Bike luggage rack design and development.

 




Hello people, this is Ruturaj Lonkar (B.E. Mechanical). Recently I have designed and manufactured a luggage carrying rack for my bike. Below is a overview of the design and manufacturing process.
I did a market survey for the available racks and their load carrying capacity. The cheapest one had load carrying capacity of 10 Kg and costed around Rs.1500.
The cost was too high for the product and what's the fun in directly buying. So, I decided to design and manufacture my own rack.


Design:

So the need for the design was to carry luggage on my bike for long rides, also to carry luggage when shopping solo.
The mounting point was a constraint for me, so was the bolt size, due to the tapping present in the chassis.
So I made a rough sketch of the packaging and made the corresponding FBD and BMD for the rack. And iterated the max load that the bolts can take.
It came out that I can make the rack with max.30 Kg load carrying capacity with current holes and packaging setup.

It was hard to go ahead with modeling as I didn't had the model of bike chassis. So, I used various images of the chassis part to make estimation of the dimensions.





Then I modeled the rack. I designed it with an approach by which it can be manufactured using laser cutting and welding only.


Projection and pockets are created for proper assembly and welding of individual parts.
(PS: the logo on the rack are my initials "RPL" ) .


Provided elongated holes to compensate any misalignment while assembly.
The holes on the plate and pockets on edges are functional. Mostly for routing and as a guide for bungee cords.
Following is the image of structural analysis.


Manufacturing:

Manufacturing process carried out was laser cutting for plates and TIG welding for their joining.





Concluded it with a nice coat of black spray paint.


Conclusion:

Was fun making this product. And it turned out pretty good (build quality wise). And is also very functional, have used it many times to carry luggage.

Do tell me what you guys think about it.

Thanks for reading.

Contact at:


@ruturajlonkar on Instagram

Or

ruturajlonkar10@gmail.com













 


   

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