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ARTICLE

Lubricating the gears of greatness

31 December 2015

Providing products for all forms of cycling – from commuter to competitor – Muc-Off officially partnered with Team Sky in 2014. In a sport where seconds can separate winning and losing in a 21-day tour, marginal gains mean everything, so Muc-Off set out to create a world-beating lubricant

"This challenge drove us to create a test system that could accurately test and measure the performance of our lubricants on professional-grade bicycle chains," says company director Alex Trimnell. "We needed to create a system that we could adjust in many different ways and still provide incredibly accurate test results that are repeatable time and time again."

The company's chemical engineers ramped up work on formulating a lubricant that could perform flawlessly, while other members of the team set about developing a proving ground for it. The rig was created in a tight time frame, and consisted of a large sprocket at the front called a chain ring, which the crank arms and pedals attach to on an actual bike. It also included a rear cassette on the back, which is the same as the gears that connect to the rear wheel on any bike, and a chain links between these two parts. The rig was designed to be mechanically adjustable to mimic countless different bicycle size and geometry combinations.

A dynamometer (dyno) was added to the test system to accurately replicate cyclist inputs to the rig and conversely obtain measurable outputs. In one of the available configurations, this rig consisted of a motor that drives the chain ring like a conventional dyno to analyse torque and speed at both input and output. Early iterations of the rig used LabJack measurement devices for data acquisition and control, but this lacked the software interface and the flexibility needed. The team needed the ability to adjust the rig to deal with different sprockets, chain types, gear ratios, power expectancies, and speeds.

Record smashed

National Instruments’ CompactDAQ platform and LabVIEW software were used to quickly create a test rig that can scale with changing requirements in a fast-paced and competitive sport. By accurately validating the performance of their revolutionary bicycle lubrication, Muc-Off helped Sir Bradley Wiggins smash the 1 hour world bicycle distance record.

National Instruments’ CompactDAQ platform and LabVIEW software were used to quickly create a test rig

An extended evaluation period of longer than a month allowed detailed evaluation without any financial risk or investment. LabVIEW provided the ability to switch to a graphical representation of the data in a form that cycling professionals can easily understand, which speeded up development time greatly.
Sir Bradley Wiggins used the Shimano Dura Ace 11 speed chain for his record attempt. Published data describes the variance in chain efficiency due to lubrication, with chain losses ranging between 4.8 and 9W.

The efficiency of the chain and lubrication is calculated using several test methodologies, each incorporating the measurement of torque and speed at different regions around the chain system. The method of load application is also critical in achieving the high-resolution results required to compare lubricant types.
From official Union Cycliste Internationale data, Sir Bradley Wiggins went 3% farther than any other man has ever cycled before in the space of 60 minutes. The lubricant does not have a drop off in performance over this timeframe, meaning friction remains consistently minimal. No other bicycle lubricant has done this successfully before.

Key Points

  • When Muc-Off chemical engineers formulated a lubricant that could perform flawlessly, a proving ground was needed
  • The rig consisted of a large sprocket at the front called a chain ring, which the crank arms and pedals attach to on an actual bike
  • LabVIEW provided the ability to switch to a graphical representation of data in a form that cycling professionals can easily understand

 

 

 
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