Design and Fabrication of an Electric Tree-wheel Bike:

The Electric Bike is a battery-powered bicycle designed to address the energy crisis and environmental
concerns. By utilizing an electric motor, it offers a sustainable alternative to conventional
transportation, promoting awareness of eco-friendly travel options. Our innovative system includes
the potential for solar panel integration, enhancing energy efficiency. E-bikes are user-friendly,
economical, and lightweight, providing a comfortable ride with high mobility efficiency. They
represent a versatile solution for local trips and contribute to a greener future.

Electric-powered vehicles are gaining popularity for short commutes, driven by advancements in
battery technology, particularly Lithium chemistry, which offers high energy density and rapid
recharge rates. Benefits include low running costs, silent operation, and zero emissions. However, to
match the range of internal combustion engines, larger, costlier batteries are needed. This Masters
project aims to explore performance improvements through advanced motor control techniques,
comparing them to typical motor controllers in a small electric vehicle.

BLDC motors are widely used because of their extraordinary characteristics and best output rate.
BLDC motors have best working characteristics like high starting torque, high efficiency around 95-
98%, etc. BLDC motors are preferred for high power density design as they display better
characteristic with compare to other motors used.
Electric vehicles use rechargeable lithium-ion batteries to power their motors, known for their high
capacity and energy density. In this project, we focus on lithium-ion batteries, as they offer superior
efficiency and are ideal for long-distance travel. We designed a battery pack that meets our
competition guidelines, leveraging the advantages of lithium-ion technology over alternatives like
LiFePO4 and lead-acid batteries.

BLDC motor selection:

Motor Selection The BLDC motor has been selected as the electric drive in this work, due to its high
efficiency, good reliability, compactness, lower susceptibility to mechanical wear, high starting torque,
less electrical noise, high range of operation and long lifespan. A load test of the BLDC motor has been
carried out and the data are shown in Table-1. From the load test data, the characteristics of BLDC
motor is analyzed and performance plots are as shown in Fig-2, Fig-3 and Fig-4.
By analyzing the characteristics of the BLDC motor, it is evident that the BLDC motor provides a
maximum efficiency of 81:8 % at a speed of 211 rpm and at an output power of 268 watts. Based on
the above test result, it is found that the selected motor is suitable for the electric bicycle, since it has
high efficiency at maximum torque conditions and the torque-speed characteristics are linear as
shown in Fig-3.

Block Diagram:
The diagram shows the parts and the connection between them so it can be easily identified. The
parts are as follows:
 1)Battery 2)Motor.  3)Controller.  4)Shaft drive.  5)Throttle.  6)Charger.

Battery: Lithium batteries, or lithium-metal batteries, use metallic lithium as the anode and are known
for their high charge density and long lifespan, though they tend to be costly. A lithium-ion battery
comprises three main components: the positive electrode (metal oxide), negative electrode (carbon),
and electrolyte (lithium salt in an organic solvent).
Motor: A DC motor is a rotary electrical machine that converts direct current into mechanical energy,
using magnetic fields. It typically includes a mechanism to change the direction of current flow.
Widely used in the past, DC motors can be powered by existing direct-current systems and offer
speed control through voltage adjustment or field current changes. Common applications include
tools, toys, and electric vehicles. The specified motor has a capacity of 750 watts and a maximum
speed of 1000 RPM.

Chain drive: A chain drive transmits mechanical power using roller chains, commonly found in
bicycles, motorcycles, and various machines. It connects a differential to the rear axle, allowing for
vertical axle movement over bumps. This design is simpler and lighter than a rigid driveshaft system,
resulting in less unsprung weight at the rear wheels compared to alternatives drive.

TRANSMISSION: A transmission is a component in power systems that controls power application,

commonly through a gearbox with gears to adjust speed and torque. Primarily used in vehicles, it
adapts engine output to drive wheels and can switch between gears manually or automatically based
on speed.
Manual transmission: A manual transmission functions similarly to a bicycle gear shifter. Pressing the
clutch disconnects the engine from the transmission, allowing the driver to shift gears. Releasing the
clutch re-engages the engine, enabling continued driving in the selected gear.
Automatic Transmission: An automatic transmission is essentially an automatic gear shifter. Instead
of manually shifting the gears with a clutch on a manual transmission car or a gear shifter on a bicycle,
the automatic transmission does everything for you. . A car with an automatic transmission has a
torque converter that senses these changes as you accelerate and shifts you to a higher gear. The
same process works in reverse as you slow down. Automatic transmissions are easy to use. However,
in the past, some automatic transmissions of this type have had a number of problems; they were
complex and expensive, sometimes had reliability problems (which sometimes caused more expenses
in repair), have often been less fuel efficient than their manual counterparts (due to "slippage" in the
torque converter), and their shift time was slower than a manual making them uncompetitive for
racing. With the advancement of modern automatic transmissions this has changed(which sometimes
caused more expenses in repair). The same process works in reverse as you slow down.

CONTROLLER: Electric bike speed controllers vary by type: adaptive or purpose-built. Adaptive bikes
add an electric system to a regular bike, while purpose-built bikes offer smoother acceleration and
additional features. Speed controllers send voltage signals to the motor hub, using mechanisms like
Hall effect sensors in purpose-built bikes for rotor orientation. Adaptive bikes may use electromotive
force for rotor detection. A half-twist throttle serves as the user control interface for motor operation.
The throttle on this system outputs a Hall-effect DC voltage that analog circuitry converts to a duty
cycle on the output waveform. The control circuit also functions as a mode selection switch, adjusting
mode as the throttle is turned. Small hysteresis is required to prevent mode-switching fluctuations,
which would cause discomfort due to rapid changes between driving and braking.
• Rated Power : 750W • Rated Current : 30A • Under-voltage protection : DC41.5V+-0.5V
• Current Limited : 30A+-0.5A • Efficiency : >=83% • Consumption : <1.5W

Throttle: The throttle on an e-bike works like a motorcycle throttle. Engaging it provides motor power
to move the bike forward, with power typically decreased by restricting current. While some e-bikes
use a twist-grip throttle, it’s often a simple button that functions like a car’s gas pedal, allowing for
easy acceleration with no additional action needed.

Charger: The charger supports charging for bike and car batteries with adjustable current settings of
2A or 4A. Charging takes 3-4 hours for bikes and 8-10 hours for cars, with shorter times if the battery
isn’t fully drained. Batteries should be stored in moderate temperatures (15-25 °C) in a dry place and
recharged after each use. Avoid charging below 0 °C and switch off the battery if it has a power
button. Charge batteries on a non-flammable, dry surface, away from heat and humidity. Recharge at
least once a month, even if unused, and use only the supplied charger.

Motor Power Rating Calculation: The motor power will be selected based on power required to
propel the vehicle. This is depends on weight of the vehicle and top speed have to go. To find out the
power required to propel the vehicle calculations are done using vehicle dynamics.
1 Wheel Speed: Initially we assumed that motor rated speed is 1750rpm from this we can calculate
the wheel speed.

Velocity: From the wheel speed velocity of the bike is calculated

Power Required

Torque @ 750 RPM

Tractive Effort

Acceleration
Static and Fatigue Simulation of Telescopic Fork Suspension System Used For Motorcycle
The use of telescopic fork suspension (TFS) in motorcycles, which are optimized for handling but often
compromise ride quality due to stiff suspension systems. Traditional TFS designs face challenges with
minor road irregularities and fatigue loads. The study focuses on modeling and simulating TFS using
various materials, including alloy steels (SAE 1541, SAE 1045, SAE 9262) and aluminum (Al 7075 T6),
through Finite Element Analysis (FEA). It analyzes fatigue simulation data under constant maximum
amplitude loading for material optimization using ANSYS Workbench and ANSYS n Code Design Life
software. Despite their advantages, many motorcycles continue to rely on telescopic forks due to
their dominance in performance, even as manufacturers explore alternative suspension solutions.
Understanding the impact of mean stress on material fatigue behavior is crucial, as fatigue
simulations evaluate the elastic-plastic stress-strain responses and damage accumulation in these
systems.

FORK MODELLING: This paper presents modelling on inverted telescopic forks, also known as
„Upside- down‟ forks which employ nowadays for modern motorcycles. In „Upside- down‟ forks
design, the larger diameter outer tubes fixed in the triple clamps, and fork inner tubes are at the
bottom, fixed to the wheel axle. These forks are well known to provide increased stability while
attempting aggressive manoeuvres. This „Upside- down‟ fork arrangement decreases the unsprung
weight and increases torsional stiffness of the motorcycle, which can improve handling. During
working, motorcycles are generally provided with two inverted telescopic forks. „Fig. 2.‟ shows
dimensions and modelling of single inverted telescopic fork considered for simplification of simulation
purpose. Inverted telescopic forks have improvement in overall riding and also offer increased side-
to-side and lateral resistance as compared to conventional telescopic forks is considered here for
design and analysis.
MATERIALS SELECTION AND CHARACTERIZATION: The motorcycle fork being examined consists of
four materials SAE 1541, SAE 1045, SAE 9262 and Al 7075 T6. The mechanical properties of SAE 1541,
SAE 1045, SAE 9262 and Al 7075 T6 materials listed in Table 1. The same material and its properties
are also listed in ANSYS ncode materials library.

Materials:

Mild Steel:
Low-cost, versatile form of steel with 0.05–0.25% carbon content, making it strong, tough, malleable,
and ductile. It has low tensile strength but can be hardened through carburizing.

Rubber:
Known for unique elasticity, rubber is vulcanizable and susceptible to cracking. It melts around 180°C
and dissolves in solvents like turpentine and naphtha, often requiring shredding for effective
dissolution.

Plywood:
Made from glued wood veneers with alternating grain direction, providing stability and resistance to
splitting. It has an odd number of plies to prevent warping and belongs to the engineered wood
family, including MDF and particle board.

Results
1. Stability: The three-wheel design enhances stability, especially on uneven terrain, making
navigation easier and more confident.
2. Off-road Capability: The rough terrain three-wheel e-bike is built to handle various off-road
conditions, including gravel, dirt trails, and rocky surfaces.
3. Electric Assistance: Equipped with a motor and battery, the e-bike offers pedal-assist or full electric
propulsion, facilitating easier traversal of rough terrain and climbing hills.
4. Enhanced Comfort: These e-bikes typically feature suspension systems that absorb shocks and
vibrations, resulting in a smoother ride and reducing physical impact on the rider.
5. Accessibility: The three-wheel design provides additional stability, making the e-bike more
accessible for riders with balance or mobility issues, allowing them to enjoy off-road adventures
confidently.

Conclusion:
With rising consumption of petrol and diesel, shifting to alternatives like electric bikes is essential.
Electric bikes, which can integrate solar panels, offer an energy-efficient, affordable option for short
distances and all ages. Key benefits include zero fossil fuel use, pollution-free operation, and low
noise, making them eco-friendly and cost-effective per kilometer. Easily charged with an AC adapter,
they also require minimal maintenance due to fewer components, which are easy to dismantle.
Light Electric Vehicles (LEVs), particularly electric tri-wheelers, are expected to gain popularity in the
next one to two decades. They offer efficient transportation for short distances, especially in urban
areas. Electric tri-wheelers are well-suited for industrial transport and benefit from improved charging
behavior due to lithium batteries, enabling high-speed charging. With modern electrical components,
they ensure safe and smooth operation, providing a long-lasting alternative that addresses current
challenges. This makes them an ideal solution for those with limited resources while maximizing
utility.
From pre-test data and post-test data analysis, there are some conclusion that we get from the
calculation of electric motor and lithium battery on Team IIRED E-BIKE: The 1000W, 48V, 3000 rpm
BLDC motor has enough capacity to drive for IIRED E-BIKE to join E-BIKE CHAMPIONHIP 2021. The
maximum efficiency of the BLDC motor is 85% at speed ranges 2900-3100 rpm. Lithium-ion batteries
have a depth of Discharge (DOD) of 61.87%, with a discharge capacity of 1950 Wh. This means that
the energy in the battery 48V 50Ah Lithium-ion battery pack is able to meet the power requirements
for the endurance round. An energy consumption efficiency on the testing track, yielding of 35
km/kWh & 25 km/kWh.

References:
The sites which were used while doing this project:
www.wikipedia.com
www.researchgate.net
www.iopscience.iop.org

1) Design and Fabrication of an Electric Bike

Srijan Manish, Jitendra Kumar Rajak, Vishnu Kant Tiwari and Rakesh, Quad Bike Design And
Simulation: A PreManufacturing Methodology, International Journal of Advanced Research in
Engineering and Technology (IJARET)Volume 5, Issue 6, June (2014), pp. 6876

2) AN INNOVATIVE METHOD FOR CREATING AN ELECTRIC TRI-WHEELER FOR LONG-DISTANCE

TRAVEL
Agus Purwadi, Jimmy Dozeno, Nana Heryana, “Testing Performance of 10 kW BLDC Motor and
LiFePO4 Battery on ITB-1 Electric Car Prototype,” Procedia Technology., pp. 1074 – 1082, Nov.2013.
 https://jnao-nu.com/Vol.%2014,%20Issue.%2002,%20July-December
%20:%202023/31_online.pdf

3) The Calculation of Electric Motor and Lithium Battery Capacity of IIRED E-BIKE
Shun xiang id , guangdi hu , ruisen huang , feng guo and pengkai zhou,“lithium-ion battery online
rapid state-of-power estimation under multiple constraints”, school mechanical engineering,
southwest jiaotong university, chengdu 610031, china, 2018.

4)DESIGN OF A ROUGH TERRAIN E-BIKE WITH THREE WHEEL

Design and Development of a 3-Wheel Electric Bicycle
https://www.researchgate.net/publication/35097911

4) Real time analysis of an intelligent torque controller for a hybrid bicycle

Muetze A & Ying CT, “Modeling and analysis of the technical performance of dc-motor electric
bicycle drives based on bi-cycle road test data”, IEEE International Conference on Electric
Machines and Drives, Vol.2, (2007), pp.1574-1581

5) Static and Fatigue Simulation of Telescopic Fork Suspension System Used For
MotorcycleYogesh Mahajan, A. A. Likhite, D.R. Peshwe, “Failure of front shock absorber of a
motorcycle,” International Journal of Advanced Research in Engineering and Technology , 5,
2014, pp. 141–148.