DESIGN AND MODIFICATION OF ELECTRIC MOTORCYCLE WITH

PROGRESSIVE TRANSMISSION

[1]Sandeep Kumar, [2]Prajath J Shetty, [3]Royd Noronha, [4]Kamil salih A P, [5]Mr. Jerome
Anthony

[1],[2],[3],[4]- Students, Department of Automobile Engineering

[5]- Associate professor, Department of Automobile Engineering

Automobile Engineering Department, Srinivas Institute Of Technology,

Valachil, Mangaluru

Sandeepkarla89@gmail.com roydnoronha@gmail.com
jeromeanthony07@gmail.com

ABSTRACT motor together with a dc rechargeable battery and

The Increasing demand for non-polluting applying an electronic accelerator to control the

mechanized transportation has increased the speed of the motor.

interest in the use of electric power for personal

transportation and also reduced reliance on
automobiles. A low cost alternative to an
automobile is an Electric motorcycle. The rate of
improvements in technologies is at
exponential level despite that the electric
motorcycle is a concept that has been very
feasible for years but has not been fully explored.
The human electric motorcycle is designed to
provide electromagnetic propulsions to
motorcycle therefore relieving the user of having
to produce the energy required to run the
motorcycle.
The system design is based on mechanically
coupling a dc motor as the primary power source
to drive the motorcycle and electric source to
recharge the battery and electrically wiring the
INTRODUCTION
There is always an increasing awareness of
alternative transportation modes. The world
an today is highly effected by the pollution rate
caused by the emission of high toxic emitants
from exhaust chamber.A DC motor powered
electric motorcycle is an electricity assisted
device that is mainly designed to provide an
a electromagnetic propulsions to an existing
motorcycle therefore relieving the user of
producing the energy required to run the
motorcycle. The setup consists of a dc motor and
enough battery power to rotate the motor to help
in generate greater motoring speeds and provide
completely few electrical transportation.
Generally electric vehicles cost more than
gasoline vehicles. The main reason for that is the
developments that has been taking in the last few
decades in the gasoline field. The electric
vehicles have been completely ignored. But now
due to increasing awareness of the effects caused
by gasoline engine and eco-friendly nature of the
electric vehicles, it has taken amajor step towards
developing the build of vehicles.The primary
reason that has helped for the rapid growth of the
electric vehicles over petrol powered vehicles
have been towards developing air quality, but this
alone is not efficient to prove its worth.Another
key advantage of the electric powered
motorcycles is that it is cost effect. The
production cost is more when compared to
gasoline vehicles but the maintenance cost is low.
No fuel is required for the vehicle to run. The
only cost required here is to charge the
battery.Generally there are other many
advantages of electric powered vehicles, these
includes reduction in oil consumption. The other
major non-market benefit would be lower
greenhouse gas emission.
METHODOLOGY
1. Literature Survey
2. Selection of Components
3. Purchasing of Components
4. Modification of Motorcycle
5. Fabrication and Assembling
6. Testing and Result
WORKING PRINCIPLE
The working of electric motorcycle will be
segmented into two stages. These are
1. The electrical system design stage
2. The mechanical coupling stage
The electrical system design stage include wiring
the battery, motor and constructing a speed
controlling circuitry to ensure proper travel speed
control during the operation of the motorcycle.
The mechanical coupling includes the proper
welding and arrangements of all these
components, especially the motor and batteries
on the framework of the motorcycle. This would
ensure that it retains a steady standing frame and
maintain its balance when in motion. Mounting
an alternator above the front wheel through belt
to a pulley.
We use a PMDC motor which is
connected to the engine i.e., it is integrated with
the engine by welding. The magneto of the
motorcycle is removed and a sprocket is welded
directly to the crankshaft through electric
welding. The head and bore of the engine was
removed for the weight reduction purpose. In the
position of the head, the dc motor is mounted by
djustable means. The DC motor and engine
crankshaft is connected by chain. The cylinder
head and bore is removed and we closed the
piston side by using a steel plate and mounted the
dc motor.
We mounted the battery above the engine, where
the battery is placed in a bracket where two
batteries are placed in series which is shackled to
frame. The 24v 500watt speed controller which is
mounted in between the frame and were the
motor wire is connected to controller. The
Throttle handle grip is placed in the bike handle
and that wire is also connected to the controller.
The bike chain is connected in between the
transmission gearbox and wheel sprocket. We
introduced a new charging system by means of
an alternator which is coupled to a pulley through
a belt to the front wheel via fabrication of
bracket.
ADVANTAGES
By choosing to drive an electronic bike
we are helping to reduce harmful air
pollution from exhaust emissions. An
electronic motorcycle has zero emissions.
Renewable energy sources used to
recharge the electric vehicles reduce the
green emissions even further.
It has certain health benefits due to the
reduced harmful exhaust emissions.
Electric vehicles are also quiter than
petrol/diesel vehicles, which means less
noise pollution.
Electric vehicles normally makes use of
eco-friendly components.
Recent findings have shown that several
electric vehicles features can improve
safety. Electric vehicles tend to have a
lower centre of gravity that makes them
less likely to roll over.
No fire hazards
Electric vehicles are easy to power from
local and renewable energy sources,
reducing our dependence on foreign oil.
Low maintenance and operation cost.
DESIGN CALCULATION
Calculations for Gear
Material used for the sprocket is high speed steel,
so as to reduce the load on the DC motor.
For driven Gear
Outer diameter of the driven gear, O.D = 53mm
Module of the driven gear,m = 1.5
We have the formula, O.D = m(Z1 +2)
Where 1 is the number of teeth on driven gear
O.D
Therefore,1 = 2
m
53
= 2
1.5
1 = 33 Teeth
For Driver gear
Outer diameter of the driver gear,O.D = 20mm
Module of the driver gear, m = 1.5
We have the formula, O.D = m(Z2 +2)
Where 2 is the number of teeth on driver gear

O.D
Therefore,2 = 2 VELOCITY (
m
RPM
20
Km/hr)
= 2
1.5 500 0.1413
1 = 11 Teeth 1000 0.2826
5.2.4 PMDC Motor 1500 0.4239
Voltage = 24 volt 2000 0.565

Power = 500 watt 2500 0.706

Torque = 1.9 Nm

RPM = 2500 Calculation of gear ratio

Weight = 4.1 kg GEAR A GEAR B

Motor Diameter = 0.1075 meter 11 33
33
Motor shaft diameter = 1.5 meter Gear ratio = = =3:1
11

Calculation of RPM
5.2.5 Speed Vs Velocity SPROCKET A SPROCKET B
260 TEETH 11 33
V= Km/hr
1000 RPM 2500 ?

20.75250060
= = 0.706 Km/hr
1000
20.75200060 33
= = 0.565 Km/hr Gear ratio = = 3: 1
1000 11
20.75100060
= = 0.2826 Km/hr 2500
1000
= = 833.33
3
20.75150060
= = 0.4239 Km/hr
1000

20.7550060
= = 0.1413 Km/hr
1000
RESULT AND DISCUSSIONS alleviate the severe environmental pollution
problem in urban areas.
Result
CONCLUSION
The maximum speed achieved from the
At the conclusion of the project, we had
motorcycle is 40km/hr.
accomplished full system integration physically.
The battery used is 17Ah battery and the
The major challenge remaining is creating a set
battery has a backup capacity of 6 hours.
of software that the microcontroller can use to
The motorcycle has a load carrying
control the system given all the feedback systems
capacity of 110kg.
that communicate with it. Some additional
Noise is reduced up to 80% of that of
features we may implement include creating a
ordinary petrol engine.
display and circuitry for monitoring the battery
The emission level is completely
state. In conclusion, we have designed an electric
eliminated because no combustion takes
bike with a minimal amount of additional weight,
place.
an integrated control system and progressive
Discussion transmission based on the decision-making of the
rider, and that is capable of greater efficiency
For an electric motorcycle which is designed for
than typical electrical bikes through its use of
single driver and its performances do not fully
regenerative motor control and various other
satisfy the requirements, but an electric
feedback control mechanisms.
motorcycle rider can use this for daily driving
distance, city run. But the travel cost is much FUTURE SCOPE
lower than gasoline motorcycles. Hence, E-rider
As the global warming is increasing day
is a good substitution for the gasoline
by day and the reservoir of fossil fuels
motorcycles and suitable to be used in all
tends to end, the electric bikes will be
directions. Emission from Electric motorcycle is
better options.
completely eliminated. Electric Motorcycles can
As compared to the fuel driven vehicle,
achieve zero urban-emission of carbon dioxide,
the electricity driven vehicles are better
carbon monoxide, NOx, UBHC benefitting
when we talk about pollution.
global warming. Considering its zero-urban-
In future, by using suitable arrangements
emission, low noise level and high energy
in electric bikes for regeneration like
efficiency features, electric motorcycles (EMs)
have become a significant transportation mode to
 motor etc. we will increase the discharge REFERENCE
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We can also give solar charging by
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placing a solar panel and also provides
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Instead of 12v alternator we can use a 24v
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We thank Staff and management of Srinivas

Institute of Technology, Mangaluru for their
support for carrying out this project.

We also thank Mr. K Nagesh and Prof. Allen Bangera

for helping in making our project.