A TECHNICAL REPORT ON THE DESIGN OF

ELECTRIC BICYCLE
BY GROUP 3B

18/EG/ME/1253 - Udokang, Gabriel Bassey

18/EG/ME/1273 - Edidiong, Emmanuel Okon
18/EG/ME/1283 - Offiong, Praise David

DEPARTMENT OF MECHANICAL AND AEROSPACE

ENGINEERING,
FACULTY OF ENGINEERING

TO BE SUBMITTED TO

THE LECTURER IN- CHARGE

DR. ANIEKAN OKON

APPLIED DESIGN 1
DEPARTMENT OF MECHANICAL AND AEROSPACE
ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITY OF UYO

JANUARY,2022
 TABLE OF CONTENT
Cover page…………………………………………………
Table of Content………………………………………
Introduction…………………………………………………
Problem definition……………………………………………
Objective of the design………………………………………
Specific Objective…………………………………………
Schematics (3-D sketch of the system)……………………
Stress analysis of the system (forces acting and stability)
Design and Dimension of members (components design)
Specification of Basic Components Parts………………
Material selection for each
member/component………………………………………
Exploded view of the system…………………………………
Different views of the assembled
system…………………………………………………..
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. Our project
proposes the solution for this above perilous problems. The
system which we innovated is the Electric Bike. This project
has various benefits both to the members of the group and
also external 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 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.

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PROBLEM DEFINTION

The central challenge in designing an electric bicycle lies in

achieving a harmonious integration of various components to
create a reliable, efficient, and user-friendly mode of
transportation. Critical aspects include addressing the
balance between weight distribution, battery capacity, and
the overall structural integrity of the bicycle.

Understanding the intricacies of these factors is vital for

developing a design that meets both performance and
sustainability objectives. The challenge extends to
accommodating the additional components required for
electric propulsion without compromising the bicycle's
traditional functionalities.

Factors such as aerodynamics, stability, and rider comfort

must be carefully considered to overcome the challenges
associated with integrating electric components into a
conventional bicycle framework. The problem definition also
encompasses anticipating potential issues related to power
delivery, charging infrastructure, and user interface design.

Additionally, safety considerations play a pivotal role in

problem definition, ensuring that the electric bicycle

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complies with regulatory standards and provides a secure
riding experience. Addressing these multifaceted challenges
requires a comprehensive understanding of mechanical
engineering, electrical systems, and sustainable design
principles.

The goal is not merely to create an electric bicycle but to

devise a solution that seamlessly marries the electric
propulsion system with the inherent characteristics of a
bicycle, presenting a holistic approach to sustainable urban
mobility. This problem definition sets the stage for the
subsequent stages of the design process, guiding the team
toward innovative solutions that align with the overarching
objectives of efficiency, sustainability, and user satisfaction.

OBJECTIVE OF DESIGN

The objective of the standard electric bicycle design is to

create a reliable, efficient, and user-friendly urban
commuting vehicle that aligns with industry best practices
and user expectations. The design aims to achieve several
key objectives:

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1. Sustainable Transportation: Promote eco-friendly
commuting by using electric power, reducing dependence on
fossil fuels and minimizing environmental impact.

2. Efficient Urban Mobility:Provide a mode of transportation

that addresses the challenges of urban congestion and offers
an efficient, maneuverable solution for city commuting.

3. User-Friendly Operation:Design an electric bicycle that is

easy to operate, catering to a wide range of users, including
both seasoned cyclists and those new to cycling.

4. Optimal Power and Range:Balance motor power and

battery capacity to achieve an optimal range for daily
commuting needs, ensuring the electric bicycle can cover
typical urban distances.

5. Safety: Prioritize safety features, including effective

braking systems, proper lighting, and a robust frame
structure to enhance rider safety in diverse urban
environments.

6. Comfortable Riding Experience:Focus on ergonomics and

comfort, incorporating features such as a step-through frame,

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suspension system, and a comfortable saddle to enhance the
overall riding experience.

7. Versatility:Design a versatile electric bicycle capable of

handling different terrains, including city streets and light
off-road paths, offering users flexibility in their commuting
routes.

8. Intuitive Control and Display:Develop an intuitive control

system and display panel that allows users to easily manage
power settings, monitor battery levels, and control additional
features for a seamless riding experience.

9. Durability and Reliability:Ensure the durability and

reliability of components through rigorous testing and
material selection, minimizing maintenance requirements
and enhancing the lifespan of the electric bicycle.

10. Affordability:Strive to make the electric bicycle design

affordable and accessible to a broad range of users,
promoting widespread adoption of sustainable transportation
solutions.

12. Ease of Maintenance:Design components with

accessibility in mind, facilitating easy maintenance and

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repairs, which can contribute to the long-term usability of the
electric bicycle.

13. Aesthetic Appeal:Consider the visual design to create an

aesthetically pleasing and modern electric bicycle that
attracts users and aligns with contemporary design trends.

SPECIFIC OBJECTIVES
The individual steps taken in order to execute the project.

• The design process: This is out using Fusions 360,a CAD

software.
• Production and assembly
• Testing

COMPONENTS OF AN ELECTRIC BICYCLE

1. Frame:The frame is the structural foundation of the

electric bicycle, providing support and housing for various
components. It is designed to be sturdy, lightweight, and
durable.

2. Motor:The electric motor is the heart of the e-bike,

providing the necessary power for propulsion. It can be

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located in the hub of the wheel (hub motor) or integrated into
the frame (mid-drive motor).

3. Battery:The battery stores electrical energy to power the

motor. Typically, lithium-ion batteries are used for their
energy density and weight-to-power ratio.

4. Controller:The controller manages the flow of electric

current from the battery to the motor, regulating speed,
power output, and other parameters.

5. Throttle:The throttle is a user interface that controls the

speed of the electric bicycle. It can be a twist grip on the
handlebar or a thumb lever.

6. Pedal Assist System (PAS):PAS is a sensor-based system

that adjusts the level of motor assistance based on the rider's
pedaling. It enhances efficiency and extends the bike's range.

Other components includes Brakes,Gears,Wheels and

Tires,Suspension, Lights,Fenders and Racks,Pedals and
Saddle, Display/Control Panel,kickstand, bell, chain guard,
and other accessories that enhance the convenience and
usability of the electric bicycle.

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SCHEMATICS (3-D SKETCH OF THE SYSTEM)

STRESS ANALYSIS AND TESTING

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DESIGN AND DIMENSIONS OF THE BASIC
COMPONENTS PARTS

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FRAME AND FORK

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HANDLE BAR

SEAT COVER OR SADDLE

12
13
14
CHAIN AND CHAIN RING

15
WHEEL,TIRE AND SPROCKET

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BATTERY AND BATTERY HOUSING

SPECIFICATION OF VARIOUS COMPONENTS

MOTOR SPECIFICATION:

1. Motor Type: 350W Rear Hub Motor

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 Power (W) = Force (N) × Speed (m/s)
- Example: 200N force × 1.75 m/s speed = 350W

2. Power Rating:Nominal Power: 350 Watts,Peak Power: 700

Watts (Assuming a peak-to-nominal ratio of 2:1)
3. Torque:
- Torque = Power / Angular Speed
- Assuming nominal angular speed (ω_nominal) of 200
RPM

w = 200RPM\60 × 2Π
w = 20.944 rad/s
Now, substitute these values into the torque formula:

T = 350 watts\ 20.944

T = 16.707 Nm

4. Efficiency = 90% (0.9) ( The remaining 10% is assumed to

be lost through heat and other factors)
5. Voltage: Typically designed for 36V for standard e-bike
systems
Power = Voltage(V) ×Current (I)
350W = V × I × 0.9
Nominal Current is 10amps

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V = 350 watts\ 10 amps × 0.9
V = 38.89 volts
6. Weight: 4kg for the motor
7. Motor Size: - Diameter: 200 mm (approx.)
- Width: 120 mm (approx.)

BATTERY SPECIFICATION:
Battery type : 36V 10Ah Lithium-ion Battery
Battery Capacity (Ah) = Power (W) × Time (hours) / Voltage
(V)
- Example: 350W motor × 2 hours / 36V = 19.4Ah
(rounded up to 20Ah)

FRAME SPECIFICATION:
Aluminum Alloy Frame (Step-through design)
- - Considered for weight and strength.
- Analyze stress on the frame.
Frame Size :Medium Size - Determined based on rider
height and inseam length.

4. CONTROLLER: Integrated Controller

- Selected based on motor and power requirements.

5. THROTTLE:
- Twist-Grip Throttle

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 - Chosen for ease of use and control.

6. PEDAL ASSIST SYSTEM (PAS:Multi-level PAS)

7. DISPLAY/CONTROL PANEL: LCD Display with

Control Buttons:
- Selected for clear visibility and user-friendly
interface.

8. BRAKE SPECIFICATION:
- Hydraulic Disc Brakes
- Chosen for effective stopping power.
- Formula: Braking Force = Mass (kg) × Acceleration
(m/s^2)

GEARS:
7-Speed Shimano Derailleur
- Selected for versatility. - Formula: Gear Ratio = Front
Chainring Teeth / Rear Cog Teeth

WHEELS AND TIRES

27.5" Wheels with Hybrid Tires
- Wheel Size: 27.5 inches
- Rim Material:Aluminum Alloy
- Rim Width: Optimized for Tire Size

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- Hubs: Boost Spacing, Front and Rear
- Spokes: Stainless Steel, Double Butted
- Nipples: Brass
- Tires:
- Type:Tubeless-Ready
-Size:2.4 inches (width)
- Tread Pattern:All-Terrain, Suitable for Trail Riding
- Pressure: Adjustable based on Rider Preference and
Terrain
- Axles: Quick Release or Thru-Axle (Front: 15x110mm,
Rear: 12x148mm)
- Wheel Weight:Balanced for Performance and Durability

- Considered for urban and light off-road use.

SUSPENSION:

Front Fork Suspension - Determined based on terrain and

comfort requirements.

LIGHTS SPECIFICATION - Integrated LED Light

- Chosen for visibility.
- Evaluated lumens required.

FENDERS AND RACKS:

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Full Fenders and Rear Rack - Selected for mud protection
and cargo-carrying capability.

RIDER SPECIFICATIONS:

- Height: 5'5" to 6'2"

- Weight: Up to 220 lbs
- Riding Style: Casual Commuting, Recreational
- Skill Level: Beginner to Intermediate
- Riding Position: Upright, Comfort-oriented
- Age Group: Adults (18+)
- Gender: Unisex Design
- Clothing: Compatible with Standard Cycling Attire
- Fitness Level: Moderate
- Health Considerations: No Severe Restrictions
- E-Bike Experience: No Prior Experience Required
- Footwear: Standard Athletic or Casual Shoes

MATERIAL SELECTION

Components Material Selection

Frame Aluminum Alloy
Fork Aluminum Alloy

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Rear suspension Elements Aluminum Alloy
Handle Bars Aluminum Alloy
Stem Aluminum Alloy
Saddle or Seat cover Synthetic material
Pedal Composite material
Crankset Carbon Fiber
Battery cells Lithium ion(Li-ion)
Battery Housing High impact Plastic
Motor Copper
Chain Stainless steel
Chain ring Stainless steel
Tires Rubber for thread and
Kevlar for puncture
resistance
Spokes Stainless steel
Fenders Plastic
Wheels(Rim) Aluminum alloy
Kickstand Steel Alloy
Brake Callipers Stainless steel
Lights Plastic and Aluminum

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 Alloy

DIFFERENT VIEWS OF THE ASSEMBLED PART

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EXPLODED VIEW

SOFTWARE USED

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Fusion 360 was the primary software utilized for the design
of the Electric bicycle. Chosen for its versatility and
powerful features, Fusion 360 offered several advantages
over other design software, contributing to a streamlined and
comprehensive design process which are:

1. Parametric Modeling:
Fusion 360 supports parametric modeling, allowing for the
creation of intelligent 3D models with dynamic dimensions
and relationships. This feature enhances design flexibility
and facilitates quick adjustments during iterations.

2. Integration of CAD and CAM:

Fusion 360 seamlessly integrates computer-aided design
(CAD) and computer-aided manufacturing (CAM). This
integration streamlines the transition from design to
manufacturing, ensuring that the design intent is preserved
throughout the entire product development process.

3. Cloud-Based Collaboration:
Fusion 360's cloud-based platform enables real-time
collaboration among team members, regardless of
geographical location. This feature fosters efficient
communication and enhances teamwork during the design
phase.

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4. Simulation and Analysis Tools:
Fusion 360 incorporates robust simulation and analysis tools,
allowing for stress testing, thermal analysis, and virtual
prototyping. This capability ensures that critical components,
such as the frame and motor, meet safety and performance
standards.

5. Ease of Use: Fusion 360 is known for its user-friendly

interface and intuitive design tools. This ease of use
facilitates a smoother learning curve for designers and
engineers, contributing to increased efficiency in the design
process.

7. Regular Updates and Improvements:

Autodesk consistently updates and improves Fusion 360,
introducing new features and functionalities. This ensures
that the software stays at the forefront of design technology
and provides access to the latest tools for continuous
improvement.

8. Cost-Effective Licensing Model:

Fusion 360 offers a cost-effective subscription-based
licensing model. This makes it accessible to both individual

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designers and larger design teams, providing flexibility in
terms of budget considerations.

9. Comprehensive Design Capabilities:

Fusion 360 encompasses a wide range of design capabilities,
from 3D modeling to rendering and animation. This
comprehensive set of tools allows for an all-encompassing
approach to electric bicycle design within a single software
environment.

CHALLENGES FACED

Our team faced lots of challenges during the project work

that hindered us from achieving some part of our objectives

1. Battery Technology Limitations:

Balancing energy density, weight, and cost in battery design.
Finding a battery that meets performance requirements
without compromising other aspects can be challenging.

2. Range Optimization:
Determining the optimal balance between motor power and
battery capacity to achieve a satisfactory range for the
electric bicycle, considering real-world usage scenarios.

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3. Low power supply : We consistently experienced power
black out during our job and as such delayed the designs of
the project work.

4. Cost Constraints:
Designing an electric bicycle that is cost-effective while
maintaining quality. Balancing the cost of components,
manufacturing, and materials was a continuous challenge.
6. Technological Advancements:
We had challenge Keeping up with rapidly evolving
technologies in electric propulsion, battery chemistry, and
smart connectivity to ensure the design remains competitive
and up-to-date.
7.Environmental Impact: During our Design,we were
affected so much by Environmental Conditions

CONCLUSION

The number of automobiles on the roads throughout the

globe is increasing at a staggering rate year by year, but the
dependence on oil based fuel grows almost unchecked. Due
to this, electric vehicles come into the picture as an
alternative. The need for an affordable and efficient mode of
transport created a growing demand for electric motorcycles.

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This research is taken as an opportunity, rather than a
challenge to design and develop the best in class electric
bicycle for the quotidian commute.

REFERENCES

• Ken Hurst, Kenneth S. Hurst Wiley, 1999 – Technology &

Engineering
• Mc Gill, 2023 – Engineering design, fundamental design
principles.
Aikenhead, G. S. (2011). Bicycle Applications for On-Board
Solar Power Generation. 9,10.
Barve, D. S. (2016). Design and Development of Solar
Hybrid Bicycle. International
Journal of Current Engineering and Technology,
377,378,379,380.
Journal of Current Engineering and Technology, 378,379.
Barve, D. S. (March 2016). Design and Development of
Solar Hybrid Bicycle. International
Research in Engineering and Technology (IJARET)Volume
5, Issue 6, June (2014), pp. 68-76
[11] T.Bhavani. (April 2015). Novel Design of Solar Electric
Bicycle with Pedal. International

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