CONTEXT

Solar Powered Walking Bicycle
ABSTRACT
As a humongous steep increase in global warming and major novice health concern
which are caused due to combustibles, are in linkage to transportation facilities as
humans are dependable, which cannot eradicate it. Solar power, a non conventional or
renewable energy source and some fitness components are used in this project which
is feasible and manoeuvre in real transportation world. So i took up an opening in
combining these two major concerns and developed a new solar panel technology to
an pre-existing bi-cycle called solar powered health cycle, which consists of a tread
mill belt and a 12V brushless dc-motor, motor controller, a sealed lead ion battery,
throttle valve and motor controllers. which are contemporarily and solely introduced
in this project in which the pre-existing cycle has a dc chargeable power source,
which works on it. But having another major problem in older version is Balancing
which is completely resolved by having an two extra guided wheels of small size
fitted to the rear wheel of this cycle which gives an immense balancing support in
long deep turns and also the pot hole on road and an additional benefit of great
gyroscopic balancing. So by this unorthodox design, human can achieve in
minimizing the rise on effect in global warming and major health theme such as
obesity, heart attack etc. and can also attain short-distance travel to homage, office,
etc. thereby reducing the pollution, as well as a great results in physical fitness by
using this cycle.
Malla Reddy Engineering College, (A) Page 1

TABLE OF CONTENTS
1- INTRODUCTION 08
1.1- STATEMENT OF PROBLEM 09
2 - OBJECTIVE 10
3 - METHODOLOGY 11
3.1- METHOD 11
3.1.1- DESIGN 11
3.2- WORKING PRINCIPLE 12
3.3- WORKFLOW 13
4- DESIGN OF WALKING CYCLE 15
4.1- DESIGN REQUIREMENTS 15
4.2- COMPONENTS OF WALKING CYCLE 16
4.2.1- TREAD MILL BELT 16
4.2.1.1- MATERIAL USED 17
4.2.1.1.A- NYLON RUBBER FABRIC 17
4.2.2- MOTOR 17
4.2.3- ELECTRIC BIKE BATTERY 17
4.2.4- BRUSHLESS DIRECT CURRENT MOTOR 21
4.2.5- SOLAR CELL/PANEL 25
4.2.6- VOLTAGE REGULATOR 26
4.2.7- LEAD ACID BATTERY 28

4.2.8- MOTOR CONTROLLER 29
4.2.9- LITHIUM-ION BATTERY 33
4.2.10- ACCELERATOR/THROTTLE 33
4.2.11- DC-DC BOOST CONVERTER 34
4.2.12- SOLAR BI-CYCLE 35
4.3- DESIGN MAIN FRAME COMPONENTS 36
4.3.1- TREAD MILL FRAME DESIGN 36
4.3.1.1- MATERIAL - MILD STEEL 36
4.3.2- DESIGN OF FRONT AND REAR END ROLLERS 37
4.3.3- DESIGN OF SUPPORTIVE ROLLERS 37
4.4- DESIGN OF SPROKETS 38
4.4.1- 1st GEAR REDUCTION RATE 38
4.4.2- 2nd GEAR REDUCTION RATE 39
4.4.3- 3rd GEAR REDUCTION RATE 39
4.5- FURTHER IMPROVEMENTS IMPLEMENTED 39
5- RESULT 40
6- CONCLUSION 41
7- FUTURE SCOPE 42
8- REFERENCE 43
LIST OF FIGURES

Serial number Name of the figure Figure number
1 CATIA DESIGNED 01
CYCLE MODEL
2 WORKING PRINCIPLE 02
DIAGRAM
3 BRUSHLESS DIRECT 03
CURRENT MOTOR
4 SOLAR PANEL/CELL 04
5 VOLTAGE 05
REGULATOR
6 SEALED LEAD ION 06
BATTERY
LIST OF TABLES

Serial Number Name Of The Table Table number
1 BRUSHLESS DIRECT 01
CURRENT MOTOR
SPECIFICATION
2 SOLAR CELL/PANEL 02
SPECIFICATIONS
3 VOLTAGE 03
REGULATOR
SPECIFICATIONS
4 LEAD ACID BATTERY 04
SPECIFICTIONS
5 1st GEAR REDUCTION 05
RATE
6 2nd GEAR REDUCTION 06
RATE
7 OVERALL GEAR 07
REDUCTION RATE
8 OVERALL SPEED RATE 08
1 . INTRODUCTION
Bicycles are one of the most ubiquitous forms of transportation in the world. Most
children remember their first bike; with it came the chance to explore their world with
more freedom than ever before. As we grow, however, bicycling becomes more than
just a childhood rite of passage. Wind in our hair and feet on the pedals, we have
several good reasons to climb on and take a trip. Much of the world uses bicycles as a
primary form of daily transportation. What would take several hours of travel on foot
becomes faster and more efficient on two wheels. Some cyclists take trips across
entire states or cross-country solely on a bicycle. Reaching speeds of 15 miles or 30
km an hour is achievable by even beginning cyclists, while more experienced riders
can reach speeds equivalent to automobile travel. "Century riders" travel 100 miles or
more within a typical day. Not to be constrained by simple transportation, bicycles
(stationary and otherwise) have helped people become healthier by losing excess
weight and improving cardiovascular fitness. The exercise benefits of cycling are well
known. Using the largest muscles in the body, bicycling allows riders to reach aerobic
heart rates that drive up metabolism, and give a good workout. With the relative
newcomer in the bicycle world, mountain bikes, this form of transportation is taking
us on rugged terrain once thought impassable by anything other than hiking boots or
pack animals. Extreme sport enthusiasts have adapted the bicycle to perform gravity
defying stunts, such as flips and mid air acrobatics, in a style known as BMX (Bicycle
Motor cross). In short, bikes remain a popular way to get people between points A
and B, whether those destinations are found on a map, from one state of health to
another, or to explore the unknown.
Bicycles have become an important part of the landscape. Most people understand the
saying, "as easy as riding a bike." Or we understand that some dormant skill is easy to
pick back up if it's "just like riding a bike." Likewise, many immediately think of
bicycles when we make an allusion to coasting", "picking up speed", or "going
downhill". Because of technological advances in storage cells and electric propulsion
systems in recent years and in response to the growing demand for clean, efficient
methods of transportation in our urban communities, electric bicycle development and
marketing has surged ahead, especially in Asia and Europe.. E-bikes are not a
replacement for conventional bicycles. However, they allow a greater number of
people to travel on two-wheeled vehicles. In the future, they could even become a
means of locomotion that could substitute for the automobile, particularly in warmer

weather. E-bikes are for everybody, especially those who are not very active in sports,
those with physical disabilities and seniors. They are also for veteran cyclists who
commute to work on conventional bicycles to save money on fuel but wish to avoid
arriving at the office covered in perspiration. Growth in e-bike use has skyrocketed
since the electrically assisted bicycle (EAB)was introduced in 1997 by the Japanese
firm Yamaha. This version of the e-bike has a small motor mounted on the back
wheel to double the power generated by the cyclist. In 1998, the company scored a
major commercial success by selling 500,000 units worldwide, making Japan the e-
bike market leader. The European market is growing as well, with more than 100,000
units sold in 1999.The mechanism used in solar health cycle is versatile of its kind in
which ,the cycling pedals are replaced a treadmill belt. The prototype design requires
an treadmill belt, shafts, the frame of treadmill, the freewheel gears, chain drive and
gear chain .The platform on which the treadmill belt is placed is fabricated.
All the links are made up of normal MS (mild steel) including the head which has a
direct contact with the treadmill belt. The system is expected to move as heavy
weights up to 150 KGs approximately. The aim of the project work is to design and
fabricate a solar walking cum cycle mechanism that makes much easier to move.
People from one place(section) to the other even while processing in the factories,
industries, etc.
Exercise are advised for health promotion, and prophylaxis for many cardiovascular
diseases and also for rehabilitation after an episode of disease. Among the exercises
aerobic exercises are appropriate for these purposes. To do aerobic exercise many
methods are available for example: running, jogging, walking, cycling and others.
Among different modes of exercises in the modern busy life, the cycling and treadmill
exercises are the commonest to perform as indoor aerobic exercises. In solar powered
motor driven treadmill exercise which is similarly to walking or jogging or running
depending upon the speed of the treadmill motor is becoming more familiar to all.
Thus we made an innovation to take that treadmill in park. This is nothing but having
a walk in a park. The electric bicycle (e-bicycle) market varies greatly by product type
and regional demand. The placement of electric motors for e-bicycles is also receiving
increased consideration. E-bicycle can have motors in one of three locations: The rear
wheel hub is the most popular location, and most of the large Chinese market and

american as well as european markets is utilising rear hub motors. Rear wheel hubs
are thought to be best for throttle-controlled bikes, whereas the other locations work
well with e-bicycles that only provide electric power when the pedals are being used
(pedal assistance). The mid-mount motor is the fastest growing segment, in part due
to strong competitors like Panasonic and relatively new competitors including Bosch.
Exercise are advised for health promotion, and prophylaxis for many
cardiovascular diseases and also for rehabilitation after an episode of disease.
Among the exercises aerobic exercises are appropriate for these purposes. To do
aerobic exercise many methods are available for example: running, jogging,
walking, cycling and others. Among different modes of exercises in the
modern busy life, the cycling and treadmill exercises are the commonest to
perform as indoor aerobic exercises. In motor driven treadmill exercise which is
similarly to walking or jogging or running depending upon the speed of the
treadmill motor is becoming more familiar to all. Thus we made an innovation to take
that treadmill in park. This is nothing but having a walk in a park.
The electric bicycle (e-bicycle) market varies greatly by product type and regional
demand. The placement of electric motors for e-bicycles is also receiving
increased consideration. E-bicycle can have motors in one of three locations: the
front wheel hub, mid-mounted at the bottom bracket (pedals), or the rear wheel
hub. The rear wheel hub is the most popular location, and most of the large
Chinese market is utilising rear hub motors. Rear wheel hubs are thought to be
best for throttle-controlled bikes, whereas the other locations work well with e-
bicycles that only provide electric power when the pedals are being used (pedal
assistance). The mid-mount motor is the fastest growing segment, in part due to
strong competitors like Panasonic and relatively new competitors including Bosch
and AEG.

1.1 . STATEMENT OF PROBLEM
Present modern day world, there are two main issues which are causing trouble for
mankind is the global warming which is caused by extensive use of combustibles and
automobiles even for short distances also. Due to this there is an immense effect on
environment and also depletion of fuel sources. The second concern is that lot of
people are now majorly suffering from novice health issues. this is because lack of
proper exercise. so i came up with the new pioneering idea in modern transportation
world and named as solar powered health bicycle which can make people walk while
they ride.
In our day to day life we see that many people’s use bikes cars as a source of
transportation. This results in environmental pollution and fuel consumption. In
manual treadmill the motion of the treadmill is rough to overcome this we use a motor
to rotate the rotors. Batteries which are widely used in automobile sector is not
rechargeable thus when they disposed create pollution. To improve all above
phenomenon we take initiative by designing something which would help to reduce
these harmful phenomenons.

2. OBJECTIVE
The solar powered health cycle is totally new gateway in transportation. with the solar
powered electrical assistance it take a very minimal effort to walk than "a walk in
park". Its main working comprises of solar panel with voltage regulator and boost
converter, a brushless direct current motor, a sealed lead ion battery, and the tread
mill belt, all these components makes cycle run smoother, easier and in very
conventional way. by this the rise in pollution can be greatly minimized and also
make people exercise while they travelling to various destinations. and ultimately the
depletion of natural resources can be minimized.

3. METHODOLOGY
3.1 . METHOD :
3.1.1 . DESIGN :
In our attempt to design a walking bike, we have adopted a very careful approach.
Total design work has been divided into two parts mainly,
1 ) System Design.
2 ) Mechanical Design.
System design mainly concern with the various physical concern and ergonomics,
space requirements, arrangement of various components on the main frame of
treadmill, arrangement of tread belt and rollers, position of braking system,
arrangement of motor, sprockets, ease of maintenance, scope of further
improvements, ground clearance etc. In mechanical design, the components are
categorized into two parts.
1) Design Parts.
2) Parts to be purchased.
For design parts, detailed design is done and dimensions thus obtained are compared
to next highest dimensions which are readily available in the market. This simplifies
the assembly as well as post production servicing work. The various tolerances on
work pieces are specified in the manufacturing drawing. The process sheets are
prepared and passed on to the manufacturing drawing. The process sheets are
prepared and pass on to the manufacturing stage. The parts are to be purchased
directly are specified and selected from standard catalogue.

3.2 . WORKING PRINCIPLE :
The working of the health cycle is as follows; they are four stages of working
mechanism, in the first stage the solar panel play a key role, as we are running on
solar energy, the sun rays contains of photons come and directly hits the solar panel
which consists of schematic arrangement of solar cells , convert the photons into
electrical energy using photovoltaic effect. The second stage consists of charge
controller, voltage regulator, battery, in which the electrical energy from panel is in
form of un controlled stage which in turns convert it into controlled state and voltage
regulator regulates the voltage i.e; input voltage is converted into higher regulated
voltage and stored in sealed lead ion battery of suitable amp power. In the third stage
the energy stored in battery is the passed through the DC-DC boost converter and is
then supplied to the brushless direct current motor which contains a permanent
magnet and provides high torque and smooth noiseless operation which is fitted into
the rear end of the cycle. Finally in the fourth stage, the sprocket and chain drive
mechanism takes place . The power from motor is then transferred to the tread mill
belt connected to the couple of rollers in front and rear of belt through sprocket and
chain which is fitted in the rear end off the wheel and treadmill belt and then the belt
turns moving the person in required direction.
Fig-01- Catia Designed Cycle Model

Fig-02- Working Principle Diagram

3.3 . WORKFLOW
sun rays consists of photons hits solar panel and electrical energy is generated
Electrical energy generated goes to battery via charge controller and voltage
regulator
Energy stored in battery is given to the motor via DC-DC boost converter
Power from motor is transferred to treadmill belt via sprocket and chain
mechanism.

4 . DESIGN OF WALKING CYCLE :
4.1 . DESIGN REQUIREMENTS :
The basis of this project is to construct a system for an electric bike. There are many
key components within the block diagram for this system. They consist of a lithium-
ion battery, a motor controller, a DC-DC converter, a photo-voltaic solar panel, and a
brushless DC motor. The power brakes and throttle/cruise controller are simple button
systems that are used to trigger the functions for increasing speed, keeping the speed
constant, and turning off the motor. The majority of the components were purchased
from Golden Motor Technology Co Ltd. This maximized the interfacing capabilities
for the separate block diagrams. The power source for the system was a DC battery
source chosen to output 48V, which was the maximum output voltage on the Golden
Motor website. The battery was primarily chosen due to the lithium ion cells used to
configure it. A lithium ion battery was the most efficient choice for an electric bike
because it offers high energy density while remaining relatively light-weight and
compact in size.
Lithium ion batteries can be very dangerous; therefore it is essential to research the
quality of the lithium ion cells and the protective implementations used. The Golden
Motor battery has a high voltage rating diode at the output, and uses it as a current
protector. This is essential to the project requirement for interfacing multiple forms of
charging such as solar energy, mechanical energy, and high AC voltage through an
outlet.
The battery block is interfaced with the motor controller block. The motor controller
controls all the functional capabilities and is the central component of the system. The
basic requirement for the control is to regulate the amount of power applied to the
motor, especially for DC motors. The motor controller can be adjusted to synchronize
with other brushless motors. There are also many built-in functions for this controller

that vary from detecting any malfunctions with the motor hall sensors, the throttle,
and the brake levers to protect functions against excessive current and under-voltage,
which are ideal for protecting the lithium ion battery. These functions are beneficial to
the success of this project and also provide a solution to any troubleshooting and
damages that may occur.
One key feature that is integrated with the interface of the controller and the motor
was the regenerative braking. A regenerative brake is an energy recovery mechanism
that reduces the bicycle’s speed by converting some of its kinetic energy into a useful
form of energy instead of dissipating it as heat from conventional brake friction. The
energy is then supplied back to the power source. The control allows the battery to
interface with the motor to be bidirectional which can supply and receive power.
Software is provided with the controller so that it can adjust the setting and operations
for several of the controller’s functions. By creating a switch that purposely is
“fooling” the controller to use the motor as a generator without completely braking
the wheel, it is possible to generate mechanical energy through pedalling.
Another source of battery charging comes from the photovoltaic solar panel. Initially
a light-weight and flexible solar panel was desired. For an output power of 20 watts or
higher the prices ranged from $200 - $400. Due to the project’s limited budget and its
investment in an expensive lithium ion battery, the budget for a solar panel was
approximately $50. The solar panel with the same requirements of output 12V and 20
watts was found on E-bay. Once a voltage and current is generated through the solar
panel a DC – DC boost converter block is needed to step the output voltage from the
solar panel to match the battery’s voltage of 48V. The power must be conserved in a
converter therefore, as the voltage in increased, the current is decreased. It is more
efficient to have a higher current input to the boost converter but for the current
budget and resources, it is not practical. Due to the inefficient charging power
supplied to the battery, it is not realistic for the solar panel to fully charge the battery.
Its primary purpose is to provide a longer life cycle for the battery and to provide
some charge when access to an outlet is not available.

4.2 . COMPONENTS OF WALKING BI-CYCLE :
Main components of Walking Bike are:
 Tread Mill Belt.
 Motor.
 Electric Bike Battery.
 Brushless Direct Current Motor.
 Solar Panel/ Cell.
 Voltage Regulator.
 Lead Acid Battery.
 Motor Controller.
 Lithium- Ion Battery.
 Accelerator/ Throttle.
 Dc-Dc Boost Converter.
 Solar Bi-cycle.
4.2.1 . Tread Mill Belt:
Tread belt comes in one-ply and two-ply options. One-ply tread belts are basically the
cheapest option, needing replacement over time whereas two-ply tread belts are
thicker and last much longer. Some tread belts come with cushioning and impact
absorption which is highly recommended for your joints and comfort level. People
with muscles or joint problems or obese users are advised to opt for a more cushioned
running surface. Tread belts having harder surface may be used but cushioned docks
are highly recommended. This is an important feature as it will help to make impact

less jarring to your joints. Many treadmills can cushion up to 23% of the impact, with
12-14% being the average.
4.2.1.1 . MATERIAL USED :
4.2.1.1.A . Nylon Rubber Fabric:
Standard material available for tread belt is nylon fabric. So we use this material for
treadmill belt. Nylon rubber fabric is cheap and easily available, less in cost & having
property of wear resistance.
4.2.2 . Motor:
While many people just compare the horsepower of the motor, actually look at the
type of motor in addition to the horsepower. Basic treadmill motor are available with
2.5hp (horsepower) and 1440 rpm. It is not suitable for driving on roads due to traffic
issues. Also it will leads to accidents so for the walking bike we use a common
traction motor with 0.3 hp and 300 rpm. With this much of speed the cycle can be
drive easily.
4.2.3 . Electric Bike Battery:
Electric bike batteries typically come in 24V, 36V, 48V and 72V batteries. Here is
another analogy: electricity is water. If it is water flowing through the wires (tubes),
then higher voltage means that the water (energy) moves faster, and through a smaller
tubes typical battery is 36V on most E-Bikes with some at 24V and some at 48V. the
electric bike manufactures spec these because they provide a good power to cost ratio.

4.2.4 . Brushless Direct Current Motor :
The hub motor is a conventional Dc motor. The rotor is outside the stator with the
permanent magnets mounted on inside. The stator is mounted and fixed onto the axle
and the hub will be made to rotate by alternating currents supplied through batteries.
Hub motor generates high torque at low speed, which is highly efficient and which
doesn’t need sprockets, brackets and drive chains.
This means they are very reliable and have a long life. The main characteristic of
Brushless DC Machines is that they may be controlled to give wide constant power
speed ranges.
Choosing a motor was the first step in creating an appropriate system for the electric
bike. Initially, the project was to be driven by DC micro motors that were configured
to turn a sprocket. The sprocket is used to transmit rotary motion between two shafts.
To change gears and speeds of the bicycle, the diameter of the sprocket needs to be
changed. Instead of having multiple sized sprockets in parallel, the initial idea was to
place multiple micro motors in parallel to increase the amount of current supplied to
the sprocket for more output power. This system seemed to be over complicated and
the micro motors would not supply enough power and torque to support a bicycle at
high speeds.
It was settled that the best solution in driving the bike is with an electric DC motor;
thus, creating an electric bike. In the DC motor, a static field flux is induced using
permanent magnets or a stator field winding. Located on the rotor of the DC motor is
the armature winding. The armature winding is the series of conducting coils, each
connected in segments of a commutator that are wound around the iron core in which
voltage is induced. This causes it to rotate within a magnetic field; if the wires are
broken or damaged, the armature will not rotate properly. For the DC motor to
generate any torque, the coils of the armature must be connected to an external DC
circuit with an even number of brush heads. a circuit model of a DC motor.

The application of DC motors has increased dramatically. As technology advances,

new and improved designs of the DC motor will be implemented. Brushless DC
(BLDC) motors are the primary choice for a wide variety of applications. The BLDC
motor system is emerging as one of the most useful drive options for a wide range of
applications ranging from small, low power fans and disc drives, through medium size
domestic appliance motors and up to larger industrial and aviational robotic and servo
drives .
When comparing a typical DC motor to an AC motor, the fundamental advantage is

the ease with which the motor can be controlled to give varying speeds, direction, and
even regenerative breaking. The main drawback to the DC motor is that the carbon
brushes of a conventional DC motor wear down and create a great amount of dust.
This in-turn requires a great amount of maintenance and lead to the overall
replacement of the motor itself. Another major problem that conventional DC motors
have is their high level of radio frequency interference (RFI). The RFI generated by
the brush gears can be of major concern to communications between certain aspects
of a DC motor application and may cause failure. Thus, the brushless DC motor was
developed to have the same advantages of a conventional DC motor, without the
problems and disadvantages caused by the brushes.
The main advantages and characteristics of a BLDC motor compared to a

conventional DC motor include :
 Longer life and higher reliability
 Higher efficiency
 Ability to operate at various speeds, including high speed applications
 Can reach peak torque from stand still
 Construction of motor rigid

 Operational in vacuum or in explosive or hazardous environments
 Eliminates radio frequency interference due to brush commutation
 Heat is generated in the stator: Easier to remove and maintain.
 Rotor has permanent magnets vs. coils thus lighter less inertia: Easier to start
and stop
 Linear torque/current relationship smooth acceleration or constant torque
 Higher torque ripple due to lack of information between sectors
 Low Cost to manufacture
 Simple, low-cost design for fixed-speed applications
 Clean, Fast and Efficient
 Speed proportionate to line frequency (50 or 60 Hz)
 Complex control for variable speed and torque
All of this contributed to the decision to use a BLDC motor as the driving source of
our electric bike. The benefits of the BLDC motor give the electric bike the reliability
and features it needs to make it a practical and reliable alternative source of
transportation.
Compared to a typical DC motor, the BLDC motor implements an electric

commutator instead of a mechanical commutator which, in effect, increases the
reliability. Additionally, the rotor magnets in a BLDC motor generate the rotor’s
magnetic flux, in turn giving it higher efficiencies than a normal DC motor. The
BLDC motor is essentially the opposite of a brushed DC commutator motor, in which
the permanent magnets in the motor rotate around the conductors while the
conductors are stationary. Current polarity in the DC commutator motor is controlled

and varied by the brushes and commutator. With the BLDC, the polarity of the
current is driven by power transistors that switch
synchronously with respect to the rotor position. In order to monitor the position of
the rotor, sensors are typically used, one of which is the Hall Effect sensor which is
not needed in conventional DC commutator motors. a conventional DC motor vs. a
BLDC motor for comparison. With the combinations of the hall sensors, the BLDC
provides the most efficient way to power and drive a bike. The stripped down view of
the motor that is being implemented in the overall design.
Table No-01-BLDC Motor Specifications
Type and Design of Motor Hub and Brushless Direct Current
Power Rating 250W
Torque 12 N-m
Speed (rpm) 300
Rated Voltage(V) 24
Efficiency(%) 80 % (approximately)
Noise(db) <65
Weight(kg) 4
Fig-03-BLDC Motor

4.2.5 . Solar Cells/ Panels
As the title suggests the bicycle is operated by solar energy. The lead acid battery is
charged with solar energy with the help of a solar cell. Solar cells convert the energy
of sunlight directly into electricity through the use of the photovoltaic effect. The
photovoltaic effect involves the creation of a voltage into an electro-magnetic
radiation. The photoelectric and photovoltaic effects are related to sunlight, but are
different in that electrons are ejected from a material’s surface upon exposure to
radiation of sufficient energy in photoelectric, and generated electrons are transferred
to different bands of valence to conduction within the material, resulting in the build-
up of voltage between two electrodes in photovoltaic.
Solar cells are electrically connected and fabricated as a module with a sheet of glass
on top to allow light to pass and protect the semiconductor from the weather. To
obtain a desired peak DC voltage we will add solar cells in series, and to obtain a
desired peak current, the solar cells are put in parallel position.
Solar cells are devices that convert the energy of sunlight directly into electricity
through the use of the photovoltaic effect. The photovoltaic effect involves the
creation of a voltage in a material upon exposure to electro-magnetic radiation The
photoelectric and photovoltaic effects are related through sunlight, but are different in
that electrons are ejected from a material’s surface upon exposure to radiation of
sufficient energy in photoelectric, and generated electrons are transfer to different
bands of valence to conduction within the material, resulting in the build up of
voltage between two electrodes in photovoltaic.
Solar cells are often electrically connected and en-capsule a sheet of glass on top to
allow light to pass and protect the semiconductor from the weather. To obtain a
desired peak DC voltage with solar cells, you add them in series, and to obtain a
desired peak current, you add the solar cells in parallel. In order to calculate the
standard energy of an application, kilowatt-hours per day is used. The general rule of
thumb is that average power is equal to twenty percent of peak power, so that each

peak kilowatt of solar array output power corresponds to energy production of 4.8
kilowatt-hours per day .
High efficiency solar cells are a class of solar electricity per incident solar power
unit. Most of the industry is focused on making the most cost efficient solar cell in
terms of cost per generated power. There are many different types of high efficiency
solar cells. The three main types of the high efficiency solar cells are multi-junction
solar cells, thin-film solar cells, and crystalline/bulk silicon. Out of all these choices
of solar cells, we selected a polycrystalline solar cell, type. solar energy has been one
of the most used, cleanest, and sustainable forms of which is the bulk type silicon. We
chose this cell over the other cells based on cost and the amount of efficiency we
needed. The multi-junction solar cell is much too expensive for our budget, and the
thin-film solar cell is not that reliable. The crystalline type solar cells were the most
reliable and commercially available Mono crystalline may be more efficient, but with
the application we’re using, it would not matter if we used either crystalline solar cell.
Polycrystalline was cheaper and provided a sufficient amount of output voltage and
wattage for the boost converter. The solar cell was bought on E-bay for about $50 by
the company A sun power Inc. It provides an output voltage of about 12V and 20 W
with a lifespan of about 25
years. This module’s efficiency is about 10%, which is sufficient in our application.
The dimensions are 22 in. × 14.2 in. × 0.98 in. We decided to mount the solar panel
on top of the battery, which is located above the rear tire. This way, the rider is not
prevented from riding the bike comfortably and protects the battery from directly
being heated by the sun. There will be housing for the solar cell that will keep it in
place and provide protection from damage.
 Advantages :
Solar energy has been one of its most used, cleanest , and sustainable form of energy
obtained through solar cells. They are environmentally friendly with no use of any
fuels or release of toxic fumes that may cause global warming. Solar cells are
independent from a power source and can charge constantly, which helps lower time

to charge through a high AC voltage charger. They also have a long life span of at
least twenty years and require little to no maintenance.
 Disadvantage :
With all its advantages, there are some disadvantage to solar cell as well. Solar cells
are not easy to manufacture, so their prices are high and increase with a watt needed.
Sunlight is not always provided, especially at night, and may not be evenly distributed
where you’re located, so it cannot always provide the sufficient amount of power.
Therefore, it cannot be used as a primary source of charging, since it is also not highly
energy efficient.
 Innovations :
There are currently more advanced ways solar cells which can be ,mounted on the top
of bike. There are bendable forms of solar cells and can be applied around the frame
to conserve space and lower weight on the bike. Solar cell wheels that act like hub
caps
to the bike are also available. These means may be more intuitive, but they are not
cost efficient. They each run for about $300 at least. If we had the means to afford it,
we would have used those solar cells instead. They are more energy efficient and have
higher output voltage and wattage.
There are also different forms of solar cells being made besides the typical solar
panels. Inflatable solar balloons, “hairlike” solar nanowires, and printed solar panels
are among the different types that have recently been made. These new forms of solar
cells are currently working and are trying to be more efficient than current forms.
They can possibly be used on the bike to conserve even more space.
Table No-02-Solar Cell Specifications
Maximum Power (Watt) 20
Charging Current (Amp) 2
Open Circuit Voltage (V) 21.6
Max Power Voltage (V) 17

Short Circuit Current 1.316
Power Measured at Standard Test 1000W per m2 at 25 C

Condition
Lifespan 25 years
Size 500mm × 338mm. × 35mm
Fig -04- Solar Panel
4.2.6 . Voltage Regulator :
It is essential to regulate the voltage output from the solar panel before it is supplied
to the battery. A voltage regulator is a power converter with an output DC voltage
greater than the input DC voltage. This is used to regulate an input voltage to a higher
regulated voltage. The output of the solar panel is not always be stable due to
fluctuations in intensity of sunlight, angular changes with respect to the direction of

sunlight, as well as other environmental factors. This is the voltage regulator/Boost

Converter comes into SAB. The output of the solar panel is the input of the boost
converter, which then outputs into the battery for charging. Because the output of the
solar panel will be varying constantly, we need a voltage regulator/boost converter
that will take an input from a wide range of voltages and output a specific, constant
voltage value. A voltage regulator/boost converter is a power converter that will take
in a DC voltage and output a higher value DC voltage. Our voltage regulator/boost
converter requires output of the solar panel, which can range from 0V to 27.2V, and
output for charging of the battery. We were initially attracted to the SPV Instruments
Module because it has the characteristics of taking in an input range of 9.6V to 13.2V
and outputting 24V at a maximum of 2-3 amps .This SPV has an area of 2.5 square
inches so it is also small in size, which makes it very feasible to be placed anywhere
on the bicycle. We go thought the battery voltage & we need to supply 24V in order
to charge it.
Table No-03- Voltage Regulator
Output Voltage 24 V
Open Circuit Voltage 26.8 V
Amp- Hour Rating 10 A
Fig-05- Voltage Regulator

4.2.7 . Lead Acid Battery :
Lead acid batteries are one of the most popular types of battery in electronics.
Although slightly lower in energy density than lithium metal, lead acid is safe,
provided certain precautions are met when charging and discharging. This have a
many advantages over other conventional types of batteries, the lead acid battery is
the optimum choice for a solar assisted bicycle. Current supplied from battery
indicates the flow of energy from the battery and is measured in amperes (or Amps) .
The higher the current flow faster the battery will discharge. A battery is rated in
ampere-hours (abbreviated Ah) and this is called the battery capacity. This project
revolves around supplying and utilizing energy within a high voltage battery . It
demands for a battery with longer running hours, lighter weight with respect to its
high output voltage and higher energy density. Among all the existing rechargeable
battery systems, the lead acid cell technology is the most efficient and practical choice
for the desired application. The battery chosen for this project was a high capacity
lead acid battery pack designed specifically for vehicles. Plastic casing is provided to
house the internal components of the battery.
Table No-04- Lead Acid Battery Specifications
Open Circuit Voltage (Volts) 28.7 V
Charging Time 8-9 Hours
Amp Hour Rating 35 Amph
Voltage 12 V
Cycle Life 5 Years
Operating Temperature C -10 TO 60

Fig-06- Lead Acid Battery
4.2.8 . Motor Controller :
The motor controller is an important component of the system. It is essential to

control the amount of power supplied and to drive the BLDC hub motor. The
controller converts the DC voltage from battery to an alternating voltage with variable
amplitude and frequency that drive the hub motor at different speeds. It basically
consists of MOSFET transistors and small microprocessor that vary from detecting
any malfunctions with the motor hall sensors, the throttle, to protect functions against
excessive current and under-voltage, which are ideal for protecting the system.
To drive and control the BLDC motor, the use of a motor controller was implemented.
The motor controller is an essential device for any motor driven device. The motor
controller is analogous to the human brain, processing information and feeding it back
to the end user. Of course, the applications of a motor controller vary based on the
task that it will be performing. One of the simplest applications is a basic switch to
supply power to the motor, thus making the motor run. As one utilizes more features
in the motor, the complexity of the motor controller increases.
To drive the BLDC motor, the motor controller sends rectangular/trapezoidal voltage
stokes that are coupled with the position of the rotor. The timing diagram of the

voltage stokes applied with respect to the rotor position dictated by the Hall Effect
sensor.
The voltage stokes of the BLDC motor need to be applied to the two phases of the 3-
phase winding system so that the angle between the stator, flux and the rotor flux is
kept close to 90 degrees in order to generate maximum torque from the motor. In
order to do that, the motor controller is used to electronically control when the voltage
strokes are applied.
The power stage of the BLDC motor uses six transistors in order to switch on and off
the signals that are being delivered to each individual phase of the motor. Any timing
offset will ruin the timing of the voltage strokes, thus running the motor less than the
maximum efficiency.
The overall system of a BLDC with the motor controller is represented. The inputs to
the controller include the speed and current signals that are supplied by the throttle.
The DC power supply feeds power to the motor controller, which then distributes the
voltage and current necessary to drive the BLDC motor. The Hall Effect sensors
provide the feedback needed for the motor to know the position of the rotor and to tell
it when to supply the voltage stoke to the different phases of the BLDC motor.
4.2.9 . Lithium- Ion Battery :
This project revolves around supplying and utilizing energy within a high voltage
battery. It demands for a battery with longer running hours, lighter weight with
respect to its high output voltage and higher energy density. Among all the existing

rechargeable battery systems, the lithium ion cell technology is the most efficient and
practical choice for the desired application. The battery chosen for this project was a
high capacity lithium ion battery pack designed specifically for electric bikes by
Golden Motor Technology Co Ltd. Aluminium casing is provided to house the
internal components of the battery yet remains at a reasonable weight below 12.12
kgs. The battery is rated is at 48V, 12AH. A maximum electrical output results at an
approximate constant speed of 50km/h (31mph). The amount of charging cycles of
the battery is greater than 800.
Lithium ion batteries are one of the most popular types of battery for portable
electronics. Although slightly lower in energy density than lithium metal, lithium-ion
is safe, provided certain precautions are met when charging and discharging. With its
many advantages over other conventional types of batteries, the lithium ion battery
was the optimum choice for an electric powered bicycle.
 Advantages :
Advantage with lithium-ion batteries are that they often are much lighter than other
energy equivalent secondary batteries. The electrodes of a lithium ion battery are
made of lightweight lithium and carbon. A key advantage of using lithium-ion
chemistry is the high open circuit voltage that can be obtained in comparison to
aqueous batteries (such as lead acid, nickel-metal hydride and nickel-cadmium). This
is beneficial because it increases the amount of power that can be transferred at a
lower rate of current. Lithium is also a highly reactive element, meaning that a lot of
energy can be stored in its atomic bonds. This translates into a very high energy
density for lithium-ion batteries and has the best energy to weight ratio than other
battery configurations. Also, the battery cells are able to hold their charge with
minimum losses when not in use. This allows for relatively long storage periods with
high residual capacity.

A lithium-ion battery pack loses only about 5 percent of its charge per month,
compared to a 20 percent loss per month for NiMH batteries. The relatively low self-
discharge is less than half that of nickel-based batteries. Another advantage with
lithium ion cells is that they have no memory effect, which means that you do not
have to completely discharge them before recharging and no scheduled cycling is
required to prolong the battery's life, as with some other battery chemistries. Thus,
there is no need to pre-discharge the battery upon fully charging the cells, which
provides low maintenance. Lithium-ion batteries can handle hundreds of
charge/discharge cycles, and therefore, performance and use are not affected. One
regular charge is all that is needed and they cause little harm when disposed. The
protection circuit board for the lithium ion battery from Golden Motor provides for
extremely safe usage. It is possible to use under extreme weather temperatures and it
is possible to be stored in insulated areas, such as a car. It also was designed to
prevent any explosions or fires upon any impacts or collisions. The protection circuit
board provides ideal protection features for bicycle applications and conditions.
 Disadvantages :
Despite its overall advantages, lithium-ion has its drawbacks. The high energy density
comes at a price. Manufacturing methods become more critical the denser the cells
become. With a separator thickness of only 20-25µm, any small intrusion of metallic
dust particles can have devastating consequences. It is fragile and requires a
protection circuit to maintain safe operation. Built into each pack, the protection
circuit limits the peak voltage of each cell during charge and prevents the cell voltage
from dropping too low on discharge. In addition, the cell temperature is monitored to
prevent temperature extremes. The maximum charge and discharge current on most
packs are is limited to between 1C and 2C. With these precautions in place, the
possibility of metallic lithium plating occurring due to overcharge is virtually
eliminated.

Aging is a concern with most lithium-ion batteries and many manufacturers remain
silent about this issue. Some capacity deterioration is noticeable after one year,
whether the battery is in use or not. The battery frequently fails after two or three
years. It should be noted that other chemistries also have age-related degenerative
effects. This is especially true for nickel-metal-hydride if exposed to high ambient
temperatures. At the same time, lithium-ion packs are known to have served for five
years in some applications.Storage in a cool place slows the aging process of lithium-
ion cells. Manufacturers recommend storage temperatures of 15°C (59°F). In addition,
the battery should be partially charged during storage. The manufacturer recommends
a 40% charge.
 Innovations :
It is also possible to create a battery for this project by using lithium ion polymers
batteries rather than lithium ion cells. The primary difference between the two is that
the lithium-salt electrolyte is not held in an organic solvent but in a solid polymer
composite. They are also much cheaper and cost efficient due to the type of materials
used to manufacture it and also eliminating the need for sophisticated protection
circuit boards and advanced battery management system. Connecting several of these
cells in series, it can provide desired voltage ratings while connecting additional cells
in parallel will provide a higher output current with respect to time.
Lithium ion polymers have faster charging capabilities and safer performance than
traditional lithium ion batteries. Currently, the leading choice for lithium ion polymers
is lithium iron phosphate (LiFePO4) because of its large capacity and high power
applications. It has characteristics that provide safer performance use, similar to lead
acid batteries, but still remains as powerful as lithium ion cells. Lithium ion polymer
batteries, the "plastic" batteries, are packed by aluminium coated foil, and are much
safer than liquid lithium-ion cells with metal cases. Their energy densities are 10
percent to 15 percent higher than the normal liquid lithium ion batteries, and are

perfect for portable devices requiring high power and low weight. The C-coated
Lithium Iron Phosphate Battery has been proven as the most environmental friendly
battery. It is the safest and most suitable for high output usage and the best for storage
battery usage.
4.2.10 . Accelerator/Throttle :
The maximum speed of a bicycle is 30 kmph. It is required to vary the speed

depending upon the road conditions & traffic. Therefore an accelerator or a throttle is
necessary. Throttle allows us to drive the motor from zero speed to full speed. The
throttle is fitted on right side of the handle bar and is connected to controller. The
throttle converts DC voltage from battery to an alternating voltage with variable
amplitude and frequency that drives the hub motor at different speeds. It consists of
MOSFET transistors and a small microprocessor. This throttle is technically referred
to as a Hall Effect type. The throttle has three wires contains a black, red, and green.
The supply voltage is via red and black wires and is usually around 4 volts. Green
wire voltage increases as the throttle is turned.
4.2.11 . DC-DC BOOST CONVERTER :
Including the solar panel into the electric bicycle not only presents an extra source for
charging the battery, but also an extra problem. The problem is that the output of the
solar panel will not always be stable due to fluctuations in intensity of sunlight,
angular changes with respect to the direction of sunlight, as well as other
environmental factors. This is where the Boost Converter comes into our project. The
output of the solar panel will be the input of the boost converter, which then outputs
into the battery for charging. Because the output of the solar panel will be varying

constantly, we need a boost converter that will take an input from a wide range of
voltages and output a specific, constant voltage value. A boost converter is a step-up
power converter that will take in a DC voltage and output a higher value DC voltage.
Our boost converter will require us to take in the output of the solar panel, which can
range from 0V to 17.2V, and output 54.6V for optimal charging of the battery. After
researching websites, we came upon two different evaluation module boards: the
TPS40210EVM from Texas Instruments and the DC1286A-A from Linear
Technology.
We were initially attracted to the Texas Instruments Evaluation Module

TPS40210EVM because it has the characteristics of taking in an input range of 9.6V
to 13.2V and outputting 24V at a maximum of 2 amps. This EVM has an area of 2.5
square inches so it is also very small in size, which makes it very feasible to be placed
anywhere on the bike. We originally thought that since the battery is rated at 48V, we
would need to supply exactly 48V in order to charge it. This could be done by using a
simple voltage doubler added to the output of the EVM and we should theoretically
have the appropriate 48V needed for charging. After more research and finding out
that we need to provide 54.6V for the battery, we began searching for another
converter which would require less modification to obtain 48V. Seeing that this board
was already in our possession, we decided to run Or Cad P-Spice simulations to find
out exactly how much modification was needed in order to get the desired output.
This can be seen in the Testing Procedures section. The Linear Technology
Evaluation Module DC1286A-A seemed very nice for our application. This EVM
operates at an input range of 5V to 36V. It outputs a constant 48V with an output
current of 2A-5A. Initially, this evaluation module is the perfect fit for charging our
battery because it takes an input in the range of our solar panel, but it also outputs the
exact amount of voltage needed to charge the battery. After discovering that we would
require a 54.6V output, changes to the voltage divider must be made to account for
this. The details can be seen in the Testing Procedures section.
4.2.12 . Solar Bicycle :

”The solar assisted bicycle is driven by DC motor fitted in front axle housing &
operated by solar energy. The solar panel mounted on the carriage is charge the
battery & which in turn drive the hub motor. When the bicycle is idle during the day,
the solar panel will charge the battery. The system will make bicycle operate more
efficiently The basic configuration of an solar bicycle drive consists of a controller
that controls the power flow from the battery to the electric motor. This power flow
acts in parallel with the power delivered by the rider via the pedal of the bike. The
rider of an solar bicycle can choose to rely on the motor completely, pedal and use the
motor at the same time or pedal only (use as a conventional bicycle).
This arrangement is replace the petrol engines, the gear box & the fuel tank in case of
a two wheeler or chain sprockets, chains & gear shifting arrangement of a
conventional bicycle being used by most common man.
4.3 . DESIGN OF MAIN FRAME COMPONENTS
4.3.1 . Treadmill Frame design:
4.3.1.1 . Material- Mild Steel:
As the standard available tread belt size is (980*340) mm. Frame design is done
according to the tread belt size. As per space availability and clearance for reduction
of friction, frame size is (1090*410) mm.
Frame consists of a 21 rollers, in which first and last roller is for movement of belt
and other are supportive rollers. Rollers are fitted in frame by means of bush.
Mild Steel:

The frame of treadmill and front & rear rollers are made up of mild steel.
Reasons:
1) Mild steel is readily available in market.
2) It is economical to use.
3) It is available in standard size.
4) It has good mechanical properties i.e. it is easily machinable.
5) It has moderate factor of safety, because factor of safety results in unnecessary

wastage of material and heavy selection.
6) It has high tensile strength.
7) Low co-efficient of thermal expansion.
Properties of Mild Steel:
M.S. has carbon content from 0.15% to 0.30%. They are easily wieldable thus can be
hardened only. They are similar to wrought in properties. Both ultimate tensile and
compressive strength of these steel increases with increasing carbon content. They can
be easily gas welded or electric or arc welded. With increase in the carbon percentage
weld ability decreases. Mild steel serves the purpose and hence selected because of
above purpose.
4.3.2 . Design of Front and Rear Roller :

Width of the frame is 410 mm. So we choose length of rollers as 400mm. To reduce
the friction of belt with frame 5 mm clearance is provided on both sides. Front roller
is of diameter 58mm and that of rear one have diameter 49mm. For easy and fast
movement of belt some taper should be provided to belt that’s why front roller is large
in diameter and rear is in small diameter. Rollers are connected to frame by using MS
rod of diameter 10 mm. PVC bush are placed in front roller and deep groove ball
bearing 6000, which is use for light weight operation is used. Rear roller is directly
welded to 10mm MS rod.
4.3.3 . Design of Supportive Rollers:
This roller serves the purpose of support to the tread belt. 19 supportive rollers are
fitted in frame structure. They are made up of a PVC material. The PVC pipes have
diameter of ¾ inch that is 19.05 mm and length is 390mm. All the design calculation
of frame and rollers is done on the basis of load carrying capacity of walking bike and
space availability. Load carrying capacity of walking bike is 100 kg.
PVC(Polyvinyl chloride):
PVC pipes are used as a supportive roller in treadmill frame. PVC pipes are used
because those are light in weight, easily available, cost is less and also having a
smooth surface finish which gives smooth motion of belt on the surface of supporting
rollers.
4.4 . DESIGN OF SPROKETS :

4.4.1 . 1st gear reduction ratio (motor to freewheel):
i=N2/N1 i=1.909
Table No-05- 1st Gear Reduction Details
Component Speed No. Of Teeth
Motor 50 RPM 42
Free Wheel 95.45 RPM 22
4.4.2- 2nd gear reduction ratio (motor to roller):
i=N2 /N1 i=1.235
Table No- 06- 2nd Gear Reduction Details
Component Speed No. Of Teeth
Free Wheel 90.45 RPM 22
Free Wheel to Cycle 70.68 RPM 16
4.4.3- 3rd gear reduction ratio (freewheel to freewheel of cycle):
i=N 2/N 1 i=0.74
1) 0.74Gear ratio is used to control the speed of cycle to 70.63 rpm and also to get
more torque.
2) We get more torque using this ratio and we can carry more weight on cycle.
Table No-07-Overall Gear Reduction Details
Primary Gear Reduction Secondary Gear Final Gear Reduction

Ratio Reduction Ratio Ratio

1.909 1.235 0.74
Table No-08- Overall Speed Details
Primary Speed Secondary Speed Final Speed
50 61.75 70.68
4.5- FUTURE IMROVEMENTS IMPLIMENTED
Walking bike has some advantages and some disadvantages. the main disadvantage of
walking bike is its discharging battery. Due sudden discharge of battery in between of
travelling leads to face many problems to overcome this disadvantage we can do some
improvements in present model.
To overcome this discharge problem we can install a solar panel to the system it will
recharge the battery and continuous movement of walking bike can be possible. Solar
panel is one of the simplest ways to charge the battery.
Another way is generation of electricity by using dynamo generator. The mechanical

energy generated by human due to walking on tread belt is converted to electrical
energy by using dynamo generator. It will produce a small amount of energy. Small
increment of energy in rechargeable battery will move the bike continuously.

5 . RESULT
The cycle which we have developed has been an important aspect in green
transportation. From my experimental observation it has been found that, solar panel
which we have installed takes 4 hours to fully charge the battery( the power of battery
and solar panel has been taken in experimental condition). It has also been founded
that the balancing of the cycle on principle of gyroscopic principle had worked out
beneficiary in every kind of road condition. Finally the cycle which i have developed
had been a satisfaction in our project.

6 . CONCLUSION
Solar powered health bicycle is modification of existing walking bicycle. In this we
have made a shear modification of treadmill and cycle running through solar assisted
energy, which is a non-conventional and renewable energy. It has a great variable
resistance feature which means people of young and old age can ride this bike with
great pleasure as well can attain great body fitness and also can travel to their short
from destination . It has also played a predominant role in global warming and also
took up some part in fuel less transportation method. It is completely eco-friendly and
emission free with no running cost and less maintenance. This cycle can be an
adaptable mode of transportation for rural and urban areas.

7 . SCOPE
What make the solar powered health bicycle amazing ? well we have the answer. It
has same fat burning features as regular treadmill . but what makes it special ? yes it
does because we can travel as well as we can do walking. Based on study, men burn
124 calorie in 1 km running on treadmill and 88 on walking. women on other hand
burn 110 and 75 respectively.
It allows you stay physically active while travelling at the same time. we can
practically stay healthy and do exercise at whatever time we can. if we go out often,
you get to exercise often. it features a rugged design and all terrain that let you down
through rough roads or any other paths.
we can travel seamless with the solar panel . But What do we do when there is no
sunlight ? No problem, we also came up with solution , we have installed a high
storage battery that let you drive up to the certain calculated distance .
It lets you jog or take a walk without getting your shoes dirty or modified. Because of
its hard wearing belt that offers grip, you don’t need to worry about slipping or falling
off the treadmill.
We also came up with new idea in balancing of this cycle. It consist of two guided
small wheel fitted to the rear end of the cycle with active spring that lets you give full
balance under steep turns and has good structural stability in pot holes.
But even if you are not active. You can still ride the bike by switching of the treadmill
and can reach the destination with solace.

8 . REFERENCE
[1] Design of machine members 1 by RS. KHURMI, S. Chand publications pvt.ltd
2016 edition(revised).
[2] A Text Book Of Power Plant Engineering by R.K. RAJPUT.
[3] Arsie, I., Rizzo, G., Sorrentino, M., “Optimal Design of a Hybrid Solar Vehicle,”
Proceedings of the International Symposium on Advanced Vehicle Control,
Department of Mechanical Engineering, University of Salemo, Italy.
[4] Khurmi R.S. & Gupta J.K., Theory of machines, S.chand, Delhi, 2008.
[5] Bhandari V.B., Design of machine elements, eighteenth edition, MC Graw-hill

companies,2003.
[6] Graham S. Aikenhead, (2011) “Bicycle Applications for On-Board Solar Power
Generation System Adaptation”. Guelph Engineering Journal, Vol. 4, page 9 - 23.
ISSN: 1916-1107.
[7] Grin Technologies Ltd., “e Zee Bike Conversion Kit”, October 2010.
[8] Solar Engineering of Thermal Process by John A Duffie and William A Beckman.
[9] Vijay Gupta “The bicycle story” publishes by Vigyan Prasar.
[10] . http://motorbicycling.com
[11] International Journal of Sports Medicine [1998, 19(7):455-461] M. Young, The

Technical Writer’s Handbook. Mill Valley, CA: University Science, 1989.
[12] S.S. Ratan; Theory of Machine, the McGraw. Hill Companies, Second Edition.



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Solar Powered Walking Bicycle

Malla Reddy Engineering College, (A) Page 1

1.1- STATEMENT OF PROBLEM 09

3.2- WORKING PRINCIPLE 12

4- DESIGN OF WALKING CYCLE 15

4.1- DESIGN REQUIREMENTS 15

4.2- COMPONENTS OF WALKING CYCLE 16

4.2.1- TREAD MILL BELT 16

4.2.1.1- MATERIAL USED 17

4.2.1.1.A- NYLON RUBBER FABRIC 17

4.2.3- ELECTRIC BIKE BATTERY 17

4.2.4- BRUSHLESS DIRECT CURRENT MOTOR 21

4.2.5- SOLAR CELL/PANEL 25

4.2.6- VOLTAGE REGULATOR 26

4.2.7- LEAD ACID BATTERY 28

Malla Reddy Engineering College, (A) Page 2

4.2.8- MOTOR CONTROLLER 29

4.2.9- LITHIUM-ION BATTERY 33

4.2.11- DC-DC BOOST CONVERTER 34

4.2.12- SOLAR BI-CYCLE 35

4.3- DESIGN MAIN FRAME COMPONENTS 36

4.3.1- TREAD MILL FRAME DESIGN 36

4.3.1.1- MATERIAL - MILD STEEL 36

4.3.2- DESIGN OF FRONT AND REAR END ROLLERS 37

4.3.3- DESIGN OF SUPPORTIVE ROLLERS 37

4.4- DESIGN OF SPROKETS 38

4.4.1- 1st GEAR REDUCTION RATE 38

4.4.2- 2nd GEAR REDUCTION RATE 39

4.4.3- 3rd GEAR REDUCTION RATE 39

4.5- FURTHER IMPROVEMENTS IMPLEMENTED 39

Malla Reddy Engineering College, (A) Page 3

Serial number Name of the figure Figure number

6 SEALED LEAD ION 06

Malla Reddy Engineering College, (A) Page 4

Serial Number Name Of The Table Table number

4 LEAD ACID BATTERY 04

5 1st GEAR REDUCTION 05

6 2nd GEAR REDUCTION 06

8 OVERALL SPEED RATE 08

Malla Reddy Engineering College, (A) Page 6

Malla Reddy Engineering College, (A) Page 7

Malla Reddy Engineering College, (A) Page 8

1.1 . STATEMENT OF PROBLEM

Malla Reddy Engineering College, (A) Page 9

Malla Reddy Engineering College, (A) Page 10

Malla Reddy Engineering College, (A) Page 11

3.2 . WORKING PRINCIPLE :

Fig-01- Catia Designed Cycle Model

Malla Reddy Engineering College, (A) Page 12

Malla Reddy Engineering College, (A) Page 13

4 . DESIGN OF WALKING CYCLE :

4.1 . DESIGN REQUIREMENTS :

Malla Reddy Engineering College, (A) Page 14

Malla Reddy Engineering College, (A) Page 15

4.2 . COMPONENTS OF WALKING BI-CYCLE :

Main components of Walking Bike are:

 Tread Mill Belt.

 Electric Bike Battery.

 Brushless Direct Current Motor.

 Solar Panel/ Cell.

 Lead Acid Battery.

 Lithium- Ion Battery.

 Dc-Dc Boost Converter.

4.2.1 . Tread Mill Belt: