Mechanical Design for Smart E-Bike: Design, Analysis, and Manufacturing

This report outlines the design, analysis, and manufacturing process of a smart e-bike for Western Sydney University. It includes performance criteria, design constraints, specifications, basic design decisions, and design analysis. The report also covers the manufacturing process of the frame, handlebars, forks, and other components.

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MECHATRONIC DESIGN
By Name
Course
Instructor
Institution
Location
Date

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Executive Summary
The aims and objectives of the project design are outlined and explained within this report. In
addition, the criteria of performance is too discussed in a manner which the standards of
design that are supposed to be achieved, development requirements and the disadvantages of
the design are well elaborated. During the methodology of design, the process of mechatronic
design is underwent which entails the consistent and outlined regular E-bike devising process
that undergoes numerous conceptual designs to approve whether they achieve the standards
of design. X (DFX) design is a process or technique in which an assessment of the assembly
design, manufacturing design, analysis effects, mode of failures and the environmental design
which all satisfies the criteria of quality.

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Table of content
Contents
Executive Summary...............................................................................................................................2
Table of content....................................................................................................................................3
Introduction and background.................................................................................................................5
Aim and objective.................................................................................................................................6
Performance Criteria and Design Constraints........................................................................................7
Specifications of design.....................................................................................................................7
Basic Design Decisions.........................................................................................................................8
Design Analysis.....................................................................................................................................8
Design for X (DFX)...........................................................................................................................8
Design for manufacturing..............................................................................................................8
Products Manufacturing...................................................................................................................11
Mechanical disc brake.....................................................................................................................15
Contrast...........................................................................................................................................15
A system of chain driven.............................................................................................................15
Belt driven system:......................................................................................................................15
Electrical motor (hub motor)...........................................................................................................17
Assembly manufacturing costs:...........................................................................................................19
Design for Environment (DFE)...........................................................................................................19
Life cycle assessment..........................................................................................................................20
Environmental impact.........................................................................................................................21
Safety design.......................................................................................................................................23
Road rules:.......................................................................................................................................23
Safety equipment:............................................................................................................................23
University of western Sydney..........................................................................................................24
Rack system of the bike:......................................................................................................................24
Design Analysis....................................................................................................................................25
Force analysis..................................................................................................................................25
Stress analysis..................................................................................................................................25
Motion analysis...............................................................................................................................27
Final Design........................................................................................................................................28
Frame – handlebars..........................................................................................................................28
Forks or frame.................................................................................................................................28
Attaching wheels, tires and hubs.....................................................................................................28
Frame-wheel....................................................................................................................................28

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brakes..............................................................................................................................................29
Frame-saddle, e-bike seat................................................................................................................29
Internal-frames................................................................................................................................29
Results.................................................................................................................................................29
Analysis for the finite elements...........................................................................................................29
Mode of failure and analysis effects....................................................................................................30
Discussion...........................................................................................................................................31
Benefits............................................................................................................................................31
Disadvantages..................................................................................................................................31
Recommendations/further work..........................................................................................................31
Acknowledgments...............................................................................................................................32
3D design files.....................................................................................................................................33
For the whole bike...............................................................................................................................36
Conclusion...........................................................................................................................................36
Bibliography........................................................................................................................................38
Appendices..........................................................................................................................................39
Appendix A – Existing E-bike.........................................................................................................39
Appendix B – Concept Designs.......................................................................................................41
Appendix C – Final Design Drawings/Model..................................................................................42
Appendix D – Bill of Materials.......................................................................................................46
Appendix E – The Addition Add-ons (Bought Items).....................................................................48
Appendix F – DFX..........................................................................................................................50

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Introduction and background
Throughout the campuses of Western Sydney university of Penrith for example, Kingswood,
North Warrington and South Warrington campuses, it has regularly discovered that it is hard
or a challenge arriving to this mentioned regions as a result of consumed time duration while
travelling. In contradiction, there are always buses and shuttles stationed at this areas to solve
the challenge although either the exact time when the busses or shuttles arrive or the accurate
time that are consumed while waiting for the arrival of the shuttles and busses which also acts
as an addition to emission of carbon (Oman, 2016). These factors entails particular issues
which relates to the amount of shuttles and buses which travels across each campus are
varying thus creating numerous challenges and the existing distance separating each campus
region or buildings to travel too. These challenges and report are vividly examined and cross
checked by this report with an aim of finding solutions towards enabling a good atmosphere
within the campus hence the need or desire of implementing the smart bikes aimed at
improving and shortening the time spent on arriving at the desired location of requirement.
And the electric bike can be shown by the following diagram;
Fig 1 : Showing an example of an electric bike (Oman, 2016)

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Aim and objective
This project mandated a main goal of developing and designing an e-bike possessing the
below listed aspect:
 Friendliness to the neighbouring environment
 Possession of aesthetically pleasing design
 Design attaining sustainability
 A functional efficiency
 Proof to theft
 Usability safety
The smart bicycle is to be designed and introduced to the community of Penrith University to
be adopted by the university students to freely travel within the institution while achieving
sustainability for the rest of the public or students within the institution. The key goal of the
entire system is coming up with a bike that avails a smart campus whereby the travelling time
duration between and across campuses and lectures around or within Kingwood, north and
south Warrington is greatly reduced to a negligible duration. It is a capability finding the
originality of locations which normally consumes time to reach while walking as an
opposition, and only deserves a couple of few minutes to reach or arrive on a smart bicycle.
Another significant target of the smart bicycle is the functionality, environment protection
and e-bike costing.

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Performance Criteria and Design Constraints
Specifications of design
There existed an intension of creating or coming up with a bike that would be utilized by a
variety of students hence the need of looking for a single design that would fit all students.
Since sizing of the bike was very significant, it became the initial step of approach hence
forming a beginning idea or concept. In relation to the design, it was a key consideration that
the chosen design met the standards best suiting all students.
Allowing easy transportation of students from or between UWS campus of Penrith since
students had to travel the distance between various campuses in order to attend lectures was
the main intention to be achieved by the bike. However, majority of the students currently
border busses and cars to reach their destinations between campuses as the travelling means
between the campuses despite this idea being not practical as it results to environmental
pollution thus coming up with an e-bike would easily facilitate travelling of the students
between the campuses cheap, faster and more friendly to the environment. Coming up with a
pedal assist bike is the main function or intention in addition to creativities such as generators
that would provide power freely as result of the pealing by the student directed to the user’s
smart phone and or light for the bike.
The bike would have to meet the goal of complying with the above listed requirements of
design as a criteria for evaluation and in addition, the degree of achieving the requirements of
design will be assessed, the most fitting design requirement and too taking a consideration to
the suitability of the most complex design of manufacture.

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Basic Design Decisions
Towards the end concept of Appendix B, figure 9 was settled on as a portion of the main idea
was having very minimal materials as the system of damping would complicate the process
of manufacturing since the support of the seat frame would need a compulsory system of
pivoting attached to the main frame of the bike. It simultaneously resulted to a consideration
to the frame force analysis leading to the choice of material being very significant. This will
be elaborated further within the report.
Design Analysis
The concepts 1 and 2 as shown in the figures 8 and 9 of the Appendix B chooses putting all
the components in a frame making the bike to look aesthetic acts as a protection of the bike
from weathering. These mentioned components entails system of the belt drive, generator and
battery, hub of the motor and all-inclusive wiring system.
Design for X (DFX)
Design for manufacturing
Design for manufacturing commonly known as DFM is a practice for development of the
entire process of manufacturing across the development of the product. Majority of the e-bike
parts that are single are usually effective in relation to cost since there exist numerous parts or
components that are accompanied to the bicycle which includes both expensive materials and
parts that have to undergo manufacturing process. All these brought together results into a
generally expensive bicycle being sold. DFM forms a general solution to the desired
processes of manufacturing in such a manner that the whole process is made simple. The
main concept in this is to generally reduce the value or the costing of the product and the
material quality as well.

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Materials
During the primary and manufacturing production process and level of production of
products, materials or substance utilized are usually known as raw materials. They usually
compose of natural resources such as soil, wood and iron just to mention a few. These raw
materials are usually modified in order to be used in other related processes. They are at
times talked about as supplies which are generally purchased and sold over the whole world.
ITEM
NO.
PART COST ($) QTY.
1 Frame 550 1
2 handle bars 50 1
3 Hub-Motor 290 1
4 side plate cover 25 1
5 E-bike seat 170 1
6 pedal assembly 1
6.1 Arm 40 2
6.2 Tube 20 1
6.3 tube pedal 30 2
6.4 Pedals 200 2
7 Battery 20 1
8 front tire assembly 1
8.1 rim front 150 1

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8.2 Tire 38 1
9 wheel back 1
9.1 Rim 150 1
9.2 Tire 38 1
10 final bike generator 1
10.1 rubber wheel 10 1
10.2 generator shaft 20 1
10.3 bike light generator 15 1
10.4 motor for generator 60 1
Table 1: showing the cost of materials of electric bike.
 Alloys of aluminium properties- very strong but light, great resistance to corrosion,
ability to recycling, friendliness to the environment and cost effective.
 Alloys of titanium properties- good strength, relatively low density, good resistance
to corrosion and possession of light weight.
 Steel alloys and its properties- better resistance to corrosion, strong or hard,
formability features, ductility, resistance to corrosion and less cost effective.
 Fibre of carbon- possession of high strength to weight ratio, high electric
conductivity, and resistance to corrosion and relatively less cost effective.

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Steel alloy and alloys of titanium were considered since the two materials were very
compatible throughout the project design. In addition to this, steel was the commonly used
material in the bike designing facility of the manufacturing process in comparison to
titanium. This material, steel, is very light, very cost effective, friendly and easy to be applied
in work, possess a low density, highly resistance to corrosion and possess high durability.
In the last moments of deciding on the materials to be used, both steel and titanium were
examined while testing their respective strengths via the process of PEA which categorically
settled on the titanium as the strongest and most viable of the two. Eventually, titanium was
utilized as the final material or product since it possessed the best strength or hardness in
addition to it having a light weight.
Products Manufacturing
Frame
The material that is selected, titanium is made smooth through heating then proceeded by
soaking in acids. Hollow pieces of the material are then made after which are measured and
cut into the desired measurement specifications. A process usually known as cold drawing is
then conducted which produces the said modified material into a shape applying a solid
material that is forced into the internal section via the hollow piece with an aim of making it
have a hollow circular shape. The materials are then passed through a butting process which
adjusts the thickness in the intended regions required.
The following step of process is the combination or joining together the material pieces that
are hollow forming a frame in a geometric shape. This mentioned process is accompanied
with gluing or welding which are adjusted when hot with an intention of getting the best

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accuracy. On completion of this, the frame is exposed to painting via spraying or chroming
with an aim of preventing it from effects of corrosion and foe the last touch (Slinn, 2010).
The resultant frame that is being produced is thus a very unique element that encompasses of
extreme differing shapes and thickness which are required in order to avail the internal
appliances which includes generator and wiring with an intension of re-ensuring the desired
thickness quantity capable of conducting the said internal appliances. The diagram below
shows frame of electric bike
Fig 2 : Showing frame of electric bike (Slinn, 2010)
Handlebars and forks
This is a process similar to the one on frame. The material that is selected, titanium is made
smooth through heating then proceeded by soaking in acids. Hollow pieces of the material are
then made after which are measured and cut into the desired measurement specifications. A
process usually known as cold drawing is then conducted which produces the said modified
material into a shape applying a solid material that is forced into the internal section via the

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hollow piece with an aim of making it have a hollow circular shape (Henshaw, 2016). The
materials are then passed through a butting process which adjusts the thickness in the
intended regions required.
The following step of process is the combination or joining together the material pieces that
are hollow forming a fork or handlebars in a geometric shape. This mentioned process is
accompanied with gluing or welding which are adjusted when hot with an intention of getting
the best accuracy. On completion of this, the handlebars is exposed to painting via spraying
or chroming with an aim of preventing it from effects of corrosion and foe the last touch too.
Fig 3 : Showing Handlebars and forks of the electric bike. (Henshaw, 2016)
Wheels or rims
The material made of aluminium is forced to pass through a template in order to make an
extrusion profile. The resultant profile is thus cut to a length, adjusted into a hoop through
rolling and combined together through jointing through welding or gluing. In addition, the
prior intended design for the wheels are extracted in forma of a component with a modern

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design of centroid instead of spokes passing via the canter. The resultant piece is a single
modern designed piece and the separate parts usually two are both glued or welded as a mode
of combination.
Fig 4: Showing wheel and rim of the electric bike (Rosay, 2011)
Saddle/seat
Injection moulding is performed on the saddle which shapes the saddle from a mould of
metal. Padding process is then conducted on the solid saddle where a cell foam surface is
glued with an aim of providing soft seat. Heavy blades are used to cut the foam. It is then
attached to a shell of plastic using an adhesive spray which is applied through use of spray
gun.

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Fig 5: Showing saddle/seat of the electric bike (Rosay, 2011)
Mechanical disc brake
Cables are used to make mechanical disc brake to work together with handlebars
levers. Nevertheless, mechanical discs are cheap in terms of cost, maintenance and
they are of lighter weight as compared to the hydraulic brakes, making mechanical
uncomplicated although hydraulic is more powerful in terms of braking and uses
cable fluids.
We bought our disc brakes from ‘ the bicycle store’ company which has a wide range of
brakes to choose from in which avid elixir for the 3 hydraulic brakes was preferred.
A bicycle without chain is known as a belt-driven bicycle whereby the chain has taken the
place for belt system connected to the crank transmitting energy from the pedal to the wheel.
Contrast
A system of chain driven
Amiable when working with it, less expensive and is able to withstand pressure, force
or wear.
Belt driven system:
Less expensive, able to withstand force, pressure and wear, and it’s a single element.

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We have decided to use belt-driven system for our design because it is harmonious with this
design given that it is of great strength than the chain driven will be.
For the e-bike to move the system of belt driven is connected onto the cranks that in turn
affects the pedal motion.
Fig 6: Showing peddle of the electric bike (Rosay, 2011)
For the purpose of this master piece we choose to buy the pedal because they were less
expensive to buy than to manufacture. We bought the pedal component from ‘The Bicycle
Store’ company. The company is the most popular online bicycle store in terms purchases in
Australia, hence it is more trustable to buy the product you need. Clip less and platform are
most common pedals used on bicycle.
 Clip-less pedal
Has a clip-less mechanism and straps.
 Platform pedals
Do not have a strap or a clip-less mechanism to secure the riders foot to the pedal.

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The most important part in the bike design is the generator because it is able to charge your
phone while travelling as it has cables connected to it that facilitate that. At night, the
generator source has enough energy to power the head and tail light. The ‘Bike World USA’
is where we choose to buy this product which offer guarantee in case the generator fails or
break it will be replaced at no cost fee.
 12V-6W universal generator
 Enduring, cheap and light
 In case of failures or breaks, maintenance or replacement required will be done at no
cost.
Electrical motor (hub motor)
‘Golden motor’ company’s smart pie model electrical motor is what we will use for the
design of the e-bike.
Smart-pie hub motor:
 Brushless gearless motor:
This electronically commutated motors is gearless dependant, noiseless due to no
gear, lasting, highly efficient and maintenance is free when required.
 Built-in controller:
It is an attractive part and easy or simple being placed at the rear wheel
 An open DC voltage:

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With an aim of attaining the intended goal of standards, alterations are applied to
speed and power and improvements are also conducted to the voltage from 24V-
48V.
 Built-in cooling fan
Can effectively disperse the heat within the motor, higher ability to climbing,
Enhanced performance.
The electric bike motor is shown in the figure below;
Fig 7: Showing electrical motor of the electric bike
 Programmable controller:
Using USB cables for control parameters programming.
The electric motor will be fitted at the back wheel where energy will be generated enabling
users to travel with the e-bike to the campuses and lectures and back.

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Assembly manufacturing costs:
The time needed to bring together every single parts together is what is known as assembly
manufacturing cost that is checked and produced to an end product. The time taken and
quality of the assembly is what lead to manufacturing cost.
Total cost of the bike:
Design for Environment (DFE)
The 3 properties for the Design for Environment
1. Recyclability design
2. Energy efficiency
3. Innovation materials

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We have taken into consideration these key factors in our design
1 recyclability Design- equipment design that is easy to raise to a higher stand and/ or
recycle
 The bike is master planned in a way that it has very few component or parts.
 The bike can be easily be dismantle for recycling purposes.
 The drained lithium Ion battery can be easily be replaced
 Non environment friendly substances such as glue and adhesive are not used.
 All components that can be recycled are marked.
 Common fasteners are used for assembly so that they can be used again when the bike
has life time has reached an end.
Life cycle assessment
With an aim of evaluating the environmental burden as a result of sustainability development
awareness, the life cycle assessment (LCA) is used. Since the loss of renewable resources,
sustainability has become the goal of global industries (figure 20, appendix F).
Life cycle assessment was applied in assessing the environmental impact of the products
entire life from the raw materials obtainment via process of production, utilization,
distribution process and reusing or recycling of the material.
China will host the manufacturing of the bike which is intended to be consumed in Australia,
UWS of Sydney. The chosen region will be utilised in assessing the environmental impacts
related to the bike transportation from the site of manufacturing to that of its utilization or
consumption. Estimations in terms of distance between the two regions are at 8700km which
utilized in the careful weighing of the transportation impact on the environment that too

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entails the fossil fuels consumption. We master planned the bike to be utilised for about ten
years at the university and to continue in existence for a period of 20 years before reaching
the end of its life time of which twenty percent of the materials will be recycled, 5.0%
cauterized and seventy five percent will end up in a dumping ground.
Environmental impact
When studying the environmental impact there are four areas we look at.
1. Acidification of air- the emission of acids to the air such as sulphur dioxide and
nitrous oxides lead to increase in rainwater acidity which further lead to acidification
of lakes and soil. The water together with land becomes hazardous for living of plants
and life of the water animals and plants in general as a result of these emissions.
Manmade building materials such as concreate can also be corroded by these acidic
rains.
2. Total energy consumed- to ascertain the amount of sources to the non-renewable
energy in relation to the lifecycle of parts which is normally measured in mega joules
units (MJ). The impacts include the energy or fuel utilised in the period of the
lifecycle of the product and also the energy of upsurge needed for acquiring and
processing these fuels in use and the incorporated materials energy of which its
burning might lead to discharge. PED is conveyed as total calorific energy value
demanded from non-renewable resources for example natural gas, petroleum and
many others. Taken in consideration are also efficiencies in energy conversion for
example heat, steam power etc.
3. Carbon footprint- the burning of fossils fuels lead to the release of carbon dioxide and
other gases accumulating in the atmosphere which in turn increased the average
temperature of the earth. Carbon footprint act as a representation of a larger impact

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factor known as Global Warming Potential (GWP). Extinction of species, loss of
glaciers and more extreme weather among others are all blamed on global warming.
4. Water Eutrophication- eutrophication occurs when overabundance of nutrients is
added to a water ecosystem. When the algae bloom as a result of nitrogen and
phosphorous from waste water and agricultural fertilizers leads to oxygen depletion in
the water as a result leading to the death both plant and animal life in water. Kg
phosphate equivalent (PO4) or Kg nitrogen (N) equivalent is usually the measure of
this impact.
Majority of the environmental effect is from acquiring the bike raw materials as noted from
the graphs in (figure 23, appendix F). Manufacturing is mostly assembled from fasteners and
very little welding used in the processes hence manufacturing accounts for very little impact
on the environment.
The little power to operate the motor also make it has little impact on the environment in
general. The environment impact of the bike can be shown by the following graph
Component environmental impact
The top ten components on the bike that contribute most to the four areas of environment
impact are shown on the component of environment impact graph. we can see when looking
at the initial design of using titanium for the whole bike that the frame and the wheel make up
for the top three component attributing most to the impact on the environment. Alternative
materials were examined in order to reduce the overall impact of the bike to the environment.
It is clear that Frames and front and rear rims made of titanium contribute the largest impact
on the environment. To reduce the impact on the environment further it was agreed that front
and rear rims materials to be changed to a different material with matching properties. the
strength and light weight properties of aluminium was the reason it was selected as well as

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the wheels would not undergo similar stresses the frame will be subjected to therefore
titanium is not needed. The LCA is run again to contrast the two different materials and we
can now confirm that the impact on the environment of the rims is largely minimized and
only accounts for the third and fourth most attributing components to the environment given
that extraction of aluminium has a lower impact on the environment.
Safety design
Road rules:
 A bicycle with a motorised component embedded to the back of the wheel (auxiliary
power) cannot produce more than 250 watts. This specific e-bike is as well limited to
a certain speed limit with a maximum speed of 25km/h which need the rider to pedal
to obtain the power which is refers to as ‘pedalec’.
 A type of a bicycle that is being aided and equipped with one more auxiliary drive
motor is what is known as pedalec.
 The e-bike has a shutdown system, that sensors the travelling speed shutting down the
power supply completely coming from coming from the motor that is if the bicycle
supplementary motor was ever to go over the required maximum speed of 25km/h.
Safety equipment:
 Light connected at the front of the e-bike for night condition.
 Safety headpiece.
 Reflectors embedded to the back and front of the e-bike for night condition.

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University of western Sydney
 Single direction for bike lanes travelling.
 More street lights to enhance vision for riding at night conditions.
 Zone safety sign directing riders to reduce speed limit approaching buildings and or
increase when in safety zones.
 Restricting speed limit to 10-15 km/h around lectures and buildings.
 Speed signs- enable awareness of the speeding conditions when buildings, lectures
and campuses.
Rack system of the bike:
Moving through lectures/ buildings and campuses, placement of e-bike is an issue needed no
be overlooked when attending lectures.
 Bike rack that provide for theft prevention.
- Able to lock the e-bike in the bike rack slot by using your student ID card to swipe
access to lock whereby only you can access the slot to remove the e-bike from the
bike rack.
 Shelter in adverse weather conditions need a bike rack.
 A separable lever slot to make the e-bike immovable at a particular place.
 A cable able to charge the electric motor.

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Design Analysis
Force analysis
Force acting on the e bike as it moves on a mountain is explained using the below diagram;
Fig 8: Showing the forces acting on the e bike as it moves on a mountain (Henshaw, 2016)
The force exerted on the frame of the e bike can be analysed as shown in the diagram below.
Fig 9: Showing the force analysis of the e bike (Rosay, 2011)
Stress analysis
The process of the stress analysis of the frame of the e bike can be summarized using the diagram
below;

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Fig 10 : Showing the process of the stress analysis (Slinn, 2010)
The frame finite element shown in figure 11 below was developed by the help of the Computer
Aided design and design loads. The self-weight and the operating loads are treated based on their
distribution on the frame. HyperView and HyperMesh are always employed for the Fenite element
modelling and post processing. But the preliminary analysis is done using the beam element to get
faster result.

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Fig 11: Showing the Von-Mises stress
Fig 12: Showing the frame part of the electronic bike developed from the CAD.
The diagram below shows the frame analysis obtain from the simulation
Fig 13 : Showing the frame of the e bike from simulation
Motion analysis
The motion analysis of the e bike is basically done to ensure how the bike will move in different
topography of the road that is, moving on the mountain, slope region and the plain grounds.

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Final Design
The process of putting together each individual part into a product that varies in solutions and
many ways is called assembly process.
Frame – handlebars
Raising, flattening and dropping may be done to the handlebars. The handlebars are made
into contact to the bicycle stem through bolting then fixed to the frame or the head tube.
Materials such as cups, bearings and locknuts also known as the components to the headset
are attached to the head tube allowing components of the headset to turn within the head tube
hence making steering and rotation of the handle bars simple and easy.
Forks or frame
These components, frame and fork makes the easiest assembling components since part of the
frame as a component needs to connect to the thread containing folk outside while the inside
the folk is threaded enable the frame and the folk screw on
Attaching wheels, tires and hubs
The organisational international standard needs to be met by the wheels in relation to size and
diameter of the wheel. On completion of the manufacturing of the wheel on the machine, it is
possible to radically and laterally straighten the wheel with an aim of achieving a consistent
and regular tension.
Frame-wheel
An axis is made to run through the wheel hub as the wheel is attached to it making the axis
capable to undergo tightening through application of screws and bolts by either quick or at
the end.

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brakes
The lever of the brake is connected to the handlebars which receives all controls from the
hands with presence of extended cables the entire frame inside to the brakes that are attached
to the callipers. Cloth or plastic made tape stands a possibility of being attached to the
handlebars where handle bars endings covers the hole through plugging.
Frame-saddle, e-bike seat
Extrusion of the saddle assembly to a limited component use is achieved by the design frame
as a result of the concept of the saddle lever being contained by the frame. The lever can be
attached to the component of frame through welding. As a result the components and limited
materials are utilised in bringing together the frame and the saddle.
Internal-frames
The opening are utilised in attaching the internals to the frame side and at times at the
opening of the back frame. The pedal shaft, motor and belt drive are first installed and then
all wires are plugged in to the battery and the added generator through the opening at the side.
It is normally the opposite of the steps DFA for the disassembly design, DFD.
Results
Analysis for the finite elements
The major analysis was conducted on the frame as it formed the main concern. A weight of
90kg was used producing a force of 2200N. The force was then exerted on the seat. A fixed
geometry on the frame vase was too applied. The seat experience a little displacement,

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Experiments were too conducted on the handle bars with a force of 80% and 20% on the seat
and handle bars respectively
Mode of failure and analysis effects
The possible failure modes that stand a possibility of happening on the components of the
bike are discussed. This process categorically determines the accurate product of potential
and simultaneously minimises the impacts originating from this. It normally ranges from 1-
1000, good-catastrophic respectively.
Its main essential concepts include the following:
 The requirement
 The possible cause
 The available solution
 The mode of failure
 The effects
In order to ensure that the bike is the most appropriate for its task, risk priority number needs
to be found out. It is used in risk assessment in identifying the failure modes involved within
the design.
The most common failure modes the bike could have include:
 Possible cracks on the bike frame as shown on figure 28, Appendix F. this had an
RPN of 328 which is not risky though closer to 1 is best.
 Excessive vibrations from the motor on a failure mode causing a lot of noise as shown
in figure 30, Appendix F. possible solutions were using stronger materials. It

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possessed a RPN of 812 which is very harmful hence a decision of using Al to reduce
the RPN.
Discussion
Benefits
Possession of the all moving components internally stands as an advantage of the design in
comparison to smart e-bike as smart e-bike contains gears and chains exposed hence making
our design safer to users. The bike is again made stronger by the application of titanium as a
design material making the bike stronger and durable saving both maintenance and
replacement cost.
Disadvantages
The choice of design was the best out of the available designs though with room for
improvements. In the design, a component enabling items storage was not made possible
unlike the smart e-bikes with pouches for storage of items such as books.
A chance of improvement too relies on the implementation of the kickstand allowing keeping
of the bike upright by the student instead supporting it on an object. This makes it dangerous
in relation to security or its distraction could cause an accident to the neighbouring person.
Redesigning of the seat making it softer would improve comfortability to students who sits
for the lecture for a long duration hence making rides for the students more at ease.
Recommendations/further work.
For a better result of the electronic bikes in future it is highly recommended to use relatively
bigger motors and very powerful battery which will be able to run these motors and makes
the bike to operate effectively both on the mountain and on the plain regions. These

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electronic bike should be as well be incorporated with pedals which can be physically
peddled by man so that when there is break down in the electrical part then it can be ridden
through the pedals .
Acknowledgments
The research paper was done successfully and it meets all the required objectives, I would
like to acknowledge the people would worked hand in hand with me to ensure that this
research paper is done successfully. Therefore it cannot go without giving thanks to the
following;
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ii. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
iii. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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3D design files
For frames

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For the whole bike
Conclusion
The following aspects were abided by our group in the design and creation of the e-bike:
friendliness to the environment, aesthetical appealing design, sustainability in design,
effective and efficient functionality safety and resistance to theft.

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A sustainable design is achieved through use of durable materials. The electricity
consumption amount is reduced by the erection of the generator. In addition, application of
materials that can undergo recycling encourages environmental friendly design. Finally, with
an aim of eradicating theft, a system of GPS is placed.
Bibliography

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Henshaw, P., 2016. Choosing, Using & Maintaining Your Electric Bicycle: The Essential
Buyer's Guide. 4th ed. Hull: Veloce Publishing Ltd.
Mann, J. Y., 2013. Bibliography on the Fatigue of Materials, Components and Structures.
2nd ed. London: Elsevier.
Oman, H., 2016. Electric Bicycles: A Guide to Design and Use. 2nd ed. Hull: Electric
Bicycle Manua.
Rosay, C., 2011. Electric Bicycle Conversion Kit Installation - Made Simple (How to Design,
Choose, Install and Use an E-Bike Kit). 3rd ed. London: AR Publishing Company.
Slinn, M., 2010. Build Your Own Electric Bicycle. 2nd ed. Manchester: McGraw Hill
Professional.
Appendices
Appendix A – Existing E-bike

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Fig 1 : Showing an example of an electric bike (Oman, 2016)
Fig 2 : Showing frame of electric bike (Slinn, 2010)
Fig 3 : Showing Handlebars and forks of the electric bike. (Henshaw, 2016)

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Fig 4: Showing wheel and rim of the electric bike (Rosay, 2011)
Fig 5: Showing saddle/seat of the electric bike (Rosay, 2011)
Fig 6: Showing peddle of the electric bike (Rosay, 2011)

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Fig 7: Showing electrical motor of the electric bike
Appendix B – Concept Designs
Figure 8 – Concept 1

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Figure 9– concept 2
Appendix C – Final Design Drawings/Model

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Figure 10
Figure 11

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Figure 12
Figure 13

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Figure 14
Figure 15

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Figure 16
Figure 17
Appendix D – Bill of Materials

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ITEM
NO.
PART COST ($) QTY.
1 Frame 550 1
2 handle bars 50 1
3 Hub-Motor 290 1
4 side plate cover 25 1
5 E-bike seat 170 1
6 pedal assembly 1
6.1 Arm 40 2
6.2 Tube 20 1
6.3 tube pedal 30 2
6.4 Pedals 200 2
7 Battery 20 1
8 front tire assembly 1
8.1 rim front 150 1
8.2 Tire 38 1
9 wheel back 1
9.1 Rim 150 1
9.2 Tire 38 1

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10 final bike generator 1
10.1 rubber wheel 10 1
10.2 generator shaft 20 1
10.3 bike light generator 15 1
10.4 motor for generator 60 1
Table 1 – Bill of Materials
Appendix E – The Addition Add-ons (Bought Items)

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Figure 19 - Disc brake
Figure 20 - Belt drive system

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Appendix F – DFX
Figure 21 - Life Cycle Assessment impact factors
Figure 20 - Manufacturing and Use Region
Fig 21 - Environmental Impact

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Figure 24 – Von Mises of the frame
Figure 25 – Displacement of the frame

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Figure 26 – Von mises of frame handle bar assembly
Figure 27: Displacement of frame handle bar assembly

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Figure 28 – FMEA of Bike Frame
Figure 29 – FMEA of Motor
Figure 30 – FMEA of Rims

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Figure 31 – FMEA of Tyres
Figure 32 – FMEA of Battery
Figure 33 - FMEA of Pedals