Design and Development of Eco-Friendly Power

Transmission System for Lightweight Electric

Motorcycle.

A PROJECT REPORT
PHASE II

Submitted by

L.DEEPAK 18604908

D.KAMESH 18604909

A. PRIYAN 18604913

M.UMA MAHESWARAN 18604514

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
(NBA ACCREDITED)

SCHOOL OF ENGINEERING
VELS INSTITUTE OF SCIENCE TECHNOLOGY AND ADVANCED STUDIES
(VISTAS)

CHENNAI - 600 117

MAY -2022
 BONAFIDE CERTIFICATE

Certified that this project “Design and Development of Eco-Friendly Power

Transmission System for Lightweight Electric Motorcycle.” is the bonafide work of
“L.DEEPAK (18604908), D.KAMESH (18604909), A.PRIYAN (18604913), M.UMA
MAHESWARAN (18604514)”, who carried out the project work under my supervision.
Certified further that to the best of my knowledge the work reported herein does not form part
of any other project report or dissertation on the basis of which a degree or award was
conferred on an early occasion on this or any other candidate.

SIGNATURE SIGNATURE

Dr. C. DHANASEKARAN Mr. S. ARUN KUMAR

HEAD OF THE DEPARTMENT SUPERVISOR

MECHANICAL ENGINEERING MECHANICAL ENGINEERING

VISTAS VISTAS

CHENNAI-600 117 CHENNAI-600 117

Submitted for the project work and viva-voce examination held on ………………. at
VISTAS, Chennai – 600 117.

INTERNAL EXAMINER EXTERNAL EXAMINER

 TABLE OF CONTENTS
CHAPTE TITTLE PAGE
R NO.

ACKNOWLEDGEMENT i

ABSTRACT ii

LIST OF FIGURES iii

CHAPTER 1 INTRODUCTION

1.1 INTRODUCTION & HISTORY OF ELECTRIC BIKE 1

1.2 ELECTRIC BIKE CONVERSION KIT 7

1.3 ELECTRIC BIKE DESIGN 8

CHAPTER 2 LITERATURE REVIEW

2.1 LITERATURE REVIEW OF ELECTRIC BIKE 9

2.2 LITERATURE REVIEW OF ELECTRIC BIKE CONVERSION KIT 11

3.3 LITERATURE REVIEW OF ELECTRIC BIKE DESIGN 13

 CHAPTER 3 EXPERIMENTAL DETAILS

3.1 INTRODUCTION 14

3.2 LIST OF MATERIALS 14

3.2.1 MOTOR 14

3.2.2 BATTERY 15

3.2.3 CONTROLLER 16

3.2.4 CONVERTER 16

3.2.5 CHARGING PORT 17

3.2.6 FUSE AND FUSE HOLDER 17

3.2.7 SPROCKET 18

3.3 DRIVE MECHANISM 19

3.4 FABRICATION PROCESS 20

3.5 ADVANTAGES 24

3.6 DISADVANTAGES 26

CHAPTER 4 RESULT AND DISCUSSION

4.1 ELECTRIC BIKE RESULT 28

CHAPTER 5 SUMMARY AND CONCLUSION

5.1 SUMMARY AND CONCLUSION 29

REFERENCES
 Acknowledgment

Any accomplishment requires the effort of many people and this work is no different staring at
ground zero; we would like to express our deep gratitude to our beloved Founder – Chairman
Dr. Ishari K. Ganesh for his kind support and encouragement.

We extend our sincere thanks to Prof. Dr. S. Sriman Narayanan, Vice-Chancellor, and
Prof. Dr. P. Swaminathan Advisor for permitting me to do the project.

We extend our sincere thanks to Dr. P. Saravanan, Registrar, and Dr. A. Udhayakumar, Controller
of Examination for permitting me to do the project.

We are very much grateful to Dr. M. Chandrasekaran, Director, Department of Mechanical

Engineering, for his encouraging support and useful suggestions during this work.

We extend our sincere thanks to Dr. C. Dhanasekaran, Coordinator, School of Engineering and
Head of the Department for his encouragement and support.

We thank our project coordinator Dr. M. Chandrasekaran for his entire support and valuable
guidance throughout the project work.

We express our sincere thanks to our guide Mr. S. Arunkumar for having extended his fullest
cooperation and guidance without which this project would not have been possible.

We take this opportunity to thank all teaching and Non-teaching staff members of our department for
their suggestion and help.

Last but not the least; we thank our parents who have been the source of inspiration and support for us
throughout this project work. We also thank all those who have either directly or indirectly helped
during this project work.

i
 ABSTRACT
The main aim of this construct the paper is to present the idea of harnessing the various
energy and use it in today’s existence of human life. Now-a-days there are so many vehicles
on road, which consumes more fuel and also hazards our environment. It is our responsibility
to reduce the consumption of fuel and its hazardous emission products. Taking this into
consideration it is our small step towards reducing the use of more fuel consuming vehicles
and attract the eye of people towards its alternatives i.e. Electric bike. So we intend to design
a bike which would run on an alternative source and also reducing human efforts called as
Battery Operated bike. In this paper we design an alternative mode of transport for betterment
of social and environment. An electric bike is also necessary because as we know that fossil
fuel sources are limited and they are depleting continuously. Keeping all these things into
consideration there is a need to find a solution for conventional fuel-powered vehicles also
the people’s vigorous awareness of environmental problems also leads to research towards
the alternate solution for the automotive vehicle. The uses of renewable energy in the place of
conventional fuel are the best solution to overcome this problem. An electric bike can be
considered a good alternative for traveling within small and medium distances. The main aim
of this paper is to present an idea of the design and development of the electric bike. Electric
vehicle drives offer a number of advantages over conventional internal combustion engines,
especially in terms of lower local emissions, higher energy efficiency, and decreased
dependency upon oil. Yet there are significant barriers to the rapid adoption of electric cars,
including the limitations of battery technology, high purchase costs, and the lack of
recharging infrastructure. With intelligently controlled charging operations, the energy needs
of potential electric vehicle fleets could be covered by existing German power plants without
incurring large price fluctuations. Over the long term, electric vehicles could represent a
sustainable technology path. In the short to mid-term, however, exceedingly optimistic
expectations should be avoided, especially with respect to the reduction of greenhouse gas
emissions. Electric vehicles as such will not be able to solve all current problems of
transportation policy. Yet they may constitute an important component of a larger roadmap
for sustainable transportation.

ii
 LIST OF FIGURES

FIGURE TITTLE PAGE

NO NO

3.1 MOTOR 14

3.2. LEAD ACID BATTERY 15

3.3 BATTERY SERIES CONNECTION 15

3.4 CONTROLLER 16

3.5 CONTROLLER WIRING DIAGRAM 16

3.6 CONVERTER 17

3.7 CHARGING PORT 17

3.8 FUSE AND FUSE HOLDER 18

3.9 SPROCKET 18

3.10 DISMANTLING SPARE PARTS 20

3.11 MOUNTING A FRAME 20

3.12 MOTOR FIXED IN FRAME 21

iii
3.13 DUAL CHAIN SPROCKET 21

3.14 ASSEMBLING REAR SPROCKET 22

3.15 WIRING OTHER BIKE ACCESSORIES 22

3.16 ELECTRIC BIKE IN OPEN VIEW 23

3.17 ELECTRIC BIKE IN CLOSED VIEW 23

iv
 CHAPTER 1: INTRODUCTION
1.1Introduction and History of Electric bike:

Introduction:

An electric bicycle, also known as an e-bike or e-bike, I with an integrated electric

motor used to assist propulsion. Many kinds of e-bikes are available worldwide, but they
generally fall into two broad categories: bikes that assist the riders without pedal-power and
bikes that add a throttle, integrating moped-style functionality[1]. Both retain the ability by
the rider and are therefore not electric motorcycles.

E-bikes use rechargeable batteries and typically travel up to 25 to 32 km/h (16 to 20 mph).
High-powered varieties can often travel more than 45 km/h (28 mph). In some markets, such
as Germany as of 2013, they are gaining in popularity and taking some market share away
from conventional bicycles, while in others, such as China as of 2010, they are
replacing fossil fuel-powered mopeds and small motorcycles. [2]

Depending on local laws, many e-bikes (e.g., peddles) are legally classified as bicycles rather
than mopeds or motorcycles. This exempts them from the more stringent laws regarding the
certification and operation of more powerful two-wheelers which are often classed as electric
motorcycles. E-bikes can also be defined separately and treated under distinct electric bicycle
laws.

E-bikes are the electric motor-powered versions of motorized bicycles, which have been in
use since the late 19th century. Some bicycle-sharing systems use them. An electric bike is
normally powered by a rechargeable battery and their practical performance is influenced by
motor power, battery capacity, road type, operation weight, control, etc. In A vehicle
propelled by an electric motor, rather than a traditional petrol or diesel engine is called as
electric vehicle. The electric motor is powered by rechargeable batteries that can be charged
using household mains electricity via an electric vehicle charge point at home or at a more
powerful electric vehicle charge station at work or in the street. [3] This paper focuses on the
design and development of the electric bike, constructional parts, manufacturing companies
in India, advantages, problems, government initiatives in India, future scope etc. An electric
vehicle
 1

(EV) is one that operates on an electric motor, instead of an internal-combustion engine that
generates power by burning a mix of fuel and gases. Therefore, such as a vehicle is seen as a
possible replacement for current-generation automobiles, in order to address the issue of
rising pollution, global warming, depleting natural resources, etc. Though the concept of
electric vehicles has been around for a long time, it has drawn a considerable amount of
interest in the past decade amid a rising carbon footprint and other environmental impacts of
fuel-based vehicles.

In India, the first concrete decision to incentivise electric vehicles was taken in 2010.
According to a Rs 95-crore scheme approved by the Ministry of New and Renewable Energy
(MNRE), the government announced a financial incentive for manufacturers for electric
vehicles sold in India.

EVs first came into existence in the mid-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.[4]

In the 21st century, EVs have seen a resurgence due to technological developments, and an
increased focus on renewable energy and the potential reduction of transportation's impact on
climate change and other environmental issues. Project Drawdown describes electric vehicles
as one of the 100 best contemporary solutions for addressing climate change.

Government incentives to increase adoption were first introduced in the late 2000s, including
in the United States and the European Union, leading to a growing market for the vehicles in
the 2010s.[3][4] Increasing public interest and awareness and structural incentives, such as
those being built into the green recovery from the COVID-19 pandemic, is expected to
greatly increase the electric vehicle market. The International Energy Agency said in 2021
that governments should do more to meet climate goals, including policies for heavy electric
vehicles[5]. Electric vehicle sales may increase from 2% of global share in 2016 to 30% by
2030.
 2

History:

In the 1890s, electric bicycles were documented within various U.S. patents. For
example, on 31 December 1895, Ogden Bolton Jr. was granted U.S. Patent 552,271 for a
battery-powered bicycle with "6-pole brush-and-commutator direct current (DC) hub
motor mounted in the rear wheel". There were no gears and the motor could draw up to 100
amperes (A) from a 10-volt battery.

Two years later, in 1897, Hosea W. Libbey of Boston invented an electric bicycle (U.S.
Patent 596,272) that was propelled by a "double electric motor" [6]. The motor was designed
within the hub of the crankset axle. This model was later re-invented and imitated in the late
1990s by Giant Lafree e-bikes.

By 1898 a rear-wheel drive electric bicycle, which used a driving belt along the outside edge
of the wheel, was patented by Mathew J. Steffens. Also, the 1899 U.S. Patent 627,066 by
John Schnepf depicted a rear-wheel friction “roller-wheel” style drive electric bicycle.
[8]
Schnepf's invention was later re-examined and expanded in 1969 by G.A.[7] Wood Jr. with
his U.S. Patent 3,431,994. Wood's device used 4 fractional horsepower motors; connected
through a series of gears.

Torque sensors and power controls were developed in the late 1990s. For example, Takada
Yutky of Japan filed a patent in 1997 for such a device. In 1992 Vector Services Limited
offered and sold an e-bike dubbed Zike. The bicycle included NiCd batteries that were built
into a frame member and included an 850 g permanent-magnet motor. Despite the Zike, in
1992 hardly any commercial e-bikes were available.

Yamaha, a Japanese automotive giant built one of the early prototypes of e-bike back in 1989
and invented the pedal assist system in 1993.

Production grew from 1993 to 2004 by an estimated 35%. By contrast, according to Gartner,
in 1995 regular bicycle production decreased from its peak 107 million units.

American car icon, Lee Iacocca founded EV Global motors in 1997, a company that
produced an electric bicycle model named E-bike SX and it was one of the early efforts to
popularize e-bikes in the United States.[8]
 3

Some of the less expensive e-bikes used bulky lead acid batteries, whereas newer models
generally used NiMH, NiCd, and/or Li-ion batteries, which offered lighter, denser capacity
batteries. Performance varies; however, in general there is an increase in range and speed
with the latter battery types.

Electric motive power started in 1827, when Hungarian priest Ányos Jedlik built the first
crude but viable electric motor, provided with stator, rotor and commutator; the next year, he
used it to power a tiny car[12]. In 1835, professor Sibrandus Stratingh of the University of
Groningen, the Netherlands, built a small-scale electric car, and between 1832 and 1839 (the
exact year is uncertain), 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[13].

The first mass-produced electric vehicles appeared in America in the early 1900s. In 1902,
the Studebaker Automobile Company entered the automotive business with electric vehicles,
though it also entered the gasoline vehicles market in 1904. However, with the advent of
cheap assembly line cars by Ford Motor Company, the popularity of electric cars declined
significantly.

Due to 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,
[15]
tow tractors and urban delivery vehicles, such as the iconic British milk float; for most of
the 20th century, the UK was the world's largest user of electric road vehicles.

Electrified trains were used for coal transport, as the motors did not use precious oxygen in
the mines. Switzerland's lack of natural fossil resources forced the rapid electrification
of their rail network. One of the earliest rechargeable batteries – the nickel-iron battery – was
favored by Edison for use in electric cars.

EVs were among the earliest automobiles, and before the preeminence of light,
powerful internal combustion engines, electric automobiles held many vehicle land speed and
distance records in the early 1900s. They were produced by Baker Electric, Columbia
Electric, Detroit Electric, and others, and at one point in history out-sold gasoline-powered
vehicles. In 1900, 28 percent of the cars on the road in the US were electric. EVs were so
popular that even President Woodrow Wilson and his secret service agents
toured Washington, D.C. in their Milburn Electrics, which covered 60–70 mi (100–110 km)
per charge[14].

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. 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[16]. 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.

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.

The emergence of metal–oxide–semiconductor (MOS) technology led to the development of

modern electric road vehicles. The MOSFET (MOS field-effect transistor, or MOS
transistor), invented by Mohamed M. Atalla and Dawon Kahng at Bell Labs in 1959, led to
the development of the power MOSFET by Hitachi in 1969, and the single-
chip microprocessor by Federico Faggin, Marcian Hoff, Masatoshi Shima and Stanley
Mazor at Intel in 1971[17]. The power MOSFET and the microcontroller, a type of single-
chip microprocessor, led to significant advances in electric vehicle technology.

MOSFET power converters allowed operation at much higher switching frequencies, made it
easier to drive, reduced power losses, and significantly reduced prices, while single-chip
microcontrollers could manage all aspects of the drive control and had the capacity for
battery management. Insulated-gate bipolar transistor (IGBT) technology made possible the
use of the synchronous AC three phase motor, by creating a synthetic three phase alternating
current from, for example, a DC traction battery pack. This technique was developed by
Hughes and GM and used in their US Electricar in 1995, but still used the heavy (26 count 12
Volt) lead acid, series connected batteries. GM later developed an electric pickup truck and
then the EV1. This motor and controller was kept alive and used in converted cars by AC
Propulsion, where they introduced the lithium battery that Elon Musk later saw and
embraced. Another important technology that enabled modern highway-capable electric cars
is the lithium-ion battery, invented by John Goodenough, Rachid Yazami and Akira
Yoshino in the 1980s, which was responsible for the development of electric vehicles capable
of long-distance travel[18].

In January 1990, General Motors' President introduced its EV concept two-seater, the
"Impact", at the Los Angeles Auto Show. That September, the California Air Resources
Board mandated major-automaker sales of EVs, in phases starting in 1998. From 1996 to
1998 GM produced 1117 EV1s, 800 of which were made available through three-year leases.

Chrysler, Ford, GM, Honda, and Toyota also produced limited numbers of EVs for California
drivers. In 2003, upon the expiration of GM's EV1 leases, GM discontinued them. The
discontinuation has variously been attributed to:

 the auto industry's successful federal court challenge to California's zero-

emissions vehicle mandate,
 a federal regulation requiring GM to produce and maintain spare parts for the few
thousands EV1s and
 the success of the oil and auto industries' media campaign to reduce public
acceptance of EVs.
 6

1.2 Electric conversion kit:

Introduction:

E-bike conversion kits are a solution that allow you to add a motor, battery and electric
controls to a non-electric bike to make it into an e-bike. Chosen with care and installed
correctly, the resulting e-bike lets you ride with electric assist just like a ‘regular’ e-bike.
With the range of readymade e-bike designs larger than ever, kits have some competition
from off-the-peg, ready to pedal e-bikes. However, they still offer positive advantages as well
as some drawbacks which are considered first-off.

Amps, volts, watts, and ohms are the main units of measure used in measuring
electricity. Ohms is a measurement of resistance that is critical for measuring electricity, but
it’s rarely used so I will leave it at that. Most e-bike kits will be advertised using volts &
watts to explain their size as it compares to the competition, i.e. 36v 800w wheel motor kit.
This number can be easily manipulated and as such is not very reliable. Some of the better
quality kits will use volts, amps and watts i.e. a 36v 25A 900w wheel motor kit. This is better
as it takes the capacity of the controller into consideration. Sadly these too can be fudged. If
you remember the formula volts x amperes = watts you will be able to accurately
determine the real output of your motor based on the components and batteries you’ll
be using. In automobile engineering, electric vehicle (EV) conversion is the replacement of a
car's combustion engine and connected components with an electric motor and batteries, to
create an all-electric vehicle.

There are two main aims for converting an internal combustion engine vehicle to run as a
battery electric vehicle. The first is to reduce the emissions of vehicles that are already on the
road, as electric vehicles do not produce any emissions themselves.

The second is to reduce the vast amount of waste created when cars reach the end of their
lifecycle – as older cars or those written off after a road traffic accident are typically
scrapped. This creates a considerable amount of metal, plastic and fabric waste, and uses a
large amount of energy to recycle discarded parts into useful materials.

Price is another key catalyst for the growing electric car conversion market. The cost of
electric car batteries and motors has fallen in recent years, and the cost of conversion is now
considerably less than the price of purchasing a new electric car

1.3 Electric Bike Design:

Solar Power Solar cells (really called “photovoltaic” or “photoelectric” cells) that
convert light directly into electricity, bypassing thermodynamic cycles and mechanical
generators. PV stands for photo (light) and voltaic (electricity), whereby sunlight photons free
electrons from common silicon. A photovoltaic module is composed of individual PV cells.
This crystalline-silicon module has an aluminium frame and glass on the front. In the field of
photovoltaic, a photovoltaic module is a packaged interconnected assembly of photovoltaic
cells, also known as solar cells. An installation of photovoltaic modules or panels is known as
a photovoltaic array or a solar panel. A photovoltaic installation typically includes an array of
photovoltaic modules or panels, an inverter, batteries (for off grid) and interconnection
wiring. Solar energy is the utilization of the radiation energy from the sun. Solar power is
used interchangeably with solar energy but refers more specifically to the conversion of
sunlight into electricity by photovoltaic and concentrating solar thermal devices, or by one of
several experimental technologies such as thermoelectric converters, solar chimneys and
solar ponds. Sunlight is composed of photons, or particles of solar energy. These photons
contain various amounts of energy corresponding to the different wavelengths of the solar
spectrum. When photons strike a photovoltaic cell, they may be reflected, pass right through,
or be absorbed. Only the absorbed photons provide energy to generate electricity. When
enough sunlight (energy) is absorbed by the material (a semiconductor), electrons are
dislodged from the material's atoms. Special treatment of the material surface during
manufacturing makes the front surface of the cell more receptive to free electrons, so the
electrons naturally migrate to the surface. When the electrons leave their position, holes are
formed. When many electrons, each carrying a negative charge, travel toward the front
surface of the cell, the resulting imbalance of charge between the cell's front and back
surfaces creates a voltage potential like the negative and positive terminals of a battery. When
the two surfaces are connected through an external load, electricity flows.
 8

CHAPTER 2: LITERATURE REVIEW

2.1 Literature Review of Electric bike :

In 1999,AVL Company proposed a hybrid system that used a 50 cc carburetted lean-

burn two-stroke engine with a 0.75 kW electric motor mounted on the engine crankshaft
mainly to provide increased torque during acceleration.

Su-Hau et al (2004) focused on the highly efficient energy usage of the battery energy and
proposed an integrated management system for electric motor.

David and Sheng-Chung (2004) proposed new parallel-type hybrid-electric-power system

comprises an engine’s energy distribution and a torque-integrated mechanism (specifically
including an engine, a motor/alternator, a CVT device, and PCM as well as a 3-helical gear
set).

Wenguang et al (2005) presented an approach to control powertrain of series hybrid electric

vehicles. A formulation of the system equations and controller design procedure were
proposed by them. They also proposed a new switching algorithm for the power converter for
motor torque and motor flux control.

Daniel (2007) designed, developed and implemented a series hybrid electric vehicle. Though
he proposed the architecture as hybrid electric vehicle architecture, he showed that the
vehicle runs well in the electric mode and left the hybrid conversion as future expansion.

Lukic et al (2007) tried to develop a driving cycle of the auto rickshaw in a typical large
Indian city, in their case, Delhi. First, they considered the existing driving cycles used in
India are considered as candidates. Since these data were not applicable, GPS data collected
at various times of the day were applied to the analysis. They derived the new driving cycle
from the gathered information via GPS data as well as surveys of auto rickshaw drivers in
India, which helped to get the entire picture for the driving cycle.[21]
Research literature was retrieved from the Web of Science and the Transport Research
International Documentation (TRID) databases The goal was to perform an extensive review
of the different research domains variables that affect ELOS.

The TRID database includes both the Transportation Research Information Services database
and the OECD’s Joint Transport Research Centre’s International Transport Research
Documentation database.

The database search was performed in November and December 2019. The same process was
conducted again in February 2020 to include newly published articles. The search protocol
included using the following terms: level-of-service, LOS, quality-of-
service, QOS, flow, comfort, convenience, easiness, travel behaviour, coupled with the
keywords bicycle, pedelecs, electric-bicycle, electric-bicycling, electric-bike, and e-bike. In
order to retrieve the literature related to BLOS, the most recent review study (BLOS) by
Kazemzadeh, Laureshyn, et al was used. Citation search was also performed as a
complementary tool to detect more topic-related studies. The search resulted in 1108 papers
from the databases along with 195 records from the review by Kazemzadeh, Laureshyn, et al.
After removing the duplicates, a screening strategy based on the PRISMA methodology was
performed to identify the relevant papers (Moher, Liberati, Tetzlaff, & Altman, Inclusion
criteria were related to the relevance to the development of ELOS indices. The material
included only peer-reviewed English-language articles and scientific reports. BLOS studies
that considered e-bike in their LOS estimation process were included. Pure e-bike flow
research and the combination of e-bike flow with vulnerable road users (cyclists and
pedestrians) were included as deemed relevant for ELOS development. Exclusion criteria
related to studies examining environmental impact, manufacture, technical characteristics
(e.g. e-bike batteries, motors, etc.), and safety of e-bikes.

In present scenario, air pollution has become a serious concern for the India. According to
recent global report, many cities in the India are most polluted cities. Major sectors
contributing to the air pollution are industrial sector and transport sector. Among this 51% of
air pollution is caused by the industrial sector and 27% by the transport sector. Air pollution
contributes to the premature deaths of 2 million Indians every year. In order to minimize the
air pollution, Electric Vehicle (EV) can act as blessing in lowering the GHG emission.
Electric Vehicles offer numerous advantages such as decreasing the pollution level and
reduction in oil import bills etc. Although there is considerable amount of threats in
establishing the Electric Vehicles in India.

10

2.2 Literature Review of Electric bike conversion kit :

MOTOR:

A DC electric motor is used to drive the bike. To have an alternative for fuel driven
bike, Now the trend is to supply larger powered brushless motor of larger wattage which can
keep an e-bike travelling with higher speed and easily go up high skills..Induction motor,
Switched reluctance motor, Brushed DC motor and BLDC motors are preferred because of no
maintenance, high efficiency, low noise, high starting torque, high no-load speed and also
because of the absence of brushes we don’t find sparking in BLDC motor which increases the
life of motor. Hub motors are preferred for light weight electric vehicle. It is the compact
electric motor placed inside the wheel and is directly connected to the rotating wheel. It
generates high torque at low rpm

Investigation of an electric assisted bicycle and determination of performance

characteristics’’ paper examines and realizes an alternative design for a front wheel hub
direct drive, which utilizes a three-phase brushless PM motor.

Hobbyists often build their own EVs by converting existing production cars to run solely on
electricity. There is a cottage industry supporting the conversion and construction of BEVs by
hobbyists.[10] Universities such as the University of California, Irvine even build their own
custom electric or hybrid-electric cars from scratch.

Short-range battery electric vehicles can offer the hobbyist comfort, utility, and quickness,
sacrificing only range. Short-range EVs may be built using high-performance lead–acid
batteries, using about half the mass needed for a 100–130 km (60–80 miles) range. The result
is a vehicle with about a 50 km (30 miles) range, which, when designed with appropriate
weight distribution (40/60 front to rear), does not require power steering, offers exceptional
acceleration in the lower end of its operating range, and is freeway capable and legal. But
their EVs are expensive due to the higher cost for these higher-performance batteries. By
including a manual transmission, short-range EVs can obtain both better performance and
greater efficiency than the single-speed EVs developed by major manufacturers. Unlike the
converted golf carts used for neighborhood electric vehicles, short-range EVs may be
operated on typical suburban throughways (where 60–80 km/h, 35–50 mph speed limits are
typical)

11

Faced with chronic fuel shortage on the Gaza Strip, Palestinian electrical engineer Waseem
Othman al-Khozendar invented in 2008 a way to convert his car to run on 32 electric
batteries. According to al-Khozendar, the batteries can be charged with US$2 worth of
electricity to drive from 180–240 km (110–150 mi). After a seven-hour charge, the car should
also be able to run up to a speed of 100 km/h (60 mph).

The power of a vehicle's electric motor, as in other machines, is measured in kilowatts (kW).
Electric motors can deliver their maximum torque over a wide RPM range. This means that
the performance of a vehicle with a 100 kW electric motor exceeds that of a vehicle with a
100 kW internal combustion engine, which can only deliver its maximum torque within a
limited range of engine speed.

Efficiency of charging varies considerably depending on the type of charger, and energy is
lost during the process of converting the electrical energy to mechanical energy.

Usually, direct current (DC) electricity is fed into a DC/AC inverter where it is converted
to alternating current (AC) electricity and this AC electricity is connected to a 3-phase AC
motor.

For electric trains, forklift trucks, and some electric cars, DC motors are often used. In some
cases, universal motors are used, and then AC or DC may be employed. In recent production
vehicles, various motor types have been implemented; for instance, induction motors within
Tesla Motor vehicles and permanent magnet machines in the Nissan Leaf and Chevrolet Bolt
 12

2.3 Literature Review of Electric bike design:

The main purpose of this chapter is to analyse, identify and make conclusion based on
the research. A literature review means a collecting related data, analysed business process,
identify underlying patterns and create the conclusion. Another description of the literature
review is a systematic, explicit and reproducible method to identifying, evaluating and
synthesizing the existing body of completed and recorded work produced by researcher,
scholars and practitioners. In order to develop a successful project, the current systems are
identified. The system of conventional electric powered bicycle, solar system and its
connection have been analysed. Studies of these systems are significant to develop a valid,
reliable and efficient upgrade project. The Literature Review part acts as a mean to discover
which methodology should be chosen in developing this system [22]. Facts and Findings Facts
and findings establishes what the existing system does and what the problems are, and leads
to a definition of a set of options from which users may choose their required system. This
section will be discussing about the domain of this project, the existing system and finally the
other techniques that applicable to be used while developing this project. It focused on the
how to design and develop the project systematically according to the requirement of
minimize the functional of conventional project. In the other situation, these will be
describing any element or method which is useful to be used for the purpose of searching and
gathered useful information in developing this project. Domain Currently, electric powered
bicycle that was studied for this project only uses a battery to get the electric powered supply
by recharge it using conventional way. Electric powered bicycle only depends on power that
charge in battery to make it functions unless using the manual way to move it. The project is
wanted to change the way a battery charge to get the electric power and generate electricity to
move the bicycle with optimum energy[23].
 13

CHAPTER 3 EXPERIMENTAL DETAILS

3.1 Introduction

The important materials are MOTOR , BATTERY , CONTROLLER ,THROTTLE

,CONVERTER .We are used chain drice for drive mechanism

3.2 List of materials:

The following list of hardware components:

3.2.1 MOTOR:

o Power rating: 750W,

o Rated voltage: 48V,
o Weight: 5Kg,
o Efficiency (%):80,
o Torque: 12 N-m Speed (rpm):500

Fig3.1 Motor
 14

3.2.2 BATTERY:

Fig 3.2 Lead acid battery

Fig 3.3 Battery series connection

Battery is the heart of the electric bike. It supplies the energy to motor. Battery acts as a
condenser by storing the electric energy produced by generator due to electrochemical
transformation and supplying it on demand. It is also known as accumulator of electric
charge. This generally occurs while starting the system. It can deliver high electrical current
for starting an engine. Lead-acid, Nickel-Cadmium, NickelMetal Hybride and Lithium-ion
batteries are currently used for electric bike. For electric bike, 2-3 battery are used and
connected in series to produce larger input supply to motor which is equal to 24-36V and it
can be extended depends upon the rating of motor. Batteries used for electric bike should
have following properties:
  lead acid battery are used in this project.
 12V 18ahms battery are connected in series so we get 48V 18ahms .thus we can
run controller .

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3.2.3 CONTROLLER:

Fig 3.4 Controller

 Voltage -48V

 Current - 30A

 Power -750w

 48V controller are used to control whole circuit like motor, throttle, barking, etc.
 Fig 3.5 CONTROLLER WIRRING

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 INSTRUMENTAL LINE - It is used for power supply from battery to controller

 MOTOR LINE - It is used for supply power from controller to motor
 THROTTLE LINE - It is used to supply power to throttle
 3 SPEED POWER LINE - It is used to control speed with 3 speed variations
 HALL LINE - It is used to supply power to motor hall sensor
 REVERSE LINE - It is used to control motor as reverse rotation
 LOW AND HIGH BRAKE - It is used to control brake from brake switch
 SELF LEARNING WIRE - It is used for automatic motor rotation
 BATTERY WIRE - It is used for supply power to controller from battery

3.2.4 CONVERTER:
 Fig.3.6 Converter

Converter are used to convert 48v to 12v supply .This is help to connect the light , indicator ,
horn,etc.

3.2.5 CHARGING PORT:

Fig 3.7 Charging port

Charging port is used to charge battery with the help of charger. It is with 3 pin port

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3.2.6 FUSE:

Fig 3.8 Fuse &fuse holder

Fuse are used to disconnect the supply when short circuit occurred.

We used 20 ahms fuse , 48V fuse holder .

3.2.7 SPROCKET:

Fig 3.9 Sprocket

Chain engaging with sprocket converts rotational power in to rotary power and vice versa.
The sprocket looks like a gear but differs in three different ways. Gear has only one or two
engaging teeths but sprockets have many teeth of gear touch and slip against each other but
there is no slippage in case of sprocket. Gears and Sprockets are having different shapes of
teethsWe are chain drive mechainsim because it gives more torque .

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3.3 DRIVE MECHANISM:

• Chain drive mechanism is used for transmission from motor to wheel.

• Dual chain drive mechanism is used (PRIMARY SPROCKET &SECONDARY

SPROCKET)

• So, four chain sprocket is used (Two is on back wheel it is fixed, other two are non-
fixed)

• Primary sprocket gives heavy torques

• Secondary sprocket gives speed

 • Direct-drive systems are characterized by smooth torque transmission, and nearly-
zero backlash. The main benefits of a direct-drive system are increased efficiency
(due to reduced power losses from the drivetrain components) and being a simpler
design with fewer moving parts. Major benefits also include the ability to deliver high
torque over a wide range of speeds, fast response, precise positioning, and low inertia.
• The main drawback is that a special type of electric motor is often needed to provide
high torque outputs at low rpm. Compared with a multi-speed transmission, the motor
is usually operating in its optimal power band for a smaller range of output speeds for
the system (e.g., road speeds in the case of a motor vehicle).
• Direct-drive mechanisms also need a more precise control mechanism. High-speed
motors with speed reduction have relatively high inertia, which helps smooth the
output motion. Most motors exhibit positional torque ripple known as cogging torque.
In high-speed motors, this effect is usually negligible, as the frequency at which it
occurs is too high to significantly affect system performance; direct-drive units will
suffer more from this phenomenon unless additional inertia is added (i.e. by
a flywheel) or the system uses feedback to actively counter the effect.

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3.4 FABRICATION PROCESS:

STEP 1:

Dismantling the original parts from internal combustion petrol bike

 Fig 3.10 DISMANTLING SPARE PARTS

STEP 2 :

Mounting a frame for motor with L angle

Fig 3.11 MOUNTING A FRAME

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STEP 3 :

Fixed a motor in mounted frame to coonect chain sprocket with chain drive
 Fig 3.12 MOTOR FIXED IN FRAME

STEP 4 :

ASSEMBLING CHAIN SPROCKET WITH DUAL CHAIN SPROCKET

Fig 3.13 DUAL CHAIN SPROCKET

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STEP 5 :

Assembling a rear sprocket with manual desgin

 Fig 3.14 ASSEMBLING REAR SPROCKET

STEP 6:

Wiring a other bike accessories like horn , headlight etc

Fig 3.15 WIRING OTHER BIKE ACCESSORIES

22

STEP 7 :

Final bike module setup after assembling all parts and modules
 Fig 3.16 ELECTRIC BIKE IN OPEN VIEW

Fig 3.17 ELECTRIC BIKE CLOSED VIEW

23

3.5 ADVANTAGES:

 No emission

 No pollution

 Eco-friendly

 Less consumption of electrical energy

 No maintenance

 Dual chain mechanism gives heavy torque at initial, and speed

 Customise of chain drive (change manually)

 No sound while driving

 No use of fossil fuel.

 Lead acid are safely (lithium-ion battery are highly combustible)

 Good efficiency: BLDC motors in e-bikes are above 90% efficient than IC engines
which are nearby 40% efficient.

 Eco-friendly: Electric bikes are eco-friendly if required power to charge the batteries
is derived from nonconventional sources

 heaper: Running cost of e-bike is less as compared to conventional bikes.

 Quiet journey: E-bikes are quietest of all transportation.

 If the battery runs out, you can still ride

 You can sell a used ebike and still make money

 40-70 miles on one battery charge

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 Environmentally friendly- the electric bike advantages and disadvantages, the biggest
selling point for electric two-wheelers is that they are environmentally friendly. They
do not burn fossil fuels, nor do they produce smoke, curbing air pollution in the
process. This, however, is under debate as the electricity required for charging these
scooters is going to be majorly produced by burning coal, which is the largest source
of electricity in the country. Unless the government comes up with cleaner sources of
electricity, this may not be the best eco-friendly alternative. That being said, electric
vehicles are significantly more environmentally friendly as compared to fuel-powered
vehicles.

 Lower Running Cost- While electric bikes and scooters are a tad more expensive to
purchase as compared to regular two-wheelers, the amount of money you will save on
fuel in the long term makes this an extremely economical choice. With rising fuel
costs, more and more people are turning to electric vehicles for lower running costs.
  Maintenance - When looking at electric scooter pros and cons, one main advantage is
that there are no complex mechanisms. As a result, the maintenance cost of electric
bikes is much lower in comparison to regular vehicles.
 Storage Space-Electric scooters do not house as many mechanical parts as regular
bikes and scooters and thus they have a large storage space that can be used to
transport a variety of objects.
 Low Noise - Most vehicles produce a lot of noise while being driven. When you step
out on a busy street, you can hear dozens of vehicles contributing to noise pollution.
Another point in the list of advantages of electric bikes is that they barely make any
sound, if at all.
 Lightweight - Electric scooters are relatively simple and have fewer parts. This makes
them compact and easy to park. The lightweight also makes it easy for a driver, since
the heavier the vehicle, the more difficult it is to drive it. Among the pros and cons of
e bikes, the low weight and compact structure also make it possible to bring your
scooter indoors during the rains.

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3.6 DISADVANTAGES:
 It is not suitable for long drive

 No automatic change chain drive

 Battery charge time is long

 Recharge Points. Electric fuelling stations are still in the development stages.
 The Initial Investment is Steep
 Electricity isn't Free.
 Short Driving Range and Speed.
 Longer Recharge Time.
 Silence as a Disadvantage.
 Normally 2 Seaters.
 Battery Replacement
 Battery Life - Electric batteries need to be replaced once they are damaged or once
they no longer give a good range. Batteries usually last for a year, and cost Rs.13,000-
20,000, depending on the rating, brand, quality, and warranties.

 Range - The range of an electric scooter is the distance that it will cover in a single
charge. The average range of the top electric scooter models in India is 100 km.
Moreover, the range decreases with the life of the battery. It takes a good 5 hours to
recharge the battery, so it might not be a great option for long-distance travel.

 Repair and maintenance - Among the pros and cons of e-bikes, repairs can be a matter
of concern as few repair centres or spare parts dealers are available for this new mode
of transport. However, over time, as electric vehicles become more popular, repair
services will become more mainstream and easily accessible

 Lack of Infrastructure - In many developed countries where electric vehicles are

mainstream, charging stations can be found every few kilometres. People can stop and
charge their e-cars or e-bikes at the charging stations. However, India barely has any
such infrastructure, so taking your electric vehicles for a long ride becomes next to
impossible.

26

 Power - When electric vehicles were first introduced in India, they had very low
power and could not be driven at high speeds. Eventually, faster e-bikes and e-
scooters have been introduced but they are still no match for fuel-powered two-
wheelers. Low driving speed is one of the major disadvantages of an electric scooter.

 Heavy without motor support

 Faster ebikes need to be registered

 E-bike manufacturing remains not environmentally friendly.

 Difficult to Transport- Electric bikes are very difficult to transport. They’re heavy and
may require towing. However, if you’re willing to pay a little more upfront, electric
bikes might be the perfect option for you. If you’re worried about these issues, it’s
 best to choose an alternative form of transportation. If you’re unable to afford an
electric bike, you might want to wait a few years to find a solution that meets your
needs.
 An electric bike can be more expensive than other bicycles. They are also much
heavier than standard bicycles, making them more difficult to carry and store. You’ll
need to find more space for charging your electric bike. Moreover, an electric bike
can be more expensive than a conventional bicycle. And since they are more
complicated than a standard bicycle, they can’t be used by everyone. Besides, an e-
bike can only be plugged into one place.

 Recharging Problems - Electric bikes’ range can be problematic. Depending on the

model, it can be difficult to charge. This can limit its usefulness in long-distance
driving. Further, electric bikes can be difficult to carry. They require towing racks.
And they’re heavier than conventional bicycles. These disadvantages make them
difficult to transport. But there are also some positives. But, be prepared for a few
problems.

The main disadvantage of electric bikes is their high cost. Because they need to be
recharged frequently, e-bikes are not cheap compared to other types of bikes. Nevertheless,
they are cheaper than public transportation and are eco-friendly. If you’re considering an
electric bike, there are a few pros and cons you should be aware of. You should choose the
model that is right for you.

27

CHAPTER 4 RESULT

ELECTRIC BIKE RESULT :

The result we found in our electric bike are:-

 Bike drives more distance than other electric bike with respect to low specifications.
 It carries in more load in primary sprocket with the maximum speed of 35km/hr
  It covers 45km in single charge
 It runs in speed of 45/hr in secondary sprocket
 Planetry gear helps to more torque than other motor
 We set a motor rotation stop when applied the brake
 We assembled the motor based on centre of gravity of vehicle thus battery handling
the vehicle is easy
 Arrangments of battery in horizontal position with leads to reduction of heat and
constant power supply
 Discharge port helps to cut power supply when not in use if we plug out the wire
 Chain drive hepls to give more torque instantly than belt drive mechanism

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CHAPTER 5 SUMMARY AND CONCLUSION

SUMMARY AND CONCLUSION:

With the increasing consumption of natural resources of petrol, diesel it is necessary

to shift our way towards alternate resources like the Electric bike and others because it is
necessary to identify new way of transport. Electric bike is a modification of the existing
cycle by using electric energy and also solar energy if solar panels are provided, that would
sum up to increase in energy production. Since it is energy efficient, electric bike is cheaper
and affordable to anyone. It can be used for shorter distances by people of any age. It can be
contrived throughout the year. The most vital feature of the electric bike is that it does not
consume fossil fuels thereby saving crores of foreign currencies. The second most important
feature is it is pollution free, eco – friendly and noiseless in operation. For offsetting
environmental pollution using of on – board Electric Bike is the most viable solution. It can
be charged with the help of AC adapter if there is an emergency. The Operating cost per/ km
is very less and with the help of solar panel it can lessen up more. Since it has fewer
components it can be easily dismantled to small components, thus requiring less maintenance.

29

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