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KERS in Bicycle


Project Guide :

Anand Krishnan T Asst. Professor Mechanical Department


Design Detail

This hub has a 18 teeth sprocket attached on one side and the other side holds a gearbox. The gearbox can be inserted in the hub.

The brake shoe is also provided in the hub making a drum brake

Brake shoe


Main Gear Front cover



Shaft Rear Cover

The gearbox has a fixed ratio gear system. For every revolution of the spur gear the pinion does 6.5 revolutions. The gearbox holds a spring loaded clutch mechanism to engage and disengage the spur gear with the pinion. The clutch is controlled by the rider using a shifter provided in the handle.

Main gear (72 teeth,dia 12.5 cm) Pinion(11 teeth,dia2.5cm)

Flywheel The flywheel used here is a 6 kg mild steel disc with a diameter of 25cm. The flywheel is attached to the pinion in the gearbox in the rear hub.

Wheel The wheel uses a standard rim of 622 mm dia and 37 mm tire width. The is attached to the hub by 32 spokes of stainless steel. Tire and Tube suited for the rim is used.

The frame used here is that of a Japanese cycle named Lumala POWER. The frame was modified by welding to hold the rear wheel.


Based on the power to be transmitted and standard chain size of cycle chain type 08B was selected it had the following features Pitch = p1 = 12.70mm Roller diameter = d1 = 8.51mm Width between inner plates = b1 = 7.75mm Transverse pitch = p1 =13.92mm Breaking load =17.8kN Factor of safety=7 Permissible speed of smaller sprockets=2400rpm (for 19 teeth sprocket) Maximum Power Transmission = 0.64kW (at 100rpm) The chain was then checked for design safety by finding the load on the chain.

The chain is checked for safety and the various parameters of the chain and sproket system found out like

Load on the chain Roller seating radius(Ri) Roller seating angle() Tooth height above the pitch polygon( ) Root diameter( ) Tooth width ( )

Tooth side radius( ) Pitch line velocity


Helical gear

The helical gear is designed based on the following parameters rated power = 200W helix angle = 15 number of teeth pinion = 11 main gear = 72 gear ratio = 6.5:1 material = steel C30 ,heat treated
Using the above factors module of the gear is found out and using which the following parameters are found Dynamic tooth load Dynamic strength of gear Limiting Load for wear The Design is checked for safety by verifying and

Flywheel Using the rated power 200Watts and Ce we calculate the change in energy using the equation

change in energy = E =


where Ce = coefficient of energy fluctuation n = mean speed

Then using change in energy E

(12 22 ) = 2

the above equation is used to find the weight of the most favorable flywheel

User sits on bicycle and starts pedaling. Power generated and cycle speeds up. User experiences excess energy in the bike.

Braking effect experienced by the user by inertia of flywheel.

Excess energy flows towards the stationary flywheel and rotates it.

User selects the drive to engage the flywheel.

Flywheel accelerates causing it to charge until the energy levels are equal.

User disengages flywheel when the desired speed or braking is obtained.

User selects the drive to engage the charged flywheel.

User experiences deficit of energy in the bike.

Charged flywheel rotates independently without any hindrance.

Flywheel decelerates causing it to dissipate energy.

Excess energy from the charged flywheel flows towards the rear wheel of the bike.

Clutch engaging lever

Brake engaging lever




Fabrication Procedure
PhaseI Selection of a suitable Cycle frame Obtaining the hub and gearbox system of a LUNA moped

Cleaning and lubrication of gearbox Phase II Choosing the suitable spokes for mounting

Assembling the rear wheel PhaseIII Alignment of crank and freewheel

Fabrication Procedure
Choosing a flywheel of suitable weight Assembling the rear wheel to the frame by welding

Phase IV

Phase V

Fixing the the clutch and brake mechanism into the cycle Attaching shifter and pedal or lever mechanism for manual control of clutch and brake system


Scope for improvement

Scope for future


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