Hands Off My Bike

ANDREW FLYNN

KEVIN MOODY

SARAH MORGAN

Group 5

Where do you store your bike at home?

Have you ever had your bike stolen?

Where do you store your bike away from home?

How much do you spend on a lock?

Shed / Garage

Public Infrastructure

Yes

£40 - 60

• Most bikes stolen from semi private locations

• Cyclists not satisfied with public bike racks

• Bikes at home lokced in shed/garage

• average spent on lock - £40 - £60

To determien the design parameters and the issues cyclists face whn securing their bikes, a survey was created. The survey was distributed among various cycling groups

THE SURVEY

SUMMARY KEY INSIGHT

Initial Survey

People will always carry a personal bike lock, regardless of public bike parking.

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Initial lock testing was carried out by the group to see what current locks available on the market were strong and which were not. A range of different tools, used by thieves, was used to replicate what it is like to break through a bike lock.

Almost every lock, except for the D lock and the chain, we were able to cut through with standard house hold tools. However the angle grinder was able to cut through them all. Although we did not have a pair of bolt cutters they can cut through almost anything up to a width of 16mm.

THE LOCKS THE TOOLS

Lock Test

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SiempreWHAT IS SIMEPRE?

CALLAN

CALLAN’S THOUGHTS

Siempre is small bicycle cafe, selling coffee and bikes in the westend of glasgow. It is place where cyclists can meet, eat and talk about what they love the most.

Callan is the owner of Siempre and our first cycling enthusiast we were able to talk to. He was very keen to help where he could and gave us some great initial insights to work with.

Keep it simple. Keep it portable. Make it accessable to the whole community.

After hearing about Siempre open we decided it would be the perfect meeting place for our group. We met in Siempre once a week for a large duration of the project to discuss our design and gain insights into the world of cycling.

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T R A K K E

To help work on the project we teamed up with glasgow based cycling company TRAKKE. We met up with the owner, Alec, near the beginning of the project to discus what he could contribute and what he thought of bicycle security. He agreed to help us with the design of our lock, offering feedback and insights. He also got us in contact with cycle couriers to discuss they’re cycling needs

“Although people value security they also value convenience”

• Aesthetic

• Multi purpose

• Practicality

• Material selection

• Ease of use

This became of the key insights we based our design around.

ALEC FROM TRAKKE

ALEC’S THOUGHTS

THINGS TO CONSIDER

“Design a personal, portable bike lock, that actively deters theft and is both desirable and affordable for the user.”

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SPEED

SPACE SECURITY

COST

PUBLICINFRASTRUCTURE

URBAN

After conducting our initial research we were able to create a list of user requirements our design would have to conform to.

REQUIREMENTS

Requirements

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Detachable, locking handlebars designed to integrate into the bike.

Movable cored lock designed to defeat angle grinders and other saw based attacks.

Fixed locking station designed around the concept of a wheel clamp. Designed to immobilise bike and components.

Wearable, portable lock based on a self tightening ratchet system to tightly fit to bike.

Saw cuts outer shell Core rotates, stopping saw

HANDLEBAR LOCK RATCHET LOCK LOCKING STATION SPINNING LOCK

Initial Concepts

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Attacks with a cutter breach the outer layerInstead of cutting, the inner core freely spins from the motion of the cutter, preventing any purchase

Problem with this dsign is that directly vertical force can induce frinction between the core and the outler layer, preventing spinning and allowing cutting

Second design looked at shaping the core so that any force that was off centre would also cause it to spin, alongside the rotation of the cutter

Spin LockINITIAL DESIGN

ADVANCED DESIGN

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Having chosen a market location and initial concept we turned our attention to the needs of city cyclists. Understanding user require-ments was an important aspect of our research. Having a cycling en-thusiast within the group helped with initial insights, however exploring the cycling community and speaking to other urban cyclists helped to paint a clear picture of what we required.

Cyclists wanted: An easier means of carrying a lock.

Cut down on size while remaining secure.

A lock that is quick and easy to use.

There are a large range of different bikes that people use within a city. From observation it appears that the most common for city commuters are road bikes, either with gears or single speed. Often used everyday, these bikes are robust offering a long life span.

Designing a lock to be used in conjuction with these bikes means it too must also be long lasting and robust. It must be able to cope with all city conditions while maintaining a high level of security for the bike.

THE CITY CYCLISTS THE BIKE

Urban Culture

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After immersing ourselves in urban cycling culture we were able to select a type of handlebar to design our lock into. Providing a simple form to work with and considering its popularity, the bullhorn bar seemed an obvious choice for our product development.

We began the design process by sketching possible ways the bars could split and lock. The simple shape of the bullhorn bar lends itself well to a simple locking mechanism. Taking the concept of the spinning mechanism, we looked at how we could implement this into the design og the handlebar.

BULLHORN BAR INITIAL CONCEPT

Handlebars

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Ways to LockBULLHORN BAR HALF SPLIT AND LOCK DETATCH AND LOCK

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We decided one of the best ways to proof test our concept was to make a quick initial prototype to get an idea of shape and form. This first prototype was made by simply bending two lengths of steel and cutting them down to size. This allowed us to gain a better understanding of how the bars should fit together.

The process of physical model making was good as it forced us to start making early decisions on how this design would be manufactured. One problem we encountered was getting a smooth bend in the tube. Cold bending the tube resulted in it kinking at the bend, something we would attempt to fix at a later stage.

When placed together the two steel tubes from the main body of the handlebar.

The tubes detach at the centre leaving to separate pieces, each with a right angled bend.

By flipping one side, the bars can be placed together in a rectangular shape which would lock off around the bike.

Prototyping

LOCK

MODELLING

DETATCH

Full Bar

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Initial testing used to gain a “feel” for the product. It was essential that our concept was intuitive and easy to use.

The prototype was tested with a friend of our group, Alex. Testing the concept on a non group member was an important aspect of our research. Alex said he “liked the aesthetic of the lock” and found it “easy to understand and use”.

User TestingUSER TESTING ALEX AND THE BIKE

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+ + =

Currenlty, many cyclists use either their own bike or their body to carry oversized bike locks.

The reason this is a problem is beacuse the more secure your lock is the larger it tends to become.

Carrying such locks can be a real hindrance when cycling and in many cases people have to compensate by having a lock they can carry but is less secure.

CURRENT SCENARIO

REMOVE THE LOCK SIMPLE RESULT

Less is More

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The widest point on a bike is the handlebars. When locking a bike to infrastructure the bars can make it awkward or impossible to do so.

By removing the handlebars from the bike, the user is able to lock it flush against a surface.

This means an easier user experience and smaller bicycle footprint are created. The bike also take up less public space.

CURRENT SCENARIO

CURRENT SCENARIO CURRENT SCENARIO

Footprint

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Cut?

Deter

Breaking a bike lock allows the thief to leave with no harm done to the bike, perhaps even using the bike as his escape.

If you cut the lock, you destroy the habdlebars. This locking systems acts to deter thieves from breaking into the bike. Additionally, a bike sitting without handlebars already looks less valuable to potential thieve.

CURRENT SCENARIO

CUT THE BARS?

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Couplings

We began to look at ways we could join the handlebars in the centre. We had been told to look at the S and S cou-pling by Alec from TRAKKE. Having already been designed for bicycle tubing they seemed to fit perfectly with what we required the bars to do.

By inserting an S and S coupling in the centre of the bars, secure locking system could created that is intuituve and quick to use.

HOW IT JOINSCOMPONENTSS AND S COUPLING

CONCEPT DESIGN

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Our first and possibly most important technical design challenge was how our system would lock together? As a group, we did extensive research into different lock types, looking to see which one would be most suitable for our design.

We decided a simple and effective option would be making use of the already very successful D Lock system. By implementing this into our design we were guaranteed a lock that would work, while appealing to our target market with an already familiar user interface.

In order not to limit the market size the bars would have to be designed with the ability to house gears.

For safety reasons, it was essential that our handlebars could be fitted with brakes. This created a problem. Where would they go?

LOCKING SYSTEM GEARS

BRAKES

Problems

BRAKES

GEARS

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Three Piece

In order to design a solution that could house both brakes and gears we decided to add a third centre piece to the handlebars. On this hollow centre piece the user wouldbe able to mount gears and brakes. However this now meant that a thief could use the small centre piece of bar as a miniture handlebar.

From our research we observed that many cyclists have their controls “in board” on the handlebars which is per-fect for this three piece design. However, some cyclists do prefer to have their controls further apart or at a differ-ent orientation. This design is a compromise, not suited to every rider but with enough credibility to continue with this design.

THREE COMPONENTS

DESIGN PROBLEM

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ConceptFlex Bar

To combat the centre handlebar problem, we designed the flex bar.

The idea behind the flex bar is that when the bar ends are removed the centre piece would be free to deform. The centre piece could still house brakes and gears but it would be impossible for anyone to steer.

CONCEPT

FLEX BAR

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Hinge Bar

A similar concept to the flex bar, the centre piece would be free to deform when the bar ends were removed, however this time with a simple hinge. As a group we decided that the problem with this concept was that the hinge only deformed in one direction, unlike the Flex Bar which could deform in two dimensions due to its elastic nature. This meant someone could probably still steer the bike using the bar ends.

HINGE BAR

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The prototype was tested by various users on a bike. This was effective way to test the concept and see if it would work for the desired purpose.

Despite the flex working well, making the centre in this way seemed to add unnecessary complications. As the centre is flexible, brakes and gears were able to twist round the handlebar. This was a problem we could not easily overcome so we decided to abandon this concept and focus our attention elsewhere.

Two different diameters of steel tube and a length of flexible foam were used.

The stem had to be wedged open to allow the bars to fit.

Steel segments were attached to the inside of the foam allowing them to flex

Centre piece is free to flex in any direction while being able to house brakes and gears.

COMPONENTS

TESTING

THE PROBLEM

THE STEM SEGMENTS FLEX BAR

Prototype 2

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We decided to turn our attention to the lock itself and how to make it as secure as possible. One way of doing this was setting a width for the handlebar.

As a group we decided that keeping the centre piece of the bar solid was the most simple and effective option. Instead we focussed on the other benefits.

Bolt cutters have a max cutting width of 16mm. The inher-ent width of handlebars is 25.4mm. By simply ensuring the handlebars are wider than 16mm we effectively made it impossible for these bars to be cut by bolt cutters.

A NEW LOOK UNABLE TO CUT? MAX CUTTING WIDTH

16mm

25.4mm

HANDLEBAR WIDTH

Simple and Secure

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Materials

After meeting with Dr Hodgkiss from the University of Glasgow, he recommended we use a layer of ceramic/metal composite (CERMET) to defend against cutting tools such as hacksaws and angle grinders.

The core of the bar would be made from hardened steel. From our lock testing, hardened steel proved to be very effective against a large range of tools making it the perfect choice for a resistive core.

A thin rubber layer would be used to coat the outside of the bars. This would increase the impact resitance of the bars preventing it from being vulberable to tools like hammers.

The locking bar ends would be made using the three above materials. The thin rubber layer would be applied as an outer coating to shield against any direct, high impact attacks. Underneath this, the layer of tungsten carbide would provide a high toughness, cut resistent shield. The hardened steel core would provide over all strength and durability to the design.

TUNGSTEN CARBIDE HARDENED STEEL

RUBBER

CERMET

STEEL

CERMET

RUBBER

RUBBER

MATERIAL LAYERING

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To make our final prototype we first had to design each working component. Certain components we needed specially machined so Solidworks drawings were made for these in order to have them made.

The planning process forced us to look at each individual component in detail, thinking about how it would be made and how it would interact with other components.

NOTCHED PINSINTERNAL COLLAR KEY AND LOCKLOCKING SHAFT

HANDLEBAR ENDS

FINAL DESIGN

CENTRE LOCK BLOCK CENTRE LOCK

Components

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Spending time creating a working prototype was a valuable experience for our group. By making a dynamic prototype several issues with the technical design and manufacture of the product were raised. Working with exact dimensions proved to be difficult in a workshop environment. A process of trial and error had to be used in order to reach the final iteration.

The most difficult manufacturing issue we faced was creating a smooth 90° bend in the metal tube. Despite heat treating the steel it ultimately kinked under the applied torque.

These issues would be easily overcome with the right tools and machinery when being mass produced.

For certain components we got Andy, one of the workshop staff to machine the parts to a high level of accuracy to ensure the prototype would work.

Each component was filed down to ensure a fine finish. This proved to be particularly important with the small dynamic components. Inaccuracy would have caused the mechanisms to jam.

When all components were finished, the model was assembled manually using a combination of mechani-cal fixtures and adhesives. A fur-ther prototype would hope to see components welded together as a stronger means of bonding.

MACHINING

ACCURACY

ASSEMBLYCOMPONENTS

Final Prototype

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Final Prototype

Creating the fully working prototype was a major group success. Having the prototype has brought the design to life, enabling us and potential users to gain a hands on expe-rience like no other. Our next step would be to take this to a professional manufacturer to be made to the exact specifications and materials.

WORKING BARS

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Bar Locks

The bar locks sit directly inside the ends of the bullhorn bar. Each lock is mechanically fixed to an internal steel tube that has a slit running down its middle. When the key turns in the lock, the steel shaft rotates. The knotched pin from the opposite bar fits inside the internal shaft and is locked into place. (See bottom diagram).

BAR LOCKS

HOW IT LOCKS

LOCK SHAFT

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The centre lock is used to lock the two bar ends back in place. We decided against the S and S coupling system as it became over complex. This system makes double use of the knotched pins as a means of securing the bars in place. There would be one lock placed vertically in the centre of the bar that is used to drive a locking shaft. When a key rotates, the shaft is rotated, locking the two pins in place.

CENTRE LOCK

SECTION VIEW

LOCK

UNLOCK

Centre Lock

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SIMPLE

SECUREFAST

ADAPTABLE

THE BULLBULLHORN BAR

THE LOCK

THE HANDLEBAR

Based on the current design of a bullhorn handlebar, this two in one locking system provides an alternative solution to carrying a heavy lock.

The design of the THE BULL is inspired by urban cycling culture. It allows the user to cut down on weight and equipment while maintaining a high level of security for their bike.

DESIGN

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INFRASTRUCTURE INCONVENIENT UNRELIABLE

HARSHURBAN

ENDURANCE

INSIGHTSENVIRONMENT

TRAKKE

Urban city cycling was chosen as the focus for this project. Research was conducted in

to the life and daily routine of city commuters and cycling enthusiasts.

We managed to team up with TRAKKE, a Glasgow based cycling company, as a

partner for this project. Working with TRAKKE lead to many useful insights that

have helped guide to our final design.

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APPROACH

PLACE

UNLOCK

LOCK

POSITIION

SECURE

Choose from an endless range of public infrastructure, wheel your bike into position and remove your key.

Place the lock around the most secure point on the bike, this is usually round the rear wheel and frame.

Remove the two ends of the bars by unlocking the centre block. Pull out to release.

Lock off each end of the bar around the infrastructure making sure it is correctly positioned and secure.

Make sure bike is sitting flush against the fence leaving the minimum space possible between the frame and fence.

Leaving a minimal footprint, the bike is now secure with a lock the actively deters thieves to cut it.

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MATERIAL

THREE PIECEFEATURES

The handlebar is made from hardened steel, coated with tungsten carbide. The bar is too wide for bolt cutter and the CERMET coating makes it very difficult to cut through with an angle grinder.

Centre Lock Centre Shaft Pin Bar End Bar Lock

A short centre bar extends from the centre locking block. This provides a housing for brakes and gears.

SPACE

LOCK PROCESS

FOOTPRINT

One component, two purposes. Save on cost and space.

Reduce footprint by removing bars for locking.

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Proffesionally manufacture the handlebar lock to make a fully functioning set of handlebars and lock.

Refine details of the design until it is exact.

Speak to Alec from TRAKKE about developing the product further.

More user testing with the final prototype, creating more video prototyping.

PROTOTYPING

REFINING

TRAKKE

TESTING

ANDREW FLYNN

KEVIN MOODY

SARAH MORGAN

What’s Next?