Motorcycle throttle lock

From DDL Wiki

Revision as of 19:07, 3 February 2011

Executive Summary

This is the executive summary.

Major Stakeholders and Product Needs

User

• easy to use
• safe
• easy to disengage
• durable
• attractive
• stays engaged over long distances and through vibrations
• intuitive to use

Installer

• easy to install and adjust for many different motorcycles

Retailer

• cheap
• attractive
• compact

Other motorists

• safe
• easy to disengage

Passenger

• safe
• reliable
• intuitive to use

Law enforcement

• Can failure lead to malfunction or an accident

Product Use

Type 1 (cruiser)

Type 2 (sport bike)

Dissection procedure and exploded assembly

Dis-assembly procedure

1. Removing clamp
   • take off clamp screw nut
   • remove washer and spring
   • separate main assembly into two sub-assemblies
     1. throttle lock sub-assembly
     2. handle bar clamp sub-assembly
2. Dis-assemble locking mechanism
   • remove metal clamp
   • remove clamp screws (3)
3. Dis-assemble thumb lever
   • remove axial screw
4. Dis-assemble handle bar clamp
   • remove screws (2)
5. Analyze auxiliary parts
   • rubber clamps
   • wide throttle adapter with screw
6. Cut out main body clamp set threads
   • cut with hack saw

Mechanical Function

Type 1 (cruiser)

This product is used to lock the throttle on a motorcycle. The usual way of riding a motorcycle requires the rider to hold the throttle on at all times to accelerate. This can lead to fatigue on long trips. This product uses a metal clamp with a plastic washer to hold the throttle in the on position while letting the rider relax his hand. There is a small spring and plastic switch for functionality and when the switch is turned off, it quickly allows the throttle to go to zero.

Type 2 (sport bike)

This product serves the same purpose as the cruiser type throttle lock. This products different in how it accomplishes the task. The sport bike throttle lock is located on the outside of the throttle (directly to the right of one's right hand). It takes the place of the right hand end weight that sport bikes have. In order to "lock" the throttle the rider must turn the large nut on the throttle lock in the same direction as the accelerator. This will cause the nut to press against a washer which then presses against the motorcycle's throttle. The added friction from the washer being tightened by the left hand nut causes the throttle to be held in place. Unlike the cruiser style lock, this product does not have a "quick" release feature like some of its competing products. The user must manually tighten and loosen the throttle lock. It is possible to move the throttle while the throttle lock is engaged so long as it has not been over tighten. Although there is no quick release, this product is a very simple and effective cruise control for sport motorcycles.

Bill of Materials and Properties

Parts List
Part #	Name	QTY	Weight (g)	Function	Material	Manufacturing Process	Image
01	Clamp screw nut	1	<1	Allows adjustment of clamp pre-load	Stainless steel, Nylon	Purchased part
02	Washer	1	<1	Allows nut to better transmit force to clamp	Stainless steel	Purchased part
03	Spring	1	<1	Returns lock to unclamped position when disengaged	Chrome plated steel	Purchased part
04	Metal clamp ring	1	13	Clamps onto plastic ring allowing one to lock the throttle	Chrome plated steel	Blanked, then bent
05	clamp ring	1	10	Fitted to the throttle, it is clamped down on by the metal clamp ring	Plastic	Injection molded, then drilled/tapped
06	Clamp ring screws	3	<1	Retention of clamp ring on the throttle assembly	Chrome plated steel	Purchased part
07	Thumb lever	1	3	Allows the rider to actuate the throttle lock	Plastic	Injection molded
08	Banjo bolt	1	<1	Provides avenue for clamping force to be applied	steel	screw machined, forged, welded
09	Thumb lever cap screw	3	~2	Gives thumb lever pivot	steel	screw machined
10	Main body	1	20	Mounting position for lock assembly, connects to handle bars	Plastic	Injection Molded
11	Main body clamp	1	8	Other half of main body's clamping connection to the handle bars	Plastic, part 12	Injection molded
12	Set threads	2	<1	Cast inside of part 11, reduce risk of stripped threads when clamping	Brass	Purchased part
13	7/8" handle adapter	2	<1	Allow used of throttle lock on 7/8" handlebars instead of 1"	plastic	Injection molded
14	Wide throttle adapter	1	<1	Allow use of throttle lock with clamping surface further from the throttle grip	plastic	Injection Molded
15	Wide throttle screw	1	3	Used in conjunction with part 14, additional length allows units used with spacer	steel	Purchased part (screw machine)
16	Small rubber throttle stop	1	4	Fitted inside of part 5, allows part 6 to easily transmit force to high friction area on large diameter throttle	rubber	cast
17	Medium rubber throttle stop	1	9	Fitted inside of part 5, allows part 6 to easily transmit force to high friction area on medium diameter throttle	rubber	cast
18	Large rubber throttle stop	1	14	Fitted inside of part 5, allows part 6 to easily transmit force to high friction area on small diameter throttle	rubber	cast
19	little plastic baggy	1	<1	contains the rubber throttle stops, wide throttle adapter parts, and 7/8" handle bar adapter	plastic	blow molded	No Image

DFMA

FMEA

DFE

Team Members and Roles

• Brandon VanTassel - Team Leader
• Matthew Doncheski - DFMA Lead
• Randall Oakes - FMEA Lead
• Nicholas Petrillo - DFE Lead

References