Development Of Retro-fit Electric Bike

Project Title

Development Of Retro-fit Electric Bike

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Fossil fuels have been a significant part of creating today’s world, and as the population increases so does the need for fossil fuels. This utilization of fuel brought pollution and an Earth-wide temperature boost. As a large portion of the fuel is utilized in transportation, we are searching for a different option, hence an Electric bike. A conventional bike is helpful especially in an urban environment, as it can accommodate two people and can be utilized to run small errands. In any case, it is not eco-friendly. Hence, the need for an Electric Bike, it can in any case do the same kind of work but with no pollution. However, the main issue with E-bike is the range, to resolve this we are using a BLDC motor with an efficient rechargeable battery to increase the range which somehow competes with a conventional bike and is more economical.

Project Objectives

The primary constraints of an EV are the batteries' capacity to provide enough energy for a driving range equivalent to gasoline-powered automobiles. To mitigate this challenge, the speed of the BLDC motor in an electric bike using an efficient battery system and a microcontroller to control the speed of the motor for the extended range is taken into consideration. The main objective of the project is to convert a motorcycle into an electric bike using a hub BLDC motor in place of the combustion engine and design a microcontroller to control the speed of the motor in an efficient and reliable way. As the global oil prices are at an all-time high an E-bike will be able to compete with its combustion engine counterpart, providing low maintenance costs and low running costs in the long run.

Project Implementation Method

The methodology for this project is to design a speed control motor controller, using Arduino UNO as the brain and using a PWM signal to control the speed of the BLDC hub motor. Pulse width modulation turns a digital signal into an analog signal by changing the timing of how long it stays on and off. To replace the combustion engine in the bike, we are using a BLDC hub motor which will be installed at the back wheel. The batteries we are using are Lithium-ion batteries as they are reliable, lightweight, and compact, has a high energy density, have more charge cycles, and low self-discharge rate.

Benefits of the Project

As the fuel prices are at all-time high and fuel reserves to go dry in the future, the only thing to replace fuel is electricity. Electric vehicles are popular in the world as they are very low maintenance and eco-friendly. Bikes have been part of our culture since the beginning of the automotive industry as they are cheap to buy and can be used in cities where traffic is an issue. The electric bike is targeted at people who ride to run errands closer to their homes or can be used in an urban environment. This type of use is highly recommended as it will not affect the environment as much as its combustion engine counterparts, and won’t cost the user as much as its counterpart.

Technical Details of Final Deliverable

The traditional internal combustion engine bike is converted to an electric bike using a 60V 1.5KW Sensored Brushless Direct Current motor. This hub motor is fitted to a rear wheel in such a way that gives the maximum amount of power produced by the motor. The BLDC motor is controlled with the help of a sine wave controller. The controller is designed with the help of 6 power MOSFETS, 3 IGBT MOSFET drivers; used for controlling the input high and low states. The drives are fed with a Pulse Width Modulation (PWM) input which is generated through an Arduino UNO microcontroller. This microcontroller provides 5V p-p input for an input high and low state. The microcontroller is programmed in a way that synchronizes the output of hall sensors of the motor with the logic defined for maximum speed and efficiency of the motor. Through this logic, the MOSFETs are switched at high speed for either increasing or decreasing the speed. The other main block of this project is the battery pack which determines the range of travel. The bigger the battery pack the more range is achieved. This battery pack is managed using a Battery Management System which controls the overflow of current, short circuitry, and cell balancing to enhance the life of the battery pack. The traditional bike is converted to retro-fit using a few mechanical adjustments for the battery pack and controller.

Final Deliverable of the Project Hardware SystemCore Industry TransportationOther Industries Energy Core Technology OthersOther Technologies RoboticsSustainable Development Goals Affordable and Clean EnergyRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	79200
1.5KW BLDC Motor	Equipment	1	28000	28000
Battery Pack	Equipment	1	40000	40000
Throttle	Equipment	1	1200	1200
Frame	Miscellaneous	1	6000	6000
Electronic Equipment	Miscellaneous	1	4000	4000