e-ISSN: 2582-5208

International Research Journal of Modernization in Engineering Technology and Science

( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:05/Issue:06/June-2023 Impact Factor- 7.868 www.irjmets.com

DESIGN AND DEVELOPMENT OF ELECTRIC BIKE FOR ON-ROAD

OFF-ROAD AND LONG DISTANCE DRIVE
Dr. Ramesh S Naik*1, Sandeep R N Shreedhar*2, Khanderao B B Ajaykumar RD*3
*1Assistant Professor, Department Of Mechanical Engineering, Basaveshwar Engineering
College, Bagalkote, India.
*2,3Final Year Student Department Of Mechanical Engineering, Basaveshwar Engineering
College, Bagalkote, India.
DOI : https://www.doi.org/10.56726/IRJMETS41922
ABSTRACT
This Paper involves study, development and fabrication of electric bike was being carried out. Now a days
market is currently witnessing the electric bike era. E-bikes are very economic as well as less noisy compared
to fuel powered bikes. But a major disadvantage of e-bike are battery life is less and short travel distance, it has
two batteries thus it cover long distance and increase mileage. The bike has excellent pickup and speed on
biking tours. This allows for high efficiency yet high power biking experience to the rider. Also it has two saddle
bags supported for tour equipment and supplies. The added backrest is for comfortable back support for long
rides.
I. 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. 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, nickel-cadmium 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 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. The two seater bike for an electric mobility
purpose, quality,
II. LITERATURE SURVEY
Bartlomiej et. al., 2003 [1] provided the evaluation of driving power and energy requirements for automotive
vehicle. A survey of most promising applications of electric and hybrid vehicles in cities with commercial line
solutions was given. Evaluation of vehicle’s energy, when is referred to urban driving cycles, reflects an
important diversification of the average and maximal power requirements. Simulation results of a small car
equipped with advanced fuel cell converter and super capacitor storage bank have indicated the power flow
between these sources at normalized urban driving conditions.
Wenguang et. al., (2005) [2] presented an approach to control powertrain of series hybrid electric vehicles. A
formulation of the system equations and controller design procedure were proposed by them. They also
proposed a new switching algorithm for the power converter for motor torque and motor flux control. The
sliding mode method is applied to excitation winding control in synchronous generator to achieve the desired
current distribution in powertrain.
Biona and Culaba (2006) [3] demonstrated the process of the development of a dynamometer test cycle that
would be reflective of the actual driving conditions in Metro Manila. The development of such test cycle would
be vital to the development of emission factors. The study covers the gathering of actual speed time data,
development of the instrumentation device for the said activity, analysis of the data gathered and extraction of
a test cycle. Results were compared to the Indian drive cycle to demonstrate the inappropriateness of adapting
drive cycles derived from other areasShweta Matey et. al., (2017) [4] carried out a study on design and

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:05/Issue:06/June-2023 Impact Factor- 7.868 www.irjmets.com
fabrication of electric Bike. It compromises with design and fabrication of Electric Bike which makes use of
Electric Energy as the primary source and solar energy if possible by attaching solar panels. It also highlights on
the design aspects of the bike. There is a provision for a charging the battery by ejecting it from the main
system. The electrical power generated which is used to run the bike can give better fuel economy compared to
conventional vehicle, better performance and also causes less pollution. It works on the principle that the
electromotive force of an A.C. motor which receives electrical energy stored in D.C. battery is converted with
the help of D.C. to A.C. converter.
Vladimir Dimitrov (2018) [5] reviews possible approaches to the design of an electric bicycle with an emphasis
on three different domains - electrical, mechanical and system level design. It reviews the available solutions to
a wide range of issues in each of the above mentioned domains. After grouping the solutions presented and
classifying them on a domain basis the paper presents a classification on the ways to design an electric bike, so
that a designer can easily obtain the required information in order to start their project.
Mohamed et. al., (2018) [6] in their study on Electric Vehicles in India Opportunities and Challenges reported
that, the replacement of ICE with electric engines will reduce pollution to a great extent and be profitable to
consumers. Many countries have implemented this technology and are contributing to the improvement of the
environment. The researcher saw the opportunities and challenges faced in India over implementing EVs.
Opportunities like Government Initiatives, Batteries, Industries, and Environment have been considered. These
challenges like the cost of EVs, the efficiency of EVs in India, and demand for EVs were taken into consideration.
The implementation of EVs in India aims primarily to scale back greenhouse emissions and cut oil expenses.
Liao et. al., (2017) [7] studied the consumer preferences for electric vehicles. They reported that widespread
adoption of EVs may contribute to a lessening of problems like environmental pollution, global warming, and
oil dependency. However, this penetration of EV is comparatively low despite governments implementing
strong promotion policies. They presented a comprehensive review of studies on consumer preferences for EV
aiming to convey policy-makers and give direction to further research. They compared the economic and
psychological approach towards consumer preference for Electric vehicles. The impact of the financial and
technical attributes of EV on its utility is generally found to be significant, including its purchase and operating
cost, driving range, charging duration, vehicle performance, and brand diversity on the market. The density of
charging stations also positively affects the utility and promotion of EV.
Shivnay and Yadav (2021)[8] conducted a study on design and analysis of Electric Bike. The increased demand
for electric bikes is the subject of this study. Our main focus is in the automobile industry, where we are
converting outdated bicycles to electric bicycles. The major goal of this study is to present an accurate picture
by linking the many energy sources that humankind has access to humanity In order for humanity to progress
in today's civilized environment, they must travel. And in order to accomplish this, his journey should be as
quick and painless as possible. The Electric Bike, which is powered by a battery and so supplies voltage to the
motor, is the subject of this study. This study is concerned with the design and construction of an electric bike
that runs on electricity as primary energy. In the main system, there is a setting for a rechargeable battery.
III. POWER TRANSMISSION
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.

Fig - 1: Block diagram of electrical components connection.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:05/Issue:06/June-2023 Impact Factor- 7.868 www.irjmets.com
IV. METHODOLOGY
The methodology used in constructing the E-Driven bike is very simple. The main aim of the project is to ensure
efficient operation of the bike by meeting the drive requirements. Considering legal limits on the speed of
electric bike, the maximum speed of the Bike was considered to be 60kmph. Since regeneration is involved,
determining the type of components to be used, given the constraints of weight and size became more crucial.
The procedure followed for methodology is as follows
 Study of Existing E Bike
 Identification of Problem
 Identify the input parameters by literature survey
 Selection of Materials
 Fabrication and optimisation
 Statistical analysis results
 Validation of final data
CALCULATIONS FOR ELECTRIC MOTORCYCLE FOR ITS LIFETIME
 Weight of vehicle = 150kg
 Distance between two wheels=6m(own measurement)
 Power
 Force
 Radius of rim
 Mileage of e-bike
 250watt battery commonly used in e- bike
 Motor speed at no load condition = 3000 rpm
 Required speed on the road = 45 km/hr = 45 km/hr *1000000/60 = 750000 mm/min
 Radius of tire = 8 inch = 203.2 mm
 Required rpm on road = 750000/203.2 = 3691 rpm • Circumference of tire = π*D = π*16 =50.265 inch • 1
mile = 63360 inc
Design Procedure For EBike With Sliding Frame
The design includes analysis of bicycle needs, calculation of electric motor power, making frames with a sliding
frame platform, and brake systems. To calculate the power requirements of an electric motor. first, calculate the
force acting on an electric bicycle. The force calculated includes the rolling resistance, aerodynamic drag,
hillclimbing force, and acceleration force.
As long as you ride an electric bike, the wheels will rotate and friction against the road. The force acting on the
bicycle when it is running is called rolling resistance. To calculate the working force, you can use equation (1).
Fr =m. g. fr ------(1) Where Fr is the rolling resistance force, m is the mass of the electric bike with the passenger
(kg), g is the force of gravity (m/ s2 ) and fr is the friction coefficient. The coefficient value of asphalt/concrete
roads is 0.013, gravel is 0.02, the soil is 0.05, and fields is 0.1 The hill-climbing force can be calculated using
equation (2), where Fg or the gradient (uphill) force, α is the angle or slope of the road. Fg =m. g. sin α -------(2)
As long as an electric bike is running, it will be upwind. This drug is often referred to as aerodynamic force. The
aerodynamic drag force is calculated using equation (3). Where FAd is the aerodynamic drag force, ρ is the
density of the air, CA is the coefficient of aerodynamic resistance and V is the speed of the electric bike. To
change the speed of an electric bike, a force that can overcome drag and give linear acceleration to an electric
bike is needed, this force is called the acceleration force. The acceleration force is calculated using equation (4).
Where FAc is the acceleration force, and a is the acceleration of the electric bike FAd=0.5 ρ CA V²--------- (3)
FAc=m. a ----------(4) To calculate the power required by adding the equations (1), (2), (3), and (4) multiplied by
the speed of the electric bike. Based on the results of calculations and various considerations with a maximum
passenger load of 100 kg, and road conditions on the Universitas Negeri Semarang campus area, 500 watts of
electric motor power is used. The type of electric motor used is BLDC. The choice of this electric motor is
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[2056]
 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:05/Issue:06/June-2023 Impact Factor- 7.868 www.irjmets.com
because it has high motor efficiency, and is easy to maintain. The electric motor used is shown in Figure 2. The
working voltage on the electric motor is 48 V.
The need for electric motor power required battery energy which is greater than electric motor power. To
calculate the power requirements for an electric motor, you can determine the battery capacity. Battery
capacity can be calculated using equation (5). Ebatt = V. Cbattery --------(5) Where Ebatt is battery energy in
units of Wh, V is battery voltage, and Cbattery is battery capacity (Ah). The battery used is a VRLA type. Using
equation (5) the energy in the battery is 576 Wh. This energy will be sufficient to meet the power usage
requirements of the e-bike. Ebike design used Autodesk Inventor software. Using Autodesk Inventor software,
the researchers analyzed the strength of the frame. The results of the analysis include von mises stress,
displacement, and safety factor. The which are shown in
The results of the finite element method simulation using the Autodesk Inventor application with iron material
and get the von mises stress of 49.98 MPa, a maximum displacement of 0.125 mm, and a safety factor is 3.
Based on the simulation results, the prone areas on the sliding frame are at the connection between the front
and rear frames, but the safety factor can still > 3 and can be categorized as safe. • The BLDC motor is used as
the main driver of an electric bike. The electric motor used has a power of 500 watts. The BLDC motor is an
electric motor that has high efficiency and is maintenance-free and does not cause noise. The battery used has a
voltage of 48 volts 12 Ah. • Electric bike batteries can be recharged by plugging in a power supply. The electric
bike takes 7 hours to charge the full battery The test track used an odometer. The odometer used can calculate
vehicle speed, operating time, average speed, and distance traveled. Based on the results of testing electric
bikes on the road, electric bikes can operate for 3.5 hours with an average speed of 20 km/hour and can travel a
distance of 75 km.
V. CONCLUSION
The results of the analysis of the frame using iron material have a von mises stress of 49.98 MPa, a maximum
displacement of 0.125 mm, and a safety factor of 3, and this value is technically safe. • based on the test track,
an electric bicycle using a sliding frame can be travel for a distance of 75 km with a maximum speed of 25
km/hour. In the future, to increase the distance and reduce electric bike weight, electric bicycle batteries can
use lithium-ion, battery system engineering for fast charging, for the e-bike frame can be optimized using
aluminum alloy or composite materials.
VI. REFERENCES
[1] Bartłomiej, Z., Piotr Chrzan and Daniel Roye, 2003, A study of energy requirements for electric and
hybrid vehicles in cities. Proceedings of the 2003 International Conference on Clean, Efficient and Safe
Urban Transport.
[2] Wenguang et al., 2005, An approach to control powertrain of series hybrid electric vehicle.
[3] Biona, J. B. and Culaba, A., 2006, Drive cycle development for tricycles. Clean Technologies and
Environmental Policy, 8: 131-137.
[4] Shweta Matey, Prajapati, D. R. And Shinde, K., 2017, Design and fabrication of electric bike.
International Journal of Mechanical Engineering and Technology. 8: 245-253.
[5] Vladimir Dimitrov, 2018, Overview of the Ways to Design an Electric Bicycle. Electronic, 10: 1-4.
[6] Mohamed, M., Tamil Arasan and Sivakumar, G., Study on Electric Vehicles in India Opportunities and
Challenges. International Journal of Scientific Research in Environmental Science and Toxicology, 3(1):
1-5.
[7] Liao, F., Molin, E. and Wee, B., 2017, Consumer preferences for electric vehicles: a literature review.
Transport Reviews: a transnational, Transdisciplinary journal, 37(3), 252- 275.
[8] Shivnay, P. and R. S. Yadav, 2021, Design and Analysis of Electric Bike. International Journal of
Advanced Research in Science, Communication and Technology, 9(1):165-171

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