AVANTHI’S SCIENTIFIC TECHNOLOGICAL &

RESEARCH ACADEMY
(Approved by A I C T E, Recognized by Govt of A.P., & Affiliated to J N T U, Hyderabad)
Gunthapally (V), Hayath Nagar (M), R R District, A.P, India, Pin code: 501512
Phone: 08415 320956, 9248923110, 8106557799; Fax: 040-66781220
Date: 10.01.2025

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that Mini Project report titled “FABRIFCATION OF SOLAR

POWERED ELECTRIC BICYCLE” is a bonafide work of Mr. G.Venkatpavan

(22PT5A0302), Mr. K.Charan goud(22PT5A0303), Mr. S.Shiva Prasad reddy (22PT5A0304),

Mr. V.Roopsingh (22PT5A0306) . They successfully completed this Mini Project Work under the

supervision of the internal guide in partial fulfillment of the requirements for the award of the

Bachelor of Technology in Mechanical Engineering to the Jawaharlal Nehru Technological

University, Hyderabad for the academic year 2024 - 25. It is further Certified that the report

submitted herein does not form part of any other Mini Project or Project report or dissertation on

the basis of which a Degree or Award was conferred on any earlier occasion on or any other

candidate.

Mr. P.Raju RAJU PODURI

INTERNAL GUIDE HEAD OF THE DEPARTMENT

Dr. UMA MAHESHWARAO

EXTERNAL EXAMINER PRINCIPAL
 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any work would
be incomplete without naming the people who made it possible, whose constant guidance
and encourage made this work perfect.

We respectfully project guide P.RAJU, M.Tech,Ph.D , Associate professor in Department

of Mechanical Engineering ,all our professors and staff members for their support ,
encouragement, advice and their guidance.

Our special thanks to Dr.P.Raju , M.Tech, Ph.D. Head of the Department of

Mechanical Engineering for having kindly to take the onus of guiding us for this project.

We wish to convey my gratitude and express sincere to all P.R.C (Project Review
Committee) members for their support and Co-operation rendered for successful submission
of our project work.

We wish to express our sincere gratitude to DR. . UMA MAHESHWARAO

Principal of Avanthi’s Scientific Technological & Research Academy, Hyderabad for
His consistent help and encouragement to complete the project work.

We are very much thankful to Shri M. SRINIVAS RAO Chairman of Avanthi’s

Scientific Technological & Research Academy & Management for their help in providing
good facilities in our college.

Submitted by

G. Venkat pavan (22PT5A0302)

K. Charan goud (22PT5A0303)
S. Shiva Prasad reddy (22PT5A0304)
V. Roopsingh (22PT5A0306)

iii
 DECLARATION

We hereby declare that the Mini Project Report Titled “FABRIFCATION

OF S0LAR POWERED ELECTRIC BICYCLE” submitted to the Department of Mechanical
Engineering, Avanthi’s Scientific Technological & Research Academy, affiliated to
JNTU, Hyderabad, is carried out by us during the year 2024-2025 in partial fulfillment
of the award of B.Tech (Mechanical Engineering) and is not submitted to any other
university or organisation for the award of any other degree or diploma or published
any time before.

Date: Febraury 10, 2025

Place: Hyderabad

Mr. G. Venkat pavan (22PT5A0302)

Mr. K. Charan goud (22PT5A0303)

MrS. Shiva Prasad reddy (22PT5A0304)

Mr. V.Roopsingh (22PT5A0306)

iv
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGENO.

ABSTRACT V

LIST OF FIGURES IX

1 INTRODUCTION

1.1 GENERAL INTRODUCTION 1

1.2 CLASSIFICATION OF ELECTRIC BICYCLE 1

1.2.1 TYPE 1 E-Bike 1

1.2.2 TYPE 2 E-Bike 1

1.2.3 TYPE 3 E-Bike 1

1.3 ADVANTAGES OF E-BICYCLE 2

1.4 OBJECTIVE 2

1.5 LITERATURE SURVEY 2

1.6 SCOPE 4

2 DESIGN OF ELECTRIC MOTOR BICYCLE

2.1 TURN ON OF E-BICYCLE 5

2.2 AUTO-CUT OFF BRAKES 6

2.3 INSTRUMENT CLUSTER 6

v
 2.4 WORKING OF LIGHT AND HORN 7

2.5 REQUIREMENT CALCULATIONS 7

2.5.1 MASS RANGE CALCULATIONS 7

2.5.2 MOTOR LOAD CALCULATION 7

2.5.3 TO FINDING Fd (GRADIENT RESISTANCE) 8

2.5.4 TO FIND Fwf (AERO RESISTANCE) 8

2.5.5 TO FIND FR (ROLLING RESISTANCE) 8

2.5.6 TOTAL PROPULSION FORCE, FP 8

2.6 SELECTION OF BATTERY PACK 8

2.6.1 CONSIDERING CYCLE APPLICATIONS 9
2.7 CONTROLLER SPEC 10
2.7.1 HOW CONTROLLER WORKS 10

3 SELECTION OF COMPONENTS OF ELECTRIC

MOTOR BICYCLE

3.1 DC HUB MOTOR (BLDC) 11

3.1.1 SPECIFICATIONS 12

3.2 CONTROLLER 15

3.2.1 SPECIFICATIONS 16

3.3 BATTERY 19

3.4 INSTRUMENT CLUSTER 21

3.5 THROTTLES 21
3 . 5 . 1 T YPE S OF T H ROT T LES 22
3.6 LIGHT 23

vi
 3.7 HORN 24

3.8 BMS 24

4 DEVELOPING AND TESTING OF ELECTRIC MOTOR

BICYCLE
4.1 SCRAP CYCLE 26

4.2 RUST PROTECTION 27

4.3 PARTS FOR CONVERSION 28

4.4 MOTOR INSTALLATION AND MAKING OF BATTERY 29

4.5 INSTALLATION OF BATTERY AND OTHER PARTS 33

4.6 TESTING OF THE ELECTRIC MOTOR BICYCLE 35

4.7 FINAL FINISH 36

5 CONCLUSION

5.1 CONCLUSION 38

5.2 FUTURE SCOPE 38

REFERENCES 39

vii
 LIST OF FIGURES

FIGURE No. TITLE PAGE No.

2.1 Block diagram of Electric Bicycle 5

2.2 Block diagram of converting Electric Bicycle 5

2.3 Block diagram for auto cut off brakes 6

2.4 Block diagram for instrument cluster 6

2.5 Block diagram for lights and horn 7

3.1 12V DC motor 11

3.2 Controller 16

3.3 Flow chart of Controller 18

3.4 Controller Connecting wires 19

3.5 Battery 19

3.6 display 21

3.7 Throttle 22

3.8 Light 23

3.9 Horn 24

3.10 Bms 25

viii
FIGURE No. TITLE PAGE No

4.1 scrap cycle 26

4.2 convertion of scrap cycle 27

4.3 painting cycle frame 28

4.4 Motor fixed in rare wheel rim 29

4.5 creating battery using cells 30

4.6 connecting cells 30

4.7 covering of cells 31

4.8 battery sealing 32

4.9 Battery testing 33

4.10 Installation of battery, controller and other parts 34

4.11 After installation 34

4.12 Testing of Electric Bicycle 35

4.13 Testing by Faculty 37

ix
 ABSRACT

There is growing demand for Electric Motor Bicycle in India as there will be
less air pollution, lower maintenance cost and reduced noise using Electric Motor
Bicycle. The motive of this research work is to design a simple, cost-effective
model of Electric Motor Bicycle with intelligent controller. The Electric Motor
Bicycle is consisting of motor, battery and controller. In this BLDC motor is fixed in
the rim of the rare wheel. The controller is connected to the motor and battery to
control speed of motor and current. The Electric Motor Bicycle can be run with
battery charge , solar power and also by pedalling. ELECTRIC BIKE
SIMULATOR was used to generate the simulation results. The results of the
experiments are also shown in a hardware assembly kit.

x
 CHAPTER 1 INTRODUCTION
1.1 GENERAL INTRODUCTION

The term "electric vehicle" refers to a vehicle that is propelled by one or more
electric motors or traction motors (EV). A self-contained electric vehicle can convert
gasoline to energy using a battery, solar panels, fuel cells, or an electric generator, or it
can be powered by electricity from off-vehicle sources using a collector system. E-
Cycle is an electric and power-assisted bicycle that is one of the bicycle industry's
fastest-growing technologies. This bicycle has an electric motor to assist you in moving
forward. As a result, you can ride it like a regular bicycle while exerting less effort. An
E-Cycle motor works by turning on automatically when you peddle or throttle. There are
two main types of E-Cycle
 Throttle assist
 Pedal assist

1.2 CLASSIFICATION OF ELECTRIC BICYCLE

1.2.1 TYPE 1 E-Bike

An electric bicycle with Pedal Assist requires you to pedal in order to run the motor. It
looks like an ordinary bicycle except that it contains a motor that recognises when
you're pedalling and assists you. It's as though you've always had a strong tailwind
behind you. This class/type of E-bike may or may not have a throttle.

1.2.2 TYPE 2 E-Bike

Throttle Only is a throttle-controlled electric bicycle. These electrics do not require
pedalling to benefit from the motor. You'll be on your way in no time if you simply
push the throttle. Accelerating in the middle of a corner will allow you to gain more
traction. Naturally, the less you cycle, the faster the battery drains.

1.2.3 TYPE 3 E-Bike

With Pedal Assist, you can go up to 28 mph. This Class/Type is the fastest "legal"
E-bike, with a top speed of 28 mph. It is still deemed a "bicycle," and no driver's
licence, licence plate, or other documentation is required. It's technically a bicycle,

1
and it's a lot of fun! Helmets are required by law. his category is best for someone
who rides their bike to work.

1.3 ADVANTAGES OF E-BICYCLE

 An E-bike is a bicycle that is environmentally friendly. It's the same as

our regular bicycle. E-Cycle, on the other hand, is powered by
electricity rather than gasoline. No harmful emissions are emitted into
the atmosphere. For the same reason, electric bikes don't produce any
additional noise.
 Electric bicycles, in general, do not require any maintenance. Lubricate
the drive system and inspect the chain and wheels on a regular basis to
keep it clean.
 Riding an electric bike is fashionable and popular right now. It's also the
most efficient approach to cut down on pollution.
1.4 OBJECTIVE
 To create an efficient E-cycle that can be used on many types
of roadways.
 To adapt the E-cycle to various requirements.
 To design an E-cycle using 3Rs (Reduce, Reuse and recycle).
-Reduce: Electric cycle can reduce the emissions.
-Reuse: The cycle can be reused from old condition.
-Recycle: The cycle has been recycled from scrap condition.

1.5 LITERATURE SURVEY

The constant news concerning the demise of fossil fuels, according to
Adithya Kumar et al., (2016), has enhanced the importance of using electricity in
the future. Electric bicycles will be used more frequently. The electric bike will be
beneficial to office workers and those who ride short distances. The electric bike
has a motor that assists the vehicle in moving ahead, and it is powered by a
variety of sources. The batteries power the motor, which in turn drives the vehicle.
Once the battery has been fully exhausted, it is recharged using a battery charger.
We used a DC motor/generator mounted to the bicycle's rear wheel for this
project. Two sets of batteries, labelled A and B, are used to power the system.

2
When one of the batteries runs out, the remaining batteries will step in to fill the
void. During this period, the wheel revolves, rotating the shaft of the dc
motor/generator, which produces a voltage output. This voltage aids in the
charging of the battery, improving the electric bike's range. It is environmentally
friendly and pollution-free because it produces no emissions. Furthermore, it is
silent and can be recharged using an AC converter in the event of an emergency
or gloomy weather. It is ideal for young and elderly individuals, and it meets the
needs of the economically disadvantaged.The most important feature of this
bicycle is that it does not consume valuable fossil fuels thereby saving the money.

Annette Muetze, et. al.,(2008) suggests that More emphasis should be

devoted to the deregulation of electric bicycles. A common standard/guideline for
electric bicycle designers/manufacturers will stimulate growing popularity while
also guaranteeing that electric bicycle quality is not compromised. Custom-
designed bicycles that are most efficient in a given operating cycle, such as city,
hill, and distance, as well as "speedy bicycles," might assist to offset the additional
cost and weight of larger components. More study into battery and drive
technologies, as well as their use with electric bicycles, would be advantageous to
the electric bicycle industry in this regard. Even if the technological maturity of
electric bicycles has increased and continues to improve, more effort is needed to
make them competitive with other vehicles.

Carlos Tovar, et. al.,(2009) proposes Novel The cities are living each day
an accumulation of excessive traffic and noise. The air quality and health are two
more components of city traffic that are badly damaged. Many air contaminants,
like as carbon monoxide mono-oxide and suspended suspension particles, are
primarily caused by transportation. It's a fantastic car that is both speedy and
efficient while still being environmentally friendly. It is possible to enjoy a leisurely
and enjoyable cruise while also arriving at locations (such as work) using this
vehicle. Surprisingly, an e-bike costs the same as a regular bicycle. This means
that when you buy this vehicle, you have all of the features of a standard bicycle
plus the added power of the battery, which allows you to go faster and for longer
than you could on your own. The bicycle's electricity is designed to help the rider

3
maintain a steady, safe speed on or off the road. Furthermore, the law considers
this vehicle to be equivalent to a standard bicycle. That is to say, the user does not
need a licence to ride an electric bicycle.

Ravina More, et. al.,(2011) proposes different models of calorie

measurement need to be reviewed and tested to find which one is the most
suitable to be adopted for a range of bicycles. For more information, To reduce the
number of calibrations required for each particular cycle, researchers can look into
developing a single model that fits all bicycles. Incentive-based ways for e-bikes
can be tested, such as switching the bicycle from manual to electric mode once
the calories burned goal has been met. It is necessary to consider a circuit that
can accomplish the same. The anti-theft system is reliant on battery power. To do
this, a more stable battery supply is required. The features will be implemented
using the bicycle's existing power supply. The end product will be cushioned,
waterproof, and temperature insensitive for a specific temperature range to protect
it from harsh environmental elements. As a result, the project attempts to
reestablish the bicycle as a more user-friendly and low-cost mode of
transportation. For the simple bicycles, an attempt will be made to model a similar
design.

1.6 SCOPE
The price of fuel is rapidly rising as the supply of fossil fuels decreases. We can
save a lot of money in the long run and reduce global warming by converting to an
electric bicycle. It also aids in our physical fitness. Electric Motor Bicycles are in
high demand in India because they produce less pollution, have fewer
maintenance costs, and produce less noise.

4
 CHAPTER 2
DESIGN OF SOLAR POWERED ELECTRIC MOTOR BICYCLE

Here the current from battery moves to controller where all the connections
are made. When the power is given to the motor, it rotates the wheel using chain
and sprocket.

Battery Controller BLDC Hub Motor

E-Cycle Wheel Rotation Chain and sprocket

Fig.2.1 Block diagram of Electric Bicycle

2.1 HOW TO TURN ON OUR ELECTRIC MOTOR BICYCLE

Insert the key and turn on the ignition. Long press the power button in the
instrument console, then the power supply will be active.

E-Cycle Wheel Rotation

Accelerator

Battery Controller BLDC Hub Motor

Chain and sprocket

Fig.2.2 Block diagram of converting Electric Bicycle

5
When we rotate the accelerator to our desired amount, the controller takes the
input and give the limited power to the motor and runs accordingly.

2.2 WORKING OF AUTO-CUT OFF BRAKES

Brakes accelerator

Battery Controller Motor

E-Cycle Wheel Rotation Chain and sprocket

Fig.2.3 Block diagram for auto cut off brakes

When the brakes are applied during running/idle conditions, the controller
cuts off the power supply to the motor till the brakes are engaged.

Working of cruise control:

When the E-cycle is running under a constant speed for 5 sec, the bike is
changed to cruise mode and maintains the same speed. For changing back to
normal mode, you can accelerate or slightly engage brake.

2.3 WORKING OF INSTRUMENT CLUSTER

VOLTAGE INDICATOR

Battery Controller

Fig.2.4 Block diagram for instrument cluster

6
 The voltage indicator indicates the solar and battery level . There is a switch
which is connected to the solar and battery power circuit .The switch is used to
switch power between solar and battery .

2.4 WORKING OF LIGHT AND HORN

Switches

Battery Controller Light

Fig.2.5 Block diagram for lights and horn

There are two switches in handle bar one is for light and another is for horn.
When the switches are pressed the controller reads it and sends the output to
light/horn.

2.5 REQUIREMENT CALCULATIONS

2.5.1 Mass Range Calculations
Person Weight = 100kg
Battery Pack = 6kg
Motor & Controller = 4kg
Cycle weight = 10kg

Total = 120kg

So, Battery & Motor are required to propel the Bicycle with the weight of
120kg.
2.5.2 Motor Load calculation
Fp = Propulsion Force
Fwf = Windage & Friction Drag
Fd = Down force from Gravity

7
Consider the Grad @ 3.14%
α = tan-1(slope)
= tan-1(3.14/100)
= tan-1(0.0314)
α = 1.8 degree
2.5.3 To Finding Fd (Gradient Resistance)
Fd = m * sinα
= 120 * 9.81 * sin 1.8
= 37 N
2.5.4 To Find Fwf(Aero Resistance)
Cd => Aerodynamic Area Co-efficient = 0.74
ρ
= Density = 1.225kg/m3
A
= Frontal Area of Bicycle = 0.37 m3
V = Velocity of Bicycle = 25 km/h=>
6.94m/s Fwf = ½ * Cd * ρ * A* V2
=
½ * 0.74 * 1.225 * 0.37 * (6.94)2
Fwf = 8.07 N
2.5.5 To Find FR (Rolling Resistance)
CR = Rolling CO-efficient => 0.0041(for cycle)
FR = CR * mg cosα
= 0.0041*120*9.81*cos1.8
= 4.8 N
2.5.6 Total Propulsion Force, FP
Fp = Fd + FWF + FR

= 37+8.07+4.8

= 49.8 N

Propulsion Power = FP * Velocity

= 49.8 N * 6.94 m/s
= 345.6 W
Thus, The Motor is to be 350 W

8
2.6 SELECTION OF BATTERY PACK
Range required: 30km
SPEED OF CYCLE: 25 km/hr
25 km for 1hr
30km for 1.2hr
 345W Power to be extracted for 1.2hrs, to cover 30km distance
 Therefore,

345*1.2h= 414wh
 414wh battery Pack is required

36v*11.5 ah=414wh
(or)
48v*8.62 ah=414 wh

2.6.1 Considering Cycle Applications And Safety

36V* 11.5Ah is selected
How many series? How many parallel?
Single cell=3.6v Normal Voltage
2.5Ah capacity
 5 cells in Parallel = 5*25Ah

= 12.5Ah
 10 cell group in series =10*3.6v

=36v
 10S, 5P configuration will yeild 36v 12.5Ah.

C Rating = 37.5(7.5*5) /12.5

= 3C For Discharge
Charging allowed is 0.5C = 05*12.5
= 6.25 Amps
Safe current is 0.2C = 0.2* 12.5

9
 = 12.5AMPS
So, 42 V 2.5A Charger needed

2.7 CONTROLLER SPECIFICATIONS

36V*xA = 350W
X=9.7Ama
 9.7< 37.5 - Battery is safe
 9.7<13 +_ – controller is safe

So 36v, 13 +_1A controller needed – normal voltage

FULL CHARGE (42V)
 42V*xA= 350W
 X =8.3A

2.7.1 How Controller Works

42V * (0 to 8.3A) = 350W
41V * (0 to 8.5A) = 350W
40V * (0 to 8.75A) = 350W
31V * (0 to 11.3A = 350W
So Required Voltage, A = 11.3 < 13 ± 1 Amp
So, find Spec arrived
350W motor
36V 12.5Ah (450Wh) battery pack
36V < 13±1A controller
42V 2.5Amp charger is suitable for:
30Km range
25Km/hr
3.14% grade
120Kg cycle load

10
 CHAPTER 3
SELECTION OF COMPONENTS

Gear reduction 12v 250

Most electric vehicles (cars, bicycles, and wheelchairs) are powered by onboard
batteries and a single, very basic electric motors that drives two or four wheels.
However, some of the most recent electric cars and electric bicycles operate in a
different manner. Instead of using gears or chains to power all of the wheels, they
integrated a motor into the hub of each one, thereby merging the motors and
wheels. A hub motor is exactly what it sounds like.

Fig.3.1 12V DC , 250W motor

3.1.1 Specifications

Gear Reduction Electric Motor,12V 250W 2950 RPM DC Electric Bicycle

BrushedMotor with 9 Tooth Sprocket :

 Voltage:12 V

11
  Maximum current:10 A
 Maximum efficiency:85 %
 Torque:45 Nm
 Nominal power:250 W
 Peak power:350 W
 Maximum speed:25 Km/h

Gear reduction motors are brushed motors (also known as brushed direct current
motors), which have a half-dozen or more independent coils and an electronic
circuit in place o

In a typical motor, the inner coil (named the rotor) rotates while the outside
magnet (called the stator) remains stationary. The roles are inverted in this motor:
the inner section with the coils is static, while the grey magnet spins around it.
Now take a look inside to see how it all works: The grey outer shell (which is a
magnet split into several portions and bent round into a circle) spins around the
copper coils and circuit board as the electronic circuit transmits power to each of
the nine copper coils in turn (which remain static).

However, between some of the coils are numerous tiny magnetic field
sensors (also known as Hall-effect sensors). As the permanent magnets on the
outer rotor sweep past them, the Hall-effect sensors figure out where the rotor's
north and south magnetic poles are and which coils to activate to keep it spinning.
The problem is that this necessitates the use of an electronic circuit to operate the
motor, which is not required for a standard DC motor.

12
 In the case of electric vehicles, the advantages are more clear. A normal
car's metal weight (including the engine, transmission, and chassis) is roughly ten
times that of its occupants, which is one of the reasons why cars are so inefficient.
When the hefty engine and transmission are replaced with hub motors and
batteries, the car becomes much lighter and more energy efficient. The engine
compartment's removal also creates a lot of space for passengers and their
luggage; the batteries may be placed beneath the back seat.

12V DC motor vehicles are much simpler (mechanically speaking) than

conventional vehicles. Assume you wish to go backwards. All you have to do is
reverse the electric current instead of employing complicated gear setups.
Backwards the motor spins, and backwards you go. On many cars, this is an
expensive alternative because it necessitates extra gears and complicated
driveshafts, but it's extremely simple to solve with hub motors. When each of a
car's four wheels has a hub motor, four-wheel drive is immediately achieved. In
theory, turning the four motors at slightly varying speeds (to aid handling and
steering) or torque is simple enough (to move you through muddy or uneven
terrain).

Brushed 12V motors are larger, bulkier, and heavier than standard wheels, and
they alter the handling of an electric car or bike by increasing the unsprung mass (the
mass not supported by the suspension), which theoretically results in increased
shock and vibration, poorer handling, and a bumpier ride. That is, at least, the
conventional wisdom. Engineers have discovered that vehicles with hub motors just
need their suspension "tweaked" to compensate for the increased unsprung mass,
and that this can even result in a better overall handling.

Because a single motor unexpected failure could cause a vehicle to slew to

one side, practical hub motors are often built up of many (usually four)
independent sub motors, each delivering a fraction (a quarter) of the overall
torque. Although this is a far safer design, it does add to the cost and complexity.
Even so,the two or four motors must be

13
 coordinated so that any serious failure in one motor can be compensated for by
one or more motors on the opposite side.

These motors must survive in a considerably harsher environment than a

traditional engine or electric motor, which is located high off the road and well
covered inside the engine compartment. They're un-sprung, so they're subjected to a
lot of vibration, and they also have to withstand high-speed hits from boulders and
stones, as we've just seen. They must deal with large temperature fluctuations
(chilling cold from the outside air, boiling hot from sudden braking), as well as
becoming entirely submerged in water or snow, down alongside the road. Isolated
hub motors are a futuristic dream come true. Hub motors are more likely to be
retrofitted to existing automobiles for the time being, therefore they must operate with
existing friction brakes, suspension systems, and other components. This may
necessitate design concessions that negate some of the benefits of hub motors in the
first place.

Another issue is producing the exact amount of torque required (turning

force). No matter what pace you're going on the road, a gasoline engine operates
best when it's turning over quickly (producing a lot of revolutions per minute).
Depending on whether you're starting from a stop, racing down the highway, going
slowly uphill, or whatever, you utilise a gearbox to transform the engine's high revs
into high torque (and low speed) or high speed (and low torque). Hub motors must
be able to provide any speed and torque combination without the use of a
gearbox; they are typically "direct drive." But there's a catch: on electric bikes,
they're housed inside the hub, at the very centre of a huge spoked wheel. When
you move a wheel's centre, its diameter acts as a lever, increasing the speed at
the rim while decreasing the torque by the same amount (see our article on how
wheels work for an explanation). You'll need a powerful engine to get enough
torque, but not so powerful that it accelerates you too rapidly and jerkily or
smashes your spokes.

These motors often obtain more torque by dramatically increasing the hub
size (a larger stator and rotor provide more torque than smaller ones); as you can

14
see in the electric bike photo above, the powered hub on an electric bike is far
larger than the unpowered hub on a regular bike. Internal gearboxes (usually an
array of planetary (epicyclic) gears in between the stator and the rotor) enhance
torque in some hub motors, but many don't since they add weight, expense,
mechanical complexity, and potential unreliability. Larger torque introduces a new
issue: If you're converting a regular bicycle wheel into a powered wheel, be sure
the rest of the wheel is strong enough to handle the twisting forces provided by a
hub motor. An electric bike's spokes are shorter and leave the hub at a tighter
angle, putting them under additional stress. Assume you install an electric motor
on the hub of a standard bicycle and turn it on. Because you're so heavy and
there's so much friction between the tyre and the ground, the engine could just
bend the spokes instead of propelling you! As a result, an electric bicycle often
requires stronger wheels (possibly with stronger and more elastic spokes, altered
spoke hole positioning, a thicker rim, or some other adjustment) than a regular
bicycle.

3.2 CONTROLLER

One of the most crucial components of an electric bike is the electric bike
controller; it is the e-brain that controls the motor's speed, start, and stop. It's
connected to everything else in the car, including the battery, motor, throttle
(accelerator), display (speedometer), PAS, and any other speed sensors.

The TA controller is made up of main chips (microcontrollers) and peripheral

components (resistors, sensors, MOSFET, etc). Inside the controller, you'll find a
PWM generating circuit, an AD circuit, a power circuit, a power device driver
circuit, a signal acquisition and processing circuit, an over-current and under-
voltage protection circuit, and a signal acquisition and processing circuit.

15
 Fig.3.2 Controller

3.2.1 Specifications

Compatible Motor : 12V motor

Body Material : Aluminium

C able Length(cm) : 15

Current Limit(A) : 15

Rated Voltage(v) : 31 to 36

Rated Power(W) : 350

Weight(gm) : 211

Length(mm) : 90

Width(mm) : 50

Height(mm) : 30

The controller supplies the working voltage to the external device, such as
the switch +5V, headlamp +5V, and so on, after attaching the battery. Based on
the input from the throttle or PAS, the PWM generates an appropriate pulse
pattern for the MOSFET driving circuit. To control the motor speed, the MOSFET
driving circuit manages the MOSFET circuit's turn-on and turn-off.

When the voltage is lower than the controller set value, the under-voltage
circuit protects the battery from discharge, and the PWM circuit stops the output.
The controller, battery, and motor cannot operate at greater currents because of

16
the over-current protection circuit. The basic job of an electric bike controller is to
collect all inputs from all electric components (throttle, speed sensor, display,
battery, motor, and so on) and determine which signal should be returned to them
(motor, battery, display).

The controller's many protection functions will differ from the controller's
design. Some basic security functions are listed below. Protection against over-
voltage. When the battery voltage becomes too high, the controller checks it and
shuts down the motor. This prevents overcharging of the battery. Protection
against low voltage.

When the battery voltage drops too low, the controller checks it and shuts
down the motor. This prevents the battery from becoming overcharged. Protection
against overheating. The temperature of the FET (field-effect transistor) is
monitored by the controller, which shuts down the motor if it gets too hot. The FET
power transistors are therefore protected. Protection against overcurrent. If the
motor is receiving too much current, reduce the current supplied to it.

This safeguards the motor as well as the FET power transistors. Protection
from braking. Even though the controller was receiving other signals at the same
time, the motor shut down while braking. When a user simultaneously presses the
brake and throttle, the brake function takes precedence.

17
 Fig.3.3 Flow chart of Controller

In most circumstances, if a motor contains hall sensors, the controller

should be hall-sensor or dual mode. The Hall sensor on the motor will detect
rotation, and based on the sensor data, the controller will provide the proper
voltage to the motor. It has a higher beginning torque, is more consistent, and
uses less power. When the motor hall sensor is destroyed, a dual mode controller
works OK, but the hall-sensor controller may give an error and stop working. The
e-bike controller's wire types and wire terminals may vary depending on the
controller design. The electric bike controller wiring schematic is required to
ensure proper wire connections.

Most e-bike controllers have the following cables: motor, battery, brakes,
throttle/ accelerator, or PAS Pedal Assist System (some controllers have both
types of wires, some have one of them).

Advanced controllers have additional wires, such as a display or

speedometer, three speeds, reverse, LED light, and so on.

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 Fig.3.4 Controller Connecting wires

3.3 BATTERY

Fig.3.5 Battery
Compared to other high-quality rechargeable battery technologies, Li-ion
batteries provide a number of benefits (nickel-cadmium or nickel-metal-

19
hydride). They have one of the highest energy densities of any battery
technology available today (100-265 Wh/kg or 250-670 Wh/L). Li-ion battery
cells can also deliver 3.6 volts, which is three times higher than Ni-Cd or Ni-MH
technology. This means they can supply a lot of current for high-power
applications, which is a good thing. Li-ion batteries are also low-maintenance,
as they don't need to be cycled on a regular basis to keep their life. Li-ion
batteries have no memory effect, which is a harmful phenomenon in which a
battery can'remember' a decreased capacity after repeated partial
discharge/charge cycles. This is an advantage over Ni-Cd and Ni-MH batteries,
which also exhibit this behaviour. In addition, Li-ion batteries have a low self-
discharge rate of 1.5-2 percent each month. They don't contain the hazardous
cadmium found in Ni-Cd batteries, making them easier to dispose of.

Li-ion batteries have supplanted Ni-Cd batteries as the market leader in

portable electronic gadgets as a result of these benefits (such as smartphones
and laptops). Lithium-ion batteries are also utilised to power electrical
equipment in some aerospace applications, such as the new and more
ecologically friendly Boeing 787, where weight is a major cost consideration.
Much of the promise of Li-ion technology in terms of renewable energy derives
from its prospective uses in battery-powered cars. The Nissan Leaf and the
Tesla Model S, which are now the most popular electric automobiles, both
employ Li-ion batteries as their primary fuel source.

Li-ion batteries, while their technological potential, have a number of

flaws, particularly in terms of safety. Li-ion batteries have a proclivity for
overheating and are susceptible to damage at high voltages. This can result in
thermal runaway and combustion in some situations. This has resulted in
severe issues, including the grounding of the Boeing 787 aircraft following
reports of onboard battery fires. A number of shipping companies refuse to
send batteries in bulk by plane due to the risks connected with these batteries.
Safety systems for lithium-ion batteries are required to regulate voltage and
internal pressures, which can increase weight and performance in some
circumstances.

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3.4 THROTTLE
The throttle mode works similarly to that of a motorbike or scooter. You can
propel the bike forward without pedaling by pressing the throttle. You can control
how much power is produced with most throttles.
Electric bikes have a variety of throttle options, ranging from thumb throttle
to full twist throttle.

Fig.3.7 Throttle

1. 5 . 1 D i f f e r e n t Types of T h r o t t l e s on E l e c t r i c Bikes

 Half-grip Twist: This functions in the same way as a motorcycle or scooter

does, with the throttle being twisted to activate it. It's the most common
throttle for electric bikes. To accelerate the bike, the rider only needs to
crank the throttle.

 Thumb Throttle: These are made to be simple to use. It's as simple as

pressing a button to start the motor. Some have multiple buttons for
controlling the bike's speed, while others only have an on/off switch.

Depending on how the throttle is engaged, different types of throttles perform

differently. It's crucial to understand whether the throttle you choose can be used
while the bike is still or only when you start pedalling.

To avoid injury if the user accidentally activates the throttle when stationary,
some throttles can only be used while pedalling. This will help you avoid mishaps

21
when you're first getting acquainted to your e-bike.Even when the bike is still,
certain bikes allow you to utilise the throttle. They claim that starting from a stop
without the normal heavy pedalling at start-up is a far simpler option. You may lift
your feet, push the throttle.

22
3.5 LIGHT

Pedal-assist sensors and a throttle are commonly found on e-bikes. Some electric
bikes contain a motor that only produces electricity when it is needed. The electric
motor is engaged and operated manually in this situation, utilising a throttle that is
often located on the handgrip, similar to those seen on a motorcycle or scooter.

These LED lights are long-lasting, simple to operate, and energy-efficient.

The lights on offer are placed in electric bikes and create a bright dazzle of light in
the evenings when there isn't enough light. Its one-of-a-kind lens design allows
light to pass through the light cup before forming the whole reflection. This results
in a more effective light beam and less light energy loss.

Fig.3.8 Light

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3.6 HORN

A horn is a device that consists of a tube, usually made of metal and curved in a
number of ways, with one tiny end into which the musician blows and one large
end from which sound emerges. The bore of a horn, unlike that of some other
bass instruments, such as the trumpet, gradually widens over its length, making it
conical rather than cylindrical. In jazz and popular music, the term "horn" refers to
any wind instrument, and a horn section is made up of brass or woodwind
instruments, or a combination of the two.

Fig.3.9 Horn
3.8 BMS

The battery management system is in place to keep track of each battery

cell's specific performance. Rather of allowing for individual performance, the BMS
assures that each battery cell drains, performs, and acts in the same way as every
other cell in the battery.

If you have uniform cell performance, which is otherwise impossible, you will have
consistent performance and full operation of your motor. The BMS also extends
the life of your battery. Individual cells without a BMS can overcharge and
explode, or they can drain too far and become un-rechargeable, hastening their
overall deterioration. A defective BMS in your battery is the cause of failure if your
Electric Motor Bicycle battery explores or fails out much sooner than the
manufacturer claims. In fact, a defective BMS is one of the most prevalent causes
of your Electric Motor Bicycle's poor performance.
24
Tips to Manage Your BMS System:
 Don't charge your battery with a charger that isn't rated for it.
 Never leave your battery in a hot, cold, or wet environment.
 After Long Periods of Inactivity, Refresh the BMS System

Fig3.10 BMS

25
 CHAPTER 4
DEVELOPING AND TESTING OF ELECTRIC MOTOR BICYCLE

4.1 SCRAP CYCLE

We went in search of cycle that was suitable for our design and budget and
luckily, we found one which was in scrape condition. We saw the cycle that was in
no condition to run. We got it to our place then changed few parts and done
repairs that made our cycle in running condition. Below the image is the day we
got the cycle for the cycle shop.

Fig.4.1 scrap cycle

26
 Fig.4.2 convertion of scrap cycle

4.2 RUST PROTECTION

The cycle which be brought it to our place has serious rust issues and few
alignment problems. So, we got sand paper and spray paint cans for paint works.
First, we removed most of the rust and cleaned the cycle with the help of sand
paper and then we resprayed our cycle giving it dual tone finish using spray paint
and then we left it to get dry.

27
4.3 PARTS FOR CONVERSION
As we got our cycle and completed the maintenance work, we got ourself
some parts for conversion of our cycle to an E-cycle. The parts contain,
 12V motor
 Controller
 Lithium- ion cells
 Half Grip Throttle
 Voltage indicator

28
4.4 MOTOR INSTALLATION AND MAKING OF BATTERY
Since we got all the components, we started to make our E-cycle.
First, we decided to install motor. So, we removed the rear wheel and Spoke of the
wheel was removed and aligned with motor. Then we installed rear wheel back to
cycle. After completion of installation of motor, we moved to making of battery.
Since we got it as cells not as a whole battery pack, we had to arranged cells and
did welding between all the battery cells and the wire connections with Battery
Management System (BMS) for the battery.

Fig.4.4 Motor used at rare wheel

29
 Fig.4.5 creating battery using cells
Battery cells were connected in parallel using the clamps set that helps to
fix the batteries in a fixed state. That was made with plastic as a frame.

Fig.4.6 connecting cells

30
 The cells were placed in frame and the cell were connected in parallel by
soldering method. Then the cells connected in parallel were covered with a thin
cover that protects the battery from the temperature and water resist. Then, the
second layer is added on that layer with thick Polythene cover that help for the
sealing of the cells.

Then the cells were connected with BMS that connects all the batteries to
make the single output. One end of the BMS is connected to the cells connected in
parallel and other end is output of the battery. Then, the cells were sealed with a
plastic seal box. Only two wires come out from the sealed container that is the
output wires.

The battery after the sealed using the multi-meter checking the battery
current and voltage.

Fig.4.7 covering of cells

31
Fig.4.8 battery sealing

32
 Fig.4.9 Battery testing

4.5 INSTALLATION OF BATTERY, CONTROLLER AND OTHER PARTS

After connecting all cell wires to BMS we heat sealed the battery pack
using a sheet of PVC heat wrap. we added fuses if the charging current is more
than 5 amp. Then we got an IP 65 box for storing the battery pack to get additional
protection for the battery. We drilled and made two holes for charging and output
of the cycle. We made a stand for the battery using scrap metal and placed it in
centre rod between the cycle handle and seat. We installed throttle, switch, light
and horn to the handle bar. Then all connections from all parts are connected to
controller. And the controller is cover with another IP box and placed it under the
seat rod.

33
Fig.4.10 Installation of battery, controller and other parts.

Fig.4.11 After installation.

34
4.6 TESTING OF THE ELECTRIC MOTOR BICYCLE
After completion of the conversion of E-cycle, we took it for testing it on
road with different condition. So, the top speed was around 30 kmph with the
range of 35+ km (depends on driving condition). The charging time was around
4hrs (0-100%).

35
4.7 A TRIP TO THE COLLEGE AND FINAL FINISH
We went to college for showing our work to college staffs and asked for the
review. Every one review on the performance of the cycle and gave it good
comment. They asked us to change the battery placement. So according their
review we have changed as per their needs. Finally, we painted it for final finish
and added some sticker for enhancement of the looks.
We enjoy the ride to college that every one in our batch raided the Bicycle
and share their feeling with others. Even the other also ride the Bicycle and share
their feeling.

36
 CHAPTER 5
CONCLUSION AND FUTURE SCOPE
5.1 CONCLUSION
From this project we have done the conversion of scrap cycle to a good
condition E-cycle which has almost every feature compared to every cycle in
market. It is cost efficient and follows all the 3Rs of the eco system. We got a good
lithium-ion battery which gives the range 40km (or even more, depends on the
driving conditions.) and a top speed of 30 km/h.

6.2 FUTURE SCOPE

In future this cycle can be developed and can add additional feature like bi-
directional controller which can regenerate battery power by peddling. Since our
project has single directional converter but it can’t be recharged while riding. So,
the regenerative braking system won’t be available. We can change to
bidirectional converter and add that feature. We can even make an attempt to
convert other vehicles like handicapped tricycle and cycle rickshaws.

37
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[3] Dill J and Rose G, 2012, Electric Bike and Transportation Policy.

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