MIT School of Engineering, Pune

Department of Mechanical Engineering

“Designing and Calculation of foldable e-

bicycle”

Group Code: ME2021MP3-11 Topic: New

Roll No. Div. Enrolment No. Name of Student
2186117 4 MITU18BTML0114 Yash Wakchaure
2186116 4 MITU18BTML0107 Viraj Surve
2186069 3 MITU18BTML0024 Ashish Date
2186122 3 MITU18BTML0068 Yash Nagargoje

Name of Guide Prof. Mangesh Dhavalikar

1 Department of Mechanical Engineering, MIT School of Engineering, Pune

 Contents
1. Introduction
2. Literature Review
3. Problem Statement
4. Objective
5. Methodology
6. Catia Design
7. Fundamental background
8. Reference

2 Department of Mechanical Engineering, MIT School of Engineering, Pune

 1.Introduction
 The conventional bicycle has been used since many
centuries, but it had its flaw like limited range, wear & tear
of brakes etc.
 This project is about designing of foldable electric
bicycle.
 The electric bicycle has various advantages over
conventional bicycle like extended range, less wear and tear
& the energy lost during is prevented by regenerative
braking system which extends the range.
 We hope for the range of 10-15 kms ride.

3 Department of Mechanical Engineering, MIT School of Engineering, Pune

 2.History
Military interest in bicycles arose in the 1890s, and the
French army and others deployed folding bikes
for bicycle infantry use. 
In 1900, Mikael Pedersen developed for the British army
a folding version of his Pedersen bicycle that weighed 15
pounds and had 24 inch wheels. It included a rifle rack
and was used in the Second Boer War.
In 1941, during the WWII, the British War Office called for
a machine that weighed less than 23 lb (this was not
achieved - the final weight was about 32 pounds) and
would withstand being dropped by parachute. In
response, the Birmingham Small Arms Company (BSA)
developed a folding bicycle small enough to be taken in
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small gliders or on parachute jumps from aircraft.
 2. Literature Review:
Ref. No. Paper Title Author Names, Name of Findings
Journal/Conference, Volume
No., Year of publication etc.
2321-9653 Design ,Analysis Shlok Desai , Kavan Mehta , 1. The objective of the
& Fabrication of Zinal Kheni, Naitik Bhatt , foldable bicycle is to
Foldable Electric Rahul Patel ; form a structure
Bicycle International Journal for whose volume is
Research in Applied Science & greatly reduced.
Engineering Technology ; 2. To improve riding
Volume 7, Issue 5 ,May – 2019. comfort through
interaction of weight.
2581-7280 Design & Anurag Bhatt,Adinath 1. Working principle of
Fabrication of Kadam,KP Mredhul,Jaydeep Regenerative
Regenerative Asodariya; Braking system.
Braking in EV. VIVA-TECH International 2. Various components
Journal for Research & used in Regenerative
Innovation; braking system.
Volume 1,Issue 2,2019.

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 Ref. Paper Title Author Names, Findings
No. Name of
Journal/Conference,
Volume No., Year of
publication etc.
81-90 Electric Vehicle GouYanan ; 1. Self charging concept for the
Regenerative International Journal of bicycle.
Braking System Hybrid Information 2. Calculation method for allowable
& Energy Technology ; static stresses.
Recovery. Volume 9 , 2016. 3. Concept of power generation by
using Dynamo.
2395- Designing & Vishal Saptarshi,Ravi 1. Choosing of adequate material &
0072
Construction of Vishwakarma,Pawan Hardware for the E-bicycle.
E- Foldable Sharma,Prafull 2. Chronology of Manufacturing the
Bicycle. Baraskar; E-bicycle.
Volume 7,Dec 2020.
Folding & self – Morteza 1. The need for foldable Electric
proppeling Hanifezade,Arian Bicycle.
Bicycle. Ashrafi; 2. The drawbacks of conventional
Vol 5,No.2,April 2014. bicycle and how to overcome
them using foldable Electric
Bicycle.

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Department of Mechanical Engineering, MIT School of Engineering, Pune
 3. Problem Statement:
 Easy to fold & carry across .
 Elimination of human effort to ride.
 To solve parking issue.

4. Objective:
 To design and manufacture an efficient foldable e-bicycle.

 To study throttle and regenerative braking system which will be applied

in e-bicycle.

7 Department of Mechanical Engineering, MIT School of Engineering, Pune

 5. Methodology:

1. Design Calculations

2. Dimensions with their explanation

3. Designing a CAD model

4. Material Selection and properties

5. Electronics

8 Department of Mechanical Engineering, MIT School of Engineering, Pune

 o Design Calculation:-
In the word document.

o Material selection:-
In the word document.

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 o Bicycle dimension with explanation:-
 The two main measurements needed to correctly size a bicycle are
your height and inside leg (inseam). To determine the appropriate
bicycle for that person.
 the inside leg measurement is taken to ensure the stand over height
of your cycle is adequate. The stand over height is the distance
between the top tube of the bike frame and the ground. It is
recommended to allow for at least 1 inch of clearance between the
top tube and your inside leg.

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 o Bicycle size chart :-
Rider height Rider height
Inside leg (in) Inside leg (cm) Suggested frame size (cm)
(ft/in) (cm)

4’10” – 5’0″ 147 – 152 24″ – 26″ 61 – 66 47 – 48

5’0″ – 5’2″ 152 – 158 25″ – 27″ 64 – 69 49 – 51

5’2″ – 5’4″ 158 – 163 26″ – 29″ 66 – 74 51 – 52

5’4″ – 5’6″ 163 – 168 28″ – 30″ 71 – 76 52 – 53

5’6″ – 5’8″ 168 – 173 29″ – 31″ 74 – 79 53 – 54

5’8″ – 5’10” 173 – 178 30″ – 32″ 76 – 81 54 – 56

5’10” – 6’0″ 178 – 183 31″ – 33″ 79 – 84 56 – 58

6’0″ – 6’2″ 183 – 188 32″ – 34″ 81 – 86 58 – 60

6’2″ – 6’4″ 188 – 193 33″ – 35″ 84 – 89 60 – 62

6’4″+ 193+ 34″+ 81+ 62+

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 2.Stack & Reach :-
 The two most fundamental elements of frame geometry are stack and
reach. Knowing the cycle's stack and reach will allow to compare the
human comfort for riding.
 Stack is measured vertically from the bottom bracket to the top of the
head tube. This gives an indication of how tall a frame is.
 Reach is measured horizontally from the bottom bracket to the top-
centre of the head tube. This gives an indication of how long a frame is.
Creating a lower frontal profile to improve aerodynamics.

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 o Head Tube :-
 The head tube has two key measurements that will influence a cycles
handling; the angle and the length.
 The head tube angle refers to the angle of the head tube to the ground
and will commonly be described as either 'slack' or 'steep'. A slack head
tube angle requires more effort to steer but performs better at slow
speeds. A steep head tube angle is found on performance road race,
requiring less effort to steer which is better for high-speed handling.
 The head tube length is measured from the bottom to the top of the
head tube. Bikes with a long head tube raises the front end of the bike,
putting the rider in a more upright position. Bikes with a short head tube
lower the front end of the bike, reducing the frontal profile of the rider,
improving aerodynamics.

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 o Seat Tube :-
 Seat tube length is measured from either the centre of the bottom
bracket to where the top tube and seat tube meet (Centre-Centre or
C-C) or to the top of the seat tube (Centre-Top or C-T). Effective seat
tube length is another phrase you may encounter which is similar to
'stack', measuring the distance from the centre of the bottom bracket
to where a virtual horizontal top tube would meet the seat tube.

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 o Chain stay length :-
 Chain stay length is measured horizontally from the bottom bracket to the
rear dropouts and influences the length of the wheelbase and handling.
Cycles with long chain stays improve stability, creating a longer wheelbase
in the process, while bikes with short chain stays result in sharper
handling and reduce the length of the wheelbase.

o Wheel Base :-
 The wheelbase refers to the distance between the front and rear drop outs
which coincide with the contact points to the ground of the front and rear
wheel. Head tube angle, fork rake, frame reach and chain stay length will
dictate the length of the wheelbase. Cycles with a 'long' wheelbase deliver
stability and comfort, whereas with a 'short' wheelbase leads to sharper
handling.
oCrank Length :-
 It is an important measurement to know in relation to other frame
geometry measures because it may influence your seat height and
potentially other areas such as handlebar height and reach. Most bicycles
will come with cranks between 170mm and 175mm, but it is possible to get
cranks ranging from 165mm to 180mm depending on rider preference.
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 6.Catia Design

1 2

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 3

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17 4
 7.Diagram of Bicycle:-

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  Battery specifications :-
Battery capacity : 20 AH
Voltage : 48V
Brand : SAMSUNG
Weight : 2 kg
Battery type : Lithium -Polymer
Battery shape : Round
Charging Current : 20000 MAH

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 Motor specifications :- Hub Motor
 Rated Voltage: 48V
 Rated Power : 250W
 Efficiency : 83.5%
 Weight : 6.2 kg
 Break type : Disc (double thread)
 No Load RPM : 404 RPM

 Controller specifications :-
 Rated Voltage : 48V
 Rated Power : 350W
 Rated Ampere : 83.5%
 Weight : 0.23 kg
 Break : Low Abs
 Wave form type: Square Wave
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  Throttle specifications :-
Material: Plastic
Color: Black
Type: Left Hand, Right Hand (optional)
Cable Length: Approx. 1.6m / 5.2feet
Suitable Handlebar Diameter: Approx. 22.5mm / 0.88inch
Voltage: Works with Any Voltage
Red Wiring: Positive +5V
White Wiring: Signal
Black Wiring: Negative -5V
Weight: Approx. 87-91g

21 Department of Mechanical Engineering, MIT School of Engineering, Pune

 Regenerative Braking System :
 Regenerative braking means capturing power kinetic energy
as you brake and putting it back into the battery to be used
again.
Working :
 In an electric bicycle, power producing source is the battery
that supplies the electric energy to operate the motor.
 The motor supplies the energy to rotate the vehicle wheels
producing Kinetic energy. The motor can operate in reverse.
 When a motor acts in reverse it acts as a generator.
 When the vehicle slows down the generator concerts the
kinetic energy into electrical energy to charge the bicycle
battery.

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 Regenerative Braking System:
Factors affecting Regenerative braking system:
 Efficiency will depend on drivers style of driving whether
they brake gradually or severely.
 Temperature of system & outside ambient temperature
affect efficiency greatly.
Advantages:
 It extends the range of Electric Bicycle by 16% - 70%.
 Reduction in brake wear.

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 Discussion
The presented work was aimed to reduce the wastage
of human power on bicycle riding.
Will provide the rider the choice of cycling or riding as
bike.
Use of hub motor is it does not require any
maintenance, highly compact and has no or very less
vibrations.
The material selected for bicycle frame is appropriate
as it is rigid, corrosion resistant, fairly light, high
strength-to-weight ratio and reasonably affordable.

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 Conclusion
Electric mode, fully Eco-friendly vehicle.
 The bicycle consists of Lithium ion battery, hub motor
and much more advanced features and economical.
It is easy to fold and light in weight it so it can be carry
and keep anywhere.
Removable battery it does not necessary to carry
whole cycle to the charging point only battery should
be carry away.
The adjustable seat and handle positions enabling both
children and adults to use the same bicycle.
Bicycle performance when fully charged = 25-30 km
(depends on road condition) at high speed.
25 Average speed of bicycle is 20-25 km/hr (electric
 Future Scope
Hydrogen as Future Fuel.
The bicycle further can be more compact and
light weight.
To develop a spokeless bicycle to reduce riders
injury, appearance of cycle.
Even low maintenance and increased useful life.
Kinetic energy reservoir system.

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 8. Reference :
1. International Journal for Research in Applied Science & Engineering
Technology , “Design ,Analysis & Fabrication of Foldable Electric
Bicycle”, May – 2019
2. L. Fordb Global Technologies, “FOLDABLE
ELECTRIC BICYCLE” . MI/US Patent US 9,469,364,
18 OCT 2016.
3. E. Thetard, “Folding Bicycle with Electric Power
Supply”. Cambiano Patent 29/315,908, 4 August 2009
4. https://youtu.be/-_ckx6YocoM
5. VIVA-TECH International Journal for Research & Innovation, “Design
& Fabrication of Regenerative Braking in EV”, 2019
6. Morteza Hanifezade,Arian Ashrafi; “Folding & self – proppeling
Bicycle”. April – 2014.
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28 Department of Mechanical Engineering, MIT School of Engineering, Pune
29 Department of Mechanical Engineering, MIT School of Engineering, Pune