I have been working independently in manufacturing electric vehicles from quite a time, the market is still evolving in India for electric vehicles with an aim to reach a mark of around 90% electric vehicles running on road in proportion to total vehicles. A lot of advancements have been made regarding the same and i have compiled some of my observations in this presentation. Hope you like it and do discuss what you feel about the new evolving market in India.

1. A Brief introduction to
electric-bicycles
By Er. Sachindeep Saini

2. Important Components of an electric bicycle
• Lithium ion Batteries :These come in various capacities ,like 24V,36V,48V . The
Ah(Ampere Hour) rating plays a crucial role in tweaking the performance of the
system. For a same Ah rating, bigger the battery, better the performance.
• BLDC electric motor: These also comes in various designs and power ratings(like
250W,300W etc.). The design includes hub motors(geared or gearless) ,Sprocket
or belt based standard motors.
• Pedal sensor in case of PAS drive systems.
• Throttle cable for throttle based drive systems.
• Motor control unit : This acts as a CPU station where all controls are actually
interpreted and executed. It provides the charging socket for battery, socket for
plugging lights or any auxiliaries like LCD speedometer, sockets for connecting
throttle cable etc.

3. Classification of ebicycles based on the control
mechanism
• Stand alone PAS (Pedal Assisted System) drive: This mechanism involves
power availability at pedal to assist a rider to pedal easily with less effort
and thereby gaining more speed. The amount of assist one gets from the
motor depends on the amount of torque being applied by the rider at the
pedal which is measured using a pedal sensor which is normally a torque
sensor.
• Throttle controlled drive : This uses a throttle cable which extracts power
from the motor based on the throttle twist as comparable to bikes and
other two wheelers
• PAS cum Throttle assisted drive: This uses both the above mechanisms
collectively to provide more flexibility to design and to give more control to
the rider

4. Selection of a drive mechanism
• Considering the availability of different drive mechanisms, a PAS system is
specifically designed for those who want to use pedal as the primary source of
power , so its basically sports or athletics oriented system. This system is also
used in those countries where throttle cable driven bicycles are not allowed e.g.
Israel. But PAS system has a disadvantage that the power from motor comes as
per the cadence or torque available on the paddle due to human effort, this
system is helpful for normal terrains but incase of uphill, the cadence available at
paddle will be too low and so the assist from the motor will be low too which
makes the system underrated in those situations. Also one has to paddle always
in this system and there is a little lag in the motor to kick in which makes this
system specifically oriented for sports loving people. Considering the cost factor,
flexibility in design and simplicity of design, a throttle controlled system is a more
preferable system. I had too worked in the past on throttle controlled mechanism
,so the discussion that follows is based on the same design which as per the
factual data is more universally accepted system and also it stands as a preferred
mechanism by the masses.

5. Legal considerations to take care as per motor
vehicle rules
• As per motor vehicle act regulations the maximum permissible speed
for an electric bike is between 30-40 kmph which is variable from
country to country but speaking in context to Indian Motor vehicles
act the maximum permissible speed is 39 kmph beyond which it
enters the slab for a MOPED vehicle which requires the registration of
the vehicle.
• Considering the legal speed regulations , 24Volt and 36Volt battery
systems are more popular as these helps to keep the speed under the
prescribed limit. So now I will try to explain in next slide how these
two battery systems can be used in ways to create a balance between
power and economy

6. Watt Hours; Calculating E-bike Range
• Watt hours is a way to measure the energy capacity of a battery pack, so you know
what to expect from your new E-bike in terms of range performance. To calculate
the watt hours (WH) of a battery pack, simply multiply the voltage by the amp hours
(Ah) of the pack. A 36-volt 10-Ah battery pack has 360 watt hours (36 X 10 = 360).
If you are concerned with your energy usage, each mile you travel will cost you
about 20 watt hours. Therefore a 360 watt hour pack will get you about 18 miles.
The range can vary widely depending on where and how you ride.
• Watt hours determine the range of your bike, the cost of your bike, and the weight
of your bike….three very important factors to consider when designing an electric
bike.
• Now what we can observe is that a 36 volt battery with 10Ah rating is equivalent to a
24Volt battery with 15Ah rating as the two provide same 360watt hours.
• A 250 watt motor will burn 250 watt hours in an hour and will last you an hour and
20 minutes at full throttle on those 360 watt hours, but it will not provide you with
very much assist.
• A 500 watt motor will burn through the same pack at full throttle in less than 45
minutes, but you will be given twice as much assist as you get from the 250 watt
motor. If you are nitty with your 500 watt motor and run it at half throttle (250 watts)
and pedal a lot, you will get the same efficiency as you get with a 250 watt motor.

7. Electric Bike Battery Basics
Volts = Horsepower!
• That is a pretty simplistic way of putting it but it is the closest analogy to a car. Electric
bike batteries typically come in 24V, 36V, 48V, and 72V batteries. More volts = more
POWER .The typical battery is 36V on most e-bikes with some at 24V and some at
48V. The electric bike manufacturers spec these because they provide a good power to
cost ratio.
• A little background on controllers…..
• Ultimately the electronic controller of an e-bike limits the maximum power output and the
maximum speed of the bike. If you buy a stock electric bike in your country, you will most
likely be buying an electric bike that complies to the max power and speed limits to be
classified as a bicycle (this is not always true though!).
• If you are building your own custom electric bike you will want to be aware of what
controller you are buying if you want it to still be classified as a bicycle. It is possible to
create an electric bike that is too powerful or too fast with a lower voltage battery if you
have a controller that allows it. Just something to be aware of if you are building your own
electric bike as I covered in the regulations section that speeds over 39kmph will make
the vehicle mandatory to be registered under the MOPED category.

8. Covering cost factor for each component
• Bicycle frame: A light weight frame is more preferable for getting maximum
potential of the bicycle. It comes in
Carbon fiber material as well as aluminum alloy
frames, a light weight aluminum frame offers a more
economic option as the metal is more easily available
and, easily machinable.
A lot of designs are available in the market ,however if
the frames are being manufactured yourself, the minimum cost involved is going
to be around Rs1500-2000 . On the other side if you are considering to buy a full
bicycle along with tyres,the minimum cost will be around Rs 3500.
Indian manufacturers : Benlui International, focal point ,Ludhiana
Cayman International, Focal Point ,Ludhiana
A complete list can be checked here:
https://dir.indiamart.com/impact/bicycle-frames.html

9. BLDC electric motor
• A Brushless DC motor offers better power and economy and are most widely used for making
electric bicycles. These again come in various capacities like 250W,300W and so on. Considering
some of the leading motor manufactures in India like Tachometric Controls,Pune , the cost for a
300W motor for 24 Volt rating at around 2000-3000 rpm which is ideal for an electric bicycle is
priced at a minimum of Rs 4000.
• The detailed list of Indian suppliers can be found here:
https://dir.indiamart.com/impcat/brushless-dc-motor.html
• But there is another category under BLDC motors i.e. HUB Motors.
• The advantage of hub motors is that it saves the labor involved in installing a normal motor via
chain and sprockets. The hub is directly installed at one of the wheels and connected directly to
the controller. These motors are a little costly in comparison to standard bldc motors but these
saves the cost of chains and sprockets, also since these are directly mounted in the wheel, it
provides better performance , thereby proving itself to be a great option. For the same
characteristics as discussed above, a hub motor will cost a minimum of rs 6000.
• The list of some Indian suppliers can be found here :
https://dir.indiamart.com/impcat/hub-motor.html

10. Li ion Batteries
• Lithium ion batteries are best suited for this purpose because of their
long life and high power to weight ratio. These batteries are costly
and a lot of research is going on to reduce the cost for these
batteries. Some of the Indian companies have started manufacturing
these batteries but are highly costly. China is the emerging market for
cost effective Li ion batteries , the average cost for a 24 V 10AH
battery is $50 and considering import duty the cost comes to $65 or
an equivalent of rs 5000-6000. Here is the link of few Chinese
manufacturers : https://www.alibaba.com/showroom/24v-lithium-
battery-for-electric-bike.html

11. Indian advancement in Li ion battery
technology
• The graphite used as anodic material provides 350mah per gram of
charge.
• Researchers at IISER Pune have found a material that gives 720mah
per gram of charge.
• This discovery can help reduce the cost of battery significantly which
can help reduce the cost involved regarding Lithium ion batteries.
• The production of these batteries is going to start soon so contacting
them for batteries is the best option available as the battery quality is
claimed to be equivalent to that being used in TESLA Automobiles.

12. Motor Electronic Control Unit
• These are electronic control unit which acts as the CPU for the whole
system and controls the charge coming from battery and powering motor.
This is the most important part because a good motor controller can
extract higher currents from battery for performance if required and has
been programmed to do so. These are to be used in accordance with the
battery Voltage and so comes with many specifications like for 24 Volt
systems ,48V,60V and so on. These are relatively easily available in market
and for a 24V configuration, the cost is around Rs 1000. You may check
suppliers here:
• https://www.banggood.com/buy/e-bike-motor-
controller.html?utm_source=google&utm_medium=cpc_elc&utm_campaig
n=ds-led-cate-rm1-
170817&utm_content=serene&gclid=Cj0KCQiA2snUBRDfARIsAIGfpqFcwQB
13cyxtLt3R6mZXmaJ-_Iro6ITVgNZE9lblRKLuTaN9tZP0c0aAsfEEALw_wcB

13. Throttle ,PAS
• A throttle grip used to control the speed of motor is easily available in market and
costs a minimum of rs 400
• If you are looking for pedal assist drive, the cadence or pedal sensor will cost
around rs 600 which can be wired with motor to enable PAS control drive. These
sensors come in various types, like torque sensors, cadence sensors etc. Some are
pure electronics based while some are mechatronics based sensors. I am
attaching a link for a mechatronics sensor which are relatively robust to
electronics sensor. Check it here:
https://www.banggood.com/58-Magnet-Electric-Bike-Pedal-Assist-PAS-Sensor-
Elektrofahrrad-Ebike-E-bike-p-
1120716.html?utm_source=google&utm_medium=cpc_elc&utm_campaign=ds-
led-cate-rm1-
170817&utm_content=serene&gclid=Cj0KCQiA2snUBRDfARIsAIGfpqFNUekECciAyo
GESXqqJuv7ohPXF1hEilvEL9_bilS5p_K00_jBMzUaAmOFEALw_wcB&cur_warehouse
=CN

14. Auxiliaries
• Flashers, led headlights , Disc brakes are some of the auxiliaries offered to increase the utility of e
bicycles. These will add additional manufacturing cost of Rs 1000 to the bicycle and these are
readily available in the market.
• If you are skeptical about the quality and performance of these cheap brakes , these are real good
and you can check a detailed review made by a professional biker. Check it out here:
• https://youtu.be/LZuuEI7yJaA
• The brakes used by the above professional costs just rs 400 but still enables him to do
professional stunts like stoppie,etc. Which needs good braking power.
• Led lights are readily available in the market and offers various varieties to choose from, the cost
is low and can be readily purchased from any of the suppliers, I have attached a link for the
reference here:https://www.banggood.com/Wholesale-Bicycle-Lights-c-
1663.html?utm_source=google&utm_medium=cpc_ods&utm_content=starr&utm_campaign=od
s-sds-rm-
cycling&gclid=Cj0KCQiA2snUBRDfARIsAIGfpqFbU8OzOFlxEecYejnIh5mSqnrBa8eAAbheNsqGcnGTb
n85rsNf0KMaAqpBEALw_wcB

15. Cost analysis for 24V system with throttle
control only
• Frame cost along with tires: Rs 4000
• A 24 Volt Li ion. Battery sourced from China: Rs 5500
• A 24 Volt 300W. (2500rpm) BLDC motor: Rs 4000-6000(hub motors priced on higher side)
• Sprockets, belts or chains : Rs 700(not included in case of hub motors)
• 24V motor controller : Rs 1000
• Throttle cable assembly: Rs 500
• Led headlight rechargeable(not taking power from motor battery): Rs 400
• Flashers for safety(white in front, red on rear): Rs 100
• Voltage meter for checking battery level: Rs 300
• Speedometer LCD display assembly : Rs 500
• Miscellaneous cost : lets Add Rs 1500 that may add up during testing of prototype
• Total cost : Rs18500-18800
• Please note that the costs involved are taken to be the maximum as of today’s market scenario. The prototypes usually cost more than the actual product. With planning and
proper cost cutting the price can be brought down for the actual product and so the expected price of finished product will be around Rs 17000
• The battery being used is rated at 24V and 15Ah which gives us 360Ah of power and considering 20Ah per mile of range, the range for this. Bike will be 18 miles without pedaling
and considering the efficiency of system around 75% it will deliver 14 miles of range without pedaling and combined with paddling , one can expect a range of around 20 miles
which is quite a descent range.
• There are a lot of factors involved in calculating the range such as weight of the bicycle, weight of the rider, size of tires, terrain etc. Most of the brands take a universally adopted
values for these variables which has rounded up the range at 20ah per mile. So I have further took the efficiency to a practical 75% to achieve practical results.

16. Cost Analysis for 24 V PAS cum throttle drive
• This will add an additional cost of Rs 1000 to the previous prototype and so the
cost can be expected to be around Rs 19500 for this project and please note that
the motor design is too specific for PAS enabled system as the motors are
connected near the pedal to the driving sprocket , so the cost of chain, sprockets
is minimized
• The range for this drive system is usually less because the motor is always
functioning either in providing pedal assist or while using the throttle cable. I
have personally not worked on this mechanism but being an enthusiast I have
been reading articles over internet by professionals and experienced mechanical
engineers and they suggest practical testing as the best measure for range in PAS
systems because it differs from individual to individual as PAS system provides
assist power based on the cadence which differs as per strength of the
individuals.
• Please note that the bicycle involved here is a non geared bicycle

17. Final Verdict
• With Indian government setting up the target to achieve 100% electric vehicles goal by 2030,
electric bicycles are going to play an important part in coming years , the prime example can be
given about Mysuru who recently badged the best non motorized transport award for its
adoption of electric bicycles initiative.
• With growing awareness about the environment risk involved , a lot of research is being carried
out in this field with the research on Li ion batteries acting as the primary deciding factor as these
are going to replace fossils as electric fuel. IISER PUNE has found low cost high quality materials
for manufacturing Li ion batteries which will further help reducing the costs involved in ebicycles
production.
• With the current scenario, we can develop energy efficient and mid powered ebicycles in around
Rs 17000 which is promised to be reduced with upcoming advancement in technologies which
thus creates s huge market for this product.
• Social media has took over as the leading marketing platform and thus we can incorporate these
measures to reach the masses in a much easier way. Just for an example FAT BIKER VAIBHAV
channel on YouTube is one of the most liked channels on YouTube with reach to millions of
viewers in his every video. We can offer our product to such people for review which will not only
provide us cheapest and best marketing but also enhance sales.

18. Queries and Discussions