Design and Fabrication of Electric Bike

We are designing and fabricating the Electric Bike using the Electric Power Train of a Brushless DC Motor along with using the Battery Backup of Lithium-ion.We will be converting the conventional gasoline bike into a fully electric model, with making some changes in bike design in order to make

Project Title

Design and Fabrication of Electric Bike

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

We are designing and fabricating the Electric Bike using the Electric Power Train of a Brushless DC Motor along with using the Battery Backup of Lithium-ion.We will be converting the conventional gasoline bike into a fully electric model, with making some changes in bike design in order to make it more practical and more appealing. At the same time, our focus is to minimize the weight factor of the bike, making it as light as possible to improve the efficiency and range of our backup battery.The final product will be a bike which can bear a load capacity of a maximum 120 kg

Project Objectives

The primary objective of the project is to design a feasible yet highly adaptable lightweight E-Bike for the current market gap of EVs in Pakistan. Due to Backlog in this Electric Transporation in Pakistan government is promoting such venture to fulfill sustainability factors and improve environmental conditions.

Our Objective includes designing maintenance-free affordable and clean Transportation for an average middle class user who can afford this and it would be a daily source of transport.

Reducing the Dependency of Fuel which is drastically increasing day by day

Project Implementation Method

We have divided our project into multiple phases in order to achieve.

Initiation Phase:

In this phase, we  started finding the best possible designs and modules which we can use to make our bike design well rounded to our customer's need

During this, we have done Research on bike design,and electrical components integrated into the conventional bike

2nd Phase:

During the second phase, we finalized the Electrical Components and then started sourcing them around PakistanSorted out Different Vendors for the equipment as they were now openly available in the markets

 3rd phase:

In the third phase we started working on our battery systems using lithium-ion cells combination. New Lithium cells cost alot which can take up to 50% of total project cost so for minimizing this cost factor we have used the old laptops' lithium cells, filtering the good quality cells making it available to provide us the good backup,for that we have tested

4th Phase: (Current Phase)

In this phase, we are working on Designing the Battery Management System( BMS) for our Battery, right according to our need, after this we will be integrating BMS with Battery and started testing our Battery backup for the final usage

5th Phase:

this Phase will be an integration phase in which we will be integrating our Electrical Equipment and Battery system into our bike chassis and taking several test , making sure every part both mechanical and electrical is working well

6th phase:

This Phase would be final in which we will be working on  designs for setting battery backups into bike and reducing the  extra weight from chassis and modification if needed to make it more better both visually and performance-wise

Final Phase:

In final Phase, we will be testing our prototype through different testing phases in order to confirm that everything is working smoothly, and remove the possible errors which could be raised during the testing

Benefits of the Project

Benefits of the Project include:

• Sustainable Transport
• More Economical in Every Aspect
• Eco-Friendly Drive mode
• Being Electric it takes just 15% of the cost of one liter of fuel for the same mileage.
• No Dependency on Fuel
• Light Weight Chasis
• One time investment, no Maintencce Required
• Easy to Drive
• Would be more Attractive in looks and performance
• Market Gap in Pakistan, more opportunities in this specific sector
• Using Lithium-ion Battery backup instead of lead-acid through which 50% of the range is increased and 70% decrease in weight.
• Average Lithium backup have 2000 charging cycle or almost 4 years life as compare to lead-acid  or dry battery

Technical Details of Final Deliverable

We are Using a Brushless DC Motor of 2000 Watts with a Lithium-Ion Battery Backup of  64 Volts and 20 Amp .for this purpose we use 18650 AAA 3.7 Volts Cells . We have used almost 200 cells to make it up to 64 volts.

Designing the Spot welder for joining the cells with each other using the old microwave oven transformer

Integrating the 16s Battery Management system with our Battery System, making sure it charge and discharges every single cell equally. keeping sure to reduce heating in cells.

BLDC motor will be controlled through our motor control system with having a phase shift of 120, which will run on 60 to 72 volts that our lithium-ion battery will give.

and For charging of the battery, we have designed 5A  350 W charger that can charge our battery from o to 100 within 4 to 5 hours

The Resulting Prototype would be able to cover 70 to 90kms under a single charge with a maximum speed of up to 80km/hr.This value may vary depending upon the mode of driving and total  weight load on ike

Final Deliverable of the Project

Hardware System

Core Industry

Transportation

Other Industries

Energy

Core Technology

Clean Tech

Other Technologies

Others

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Sustainable Cities and Communities

Required Resources

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