Research and Innovation

GBC E-Bike

A Green Alternative to Urban Commuting

Pradeep Kalsi May 15, 2009

Team Members
Edward Wong

Tool & Die Graduate & Engineering Design Student (design & fabrication specialist)

Andy Lau

Tool & Die student (research & design specialist)

Michael Joyette

Electro-Mechanical Graduate (research & electrical specialist)

Clayton Wozney

Tool & Die and Mechanical Engineering Design Graduate (scheduler, & motivation specialist)

Professor Leo Salemi

Electrical Advisor and Great Guy!

Professor Ted Lewis

Electrical Advisor and Good Friend!

Professor Pradeep Kalsi

Mastermind and Project Lead

Introduction

To create an urban Electric Bicycle that has increased

power and range, to fit the urban lifestyle.

Objectives
Signature Vehicle
To develop a vehicle whereby GBC students, faculty and staff from the ElectroMechanical & Mechanical Engineering cluster can collaborate on a common
project to develop inter-disciplinary skills and strengthen relationships
Racing Competitions
To provide GBC students an opportunity to enhance this vehicle on a yearly
basis for racing competitions between like minded institutions
Relationships
To develop relationships between GBC, Industry Partners and The Municipality
Of Toronto as participants and sponsors for Electric Bike Racing Competitions

Research Objectives
Building An Electric Bicycle For
Efficiency
For riding safely throughout the Toronto downtown core (ensuring visibility
and ease of mobility)

Long Distance Travel

Go a farther distance to and from a specific location without draining the
batteries (re-plenishing the batteries as you ride)

Power Requirements
Extra power for initial take off , climbing steep inclines, and maintaining a
safe speed without impeding traffic to make it a stress free ride

Main Questions for Research

Dual Battery Packs

Can the electric bicycle be fitted with two battery packs working in tandem to provide
enough energy to travel great distances without discharging?

Controller Capacity

Can the main controller effectively manage to control and process information to drive the
two hub motors?

Re-Generation

Can the braking action of the bike be directed to re-generate a depleted battery pack?

Storage Rack

Can a carrier be designed to house two lithium ion battery packs and pradeeps sitar
without hindering maneuverability?

Methodology
1.Collaboration

Group brain- storming among stakeholders; students, faculty and staff in meeting objectives,
outcomes, time-lines and duties

2. Design Stage

Design of hard components; namely rear carrier housing, lighting housing, controller, ignition
housing, wiring and schematics of electrical hook ups to throttle, controller, hub motors,
lighting system

3. Development Stage

Equipment and materials (type of batteries, capacity of electrical motors and controller) to be
used and purchased as well as functionality considerations and specifications of the bike after
completion

4. Manufacturing Stage

D Building Labs to be used and availability, logistics, machinery and equipment required
(manual and cnc machinery), Cad-Cam labs, time-lines, Faculty assistance and supervision

5. Testing Stage

Testing the vehicle for handling, safety, performance, functionality and specifications

6. Electrical Wiring

Leos Infrastructure Testing Lab

Improvements
Rear Carrier

Build and design a rear carrier to house two lithium ion battery packs for longer travel
time

Controller
Configure one controller with a throttle to activate (or de-activate) the front and rear
hub motors when necessary

Re-Generation

Have one battery pack that was replete of energy being re-charged when braking or
slowing down

Braking System

Fit the braking system to activate brake lights

Configure the batteries to the braking system for power re-generation

Turning Signals

Fit a switch to activate turning signals

Result Thus Far

1.Rear Carrier

Developed and attached a rear carrier to house two lithium batteries

2. Electrical System

A Controller is hooked up to a throttle to power a rear hub motor

A front switched attached to the braking system actives rear brake lights

3. Brake Light Housing

Developed and hooked up a system with brake lights

Work in Progress

Electrical hook-up between two hub motors is still in the development stage as
schematics for the controller are being investigated
The battery packs are ready to be mounted in a manufactured rear carrier
The turn signals require a housing and a switch is required for activation at
the hand controls

Result Thus Far

Lessons Learned
Research Projects Take Time
- juggling a teaching schedule and managing a research team can be challenging

Learning New Things

Takes time and patience (electrical)

After Market Components

Components obtained from an unknown distributor can be difficult to troubleshoot and specifications can be difficult to
obtain (namely specs. & schematics for the controller)

Dedicated & Motivated Team

Developing a dedicated team to take responsibilities can be a big concern on such projects
Delegating responsibilities can be difficult at times

Communication & Involvement

It is okay to ask for help from faculty, staff and industry partners

Cooperation & Participation

It is sometimes difficult accessing other labs

It can be difficult to get faculty, staff and students to participation in projects such as this

Expectations

Sometimes too many or too high expectations can delay the outcomes
Sometimes being over ambitious can hinder progress and may not be contagious
Punjab was not invented in one day

Simplicity

Try to make things simple

The Sitar

Future Research
Electrical System

Developing the electrical system to be hooked up to the two hub motors so that they can be activated
together or independently when required
Developing an activation switch for turn signals
Developing a method for re-generating a depleted battery

Mechanical System

Developing a housing for the controller, ignition switch and turn signals

Testing

Testing the bike to determine specifications of distance on one charge, manoeuverability, speed,
mobility

Racing Potential

Develop the bike to enter into competitions

Testing the market for interest in developing e-bike racing competitions

Acknowledgements
And

Questions
Michael Joyette
Edward Wong
Andy Lau
Clayton Wozney
Leo Salemi
Taesu Yim
Mark Dagenais
Ted Lewis
Laura Sauer
Green Rider: Neil and Julian
Robert Luke
Meadow Larkins
Dawn Davidson
Baaba Lewis
Nancy Sherman
Jeff Litwin
Erin Agnew
My Wife, Jasmine
GBC