An EMV Zap Solar E Bike

Introduction

The Industrial Revolution brought in a grandiose movement to change agricultural lifestyles to industrialized and urban societies. It changed the way people traversed from point A to point B in a faster and comfortable manner i.e. the invention of steam-engine powered automobile to petrol and diesel vehicles. But today, the tables have changed completely because these petrol and diesel vehicles are now backfiring all of us by creating all types of pollution, which are causing global climate change and health issues.

Green revolution has caused a dramatic rise in concern about the environment in the industrialized countries, where its technology and by-products don’t cause damage to the global climate and human health if disposed, recycled, reused and reduced in the right way. One of its inventions was the EV or better known as electric vehicle.

An EV or electric vehicle is one of that which operates on an electric motor and batteries, instead of an internal-combustion engine that generates power by burning a mix of fuel and gases. What makes an EV a green technology is its fuel, rechargeable batteries (i.e. I am using LiFePo4 batteries).

The conversion to EVs is the first step towards reducing per capita carbon footprints. Its charging source might be a polluted one in India i.e. lignite coal, but its final usage will be green because its only output will be dynamic motion without any extra releasing of polluted gases in the atmosphere.

To reduce further pollution, I have installed solar panels on the vehicle so that the on-grid charging is reduced as much possible and consequently reducing our COx emissions as well.

What do you need:

Bike parts

1. An old 'Kinetic Honda ZX' scooter chassis

2. Front and Rear wheels of the scooter

3. Front Fork Suspension of the scooter

4. Ignition key system with the red and black wires of the scooter

5. Hub and drum brake shoe system of the scooter

6. 2 rear suspensions of any old Honda Activa

7. Rear brakelight, rear frame and front mud guard of any old TVS Apache

8. Pulsar seat lock set, rear pillion holders an front and rear foot-rests (2 of each)

9. Passion Pro old front suspension with the handle and ignition holder, ABS seat frame, sponge and its rexine covering and front brake wire

10. TVS XL 100 Yoke assembly, headlight and rear brake wire

11. Yamaha FZ handle bar

12. TVS Boxer Windshield

13. Old broken Royal Enfield fuel tank

14. Front, Rear, Side LED Indicator Light for KTM, Universal Bike (https://www.amazon.in/Front-Rear-Indicator-Light-U...)

15. Electronicspices Solar for DIY Square Shape Mini Solar Panel 6V-180 mAh (99 x 69 x 03 mm) pack OF 10

(https://www.amazon.in/gp/product/B082VF9PK1/ref=pp...)

16. 22V 0.58 A Solar panel (which will be installed on the fuel tank)

17. 2 Fancy small bike mirrors

18. 2 Brake springs

E bike spare parts (Okinawa)

1. 800W motor 10-inch 60V/48V

2. Rear brake shoe kit

3. Motor controller 60V/48V

4. DC to DC convertor 36V-64V to 12V (https://myebikeshop.com/product/converter-48v12v-e...)

5. Accelerator

6. Digital Meter

7. 48V 24 Ah LiFePO4 rechargeable battery pack with BMS board

8. 48V 20 Ah charger

9. Anti-Theft Alarm with remote control

10. Assembly connectors

11. 4 pin connector power box screw and bold type

Electrical components

1. 2 XT 90 connectors

2. 25 A UPS male and female connectors

3. 10 Male to female connectors

4. Extra multi-colour wires

5. Indicator beeper and flasher

6. Horn

7. MCB tripper 30 A

8. IN 4007 Diode

Other components:

Oil Engine Tank Belt 7.5 hp

Metal used:

Mild steel or MS sheets

Paint used:

Car finishing paints: BMW sea blue, BMW alpine white, mat and shiny black and silver

The total cost of the project was: Rs. 75000 approx.

Before designing this two-wheeler, it took me 3 months to understand the electrical circuitry of an e-bike and what are its necessary components which will be installed on the vehicle. After comprehending clearly the concept of e-bikes, I designed my 25 years old Kinetic Honda ZX scooter's chassis (I dissembled the vehicle and then took a photo of it). The idea behind designing this vehicle was first I will design it like a bike. The main difference between a scooter and bike chassis is that a bike has a centre rod in between the seat and the front suspension holder. After drawing that I drew accordingly the components inside and outside the vehicle.

Note: Please see the figures and photos from left to right

Experiment 1:

For testing the e-bike spare parts, I got an old Suzuki Spirit scooter from a known mechanic. Suzuki Spirit and Kinetic Honda have similar dry weight and they have only one rear suspension, hence experimenting with the Suzuki scooter is perfect.

Seeing the figures in a chronological manner and you will understand clearly the electrical circuitry of the e-bike.

After connecting everything and doing the test drive, I drew few conclusions:

1. The vehicle which I am going to make needs 2 rear suspensions because when a pillion will sit on the vehicle which has one rear suspension, the weight will fall directly on the rear brake and hub motor system, hence to distribute the weight equally I will put two rear suspensions

2. With a weight of 80 to 83 kg as a external load on the vehicle, it ran at 37 km/h on E or economical mode and 48-50 km/h on S or sport mode

Refer back to step 2 and make the connections accordingly.

Connect six 6V 180 mAh solar panels in series with the 22V 0.58 Ah solar panel. Then connect the solar mini PV array system in series with the IN 4007 diode (as function of a blocking diode directed towards the batteries) and the 48V 24 Ah LiFePO4 rechargeable batteries.

After completing the project, here are the final results of the product:

1. On E mode, the vehicle ran at 30 km/h

2. On S mode, the vehicle ran at 42 to 45 km/h

3. According to my calculations and verifying those calculations practically I saw that the mileage of the vehicle without solar panels measured to about 85 km/charge. But when the solar panels were integrated, the mileage increased to 110 km/charge (as you can see on the picture)

4. Charging time 3-4 hours

5. External load can be 200 kg max (excluding the dry weight of the vehicle)

6. The Kinetic Honda tyres can tolerate about 200 kg max as well

7. It runs very smoothly without any jerk unlike other e bikes

If you have any queries please comment in the comment section