International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 p-ISSN: 2395-0072 www.irjet.net Design and Development of Electric Bike Saurabh Gawali, Vishal Kagade, Priyanka Vyavahare, Shravani Kulkarni, Shraddha Potadar Mechanical Engineering Department, Savitribai Phule Pune University, Maharashtra, India. ---------------------------------------------------------------------***--------------------------------------------------------------------1.1 Power Transmission Abstract – The depleting non-renewable energy sources and its hazardous impact on an environment has forced us to think out of the box and take active moves in the field of renewable energy sources. Conventional Internal Combustion Engines use the maximum share of the non-renewable energy sources and as soon as possible we need to find alternatives for the same. In this study, we have designed an Electric Bike which is completely eco-friendly and based on the electric motor concept as an alternative to the Internal Combustion Engine. The selection of batteries and motors while designing such concept totally depends on the desired output or the working load conditions. This dissertation concentrates on designing and analysing the frame of a two-wheeler, twoseater bike for an electric mobility purpose, while considering strength, safety and optimum performance of the vehicle. Electric vehicle is one of the best future technologies for reducing the use of fossil fuels and also to act as environmental friendly by reducing the emission of harmful gases. The electric vehicle has many components like charging module, converters, controllers, batteries, electric motor etc. Key Words: Energy sources, environment, electric bike, ecofriendly, electric mobility. Fig -1: Block diagram of electrical components connection. The power supply is obtained externally by using Power source to generate electricity or from domestic AC supply. This power is then rectified using converter and is made available to the battery through charging module. 1. INTRODUCTION Electric motor is used as a prime mover in the electric bikes. The motion of an object is achieved by transforming the electric energy into movement. The electric bikes are equipped with rechargeable batteries and this phenomenon helps to power the bike according to individual needs. Motor controllers are used to supply the power of batteries, which helps in controlling the input and output parameters of the motor. Drive shaft is used to transfer the mechanical power from the motor to the wheels. In this way, electric power flows through various components in an electric bike and gets converted into mechanical power. Therefore, it is clear that an electric motor determines the output characteristics of vehicle as a whole in terms of power, torque, speed, etc. Two important types of motors used in the electric bikes are brushed and brushless DC motors. The functionality of these kinds of bikes can be improved by introducing an electric power assist system. The alternatives available while making a choice of batteries are lithium-ion batteries, nickelcadmium batteries, lead-acid batteries etc. The configuration of battery changes according to the voltage and capacity required for the vehicle. It is really an important task to select the appropriate rating of motor based on the load to be carried. The electric motor selected for driving a bike must have the ability to provide sufficient power and torque to overcome the force due to load and other opposing forces acting on the bike. The entire Electric vehicle has one thing in common that all of them use direct electric current motors to drive the wheels. However these motors are available with the number of variation in speed, size and method of operation, the torque required from the vehicle to obtain desirable characteristics is the same. It is the torque that forms the part of force to drive the wheels and set the vehicle in motion. In simple terms the torque is defined as the turning power of the motor. The bike frame is a non-standard structural component of bike that links various components of the vehicle systems and provides the vehicle rigidity and strength while operating on various road conditions. This study aims designing and analysing the frame of a two-wheeler, twoseater bike for an electric mobility purpose, where the quality of safety, strength and optimum performance of the vehicle are utmost. © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 505 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 p-ISSN: 2395-0072 www.irjet.net 2. DESIGN Table -1: Values of co-efficient of Rolling Resistance Contact Surface Crr 2.1 Motor Power Concrete(good/fair/poor) 0.010/0.015/0.020 While deciding the power rating of motor for an electric vehicle, vehicle dynamics has to be considered like rolling resistance, aerodynamic drag or acceleration resistance force and gradient resistance. Asphalt(good/fair/poor) 0.012/0.017/0.022 Macadam(good/fair/poor) 0.015/0.022/0.037 Snow(2 inch/4 inch) 0.025/0.037 FTotal = PTotal = Where, FTotal Fr Fg Fa Pg Dirt(smooth/sandy) 0.025/0.037 Mud(firm/medium/soft) 0.037/0.090/0.150 Grass(firm/soft) 0.055/0.075 Sand(firm/soft/dune) 0.060/0.150/0.300 Fr + Fg + Fa Pg + Pr + Pa = Total force = Force due to rolling resistance = Resistance due to road inclination = Resistance offered by air drag = Power required to overcome gradient resistance Pr = Power required to overcome rolling resistance Pa = Power required to overcome aerodynamic drag PTotal = Total power required to overcome the resistance In order to run the vehicle on road, motor has to overcome FTotal (i.e Total tractive force) means output of motor must be greater than PTotal. Therefore while selecting drive motors for an electric vehicle, some factors like Rolling Resistance, Grade Resistance and Acceleration Force must be taken into consideration to determine the required maximum torque. 2.3 Gradient Resistance Fig -3: Gradient Resistance of Wheel It is the force that pulls down when it’s climbing an inclined surface. It is a form of gravitational force. If the vehicle is trading uphill at a slope of θ, as shown in figure, then the weight of the vehicle “W” has two components; One perpendicular to road surface (Wcosθ) and other along the road surface (Wsinθ). 2.2 Rolling Resistance Fg = GVW*sinθ Pg = Fg*V Where, Pg = Power required to overcome Grade Resistance θ = Inclination Angle 2.4 Acceleration Force Acceleration force is the force that helps the vehicle to reach a predefined speed form rest in a specified period of time. Fig -2: Rolling Resistance of Wheel Fr = GVW*Crr Pr = Fr*V Where, Pr GVW Crr F = 0.5*Cd*A*ρ*V Pa = 0.5*Cd*A*ρ*V^2 Where, Pa = Power required to overcome aerodynamic drag Cd = Drag co-efficient ρ = Density of Air V = Speed of the body relative to the fluid. = Power required to overcome rolling resistance = Gross Vehicle Weight = Co-efficient of rolling resistance According to different shape of vehicle which is exposed in the opposite direction to air, the values of drag coefficients are; Sphere – 0.47, Half Sphere – 0.42, Cone – 0.50, Cube – 1.05, Angled Cube – 0.80, Long Cylinder – 0.82, Short Cylinder – 1.15, Streamlined Body – 0.04, Streamlined Half Body – 0.09. Depending on different roads conditions, the values of coefficient of rolling resistance changes. For design consideration, the concrete road surface with fair condition is taken into account. © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 506 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 p-ISSN: 2395-0072 www.irjet.net In case of bike the opposing surface to air is similar as a long cylinder shape so that for design purpose 0.82 drag coefficient is considered. 2.7 Battery Calculations Motor of 900 W, 48 V is selected. Therefore maximum drawing current will be; 2.5 Total Tractive Power P = V*I 900 = 48*I I = 18.75 Amp The total tractive power is to run the vehicle on the road is calculated by summing up all above three forces. But electric motor of such power not selected because there are some transmission losses which have to take into account. Therefore the mechanical power output (Ptractive) required to drive the vehicle is given by; = 19 Amp Therefore, if drawing current is 19 Amp for continuous 1 hour then battery should of 26 Amp. For better lasting, battery having capacity of 26 Amp is selected. Now battery having capacity of 26 Amp easily gives backup more than 1 hour. So, final selected battery is shown in figure. In this battery pack, four batteries are taken having individual capacity of 12V and 26 Amp to get required power to drive the motor. The batteries are connected in series. So the final output of battery pack is 48V 26 Amp. Ptractive= PTotal/ η Where, η = Efficiency of the transmission gear system PTotal = Pg+Pr+Pa Consider the efficiency of the transmission system to be 0.98 (Chain Drive). 2.6 Mathematical Calculations Considering, gross vehicle weight 150 kg with rider i.e. 150 * 9.81= 1471.5 N= 1472 N Velocity of vehicle 40 kmph i.e. 40*5/18= 11.11 m/sec. Pr = 1472*0.015*11.11 = 245.30 W Here, Crr= 0.015 is taken from table-1 for concrete fair road conditions. Let, the bike runs on a flat road surface, therefore, the angle θ=0°. In this case, the power required to overcome gradient resistance is also zero. Fig -4: Battery Connection Pg = 1472*sin(0)* 11.11= 0 2.8 Power Train Calculations Let, drag coefficient from a table 1 for long cylinder shape i.e.0.82 and area of vehicle that resists dragging force is 750 mm width and 1000 mm height. Motor speed at no load condition = 3000 rpm Required speed on the road = 45 km/hr = 45 km/hr *1000000/60 = 750000 mm/min PTotal = PG+PR+PA Radius of tire = 8 inch = 203.2 mm PTotal = 0+245.3+3.82 = 249.12 Required rpm on road Consider the efficiency of the transmission system to be 0.98 (Chain Drive). = 750000/203.2 = 3691 rpm Circumference of tire = π*D = π*16 =50.265 inch Pa= 0.5*0.82*(0.75*1)*1.2*11.112 Ptractive = PTotal /η Ptractive = 250/0.98 = 3.82 W = 255.10 W 1 mile = 63360 inch Therefore, Revolutions of wheel required to go for 1 mile = 63360/50.265 =1260.52 revolutions As per above calculations and conditions total power of motor required to run the vehicle on road is around 260 W, but considering gradient resistance which changes respect to road conditions required more than 500 W of motor power, therefore motor of 750 W is selected. 45km/hr Therefore to go 27.962 mph; After studying the various aspects related to EV, the drafted prototype of the vehicle frame is ready and the calculations comes at the point that the motor required to run the vehicle is of 750 W with 48 V rating then continues drawing current is 15.625 A, therefore battery of 20 Ah capacity is selected. © 2021, IRJET | Impact Factor value: 7.529 = 27.962 mph = 1260.52*27.962 = 35247 revolutions/hr = 35247/60 = 587.45 rpm (at wheel) Now motor will spin at 3691 rpm and wheel will spin at 587.45 rpm. | ISO 9001:2008 Certified Journal | Page 507 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 p-ISSN: 2395-0072 Gear ratio www.irjet.net = N motor/N wheel =3691/587.45 =6.28 Advantage offered by the hand lever: 2.9 Selection of Chain Drive Chain drive is a mechanism in which power is transmitted from an engine to the wheels of a vehicle or a boat's propeller by means of a moving endless chain. It is an array of links held together with each other with the help of steel pins. This type of arrangement makes a chain more enduring, long lasting and better way of transmitting rotary motion from one gear to another. Chain drive is selected from the above calculations. Fig -6: Arrangement of Front Drum Brake Advlever1 In traditional method number of gears were linked together in order to transmit the required motion. This problem of large number of gears is resolved by introducing a chain drive, and the motion is transmitted with the help of two gears and a chain over a long distance. = (l2/l1) Advantage offered by the drum lever: Advlever2 = (l3/l4) Cable efficiency: η = 0.8 2.10 Braking System Force applied at the cam: Fcam=Flever*Advlever1*Advlever2 There are number of different types of braking systems available in the market. Here we are using the Drum Brakes to carry out our application. =4 =5.278 =337.792kgf Coefficient of friction between shoe and drum: μ = 0.4 1. Rear Braking System Maximum force achieved by the brake: Fmax = 2*Fcam*μ =270.234kgf Maximum brake torque: Tmax =Drum Diameter*Fmax =0.13*270.234 =35.13kgf-m RESULTS: Maximum brake force for a rear drum brake = 395.565 kgf Maximum brake force for a front drum brake = 270.234 kgf Maximum brake torque for a rear drum brake = 51.42 kgf-m Maximum brake torque for a front drum brake = 35.13 kgf-m Fig -5: Arrangement of Rear Drum Brake 3. BIKE FRAME CAD MODEL Force applied on the lever: Flever = 20 kgf Advantage offered by the lever: Advlever = (a/b) =2.625 Advantage offered by the drum lever: Advlever = (d1/c1) = 5.278 Force applied at the cam: Fcam = Flever*Advhand lever*Advlever =494.465kgf Coefficient of friction between brake shoe and brake drum: μ = 0.4 Maximum force applied by the brake shoes: Fmax =2*Fcam*μ =395.565kgf Fig -7: CAD Model of bike frame Maximum brake torque: Tmax =Drum Diameter*Fmax =0.13*395.565 =51.42kgf-m. The most important step in the manufacturing of electric bike is to design the frame of bike. Frame of bike is designed on CATIA software. All the dimensions are as follows: 2. Front Braking System Length = 36 inch Width = 13 inch Height = 21inch Weight of bike = 150-170Kg (with rider) Force applied on the lever: Flever = 20 kgf © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 508 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 p-ISSN: 2395-0072 www.irjet.net Table -1: Values of co-efficient of Rolling Resistance 4. ANALYSIS Fig -8: CAD Model of bike frame 4.1 Strength Analysis The 30 at the end of the grade number designates that it has approximately 0.30% carbon by weight. The added chromium and molybdenum help to give the steel different properties from its mild steel counterpart, AISI 1030, even though they have same percentage of carbon. The alloying elements found in AISI 4130 help to increase the strength to a level higher than that of AISI 1030 which is increased even more using proper hardening procedure. The added chromium helps to increase the steels hardenability and also the corrosion resistance; although other types of material with more corrosion resistance property are considered if the material is to be used in corrosive environment. The added molybdenum helps to increase the toughness. To understand the products performance, lifecycle and possible failure modes we need to carry out the strength analysis. Mechanical loading, thermal stress, bolt tension, pressure conditions and rotational acceleration are just some of the factors that will dictate strength requirements for materials and designs. ANSYS Mechanical ensures your products viability and safety by predicting the strength required for the loads your design will experience in service. 4.2 Structural Analysis ANSYS structural analysis software enables to solve complex structural problems and make better and faster design decisions. It is used to optimize their product design and reduce the cost of actual physical testing. In the analysis of the e-bike frame, on the front side 5g force has been applied and on the sides 2g force has been applied. Analysis is done on frame with outer diameter of pipe is 1inch and 0.1mm thickness. Other important benefits of AISI 4130 includes the ability to be easily hardened by heat treating or work hardening and the ability to be case hardened by using a process called Carburizing. In its annealed state, AISI 4130 has good formability, machinability and weld ability. 5. ADVANTAGES OF USING ELECTRIC MOTORBIKES 4.3 Material Selection and Specification The key design decisions of our frame that would greatly increase safety, reliability and performance is material selection. For ensuring selection of the optimal material, extensive research and material comparison in multiple categories is carried out. Key categories for comparison were strength, availability, weight, and cost. A steel tube with bending stiffness and bending strength exceeding that of circular steel tubing with an outside diameter of 25.4mm and a wall thickness of 1.25 mm and a carbon content of 0.32% is selected. i. Electric bike has better 0 to 60 kmph acceleration as compared to gasoline powered bike, because it develops full torque immediately and without clutch the torque is instantly available. ii. The prices on fuels like petrol and diesel are at peak these days where the charging on batteries using available resources is possible at very minimal cost. iii. Electric bikes and scooters need very low maintenance as compared to gasoline based bikes. In electric bikes one basically worries about the consumables for example, brake pads, tires, etc. iv. The electric bikes are eco-friendly, fossil fuels like petrol, diesel produces harmful gases like hydrocarbons, CO2, NOx, etc. and these gases are extremely hazardous to human health as well as a reason of increasing global warming. 4.4 Material Selection and Specification From this matrix it is concluded that the best available material is Chromoly AISI4130. Chromoly (AISI 4130) steel is a type of low alloy steel that gets its name from combination of the words Chromium and Molybdenum – two of the major alloying elements. Chromoly steel is often used when more strength is required than mild carbon steel. Chromoly steel is actually alloy steel grade 4130. © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 509 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 08 Issue: 03 | Mar 2021 p-ISSN: 2395-0072 www.irjet.net 6. CONCLUSION i. ii. iii. The increasing global warming is extremely hazardous to the human life existence on the earth and completely opting out of the factors that affect the environment health negatively is necessary. This paper is an attempt to find alternative power source in place of the Internal Combustion Engine and its effective application in daily life. In the design process, various calculations are done to calculate the resistance which is offered by the electric bike. The battery rating is calculated by referring different research papers. Lead acid battery of capacity 48V 26A is selected. CAD Model of the frame is made on CATIA V5 software where the analysis is carried out in ANSYS software. Considering all the calculations and parameters, the Bike is designed to run at a speed of 45kmph. REFERENCES [1] [2] [3] [4] [5] [6] [7] www.bicyclehistory.net[http://www.bicyclehistory.net/ motorcycle-history/electricbicycle] accessed on 30/10/18.M Saurabh Rege, Chirag Khatri, Mrudul Nandedkar, Noopur Wagh, “Design and Analysis of Frame for Electric Motorcycle” IJIRSET, 2017,6(10), pp. 1950019507 T. Porselvi, Srihariharan. M.K, Ashok. J, Ajith Kumar S., “Selection of Power Rating of an Electric Motor for Electric Vehicles”, International Journal of Engineering Science and Computing, 2017, 7(4), pp. 6469-6472 Kunjan shinde, “Literature review on electric bike”,IJRMET, 2017, 7(1), pp. 73-77 M. Trivedi, M. Budhvani, K. Sapovadiya, D. Pansuriya, C. Ajudiya, “Design & Development of E-Bike - A Review” Iconic Research and Engineering Journals, 2017, 1(5), pp. 36-43 L. Nehaoua, A. Khettat, H. Arioui, H. Imine, S. Espie, “Rider Steer Torque Estimation for Motorcycle Riding Simulator”, IFAC Symposium on Mechatronics, 2010,pp.25–31 H.Keshan, J.Thornburg, T.Ustun, “Comparison of LeadAcid and Lithium Ion Batteries for Stationary Storage in Off-Grid Energy Systems”,IEEE, 2018. © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 510