1 Trailer U-Joint
A5
Figure 10 Alternate Design 2 Trailer Frame
A6
Figure 11 Alternate Design 2 Tongue Weight Analysis
Figure 12 Alternate Design 2 Tongue Weight Calculation
A7

Authored By: Art Gostick Student Number:: Prepared For Prof Neil Walker

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Authored By: Art Gostick Student Number:: Prepared For Prof Neil Walker

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PREPARED FOR PROF NEIL WALKER

Authored by: Art Gostick

Student Number: 9500734

2.0 Design Requirements 3

3.0 Proposed Design Concepts 5

3.2 Trailer Frame 6

3.2.1Horizontal Support Members 6

3.2.2 Vertical Side Wall Columns 6

3.2.3 Trailer Attachment Device 6

3.3 Analysis Plan 7

4.0 Alternative Design Concepts 7

4.1 Alternate Design 1 7

4.2 Alternate Design 2 7

5.0 Project Plan 8

Table 1- Compliance Matrix..........................................................................................................3

Figure 1 Project Plan Gantt Chart................................................................................................8

Figure 2 Kids Bike Trailer [4]......................................................................................................A1

Figure 3 Proposed Design Concept...........................................................................................A2

Figure 4 Proposed Design Tongue Weight Analysis..................................................................A2

Figure 5 Proposed Design Tongue Weight Calculations...........................................................A3

Figure 6 Universal Mounting Bracket.........................................................................................A3

Figure 7 Rod End Ball Joint [5]..................................................................................................A4

Figure 8 Alternate Design 1 Seat Post Clamp...........................................................................A4

Figure 9 Alternate Design 1 Trailer U-Joint................................................................................A5

Figure 10 Alternate Design 2 Trailer Frame...............................................................................A6

Figure 11 Alternate Design 2 Tongue Weight Analysis..............................................................A7

Figure 12 Alternate Design 2 Tongue Weight Calculation.........................................................A7

This project is to design a prototype cargo trailer to be towed behind a bicycle. It is to be

2.0 Design Requirements

Table 1- Compliance Matrix

Requirement Requirement Statement of Compliance

Requirement Requirement Statement of Compliance

3. The trailer should be strong The trailer will be constructed of

4. A design factor (i.e., minimum The trailer will be designed to safely

5. The trailer should be as light as The trailer will be constructed of

6. The trailer should be constructed The trailer will be constructed of

7. Standard, commercially-available Any parts that can be sourced from

Requirement Requirement Statement of Compliance

8. The trailer should be reasonably The trailer frame will be designed

3.0 Proposed Design Concepts

3.2 Trailer Frame

3.2.1Horizontal Support Members

3.2.2 Vertical Side Wall Columns

3.2.3 Trailer Attachment Device

3.3 Analysis Plan

4.0 Alternative Design Concepts

4.1 Alternate Design 1

4.2 Alternate Design 2

5.0 Project Plan

Figure 1 Project Plan Gantt Chart

[1 W. Nichols, "AutoZone Reference Library," Chilton, 1998. [Online]. Available:

] www.procare.com. [Accessed 29 January 2012].

[2 "MatWeb Material Property Data," [Online]. Available: http://www.matweb.com.

[3 R. Budynas and J. K. Nisbett, Shigley's Mechanical Engineering Design, New York:

[4 "Bicycle Trailers," [Online]. Available: www.bicycletrailers.com. [Accessed 30 January

[5 "Accent Bearings," 12 October 2007. [Online]. Available: www.accentbearing.com.

Figure 2 Kids Bike Trailer [4]

Figure 3 Proposed Design Concept

Figure 4 Proposed Design Tongue Weight Analysis

Figure 5 Proposed Design Tongue Weight Calculations

Figure 6 Universal Mounting Bracket

Figure 7 Rod End Ball Joint [5]

Figure 8 Alternate Design 1 Seat Post Clamp