A RESEARCH ON THE DESIGN OF ELECTRIC

BICYCLE

WRITTEN BY

UDOKANG,GABRIEL BASSEY
I8/EG/ME/1253
MECHANICAL AND AEROSPACE ENGINEERING

TO BE SUBMITTED TO

DR. ANIEKAN OKON

(COURSE LECTURER)
MEE 512(APPLIED DESIGN)

26th OCTOBER,2023.
 Table of Content
Title page
Table of content……………………………………………………………………….
Introduction……………………………………………………………….
Overview of Electric Bicycles……………………………………………………………
Brief History of Electric Bicycles…………………………………………………
Concept of Electric Bicycles……………………………………………………………….
Basic components of Electric Bicycles……………………………………………….
Design and Fabrication of Electric Bicycles…………………………………………
Advantages and Disadvantages……………………………………………………….
Maintenance……………………………………………………………….
Safety and Regulations……………………………………………………………….
Future Trends……………………………………………………………….
Conclusion……………………………………………………………….
References………………………………………………………………………

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 INTRODUCTION

Energy crisis is one of the major concerns in today’s world due to fast depleting resources
of petrol, diesel and natural gas. In combination with this, environmental decay is an
additional factor which is contributing to the depletion of resources which is an alarming
notification. This mini project assignment proposes the solution for this above perilous
problems. The system which we innovated is the Electric Bicycle. This project has
various benefits both to the team and the society at large benefits thereby making
awareness of using alternative modes of transport. The Electric Bike which works on the
battery that is powered by the motor is the general mode of transport for a local trip. The
solar panels can be alternative source for this by adding it to the system. The Electric bike
which will be running on battery, the power is supplied by the motor,thereby supplying
this power to drive the other gear components. The main purpose of using this E-bike is
that it is user friendly, economical and relatively cheap. The efficiency of this
system undeniable compared to conventional modes of transport.

OVERVIEW OF ELECTRIC BICYCLES

Electric bicycles have been gaining increasing attention worldwide, especially in China,
Europe, Japan, Taiwan, and the United States. In the following, the most distinguishing
aspects of electric bicycles in these countries are summarized, based on the authors’ own
studies and Frank Jamerson’s Electric Bikes Worldwide 2002

Today, China is the largest manufacturer of electric bicycles, exporting the majority of the
electric bicycles while also meeting a strong local demand. According to China’s Electric
Bike General Technical Qualification GB17761-1999 , Chinese electric bicycles may not
exceed 20 km/h and may not be heavier than 40 kg.

In Europe, most electric bicycles are manufactured in Germany and the Netherlands, and
pedelec-type electric bicycles are more common. In Japan, most electric bicycles are
produced by the automotive industry, and electric bicycles are required by law to be
pedelec-type bicycles. Electric bicycles produced in Taiwan are mostly exported to
Europe.

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In regard to the United States, electric bicycles are not as popular as in the other countries
mentioned and most electric bicycles are imported. In some states, the federal law and the
state law for electric bicycles differ.

Fig 1.0 Diagram of the Electric Bicycle

BRIEF HISTORY OF ELECTRIC BICYCLE

In the 1890s, electric bicycles were documented within various U.S. patents. For
example, on 31 December 1895, Ogden Bolton Jr. was granted a patent for a
battery-powered bicycle with "6-pole brush-and-commutator direct current (DC) hub
motor mounted in the rear wheel" (U.S. Patent 552,271). There were no gears and the
motor could draw up to 100 amperes 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". 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. An 1899 patent by John Schnepf
(U.S. Patent 627,066) depicted an electric bicycle with a rear-wheel friction,

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"roller-wheel"-style drive.In 1969, Schnepf's invention was expanded by G. A. Wood Jr.
(U.S. Patent 3,431,994). Wood's device used four fractional horsepower motors
connected through a series of gears.

The Japanese automotive giant Yamaha built a prototype e-bike in 1989, and invented the
pedal assist system in 1993.From 1992, Vector Services Limited offered the Zike e-bike.
The bicycle included NiCd batteries that were built into a frame member and included an
850 g permanent-magnet motor.

Apart from the Zike, in 1992, hardly any commercial e-bikes were available. However, in
a 10-year period from 1993 onwards, production grew by an estimated 35%. According
to Gartner,regular bicycle production decreased from its peak of 107 million units (1995).

Torque sensors and power controls were developed during the late 1990s. For example, a
Japanese patent (6163148) was granted in 1997 to a team led by Yutaka Takada, for a
"Sensor, drive force auxiliary device ... and torque sensor zero point adjusting
mechanism".

American car executive 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 US.

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.

By 2001, the terms e-bike, power bike, pedelec, pedal-assisted, and power-assisted
bicycle were commonly used to refer to e-bikes. By contrast, the terms "electric
motorbike" or "e-motorbike" referred to more powerful models that attain higher speeds
(up to 80 km/h (50 mph) or higher).

By 2007, e-bikes were thought to make up 10 to 20 percent of all two-wheeled vehicles

on the streets of many major Chinese cities.A typical unit requires eight hours to charge
the battery, which provides the range of 25 to 30 miles (40 to 48 km), at the speed of
around 20 km/h (12 mph).

CONCEPT OF ELECTRIC BICYCLE

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An electric bicycle, or e-bike, combines a standard bicycle frame and components with
an electric motor, battery, and control system.The electrical system provides additional
power to assist the rider, making cycling easier, especially on hills or over long
distances.The rider can choose between pedaling without electric assistance, using
electric power alone, or a combination of both.

BASIC COMPONENTS OF AN ELECTRIC BICYCLE

- Electric Motor:
Typically, e-bikes have a hub motor (located in the wheel hub) or a mid-drive motor
(mounted near the bike's pedals). The motor provides extra power when needed.
The electric motor turns electrical energy from the battery into mechanical power to
move the bike. The motor can be located in many places on a bike but we shall focus
exclusively on hub motors.
In a hub motor, the electric motor is inside either the front or rear bicycle hub, allowing
for a fairly simple conversion where you replace a regular bike wheel with the motorized
wheel. Nearly all ebike motors these days are permanent magnet Brushless DC (BLDC)
motors which have 3 phase wires for supplying motor power. In addition to these 3 phase
wires to power the hub, they also typically have 5 hall sensor wires that allow the
electronics to determine the motor position in order to spin the smoothly at low speed.
These wires may be split into separate connectors, or integrated into a single plug that has
both the power and signal wires in one.

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 Fig 1. Diagram of an electric Motor

-Battery:
The battery stores electrical energy and is rechargeable. It powers the motor and is
usually mounted on the frame, often near the downtube or in the rear rack.
The battery is the energy source that powers an electric bicycle and is typically the most
expensive part of an ebike system. In the early days of ebikes most batteries were lead
acid, Nickel Cadmium, or NiMH, but modern ebike batteries are almost exclusively
lithium-ion. As lithium battery technology matured it got lighter, more powerful, more
reliable, and with increasingly long cycle life. It's at a point that now a modern lithium
battery made with top-tier cells is 8-10 times lighter than the lead batteries of yesteryear,
and when not abused they can be expected to provide well over 5-6 years of regular use.

Fig 1.2 Diagram of batteries

- Controller:
The controller regulates the flow of electricity from the battery to the motor, allowing for
different power levels and control mechanisms.

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The motor controller is a component that is unfamiliar to many people, but it is an
essential piece of any ebike hardware since you can't directly connect a brushless motor
to a battery pack. The motor controller serves two critical functions
● 1) It converts the DC voltage of the battery pack into 3 phase alternating current
for the motor windings without which the motor could not spin, and
● 2) It can continuously adjust the voltage going to the motor, from 0V up to the full
battery pack voltage, in response to the user's throttle signal, pedal sensors, and
various current limits.
This latter bit is the most vital aspect to understand. The motor controller can reduce the
voltage that makes it to the motor to any value between zero and the battery voltage. If
you have a 48V battery pack, the voltage that the motor sees might be only 10-12V at low
speeds, ~25V at moderate speeds, and only reach 48V when you approach the final
cruising speed of the bike. If you have a 48V battery pack and ride at just 50% throttle,
then the motor will see 24V, and will perform exactly the same as it would with a 24V
battery at full throttle.
It is by varying the voltage to the motor via the controller that you can adjust and
modulate the power output of the motor as you ride the bike, which is pretty essential to
the idea of controlling an EV. Those with an electronics background should appreciate
that the controller acts as an efficient DC-DC buck converter. While it steps down the
voltage going to the motor, it simultaneously steps up the current by the same ratio. You
can have 48V and 10 amps flowing from the battery into the motor controller, and have
24V and 20 amps flowing from the controller to the motor.

The motor controllers contain at least 6 power mosfets, large capacitors, and connectors
for throttles, brake cutoffs, and displays. The controller circuit board is often fit in an
extruded aluminum box, either mounted externally on the bike or tucked inside the
chassis somewhere. It's also common to have the motor controller located inside the hub
motor or inside the battery mounting cradle. In these latter options, the controller is

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hidden from view for cleaner ebike with fewer visible components, but it is more
challenging to repair or replace a damaged controller when it is integrated this way.
Motor controllers usually have a specific voltage range they they will work in, and they
will also have a current limit that defines the maximum amperage that they will draw
from the battery pack. A small low current motor controller might be rated for 14 amps,
which means it will only draw a maximum of 14 Amps from the battery pack. When the
motor attempts to draw more current than this, the controller then automatically reduces
the voltage provided to the motor in order to keep the battery current draw right at the
limit. If you use a low amperage motor controller with a large hub motor, the system will
work fine but you won't be getting nearly as much power from the motor as it is capable
of. Conversely, if you use a high amperage motor controller with a small sized motor,
then you risk overheating and damaging the motor or stripping the internal gears or
clutch.

OTHER IMPORTANT PARTS INCLUDES:

- Pedal Assist and Throttle:
E-bikes can provide assistance based on pedaling (pedal-assist) or have a throttle like a
motorcycle for direct control of the motor.
A throttle is the most basic and familiar way of allowing the rider to regulate the amount
of power they get from the motor by pressing a throttle lever or twisting a grip that is
mounted on the handlebar. A throttle gives the rider full control of the amount of power
coming from the electric motor at any given time, regardless of how hard they are
pedaling.

Fig 1.4 Diagram of the Throttle

Almost all controllers have a throttle input plug, and luckily the throttle signal is one of
the few things that has been very well standardized in the ebike industry, even if the
connectors that they use are all over the map. Virtually all throttles use hall sensors and a

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magnet to detect the throttle position and sit at about 0.8-0.9V when thee throttle is off,
and rise to 3.6-4V as the throttle is engaged.
The two most common throttle types would be categorized as thumb or lever throttles
which are actuated by the thumb pushing on a paddle, or twist grip throttles that operate
from rotating a handgrip. Throttles are pretty cheap, and even though they often feel
cheap in practice they are quite dependable.

Mechanical Integration:
- E-bike designers must carefully integrate the electrical components into the bicycle
frame without compromising its structural integrity and handling characteristics.
- The weight distribution, frame design, and alignment are crucial considerations in the
mechanical integration of the electrical system.

DESIGN AND FABRICATION OF ELECTRIC BICYCLE

Notations
P = Power
N = revolution per min
T = Torque
σs = Shear stress
σt = Tensile stress
σut = Ultimate Tensile Stress
fos = Factor of safety

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Here we have used a permanent magnet self generating motor with 250 watt power and
2100 rpm.The motor runs on 48 volts and a 7.5amps power source. This motor can reach
a peak current during starting equal to 15 amps. (Barve, Design and Development of
Solar Hybrid Bicycle,March 2016)

P = 2 x 3.14 x N x T /60
250 = 2 x 3.14 x 2100 x T /60
T = 1.13 N m = 1136 N-mm
Reduction in chain drive
R chain = 66/11 = 6:1
Torque at wheel shaft = T x R chain = 1136 x 6 = 6820 N mm
Speed of wheel shaft = 2100 /6 = 350 rpm

DESIGNING OF SHAFT
BENDING:
The force which develops across a specific cross section of the shaft, it generates stress at
that point of cross section that is subjected to maximum loading. This internal or resisting
moment gives rise to the stress called bending stresses.

Torsion: When the shaft which is twisted by the couple such that the axis of that shaft and
the axis of the couple harmonize, that shaft is subjected to pure torsion and the stresses
generated at the point of cross section is torsion or shear stresses.
Combined Bending and Torsion: In actual practice the shaft is subjected to combination
ofthe above two types of stresses i.e. bending and torsion. The bending stresses may
occur due any one of the following reasons:
1. Weight of belt
2. Pull of belts
3. Eccentric Mounting of shafts/gears
4. Misalignment of shafts/gears

On contrary, the torsional movement occurs due to direct or indirect twisting of the shaft.
Hence at any given point on cross-section of the shaft, the shaft is subjected to both
bending and torsional stresses simultaneously. Following stresses are taken in
consideration while designing the shaft:

Shaft design

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T = 36000 N mm
T = 3.14 / 16 x σs x d3
Fs allowable = 80 N/mm2
6820 =3.14 x σs x d3
/16
σs = 34.73 N/mm2
Material = C 45 (mild steel)
σ ut = 320 N/mm2 ------------ PSG design data book.
factor of safety = 2
σt = σb = σ ut/ fos
= 320/2
= 160 N/mm2
σs = 0.5 σt
= 0.5 x 160
= 80 N/mm2
σs is less than allowable so our shaft design is safe.
Design of Sprocket and Chain for Electric Bike
We know,
TRANSMISSION RATIO = Z2 / Z1 = 66/11 = 6
For the above transmission ratio number of teeth on pinion and the number of teeth
sprocket is in the range of 21 to 10, so we have to select number of teeth on pinion
sprocket as 11 teeth.

So, Z1 = 11 teeth

SELECTION OF PITCH OF SPROCKET

The pitch is decided on the basis of RPM of the sprocket.

RPM of pinion sprocket is variable in normal condition it is = 2100 rpm
For this rpm value we select the pitch of the sprocket as 6.35mm from the table.
P = 6.35mm

CALCULATION OF MINIMUM CENTER DISTANCE BETWEEN SPROCKETS

THE TRANSMISSION RATIO = Z2 / Z1 = 66/11 = 6 which is less than 7

Dia. of small sprocket,

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Periphery = π × dia. Of sprocket
11 × 6.25 = π × D
D = 11 × 6.25 / π
D = 21.8 mm
Dia. of sprocket,
Periphery = π × dia. Of sprocket
66 × 6.25 = π × D
D = 66 × 6.25/ π
D = 131.3 mm
So from table, referred from PSG Design Data book
The minimum centre distance between the two sprocket = C’ + (80 to 150 mm)
Where C’ = Dc1 + Dc2
2
C’= 131.3 + 21.8
2
C’ = 76.5 mm
MINIMUM CENTER DISTANCE = 76.5 + (30 to 150 mm) MINIMUM CENTER
DISTANCE = 170 mm

CALCULATION OF VALUES OF CONSTANTS K1 K2 K3 K4 K5 K6 – (with

help of PSG Design Data)

Load factor K1 = 1.25 (Load with mild shock)

Distance regulation factor K2 =1.25(Fixed center distance)
Center distance of sprocket factor K3 =0.8
Factor for position of sprocket K4 = 1
Lubrication factor K5 = 1.5 (periodic)
Rating factor K6 = 1.0 (single shift)

CALCULATION OF VALUE OF FACTOR OF SAFETY

For pitch = 6.35 & speed of rotation of small sprocket = 2100 rpm
Factor of Safety for this drive = 8.55
Calculation of Allowable Bearing Stress:
For pitch = 6.35 & speed of rotation of small sprocket = 2100 rpm
Allowable Bearing stress in the system = 2.87kg / cm2
=2.87 * 981/100 =28 N /mm2

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Calculating Maximum Tension on Chain
Maximum torque on shaft = Tmax = T2 = 6820 N-mm
Where,
T1 = Tension in tight side
T2 = Tension in slack side
O1, O2 = center distance between two shaft
Sin ∝ = R1 - R2
O1O2
Sin ∝ = 65.65 - 10.9
170
Sin ∝ = 0.33
∝ = 18.78
TO FIND θ
θ = (180 –2∝ ) X 3.14/180
θ = (180 –2*18.78) X 3.14/180
θ = 2.48 rad
According to this relation,
T1/T2 = eµθ
T1/T2 = e0.35 x 2.48
T1 = 2.38T2
We have,
T = (T1 – T2) X R
6820 = (2.38 T2 – T2) X 65.65
T2 = 75.27 N
T1 = 2.38 X 75.27
T1 = 179.16 N
So tension in tight side = 179.16 N
We know,
Stress = force / area x 2
Stress induced = 179.16/ (3.14 * 32
/ 4) x 2
Stress induced = 12.67 N /mm2
As induced stress is less than allowable stress =28N /mm2design of sprocket is safe.

ADVANTAGES OF ELECTRIC BICYCLE

• Easy to commute with low fatigue.

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• Less maintenance cost.
• Normal Drag/Pedal is possible when power is not in use.
• Deployable batteries – can be taken inside the house.
• Cost of the unit is very low.
• Easy to carry since it is portable.
• Less energy consumed.
• High efficiency can be obtained if inverter is used.
• If using solar panel, free utilization of energy can be done.
(T.Bhavani, April 2015)

DISADVANTAGES OF ELECTRIC BICYCLE

• High intensity of wind load.

• High centre of gravity.
• Cannot tolerate drastic changes in the environment.
• Needs Periodic Monitoring.
(T.Bhavani, April 2015)

MAINTENANCE OF ELECTRIC BICYCLE

- Maintenance of e-bikes involves both traditional bicycle care (e.g., tire inflation,
brake adjustments) and electrical component upkeep.
- Regular checks of the battery, motor, and electrical connections are essential to ensure
safety and performance.

SAFETY AND REGULATIONS

- E-bikes are subject to regulations that vary by region, such as maximum motor power,
speed limits, and where they can be used (e.g., bike paths or roads).
- Understanding and adhering to these regulations is vital for the safe and legal
operation of e-bikes.

FUTURE TRENDS

- Advancements in battery technology, motor efficiency, and control systems continue

to drive innovation in e-bike design.
- Smart features, including smartphone connectivity, GPS, and regenerative braking, are
becoming more common.

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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 increasein energy production. Since it is energy efficient, electric bike is
cheaper and affordable to anyone. It can be used forshorter 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.

REFERENCES

● Barve, D. S. (2016). Design and Development of Solar Hybrid Bicycle.

International Journal of Current Engineering and Technology, 377,378,379,380
● History of Electric Bicycles- https://en.m.wikipedia.org/wiki/Electric_bicycle
● Shweta Matey, Deep R Prajapati, Kunjan Shinde, Abhishek Mhaske and Aniket
Prabhu, Design and Fabrication of Electric Bike, International Journal of
Mechanical Engineering and Technology, 8(3), 2017, pp. 245–253.

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