In the motorcycle industry, especially within the field of motorcycle rallying, innovative solutions such as the navigation tower play a crucial role in reducing motorcycle weight and enhancing aerodynamic properties. During a recent design and production meeting, we discussed the implementation of an advanced navigation tower, which has the potential to become a groundbreaking product in the market. The primary objective of the project was to create a lightweight yet durable structure capable of withstanding forces up to 20G, combining an aerodynamic design with effective protection for navigation devices.
Key decisions focused on the use of modern technologies, such as 3D printing and advanced simulation tools, which have optimized both production and assembly processes. The product is already receiving positive feedback from users, highlighting the effectiveness of the chosen strategy. A decision was also made to continue production optimization and gather customer feedback to further refine the tower and adapt it to the evolving needs of the market.
This article will take a closer look at the details of this innovative approach and outline future plans aimed at aligning the product even more closely with the expectations of motorcyclists.
In this article, you’ll learn about:
- The concept and purpose of the navigation tower.
- The structure and functions of the navigation tower.
- The design and production process.
- Production and assembly optimization.
- Feedback from riders and mechanics.
- Summary.
1. Concept and Purpose of the Navigation Tower
The motorcycle navigation tower we developed is inspired by designs used in rally motorcycles, known for their exceptional performance in harsh, extreme conditions. The main goal of this project was to create a modern, functional, and technologically advanced tower that would enhance both comfort and safety for motorcyclists, whether for daily riding or off-road adventures.
The primary concept was to achieve optimal aerodynamics, which is essential for stability and motorcycle performance, especially at high speeds. The precisely engineered windscreen, mounted on the tower, reduces air resistance while the tower itself serves as a base for securing the windscreen, instruments, and other equipment. This design not only enhances vehicle efficiency but also improves rider comfort, shielding navigation devices from external factors like wind, dust, and rain.
Key Features of the Navigation Tower
The tower’s construction is designed to be lightweight and durable, providing a significant advantage over traditional solutions available on the market. By employing modern materials and technologies, such as autoclave processes, we have reduced weight without compromising resistance to mechanical damage and high G-forces. This makes our tower not only more functional but also versatile, catering to the needs of both professional motorcyclists and off-road enthusiasts.
Our navigation tower is distinguished by its low weight, which improves motorcycle maneuverability in challenging terrains. Another crucial feature is its high durability, ensuring component longevity and, consequently, lower operating costs. The tower’s wear resistance minimizes the need for frequent replacements and repairs, making it a cost-effective long-term investment. Even under intensive use in harsh conditions, the components retain their properties, providing stability and reliable performance.
Another vital aspect is the mechanical strength of the tower, which is crucial for safety and reliability during demanding rides. The structure is engineered to withstand forces up to 20G, ensuring that the tower remains stable and functional even in the most challenging situations.
The use of modern materials like carbon fiber plays a key role in achieving the optimal specifications of our navigation tower. Carbon fibers are incredibly lightweight and, at the same time, offer high tensile and impact resistance, allowing us to reduce the construction’s weight without sacrificing load resistance.
Shape and Laminate Optimization
To ensure maximum strength and functionality, we applied shape and laminate optimization in the tower’s design. A critical factor was using the correct fiber layouts in the laminate, which increase the structure’s resistance to variable loads and stresses encountered during off-road riding. Precisely arranged fibers effectively distribute the forces acting on the tower, resulting in extended durability.
The project focused on weight reduction in areas where it was feasible, without compromising strength. The result is a structure that is both aerodynamic and exceptionally robust, enhancing motorcycle performance and rider comfort.
A key component of the design process was the use of computer simulations. Load analysis enabled precise placement of reinforcements in critical areas, boosting resistance to mechanical damage and high G-forces. By utilizing advanced simulation tools, we could optimize the design prior to physical production, reducing both implementation time and production costs.
2. Structure and Functions of the Navigation Tower
The navigation tower designed for motorcycles consists of two main components: the navigation tower itself and the Light Bracket, which serves as the mount for the motorcycle’s lighting system.
The navigation tower is the central structural element that allows for the installation of navigation equipment such as GPS, first aid kits, and other accessories essential for long trips or challenging terrain. It also serves as a wind shield, which improves the motorcycle’s aerodynamics and enhances ride comfort, especially at high speeds. Thanks to its precise construction, navigation devices are optimally positioned, making them easy to operate and highly visible while riding. This arrangement allows riders to stay focused on the road with all necessary information within view.
The second key component, the Light Bracket, facilitates the installation of road-legal lighting.
Lightweight and Durable Construction
Minimizing weight was a critical goal in designing both components. Using lightweight but durable materials like carbon fiber allowed for a structure that doesn’t weigh down the motorcycle while offering high shock resistance and stability under varying loads.
Game-Changer: The Navigation Device Carrier
An integral part of the navigation tower is the carrier for navigation devices, a key feature for mounting various devices. It was designed with versatility and functionality in mind, making it easy to adapt to different rider needs. A standout feature of the carrier is its shock-absorbing design, which protects mounted devices from the shocks and vibrations experienced during off-road rides.
With compatibility for different navigation systems, the carrier enhances versatility, allowing users to easily mount GPS devices, smartphones, tablets, and other equipment used for navigation and route tracking. Universal mounts make the carrier straightforward to use, enabling quick and intuitive device attachment and detachment, so riders can adjust their setup according to travel conditions and personal preferences.
Innovative Inlet for Improved Aerodynamics
The innovative inlet is a key aerodynamic component that reduces air resistance, improving the motorcycle’s performance. With this design feature, riders experience higher speeds and increased riding efficiency, crucial for motorcycle sports and long-distance travel.
Carefully designed, the inlet directs airflow in a way that minimizes turbulence around the rider. This not only enhances comfort but also reduces rider fatigue from battling air resistance. The efficient airflow around the motorcycle boosts stability, which is particularly valuable in tough terrain and at high speeds, ultimately providing riders with greater control over the vehicle, contributing to improved safety.
Use of Hella M60 Homologated LED Lighting
The navigation tower project incorporates Hella M60 homologated LED lighting, combining high light output and low power consumption at just 26 watts.
Hella M60 lighting modules are designed to meet current standards, making them road-legal. The high-performance lighting improves rider visibility, helping other road users spot them from a distance, thus increasing safety. The Hella M60 also provides effective light distribution, minimizing glare for other drivers. This smart beam pattern ensures riders enjoy optimal visibility while maintaining a comfortable environment for other drivers.
3. Design and Production Process
Key Aspects of the Navigation Tower Design Process
3D Printing for Rapid Prototyping
Utilizing 3D printing was crucial in the navigation tower design process, enabling rapid verification of shape and component fit on the motorcycle. This technology allowed the design team to quickly produce prototypes, enhancing the accuracy and efficiency of the overall process while helping to avoid issues in the production phase. The iterative design approach enabled swift adjustments, offering flexibility and better alignment with user needs.
Advanced Simulation Tools (Fibersim)
A key part of the tower’s design was the integration of advanced simulation tools like Fibersim, which models composite material behavior under varying load conditions. This software allows engineers to accurately predict stress distribution and potential failure points in composite structures, optimizing the tower’s design for increased strength and safety. Fibersim’s analysis capabilities provided valuable insights, helping identify structural weaknesses before production even began.
Fibersim’s seamless integration with CAD systems enables smooth transitions from design to analysis, accelerating project timelines and allowing for quick adjustments. This streamlined approach makes the design process more organized and effective, resulting in a more reliable and functional final product.
Iterative Mold Creation: From Metal to Composite
The iterative mold creation process for the navigation tower included several stages aimed at improving quality and production efficiency. Initially, an aluminum mold was used, allowing precise partitioning, but challenges such as material shrinkage impacted final quality and required further adjustments.
In response, the team transitioned to composite molds with better thermal expansion properties, which prevented temperature changes from compromising production quality, improving both repeatability and accuracy. Composite molds also allowed for more complex shapes, enhancing the navigation tower’s design.
CNC tools were also employed for precise positioning of elements, which greatly increased production efficiency and component accuracy, leading to higher-quality final parts.
Hexagonal Rivet Nuts for Durable Fastening
In the tower’s construction, hexagonal rivet nuts were used for durable and reliable fastening in composite materials. Their innovative design minimizes rotation risk during assembly and disassembly, enhancing user comfort and safety during maintenance and repairs.
These rivet nuts ensure secure and easy component fastening, significantly improving production efficiency. Designed for simplicity, they make the assembly process faster and more intuitive.
4. Production and Assembly Optimization
Key Aspects in the Production Process of the Navigation Tower
Optimizing Production and Assembly
In the navigation tower production process, optimizing both production and assembly greatly enhanced efficiency and product quality. One solution was the development of custom gripping tools for CNC machining, ensuring high repeatability and precise quality in parts manufacturing. These tools were designed for easy mounting and dismounting, simplifying their use and improving workflow.
Another significant improvement was the introduction of a maintenance access panel, which provides easy access to the tower’s internal components. This feature simplifies both assembly and maintenance, eliminating the need for complex maneuvers in confined spaces. The access panel not only increases work comfort but also improves mechanics’ efficiency, allowing for faster and more precise repairs and inspections.
Production of a Lighter Structure Compared to the Original
Using composite materials and advanced lamination technology allowed for a substantial weight reduction in the navigation tower, a critical factor for motorcycle performance. The new tower is nearly half the weight of the original KTM design, positively impacting vehicle performance by improving maneuverability and riding efficiency in challenging terrain.
Through meticulous shape and fiber orientation optimization, the design team achieved increased tower durability while reducing its weight. Composite materials, with their exceptional properties, offer the ideal balance of flexibility and damage resistance, making the navigation tower not only lighter but also more durable.
As a result of these innovations, riders benefit from a product that enhances both riding comfort and vehicle dynamics. The lighter navigation tower enables better performance, an essential factor in motorcycle sports where every gram matters. These advancements demonstrate how technology can drive the design and production of components that meet high standards of quality and performance.
5. Rider and Mechanic Feedback
Positive Feedback from Riders and Mechanics on the Navigation Tower
Riders using the new navigation tower praise its durability and high-quality construction. They emphasize that the tower performs exceptionally well in extreme conditions, providing stability and reliability, which are crucial during races and long off-road rides. With innovative composite materials and precision engineering, riders feel confident that their equipment can handle any challenge.
Mechanics also value the easy access to the tower’s internal components, made possible by the maintenance access panel. This feature allows for quick and efficient repairs and maintenance, greatly enhancing service efficiency. The simple mounting and dismounting process lets mechanics focus on essential tasks rather than complex maneuvers, saving valuable time.
Compatibility with KTM parts is another significant advantage, increasing both functionality and component interchangeability. This compatibility gives riders the option for easy customization of their motorcycles, catering to individual preferences. Such versatility makes the navigation tower a valuable addition and an integral component of racing equipment, meeting the needs of both professionals and enthusiasts.
Zero Complaints About Product Durability
The high-quality materials used in the navigation tower ensure long-term durability. The advanced composites, both lightweight and damage-resistant, allow the tower to perform reliably in extreme environments like intense races (such as the Dakar Rally and Baja Rally) and rough terrain. Precision design and cutting-edge technology give users confidence in their equipment’s dependability, contributing to the product’s success in the motorcycle market.
Customer satisfaction, evidenced by zero durability-related complaints, is the ultimate confirmation of the engineering solutions employed. Customers appreciate not only the build quality but also the functional efficiency of the tower, translating into positive user experiences. This track record strengthens our reputation, building trust among professional riders and motorsport enthusiasts seeking reliable solutions for their equipment.
6. Summary
In summary, the carbon fiber navigation tower project has been a complete success, offering innovative technological solutions. By employing advanced technologies, we have created a structure that is both lightweight and highly durable. Users appreciate the improved aerodynamic properties of their motorcycles, leading to better stability and riding performance. Satisfied customers, particularly those competing in the Dakar Rally, confirm the uniqueness of our design. As Carbon Fox, we take great pride in the project and the effort we invested in the development of the navigation tower.
