2018 International Conference On Advances in Communication and Computing Technology (ICACCT)

Amrutvahini College of Engineering, Sangamner, Ahmednagar, India. Feb 8-9, 2018

Design and analysis of Hub Dynamo For Electric

Vehicle
Manoj K. Jadhav1, Saurabh A. Jadhav2, Akash A. Kate3, Mr.Sunny G. Gholap4
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Students, 4Asst.Prof. At SVPM’s COE, Malegaon (BK)
Department of Electrical Engineering, Savitribai Phule Pune University.
SVPM’s COE, Malegaon (Bk),
Baramati, India
Jadhavmanoj712@gmail.com1,jadhavsaurabh121@gmail.com2,akashkate49@gmail.com3,sunny.gholap@gmail.com4

Abstract— Aim of the paper to design the variable speed
permanent magnet based hub generator. This dynamo is suitable
for supplying power from ebike motion and use to driving hub
motor. The hub dynamo have a hub axel, a hub housing rotatable
mounted around the hub axel with bearing. The power
generating mechanism with coil fitted to hub axel that has
connected to output wires. In this hub dynamo, the magnet
rotates with the speed of ebike; here we get power output from
dynamo. We use that power for battery charging of ebike with
proper charging circuitry. Hence we can improve the
performance of ebike. In this paper, we are going introduce the
power output of our own designed hub dynamo.
Keywords— Hub dynamo,Ebike,Generation,Drum,Coil
coiling assembly. Rotor is wheel with permanent magnets and
stator with coils. The whole model of dynamo is brushless.
The stator is combination of two coils arranged in parallel
connection. Stator has two coils each 12v, 1amp.Dynamo
produce alternating current (AC), but the battery accepts only
DC supply. The solution is to include a rectifier, which is a
device that changes the dynamo’s AC output to DC, so it can
be stored in the battery.Rectifire is stationary device. We use
regulator to regulate the variable generated voltage of dynamo
to provide constant AC supply to charging unit of battery.
Nowadays, in market combination of regulator and rectifier
circuit are available for charging system. This system
performs work preciously for battery charging.

I. INTRODUCTION
From 1950s various types of dynamo are famous.
Standard bottle generators running on the tire tread or rim.
This dynamo has problem about frictional losses at the wheel.
This type of generators is defective in rainy season. Hub
generator is very easy way to generate power for bicycle’s
front wheel. Now a day’s ebikes are available in market. They
powered by batteries, so they have limited running distance.
Solution for this problem of ebike, we are going to increase
the running average of ebike with the help of hub dynamo. In
this dynamo generated power used for mainly battery charging
purpose. Otherwise, we will use that power for head light and Fig.1 Dynamo arrangement in Ebike
indicator light. The device is very suitable for the village and
those areas where electricity is not available in time. It can be III. PRINCIPLE OF OPERATION
a completely self-energy source with less maintenance
requirement. Our designed dynamo is suitable for fitting in In our project, rotor has magnets which are rotating part.
ebike’s front wheel hub assembly. Stator has coil assembly. Rotary part rotates around the stator
coil with flux, which are cuts by the stator coils. As per
II. DESIGN CONCEPT principle of generator, some current is induced in coils. From
that coils, we collect the output for charging purpose.
A. Requirement for hub dynamo
For designing the hub dynamo we are going to use coil, As ebike is start, speed of the ebike increases, the output of
magnets and Front wheel hub assembly of bike. Stator plate the dynamo also increases. The current is conducted by the
assembly & coils are used in this dynamo for generation wiring harness to the regulator. This regulated supply reach to
purpose. the rectifier as alternating current. Rectifier rectifies that
supply, so only the positive voltage reaches to the battery.
B. Model of hub dynamo
Dynamo consists of coils. It has permanent magnet with
strong Flux strength. Simply it is dynamo with rotor, stator
and

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 IV. MEASUREMENT OF HUB DYNAMO We are going to fit the hub dynamo in the Front
TABLE I. DIMENSIONS OF HUB DYNAMO Wheel of the bike. By the use of this dynamo we can generate
AC power at low rpm and fed to the controller. This is not
Stator Core Od 140mm much large power, so we use capacitor bank or other step up
equipment for better performance of power supply. Controller
Stator Core Id 114.7mm consist various electric equipment such as rectifier, capacitor
Magnet Length 50mm bank, which is used to supply power to the battery. Battery is
used for powered to hub motor of vehicle.
Magnet width 25mm
Rotor core OD 160mm
Rotor core ID 140mm
Air gap 0.3mm

Fig.4 Stator and Rotor of Dynamo

Fig.2 Component of Hub Dynamo

VI. SETUP OF PROJECT
TABLE II We are going set up hub dynamo in front wheel of
ebike. But for result analysis purpose we are create some
SPECIFICATION OF HYB DYNAMO driving conditions in experiment room related to ebike speed.
Coil 12v (2 coil) Because of it is not possible to take reading at motion
Voltage rating 24v condition of ebike. In this setup, we create No load condition
Current rating 2 amp.(max) for taking reading of generated output of hub dynamo.
Average Speed of wheel 40Km/hr.
regulator Variable 24v to stable 12v

V. BLOCK OF HUB DYNAMO

Fig.5 setup of Hub Dynamo

Fig.3 Block digram of Hub Dynamo
As shown in above setup, we use small motor as exciter to
create required speed of wheel as similar in ebike. Here we

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used 12v/35w blub for result purpose. Also we calculated the
output power of dynamo using multi-meter. Speed is varied by
using motor controlling unit which can be seen in fig.5. We
have Vmax=24V but due to some variable flux linkage and
various speed conditions, we get voltage up to Vmax= 15V and
Imax=1.8 amp.
we will increase running average of the ebike. As compared to
other renewable energy sources, dynamo is noiseless,
pollution free. From the analysis result, hub dynamo is capable
to recharge the battery unit with proper charging system.
REFERENCES

[1] Christoph Valerius, Krupar and Wolfgang Schwarz Faculty of Electrical

VII. CALCULATION
For calculation purpose in setup, we create some
conditions. We rotate hub dynamo with exciter and that speed
of rotation is measured in m/min. with the help of tachometer.
This m/min is then converted into Km/hr. as same as bike
speed.
We consider regular average speed of ebike as
40km/hr. For this condition, we have to rotate exciter at 650
m/min
1] 350 m/min- 350/60 = 5.83 m/sec = 20.98 km/hr.
2] 500 m/min- 500/60 = 8.33 m/sec = 30 km/hr.
3] 650 m/min- 650/60 = 10.83 m/sec = 39 km/hr.
4] 1000m/min- 1000/60= 16.66m/sec = 60 km/hr.
From above various speed conditions, we calculate output of
generator.
VIII. RESULT
The outputs of dynamo are as shown in table below.
TABLE III. SPEED AND GENERATED VOLTAGE OF HYB
DYNAMO
Sr. Speed Generated Voltage
No. (Km/hr.)
1 20
2 30
3 40
4 60
Engineering and Information Technology Technische Universitat
Dresden Helmholtzstr. 1001069 Dresden, Germany, “Electronic Power
Management for Bicycles” 2005.
[2] Vivek Kumar, Dr. Prakash Verma “Design And Fabrication Of
Planetary Drive Magnet Pedal Power Hub-Dynamo ” September 2015
[3] Vivek Kumar1, Dr. Prakash Verma Research scholar (Machine Design),
Professor, ,Department of Mechanical Engineering, Jabalpur
Engineering College, Jabalpur (MP),India. “Finite Element Analysis Of
Pedal Power Hub Dynamo” December 2015
[4] Noboru Niguchi, Katsuhiro Hirata, Shugo Nobuhara, and Kazuya
MoritaOsaka University, Suita, Osaka 5650871, Japan “Power
Generation Performance Analysis of a Hub Dynamo Considering a
Magnetic Hysteresis”. JUNE 2017
[5] Norman Borchardt Otto-von-Guericke University Institute of Mobile
Systems / Chair of Mechatronics Magdeburg, Germany
norman.borchardt@ovgu.de Roland Kasper1, Wolfgang Heinemann
Otto-von-Guericke University Institute of Mobile Systems / Institute
Director1 Magdeburg, Germany
“Design of a Wheel-hub Motor with Air Gap Winding and Simultaneous
Utilization of all Magnetic Poles.”
[6] David G. Dorrell University of Technology Sydney Sydney, Australia
david.dorrell@uts.edu.au. Mircea Popescu Motor Design Ltd Elsmere,
UK. “Drive Motor Designs for Electric Motorcycles.”
[7] J. Jürgens, A. Brune, B. Ponick “ Electromagnetic Design and Analysis
of a Salient-Pole Synchronous Machine with Tooth-Coil Windings for
Use as a Wheel Hub Motor in an Electric Vehicle.”
S.Abirami, S.Madhu bala, R.Jaya priya Post Graduate Students, School
of Electrical Sciences,Department of Electrical and Electronics
Engineering, Kongu Engineering College, Perundurai, Erode – 638 052.
“Design of BLDC Hub Motor Using FEM Analysis”
(V) [8] W. CHLEBOSZ G. OMBACH Brose Fahrzeugteile GmbH
“ANALYSIS AND OPTIMIZATION OF DRIVE SYSTEM USED IN
5V ELECTRIC BIKE”
7V
10V
12V

14
12
10
Voltage

8
voltage
6
4
2
0
0 20 30 40 60
Speed

Fig.6 Speed vs. Generated voltage of hub dynamo

IX. CONCLUSION
In this paper, we discussed about design concept and
manufacturing of hub dynamo. By using these, we can
improve the performance of ebike. Hence using this dynamo

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