DESIGN AND FABRICATION OF

SOLAR E-BIKE

Final Year Project Report

DESIGN AND FABRICATION OF SOLAR E-BIKE

Authors:

Syed Ahmad 2011-ME-305 syedahmad501@gmail.com

Muhammad Asif Sarwar 2011-ME-321 asif321mech.engr@gmail.com
Muhammad Asad Rana 2011-ME-323 asad_rana1993@live.com

B.Sc. Mechanical Engineering

Department of Mechanical Engineering KSK Campus
University of Engineering and Technology Lahore

A Project Thesis submitted in partial fulfillment of the requirements for the degree of

B.Sc. Mechanical Engineering

Project Thesis Supervisors:

Mr. Muhammad Moeen Sultan

Department of Mechanical Engineering KSK Campus
University of Engineering and Technology Lahore

Mr. Faraz Fazal

Department of Mechanical Engineering KSK Campus
University of Engineering and Technology Lahore

External Examiner Signature: ______________________________________

Internal Examiner Signature: ___________________________________

 DESIGN AND FABRICATION OF SOLAR E-BIKE

Internal Examiner
Name:

Signature:

Dated:

External Examiner
Name:

Signature:

Dated:

Department of Mechanical Engineering – KSK Campus

University of Engineering and technology Lahore - Pakistan
 DEDICATION

To Allah Almighty

&

To our Parents and Teachers

CONTENTS
Acknowledgement ............................................................................................................................... viii

Abstract .................................................................................................................................................. ix

1 Introduction To Electric Bicycle .................................................................................................... 10

Introduction ...................................................................................................................................... 10
1.1.1 History of Bicycle........................................................................................................... 11

1.1.2 History of Electric Bicycles ............................................................................................ 11

1.1.3 Future of Electric Bicycles ............................................................................................. 15

1.1.4 Laws and Regulations governing Electric Bicycles ........................................................ 16

Solar E-Bike ....................................................................................................................................... 17

Types of E-Bike Drives ....................................................................................................................... 18
1.1.5 Hub Motor..................................................................................................................... 18

1.1.6 Mid Drive Motor ........................................................................................................... 19

1.1.7 Side Mounted ................................................................................................................ 19

Types of MOTORS ............................................................................................................................. 20

Modes of E-bike ................................................................................................................................ 20
Types of BATTERIES ........................................................................................................................... 21
Types of TRANSMISSIONS ................................................................................................................. 22
1.1.8 Belt-drive transmission ................................................................................................. 22

1.1.9 Direct drive (in-line chain-drive) ................................................................................... 22

1.1.10 Geared transmission-style shaft drive .......................................................................... 23

Gear Ratios ........................................................................................................................................ 23

2 Literature Review .......................................................................................................................... 24

literature survey................................................................................................................................ 24
3 Methodology................................................................................................................................. 30

Design: .............................................................................................................................................. 30
3.1.1 Motor ............................................................................................................................ 30

3.1.2 Drive Type ..................................................................................................................... 34

3.1.3 Transmission Type......................................................................................................... 35

3.1.4 Battery Type .................................................................................................................. 35

v
 3.1.5 Controller ...................................................................................................................... 38

3.1.6 Bicycle Frame ................................................................................................................ 38

3.1.7 Solar Panels ................................................................................................................... 39

3.1.8 Throttle ......................................................................................................................... 40

Fabrication ........................................................................................................................................ 40
3.1.9 Purchasing of Components: .......................................................................................... 41

3.1.10 Fabrication of non-ready made parts ........................................................................... 41

3.1.11 Assembly ....................................................................................................................... 43

Cost Analysis ..................................................................................................................................... 45

4 Results & Discussion ..................................................................................................................... 46

4.1 Cost analysis of Gasoline and E-bike Mileage: ............................................................................ 46

4.1.1 For Gasoline bike:.......................................................................................................... 46

4.1.2 For E-Bike: ..................................................................................................................... 46

4.1.3 Comparisons between Gasoline bike and E-bike: ......................................................... 47

4.2 Experimental results: .................................................................................................................. 49

4.3 Overall cost and time Relation: ................................................................................................... 49
5 Future Recommendations and Conclusions ................................................................................. 50

5.1 Conclusions: ................................................................................................................................ 50

5.2 Challenges faced : ....................................................................................................................... 50
5.3 Future recommendation: ............................................................................................................ 51
REFERENCES .......................................................................................................................................... 52

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Table of Figures
Figure 1:Powered bicycle with a hub motor in its rear wheel .............................................................. 12
Figure 2: Rear wheel with motor and peripheral belt .......................................................................... 13
Figure 3: Top view showing the motor armature and drive wheel ...................................................... 13
Figure 4: Closeup of motor and drive wheel......................................................................................... 14
Figure 5: Hub motor assembly .............................................................................................................. 18
Figure 6: Mid drive motor assembly ..................................................................................................... 19
Figure 7: Side mounted motor assembly .............................................................................................. 19
Figure 8: Belt drive transmission .......................................................................................................... 22
Figure 9: In line chain drive ................................................................................................................... 22
Figure 10: Benefit of using gear ratios .................................................................................................. 23
Figure 11: Ways to charge battery ........................................................................................................ 27
Figure 12: Graph showing the relation of torque with speed .............................................................. 28
Figure 13: Graph demonstrating the effect of power on speed ........................................................... 28
Figure 14: Layout of Mid Drive E-bike................................................................................................... 30
Figure 15: Throttle used in E-bike ......................................................................................................... 40
Figure 16: Design of Extended Axle ...................................................................................................... 41
Figure 17: Extended Axle Fitting ........................................................................................................... 43
Figure 18: Fitting of Flywheel................................................................................................................ 44
Figure 19: Picture demonstarting E-bike motor fitting ........................................................................ 44
Figure 20: Controller and wire fitting ................................................................................................... 44

Table of Tables
Table 1: Laws and regulations governing electric bicycles ................................................................... 17
Table 2: Types of motor, their advantages, disadvantages and applications ....................................... 20
Table 3: Types of batteries, their advantages and disadvantages ........................................................ 21
Table 4: Performance Evaluation Parameter ........................................................................................ 26
Table 5: Spesifications of Motor ........................................................................................................... 31
Table 6: Battery Specifications.............................................................................................................. 36
Table 7: Specifications of Motors ......................................................................................................... 38
Table 8: Design Parameters of Gears .................................................................................................... 39
Table 9: Specifications of Solar Panels .................................................................................................. 40
Table 10:................................................................................................... Error! Bookmark not defined.
Table 11: Cost Analysis.......................................................................................................................... 45

vii
ACKNOWLEDGEMENT

In the name of Allah, the most Gracious, the most Merciful. All praise be to Allah, the
Cherisher and Sustainer of the world.

In a cooperative endeavor, there are many personalities who deserve special

acknowledgement due to their very special contribution and enlightened suggestions during
the course of our project on Design &Fabrication of Solar E-bike. Without Their cooperation
and encouragement this project would not have been possible.

We wish to express our gratitude to Mr. Moeen Sultan and Mr. Faraz Fazal for guiding and
directing us on various occasions & giving insightful thoughts about the project.

Syed Ahmad

Muhammad Asif Sarwar

Muhammad Asad Rana

Department of Mechanical Engineering & Technology

U.E.T Lahore

K.S.K Campus

viii
ABSTRACT

Electric bikes have gained popularity in many regions of the world e.g. China, Western Europe, North
America etc. and some have suggested that it could provide an even higher level of service
compared to existing systems. The project “Design and Fabrication of Mid Drive Solar Electronic
Bike” is a unique addition in Pakistan bicycle industry. The project aims to show that how normal
bicycle can be upgraded into electric one (E-bike) by means – that includes the development of Mid
Drive geared motor, torque sensor – but also uses real-time sensing and the powers of crowd
sourcing to improve the cycling experience; get more people riding bikes; and to aid in the design
and development of cities. There are several challenges that are related electric bike design: electric-
assisted range, recharging protocol, and bike and battery checkout procedures. In this project an
attempt has been made to design and fabricate Mid Drive E-bike with the concept of charging
through solar cells, which in comparison to the bikes available in global market that uses hub motor
is a better choice as it give varying torque and RPM (revolution per minute). We have achieved a
pollution free, noise free, cost effective and a cheap substitute of petrol. Moreover, this work will
provide a decent foundation for the further modification and improvement in the design,
fabrication and even application of solar E-bikes especially in developing countries like Pakistan.

ix
1 INTRODUCTION TO ELECTRIC BICYCLE

INTRODUCTION
We often hear the challenge; "Why would you want to use an electric-powered bicycle when the
whole purpose of a bicycle is to get exercise?" because in this mode, you have options available that
you can pedal if you wish or to depend on electric motor if you are exhausted. In short, riders can
enjoy adventurous journey.
Bicycle invented for exercise? Probably not, because it was invented to cover distances, as if you
want to go to market or office. So if distances are lengthy, then instead of conventional bicycle there
must be some alternative in form of e-bike, to cover more distances with ease because bicycle with
an electric motor has as much power as in an automobile with a gasoline engine.
A traditional bicycle is a two-wheel vehicle that is propelled by the rider who delivers muscle power
through pedals that rotate one of the vehicle’s two wheels. The rider keeps the bicycle upright by
steering the front wheel to create a force that restores the vehicle’s center of gravity to its stable
zone whenever necessary to prevent tipping. Today's motorcycle is a two-wheel vehicle that is
propelled by a fuel-burning engine. An electric bicycle carries batteries or fuel cells that deliver
electric power to a motor that is coupled to either wheel. In most electric bicycles the rider can
chose to use muscle power to deliver all, part, or none of the propulsion power required to maintain
his or her adopted travel speed. Some models even sense your pedal pressure and command the
motor to deliver more power whenever you pedal hard.
Many electric bicycles are specifically designed and built for travel. Average travel speed, when
compared to pedaled-only bicycles, can be increased by 8 to 10 km/h (5 to 6 mph) above the
speed an average person could travel by pedaling. An exception is the athlete or world-class
competitor. These athletes can pedal a bicycle faster than an ordinary cyclist can move on a
conventional electric bicycle.
The principle objective of this chapter is to throw some light on the overall project. The
main focus of the project was the suitable designing and fabrication of solar e-bike. In this
chapter first of all, discussion about solar e-bike and its types of drives are mentioned. After
that the background, aims and objectives of the project are discussed.

10
1.1.1 History of Bicycle
Pierre Lallenent in France first conceived the two-wheel pedal-powered bicycle in 1862 and
demonstrated it the next year. By 1870 wire spokes had been developed, and nipples for tightening
spokes came in 1874. In 1871 James Starley, a 67year- old foreman at Coventry Sewing Machines,
patented the Ariel bicycle, which as an option offered levers that doubled the distance traveled per
pedal stroke.
In 1880, when the League of American Wheelmen was formed, the "ordinary" bicycle had a small
rear wheel and a front wheel that had a diameter of up to 5 ft. Pedals were solidly coupled to the
front wheel. The average bicycle weighed 50 lb., but some were as light as 21 Ib. In "century runs"
athletic bicyclists on "ordinaries" pedaled 100 miles in 1 day during an age in which the self-powered
alternative was hiking, with a practical limit of 20 miles.
Chain drives and pneumatic tires, invented by John Dunlop in 1888, made possible the safety bicycle
in which the two wheels had the same diameter. Now the rider could at any time touch the ground
with his feet, and crank the pedals an optimized speed that differed from the wheel speed.
Pneumatic tires made it possible to ride over rough roads with reasonable comfort.
The Sturmey Areher rear-wheel hub, which contained an epicycle gear train, also called planetary
gears, was patented in the 1901 to 1906 period. With the first design the cyclist could select a "low"
gear ratio when climbing hills, and a “high" ratio for fast bicycling on level ground with a tail wind.
Later designs had three ratios. In the high-speed position the rear wheel was coupled directly to its
driving sprocket. The latest version achieved five ratios of pedal speed to wheel speed with two
planetary gear sets and hubs lost popularity when Derailleur gear shifting became practical. On
Derailleur-equipped bicycles, the cyclist can shift the chain among up to seven "free-wheel"
sprockets that have various diameters. These sprockets are coupled to the rear wheel through an
over-running elute, which permits coasting downhill without the pedals being turned by the chain.
The cyclist canals select one of three "chain wheel" sprockets that have different diameters. The
chain wheel assembly is coupled solidly to the pedal cranks. Now, with the available gear ratios, the
bicyclist can crank the pedals at a pedal speed that delivers maximum muscle power. The bicycle
then moves at a speed in which all net power is consumed in the air drag, friction, and hill climbing.

1.1.2 History of Electric Bicycles

Electric bicycles first appeared in the late 1890s. On December 31, 1895 Ogden Bolton, Jr., was
granted U.S. Patent 552271 for a battery-powered bicycle with 6-pole brush-and-commutator
direct-current (dc) hub motor mounted in the rear wheel. The motor contained no internal gears. It
could draw 100amperes (A) from a 10-V battery. On December 28, 1897, Hosea W. Libby of Boston

was issued U.S. Patent596272, for an electric bicycle that was propelled by a "double electric motor
“that was in the hub of the crankshaft axle (Fig, 1.2). The 5-pole brush-and commutator dc motor
11
drove two closely spaced rear wheels, a configuration that Libbey had invented earlier in 1893. His
patent showed crank rods for carrying the motor torque to the rear wheels. However, he soon
adopted the sprocket wheel and chain drive for delivering power to the rear wheels. He also used a
double battery, consisting of cylindrical cells with a central partition, which he invented in April
1895. One-half of the battery was to be used for travel on level ground, and both halves were used
when climbing hills. The battery acid was refilled from a reservoir mounted under the rider's seat. A
fabric saturated with the diluted sulfuric acid separated the battery plates. This avoided the spilling
of sulfuric acid.

Figure 1: Powered bicycle with a hub motor in its rear wheel

In 1898 in Chicago, Illinois, Mathew J. Steffens invented an electric bicycle on which the driving belt

rode on the periphery of the real wheel (V.S. Patent613752). The rounded belt rode in a tire groove
and eliminated belt slippage problems by applying force at its contact with the ground. The motor,
mounted on the seat post, drove the belt pulley through sprocket wheels and sprocket chain.
Steffens said his idea could be applied to "tricycles and other similar vehicles.
John Schlep in New York patented a design in which a pulley on the motor shaft delivers propulsion
power to the top surface of the rear wheel of the bicycle. The V.S. Patent number is 627066. He also
suggested that the battery could be charged by the motor acting as a dynamo when the bicycle
coasts downhill. However, he admitted that the battery would also need the normal means for fully
recharging it after a trip.

12
 Figure 2: Rear wheel with motor and peripheral belt

Figure 3: Top view showing the motor armature and drive wheel

In 1969 G. A. Wood, Jr., expanded on the friction-wheel drive in his V.S.Patent 3,431,994. He used
multiple sub-fractional horsepower motor, each rated less than 4horsepower. Four motors were
coupled together to drive the bicycle’s front wheel through a friction drive wheel that pushed
against the bicycle's front wheel. Each motor powered the friction drive through a set of series-
connected gears. Torque sensing and control of the power supplied by the motor was developed in
the late 1990s. Takada Yutan of Susa, Japan, filed a patent in 1997 for such a system. Shu-Shian of
Taipei and others followed him in 2001.

13
In the 1920s a rear bicycle wheel with an integral gasoline engine was offered. Also, a small handle-
bar-supported engine was sold for driving the front wheel with a tire-riding roller. Larger engines
were mounted between the rider legs on vehicles called "motorcycles."
Hugo proposed electric bicycle propulsion in his January, 1924, Science and Invention magazine.
His concept featured an underground cable that radiated radio-frequency (RF) power, collected by
an antenna on the bicycle.

Figure 4: Close-up of motor and drive wheel

In 1992 Vector Services Limited offered a practical electric bicycle, the Like. A nickel-cadmium
battery built into a frame member and an 850-g permanent-magnet motor powered it. It weighs
24Ib and can carry load with it. With the Zike doing all the work, the range is "up to one hour's
riding." Having Zike doing just most of the work extends the range by a half-hour. Pedaling normally,
with Zike helping on hills and during strong headwinds, gives 3 hours of travel on one battery charge.

14
1.1.3 Future of Electric Bicycles
Economics, the cost of gasoline and diesel fuel, and air pollution will affect the use of electric
bicycles and bicycles in general. Today's fuel price in some nations is related to the cost of
production and in other nations to the need to control imports. The price of fuel in the future will be
affected by the exhaustion of reserves of petroleum and natural gas, and the need to limit
1. The pollution of the environment
2. The generation of carbon dioxide.
Atmospheric pollution by motor vehicles in cities can be prevented only by prohibiting these vehicles
in downtown zones. One type of bus, used in Seattle, is propelled by a diesel engine when traveling
in the suburbs and by electrical power in city-center tunnels. Buses and light rail suffer from the
rarely mentioned user-inconvenience features, which drove the electrified interurban railroads into
bankruptcy in the 1930s. Again bicycles, and especially battery powered electric ones, can become
common vehicles for commuting to down town workplaces.
The problems in bringing every day a million people to work in a skyscraper-filled downtown of a
large city are easy to identify. New York City built a useful subway network with immigrant labor at a
time when environmental questions did not delay construction. Today subway riders grumble but
chose not to go to work in buses or cars. A subway network feeding a downtown zone would not
work in Los Angeles or Seattle where the big employers are in outlying suburbs.
We can look to European and Chinese cities to see that bicycling to work places is a solution that
worked. Every day in Shanghai over a million people go to work, with bicycles. Availability of electric
bicycles would further enhance the bicycle for commuting to work. A freeway lane built for
automobiles could easily be converted to a bicycle lane, quadrupling its commuter-delivering
capacity. The alternative of quadrupling the number of automobile lanes would require a hopeless
environment a impasses. The pavement and bridges would need to carry only riders on bicycles that
weigh less than 200 lb. each, rather than cars and buses. Bicycling to work could be made more
comfortable with rain covers over the bicycle ways. The supporting infrastructure could include coin-
operated recharging stations at workplaces.
If you want to ride daily, i.e. from home to office or some station then electric bike is best solution
that can save time and you will be in time, with any exhaust.
A lightweight foldable electric bicycle that the rider could carry on the train and bicycle from the
downtown station to his workplace would be even better. In this new environment electric bicycle
performance will improve in terms of travel range on a charged battery, battery life, reliability, riding
comfort, and many other features. New electric bicycle builders will spend substantial money on
improved bicycle performance in order to capture a leading marketing position from the existing
producers. For example, China will undoubtedly market low cost electric bicycles from a high-

15
production factory. In our American consumer market, a new better performing electric bicycle can
become popular for a limited time, even if it costs more.
We expect to see significant and continuing improvements in the travel range of electric bicycles
from improvements in the energy content of batteries. One example is the zinc-air fuel cell, which is
being developed for electric cars. It can't be recharged by the owner but could be recharged at
"filling stations “where a discharged fuel cell can be quickly exchanged for a recharged fuel cell.
Hydrogen storage in Neon-tube grids is another coming technology.

1.1.4 Laws and Regulations governing Electric Bicycles

Regulations that will affect the design and use of electric bicycles are evolving throughout the
world. The approach is to define the electric-powered bicycle as a class of bicycle and then
impose an upper limit on bicycle speed when motor-powered. This limit is then related to speeds
normally observed with regular bicycles in the city.
Other regulations deal with insurance, helmets, operator age, and travel on roads and pathways.
Whenever existing limitations are exceeded, the regulations are made stricter in terms of
application. Motor-vehicle-related regulations cover topics such as licensing, road use, required
insurance, and age limits of drivers. They may be applied to electric bicycle riders as soon as their
presence on streets becomes significant. In the United States electric-powered bicycles are
consumer products, as defined by the federal government. The City Electric International Consulting
Group cites possible regulations in Table 2. The electric bicycle has two or three wheels and is
powered either by pedals or an electric motor. Likely regulations would restrict the motor power to
a value of less than 750 W. The bicycles' maximum speed on a paved level surface might be held to
less than20 mph when the rider is a person weighing over 170 lb., and the bicycle is powered only by
the motor.
Very specific standards limit the voltage of conductors to which a vehicle occupant might be
exposed. For example, engine-starting batteries in automobiles are generally limited to 40 V for
safety reasons.

16
Table 1: Laws and regulations governing electric bicycles

Location Motor Power Speed Limit Weight Limit Other

Limit (km/h) (kg) Limitations
(W)
European Union 250 25 0 No Pedal assist

United Kingdom 200 b 25 c 40 d Must have pedals

and on/off
Switch
Canada 500 e 32 No Must have pedals
and less than 4
wheels and on/off
switch
Taiwan No! 30 40
Japan No8 24 No
China 240 20 No Must have pedals
United States 750 32.2 h No Must have pedals
and less than 4
Wheels

In the United States there will also be the pertinent state laws, rules, and regulations with which to
be concerned. Each state will define where the bikes can go, how fast they can go, and how the
state's insurance codes apply. Some states may require inspection and certification of electric
bicycles. Firms that manufacture, sell, or service electric bicycles may be required to have permits or
licenses. Some states might define an electric bicycle as a motorcycle. Then, in order to obtain a
driver license, the electric bicycle rider would have to pass a special written test and also a driving
test. Helmet requirements may be the same as those for the conventional bicycles. The electric
bicycle would normally not require registration, licensing, or operator qualification.
Some other nations regulate the application of electric motor power to bicycles. For example, some
require that motor power alone must not propel the bicycle. Some countries say that the motor
power must not exceed the operator pedal power, while others say the pedals must be used before
motor power is applied. Many have some speed limit at which the mot or power must be cut off.

SOLAR E-BIKE
An electric bike is a conventional bicycle with frame, pedals, cranks, chain, and freewheel
assembly but in addition electric propulsion replaces or supplements muscle power. This
adds to the bicycle an electric motor, gear reducer, battery, and power control. Here solar
panel is also installed to charge battery by the help of solar energy.

17
Considering solar e-bike as final year project:

 Renewable source of energy, that is available all time

 Efficient
 Environmental friendliness
 Quiet
 Inexpensive mean of transport
 No issues regarding petroleum crisis

TYPES OF E-BIKE DRIVES

An extensive and detailed reviews of different types of drives fore-bike are given below:

1.1.5 Hub Motor

Hub motor is actually hub of wheel and to install it, only hub of rear or front wheel is
replaced with hub motor. It is operated with battery. Controller can take less or more
current from battery (according to throttling by rider) to rotate motor with low or high rpm
accordingly. When motor rotates, it actually turn wheel so bicycle tends to move. In hub
motor, two drawbacks; first is that it will always struggle while you are in hilly area, as
motor keep on rotating with same high speed (less torque) so you will feel some difficulty
and second is that mass distribution is not good and can cause system to become instable to
some extent.

Figure 5: Hub motor assembly

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1.1.6 Mid Drive Motor
Mid drive motor is always mounted at mid. Sometimes it is attached with free wheel and it
replaces the free wheel that is already fixed and sometimes it is separate and is fixed near
the free wheel and finally power transmission is done by chain from motor to free wheel.
Here mass distribution is quite good and system remain stable enough to withstand jerks.
This motor is actually geared motor, so according to your choice torque and speed are
adjusted. Even in case of hill climbing, controller senses it, then offers more torque to
provide ease. Mid drives are usually very expensive than hub motors.

Because of benefits of mid drive, we selected this type for our project and is suitable for us.

Figure 6: Mid drive motor assembly

1.1.7 Side Mounted

Here motor is mounted separately near rear wheel or front wheel and by means of chain drive
power is transmitted. Here some issues regarding mass distribution arises, that cause system to
become instable. It is also inexpensive than mid drive.

Figure 7: Side mounted motor assembly

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 TYPES OF MOTORS
Motors are distinguished on their working principles and mechanisms. Each type having some
advantages and disadvantages as well. Types are:

 Stepper DC
 Brushless DC electric motor
 Brushed DC electric motor

Here is overview of all types of motors:

Table 2: Types of motor, their advantages, disadvantages and applications

TYPE ADVANTAGES DISADVANTAGES APPLICATION

Stepper DC Precision positioning Slow speed Positioning in printers

Stepper DC high Requires a controller and floppy drive
holding torque
Brushless DC Long life High initial cost Hard drives, CD/DVD
electric motor Low Maintenance Requires a controllerplayers, and
High efficiency Electric vehicles
Brushed DC electric Low initial cost High maintenance Treadmill exercisers,
motor Simple speed control Brushes have limited Automotive starters,
lifespan Toys

Out of motor types, brushless DC electric motor is best for e-bike because of it long lifespan and
efficiency. Though expensive but it can fulfill the requirement.

MODES OF E-BIKE
Mode of e-bike means, how motor is being driven by controller e.g. motor is driven by throttle by
rider or controller automatically senses what to do. Modes of e-bike are as follows:

 Throttle mode
 Pedal Assist (pedelec) mode
 Low pedal assist
 Medium pedal assist
 High pedal assist
 Torque sensor system
 Cadence sensor system
 Hybrid power control

20
Throttle mode means, rider is going to throttle as he desires. While another is pedal assist, in which
upon pedaling controller senses it and send signal to motor to assist you. Means whenever you
pedal, motor assists you and this assist level can be set from low to high, depending upon the choice
of rider. Moreover combination of both modes (hybrid power control) is also available.

TYPES OF BATTERIES
Battery is the main component of e-bike, as it is the battery which drives the motor. Battery is
usually chargeable and you can charge it with conventional electricity supply (120 V), solar panel or
by regenerative braking system. It is totally up to you, to charge battery by any means but each
mean require something to able to charge battery without damaging it. Here types of batteries are:

 Lead Acid (sealed)

 Lithium ion
 NiCad
 NiMH

Overview of all types of batteries is given in table, as follows:

Table 3: Types of batteries, their advantages and disadvantages

BATTERY ADVANTAGES DISADVANTAGES

Lead Acid (sealed) Inexpensive and simple to
manufacture
Mature, reliable and well-
known technology
Li-Ion Highest energy density to
weight ratio
Long life
Environment friendly
NiCad Fast and simple charge (more
backup)
Economical price
NiMH Environment friendly
30%-40% higher capacity over a
standard NiCad. The NiMH has
potential for yet higher energy
densities
Low energy density to weight
ratio
Not to be stored in discharge
condition
Environment unfriendly
Require a protection circuit
It must be protected from
overheating
Over charging can cause
damage
Low energy density to weight
ratio
Environment unfriendly
High maintenance required
Performance can be affected at
high temperature
Limited service life

Out of these batteries, all have some advantages and some disadvantages, but it can be checked
thoroughly and consider their advantages as well as disadvantages, so Lithium Ion is best out of all
types because of its highest energy density to weight ratio and long lifespan.

21
 TYPES OF TRANSMISSIONS

1.1.8 Belt-drive transmission

A specially designed motor is mounted low in the frame, and drives the rear wheel by use of a belt. .
It is quiet operation but may reduce the performance due to slippage.

Figure 8: Belt drive transmission

1.1.9 Direct drive (in-line chain-drive)

This method has the motor working with the primary bicycle chain (the same chain that the rider
uses when pedaling). Here sprockets are used and motor drives the sprocket, so this power is
transmitted to sprocket attached to free wheel or rear wheel by means of chain. This type of
transmission is good enough to transmit power efficiently, as no slippage is observed.

Figure 9: In line chain drive

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1.1.10 Geared transmission-style shaft drive
This type of electric drive is like a shaft-driven motorcycle. The cycle does not have a chain. The
motor and the pedals apply power to a sealed and protected shaft that has bevel gears in front and
back. Multiple gears (speeds) are supported.

GEAR RATIOS
In mountain bicycle, certain gear ratios can be set accordingly when you are climbing hill, then there
must be more torque and less speed for easy climbing and when you are at plane road, if you need
more speed, then by setting suitable gear ratio it can be done easily.

Figure 10: Benefit of using gear ratios

23
2 LITERATURE REVIEW

In this chapter a comprehensive literature review that includes the current knowledge and
substantial findings as well as theoretical and methodological contribution in the field of
electric bikes. Provided for the selection of different techniques used for the project.

LITERATURE SURVEY

Developed at the MIT Sensible city lab “the Copenhagen wheel”, Christine Out Ram[2], the group
leader and his other team members. Their idea was to have everything within inside a single box
placed at the rear hub and no use of electric wires or throttle. They introduced a regenerative
braking system, an innovative motor control that sense the torque and aids you according to your
demand in riding. Further they insert a unique concept of “smart phone app” i.e. you can control the
aiding of motor by different options available in the smart app. For example if you are riding a hill
you can set the motor to assist you more in riding by setting a unique option available in the smart
phone app. They further hope that this bike is going to improve the cycling experience and believe
that their particular design has the power to foster again the culture of cycling in the cities.

Zhenying Shao [3] along with his group mates interviewed 27 e-bikers in Sacramento-Davis area and
founded that there are four unique benefits of riding e-bike i.e. speed, acceleration, green and
enabling. After interviews they come to the point that e-bikes are fast and cut commute time and e-
bikers ride more frequently than if they ride traditional bikes, especially during hot and windy days.
The electric motor provide ease in riding uphill and provide an option for green transportation. The
barriers to the expansion of e-bikes ridership are initial cost, unsafe roads, lack of emergency
charging and government policies. However they concluded with these facts e-bikes can play a
substantial role in reducing carbon dioxide emissions.

[4]
Dave Hurst the principle analyst and his fellow mate John Gartner the research director , they
carried out a market analysis highlighting the global market opportunities for e-bikes, the barriers
that are hindrance for its expansion, technology issues and demand forecast. They came up with the

24
results that an ample amount of variety in e-bikes is available to the consumers in market and
concluded that the market is getting mature. Trends are changing people have started using lithium
ion batteries instead of sealed lead acid batteries they used in the past and changing of trend from
hub motor to mid drive. From their survey they predict that the market is expected to grow 3.1 %
compound annual growth rate (CAGR) between 2013 -2020.

Chetan Mahadik along with his fellow mates under the supervision of their professor Jayashree
Deka[5] designed and fabricated an e-bike. Their aim includes up gradation of normal bi-cycle into e-
bike, introduction of regenerative braking system, brushless DC (BLDC) motor to improve cycling
experience, to get more people riding bikes and to aid in the design and development of cities. They
used peripheral interface controller (PIC) to control power supply and to drive and control BLDC also
to protect under voltage and over current. Further they introduced a dynamometer on the front
wheel for the conversion of mechanical energy into electric energy for charging the battery. They
also introduced solar cell for charging the dry cell battery.

Manoj.E, Dino Isa and Roselina Arelhi[6] designed and fabricated an e-bike using a hub motor in the
front wheel. They introduced a super capacitor connected in parallel to the battery pack via custom
made microcontroller based boost convertor which arbitrates power between the battery and the
supercapictor. Their aim was to improve uphill acceleration of bicylce avaioding deep discharge from
the battery. Based on the implemented system experimental results show an improvement in the
up-hill acceleration of the bicycle as a direct result of the boost converter being responsive enough
to harvest the extra current from the high power complementary supercapacitor module avoiding
deep discharges from the battery. This enhanced battery life.

Chris Cherry and Robert Cervero[7] carried out research on popularity of e-bikes, as 10 million e-
bikes were sold out in China. There they conducted survey in populated but small cities of China
(Shanghai and Kunming) and positive results appeared. They concluded in a way that though e-bikes
cannot replace petrol engine powered bikes, but this is affordable option available for riders and this
is a good sign indeed. It is a transitional state between human powered vehicles and petrol engine
powered bike. In short, e-bikes are making their way in market day by day.

25
Annette Muetze&Ying c. Tan[8] worked to have a review on performance evaluation of e-bike. In
Performance evaluation, various factors were studied upon which performance of e-bike can be
evaluated. Basic configuration was categorized in three i.e. rely on only pedal or motor and their
combination. Factors on which performance depends i.e. technical performance, practicability,
design, environment friendliness and cost. They worked on all parameters and concluded that each
one of them is so important to discuss and can affect overall performance of e-bike.

Here are performance evaluation parameters:

Table 4: Performance Evaluation Parameter

Power
Torque
Technical Performance Speed
Efficiency
Distance covered for full charge
Technical maturity
Practicability Battery charging
Operating condition
Service/Maintenance
Ergonomics
Design Safety
Battery
Environment Friendliness Pollution
Noise
Cost Unit price
Other costs

Srivatsa & Raghunath[9] worked on hardware design of e-bike, as hardware specifications is

important to discuss and most importantly which component is to be used along with its placement,
can affect performance of bike or it can cause instability. They conclude some requirements; first is
that e-bike must have lowest practical mass to facilitate rider to cover more distance and secondly it
must remain stable, so placement of mass is important. Further they studied different types of
transmissions, and selection of it on the basis of efficient performance. In short they worked on
selection of electric motor, battery, gear reducer, transmission and power control with the help of
design calculations and finally with their work, one can select relevant components to get 100% out
of them without wastage of money.

26
Basic concept was to facilitate ride r, regarding charging issues. Robert Cong and Rodney
Martinez[10] worked on three ways to charge battery i.e. by solar panels and regenerative braking
system along with conventional electricity supply (120 V). They used brushless direct current (BLDC)
hub motor (reliable than brushed motor) and Li-Ion battery (highest energy density to weight ratio)
along with DC-DC boost converter to charge battery by solar panel, as output of solar panel is
fluctuating, so it must be constant to charge battery.

Figure 11: Ways to charge battery

Ian Vince Mc Loughlin and I. Komang Narendra[11] worked on campus mobility for bright future. As
energy crisis is common in our country, so there must be some alternative along with petrol engine
powered bike. They studied e-bike effectiveness in terms of friendly environment, means if you are
riding e-bike, then no pollution for environment. So it is good enough to ride with green
environment. Results of survey were collected in terms of barriers to conventional cycling i.e. Hill
climbing, no facilities for cycling, and danger on road including distance/time issues also. So by the
introduction of e-bike, almost all barriers will be gone, and here it can be a promotion of cycling, as
you can pedal or throttle what so ever you want depending upon your mood.

27
Design of electrical drive is so important to discuss, that it can tell maximum speed and torque which
an e-bike can attain and similarly how much power is required to move some kilogram of mass.
C. Boccaletti&G. Duni[12] studied technical performance parameters to plot relationship between
them, so that electrical drive system can be designed accordingly. They plot graph between torque
and speed, concluding that in case of more speed, torque must be lesser and vice versa. Moreover
graph between power and speed (as a function of mass) was also studied. So from graphs, one can
choose optimum situation where basic task can be accomplished with ease, as this situation is
always economical. Furthermore they also worked on control method and regenerative braking
system.

Figure 12: Graph showing the relation of torque with speed

Figure 13: Graph demonstrating the effect of power on speed

28
After production of e-bike, it must be checked thoroughly to verify its aesthetics and performance in
some testing station. Jaromir Konecny & Martin Pies[13] developed e-bike testing station where
performance of e-bike can be judged, after couple of tests. Tests carried out i.e. support test, quick
stop test, reverse pedals spinning test and load test. Their concept of testing station became famous
for its quality, then all e-bike factories installed such system to verify their product. Obviously, from
now onwards all e-bikes are checked before their departure. Moreover by the help of testing station,
efficiency of e-bike was also calculated in terms of graph between speed and efficiency. In short, e-
bikes are checked regarding each and every aspect, to ensure its 100% performance.

29
3 METHODOLOGY
The focus of this chapter is to study the processes and different steps involving in the design
and fabrication of a Solar E-bike. First portion is based on the design process. Second
portion involves the fabrication data and its process. The last portion is based on its
automation.

3.1 DESIGN:
The first step in the project was to make a suitable design which is easy to fabricate and
fulfilled all the objectives. The software used for the design is AutoCAD 2013. It was used to
generate the layout of the frame according to the required size.

Figure 14: Layout of Mid Drive E-bike

3.1.1 Motor

3.1.1.1 Motor Types

Two most common types of motors are used brushed and brushless. Other many possible types of
electric motors with varying cost and complexity either direct drive or geared units.

30
A brushed motor is internally commutated electric motor designed to operate on direct current
power source. We have brushes pressed against the axle of a normal motor. Whereas in brushless
we replace the commutator and brushes with half-a-dozen or more separate coils and an electronic
circuit. The circuit switches the power on and off in the coils in turn creating forces in each one that
make the motor spin.

3.1.1.2 Selection
We selected brushless direct current electric motor, because of its advantages:

 Long life
 Frictionless
 Low Maintenance
 High efficiency

3.1.1.3 Parameters
Table 5: Specifications of Motor

Motor Specifications
Model MY1616
Type Brushless geared motor
Current 18 A
Voltage 24 volt
Power 350 watt
Teeth of gear 12 teeth

3.1.1.4 Calculations for Selection of Motor [1]

Total Power required = P = 𝑃𝑎 + 𝑃𝑑 + 𝑃𝑟𝑓 + 𝑃ℎ …….. (1)

Accelerating Power:

As according to Newton’s 2nd Law of motion:

F = ma

Using 2nd equation of motion:

1
S = 𝑣𝑖 t + 2a𝑡 2

While accelerating from rest, means 𝑣𝑖 = 0, so equation becomes

1
S = 2a𝑡 2

So work done will be as follows

1
W = FS = (ma) (2a𝑡 2 )
1
W = 2m𝑎2 𝑡 2

Now power is defined as rate of doing work, so

31
 𝑊
P= 𝑡

So by putting value of W, after simplifying, we get final form of accelerating power:

𝟏
𝑷𝒂 = 𝟐mta2 ........(2)

Putting values (i.e. m = 100Kg, t = 1s, a = 1m𝑠 −2 )

1
𝑃𝑎 = 2 (100)(1)(1)2

𝑷𝒂 = 50W

Drag Power:

As frictional force due to drag is

𝐹𝑑 = 𝐶𝑑 mg

Considering friction per unit length

𝐶𝑑 mg
𝐹𝑑 = 𝐿
*L

Multiplying and dividing by L2

𝐶𝑑 mg
𝐹𝑑 = 𝐿3
*L*L2

Here L2 = A and L3 = V, so equation becomes

𝐶𝑑 mg
𝐹𝑑 = 𝑉
*L*A
𝑚
Now 𝜌= , so equation becomes
𝑉

𝐹𝑑 = 𝐶𝑑 𝜌g*L*A

As,

S = 𝑣𝐺 t

Now work done will be

W = 𝐹𝑑 S
𝑣𝑤 + 𝑣𝐺
= (𝐶𝑑 𝜌g*L*A)( )t
2

As Power is rate of doing work, so

𝑣 +𝑣
𝑊 (𝐶𝑑 𝜌g∗L∗A) ( 𝑤 𝐺 )t
2
P= =
𝑡 𝑡
𝑣𝑤 + 𝑣𝐺
𝑃𝑑 = (𝐶𝑑 𝜌g*L*A)( 2
)

Separating gL, i.e. 𝑣 2 because of dimensions i.e. 𝑚2 𝑠 −2 or (𝑚1 𝑠 −1 )2

Here v = relative velocity * ground velocity

v = (𝑣𝑤 + 𝑣𝐺 ) * 𝑣𝐺
32
So after simplifying, we get final form of drag power:
𝟏
𝑷𝒅 = 𝟐 𝑪𝒅 𝝆 A (𝒗𝒘 + 𝒗𝑮 )2𝒗𝑮 ………(3)

Putting values (i.e. 𝐶𝑑 = 1, 𝜌 = 1.2kg𝑚−3 for air, A = 0.5𝑚2 , 𝑣𝑊 = 5m𝑠 −1 and 𝑣𝐺 = 7m𝑠 −1 )
1
𝑃𝑑 = 2 (1)(1.2)(0.5)(5+ 7)2(7)

𝑷𝒅 = 302.4W

Rolling friction power:

As frictional force due to drag is

𝐹𝑟𝑓 = 𝐶𝑟 mg

As,

P = Fv

So final form becomes:

𝑷𝒓𝒇 = g 𝑪𝒓 m 𝒗𝑮 ………(4)

Putting values (i.e. g=9.81m𝑠 −2 , 𝐶𝑟 = 0.01, m = 100Kg, 𝑣𝐺 = 7m𝑠 −1 )

𝑃𝑟𝑓 = (9.81)(0.01)(100)(7)

𝑷𝒓𝒇 = 68.6W

Hill climbing power:

As frictional force due to drag is

𝐹ℎ = Gmg

As,

P = Fv

So final form becomes:

𝑷𝒉 = m x g x G x 𝒗𝑮 ………(5)

Here, we are not considering hill climbing power because we are fabrication E-bike for plain areas.
So 𝑷𝒉 will be negligible.

𝑷𝒉 = 0

Here, values used in calculations:

m = total mass = 100kg

𝑉𝑓 = final velocity = 25km/h = 6.94m𝑠 −1 (approximately 7 is taken)

𝑉𝑖 = Initial velocity = 0

33
𝐶𝑑 = drag coefficient = 1

𝜌 = density of air = 1.2 kg/𝑚3

𝑣𝑊 = wind speed = 5m𝑠 −1 (assumed)

𝑣𝐺 = Ground speed =25km/h = 6.94m𝑠 −1 (approximately 7 is taken)

𝐶𝑟 = rolling friction coefficient = 0.01

G = steep grade (not used in calculations)

A = frontal area = 0.5 𝑚2

Total power required:

From (1)

P = 𝑃𝑎 + 𝑃𝑑 + 𝑃𝑟𝑓 + 𝑃ℎ

P = 50 + 302.4 + 68.6 + 0

P = 421W

We calculated total power in case of 100kg mass (e-bike including rider) and to attain velocity of
25 km/h, is 421W. But we finalized to buy 350Wbrushless DC electric motor (mid drive), and we
selected Ni-Cd dry cell battery of 12V (2 in quantity, connected in series to have 24V) according to
our motor.

350W motor

At start, no drag power is required but only accelerating and rolling friction powers are required
(approximately 120 W is required to start). Then afterwards no significant values of accelerating and
rolling friction powers are required (because body is now in motion, motor will accelerate it easily
and overcome rolling friction to some extent), so significant power required is only drag power and
we have 350W in total but drag is 302W. So 350W is enough to compensate all powers required.

Here main concept was to optimize the situation i.e. to purchase the motor that can bear all powers
required. Cost is the major problem, that’s why we optimized it, to get 100% out of it.

3.1.2 Drive Type

Hub Motor:
An electric motor that is incorporated in the hub of the wheel and drives it directly. Typically they
are brushless motors (sometimes called brushless direct current motors or BLDCs), which replace the
commutator and brushes with half-a-dozen or more separate coils and an electronic circuit. The
circuit switches the power on and off in the coils in turn creating forces in each one that make the
motor spin. Since the brushes press against the axle of a normal motor, they introduce friction, slow
it down, make a certain amount of noise, and waste energy. That's why brushless motors are often
more efficient, especially at low speeds. Getting rid of the brushes also saves having to replace them
every so often when friction wears them down.

34
Mid Drive:
With this system, the electric motor is not built into the wheel but is usually mounted near (often
under) the bottom bracket shell. In more typical configurations, a cog or wheel on the motor drives a
belt or chain that engages with a pulley or sprocket fixed to one of the arms of the bicycle's crank
set. Thus the propulsion is provided at the pedals rather than at the wheel, being eventually applied
to the wheel via the bicycle's standard drive train.

3.1.2.1 Selection
We selected mid drive, because in mid drive there are various advantages that are:

 Mass Distribution is good (no effect on stability)

 Hill climbing is no problem (as it is geared motor)
 Keeps the motor in the best RPM range

3.1.3 Transmission Type

Various transmissions are used according to their applications that are following:

 Belt Drive
 Geared Drive
 Chain Drive

3.1.3.1 Selection
We selected chain drive transmission for its beneficial aspect i.e.

 Chain drive can attain good power transfer without complications, as no slippage
 Simple fitting
 Economical
 Reliable than belt drive

3.1.4 Battery Type

 Sealed Lead Acid (SLA)
 Nickel Metal Hydride
 Lithium-Ion
 Ni-Cd Dry Cell Battery

Sealed Lead Acid batteries (or SLA) were once the standard battery type for most electric scooters
and electric bicycles. These days, most electric scooters still use SLA batteries, while electric bikes
(which often require human input) have opted for newer battery technologies to keep the bike as
light as possible. This is largely due to the fact that SLA batteries are particularly heavy. While they
are heavier and bulkier, SLA batteries do maintain one advantage: they are easy to come by and they
are inexpensive.

Nickel Metal Hydride batteries (or NiMH) have been around for a while now. They are significantly
lighter than SLA batteries. While there is a jump in the price and while these batteries are usually
designed specifically for their respective electric bikes, they represent many improvements. A NiMH

35
battery has about 2 times the life of a Sealed Lead Acid battery but weights about 30% less. NiMH
batteries need to be recharged about once a month if not in use to maintain their full capacity.

Lithium Ion batteries (or Li-Ion) are the newest technology in batteries. A Lithium battery has a
lifetime of roughly 2-3 times of a Sealed Lead Acid battery. Lithium batteries are the lightest yet, on
average weighing approximately 15% less than NiMH batteries and about 50% less than SLA's.
Lithium batteries also feature the benefit of being largely maintenance free.

3.1.4.1 Selection
Out of all, Li-Ion battery is best because of its various advantages, which are as follows:

 Highest energy density to weight ratio

 Eliminates need for periodic care for a long Life
 Achieves a better cost-performance ratio for battery packs in series than for single cell
 Environment friendly
 Li-ion-Cobalt is the most developed Li-ion technology, with flexible shape options
But we selected Ni-Cd Dry cell battery, having reasonable price and can provide us suitable backup.
(Li-Ion is too expensive)

3.1.4.2 Parameters
The motors require a 24 V supply to work. So, in order to achieve that goal, two batteries
with 12 volts each had to be connected in series to supply the required voltage. The

Table 6: Battery Specifications

Model 𝑨𝑮𝑺

No. of Batteries 02
Volts 12 𝑉
Electric charge 18 𝐴ℎ
Weight of each Battery 5 𝐾𝑔

3.1.4.3 Calculations
Calculations of batteries and motors to find operating time of mower on a single charge is given as:

𝑇ℎ𝑒 𝑝𝑜𝑜𝑙 𝑜𝑓 𝑏𝑎𝑡𝑡𝑒𝑟𝑖𝑒𝑠 ℎ𝑎𝑠 𝑡ℎ𝑒 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 18 𝐴ℎ

𝑇ℎ𝑒 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑏𝑦 𝑚𝑜𝑡𝑜𝑟 = 350 𝑊

𝑇ℎ𝑒 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑜𝑓 𝑏𝑎𝑡𝑡𝑒𝑟𝑦 𝑝𝑜𝑜𝑙 = 24 𝑉

𝑆𝑜, 𝑡ℎ𝑒 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑏𝑎𝑡𝑡𝑒𝑟𝑖𝑒𝑠 = 𝑃 = 𝑉𝐼

36
Where,

𝑃 = 𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟𝑠

𝑉 = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑟𝑎𝑡𝑖𝑛𝑔 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟𝑠

𝐼 = 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑟𝑎𝑡𝑖𝑛𝑔 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟𝑠

𝐹𝑟𝑜𝑚 𝑡ℎ𝑖𝑠;

𝑰 = 𝑷/𝑽

𝑰 = 𝟑𝟓𝟎/𝟐𝟒

𝑰 = 𝟏𝟒. 𝟓𝟖 𝑨

So, the current drawn by motors from batteries is 14.58 amperes. Now, as the current rating
of batteries remains the same in case of series combination, hence;

𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 𝐴𝑚𝑝𝑒𝑟𝑒𝑠 ∗ 𝐻𝑜𝑢𝑟𝑠

So,

𝐻𝑜𝑢𝑟𝑠 (𝑟𝑢𝑛 − 𝑡𝑖𝑚𝑒) = 𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦/𝐴𝑚𝑝𝑒𝑟𝑒𝑠

𝑅𝑢𝑛 − 𝑡𝑖𝑚𝑒 = 18𝐴ℎ/14.58𝐴

𝑹𝒖𝒏 − 𝒕𝒊𝒎𝒆 = 𝟏. 𝟐𝟑 𝒉𝒐𝒖𝒓𝒔

At 50%, the capacity, the dry cell batteries should be recharged for the proper operation
and extended life of the battery. Hence, the actual operation time will be:

𝐴𝑐𝑡𝑢𝑎𝑙 𝑟𝑢𝑛 − 𝑡𝑖𝑚𝑒 = 𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 ∗ 0.5

𝐴𝑐𝑡𝑢𝑎𝑙 𝑅𝑢𝑛 − 𝑡𝑖𝑚𝑒 = 1.23 ∗ 0.5

𝑨𝒄𝒕𝒖𝒂𝒍 𝑹𝒖𝒏 − 𝑻𝒊𝒎𝒆 = 𝟎. 𝟔𝟏𝟓 𝑯𝒐𝒖𝒓𝒔

37
3.1.5 Controller
 Controllers for Brushless Motors:

They have Hall Sensor for speed and commutation. An electronic controller provide assistance as a
function of sensor input, the vehicle speed and the required force. The controllers generally allow
input by means of potentiometer or Hall Effect twist grip, closed-loop speed control for precise
speed regulation, protection logic for over-voltage, over-current and thermal protection. Bikes with
a pedal assist function typically have a disc on the crank shaft featuring a ring of magnets coupled
with a Hall sensor giving rise to a series of pulses, the frequency of which is proportional to pedaling
speed. The controller uses pulse with modulation to regulate the power to the motor.

 Controllers for Brushed Motors:

Brushed motors are also used in e-bikes but are becoming less common due to their intrinsic lower
efficiency. Controllers for brushed motors however are much simpler and cheaper due to the fact
they don't require hall sensor feedback and are typically designed to be open-loop controllers.

3.1.5.1 Selection
As we are using a brushless direct current (BLDC) motor so we will use a controller according to the
above mentioned specifications.

3.1.5.2 Parameters

Table 7: Specifications of Motors

Model 𝒁𝒀 − 𝟎𝟔

Volts 24𝑉
Power 350𝑊
Maximum Current 25𝐴
Under Voltage Protection 20𝑉

3.1.6 Bicycle Frame

As the main objective of the frame is to be light weight therefore we selected a phoenix bicycle. Also
it is easier to alter a bicycle frame rather than manufacturing a whole light weight frame for E-bike.
No doubt a carbon fiber frame would suit us in best manner but that would be very difficult for us
for manufacture that frame in this short time frame of Final year project therefore we decided to
modify an already manufactures frame of phoenix

3.1.6.1 Alterations
As described in the previous section we decided to make alterations with the frame of phoenix
bicycle. Our alterations include the addition of following parts to the frame

1. Mounting – To hold the motor firmly

2. Extended length axle – to accommodate the mounting and provide space for motor fitting
3. Motor – To provide power in case of throttle mode
4. Axle cups – For proper adjustment of mounting and alignment of motor and freewheel gears
5. Batteries – To provide backup for motor power
6. Throttle – For rider input of required power and speed
38
 7. Controller – For the processing of electric signals e.g. to motor and from throttle etc.
8. Back gear assembly – To adjust between required torque and speed
9. Idler – To provide proper tension in chain
10. Free wheel – Two sprocket free wheel with two chain mechanism

As few of the alterations were ready made and we only have to properly install them properly
but others like mounting have to be designed first and then installed. An overview of the
installation and designing will be provided in next section.

3.1.6.2 Parameters

Table 8: Design Parameters of Gears

Free wheel First gear 44

teeth
Second gear 38
teeth
Motor gear Gear 12
teeth
First gear 28
teeth
Second gear 24
teeth
Third gear 21
teeth
Back gear Assembly Forth gear 18
teeth
Fifth gear 16
teeth
Sixth gear 14
teeth

The parameters of the mounting of motor and extended length axle will be provided in the 3D
model.

3.1.7 Solar Panels

Solar panels are available in the markets from four panel system to ten panels directly attached to
provide rapid charging. They are in the range from 120 watt to 300 watt attached with an inverter to
get power according to the requirement of your battery.

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3.1.7.1 Parameters
The parameters of panels used for solar e-bikes are given below:
Table 10: Specifications of Solar Panels

Panels 4 to 10
Availability 120 – 300 Watts
Price per watt of panel $1-2
Inverter Price $43–80

3.1.8 Throttle
The throttle is quite similar to the throttle used in motorbike or scooter. When the throttle is
engaged the motor provides power and propels you and the bike forward. The most prominent
advantage of using it, is that it gives you the freedom to either ride by pedaling or just sit and enjoy a
free ride by using throttle.

Figure 15: Throttle used in E-bike

FABRICATION
The fabrication involves these steps:

Step 1: Purchasing of the components available in the market

Step 2: Fabrication of the products unavailable in the market

Step 3: Assembling all the parts according to the required design

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3.1.9 Purchasing of Components:
The first step includes the purchasing of the components. We had a complete overview of the
market but we were unable to get desired parts so we had to search internet and eventually
imported components from China.

 Throttle
 Motor
 Controller

3.1.10 Fabrication of non-ready made parts

3.1.10.1 New Extended Axle

The previous axle holds just a single chain sprocket mechanism only for pedaling but we needed an
axle that would provide us free space for motor installation and also to hold our designed mounting
for the support of motor. We designed it on Sketch up and then fabrication was done.

Figure 16: Design of Extended Axle

3.1.10.2 Mounting

To hold motor on the bicycle we need a part that can hold it firmly during the riding and also provide
proper alignment of gear of motor and gear of free wheel otherwise chain will not settle properly and
power transmission would not be possible. Mounting should be designed that it could provide
maximum support with minimum weight and space therefore we designed a hollow mounting of light
weight material. For that we designed a model on Sketch Up Pro and fabricate it.

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Figure 17: 3D View

 Figure 18: Front View

Figure 19: Top View

Figure 20: Side View

3.1.10.3 Free Wheel

To have a smooth rotation of both pedals and motor, we need a free wheel that could support two
chains and sprocket mechanism. For that a 2D AutoCAD model was first designed to check the
dimensions according to the extended axle. Weather both will fit. Than fabrication was done

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 Figure 21: Free Wheel CAD Model

3.1.11 Assembly
Assembly include all the parts to be fixed on the Frame with the help of welding or Nut & Bolts in a
specific manner where they can perform their job properly.

3.1.11.1 Extended Axle Fitting

Figure 22: Extended Axle Fitting

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3.1.11.2 Flywheel Fitting

Figure 23: Fitting of Flywheel

3.1.11.3 Motor Fitting

Figure 24: Picture demonstrating E-bike motor fitting

3.1.11.4 Controller & Wire Fitting

Figure 25: Controller and wire fitting

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3.3 COST ANALYSIS
The cost Analysis Includes the Cost which has been spent on the Purchasing of Ready-made
elements, Manufacturing of some parts, Labor, Transportation, etc. Some of the analysis are
given below:

Table 9: Cost Analysis

Component Expenses in PKR

Motor 4000
Free wheel 1500
Center axle 1000
Crank arms 800
Controller 3000
Batteries 3500
Throttle 1000
Axle cups 100
Mounting 500
Casing 200
Back gear 300
Labor 1000
Transportation 1000
Chain 200
Bearings 100
Custom 4000
Paint 250
Bolts, Nuts 100
Wheels 700
Others 500
Total 23750

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4 RESULTS & DISCUSSION

4.1 COST ANALYSIS OF GASOLINE AND E-BIKE MILEAGE:

4.1.1 For Gasoline bike:

Table 13: Gasoline Bike Specifications

Mileage 45km/liter
Petrol cost Rs. 79/liter
Cost of 1km (without maintenance) Rs. 1.75
Maintenance cost ( after 1500 km) Rs. 700
Maintenance cost /km Rs. 0.47
Net cost of 1 km (with maintenance) Rs. 2.22

4.1.2 For E-Bike:

Table 14: E-bike Specifications

Mileage 15km/charge
Unit of electricity consumed 0.432 kWh
Cost of 1 unit (kWh) Rs. 12
Cost of charging Rs. 5.184
Maintenance cost for month Negligible
Cost of 1 km (WAPDA) Rs. 0.69

Above calculations clearly shows that E-bike is cheaper than gasoline bike. But It also has some
demerits like repeated charging and short life of electrical parts as compared to long life mechanical
parts. Developed countries are working on these electrical bikes to maximize the efficiency and
performance along with minimizing the charging and losses issues.

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4.1.3 Comparisons between Gasoline bike and E-bike:
Further comparisons between these two bikes (in form of graphs) are given below:

Speed Comparison in Km/hr

90
80
70
60
Gasoline Bike
50
E-bike
40
E-bike
30
20
10
Gasoline Bike
0

Speed

Cost Comparison in Rupees

120000

100000

80000
Gasoline Bike
60000 E-bike
40000 E-bike

20000
Gasoline Bike
0

Cost (yearly)

Backup Capacity Comparison in Km

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 400
350
300
250 Gasoline Bike
200 E-bike
150 E-bike
100
50
Gasoline Bike
0

Backup Capacity

Life Comparison in years

10

6 Gasoline Bike
E-bike
4 E-bike

2
Gasoline Bike
0

Life

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 4.2 EXPERIMENTAL RESULTS:
In the designing phase basic theoretical calculations were done according to requirement. After
proper assembling and fitting the bike has to be tested to satisfy these calculations. Theoretical and
practical calculations always differ due to uncertain losses which cannot be theoretically considered.
Therefore practical values are always lesser than theoretical values .Listed below are the
experimental results:

Top speed: 30-35 km/hr

Mass of batteries: 9 kg

Mass of bike: 22 kg

Maximum load tested: 110 kg (Including the weight of rider)

Kilometers travelled in single charging: 15 km

4.3 OVERALL COST AND TIME RELATION:

In any bike, if we want to have total cost, there is always three type of costs i.e. Running cost (𝐶𝑅 ),
Maintenance cost (𝐶𝑀 ) and Bike cost (𝐶𝐵 ). So

Total cost = 𝐶𝑅 + 𝐶𝑀 + 𝐶𝐵

Also there is define period, after which performance of bike reaches to zero (as life of each part is
defined) and periods of E-bike and gasoline bike are 2 years and 10 years respectively. Means in case
of E-bike, after 2 years there must be replacement of batteries and chances of failure in performance
of motor. While gasoline bike is good enough to bear such circumstances i.e. it can run till 10 years
of operating tenure.

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Expenses on Yearly Basis

70000
60000
50000
40000
30000 Gasoline Bike
20000 E-bike
10000
E-bike
0
Gasoline Bike
Running Cost
Maintenance
Cost Bike cost

5 FUTURE RECOMMENDATIONS AND CONCLUSIONS

5.1 CONCLUSIONS:
Our main objective was to build such a bike which would give zero emissions and promote physical
health in an environmental friendly way. Being able to complete this project, it offered a great
experience to the entire team. However, one lesson learned is that the practical field experience is
quite different from the academic experience. This project could not have been accomplished
without the strong determination and efforts of whole team during critical phases. The project
valued us the practical experience and we have learned how dedication and hard work pay off.
The most important phase was the calculation and fabrication since the whole working of the bike
was depending upon it. The selection of the motor for bike and the alignment and balancing of the
chain and gears were also analyzed critically and by using sound engineering approach. The phoenix
bike we are using was found to have strong and firm structure and light weight. It was found to be
suitable for our project because light weight was our prime purpose.

5.2 CHALLENGES FACED:

Although the project was completed successfully and on time yet there were several challenges that
we encountered during the completion of our project.

 The first and the foremost challenge were the motor selection calculations and the type of
transmission to be used. Since, the working of our bike was solely dependent upon the
proper weight distribution because uneven weight distribution will cause improper
operation of bike balancing during riding.
 Secondly, the motor that we purchased was imported one and not a local assembled. Some
motors that we found in local market were not suitable either by size or by specifications

50
 therefore we had to order our best suitable motor from china which requires almost a
month to for delivery.

 Since the working of bike requires proper alignment of gears and chain to ensure proper
power transmission. Alignment was one of the major problems we faced during assembling
due to which we were not able to continue our further process. This issue was resolved by
making amendments in our designed extended axle

 Core problem of the project was the finalizing and deciding the proper mechanism for the
function of both pedal and motor at the same time. As our design was to assist the throttle
mode with pedals therefore the mechanism should be such that the pedals will also help in
riding along with the throttling of electric motor. Using of bearings and lock collars we were
able to make out solution for this problem.

 Another problem was faced during the initial running of the bike. The problem was
associated with the wiring of controller as we are not that much familiar with the field of
electronics but with the help of our advisor and some hit and trial methods we were able to
resolve these issues.

5.3 FUTURE RECOMMENDATION:

E-bikes are becoming popular in all over the world, as people are working on it to achieve best out of
it. Our project can be a foundation for further development and research on it. In future, there may
be ample of thoughts which can be considered in future. Some future recommendations are as
follows:

 The future of Pakistan can be very green if the vehicles utilizing electric energy are
introduced on the roads reducing the dangerous emissions. It will also be economical since
electric charge is a cheap fuel, as compared to gasoline.

 Charging stations should be provided in drive ways as to promote the usage of electric bikes
which are friendlier to health and environment.

 New electronic technologies should be introduced in which the charging time should be
reduced so that the only disadvantage of the e-bike will be tackled. European countries are
investing in this field to secure a better future and reduce their demand of petroleum.

 Companies of bicycle should surely introduce this e-bike as they are an outstanding hybrid of
bicycles and motorbikes and are also reasonable in price.

 E-bikes are an alternative to promote health along with your busy schedule routine. People
have moved towards motor bikes to reduce their time of travelling but have become
unhealthy while E-bike provides you both advantages to less travelling time and better
health from physical exercise (on your choice or after batteries are out).

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REFERENCES

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