Special Issue - 2018 International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
ETEDM - 2018 Conference Proceedings

Design and Fabrication of Electric Bicycle

Ranjan Kumar1, Munna Kumar2, Pradyumn Sah3, Mustaim Alam4
Prof. Dr. M. Asok Raj Kumar,
M. E. Ph.D5.
1
UG Student, ,
2
Department of Mechanical Engineering,
Gnanamani College Of Technology( Nh-Ak.Samuthiram Pachal(Po),
Namakkal Dt.Tamilnadu.Pin:637018)

Abstract- The main aim of this review paper is to

bicycles. The single biggest advantage of electric
present the idea of harnessing the various energy and
use it in today’s existence of human life .Now-a-days bicycle is that it is cost operative as it mainly only
there are so many vehicles on road, which consumes entails building cost as running cost would only require
more fuel and also hazards our environment. It is the charging of the battery. An Electric bicycle would,
our responsibility to reduce the consumption of fuel however offer other solid benefits that are
and its hazardous emission products. Taking this into overlooked by the marketplace. These include the
consideration it is our small step towards reducing the intense reduction in oil consumption that its widespread
use of more fuel consuming vehicles and attract the
use would bring about. Much less oil would be
eye of people towards its alternatives i.e. Electric
bicycle. So we intend to design a cycle which would needed because only a tiny proportion of electricity is
run on an alternative source and also reducing generated from oil. The further major non-market
human efforts called as Battery Operated Cycle. In benefit would be lower greenhouse gas emissions.
this paper we design an alternative mode of transport
for betterment of social and environment.
II. DC MOTOR
Keywords: Direct Current Motor (DC Motor), A DC motor is one of a class of rotary
electrical machines that converts direct current
I. NTRODUCTION electrical power into mechanical power. The most
The electric bicycle is an electrical-assisted device that mutual types rely on the forces created by magnetic
is designed to deliver the electromagnetic momentums fields. Nearly all types of DC motors have specific
to a present bicycle therefore relieving the user of internal mechanism, either electromechanical or
producing the energy essential to run the bicycle. It electronic, to periodically change the direction of current
contains a strong motor and enough battery power that flow in portion of the motor.
just needs charging to help in hill climbing, DC motors were the first type commonly used,
generate greater motoring speeds and provide since they could be powered from present direct-current
completely free electric transportation. Electric vehicles lighting power distribution systems. A DC
price more and perform poorer than their gasoline motor's speed can be controlled over a extensive
counterparts. The aim is that mainly because gasoline range, using either a variable supply voltage or by
cars have promoted from a century of intensive changing the strength of current in its field
development; electric cars have been virtually windings. Tiny DC motors are used in tools, toys,
overlooked for several years. Even today, gasoline cars and appliances. The universal motor can operate on
profit from billions of dollars of research every year direct current but is a lightweight motor used for
while electric vehicles receive a small fraction of convenient power tools and appliances. Bigger DC
that quantity of money. The primary principle for motors are used in propulsion of electric vehicles,
the Universities‟ support of the electric- powered elevator and hoists, or in drives for steel rolling mills.
over the petrol powered has been towards The arrival of power electronics has made
improving air quality, though air quality alone is not a replacement of DC motors with AC motors possible
satisfactory justification to mandate electric in many applications.

Volume 6, Issue 04 Published by, www.ijert.org 1

Working Principle: - A motor is an electrical machine
which translates electrical energy into mechanical energy.
The principle of working of a DC motor is that "whenever a
current carrying conductor is placed in a magnetic field, it
practices a mechanical force".

Fig.2 Controller Device

Fig.1 Working of Electric DC Motor.

III. CONTROLLER

A) Speed Control Basics:-

The speed controller of an electric bike is an electronic
circuit that not only controls the speed of an electric motor
but also serves as a dynamic brake. This controller
unit uses power from the battery box and drives it to Fig.3 Functions of Pins
the motor. Different forms of controllers are used for C) Plug:-
brushed
and brushless motors. For adaptive e-bikes, a 1.Red & Black (large cable) : Battery connections
conversion kit is used and the controller is the core 2. Yellow & Blue : Motor
connections 3.Red & Blue : Key
component of that kit.
Switch(power lock)
(If there is no power door locks, red connection to
B) Function:- blue)
The electric bike speed controller sends signals to the bike's 4.Yellow & black : brake
motor in many voltages. These signals detect the direction 5.Red & Yellow: Brake light
of a rotor relative to the starter coil. The suitable function of 6.Red&Black(small cable) : indicator light
a speed control depends on the employment of various 7. Red, Black & Blue: Speed Regulator 1-4 V
mechanisms. In a purpose-built electric bike, Hall effect Throttle (Red : +5v, Black : - , Blue :Signal Wire)
8.Red & Black (small cable): Charger
sensors help detects the location of the rotor. If your speed
controller does not include such sensors and the speed
controller on an adaptive bike may not the IV. WORKING
electromotive force of the un-driven coil is calculated to
The working of our project basically explain by using the
get the rotor orientation.
five blocks as follows
The mechanism of an electric speed controller differs
depending on whether you own an adaptive or purpose-
a) Battery.
build electric bike. An adaptive bike includes an electric
b) Motor Controller Circuitry.
drive system installed on an normal bicycle. A purpose-
c) Electric motor.
built bike, more expensive than an adaptive bike, provides
d) Chain and Sprocket.
easier acceleration and affords extra features.
e) Bicycle speed Rotation.
 N2 = 169 rpm
Step 3:-
Diameter of wheel =650mm
Circumference of wheel =
=3.14*650
=2041mm
Step 4:-
Speed of vehicle = speed of wheel X circumference
Fig 4 Block diagram of the Electric bicycle construction process
of wheel
=169 X 2041
=344418075 mm/min
A) Battery:- =344.41 m/min
Two lead acid rechargeable batteries of 12v, 9 amp are =20665 m/hr
used which are connected in parallel position. It =20.66 Km/hr
basically stores the electrical energy generated and
utilise it to run the motor. A battery has a positive VI. REQUIRED POWER TO DRIVE BICYCLE
terminal called cathode and negative terminal called
anode. The terminal marked positive is at higher electric Step (1)
potential energy and the terminal marked negative is Total load act on bicycle is as follow
source of electrons when connected to external Normal weight of person =65 kg
circuit will flow and deliver energy to external =65*9.81
device Rechargeable batteries are recharged multiple =637.65N
times. Weight of bicycle = 5 kg
= 5*9.81
B) Motor Controller Circuitry:- = 49.N
It used to control all the working of cycle. N Other Miscellaneous load =5
Kg
=5*9.81
C) Electric Motor:- = 49.05 N
Use the specific motor having suitable power and torque The total load = (637.65+49+49.04)
according to design. = 735.65N
Step (2)
D) Chain and Sprocket:- To find reaction on each wheel, The above total load
Take the suitable material & no. of teeth according to which is divided equally on both wheel
center distance. Force (Ffw) =Force(Frw)
=735./2
E) Bicycle Wheel Rotation:- =367.8N
Provide the torque and speed to the wheel through Where reaction on rear and front wheel are as follows
out sprocket. Rfw=Rrw
=0.2*340.5
V. NO LOAD SPEED CALCULATION =73.56 N
Step 1 :- Step (3)
Number of teeth on smaller sprocket ( motor) (t1) = 9 To find torque on each wheel
Number of teeth on larger sprocket ( bicycle) (t2) = 18 Total torque=Tfw+Trw
Speed on smaller sprocket (motor) (N1) = 3300 rpm To find Torque on Front Wheel
By using reduction ratio (9.78), speed will be reduced T1 = Rfw*(D÷2)
to 338 rpm =68.1*[(65*10-2)/2]
Speed on larger sprocket (bicycle) ( N2) = ? =22.1325Nm
T1=T2=22.1325Nm
Total torque on wheel=44.265 Nm
Step 2 :-
Using speed ratio formulae, Step(4)
N1t1 = N2t2 To find power on motor = 391.69 watt
 PRO E DESIGN
[4] Ian Vince McLoughlin, I. Komang Narendra, Leong Hai Koh,
Quang Huy Nguyen,Bharath Seshadri, Wei Zeng, Chang Yao,
Campus Mobility for the Future: The Electric Bicycle, 2011.
[5] Olakunle Alao , The Design and Construction of an Electric
Bicycle,2015.
[6] Muhsin Abdur-Rahman, Bo Hu,2007.
[7] Srivatsa Raghunath, Hardware Design Considerations for an
Electric Bicycle
[8] Using a BLDC Motor, 2014.
[9] Rony Argueta, The Electric Vehicle, 2010.
[10] FABIAN FOGELBERG, Solar Powered Bike Sharing System
with Electric Bikes,2015.
[11] Christopher Cherry, Electric Bike Sharing--System
Requirements "! and Operational
Concepts,2010.
[12] Kevin Antalek, Electric Motorbike with Regenerative Braking
,2014.
[13] Linus Garrett1,Jack Baker2,Jon Higginbotham, Electric
Bicycle and Agricultural Trailer,2013.
VII. CONCLUSION PHOTOGRAPHY

This project is designed to improve the normal

bicycle and make it extra efficient. The electric bicycle is
a hybrid and so it can run electrically and can also be
pedaled thereby still retaining the exercise people drive
from riding bicycle.
The calculated No load speed of bicycle is
=
20.66Km/hr

The Required power is =391.69 watt

REFERENCES

[1] Chetan Mahadik, Sumit Mahindraka, Prof. Jayashree Deka ,

“An Improved & Efficient Electric Bicycle system with
the Power of Real-time Information Sharing” ,2014.
[2] D. M. Sousa, P. J. Costa Branco, J. A. Dente, Electric
bicycle using batteries and Supercapacitors, 2007.
[3] Arun Eldho Alias1, Geo Mathew2, Manu G3, Melvin
Thomas4,Praveen V Paul5, Energy Efficient Hybrid Electric
Bike with Multi -Transmission System, 2015.