Indigenous Design and Fabrication of Electric Bicycle with Regenerative Braking System

This project revolves around two wheeler E-Bike with specification of Regenerative Braking System . Car alternator as a Motor .Project provides the making of an electric bicycle using spare parts of car and connecting them with different circuits to produce cheap and efficient bicycle with the abili

Project Title

Indigenous Design and Fabrication of Electric Bicycle with Regenerative Braking System

Project Area of Specialization

Robotics

Project Summary

This project revolves around two wheeler E-Bike with specification of Regenerative Braking System . Car alternator as a Motor .Project provides the making of an electric bicycle using spare parts of car and connecting them with different circuits to produce cheap and efficient bicycle with the ability of regeneration for longer battery life. There are four main subsystems, the first subsystem is conversion of alternator into motor which includes its linkage with controllers. The second subsystem is designing of regenerative circuit. The third subsystem is designing of battery while the fourth subsystem deals in the dimensions and connectivity of all circuits. The type of this bicycle is pedal-assist.

Project Objectives

Following are the main objectives of the project:

• Design an economical and efficient bicycle with low maintenance cost.
• To have regeneration for increase battery life.
• Altenator modelling in ANSYS Maxwell Software.
• Design of Regeneration Ciruit with proper protection.
• Controlling of Regeneration Circuit with Arduino Nano.

Project Implementation Method

Motor is operating with 48V Controller through DC battery where as field of the motor is supplied 12V  for exitation ,as the motor starts further it is controlled by throttle for changing the speed accordingly,  When brakes are applied during the movement of the Bike the existing inertia of the bike results in back emf from the alternator which charges the battery ,while charging with back EMF during regenration process , the fuction of BMS battery management system here plays a vital role with feeding the power back equally to the battery. Circuit breakers are used in between battery and motor in case of fault the breakers trip while circuitry remain safe.

Following are the parameters which has studied for the implementaion of the final product ( E-bike ):

• Study and Selection of Motor .
• Study and Selection of Battery.
• Selection of DC Drive.
• Selection of Switching Methodology.
• Selection and Logic of Circuit Breakers.
• Selection light bike body frame.

Benefits of the Project

The project " ELECTRIC BIKE " has various benefits in terms of Green environment ,  Nature Friendly , Assisted Pedaling , low purchasing cost , Practically zero fuel expenses as compare with IC engine bikes, improve fitness etc .

Following are the main benifits of the project :

• Regenerative braking will increase Mileage.
• Economical Transport alternative compared to IC Engine Vehicle.
• Motor Propulsion will allow Noise Free Transport.
• Zero fuel combustion will result in zero Carbon Emission

Technical Details of Final Deliverable

1. Prototype of E-Bike:  A Car Alternator converted into motor propels a bicycle frame. More features of the prototype includes Throttle , Brushless Motor Controller, Regeneration Module,Relay Module, DC Drive,Arduino Module, Battery Pack and suitable Drive Train.
2. DC Drive: A compact DC drive is designed to output 48V, 12V and 5V DC.
3. Relay Module: This module is designed to isolate motor power input and machine output during regeneration. Apart of the module also control the Field Excitation of motor.
4. Regeneration Module: This module converts 3-phase AC output of the machine to DC and step ups these voltages to 54V. 
5. Battery Pack: A 13S Li-Po battery pack is prepared to power the E-bike.
6. Arduino Module: This module controls and moniters battery power, regeneration and the motor speed.

Final Deliverable of the Project

Hardware System

Type of Industry

Energy , Transportation

Technologies

Clean Tech

Sustainable Development Goals

Affordable and Clean Energy, Sustainable Cities and Communities, Climate Action, Life on Land

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com