E-BIKE RACING CHALLENGE 2015

DESIGN REPORT
The objective of this project is to design and fabricate an
Electric powered bike which is performance oriented. In the
process each of the member gains a vast practical experience
and exposure for working in extreme conditions thus testing
the skills like discipline, sincerity, hard work, teamwork etc.
Working in this project also gives a practical experience of
corporate sector thus building up the personality of the team
members. While designing this Electric bike the prime
consideration was to keep utilize to make a performance, eco-
T E A M V A J R A friendly vehicle under a stipulated budget. The designing of
frame is done keeping in mind the weight, thus making the
U N I V E R S I T Y O F P E T R O L E U M frame as light as possible so that higher speed and stability
A N D E N E R G Y S T U D I E S can be achieved. The braking system was designed to stop the
vehicle in minimum distance, thus using disk brakes in the
DEHRADUN
front and drum in the rear. All the designing was done keeping
in mind the safety of the driver thus preventing the driver
from severe conditions.
TECHNICAL SPECIFICATIONS

1. Frame
 Material AISI 1018
 Weight :24 kg
 Pipe Used : Seamless Circular Cross Section
 Dimensions : Front- 2” Rear – 1”
 Thickness : Front –8gauge Rear – 11 gauge
2. Motor Output
 750W PMDC
3. Battery Type
 VLRA 33AH/48V
4. Suspension
 Front - Telescopic fork suspension
 Rear - Nitrox Mono suspension
5. Brakes
 Front – disc 240mm
 Rear – drum 130mm
6. Tires

Front- 2.75-18”

Rear- 100/90-18
7. Top Speed – 60km/hr
8. Range – 35km
9. Dimensions
 Length – 1734mm
 Width – 756mm
 Wheelbase – 1226.415mm
 Height – 1100mm

DESIGN AND CALCULATIONS

FRAME
The frame acts as the skeleton of the whole bike. It gives support to the whole chassis components
and holds the driver. The design of frame is done by using the basic principles of strength of material
and engineering mechanics. The theories of mechanics help to design a frame which can sustain under
severe conditions and adds up to the minimal weight to the electric bike. The frame also provides
strength to the whole bike.
Thus frame is designed under the constraints and is subjected to various tests by stimulating it. The
basic aim behind frame design is to ensure safety of the driver under impact loads. It must also
incorporate other components like motors and batteries. Various chassis designs of similar vehicles
have been taken into consideration while setting up the basic structure.

Material Used AISI 1018

Tensile Strength 440 MPa
Yield Strength 370 MPa
Pipe Dimensions Front – 2” 8 gauge Rear – 1” 11 gauge
Mass 24 Kg
ANALYSIS
1) FRONT IMPACT

FOS – 3.21

FOS – 1.07

2) REAR IMPACT

FOS – 1.53

FOS – 8.51

3)
4)
5)
3) SIDE IMPACT

FOS – 166.1

FOS- 39.24

TRANSMISSION CALCULATION
Gross Vehicle Weight => 180Kg
Rolling resistance => GVW*Rolling resistance coefficient
=> 180*9.8*0.015= 26.46N
Air resistance =>
is the drag force, is the density of the fluid,
is the speed of the object relative to the fluid,
is the cross sectional area, and
is the drag coefficient – a dimensionless number.
=>0.5*1.22* 16.672 *0.3*0.6 = 30N
Total Resistive force => 57N
Power => Force * velocity = 57*16.67 = 950W
REDUCTION CALCULATION
Motor Specs
Efficiency = 80%
Torque = 5Nm
r.p.m = 1500
r.p.m reduction
V = 2 rN/id *60
16.67= 2*3.148*0.3*1500/(60*id )
Id = 2.82
Torque reduction
F*r = T
60*0.3 = 5* id * 0.8
Id = 4.5
Reduction due to weight
Frictional force * radius of tire = torque
0.6*180*0.7*9.8*0.3 = 5*id *0.8 Id =55.56
Final Reduction Taken = 5

STEERING GEOMETRY
Data taken
Wheel Base - 1226.415mm

STEERING CALCULATION

=63.2 degree
Outside Diameter of wheel= 18”
Fork Offset=0

Rw = radius of wheel
Ah = rake angle of vertical
Trail = 4.5”
The radius of the front wheel is R, the rear wheel r.
From the figure above we conclude:
Sinw/R
R = w/sin
Also
an w/r
r = w/tan
r = 1226.415/tan(40)
r = 1.1461mm = 1.1461 m
Hence Turning radius = 2.433m

Braking Calculation
Brakes are one of the most important criterions in designing of
any vehicle. The safety of the driver depends primarily on its
breaking systems.
FRONT BRAKE
Fbp = FD * (L2/L1)
Where, Fbp = Force output of Brake assembly
FD = Force applied to the pedal by driver
L2/L1 = Pedal Ratio

∴ Fbp = 90* 5 ( Pedal ratio is 4)

=450 Newton

Pmc = Fbp/A = 450/3.8*10-4 = 1184210.526N/m2

( 3.8*10-4 is area of master cylinder)
Where, Pmc= Hydraulic Pressure generated by master cylinder
A = Master Cylinder Piston Area

Pmc = Pca
Where Pcal = Hydraulic Pressure transmitted to the Caliper.
Fcal = Pcal * Aca
Where, F cal= One sided linear force generated by caliper

Acal = Effective Area of caliper piston found on half of caliper body

∴ Fcal = 1184210.526* ( Area of Caliper Piston=1.48 inch2)

=2710.657 N
Fclamp= Fcal *2
Where, Fclamp= Clamp for generated by caliper
Fclamp= 843.34 * 2 =5421.315 Newton

Ffriction= Fclamp * μ
Where, Ffriction=Friction Force generated by brake pads
μ = Coeff. Of friction b/w brake pad and rotor, 0.42

∴ Ffriction= 5421.315* 0.42 = 2277.06 Newton

⇒Tr = Ffriction * Reff
Where, Tr = Torque generated Rotor (Discs_
Reff= Effective radius of Rotor
Tr = 708.40*0.11 (radius of rotor)
= 250.47 Nm
Effective force on wheel = 250.47/0.3 = 834.924

REAR BRAKE
Force by foot = 100 N
Force on brake wire = 5 x 100 = 500 N
Force on brake shoe = 8.5/ (1.84/2) x 500
= 4619.565 N
Force on friction between drum & shoe = 1469.565 x 0.42
= 1940.247 N
Opposing torque applied by drum brake = 1940.247 x 6.5 / 100
= 126.114 N-m
Opposing torque on tire = F x 0.3 N-m (radius of tire = 0.3)
Now,
F x 0.3 = 45.40
F = 420.38 N
Total braking force = braking force from rear brake + braking for front brake
= 420N + 834.924
= 1255.30 N
For retardation frictional force acting on bike = 1234.30
 Retardation(a) = force/mass
= 1234.30 / 180
= 6.86 m/sec2
 Stopping distance at 40 kmph:
D40 = 11.112 / (2 x 6.86) m
= 8.9 m
 Stopping distance at 60 kmph:
D60 = 16.672 / (2 x 6.86) m
= 20.254 m
SUSPENSION
A motorcycle's suspension serves a dual purpose: contributing to the vehicle's handling and braking,
and providing safety and comfort by keeping the vehicle's passengers comfortably isolated from road
noise, bumps and vibrations.
The typical motorcycle has a pair of fork tubes for the front suspension, and a swingarm with one or
two shock absorbers for the rear suspension electric bike we are using telescopic fork for the front
suspension and nitrox mono shock suspension for the rear suspension.
Mono-shocks eliminate torque to the swingarm and provide more consistent handling and braking.
They are also easier to adjust, since there's only one shock to adjust, and there is no worry about
matching two shocks.
SUSPENSION CALCULATION
Spring load when load is applied = 250 kg (for safety purpose)
Weight of bike = 180 kg
 Load applied on front spring is 40%
So,
250*(40/100) = 100 kg = 1000 N
 Load applied on rear spring is 60%
So,
250*(60/100) = 150 kg = 1500 N
 180 kg = 396 lbs.
 250 kg = 550 lbs.
 100 kg = 220 lbs.
 150 kg = 330 lbs.
For rear spring,
A. Wire diameter = 0.4 inch
B. Outer diameter = 2.3 inch
C. Free length = 7.0 inch
D. No. of active coils = 6
Material used: Stainless 302A313 Steel
Rates and loads:
 Spring rate(spring constant) k = 773.639 lbs/in
 True maximum load Fmax = 678.067 lbs.
 Maximum load considering solid weight = 678.067 lbs.
Safe travel:
 True maximum travel = 0.876 in
 Maximum travel considering solid height = 0.876 in
 Minimum loaded height = 6.124 in
Physical dimensions:
 Diameter of spring wire, d = 0.4 in
 Outer diameter of spring = 2.3 in
 Mean diameter of spring = 1.9 in
 Free length of spring = 7 in
 No. of active coils = 6
 No. of total coils = 8
Physical loads:
263.037 lbf @ 6.660 loaded weight
Maximum load for this spring = 678.067 lbf
For front spring,
A. Wire diameter, wd = 0.25 in
B. Outer diameter, od = 1.3 in
C. Free length, Lfree = 5.0 in
D. No. of active coils = 5
Material used: Stainless 302A313 Steel
Rates and loads:
 Spring rate(Spring constant) = 839.329 lbs/in
 True maximum load, Fmax =348.092 lbf
 Maximum load considering solid height = 348.092 lbf
Safe travel:
 True maximum travel = 0.415 in
 Maximum travel considering solid height = 0.415 in
 Minimum loaded height = 4.585 in
Physical dimensions:
 Diameter of spring wire, d = 0.215 in
 Outer diameter of spring, Douter = 1.3 in
 Inner diameter of spring, Dinner = 0.8 in
 Mean diameter of spring, Dmean = 1.05 in
 Free length of spring, Lfree = 5.0 in
 No. of active coils = 5
 Total no. of coils = 7
 Solid height, Lsolid = 2.0 in
 Spring index, C = 4.2 in
 Distance between coils, coil pitch = 0.85 in
 Rise angle of coils = 14.45 degrees
 Types of ends = Closed & Squared
Possible loads:
251.799 lbf @ 4.700 loaded height
Maximum load for this spring = 348.092 lbf

MOTOR CONTROLLER
A motor controller is an electronic device that acts as an intermediate device between a
microcontroller, a power supply or batteries & the motor.

Although the microcontroller decides the speed & the direction of the motors, it cannot drive them
directly because of its very limited power output. The motor controller, on the other hand, can provide
the current at the required voltage but cannot decide how fast the motor should turn.

Thus, the microcontroller & the motor controller have to work together in order to make the motors
move appropriately.

The motor controller consists of a driver IC. Motor driver IC is a replication of a device more
commonly known as an “H Bridge”. Generally, it controls the direction of current through the DC
motor thus forcing the rotor to turn clock-wise (or counter clock-wise). It should be powered with
12V to 50V. Following is the description of the component of the motor driver IC & there working.
C1 &C2-;
Filter caps used to minimize the voltage ripple from the power source.

D1, D6 & D7-;

The TVS diode ,used to suppress voltage spikes. These are like super zeners optimized to clip high
current pulses that exceed the voltage limit of the device.
Q1 TO Q16-;
MOSFETS (metal oxide semiconductor structure) is a type of transistor used for amplifying or
switching electronic signals.
D2, 3, 4, 5, 8, 9, 10, 11-;
The zeners are used to clamp the gate drive voltage. These diodes protect the gate from transients
caused by the rapid charge and discharge of the gate capacitance.

R2 TO R9 & R13 TO R20-;

These resistors, placed in series with the MOSFET’s gate are used to slow down the turn-on rate of
the MOSFET.
D16 to D31-;
These Schottky diodes provide a path for the MOSFETs to rapidly dissipate their energy, i.e. turn off.
D12 & D14-;
These are source return diodes. These diodes recover charge for the voltage boost circuit when the
upper FETs are turned on. This allows the boost circuit to start at nearly the positive battery voltage
and work less hard to boost the drive voltage 10V higher.
R1/C2 & R10/C3-;
These are Motor RC-snubber networks. These components form an RC filter across the motor leads.
They absorb high-frequency noise and spikes to keep the battery supply voltage clean.
D15-;
It is a Power indicating LED. A red 5mm led.
Molex 70227 Header-;
Connects to the MOB via data cable and receives the data. Use a shrouded polarized connector with
locking tabs for maximum reliability under heavy vibration and shock loads.
HIP4081A-;
Full-bridge MOSFET driver . Also used in some of the Vantec controllers.
LM2574H VN-12-;
This is a Voltage Regulator Switching step-down regulator. Highly efficient at dropping high battery
supply voltages to a stable.
L1, D13, C5 -;
Voltage regulator support components.
These components are required for operation of the 2574 switching regulator. These components
work as a LC filter.

Electrical Wiring
Electrical wiring refers to the system of conductors & other devices that are used to carry electricity.
The wires used are comprised of electrical conductor made up of copper & other similar devices. The
wires are insulated in order to protect the conductor from becoming damaged. Insulation is made from
materials such as plastic & fibers.

Electrical bike in our e-bike would be done according to the following circuit. Different components
in the circuit & there working are given below-;
Sw1 & Sw2-;

These are the kill switches. A kill switch, also known as an emergency stop or e-stop, is
a safety mechanism used to shut off a device in an emergency situation in which it cannot be shut
down in the usual manner. Unlike a normal shut-down switch/procedure, which shuts down all
systems in an orderly fashion and turns the machine off without damaging it.

So whenever we press kill switch the circuits opens so no current will flow through the circuit &
hence this will stop the particular work.

VCC-;

This is the point which would be connected to the battery. So, all the current would be flowing
through this point.

J1 to 1(in the right)-;

These points are connected to the microcontroller. All the signals through microcontroller enters in
the circuit through these points.

SL1, SL2, SL3, SL4, SL5, SL6-;

These are the slots given for the attachment of the indicators, head light, tail light, horn etc. There are
2 wires attached to each slot i.e. 1 & 2

1= this wire receives current from the battery.

2= this wire is grounded.

K1, K2, K3, K4, K5-;

These are the switches which receives signals from the microcontroller.

When the switch receives the signal of +5v, it closes & the current starts flowing through the circuit.

Innovation

ESBS(Energy Storing and Boost System)

The development and research in the field of electric vehicle is the need of the hour. The people are
now inclined towards electric vehicles from the conventional mode of transportation, in times like
these innovative ideas are evolving.
We aim to make the electric bike more performance based by targeting at increasing the acceleration
of our vehicle by introducing ESBS(Energy Storing and Boost System). This system helps us store the
energy of the battery while our bike is idling, and then it can be used later at the disposal of the rider.
Construction
Basic components of the construction are
1. Weight Disc
2. Chain driven mechanism: to transmit power
3. Clutch assembly
4. The Weight Disc is connected with the motor by the chain linking mechanism, so that the
Weight Disc can be rotated by the motor when the clutch assembly is engaged.
Working
When the vehicle is idling, or when there is braking situation the motor gets connected to the Weight
Disc with a mechanism rather than the wheels. As we rev the motor the Weight Disc stores rotational
energy in it. We then disengage the Weight Disc from the motor and connect the wheels to the motor.
By this we store energy in the Weight Disc which can be used whenever needed by the rider.
By this we create a boost system for the bike which can be used to increase the pickup of the electric
bike, or may be used when the bike has to accelerate after braking in riding conditions.
Weight disc Calculation
Loss in energy of weight disc = Gain in kinetic energy of bike + Losses
½ Ifw(wi2-wf2) = ½ mvh(v2-u2) + losses
Losses = 50% of ½ Ifw(wi2-wf2) (Assumption)
Hence,
¼ Ifw(wi2-wf2) = ½ mvh(v2-u2)………………………………………………………. (1)
Maximum force applied by the motor on wheels, F = (id x 5 x 0.8)/0.3
(torquemotor = 5; efficiency = 0.8)
F = (5 x 5 x 0.8)/ 0.3 = 66.67 N
a = F/m
a = 66.67 / 180 = 0.37 m/sec2
Calculating velocity after 3 sec when weight disc is engaged:
Initial velocity of tire, u = 1.11 m/sec
Final velocity of tire, v = ?
Wi = (1500 x 2π)/60 = 157.08 per sec2 (rpm of weight disc = 1500)
Wf = 5v/r = 16.67v (gear reduction = 5; radius of tire = r = 0.3 m)
Ifw = 2 x(7 x 0.1202)/2 = 0.101
Putting the above in equation 1:
0.101(157.082 – (16.67v)2) = 2 x 180(v2-1.112)
V = 2.75 m/sec
Ultimate tensile force of chain drive = 8800 N
So, F = m(v-u)/t
t = 180 x (2.75 -1.11)/ 8800
t = 0.0335 sec
For safety impact time taken = 0.5 sec
So, velocity after 3.5 sec = 2.75 m/sec (using weight disc)
Velocity after 3.5 sec without using weight disc = 1.295 m/sec

Air cooled Motor

The development and research in the field of electric vehicle is the need of the hour. The people are
now inclined towards electric vehicles from the conventional mode of transportation, in times like
these innovative ideas are evolving.

We aim to make the electric bike more performance based by targeting at increasing the torque output
of our vehicle by introducing an innovative Cooling mechanism for the motor.

We know that by reducing the temperature of the motor, the torque output of the motor can be
increased. This increase in torque leads to the better acceleration.

We have designed fins which push the air towards the motor while the vehicle is running at
considerable speeds. By this the channelization of maximum air towards the motor is achieved which
cools it down.

Feasibility: our concept is highly feasible since the fins can be made easily in any manufacturing
spot.

Cost vs. Utility: The design and manufacturing of fins is very economical however they have an
important role in cooling the motor. Thus this design has an edge over cost vs. utility criteria.

Light Weight Frame

There are basically two approaches while designing the frame of any body. One is the top to bottom
approach where a frame with many number of cross and side beams are added and then tested. After
that one by one extra beam is reduced and the frame is tested making the frame as per the
requirement. This type of frame is comparatively strong but are heavy since there are extra number of
beams. The other way is the bottom to up approach where the basic frame of the vehicle is made and
then as per the strength requirement extra beams as cross or side members are added. This type of
approach is makes the frame light.

Effects on environment: the design of this entity only requires the computer software stimulation,
and manufacturing includes only the bending of pipes and the welding used is the metal inert gas
welding which are all pollution free processes.

This innovative frame is made by applying the concepts of beams bending and loading theories of
strength of material and is modified after testing again and again by stimulating. Thus the amount of
deflection is reduced and the safety factor is increased as much as possible. And thus an innovative
light frame is obtained which can on subjecting to even hard tests tolerates them with very less
deflections. These can be seen from the various stimulations.

Feasibility: The new design is feasible since it’s just made of pipes of the material AISI 1018 which
are easily available in the market. Welding and pipe bending is the only requirement process for the
design of the frame.

Cost VS Utility: Since weight plays a major factor in acceleration and performance of the vehicle, the
utility of a light weight frame is increased.
Light emitting diode (LED)
A light-emitting diode (LED) is a two-lead semiconductor light source. It is a pn-junction diode,
which emits light when activated. LEDs are small, durable and need little power. With the
development of high-efficiency and high-power LEDs, it has become possible to use LEDs in lighting
and illumination. Replacement light bulbs have been made.

As they consume very little power, our electric bike uses this technology rather than the conventional
lighting by bulbs. This gives us higher range, it is not expensive and most importantly, saves us
power. LED’s are lightweight and requires less maintenance too.

As in an electric bike the fuel which we use is the power from the battery, each and every component
which requires electric current to function acts as a parasite for the battery. So by using LED’s we in
turn are increasing the battery performance of the vehicle.

SOLAR CELLS
Solar energy is radiant light and heat from the sun harnessed using a range of ever-evolving
technologies such as solar heating, solar photovoltaic, solar thermal energy. A solar cell,
or photovoltaic cell, is an electrical device that converts the energy of light directly into electricity by
the photovoltaic effect.

Our team has tried to harness the same solar energy to charge the batteries of the e-bike. By this we
are saving electrical energy and using an abundant source of energy, that is, the sun.

The energy which we are getting from the solar cells is used to charge a small battery which is
responsible for the headlights, horn, and indicator. This helps us hugely, as we do not have to power
these components via the main battery connected to the motor. So the battery powers only the motor
as a result we get a better range. And it also reduces the number of connections on the main battery
thus resulting in fewer complications.
 ENVIRONMENT REPORT

These days the issue of global warming is the hottest topic of discussion from the conference rooms of
governments to that of the common man's dinner table. The emissions of the transportation sector have
been a major contributor to the problem of global warming. Also, due to the rising air pollution, many
lung and breathing problems have become common. Especially in the city limits, the authorities have
reported rising number of cases of asthma, bronchitis and other breathing problems. The smoke
generated due to the burning of the hydrocarbons in the fuel of vehicles causes air pollution and
hampers the aesthetic beauty of the surrounding. Also the fuel used in the vehicles i.e. petrol and diesel
are non-renewable source of energy and their rate of consumption is higher than their rate of production.

Now we are in the 21st century, we must be aware of our natural resources and try to limit their usage.
Cars are extremely harmful to our environment and contribute massively to the increasing problem of
global warming. To reduce greenhouse emissions and protect our environment, we must turn our
attentions towards alternative methods. Electric bikes are one of these favorable methods as they boast
zero-emissions technology. By choosing to cycle rather than drive you will be contributing towards a
cleaner and safer environment. Electric bike is the best option which one can opt for, the biggest benefit
is that they reduce the impact of the emissions of the transport sector into the atmospheric pollution as
well as to the global warming phenomena. Since, they run on electricity or are battery operated, so there
will be a substantial decrease in the rate of consumption of petrol and diesel.

E-bikes are zero-emissions vehicles, as they emit no combustion by-products. However, the
environmental effects of electricity generation and power distribution and of manufacturing and
disposing of (limited life) high storage density batteries must be taken into account. Even with these
issues considered, e-bikes will have significantly lower environmental impact than
conventional automobiles, and are generally seen as environmentally desirable in an urban environment.

One major concern is disposal of used lead batteries, which can cause environmental contamination if
not recycled. In this regard there should a check made on disposal techniques of the batteries and
methods of recycling and disposing off lead batteries should be improvised.

Adding to the above mentioned merits of an e-bike, we have solar cells used in our recharging unit,
Renewable energy is a necessity that is slowly being appreciated by everyone today. There are a
growing number of homes, buildings, outdoor establishments that utilize solar batteries. Sunlight is the
main source of energy which solar cells derive their power from. As long as the sun keeps shining, your
batteries never run out of power. Solar energy does not contribute to pollution. It is a renewable energy
that does not emit harmful toxins that destroy our environment.