Development and Fabrication of Hybrid Electric Bicycle 2024-25

CHAPTER 1
INTRODUCTION
The rapid growth in urban populations and the increasing awareness of climate change have
amplified the demand for eco-friendly transportation alternatives. Among these, electric bicycles
have emerged as a practical and sustainable option, offering a clean and efficient way to travel
short to medium distances. However, the reliance of e-bikes on electricity for recharging presents
a challenge in terms of range and the availability of charging infrastructure. To address these
limitations, this project focuses on the development and fabrication of a geared hybrid solar-
powered electric bicycle, combining the benefits of solar energy and electric drive systems to
create a more versatile and sustainable mode of transport. This project aims to integrate solar
power with an electric drive system to extend the operational range of the bicycle and reduce
dependence on traditional electrical charging sources. By incorporating a geared system, the
bicycle is designed to offer enhanced performance and efficiency, enabling smoother rides across
different terrains. The combination of gears with a hybrid power source allows for better power
management, ensuring that the energy harvested from the sun is utilized effectively, while the
electric motor provides additional power when needed. The development of this hybrid bicycle
involves designing a robust frame, selecting suitable solar panels, optimizing battery storage, and
integrating the electrical components with the mechanical drive system. The geared mechanism
ensures that the bicycle can adapt to various speed and power requirements, making it suitable for
urban commuting as well as recreational use. This innovation not only supports the transition to
greener transportation options but also provides a cost-effective solution for users looking to
reduce their carbon footprint while maintaining flexibility in their travel needs. It empowers users
to reduce their carbon footprint, cut operational costs, and enjoy a reliable means of
transportation that is less dependent on the existing energy grid. With its enhanced range,
performance, and versatility, this project paves the way for future advancements in sustainable
mobility solutions. Moreover, the project emphasizes affordability and practicality, making it
accessible to a wide range of users. By reducing dependence on grid electricity and lowering
operational costs, this hybrid e-bike offers a compelling solution for eco-conscious commuters.
Its ability to harness renewable energy while providing reliable performance positions it as a key
player in the transition to greener urban mobility. As cities continue to grow and environmental
concerns intensify, this solar-powered e-bike stands out as a forward-thinking, sustainable
alternative for modern transportation needs.

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Development and Fabrication of Hybrid Electric Bicycle 2024-25

1.1 CONCEPT OF THE PROJECT

Fig 1.1 : Starting model of E-bicycle

Electric bicycles have evolved significantly over the years, transitioning from basic pedal-driven
designs to modern hybrids that integrate motors and advanced energy systems. However, many
existing designs still rely on plug-in charging, limiting their practicality in remote areas and
increasing dependency on non-renewable energy. Our project seeks to address these limitations
by creating a hybrid electric bicycle that combines mechanical innovation and renewable energy
integration to improve both performance and efficiency. By incorporating a geared transmission
system and a BLDC hub motor, this project aims to revolutionize how bicycles perform across
various [Link] core concept involves a dual-sprocket gear system where the pedalling
mechanism connects to a smaller sprocket, which drives a larger sprocket on the same shaft. This
setup efficiently transfers power to the rear wheel, maximizing torque and mechanical efficiency
during pedalling. Alongside this mechanical innovation, a BLDC Hub motor on the front wheel
automates propulsion, offering a smoother and more powerful riding experience, especially on
inclines or challenging terrains. The integration of these systems ensures a balance between
manual and motorized functionality, catering to diverse user needs.

To enhance sustainability and energy independence, the bicycle is equipped with solar panels that
charge the battery, reducing reliance on external power sources. The solar- assisted charging
system ensures that the bike can operate continuously, even in areas without charging
infrastructure. This innovative combination of solar energy, automatic motor assistance, and
efficient gear arrangements creates a highly versatile and eco-friendly transportation solution. It
addresses the key challenges like limited range, energy dependence, and adaptability, making it
suitable for both urban commutes and rural applications. As shown in the above Fig1.1.

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1.2 TYPES OF ELECTRIC CYCLE

Electric cycles, also known as e-bikes, come in various types, each designed for different
purposes and terrains. Here are some common types:

 City/Urban E-Bikes
These are designed for commuting in urban environments. They often have a sleek design,
integrated lights, fenders, and racks for carrying cargo. They usually have a moderate level
of assistance for navigating city streets and often have a comfortable upright riding
position.

 Mountain E-Bikes
These are built for off-road trails and rough terrain. They have rugged frames, wide tires
with aggressive tread, and powerful motors to assist with climbing steep hills and
navigating technical trails. Some models may have full suspension for added comfort and
control.

 Road E-Bikes
These are designed for paved roads and long-distance rides. They often have lightweight
frames, narrow tires, and a more aerodynamic riding position compared to other types of
e- bikes. They provide assistance to help riders maintain speed and tackle hills during
road rides.

 Hybrid/Commuter’s E-Bike
These are versatile bikes designed for a variety of riding conditions, including paved
roads, bike paths, and light trails. They typically have a comfortable riding position,
moderate tire width, and features like racks and fenders for commuting utility.

 Step Through E-Bike

These have a low or absent top tube, making it easier to mount and dismount, particularly
for riders who may have mobility issues or prefer a more accessible frame design. They
typically have a comfortable riding position, moderate tire width, and features like racks
and fenders for commuting utility making it easier for people to move.

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1.3 TYPICAL CHARGING METHODS OF E-CYCLE

Traditional charging methods for electric bicycles (e-cycles) primarily rely on

 Plug-in charging using an AC mains supply: In this method, the battery is removed from
the bicycle and connected to a charger, which is plugged into a standard electrical outlet.
This method is simple and widely used, allowing ecycles to be charged at home,
workplaces, or public charging stations.

 Direct Charging This method involves directly charging the battery while it is still
mounted on the e-cycle. The charger is connected to the battery through a port on the
bike, and the e-cycle is plugged into a wall socket. This method is convenient as it
eliminates the need to remove the battery, making it suitable for users who prefer to
charge the bike in its entirety. The charging process typically takes several hours,
depending on the battery's capacity and the charger's power output.

 Solar charging This is an increasingly popular method for recharging electric bicycles
(e- cycles), especially in areas with abundant sunlight. This method utilizes solar panels
to convert sunlight into electrical energy, which is then used to recharge the e-cycle’s
battery. Solar charging can be integrated in two primary ways: on-board solar panels and
external solar charging stations. Onboard solar panels are mounted on the frame or other
parts of the e-cycle, providing a continuous source of energy while the bike is stationary
or in motion.

These panels can trickle charge the battery, but typically, the charging process is slower
compared to conventional AC charging. External solar charging stations are standalone
units, often in the form of larger panels, that users can connect to the bike’s battery for a
more efficient recharge. Solar charging is particularly beneficial for those who want to
reduce their carbon footprint and rely on renewable energy sources.

It is a sustainable, eco-friendly option. This method utilizes solar panels to convert

sunlight into electrical energy, which is then used to recharge the e-cycle’s battery. Solar
charging can be integrated in two primary ways: on-board solar panels and external solar
charging stations. This is an increasingly popular method for recharging electric bicycles
(e- cycles), especially in areas with abundant sunlight.

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1.4 REASONS FOR SELECTING THIS PROJECT

Here are several reasons for selecting the project of developing a geared solar ebike:

1.4.1 Sustainability and Environmental Benefits

 The geared solar e-bicycle leverages renewable energy, specifically solar power, for
charging. This reduces dependency on fossil fuels and helps decrease carbon emissions,
contributing to a more sustainable transportation option.
 It aligns with global initiatives towards reducing greenhouse gas emissions and promotes
a shift to cleaner energy sources in the transportation sector.

1.4.2 Extended Range and Versatility

 By integrating a solar charging system directly onto the e-bicycle, users can extend the
range of the vehicle beyond what is possible with a single battery charge. This makes the
e-bicycle suitable for longer trips and usage in areas with limited access to charging
infrastructure.
 The addition of gears allows the rider to adapt to different terrains and conditions,
providing better control and efficiency in both urban and rural settings.

1.4.3 Cost-Effective Transportation

 Using solar energy for charging reduces the cost of electricity and operational expenses,
making the e-bicycle more affordable over its lifecycle. This is particularly beneficial for
users who rely on their e-bicycle for daily commuting.
 The regenerative braking system can further save energy by converting kinetic energy
back into electrical energy, adding to the overall efficiency and reducing wear on
traditional braking components.

1.4.4 Technological Advancement and Innovation

 This project offers an opportunity to explore innovative technologies such as solar-

assisted charging, energy regeneration through braking, and advanced motor control
systems. It pushes the boundaries of existing e-bicycle technology.
 It is particularly suitable for remote areas or developing regions where infrastructure
electric vehicle charging is not yet well established.

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 The project encourages the development of a more adaptable and efficient drive system,
contributing to the advancement of electric vehicle technology and renewable energy
integration.

1.4.5 Promoting Green Mobility

 E-bicycle are already a popular mode of transport due to their low operational costs and
ease of use. By integrating solar charging, this project can further increase the adoption of
e- bicycle as a green alternative to conventional vehicles in both urban and rural areas.
 It supports the vision of eco-friendly cities and can help address traffic congestion,
pollution, and high transportation costs in densely populated areas.

1.4.6 Practical Solution for Energy Challenges

 In many regions, power outages and limited access to charging stations can hinder the use
of electric vehicles. A solar-powered e-bicycle provides a practical solution, allowing
users to charge their e-bicycle off-grid using natural sunlight.
 It is particularly suitable for remote areas or developing regions where infrastructure for
electric vehicle charging is not yet well established.

1.4.7 Potential for Commercialization

 With the growing demand for clean and efficient transportation, a geared solar e- bike has
strong potential for commercialization. It can be marketed to commuters, delivery services,
and recreational riders looking for an eco-friendly and efficient travel option.
 The project can serve as a prototype for future innovations in the e-bicycle industry,
opening avenues for further research and development.

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CHAPTER 2

LITERATURE REVIEW
2.1 DETAILS OF LITERATURE SURVEY

[1] Ian Vince McLoughlin et al.

This paper explores the use of electric bicycles for campus mobility, emphasizing the
environmental benefits and user convenience. The authors highlight that electric bicycles can be
an effective alternative for short-distance travel, reducing carbon emissions compared to
traditional vehicles. It also discusses the integration of regenerative braking systems to improve
energy efficiency, which is a key component in self-charging electric bicycles.

[2] Vivek Kumar et al.

This study focuses on the design and implementation of an electric bicycle that incorporates a
self- recharging mechanism using regenerative braking. It highlights the potential of capturing
kinetic energy during braking and converting it into electrical energy, which is then used to
recharge the battery.

This design allows for an extended range and less dependency on external charging
infrastructure. The study is relevant for understanding how energy recovery during pedaling and
braking can be efficiently utilized in electric bicycles.

[3] Adithya Kumar et al.

This research presents the fabrication of a self-charging electric bike that integrates a mechanism
for harnessing energy during pedaling. The study demonstrates the effectiveness of using a
BLDC motor in generator mode to convert mechanical energy into electrical energy during
pedaling, which can be stored in the battery.

Additionally, the incorporation of solar panels enhances the charging capacity, providing an
additional renewable energy source. This research serves as a foundation for hybrid systems that
combine both solar and pedaling energy for battery charging.

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[4] Shubham U. Tayde et al.

The authors propose a self-power generating electric bicycle that utilizes both regenerative
braking and pedaling mechanisms to generate power. They discuss the importance of using a
motor as a generator to capture energy during deceleration, which is then used to charge the
battery. This work highlights the potential for improving the efficiency of electric bicycles by
maximizing energy recovery during operation, making it a crucial reference for the design of
energy-efficient hybrid bicycles.

[5] D. M. Sousa et al.

This study explores the use of both batteries and supercapacitors in an electric bicycle to enhance
energy storage and manage power delivery. It discusses the advantages of using supercapacitors
to handle the rapid energy fluctuations that occur during regenerative braking, while batteries
store the long-term energy. This combination improves the overall efficiency of the system,
making it a useful study for understanding advanced energy storage solutions in hybrid electric
bicycles that aim to integrate multiple charging methods.

[6] Ettore Pennestrì [Link]

This paper aims to find a way to make hybrid vehicle gear systems (using both gas and electric
power) more efficient. It focuses on improving the design of gear setups like the ones in hybrid
cars, using mathematical and graph-based tools to analyze different gear configurations. It uses a
graph- based approach to break down these complicated systems, making it easier to analyze
how well they transfer power. This helps engineers design better, more efficient hybrid vehicles.

[7] Lorenzo Mariti [Link]

The paper explores a systematic approach to analyzing and modeling power split transmissions
with a focus on epicyclic gear trains used in hybrid vehicles. Prior research has addressed the
efficiency of various gear types and their combined performance in planetary or differential
configurations. Key contributions include models by Martin (1981) and Anderson &
Loewenthal, and it was done in (1982), which focus on mechanical efficiency in ordinary gear
trains. Further studies by Hedman, del Castillo, and Chen emphasize epicyclic gear trains'
performance. Despite existing models, the need for a detailed, systematic approach to evaluating
parallel hybrid vehicle transmissions remains, particularly when incorporating continuously

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variable transmission (CVT) elements. This study utilizes a graphbased approach to efficiently
analyze kinematic chains and power flow in such systems, offering a novel framework for
assessing the complex interactions of planetary gear hybrid powertrains (PGHPs).

2.2 SUMMARY OF LITERATURE SURVEY

The literature on electric bicycles with self-recharging mechanisms highlights significant

advancements in improving energy efficiency and reducing carbon emissions. McLoughlin et al.
(2012) emphasize the environmental benefits of ebikes for short-distance travel, particularly
through regenerative braking systems that enhance energy efficiency. Kumar et al. explore self-
recharging mechanisms using regenerative braking to convert kinetic energy into electrical
energy, reducing reliance on external charging sources. Adithya Kumar et al. (2018) further
integrate solar panels, combining both solar and pedaling energy for battery charging. Tayde et
al. (2017) focus on using BLDC motors in generator mode during braking to capture energy and
recharge the battery. Sousa et al. (2018) discuss the use of batteries and supercapacitors to optimize
energy storage and power delivery, effectively managing energy fluctuations during braking.
Pennestrì et al. (2011) and studies on hybrid vehicle gear systems provide insights into
optimizing power split transmissions, contributing to the broader understanding of hybrid
powertrains. Overall, these studies lay the foundation for designing hybrid electric bicycles that
incorporate advanced energy recovery, storage, and power management systems to enhance
sustainability and efficiency in daily use. Sousa et al. (2018) discuss the use of batteries and
supercapacitors to optimize energy storage and power delivery, effectively managing energy
fluctuations during braking. Pennestrì et al. (2011) and studies on hybrid vehicle gear systems
provide insights into optimizing power.

2.3 PROBLEM STATEMENT

Conventional electric bicycles often rely solely on plug-in charging methods, limiting their range
and usability in remote areas without access to charging stations. Furthermore, the dependence
on traditional energy sources for charging these bicycles can contribute to increased carbon
emissions. To address these challenges, there is a need to develop a geared solar e-bicycle that
integrates solar energy for charging. This e-bicycle would feature a solar-assisted charging
system using highefficiency photovoltaic panels mounted on the bicycle, enabling continuous
charging while in use or when parked. By incorporating a geared transmission system, the e-

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bicycle aims to provide enhanced torque and efficiency, especially in varied terrains. The
proposed solution aims to extend the range of electric bicycles, reduce dependency on non-
renewable energy sources, and promote sustainable transportation options suitable for urban and
rural environments.

2.4 OBJECTIVES OF THE PROJECT

 To Develop a Solar-Assisted Charging System

 To Enhance the E-Bicycle's Performance through a Geared System
 To Improve Energy Efficiency with Regenerative System of charging

 To Provide a Cost-Effective and Practical Mobility Solution

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CHAPTER 3

METHODOLOGY
3.1 METHODOLOGY

We followed a structured methodology to develop and fabricate a hybrid electric bicycle.

Starting with problem identification and design conceptualization, we selected key
components like a BLDC motor, battery, and controller. After integrating and testing the
system, we optimized performance and safety, resulting in a functional prototype. The
process concluded with documentation and validation of the final design

Fig 3.1 Methodology

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3.2 BLOCK DIAGRAM

Buck- BLDC Hub

Boost Motor/Generato
Converter r
AC AC – DC
Grid Converter
Supply

Battery Controller Wheel

Buck – Boost
Solar Panel
Converter
Torque Pedal
Sensor

Fig 3.2 Block diagram for Hybrid E-Bicycle

3.3 BLOCK DIAGRAM EXPLANATION

 AC Grid Supply: This serves as an optional source of power, providing electricity

directly from the grid to the system when needed.
 AC-DC Converter: This component converts the AC power from the grid into DC
power, which is suitable for charging the battery. It acts as an interface between the grid
supply and the battery.
 Solar Panel: The solar panel harnesses solar energy and converts it into electrical energy.
It serves as the primary renewable energy source for the bicycle, helping to charge the
battery.
 Buck-Boost Converter: This converter regulates the voltage from the solar panel,
ensuring that the output is consistent and suitable for charging the battery. It adjusts the
voltage to either increase (boost) or decrease (buck) as required for the system to work
efficiently.

 Battery: The battery stores the electrical energy converted from both the solar panel and
the AC-DC converter. It provides power to the BLDC motor, ensuring continuous
operation even when solar energy is not available.
 BLDC Hub Motor: The BLDC (Brushless DC) hub motor, fitted to the front wheel,

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provides electric assistance for propulsion, reducing the physical effort required from the
rider. It is powered by the stored energy in the battery.
 Wheel: The wheel receives mechanical power from the BLDC motor, assisting the rider
in forward movement and ensuring smoother riding experience.
 Pedal: The pedal allows the rider to manually propel the bicycle. It is directly connected
to the generator, enabling the conversion of mechanical energy into electrical energy
during pedalling.
 Generator: The generator, connected to the pedal, converts the mechanical energy
generated during pedalling into electrical energy. This energy is then fed back into the
battery for storage, helping to extend the battery life and providing additional power for
the motor.
 Torque Sensor: It measures the force applied on the pedal during manual pedalling and
sends data to the controller, which uses this input to regulate motor assistance
proportionally to the rider's effort.

3.4 CIRCUIT DIAGRAM

DPDT SPDT TPDT

Fig 3.4 Circuit diagram for Hybrid E-Bicycle

The circuit diagram depicts a hybrid e-bicycle system that integrates solar energy and battery
power for efficient operation. The system includes a solar panel to harness renewable energy,
which is then regulated by a DC-DC buck-boost converter to ensure stable voltage levels. A
battery is used to store energy, providing power to the motor through a controller that manages
the energy flow. The rectifier converts AC to DC if needed, ensuring compatibility with the
system's components. This hybrid setup allows the e-bicycle to utilize both solar power and
battery energy, enhancing sustainability and extending the range of the bicycle as shown in
above Fig 3.4.

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3.5 WORKING MECHANISM

The hybrid electric bicycle, powered by solar energy and AC grid supply, operates efficiently
through three distinct modes: Motoring, Motoring with Pedalling, and Regenerative charging.
This system integrates key components such as the BLDC hub motor/generator, battery,
controller, solar panel, pedal with a torque sensor, and buck-boost converters to ensure seamless
operation. The bicycle is designed to reduce dependency on traditional power sources while
enhancing energy recovery and user efficiency as shown in above Fig 3.3.

In Motoring Mode, the bicycle runs purely on electric power stored in the battery. The battery,
which can be charged either through the solar panel (using a buckboost converter) or the AC grid
supply (via an AC-DC converter), supplies power to the BLDC hub motor through the controller.
The controller regulates the power flow and ensures smooth operation of the motor. The motor
converts this electrical energy into mechanical energy to drive the wheel, allowing the rider to
travel without the need for manual pedalling. This mode is particularly useful for minimizing
physical effort, making it ideal for urban commuting.

In Motoring with Pedalling Mode, the bicycle combines both manual pedalling and motor
assistance to propel the wheel. A torque sensor mounted on the pedal measures the force exerted
by the rider during pedalling. This information is sent to the controller, which adjusts the motor's
output to provide proportional assistance. As a result, the rider's effort is significantly reduced,
while simultaneously conserving battery power. This mode extends the battery life and range of
the bicycle, as part of the energy required for propulsion is supplied by the rider's pedalling. The
combination of motor assistance and manual effort makes this mode efficient for longer rides or
hilly terrains.

The Regenerative Charging Mode leverages the dual functionality of the BLDC hub motor,
allowing it to act as both a motor and a generator. During braking or manual pedalling without
motor assistance, the rotational energy of the wheel is transferred back to the BLDC motor,
which operates as a generator. This mechanical energy is converted into electrical energy and fed
back to the battery through a buckboost converter for storage. Additionally, during downhill
rides or deceleration, the motor captures otherwise wasted energy, improving the overall energy
efficiency of the system. This mode not only extends the range of the bicycle but also reduces
energy loss, making it a sustainable solution.

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3.6 SYSTEM DESIGN AND COMPONENTS

3.6.1 Frame Design

Fig 3.6.1 Frame Design for Hybrid E-Bicycle

It is the skeleton of the vehicle which acts as the back bone of the vehicle and supports and unitizes
the body parts of the vehicle. It also provides good handling and safety. A vehicle such as an
electric vehicle draws an advantage if it is light in weight. The Frame of the vehicle mustbe
designed such that it must be able to accommodate the battery pack.

The vehicle draws its main structural rigidity from the frame and it's supporting members on
which all components are mounted. One of the key elements of the design process of objects
under cyclical changingloading is the knowledge of service load history. Bike frames encounter a
complex set of stresses which in most cases cannot be calculated by hand as shown in Fig 3.6.1.
Therefore, in designing a frame, engineers usually make use of an older design which has proven
reliable asa starting point .

To ensure the safety of the user and promote efficient cycling, the dimensions of the bike and
cyclist must be taken into account, along with the amount of lateral and vertical clearance
needed, in the planning and design of bicycle facilities.
The dimensions of a typical bicycle area handlebar height of 0.75 - 1.10 m (2.5 - 3.5 ft.),
handlebar width of 0.6l m (2 t.), and bicycle length of 1.5 - 1.8 m (5 -6 ft.). They often provide
little traction. The general dimensions adopted for the design was (1200 x 200x 860) mm.

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3.6.2 Flywheel Design

Fig 3.6.2 Freewheel Design for Hybrid E-Bicycle

Flywheels are designed to store and release kinetic energy. A Flywheel is discshaped, and trueto
its weight on all sides and locations of the disk. The flywheel is designed to provide a
steadierflow of momentum. The size and weight of the flywheel will determine the amount of
energy that can be produced from peddling the bike. The mechanical advantages of using a
flywheel is that its energy output is consistent and, depending on the size of the flywheel, it is
able to store and release great amounts of energy even after the peddling has ceased as shown in
the above Fig 3.6.2.
The kinetic energy stored in the flywheel is given as:
KE =1/2*I* ω where, I=polar moment of inertia ω= angular velocity of the flywheel

3.6.3 BLDC Hub Motor

Fig 3.6.3 BLDC Hub Motor for Hybrid E-Bicycle

The BLDC Hub Motor (Brushless DC Motor) is a vital component in this hybrid electric bicycle
project, enabling both propulsion and energy recovery. Unlike traditional brushed motors, the
BLDC motor operates without mechanical brushes, relying instead on electronic commutation
controlled by a controller. This design minimizes friction, reduces maintenance, and improves
efficiency, making it an ideal this reduces rider fatigue, especially on longer rides or challenging
terrains, while conserving battery power as shown in the above Fig 3.6.3.

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choice for electric bicycles. In this project, the motor is integrated directly into the hub of the
wheel, eliminating the need for external chains or gears. This compact integration ensures a
lightweight, streamlined design with minimal energy losses.

During motoring mode, the BLDC hub motor converts electrical energy from the battery into
mechanical energy to drive the wheel and propel the bicycle forward. The controller regulates the
power supply to the motor, ensuring smooth and efficient operation. In motoring with pedalling
mode, the motor works in conjunction with a torque sensor attached to the pedal. The torque
sensor measures the rider's pedalling force and sends the data to the controller, which adjusts
motor output to provide proportional assistance. This reduces rider fatigue, especially on longer
rides or challenging terrains, while conserving battery power.

The BLDC hub motor also features regenerative capabilities, allowing it to act as a generator
during braking or pedalling without motor assistance. When the wheel rotates due to rider effort
or momentum, the motor converts the mechanical energy back into electrical energy. This energy
is then fed back to the battery through a buck- boost converter, increasing the system's overall
efficiency by capturing otherwise wasted energy. This regenerative feature is particularly useful
during downhill rides or braking, where kinetic energy can be effectively harnessed and stored.

Overall, the BLDC hub motor is a highly efficient, low-maintenance solution for hybrid electric
bicycles. Its dual functionality as both a motor and a generator enhances energy utilization,
contributing to extended battery life and improved performance. By providing smooth
propulsion, silent operation, and energy recovery, the BLDC hub motor plays a crucial role in
making the hybrid bicycle an eco-friendly and sustainable mode of transportation.

The torque sensor measures the rider's pedalling force and sends the data to the controller,
which adjusts motor output to provide proportional assistance. This reduces rider fatigue,
especially on longer rides or challenging terrains, while conserving battery power. This
regenerative feature is particularly useful during downhill rides or braking, where kinetic energy
can be effectively harnessed and stored.

A 36V, 250W, 450 rpm BLDC Hub Motor is used in this project.

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3.6.4 Controller

Fig 3.6.4 BLDC Motor Controller for Hybrid E-Bicycle

The core function of an electric bike controller is to take all the inputs from all the electric
components (throttle, sped sensor, display, battery, motor, etc.) and then determine what should
be signalled in return to them (motor, battery, display). Other multiple protection functions of the
controller will be different from the controller's design as shown in Fig 3.6.4.

Following are some basic protection functions.

Over-voltage protection
The controller monitors the battery voltage and shut down the motor when the battery voltage is
too high. This protects the battery from over-charge.
Low-voltage protection
The controller monitors the battery voltage and shut down the motor when the battery voltage is
too low. This protects the battery from over-discharge.
Over-temperature protection
The controller monitors the temperature of the FET( field effect transistor) and shut down the
motor if they become too hot. This protects the FET power transistors.
Over-current protection
Reduce the current to the motor if too much current is being supplied. This protects both the
motor and the FET power transistors.
Brake protection
The motor shut down when braking even though other signals taken by the controller at the same
time. For example, if the user applies brake and throttle at the same time, the brake function wins.

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3.6.5 Battery

Fig 3.6.5 Battery for Hybrid E-Bicycle

Despite its relatively lower energy-to-volume and energy-to-weight ratio compared to modern
counterparts, the Lead-acid battery maintains enduring relevance due to distinct advantages.
Notably, its capacity for high surge currents suits applications requiring sudden, substantial
power release, such as automotive starting and uninterruptible power supply (UPS) systems
during outages. Operating reversibly in electrochemical reactions, the Lead-acid battery's
durability and ability to undergo numerous charge-discharge cycles make it ideal for frequent use
scenarios. Widely adopted in a 12-volt configuration in automotive settings, its durability, low
cost, and high current output continue to make it a preferred choice.

In electric bicycles, the implementation of lead-acid batteries offers reliable, cost-effective

power storage solutions, leveraging robust surge current delivery and long cycle life for
sustained efficiency. The battery's resilience to varying environmental conditions further
enhances its practicality in demanding outdoor settings, contributing to the overall accessibility
and affordability of electric bicycles across diverse consumer markets. Moreover, the Lead-acid
battery's resilience and ability to withstand diverse environmental conditions enhance its
practicality for electric bicycles, especially in demanding outdoor settings. Its widespread
availability and comparatively lower cost contribute significantly to the overall accessibility and
affordability of electric bicycles, fostering their adoption across various consumer markets as
shown in the above Fig 3.6.5.

A 36V, 8.5 Ah Battery is used in this project.

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3.6.6 Solar Panel

Fig 3.6.6 Solar panel for Hybrid E-Bicycle

A solar panel is a device that converts sunlight into electricity. It is a crucial component in the
field of renewable energy, enabling the capture of solar energy and transforming it into usable
power. Solar panels are made up of numerous photovoltaic (PV) cells that harness the energy
from the sun's rays as shown in the above Fig 3.6.6.

Solar panels operate on the photovoltaic effect, where photons from sunlight strike the
semiconductor material (usually silicon) in the PV cells, creating an electric field across the
layers. This electric field forces the flow of electrons, generating direct current (DC) electricity.

The PV cells are sandwiched between layers of protective materials such as glass and polymer,
providing durability and weather resistance. A standard solar panel consists of multiple
interconnected PV cells, usually arranged in a grid pattern, to maximize energy production.

A 36V, 9W Solar Panel is used in this project.

3.6.7 Torque Sensor

Fig 3.6.7 Torque Sensor for Hybrid E-Bicycle

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The Double Hall Pedal Assist System (PAS) with 12 magnets is an advanced sensor mechanism
used in electric bicycles to detect the rider's pedalling motion and provide motor assistance
accordingly. This system consists of two Hall effect sensors and a circular disc embedded with
12 evenly spaced magnets. The magnet disc is typically mounted on the crank arm or bottom
bracket of the bicycle near the pedals, while the Hall sensors are fixed in proximity to this
rotating disc. As the rider pedals, the magnets pass by the Hall sensors, generating a series of
pulses. The system uses these pulses to determine the pedalling speed (cadence) and direction of
rotation.

The inclusion of 12 magnets ensures higher resolution and accuracy in detecting the pedalling
motion compared to systems with fewer magnets. A greater number of magnets allows for
quicker response times, as the system detects smaller increments of pedal movement. This results
in smoother and more immediate motor assistance, providing a natural riding experience. The
double Hall sensor setup further enhances the system by enabling precise detection of pedal
rotation direction. By analyzing the sequence in which the magnets pass the two sensors, the
system can determine whether the rider is pedalling forward or backward. This prevents
accidental motor activation when the pedals are rotated in reverse, improving safety and energy
efficiency as shown in the above Fig 3.6.7.

In operation, when the rider starts pedalling, the Hall sensors detect the motion and send signals
to the controller, which calculates the cadence and activates the motor to provide proportional
assistance. The faster the pedalling motion, the higher the cadence, and the controller increases
the motor output accordingly. This seamless coordination between the pedal assist system and
motor ensures efficient power delivery while reducing rider effort, particularly on inclines or
during long rides.

Overall, the double Hall pedal assist system with 12 magnets enhances the responsiveness,
accuracy, and safety of the hybrid electric bicycle, delivering a smoother and more intuitive
riding experience. fossil fuels and minimizing carbon emissions. It can be used for commuting,
recreational rides, and short-distance travel in urban areas and safety of the hybrid electric
bicycle, delivering a smoother and more intuitive riding experience.

A Torque sensor with 12 magnets is used in this project.

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3.6.8 Buck – Boost Converter

Fig 3.6.8 Buck – Boost Converter for Hybrid E-Bicycle

A buck-boost converter is a type of DC-DC converter that regulates voltage by either stepping it
up (boost) or stepping it down (buck) depending on the input and output requirements. In this
hybrid electric bicycle project, the buck-boost converter plays a crucial role in managing power
flow between the solar panel, battery, and BLDC hub motor/generator. It ensures that the voltage
from the solar panel or regenerative braking system is matched to the battery's charging
requirements, regardless of fluctuations in the input voltage.

The buck-boost converter operates using a combination of inductors, capacitors, a switch

(usually a MOSFET), and a diode. When the input voltage is lower than the desired output
voltage, the converter operates in boost mode, stepping up the voltage to charge the battery or
power the motor. Conversely, if the input voltage is higher than the required output voltage, it
operates in buck mode, stepping the voltage down to prevent overcharging or overloading the
system. This dual functionality makes the buck-boost converter highly efficient in systems where
input voltage can vary, such as with solar panels, which generate varying voltages depending on
sunlight intensity as Shown in the above Fig 3.6.8.

In regenerative braking, when the BLDC motor acts as a generator, the output voltage can
fluctuate based on the wheel's rotational speed. The buck-boost converter regulates this varying
voltage to ensure consistent and safe charging of the battery. It ensures that the voltage from the
solar panel or regenerative braking system is matched to the battery's charging requirements,
regardless of fluctuations in the input voltage. It can be used for commuting, recreational rides,
and short-distance travel in urban areas and safety of the hybrid electric bicycle, delivering a
smoother and more intuitive riding experience.

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Similarly, for the solar power input, the converter ensures that the power generated, even under
low sunlight conditions, is effectively utilized to charge the battery. Overall, the buck-boost
converter's ability to adaptively regulate voltage improves energy efficiency, optimizes power
transfer, and ensures reliable operation of the hybrid electric bicycle.

A Buck – Boost Converter with output from (1 - 40)V is used in this project.

3.6.9 Rectifier

Fig 3.6.9 Rectifier for Hybrid E-Bicycle

In the regenerative mode of the hybrid electric bicycle, the rectifier plays a key role in converting
the AC output from the BLDC hub motor, acting as a generator, into DC voltage to charge the
battery. When the rider pedals or the bicycle moves downhill, the kinetic energy of the rotating
wheel causes the BLDC motor to function as a generator, producing an alternating current (AC).
However, the battery can only store energy in the form of direct current (DC). To facilitate this
conversion, a rectifier circuit is used as shown in the above Fig 3.6.9.

The rectifier employed in this system is typically a bridge rectifier, which consists of four diodes
arranged in a specific configuration. As the AC voltage generated by the BLDC motor alternates
between positive and negative cycles, the diodes in the bridge rectifier allow current to flow in
only one direction, effectively converting the bidirectional AC waveform into a unidirectional
DC voltage. During each half-cycle of the AC input, two diodes conduct to ensure that the output
across the rectifier remains positive, resulting in a pulsating DC output.

To smooth this pulsating DC voltage and make it suitable for battery charging, a capacitor is
added at the rectifier's output. The capacitor acts as a filter, reducing the ripples in the voltage
and providing a relatively steady DC output. The buck-boost converter further processes this DC

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voltage to match the required charging voltage level of the battery, ensuring efficient energy
transfer and protecting the battery from overvoltage or undervoltage conditions.

Overall, the rectifier is a critical component in the regenerative mode, enabling the BLDC hub
motor to act as a generator and efficiently charge the battery. By converting the generated AC
power into DC, it ensures that the energy recovered during braking or pedalling is properly
utilized, improving the overall efficiency and sustainability of the hybrid electric bicycle.

A 3 phase Rectifier is used in this project.

3.7 FABRICATION PROCESS

3.7.1 Acquisition of an Old Bicycle

Fig 3.7.1 Acquisition of an Old Bicycle

 An old bicycle was procured as the base for the project.

 This served as the foundational structure for modifications to improve efficiency and
convert it into an electric bicycle as shown in the above Fig 3.7.1.

3.7.2 Modification of Gear Setup

Fig 3.7.2 Modification of Gear Setup

o A gear sprocket was taken from another cycle, cut, and welded onto the pedaling bar.
o The additional sprocket allowed the chain to be reconfigured, improving the mechanical
efficiency of the bicycle as shown in the above Fig 3.7.2.

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3.7.3 Welding Work

Fig 3.7.3 Welding Work

 Necessary welding was performed to securely attach the modified sprocket and reinforce
other structural components as shown in the above Fig 3.7.3.

 This ensured the durability and proper alignment of the modified setup.

3.7.4 Installation of BLDC Hub Motor

Fig 3.7.4 Installation of BLDC Hub Motor

 A Brushless DC (BLDC) hub motor was installed on the front wheel.

 This motor transformed the bicycle into an electric-powered vehicle by delivering
controlled torque and speed as shown in the above Fig 3.7.4.

 The hub motor was carefully mounted on the front wheel, and its connections were
aligned to maintain balance and smooth rotation during operation.
 The motor's parameters, such as speed control and torque output, were, configured through
the controller to meet the operational needs of the e-bicycle.

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3.7.5 Electrical System Setup

Fig 3.7.5 Electrical System Setup

 A battery and other essential electrical components were connected to power the hub
motor as shown in the above Fig 3.7.5.
 The wiring was carefully arranged to integrate the motor, controller, and power source.
3.7.6 Placement of Solar Panel

Fig 3.7.6 Placement of Solar Panel

 A solar panel was mounted on the bicycle's rear carriage.
 This panel serves as a renewable energy source to charge the battery, enhancing the
project's sustainability as shown in the above Fig 3.7.6.

 The solar panel was wired into the electrical system to provide a supplementary charging
option, reducing dependence on external power sources.
 The panel was strategically placed to maximize exposure to sunlight during
movement and stationary periods, enhancing energy harvesting capabilities.

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3.7.7 Final Assembly and Testing

Fig 3.7.7 Final Assembly and Testing

 After completing the modifications and installations, the bicycle was assembled and
tested to ensure all systems functioned effectively.

 Adjustments were made as needed to achieve optimal performance. As shown in the

above Fig 3.7.7

3.8 FABRICATED MODEL

Fig 3.8 Fabricated Model

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CHAPTER 4

RESULTS AND DISCUSSION

4.1 FOR MODE 1- MOTORING

Table 4.1: For Mode-1 at 10Km/hr

Sl No Load in Kg Voltage in V Current in A

01 60 4.96 9.81

02 66 5.2 9.90

03 76 5.4 10.2

04 82 5.8 10.03

The Hybrid E-Bicycle was driven with different load conditions with a constant speed at 10 km/hr
.The different readings tabulated are shown in table 4.1. The graph was plotted for voltage,
current vs load as shown in Table 4.1.1

4.1.1 Graphical Representation

For Mode -1at 10 km/hr (Max Speed 16km/hr)

Fig 4.1.1: Graphical representation of Mode -1

The current and voltage versus mechanical load (weight in kg) is plotted as shown in the graph.
The graph reveals that as mechanical load increases the load current increases where in the
voltage remains constant.

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4.2 FOR MODE -2 MOTORING WITH PEDALLING

Table 4.2: For Mode-2 at 15km/hr

Sl No Load in Kg Voltage In V Current in A

01 62 4.0 9.8

02 69 3.5 9.9

03 71 3.3 10.2

04 74 2.99 10.03

Hybrid E-Bicycle was driven with different load conditions with a constant speed at 15 km/hr
.The different readings tabulated are shown in table 4.2 The graph was plotted for voltage,
current vs load as shown in fig 4.2.1

4.2.1 Graphical Representation For Mode -2 at 15Km/hr

Fig 4.2.1: Graphical representation of Mode-2

The current and voltage versus mechanical load (weight in kg) is plotted as shown in the graph.
The graph reveals that as mechanical load increases the load current increases where in the
voltage remains constant.

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4.3 FOR MODE -3 REGENERATIVE MODE

Table 4.3: For Mode-2 at 20km/hr

Sl No Load in Kg Voltage in V Current in A

01 91 29.8 9.8

02 80 24 10.0

03 68 39.9 10.3

04 56 27 10.6

Hybrid E-Bicycle was driven with different load conditions with a constant speed at 15 km/hr
.The different readings tabulated are shown in table 4.3 The graph was plotted for voltage,
current vs load as shown in fig 4.3.1

4.3.1 Graphical Representation

For Mode -3 at 20Km/hr

Fig 4.3.1: Graphical representation of Mode-3

The current and voltage versus mechanical load (weight in kg) is plotted as shown in the graph.
The graph reveals that as mechanical load increases the load current increases where in the
voltage remains constant.

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4.4 ADVANTAGES OF OUR PROJECT

 Eco-Friendly Solution
The bicycle utilizes solar energy and regenerative braking, reducing reliance on non- renewable
energy sources and minimizing environmental pollution.

 Energy Recovery through Regenerative Braking

The BLDC hub motor acts as a generator during braking, converting kinetic energy into
electrical energy to recharge the battery, improving overall energy efficiency.

 Cost-Efficient Operation
By leveraging solar power and energy recovery, the operating cost is significantly reduced
compared to conventional fuel-powered vehicles.

 Extended Battery Life

The system uses solar charging, AC grid supply, and regenerative braking, ensuring multiple
sources of power to maintain the battery's charge and extend its usage time.

 Reduced Rider Fatigue

The double Hall pedal assist system provides proportional motor assistance based on pedalling
effort, reducing physical strain on the rider, especially on inclines or long-distance rides.

 Versatility in Power Sources

The ability to charge the battery through solar panels and AC grid supply makes the bicycle
versatile and reliable in all weather conditions or locations.

 Smooth and Efficient Operation

The buck-boost converter ensures stable voltage levels for efficient power transfer, while the
BLDC hub motor provides smooth, noise-free operation.

 Compact and Lightweight Design

The integration of components, such as the BLDC hub motor and battery, is compact,
maintaining the lightweight nature of the bicycle while enhancing its functionality.

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4.5 DISADVANTAGES OF OUR PROJECT

 High Initial Cost

The inclusion of components like the BLDC hub motor, solar panel, battery, and control systems
increases the initial investment required for the bicycle.

 Dependency on Weather for Solar Charging

Solar charging is highly dependent on sunlight availability, which can be inconsistent in
regions with cloudy or rainy weather, reducing efficiency.

 Limited Battery Capacity

The range of the bicycle is constrained by the battery’s energy storage capacity, which might not
be sufficient for very long-distance travel without frequent charging.

 Complex System Integration

The integration of multiple components, such as the controller, rectifier, and buck- boost converter,
requires careful design, wiring, and maintenance, which adds complexity to the system.

 Maintenance Requirements
Advanced systems like the torque sensor, pedal assist system, and buck-boost converter require
regular checks and maintenance, adding to operational challenges.

 Weight of Additional Components

While compact, the addition of a motor, battery, and sensors increases the bicycle's overall
weight, which could impact manual pedalling when motor assistance is unavailable. The weight
of additional components may also induce significant vibrations into the system which may
subsequently affect the performance of the system and thus the efficiency of the system may also
slightly reduce which is an issue and a concerned problem.

 Limited Regenerative Efficiency

Although regenerative braking recovers energy, the amount of energy recovered is relatively
small compared to the energy expended during motoring, especially in flat terrains.

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4.6 APPLICATIONS OF OUR PROJECT

 Eco-Friendly Transportation
The hybrid electric bicycle can serve as an eco-friendly mode of transportation for individuals,
reducing dependence on fossil fuels and minimizing carbon emissions. It can be used for
commuting, recreational rides, and short-distance travel in urban areas, contributing to cleaner
and greener cities.

 Solar-Powered Commuting
This bicycle is ideal for individuals who live in regions with abundant sunlight, as it can harness
solar energy to charge the battery. Solar-powered commuting can reduce reliance on the electric
grid, making it an environmentally sustainable option for daily travel, especially in urban and
suburban areas.

 Tourism and Recreational Riding

The hybrid electric bicycle can be used in tourism, where long-distance travel on bike tours
becomes easier with motor assistance. It can also be used for recreational purposes, offering
a relaxing and enjoyable experience while reducing the rider's physical effort, especially on
hilly terrains.

 Sustainable Delivery Services

Bicycle for local deliveries. Its eco-friendly nature, combined with regenerative braking to
recover energy, makes it a perfect fit for last-mile delivery solutions, reducing the carbon
footprint of urban logistics the regenerative energy utilization System.

 Regenerative Energy Utilization

The regenerative braking system in this bicycle can be applied to other electric vehicles, such as
electric scooters or small e-bikes, helping recover energy during braking to recharge the battery.
This feature can also be integrated into electric public transport systems like buses to improve
energy efficiency.

 Healthcare and Rehabilitation

The bicycle's pedal-assist system can be used in healthcare and rehabilitation centers. It can help
people with mobility issues or those in physical therapy by providing them with an easier way

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to exercise with minimal physical effort. The motor assist provides the right balance of support
for individuals with limited strength or stamina.

 Environmental Awareness Campaigns

The hybrid electric bicycle could be used in environmental campaigns and exhibitions to
demonstrate renewable energy applications in everyday life. It can highlight the potential of
integrating solar power and energy recovery systems into transportation, promoting sustainable
living practices.

 Elderly and Disabled Mobility Solutions

The hybrid electric bicycle’s motorized assist feature can help elderly or disabled individuals
maintain mobility while reducing physical strain. It provides a practical solution for
independent mobility, especially for those who may struggle with traditional bicycles.

 Educational and Research Applications

This project can be used in educational institutions as a research tool to study renewable energy
applications, hybrid systems, and regenerative energy technologies. It can also serve as a
practical demonstration of how multiple renewable energy sources (solar and kinetic) can be
integrated into a single.

 Smart City Infrastructure

Hybrid electric bicycles can be integrated into smart city initiatives, providing a sustainable
mode of personal transportation for residents and tourists. They could be part of city bike- sharing
programs, regenerative energy technologies which are powered by renewable energy sources,
reducing urban congestion and pollution especially for those mobility while reducing physical
strain who may struggle with traditional bicycles.

 Disaster Relief Operations

The bicycle could be used in remote or disaster-stricken areas where traditional transport might
not be available. It can operate independently from the grid, relying on solar power and
regenerative braking for charging, making it a reliable transportation solution in off-grid locations
or during emergencies.

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CHAPTER 5

CONCLUSION AND FUTURE SCOPE

5.1 CONCLUSION

The Development and Fabrication of a Hybrid Electric Bicycle successfully demonstrates the
integration of electric propulsion with conventional pedaling, enhancing efficiency,
sustainability, and user convenience. By incorporating a battery-powered motor alongside a
pedal-driven mechanism, the project achieves a balance between human effort and electrical
assistance, making it an eco-friendly alternative to traditional bicycles and motorcycles. The
design effectively reduces reliance on fossil fuels, lowers carbon emissions, and provides a cost-
effective transportation solution.
The fabrication process involved careful selection of components, including the motor, battery,
controller, and regenerative braking system, ensuring optimal performance and durability. The
integration of these elements allows for improved speed control, energy efficiency, and extended
range, making the hybrid bicycle a viable solution for urban mobility. The project highlights the
importance of renewable energy applications in transportation and serves as a foundation for
further advancements in hybrid vehicle technology. Overall, the hybrid electric bicycle project
successfully achieves its objectives, offering a sustainable, practical, and innovative mode of
transport.

5.2 FUTURE SCOPE

 Replace the normal changeover switch with an automatic system using MOSFETs or
IGBTs.
 Upgrade the solar panel wattage to improve charging efficiency.
 Add a charge indicator to display charging activity during regenerative mode.
 Install a gearing system on the second prewheel for enhanced performance.

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