The Challenge:
Indian Motorcycle needed a starter motor that could provide very high power in a very small footprint to meet the engine’s unique performance demands. Off-the-shelf starter motors were not an option, as they prioritized low cost and ease of manufacturing over the specialized size and torque requirements that Indian’s road bikes needed. Additionally, because of Indian’s continuous drive for higher quality and reliability, they tripled the cycle life requirement from previous models, making durability a key consideration.
Solution and Custom Design:
OMI was chosen for this critical project due to our proven ability to deliver innovative, customized solutions for new customers. Our team conducted a comprehensive analysis of the engine’s requirements, focusing on creating a motor that delivered significantly more power while maintaining the compact size necessary for Indian’s high-performance bikes.
We used advanced engineering techniques and cutting-edge materials to optimize the motor’s design, ensuring it met the required power and torque specifications. In collaboration with Indian Motorcycle, we also addressed the unique gearing design of the engine. This resulted in a custom gear design that met the increased cycle life requirement while avoiding costly redesigns of the engine’s flywheel.
Testing and Challenges:
OMI carried out extensive simulations and real-world testing to validate the motor’s performance under the engine’s demanding conditions. This testing included mechanical force analysis, magnetic field strength evaluations, and assessments of motor harmonics. Our tests confirmed that the motor not only met but exceeded Indian’s power and durability requirements.
Results and Impact:
The final starter motor design delivered 25% more power while maintaining the same compact footprint, surpassing Indian Motorcycle’s expectations. The motor’s durability was proven through rigorous testing, fully meeting the new cycle life standard. By overcoming the unique challenges of the engine, OMI helped Indian bring a high-performance product to market on time.
Commitment to Quality:
OMI’s focus on quality was a key factor throughout the project. When a previous starter motor model was returned due to a cracked component, we proactively introduced a new manufacturing step to detect and prevent similar issues. This commitment to continuous improvement is central to OMI’s approach to delivering reliable, high-performance products.
Conclusion and Takeaways:
This case study showcases OMI’s expertise in developing custom solutions for complex engineering challenges. Through close collaboration and early engagement in the R&D process, we were able to design a starter motor that exceeded Indian Motorcycle’s expectations. The success of the engine’s starter motor highlights the importance of innovative design, thorough testing, and unwavering quality in creating high-performance products for industry-leading brands.
Building Long-Term Partnerships:
OMI’s ability to provide purpose-built solutions from design through production allows us to meet the evolving needs of our partners, like Indian Motorcycle. Our work on the engine starter motor demonstrates how collaboration and innovation lead to exceptional results, helping our customers achieve their goals and maintain their competitive edge.