EsCargo
Oscar Fehlberg
A cargo motorcycle
Author and designer Oscar Fehlberg Supervising lecturer Simon Curlis University and course RMIT, Industrial Design
Date
11/2015 Thanks to
All RMIT workshop tech assistants Craig Longhurst of Mischief Makers Ron Ellazam Rafael Diem Drew Harper
Blane Muntz of Cargone Couriers Peter Santos of PS Bikes Paul of Discount Motorcycle Wreckers Flexible Drive Rob Perrone Peter Stevens Motorcycles
Abstract Melbourne is a city undergoing a rapid population growth. Through the next 35 years an estimated 8 million citizens will see a sustained and increasing load placed upon our transport systems. Coupled with the adoption of online shopping and global distribution, these factors will further crowd our road systems and increase environmental pressures. This project addresses an emerging wicked problem where the demand for goods transport in an increasingly crowding city with minimal environmental impact appears to be impossible. EsCargo is a cargo motorcycle designed to address the need for moving small scale freight in a timely manner on congested urban streets. It is a proposition for a modal shift in the way that we transport goods without building more infrastructure and maintaining our current logistics paradigm of large loads on large vehicles.
EsCargo is an agile solution that augments localised delivery, but has the ability to cross the metropolitan area. A small footprint and nimble handling allow it to cut through congestion, while the clean, quiet and efficient, electric drivetrain minimises impact on the environment. Combined with Green Energy infrastructure EsCargo aims to achieve zero emissions delivery. The cargo hold of the bike increases it’s carry capacity tenfold over existing motorcycles and the strong ladder-frame can handle loads up to 200kg. The design is easily adaptable to suit many jobs, whether it be delivering mail, consumer goods or even fresh foods. Time is of the essence with fresh food and waiting for a truck to navigate the city traffic can be costly. Whilst cargo bicycles are quick through the CBD, they become less practical towards the outer suburbs. It is these fast, short to mid trip distance scenarios where EsCargo steps in.
Sketch ideation
CAD development
1:1 modelling
Frame design
Wiring schematics
CAD assembly
Construction process
Construction process
The finished prototype
EsCargo A cargo motorcycle designed for Melbourne’s future, today. A high carrying capacity combined with nimble steering and a narrow footprint are the key elements within EsCargo’s design. The ability to quickly and reliably move small freight through a congested city will become more critical as the population grows and faster distribution is further demanded. EsCargo is powered by a quiet, efficient and exhaust-free electric drive-train. It has a unique, cable operated, doubleknuckle steering that is compact and agile. The tubular steel frame is tough and built to last through the day to rigours of delivering goods. The riding experience is simple and straight forward, with easy controls and an upright seating position. EsCargo is designed to do one thing well: Efficiently carry as much cargo as possible, without compromising performance.
Delivering goods right to the door step EsCargo takes advantage of Melbourne’s laws that allow motorcycles and scooters to park free on footpaths. This means deliveries can be made quickly, with no fuss spent on finding a parking space. The open cargo hold allows speedy loading and unloading of goods, with a variety of tie down methods possible.
Flexible space The open cargo bay is situated right in the centre of the bike and the cargo deck is as low possible. This means that while heavy cargo is added, the centre of gravity stays low and central, and the bike will remain easy to handle. The cargo area is open to allow the bike to be adapted to suit many different purposes and cargo. This flexibility means it can be used for anything from couriering, to food vending. The vehicle is merely a tool and what it is used for is up to the user. The cargo rails and moveable loops allow a huge number of different tie down solutions to be utilised, whether it be ratchet straps, quick straps, bungee cords or anything else. A permanent and lockable cargo box can be bolted to the cargo rails to keep goods more secure and out of the weather.
At your finger tips All the controls on EsCargo are within reach of your hands. The handle bar cluster contains everything you need: A phone mount to display job lists. A digital display with vehicle stats and sat nav. Throttle, auxiliary and brake controls. By simplifying the riding experience, a rider can focus more on the road ahead and continue their journey in a safe and timely manner.
Cable steering A pull-pull cable steering system transfers the handle bar inputs from the middle of the bike to the front wheel. The steering controls run through a steering column before switch to dyneema rope via a drive pulley. The dyneema rope is attached to turnbuckles, which are used to tension the system. The turn-buckles are then connected to sheathed cables, which run up to the steering knuckle in order to pull the wheel one way or the other. This system is unique to EsCargo and had to be developed from the ground up.
Drive-train EsCargo’s electric drive-train is extremely simple and compact. A chain drive was chosen for it’s good efficiency and simplicity. Due to the high torque of the electric motor, a single gear ratio is all that is needed to perform at both low and max speed. The lack of gearbox, reduces weight, complexity and maintenance. The motor is small and light enough that it can be mounted straight onto the swing arm, which removes the need for chain slack.
Manoeuvrability EsCargo will be frequently stopping and starting to make deliveries. Parking on footpaths means navigating tight spaces at slow speed. Bumping up or down kerbs is also common in these situations. To help with this, EsCargo delivers power gently at low speed, while front and rear disc brakes allow for higher control over certain low speed manoeuvres. There is ample ground clearance for most urban obstacles like speed bumps, kerbs and pot holes, while the chosen wheel size offers the best compromise between tight handling and rolling comfort.
Electronics The electronics embedded within the EsCargo prototype are simply the bare bones needed to operate safely. The controller is mounted up front and straight to the aluminium belly pan to allow it to stay cool. The battery is mounted centrally and low down, to improve the centre of gravity and aid stability. There is a keyed battery cut-off switch and a handlebar kill switch that can be used to cut power in emergencies. These switches work in conjunction to run power through a high current solenoid that makes sure the circuit is completed safely. The battery is easily accessible through removing the cargo deck, which opens the possibility for battery swap implementation.
Bicycle mode The Melbourne CBD is moving further away from cars and aiming more towards pedestrians and cyclists. There are certain thoroughfares only accessible to cyclists via bike paths. These paths offer more options for bike messengers to travel along, making them more efficient through the CBD. EsCargo is no bigger than a cargo bicycle and emits no exhaust fumes or loud noises. The electronics can be programmed to allow EsCargo to
run at different performance modes. With the touch of a button the cargo motorcycle could be limited to a top speed of 25km/h with reduced acceleration. At these specs, the bike could safely ride alongside cyclists. Goods delivery would be greatly impacted by moving towards a car-less CBD, and so a delivery vehicle that can transit between no-car zones and outer roads would be highly advantageous.
Performance comparison How does EsCargo stack up to a standard, low-power motorcycle? I bought the Suzuki GN250 (pictured) at the beginning of the EsCargo project to understand motorcycling. It quickly became my main mode of transport, commuting throughout the inner suburbs and CBD. Below is a comparison of between the GN250, the current EsCargo prototype and the ideal-world EsCargo motorcycle.
Suzuki GN250
EsCargo (Prototype)
EsCargo (Ideal)
Brushed electric motor
Brushless electric motor
Fuel
250cc internal combustion engine Standard unleaded petrol
Wall charger electricity
Power
16kW
5kW
Fast charger, green-source electricity 15kW
Top speed
115km/h
35km/h (est.)
80km/h
Range
210km
15km (est.)
250km
weight
129kg
70kg (est.)
90kg
Length
2040mm
2200mm
2200mm
Cargo
50L
175L
175L
Motor
Brighter is better Bright colour-ways were chosen for EsCargo in order to stand out from the bluestone streetscapes of Melbourne. Whilst better visibility doesn’t guarantee better safety, brighter is better than nothing.
Photographer credits Rob Perrone Marcel Gleeson Alin Coop Jordan Grech Sebastian Damn Hannah Micich Oscar Fehlberg