* * Virginia Tech engineering students build an electric racing bike
I wrote this article for the Roanoke Business magazine. Hope you enjoy it!
Racing vehicles always exude a raw, edgy, purposeful look, even when they’re sitting still. Even ones that plug into a wall socket.
Thus it is with the BOLT, an electric racing motorcycle built by 25 Virginia Tech undergraduate students headed by John Marshall, a senior in mechanical engineering from Loudon County. A series of sub-teams is working on different aspects of the motorcycle’s design: the suspension, the battery pack, the cooling system. Most of the participants are mechanical engineering students, but there are also electrical engineering and computer science people. BOLT stands for Battery Operated Land Transportation.
Marshall started with the project as a junior, the sole volunteer. The year before, another team did some work on a bike but ran out of money. This bike has been raced successfully.
“It is a senior design project, but it goes well beyond just a class,” Marshall beams. “It becomes an obsession. When things start coming together, it really gets rewarding.”
Tech has contributed working space for the group in a building called the Joseph F. Ware, Jr. Advanced Engineering Lab. It has housed a number of similar projects, including Indy race cars, radio-controlled airplanes, even a miniature human-powered submarine. But most of the money for the BOLT has been provided by sponsors including Kollmorgen, Dunlop, Boeing, Ariva, and Go Race, whose decals adorn the burnt orange and white plastic cowlings.
“On this bike, we’ve spent $70,000,” Marshall says. “It is a highly capitol-intensive project.”
The bike’s chassis is a 2009 Honda CBR 600RR. Conventional motorcycles have a gas tank, carburetors or fuel injectors, an internal combustion engine, a transmission, a chain and sprockets. An electric vehicle is much simpler, with just a battery pack, a controller, a motor, a chain and sprockets. The batteries act as the fuel. The controller monitors the discharge energy from the batteries to the motor, which transfers the electricity to a rotating shaft. The bike has no transmission or clutch. The rider twists the “throttle” on the right handgrip and away he goes.
“We run in the TTX-GP Grand Prix Series, which is the first all electric circuit in the world. It is international in scope,” Marshall says. “This year, we’re the only team that isn’t comprised of professionals. Everyone on our team except the rider – who is a professional racer – is a student here at Tech.”
The battery pack is comprised of separate units that resemble an iPad in size, shape, and weight. It has two metallic foil strips that protrude from one end that are the terminals. There are 23 of these units in the BOLT. The battery type is lithium polymer, chosen because it has a high ratio of stored energy to weight and the ability to discharge rapidly. Each battery costs about $315 – that’s $7250 worth of batteries. Marshall says they “last between 500 and 1000 re-charge cycles, probably at the lower end since we push them so hard.”
The batteries that move the bike around the track are also what hold electric bikes back from really competing with the fossil fuel driven two-wheelers. TTXGP races cover about 20 miles. Gasoline powered bikes race for 200 miles. Tech’s BOLT can hit 100 mph. Next year, the team hope to hit 150 mph, which will still be 20 mph behind gas racers.
“What holds electric motorcycles back from being competitive with conventional gasoline powered bikes is the batteries,” Marshall says. “In the grander scheme of things, battery technology holds the world back. There’s plenty of energy on earth, but the ability to store and use it whenever and wherever we need it is a challenge.
“Potentially the goal of this project is to develop electric technologies that will transfer over to commercial use in much the same way that everyday cars benefit from racing technologies from a few years ago. We’re on the forefront of electric motor technology and battery technology.”
Electric motorcycles are already on the market, but they are limited in range and overall speed. The benefit is effortless driving, quiet operation, and low “fueling” and maintenance costs.
Kollmorgen, the lead sponsor, has devoted several engineers to help Marshall’s team, which maintains close contact with the local division of the company in Radford.
The engineering faculty advisor for the team, Saied Taheri, said, “The BOLT Project has evolved in a university-based race team that has competed with professional race teams all over the States. This shows the dedication of the students and their willingness to work long hours, apply what they have learned in the classroom and to learn what is necessary to complete their tasks. They have learned how to work in a team and help one another for the same goal. They have learned that engineering ethics is the key to a successful outcome. And they have become excellent engineers that can go out today and take on the most complex project and feel good about themselves and the fact that they are able to deliver what is needed.
“The Mechanical Engineering Department, the College of Engineering, and Virginia Tech, are proud of them and their accomplishments and hope that they continue this road to success when they graduate. This has also brought recognition to Virginia Tech as one of the best engineering universities in the nation and worldwide.”
The professional rider Marshall mentioned is Matt Kent, a Senior Engineer with Goodyear Tire & Rubber Company. He said, “The electric bike has similar handling characteristics to a gas powered bike, but at the same time different power delivery characteristics. In fact, after the development that we conducted during our last race weekend, we discovered a programming change that makes the bike much similar to a gas powered bike in terms of controlling the power. This is a fundamental change that will drastically improve the handling characteristics of the bike from the rider’s perspective. Another big difference is that the electric bike only has no gearbox and is only a single speed. There is no gear shift lever or clutch.
“An interesting concept is that the electric bike has much less rotating mass than a gas powered bike. Therefore, an electric bike that weighs significantly more than a gas bike can actually feel lighter from the rider's perspective. This is because decreased effort is needed to turn the bike since you are not fighting the rotational forces that are inherent to a crank, rods, pistons and transmission of a gas powered bike.”
Kent piloted the BOLT in three races this summer, winning its class in all three and earning a spot in the series championship at Daytona.
Standing beside the bike, Marshall turned on the controller and twisted the throttle. The back wheel spun frantically, held aloft on a work stand. The bike was nearly noiseless, other than the mechanical chatter of the final drive chain and sprockets.
“Being on a motorcycle is a liberating experience,” Marshall says. “Being on an electric motorcycle takes it to a whole new level.”