Implementation of EFI and Hybrid System on a bike

Project Title

Implementation of EFI and Hybrid System on a bike

Project Area of Specialization Internet of ThingsProject Summary

The purpose of the project is to implement EFI (Electronic Fuel Injector) and Hybrid Mechanism on motorbike. The project is divided into two phases i.e. the installation of EFI system and the implementation of hybrid system.   Electronic fuel Injection system enhances the fuel efficiency with the help of the ECU (Electronic Control Unit). ECU takes readings from various sensors and controls the amount of fuel injected into the system. EFI is not only essential because it optimizes the fuel efficiency but is also responsible for low carbon emissions. EFI is implemented by integration of Chinese EFI kit on conventional cd70 bike. The efficiency in fuel consumption is increased up to 40 %. As for the hybrid part, it has a planetary gear system which connects Engine and Motor simultaneously is implemented and aligned with the engine. Motor installation and coding for a hybrid Mechanism allows bike to run on fully or partially by electric motor and engine. The integration of this system as a whole reduces the fuel consumption by delivering adequate amount of fuel to the engine for a required output and by running on an electric motor. 

Project Objectives

To optimize the fuel efficiency, the installation of EFI is very essential. It not only increases the fuel efficiency but also caters to the problem of excess fossil fuel consumption. However, the EFI alone does not cater to the problem of excessive fuel consumption and does not enhance the smoothness of the bike. Furthermore, the hybrid system also increases the efficiency of the fuel by getting an assistance of a motor that is powered by a battery. This reduces the fuel consumption to some extent. For adding RPMs from both the motor and the engine the problem is that if the rpm of one of the system is greater than the other than the other system starts acting as a load to the one which is rotating faster, so to overcome this issue we are using parallel hybrid mechanism. Our objective is to reduce the fuel consumption and carbon emissions. The objective can be completed by installing and Electronic Fuel Injection System and a hybrid mechanism.

Project Implementation Method

The design and installation of the hybrid system faced several challenges. Developing the system where both the powers from the engine and motor could be added was the initial challenge. After having dealt with it, the balancing of the system was a concern since all the planetary and the motor arrangement were done on the right hand side of the bike, this   disturbed the alignment and balance of the system. Furthermore, the kick had to been installed on the right side of the bike because of the lack of space on the right side. In general, space limitation was a major problem because of the compact shape of the bike. After having done   and dealt with all of it, the coding had to be done in such a way that would cater our proposed solution.

The following is the procedure followed:

• Purchased Metro CD 70cc.

• Installed EFI on the bike. EFIs available in the market are for a car, but couldn’t be installed due to the size of the cam sensor so a customized kit was purchased   and Installed fuel pump.

• The already installed drop pin carburetor was removed and butterfly carburetor is   installed as per required for the EFI.
  In addition to the EFI the following sensors were also installed:
• O2 sensor
• Mass air flow (MAF) and Throttle position sensor (TPS)
• ECU
• Capacitor Discharge Ignition (CDI)

• Silencer was also removed as to keep an open flow is needed to keep the sensors cool.

• After the complete integration of the EFI and all the sensors, a device was needed to   add the powers of both the engine and motor and so a planetary gear set was chosen.

•  

• For the planetary gears to be added, modifications to the shafts were done. An idler   shaft was added to support the clutch system which is originally placed on the engine shaft.

• The carrier gears were connected to the engine, the sun gear to the motor and the ring gear to the transmission via a clutch mechanism just so that power source from the transmission can be engaged or disengaged

• As the motor could not be attached directly due to the limitation of space, it was   proposed to connect the motor to the carrier with the help of the belt system. But, the   belt system gave rise to the lubrication problem that had to face later on because the    belt would fail to transmit power to the shaft because of slipping. Hence, the mechanism of belts was changed to sprocket and chain system.

• After the integration of the planetary system, clutch system, and the motor, following picture shows the final assembly.

Benefits of the Project

• Protection of the environment
• Increased mileage
• Improved efficiency
• Affordability
• Ease of use
• Can Generate employment if taken as a startup
• Can reduce imports if manufacturing is started in Pakistan

Technical Details of Final Deliverable

For conclusion of this project we have been able to obtain the desirable results. In light of the problem statement, which emphasized on improving mileage and reducing emissions, this project has been a success. As stated earlier, the project had two phases i.e. Implementation    of EFI and the Implementation of a hybrid system. Both of these phases have been a    completed successfully as the first phase helped increase the mileage from 45km/l to 65km/l, which is a very impactful achievement. The second phase i.e. the implementation of hybrid system increased the output from 65km/l to 85km/l. With these both systems installed together on a single bike, the bike consumes very less fuel and hence the problem of fossil fuel burning   is minimized to a great extent. The idea is to create a safe and clean environment for the future generations and save them from the adverse effects of greenhouse gases.

Another point of consideration and achievement is the fact the designed EFI kit is ready to be installed on any 70cc motor bike and give it a thumbs up i.e. it is good to go. And also, the   design of the hybrid is pretty unique and is expected to be a great success if followed according to the original base design after improvements.

Although, a lot has been effort has been done on this but there is always a room for more. The budget, time, workforce and the limitation of the space have been the main constraints. With    the increase in budget, brushless motor can be used instead of brushed since it is everlasting with lesser wear and tear, and has a greater rpm. Moreover, the planetary can be designed especially for this system. Currently, the planetary gear system has been used of the Suzuki   alto and so lots of modifications had to be done hence increasing the complications. Apart from this, with lesser complications in the system and higher budget a proper casing for the purpose of lubrication can be made to drive the smoothly and efficiently.

Final Deliverable of the Project Hardware SystemType of Industry Transportation , Others Technologies Internet of Things (IoT), OthersSustainable Development Goals Affordable and Clean Energy, Climate ActionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	80000
EFI kit	Equipment	1	40000	40000
Motor+Controller	Equipment	1	10000	10000
Bike	Equipment	1	20000	20000
Planetary Purchasing, modification and installation	Miscellaneous	1	10000	10000