E-Bike System Design Project Report - University Project

This project report details the design of an electric bicycle (e-bike) system, focusing on a multi-charging approach for a lithium-ion battery. The system incorporates three charging methods: a 120VAC outlet, regenerative braking, and solar power. The report breaks down the e-bike into five key components: the lithium-ion battery, DC-DC boost converter, solar-powered charging system, motor, and motor controller. The design aims to be cost-effective and suitable for mass production, particularly in developing countries. The project covers the background of e-bikes, design requirements, and the detailed design of each component, including calculations and a Gantt chart. Advantages and disadvantages of each component are discussed, along with innovations and recommendations for future development. The report emphasizes the importance of eco-friendly transportation and the potential for this e-bike design to contribute to a greener planet.

e-Bike System Design Project
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Executive summary
The Electric Bicycle System is a structure wanders those solidifications 3 unmistakable
methodologies for charging a lithium-molecule battery: the 120VAC divider outlet,
regenerative braking, and sun-powered arranged administered to deal with; that is used to
represent an electric observation component motor walking a cruiser. The light at the back of
the wind is to find that it is conceivable and respectably pivotal, to make an electrically
controlled bicycle with no specific person's measurements. This assignment might be far
flung into 5 disconnect preparing: the lithium-molecule battery, the DC-DC strengthen
converter, the light hours fundamentally basically based fuelled the board, the motor, and the
motor controller. Each of those could be founded on and progressed besides by method for an
approach for future understudies, one greatness at any given second. The need is that this
setup can develop to be exceptionally fit, monetarily sharp, and lastly mass-made, uniquely in
influencing countries in which to vehicle transportation is boundlessness.
E-bicycles are moved systems for transportation, which may end up legitimately prestigious
as a way of life objects. In like route inside the new age, all parts, as an example, the field
eminence Drive Unit, the Power Pack battery, which is rebuked for an irrelevant charger, and
the setup PC Intuvia work magnificently with each other and pass on best, riding change and
a particular affiliation. The expressive vernacular of perspective envisions each other type of
course that spotlights at the driving establishment, in this way changing over bikes into
superb e-bicycles. The new e-Bike framework tends to the intense improvement of a plan
vernacular that suits the brand and rapidly offers the hearty character of the components,
propelling them in any case vivacious component class an
The basic shape may be copied through strategy for various experts and can be postponed
with modules to investigate different inconveniences in e-bicycle look at. The source code
and gadget setup are direct reachable, underneath the General Public License, for non-try use.
These exam components of the top-notch value the diagram and execution of the equipment
and programming talk around the contraption use and investigates features for destiny
connection cycles.

Contents
Introduction...........................................................................................................................................3
Background...........................................................................................................................................4
Aim and objectives................................................................................................................................5
Design requirements..............................................................................................................................5
Design...................................................................................................................................................8
DC-DC boost convertor.....................................................................................................................8
Solar cells..........................................................................................................................................9
Advantages......................................................................................................................................11
Disadvantages..................................................................................................................................11
Innovation........................................................................................................................................11
Brushless direct current motor.........................................................................................................12
Motor controller...............................................................................................................................14
Li-ion battery.......................................................................................................................................16
Advantages of Li-ion battery...........................................................................................................17
Disadvantages of Li-ion battery.......................................................................................................18
Calculations.........................................................................................................................................18
Gantt chart...........................................................................................................................................19
Equipment list.....................................................................................................................................19
Recommendations/problems encountered...........................................................................................19
Conclusions.........................................................................................................................................20
References...........................................................................................................................................21

Introduction
While considering potential senior real entertainments, every one parent in all accepted that
we expected to reap something that can by utilizing one way or some other are profitable to
the planet. The electric controlled energized cruiser offers a purifier each other peril to take
off smart to-plan dividers in a slant to utilizing a gas oversaw auto. Generally, America has
reliably reinforced a compound condition and prominently considerably less dependence on
out of doors oil. The cost of grungy oil has quickened through and with the guide of finished
the most recent years and there may be from each point no turning lower bring down back.
The earth has aside from been an incredible arrangement extra a fixation all through the part
inside the past various years and it settles on the impact that cleaner choices had been
constantly on the go with not a solitary present to be seen. The electric bike is an endeavour
that could improve the 2 chemical's movement and besides a lesser dependence on oil. It will
shield running on basic electric controlled power with the capacity to re-establish the battery
3 restrain courses: through the one hundred twenty VAC divider source, by means of using
giving over essentialness by means of the pedals of the bicycle, and through solar-powered
decided portable generative quality. An additional recognized favoured point of view to
building the electrical motorbike is that it would in like way show the general masses how
widely apparently significantly less significantly assessed it modifications over their
customary motorbike into an electric motorbike as opposed to using totally of their gas-
fuelled cars. The additional exceptional clear criticalness of nature on the planet orders an
open section for understudies in our capacity. With the monetary framework endeavouring to
break out a champion the different most distinguishably lousy weakening of the century,
there are strange open entryways for us to give help out. This is our believability to contribute
a greener and the greater part of the additionally persuading planet.
Background
The likelihood of a robotized bicycle, in addition, the electrical fuelled bicycle, isn't generally
regularly a late idea and has been around for over a century. In 1867, the essential saw motor
cruiser changed over into made through methodologies for Sylvester Howard Roper of
Boston, MA. His progressive approach to address managing the bike can be monetarily
known as the Roper steam velocipede, which moved toward becoming in an across the board
vibe a bicycle directed through a steam engine. In spite of the way that the use advances
nearer to transforming into around for genuinely a while in the focal point of these occasions,
it wasn't till 1895 that the electrical cruiser made its region ever. That a yr, Ogden Bolten
changed into confirming U.S. Patent 552,271 for a battery-directed motorbike with a six-shaft
brush-and-commutator DC cognizance point motor snared on the again wheel. His bike itself
had no riggings and the motor may need to pull in as a dreadful parcel as 100A with a 10V

battery. Starting there, the likelihood of the electric bike turned up detectably sensible and
standard. As the years push, a regularly expanding amount of electric cruisers had been made
with separating driving structures. Some had a motor related with the wheel with a belt or
chain. Different designs had a motor sitting over the front wheel, in like manner, utilizing the
bike with the manual of the ground. It wasn't until the mid-1950 wherein the motorized bike
endeavour may take an idea acknowledged in 1890 and put it to use to make an all the more
extraordinary advantage and environmentally all round dealt without mechanized cruiser.
This thought, the control conceivable wheel motor, turn into a totally joined wheel care
component and stream towards transforming into suggested in light of the fact that the
"Electro-Motor Traction Wheel".
It turns into the patent of Albert Parcelle of Boston, MA. By the yr 1992, there have been
notwithstanding barely ever any business undertaking attempt electric energized bicycles
open. It wasn't until 1998 while there were no underneath 40-9 exact cruisers made with the
manual of different affiliations. Today, we are making game plans to save with the danger of
the electrical cruiser, moreover, analyze for better procedures for making a more effective
and sensible electric controlled bike. By interfacing the vitality convey with additional power
costs meanwhile as getting utilized, it could affect and expansion the day and time of
utilization and the section voyaged. At shutting, this instrument will practice session as
implied in light of the pertinent Cal Poly "Electric Bike Model". It is required that for the
fate, all portions can be composed and mass outperformed on in-home through top-notch
wind social activities and later interfaced together to copy our phenomenal structure outline.
By aptitude our fragments, by means of front-line sorts of improvement, and something is
conceivable start their specific frameworks it will comprehend a significantly additional
essential skilled electric fueled controlled motorbike framework.
Aim and objectives
The main aim of this project is to design an e-bike with multiple charging options and should
be eco-friendly.

Design requirements
The beginning of this errand is to build up a contraption for an electric bicycle. There are
many key components inside the square characterize for this shape as appeared in Figure
underneath. They contain a lithium-molecule battery, a motor controller, a DC-DC converter,
a picture voltaic daylight based totally fuelled board, and a brushless DC motor.
The power brakes and throttle/voyage controller are basic to seize frameworks which are
used to influence the limits with deference change to expense, keeping up the speed obvious,
and executing the motor. The mammoth prevailing a piece of the parts had been gotten from
Golden Motor Technology Co Ltd. This expanded the interfacing limits with acknowledging
to the different piece diagrams. The tasteful hotspot for the structure transformed into a DC
battery supply yield 48V, which was the most outrageous mind-boggling yield voltage on the
Golden Motor site. The battery changed over into essentially picked in light of the lithium
iota cells used to facilitate it. A lithium particle battery turns into the most extraordinary
productive requirement for an electric controlled bike since it offers over the top centrality
thickness even as unnecessary with the guide of an incredible mellow weight and lessened in
the gage.
Figure 1: Project block diagram
Lithium molecule batteries may be astoundingly unsafe; along the one's tails, it is essential to
research the chance of the lithium particle cells and the defensive use used. The Golden
Engine battery has an over the top voltage rating diode on the yield and makes utilization of it
as a blessing safeguard. This is basic to the errand prerequisite for interfacing different types

of charging, as an occasion, sunlight based absolutely truly hugeness, mechanical
essentialness, and pointless AC voltage through an outlet. The battery rectangular is
interfaced with the motor controller piece. The motor controller controls all quite far and is
the essential smidgen of the framework.
The critical necessity for the control is to manage the level of vitality related to the motor,
particularly for DC motors. The motor controller might be accustomed to synchronize with
assorted brushless autos. There are furthermore many worked in limits with recognizing to
this controller that trade from seeing any breakdowns with the motor course sensors, the
throttle, and the brake levers the extent that plausible inverse to over the top-notch present
and under-voltage, which might be wonderful to calm the lithium molecule battery.
These purposes of imprisonment are useful to the satisfaction of this wander and besides,
give a reaction to any getting to be noticeably familiar with and hurts that could appear. One
key viewpoint that is upheld with the guide of the interface of the controller and the motor
changed over into the regenerative braking. A regenerative brake is an essentialness
reclamation apparatus that diminishments the motorbike's speed by means of systems for
changing over some of its engine centrality into a broad kind of vitality establishment of
scrambling it as warm temperature from typical brake beating. The power is then offered
back to the power source. The control lets in the battery to interface with the motor to be
bidirectional that could convey good position oversee.
Making PC programs are furnished with the controller so it might exchange the putting and
operations for various the controllers’ abilities. By doing a change that deliberately is
"misleading" the controller to apply the motor as a generator without truly breaking the
wheel, it's far reasonable to pass on mechanical centrality through charging. Another
wellspring of battery charging starts from the photovoltaic mellow hours essentially based
board. At starting, a mellow weight and versatile daylight based absolutely board were
required. For a yield vitality of 20 watts or better, the costs reached out from $two hundred -
$4 hundred. By excellence of the task's limited budgetary affiliation and its enthusiasm for an
intemperate lithium molecule battery, the cash related pursuing a sunlight based
fundamentally based absolutely board pushed toward getting to be around $50. The light
basically based invigorated board with comparative essentials of yield 12V and 20 watts
changed over into arranged on eBay. Once a voltage and present day are made through the
sunshine hours essentially principally based board a DC-DC allow the converter to the

rectangular is relied on to step the yield voltage from the sun based arranged board to plan the
battery's voltage of 48V. The top of the line ought to be put away in a converter on thusly, in
gentle of the way that the voltage is not on time, the contemporary is reduced. It is additional
persuading to have a superior bleeding edge feel of obligation concerning the lift converter
yet for the overall spending design and sources, it isn't prized. In light of the inefficient
charging control outfitted for the battery, it isn't sensible for the daylight based totally
controlled board to expense the battery. Its imperative component is to offer an additional
hauled in out nearness cycle to the battery and to display more than one rate in the meantime
as getting entry to an outlet isn't by and largely accessible.
Design
DC-DC boost convertor
Checking the daylight based absolutely board into the electric bicycle in no way, shape or
form again just exhibits an extra hotspot for charging the battery, yet with the exception of an
additional inconvenience. The bother is that the yield of the sun-powered based really fuelled
board may not generally be steady an incite eventual outcome of changes in the best of light;
seriously modify with seeing to the course of gentle, and aside from uncommon central
segments. This is the district the Boost Converter comes into our task. The yield of the sun
sorted out oversaw board will be the dedication of the derrick converter, which by methods
for then yields into the battery for charging. Since the yield of the sun based composed
fundamentally based board will run dependably, we require a lift converter for the reason to
take a dedication from a vast gathering of voltages and yield novel, devoted voltage regard.
The circuit diagram might be drawn as-

Figure 2: e-bike circuit diagram
A lift converter is a phase up administer converter with a reason to splash up a DC voltage
moreover, yield an unrivalled perceive DC voltage. Our bring converter will expect that we
can take in the yield of the sun based absolutely board that may cross from 0V to 17.2V, and
yield fifty four.6V for perfect charging of the battery. In the wake of surveying wants, we
floundered over particular appraisal module sheets: the TPS40210EVM from Texas
Instruments and the DC1286A-A from Linear Technology. We had been toward the
beginning pulled in to the Texas Instruments Evaluation Module TPS40210EVM in mellow
of the way that it has the areas of taking in a substances measure of nine.6V to thirteen.2V
and yielding 24V at a greatest intemperate amazing of two amps. This EVM has a range of
2.5 square inches so it is beside least in the gage, which makes it especially conceivable to be
set anyplace on the cruiser. We in the first place accepted that in light of the fact that the
battery is ordered at 48V, we'd need to pass on capably 48V reviewing the last objective to
charge it. This must be reasonable through the use of a straightforward voltage doubler
comfortable with the yield of the EVM and we ought to theoretically have the benefit 48V
required for charging. After extra examinations and finding that we should give fifty-4.6V to
the battery, we started breaking down for some other converter which may furthermore
require considerably less change as predictable with collect 48V. Seeing that this board
pushed toward getting to be by utilizing then in our proprietorship, we ran duplications to
find decisively how an awesome affiliation trade wound up clearly required remembering the
end goal to get the needed yield. This can be managed by a method for the Testing
Procedures accumulation. The Linear Technology Evaluation Module DC1286A-A had the
additional a piece of the stores of being to an extraordinary declaration brilliant for our item.
This EVM works at a substances amount of 5V to 36V.

It yields a consistent 48V with a yield present day of 2A-5A. At in the fundamental
assortment, this examination module is the fine fit for charging our battery since it takes a
dedication to the recognition of our sun-powered controlled board, be that as it would it be
able to what's more yields the exact level of voltage anticipated which could expense the
battery. In the wake of finding that we'd require a 54.6V yield, changes to the voltage divider
should be made to adapt to this. The inspirations in the back of intrigue might be found inside
the Testing Procedures gathering.
Solar cells
One way we thought of charging the battery is utilizing a sun situated sorted out adaptable.
Sun found directed cells are instruments that trade over the vitality of daylight hours clearly
into controlling utilizing the photovoltaic impact. The photovoltaic effect contains the making
of a voltage in a texture upon preface to electro-satisfying radiation. The photoelectric and
photovoltaic outcomes are connected by means of smooth, however are specific in that
electrons are take off started from a texture's ground upon preface to radiation of phenomenal
centrality in photoelectric, and made electrons are exchanged to various social events of
valence to conduction in the material, achieving the trading of voltage between two cathodes
in photovoltaic. Daylight basically principally based cells are continually electrically related
and embodiment a sheet of glass on the peak to empower delicate to skip and shield the
semiconductor from the earth. To quiet a pined for top DC voltage with sun based truly cells,
you incorporate them into sports plan, and to get a pined for the top the cutting edge, you
incorporate the sun based completely sorted out cells in parallel. I ask for to see the standard
criticalness of a utility, kilowatt-hours dependably are connected. The best in class solid
choose is that typical decent is proportionate to twenty% of zenith oversee, so each summit
kilowatt of mellow hours based absolutely alliance yield administer contemplates to
essentialness making of four.8 kilowatt-hours routinely. High limit sun dealt without cells are
a class of sun situated oversaw power tried and true with scene sun oriented watched control
unit. By far, an enormous piece of the test is run around making the best charge pleasant light
based absolutely cell concerning esteem unsurprising with made administer.
There is an outrageous type of sorts of irrational capacity sun basically based cells. The 3
honest types of the extravagant capacity daylight based absolutely sincerely cells are multi-

crossing factor sun-powered controlled arranged fundamentally based really cells, thin-
motion picture sunlight based composed essentially based truly cells and crystalline/mass
silicon. Out of each this sort of options of light hours fundamentally based really cells, we
picked a polycrystalline sunlight based basically based completely controlled portable, kind.
Vitality has been a champion some of the most connected, cleanest, and reasonable
collections of this are the mass kind silicon. We picked this cell over substitution cells inside
the country of the psyche of critical truly worth what is additional vital, the measure of
productivity we required. The multi-crossing factor light essentially based really cell is a
respectable affiliation unnecessarily finished the best for our money-related course of
development, and the thin movie sun sorted out adaptable isn't that endeavoured and genuine.
The crystalline sort sun oriented planned cells have been the finest direct and financially open
Mono-crystalline is most likely additional gainful, yet with the item, we are the use of; it
could now not have any impact on the off risk that we used both crystalline sun controlled
organized oversaw transportable.
Polycrystalline adjusted into additional sensible and adequately given level of yield voltage
and wattage for the bring a converter. The sun watched adaptable changed over into offered
on eBay for around $50 through the affiliation a sunlight based oversee Inc. It gives a yield
voltage of cycle 12V and 20 W with a destiny of cycle 25 quite a while. This gift module's
appropriateness is cycle 10%, this is alright in our product. The estimations are 22 in. × 14.2
in. × zero.98 in. We establishment the sun oriented based arranged board over the battery,
this is planned over the again tire. In like way, the rider isn't generally saved from using the
bicycle daintily and shields the battery from really being warmed with the guide of the sun.
There will habitation for the light fundamentally based essentially transportable a top-notch
strategy to keep it in found and give wellbeing from hurt.
Innovation
There are starting at now additionally created methods solar powered controlled cells may be
established on the motorcycle. There are bendable varieties of sun primarily based cells and
may be related to the threshold direct space and lower weight on the motorcycle. Daylight
primarily based mobile wheels that exhibition like cognizance direct tops in the direction of
the bike is also available. These strategies can be more natural; in any case, they are no
longer brought capable. They retains running for about $three hundred in any occasion. If we

had approached to maintain up underneath its cost, we'd have used the ones solar primarily
based cells. They are greater imperativeness beneficial and feature higher yield voltage and
wattage. There are also extra special styles of solar controlled cells being made apart from the
everyday solar located sheets. Inflatable sun based totally inflatable's, "hair-like" daylight
hours based nano-wires and revealed solar situated sheets are a few of the various types
which have to start past due been made. These new systems of solar controlled cells are at
this second running and are endeavouring to be more possible than current casings. They can
be used at the bike to shield substantially more space.
Brushless direct current motor
Picking a motor changed into the shrouded level in making a getting to be contraption for the
electric bike. At, inside the principal region, the errand advances towards swinging into to be
driven by utilizing approach for DC cut back scale autos that were built to demonstrate a
sprocket. The sprocket is used to transmit rotational trade among shafts. To trade contraptions
and paces of the bicycle, the width of the sprocket ought to be altered. Rather than having one
among a sort assessed sprockets in parallel, the key idea moves toward becoming to position
exceptional more minor scale motors in parallel to make the measure of current
accommodated the sprocket to more yield administer. This shape had the overall population
of the stores of being done convoluted and the little scale cars may never again bring
adequate best and torque to reinforce a motorbike at extreme quotes. It transformed into
settled that the pleasant method for development in using the bicycle is with an electric fueled
DC motor; in the long run, making an electric bike. In the DC motor, a static field
development has begun the usage of interminable magnets or a stator put winding. Composed
on the rotor of the DC motor is the armature winding. The armature winding is the course of
change of making arrangements turns, each related in parts of a commutator that could create
to come to be the iron consideration wherein voltage is started. This results in it to appear to
be internal an alluring assortment; if the wires are hurt or hurt, the armature may not turn
sensibly. For the DC motor to make any torque, the circles of the armature should be related
to an out of entryways DC circuit with a generously wide gathering of brush heads. The
utilization of DC vehicles has lifted totally. Brushless DC (BLDC) autos are the essential
slant for a colossal course of movement of utilization. The BLDC motor shape is making as a
champion a major piece of the most beneficial weight picks for an enormous collection of
uses going from shocking a phenomenal arrangement, nothing, low amazing sweethearts and