ABSRACT

There is growing demand for Electric Motor Bicycle in India as there will be less
air pollution, lower maintenance cost and reduced noise using Electric Motor Bicycle. The
motive of this research work is to design a simple, cost-effective model of Electric Motor
Bicycle with intelligent controller. The Electric Motor Bicycle is consisting of motor,
battery and controller. In this BLDC motor is fixed in the rim of the rare wheel. The
controller is connected to the motor and battery to control speed of motor and current. The
Electric Motor Bicycle can be run with battery charge and also by pedalling. ELECTRIC
BIKE SIMULATOR was used to generate the simulation results. The results of the
experiments are also shown in a hardware assembly kit.
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGENO.

ABSTRACT V

LIST OF FIGURES IX

1 INTRODUCTION

1.1 GENERAL INTRODUCTION 1

1.2 CLASSIFICATION OF ELECTRIC BICYCLE 1

1.2.1 TYPE 1 E-Bike 1

1.2.2 TYPE 2 E-Bike 1

1.2.3 TYPE 3 E-Bike 1

1.3 ADVANTAGES OF E-BICYCLE 2

1.4 OBJECTIVE 2

1.5 LITERATURE SURVEY 2

1.6 SCOPE 4

2 DESIGN OF ELECTRIC MOTOR BICYCLE

2.1 TURN ON OF E-BICYCLE 5

2.2 AUTO-CUT OFF BRAKES 6

2.3 INSTRUMENT CLUSTER 6

 2.4 WORKING OF LIGHT AND HORN 7

2.5 REQUIREMENT CALCULATIONS 7

2.5.1 MASS RANGE CALCULATIONS 7

2.5.2 MOTOR LOAD CALCULATION 7

2.5.3 TO FINDING Fd (GRADIENT RESISTANCE) 8

2.5.4 TO FIND Fwf (AERO RESISTANCE) 8

2.5.5 TO FIND FR (ROLLING RESISTANCE) 8

2.5.6 TOTAL PROPULSION FORCE, FP 8

2.6 SELECTION OF BATTERY PACK 8

2.6.1 CONSIDERING CYCLE APPLICATIONS 9
2.7 CONTROLLER SPEC 10
2.7.1 HOW CONTROLLER WORKS 10

3 SELECTION OF COMPONENTS OF ELECTRIC

MOTOR BICYCLE

3.1 DC HUB MOTOR (BLDC) 11

3.1.1 SPECIFICATIONS 12

3.2 CONTROLLER 15

3.2.1 SPECIFICATIONS 16

3.3 BATTERY 19

3.4 INSTRUMENT CLUSTER 21

3.5 THROTTLES 21
3 . 5 . 1 T YPE S OF T H ROT T LES 22
3.6 LIGHT 23
 3.7 HORN 24

3.8 BMS 24

4 DEVELOPING AND TESTING OF ELECTRIC MOTOR

BICYCLE
4.1 SCRAP CYCLE 26

4.2 RUST PROTECTION 27

4.3 PARTS FOR CONVERSION 28

4.4 MOTOR INSTALLATION AND MAKING OF BATTERY 29

4.5 INSTALLATION OF BATTERY AND OTHER PARTS 33

4.6 TESTING OF THE ELECTRIC MOTOR BICYCLE 35

4.7 FINAL FINISH 36

5 CONCLUSION

5.1 CONCLUSION 38

5.2 FUTURE SCOPE 38

REFERENCES 39
 LIST OF FIGURES

FIGURE No. TITLE PAGE No.

2.1 Block diagram of Electric Bicycle 5

2.2 Block diagram of converting Electric Bicycle 5

2.3 Block diagram for auto cut off brakes 6

2.4 Block diagram for instrument cluster 6

2.5 Block diagram for lights and horn 7

3.1 BLDC hub motor 11

3.2 Controller 16

3.3 Flow chart of Controller 18

3.4 Controller Connecting wires 19

3.5 Battery 19

3.6 display 21

3.7 Throttle 22

3.8 Light 23

3.9 Horn 24

3.10 Bms 25
FIGURE No. TITLE PAGE No

4.1 scrap cycle 26

4.2 convertion of scrap cycle 27

4.3 painting cycle frame 28

4.4 Motor fixed in rare wheel rim 29

4.5 creating battery using cells 30

4.6 connecting cells 30

4.7 covering of cells 31

4.8 battery sealing 32

4.9 Battery testing 33

4.10 Installation of battery, controller and other parts 34

4.11 After installation 34

4.12 Testing of Electric Bicycle 35

4.13 Testing by Faculty 37

 CHAPTER 1
INTRODUCTION

1.1 GENERAL INTRODUCTION

The term "electric vehicle" refers to a vehicle that is propelled by one or more electric
motors or traction motors (EV). A self-contained electric vehicle can convert gasoline to energy
using a battery, solar panels, fuel cells, or an electric generator, or it can be powered by
electricity from off-vehicle sources using a collector system. E- Cycle is an electric and power-
assisted bicycle that is one of the bicycle industry's fastest-growing technologies. This bicycle
has an electric motor to assist you in moving forward. As a result, you can ride it like a regular
bicycle while exerting less effort. An E-Cycle motor works by turning on automatically when
you peddle or throttle. There are two main types of E-Cycle
 Throttle assist
 Pedal assist

1.2 CLASSIFICATION OF ELECTRIC BICYCLE

1.2.1 TYPE 1 E-Bike

An electric bicycle with Pedal Assist requires you to pedal in order to run the motor. It looks
like an ordinary bicycle except that it contains a motor that recognises when you're pedalling
and assists you. It's as though you've always had a strong tailwind behind you. This class/type
of E-bike may or may not have a throttle.

1.2.2 TYPE 2 E-Bike

Throttle Only is a throttle-controlled electric bicycle. These electrics do not require pedalling
to benefit from the motor. You'll be on your way in no time if you simply push the throttle.
Accelerating in the middle of a corner will allow you to gain more traction. Naturally, the less
you cycle, the faster the battery drains.

1.2.3 TYPE 3 E-Bike

With Pedal Assist, you can go up to 28 mph. This Class/Type is the fastest "legal" E-bike,
with a top speed of 28 mph. It is still deemed a "bicycle," and no driver's licence, licence
plate, or other documentation is required. It's technically a bicycle,
and it's a lot of fun! Helmets are required by law. his category is best for someone who rides
their bike to work.

1.3 ADVANTAGES OF E-BICYCLE

 An E-bike is a bicycle that is environmentally friendly. It's the same as our

regular bicycle. E-Cycle, on the other hand, is powered by electricity rather
than gasoline. No harmful emissions are emitted into the atmosphere. For the
same reason, electric bikes don't produce any additional noise.
 Electric bicycles, in general, do not require any maintenance. Lubricate the
drive system and inspect the chain and wheels on a regular basis to keep it
clean.
 Riding an electric bike is fashionable and popular right now. It's also the most
efficient approach to cut down on pollution.
1.4 OBJECTIVE
 To create an efficient E-cycle that can be used on many types of
roadways.
 To adapt the E-cycle to various requirements.
 To design an E-cycle using 3Rs (Reduce, Reuse and recycle).
-Reduce: Electric cycle can reduce the emissions.
-Reuse: The cycle can be reused from old condition.
-Recycle: The cycle has been recycled from scrap condition.

1.5 LITERATURE SURVEY

The constant news concerning the demise of fossil fuels, according to Adithya
Kumar et al., (2016), has enhanced the importance of using electricity in the future.
Electric bicycles will be used more frequently. The electric bike will be beneficial to office
workers and those who ride short distances. The electric bike has a motor that assists the
vehicle in moving ahead, and it is powered by a variety of sources. The batteries power the
motor, which in turn drives the vehicle. Once the battery has been fully exhausted, it is
recharged using a battery charger. We used a DC motor/generator mounted to the bicycle's
rear wheel for this project. Two sets of batteries, labelled A and B, are used to power
the system.
When one of the batteries runs out, the remaining batteries will step in to fill the void.
During this period, the wheel revolves, rotating the shaft of the dc motor/generator, which
produces a voltage output. This voltage aids in the charging of the battery, improving the
electric bike's range. It is environmentally friendly and pollution-free because it produces
no emissions. Furthermore, it is silent and can be recharged using an AC converter in the
event of an emergency or gloomy weather. It is ideal for young and elderly individuals,
and it meets the needs of the economically disadvantaged.The most important feature of
this bicycle is that it does not consume valuable fossil fuels thereby saving the money.

Annette Muetze, et. al.,(2008) suggests that More emphasis should be devoted to
the deregulation of electric bicycles. A common standard/guideline for electric bicycle
designers/manufacturers will stimulate growing popularity while also guaranteeing that
electric bicycle quality is not compromised. Custom- designed bicycles that are most
efficient in a given operating cycle, such as city, hill, and distance, as well as "speedy
bicycles," might assist to offset the additional cost and weight of larger components. More
study into battery and drive technologies, as well as their use with electric bicycles, would
be advantageous to the electric bicycle industry in this regard. Even if the technological
maturity of electric bicycles has increased and continues to improve, more effort is needed
to make them competitive with other vehicles.

Carlos Tovar, et. al.,(2009) proposes Novel The cities are living each day an
accumulation of excessive traffic and noise. The air quality and health are two more
components of city traffic that are badly damaged. Many air contaminants, like as carbon
monoxide mono-oxide and suspended suspension particles, are primarily caused by
transportation. It's a fantastic car that is both speedy and efficient while still being
environmentally friendly. It is possible to enjoy a leisurely and enjoyable cruise while also
arriving at locations (such as work) using this vehicle. Surprisingly, an e-bike costs the
same as a regular bicycle. This means that when you buy this vehicle, you have all of the
features of a standard bicycle plus the added power of the battery, which allows you to go
faster and for longer than you could on your own. The bicycle's electricity is designed to
help the rider
maintain a steady, safe speed on or off the road. Furthermore, the law considers this
vehicle to be equivalent to a standard bicycle. That is to say, the user does not need a
licence to ride an electric bicycle.

Ravina More, et. al.,(2011) proposes different models of calorie measurement need
to be reviewed and tested to find which one is the most suitable to be adopted for a range
of bicycles. For more information, To reduce the number of calibrations required for each
particular cycle, researchers can look into developing a single model that fits all bicycles.
Incentive-based ways for e-bikes can be tested, such as switching the bicycle from manual
to electric mode once the calories burned goal has been met. It is necessary to consider a
circuit that can accomplish the same. The anti-theft system is reliant on battery power. To
do this, a more stable battery supply is required. The features will be implemented using
the bicycle's existing power supply. The end product will be cushioned, waterproof, and
temperature insensitive for a specific temperature range to protect it from harsh
environmental elements. As a result, the project attempts to reestablish the bicycle as a
more user-friendly and low-cost mode of transportation. For the simple bicycles, an
attempt will be made to model a similar design.

1.6 SCOPE
The price of fuel is rapidly rising as the supply of fossil fuels decreases. We can save a lot
of money in the long run and reduce global warming by converting to an electric bicycle. It
also aids in our physical fitness. Electric Motor Bicycles are in high demand in India
because they produce less pollution, have fewer maintenance costs, and produce less noise.
 CHAPTER 2
DESIGN OF ELECTRIC MOTOR BICYCLE

Here the current from battery moves to controller where all the connections are
made. When the power is given to the motor, it rotates the wheel using chain and sprocket.

Battery
Controller BLDC Hub Motor

E-Cycle Wheel Rotation Chain and sprocket

Fig.2.1 Block diagram of Electric Bicycle

2.1 HOW TO TURN ON OUR ELECTRIC MOTOR BICYCLE

Insert the key and turn on the ignition. Long press the power button in the
instrument console, then the power supply will be active.

Accelerator

E-Cycle
BatteryWheel Rotation Controller BLDC Hub Motor

Chain and sprocket

Fig.2.2 Block diagram of converting Electric Bicycle

When we rotate the accelerator to our desired amount, the controller takes the input
and give the limited power to the motor and runs accordingly.

2.2 WORKING OF AUTO-CUT OFF BRAKES

Brakes accelerator

Battery Controller BLDC Hub

E-Cycle Wheel Rotation Chain and sprocket

Fig.2.3 Block diagram for auto cut off brakes

When the brakes are applied during running/idle conditions, the controller cuts off
the power supply to the motor till the brakes are engaged.

Working of cruise control:

When the E-cycle is running under a constant speed for 5 sec, the bike is changed
to cruise mode and maintains the same speed. For changing back to normal mode, you can
accelerate or slightly engage brake.

2.3 WORKING OF INSTRUMENT CLUSTER

Instrument Console

Battery Controller

Fig.2.4 Block diagram for instrument cluster

 The instrument console displays speed, battery level, odometer. It has three buttons
(power button, motor power up button and motor power down button). Power button has
two function, long press - for turning on ignition. Short press - for toggling between
voltage level, trip meter and odometer.

2.4 WORKING OF LIGHT AND HORN

Switches

Battery Controller Light/Horn

Fig.2.5 Block diagram for lights and horn

There are two switches in handle bar one is for light and another is for horn. When
the switches are pressed the controller reads it and sends the output to light/horn.

2.5 REQUIREMENT CALCULATIONS

2.5.1 Mass Range Calculations
Person Weight = 100kg
Battery Pack = 6kg
Motor & Controller = 4kg
Cycle weight = 10kg

Total = 120kg

So, Battery & Motor are required to propel the Bicycle with the weight of 120kg.
2.5.2 Motor Load calculation
Fp = Propulsion Force
Fwf = Windage & Friction Drag
Fd = Down force from Gravity
Consider the Grad @ 3.14%
α = tan-1(slope)
= tan-1(3.14/100)
= tan-1(0.0314)
α= 1.8 degree
2.5.3 To Finding Fd (Gradient Resistance)
Fd = m * sinα
= 120 * 9.81 * sin 1.8
= 37 N
2.5.4 To Find Fwf(Aero Resistance)
Cd => Aerodynamic Area Co-efficient = 0.74
ρ = Density = 1.225kg/m3
A = Frontal Area of Bicycle = 0.37 m3
V = Velocity of Bicycle = 25 km/h=> 6.94m/s
Fwf = ½ * Cd * ρ * A* V2
= ½ * 0.74 * 1.225 * 0.37 * (6.94)2
Fwf = 8.07 N
2.5.5 To Find FR (Rolling Resistance)
CR = Rolling CO-efficient => 0.0041(for cycle) FR
= CR * mg cosα
= 0.0041*120*9.81*cos1.8
= 4.8 N
2.5.6 Total Propulsion Force, FP
Fp = Fd + FWF + FR

= 37+8.07+4.8

= 49.8 N

Propulsion Power = FP * Velocity

= 49.8 N * 6.94 m/s
= 345.6 W
Thus, The Motor is to be 350 W
2.6 SELECTION OF BATTERY PACK
Range required: 30km SPEED
OF CYCLE: 25 km/hr
25 km for 1hr 30km
for 1.2hr
 345W Power to be extracted for 1.2hrs, to cover 30km distance
 Therefore,

345*1.2h= 414wh
 414wh battery Pack is required

36v*11.5 ah=414wh (or)

48v*8.62 ah=414 wh

2.6.1 Considering Cycle Applications And Safety

36V* 11.5Ah is selected
How many series? How many parallel?
Single cell=3.6v Normal Voltage
2.5Ah capacity
 5 cells in Parallel = 5*25Ah

= 12.5Ah
 10 cell group in series =10*3.6v

=36v
 10S, 5P configuration will yeild 36v 12.5Ah.

C Rating = 37.5(7.5*5) /12.5

= 3C For Discharge Charging
allowed is 0.5C = 05*12.5
= 6.25 Amps
Safe current is 0.2C = 0.2* 12.5
 = 12.5AMPS
So, 42 V 2.5A Charger needed

2.7 CONTROLLER SPECIFICATIONS

36V*xA = 350W
X=9.7Ama
 9.7< 37.5 - Battery is safe
 9.7<13 +_ – controller is safe

So 36v, 13 +_1A controller needed – normal voltage FULL

CHARGE (42V)
 42V*xA= 350W
 X =8.3A

2.7.1 How Controller Works

42V * (0 to 8.3A) = 350W
41V * (0 to 8.5A) = 350W
40V * (0 to 8.75A) = 350W
31V * (0 to 11.3A = 350W
So Required Voltage, A = 11.3 < 13 ± 1 Amp So,
find Spec arrived
350W motor
36V 12.5Ah (450Wh) battery pack 36V
< 13±1A controller
42V 2.5Amp charger is suitable for: 30Km
range
25Km/hr 3.14%
grade
120Kg cycle load
 CHAPTER 3
SELECTION OF COMPONENTS

3.1 DC HUB MOTOR (BLDC)

A brushless DC (BLDC) motor with permanent magnets is used in this system. In a
BLDC motor, which is a type of synchronous motor, the magnetic fields generated by the
stator and rotor have the same frequency. The BLDC motor lasts longer since it does not
require brushes. It also boasts a high starting torque, a fast no-load speed, and low energy
losses. Three phase motors are the most common and commonly utilised in e-bikes out of a
variety of layouts. Because the motor replaces the wheel hub, the system is chosen with a
hub motor. Coupling loss is decreased, and mounting is simple without the use of chains or
belts, resulting in a smaller and lighter e-bike.

Most electric vehicles (cars, bicycles, and wheelchairs) are powered by onboard batteries
and a single, very basic electric motor that drives two or four wheels. However, some of
the most recent electric cars and electric bicycles operate in a different manner. Instead of
using gears or chains to power all of the wheels, they integrated a motor into the hub of
each one, thereby merging the motors and wheels. A hub motor is exactly what it sounds
like.

Fig.3.1 BLDC hub motor

3.1.1 Specifications

BLDC HUB MOTOR RARE WHEEL 36v, 250W

 Voltage:36 V
 Maximum current:10 A
 Maximum efficiency:85 %
 Torque:45 Nm
 Nominal power:250 W
 Peak power:350 W
 Maximum speed:30 Km/h

Hub motors are brushless motors (also known as brushless direct current motors or
BLDCs), which have a half-dozen or more independent coils and an electronic circuit in
place of the commutator and brushes. The circuit turns on and off the power in the coils,
creating forces in each one that cause the motor to spin. Brushes press on the axle of a
regular motor, causing friction, slowing it down, producing some noise, and wasting
energy. Brushless motors are more efficient because of this, especially at low speeds.
Getting rid of the brushes also eliminates the need to replace them when friction wears
them down.

In a typical motor, the inner coil (named the rotor) rotates while the outside magnet
(called the stator) remains stationary. The roles are inverted in this motor: the inner section
with the coils is static, while the grey magnet spins around it. Now take a look inside to
see how it all works: The grey outer shell (which is a magnet split into several portions and
bent round into a circle) spins around the copper coils and circuit board as the electronic
circuit transmits power to each of the nine copper coils in turn (which remain static).

However, between some of the coils are numerous tiny magnetic field sensors (also
known as Hall-effect sensors). As the permanent magnets on the outer rotor sweep past
them, the Hall-effect sensors figure out where the rotor's north and south magnetic poles
are and which coils to activate to keep it spinning. The problem is that this necessitates the
use of an electronic circuit to operate the motor, which is not required for a standard DC
motor.
 In the case of electric vehicles, the advantages are more clear. A normal car's metal
weight (including the engine, transmission, and chassis) is roughly ten times that of its
occupants, which is one of the reasons why cars are so inefficient. When the hefty engine
and transmission are replaced with hub motors and batteries, the car becomes much lighter
and more energy efficient. The engine compartment's removal also creates a lot of space
for passengers and their luggage; the batteries may be placed beneath the back seat.

Hub motor vehicles are much simpler (mechanically speaking) than conventional
vehicles. Assume you wish to go backwards. All you have to do is reverse the electric
current instead of employing complicated gear setups. Backwards the motor spins, and
backwards you go. On many cars, this is an expensive alternative because it necessitates
extra gears and complicated driveshafts, but it's extremely simple to solve with hub motors.
When each of a car's four wheels has a hub motor, four-wheel drive is immediately
achieved. In theory, turning the four motors at slightly varying speeds (to aid handling and
steering) or torque is simple enough (to move you through muddy or uneven terrain).

Hub motors are larger, bulkier, and heavier than standard wheels, and they alter the
handling of an electric car or bike by increasing the unsprung mass (the mass not supported
by the suspension), which theoretically results in increased shock and vibration, poorer
handling, and a bumpier ride. That is, at least, the conventional wisdom. Engineers have
discovered that vehicles with hub motors just need their suspension "tweaked" to
compensate for the increased unsprung mass, and that this can even result in a better
overall handling.

Because a single hub motor's unexpected failure could cause a vehicle to slew to
one side, practical hub motors are often built up of many (usually four) independent sub
motors, each delivering a fraction (a quarter) of the overall torque. Although this is a far
safer design, it does add to the cost and complexity. Even so, with hub-motor electric
automobiles, the two or four motors must be
coordinated so that any serious failure in one motor can be compensated for by one or
more motors on the opposite side.

Hub motors must survive in a considerably harsher environment than a traditional engine
or electric motor, which is located high off the road and well covered inside the engine
compartment. They're un-sprung, so they're subjected to a lot of vibration, and they also
have to withstand high-speed hits from boulders and stones, as we've just seen. They must
deal with large temperature fluctuations (chilling cold from the outside air, boiling hot
from sudden braking), as well as becoming entirely submerged in water or snow, down
alongside the road. Isolated hub motors are a futuristic dream come true. Hub motors are
more likely to be retrofitted to existing automobiles for the time being, therefore they must
operate with existing friction brakes, suspension systems, and other components. This
may necessitate design concessions that negate some of the benefits of hub motors in the
first place.

Another issue is producing the exact amount of torque required (turning force). No
matter what pace you're going on the road, a gasoline engine operates best when it's turning
over quickly (producing a lot of revolutions per minute). Depending on whether you're
starting from a stop, racing down the highway, going slowly uphill, or whatever, you
utilise a gearbox to transform the engine's high revs into high torque (and low speed) or
high speed (and low torque). Hub motors must be able to provide any speed and torque
combination without the use of a gearbox; they are typically "direct drive." But there's a
catch: on electric bikes, they're housed inside the hub, at the very centre of a huge spoked
wheel. When you move a wheel's centre, its diameter acts as a lever, increasing the speed
at the rim while decreasing the torque by the same amount (see our article on how wheels
work for an explanation). You'll need a powerful engine to get enough torque, but not so
powerful that it accelerates you too rapidly and jerkily or smashes your spokes.

Hub motors often obtain more torque by dramatically increasing the hub size (a
larger stator and rotor provide more torque than smaller ones); as you can
see in the electric bike photo above, the powered hub on an electric bike is far larger than
the unpowered hub on a regular bike. Internal gearboxes (usually an array of planetary
(epicyclic) gears in between the stator and the rotor) enhance torque in some hub motors,
but many don't since they add weight, expense, mechanical complexity, and potential
unreliability. Larger torque introduces a new issue: If you're converting a regular bicycle
wheel into a powered wheel, be sure the rest of the wheel is strong enough to handle the
twisting forces provided by a hub motor. An electric bike's spokes are shorter and leave the
hub at a tighter angle, putting them under additional stress. Assume you install an electric
motor on the hub of a standard bicycle and turn it on. Because you're so heavy and there's
so much friction between the tyre and the ground, the engine could just bend the spokes
instead of propelling you! As a result, an electric bicycle often requires stronger wheels
(possibly with stronger and more elastic spokes, altered spoke hole positioning, a thicker
rim, or some other adjustment) than a regular bicycle.

3.2 CONTROLLER

One of the most crucial components of an electric bike is the electric bike
controller; it is the e-brain that controls the motor's speed, start, and stop. It's connected to
everything else in the car, including the battery, motor, throttle (accelerator), display
(speedometer), PAS, and any other speed sensors.

The TA controller is made up of main chips (microcontrollers) and peripheral components

(resistors, sensors, MOSFET, etc). Inside the controller, you'll find a PWM generating
circuit, an AD circuit, a power circuit, a power device driver circuit, a signal acquisition
and processing circuit, an over-current and under- voltage protection circuit, and a signal
acquisition and processing circuit.
 Fig.3.2 Controller

3.2.1 Specifications

Compatible Motor : Hub Motor

Body Material : Aluminium

Cable Length(cm) : 15

Current Limit(A) : 15

Rated Voltage(v) : 31 to 36

Rated Power(W) : 350

Weight(gm) : 211

Length(mm) : 90

Width(mm) : 50

Height(mm) : 30

The controller supplies the working voltage to the external device, such as the
switch +5V, headlamp +5V, and so on, after attaching the battery. Based on the input from
the throttle or PAS, the PWM generates an appropriate pulse pattern for the MOSFET
driving circuit. To control the motor speed, the MOSFET driving circuit manages the
MOSFET circuit's turn-on and turn-off.

When the voltage is lower than the controller set value, the under-voltage circuit
protects the battery from discharge, and the PWM circuit stops the output. The controller,
battery, and motor cannot operate at greater currents because of
the over-current protection circuit. The basic job of an electric bike controller is to collect
all inputs from all electric components (throttle, speed sensor, display, battery, motor, and
so on) and determine which signal should be returned to them (motor, battery, display).

The controller's many protection functions will differ from the controller's design.
Some basic security functions are listed below. Protection against over- voltage. When the
battery voltage becomes too high, the controller checks it and shuts down the motor. This
prevents overcharging of the battery. Protection against low voltage.

When the battery voltage drops too low, the controller checks it and shuts down the
motor. This prevents the battery from becoming overcharged. Protection against
overheating. The temperature of the FET (field-effect transistor) is monitored by the
controller, which shuts down the motor if it gets too hot. The FET power transistors are
therefore protected. Protection against overcurrent. If the motor is receiving too much
current, reduce the current supplied to it.

This safeguards the motor as well as the FET power transistors. Protection from
braking. Even though the controller was receiving other signals at the same time, the motor
shut down while braking. When a user simultaneously presses the brake and throttle, the
brake function takes precedence.
 Fig.3.3 Flow chart of Controller

In most circumstances, if a motor contains hall sensors, the controller should be

hall-sensor or dual mode. The Hall sensor on the motor will detect rotation, and based on
the sensor data, the controller will provide the proper voltage to the motor. It has a higher
beginning torque, is more consistent, and uses less power. When the motor hall sensor is
destroyed, a dual mode controller works OK, but the hall-sensor controller may give an
error and stop working. The e-bike controller's wire types and wire terminals may vary
depending on the controller design. The electric bike controller wiring schematic is
required to ensure proper wire connections.

Most e-bike controllers have the following cables: motor, battery, brakes, throttle/
accelerator, or PAS Pedal Assist System (some controllers have both types of wires, some
have one of them).

Advanced controllers have additional wires, such as a display or speedometer, three

speeds, reverse, LED light, and so on.
 Fig.3.4 Controller Connecting wires

3.3 BATTERY

Fig.3.5 Battery
Compared to other high-quality rechargeable battery technologies, Li-ion batteries
provide a number of benefits (nickel-cadmium or nickel-metal-
hydride). They have one of the highest energy densities of any battery technology
available today (100-265 Wh/kg or 250-670 Wh/L). Li-ion battery cells can also deliver
3.6 volts, which is three times higher than Ni-Cd or Ni-MH technology. This means they
can supply a lot of current for high-power applications, which is a good thing. Li-ion
batteries are also low-maintenance, as they don't need to be cycled on a regular basis to
keep their life. Li-ion batteries have no memory effect, which is a harmful phenomenon in
which a battery can'remember' a decreased capacity after repeated partial discharge/charge
cycles. This is an advantage over Ni-Cd and Ni-MH batteries, which also exhibit this
behaviour. In addition, Li-ion batteries have a low self- discharge rate of 1.5-2 percent each
month. They don't contain the hazardous cadmium found in Ni-Cd batteries, making
them easier to dispose of.

Li-ion batteries have supplanted Ni-Cd batteries as the market leader in portable
electronic gadgets as a result of these benefits (such as smartphones and laptops).
Lithium-ion batteries are also utilised to power electrical equipment in some aerospace
applications, such as the new and more ecologically friendly Boeing 787, where weight is
a major cost consideration. Much of the promise of Li-ion technology in terms of
renewable energy derives from its prospective uses in battery-powered cars. The Nissan
Leaf and the Tesla Model S, which are now the most popular electric automobiles,
both employ Li-ion batteries as their primary fuel source.

Li-ion batteries, while their technological potential, have a number of flaws,

particularly in terms of safety. Li-ion batteries have a proclivity for overheating and are
susceptible to damage at high voltages. This can result in thermal runaway and
combustion in some situations. This has resulted in severe issues, including the
grounding of the Boeing 787 aircraft following reports of onboard battery fires. A
number of shipping companies refuse to send batteries in bulk by plane due to the risks
connected with these batteries. Safety systems for lithium-ion batteries are required to
regulate voltage and internal pressures, which can increase weight and performance in
some circumstances.
3.4 INSTRUMENT CLUSTER

We're utilising a cluster to show how much the battery is charging and how fast the
bicycle is going. The instrument cluster is an important aspect of every vehicle because it
is the vehicle's face that displays its current state. It can provide critical signals of electrical
component faults (EFI/ISG related) in addition to basic vehicle information. Clusters can
collect vehicle data using simple technologies like encoders as well as more complicated
interfaces like CAN, SAEJ1850, and so on.

Although electric car instrument clusters have a lower system complexity, they
must be more user-friendly, power-efficient, and cost-effective. To achieve the strict
compliance standards, careful design and selection of cluster components is required. The
MCU is the most common of the constituent components, with only a few vendors
supplying automotive grade with the requisite feature sets.

Fig.3.6 display

3.5 THROTTLE
The throttle mode works similarly to that of a motorbike or scooter. You can propel
the bike forward without pedalling by pressing the throttle. You can control how much
power is produced with most throttles.
 Electric bikes have a variety of throttle options, ranging from thumb throttle to full
twist throttle.

Fig.3.7 Throttle

1. 5 . 1 D i f f e r e n t Types of T h r o t t l e s on E l e c t r i c Bikes

 Half-grip Twist: This functions in the same way as a motorcycle or scooter does,
with the throttle being twisted to activate it. It's the most common throttle for
electric bikes. To accelerate the bike, the rider only needs to crank the throttle.

 Thumb Throttle: These are made to be simple to use. It's as simple as pressing a
button to start the motor. Some have multiple buttons for controlling the bike's
speed, while others only have an on/off switch.

Depending on how the throttle is engaged, different types of throttles perform

differently. It's crucial to understand whether the throttle you choose can be used while the
bike is still or only when you start pedalling.

To avoid injury if the user accidentally activates the throttle when stationary, some
throttles can only be used while pedalling. This will help you avoid mishaps when you're
first getting acquainted to your e-bike.Even when the bike is still, certain bikes allow you
to utilise the throttle. They claim that starting from a stop without the normal heavy
pedalling at start-up is a far simpler option. You may lift your feet, push the throttle, and
go with this style of throttle.
3.6 LIGHT

Pedal-assist sensors and a throttle are commonly found on e-bikes. Some electric bikes
contain a motor that only produces electricity when it is needed. The electric motor is
engaged and operated manually in this situation, utilising a throttle that is often located on
the handgrip, similar to those seen on a motorcycle or scooter.

These LED lights are long-lasting, simple to operate, and energy-efficient. The
lights on offer are placed in electric bikes and create a bright dazzle of light in the evenings
when there isn't enough light. Its one-of-a-kind lens design allows light to pass through the
light cup before forming the whole reflection. This results in a more effective light beam
and less light energy loss.

Fig.3.8 Light
3.7 HORN

A horn is a device that consists of a tube, usually made of metal and curved in a number of
ways, with one tiny end into which the musician blows and one large end from which
sound emerges. The bore of a horn, unlike that of some other bass instruments, such as the
trumpet, gradually widens over its length, making it conical rather than cylindrical. In jazz
and popular music, the term "horn" refers to any wind instrument, and a horn section is
made up of brass or woodwind instruments, or a combination of the two.

3.8 BMS Fig.3.9 Horn

The battery management system is in place to keep track of each battery cell's
specific performance. Rather of allowing for individual performance, the BMS assures that
each battery cell drains, performs, and acts in the same way as every other cell in the
battery.

If you have uniform cell performance, which is otherwise impossible, you will have
consistent performance and full operation of your motor. The BMS also extends the life of
your battery. Individual cells without a BMS can overcharge and explode, or they can
drain too far and become un-rechargeable, hastening their overall deterioration. A
defective BMS in your battery is the cause of failure if your Electric Motor Bicycle battery
explores or fails out much sooner than the manufacturer claims. In fact, a defective BMS is
one of the most prevalent causes of your Electric Motor Bicycle's poor performance.
Tips to Manage Your BMS System:
 Don't charge your battery with a charger that isn't rated for it.
 Never leave your battery in a hot, cold, or wet environment.
 After Long Periods of Inactivity, Refresh the BMS System

Fig3.10 BMS
 CHAPTER 4
DEVELOPING AND TESTING OF ELECTRIC MOTOR BICYCLE

4.1 SCRAP CYCLE

We went in search of cycle that was suitable for our design and budget and luckily,
we found one which was in scrape condition. We saw the cycle that was in no condition to
run. We got it to our place then changed few parts and done repairs that made our cycle in
running condition. Below the image is the day we got the cycle for the cycle shop.

Fig.4.1 scrap cycle

 Fig.4.2 convertion of scrap cycle

4.2 RUST PROTECTION

The cycle which be brought it to our place has serious rust issues and few alignment
problems. So, we got sand paper and spray paint cans for paint works. First, we removed
most of the rust and cleaned the cycle with the help of sand paper and then we resprayed
our cycle giving it dual tone finish using spray paint and then we left it to get dry.
 Fig.4.3 painting cycle frame

4.3 PARTS FOR CONVERSION

As we got our cycle and completed the maintenance work, we got ourself some
parts for conversion of our cycle to an E-cycle. The parts contain,
 BLDC Hub Motor
 Controller
 Lithium- ion cells
 Half Grip Throttle
 Instrument cluster
4.4 MOTOR INSTALLATION AND MAKING OF BATTERY
Since we got all the components, we started to make our E-cycle.
First, we decided to install motor. So, we removed the rear wheel and Spoke of the wheel
was removed and aligned with motor. Then we installed rear wheel back to cycle. After
completion of installation of motor, we moved to making of battery.
Since we got it as cells not as a whole battery pack, we had to arranged cells and did
welding between all the battery cells and the wire connections with Battery Management
System (BMS) for the battery.

Fig.4.4 Motor fixed in rare wheel rim

 Fig.4.5 creating battery using cells
Battery cells were connected in parallel using the clamps set that helps to fix the
batteries in a fixed state. That was made with plastic as a frame.

Fig.4.6 connecting cells

 The cells were placed in frame and the cell were connected in parallel by soldering
method. Then the cells connected in parallel were covered with a thin cover that protects
the battery from the temperature and water resist. Then, the second layer is added on that
layer with thick Polythene cover that help for the sealing of the cells.

Then the cells were connected with BMS that connects all the batteries to make the
single output. One end of the BMS is connected to the cells connected in parallel and other
end is output of the battery. Then, the cells were sealed with a plastic seal box. Only two
wires come out from the sealed container that is the output wires.

The battery after the sealed using the multi-meter checking the battery current and
voltage.

Fig.4.7 covering of cells

Fig.4.8 battery sealing
 Fig.4.9 Battery testing

4.5 INSTALLATION OF BATTERY, CONTROLLER AND OTHER PARTS

After connecting all cell wires to BMS we heat sealed the battery pack using a
sheet of PVC heat wrap. we added fuses if the charging current is more than 5 amp. Then
we got an IP 65 box for storing the battery pack to get additional protection for the battery.
We drilled and made two holes for charging and output of the cycle. We made a stand for
the battery using scrap metal and placed it in centre rod between the cycle handle and seat.
We installed throttle, switch, light and horn to the handle bar. Then all connections from
all parts are connected to controller. And the controller is cover with another IP box and
placed it under the seat rod.
Fig.4.10 Installation of battery, controller and other parts

Fig.4.11 After installation

4.6 TESTING OF THE ELECTRIC MOTOR BICYCLE
After completion of the conversion of E-cycle, we took it for testing it on road
with different condition. So, the top speed was around 30 kmph with the range of 35+ km
(depends on driving condition). The charging time was around 4hrs (0-100%).

Fig.4.12 Testing of Electric Bicycle

4.7 A TRIP TO THE COLLEGE AND FINAL FINISH
We went to college for showing our work to college staffs and asked for the review.
Every one review on the performance of the cycle and gave it good comment. They asked
us to change the battery placement. So according their review we have changed as per their
needs. Finally, we painted it for final finish and added some sticker for enhancement of the
looks.
We enjoy the ride to college that every one in our batch raided the Bicycle and
share their feeling with others. Even the other also ride the Bicycle and share their feeling.
Then the faculty members raided the Bicycle and check the performance of the
Bicycle. The acceleration speed was good enough that it can pickup the top speed as soon
the throttle is twisted. It was a best moment while the faculty members raiding the bicycle
it makes us happy.
Fig.4.13 Testing by Faculty
 CHAPTER 5
CONCLUSION AND FUTURE SCOPE
5.1 CONCLUSION
From this project we have done the conversion of scrap cycle to a good condition
E-cycle which has almost every feature compared to every cycle in market. It is cost
efficient and follows all the 3Rs of the eco system. We got a good lithium-ion battery
which gives the range 40km (or even more, depends on the driving conditions.) and a top
speed of 30 km/h.

6.2 FUTURE SCOPE

In future this cycle can be developed and can add additional feature like bi-
directional controller which can regenerate battery power by peddling. Since our project
has single directional converter but it can’t be recharged while riding. So, the regenerative
braking system won’t be available. We can change to bidirectional converter and add that
feature. We can even make an attempt to convert other vehicles like handicapped tricycle
and cycle rickshaws.
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