ELECTRIC BICYCLE

PROJECT REPORT

“Submitted In Partial Fulfillment of the Requirement for the Award

of the Degree of the Bachelor of Technology in Mechanical Engineering
to
Rajasthan Technical University, Kota”
SUBMITTED BY
Ajay Sharma (17ME001)
Manish Kumar Mahawar (17ME013)
Omprakash Saini (17ME016)
Pankaj Kumar Verma (17ME017)
Vishnu Kumar Kholia (17ME025)
Syed Qaim Abbas (18ME200)

UNDER THE GUIDANCE OF

Mr. Sonu Saini

Mr. Sourabh Jain
Assistant Professor
(Mechanical Engineering)

Department of Mechanical Engineering

Anand International College of Engineering, Jaipur
2020-21
 Acknowledgment
It is a great pleasure and privilege for me to present this practical training report carried
out at “Electric Bicycle” and submitted in partial fulfilment of the requirement for the
award of the degree of the Bachelor of Technology in Mechanical Engineering to
Rajasthan Technical University, Kota.

We express our sincere thanks to H.O.D. Mechanical Engineering Department of our

college for his kind co-operation and valuable suggestions.

We are very much thankful to Mr. Sonu Saini and Mr. Sourabh Jain, Project Guide of
our Projects for his encouragement and inspiration at every step to a great extent. This
training would not have been possible without his support and able guidance. He was
very supportive throughout the given period in sharing their knowledge and technical
aspects.

Finally, we express earnest and sincere thanks to the whole “Mechanical Engineering
Department” for the generous help and co-operation in every possible manner.

Name of Students: College ID

1. Ajay Sharma 17ME001
2. Manish Kumar Mahawar 17ME013
3. Omprakash Saini 17ME016
4. Pankaj Kumar Verma 17ME017
5. Vishnu Kumar Kholia 17ME025
6. Syed Qaim Abbas 18ME200
 Candidate’s Declaration
I hereby declare that the work, which is being presented in the project report entitled
“ELECTRIC BICYCLE”submitted in partial fulfilment of the requirement for the
award of the degree of the Bachelor of Technology in Mechanical Engineering to
Rajasthan Technical University, Kota is a record of my training carried under the
Guidance of Mr. Sonu Saini and Mr. Sourabh Jain, Assistant Professor, Anand
International College of Engineering, Jaipur..

Ajay Sharma (17ME001)

Manish Kumar Mahawar (17ME013)
Omprakash Saini (17ME016)
Pankaj Kumar Verma (17ME017)
Vishnu Kumar Kholia (17ME025)
Syed Qaim Abbas (18ME200)

Mr. Sonu Saini (Guide)

Mr. Sourabh Jain (Co-Guide)
Assistant Professor (Mechanical Engineering Department)
Anand International College of Engineering, Jaipur
 Abstract
An electric bicycle uses an electric motor for the purpose of moving. On this bicycle,
people do not have to use their muscular force to move. It uses electrical energy for
motion. They are also known as e-bikes. There are many varieties of electric bicycles.
Some of these bikes have a rechargeable battery. This makes it easy to power the bike
whenever you want. They make use of stored electrical energy in some or the other form.
Due to this form of energy, the bikes have more power and speed. These bikes are more
convenient than regular ones. Many kinds of e-bikes are available worldwide, but they
generally fall into two broad categories: bikes that assist the rider’s pedal-power (i.e.,
pedelecs) and bikes that add a throttle, integrating moped-style functionality. Both retain
the ability to be pedaled by the rider and are therefore not electric motorcycles’-bikes are
the electric motor-powered versions of motorized bicycles, which have been in use since
the late 19th century. In the 1890s, electric bicycles were documented within various U.S.
patents. “6-pole brush-and-commutator direct current (DC) hub motor mounted in the rear
wheel”.Two years later, in 1897, Hosea W. Libbey of Boston invented an electric bicycle
(U.S. Patent 596,272) that was propelled by a “double electric motor”.
There is growing demand for Electric Bikes in India as there will be less air pollution,
lower maintenance cost and reduced noise using Electric-Bikes. Structural Analysis is
carried out to support the product development team in validating the designs and
improving the existing designs.
 CONTENTS

 Acknowledgement
 Candidate’s Declaration
 Abstract
 List of Figures
1. Chapter – 1
1.1. Introduction
1.2. Why We Use Electrical Bicycle
1.3. Classes of Electrical Bicycle
1.3.1. Class-1 Pedal Assist
1.3.2. Class-2 Throttle
1.3.3. Class-3 Speed Pedelecs
1.4. Objective of Electrical Bicycle
2. Chapter – 2
2.1. Literature Review
2.2. History
2.3. Overview of Electrical Bikes
3. Chapter – 3
3.1. Components of Electrical Bicycle
3.1.1. Motor
3.1.2. Controller
3.1.3. Battery
3.1.4. Throttle
3.1.5. Pedal Assist
3.1.6. Sprockets
3.1.7. Electrical Brake
3.1.8. Display and Switch
3.2. Principle of Electrical Bicycle
3.3. Working
3.4. Working of DC Motor
3.4.1. Rotor
3.5. Project
 3.6. Battery
4. Chapter – 4
4.1. No Load Speed Calculation
4.2. Required Power to Drive Bicycle
5. Chapter – 5
5.1. Advantages
5.2. Disadvantages
 Future Scope
 Conclusion
 References
 List of Figures

1) Fig 2.1 - No. of articles published per year

2) Fig 2.2 – No. of electric bikes sold in thousand

3) Fig 3.1 – Crank Driven Motor

4) Fig 3.2 – Hub Moto

5) Fig 3.3 – Brushed and Brushless Driven Motor

6) Fig 3.4 - Friction Drive Motor

7) Fig 3.5 – Controller

8) Fig 3.6 – Throttle

9) Fig 3.7 – Pedal Assist

10) Fig 3.8 – Electric Brakes

11) Fig 3.9 - Block diagram of the Electric bicycle construction process

12) Fig 3.10 - Rotor Magnet Cross Section

13) Fig3.11 – Picture of EV36

14) Fig3.12 – Hub Motor Kit

15) Fig3.13 – After Complete work on EV-36

16) Fig3.14 - Nickel Cadmium Battery

17) Fig3.15 – Nickel Metal Hydride Battery

18) Fig3.16 – Lithium-ion Battery

19) Fig3.17 – Lead Acid Battery

 Chapter – 1
Introduction
General information: An E-bicycle is one with an electric motor (attached to the
bottom bracket or front wheel) that assists the rider with their pedaling. This means that
while you're still getting a workout – and enjoying the scenery – you don't need to pedal
nearly as hard, especially up hills. An electric bicycle, also known as an e-bike or booster
bike it has integrated electric motor which can be used for propulsion. It has great variety
of different types but some common are:- 1. Small motor-pedal power 2. Powerful bikes
closer to moped E-bikes use rechargeable batteries and the lighter varieties can travel up
to 25 to 32 km/h(16 to 20 mph), depending on the laws of the country in which they are
sold, while the more high-powered varieties can often do in excess of 45 km/h (28 mph).
Depending on local laws, many e-bikes (e.g., peddles) are legally classified as bicycles
rather than mopeds or motorcycles. This exempts them from the more stringent laws
regarding the certification and operation of more powerful two-wheelers which are often
classed as electric motorcycles. E-bikes can also be defined separately and treated under
distinct Electric bicycle laws.
E-bikes are the electric motor-powered versions of motorized bicycles, which have been
in use since the late 19th century. Some bicycle-sharing systems use them.
An electric bike or scooter is a battery operated vehicle that is very economical with low
maintenance cost and zero pollution. Electric two wheelers use the electrical technology
of rechargeable battery that converts the electrical energy into mechanical energy. The
battery of an EV can be charged easily using a power connection. There are many
possible types of electric motorized bicycles with several technologies available, varying
in cost and complexity; direct-drive and geared motor units are both used. An electric
power-assist system may be added to almost any pedal cycle using chain drive, belt drive,
hub motors or friction drive. The power levels of motors used are influenced by available
legal categories and are often limited to fewer than 700 watts.
Electric bicycles use rechargeable batteries, electric motors and some form of controls.
This can be a simple as an on-off switch but is more usually an electronic pulse width
modulation control. Electric bicycles developed in Switzerland in the late 1980s for the
tour de sol solar vehicle race came with solar charging stations but these were later fixed
on roofs and connected so as to feed into electric mains. The bicycles were then charged
from the mains, as is common today. Battery systems in use include lead acid, NiCd,
NiMH and Li-ion batteries.
Electric motorized bicycles can be power-on-demand, where the motor is activated by a
handlebar mounted throttle, and/or a peddles, also known as electric assist, where the
electric motor is regulated by pedaling. These have a sensor to detect the pedaling speed,
the pedaling force, or both. An electronic controller provides assistance as a function of
the sensor inputs, the vehicle speed and the required force. Most controllers also provide
for manual adjustment.
Range is a key consideration with electric bikes, and is affected by factors such as motor
efficiency, battery capacity, efficiency of the driving electronics aerodynamics, hills and
weight of the bike and rider. The range of an electric bike is usually stated as somewhere
between 7 km to 70 km and is highly dependent on whether or not the bike is tested on
flat roads or hills.
Some experiments have also been undertaken with super capacitors to supplement or
replace batteries for cars and some SUVS.

Why We Use Electric Bicycle:

Global warming is a major concern all around and to save Mother Earth, there are several
policies, promises and pledges. With the ever increasing emission of greenhouse gases,
there is an increased fear of environment pollution at every step. With modern technology
and innovation, transportation and communication have undergone a paradigm shift.
Along with this, we are also experiencing the negative effects of industrialization in the
form of global warming. Under these circumstances, when there are traffic jams, when
you need to run an errand at an odd hour of the day, when you need to go to workplace
quickly, you stumble and fumble as there are so many vehicles emitting soot and CO2
polluting the air incessantly. With increased number of fossil-fuel dependent vehicles,
they not only add to greater level of pollution but are also leading to depletion of fuel
resource. It is here that automobile companies felt the need to innovate motorized vehicle
that will get charged through electricity and will not be depending on fossil fuels.

This led to expansion of eco-friendly initiatives and many automobile manufacturing

companies invested in research and development to bring forth electric bikes that will
help people save a few bucks by reducing consumption of already spiraling fuel price,
besides fighting global warming. Most electric bikes are emission free bikes and this is
the USP of the company’s manufacturing them in these days of global warming. It will
not add to urban pollution. The only thing required is to keep this bike charged with a
battery. Electric bike manufacturing is considered as a grass root movement away from
fossil fuels.
It is evident that electric bikes can reduce the air pollution. But there are also some
environmental problems caused due to these electric bikes. Disposal of worn out batteries
can be a cause of major concern for environmentalists. If this can be addressed, electric
bikes can definitely reduce environmental pollution.

Classes of Electrical Bicycle:

E-bikes are classed according to the power that their electric motor can deliver and the
control system, i.e., when and how the power from the motor is applied. Also the
classification of e-bikes is complicated as much of the definition is due to legal reasons of
what constitutes a bicycle and what constitutes a moped or motorcycle. As such, the
classification of these e-bikes varies greatly across countries and local jurisdictions.
I. CLASS 1- Pedal assist: The most common type of electric bike is the pedal assist
or pedelecs. The rider pedals the bike normally while a motor provides assistance,
increasing the power transmitted to the rear wheel. The pedaling takes far less
effort than it normally would, even in high gears, which allows for higher speeds
and effortless climbing over steep hills.
Settings can control the amount of assistance the rider desires but to be considered
a Class 1 e-bike in most of Europe, the system cannot provide assistance over 25
kilometer per hour (kph) or approximately 15 miles per hour. In the US this class
is limited to approximately 32 kph or 20 mph. A class 1 designation allows these
bike to be used on most roads and paths where normal bikes are allowed and do
not require any additional licensing.
II. CLASS 2-Throttle: Much like a motorcycle or scooter, a throttle operated e-bike
propels the bike forward without any additional pedaling from the rider. Most can
provide a variable amount of power depending how far the throttle is pushed.
These are much less common than their peddle assist counterparts as many
countries have laws that prohibit them entirely.
The European union requires an e-bike only provide power while the pedals are
moving forward, so throttle e-bike are most common in the United States and
china where little legislation exists to limit their use.
III. CLASS 3-Speed Pedelecs: The design of a speed pedelecs is similar to a standard
pedelecs but as the name implies, they allow for a higher top speed of 45 kph or
approximately 28 mph. In many areas this class of e-bike is considered a motor.

Objective of Electrical Bicycle:

 In human transportation as a personalized vehicle.
 For inter departmental transportation in huge campuses.
 In Industries for different level personnel to move around to inspect the work
progress.
 In hospitals, Airports, Shopping malls, IT campuses, Hotels & Resorts, Power
stations, manufacturing units, etc.
 Light weight & easy to control, makes convenient for use by anyone.
 Controlled speed ensures rider’s safety.
 Can be used by old aged demography.
 On site charging facility, No need to visit fuel station.
 Chapter – 2
Literature Review
Electric powered bicycle only depends on power that charge in battery to make it
functions unless using the manual way to move it. The project is wanted to change the
way a battery charge to get the electric power and generate electricity to move the bicycle
with optimum energy.
History:
In the 1890s, electric bicycles were documented within various U.S. patents. For
example, on 31 December 1895, Ogden Bolton Jr. was granted U.S. Patent 552,271 for a
battery-powered bicycle with "6-pole brush-and-commutator direct current (DC) hub
motor mounted in the rear wheel". There were no gears and the motor could draw up to
100 amperes (A) from a 10-volt battery.

Two years later, in 1897, Hosea W. Libbey of Boston invented an electric bicycle (U.S.
Patent 596,272) that was propelled by a "double electric motor". The motor was designed
within the hub of the crankset axle. This model was later re-invented and imitated in the
late 1990s by Giant Lafree e-bikes.

By 1898 a rear-wheel drive electric bicycle, which used a driving belt along the outside
edge of the wheel, was patented by Mathew J. Steffens. Also, the 1899 U.S. Patent
627,066 by John Schnepf depicted a rear-wheel friction “roller-wheel” style drive electric
bicycle. Schnepf's invention was later re-examined and expanded in 1969 by G.A. Wood
Jr. with his U.S. Patent 3,431,994. Wood's device used 4 fractional horsepower motors;
connected through a series of gears.

Torque sensors and power controls were developed in the late 1990s. For example,

Takada Yutky of Japan filed a patent in 1997 for such a device. In 1992 Vector Services
Limited offered and sold an e-bike dubbed Zike. The bicycle included NiCd batteries that
were built into a frame member and included an 850 g permanent-magnet motor. Despite
the Zike, in 1992 hardly any commercial e-bikes were available.

Yamaha, a Japanese automotive giant built one of the early prototypes of e-bike back in
1989 and invented the pedal assist system in 1993.

Production grew from 1993 to 2004 by an estimated 35%. By contrast, according to

Gartner, in 1995 regular bicycle production decreased from its peak 107 million units.
American car icon, Lee Iacocca founded EV Global motors in 1997, a company that
produced an electric bicycle model named E-bike SX and it was one of the early efforts to
popularize e-bikes in the United States.

Some of the less expensive e-bikes used bulky lead acid batteries, whereas newer models
generally used NiMH, NiCd, and/or Li-ion batteries, which offered lighter, denser
capacity batteries. Performance varies; however, in general there is an increase in range
and speed with the latter battery types.

By 2001 the terms e-bike, power bike, "pedelecs", pedal-assisted, and power-assisted
bicycle were commonly used to refer to e-bikes. The terms "electric motorbike" or "e-
motorbike" refer to more powerful models that attain up to 80 km/h (50 mph).

In a parallel hybrid motorized bicycle, such as the aforementioned 1897 invention by

Hosea W. Libbey, human and motor inputs are mechanically coupled either in the bottom
bracket, the rear wheel, or the front wheel, whereas in a (mechanical) series hybrid cycle,
the human and motor inputs are coupled through differential gearing. In an (electronic)
series hybrid cycle, human power is converted into electricity and is fed directly into the
motor and mostly additional electricity is supplied from a battery.

By 2007 e-bikes were thought to make up 10 to 20 percent of all two-wheeled vehicles on

the streets of many major Chinese cities. A typical unit requires 8 hours to charge the
battery, which provides the range of 25 to 30 miles (40 to 48 km), at the speed of around
20 km/h.

Overview of Electrical Bikes: The e-bikes in the thesis are referred to as three
different types: bicycle style e-bikes, hybrid style e-bikes, and scooter style e-bikes. All
three types of e-bikes have similar characteristics: two wheelers, electric assisted power,
and low speed. The electric motorcycles are excluded. The reviewed papers were mainly
scanned via Scopus, using the key terms such as “electric bicycle”, “electric bike”, “e-
bike”, and “electric 39 two-wheeler vehicles”. The review was restricted to English
publications and high quality Chinese literatures, including books, peer-viewed journal
papers, conference papers, and conference reviews. Figure 3.1 shows the articles relevant
to e-bike topics published since 1974. The total number of e-bike articles scanned by
Scopus is approximately 400. The very first article published in 1974 announced that e-
bikes had been assembled in Dublin (Anon, 1974). The number of published e-bike
articles is no more than five each year before 1999. However, this started to increase after
2000, which could be an indicator that e-bikes may emerge in the niche market. In the
following years, the number of published e-bike articles fluctuated between 2003 and
2009. After that, the number of published e-bikes had an explosive growth, especially in
2013 and 2014, with 52 and 67 published articles, respectively. The increase in published
e-bike articles may imply that the e-bike industry developed very quickly and has been a
highly notable social phenomenon, and therefore attracted the attention of the academic
world.

Fig 2.1 - No. articles published per year

Most of the published articles are in the engineering subject area, with only a few in the
social science. The themes in the engineering subject area mainly consist of the research
of batteries (Kumar, et al., 1993; Yan, 2001; Hwang et al., 2005; Ke and Zhang, et al.,
2007; Guo et al., 2009; Manoj et al., 2011; Zhao et al., 2014; Berjoza and Jurgena, 2014),
motors (Chan et al., 2002; Trifa et al., 2007; Son and Kang, 2010; 40 Lu and Jen, 2014;
Wu and Lin, 2014), controllers (Haobin et al., 2008; Zhang et al., 2011; Zhou et al., 2013;
Zhang et al., 2013), wheel hubs (Espanet et al., 2001; Wu and Sun, 2013), frame designs
(Wang et al., 2001; Du et al., 2008; Xiao et al., 2012; Dong et al., 2012), propulsion
systems (Scott, 2008; Tal et al., 2013; Ren and Ren, 2014), and brake systems (Liu et al.,
2008; Hua and Kao, 2011; Chuang et al., 2012). These themes explored important
technology components of e-bikes, for the purpose of breaking through the technology
bottlenecks, optimising e-bike technology, and achieving e-bike industrialisation.
Adapted from: Jamerson and Benjamin, 2013; Fishman and Cherry, 2016. Figure 3.2
Global e-bike sales.

Fig 2.2 – No. of electric bikes sold in thousand

The research scopes of the e-bike studies in China and other countries are very different.
China is the largest producer and market of e-bikes, with 35 million in production and
32.40 million sales in 2014 (Tian, 2015). In comparison, the market in Europe, India, the
USA and Japan are still in the elementary stages (Figure 3.2). Although e-bike sales in
these countries are increasing every year, they are still much lower than that in China.
The unbalanced regional e-bike development leads to different preferences for e-bike
research themes. Eastern studies, especially in China, tend to concentrate on the e-bike
operations, technology improvement, e-bike user 41 characteristics, environment issues,
safety issues, market growth, and the reasons for the rapid development of e-bikes. In
comparison, western studies, especially in North America and Europe, focus on emerging
markets, the behaviour of early adoption, and health issues. The following sections will
explore the e-bike themes in China and other areas, respectively.
 Chapter – 3

Components of Electrical Bicycle

I. Motor: The two most common types of hub motors used in electric bicycles are
brushed and brushless. Many configurations are available, varying in cost and
complexity; direct-drive and geared motor units are both used. An electric power-
assist system may be added to almost any pedal cycle using chain drive, belt
drive, hub motors or friction drive. BLDC hub motors are a common modern
design. The motor is built into the wheel hub itself, while the stator is fixed solidly
to the axle, and the magnets are attached to and rotating with the wheel. The
bicycle wheel hub is the motor. The power levels of motors used are influenced by
available legal categories and are often, but not always limited to fewer than
750 watts.

Another type of electric assist motor, often referred to as the mid-drive system, is

increasing in popularity. 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 crankset. 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.

Because the power is applied through the chain and sprocket, power is typically
limited to around 250–500 watts to protect against fast wear on the drive train. An
electric mid-drive combined with an internal gear hub at the back hub may require
care due to the lack of a clutch mechanism to soften the shock to the gears at the
moment of re-engagement. A continuously variable transmission or a fully
automatic internal gear hub may reduce the shocks due to the viscosity of oils
used for liquid coupling instead of the mechanical couplings of the conventional
internal gear hubs.

Types of Electric Motors for Electric Bikes

i) Crank Drive Motors: Crank drive motors were the first advanced electric
bike motors, and were developed in Japan in the early 1990s by Panasonic and
Yamaha. As the name clearly indicates, they are situated in the crank (the
crank set being the round thing that cleverly converts the energy from your
legs into energy that moves the chain and therefore moves the bike). These
motors drive additional power (over and above your own leg power) through
the rear gear system.

Fig 3.1 – Crank Driven Motor

ii) Hub motor: As the early crank drive motors were so expensive, hub motors
were developed as a cheaper alternative. These motors, again as the name
indicates, are mounted in the hub (the centre part) of the wheel, usually the
rear wheel. These are now the most common motors. They basically have only
one gear, so although some of them are very powerful, they are not ideal for
hilly areas. If you live in a flat city, these are just fine.

Fig 3.2 – Hub Moto

iii) Brushed and brushless motor : Motors for electric bikes may be brushed, or
they may be brushless DC motors (BLDC motors).The industry default has
become brushless motors, because generally they are quieter, smaller, and
lighter, and they don’t need to be serviced. However, there are some
knowledgeable people in the industry who support brushed motors,
maintaining that they are more robust and reliable, that they are a relatively
cheap way (in terms of cost and power) to gain hill-climbing ability, and that
they are cheap and simple to service and don’t have to be serviced often (some

only at intervals of 8,000 miles). Moreover, once they are serviced, they are as
good as new. Finally, brushed motors are very robust, and offer hill climbing
capacity at a lower price point.
 Fig 3.3 – Brushed and Brushless Driven Motor
iv) Friction Drive motor: These are simple, light motor that basically work by
spinning a roller that is pressed against the bicycle’s tire. There is a limit to
how much power can be put through a friction drive, because the acceleration
is dependent on the roller maintaining solid contact with a small patch of the
tire.
These engines have their proponents, but they are very much in the minority. I
would say that friction motors are better suited to techie people who like to
assemble engines themselves, using parts from model airplanes.

Fig 3.4 - Friction Drive Motor

II. Controller: There are two distinct types of controllers designed to match either
a brushed motor or brushless motor. Brushless motors are becoming more
common as the cost of controllers continues to decrease. (See the page on DC
motors which covers the differences between these two types.)

Controllers for brushless motors: E-bikes require high initial torque and therefore
models that use brushless motors typically have Hall sensor commutation for
speed and angle measurement. An electronic controller provides assistance as a
function of the sensor inputs, the vehicle speed and the required force. The
controllers generally allow input by means of potentiometer or Hall Effect twist
grip (or thumb-operated lever throttle), 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 width modulation to regulate the power to the motor. Sometimes
support is provided for regenerative braking but infrequent braking and the low
mass of bicycles limits recovered energy. An implementation is described in
an application note for a 200 W, 24 V Brushless DC (BLDC) motor.

Fig 3.5 - Controller

 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 do not
require hall sensor feedback and are typically designed to be open-loop
controllers. Some controllers can handle multiple voltages.

Function: The electric bike speed controller sends signals to the bike's motor in
many voltages. These signals detect the direction of a rotor relative to the starter
coil. The suitable function of a speed control depends on the employment of
various mechanisms. In a purpose-built electric bike, Hall Effect sensors help
detects the location of the rotor. If your speed controller does not include such
sensors and the speed controller on an adaptive bike may not the electromotive
force of the un-driven coil is calculated to get the rotor orientation. The
mechanism of an electric speed controller differs depending on whether you own
an adaptive or purpose-built electric bike. An adaptive bike includes an electric
drive system installed on an normal bicycle. A purpose-built bike, more expensive
than an adaptive bike, provides easier acceleration and affords extra features.

Plug:

i. Red & Black (large cable) : Battery connections

ii. Yellow & Blue : Motor connections

iii. Red & Blue : Key Switch(power lock) (If there is no power door locks, red
connection to blue)

iv. Yellow & black : brake

v. Red & Yellow: Brake light

vi. Red & Black(small cable) : indicator light

vii. Red, Black & Blue: Speed Regulator 1-4 V Throttle (Red : +5v, Black ,
Blue :Signal Wire)

viii. Red & Black (small cable): Charger

III. Battery: E-bikes use rechargeable batteries, electric motors and some form of

control. Battery systems in use include sealed lead-acid (SLA), nickel-
cadmium (NiCad), nickel-metal hydride (NiMH) or lithium-ion polymer (Li-ion).
 Batteries vary according to the voltage, total charge capacity (amp hours), weight,
the number of charging cycles before performance degrades, and ability to handle
over-voltage charging conditions. The energy costs of operating e-bikes are small,
but there can be considerable battery replacement costs. The lifespan of a battery
pack varies depending on the type of usage. Shallow discharge/recharge cycles
will help extend the overall battery life.

Range is a key consideration with e-bikes, and is affected by factors such as motor
efficiency, battery capacity, efficiency of the driving electronics, aerodynamics,
hills and weight of the bike and rider. Some manufacturers, such as the
Canadian BionX or American Vintage Electric Bikes, have the option of
using regenerative braking, the motor acts as a generator to slow the bike down
prior to the brake pads engaging. This is useful for extending the range and the life
of brake pads and wheel rims. There are also experiments using fuel cells. e.g.
the PHB. Some experiments have also been undertaken with super capacitors to
supplement or replace batteries for cars and some SUVS. While e-bike batteries
were produced mainly by bigger companies in past, many small to medium
companies have started using innovative new methods for creating more durable
batteries. State of the art, custom built automated precision CNC spot welding
machines created 18650 battery packs are commonly used among Do-it-yourself
e-bike makers.

IV. Throttle:A throttle is basically like a motorcycle. Usually mounted on the

Fig 3.6 – Throttle

 Handlebar, and activated by twisting, you can get power from the electric motor
without doing any pedalling at all. Some bikes come with just the throttle and not
a pedal assist system, and others come with the option to use pedal assist
or throttle.

V. Pedal Assist: Pedal assist is a mode on your electric bike that provides power
from the motor to help you pedal easier and move faster. When you turn on pedal
assist and choose your level of assist, the motor will provide a certain level of
power output as you pedal. This may feel like a slight push as you ride. Pedal
assist is different from throttle mode because it requires riders to pedal, along with
receiving power from the motor. The throttle mode does not require pedalling and
solely uses the motor to make the bike move forward.

Fig 3.7 – Pedal Assist

VI. Sprockets: Sprockets are used in bicycles, motorcycles, cars, tracked vehicles,

and other machinery to transmit rotary motion between two shafts where gears are
unsuitable or to impart linear motion to a track, tape etc. 
VII. Electrical Brake: When we pull the lever of brake , a connecting wire send a
signal to controller and controller cut the power of hub motor . And due to pulling
lever the normal brake come in play. At the end braking pads do their works at the
area of work.
Most bicycle brake systems consist of three main components: a mechanism for
the rider to apply the brakes, such as brake levers or pedals; a mechanism for
transmitting that signal, such as Bowden cables, hydraulic hoses, rods, or the
bicycle chain; and the brake mechanism itself, a caliper or drum, to press two or
more surfaces together in order to convert, via friction, kinetic energy of the bike
and rider into thermal energy to be dissipated.

Fig 3.8 – Electric Brakes

VIII. Display and Switch: The display is connected with throttle at right handle of
bicycle. This display shows only two parameters; battery percentage and speed of
e-cycle. This switch is connected with throttle or accelerator at right handle of
bicycle. The switch is connected by wiring to controller. This switch starts the
motor when you are using throttle for acceleration and after switch on the display
shows.
Principle of Electric Bicycle:

Motor is a device that converts electrical energy into mechanical energy. The principle of
electric bikes motor is to generate the rotating magnetic field by using the electrified coil
(that is, the stator winding) and act on the rotor squirrel-cage closed aluminium frame to
form the magneto electric rotating torque.

The motor is divided into DC motor and AC motor according to the power supply. Most
of the motors in the power system are AC motors. Can be synchronous motor or
asynchronous motor stator magnetic speed and rotor rotation speed do not maintain
synchronous speed.
The motor is mainly composed of the stator and the rotor. The direction of the force
motion of the electric wire in the magnetic field is related to the direction of the current
and the direction of the magnetic sense (the direction of the magnetic field). The working
principle of the motor is the effect of magnetic field on the current force, which makes the
motor rotate.
Electric bikes motor power is different, such as the general assembly of 12AH battery
four blocks of motor power is 350 W, this refers to the internal gear of the high speed
motor. In the case of a brushless toothless motor, the actual power is 250 W.

Working:
The working of our project basically explain by using the five blocks as follows
a) Battery.
b) Motor Controller Circuitry.
c) Electric motor.
d) Chain and Sprocket.
e) Bicycle speed Rotation.
 Fig 3.9 - Block diagram of the Electric bicycle construction process

A) Battery: Two lead acid rechargeable batteries of 12v, 9 amp are used which are
connected in parallel position. It basically stores the electrical energy generated and
utilize it to run the motor. A battery has a positive terminal called cathode and negative
terminal called anode. The terminal marked positive is at higher electric potential energy
and the terminal marked negative is source of electrons when connected to external
circuit will flow and deliver energy to external device Rechargeable batteries are
recharged multiple times.

B) Motor Controller Circuitry: It used to control all the working of cycle.

C) Electric Motor: Use the specific motor having suitable power and torque according to
design.

D) Chain and Sprocket: Take the suitable material & no. of teeth according to centre
distance.

E) Bicycle Wheel Rotation: Provide the torque and speed to the wheel throughout
sprocket.
DC Motor:In this a DC waveform which is obtained id made sinusoidal due to
operational transistorized D.C. to A.C. amplifying circuit by switching the electric energy
in the form of electric current which flows from battery to D.C. to A.C. converter circuit.
By using amplifier circuit the small A.C. current is amplified again. In order to drive the
circuit through the condenser, this amplified current is fed to the stator winding of the
A.C. motor. The condenser which is used acts as an storage of electric energy and delivers
atthe time of requirement. The sprocket wheel installed on motor shaft is driven by the
motive power of the electric energy. The rear sprocket wheel is being rotated by the chain
drive mechanism on which the other two remaining sprocket wheels are installed. The
wheel is driven by the rear wheel installed on the rear sprocket. Thus the electric bike is
mobilized by using electric power.
Rotor: The rotor is made of permanent magnet and can varyfrom two to eight pole pairs
with alternate North (N) andSouth (S) poles.Based on the required magnetic field density
in therotor, the proper magnetic material is chosen to makethe rotor. Ferrite magnets are
traditionally used to makepermanent magnets. As the technology advances, rareearth
alloy magnets are gaining popularity. The ferritemagnets are less expensive but they have
the disadvantageof low flux density for a given volume. In contrast,the alloy material has
high magnetic density per volume and enables the rotor to compress further for the same
torque. Also, these alloy magnets improve the size-to-weight ratio and give higher torque
for the same size motor using ferrite magnets. Neodymium (Nd), Samarium Cobalt
(SmCo) and the alloy of Neodymium, Ferrite and Boron (NdFeB) are some examples of
rare earth alloy magnets. Continuous research is going on to improve the flux density to
compress the rotor further.

Fig 3.10 - Rotor Magnet Cross Section

Project:
In this new developing world where the petrol prices are going up day by day and the
natural resources are going blank of petrol and other oils. We think about to save the
natural resources for our next generation and start to build an electrical bicycle which we
named as Electro-Volt 36 or EV36.
 Fig 3.11 – Picture of Electro-Volt 36

Electro-Volt 36 is run on electricity by using batteries. For making EV36 here we use a
rear wheel DC hub motor which converts the electricity power of batteries into rotating
power. We made it like to save the battery power when you pedal it. This thing is simply
called pedal assisting which saves 50% power of batteries so it can run extra Kilometers.
Here we are using an Electric hub motor kit in which we have all the necessary parts of
Electric Bicycle. We are using an old Bicycle where we can fix parts of this kit.

Fig 3.12 – Hub Motor Kit

Parts which are provding in this Electrical Hub Motor kit:

a) DC Hub Motor 36V 250W

b) Controller
c) Electric Brakes
d) Display Meter
e) On-off Switch and switch key
f) Pedal Assist
g) Spokes
h) Nut and Bolts
i) Extra wires for connection

For EV 36 we are using 3 separate Lead Acid batteries of 12V and 7.5 ampere and
connect all the batteries into series connection so it can provide 36V to run the motor.
 Fig 3.13 –After Complete work on EV-36

Specifications of Rear Wheel DC Hub Motor:

Usage: Bicycle
Operating Voltage: 36V
Working Temperature: -20 0C-45 0C
Rated RPM: 180-290rpm
Unload Amp/ Peak Amp: 1A/12A
Continuous Power Rated & Peak: 250/550w
Torque (nm) Peak: 38nm
Peak Efficiency: 85%
Water & Dust protection Level (IP Rating): IP65
Weight of motor: 2.3kg
Maximum Speed: 25km/hr.
Motor shaft size: 110mm.
Package Includes - 1pc x 250W Hub motor
1pc x 250W controller
1pc x Brake Set
1set x Spokes for Wheel
1pc x Throttle with 3 way speed mode
1pc x Headlight with battery indicator
1pc x central locking system for keyless start
1pc x Indicator switches
1set x Screws and nuts for fixture

Battery:

Type of Batteries:-
1. NICKEL CADMIUM BATTERIES

The active components of a rechargeable NiCd battery in the charged state consist of
nickel hydroxide (NiOOH) in the positive electrode and cadmium (Cd) in the negative
electrode. For the electrolyte, potassium hydroxide (KOH) is normally used. Due to their
low internal resistance and the very good current conducting properties, NiCd batteries
can supply extremely high currents and can be recharged rapidly. These cells are capable
of sustaining temperatures down to -20°C. The selection of the separator (nylon or
polypropylene) and the electrolyte (KOH, LiOH, NaOH) influence the voltage conditions
in the case of a high current discharge, the service life and the overcharging capability. In
the case of misuse, a very high-pressure may arise quickly. For this reason, cells require a
safety valve. NiCd cells generally offer a long service life thereby ensuring a high degree
of economy.

Fig 3.14 – Nickel Cadmium Battery

 2. NICKEL METAL HYDRIDE BATTERIES

The active components of a rechargeable NiMH battery in the charged state consist of
nickel hydroxide (NiOOH) in the positive electrode and a hydrogen storing metal alloy
(MH) in the negative electrode as well as a potassium hydroxide (KOH) electrolyte. 
Compared to rechargeable NiCd batteries, NiMH batteries have a higher energy density
per volume and weight.

Fig 3.15 – Nickel Metal Hydride Battery

3. LITHIUM ION BATTERIES

The term lithium ion battery refers to a rechargeable battery where the negative electrode
(anode) and positive electrode (cathode) materials serve as a host for the lithium ion
(Li+).  Lithium ions move from the anode to the cathode during discharge and are
intercalated into (inserted into voids in the crystallographic structure of) the cathode. The
ions reverse direction during charging.  Since lithium ions are intercalated into host
materials during charge or discharge, there is no free lithium metal within a lithium-ion
cell.  In a lithium ion cell, alternating layers of anode and cathode are separated by a
porous film (separator). An electrolyte composed of an organic solvent and dissolved
lithium salt provides the media for lithium ion transport.  For most commercial lithium
ion cells, the voltage range is approximately 3.0 V (discharged, or 0 % state-of-charge,
SOC) to 4.2 V (fully charged, or 100% SOC).

Fig 3.16 – Lithium-ion Battery

4. SMALL SEALED LEAD ACID BATTERIES

Rechargeable small sealed lead acid (SSLA) batteries, which are valve-regulated lead
acid batteries, (VRLA batteries) do not require regular addition of water to the cells, and
vent less gas than flooded (wet) lead-acid batteries.SSLA batteries are sometimes referred
to as “maintenance free” batteries.  The reduced venting is an advantage since they can be
used in confined or poorly ventilated spaces.

There are two types of VRLA batteries,

 Absorbed glass mat (AGM) battery

 Gel battery (“gel cell”)
An absorbed glass mat battery has the electrolyte absorbed in a fiber-glass mat separator.
A gel cell has the electrolyte mixed with silica dust to form an immobilized gel.

SSLA batteries include a safety pressure relief valve. As opposed to flooded batteries, a
SSLA battery is designed not to spill its electrolyte if it is inverted.
Fig 3.17 – Lead Acid Battery
 Chapter – 4

NO LOAD SPEED CALCULATION

Step 1 :-
Number of teeth on smaller sprocket (motor) (t1) = 9
Number of teeth on larger sprocket (bicycle) (t2) = 18
Speed on smaller sprocket (motor)
(N1) = 3300 rpm
By using reduction ratio (9.78), speed will be reduced to 338 rpm
Speed on larger sprocket (bicycle) (N2) = ?
Step 2 :-
Using speed ratio formulae,
N1t1 = N2 t2
N2 = 164 rpm
Step 3:-
Diameter of wheel = 648mm
Circumference of wheel = 3.14*648
= 2035mm
Step 4:-
Speed of vehicle = speed of wheel X circumference of wheel
= 164 X 2035
= 333740 mm/min
= 333.74 m/min
= 20024.4 m/hr
= 20.024 Km/hr
REQUIRED POWER TO DRIVE BICYCLE
Step (1)
Total load act on bicycle is as follow
Normal weight of person = 80 kg
= 80*9.81
= 784.8N
Weight of bicycle = 30 kg
 = 30*9.81
= 249.3.N
N Other Miscellaneous load = 5Kg
= 5*9.81
= 49.05 N
The total load = (784.8+249.3+49.05)
= 1083.15 N
= 1083 N
Step (2)
To find reaction on each wheel, The above total load which is divided equally on
both wheel
Force (Ffw) = Force (Frw)
= 1083/2
= 541.5N
Where reaction on rear and front wheel are as follows
Rfw = Rrw
= 0.2*340.5
= 73.56 N
Step (3)
To find torque on each wheel
Total torque = Tfw+Trw
To find Torque on Front Wheel
T1 = Rfw*(D÷2)
= 73.56*[(64.8*10)/2]
= 23.8334Nm
T1 = T2 = 23.8334Nm
Total torque on wheel = 47.6668 Nm
Step (4)
To required brake power
= [(m)*(g)*(v)*(R)] + [air density*Cd*Area*V3]
= [30*9.8*11.24*0.01] + [0.6465*0.88*0.1769*0.915*(11.24)3]
= 33.05 + 130.76 watt
= 163.81 watt
The calculated No load speed of bicycle is = 20.24Km/hr
The Required brake power is = 163.81 watt
 Chapter - 5
Advantages

 They are rechargeable: Either lithium-ion or nickel-metal hydride batteries

power electric bikes and motorcycles. Charging the batteries is easy as you can
plug-in at any wall outlets. On average, they take eight hours to recharge
completely.

 Low Maintenance: Electric bikes require less maintenance in comparison to

standard bikes. While standard bikes need a regular check on lubricating and
adjusting, an electric bike saves you from all the fuss. However, you still have to
be aware of the brake pads, tyres, and fluid flush.

 Low Fuel Cost: Electric bikes also enjoy the advantage of a low fuel cost. Around
250 watts of power is used for 20 minutes of driving. The cost of electricity per
unit is Rs 5, which makes electric bikes quite affordable.

 Does not add to the Noise: Indian roads are perennially noisy. With the
unnecessary honks and endless squabble of people, the roads are always in a state
of pandemonium. Electric bikes breeze through the streets with surprising silence.
Some bikes have now come up with an artificial noise device to warm the
commuters of the approaching vehicle.

 Assisted biking: E-bikes have what they call battery-powered “pedal assist.”
Technically, this is a machine integrated within the bike to give your pedalling a
boost. This can reduce stress and impact on your knees and thighs. Say goodbye to
sweaty rides.There are E-bikes that have specific boosting technology that can
assist you to conquer hills and inclines, so you don't have to worry about any
challenging terrain. People of all ages and health can ride flawlessly and for much
longer with an E-bike. Longer rides mean more views and more possibilities for
lunch stops!

 Fast and flexible: The technology gives you the extra oomph you need to cover
miles of distance with little effort. You can also still take advantage of the multi-
purpose cycle lane and paths that are traffic free, brilliant if you’re living in a city
to slash your commute time.  These are getting more and more popular in cities as
 governments and councils urge people to give up their car. The bikes have been
developed over the years and now look almost like a normal bike frame, with only
the subtle ‘hum’ giving them away. Take advantage of the lithe form and
durability of an E-bike without anyone being the wiser!

 Improve fitness: According to a study of scientists at Switzerland's University of

Basel, riding an E-bike is just as good as regular bikes at improving fitness.
Although cycling with an E-bike is pedal assisted, it's still an exercise after all and
therefore good for your health, both mentally and physically. If you are more into
fitness, there are customizable ones suitable for exercise, try looking at and
comparing these before purchasing an E- bike.

 Cut back expenses: If you use the E-bike instead of a motor vehicle it will save
you money in the long run. Petrol and diesel are costly in most countries, and
occasional price surges can really impact on your budget. While with E-bikes, you
can buy affordable batteries which can last you 18-50 miles after a full charge
depending on the level of assistance you use.

 They’re the future of transportation: We have all seen it in sci-fi movies. Sleek
and sexy vehicles, none of which look old, bulky or have jets of smoke coming
out the back, un-futuristic transportation is no longer being made. The electric
bike is on its way to being up there with its smart counterparts. Considering that
this invention will improve continuously over time, what we have now might be
the prototype of this promising transport. Many countries in Southeast Asia took
the lead in using E-bikes as sustainable mode of transportation, and with the
continuous rise of urban air pollution, there is a big future for E-bikes.

 Nature-friendly: Climate change and global warming are serious issues and we
all need to play our part. We might be facing our last stand to save our dying earth,
and we can all contribute to this. E-bikes emit lower pollution per kilometre than
motorcycles and cars. You can help by using an E-bike instead of a petrol or diesel
car. They use energy with an average rate of 100 to 150 watts compared to 15,000
or so for a car. As a result, this can help to improve air quality.

 Wide variety of designs: With technology, everything is almost possible, and as

the marketability of bikes increases, companies produce a variety of designs that
 can accommodate your needs.  If there isn't the perfect one out there right now,
you can be pretty sure there will be soon. 

 Easy to get one (in some countries): In some countries’ laws, E-bikes are still
considered as a bicycle, so if you don’t like the process of registration or getting
license plates or insurance, getting an E-bike can be a good choice.  You can pop
into your local Halfords or cycle shop and purchase one today, alternatively you
can buy them from Amazon and other online vendors... easy peasy!

Disadvantages

 E-bikes are overall pricey;

 Battery has a rather short lifespan;
 Battery charge time is long;
 Riding range remains low;
 E-bikes are considerably heavier;
 Maintenance and repairs are costly;
 E-bikes tend to have low resale value;
 E-bike manufacturing remains not environmentally friendly.
 Future Scope
India E-bicycle was valued at USD 1.02 million in 2020, and it is expected to reach USD
2.08 million by 2026, projecting CAGR of 12.69 % during the forecast period. (2021-
2026).In 2020, the market generated revenue of USD 1.02 million, as compared to USD
1.70 million in 2019.
In the future, people will come forward to come on this drive and get the knowledge of
usage distinct. And due to its design, eco-friendly nature, less noise play, it’s different
functions and due to motor, the customers willing to pay for it.

Future Scope in India

 India has the largest market of EV in the world.
 With the development of infrastructure, technology and power source there is
chances for a shift towards EVs.
 To increase the public awareness in our country, the initial approach of central
government should be to encourage market players at international level to carry
out studies for finding potential locations for the development of EV charging
infrastructure and EV supply Equipment.
 There is a wide scope for EVs in two wheeler market, auto rickshaws, goods
vehicle, and bus as well as four wheelers. All of this market is waiting for the
change.
 Month

Activity 1 2 3 4 5 6
Literature Survey

Development and Material

Procurement of proposed
Project

Properties Characterization
of Project

Assembly of Project
Data Processing and
optimization
Report Writing &
Publication

Conclusion
During this semester the electric bicycle project has provided an opportunity to grasp the
full scope of what it means to design a product. This opportunity allowed an initial
idea/goal to be realized in a team environment.
The idea developed as research and various other information on the topic was obtained.
The project evolved and changed as the team limitations and financial constraints were
realized. Due to a lack of funding, the initial design of an electrical go cart was downsized
to the current project, the electric assisted bicycle.
The initial design of the electric assisted bicycle, carried along with it constraints that had
to be worked around. The constraints were mainly financial in nature. They represent
pieces of equipment consisted of the battery, motor, and the bicycle frame. The motor
bicycle relationship could not be altered, mainly due to the type of mounting on the
motor. These constraints limited, but did not totally restricts the team’s ability to design a
‘new’ system.
Once all constraints were known, the goals for the design clearly identified. The goals
were divided among the team members. In order to meet the deadline for the final project,
progress was monitored weekly and individual goals were readjusted as needed. With
communication between the team, and hard work, the final objective was obtained. The
design project provided the team with the valuable experience in design and teamwork. It
allowed the team members to develop skills that will be useful in future endeavors.
 References
[1.]https://www.mordorintelligence.com
[2.]https://www.researchgate.net
[3.]https://en.m.wikipedia.org/wiki/Electric_bicyclehttps://www.mdpi.com/1996-
1073/11/7/1894/pdf
[4.]https://www.slideshare.net/erpky22/project-report-69490349
[5.]https://robu.in/product-category/ebike-parts/
[6.]https://www.radpowerbikes.com/blogs/the-scenic-route/the-history-of-ebikes
[7.]https://www.bicycling.com/skills-tips/a20044021/13-things-about-e-bikes/
[8.]https://evelo.com/pages/electric-bikes-101
[9.]https://www.skipeak.net/blog/8-benefits-of-using-electric-bikes