DESIGN AND FABRICATION OF PORTABLE

ELECTRIC BIKE

SUBMITTED BY:
Under the guidance of
NAME USN NO GANGADHAR BIRADAR
AKASHKUMAR 3GN17ME401 Professor,
PANDURANGA 3GN17ME409 Department of Mechanical Engineering
PREMKUMAR 3GN17ME411 GNDEC BIDAR
RAHUL.H 3GN16ME075
ABSTRACT:

There is growing demand for electric bikes in India as there will be less air
Pollution and Less maintenance Cost and Reduced noise by Using Electric
bikes. Battery powered electric scooters, replacing the heavily polluting
scooters with 2-cycle internal combustion engines to provide zero-
emission transportation for many parts of the world. Electric motorcycles
and scooters are plug-in electric vehicles with two or three wheels
powered by electricity. The electricity is stored on board in a rechargeable
battery, which drives one or more electric motors. By making it light in
weight and compact in size it will be adoptable, need of parking place is
less.
LITERATURE REVIEW:

Kunjan B. Shinde student of Lokmanya Tilak College of Engineering,

Koparkhairane, Navi Mumbai currently pursuing my final year of engineering
and working on final year project named ‘Design and Fabrication of Electric
Bike’ and research on the same topic as well. I have done Diploma in
Mechanical Engineering from Larsen & Toubro Institute of Technology (2010-
2014), Powai, Mumbai and passed with distinction class. I have participated
technical project competition in my final year of diploma. I have done
internship in year June 2012-5th sem and Jan 2014-8th sem in Larsen & Toubro
ltd. I aspire to pursue Masters in Fluid Engineering and Machinery. (IJRMET
Vol. 7, Issue 1, Nov 2016 - April 2017).
INTRODUCTION :

Electric Bikes consist of a modified or custom bicycle frame with pedals but
include an electric motor, usually in the form of a hub motor, mid-drive motor or
belt drive connected to the rear wheel. They allow a rider to either pedal the bike
or leverage the power of a battery and motor drive system. To use an electric bike
you have to charge the battery, turn the controller system on and then twist a
throttle, pull a trigger or pedal the bike forward to initiate the motor drive system.
Throttle only drive behaves much like a traditional gas powered scooter because
the rider doesn’t have to pedal, the bike just goes! By contrast, pedal-assist mode
uses the rider’s input as the throttle signal and is more popular in Europe where
bicycle laws are a bit more restrictive regarding motor and battery power.
European bikes are usually limited to 250 Watt motors whereas the US has many
bikes with motors as strong as 500 or even 600W.
1.1. Importance of electric vehicles:

During the last few decades, environmental impact of the petroleum-based

transportation infrastructure, along with the peak oil, has led to renewed
interest in an electric transportation infrastructure. Electric vehicles differ
from fossil fuel-powered vehicles in that the electricity they consume can be
generated from a wide range of sources, including fossil fuels, nuclear
power, and renewable sources such as tidal power, solar power, and wind
power or any combination of those. An electric vehicle (EV), also referred to
as an electric drive vehicle, uses one or more electric motors or traction
motors for propulsion. Three main types of electric vehicles exist, those that
are directly powered from an external power station, those that are powered
by stored electricity originally from an external power source, and those that
are powered by an on-board electrical generator, such as an internal
combustion engine (a hybrid electric vehicle) or a hydrogen fuel cell.
1.4. Environmental effects:
E-bikes are zero-emissions vehicles, as they emit no combustion by-products.
However, the environmental effects of 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 are claimed to have
a significantly lower environmental impact than conventional automobiles, and are
generally seen as environmentally desirable in an urban environment.
The environmental effects involved in recharging the batteries can of course be
reduced. The small size of the battery pack on an e-bike, relative to the larger pack
used in an electric car, makes them very good candidates for charging via solar
power or other renewable energy resources. Sanyo capitalized on this benefit when
it set up "solar parking lots", in which e-bike riders can charge their vehicles while
parked under photovoltaic panels.
OBJECTIVE’S:

 To make power assisted electric bike.

 To make the electric bike light in weight and compact in size.
METHODOLOGY :
Design and development

Selection of material

Fabrication of chassis

Assembly of bike components

Testing of bike
TECHNICAL SPECIFICATIONS
• Folded size 13" x 24" x 35"
• Weight of model 18kg
• Weight of Rider 80kg
• Folding time 15 seconds
• Tires Kenda 20 (406mm) x 1.5" front and 20 (406mm) x 1.75" rear
• Height of model 80cm (32")
• Length of model 130cm(52")
•
 2. Components
2.1 Battery

Sealed Lead-Acid battery:

A sealed lead acid battery or gel cell is a lead acid battery that has the sulphuric
acid electrolyte coagulated (thickened) so it cannot spill out. They are partially sealed, but
have vents in case gases are accidentally released for example by overcharging. They can
be used for smaller applications where they are turned upside down. They are more
expensive than normal lead acid batteries, but they are also safer. They use different
chemicals than dry cells, so they are rechargeable. It contains plates of lead and lead (IV)
oxide in a sulphuric acid solution. The lead (IV) oxide oxidizes the lead plate, making
an electrical current.
2.2. Motor:

24v dc motor, 13.7 amps, output 250watt

DC Motor Principle a machine that converts dc power into mechanical energy is known as
dc motor. Its operation is based on the principle that when a current carrying conductor is
placed in a magnetic field, the conductor experiences a mechanical force.
2.3 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. It takes all the inputs from
all the other components and determines what should be signaled to them in return. The
controller has to be fitted to the other parts.
3. Materials and design

3.1. Chassis
The material Used for chassis is mild steel square tube of 16 gauge.
 
Mild steel (iron containing a small percentage of carbon, strong and tough but not
readily tempered), also known as plain-carbon steel and low-carbon steel, is now the
most common form of steel because its price is relatively low while it provides
material properties that are acceptable for many applications. Mild steel contains
approximately 0.05–0.25% carbon making it malleable and ductile. Mild steel has a
relatively low tensile strength, but it is cheap and easy to form; surface hardness can
be increased through carburizing
In applications where large cross-sections are used to minimize deflection, failure by
yield is not a risk so low-carbon steels are the best choice, for example as structural
steel. The density of mild steel is approximately 7.85 g/cm3 (7850 kg/m3) and
the Young's modulus is 200 GPa (29,000 ksi).
3.2. Shaft
The material Used for shaft is bright Rod.

Bright Bars are cold drawn/ground/peeled plain bars produced from hot rolled plain
bars/wire rods. Bright Bars have a smooth and a bright surface with Accurate Tolerance
on the dimensions, they possess improved mechanical properties, greater dimensional
accuracy, better surface integrity and higher machinability, and these superior product
qualities provide a number of significant design advantages & benefits.  Advantages
achieved include improved machining, less wastage at component production stage,
enhancement of physical and mechanical properties and improved dimensional
tolerances and straightness
 3.3 Sprocket and Chain:

 
A sprocket or sprocket-wheel is a profiled wheel with teeth, or cogs, that mesh with
a chain, track or other perforated or indented material. The name 'sprocket' applies generally
to any wheel upon which radial projections
From a gear in that sprockets are never meshed together directly, and differ from a pulley in
that sprockets have teeth and pulleys are smooth. Sprockets are used
in bicycles, motorcycles, cars, tracked vehicles, and other machinery either to transmit rotary
motion between two shafts where gears are unsuitable or to impart linear motion to a track,
tape etc. Perhaps the most common form of sprocket may be found in the bicycle, in which
the pedal shaft carries a large sprocket-wheel, which drives a chain, which, in turn, drives a
small sprocket on the axle of the rear wheel. Early automobiles were also largely driven by
sprocket and chain mechanism, a practice largely copied from bicycles.
 
 Roller Chain:

The original Roller chain or bush roller chain is the type of chain drive most commonly
used for transmission of mechanical power on many kinds of domestic, industrial and
agricultural machinery, including conveyors, wire-and tube-drawing machines, printing
presses, cars, motorcycles, and bicycles. It consists of a series of short cylindrical rollers
held together by side links. It is driven by a toothed wheel called a sprocket. It is a
simple, reliable, and efficient means of power transmission. The roller chain design
reduces friction compared to simpler designs, resulting in higher efficiency and less
wear.
3.4.Bearings:

A ball bearing is a type of rolling-element bearing that uses balls to maintain

the separation between the bearing races. The purpose of a ball bearing is to
reduce rotational friction and support radial and axial loads. It achieves this by
using at least three races to contain the balls and transmit the loads through
the balls. In most applications, one race is stationary and the other is attached
to the rotating assembly (e.g., a hub or shaft). As one of the bearing races
rotates it causes the balls to rotate as well. Because the balls are rolling they
have a much lower coefficient of friction than if two flat surfaces were sliding
against each other.
 4. Fabrication.

4.1 Arc welding:

Arc welding is a process that is used to join metal to metal by using electricity to
create enough heat to melt metal, and the melted metals when cool result in a
binding of the metals. It is a type of welding that uses a welding power supply to
create an electric arc between an electrode and the base material to melt the metals at
the welding point
4.2 Drilling:

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in

solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit
is pressed against the work-piece and rotated at rates from hundreds to thousands
of revolutions per minute. This forces the cutting edge against the work-piece, cutting
off chips  from the hole as it is drilled. Drilled holes are characterized by their sharp edge
on the entrance side and the presence of burrs on the exit side (unless they have been
removed). Also, the inside of the hole usually has helical feed marks.
4.3 Fasteners:

A fastener (US English) or fastening (UK English) is a hardware device that

mechanically joins or affixes two or more objects together. In general, fasteners are
used to create non-permanent joints; that is, joints that can be removed or dismantled
without damaging the joining components. Welding is an example of creating
permanent joints. There are three major steel fasteners used in industries: stainless
steel, carbon steel, and alloy steel. The major grade used in stainless steel fasteners:
200 series, 300 series, and 400 series.
5. Calculations:

Here we have used dc motor with 250 watt power and 2100rpm. The motor runs on
24volts and 7.5amps power source.
Therefore available torque is
P = 2* π* N* T/ 60
250 = 2*3.14*2100*T/60
T = 1.1368 N-m.
T = 1136 N-mm.
Reduction in chain drive:
R chain = 36/6 = 6:1
Torque at wheel shaft = T x R chain = 1136 x 6 = 6820 N mm.
Speed of wheel shaft = 2100 /6 = 350 rpm.
 
Required torque;
TR = mass (kg) * acceleration due to gravity *co efficient of friction * radius of
wheel(m) = 50*9.81*0.5*0.1
TR = 24.52 N-m.
SHAFT DESIGN:
Bending: The force which develops across a specific cross section of the shaft, it
generates stress at that point of cross section that are subjected to maximum loading.
This internal or resisting moment gives rise to the stress called as bending stresses.
Torsion: When the shaft which is twisted by the couple such that the axis of that
shaft and the axis of the couple harmonize, that shaft is subjected to pure torsion and
the stresses generated at the point of cross section is torsion or shear stresses.
Combined Bending and Torsion: In actual practice the shaft is subjected to
combination of the above two types of stresses i.e. bending and torsion. The bending
stresses may occur due any one of the following reasons:
1. Weight of belt
2. Pull of belts
3. Eccentric Mounting of shafts/gears
Shear stress,
Allowable shear stress = 80 N/mm2
TW = 3.14 / 16 * τ * d3
6820 = 3.14/16 *τ*103
τ = 34.73 N/mm2.
Material = C 45 (mild steel)
σ ut = 320 N/mm2 ------------ K Balveera reddy design data book.
Factor of safety = 2
σt = σb = σ ut/ fos = 320/2 = 160 N/mm2
τ = 0.5 σt = 0.5 x 160 = 80 N/mm2
τ is less then or equal to allowable so our shaft design is safe.
Notations
σt = torsion stress
σb = bending stress
σut = ultimate stress
τ = shear stress
ADVANTAGES

1.Health Benefits

2.Traffic Road safety

3.Environmental effect

4.Energy efficiency
DISADVANTAGES

1.only one seat carrying capacity

2.power and pick-up

3.over charging battery

COST ESTIMATION:
SR. NO. MATERIAL REQUIREMENT COST PER UNIT TOATAL COST

1 Battery 12V (2) 3000 6000

2 Motor 250W(1), 24 V 5000 5000

3 Controller 12A(1) 2000 2000

4 Handle bar 1 550 550

5 Throttle 1 900 900

6 Wheel assembly 1 1400 1400

7 M S square tube 5 to 7 kg 100 700

8 Miscellaneous   2000 2000

TOTAL COST 18550/-

REFERENCES
 

1) Electric Bicycle (a guide to use) by William C. Morchin , Henry Oman.

2) International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 3, March 2017, pp. 245–253 Article ID: IJMET_08_03_027.

3) Manufacturing Science, by Amithabh gosh and Ashok Kumar Mallik.

4) Design data hand book, by K. Balveera reddy.

5) Manufacturing Process-III, by Kestoor Praveen.

6) www.diva-portal.se/smash/get/diva2:232518/FULLTEXT01.pdf
7) https://www.scribd.com/doc/29308223/project-report-on-electronic-bikes-e-bikes
8) 197.14.51.10:81/pmb/.../Battery%20Technology%20Handbook/DKE39_CH01.pdf
Conclusion:
With the increasing consumption of natural resources of petrol, diesel it is
necessary to shift our way towards alternate resources like the Electric bike and
others because it is necessary to identify new way of transport. Electric bike is a
modification of the existing cycle by using electric energy and also solar energy
if solar panels are provided, that would sum up to increase in energy
production. Since it is energy efficient, electric bike is cheaper and affordable to
anyone. It can be used for shorter distances by people of any age. It can be
contrived throughout the year. The most vital feature of the electric bike is that
it does not consume fossil fuels thereby saving crores of foreign currencies. The
second most important feature is it is pollution free, eco – friendly and noiseless
in operation. For offsetting environmental pollution using of on – board Electric
Bike is the most viable solution. It can be charged with the help of AC adapter
if there is an emergency. The Operating cost per/km is very less and with the
help of solar panel it can lessen up more. Since it has fewer components it can
be easily dismantled to small components, thus requiring less maintenance.
 
THANKS