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, 5th 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
Tech Geek question: E-Bikes for a Greener India: Share Your Story!
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..
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..
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.
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: 6
- 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.
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.
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
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: 1
- Joined: Tue Oct 29, 2024 10:42 am
Hey everyone,
I haven’t built an E-bike yet, but after researching for the last couple of days, I’ve realized there are many factors to consider to ensure a reliable E-bike right from the start, even when keeping budget, time, and maintenance in mind.
Key ingredients in building a Reliable E-Bike
1. Motor
I discovered that a 250W Hub Motor would be in high demand in India since these motors are affordable and meet the legal requirements for urban areas (250W power and a speed limit of 25km/h). In short, it simplifies things and minimizes potential issues while riding in the city. Link to buy this from robu https://robu.in/product/my1016-250w-ebi ... combo-kit/
2. Controller
The display and Controller Combo is a great choice. A controller that works well with a hub motor ensures consistent power output, and its user-friendly programming makes it easy to adjust settings for energy efficiency or a smoother throttle response.
3. Battery
I saw that li-0n batteries are the best option when wanting to have both range and durability, even though they may have a higher cost. You could aslo buy a second hand battery . A 48V, 13Ah Li-ion battery would offer a decent range of about 50-70 km, depending on how you use it, while keeping the weight less. Its really hard to find a battery the size you want in budget as higher Ah batteries cost more, for size you can make a custom battery pack from robu itself. To get a custom battery check this out https://robu.in/product/custom-battery-pack/
Determine Your E-Bike’s Energy Consumption
Motor Power: 250W
Voltage (V): 36V
Average Speed: 20 km/h
Desired Range: 50 km
Step 2: Calculate Required Watt-Hours (Wh)
The battery’s capacity (in Watt-hours) should meet the energy consumption of your motor for the entire range.
Calculate Battery Capacity in Watt-Hours
Energy required (Wh) = Motor Power (W) × Range (km) / Speed (km/h)
Energy required = 250W × 50 km / 20 km/h = 625 Wh
Step 3: Select Battery Voltage and Amp-Hours (Ah)
If we use a 36V battery:
Battery Capacity (Ah) = Energy required (Wh) / Battery Voltage (V)
Battery Capacity = 625 Wh / 36V ≈ 17.36 Ah
Step 4: Factor in Efficiency and Round Up
Battery performance varies, so adding a 10–20% buffer ensures enough energy.
Final Capacity = 17.36 Ah × 1.2 = 20.8 Ah
You can also do all of these caclulation with AI
4. Display
A display makes it easy to monitor speed, battery level, and distance. A LCD would be cheap and perfect for your need and covers all the basics and works well with many controllers, providing a simple interface without much coding. https://robu.in/product/sunding-36v-ele ... rol-panel/ . This display is cheap and waterproof and best thing you can buy it from robu itself.
5. Throttle & Pedal Assist
This thing allows for both thumb throttle and pedal assist, giving you flexibility and better control over power usage. Pedal assist helps get more battery life, which is good for increasing your range.
https://robu.in/product/3-speed-throttle-for-ebike/
6. Brakes
E-bikes should have disc brakes. I would choose disc brakes, as they are cheap while still offering good braking power. Hydraulic brakes are very good but come with a higher price and are harder and costlier to maintain.
https://robu.in/product/brake-for-my1016/
7.Horn
Horn is really important for any vechile running on road. You can use a old horn from you car or a bike and add a seperate button for it.
Realistic Challenges
Considering all that I have read thus far, here are a few common issues and things to consider,
Budget: Quality components can be costly, especially in terms of batteries. To not blow over a budget of 15-20K INR, it would be wise to procure parts which provide quality yet affordability such as opting for an easier controller or starting small with the battery.
Time: Time it takes to do everything right is always underestimated. Alignment of the motor and securing the battery are some of the steps, and the routing of wiring is also very important to ensure reliability and safety.
Legal Compliance: This bike will stay within the 250W power and 25 km/h speed limits, which are crucial to prevent it from needing licensure and registration. The 250W hub motor and matching controller are always considered in its design. If you buy a motor higher than 250 Watt you need to apply for license which can be time taking.
Low Maintenance: I want to reduce the maintenance as much as possible; a hub motor with an easy-to-understand controller would do the trick. This type of design requires fewer maintenance needs and calibration as opposed to complex mid-drives.
A kit for simplicity https://robu.in/product/my1016-250w-ebi ... combo-kit/
I haven’t built an E-bike yet, but after researching for the last couple of days, I’ve realized there are many factors to consider to ensure a reliable E-bike right from the start, even when keeping budget, time, and maintenance in mind.
Key ingredients in building a Reliable E-Bike
1. Motor
I discovered that a 250W Hub Motor would be in high demand in India since these motors are affordable and meet the legal requirements for urban areas (250W power and a speed limit of 25km/h). In short, it simplifies things and minimizes potential issues while riding in the city. Link to buy this from robu https://robu.in/product/my1016-250w-ebi ... combo-kit/
2. Controller
The display and Controller Combo is a great choice. A controller that works well with a hub motor ensures consistent power output, and its user-friendly programming makes it easy to adjust settings for energy efficiency or a smoother throttle response.
3. Battery
I saw that li-0n batteries are the best option when wanting to have both range and durability, even though they may have a higher cost. You could aslo buy a second hand battery . A 48V, 13Ah Li-ion battery would offer a decent range of about 50-70 km, depending on how you use it, while keeping the weight less. Its really hard to find a battery the size you want in budget as higher Ah batteries cost more, for size you can make a custom battery pack from robu itself. To get a custom battery check this out https://robu.in/product/custom-battery-pack/
Determine Your E-Bike’s Energy Consumption
Motor Power: 250W
Voltage (V): 36V
Average Speed: 20 km/h
Desired Range: 50 km
Step 2: Calculate Required Watt-Hours (Wh)
The battery’s capacity (in Watt-hours) should meet the energy consumption of your motor for the entire range.
Calculate Battery Capacity in Watt-Hours
Energy required (Wh) = Motor Power (W) × Range (km) / Speed (km/h)
Energy required = 250W × 50 km / 20 km/h = 625 Wh
Step 3: Select Battery Voltage and Amp-Hours (Ah)
If we use a 36V battery:
Battery Capacity (Ah) = Energy required (Wh) / Battery Voltage (V)
Battery Capacity = 625 Wh / 36V ≈ 17.36 Ah
Step 4: Factor in Efficiency and Round Up
Battery performance varies, so adding a 10–20% buffer ensures enough energy.
Final Capacity = 17.36 Ah × 1.2 = 20.8 Ah
You can also do all of these caclulation with AI
4. Display
A display makes it easy to monitor speed, battery level, and distance. A LCD would be cheap and perfect for your need and covers all the basics and works well with many controllers, providing a simple interface without much coding. https://robu.in/product/sunding-36v-ele ... rol-panel/ . This display is cheap and waterproof and best thing you can buy it from robu itself.
5. Throttle & Pedal Assist
This thing allows for both thumb throttle and pedal assist, giving you flexibility and better control over power usage. Pedal assist helps get more battery life, which is good for increasing your range.
https://robu.in/product/3-speed-throttle-for-ebike/
6. Brakes
E-bikes should have disc brakes. I would choose disc brakes, as they are cheap while still offering good braking power. Hydraulic brakes are very good but come with a higher price and are harder and costlier to maintain.
https://robu.in/product/brake-for-my1016/
7.Horn
Horn is really important for any vechile running on road. You can use a old horn from you car or a bike and add a seperate button for it.
Realistic Challenges
Considering all that I have read thus far, here are a few common issues and things to consider,
Budget: Quality components can be costly, especially in terms of batteries. To not blow over a budget of 15-20K INR, it would be wise to procure parts which provide quality yet affordability such as opting for an easier controller or starting small with the battery.
Time: Time it takes to do everything right is always underestimated. Alignment of the motor and securing the battery are some of the steps, and the routing of wiring is also very important to ensure reliability and safety.
Legal Compliance: This bike will stay within the 250W power and 25 km/h speed limits, which are crucial to prevent it from needing licensure and registration. The 250W hub motor and matching controller are always considered in its design. If you buy a motor higher than 250 Watt you need to apply for license which can be time taking.
Low Maintenance: I want to reduce the maintenance as much as possible; a hub motor with an easy-to-understand controller would do the trick. This type of design requires fewer maintenance needs and calibration as opposed to complex mid-drives.
A kit for simplicity https://robu.in/product/my1016-250w-ebi ... combo-kit/
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. 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.
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. 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.
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