Tech Geek question: E-Bikes for a Greener India: Share Your Story!

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Robu
Posts: 43
Joined: Fri May 17, 2024 4:29 pm
Location: Pune
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The lucky winner of Tech Geek's fifth Question (First Robot: What Did You Build) is @Vaibhavsul.

The sixth question for the Tech Geek competition is,

What essential components do you think are important to build a reliable E-bike? Have you made an E-bike?
What challenges did you face when building your first E-bike, and how did you overcome them?



Share Your Experience with E-Bikes and Their Role in India's Green Revolution. Feel free to include images of the projects, component list, challenges, and unique insights if you've built your project.

Submit your answers by Tuesday, 12th November, 2024, by evening. One lucky winner will be randomly selected to receive 250 Robu Points! We’ll announce the winner the following week. Good luck!

Note: AI-generated answers are not allowed
Mansi
Posts: 52
Joined: Mon Jun 10, 2024 11:57 am

Hello,

Essential components which are important to build a reliable E-bike:

1. E-bike Motor: Choose between a brushless hub motor or a brushed motor, depending on your performance needs and efficiency preferences.

2. E-bike Controller: This component must be compatible with your chosen motor, whether it's brushless or brushed.

3. Battery: Select a battery that matches your motor's requirements and your desired range.

4. Throttle with Key: The throttle allows you to control the speed of the E-bike

In addition to these core components, you might want to add features that enhance safety and convenience, such as turn indicators, bright headlights for nighttime visibility, a digital display to monitor speed and battery status, and a horn for alerts.


Last year, I successfully built my E-bike using various components sourced from Robu, and it has significantly enriched my riding experience.


Challenges Encountered When Building an E-bike:

1. Assembly: The process of putting together various components can be intricate and requires precise alignment and secure fittings to ensure the bike functions smoothly.
I have overcome this challenge by using clear instructions and guides to ensure that every piece is correctly placed and secured.

2. Wiring and Connections: Properly routing the electrical wiring is crucial. It involves connecting multiple components, such as the battery, motor, while avoiding interference and ensuring safety throughout the system.
I have used color-coded wires for easier identification to avoid misconnection and checked all the wiring before connecting the battery supply.

3. Compatibility of Space and Component Sizes: One of the key challenges in building an e-bike is ensuring that all components fit comfortably within the designated space.
I have measured space between the bike and compare it with the dimensions of the components to overcome this challenge..
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Shraddha
Posts: 61
Joined: Fri Jun 14, 2024 3:54 pm

I'm willing to build a E-bike and I'm in the process of understanding the parts and the whole process. So, here I'm sharing my experience I got so far.
Here are some key components required to build a E-bike,
1. Frame: A strong frame to support the motor and battery.
2.Battery: A good lithium-ion battery for range and power.
3.Controller: This manages the power from the battery to the motor.
4.Throttle/Pedal Assist: To control the motor’s power.
5. Brakes: Reliable brakes, like hydraulic disc brakes.
6. Display: To monitor speed, battery level.
7. Wiring and Connectors: Quality wiring for reliable connections.
8. Charger: For battery.

As I have mentioned before, I haven’t built an E-bike myself yet. But, based on my study of different projects by enthusiasts, here are some common challenges people face.
1. Battery Placement: Finding the right spot for balance.
2. Wiring Management: Keeping wires organized and protected.
3. Compatibility Issues: Ensuring all parts work well together.
4. Weight Distribution: Balancing the motor and battery for good handling.
Last edited by Shraddha on Wed Oct 23, 2024 6:01 pm, edited 1 time in total.
Kalpesh Borle
Posts: 15
Joined: Mon Sep 30, 2024 12:45 pm

Key Components for a Reliable E-Bike:
Motor – Either hub or mid-drive for good power and efficiency.
Battery – A strong lithium-ion battery for longer range.
Controller – Manages power smoothly between the motor and battery.
Throttle & Pedal Assist – Helps control manual and electric input.
Brakes – Good disc brakes for better safety.
Frame & Fork – A strong, durable frame, ideally with suspension.
Wheels & Tires – Durable, puncture-resistant tires.
Display – Shows speed, battery level, and diagnostics.

Challenges I Faced When Building My First E-Bike-
Motor and Battery Compatibility – Matching the motor and battery was tough, but I figured it out by researching what works best for the bike's weight and terrain.
Weight Distribution – E-bikes are heavy, so I had to balance the weight well, especially placing the battery in the center for better control.
Range Anxiety – I underestimated how far the bike could go, so I upgraded to a bigger battery and used pedal-assist to go further.
Regenerative Braking – I wanted to try regenerative braking but found it too complex, so I focused on riding more efficiently instead.
Legal Compliance – I stayed within India’s rules for motor power (250W) and speed (25 km/h) to avoid legal issues.

E-Bikes and Their Role in India’s Green Revolution
E-Bikes and Their Role in India’s Green Revolution: E-bikes are key in India’s green movement by making city travel more eco-friendly. They help reduce pollution, noise, and the need for fuel. E-bikes are also affordable and great for crowded cities, offering a cleaner, greener way to commute.
Angry@u
Posts: 11
Joined: Wed Aug 14, 2024 3:44 pm

To make an e-bike/vehicle can be challenging we not only require the electronic components but one should the the detailed knowledge about bikes and other stuff
We can make a e-bike in the budget of 10-20k (Without battery) Including labour charges for welding, grinding Etc . You use this bike for day to day requirements Eg Market jana, Geddi marna in low cost.

There are two methods to make an e-bike
1. We can use chain driven system
2. We can use a HUB motor.

The 1st method can be Cost effective but its not an easy job as compared to the second one, While using the 1st method he/she must take care about the balance weight, the motor should be in exactly at the centre of the chassis and all the calculation must be correct
Eg:- The Chain/belt teeth distance,
Sprockets Etc

The 2nd method can be quite easy, we just need to put a tyre on the hub motor and make the connections, but every good thing has it bad side, The cost can be concern i this case.

The batteries can either make your life or take your life, It is very important to choose a right battery for your bike,
There are issue to be taken care of:
Eg: Environment temperature can be headache while making a e-bike
Range
Charging/discharging time
BMS (imp)
https://robu.in/product/pro-range-icr-1 ... y-pack-3c/
If you are rich, buy More Mah battery it can increase the range

Controller are the brains kind of thing in the E-bike, The controller must be a Compatible with your motor, NOTE: Do not go for the controller with many features as i may cause confusion and heating like issues. Try to buy a Simple controller, you can add features later on as may create less confusion.
Note: Do not go for cheaper once as it may have poor quality of components
Most of the time the key and throttle comes with the controller.

Charger
As we are not adding features, we have lot of space remaining, you can adjust the charger under the seat etc, and directly connect the plug anywhere, no need to make any other connection. Link for charger
https://robu.in/product/lithium-battery ... connector/


Here is the link to make a E-Bike
https://robu.in/product/my1016z2-24v-25 ... combo-kit/

These components can be used to make a most basic e-bikes components, Instead of going for a new frame/chassis, we can make e-bike with our old bike/scooty this may reduce the time and cost.



Calculation
Range (km) ≈ (Battery Capacity (Ah) x Voltage (V) x Efficiency x Speed (km/h)) / (Motor Power Consumption (W) x 3.6)

Note: This calculation assumes:

- Constant motor power consumption
- No energy losses due to heat, friction or other factors
- Ideal battery discharge characteristics
Battery: 30Ah, 12.8V, 3C discharge
Motor: 250W, 13.4A, 78% efficiency, 9.78 reduction ratio
Vehicle: 50kg, 0.03 RR, 0.5 Cd, 0.5m² frontal area

1. Battery Energy = 30Ah x 12.8V = 384Wh
2. Motor Power Consumption = 250W / 0.78 = 320.51W
3. Motor Current Consumption = 320.51W / 12.8V = 25.04A
4. Battery Discharge Time = 30Ah / 25.04A = 1.2 hours
5. Vehicle Speed ≈ (400 RPM x 60) / 9.78 ≈ 246.15 km/h
6. Range ≈ 246.15 km/h x 1.2 hours ≈ 295.38 km

This is how we calculate the KM based on battery rating
Do not worry AI will do it for you. Just mention the Specs of components
Note: 19/20 ka farak hoga, Even if the calculations are perfect

Note:- add the Throttle, display Power consumption
Khushit Shah
Posts: 3
Joined: Tue Oct 29, 2024 10:42 am

Option 1: Refurbish an Old Bike

Modifying an existing motorcycle is the cheapest option. Let us now look at each one of those parts in turn, including how they work and some related law aspects.

Detailed Description of the Components Used in Cycle Conversion
Motor Application (MY1016Z2 Motor, 250W, 24V)
Usage: The motor is, in effect, the locomotion or movement of one’s E-bike. Regular commutes can utilize a 250W hub motor without fussing over battery stress. It is most preferably placed at the rear for better traction and balancing, although it may also be situated in the front wheel.
Performance: Enables up to 25 km/h speeds, which interestingly happens to be the rental speed limit of electric bicycles for registration authorities in India, where speeds do not require registration of the owner.
Legal Consideration: A motor with a power rating under 250 Watts and achievable speed under 25 km/h can be used without licensing and registration in India. This specification allows an electric bicycle with a powered wheel to stay within these boundaries.
Price: Rs. 2500 – 3000
Battery: 36V, 20Ah Li-ion Battery Pack
How it Works: Powers the engine as well as other electrical components. A 36V, 20Ah battery, in practical terms, should provide a range of about 50-60 km depending on the actual riding conditions. Li-ion batteries are preferred as they offer higher energy density, longer life spans, and greater stability compared to LiPo batteries that tend to overheat.
Battery Sizing: To achieve a 50 km range on a 250W motor, the battery capacity needed is calculated as follows:
Battery Capacity = Motor Power * Range / Average Speed
= 250W * 50 km / 20 km/h = 625 Wh; adding some extra range, a 36V 20Ah battery is ideal.
Cost: Rs. 8000 - 10000
Controller – 24V/36V 500W E-bike Controller
Application: The controller functions by managing how the power input from the battery is supplied to the e-bike motor.
Option 2: Construct a Brand New E-bike from Scratch
Building a brand new e-bike from scratch gives full freedom in selecting the components and laying out the same. Some of the components are listed below along with a few additional considerations to keep in mind: It comes with a frame, e-bike frame with space for the battery:.
Application Usage: A particular frame is sturdier and mainly with storage mounted for the battery, which provides an appeal to the look of the bike as well as its balance. E-bikes frames are heavy-duty as the added weight that comes with the motor and the battery.
Price: ₹ 5,000- ₹ 8,000

Motor, 500W 36V Rear Hub Motor
Application: A 500W motor would boost more power than a 250W. It is more suitable for slopes and higher speeds. Above 250W means that it may make you register it as one since this falls above the legal limit given for non-licensed bikes in India.
Legal Consideration: Above 250W or speeds above 25 km/h, then registration and insurance needs to be done, and the rider must have a driver's license. :roll:
Cost: ₹4,000 - ₹5,000
 

Battery (48V, 15Ah Li-ion Battery Pack)
Application: As we have high power in the motor, a 48V, 15Ah battery would ensure good power for this high usage and would not require frequent recharging. Li-ion batteries are chosen in this application also due to excellent balance among weight, safety, and lifetime.
Cost: ₹10,000 - ₹12,000

Controller 48V 1000W E-bike Controller
Application: This HP controller will regulate the given high voltage and wattage supplied from the battery and will protect the motor from overloading.
Cost: ₹2,000 - ₹3,000

Throttle with Display and Key Switch
Application: It will serve the same functionalities as the modified bike option but it is more robust and feature-rich for higher speeds.
Cost: ₹800 - ₹1,200

Lights and Horn Kit

Usage: Guarantees safety, particularly in below-average visibility places and night time.
Price: ₹500 - ₹1,000

Battery Charger 48V 2A Charger

Usage: With the given above 48V battery, a 15Ah battery will be charged within 5-6 hours.
Cost: ₹1,000-₹1,500

Overall Estimated Cost of a New E-bike Build
Approx. ₹25,000-₹30,000 :o

Legal and Licensing Aspects for E-bikes in India
India classifies the E-bikes based on the motor power and maximum speed :

Above 250W and 25 km/h: No license, insurance or registration required. This class is treated as a bicycle under Indian law.
More than 250W or more than 25 km/h: Registration, insurance, a valid license are required. These are considered motor vehicles; therefore, all the road traffic rules apply to them also, like keeping a registration and paying a road tax.
Like, in case you build a 500W E-bike, then it will have to go through an RTO process, and perhaps after some inspection. That too, then would cost a one-time charge for registration of approx. ₹500-₹1,000 apart from the insurance cost that could be another ₹1,000-₹2,000 annually. If you are within a 250W motor, you would not even have to go through all the tedious maneuvers mentioned above, hence relatively painless for city riding.

Issues in Designing an E-bike


Battery Management: Dealing with a bulk battery is cumbersome because overcharging or short circuits can be dangerous. To be on the safe side with the aforementioned issues, one should opt for a BMS-equipped battery.
Weather proofing: The Indian weather being variable demands that waterproofing is attached to electronics and motors in the important parts.
Cost Balancing: Quality components are mostly costly, hence a balancing between high and low performance is done.
Legal Compliance: Higher motor limits is staying inside the legal limit, which avoids the need for registration but limits the power.
Both options have their merits: tuning an old bike is less expensive and quite easy for a beginner, but a new bike to be built from scratch is sure to offer more and more possibilities in the way of customization and performance. Be it either, this setup contributes to India's green revolution by providing a viable means of transport that is efficient and very affordable! :D
Last edited by Khushit Shah on Mon Nov 11, 2024 5:32 pm, edited 1 time in total.
kumarsid
Posts: 5
Joined: Thu Sep 12, 2024 10:07 am

I bought this old bike hoping to convert it to an e bike. I'm currently in the process of figuring out the best way to do this. My biggest challenge is re-doing the hub. And deciding the power of the motor.

So I'm leaning more towards a kit that is attached to the tire, like below. And siphon power off of it to add a headlight.
rubbee-x-03-2018138627.jpg
This would be perfect for me as I can also detach or when necessary. So below is my very simple yet effective plan to remodel my old bicycle into an electric cycle.
IMG_20241027_091358213.jpg
You do not have the required permissions to view the files attached to this post.
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Robu
Posts: 43
Joined: Fri May 17, 2024 4:29 pm
Location: Pune
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Congratulations to Our Tech Geek Challenge Winner!

Dear Participants,

We are thrilled to announce the lucky winner of our Tech Geek question: E-Bikes for a Greener India: Share Your Story!

Congratulations to @Khushit Shah ! 🎉

Khushit impressed us with their their standout project—transforming an old bike into a brand-new, fully functional e-bike—showcased incredible innovation, overcoming cost challenges with resourcefulness and skill. This e-bike is a testament to their creativity and technical expertise. It will be treated if you will post some photos/images of your creativity!

As a reward, @Khushit will receive 250 robu points. Thank you to everyone who participated and made this competition a success!

We hold these weekly competitions, so be prepared to grab the next prize!
Khushit Shah
Posts: 3
Joined: Tue Oct 29, 2024 10:42 am

I feel glad to be participating in the Robu's Tech Geek Challenge and find it inspiring how Robu.in helps people learn about new topics and at the same time inspires innovation.
Robu is doing an amazing job! :D
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