ME5692- PRODUCT

DESIGN AND
PROCESS
DEVELOPMENT
ASSIGNMENT - II

LALITHA M
2020502021
AUTOMOBILE ENGINEERING

1
 STEPS IN CONCEPT GENERATION

• As per the FIVE STEP METHOD, we generate our

concept and the product name is ELECTRIC BICYCLE.

2
 STEPS IN CONCEPT GENERATION

CLARIFY THE PROBLEM:

Clarifying the problem consists of developing a general understanding
and then breaking the problem down into subproblems if necessary. The
mission statement for the project, the customer needs list, and the
preliminary product specification are the ideal inputs to the concept
generation process, although often these pieces of information are still
being refined as the concept generation process.

CONCEPT CLASSIFICATION TREE:

The concept classification tree is used to divide the entire space of
possible solutions into several distinct classes that will facilitate
comparison and pruning.

CONCEPT COMBINATION TABLE:

The concept combination table provides a way to consider combinations
of solution fragments systematically 3
 CLARIFY THE PROBLEM
Some of the assumptions in the mission statement,
• The e-bicycle will be eco-friendly when compared to fuel
vehicles.
• The e-bicycle will be compactable with less complexity of
electrical components.
• The e-bicycle will provide emergency battery generator.
• The e-bicycle will be lightweight and cheaper than the bikes.
Based on the assumptions customer needs had been identifies,
they are;
• The e-bicycle provides efficient motor support.
• The e-bicycle is foldable with detachable components.
• The e-bicycle improves braking.
• The e-bicycle is hybrid ( power generated by both electrically and
manual pedaling)
• The e-bicycle is lightweight.
• The e-bicycle provides longer battery life with less charging time. 4
 EXPLORE SYSTEMATICALLY
CONCEPT CLASSIFICATION TREE:

Lead Acid Battery

Lithium Manganese
204
Nickel Metal
Hydride
High Lithium Cobalt
Efficient
Battery Lithium
Ion Battery
Lithium Polymer

Fuel Cell

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 CONCEPT COMBINTAION TABLE:

BATTERY VOLTAGE MOTOR

Lead Acid Battery 36 volts (15 ampere)

DC Motor

Nickel Metal Hydride 48 volts (10-40 ampere)

Battery Brushless DC Motor
(BLDC motor)
52 volts
Lithium Ion Battery

Fuel Cell

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TARGET SPECIFICATION PROCESSES
For technology-intensive products this is rarely possible. For such
products, specifications are established at least twice. Immediately
after identifying the customer needs, the team sets target
specifications. These specifications represent the hopes and
aspirations of the team, but they are established before the team
knows what constraints the product technology will place on what
can be achieved.
The process of establishing the target specifications contains four
steps:
1. Prepare the list of metrics.
2. Collect competitive benchmarking information.
3. Set ideal and marginally acceptable target values.
4. Reflect on the results and the process

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 TARGET SPECIFICATION PROCESSES

These basic needs were translated into target product specifications.

The target specification included the following,
• The e-bicycle lengths from 1800-2000mm.
• The maximum speed ranges from 25km-15.5mph.
• The battery ranges from 400-500 Wh.
• The motor rated power is 250 W.
• Total mass less than the 25 kg.
• The rated speed is ranges up to 200 rpm.

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REFLECT ON THE SOLUTIONS & PROCESSES

We decided that the battery issues remained at the core

of the problem and that the decision to focus on these issues
first was justified. They had pursued to many branches of
classification tree. Initially had pursued lead acid batteries,
nickel metal hydride batteries concepts before settling on
lithium ion batteries.
Ultimately, lithium ion batteries proved to be the most
technically feasible approach and the final product based on
this concept because, much more efficient in storing and
utilizing energy, and also the voltage does not drop like lead
acid batteries.

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 LIST OF TARGET SPECIFICATIONS
Metric Need Marginal Ideal
No. Nos Metric Imp. Units value value

1 15 Total mass 2 Kg 20-25 <25

2 2 Capacity of the battery 1 Wh >450 400

3 3 Rated power of the motor 1 W 200-300 250

4 51 Wheel diameter 4 mm <660 660

5 5 Frame sizes 3 inch 16 <19

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 CONCEPT SELECTION MATRIX

To summarize the needs of the client and of the intended end users,
eight criteria has been established on which the choice of a product
concept would be based:

• Efficient and longer life battery

• High efficient motor support
• Weightless for manual pedaling
• Detachable battery system
• Eco-friendly
• Improve braking system
• Waterproof
• Durability
• Ease of use and handling

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 SCREENING MATRIX
CONCEPTS
SELECTION CRITERIA A B
Lithium ion Lithium ion
battery with battery with
BLDC motor DC motor
Efficient and longer life battery 0 0
High efficient motor support 0 0
Weightless for manual pedaling 0 0
Detachable battery system 0 0
Improve braking system 0 0
Durability + 0
Ease of use and handling + 0
C D
Lead acid Lead acid
battery with battery with
BLDC motor DC motor
0 -
- -
0 +
0 0
0 0
- -
+ 0

Sum +’s 2 0 1 1
Sum 0’s 5 7 4 3
Sum –’s 0 0 2 3
Net score 2 0 -1 -2
Rank 1 3 6 7
Continue? yes combine no no

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 DESCRIPTION OF THE CONCEPT

LITHIUM ION BATTERY WITH BLDC MOTOR:

Lithium-ion batteries charge faster, last longer and have a higher

power density for more battery life in a lighter package. Lithium is the
primary source for Li-Ion battery packs as it is more stable and safer in
charging and discharging energy compared to other minerals. lithium
batteries provide up to 10 times longer life than lead-acid batteries.
BLDC is an electric motor powered by a direct current voltage
supply and commutated electronically instead of by brushes like in
conventional DC motors. BLDC motors are high durability, high
efficiency, relatively low weight and small dimensions in comparison to
other electric motor constructions. It has high speed range when
compared to a DC motor because of the absence of the brushes and
commutator.

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 LIST OF KEY UNCERTAINTIES

1. BATTERY LOCATION & OPERATING CONDITION:

The battery is considered the most vital part of an E-bike and is most
susceptible to damage due to its location and operating conditions. The
damage often incurred to the result of improper usage of e-bicycle ;
another reason could be the unsecured washing methods employed using
a pressurized water source that subsequently results in the accumulation
of moisture throughout the E-bike.

SOLUTION/ACTION TO BE TAKES:
The battery should be mounted inside the frame tube especially below
the handle bar and the frame tube must be sealed properly . It is also
recommended to disengage the battery after using the e-bicycle and
turning off the e-bicycle.

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 LIST OF KEY UNCERTAINTIES

2. HUB MOTOR CREATES NOISE AND CAN STOP SPINNING:

• Hub motor is one of the common issues that creates hub motor noise. It
is a common issue that arises if the motor has worn-out gears, disk brake
or bearings.
• Another problem that can occur with the hub motor is that it can stop
spinning. This shows that there is a problem with the controller. It can
either be in a loose connection or not connected at all, which is why the
motor isn’t getting the electricity to be started. check if your controller is
functional and check its connection with the motor. In case there is a
damaged part in the controller or wiring, get it replaced.

SOLUTION/ACTION TO BE TAKEN:
Replacing worn out part can solve the problem but in case it
persists, it is likely that the motor bearings need a lubricant and the
noises being produced are because of the friction. Check if the controller
is functional and check its connection with the motor. In case there is a
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damaged part in the controller or wiring, get it replaced.
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