e bike presentation for mechatronics students

E-bike

1. CONVENTIONAL BICYCLE CONVERSION TO E-BICYCLE

2. Introduction to E-Bike Conversion What is E-Bike Conversion? Definition : It's the process of converting a regular bicycle into an electric bike (e-bike) by integrating an electric motor , battery , and controller system. Purpose : The goal is to enhance performance , increase speed , reduce the rider’s effort, and offer a more sustainable mode of transport. Mechatronics Relevance : It involves mechanical , electrical , and control systems to make everything work smoothly—this is the core of mechatronics.

3. Opportunity Identification Process The Opportunity Identification Process consists of 5 key stages that guide the creation of an innovative, efficient, and effective e-bike conversion system: Establish a Charter Generate and Sense Many Opportunities Develop Promising Opportunities Select Exceptional Opportunities Reflect and Evaluate Results Each of these steps helps in identifying, analyzing, and refining the most effective opportunity for creating a successful e-bike conversion system.

4. 1. Establish a Charter What is a Charter? A charter defines the purpose , goals , scope , deliverables , and success criteria of a project. It acts as a foundational document to keep the project focused, aligned, and organized. Components of the Charter : Purpose : Convert a traditional bicycle into an electric bicycle by adding a motor, battery, and controller to improve speed, reduce physical effort, and make transportation more sustainable. Objectives : Safety : Ensure the bike meets e-bike regulations (brake sensors, motor power limits). Performance : Set target range , speed , and battery life . Cost : Specify a budget for motor kits, battery, wiring, etc. Sustainability : Use eco-friendly components like rechargeable lithium-ion batteries.

5. Key Deliverables : A functional e-bike conversion kit with motor, battery, controller. Installation instructions and safety guidelines . Scope : Focus on motor , battery , and controller integration; not on redesigning the entire bike frame unless required. Success Criteria : Operational e-bike with acceptable range , speed, and user comfort.

6. 2. Generate and Sense Many Opportunities Brainstorming Ideas : Generate a variety of ideas about how to approach the e-bike conversion, including different components and configurations: Motor Types : Hub Motors : Motor mounted in the wheel hub, easier to install but limited in torque. Mid-Drive Motors : Positioned at the bike's bottom bracket for better performance but can be harder to install. Battery Types : Lithium-ion batteries : Lightweight, long-lasting, and charge quickly. Lead-acid batteries : Heavier and less efficient but cheaper. Compatibility with Bike Types : Consider what type of bikes to convert (e.g., mountain, hybrid, or road bikes).

7. Evaluate Feasibility: Assess the feasibility of each opportunity by analyzing: Performance: How much power and range can each motor/battery combination provide? Cost: What is the cost-to-performance ratio? Is it affordable for the target market? Usability: Will the e-bike be comfortable and easy to use for a wide range of riders?

8. 3. Develop Promising Opportunities Refining Ideas : Combine the best ideas from the previous step into a single, promising opportunity: Mechanical Design : Plan where to mount the motor and battery. Consider bike frame structure, motor placement (hub or mid-drive), and battery compartment. Electrical Design : How will the motor, battery, and controller connect? What type of wiring will be needed to ensure safety and efficiency? Control Systems : Decide on how to control motor power, throttle, and pedal assist. Will there be a digital display? Will you have options for customizing power modes?

9. Prototype Development : Create prototype versions of the e-bike conversion system, focusing on how well it performs in real-world conditions. Testing should check: Speed : How fast can the e-bike go? Is it suitable for city commuting? Battery Life : How far can the e-bike travel on a single charge? Ease of Use : Can anyone easily operate the conversion kit? Is the installation user-friendly?

10. 4. Select Exceptional Opportunities Selection Criteria : After testing different prototypes, choose the one that stands out based on several important criteria: Performance : Does it meet expectations for speed, range, and overall performance? Cost-effectiveness : Does it deliver good value for money while maintaining quality? Sustainability : Does it use energy-efficient systems and eco-friendly materials? User Experience : Is the e-bike comfortable, easy to use, and reliable? Decision Making : Select the final design based on a comparison of performance, costs, sustainability, and user satisfaction.

11. 5. Reflect and Evaluate Results Testing & Evaluation : Test the final e-bike conversion prototype in different conditions (hills, battery drainage) to assess: Battery life : The battery of an e-bike typically lasts 3 to 5 years under normal use Overall experience : Does the e-bike meet the user’s expectations for comfort and convenience? Reflection : Reflect on the results: What Needs Improvement : What were the challenges (e.g., motor noise, weight balance)? Iterative Improvement : Based on feedback and performance results, adjust the design to improve any weaknesses or to enhance the user experience.

12. Mechatronics System Design Integration Mechanical : Frame modifications (motor mounts, battery housing) for easy integration. Electrical : Battery placement and wiring connections to the motor and controller, ensuring a secure and efficient power flow. Control : Throttle, pedal-assist system, and display for controlling motor power, monitoring battery levels, and customizing user experience. User Interface : Clear, user-friendly interface with easy-to-read displays showing speed, battery percentage, and motor mode.

13. Product Planning for E-Bike Conversion 1. Product Planning Overview Product planning refers to the P rocess of defining the goals S cope R esources

14. a. Evaluate and Prioritize Before starting the e-bike conversion, it’s important to evaluate the different components of the bike that need modification and prioritize them based on the following factors: Market Need and Customer Demand : Is there a demand for affordable e-bike conversions? Will this product have a strong customer base (e.g., commuters, enthusiasts)? Technological Feasibility : Can current technologies (motors, batteries, controllers) be integrated into existing bicycle models? What are the constraints? Cost-Effectiveness : Will the cost of converting the bike provide a competitive product in the market? What are the trade-offs in terms of quality vs. cost? Safety and Regulations : What legal constraints exist in terms of e-bike conversions (e.g., local regulations about speed limits, motor power)?

15. b. Allocate Resources Allocating resources means planning how to use the available financial, human, and technical resources for the e-bike conversion project. This step will help ensure the project stays on track and within budget. Resources to Consider : Material and Components : Motors (Hub motors, Mid-drive motors) Batteries (Lithium-ion preferred for long lifespan) Controllers (For managing motor power) Wiring, sensors, and other electrical components Frame and mechanical parts (brakes, gears, etc.)

16. 2. Human Resources: Engineers (Mechanical, Electrical, and Software Engineers) Designers for the conversion kit and user interface Project managers to oversee the workflow Testing and QA personnel for product validation 3. Financial Resources : Budget for material procurement and labor costs Budget for testing and R&D (Research & Development) 4. Time Resources : Timeline to complete design, testing, and launch

17. c. Complete Project Pre-Planning Pre-planning ensures that all assumptions and constraints are considered and a clear path forward is defined. 1. Mission Statement The mission statement clearly articulates the project's goals and purpose. For an e-bike conversion project, the mission statement might look like this: "Our mission is to provide a cost-effective and sustainable solution for converting regular bicycles into electric bicycles, enabling environmentally-friendly transportation for all types of riders while maintaining safety, performance, and user-friendliness."

18. Key Goals : Develop a conversion kit that is compatible with various bicycle models. Ensure the e-bike conversion kit offers sufficient power and range for urban commuting. Maintain high safety standards and conform to regulations. 2. Assumptions Assumptions are things that are presumed true for planning purposes. For example: Bicycle Compatibility : It’s assumed that most bikes will be compatible with the conversion kit (i.e., the frame size and structure are standard). Power Source : The battery will provide adequate power for distances up to 50 miles (depending on motor capacity and usage). Technology Availability : High-quality motors and batteries are available within the planned budget.

19. 3. Constraints Constraints are limitations or restrictions that could affect the project's execution. Some common constraints include: Budget Limitations : A limited budget for the entire project could affect the quality or features of the conversion kit. Regulatory Constraints : Local laws might limit motor power, maximum speeds, or other aspects of e-bikes that could limit design options. Time Constraints : A limited timeline for product development or market entry may result in rushed testing or incomplete features. Technical Limitations : The conversion kit must be easy to install, requiring minimal modifications to existing bicycles, which could restrict some design choices.