ELECTRIC CYCLE

CENTRAL POLYTECHNIC COLLEGE

THIRUVANANTHAPURAM

DEPARTMENT OF MECHANICAL
ENGINEERING

PROJECT REPORT ON

ELECTRIC CYCLE
SUBMITTED BY
ARJUN S K
18020023

SIXTH SEMESTER DIPLOMA IN MECHANICAL

ENGINEERING 2018-2021

[Type here]
MECHANICAL ENGINEERING
ELECTRIC CYCLE

CENTRAL POLYTECHNIC COLLEGE

VATTIYOORKAVU, THIRUVANANTHAPURAM

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the project report on “ELECTRIC BICYCLE” is done by
ARJUN S K, Student of sixth semester Mechanical Engineering in partial
fulfilment for the award of Third Year Diploma in mechanical Engineering during
the academic year 2020-2021under the Board of Technical Education, Government
of Kerala.

Mr. Saju R Mr. Anoop C

(Project Guide) (Head of Department)

[Type here]
MECHANICAL ENGINEERING
ELECTRIC CYCLE

ACKNOWLEDGEMENT
I feel very fortunate to have the support of the number of key individuals in the department of
Mechanical Engineering in this institution.

We take this opportunity to express my deep sense of gratitude to our Head of Mechanical engineering
department Mr Anoop C for his guidance, help, suggestion and supporting us to clear all our doubts
during the preperation of our project and inspiring us to put our best of efforts.

We will be falling in my duty if we don’t offer our gratitude toward our Guide Mr Saju R who helped
us time to time to complete our project and the various related cases.

Last but not least Acknowledgement will not be over without mentioning word of thanks towards all
the faculty members of Mechanical Engineering Department , Friends, and my colleagues who helped
me directly or indirectly in all the way through our project preparation.

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ELECTRIC CYCLE

ABSTRACT

The primary objective of the project is to design a feasible yet highly adaptable electric
bicycle. The main aim of this project is to design a simple electric bicycle with cost effective. In this
bicycle we can utilize electrical energy and normal pedal system for the purpose of moving. In case of
fault occurring in the electrical section, electrical bicycle can be moved by pedal system. Electric
bicycles have simultaneously gained popularity in many regions of the world and some have suggested
that it could provide an even higher level of service compared to existing systems. There are several
challenges that are related to electric bike design: electric assisted range, recharging protocol and bike
and battery checkout procedures. This project outlines system requirements to successfully develop
and deploy an electric bicycle, focusing on system architecture, operational concepts, and battery
management. Although there is little empirical evidence, electric bike could be feasible, depending on
demand and battery management and can potentially improve the existing bike systems.
ELECTRIC CYCLE

LIST OF ACRONYMS (SYMBOLS) USED IN THE

REPORT

Symbol Definition

𝑅𝑐 Radius of Crank

𝑅𝑝 Distance from Pedal To Center of Crank

𝑅𝑔 Radius of Rear Multi-Gears

𝑅𝑡 Radius of Tire

W Mass of The Rider

T Tension

τ Torque

τ𝑐 Torque on Crank

τ𝑇 Torque on Rear Wheel

f Friction Force

I Moment of Inertia
ELECTRIC CYCLE

TABLE OF CONTENTS

Abstract............................................................................................................................................2
Acknowledgment.............................................................................................................................3
List of Acronyms (Symbols) Used in the Report............................................................................4
Table of Contents.............................................................................................................................5
List of Figures..................................................................................................................................7
List of Tables...................................................................................................................................9
Chapter 1: Introduction..................................................................................................................10
1.1 Project Definition:................................................................................................................10
1.2 Project Objectives:................................................................................................................10
1.3 Project Specifications:..........................................................................................................11
1.4 Applications:.........................................................................................................................12
Chapter 2: Literature Review.........................................................................................................13
2.1 Project Background and History of Bicycles:......................................................................13
2.2 Previous Work:.....................................................................................................................15
2.3 Comparative Study...............................................................................................................20
2.4 Parts:.....................................................................................................................................20
2.4.1 Gear Mechanism of Bicycles:.......................................................................................21
2.4.2 Clutch:...........................................................................................................................22
2.4.3 DC Motor.......................................................................................................................24
2.4.4 Generator:......................................................................................................................25
Chapter 3: System Design.............................................................................................................26
3.1 Design Constraints:..............................................................................................................26
3.2 Design Methodology............................................................................................................26
3.3 Product Subsystems and Components:.................................................................................27
3.4 Implementation:....................................................................................................................28
3.4.1 Sprocket Ratio:..............................................................................................................31
3.4.2 Torque Calculations:.....................................................................................................31
Chapter 4: System Testing and Analysis.......................................................................................36
4.1 Motor:...................................................................................................................................36
4.1.1 Bicycle Motor Simulation:............................................................................................38
ELECTRIC CYCLE

4.2 Power Generation:................................................................................................................44

4.3 Overall Results, Analysis and Discussion:...........................................................................45
Chapter 5: Project Management....................................................................................................48
5.1 Project Plan:..........................................................................................................................48
5.1.1 Gantt Chart:...................................................................................................................50
5.2 Contribution of Team Members:..........................................................................................51
5.3 Project Execution Monitoring..............................................................................................52
5.4 Challenges and Decision Making.........................................................................................53
5.4.1 Problems with Team Members:.....................................................................................53
5.4.2 Challenges of Project Parts:...........................................................................................54
5.4.3 Problems with Equipment:............................................................................................54
5.5 Project Bill of Materials and Budget:...................................................................................54
Chapter 6: Project Analysis...........................................................................................................56
6.1 Life-long Learning...............................................................................................................56
6.1.1 Project Analysis.............................................................................................................56
6.1.2 Equipment’s Specifications:..........................................................................................56
6.1.3 Installation:....................................................................................................................57
6.1.4 Problem Solving............................................................................................................57
6.1.5 Teamwork:.....................................................................................................................57
6.1.6 Engineering Sense.........................................................................................................57
6.2 Impact of Engineering Solutions:.........................................................................................58
6.3 Contemporary Issues Addressed:.........................................................................................58
Chapter 7: Conclusion and Future Recommendations..................................................................60
7.1 Conclusions:.........................................................................................................................60
7.2 Future Recommendations:....................................................................................................60
References:....................................................................................................................................61
ELECTRIC CYCLE

LIST OF FIGURES

Figure 2.1: Bicycle sketch…........................................................................................................14

Figure 2.2: Karl Drais design….....................................................................................................14
Figure 2.3: McCall design..............................................................................................................15
Figure 2.4: Eugène Meyer high front wheel bicycle......................................................................15
Figure 2.5: A free body diagram for the bicycle............................................................................16
Figure 2.6: A free body diagram for the bicycle with a motor.....................................................17
Figure 2.7: A motor connected to the chain wheel…...................................................................18
Figure 2.8: An electric assisted bicycle.........................................................................................18
Figure 2.9: The motor connected the hub by a chain…................................................................19
Figure 2.10: The final fabrication of the motor in the bicycle…..................................................19
Figure 2.11: Chainless bicycle…...................................................................................................20
Figure 2.12: Gear mechanism of bicycles…..................................................................................21
Figure 2.13: Clutch description…..................................................................................................23
Figure 2.14: Clutch pushing lever mechanism in motorcycle......................................................24
Figure 2.15: DC motor connected to a gear…...............................................................................25
Figure 3.1: The components of the project…...............................................................................27
Figure 3.2: Side view of prototype showing the motor…............................................................29
Figure 3.3: Components of the prototype.....................................................................................29
Figure 3.4: The designed gear mechanism attached to the motor….............................................30
Figure 3.5: Torque developed on crank........................................................................................32
Figure 3.6: Torque developed on rear wheel….............................................................................32
Figure 3.7: Motor…......................................................................................................................34
Figure 3.8: The Motor fabricated with a gear…...........................................................................34
Figure 3.9: Electrical connection drawing....................................................................................35
Figure 4.1: A Multimeter...............................................................................................................36
Figure 4.2: Testing setup...............................................................................................................37
Figure 4.3: Parallel connection diagram…...................................................................................37
Figure 4.4: Graphical power, efficiency, torque, and load data….................................................39
ELECTRIC CYCLE

Figure 4.5: Graphical power, efficiency, torque, and load data…................................................40

Figure 4.6: Bicycle simulation at speed of 20.1 km/h...................................................................41
Figure 4.7: Speed vs. distance traveled graph................................................................................41
Figure 4.8: Bicycle simulation at speed of 5 km/h and 5% inclined surface................................42
Figure 4.9: Speed vs. distance traveled at 5% inclined surface.....................................................42
Figure 4.10: Bicycle simulation at speed of 10 km/h and 10% inclined surface..........................43
Figure 4.11: Speed vs. distance traveled at 10% inclined surface.................................................43
Figure 4.12: Solar panel.................................................................................................................44
Figure 4.13: Workshop..................................................................................................................45
Figure 4.14: Generator…...............................................................................................................45
Figure 4.15: First test…................................................................................................................46
Figure 4.16: Batteries connected in parallel….............................................................................46
Figure 4.17: Thick Wires..............................................................................................................47
Figure 4.18: Final installed system…...........................................................................................47
ELECTRIC CYCLE

LIST OF TABLES

Table 1.1: The specifications for the bicycle used in the project…...............................................11
Table 2.1: The effect of the required power when varying the inclement of a surface…..........................18
Table 2.2: Parts description for gear mechanism.......................................................................................22
Table 2.3: Types of clutches according to the method of transmitting torque..............................23
Table 3.1: Installation parts….......................................................................................................28
Table 3.2: Gear mechanism dimensions…....................................................................................30
Table 3.3: Design parameters…....................................................................................................31
Table 3.4: Motor specifications….................................................................................................33
Table 4.1: One battery direct connection values…........................................................................36
Table 4.2: Two batteries connection in parallel outputs…...........................................................38
Table 5.1: List of items..................................................................................................................48
Table 5.2: Tasks for team members...............................................................................................49
Table 5.3: Bill of Material and Budget.........................................................................................55
 Chapter 1: Introduction
CHAPTER 1: INTRODUCTION

1.1 PROJECT DEFINITION:

A bicycle, also called a cycle, is a human powered, pedal- driven, single track vehicle having two
wheels attached to a frame, one behind the other. Bicycles were introduced in the 19
th century in Europe, and by the early 21 st century, more than 1 billion were in existence at a given
time. They are the principal means of transportation in many regions. One important advantage of a
bicycle is that it is non- polluting. They also provide a popular form of recreation, general fitness,
military and police applications etc.

In the 1890s, electric bicycles were documented within various U.S patents. Two years later, in
1897, Hosea W.Libbey of Boston invented an electric bicycle that was propelled by a - double
electric motor. IIAn electric bicycle is also known as an e-bike is a bicycle with an integrated electric
motor which can be used for propulsion. Many kinds of e-bikes are there ranging from those which
use a small motor to assist the rider’s pedal power to more powerful e-bikes which are closer to
moped-style functionally.

E-bikes use rechargeable batteries and the lighter ones can travel up to 25 to 32 km/ hr (16 to19

mph), depending on local laws, while the more high-powered varieties can often do more than 45
km/hr. (28 mph).

The main aim of our project is to design a simple electric bicycle with cost effective. In this e-
bicycle we can make use of both electrical energy and normal pedal system. If any fault occurs in
the electrical mechanism we can move the bicycle by using the pedal system. We can have a closer
look on various parts and working of our e- bicycle in the upcoming chapters.

In this project a design and installation of a new gear mechanism attached to a motor on a bicycle that
contributes in decreasing the required torque efforts from the rider on inclined surfaces to accelerate a
bicycle. This project mechanism will be applied in two main scenarios while going up on a hill and
by going down. When going uphill, the driver of the bicycle will have to increase the effort, with
that more pedaling will be required to overcome all forces acting against the bicycle.

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 Chapter 1: Introduction

The first part of the project is by utilizing a motor that will be connected to the rear gear hub by a
chain initiated by a switch fixed right next to the rider’s left hand. This switch will start/stop the
motor to contribute in reducing the pedaling force.

The second part of the project is by a generator connected to clutch to be engaged in the hub to
charge the battery and decelerate the bicycle at the same time. Mainly it is a mechatronic project; it
will have a motor, gears, battery, clutch, and a generator.

The project is applicable and useful for sports activities, daily bicycle uses of transportation, and
those who cycle/pedal on hills which vary in ground elevation. It is also important from the safety
part, decreasing the speed while going down, and increasing the speed while going up.

CASE STUDY

Travelling is unavailable for us.Every day we travel to meet our needs.During this traveling,we are
depending vehicles which runs with ic engines.Its advantage is that it can travel as far as it needs to
fill up as it runs out of fuel and also the availability of fuel stations are high, time requied for fuel
filling is less. In the past years most people depended public transport for traveling.But lifestyle
changes and hustle and bustle made them think differently.

But today the situation has changed,The vehicle has become a necessity rather than a luxury.One of
the reasons for this is the increase of purchasing power of the people. Companies have taken
advantage of this opportunity by launching vehicles in various budgets and segments.Thus the
vehicle also became a symbol of status and culture.

The arrival of the Corona and the lack of public transport have increased the demand for
vehicles.Vehicles became more popular.The vehicle has become a necessary component to meet their
needs. Today the roads are overcrowded with vehicles

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 Chapter 1: Introduction

This graph showing the total number of vehicles registered during 1951 to 2016.the number of

registered vehicles in 1951 wast just only 0.31 million..but in 2016 the situation changed the total

number of registered vehicles in 2016 is around 230 million, there was a large hike in vehicles

during this period.yes,it shows the importance that people give to the vehicle.This shows a huge

jump in the vehicle market.

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 Chapter 1: Introduction

This chart shows the composition of vehicle populations.As we know, most of the people in india

adre middle class families, everyone cannot afford a car.But they also cant avoid vehicles In today's

busy life.So that, most of the people are purchasing two wheeler. Two wheeler is the hot selling

segment in indian automobile market.during 1951 the market of two wheelers are only 8.8% and

during those time cars was the hot selling item.but now a large change occurred.No the market

share of two wheelers are around 73.5%. which means a large hike.Parking area,compact size and

flexibility also become a reason for this.

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 Chapter 1: Introduction

This table shows the annual growth of vehicles till 2016 as a time interval of 10 years.Almost 10%

growth is happend in the sales of all category of vehicles.cars and two wheelers has 10.1 % growth

during 2006 to 2016,but buses has only 5.9 % during this interval.and average of all segment is

9.9% of growth

IMPACT

POLLUTION

See this pie chart, 24 % of the total pollution is Carried by the transportation system.which means

vechicles makes marginally large pollution.

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 Chapter 1: Introduction

GLOBAL FOSSIL FUEL CONSUMPTION

See this graph Technologies and methods are developing,but the usage of Fossil fuels are

increasing day by day ..If it continues, fossil fuels will end soon.tge world didnt trying to find the

subtitutionary method for this.still we stick on to fossil fuels.And large requirements of fossil fuel

will leads to hike in fuel price.This graph represents the defference and hike in petrol price in

india.In 2011 petrol price was below 70 rupees but now it crossed 100.We need to find a remedial

solution.

1.2 PROJECT OBJECTIVES:

 Converting mechanical energy from wheel rotation to electrical energy.

 The design of an energy efficient bicycle.

 Reducing the required pedeling effort by utilizing a motor.

 Increasing the validity period of brakes.

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 Chapter 1: Introduction

1.3 PROJECT SPECIFICATIONS:

The project is applicable for any bicycle available in the market. The bicycle that has been selected for

this project has the specifications as listed in Table 1.1.

Table 1.1: The specifications for the bicycle used in the project [1]

Item Specification

Best Use Mountain Biking

Frame 6061 Aluminum

Fork SR Suntour XCT, 75mm travel

Crankset SR Suntour XR-170 24/34/42T

Bottom Bracket Sealed cartridge

Shifters Shimano EZ-Fire 8-speed

Front Derailleur Shimano FD-C050

Rear Derailleur Shimano Acera

Shimano HG30 cassette, 11-

Rear Cogs
32T, x8

Brakes Tektro alloy linear pull

Brake Levers Shimano EZ-Fire

Rims Alex alloy

Front Hub Alloy

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 Rear Hub Alloy

Tires Kenda Klaw XT 26x2.1"

Handlebar Steel riser

Stem Alloy 1-1/8" threadless

Seat Post Alloy micro-adjust,

Saddle K2 Sport MTB

Pedals Resin MTB

Headset 1-1/8" threadless

Chain KMC Z7

1.4 APPLICATIONS:
The application of this new mechanism is not complicated in terms of the design and motor

installation. It is applicable for lots of utilizations such as:

 Sport activities using bicycles where people use to cycle/pedal for long distances.

 Daily life bicycle uses as a main tool of transportation for some people.

 Contribution to motivate old age people to use bicycles to exercise their legs.
 CHAPTER 2: LITERATURE REVIEW

2.1 PROJECT BACKGROUND AND HISTORY OF

BICYCLES:
Gupta (2009) [2] states “A bicycle is the most efficient vehicle ever designed.” (p.3.). A bicycle

is a widely-known tool of transportation in many countries. Bicycles have been invented back in

the 1500s. There are many claims describe the invention of bicycles and their designs. In 1493,

Gian Giacomo Caprotti alleged that he sketched a design of a bicycle as in Figure 2.1. In 1817,

Karl Drais designed a new generation of bicycles as shown in Figure 2.2. Karl’s design has been

developed and readjusted by other designers. The big evolution was in the 1860s which let

bicycles have become more common around the world. In 1869 Thomas McCall has built a

bicycle that inspired French designers as shown in Figure 2.3. In the 1870s, Eugène Meyer was a

French mechanic who invented a new generation of the bicycles in Figure 2.4. He designed the

high front wheel bicycles in order to increase the speed of bicycles. In the 1880s and 1890s, the

safety bicycles have become the aim of John Kemp Starley who invented the first safety bicycle

in order to decrease the danger of bicycle accidents. In the 20 th century, more developments have

been applied to bicycles in chain and gear mechanisms. In 1939 to 1945 military bicycles were

used effectively during World War II for military purposes. In the 21 st-century, technological

advancement in bicycle manufacturing has become more effective in designing in terms of

aerodynamics, materials, and computer aided design.[2]

 Chapter 2: Literature Review

Figure 2.3: McCall design [5]

Figure 2.4: Eugène Meyer high front wheel bicycle [6]

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 Chapter 2: Literature Review

2.2 PREVIOUS WORK:

Hung, Jaewon, & Lim (2017) [7] hypothesis that “In order to develop a high performance

electric bicycle, a simulation study of its dynamic characteristics and required power is

conducted based on the effects of various input parameters such as rider mass, bicycle mass.

wind speed, crank length, wheel diameter, and grade.” (p.1.). They believe in order to select the

proper motor the required power for the system has to be calculated first. The required power can

be calculated using MATLAB or other mathematical software. According to their study, there

will be two situations for the free body diagram force analysis as shown in Figure 2.5 and Figure

2.6. The total power needed to push the bicycle will be a summation of the slope from the

inclined surface, air resistance, and friction from the surface. They concluded after their

calculations for a rider with a mass of 57 kg the suitable motor will be with a rated power of 250

Watt.

Figure 2.5: A free body diagram for the bicycle [7]

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 Chapter 2: Literature Review

Figure 2.6: A free body diagram for the bicycle with a motor [7]

Alkhalifa, Al-Ghumgham, Alsalah, & Alsubaie (2015) [8] propose a solar assisted bicycle. They

fabricated motor attached to rear hub gear as illustrated in Figure 2.7. Their objective was to

assess power consumption required when a motor is attached to a bicycle. Furthermore, they

used a solar panel to recharge the batteries and according to calculation the rated a 100 Watt

output from the solar panel. They installed a motor with a rated power of 500 Watt, battery

voltage of 48 V to run the motor. Their design is based on a rider with a mass of 105 kg. They

concluded From Table 2.1 as the surface getting more inclined the power needed to overcome

uphill cycling/pedaling increases.

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 Figure 2.7: A motor connected to the chain wheel [8]

Table 2.1: The effect of the required power when varying the inclement of a surface [8]

Inclination Speed Range Weight (Kg) Power to Power to Power

(%) (Km/h) (Km) overcome air overcome consumption
resistance rolling (Wh/Km)
(W) resistance
(W)
0 30 87 105 146 111 10.7
15 16 14 105 22 792 59.75
25 9.9 9 105 5 791 97.09

Scholten (2017) [9] proposed the electrically powered bicycle motor to be used as shown in

Figure 2.8. A motor with rated power of 250 W was used to achieve the target of an electric

assisted bicycle. The motor is fixed on the frame of the bicycle and connected the hub gear by a

chain as shown in Figure 2.9.

Figure 2.8: An electric assisted bicycle [9]

 Figure 2.9: The motor connected the hub by a chain [9]

Racer (2009) [10] has done a somehow similar project that has been in the making for about 3

years. He converted regular bicycle to a motor bicycle by installing a small engine on the

bicycle. He started with just the frame of the bicycle. Then, he welded the motor and fixed it on

the frame of the bicycle. The motor then is connected to rear hub gear by a chain to drive the

wheel. The distance between the wheels is about a 55 inches. He concluded that it was not a

practical application for a Board Track..

2.3 COMPARATIVE STUDY:
Hanlon (2006) [11] hypothesis that most children would have many incidents when using

bicycles involving lost skin, derailed chain, a destroyed cloth, and lost a bicycle. Furthermore,

bicycles are the world’s favorite vehicle of transport “More than 100 million bicycles are sold

each year – double the number of cars” (p.1). He believes that bicycles are highly-efficient but

potentially dangerous chain drive. Therefore, he prefers the idea of a chainless bicycle. US-based

Dynacraft has designed a bike has an internal drive shaft mechanism as illustrated in Figure 2.11

which requires less maintenance compared with chain bicycles. It is more expensive than regular

chain bicycles how it is less efficient around 10% less [12].

Figure 2.11: Chainless bicycle [11]

2.4 Parts:
This section is a general description of the functions of the main parts that are involved in a

bicycle movement.
2.4.1 Gear Mechanism of Bicycles:

Bicycle gearing system is the most fundamental mechanism which converts a rider’s force on

pedals into a driving force to accelerate bicycles. Bicycles differ in gear combination number and

gear ratios. Most bicycles now have multiple shifting gears between high and low in order to

increase the efficiency or to have a smoother pedaling effort. Figure 2.12 shows the gear

mechanism of bicycles that is responsible for how bicycles move. Table 2.2 summarizes the

function of each part involved in converting the force from a rider to a wheel motion.

Figure 2.12: Gear Mechanism of bicycles [13]

 Gear Ratio:

Gear ratio calculation is very significant to be determined. There are some parameters for gear

ratio calculation such as the number of teeth per gear, the diameter of the gear, the radius of the

tires, the length of the pedal crank.

 Table 2.2: Parts description for gear mechanism [14]

Part Function

Enables bicycle riders to push by their foot to drive the bicycle. ( A flat
Pedal
part, connected to the crank)

Takes the force from the pedal and produces a rotational motion to
Pedal Crank
rotate the chain wheel.

Transmits the pedaling torque to the chain. ( It is a gear that connects

Chain Wheel (sprocket)
the pedal crank and the chain)

Used for power transmission from the pedal crank to cogs in order to
Chain
rotate the wheels.

Attached to the hub in order to move the bicycle forward. ( Rear gears
Cogs
combination)

Gear Shifter Shifting the gear between high and low to adjust the desired gear ratio.

Wheel The tool for the rotation.

2.4.2 Clutch:

It is a mechanical tool which connects and disconnects gears together in a mesh to transmit

power as shown in Figure 2.13. Table 2.3 summarizes the types of clutch that one has to be

selected for the application project to attach the hub gear to the generator.
 Figure 2.13: Clutch description [15]

Table 2.3: Types of Clutches According to the method of transmitting torque [15]

Clutch Type Description

Both driving and driven shaft

Positive clutch
revolve together.

The friction force is used to

Friction clutch engage and disengage the

clutch.

A hydraulic fluid is used to

Hydraulic clutch
transmit the torque.

ELECTRIC BICYCLE CONTROLLER

The e-bike controller is the brain of the e-bikes. It is connected to all the other electronic parts

such as the battery, motor and the throttle if it takes all the inputs from all the other

components and determines what should be signaled to them in return.

 Figure 5.2.6

2.4.3 DC Motor:

It is an electric motor that converts the electrical energy into mechanical energy. DC motors are

electric motors that are powered by the direct current which called DC, such as from a battery or

DC power supply. The installed in the bicycle DC motor helps the rider during downhill and

uphill cycling as the example in Figure 2.15. During the uphill cycling, where a high effort from

the rider is required to get the desired speed. Also, during downhill cycling, speed increases and

riders apply brakes decelerate the speed of bicycles. However, by installing DC-motor

mechanism that is connected to the chain drive, the speed will be reduced [19].
 Figure 2.15: DC Motor connected to a gear [20]

 Performance Specifications:

Speed, torque, and operating voltage are the most important performance parameters for DC

motors. Supplier datasheets list these specifications as numerical values.

2.4.4 Generator:

An electrical generator is a machine that converts mechanical energy to electrical energy. The

mechanical energy can be supplied from wheel rotation then the generator converts it and

recharges the battery.

 CHAPTER 3: SYSTEM DESIGN

3.1 DESIGN CONSTRAINTS:

One of the most common difficulties students face in Saudi Arabia is the lack of the required

parts for the projects in local markets. One of the constraints for this project is the motor weight

and power output. A light weight motor has to be selected in order to avoid additional weight to

bicycle. Furthermore, design and dimension accuracy constraints the project because the chain

might impact the rider’s legs. Additional to that it is not easy to weld the motor on the aluminum

frame for the bicycle. The power of the motor has to overcome steeply inclined surfaces.

3.2 DESIGN METHODOLOGY:

The design methodology for accomplishing the objectives of the project has to go through some

significant stages. The result will be based on what has been used correctly in the design

methodology to get the final prototype of the project. To get the final prototype we have to

follow the following stages:

 A good relevant research and background of the project have to be completed at the first

stage of the project.

 Design the preliminary drawings for the system through SOLIDWORKS.

 Selecting for a motor that is suitable for the prototype based on light weight and power of

280 W.

 Selecting for a generator that is able to charge the battery.

 Selecting for a solar panel with an enough rated power to contribute in battery charging.

 Fabrication and assembly of the prototype.

 Chapter 3: System Design

 Testing of the prototype to ensure that it is applicable.

 Generate future recommendations for bicycle manufacturers.

3.3 PRODUCT SUBSYSTEMS AND COMPONENTS:

Generally, the major components of the prototype that have been designed are shown in Figure

3.1. Each item is summarized in Table 3.1 to explain the function involved from the components.

Figure 3.1: The components of the project

Figure 3.1 shows the first approach, in this approach the motor is attached to the rear hub by a

chain. We believe this approach is more efficient, safer, and can be applicable easily. The whole

system will be connected to main hub gear in the wheel to engage the motor when it is needed.

The system is connected to the battery to supply power to the motor.

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 Table 3.1: Installation parts

Part Comment

Switch To run the motor (start/stop)

Electrical Wires For connections

Battery For electrical power supply

Motor To produce torque for wheel rotation

To convert wheel rotation to electrical power to

Generator
charge the battery

3.4 Implementation:
When the research has been completed, we started to implement the prototype by drawing the

motor and the gear mechanism on SOLIDWORKS. Figure 3.2 and Figure 3.3 show the motor

located at the upper gear and connected with a chain to rear hub of the bicycle. Table 3.2

illustrates all the dimensions between the rear hub gears and the motor.
Figure 3.2: Side view of prototype showing the motor

Figure 3.3: Components of the prototype

Figure 3.4: The designed gear mechanism attached to the motor

Table 3.2: Gear mechanism dimensions

Term Dimension

Motor to rear gear 680 mm

Pedal to rear gear 465 mm

Teeth number of motor gear 44 teeth

D1 180 mm

D2 180 mm

d1 80 mm

d2 60 mm

Teeth number of rear gear1 20 teeth

Teeth number of rear gear2 16 teeth

3.4.1 Sprocket Ratio:

Sprocket ratio or gear ratio is the ratio is a mathematical representation of the mechanical

advantage of a gear train system. It shows the change in speed between the sprocket of the motor

and the rear hub of the bicycle [2].

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 𝑑𝑟𝑖𝑣𝑒𝑟

Sprocket ratio =𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 𝑑𝑟𝑖𝑣𝑒𝑛

44
Sprocket ratio = = 2.75
16

3.4.2 Torque Calculations:

Equation 3.1 is used to calculate the minimum torque required to accelerate the bicycle by

normal pedaling without a motor, there are some parameters have to be known and they are

listed in Table 3.3.

Table 3.3: Design parameters

Symbol Definition Dimension

𝑅𝑐 Radius of Crank 80.0 mm

𝑅𝑝 Distance from Pedal To Center of Crank 100.0 mm

𝑅𝑔 Radius of Rear Multi-Gears 20.0 – 50.0 mm

𝑅𝑡 Radius of Tire 300.0 mm

W Mass of The Rider Assuming Average Mass of 75 kg

T Tension -

τ Torque -
 τ𝑐 Torque on Crank -

τ𝑇 Torque on Rear Wheel -

f Friction Force -

I Moment of Inertia -

Based on the bicycle’s dimensions that have been determined, the torque equations:
 Torque on crank

Figure 3.5: Torque developed on crank

τ𝑐 = 𝑅𝑐 T - 𝑅𝑝 W (Eq 3.1)
0 = 𝑅𝑐 T - 𝑅𝑝 W (Assuming constant speed)
𝑅𝑝 W 100.0 𝑚𝑚 𝑋 75 𝑘𝑔 𝑋 9.81 𝑚/𝑠2
T= = = 919.70 N
𝑅𝑐 80.0 𝑚𝑚

 Torque on rear
wheel

Figure 3.6: Torque developed on rear wheel

 τ𝑇 = 𝑅𝑔 T (Eq 3.2)
τ𝑇 = 20.0 mm ∙ 919.70 N
τ𝑇 = 0.02 m ∙ 919.70 N = 18.40 N m

τ𝑇 (Total) = τ𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 -
τ𝑇 τ𝑇 (Total) = 𝑅𝑡 f -
𝑅𝑔T
0 = 𝑅𝑡 f - 𝑅𝑔T
𝑅𝑔
𝑅𝑔
f= T
𝑅𝑡
f= 𝑅𝑝 20.0 mm X 100.0 mm 2
( W) = X 75 kg X 9.81 = 6.25 N
𝑅𝑡 𝑅 300.0 𝑚𝑚 𝑋 80.0 𝑚𝑚
𝑚/𝑠 𝑐

3.4.2 Motor Details:

The selected motor for the prototype has fixed specifications which are listed in Table 3.4. The

original motor used in the project is shown in Figure 3.7. The motor was not suitable to be

attached to the chain. Therefore, we had to fabricate and weld a gear on the motor to for reaching

the objective of the project. Figure 3.8 shows the new shape of the motor after the fabrication

with gear to be connected to the rear hub.

Table 3.4: Motor specifications

Term Value

Voltage 24 V

Power 280 W

Current 15.4 A

Weight 2.04 kg

RPM 2750 rpm

 Figure 3.7: Motor

Figure 3.8: The Motor fabricated with a gear

Figure 3.9 shows the electrical connection diagram between the batteries and the motor then the

switch. It has to be in parallel to ensure that the voltage is distributed the same through the

circuit.

Figure 3.9: Electrical connection drawing [21]

 CHAPTER 4: SYSTEM TESTING AND ANALYSIS

4.1 MOTOR:
The main component in the prototype is the motor performance output produced to accelerate the

bicycle. Where the torque produced will contribute to reducing pedaling efforts. The objective of

this test is to ensure that the motor is performing as design calculations.

A Multimeter has been used to test the output voltage and current through the system. The

testing setup is shown in Figure 4.1 and 4.2. The values of the test are shown in Table 4.1.

Table 4.1: One battery direct connection values

Term Value

Voltage 12 V

Current 12 A

Figure 4.1: A Multimeter to measure the voltage

 Chapter 4: System Testing and Analysis

Figure 4.2: Testing setup

As the results above show that the values have not met the requirements of the motor. Therefore,

we have to connect two batteries in the system instead of one. The connections were set in series

and due to the excessive load the switch was burned as a result, we have redesigned the

connections to be in the parallel set as illustrated in Figure 4.3. As shown in Table 4.2 the values

of the voltage and current when connected in parallel.

Figure 4.3: Parallel connection diagram [23]

Page 37 of 92
 Table 4.2: Two batteries connection in parallel outputs

Term Value

Voltage 12 V

Current 24 A

4.1.1 Bicycle Motor Simulation:

A bicycle simulator was used to analyze the power and torque of the motor under various loads

and deferent inclement. The red line shows the power output of the hub motor. The power output

is zero at 0 rpm, rises up to a maximum, and then falls back down to zero once the wheel is

spinning at its normal unloaded speed.

The green curve is the efficiency curve for the electrical drive system. It is a ratio of the

mechanical power coming out of the hub motor to the electrical power going into the controller.

The blue curve can be configured to display either the torque output of the hub in Newton-meters

or the thrust of the wheel in pounds. Thrust naturally increases as you select smaller wheel sizes,

while the torque of the motor is independent of wheel diameter. The pounds thrust needed to

overcome gravity when climbing a hill is simply weight * %grade.

The black curve shows the load line of the vehicle, or the % grade hill that the system will climb

at steady state. The load line is the default choice, and it directly shows the amount of power

necessary to move the bicycle.

 Figure 4.4: Graphical power, efficiency, torque, and load data

Figure 4.4 shows the torque needed to accelerate the bike. Also, it shows the maximum power

needed at grade 1.5%. The maximum power needed in this situation is 268W.
 Figure 4.5: Graphical power, efficiency, torque, and load data

Figure 4.5 shows how the torque and the maximum power effected when the grade % is changed.

When the grade is 2% the torque went up to 13.3 N.m and the maximum power went up to 290

W.
The bicycle parameters have been set in a bicycle simulator to test and analyze the power and

torque inputs. The below Figures 4.6-4.11 simulate and analyze the inputs of the bicycle at

different speeds and at straight line surface.

Figure 4.6: Bicycle simulation at speed of 20.1 km/h

Figure 4.7: Speed vs. distance traveled graph

Figure 4.8: Bicycle simulation at speed of 5 km/h and 5% inclined surface

Figure 4.9: Speed vs. distance traveled at 5% inclined surface

Figure 4.10: Bicycle simulation at speed of 10 km/h and 10% inclined surface

Figure 4.11: Speed vs. distance traveled at 10% inclined surface

 Figure 4.13: Workshop

Figure 4.14: Generator

4.2 OVERALL RESULTS, ANALYSIS AND DISCUSSION:

We have conducted two tests described as follows:

 First Test:

As the motor has been installed on the bicycle’s frame, a 12 V battery was connected to the

motor to start the test figure 4.15. As a result of the lack of voltage, the bicycle did not move at

all and the battery got empty within 30 seconds. Therefore, group members were evaluating the

problem that prevented the bicycle from moving. We had to seek assistance from electrical and
mechanical instructors to assist in finding the issue, the final decision was to connect two

batteries in parallel to get 12V and 24aH figure 4.16.

Figure 4.15: First test

Figure 4.16: Battery is connected

 Second Test:

The test has been conducted again with holding the bicycle at a certain level from the ground and

giving the rear wheel a little push. The result was a good start and it worked. One more thing, we

have noticed that the wires connected to the motor plus motor itself got heated during the

process. The wires we had are thin wires and the switch was burned, therefore, we have replaced

it with thick wires figure 4.17.

 Figure 4.17: Thick Wires

 Third Test:

After doing two tests, fixing the problems mention before, in addition to installing the solar

panel, the system seemed to be working fine. Weight was added to the bicycle, however, the

system worked properly figure 4.18. At the end, a third test was initiated, the results were as

expected, the motor worked properly, the wires did the job perfectly, and the switch worked fine.

Figure 4.18: Final Installed System

 CHAPTER 5: PROJECT MANAGEMENT

5.1 Project Plan:

Table 5.1 shows the items that were needed to be purchased from the market to be assembled in

our prototype. After research and looking through the chalai market, we have found all of the

items except for the motor. We had to buy it from online. We have searched online for the motor

with an exact performance that fulfills our need for the project. Regarding the rest of the items,

we have purchased from the local market.

Table 5.1: List of items

Item Quantity

Motor 1

Battery 2

Chain 1

Gear 1

Switch 1

Wires 2 colors

Solar panel 1

Generator 1

Table 5.2 shows the tasks for each member. For the bicycle, we have decided that Vishak V and

Adarsh K should get a proper bicycle that meets our specifications in the project. For the motor,

after doing a search on the internet and looking through previous works,
 Chapter 5: Project Management

we have found a proper motor on the website Amazon, which was purchased by the member

Muhammed faris and Rahul M S. For the electric parts of the project, Alif Mohammed, Deepak

D R, and Sreeraj R S went to an electric shop in palayam called “electro solutions”, they had the

electrical components that we were looking for. Going through our project we had to buy Gears

and Chains to assemble them in the system, Sajin Santhosh ,Arjun S K , Sajeeb S went to chala

looking for these parts, eventually, they found the needed parts. Last but not least a generator

was needed, as same as the way of purchasing the motor we did it for the generator.Arjun S K ,

Sajeeb S and Sajin Santhosh are participated in designing process

Table 5.2: Tasks for team members

Item Team Member

Bicycle Vishak V ,Adarsh K

Muhammed Faris, Deepak D R

Motor

Battery, wires, and Sreeraj R S ,Alif Muhammed , Rahul M S

switch
Gear, chains Arjun S K , Sajeeb S and Sajin Santhosh

Designing Arjun S K , Sajeeb S and Sajin Santhosh

Page 49 of 92
5.1.1 Gantt Chart:

Task Name Duration 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 16

0 1 2 3 4 5
1 . Initiation 12d
1.1. Kick-off meeting 1d
1.2. Gantt chart 4d
1.3. Project definition 2d
1.4. Project objectives 4d
1.5. Project specification 1d
1.6. Application 2d
2 . Planning 10d
2 .1 . Literature review 10d
2.1.1. Project background and history of bicycles 2d
2.1.2. Previous work 2d
2.1.3. Comparative study 1d
2.1.4. Parts 3d
2.1.4.1. Gear mechanism 3d
2.1.4.2. Clutch 1d
2.1.4.3. DC motor 1d
2.1.4.4 Generator 1d
3 . Execution 10d
3 .1 System design 10d
3.1.1 design constraints 3d
3.1.2 design methodology 6d
3.1.3 product subsystems and components 2d
3 .2 system implementation 7d
3.2.1 torque calculations 4d
3.2.2 drawings 4d
4 . Controlling 7d
4 .1 system testing and analysis 3d
4.1.1 motor 1d
4.1.2 power generation 2d
4.1.3 overall results, analysis and discussion 2d
5 . Monitoring 28d
5 .1 project management 16d
5.1.1 project plan 2d
5.1.2 contribution of team members 2d
5.1.3 project execution monitoring * 2d
5.1.4 challenges and decision making 11d
5.1.4.1 problems with team members 2d
5.1.4.2 challenges of project parts 4d
5.1.4.3 problems with equipment 3d
5.1.5 project bill of material and budget 4d
5 .2 project analysis 13d
5.2.1 life-long learning 4d
5.2.2 impact of engineering solutions 4d
5.2.3 contemporary issues addressed 5d
5 . Close-out 9d
6 .1 conclusion 2d
6 .2 recommendations 2d
6 .3 Final report and presentation 5d
5.2 CONTRIBUTION OF TEAM MEMBERS:

 Arjun S K :

a. Team Leader

b. Designer “Solid-Works drawings”

c. Parts decider

d. Tasks distributor

 Sajeeb S and Sajin Santhosh :

a. Calculation analysis

b. Engineering concepts and analysis

c. Report organizer

d. Workshop connections

 Muhammed faris and Alif muhammed ;

a. Online shopping

b. Group enthusiasm

c. New ideas

 Vishak S and Adarsh k :

a. Market expert

b. Parts installation

 Rahul M S , Sreeraj R S and Deepak D R;

a. Prototype transportation

b. Market expert
5.3 PROJECT EXECUTION MONITORING:

The executing, monitoring and controlling phases of the project management lifecycle consist of

completing and managing the work required to meet the project objectives. This phase also

ensures that the project performance is monitored and adjustments to the project schedule are

made as needed. Since the first lecture, we attended we have created a WhatsApp group to make

sure every member of the group is updated with the progress. Also, we have used Telegram to

share the documents we needed and to upload the research so we all worked on the same word

file and that was very helpful and effective.

We have started our meetings on the 16 December and we agreed to have at least two

meetings per week. Every member was a cooperative and willing to do his best. We arranged the

meetings days through the WhatsApp group considering all the group member’s exams or any

other work. That was a good experience for the group members and helped us to go over many

barriers and obstacles.

On the other hand, we have had several meetings with our advisor and co-advisor. To reviewing

our research with them and get their comments and feedback. Also, we went to the advisor to

help us with some calculation and design specifications. Those meetings had a great impact on

our project and played the main role in our performance and progress. Furthermore, we had two

meetings with some of the electrical engineering faculties to discuss some calculation with them
5.4 CHALLENGES AND DECISION MAKING:

Through the senior year semester, we have faced a couple of challenges such as:

 Corona pandermic

 Transportation issue

 Problems with team members.

 Challenges of project parts allocation.

 Problems with equipment.

5.4.1 Problems with Team Members:

First, we had a time conflict with group meetings because of the classes’ schedules. Also, it was

the first time of working on a project with the team members. Furthermore, when the ending
.

5.4.2 Challenges of Project Parts:

First, we have faced problems with the motor; we could not find the required motor

specifications in the local market. We have decided to order the missing part from the abroad

website markets. Secondly, the chain was not fitted on the chain wheel gear. Therefore, we have

tried two different sizes of the chain to get the proper one. Thirdly, the connected motor gear was

small difficult as a result, we have fabricated bigger gear that connects the rear gear to the motor.

5.4.3 Problems with Equipment:

We had a problem with the motor switch because it was burned while we were testing the project

due the overload. Also, we have tried to find a proper battery because it became empty while we

were testing the motor.It was difficult to balance the weight of motor and battery.

5.5 Project Bill of Materials and Budget:

At the beginning of the project, we have estimated the amount of our budget to be around 17000

Rs. As we kept purchasing the equipment that is required to build the prototype, we have noticed

that the required equipment is more expensivethan our estimation. When we have reached the

final shape of our project, we have calculated each part so the total was 19000 which is more

than our approximate budget. Table 5.3 shows all the needed components to complete building

the prototype and their costs.

 Table 5.3: Bill of Material and Budget

Part Name Description Quantity Unit Price Total Amount

(Rs) (Rs)

Bicycle - 1 6000 6000

Battery 12 V, 12 Amp 2 1500 3000

Battery Charger 10 Amp 1 2000 2000

Battery level
indicator - 1 500 500

Switch - 1 100 100

Motor 12 V, 280 Watt 1 3500 3500

controller and
accelerator

Lathe work and - - 2500 2500

other expenses

luggage carrier - 1 1000 1000

and battery box

Chain - 2 400 400

Total 19000
 CHAPTER 6: PROJECT ANALYSIS

6.1 LIFE-LONG LEARNING:

The senior project is assigned for students to gain experience, problem-solving, and learning. To

have a project to do within the four-month period is not as easy as it seems, it includes a lot of

challenges, time management, and writing reports. With these factors, gaining knowledge is a

must. The following points will specify in detail the knowledge we have gained during this

project:

6.1.1 PROJECT ANALYSIS:

Starting a project, as engineers we must have design calculations before even purchasing parts.

While going through the phases of the project, we have learned from our mistakes which enable

us to resolve some trouble with getting a better-quality part. The analysis took place on the tasks

given and the target that we must achieve. At the end, we have had better outcomes because we

started with analyzing the project.

6.1.2 Equipment’s Specifications:

Choosing the proper equipment and parts for our project was a challenge for us. We had to be

specific to each part. We had to choose proper parts relating to our initial design. Finding this

equipment was not easy since some of the parts were purchased locally, the rest was purchased

from abroad through online shopping websites. The knowledge in this factor was to learn about a

new local market, and searching online for specific equipment.

 Chapter 6: Project Analysis

6.1.3 Installation:

At the beginning, we have struggled in motor installation; the problem was with the frame. The

frame material was made from aluminum. The initial idea was to weld the motor to the frame.

When we tried to weld the motor, we have noticed that there was no sign for welding. The reason

we have discovered was that the aluminum is not easy in to be welded, more advanced welding

technology is needed to do this job.

6.1.4 Problem Solving:

Going through the phases of the project, we have faced a lot of problems that was solved

eventually. The first problem was related to the battery. When we started the motor the battery

got drained out in almost thirty seconds. The second problem we faced was regarding locating

the motor in a proper distance that will suit our final mechanism. The knowledge we have gained

through all problems is finding solutions.

6.1.5 Teamwork:

One of the major factors of being successful at any workplace is teamwork. We have scheduled

meetings for brainstorming, discussion, and sharing ideas. We have learned patience while

working together, we stood up for each other, and we went through a lot together. The

knowledge gained by this important factor is patience and team management.

6.1.6 Engineering Sense:

Page 57 of 92
Relating what we have studied in the university to our project was a major use in our decisions.

We have applied many formulas learned in different courses. Some problems we faced could not

be solved by formulas; the solution was to think in engineering sense regarding our eminent

experience and creativity throughout the courses' projects we have done. The knowledge in this

factor was to mix critical thinking and creativity to engineering.

6.2 IMPACT OF ENGINEERING SOLUTIONS:

The impact of our project on the society is to reduce pedaling effort on bicycles for riders.

Cycling in various roads and landscapes conditions easily is our target. Moreover, the impact on

the environment is by ignoring the use of Internal Combustion Engines (ICE). Our project is not

consisting of any Internal Combustion engines (ICE), it is only depending on a mechanism that

we get its power from an electric source. For example, batteries usually charged by chargers. On

the other hand, we use a small generator to charge the battery that acts as the power supplier.

This kind of mechanism is not affecting the environment. Furthermore, our project is a simple

example of an efficient economic bicycle. The installed parts are not that expensive, its range

around 70 – 150 SR each. The total amount and its efficiency are better to use rather than other

bikes which cost and consume more budget.

6.3 CONTEMPORARY ISSUES ADDRESSED:

Renewable energy sources in Saudi Arabia are still under development in some new applications.

The main use of solar panel is to generate electrical energy from sun heat and radiations, in

addition to that, it is a source of clean energy that does not affect the atmosphere comparing to

gasoline engines. Automobiles in Saudi Arabia are the most major mean of transportation, which

pollutes the environment. We have focused on renewable energy (solar panel) and its design
calculations, which is friendly to the environment. In Saudi Arabia the weather conditions are hot

in summer and cold in winter, bicycles will be useful in both conditions. First, the hot climate

will be a great opportunity for reducing the weight of people. Secondly, the cold weather is a

great time for cycling and getting warmed up. Linking our new mechanism to both scenarios (hot

and cold weathers) will contribute in both of the conditions mentioned earlier about the

difference in inclement.
 CHAPTER 7: CONCLUSION AND FUTURE
RECOMMENDATIONS
7.1 CONCLUSIONS:
After we have completed our research project we have conducted a lot of results regarding our

project. First, we have learned a lot about the local market, compared parts, dimensions, decision

making, and finally installation and fabrication. Second, our project works effectively, we had a

minor problem with the motor it kept getting heated when working. The problem was due to the

extra load on the motor because we were starting the motor while the bicycle is not moving. One

of the major challenges that we faced was the battery until finally, we solved that problem as

mentioned before.

7.2 FUTURE RECOMMENDATIONS:

 We recommend and motive people to start utilizing electric bicycles since they are

effective in reducing the pedaling efforts.

 Installing a motor that produces more power than 280 W to overcome steeply inclined

surfaces.

 Installing a wind turbine on the front side of the bicycle to generate power in order to

charge the connected batteries.

 Connecting a controller in the system to control the performance of the motor when

needed.

 Installing a larger solar panel to absorb a large amount of sunlight in order to accelerate

the charging time.

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