Electric scooter report

1. PCET’S NMIET, B.E (Mechanical)
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1. INTRODUCTION
Around 93% of today's automobiles run on petroleum based product, which are
estimated to be depleted by 2050. Moreover, current automobiles utilize only 25% of the
energy released from petroleum and rest is wasted into the atmosphere. Despite recent
efforts to improve fuel efficiency and reduce toxic emissions in cars, emissions have
continued to increase steadily in the past two decades. For preservation of gasoline for
future and increasing the efficiency of vehicle an electric vehicle can be a major
breakthrough. An electric vehicle is pollution free and is efficient at low speed conditions
mainly in high traffic areas. But battery charging is time consuming. Moreover, it cannot
provide high power required by drives during high speed conditions or in slopes of hilly
areas. Gasoline engine proves its efficiency at higher speeds in high ways and waste a lot
of energy in urban areas.
The system we designed is an electric bike. The project has a number of benefits
to both the team members as well as external benefits through increasing awareness of
alternative transportation modes. Despite the environmental friendliness of the project or
the projected benefits of more people relying on non-polluting modes of transport, the
main reason we selected the project was for the conversion of conventional vehicle into
electric vehicle to reuse the old vehicle. We plan to convert an already build Bajaj Spirit
scooter from gasoline based to purely electricity based scooter. The electric scooter after
being built should not be in anyway less than a Bajaj Spirit and should provide equal
convince to consumer who uses it on gasoline. We have electric scooters only which are
not preferred by most of the people because of its high price. Secondly there are no
electric two wheelers providing such a great performance in the terms of power, pick-up,
top speed and smooth ride.
Increasing awareness of air quality and interest in innovative vehicles stimulate
research activity to improve the propulsion system by reducing the vehicle emissions.
Different types of electrical vehicles have being recently designed with the aim of solving
pollution problems caused by the emission of gasoline powered engines. Environmental

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problems promote the adoption of new generation electric vehicles for urban
transportation. Moreover, the torque generated by the electrical motor can be
appropriately controlled, so that the vehicle stability and safety are greatly improved. An
electric bike or scooter is a battery operated vehicle that is very economical with low
maintenance cost and zero pollution. Electric scooter as a new green transport is
accompanied by mankind in solving the environmental pollution, energy crisis and other
social development. Electric scooter with battery as power, contains electrical, electronic,
mechanical control and chemical technology and other high technologies, is a new clean
and efficient transport. It provides auxiliary power through battery to the motor, at the
same time improving the performance of scooter emissions, but also may solve some of
the increasing depletion of oil resources. The batter of an EV can be charged easily using
power connection. Electric vehicles are maintenances free. It has no gears, no engine, no
belt or chain drive, zero emission, no pollution, electronic start and accelerator.
These days one of the major problems faced by our country is the increased demand
and high prices of fuel with the increase in number of vehicles on the road. Air pollution
is of serious concern in many Asian countries, especially in densely-populated countries
like India where majority of the people use two wheelers as the means of their
transportation. Internal combustion engines are relatively less efficient in converting the
on-board fuel energy to propulsion as most of the energy is wasted as heat. On the other
hand, electric motors are efficient in converting the stored energy in driving a vehicle, and
electric drive vehicles do not consume power while coasting. Typically petrol engines
effectively use only 15% of its fuel content to move the vehicle. Whereas an electric drive
vehicle has an on-board efficiency of about 80%. But due to reasons such as cost, inability
to reach higher speeds electric drive vehicles failed to capture markets. Opposite to this
petrol vehicles can cover longer distances with higher speed but it cannot cover shorter
distance with slow speed (say in traffic) in an efficient way.

3. PCET’S NMIET, B.E (Mechanical)
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1.1 Problem statement
 Fuel we are use that is very costly and it emits hazardous gases.
 Old vehicle scrap after its engine efficiency decreases.
 Electric vehicles that are in the market have high cost, low speed and low millage,
charging time of battery is high.
1.2 Objectives
 To develop a plug-in electric two-wheeler by converting available conventional
two-wheeler with a suitable motor and battery.
 To increase the speed and millage of vehicle and make it efficient by reducing
charging time of batteries and cost.

4. PCET’S NMIET, B.E (Mechanical)
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1.3 Scope
Urbanization has caused many affects on public life. Presently, the daily activities are
mainly dependent on vehicles. So the density of vehicles in city areas is increasing day by
day. Mainly, many of these vehicles are all dependent on nonrenewable energy resources
like petrol and diesel. These resources are extinguishing day by day and may not last long.
People are also taking war in certain countries because of oil crisis with political
instability. With all these factors, it’s seen that the prices of oil going high day by day
making the common man’s life unbearable. It is really good that people have started
understanding the need of environment and have started the use of green mobility solutions.
1.4 Methodology
 A simple control strategy has to be developed for Indian city driving conditions
with less fuel consumption for reducing emissions.
 A conventional two-wheeler will be converted into a plug-in hybrid electric two-
wheeler by fitting a hub motor in the front wheel.
 Experiments will be carried out on engine and electric hub motor to estimate the
power and torque requirements for various operating conditions.
 A detailed investigation will be carried out to estimate the battery energy and
power requirements for various conditions.
 A cost benefit analysis will be carried out to estimate the battery pack cost and its
payback period.

5. PCET’S NMIET, B.E (Mechanical)
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1.5 Plan of Action
The work of the system will be carried out according to the following chart:
Table 1:Plan of action
Work June July Aug Sept Oct Nov Dec Jan Feb Mar
Search for topic
Selection of topic
Budget &
calculation
Literature Survey,
search for moped
vehicle
Manually layout of
bike
Purchasing the Bike
Search electric
components
Purchase Hub
motor, Throttle,
Controller, Battery
Motor Mount
Electric Assembly
Testing
Demo

6. PCET’S NMIET, B.E (Mechanical)
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2. LITERATURE REVIEW
1) “ Energy and Pollutant Damage Costs of Operating Electric, Hybrid, and
Conventional Vehicles in Singapore ” by Samir NAZIRa et al.,2011
The paper presents that a model was built to capture the energy and pollutant damage
costs associated with using electric vehicles, hybrid vehicles and internal combustion
engine cars in Singapore based on vehicles currently available in the Singapore market.
The objective of this research is to compare the energy and emissions damage costs of
various vehicle technologies as deployed in Singapore. A key question to answer is
whether electric vehicles will provide emissions benefits if charged from a grid that
derives no energy from zero emission sources. Despite being charged by an electric grid
fueled by fossil fuels, driving the electric results in the lowest energy and damage costs.
As more electric vehicles enter the market and more data becomes available, this analysis
may be refined. Electric vehicles in Singapore do have the potential to reduce pollutant
emissions and limit the cost of their resulting damages.This work is part of broader
analysis to compare the costs and benefits of electric vehicles, hybrids and internal
combustion vehicles in Singapore. Although energy costs are borne by the owner of the
vehicle.
2) “Design and Development of an Innovative E-Bike” by C. Abagnalea et al., 2016
The paper presents that the large use of the travelling vehicles has increased the problems
connected to the air quality and to the use of the human sensibility for the energetic and
environmental problems are encouraging the research in alternative solutions for the
automotive field, as multiple-fueling, hybridization and electrification. At the same time,
particularly as concerns urban areas, new standards have imposed substantial
modifications in the mobility. In this context, a vehicle as the electrically assisted bike can
be considered a promising alternative vehicle for both personal mobility and goods
delivery, especially for small and medium distances: an assisted bike is able to move with
an average speed equal to the typical one of the town traffic but it requires energy for its
mobility that is very close to the necessary energy for the displacement of the transported
people. The experimental results have allowed to compare the total energy and the electric

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one for both the tracks, so, Individualizing the optimum trip. This study, then, has
provided several results and guidelines that can assist for such improvements in the
performance of electric bicycles.
3) “Development of a range-extended electric vehicle power train for an integrated
energy systems research printed utility vehicle” by Paul Chambon et al.,2017
The paper presents that the rapid vehicle and power train development has become
essential to for the design and implementation of vehicles that meet and exceed the fuel
efficiency, cost, and performance targets expected by today’s consumer while keeping
pace with reduced development cycle and more frequent product releases. This paper
demonstrated the combination of big area additive manufacturing and hardware in the
loop methodologies which has the potential to speed up the overall vehicle development
process by paralleling these rapid prototyping techniques. This study did not attempt to
quantify the potential acceleration using this approach. Further study is needed to
establish the correct baseline on which to make any comparison. Instead the focus of the
paper is to validate this approach leading to the development and experimentation of a
hybrid electric powertrain for implementation in a flexible printed vehicle platform.
4) “E-bikes and E-scooters for smart logistics: environmental and economic
sustainability in pro-E-bike Italian pilots” by Roberto Nocerino a et al., 2016
The paper presents the final results of the Italian pilots of Pro-E-Bike, a project funded
under the Intelligent Energy Europe program, started on April 2013 and ending on March
2016. The project promotes clean and energy efficient vehicles, analyses the performance
of electric bicycles and electric scooters for the delivering of goods in urban areas and
tests the use of these vehicles in seven European countries with thirty-nine companies,
both freight transport operators, companies that deliver their own products and services
providers, in order to demonstrate that light electric vehicles can replace traditional
combustion engine ones contributing on mitigating logistic impacts in urban areas.

8. PCET’S NMIET, B.E (Mechanical)
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5) “R&D on electric bike” by Yashwant Sharma, et al.,2018
The paper presents the Sustainable and personal mobility solutions for our world
environment have traditionally revolved around the utilization of bicycles or provision of
pedestrian facilities. An electric bicycle offers a cleaner various travel short–to-moderate
distance instead of fossil fueled automotive. From conventional automobile for transport
we experience problems like traffic congestion, parking difficulties and pollution from
fossil fueled vehicles. His team innovate an idea to develop an e-bike which discards the
orthodox mentality i.e. only pedal power can be used to move a bi-cycle. This paper
presents the results from a year-long study into electric bicycle effectively. This paper
identifies potential barriers of electric bicycle. Overcomes it by using innovative
“redemption Springer forks” in front suspension with electric motor for assistance.
6) “Literature Review on Electric Bike” by Kunjan Shinde.,2017
The paper present the idea of harnessing the various energy and use it in today’s existence
of human life. For human being travelling has become vital. In order to sustain in this fast
forward world he must travel from place to place. It is very important that time taking for
travelling should be less; also it should be economical and easily available. With the fast
depleting resources of petrol and diesel, there is need to find intermittent choice. Taking
all this into account, a shift away from conventional based fuels to using renewable
sources of energy is a must. The Operating cost per/ km is very less and with the help of
solar panel it can lessen up more. Since it has fewer components it can be easily
dismantled to small components, thus requiring less maintenance.

9. PCET’S NMIET, B.E (Mechanical)
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3. SIMULATION WORK
Selection of Components
Based on the literature survey and availability, we have listed the required components of
the electric vehicle.
i. Bajaj Spirit
ii. Brushless DC Hub Motor
iii. Speed controller
iv. Battery (Power supply unit)
v. Battery Charging Kit
3.1 Vehicle specification of Bajaj Spirit
Table 2: Vehicle specification of Bajaj Spirit
Displacement 59.86 cc
Maximum Power 3.6 BHP @ 6500 rpm
Maximum Torque 4.32 NM @ 5500 rpm
Number of Cylinders 1
Ground Clearance 120.00 mm
Kerb/Wet Weight 76.00 kg
Body Type Scooter
Fuel Type Petrol
Engine Description Air Cooled
Overall Length 1685.00 mm
Overall Height 1020.00 mm
Ground Clearance 1165.00 mm

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3.2 Calculations
3.2.1 Motor selection
Weight of vehicle : 200 kg=1962 N
Length of vehicle : 1.685m
Width of vehicle : 0.635m
Height of vehicle : 1.02m
Wheel radius : 0.127m
Gearbox ratio : 6:1
Vehicle speed : 65kmph
Area of vehicle : 1.069975 m2
Rolling coefficient of friction : 0.018
Drag coefficient : 0.0032
i. Rolling resistance
Rr= (Rolling coefficient of friction × Weight in N) = 35.316 N
ii. Air resistance
Ra= (Drag coefficient × Area of vehicle × (velocity)2
) = 14.466 N
iii. Gradient resistance
Slop in degree(α) = 450
=0.0137 rad
Rg = (W × sin α )= 0.483 N
iv. Total resistance
Rt= ( Rr +Ra +Rg) = 50.265 N
v. Torque required for wheel
Tw= Total resistance × radius of wheel=6.383 Nm
vi. Torque for motor
Tm = (torque required for wheel) ÷ (gear ratio)=1.063 Nm

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vii. RPM for wheel
(Speed of vehicle in m per min) ÷ (2×π×Radius of wheel) = 626.912 rpm
viii. RPM for motor
Nm= (gear ratio× rpm for wheel) = 3761.472 rpm
ix. Motor power
Pm= (2×π×Nmotor×Tmotor) ÷ 60= 418.882 watt
Hence, the power required to propel the vehicle is 418.882 W, which is just below our
motor specification 500 W. And the design is safe.
3.2.2 Battery Calculation:
Since motor selected is of 48V hence battery voltage rating should also be 48. Therefore
we select four batteries of 12V and 20 Ah in parallel combination of we get 48V and
20Ah.
Charging time
Time required to charge the battery by adapter 48 V 6 Ah
P= 48* 6= 288 W
T= (48*20) / 288
= 3.33 hours

12. PCET’S NMIET, B.E (Mechanical)
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3.3 Components Description
The components used in this project are BLDC hub motor, motor controller, sealed
batteries, charging circuit, ignition switch, Display unit, Throttle.
3.3.1 I C Engine
It had a 59.86cc Engine with a single cylinder, 2-stroke, forced air cooled, which gave
maximum power of 3.6bhp@6500rpm and maximum torque of about 4.32Nm
@5500rpm. It had 2-speed automatic transmission and drum brakes at front and at rear
end, which made it suitable to drive on busy roads.
Figure 1: Bajaj Spirit of IC Engine [7]

13. PCET’S NMIET, B.E (Mechanical)
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Table 3: Engine Specification
Engine Specifications
Engine Description Air Cooled
Displacement 59.86 cc
Maximum Power 3.6 BHP @ 6500 rpm
Maximum Torque 4.32 NM @ 5500 rpm
Number of Cylinders 1
Gearbox & Clutch
Number of Gears Automatic
3.3.2 Hub motor
Hub motors are an interesting development which could offer benefits such as
compactness, noiseless operation and high efficiency for electric vehicles. These motors
have stators fixed at the axle, with the permanent magnet rotor embedded in the wheel.
The traditional “exterior rotor” design has the hollow cylindrical rotor spinning around a
stator axle. There is a “radial air gap” between the stator and rotor. The stator consists of
stacked laminated steel plates with wound coils. Pulse width modulated current is used to
supply current to the stator.
Hub motors must run at relatively low speed equal to the actual rotation of wheel
if there is no final gearing stage. The benefit is about a 10% increase in efficiency due to
the lack of transmission .The main reason for choosing a hub motor is that it does not
require a transmission system which helps in reducing the transmission losses. Since it has
no brushes to wear out the life of motor is increased. It has a greater traction control. The
back emf created by BLDC motor can easily be stored in the batteries.

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Figure 2: Hub motor [8]
Brushless Direct Current (BLDC) motor is a type of synchronous motor, where magnetic
fields generated by both stator and rotate have the same frequency. The BLDC motor has
a longer life because no brushes are needed. Apart from that, it has a high starting torque,
high no-load speed and small energy losses. The BLDC motor can be configured in 1-
phase, 2-phase, and 3-phase. Three-phase motors are the most popular among all the
configurations and are widely used in e-bikes.
We have selected hub motor because the motor replaces the hub of wheel.
Coupling loss is reduced and mounting can be made easy without the use of chains or
belts, and that reduces size and weight of the scooter.

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The specifications of hub motor are listed below:
Table 4: Technical Specifications of hub motor
500 W BLDC Gearless 12-inch Hub motor
Position Front
Construction Brushless Gearless Hub motor
Rated Voltage (DCV) 48V
Rated Power (W) 500
Rated Speed 250 - 600 rpm
Rated Torque 12 - 25 N.m
Gross Weight 8.2 kg
Tire Diameter 15 x 3.00 (10 x 3)
Tire Width 83 mm
Motor Cable 20 to 50 cm
Rated Efficiency >85 %
Load Carrying Capacity(maximum) 250 kg
Color Silver
Maximum Speed can be achieved 70 km/hr
Constant Current at Ideal Load 10 – 20 Ampere
3.3.3 DC Controller
The controller connects the power source to the motor. It controls speed, direction
of rotation, and optimizes energy conversion. While batteries produce constant voltages
which decrease as they are used up, some controllers require a DC to DC converter to step
down this changeable voltage to the motor’s expected constant operating voltage, but
other controllers incorporate a DC-to-DC converter and can accept a varying voltage.
Converter efficiencies are typically greater than 90%. The voltage control is achieved by
“chopping” the source current - the voltage is switched on and off, with the ratio of on to

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off determining the average voltage. Chopping is performed by power electronic circuitry
such as diodes and thrusters and silicon control rectifiers (SCR). Controllers also effect
regenerative braking, by which the motor is acted as a generator to recharge the batteries.
The controller for the motor is being interfaced with the motor speed regulation.
The speed controlling throttle is being interfaced through the motor controller circuit. The
motor used here is 48V, 250W, Ampere made hub motor.
The controller for the motor is also Ampere made suitable for controlling the
specified motor. The throttle is an ampere made throttle for speed regulation of the
specified motor. The input to the motor is supplied by four Exide made Electra lead-acid
batteries each of 12V, 26Ah through controller for testing purpose. Two independent
propelling sources are being employed for obtaining total propulsion of the vehicle.
Figure 3: DC Controller [9]

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Controller Function:
1. Battery power input cable.
2. Motor phase cable.
3. Battery power output cable (24V output).
4. Power lock (switch on/off) cable.
5. Reverse switch cable.
6. Braking switch cable.
7. Throttle cable.
8. Motor hall sensors cable.
9. PAS cable (electric sensors cable).
10. Lower speed switch on/off cable.
11. Auto cruising connector.
12. Intelligent learning cables.
The Functions of DC Controller are listed below:
1. Super low noise when starting up.
2. Speed limit/3 speed.
3. Under-voltage protection.
4. Under-current protection.
5. Cruising control.
6. Water proof.
Table 5: Technical Specifications of DC controller
Sr. NO Features Description
1 Rated Voltage (V) 48
2 Rated Power (W) 500
3 Rated Current (A) 30
4 Efficiency (%) >=83
5 Consumption (W) <1.5

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3.3.4 Batteries
Figure 4: Lithium ion Battery pack [10]
Lithium-ion batteries are the most suitable in existing technology for electric vehicles
because they can deliver high output because of having capability to store high power per
unit of battery mass, allowing them to be lighter and smaller than other rechargeable
batteries. These features also explain why lithium-ion batteries are already widely used for
consumer electronics such as cell phones, laptop computers, digital cameras/video
cameras, and portable audio/game players. Other advantages of lithium-ion batteries
compared to lead acid and nickel metal hydride batteries include high-energy efficiency,
no memory effects, no self discharging and a relatively long cycle life. The electric
scooter uses battery having capacity of 48V 20Ah capacity.
Table no 6: Battery Specification
Battery Type Li ion
Battery Capacity 20
Capacity (ampere hour) 20Ah
Model 48Volts 20Ah
Warranty 1 Years/2 Years
Product Type Li ion battery
Voltage (V) 48
Weight (g) 6000
Condition New
Weight (kg) 6
Current 30 Amps
Use E bikes
Charge Current 10
Max Pulse Discharge Rate 40 Amps
Charging Current 10
Battery Dimensions 265mm x 175mm x 68mm
Cycles 1000 cycles @ 80% DOD
Voltage 48
Amperage 20

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3.3.5 Battery Charging Kit
Figure 5: Battery Charging Kit [11]
Lithium ion (Li-ion) batteries’ advantages have cemented their position as the primary
power source for portable electronics, despite the one downside where designers have to
limit the charging rate to avoid damaging the cell and creating a hazard. Fortunately,
today’s Li-ion batteries are more robust and can be charged far more rapidly using “fast
charging” techniques.

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4. SCOPE FOR THE FUTURE WORK
 We can charge the batteries with help of solar energy.
 We can charge the batteries by using alternator.
 We can use motor with greater power for greater speed.

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5. References
1. Samir NAZIR, Y.S. WONG , ‘Energy and Pollutant Damage Costs of Operating
Electric, Hybrid, and Conventional Vehicles in Singapore ,2011
2. C. Abagnalea, M. Cardoneb, P. Iodicea, R. Marialtoc, S. Stranoa, M. Terzoa, G.
Vorraro ‘Design and Development of an Innovative E-Bike’,2016
3. Paul Chambon, Scott Curran, Shean Huff, Lonnie Love, Brian Post, Robert
Wagner, Roderick Jackson, Johney Green Jr ‘Development of a range-extended
electric vehicle power train for an integrated energy systems research printed
utility vehicle’,2017
4. Roberto Nocerino a, Alberto Colorni a,b, Federico Lia a, Alessandro Luè a,b “E-
bikes and E-scooters for smart logistics: environmental and economic
sustainability in pro-E-bike Italian pilots”,2016
5. Yashwant Sharma,Praveen Banker,Yogesh Raikwar, Yogita Chauhan, Madhvi Sharma
‘R&D on electric bike’,2018
6. Kunjan Shinde ‘Literature Review on Electric Bike’,2017
7. https://www.bmsparts.nl/diverse-motorblokken/15297-motorblok-bajaj-spirit-
45km-framenr-md2600129yw-bouwjaar-voor-2005.html
8. https://www.amazon.in/GoGoA1-Hub-Motor-BLDC-
Conversion/dp/B076HRLH7T
9. https://www.uumotor.com/uuen/wp-content/uploads/2015/02/uumotor-
HW24250W-controller-user-guide.pdf
10. https://www.indiamart.com/proddetail/48v-20ah-lithium-ion-battery-pack-
12574743891.html
11. https://www.indiamart.com/proddetail/gogoa1-48v-6amp-lithium-ion-battery-
charger-15185611397.html