Newsletter November 2013
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NovaBike NOVEMBER
Foreword In this edition NovaBike04 4 A year in review
UfD Award 5 Joris Koudijs DREAM-team member of the year!
Hardware Department 05
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Engine Department 05
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Sponsors in the spotlight
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Building the chassis of the new Novabike
Pushing our engine to the limit
PMI & Powerseal
NovaBike NOVEMBER
Welcome to the Newsletter of the NovaBike Racing Team. This is the edition of November 2013. About three months ago the new NovaBike team was formed. Fifteen new enthusiastic students from all walks of life were ready take on the challenge. This newsletter will reveal our plans and goals for this year. I’m very proud of everything we’ve achieved so far and am already looking forward to what the season will bring us. With new circuits, such as Snetterton, on the agenda we’ll be proving the power of bio-ethanol on more and more places. Our competitors better watch out, as the NovaBike will be back next year and we will make sure that our fifth year will be our best yet! A lighter, more powerful bike is currently being designed and built, that should have the potential to secure multiple podium finishes in the European Supermono Championship! David Meijer Team Manager NovaBike05
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NovaBike04
A year in review
It already seems such a long time ago, but the fourth NovaBike year started in September 2012. Approximately 25 new faces came together and decided to tackle one of the biggest issues NovaBike had had until then: the reliability of the Motorcycle. The new NovaBike team decided to finish the season of their predecessors and decided to contact a new rider for the NovaBike via the Dutch Motorsport Authorization (KNMV). Ricardo van Duijn immediately did great on the NovaBike and showed interest to be the rider for season of NovaBike04. The first steps towards a more professional, reliable racing team were made. With a regular rider signed for their season the team was ready to start designing and building their new bike. Unfortunately, the team soon recognized that building a completely new, self-build motorcycle in just half a year was task that could not be completed. With the main goal of reliability still fresh in their minds the team decided to perfect the current NovaBike, instead of trying to build a new one. New parts were added to shed weight, the starting engine was removed and a lot of minor adjustments were made to perfect the bike. During training sessions the team got to know the NovaBike and racing in general. Although some issues arose during the winter training the team solved most of them. NovaBike as a project took huge steps in the organization of races and with their new race-structure the training and races would be smoother than ever. 4
The first races went great and with Ricardo on the NovaBike we proved the reliability of the current NovaBike. Races were finished without major problems, a first for NovaBike. However, the power was still lacking and during the season the NovaBike team developed the bike further. Each race we were doing better. The approach chosen by the NovaBike04 team was starting to show it’s positive effects. By focusing on reliability first and then adding more power and shedding more weight the Novabike started to prove itself on the circuit. With steady subtop finishes in the European Championship we were ready for the best race of the season. During the HAMOVE road races in Assen we had a great weekend. With our first podium finishes ever in NovaBike history the team not only proved the power of our team, but also the power of bio-ethanol in a racing arena. The last races of the season, again on the TT Circuit on Assen, we even had chances to take the podium in the overall Dutch Championship. Starting from pole-position we hoped to finish strong. We went into the races with an all-or-nothing mindset, but because of a crash and a DNF we were unable to claim a podium in the Championship. However, the NovaBike project took huge steps last year. Our team pushed NovaBike to new heights and with great dedication we’ve shown the potential of bio-ethanol as a sustainable fuel! Many, many thanks to everyone who supported us last year, through sponsoring, following and showing interest in our great project. We’ve had a great time and hope to see the new NovaBike do even better this year! NovaBike NOVEMBER
UfD Dream-Team Award On Wednesday the 22nd of October, yet for the second time, the UfD-DreamTeam award was rewarded. The DreamTeams are teams that, in the course of a half or a whole year, accomplish a special achievement by extending the boundaries of technological development. The end result is due to the dedication and commitment of the entire team. The award, however, is meant to reward one extraordinary team member that has proven to be of special importance to the team. One by one, all team managers had the opportunity to pitch on stage why their nominee most deserved to be the winner. The title DreamTeam member of the year was then awarded, by member of the board Nienke Maas, to Joris Koudijs of the NovaBike Racing Team Delft. Joris forms an essential part of the team. He is a real hard worker who, not only for his own team, but also for the other DreamTeams is of utter importance in the hall. If an emergency arises, he will work through the entire night just to make sure that the NovaBike is ready to race again in the morning. In short, his commitment to the team is one hundred percent, and therefore he is the just winner. Koudijs received a sash and a big bottle of Champaign, beside this his name was immortalised on the board in de entree of the D:Dreamhall. The amount of ₏1.500 went to his team: the NovaBike Racing Team Delft. We’re proud that Joris is a part of our team, and would like to thank him once again for his commitment to the NovaBike project!
NovaBike NOVEMBER
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Performance Motorsports Inc. Group
PowerSeal
PMI Europe is part of Performance Motorsports (PMi) which is an accumulation of independent businesses that are all owned by Dover Corporation, each with market leading brand recognition that sells primarily pistons, and other engine related components into the Motorsports and Powersports markets (high performance racing, motorcycles, all-terrain vehicles, snowmobiles, personal watercraft, etc.). The companies are market leaders in manufacturing highly engineered engine components on their respected fields.
During the years Powerseal has specialized itself in developing a technological high quality coating which is applied on cylinders of aswell cars as motorcycles.
PMI Europe’s customer base runs the gamut from recreation to the very highest levels of professional racing, in every facet of the Motorsports and Powersports Industries. The products supplied are forged and cast pistons, connecting rods, and crankshafts; along with their complimentary components, piston rings, bearings, gaskets, camshafts, and a variety of other internal valve train and engine components. Other products include suspension, braking, clutching, and chassis components. With PMi’s ability to engineer solutions for their customers and the infrastructure to test, manufacture, and distribute these products worldwide, PMi really has no equal in the field. PMi is truly at the cutting edge of Performance and Racing components worldwide!
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By a development of several years and applying the newest technologies the Powerseal coating is of a very high quality. This hard coating, which includes nickel and silicon carbide, ensures a durable surface whereby the life of your cylinder is lengthened considerably. By producing in a controlled environment Powerseal is able to deliver a perfect endproduct with the right dimensions. The associated piston will be calibrated by Powerseal aswell. The thickness of the cylinder wall is adjusted to the piston, resulting in a perfect fit. This results in turn to better properties of the cylinder. Briefly summarized, the Powerseal coating offers you the following advantages, o Higher durability resulting in a longer lifetime o Better friction properties and optimal oil lubrication o Revision cylinders can be made optimal again with a Powerseal coating o Perfect upgrade for Alusil cylinders; properties improve and repair is nearly always possible o Perfect fit o Cheaper than buying a new cylinder or cylinder block
NovaBike NOVEMBER
Hardware Department 05 The NovaBike05 team wants to build a new racing motorcycle based on some main components taken from the design made by the previous team. The new NovaBike should be ready to race together with the current NovaBike. This means that nearly every part on the motorcycle needs to be reconsidered and designed; resulting in a huge task for the Hardware Department of NovaBike05. Every part that is not directly required by the engine to drive the rear sprocket and is also not a part of the electronic circuit is considered to be a Hardware Department part. Some main examples of the Hardware Department’s projects are the frame, suspension, braking system and steering installation. The Hardware Department is given the task to transfer the power from the engine to the asphalt in the best possible way while combining this with great overall handling resulting in good laptimes. Luckily for the new team, a large portion of the core development for the new NovaBike has already been done by their colleagues of the 04 team. This year we are going to use the best parts from the 04 design and design around an already solid base. The biggest point for the hardware department will the usage of the 04 frame. This tubular frame made of lightweight steel is an evolved edition of the original inhouse frame design. It has been updated to allow for better accessibility of the engine componenents and shifted supporting material to the required position. This allows the mechanics to save valuable time during the racing season when working on the engine and it’s surrounding components. Having set this firm base allows the new team to focus on other parts that form the motorcycle as a whole and leave room for improvements on performance for the new NovaBike. NovaBike NOVEMBER
One of those areas of promosing performance gain is that of the rear swingarm. A swingarm functions as the structural part between the frame and rear wheel while allow the vertical travel of the rear suspenion. The current rear swingarm is designed for the second NovaBike and is made of the same material as used in the frame. The NovaBike05 team is designing a new fully aluminium swingarm with the goal to reduce unsprung mass within the limits of keeping the same structural properties as the current swingarm design. The swingarm project will be expanded with a quick wheel change to be able to swap tires and have an advantage to quickly adapt to changing weather conditions, again allow the pit mechanics to efficiently work with the new NovaBike. A final main project for the Hardware Department is the suspension setup at both the front and rear side. The main geometry of the overall motorcycle is setup within the dimension of the frame. This geometry will be completed with telescopic forks at the front and a single shock damper at the rear combined with an inhouse made linkage system. This linkage system translate the travel of the rear swingarm into either compressive or extensive motion of the rear shock absorber. The linkage system is designed to use the rear shock to its full capabilities and is optimized for track behaviour. Combining all the above is a challenge on which the Hardware Department is working very hard to tackle. As the team is getting further in the designing phase, parts of the motorcycle are starting to shape and are getting more real every day. Over the coming months the production phase will properly start and it will only be a matter of time before all pieces of the puzzle can come together. 7
Engine Department 05 In the coming months we want to achieve our goals: 95 HP at the rear wheel. Currently our engine produces 85 HP, so this means an increase of 10 HP. This will be achieved by modifying the intake trajectum, the exhaust and the engine itself. All the planned modifications are briefly setted out in this newsletter. The first planned upgrade is the new intake traject. As for now the plans are that we will make the whole intake on our own. The advanatage of a homemade throttlebody and injectorhousing is that we can make it out of one piece, so the drag is minimized due to the absence of any connections. Besides that we will introduce a twin-injector intakesystem. This will consist of a normal injector after the butterflyvalve and a showerinjector before it. The reason for this change is that the current injector is almost open all the time at full throttle and rpm. With a showerinjector we hope to solve this problem. But because the showerinjector will not work properly at low airflow and thus low rpm we put a second normal injector near the intakemanifold to get a proper throttle respons.
get fitting pistons who we will design in cooperation with PMI. The last subject regarding to the engine performance is the exhaust. Because of all the changes made to the bike in comparison to the previous model a new exhaust has to be designed and built. For the coming months we will be designing the new exhaust in a rough way, this means that the key dimensions and length will be set. The final layout will be determined after some dyno-testing at the location of production from our partners HGS. With these improvements we hope to achieve the goals we set at the end of september. The enthousiasm won’t be a problem. All together the whole engine department is looking forward to starting up the engine for the first time. According to the planning this will take place around the end of januari. We will be happy to inform you by means of this newsletter at that time.
When we take a look at the planned operations for the engine itself we first have to announce that we are building up the second engine this year. This engine, a KTM LC4 660cc, is for now completely stock so we will have to put all the sensors and ‘normal’ modifications to it as the current one. Besides that we will put in a new even more agrassive camshaft and we will design and build our own big-bore. For this big-bore we will have to 8
NovaBike NOVEMBER
Partners NovaBike Faculteit Industrieel Ontwerpen Faculteit Luchtvaart- & Ruimtevaarttechniek Faculteit Werktuigbouwkunde Faculteit Elektrotechniek, Wiskunde en Informatica