Field Load Acquisition and variable amplitude fatigue testing on maxi-scooter motorcycles

Aim of the present work was the instrumentation of a maxi scooter for the field collection of service loads acting on the scooter main components such as frame, fork, handlebar, rear frame and suspension. Service loads were collected on an instrumented Yamaha Tmax scooter equipped with 22 channels during a set of field tests that were representing a predefined road mix, covering a mileage of 270 km. Field load histories were used to develop an accelerated test procedure for the accelerated bench fatigue testing of a new model prototype whose mission was set to 50000 km. The acceleration procedure allowed a time reduction from 1600 hrs to 122 hrs bench equivalent testing. Both the benchmark scooter Tmax and a maxi-scooter prototype under development underwent the bench variable amplitude fatigue testing. The results of the fatigue tests on the prototype allowed to identify some critical bolted connections and to reduce some stress concentration features causing the appearance of small cracks that were found also after during 50000 km of driving tests.