DESIGN AND FABRICATION (DEVELOPMENT) OF E-BIKE

K. Sai Chandu, G M V. Siva Kumar, G. Kannaji, K. Kiran Kishore

U.G Student , Bachelor of Engineering, Department of Mechanical Engineering . Avanthi Institute of Engineering &
Technology, Narsipatnam , Andhra Pradesh , India.

Professor , Department of Mechanical Engineering, Avanthi Institute of Engineering & Technology, Narsipatnam ,
Andhra Pradesh , India.

ABSTRACT
The technology has been changing day by day, every day new invention
and new techonology will arriving . Whenever a new techonology invented is to
solve a past , existing problems .In this era the major problem is pollution and
future problem is fossil fuel scarcity.In order to solve this problems many new
techonology as been invented . In this invention one of best invention is electrical
vehicals . These vehicals are free from pollution and also it will helps to preserve
some amount of fuel to future generation . The current rate of usaging of fuels
continuously for next 5 decads their will be arising of fuel drought.

KEY WORDS

Bi-Cycle , Motor (BLDC Motor with Hub) , Battery , Dynamo , Throttle , LED
light with Horn , and other bicycle components.

INTRODUCTION

In this generation bike or vehicle is very important in our

fast life for traveling, and also it will helps in economy growth but it has
drawbacks like pollution, fossile fuel shortage and globel warming for this we need
a new techonology like eco-friendly vehicals for travelling , is E-Bike (electrical
bicycle). This E-Bike runs on electricity and this techonology has some drawbacks
like on full charging of battery works on period of time only, after that again we
have to recharge it for this I introduced a new techonology which will generate
electrical power with attaching some extra components,it helps to travel somemore
kilometers. It basically suitable for young people, the person who like cycling as an
exercise.These E-bikes are futures one of most demanding vehicles
LITERATURE REVIEW

1. Design & Development of E-Bike - A Review

In this paper, author explain the modification of E-Bike in order to get

maximum speed, and efficiency in low cost by reference of previous papers

2. Design and Fabrication of a Pedal Operated Power Generator

In this paper , author explain how to generate energy from exercise
cycle to use household purposes. He clearly explain how clarioes are we
burn to generate an electrical energy
Block diagram of the generation system

PRIME MOVER D C GENERATOR STROGE

EXERCISE BIKE BATTERY(12V)

LOAD INVERTOR
SYSTEM
Graphical depiction of voltage against speed

3.Campus Mobility For The Future: The Electric Bicycle

This paper presents the various outcomes and results of the study containing
visions into the scheme. Electric bikes, of much sort have been surveyed by and by
in a semi-open contract conspire on the Nanyang Technological University campus
in Singapore. According to this campus, it is a famous and helpful administration,
with a few models of electric bike being exceptionally very much utilized. Riders
contemplate the premier of the electric bikes to be both agreeable and engaging
while at the same time utilizing it, and extremely suitable for campus travel.
Understudies and general society alike view the plan unhesitatingly, and creators
have seen a lessening in the quantity of miles driven via auto inside the grounds for
the dominant part of clients who are additionally drivers.

In this paper, authors have sensibly inspected the utilization of bikes on campus,
displaying and investigating review results that endeavor to clarify blocks to bigger
acknowledgment of the bike. Authors likewise bolster the general public by giving
arrangement that if this information is coordinates with a portion of the qualities of
the campus encompassing, it is conceivable to suggest specialized, arranging and
reasonable arrangements that together should help the more prominent
acknowledgment of bike transport. This is the concentration of the rest of the
paper.
WORKING OF ELECTRICAL BICYCLE

PEDAL
OPERATING

WALL CHARGER BATTERY DYNAMO

CONTROLLER MOTOR MECHANICAL

OUT PUT

THROTTLE LED LIGHT &

HORN

In this process the components are used bldc motor (350 watts = ½ HP 24v)
, battery(12v 18ah*2), controller (350watts), throotle (accelerator), head
light , fly wheel , and some other components. When the power supply
passes through motor through controller , the motor convertes electrical
energy to mechanical output it results wheel rotate along with wheel fly
wheel rotate which is connected to the rear axle . with the help of dynamo
we generate power as shown in fig.

MAIN COMPONENTS

PMDC MOTOR

BATTERIES

FLY WHEEL

DYANAMO
PMDC MOTOR

Motor is a device which converts electrical energy into mechanical output. In

PMDC(Permenent Magnet Direct Current) motor consists of permenent magenents
in the stator, and winded coil are in rotor. Commutator is connected to the T ends
of the winding coilsin order to make slipping contact with the brushes.These
Brushes are directly connected to DC power supply across motor terminals.
Change of direction of rotation can be achieved by reversal of voltage polarity. The
when the current flow passes through the coils that creates magnetic poles in the
rotor these poles are intrect with permanent magnet poles. In order to maintain the
torque generation in same direction, then the current flow must be reversed when
the stator south pole passes to the rotor north pole. For this the slipping contacts
are segmented. This segmented slip ring are called commutator.

Motor Specifications:- Power: 350W; Voltage: 24V; Current: 19.2A; speed (after
reduction):324 RPM;stall Torque:55 N.m; Weight: 2.98Kg.

BATTERY
Bateries are the divices which stores an energy .The batteries are stores energy in
the form of chemical action and it delivers the in form of electrical energy. These
batteries are consists of two teriminals are positive electrode and negitive electrode
in this batteries the positive electrode use as a lead oxide(pbo2) ,and the negitive
electrode is lead(pb) here electrolyte is a sulfuric acid(H2SO4) these batteries are
invented 1859 by french scientist Gaston Planted and this is the first reachargble
batteries these batteries are low cost and ability to supply a high voltage compared
to other batteries therefore these batteries are commonly used for any vechiles
depnds upon required capacity these batteries are can be recycle. In US during in
the year of 2009 to 2013.gel designs sre sealed ,do not require any watering or gas
blow off operations for this reason we can use these batteries with less maintiance.

SPECIFICATIONS
Lead acid battery: Rated voltage : 12V; Rated current: 18Ah; Number of
batteries:2; Battery Rating = 12 V * 18 Ah = 216

FLY WHEEL

In this project A flywheel is a mechanical device specially designed to efficiently

transfer rotational energy to the dynamo.In this fly wheel the rotational speed is
depends upon the its moment of inertia .in this process the fly wheel is directly
attached to the rear axle socket, and the wheel with a groove to aviod the belt
tripping. when the rear axle rotates fly wheel also rotates.This fly wheel is
connected to the generator with the help of belt(A51grade) drive mechanism.it
results when the bicycle is moving then along with back wheel socket fly wheel
rotates and dynamo also rotates by connecting with fly wheel by belt as shown in
fig.this fly wheel is made up of iron.

Flywheel specification: -
Diameter: 14 cm , material :stainless steel

DYNAMO

The word dynamo is taken from greek words it means force or power and it also
called as electrical generator.The word “dynamo” was coined by Michael Faraday
who utilized for his inventions in electricity.Farday discovers electrical induction
and magnetism. The original principal of dynamo was explined by Wehrner von
Siemens he refferd only on dc generators which use exclusively self-introduction
principal to generate a DC power. In the early years dc generators which used
permanent were not considered “dynamo electric machines”. This invention helps
in the total industrical scale converts to electrical power generation in techanically
and also economically.after the invention of an alternator alternating current that
can be used as power supply now a days the dynamo was directly commutated
with the dc electrical generator.
In this project the dynamo is used to charge the batteries during
running of the vehicle
CONCULISION

It is clearly seen that the electrical bicycle gives a clean and more economical
solution to the energy crisis. People use bikes and fuelled vehicles for even
travelling short distances without making use of bicycles and other non – fuelled
vehicles. Most number of people have been think riding a cycle is equivalent to
providing extra effort for cycling. In order to avoid this situation, electric
assistance has been provided to the cycle that will ease the user to ride the unit
with the help of a motor. Even the hardship of climbing slopes and riding on rough
terrains has been reduced. All these aspects are available keeping in mind the
factor of pollution being affected at all. The factors that our prototype design of
bicycle provides to the raider are:
  Simplified riding with minimal effort on flat as well as gradients.
 Easiness of riding on rough terrains.

ACKNOWLEDGEMENT

We are very grateful to our guide Mr. RAMA KRISHNA Assistant Professor,
Faculty of the Mechanical Department who spent a lot their precious time with us
on our work always even though being very busy persons with academic works of
the Department, for their background knowledge and patience in the competition
of our project. We are very grateful to them for enlightening intellectually and
spending a lot of their precious time with us even though they got a very hectic
schedule. And also we extend our sincere thanks for their extreme guidance and
support during the entire project. Their constant encouragement and suggestions
helped us a lot

BIOGRAPHIES

Prof .P. RAMA KRISHNA, M Tech

He is currently working as assistant professor in Mechanical from Avanthi

Institute of Engineering & Technology, Narsipatnam , Andhra Pradesh ,
India.

K. SAI CHANDU

He is currently pursuing Bachelor of Engineering in Mechanical from

Avanthi Institute of Engineering & Technology,Narsipatnam,Andhra
Pradesh , India.

G.M.V. SIVA KUMAR

He is currently pursuing Bachelor of Engineering in Mechanical from

Avanthi Institute of Engineering & Technology, Narsipatnam , Andhra
Pradesh , India.
 G.KANNAJI

He is currently working as assistant professor in Mechanical from

Avanthi Institute of Engineering & Technology, Narsipatnam , Andhra
Pradesh , India.

B.KIRAN KISHORE

He is currently working as assistant professor in Mechanical from

Avanthi Institute of Engineering & Technology, Narsipatnam , Andhra
Pradesh , India.

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Abhishek Sanghi “Generation of Electrical Power using Bicycle Pedal”,
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Graw Hill Publication.

[4] A text book on “Electrical technology By B. L. Thereja”, S. Chand Publication.

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