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Design and Development of Electric Two Wheeler

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IJSRD - International Journal for Scientific Research & Development| Vol. 6, Issue 02, 2018 | ISSN (online): 2321-0613

Design and Development of Electric Two Wheeler

Rahul B. Gupta1 Parth C. Patel2 Azlankhan A. Pathan3 Viranchi Shastri4
1,2,3
Student 4Assistant Professor
1,2,3,4
Department of Automobile Engineering
1,2,3,4
Institute of Technology & Management, Vadodara , Gujarat, India
Abstract— Nowadays due to increasing emissions from the powered and hydrogen fuel. Because of a combination, such
vehicles; global warming, greenhouse gases level increases, as environmental concerns, high oil prices and the potential
and the mass use of fossil fuels, the electric vehicles came for peak oil, development of cleaner alternative fuels and
into existence as they deliver good results in performances advanced power systems for vehicles has become a high
and efficiencies in recent years. Electric vehicles are in used priority for many governments and vehicle manufacturers
in the automotive world as it is the most reliable option to around the world. The electrically assisted bikes are
overcome Environmental issues like global warming and normally powered by rechargeable battery, and their driving
greenhouse effect. In batteries, lithium ion has good features performance is influenced by battery capacity, motor power,
like lightweight, fast charging, low self-discharge and long road types, operation weight, control, and, particularly, by
lifespan so it is used widely. The performances of the the management of the assisted power.
Electric Vehicles are affected by the performance of battery This paper contains design analysis for the electric
packs. whereas in motors Brushless DC motors have better bike which includes frame analysis, calculation for the
specifications over conventional brushed DC motor, which performance of the vehicle and test run result of the same.
have advantages better speed versus torque characteristics,
high efficiency, high dynamic response, long operating life, II. FRAME ANALYSIS
noiseless operation higher speed ranges, low maintenance.
A. Design of Frame
To control and operate the motor and battery smoothly for
the long run efficient drive controller and battery The following is the frame design used in making electric
management system is used. Thus the above components bike,
makes the complete electric vehicle which is better option to
conventional vehicle in order to reduce environment issues.
This paper compromises with design and fabrication of
Electric Bike which makes use of Electric energy and 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 no pollution.
Key words: Electric Bike, BLDC Motor, Battery
Management System (BMS), Battery Charging System,
Motor Controller, Battery Thermal Management System

I. INTRODUCTION
The transport sector is one of the major contributors to
global energy consumption and greenhouse gas emissions.
At the time when problems, such as increasing greenhouse This Static Study, it includes linear static study type. The
gas emissions and air pollutions, as well as growing mesh generated during this analysis is Tetrahedral mesh.
dependency on energy import, related to the conventional Material selected during analysis is steel due to its properties
passenger cars transport based on fossil fuels, are becoming such as:
more and more visible, the use of alternative, fuels and  Strength
power trains seems to be a key strategy for heading towards  Toughness
a sustainable transport system Which will be  Ductility
environmentally friendly. Mainly cities has major  Weldability
development in transportation due to urbanization  Durability.
development and development in transportation is more Traditionally an alloy of iron and carbon, steel
important, there is need for action to cope with transport stands as one of the most commonly used metals in the
problems. One of the problems related to City areas is local world across industries from construction to blacksmithing
air pollution and noise, could be reduced by using zero- to sewing. Early steels had variable carbon content –usually
emission battery electric vehicles. It is estimated that 25% of added in the forging process with charcoal — from 0.07
the total cars across the world will run on electricity by percent to 0.8 percent, the latter being the threshold at which
2025. the alloy can be considered proper steel. Modern steel
Other vehicles alternative fuel vehicle is a vehicle content usually maxes out at 2 percent, a material often
that runs on a fuel other than traditional petroleum fuels called cast iron. Early iterations of the alloy can be seen in
petrol or diesel fuel; and also refers to any technology of Egyptian and Chinese artifacts, dating back to circa 900
powering an engine that does not involve solely petroleum B.C. and 250 B.C., respectively. Since then, new
such as Electric Vehicle, hybrid electric vehicles, solar developments and the discovery of new elements have

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Design and Development of Electric Two Wheeler
(IJSRD/Vol. 6/Issue 02/2018/1007)

changed the nature of steel and allowed producers to create can’t travel too fast and have less tyre wear. All electric
steel specialized for specific jobs. vehicles have one thing in common and that is that all of
Some Values for Mechanical properties are as them use Direct current electric motors to drive the wheels.
follow, The density of steel is 7833.000 kg/m3, Its Modulus However, these motors are available with a number of
of Elasticity is 199947.953 MPa , Yield Stress of Steel is variations in speed, size and method of operation, the torque
262.001 MPa, whereas Ultimate Stress is 358.527 MPa. required from the vehicle to obtain desirable characteristics
Steel doesn't show any Elongation property. is the same. It is the torque that forms the part of the force to
These analysis includes Load distribution over per drive the wheels and set the vehicle in motion. In simple
Entity, the load type is force and the value of this load is terms the torque may be defines the turning power of the
2.1e+003 mN along a vector (0.00, -0.79, 0.61). The motor. The following paper presents one such method of
constraint type is fixed hence the Degree Of freedom is calculating the torque.
none.
A. Factors Affecting the Required Torque
The Total number of bodies meshed is 1, Total
number of elements are 35484 and the number of nodes When selecting drive motor for the electric vehicle, a
generated are 67,359. The following mesh generated is of number of factors must be taken into account to determine
size 3. the maximum torque required. These factors are:
1) Rolling resistance
III. RESULTS 2) Grade resistance
3) Acceleration force
A. Displacement Results 4) Aerodynamic drag
Result component: Total Translation COMPONENT NAME WEIGHT(KG)
Extent Value X Y Z Frame 15
131.380 215.183 -365.221 Battery(4*6) 24
Minimum 0 mm
mm mm mm Motor 6
0.0161 0.000 433.518 306.114 Auxiliary Components 5
Maximum
mm mm mm mm Pinion (2*70) 140
Table 1: Displacement Results Total 190
Table 3: Specification weight
1) Rolling Resistance:
Rolling Resistance is the opposing force that the vehicle has
to overcome due to the rolling motion between the wheels
and the surface of motion of the vehicle. The rolling
resistance depends on the co-efficient of rolling friction
which varies depending upon the material of tyres and the
roughness of the surface of motion. The Rolling resistance
can be calculated as:
Rr=W×g×Crr
Where ,W=Weight of bike ,g=gravitational force(9.81 m/s2)
B. Stress Results ,Crr=Co-efficient of rolling resistance
Result component: Von Mises Rr=190×0.012×9.81=22.36 N
Extent Value X Y Z 2) Drag Resistance:
2.95e- -26.072 243.028 -1107.123 Drag resistance is resistance provided by air to bike. Drag
Minimum resistance is product of air density, square of velocity and
012 MPa mm mm mm
0.421 146.449 18.500 46.601 cross-section area. Drag resistance should be consider when
Maximum the speed of vehicle is above
MPa mm mm mm
DR[N]=0.5×Cd×ζ×v2×A
Table 2: Stress Result
Where, Cd= Co-efficient of drag(0.48 To 0.88 for
bike) ,ζ=Density of air (1.2 Kg/m3) ,v=velocity of vehicle
,A=frontal area of bike(1 m2)
DR=0.5×0.48×1.2×1×22.222 =142.19 N
3) Acceleration Force:
Acceleration force is the force that helps the vehicle to reach
a predefined speed form rest in a specified period of time.
The motor torque bears a direct relationship with the
acceleration force. Better the torque, lesser the time required
by the vehicle to reach a given speed. The acceleration force
is a function of the mass of the vehicle. Acceleration force is
IV. DESIGN CALCULATION calculated as:
AF= [W×v]÷t
Electric vehicles save fuel cost, cause less pollution and
bring lucrative tax cuts. They are a much safer ride as they

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Design and Development of Electric Two Wheeler
(IJSRD/Vol. 6/Issue 02/2018/1007)

Where, W=weight of vehicle (Kg) v=velocity of bike (m/s2),  Best for mountain bicycles as they have good hill-
V=80Km/hr=22.22 m/s2 t= Time required for desired climbing characteristics.
velocity (60s) Disadvantage:
AF=190×22.22÷60=70.36 N  Harmful for drive-train components. As power is being
4) Gradient Resistance: transformed through the drive-train, more wear is
Grade resistance is the form of gravitational force. It is the applied on drive-train components.
force that tends to pull the vehicle back when it is climbing  Requires custom frame design and commitment to one
an inclined surface. The grade resistance acting on the motor supplier from the very beginning.
vehicle can be calculated as:
GR [N] = W×g×Sin θ A. Design of drive-train
Where, W= weight of vehicle (Kg), g=gravitational force 1) Design calculation of diameter of chain sprocket:
(9.81 m/s2), θ= angle of inclination (0oto25o) n1 =3000,n2=696.21,
GR [N] = 190×9.81×Sin 0=0 N ,let d1=50mmtherefore, d2=215.45 mm.
5) Torque:
2) Length of chain:
The torque that is required on the drive wheel will be the
one that the drive motor requires to produce so as to obtain L=2C+π ,c=420mm
the desired drive characteristics. The Total Tractive Effort is L=840+417+84=1395mm
the total force required to move the vehicle with the desired 3) Number of teeth:
characteristics and is the sum of the forces calculated in ratio=3000/696.21=3.8,z2/z1=3.8,let standard z1=15,Z2=52
above three sections. Therefore, the Total Tractive Effort 4) Pitch of sprocket/chain:
can be calculated as: a=420,a=centre distance of two sprocket
TTF [N] =RR [N] +DR [N] +GR [N] +AF [N] pmax=420/30=14mm
Where, T=Torque, TTF=Total tractive force, R=radius to pmin=420/50=8.4mm
tire (0.1524 m) therefore from standard pitch=12.7mm
TTF=70.36+22.36+142.19=234.91 N 5) Power transmit capacity of chain
T=TTF×R=35.8 N-m P=Pt+Pc+Ps,pt=tangential power,pc=centrifugal
6) Power Required: power,ps=sagging power
The power required for motor is function of angular velocity Pt=Power of motor/velocity
and Torque v=z1*p*n2/(60*1000)=15*12.7*696.21/60000=2.21 m/s
P= 2πNT÷60 Pt =Pm/v=2000/2..21=904.97 N
Where, N= RPM of rear wheel to reach top speed, T= Pc=m*g=17.81*9.81=91.31N ,m=17.81 from design data
Torque,r=Size of rear wheel book
N=Km÷(2πr×60) ,N=80000÷[2π(12×.00254)×60] =696.21 Ps=k*w*a=448.5 ,k=6,coefficent of sag
RPM w=17.81*10=178.1 kgf ,a=0.42m
P= 2π×696.21×35.80÷60=2610.06W total power = (Pt+Pc+Ps)* Cs=1444.78*1.6=2311.64 N
Hence from the standard Power rating and Cs= service factor of chain standard from design data
considering gradient Force the motor required to propel the book=1.6
bike =2KW.The above results show that the motor torque
for an electric vehicle can be determined if some parameters VI. COMPONENTS AND THEIR SPECIFICATION.
of the vehicle like required grade ability and acceleration are
known. Further, if the required torque calculated is not A. Battery
produced by the available motor specifications then Many batteries, such as lead acid, NiMH, lithium-ion
modifications can be made in vehicle parameters like Gross batteries have been used in an Electric Vehicle. Among
Vehicle Weight, Wheels size, Material of the wheels and them, lithium-ion battery is mostly used due to its high
transmission system. energy density, long lifespan and high efficiency. Because
of its good features, a lot of investments and experimental
V. PLACEMENT OF MOTOR studies have already been made to enhance the stability and
stamina of lithium-ion battery. Besides its high cost, growth
Decision was made in favor of the static motor. It doesn't
of lithium-ion battery has been increasing steadily and is
require special frame design, therefore it's easier to change
expected to continue its growth. The demands required for
motor supplier in the future if needed, it provides the best
riding experience and does have influence drive train batteries are constantly increasing. So, effective control and
management is needed to ensure the safe operation of
components durability (as mid-drive does).Advantage
batteries, with the optimum performance.
include that as mid-drive motor results in good weight
balance and makes it comfortable to lift and it is good for
hill cross-country hill climbing as mid-drive it is.
Advantages:
 Removing both, the rear and front wheel is easy as there
are no additional cables.
 Best weight balance - low and centered.

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Design and Development of Electric Two Wheeler
(IJSRD/Vol. 6/Issue 02/2018/1007)

Fig. 4: volt vs torque

Fig. 1: lithium ion battery

B. Battery Specification
Battery voltage 48V
Battery ampere 42Ah
Table 3: Technical Specifications of Battery.
C. Motor
Brushless DC motors have advantages over brushed DC
motors, they are better speed versus torque characteristics,
high efficiency, high dynamic response, long operating life, Fig. 5: rpm vs torque
noiseless operation higher speed ranges, low maintenance.
So these motor rapidly gains popularity, BLDC motors have
been mostly used in the areas of appliances production,
medicine, aeronautics, Medical equipment, chemical,
automotive, textile, industrial automation and so on. The
small sized motors with external rotors are widely used in
equipment like computer disc drives, tape recorders and
digital audio tapes.
The good operation of BLDC obtains everybody's
favour, but to control is complex and high cost of the dive
are the drawbacks of BLDC motors. Reduce cost drive Fig. 6: Efficiency vs torque
controllers for BLDC motors are more in demand. 2) Motor Specification:
Sr No Feature Description
1 Rated voltage(V) 48 DC
2 Rated power (W) 2000
3 Controller current limit (A) 40.1
4 No load speed (rpm) 3000
5 Max. torque (N-m) >21
6 Max. Power (W) >4000
7 Max. efficiency >82%
Table 3: Technical Specifications of motor
D. Drive Controller
Fig. 2: BLDC Motor The working principle of electronic drive controller is as
1) Graph of motor: follows: with output signal of the position sensor which
The graph stimulate the output of speed, torque, efficiency reflects the position of the rotor, electronic commutation
and voltage required. circuit drives the corresponding power switching device
with the armature winding connection, in turn makes the
armature winding feed, thus generates jumping rotating
magnetic field in the stator, and drives the permanent
magnet rotor to rotate. With the rotation of the rotor,
position sensors constantly send signals, change the power
state of armature windings.

Fig. 3: rpm vs torque

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Design and Development of Electric Two Wheeler
(IJSRD/Vol. 6/Issue 02/2018/1007)

electric vehicle and should be replaced. Battery management

system (BMS) is developed to achieve following goals:
 over voltage protection;
 under voltage protection;
 programmable protection features (voltage, current,
temperature, components);
 internal cell balancing;
 Accurate state of charge and battery health calculation.
Battery management system has two main
components which dictate its design. Firstly and most
important - battery monitoring chip which is responsible for
under and over voltage protection, monitoring and balancing
Fig. 7: Drive Controller internal battery cells.
1) Drive Controller Specification:
Sr No Feature Description
1 Rated voltage(V) 48 DC
2 Rated power (W) 2000
3 Controller current limit (A) 40.1
4 Under voltage protection(V) 41.5 + -0.5
5 Current limited (A) 40+-0.5
6 Consumption (W) =>2000
7 Max. efficiency >82%
Table 4: Technical Specifications of Controller
E. Charger
A battery-assisted charging system has been developed to Fig. 9: Battery management system.
improve the performance of a quick charger for electric
vehicles. Electric Vehicle charging can be divided as VII. READING AND COMPARISON
follows: slow charging up to 4 kW, fast charging with power
of 10-20 kW, and ultrafast charging which is capable of A. Reading
supplying up to 50 kW or higher. Sr no Feature Description
1 Dead Weight of vehicle(kg) 90
2 Battery voltage(V) 48
3 Battery capacity(Ah) 45
4 Distance travelled (KM) 30
5 Top speed 50
6 Weight Carrying Capacity(Kg) 150
Table 5: Reading
B. Comparison
Electric IC Engine
Feature
bike bike
Fig. 8: Battery Charger
Distance travelled per
30 50
F. Battery Management System charge/per liter(KM)
A system called Battery Management System using the Cost to travel per KM(Rs) 0.33 1.42
lithium-ion battery is compulsory so that battery can work Charging time/refuelling
3.5 0.05
safely and reliably preventing any physical damages, and time(h)
handle thermal degradation and cell unbalancing. Further, Air pollution No yes
different states of the battery such as the state of health Maintenance cost month(Rs) 100 500
(SOC), state of health (SOH) can be obtained through an Table 6: Comparison
efficient battery management system. The State of Charge
(SOC) signifies the remaining energy in a battery which
gives an idea about charging and discharging strategies and
protect the battery from overcharging and over discharging.
The State of Health shows the ability of a battery to store
and supply energy with respect to its initial conditions. It
also reflects the current condition of the battery in terms of a
percentage, referenced to a new cell. At State of Health <
80%, the battery is considered no longer usable by an

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Design and Development of Electric Two Wheeler
(IJSRD/Vol. 6/Issue 02/2018/1007)

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