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.
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
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!
