Design and Development of a Hybrid Bicycle

This project involved the conversion of a conventional bicycle into an electric hybrid bicycle using a hub motor, battery, controller, throttle, and battery indicator. The selection of a flywheel-based regenerative mechanism was justified based on its superior energy storage capabilities. The challenges faced during the assembly, including bearing and clutch drive iterations, were overcome through the use of multiple bearings, metal casting, and welding. The implementation of an indirect transmission system resolved the issue of rear wheel disengagement and facilitated efficient energy transfer. The successful integration of the flywheel-based regenerative mechanism into the hybrid bicycle has demonstrated the potential for enhanced energy efficiency and prolonged battery life. By capturing and storing energy during cycling, it enhances energy efficiency, extends battery life, reduces reliance on external charging, and contributes to a cleaner and greener environment. As the demand for sustainable transportation solutions continues to rise, the integration of regenerative mechanisms in bicycles has the potential to transform the way we commute, exercise, and interact with our cities.

Table of Contents

Chapter 1: Introduction ............................................................................................... 1

1.1 Background ..................................................................................................... 1

1.2 Motivation ....................................................................................................... 2

1.3 Objectives ....................................................................................................... 3

1.4 Scope ............................................................................................................... 4

1.5 Thesis Organization ........................................................................................ 4

Chapter 2: Literature Review ..................................................................................... 5

2.1 History of Electric-Powered Bicycles ............................................................. 7

2.2 Market ............................................................................................................. 9

2.3 Electric Bicycle Components ........................................................................ 10

2.3.1 Motor. .................................................................................................... 10

2.3.2 Frame .................................................................................................... 11

2.3.3 Gears and Sprockets .............................................................................. 11

2.3.4 Batteries ................................................................................................ 11

2.3.5 Throttle/PAS ......................................................................................... 13

2.4 History of KERS ........................................................................................... 13

2.5 Comparative Study of Different Types of KERS ......................................... 15

2.5.1 Mechanical KERS ................................................................................. 15

2.5.2 Electrical KERS .................................................................................... 15

2.5.3 Hydraulic KERS ................................................................................... 16

2.5.4 Hydro-electric KERS ............................................................................ 16

2.6 Importance of Flywheel ................................................................................ 16

2.7 Types of Mechanical KERS.......................................................................... 17

2.8 Inference from Literature Survey.................................................................. 17

Chapter 3: Design Methodology. .............................................................................. 19

3.1 Project Selection ........................................................................................... 19

3.1.1 SWOT Analysis .................................................................................... 19

3.1.2 Pro-Con Analysis .................................................................................. 21

3.2 Functional Decomposition ............................................................................ 22

3.3 Form Generation of the Bicycle .................................................................... 23

3.3.1 Selection of the Final Design ................................................................ 25

3.4 Motor Selection ............................................................................................. 26

3.4.1 Motor Power Calculation ...................................................................... 26

3.4.2 Motor Torque Requirement .................................................................. 28

3.5 Battery Selection ........................................................................................... 29

3.6 Regenerative Mechanisms ............................................................................ 29

3.6.1 Flywheel Based ..................................................................................... 29

3.6.2 Linear Spring Based .............................................................................. 30

3.6.3 Torsional Spring Based ......................................................................... 30

3.7 Spring Energy Storage Calculations ............................................................. 30

3.8 Flywheel Calculations ................................................................................... 31

3.9 Flywheel Design ........................................................................................... 33

3.10 Flywheel Optimization Using CREO ....................................................... 34

3.11 CAD Modeling. ......................................................................................... 34

3.12 Clutch Drive Calculations ......................................................................... 43

Chapter 4: Analysis & Fabrication .......................................................................... 45

4.1 Assumptions.................................................................................................. 45

4.2 Supporting Frame. ........................................................................................ 46

4.2.1 Mesh Convergence. ............................................................................... 46

4.2.2 Total Deformation ................................................................................. 47

4.3 Central Shaft ................................................................................................. 47

4.3.1 Mesh Convergence. ............................................................................... 47

4.3.2 Total Deformation ................................................................................. 49

4.4 Secondary Shaft ............................................................................................ 49

4.4.1 Mesh Convergence. ............................................................................... 49

4.4.2 Total Deformation ................................................................................. 50

4.5 Clutch Drive .................................................................................................. 51

4.5.1 Mesh Convergence. ............................................................................... 51

4.5.2 Total Deformation ................................................................................. 52

4.5.3 Optimization ......................................................................................... 52

4.6 Clutch Plate ................................................................................................... 53

4.6.1 Mesh Convergence. ............................................................................... 53

4.6.2 Total Deformation ................................................................................. 54

4.6.3 Optimization ......................................................................................... 54

4.7 Flywheel ........................................................................................................ 55

4.7.1 Mesh Convergence. ............................................................................... 55

4.7.2 Total Deformation ................................................................................. 56

4.7.3 Optimization ......................................................................................... 56

4.8 Manufacturing & Assemblage ...................................................................... 57

4.8.1 Components of Flywheel Mechanism ................................................... 57

4.8.2 Design and Fabrication of the Mechanism ............................................ 60

4.8.3 Assembly of the Mechanism ................................................................. 61

4.8.4 Components of E-Bike .......................................................................... 62

4.8.5 Design and Procurement of E-Bike Components ................................. 63

4.8.6 Assembly of the E-Bike Components ................................................... 63

4.9 Summary ....................................................................................................... 64

Chapter 5: Results and Discussion ........................................................................... 66

5.1 Challenges Encountered During the Fabrication .......................................... 66

5.1.1 Bearing and Clutch Drive Iterations ..................................................... 66

5.1.2 Solving Rear Wheel Disengagement .................................................... 66

5.1.3 Indirect Transmission Design ............................................................... 67

5.2 Modifications Made While Fabrication ........................................................ s67

5.2.1 Flywheel Procurement .......................................................................... 67

5.2.2 Clutch Drive Fabrication. ...................................................................... 67

5.2.3 Modification in the Chain Drive Transmission ..................................... 67

5.3 Applications of the Product .......................................................................... 68

5.3.1 Urban Commuting................................................................................. 68

5.3.2 Sustainable Tourism. ............................................................................. 68

5.3.3 Fitness and Recreation .......................................................................... 69

5.3.4 Last-Mile Delivery ................................................................................ 69

5.3.5 Green Initiatives and Smart Cities ........................................................ 69

5.4 Sustainable Development Goals ................................................................... 69

Conclusion .................................................................................................................... 71

References ..................................................................................................................... 72

Appendix ....................................................................................................................... 75