Design and implementation of e-bike
Global warming and shortage of common sources are turning into important issues in the present day scenario. Due to the monetary challenges India is going through in car zone the hybrid bicycle market has a massive increase potential. People strive to cross closer to "clean" energies. These information amongst others will leverage the electric powered bicycle enterprise on the pinnacle of the agendas now not solely in India. Moreover the imaginative and prescient of an electric powered engine, which helps the muscular strength, grew to become reality. Bicycles with such a assisting electric powered engine belong to the progressive vehicles, which are wholeheartedly appropriate for daily life. In face of non-stop local weather discussions and everlasting visitors jams, electric powered bikes have the doable of fixing such troubles and making a extra electricity environment friendly and surroundings pleasant mobility possible. Accordingly a non-stop fashion in the direction of electric powered bicycles can be predicted concurrently in complete of India. So it will become very indispensable to manufacture the electric powered cycles so cheaply that the frequent humans in our us of a can have the funds for to purchase it. The presently present electric powered scooters are a ways greater expensive and due to budgetary constraints a center classification man or woman can't have enough money such a locomotive at his place. Along with the improvement of applied sciences the principle have to be additionally applied to diagram and manufacture a product that can be bought off at a higher frequency, which has a very low manufacturing price and one that is of properly quality. In order to put into effect all the above ideas, we deliberate to make the sketch and product in such a manner that it can be done with the present “E-Bikes” in the market.
A. Background
The fundamental notion is to connect a motor to the cycle for its motion. A motor that is powered via a battery and that can be switched on in the course of challenging terrains and switched off and pedal to get the battery re-charged throughout action in a flat terrain. The thinking got here into our thinking as one-of-a-kind levels of assignment planning, first off we desired to put into effect a easy transferring machine so the projection of cycle as a machine got here into our mind, and 2d stage was once including a always beneficial issue into it that can be really helpful in the future and for frequent people, falling into the modern fashion was once that of hybrid gadget so we ended up planning to gather a motor unit into the cycle drive. There have been many troubles that got here up whilst making such a machine principal one of them being the energy of the motor to be used, seeing that no such preceding structures have been made we should now not predict the kind of motor which we need to go for. Second factor being the weight factor, the addition of greater weight on to the system, which can purpose pain to the rider whilst ordinary pedalling. Third was once the kind of battery to be used, we need to go for a battery that has longer life, economically viable, and additionally has much less preservation issues. Fourth trouble used to be that self-recharging a battery with a motor alternator unit that too with the easy cranking movement of the cycle used to be now not viable, we had to make use of a mechanism that can come in reachable right here and that was once via the use of the flywheel rotation technique.
B. Mechanical Design and System Integration
The foremost purpose was once to fabricate a prototype that would be very mild and relaxed for the rider to take care of . As the motor and other force aspects would take in most of the free area in the machine our sketch mission was once to make the motor-alternator unit as a single system. This used to be our primary challenge, for this reason we developed the motor cum alternator at its minimal viable measurement and additionally at the lowest feasible cost. Mounting the battery used to be every other challenge, the area of the mounting ought to have been somewhere in the relaxation of the house reachable close to the motor or we ought to have used up the empty area close to the carrier. Keeping in thinking the remedy of the rider the battery casing used to be set up in the back of the rider, close to the provider location. Looking at the difficult association of the device one may additionally without problems suppose that the drive
arrangement should have been executed in a single step i.e. the direct hyperlink from the motor to the drive. But the actual reality is that this would make the cranking for self-recharging mechanism difficult, because the pace for alternator recharging can't be executed by using easy cranking a flywheel has to be used to keep the cranking strength and accordingly the rotation and cranking at ordinary biking will become easier.
3.1 HYBRID SYSTEMS
A. Overview
This area of the paper offers with the mechanical sketch of the gadget and the a number components used in the gadget integration. The electricity transmission gadget consists of the motor , the chain sprockets, flywheel, housing and the rear wheel. However, earlier than we ought to pick out these components, we carried out some primary calculations touching on power switch thru the system. Primarily we targeted on the contemporary necessities of the system, and a range of torque-speed relationships. Both the acceleration on flat floor and hill hiking capacity of the machine rely on how a good deal torque can be delivered with the aid of the a range of gadget components. Before we may want to measurement the batteries, we wanted to estimate when the motor would demand the most cutting-edge and the period that it would draw its height current. These conditions would be at begin up (acceleration) and when mountaineering a gradient. The foremost factors affected by means of the following calculations are the motor and the battery.
B. Components of Hybrid System
1. PMDC MOTOR (Permanent magnet DC motor):
Permanent magnet DC brushed motors (PMDC motors) consist of everlasting magnets, positioned in the stator, and windings, positioned in the rotor The ends of the winding coils are related to commutator segments that make slipping contact with the stationary brushes. Brushes are related to DC-voltage grant throughout motor terminals. Change of path of rotation can be performed by using reversal of voltage polarity. The contemporary glide thru the coils creates magnetic poles in the rotor that engage with permanent magnet poles. In order to maintain the torque era in equal direction, the modern-day float have to be reversed when the rotor north pole passes the stator south pole. For this the slipping contacts are segmented. This segmented slip ring is known as commutator. Figure suggests angular role simply earlier than commutation of rotor winding modern and Figure after it.
The foremost purpose was once to fabricate a prototype that would be very mild and relaxed for the rider to take care of . As the motor and other force aspects would take in most of the free area in the machine our sketch mission was once to make the motor-alternator unit as a single system. This used to be our primary challenge, for this reason we developed the motor cum alternator at its minimal viable measurement and additionally at the lowest feasible cost. Mounting the battery used to be every other challenge, the area of the mounting ought to have been somewhere in the relaxation of the house reachable close to the motor or we ought to have used up the empty area close to the carrier. Keeping in thinking the remedy of the rider the battery casing used to be set up in the back of the rider, close to the provider location. Looking at the difficult association of the device one may additionally without problems suppose that the drive
arrangement should have been executed in a single step i.e. the direct hyperlink from the motor to the drive. But the actual reality is that this would make the cranking for self-recharging mechanism difficult, because the pace for alternator recharging can't be executed by using easy cranking a flywheel has to be used to keep the cranking strength and accordingly the rotation and cranking at ordinary biking will become easier.
3.1 HYBRID SYSTEMS
A. Overview
This area of the paper offers with the mechanical sketch of the gadget and the a number components used in the gadget integration. The electricity transmission gadget consists of the motor , the chain sprockets, flywheel, housing and the rear wheel. However, earlier than we ought to pick out these components, we carried out some primary calculations touching on power switch thru the system. Primarily we targeted on the contemporary necessities of the system, and a range of torque-speed relationships. Both the acceleration on flat floor and hill hiking capacity of the machine rely on how a good deal torque can be delivered with the aid of the a range of gadget components. Before we may want to measurement the batteries, we wanted to estimate when the motor would demand the most cutting-edge and the period that it would draw its height current. These conditions would be at begin up (acceleration) and when mountaineering a gradient. The foremost factors affected by means of the following calculations are the motor and the battery.
B. Components of Hybrid System
1. PMDC MOTOR (Permanent magnet DC motor):
Permanent magnet DC brushed motors (PMDC motors) consist of everlasting magnets, positioned in the stator, and windings, positioned in the rotor The ends of the winding coils are related to commutator segments that make slipping contact with the stationary brushes. Brushes are related to DC-voltage grant throughout motor terminals. Change of path of rotation can be performed by using reversal of voltage polarity. The contemporary glide thru the coils creates magnetic poles in the rotor that engage with permanent magnet poles. In order to maintain the torque era in equal direction, the modern-day float have to be reversed when the rotor north pole passes the stator south pole. For this the slipping contacts are segmented. This segmented slip ring is known as commutator. Figure suggests angular role simply earlier than commutation of rotor winding modern and Figure after it.
2. Flywheel:
A flywheel is a rotating mechanical system that is used to shop rotational energy. Flywheels have a tremendous second of inertia and for that reason face up to modifications in rotational speed. The quantity of power saved in a flywheel is proportional to the rectangular of its rotational speed. Energy is transferred to a flywheel through making use of torque to it, thereby growing its rotational speed, and for this reason its saved strength . Conversely, a flywheel releases saved power with the aid of making use of torque to a mechanical load, thereby lowering its rotational speed. Flywheels are normally made of metal and rotate on conventional bearings; these are commonly restricted to a revolution price of a few thousand RPM. Some current flywheels are made of carbon fiber substances and rent magnetic bearings, enabling them to revolve at speeds up to 60,000 RPM. Our design, due to the simplicity of its application, makes use of a flywheel which is made up of solid iron having a diameter of 17cm.Carbon-composite flywheel batteries have currently been manufactured and are proving to be possible in real-world assessments on important movement cars. Shows the CAD drawing of the flywheel.
A flywheel is a rotating mechanical system that is used to shop rotational energy. Flywheels have a tremendous second of inertia and for that reason face up to modifications in rotational speed. The quantity of power saved in a flywheel is proportional to the rectangular of its rotational speed. Energy is transferred to a flywheel through making use of torque to it, thereby growing its rotational speed, and for this reason its saved strength . Conversely, a flywheel releases saved power with the aid of making use of torque to a mechanical load, thereby lowering its rotational speed. Flywheels are normally made of metal and rotate on conventional bearings; these are commonly restricted to a revolution price of a few thousand RPM. Some current flywheels are made of carbon fiber substances and rent magnetic bearings, enabling them to revolve at speeds up to 60,000 RPM. Our design, due to the simplicity of its application, makes use of a flywheel which is made up of solid iron having a diameter of 17cm.Carbon-composite flywheel batteries have currently been manufactured and are proving to be possible in real-world assessments on important movement cars. Shows the CAD drawing of the flywheel.
3. Housing:
Housing is used for making an interconnection between the rotating flywheel and the sprocket at the different end. It is this sprocket from the rotating flywheel linked to a shaft that drives the multi crank free wheel. The housing is connected with a rubber bush to keep away from the shocks. They are generally used in door hinges for making perpendicular movable connections. The ball bearing inner the housing chamber approves the free rotation of the connecting shaft interior the housing.
Design Specifications:- Length: 1m; External Diameter: 0.7m; Internal Diameter: 0.5m; Thread Pitch:0.024m.
4. Multi-crank Freewheel:
Multi crank freewheel is developed as alternate mechanism to power the rear wheel from the motor strength the crank is developed in such a way that the ball bearing has a specific impact when rotation on one course via motor occurs the ball bearing exterior lock holds the shifting pedal consequently limiting its motion, on the different hand when the rotation with pedal occurs the bearing engages with the pedal and as a result the force via cranking happens. For developing, the crank was once connected with some other crank of the equal diameter so that there will now not be any distinction in the pedaling impact to the rider.
5. Sprockets:
A sprocket or sprocket-wheel is a profile wheel with teeth, cogs, or even sprockets that mesh with a chain, music or different perforated or indented material. The identify 'sprocket' applies usually to any wheel upon which are radial projections that interact a chain passing over it. It is individual from a tools in that sprockets are in no way meshed collectively directly, and differs from a pulley in that sprockets have enamel and pulleys are smooth. Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and different equipment to transmit rotary movement between two shafts the place gears are unsuitable or to impart linear movement to a track, tape etc. Perhaps the most frequent structure of sprocket may additionally be determined in the bicycle, in which the pedal shaft contains a giant sprocket-wheel, which drives a chain, which, in turn, drives a small sprocket on the axle of the rear wheel. Early vehicles have been additionally generally pushed by means of sprocket and chain mechanism, a exercise mostly copied from bicycles. Sprockets are of a number of designs, a most of efficiency being claimed for every by using its originator. Sprockets generally do no longer have a flange. Some sprockets used with timing belts have flanges to maintain the timing belt centered. Sprockets and chains are additionally used for electricity transmission from one shaft to every other the place slippage is now not admissible, sprocket chains being used as a substitute of belts or ropes and sprocket-wheels rather of pulleys. They can be run at excessive velocity and some types of chain are so built as to be noiseless even at excessive speed.
Design Specifications:- Crank Diameter: 0.18m; Number of Teeth: fifty two the CAD drawing of multi-crank freewheel.
Sprockets (Front and
Side Views)
Design Specifications:-
Sprocket 1 (connected with
the motor) Number of Teeth: 16; Diameter: 70mm.
Sprocket 2 (connected with housing) Number of Teeth: 16; Diameter: 70mm the CAD
drawing of multi-crank freewheel.
3.2 ELECTRICAL SYSTEM DESIGN
A. Overview
The PMDC motor had to be regulated by means of a mechanism which concerned a DC motor driver .This driver had specs in a position to stand up to up to 20A which was once key to this venture as various masses would certainly draw greater current. So the rated modern-day ranking had to be excessive adequate to face up to this. The driver is managed with the aid of an Arduino Board which receives enter indicators via. a potentiometer (variable resistance). The Arduino board was once programmed in such a way that various the resistance in the potentiometer would end result in an equal cost of bytes which the application should understand and translate to proportional DC motor speeds.
B. Programming
The programming was once finished on the software program accompanied with the Arduino Board. When the “initialise motor” command is used cost starts offevolved flowing to the motor thru the driver. When the software enters the loop, the potentiometer values (read as resistance pulse values) receives translated to equal bytes that lets the Board enable cost to bypass via the motor hence increasing/decreasing the speed. Once the loop is exited, the software goes lower back to preliminary value.
C .Electrical Connections
There are exceptional methods to using a motor when it comes to riding a motor with Arduino. If a easy relay is used to pressure a motor it can solely turn the motor on and off. In case a single transistor like TIP120 (BJT) or IRF510 (MOSFET) is used, it is feasible to manipulate the pace of the rotation. There exist smarter DC motor drivers (so referred to as H-bridge) that can manipulate the path of rotation and even brake. An instance of such a driver is MC33887 Motor Driver which is less costly and versatile. This driver can manage a single DC motor with most consumption of 2.5A and peaks of 5A. Motor voltage can vary from 5-28V which makes it an first-rate customary reason motor driver indicates the circuit sketch and indicates the electrical connection.
The programming was once finished on the software program accompanied with the Arduino Board. When the “initialise motor” command is used cost starts offevolved flowing to the motor thru the driver. When the software enters the loop, the potentiometer values (read as resistance pulse values) receives translated to equal bytes that lets the Board enable cost to bypass via the motor hence increasing/decreasing the speed. Once the loop is exited, the software goes lower back to preliminary value.
C .Electrical Connections
There are exceptional methods to using a motor when it comes to riding a motor with Arduino. If a easy relay is used to pressure a motor it can solely turn the motor on and off. In case a single transistor like TIP120 (BJT) or IRF510 (MOSFET) is used, it is feasible to manipulate the pace of the rotation. There exist smarter DC motor drivers (so referred to as H-bridge) that can manipulate the path of rotation and even brake. An instance of such a driver is MC33887 Motor Driver which is less costly and versatile. This driver can manage a single DC motor with most consumption of 2.5A and peaks of 5A. Motor voltage can vary from 5-28V which makes it an first-rate customary reason motor driver indicates the circuit sketch and indicates the electrical connection.
3.4 WORKING OF THE PROTOTYPE
The one hundred fifty watt PMDC motor which offers a one thousand RPM at 12V and 15A ranking was once linked with a flywheel the use of the sprocket ratio at 16:40 (motor : flywheel) enamel ratio, the shaft from the flywheel used to be then linked to the sprocket on the different aspect with a housing. The force from this sprocket to the multi crank freewheel is connected once more at 16:52(sprocket: crank freewheel) enamel ratio. These ratios had been chosen for most environment friendly strength transmission with minimal loss. The power from this crank is at once linked with rear wheel sprocket that helps its motion. When the motor is switched ON, the motor attracts modern from the two dry mobile batteries related in parallel that would supply an high-quality discharge of 12V and 14A. Since the motor makes use of most modern (11 amp) at some point of beginning a battery of that specification was once used. Later on as the nice pace will increase the cutting-edge drawn reduces to 1.77A. Figure suggests the ultimate assembled prototype of the hybrid bicycle.
The one hundred fifty watt PMDC motor which offers a one thousand RPM at 12V and 15A ranking was once linked with a flywheel the use of the sprocket ratio at 16:40 (motor : flywheel) enamel ratio, the shaft from the flywheel used to be then linked to the sprocket on the different aspect with a housing. The force from this sprocket to the multi crank freewheel is connected once more at 16:52(sprocket: crank freewheel) enamel ratio. These ratios had been chosen for most environment friendly strength transmission with minimal loss. The power from this crank is at once linked with rear wheel sprocket that helps its motion. When the motor is switched ON, the motor attracts modern from the two dry mobile batteries related in parallel that would supply an high-quality discharge of 12V and 14A. Since the motor makes use of most modern (11 amp) at some point of beginning a battery of that specification was once used. Later on as the nice pace will increase the cutting-edge drawn reduces to 1.77A. Figure suggests the ultimate assembled prototype of the hybrid bicycle.
Final Assembled Prototype
The action of the motor actuates the flywheel whose rotation in flip drives the shaft via the housing and make the sprockets at the different quit cross which would pressure the multi crank and therefore the rear wheel. It need to be stated that whilst the motor is in working mode the pedals won’t rotate which would in any other case purpose soreness to the rider. For this to work we have delivered a ball bearing at the crank spot that would disengage the internal ring whilst motor is in rotation and interact them when the motor is switched off.
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