A E-Bike Made by Diploma Mechanical Students . College: Tolani Foundation of Ghandhidham Polytechnic , Adipur, Kutch

1. Electric Bike
TOLANI FOUNDATION GANDHIDHAM
POLYTECHNIC-ADIPUR
BY – BATCH NO :- 2 Guided BY:- PROF. Hiren Sager
GROUP NO :- 4 PROF. Mrunal Solanki

2. GROUP MAMBERS :- ENROLLMENT NO :-
1. VIVEK CHAWDA 206510319501
2. MEHUL PRAJAPATI 206510319502
3. DHAVAL GADHIYA 206510319503
4. PRINCE MAHESHWARI 206510319504
5. MAHESHGAR GUSAI 206510319508
6. JAY JANGAM 186510319019
7. PRINCE PATEL 186510319042
8. SAGAR HUMBAL 176510319017

3. Bike drawing :-1

4. Bike drawing:- Side View

5. Bike drawing:- Top View

6. Actual Project E-Bike:-

7. SODHYATRA
 welspun india pvt ltd :- anjar
 ratnamani metals & tubes ltd :- anjar
 shreenathji cotton mills :- anjar
 arya cotton mills :- anjar
 manaksia coated metals & industries ltd :- chandrani ( anjar )
 hindustan unilever :- kasez ( Gandhidham )
 ice plant :- adipur
 vivek engineering works :- anjar etc

8. What are electric bike?
 When someone hears electric bike, the first image they imagine may be scooter or bike
- but they actually look pretty different. Just picture a regular bike, then add several
electrical components to it like a motor, a battery, and a controller – all seamlessly
integrated into the design. These items make up the fundamentals of all electric bike on
the market.
 There is a common myth that electric bike are like scooters, but they are actually
very similar to regular bike, but with an electric motor. The only significant
difference in appearance is the inclusion of the electrical drive system. This
includes a motor, a battery, and sometimes a display screen.

9. How electric bikes work:
 Most electric bikes use lithium-ion battery packs, varying in size
depending on the type and price of bike they’re fitted too. Most e-bikes
will have one battery system on board, however, some touring and
commuter e-bikes are capable of taking two, even three battery packs at
a time.
 These batteries are rechargeable via a standard wall power outlet.
Recharge times and charge cycle counts vary based on the quality of the
system

10. Components Of E-Bike:-
1. BLDC MOTOR
2. LITHIUM-ION BATTERY
3. DISPLAY
4. Controller
5. Accelerator

11. Motor:-
 Electric bike motors come in a wide variety of power ratings, from 200W
to 1,000W or more. The legal limit in the US is 2400W, although different
states can set their own limits.
 A higher rating means that the bike will be able to pull more weight with
greater ease – but at the expense of using more battery capacity while
doing so. Consequently, a 2400W motor will drain the battery much
quicker than a 250W one, but it will be more powerful.

12. SPECIFICATION OF E-BIKE PARTS
1) DC GEARERD MOTOR
 RATED VOLTAGE: 48 VOLT DC
 RATED POWER: 1000W
 RPM (AFTER REDUCTION) – 3000RPM
 RATED CURRENT – 40A
 RATED TORQUE – 4.5 NM
 MAX. OUTPUT TORQUE – 11 NM

13. LITHIUM-ION BATTERY:-
 electric bikes are powered by our 48V Flight Speed™
Lithium-Ion Battery. These rechargeable batteries are
efficient and long-lasting for years of fun riding. Lightweight
and easy to recharge, the batteries are also designed to fit
seamlessly into the aesthetic of the bike thanks to the down
tube design. Enjoy an impressive 48 voltage battery capacity
of 20Ah (1000 WH).

14. SPECIFICATION OF E-BIKE PARTS
2) LITHIUM-ION BATTERY
 VOLTE – 48V
 AMPERE - 20AH
 BATTERY WEIGHT – 6 kg
 SIZE – 15*6*10 cm

15. The LCD Display:-
 This LCD display with a high-contrast LCD display delivers all important
information, including the motor power and temperature, battery
voltage, and charge status parameters. With a true reflection of the
battery charge. the LCD makes it very easy for users to know the power
level and the speed. the instrument has good compatibility and
interchangeability, different instruments can be conducted the data
exchanges and parameter copy directly.

16. Controls:-
 Available in a variety of styles, the controller lets you operate the electric
assistance on your electric bike and is an important part in how electric
bikes work. The controller is located on the handlebar for ease of use.
There are two main styles of controllers – pedal-activated and throttle-
based controllers.
 Pedal-activated systems offer electric assistance as you press down on
the pedals. There is no need to engage a throttle – simple pedaling will
do the trick. Electric bikes with pedal-activated systems have a controller
mounted on the handlebar that lets you adjust the level of assistance that
you receive as you pedal. You can dial in the amount of assistance you
want, ranging from no assistance to a great deal of assistance.

17. SPECIFICATION OF E-BIKE PARTS
3) CONTROLLER
 VOLTAGE: DC 48V
 CURRENT LIMIT: 35A
 LEVEL BRAKE: LOW LEVEL
 LENGTH : 210 MM
 WIDTH : 80 MM
 POWER: 1680W

18. Accelerator:-
 An e-bike throttle functions similar to a motorcycle. ... To engage the
throttle, you simply twist the handlebar, and the bike will accelerate.
 Let go of the throttle, and the bike will stop. Some e-bikes feature a
thumb throttle, which requires pushing the throttle button to engage the
motor.

19. SPECIFICATION OF E-BIKE PARTS
6) CHAIN AND SPROCKET

20. Working Principle:-
 A motor is an electrical machine
 which translates electrical energy into mechanical energy.
 The principle of working of a DC motor is that "whenever a current
carrying conductor is placed in a magnetic field, it practices a mechanical
force".

21. Objectives:-
 E-bikes use rechargeable batteries that can travel up to 25 to 45 km/h,
much faster than most people would cycle, getting you to your
destination quicker and in better shape.
 In a nutshell they offer low cost, energy efficient, and emission-free
transportation which also has physical and health benefits.

22. SR NO. ITEM SPECIFICATION QUANTITY COST
(RS)
1. Bike
(From Scrap)
Bajaj boxer
(Old model)
1 Nos 5000
2. Motor 48 VOLT,
1000 WATT
Electrical Motor
1 Nos 4000
3. Battery 48 VOLT,
20 AMPERES
1 Nos 8000
4. Motor Controller Motor controller
48 VOLT 35 A
1 Nos 500
5. Sproket drive 12 cm diameter
28 teeth
1 Nos 400
6. Wire 4 – Meter Copper
Wire
4 Nos 250
7. Accelerator 12-99 V 1 Nos 300
8. Display 48 v 1 Nos 450
Bill Of Material :-

23. E-Bike Specifications:-
Price RS. 18,900
Maximum Power 200 Watt’s
Type of Motor DC Motor
Fuel Economy 40 Km for each charge
Starting Mechanism Self-start only
Maximum Speed 40 Kmph
Gear box Not Gear’s
Battery Recharge Time 6 to 8 hours
Front Wheel 16 inch
Rear wheel 16 inch
Rear Suspension Soft suspension
Ground Clearance 140 mm

24. Advantages:-
 Environmentally friendly
 Lower Running Cost
 Large Storage Space
 Low Noise
 Lightweight

25. Disadvantages:-
 Battery Life
 Electric batteries need to be replaced once they are damaged or once they no longer
give a good range. Batteries usually last for a year, and cost Rs.13,000-20,000,
depending on the rating, brand, quality, and warranties.
 Low Range
 The range of an electric bike/scooter is the distance that it will cover in a single charge.
The average range of the top electric bike/scooter models in India is 100 km. Moreover,
the range decreases with the life of the battery. It takes a good 5 hours to recharge the
battery, so it might not be a great option for long-distance travel.
 Low Power
 When electric vehicles were first introduced in India, they had very low power and
could not be driven at high speeds. Eventually, faster e-bikes and e-scooters have been
introduced but they are still no match for fuel-powered two-wheelers. Low driving
speed is one of the major disadvantages of an electric bike/scooter.

26. Actual work done:-
 First of all we have conducted a market survey for the required parts
for our project in nearer local market and collected required
specification of components. We have visited several shops in local
market this are listed below:-
- HERO ELECTRIC (Mahendra E Bike)
- Masaaji no vado
- Ajanta electric bike and solar light
 Prepared design for project.

27. Actual work done:-
 Work has been allotted to all the group members.
 From market survey we have prepared Bill of Material.
 Than we have performed SWOT analysis under the guidance of Prof. H.G
Sagar & Prof. M.S. Solanki.
 We have done stress analysis of our project design analytically from which
we find that our design fails in bending stress exerted by bearing in a
shaft, so we changed our whole design in order to make it safe.

28. Actual work done:-
 We have calculated the weight of each component analytically.
 Performed market survey to find the social impact of our project in local
INDIAN market.
 Manufactured required components (Hub, Rotary Joint, Shaft etc.) at our
T.F.G.P workshop.
 Changed Design of our project according to guidance provided by
workshop staff to easily meet the requirement of manufacturing.

29. Actual work done:-
 From Market survey we have selected the product of required specification
and purchase it time to time.
 Maintained and recorded the activities performed during the project labs
in log book.
 Prepared Route Sheet of the components we manufactured.

30. Expected Outcome:-
 In future we are thinking to add More Efficient Battery and more powerfull Motor
so, which can increase Overall Bike efficiency,and we will Travel more Distance.
 Right now we have made only Normal e-bike with normal budget. It's only demo
project but we will also try our best on it.
 If we succeed in this project then it will help the needed persons. We think that our
project has a better market in INDIA.
 We assume that our project has a good market potential in INDIA, once we
elaborate its advantages.
 And also now current situation rising of fuel price people have to find another
option and Electricity is better and eco friendly option.
 "So our project more changes of success in Future."

31. SWOT Analysis:-
Strengths:-
 Eco-friendly
 Silent
 Low cost of ownership cheaper to run
 Simpler mechanism easy to Drive
 Pollution Free
 Ability to sell Product. Qualified team
 Start up Opportunity

32. SWOT Analysis:-
Weaknesses:-
 Needs time to recharge
 Lack of recharging infrastructure.
 If Batteries change is expensive
 Safety Issues
 in our are no Charging stetiones
 We Can't achieve speed more than 45 km/h
 we not able to travel more than 40 km it has no features
like standard car

33. SWOT Analysis:-
Opportunities:-
 Governments subsidy for ownership
 No congestion charge
 Lower taxes
 Increasing fossil fuel costs
 we can start Start up business
 Growth of e- vehicles

34. SWOT Analysis:-
Threats:-
 Competition in form of electric hybrids, alternative fuel,
hydrogen-powered Bike
 Rise in cost of electricity
 Negative Review of students can effect on our confident.

35. BAR Chart:-

36. BAR Chart:-

37. Refrance
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38. THANK YOU