SANDIP

UN I V E
R S I T Y

-UGC Recognised

Internship Project Report

Name :- Abhishek Kumar
PRN No. :-230201082001
Branch :- Electrical Engineering
:- 5th
Semester
Year:- 3rd
PROJECT ON
FABRICATION OF AN
ELCTRICTWO
WHEELER
FABRICATION OF AN ELECTRICTWO-WHEELER

-
Abstract India is the second largest producer and Environmental problems caused by fossil fuel run vehicles
manufacturer of two-wheelers within the world. It stands next and fuel economy have become a very serious issue in the
to China and Japan in terms of the number of two-wheeler recent years which has led to the earth's temperature to
vehicles produced and domestic sales. In this paper, the increase and also causing various global warming effects. It
following work is carried out with respect to thefabrication of is a necessity to find an alternate to these fossil fuel run
an electric two-wheeler. The chassis ofan existing two-wheeler vehicles which have a significant role in being green,
is selected (1 10cc bike). The engine is replaced by a battery environmentally friendly and economical and most
motor system. The various calculations like power, torque, importantly leaves no carbon footprint behind. Electricity
specifications of battery and motor and range calculation are powered vehicles, meet these conditions and because of this,
carried out. The wiring harness is prepared for the electric it has become the important goal for all vehicle
two-wheeler. The components like the electric motor having manufacturing companies to manufacture vehicles with new
60V are selected and the respective battery with the battery energy which is green, environmentally friendly and
management system for the motor is conjoined. The motor economical. Being an e-scooter, the electrical system plays a
controller, digital display, electric throttle, etc. are assembled promising role in its designing and creation. The electric
to the motor system. The fabrication ofthe electric 2-wheeler system consists ofbattery, mnotor, motor controller and other
is carried out by using the procured components and with the equipment. The most important thing that electric system
help ofthe calculations, the output ofthe vehicle is calculated. does is that it gives power to the motor which helps within
The testing of thevehicle is performed and compared with the the running of the scooter. E-vehicles now include cars,
internal combustion engine. transit buses, trucks, and even big-rig tractor trailers that are
a minimum of partially powered by electricity. Electric
Key Words: Electric vehicles, Battery, Chassis, IC Engine,
vehicles have a very negligible amount of carbon footprint
Fabrication, Testing, Motor, Controller. than gasoline-powered cars, no nmatter where your
electricity comes from. It can easily be said that EV is better
1. INTRODUCTION
to the environment taking into considerations the
India is one among the highest automotive markets within advantages it poses over internal combustion engines. Since
the world these days and having extremely increasing class it run on batteries, it needs to be charged if exhausted and
population with shopping for potential and therefore the this can be done at any place, provided there is an electrical
steady economic process. However, gasoline value has outlet, be it an office or at home.
multiplied over 50% in thirteen completely different steps in
last 2 years. Here comes the potential need for various 2. LITERATURE REVIEW
technologies in vehicles like electrical vehicles (EV) in India. Patent drawing for an "Electric Bicycle" (1895)
though the initial investment is around 1.5 times than
The history of electrical motorcycles is somewhat unclear.
standard IC engine, however time has come back once price On 19 September 1895, an application for an "electrical
of setting is currently additional concern than the price of
car the aim of this report is to explain the technology bicycle" was filed by Ogden Bolton Jr. of Canton Ohio. On 8
November of an equivalent year, another application for an
accustomed manufacture an electrical vehicle and explain "electric bicycle" was filed by Hosea W. Libbey of Boston. At
why the electrical engine is best than the interior
the Stanley Cycle Show in 1896 in London, England, bicycle
combustion engine. It includes reasons why the electrical
vehicle grew apace and therefore the reason it's a necessity
manufacturer Humber exhibited an electrical tandem.
to raise the planet these days. The report describes the Powered by a bank ofstorage batteries, the motor was placed
ahead of the rear wheel. Speed of the tandem was controlled
foremost necessary components in an electrical vehicle and
by a resistance placed across the handlebars. The main intend
hybrid vehicle. It compares the electrical to the hybrid and
of this electric bicycle was mainly for racetrack use.
burning engine vehicle. It conjointly includes the long run of
the electrical vehicle. The general impact of the electrical The October 1911 issue ofstandard Mechanics mentioned the
vehicle ultimately advantages the individuals. Compared to introduction of an electrical motorbike. It claimed to own a
gasoline steam-powered vehicles, electrical vehicles square speed of seventyfive miles (121 km) to a hundred miles (160
measure thought of to be cardinal cleaner, manufacturing no km) per charge. The motorbike had a three-speed controller,
piping emissions that may place stuff into the air. with speeds of four miles (6.4 km), fifteen miles (24 km) and
thirty five miles (56 km) per hour.
In 1919, Ransomes, Sims & Jefferies created a prototype 1) Battery-Lithium lon Battery
electrical motorbike during which then batteries were fitted
Batteries are a group of one or more cells whose chemical
below the seat of the sidecar. Despite the fact that the vehicle
was registered for road use, it never went past the trial stage. reactions create a flow of electrons during a circuit. All
batteries are made from three basic components:
In the 1970s, Mike Corbin built a street-legal electric
motorbike called the Corbin Electric. > An anode(the'-' side),
Later in 1974,Corbin, riding a motorcycle called the quick >A cathode (the '+' side),
Silver, set the new electrical motorcycle speed record at > Electrolyte.
165.387 mph (266.165 km/h). The motorcycle used a 24-volt
electric starter from a Douglas A-4B fighter plane.[14] In When the anode and cathode of an electric battery is
1975, Corbin built a battery-powered prototype street connected to a circuit, reaction takes place between the
motorcycle called the city Bike. This E-cycle used a battery anode and therefore the electrolyte. This reaction between
manufactured by Yardney Electric. anode and cathode causes electrons to flow through the
circuit and back to the cathode where another reaction takes
On 26 August 2000, Killacycle establisheda problem athletics
mile (400 m) in 9.450 seconds on the place. Li-ion batteries are most commonly found in all the
record offinishing 1/4 electric vehicles in the present market.
Woodburn track in Beaver State. Lead acid batteries are used
here at a speed of 152.07 mph (244.73 km/h). Later, LITHIUM-ION BATTERY
Killacycle exploitation A123 Systems Li-ion nano-phosphate DISCHARGE
cells seta brand new 440 yards record of 7.824 seconds SEPARATOR
ELECTROLYTE
ANODE )
breaking the eight seconds barrier at 168 miles per hour (270 CATHODE (+) COPPER CURRENT
km/h) in Phoenix, Arizona at the All Harley Drag racing ALUMINIUM CURRENT
COLLECTOR
COLLECTOR
Association (AHDRA), on 10 November 2007.
In 2012 Electro Force cycles made their debut as a commuter
cycle for commuters to ride to figure or for enjoyment. These
cycles were built by Jennifer Northern of lssaquah WA. She
became the primary woman todevelop and manufacture an LI-METAL
CARBON
electrical vehicle within the US. The speeds reached up to ecoic LITHIUM ION
96.5 kmph in 6 seconds, programmable with regenerative ELECTRON
LI-METAL
braking or on the throttle. Their range was up to 100miles OXIDEs

whilemaintaining 104.6 kmph altogether weather and hills. Figure 1: Lithium-lon Battery.
It was the primary of their kind built by a lady within the US.
VinFast from Vietnam developed two electric scooter models SI.No Item Specification
in Hanoi, with 4 models: Vin Fast Klara A1 (Lithium-ion
battery),VinFast Klara A2 (Lead-acid battery), VinFast Impes 1 Type of Battery pack Li-ion Battery
and VinFast Ludo,On November 20, 2018.
2 Battery Voltage 60 V

3.OBJECTIVES
3 Current 30 A
Fabrication of an Electric two wheeler using an
existing chassis of an Internal Combustion Engine.
4 Configuration 16S12P
> A Chassis of an Internal Combustion Engine two
wheeler was taken.
5 Upper & Lower Voltage 67 V& 51 V
4. METHODOLOGY

I. COMPONENTS USED 6 Voltage & Current per cell 3.7 V & 2550 mah
Literature survey was conducted using various journal 192 cells-12parallel
papers to understand and select the best suited battery and 7 Number of cells
motor and also to know the calculations required pertaining 16 series
the battery, motor and chassis. Maximum Current 10 Amps

Operating Temperature -200 to 600

Table 1: Battery Specifications.

2) Motor-Brushless DC Motor the acceleration and speed of the vehicle. With this sort of
A brushless DC electric motor (BLDC motor or BL motor), controller, full current and power was drawn from the
also known as an electronically commutated motor (ECM or battery all of the time. At slow speeds, when full power
EC motor) or synchronous DC motor, is a synchronous motor wasn't needed, a high resistance was wont to reduce the
present to the motor. With this sort of system, an outsized
using a direct current (DC) electric power supply. It uses an
percentage of the energy from the battery was wasted as an
electronic closed-loop system controller to modify DC energy loss within the resistor. The only time that each one of
currents to the motor windings producing magnetic fields
which effectively rotate in space and which the static magnet the available power was used was at high speeds. The electric
rotor follows. The controller adjusts the phase and amplitude vehicle controller is that the electronics package that
operates between the batteries and therefore the motor to
of the dc current pulses to regulate the speed and torque of
the motor. This system is an alternate to the mechanical regulate the electrical vehicle's speed and acceleration very
commutator (brushes) utilized in many conventional electric similar to a carburetor does in a gasoline-powered vehicle.
motors. The controller transforms the battery's DC into AC and
regulates the energy flow from the battery. Unlike the
carburetor, the controller will also reverse the motor
rotation, and convert the motor to a generator (so that the
kineticenergy of motion is often wont to recharge the battery
when the brake is applied).

Figure 2: Motor.

SI.No Item Specification

BLDC middrive
1
Type Of Motor Figure 3: Controller.
motor
2 Voltage 60 V SI.No Item Specification

3 Normal Torque 39.6 N-m 1 Voltage 60V

Peak Torque 2 Current 60 A

4 114.2 N-m
3 Power 3600 Watt
5 Nominal RPM 3000rpm
Table 3: Controller Specifications.
6 Peak RPM 2500rpm
4) Miniature Circuit Breaker
7 Normal output power 1244 Watt Miniature Circuit Breaker is used to break off circuit
connection during over loading. It works as a fuse.
Peak output power 2991 Watt

Normal Current 25.1 A

10 Peak Current 60.387A

Table 2: Motor Specifications.

3) Controller
In the early electric vehicles with DC motors, a
straightforward variable-resistor-type controller controlled
Figure 4: MCB.
5) Throttle
Throttle is used to control the speed of the motor.
CONNECTION DIAGRAM
Connection Controller +48V 60V for on

Hall sensor wire

Thin red wire (+5V)
Thin yellovw wire (a)
-Thin blue wire (b) 2.88-6|
Thin green wire (c)
Thin black wire (earth wire)
Forward Connection Throttle
Thin green wire
Thin red wre (+5V) 28A-3
Thin blace wirefearth wire)
Reverse Connection Throttle

Figure 5: Throttle. 2.88-2

Speed Meter wire
6) Digital Display GREEN

Display is an essential component which shows all the details High level voltage brake

regarding the vehicle such as speed, range, battery status etc. The signa line zBA-o
Third gear transmission line
BLUE hin green white wire
Thin black wire
Thin pink wire
bj 2.88-3
48V Connection for controller on arm ine
TELLOW

Motor ne 28-4
Alarm line

Sott
+48V
starhard start coversion
133 Thin white wire

Forward/everse
Thin Grey wire

Figure 9: Connection Diagram for Controller.

mm

Figure 6: Digital Display.

Pack
7) DC-DCConverter
Battery
wwoSt
The DC-DCconverter has one function and that is to convert
2.1
the voltage from the battery to supply voltage to the auxiliary puno9
Li-ion

systems.
Conduit 150Omm

60V

DC/OC convertes

wwooz
MCB

line
DM 60V

Figure 7: DC-DC converter.

WwoSt

II. CONNECTIONS 0.7mmess

200mm

Power
Battery
Battery Electronic Motor
Charger
Converter

Controller

Mechanical Link
Unidirectional Electrical Link
User Throttle Demand
Feedback Controller Transmision Wheets
Control Signal

Figure 10: 60V Harness.

Figure 8: Assembly of Components.
12V harness
*all wires are 0.7mm

Conduit

600mm,
5 Headlight
1100mm 4 RH Indicator
400mm 1 LH Indicator
321
2 Speedometer F(F) Display
60V SOC
3 Ground SOC
500mm 400mm
400mm
(A(M)
1
Sgnal
Throttle
400mm
400mm
1 Key o/p(E(F))
2 Key i/p Key
400mm
line/
2 12V i/p (B(M)
1 Brake o/p 21 Brake
Throttle 6dV
400mm 650mm 400mm
Speed

23 1 3
650mm

cket
Bullet (D(F)
(B(F)
C) CM) (A(F)) (B(M)
(A(F)) 12
21 400mm 12
a2 1

(Controller side) DC-DC Converter 12V Auxiliary

Figure 11:12V Harness.

5. RESULT AND DISCUSSIONS M=181kg

g-9.81
Motor- battery Calculations =.004*181*9.81 =7.10N
Given
• Grade Resistance
Vehicle weight: 75 kg
Battery weight: 16kg Fgrad= M*g*sin2.5o
Motor weight: 8+2 kg =181*9.18*sin2.5o= 77.9N
Rider weight: 80 kg • Aerodynamic Drag
Gross total weight: 181kg
Faerodynamie=0.5*Ca*Ap*y2
Motor specification =0.5*0.5*0.7*1.16*(16.6)2 = 55.93N
Volts (v) = 60V Ftota|=55.93+77.9+1.10 = 140N
Power (P) = 1200W
Battery Calculations
Speed=60kmph
Velocity= 60*5/18 = 16.6m/s Watthour=watt*1hour
•
=1800w*1hour
Speed of Motor in RPM
Out of the full battery 80% should be in use and
Nmotor"Speed/ (d*0.001885) 20% should be remaining in thiscase.
d- Wheel dia in cm= d =45.72
Nmotor=60/ (45.72*.001885) = 696.86rpm Watthour=1800*1.20 = 2160wh
Current=2160wh/60V = 36Ah
Motor Torque-Torque on the wheel
• Battery specifications
Tmotor=P*60/ (2*pi*Nmotor) Voltage rating=60V
=1200*60/(2*3.14*696.86) = 16.45 Nm Current rating=36Ah
• Selection of Motor Wattage of battery = 60*36
Force required for moving the vehicle =2160wh
Ftota|=Froling+Fgradient+Faerodynamic • Range Calculations
• Rolling Resistance Power=V*I
Battery=1.8kwh
Frolling=Cr"mass*g Motor=1.2kw
Crr=0.004-tire on asphalt road =1.8kwh/1.2kw
=1.5h
Assuming the motor runs at 80% efficiency
80% of 5h
=0.8*1.5h
=1.2h
Assuming top speed as 60kmph
Range=60km/h * 1.2h = 72km
6. CONCLUSION
The project on Design and analysis of electric two-wheeler
has the following outputs
This paper presented the conversion of a standard IC
Engine vehicle into an electrical Vehicle.
All batterymotor calculations were carried out and
noted for further use
The chassis of the bike was modeled using CATIA
software and it was exported to ANSYS for the analysis
on it
• From the analysis we can say that the chassis is safe to
take on the newly added weight of the Battery and
Motor and other electrical components.
The vehicle will be a fully operational and eco-friendly
electric vehicle.
The comparison between the internal combustion
engine and the electric vehicle is performed