S.D.M.

E Society’s
S.D.M. COLLEGE OF ENGINEERING &
TECHNOLOGY DHAVALAGIRI, DHARWAD-
580002

(AFFILIATED TO VISVESWARAYA TECHNOLOGICAL UNIVERSITY)

Minor Project Report on

“DESIGN, FABRICATION & TESTING OF E-BIKE”

Bachelor of Mechanical Engineering

VI Semester

Under the Guidance of

Dr. Vijay S Kamate
Assistant Professor, Mechanical Engineering
Department, SDMCET, Dharwad

Submitted by

Sl.No. USN Name

1 2SD20ME020 CHANDRAMOULIESHWAR KASBEKAR
2 2SD20ME026 GAUTAM KOLIWAD
3 2SD20ME060 SHIVASHANKARAPPA
GALAPPANAVAR
4 2SD20ME082 NIHAL M
JODALLI

DEPARTMENT OF MECHANICAL ENGINEERING

S.D.M.C.E.T, Dharwad
2022-23
 S.D.M.E Society’s

S.D.M. COLLEGE OF ENGINEERING & TECHNOLOGY

DHAVALAGIRI, DHARWAD-580002
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
Certified that the Introductory project work entitled “Design and Fabrication of
E-bike Chassis” is a bonafide work carried out at SDM College of Engineering and
Technology, Dharwad, by Mr. Chandramoulieshwar Kasbekar USN: 2SD20ME020;
Mr. Gautam Koliwad USN: 2SD20ME026; Mr. Shivashankarappa Galappanavar
USN: 2SD20ME060 & Mr. Nihal M Jodalli USN: 2SD20ME082, in partial fulfilment
for the award of B.E. in “Mechanical” of Visveswaraya Technological University,
Belagavi during the year 2022-2023. It is certified that all corrections /
suggestionsindicated for Internal Assessment have been incorporated in the report
deposited in the departmental library. The project report has been approved as it satisfies
the academic requirements in respect of Project work prescribed for the said Degree.

Dr. Vijay S Kamate Dr. I. Sridhar

Project Guide HoD Mechanical

Name of the Reviewers Signature with date

1.

2.

3.

4.
 3

ABSTRACT

The automobile sector started shifting its dependency from fossil fuel to electrical energy
in the last few decades to mitigate adverse environmental scenarios like global warming,
air pollution, etc. Due to this, the battery is emerging as the new source of power. At the
same time, the use of bikes for city transportation has been growing at a high rate in
developed countries. For a heavily congested mega city like Dhaka, electric bikes can
provide a better alternative to traditional fossil fuel vehicles. They are not only cost-
effective but also faster and can contribute to improved public health outcomes. With such
a background study, an initiative was taken to fabricate an electric bike. This paper
presents a study of its chassis design and analysis. The triangular structure was used as
thebasis of the design since this concept provides the best structural strength. Mechanical
properties such as stress, strain, and deformation at critical locations within the fabricated
chassis were compared with numerical results obtained from the state-of-the-art FEA
software ANSYS. The validated numerical method allowed to simulate the dynamic
performance of the chassis by predicting the forces on the structural member during
acceleration and braking. It is expected that the developed numerical methodology will
allow conducting exploratory designs with confidence.

An effective design performs the required task efficiently and is safe under extreme
operating conditions while being economical in the material used as well as the
manufacturing process needed yet having an aesthetic appeal. Analysis facilitates
understanding the behavior of a component under a particular loading cycle for both
failures and redundancies. Therefore, the analysis provides us with a mathematical model
which indicates the scope for optimization and weight reduction for an overdesigned
component. Keywords: Global warming • Electric bike • Chassis • Triangulation • ANSYS

Design , Fabrication and testing of E-Bike

 4

AKNOWLEDGEMENT

It’s queer to think of a clap without the striking of two human hands, similarly this work
owes a lot of credit to many people who have helped or influenced for this project

We would thank our guide Dr. Vijay S Kamate Mechanical Engineering Department
S.D.M College of Engineering & technology , for his constant support, invaluable advice,
guidance and permitting me to carry out project.

We express our earnest profound gratefulness to introductory project committee Prof.

G.L.Rajabanshi , Prof. A.V.Javali , Prof. Jayaram Bhat, Prof. Sandeep I Akki
for helping us throughout the project period in every manner.

We wish to thank Dr. K. Gopinath Principal and Dr. I. Shridhar, H.O.D Mechanical
Engineering, & Deans of S.D.M College of Engineering & technology, Dharwad for
permitting us to carry out my project.

We extend our thanks all teaching & non teaching staff members of mechanical
engineering department for the invaluable guidance, advice, and encouragement extended
by them at every phase of our work.

We would also like to thank all our friends for their support and encouragements. Finally,
Sincere thanks to our parents brothers and sisters who have always been the impetus in all
my endeavours.

Student’s name:

Sl.No. STUDENT’S NAME USN

1 Chandramoulieshwar Kasbekar 2SD20ME020
2 Gautam Koliwad 2SD20ME026
3 Shivashankarappa Galapanavar 2SD20ME060
4 Nihal M Jodalli 2SD20ME082

Design , Fabrication and testing of E-Bike

 5

CONTENTS

Certificate 2

Abstract 3

Acknowledgement 4

Table of Contents 5

List of tables and figures 6

Chapter 1 : Introduction

1.1 : Introduction to electric Vehicles 8

Chapter 2 : Literature Survey 9

Chapter 3 : About E-Bikes

3.1 : History of E-Bikes 11

3.2 : Types of E-Bikes

1. Class 1 E-Bike 13

2. Class 2 E-Bike 14

Design , Fabrication and testing of E-Bike

 6

Chapter 4 : Design Calculations

4.1 : Calculation of Drive train 15

4.2 : Selecting the size of sprocket 16

Chapter 5 : Vehicle Components 17

Chapter 6 : Testing 17

Chapter 7 : Vehicle Assembly 18

Conclusion 19

Future Scope 20

References 21

Design , Fabrication and testing of E-Bike

 7

Sl no Figure No. Content Page No

1. 1.1 Modern Electric Vehicles 8
2. 1.2 Modern Electric Vehicles 8
3. 3.1 1st Electric Bike 11
4. 3.2 Modern electric Bike 12
5. 3.3 Class 1 E-Bike (mini) 13
6. 3.4 Class 1 E-Bike (MTB) 13
7. 3.5 Class 2 E-Bike (Moped) 14
8. 3.6 Class 2 E-Bike (Motorcycle) 14
9. 6.1 Assembled E-Bike 18
List of Figures

Design , Fabrication and testing of E-Bike

 8

CHAPTER 1

INTRODUCTION

1.1 Introduction to electric vehicles

The need for alternative fuel vehicles emerged in the 1960s and 1970s due to the increased pollution from
internal combustion engines, rising prices, reliance on crude oil, and its diminishing supply. Since then,
significant efforts have been made to develop workable electric vehicles to replace present IC engine
vehicles. Despite rapidly expanding technology, electric two-wheelers have some flaws that must be tackled
to improve the vehicle's overall performance. The weight and size of the systems and components are the
primary concerns that need to be addressed to increase the vehicle's range, speed, payload, and grade ability.
Advancements in materials, improved design and analysis methods, fabrication processes, and optimisation
techniques paved the way for weight reduction. Topology optimisation can be an effective procedure to
obtain a minimum weight with maximum performance, based on the removal of conflicting constraints,
design boundaries, and design uncertainties, such as design clearance and material defects.

Fig 1.1 & 1.2 : Modern Electric Vehicles

The automotive industry has become one of the most important world-wide industries, not only at economic
level, but also in terms of research and development. Increasingly, there are more technological elements
that are being introduced on the vehicles towards the improvement of both passengers and pedestrians’
safety. In addition, there is a greater number of vehicles on the roads, which allows for us to move quickly
and comfortably. However, this has led to a dramatic increase in air pollution levels in urban environments
(i.e., pollutants, such as PM, nitrogen oxides (NOX), CO, sulfur dioxide (SO2), etc.). In addition, and
according to a report by the European Union, the transport sector is responsible for nearly 28% of the total
carbon dioxide (CO2) emissions, while the road transport is accountable for over 70% of the transport sector
emissions [1]. Therefore, the authorities of most developed countries are encouraging the use of Electric
Vehicles (EVs) to avoid the concentration of air pollutants, CO2, as well as other greenhouse gases. More
specifically, they promote sustainable and efficient mobility through different initiatives, mainly through tax
incentives, purchase aids, or other special measures, such as free public parking or the free use of
motorways.

Design , Fabrication and testing of E-Bike

 9

EVs offer the following advantages over traditional vehicles:

1. Zero emissions: this type of vehicles neither emit tailpipe pollutants, CO2, nor nitrogen dioxide (NO2). Also,
the manufacture processes tend to be more respectful with the environment, although battery manufacturing
adversely affects carbon footprint.

2. Simplicity: the number of Electric Vehicle (EV) engine elements is smaller, which leads to a much cheaper
maintenance. The engines are simpler and more compact, they do not need a cooling circuit, and neither is
necessary for incorporating gearshift, clutch, or elements that reduce the engine noise.

3. Reliability: having less, and more simple, components makes this type of vehicles have fewer breakdowns. In
addition, EVs do not suffer of the inherent wear and tear produced by engine explosions, vibrations, or fuel
corrosion.

4. Cost: the maintenance cost of the vehicle and the cost of the electricity required is much lower in comparison
to maintenance and fuel costs of traditional combustion vehicles. The energy cost per kilometer is
significantly lower in EVs than in traditional vehicles

5. Comfort: traveling in EVs is more comfortable, due to the absence of vibrations or engine noise

6. Efficiency: EVs are more efficient than traditional vehicles. However, the overall well to wheel (WTW)
efficiency will also depend on the power plant efficiency. For instance, total WTW efficiency of gasoline
vehicles ranges from 11% to 27%, whereas diesel vehicles range from 25% to 37% By contrast, EVs fed by a
natural gas power plant show a WTW efficiency that ranges from 13% to 31%, whereas EVs fed by renewable
energy show an overall efficiency up to 70%.

7. Accessibility: this type of vehicle allows for access to urban areas that are not allowed to other combustion
vehicles (e.g., low emissions zones). EVs do not suffer from the same traffic restrictions in large cities,
especially at high peaks of contamination level. Interestingly, there was a recent OECD study that suggests
that, at least in terms of Particulate Matter (PM) emissions, EVs will unfortunately not improve the air quality
situation.

8. Driving range: range is typically limited from 200 to 350 km with a full charge, although this issue is being
continually improved. For example, the Nissan Leaf has a maximum driving range of 364 km, and the Tesla
Model S can reach more than 500 km.

9. Charging time: full charging the battery pack can take 4 to 8 h. Even a “fast charge” to 80% capacity can take
30 min. For example, Tesla superchargers can charge the Model S up to 50% in only 20 min, or 80% in half an
hour.

10. Battery cost: large battery packs are expensive.

11. Bulk and weight: battery packs are heavy and take up considerable vehicle space. It is assumed that the
batteries of this type of vehicles have an approximate weight of 200 kg [8], which can vary, depending on the
battery capacity.

Design , Fabrication and testing of E-Bike

 10

CHAPTER 2
LITERATURE SURVEY

1. Battery Electric Vehicles (BEVs): vehicles 100% are propelled by electric power. BEVs do not have
an internal combustion engine and they do not use any kind of liquid fuel. BEVs normally use large
packs of batteries in order to give the vehicle an acceptable autonomy. A typical BEV will reach
from 160 to 250 km, although some of them can travel as far as 500 km with just one charge. An
example of this type of vehicle is the Nissan Leaf , which is 100% electric and it currently provides a
62 kWh battery that allows users to have an autonomy of 360 km.

2. Plug-In Hybrid Electric Vehicles (PHEVs): hybrid vehicles are propelled by a conventional
combustible engine and an electric engine charged by a pluggable external electric source. PHEVs
can store enough electricity from the grid to significantly reduce their fuel consumption in regular
driving conditions. The Mitsubishi Outlander PHEV provides a 12 kWh battery, which allows it to
drive around 50 km just with the electric engine. However, it is also noteworthy that PHEVs fuel
consumption is higher than indicated by car manufacturers .

3. Hybrid Electric Vehicles (HEVs): hybrid vehicles are propelled by a combination of a conventional
internal combustion engine and an electric engine. The difference with regard to PHEVs is that
HEVs cannot be plugged to the grid. In fact, the battery that provides energy to the electric engine is
charged thanks to the power generated by the vehicle’s combustion engine. In modern models, the
batteries can also be charged thanks to the energy generated during braking, turning the kinetic
energy into electric energy. The Toyota Prius, in its hybrid model (4th generation), provided a 1.3
kWh battery that theoretically allowed it an autonomy as far as 25 km in its all-electric mode

4. Fuel Cell Electric Vehicles (FCEVs): these vehicles are provided with an electric engine that uses a
mix of compressed hydrogen and oxygen obtained from the air, having water as the only waste
resulting from this process. Although these kinds of vehicles are considered to present “zero
emissions”, it is worth highlighting that, although there is green hydrogen, most of the used hydrogen
is extracted from natural gas. The Hyundai Nexo FCEV is an example of this type of vehicles, being
able to travel 650 km without refueling.

5. Extended-range EVs (ER-EVs): these vehicles are very similar to those ones in the BEV category.
However, the ER-EVs are also provided with a supplementary combustion engine, which charges the
batteries of the vehicle if needed. This type of engine, unlike those provided by PHEVs and HEVs, is
only used for charging, so that it is not connected to the wheels of the vehicle. An example of this
type of vehicles is the BMW i3 , which has a 42.2 kWh battery that results in a 260 km autonomy in
electric mode, and users can benefit an additional 130 km from the extended-range

Design , Fabrication and testing of E-Bike

 11

CHAPTER 3
ABOUT E-BIKE

3.1 History of E-Bikes

An electric vehicle (EV) is a vehicle that uses one or more electric motors for propulsion. It can be powered
by a collector system, with electricity from extravehicular sources, or it can be powered autonomously by
a battery (sometimes charged by solar panels, or by converting fuel to electricity using fuel cells or
a generator). EVs include, but are not limited to, road and rail vehicles, surface and underwater
vessels, electric aircraft , and electric spacecraft. For road vehicles, together with other emerging automotive
technologies such as autonomous driving, connected vehicles, and shared mobility, EVs form a future
mobility vision called Connected, Autonomous, Shared, and Electric (CASE) Mobility.

EVs first came into existence in the late 19th century, when electricity was among the preferred methods
for motor vehicle propulsion, providing a level of comfort and ease of operation that could not be achieved
by the gasoline cars of the time. Internal combustion engines were the dominant propulsion method
for cars and trucks for about 100 years, but electric power remained commonplace in other vehicle types,
such as trains and smaller vehicles of all types.

Fig 3.1: 1st Electric Bike

Electric motive power started in 1827, when Hungarian priest Ányos Jedlik built the first crude but viable
electric motor, which used a stator, rotor, and commutator; and the next year he used it to power a small car.
In 1835, professor Sibrandus Stratingh of the University of Groningen, in the Netherlands, built a small-
scale electric car, and sometime between 1832 and 1839, Robert Anderson of Scotland invented the first
crude electric carriage, powered by non-rechargeable primary cells. American blacksmith and
inventor Thomas Davenport built a toy electric locomotive, powered by a primitive electric motor, in 1835.
In 1838, a Scotsman named Robert Davidson built an electric locomotive that attained a speed of four miles
per hour (6 km/h). In England a patent was granted in 1840 for the use of rails as conductors of electric
current, and similar American patents were issued to Lilley and Colten in 1847.

Due to lack of electricity grids and the limitations of storage batteries at that time, electric cars did not gain
much popularity; however, electric trains gained immense popularity due to their economies and achievable
speeds. By the 20th century, electric rail transport became commonplace due to advances in the
development of electric locomotives. Over time their general-purpose commercial use reduced to specialist
roles as platform trucks, forklift trucks, ambulances, tow tractors, and urban delivery vehicles, such as the
Design , Fabrication and testing of E-Bike
 12

iconic British milk float. For most of the 20th century, the UK was the world's largest user of electric road
vehicles.

Most producers of passenger cars opted for gasoline cars in the first decade of the 20th century, but electric
trucks were an established niche well into the 1920s. A number of developments contributed to a decline in
the popularity of electric cars. Improved road infrastructure required a greater range than that offered by
electric cars, and the discovery of large reserves of petroleum in Texas, Oklahoma, and California led to the
wide availability of affordable gasoline/petrol, making internal combustion powered cars cheaper to operate
over long distances. Electric vehicles were not seldom marketed as a women's luxury car, which may have
been a stigma among male consumers. Also, internal combustion powered cars became ever-easier to
operate thanks to the invention of the electric starter by Charles Kettering in 1912, which eliminated the
need of a hand crank for starting a gasoline engine, and the noise emitted by ICE cars became more bearable
thanks to the use of the muffler, which Hiram Percy Maxim had invented in 1897. As roads were improved
outside urban areas, electric vehicle range could not compete with the ICE. Finally, the initiation of mass
production of gasoline-powered vehicles by Henry Ford in 1913 reduced significantly the cost of gasoline
cars as compared to electric cars.

Fig 3.2 : Modern lectric Bike

In the 1930s, National City Lines, which was a partnership of General Motors, Firestone, and Standard Oil
of California purchased many electric tram networks across the country to dismantle them and replace them
with GM buses. The partnership was convicted of conspiring to monopolize the sale of equipment and
supplies to their subsidiary companies, but were acquitted of conspiring to monopolize the provision of
transportation services.

Copenhagen climate conference, which was conducted in the midst of a severe observable climate change
brought on by human-made greenhouse gas emissions held in 2009. During the summit, more than 70
countries developed plans to eventually reach net zero. For many countries, adopting more EV will help
reduce use of fossil fuels.

Design , Fabrication and testing of E-Bike

 13

3.2 Types of E-Bikes

1. Class 1 E-Bike :

Type 1 electric bbikes have a maximum speed of 20 MPH and are equipped with an eelctric motor
without throttle that works when the rider is pedaling, also known as pedal-assist. 

What is pedal assist? An electric motor with pedal assist is an ebike whose drive system is only
activated once you start pedaling. Once you start pedaling you will be able to get up to 20 mph
(miles per hour) on your e-bike. Type 1 ebike riders are given the permission to ride anywhere you
would ride any other type of bike due to the low speed and operation. Meaning electric bikes are
allowed on bike lanes, bike paths, and on the road. To sum, e-bikes are classified as type 1 when they
have PEDAL ASSIST ONLY that tops off at 20 mph and no throttle.

Fig 3.3 : Class 1 E-Bike Fig 3.4 : Class 1 E-bike

(Mini) (Mountain Bike)

Design , Fabrication and testing of E-Bike

 14

2. Class 2 E-Bike :

Electric motorcycles and scooters are plug-in electric vehicles with two or three wheels. Power is
supplied by a rechargeable battery which drives one or more electric motors. Electric scooters are
distinguished from motorcycles by having a step-through frame, instead of being straddled. Electric
bicycles are similar vehicles, distinguished by retaining the ability to be propelled by the rider pedalling
in addition to battery propulsion.
Electric scooters with the rider standing are known as e-scooters.

Fig : 3.5 : Class 2 E-Bike Fig 3.6 : Class 2 E-Bike

(Moped) (Motorcyle)

Design , Fabrication and testing of E-Bike

 15

CHAPTER 4
DESIGN CALCULATIONS
4.1 : Calculation of Drive train

Mass of the bike = 300Kg = m

1N = 1Kg m/s2
a) Rolling resistance = f*m*g

f = coefficient of friction 0.015 < f > 0.3

according to Indian road congress f = 0.15

Rolling resistance = 0.15 * 300 * 9.81

= 441.45 N
~ 450 N

b) Gradient Resistance = m*g*sinθ

θ = angle of inclination of the steep road

θ max = 45 degrees

Gradient Resistance = 300 * 9.81 * Sin45

= 2081.0152 N
~ 2100 N

c) Aerodynamic Drag Forces = (ρ*C*V2*A)/2

ρ = Density of air = 1.209 Kg/m3

C = Coeff of drag = 0.5 to 1
A = Frontal area = 0.5m2 (considering ground clearance & rider’s
V = Velocity

Aerodynamic Drag Forces = (1.209 * 0.5 * 602 * 0.5)/2

= 1083.6 N
~ 1100 N

Total resistance = 1100 + 2100 + 450 = 3650 N

Torque = F * r

F = Total resistance
r = Radius of the drive wheel

Torque = 3650 * 0.457 * 10-2 = 16.68 Nm

Motor Specification
Design , Fabrication and testing of E-Bike
 16

a) Power = 1000 Watt

b) Voltage = 48V
c) Current = 15 Amp
d) Average Torque = 14 Nm
Peak Torque = 28 Nm

Hence by obtained results we conclude that the torque created by the drive line is very much greater than the
calculated torque.
Therefore it concludes that a motor of 1000 watt is usable.

4.2 : Selecting the size of sprocket

Torque required = 16.5 Nm

Output required = 28 Nm

Required reduction = TR/OT

= 16.6/28
= 4.1:7
From the standard drive ratio chart , for long and high high durability we select

43 T in the rear
14 T in the front
Chain with 106 links

The above values best suits for the power transmission through motor to the wheel

Design , Fabrication and testing of E-Bike

 17

CHAPTER 5

VEHICLE COMPONENTS

1. MS Chassis

2. 48V 1KW Gear BLDC motor kit

3. 48V 18Ah Lead acid battery pack (x4)

4. Motor Controller

5. Drum brake kit (x2)

6. Sprocket-Motor 14 Teeth-Hardened Steel

7. Sprocket-Drive wheel 43 Teeth-Hardened steel

8. Throttle

9. Tires

10.

Design , Fabrication and testing of E-Bike

 18

CHAPTER 6

VEHICLE ASSEMBLY

Fig 6.1 : Assembled E-Bike

The chassis here is initially mounted with the swing arm and the handle rod and handlebar. Further more
the Wheels and brakes and shock absorbers are assembled with the help of fasteners. The electric
components like the Motor kit and the battery pack is assembled. The chain is connected thereby completing
the drive train.
The motor is supplied with electric current with the help of battery through a controller which modulates
the speed of the motor accordingly with the throttle or accelerator . The electrical components are covered
with a layer of glass fiber fitted with fasteners to protect against elements.

Design , Fabrication and testing of E-Bike

 19

CONCLUSION

Design , Fabrication and testing of E-Bike

 20

FUTURE SCOPE

 Future research work on more lighter and efficient components can be incorporated.

 The aerodynamic analysis done on the bike when completely covered in the FRP
structure made of glass fiber. For further improvement of the system and observing the
behaviour of the glass fiber more lighter and hard materials like composite fiber
materials can be used.

 The study does not include optimization of body FRP to reduce weight withoit
compromising much on the safety of the electrical components. Thus further analysis
and optimization can be performed

 Similar to the body FRP, many other components can be designed and subjected to the
FEA study to be used in the design and developments of the electric Bikes

Design , Fabrication and testing of E-Bike

 21

REFERENCES

1. Prathamesh Nigam, “Design and Development of Modern Electric Bike”, Vol. 9

Issue11, November-2020, IJERT.

2. Saurabh Rege, “Design and Analysis of Frame for Electric Motorcycle”, Vol. 6, Issue
10,October 2017, IJIRSET.

3. Kunal D Topiwala, “Design and Fabrication of Electric Motorcycle”, Vol. 9 Issue

04,April-2020, IJERT

4. Fahim Foysal Arnob, “Design, Fabrication and Analysis of Chassis for Electric
Bike”,Vol.3, Issue 4, 025-031, IJIRSET.

5. P. N. V balasubramanyam, “Impact Analysis on E-Bike Chassis Frame”,

Volume-8Issue-4, April 2019, IJEAT.

6. The Electric Bicycle: Worldwide Research by Esther Salmeron

Manzano & Francisco Manzano Agugliaro, Published 20th July 2018

Design , Fabrication and testing of E-Bike

 22

Design , Fabrication and testing of E-Bike