hybrid bike using range extended electric vehicle (reev) technology … · combustion engine drives...

HYBRID BIKE USING RANGE EXTENDED ELECTRIC VEHICLE (REEV) TECHNOLOGY

PROJECT REFERENCE NO.: 39S_BE_0861

COLLEGE : G M INSTITUTE OF TECHNOLOGY, DAVANGERE

BRANCH : DEPARTMENT OF MECHANICAL ENGINEERING

GUIDE : MR.NANDEESHA H L

STUDENTS : MR. NIKHIL M S

MR. PAVAN J K

MR. NINGARAJA B N

MR. GOWTHAM K M

HYBRID BIKE USING REEV TECHNOLOGY

Department of Mechanical Engineering, GMIT, Davangere Page 1

CHAPTER -1

INTRODUCTION

Several economic and environmental factors are contributing to increasing

interest in alternative vehicle technologies. These factors include rising global demand for

oil, concomitant increases in fuel prices and anthropogenic climate change. Rising global

demand for oil has both economic and political consequences. Increasing demand has a

direct economic impact via increased commodity prices as well as a number of

geopolitical implications that create political challenges for countries that rely on

imported oil for economic activity. Moreover, evidence of the increasing dangers posed

by climate change adds to the urgency to reduce the Green House Gas (GHG) emissions

from all sources. GHG emission from the transportation sector is growing more rapidly

than from any other economic sector and INDIA is accounted for 5.7% of total GHG

emissions in 2010[1].

The invention of internal combustion engine is one of the greatest inventions of mankind.

The conventional vehicles with ICE provide a good performance and long operating

range. However they have caused and continue to cause serious problems for poor fuel

economy, environment pollution and human life. Reducing fuel consumption and

emissions is one of the most important goals of modern design. The hybridization of a

convectional combustion engine vehicle with an advanced electric motor drive may

greatly enhance the overall efficiency and achieve higher fuel with reduced emissions.

Considering the urban status in India, a well-organized and fuel efficient scooter has to be

designed and developed.

Internal combustion engines are relatively less efficient in converting the on-board fuel

energy to propulsion as most of the energy is wasted as heat. On the other hand, electric

motors are efficient in converting the stored energy in driving a vehicle, and electric drive

vehicles do not consume power while coasting. Some of the energy loss in braking is

captured and reused by regenerative braking. With the help of regenerative braking one

fifth of the energy loss can be regenerated. Typically petrol engines effectively use only

15% of its fuel content to move the vehicle. Whereas an electric drive vehicle has an on-

board efficiency of about 80%. But due to reasons such as cost, inability to reach higher

speeds electric drive vehicles failed to capture markets. Contrary to this petrol vehicles



can cover longer distances with higher speed but it cannot cover shorter distance with

slow speed (say in traffic) in an efficient way. By increasing the range of electric vehicles

they could easily capture the automobile industry. Hybrid technology is the most

promising technology that could be implemented for increasing the EV range as current

electric vehicle industries are switching towards this concept for increasing the vehicle

range [3]. The concept of Electric-Electric hybrid system which incorporates two separate

Brushless DC motors for its propulsion.

A hybrid vehicle is a vehicle with multiple distinct energy sources which could be

separately or simultaneously operated to propel the vehicle. Many hybridization

configurations such as fuel cell, gas turbine, solar, hydraulic, pneumatic, ethanol, electric

and many more are proposed over the years. Among these, the hybrid electric vehicles,

integrating two technically and commercially proven and well established technologies of

electric motors and I.C. engine, allowing drawing upon their individual benefits have

been widely accepted by the technologies and users.

This is the most commonly adapted hybrid vehicle which combines propulsion sources of

an electric motor and an I.C. engine. The power supply to the electric motor comes from

on board batteries. In a HEV, the I.C. engine cooperates with an electric motor which

leads to a more optimal use of the engine. Driving in city traffic involves frequent starts

and stops of the vehicle. During idling, the engine consumes more fuel without producing

useful work thus contributing to higher fuel consumption, less efficiency and unnecessary

emission from exhaust. The HEV solves the problem by switching to power transmission

through the motor and shutting off the engine. This way no fuel will be consumed during

idling with no exhaust emission. Another advantage of HEV is that when fuel tank gets

empty while driving the engine, the vehicle can be driven on electric power within its

maximum range.

The Plugin Hybrid Electric Vehicle (PHEV) is one technology that is nearing

commercial deployment and has the potential to address all three of these issues to

varying degrees. PHEVs, like current hybrid electric vehicles are equipped with an

internal combustion engine, an electric motor and a battery that can be charged both by a

generator driven by the internal combustion engine. In contrast to current HEVs,

however, PHEVs have much greater battery capacity and most importantly, the capacity

to charge the battery from external electricity sources, including the electrical grid. The



ability to charge directly from the electrical grid means that PHEVs can displace a portion

of the fossil fuels used in the transportation sector.

Compared with the pure electric vehicles, range-extended electric vehicle adds on-board

generator system (range extender) [2]. The range-extender consists of engine, generator,

and rectifying device. The engine can persistently charge the power battery, so the trip

mileage is substantially increased near the conventional fuel vehicle. The range-extended

electric vehicle can optimize the working condition of the engine and power battery at the

same time. On the one hand the engine efficiency is increased. The internal-combustion

engine can work in low fuel consumption and pollution and the optimum working point

can realized. On the other hand, the power battery working condition is optimized, the

power battery can keep working in good condition, avoiding over charge or discharge.

The utility life is increased, the braking energy can be recovered, and the energy

consumption and cost is decreased.

Extended-range electric vehicles (EREV) or range-extended electric vehicles (REEV)

were designed to be run mostly by the battery, but have a petrol or diesel generator to

recharge the battery when charge becomes low. However, range extension can be

accomplished with either series or parallel hybrid layouts. In a series-hybrid system, the

combustion engine drives an electric generator instead of directly driving the wheels. The

generator provides power for the driving electric motors by charging batteries. In short, a

series-hybrid is a simple vehicle, which is driven only by electric motor traction with a

generator set providing the electric power.

The Extended Range Electric Vehicle (EREV) is unique vehicle, where battery and

propulsion system are sized such that the engine is never required for operation of the

vehicle when energy is available from the battery. As a full-performance electric vehicle,

battery, motor and power electronics must be sized for the full capability of the vehicle.

An E-REV does not need to start the engine for speed or power demands and therefore

does not need to be on when battery energy is available.

The engine is used only when the battery charge is low and to charge the battery in such

cases. Unlike an internal combustion engine, electric motors are highly efficient with

exceptionally high power-to-weight ratios providing adequate torque when running over a

wide speed range. Internal combustion engines run most efficiently when turning at a

constant speed. An engine turning a generator can be designed to run at maximum



efficiency at constant speed. Conventional mechanical transmissions add weight, bulk and

sap power from the engine with automatic shifting being complex [4]. Unlike

conventional transmission mechanism, electric motors are matched to the vehicle with a

simple constant-ratio gearbox hence multiple-speed transmission can be eliminated.

HEV are the vehicles with more than two energy sources are present. The major

challenges for HEV design are managing multiple energy source, highly dependent on

driving cycles, battery sizing and battery management. HEV’s has advantage of electric

drive to compensate the inherent weakness of ICE, namely avoiding the idling for

increasing the fuel efficiency and reduce emission during starting and speeding

operations, to use regenerative braking instead of mechanical braking during deceleration

And down slope driving. HEV can meet customers need and has added value but cost is

the major issue. These vehicles are of high cost and certain program should be supported

by the specific government for marketing HEVs. The HEVs are classified into two basic

kinds- series and parallel. Recently with introduction of some HEVs offering the features

of both series and parallel hybrids, the classification has been extended to three kinds-

series, parallel and series-parallel. It is interesting to note that some newly introduced

HEVs cannot be classified into these three kinds. Hereby final classification involves

series, parallel, complex hybrid.



CHAPTER – 2

FUNDAMENTALS

2.1 Basics

Internal combustion engines are relatively less efficient in converting the on-board

fuel energy to propulsion as most of the energy is wasted as heat. On the other hand,

electric motors are efficient in converting the stored energy in driving a vehicle, and

electric drive vehicles do not consume power while coasting. Some of the energy loss in

braking is captured and reused by regenerative braking. With the help of regenerative

braking one fifth of the energy loss can be regenerated.

Typically petrol engines effectively use only 15% of its fuel content to move the vehicle.

Whereas an electric drive vehicle has an on-board efficiency of about 80%. But due to

reasons such as cost, inability to reach higher speeds electric drive vehicles failed to

capture markets. Contrary to this petrol vehicles can cover longer distances with higher

speed but it cannot cover shorter distance with slow speed (say in traffic) in an efficient

way. By increasing the range of electric vehicles they could easily capture the automobile

industry. Hybrid technology is the most promising technology that could be implemented

for increasing the EV range as current electric vehicle industries are switching towards

this concept for increasing the vehicle range. In this paper, the concept of Electric-

Electric hybrid system which incorporates two separate Brushless DC motors for its

propulsion.

The Brushless DC (BLDC) motors are fixed to the Hub of both front and rear wheel. The

reason for choosing BLDC motor is its compactness, noiseless operation and motor

generating principle.

2.1.1 Electric motorcycles

Electric motorcycles and scooters are plug-in electric vehicles with two or three

wheels powered by electricity. The electricity is stored on board in a Rechargeable

battery, which drives one or more electric motors. Electric scooters (as distinct from

motorcycles) have a step-through frame.



Most electric motorcycles and scooters today are powered by rechargeable lithium ion

batteries, though some early models used nickel-metal hydride batteries. Scooter maker Z

Electric Vehicle has pioneered use of a lead/sodium silicate battery that compares

favorably with lithium batteries in size, weight, and energy capacity, at less cost.

All electric scooters and motorcycles provide for recharging by plugging into ordinary

wall outlets, usually taking about eight hours to recharge (i.e. overnight). Some

manufacturers have designed in, included, or offer as an accessory, the high-power level 2

charger, which can charge the batteries up to 95% in an hour.

Electric scooters and motorcycles need virtually no maintenance. With only a battery, a

motor, and a black box (i.e. the controller) to keep you moving, electric motorcycles are a

breeze to maintain compared to a conventional motorcycle, what with all the lubricating

and adjusting and tuning you have to do. You basically just worry about consumables:

brake pads, tires, maybe a brake fluid flush.

Electric vehicles are far quieter than gas powered ones, so silent they may sneak up on

unwary pedestrians. Some are equipped to emit artificial noise. Popular Mechanics called

the comparative quiet of electric motorcycles the greatest difference between them and

their gas counterparts, and a safety bonus because the rider can hear danger approaching

[5]. Whether a loud motorcycle is more noticeable and thus safer than a quiet one is

contested. At high speed the whine of an electric motorcycle is said to sound "like a

spaceship."

2.1.2 Hybrid bike

A hybrid bike is a vehicle with multiple distinct energy sources which could be

separately or simultaneously operated to propel the vehicle. Many hybridization

configurations such as fuel cell, gas turbine, solar, hydraulic, pneumatic, ethanol, electric

and many more are proposed over the years. Among these, the hybrid electric vehicles,

integrating two technically and commercially proven and well established technologies of

electric motors and I.C. engine, allowing drawing upon their individual benefits have

been widely accepted by the technologies and users [6].

The most commonly adapted hybrid vehicle which combines propulsion sources of an

electric motor and an I.C. engine. The power supply to the electric motor comes from

onboard batteries. In a HEV, the I.C. engine cooperates with an electric motor which



leads to a more optimal use of the engine. Driving in city traffic involves frequent starts

and stops of the vehicle. During idling, the engine consumes more fuel without producing

useful work thus contributing to higher fuel consumption, less efficiency and unnecessary

emission from exhaust. The HEV solves the problem by switching to power transmission

through the motor and shutting off the engine. This way no fuel will be consumed during

idling with no exhaust emission. Another advantage of HEV is that when fuel tank gets

empty while driving the engine, the vehicle can be driven on electric power within its

maximum range.

HEV are the vehicles with more than two energy sources are present. The major

challenges for HEV design are managing multiple energy source, highly dependent on

driving cycles, battery sizing and battery management. HEVs take the advantages of

electric drive to compensate the inherent weakness of ICE, namely avoiding the idling for

increasing the fuel efficiency and reduce emission during starting and speeding

operations, to use regenerative braking instead of mechanical braking during deceleration

and down slope driving. HEV can meet customers need and has added value but cost is

the major issue [10]. These vehicles are of high cost and certain program should be

supported by the specific government for marketing HEVs.

2.2 Types of Hybrid powertrain

2.2.1 Series Hybrid

This is an electric power train for which an I.C. engine acts as a generator to charge

batteries and/or provide power to the electric drive motor which can be seen in Fig.2.2.1.

These vehicles usually have a larger battery pack and larger motors with smaller I.C.

engines.

Figure 2.1: Series hybrid powertrain



In a Series Hybrid bike (SH) the user powers a generator using the engine. This is

converted into electricity and can be fed directly to the motor giving a chainless bicycle

but also to charge a battery. The motor draws power from the battery and must be able to

deliver the full mechanical torque required because none is available from the pedals.

Series Hybrid bikes are commercially available, because they are very simple in theory

and manufacturing.

They are referred to as "Plug-In Hybrids" (or a Plug-In Electric Vehicle, PHEV) and

"Range-Extended Electrics." The drive train for a series hybrid is mechanically simple,

compared to other hybrids [10]. Disadvantages to this drive train are lower efficiencies at

greater trip distances and the higher cost of batteries and components, since the vehicle is

all-electric. Regardless, of the three hybrid options, it is the most efficient in fuel use [1].

2.2.2 Parallel Hybrid

More mechanically complex than a series hybrid, the parallel power train is dual-

driven, allowing both the combustion engine and the electric motor to propel the car.

Fig.2.2.2 shows that the I.C. engine and motor operate in tandem. Usually the combustion

engine operates as the primary means of propulsion and the electric motor acting as a

backup or torque/power booster. The advantages of this are smaller batteries (less weight)

and generally more efficient regenerative braking to both slow the car and capture energy

while doing so. Another advantage is that it can easily be incorporated into existing

vehicle models. Most hybrids on the road are of the parallel type.

Figure 2.2: Parallel Hybrid Powertrain



In a Parallel Hybrid vehicle human and motor power are mechanically coupled at the

pedal drive train or at the rear or the front wheel, e.g. using a hub motor, a roller pressing

onto a tire, or a connection to a wheel using a transmission element. Human and motor

torques are added together. Almost all manufactured Motorized bicycles, Mopeds are of

this type.

The major disadvantage of this power train is that it adds more weight to the vehicle

without necessarily shrinking the engine and other components [11]. While the addition

of the motor does increase fuel mileage by allowing the engine to operate at lower

rotations per minute (thus using less fuel). These vehicles are poor highway performers,

gaining most of their efficiency in city driving at lower speeds.



CHAPTER 3

COMPONENTS DESCRIPTION

3.1 Components

The components used in this project are IC engine, generator, BLDC hub motor,

DC motor controller, sealed batteries, charging circuit, chassis, ignition switch,

accelerator, wiring kit.

3.1.1 I C Engine

In the project, the hero Honda cd 100 is used. it will run by a 97cc, 4 stroke, single

cylinder and air- cooled engine. It produces peak power of 7.5 bhp @ 8000 rpm which is

more than sufficient to charge the batteries through the charging circuit. And the

specifications of engine are listed below;

Figure 3.1 Hero Honda CD-100 engine



Table 3.1 Technical specifications of Hero Honda cd 100

Type Motorcycle

Engine displacement 97.00 cc

Engine type 4-stroke, single cylinder, air cooled

Engine starting Kick start

Maximum power 7.5bhp @ 8000rpm

Maximum torque 0.73 @5000 rpm

Transmission 4- speed constant mesh

Top speed 85kmph

Brakes

Front brake Drum brakes ,110mm

Rear brake Drum brakes, 100mm

Chassis and suspension

Front suspension Telescopic hydraulic fork

Rear suspension Swing arm with hydraulic dampers

Type

Front tyre 2.50

Rear type 2.75

Dimensions

L x b x h 1885x770x1060 mm

Wheelbase 1210 mm

Weight 95 kg

Ground clearance 135 mm

Petrol tank capacity 10.1 litres

3.1.2 Generator

The PMDC motor is used as a generator in this project. These types of motor are

essentially simple in construction. As the magnetic field strength of a permanent magnet

is fixed it cannot be controlled externally, field control of this type of dc motor cannot be

possible. Thus permanent magnet dc motor is used where there is no need of speed

control of motor by means of controlling its field.

mailto:7.5bhp@8000rpm



Figure 3.2 Generator

The specifications of generator are listed below;

Table 3.2 Technical specifications of generator

Sl No. Features No.

1 Rated voltage(v) 110

2 Voltage range(v) 110-130

3 Rated load (mm-m) 300

4 Rated speed (rpm) 7000

5 Rated current (ma) 1050

6 Starting torque (mm-m) 540

7 Rotation cw and ccw

3.1.3 Hub motor

Hub motors are an interesting development which could offer benefits such as

compactness, noiseless operation and high efficiency for electric vehicles. These motors

have stators fixed at the axle, with the permanent magnet rotor embedded in the wheel.

The traditional “exterior rotor” design has the hollow cylindrical rotor spinning around a

stator axle. There is a “radial air gap” between the stator and rotor. The stator consists of

stacked laminated steel plates with wound coils. Pulse width modulated current is used to

supply current to the stator. Hub motors must run at relatively low speed – equal to the



actual rotation of wheel if there is no final gearing stage. The benefit is about a 10%

increase in efficiency due to the lack of transmission.

The main reason for choosing a hub motor is that it does not require a transmission

system which helps in reducing the transmission losses. Since it has no brushes to wear

out the life of motor is increased. It has a greater traction control. The back emf created

by BLDC motor can easily be stored in the batteries.

Figure 3.3 BLDC Hub motor

The specifications of Generator are listed below;

Table3.3 Technical Specifications of hub motor

SL NO Features Description

1 Rated voltage(V) 48 DC

2 Rated power (W) 1000

3 Controller current limit (A) 33

4 No load speed (rpm) 518

5 Max. torque (N-m) >50

6 Max. Power (W) >1000

7 Max. efficiency 82%



3.1.4 DC Controller

The controller connects the power source to the motor. It controls speed,

direction of rotation, and optimizes energy conversion. While batteries produce constant

voltages which decrease as they are used up, some controllers require a DC to DC

converter to step down this changeable voltage to the motor’s expected constant operating

voltage, but other controllers incorporate a DC-to-DC converter and can accept a varying

voltage. Converter efficiencies are typically greater than 90%.

The voltage control is achieved by “chopping” the source current - the voltage is switched

on and off, with the ratio of on to off determining the average voltage. Chopping is

performed by power electronic circuitry such as diodes and thyristors and silicon control

rectifiers (SCR). Controllers also effect regenerative braking, by which the motor is acted

as a generator to recharge the batteries.

The controller for the motor is being interfaced with the motor speed regulation. The

speed controlling throttle is being interfaced through the motor controller circuit. The

motor used here is 48V, 250W, Ampere made hub motor. The controller for the motor is

also Ampere made suitable for controlling the specified motor. The throttle is an ampere

made throttle for speed regulation of the specified motor. The input to the motor is

supplied by four Exide made Electra lead-acid batteries each of 12V, 26Ah through

controller for testing purpose. Two independent propelling sources are being employed

for obtaining total propulsion of the vehicle

Figure 3.4 DC controller



The Functions of DC Controller are listed below

1. Super low noise when starting up.

2. Speed limit/3 speed.

3. Under-voltage protection.

4. Under-current protection.

5. Cruising control.

6. Water proof.

Table 3.4 Technical Specifications of DC controller

SL NO. Features Description

1 Rated Voltage (V) 48

2 Rated Power (W) 500

3 Rated Current (A) 30

4 Under voltage protection(V) 41.5 + -0.5

5 Current limited (A) 30+-0.5

6 Efficiency (%) >=83

7 Consumption (W) <1.5

3.1.5 Sealed Batteries

Sealed batteries are a type of lead acid rechargeable batteries. Due to their

construction the gel and AGM types of VRLA can be mounted in any orientation and do

not require constant maintenance.

Figure 3.5 Sealed Battery



In this project, 48V (12*4) V sealed batteries are used. Each battery is of 12 V and

26 Ah capacity. Sealed battery has a good Energy density and power density ratio. It has

about 80% of charge /discharge efficiency. Lead acid batteries, used currently in many

electric vehicles, are potentially usable in hybrid applications. Lead acid batteries are

inexpensive, safe, and reliable. But cold temperature performance, short calendar and

cycle life are still impediments to their use. Advanced lead acid batteries are being

developed for hybrid electric vehicle applications. They are wide used for large amounts

of storage are needed at a lower cost than lead acid batteries.

3.1.6 Ignition Switch

An ignition switch is a switch in the control system of IC engined motor vehicle

that activates the main electrical systems for the vehicle. It also usually switches on

power to many accessories. The ignition switch usually requires a key be inserted that

works a lock built into the switch mechanism. It is frequently combined with the starter

switch which activates the starter motor. It may be bypassed by disconnecting the wiring

to the switch and manipulating it directly. This is known as hot wiring.

Figure 3.6 Ignition Switch



3.1.7 Chassis

In this project, Hero Honda CD-100 Chassis being used. A chassis includes the

head tube that holds the front fork and allows it to pivot. Some motorcycles include the

engine as a load bearing, stressed member. The rear suspension is an integral component

in the design. Traditionally chassis were steel but titanium, aluminum, magnesium and

carbon fiber, along with composites of these materials are now used. Because of different

motorcycles varying needs of cost, complexity, weight distribution, stiffness, power

output and speed, there is no single ideal frame design.

Figure 3.7 Chassis

3.1.8 Accelerator

The accelerator mode is similar to how a motorcycle operates. When the

accelerator is engaged the motor provides power and propels you and the bike forward. It

allows you to kick back and enjoy a free ride. Most accelerators can be fine-tuned like a

volume dial between low and full power.



Figure 3.8 Accelerator

3.1.9 Wiring Kit

The wiring kit place a major role in an electric bike. The main connecting unit is

DC controller.

The Connections to DC controller:

1. Three wire throttle control for speed control

2. Brake control for controlling supply to motor

3. Input supply from battery

4. Output to motor

Figure 3.9 Wiring kit



3.1.10 Charging Circuit

Electric Bike Chargers are designed to fulfill all kind of power requirements of Electric

Bike. Battery charging which operates in wide AC input range (170 - 300VAC) and to

withstand the adverse Indian power conditions. These are designed with high frequency

switching technology that makes product highly reliable, cost effective, compact in size

and light in weight

When the charge level in the charge indicator shows less, then the Engine is switched on

mechanically. The power developed from the engine generates electricity through the

PMDC motor and charges the batteries through the Charging Circuit.

Figure 3.10 Charging Circuit diagram



CHAPTER 4

METHODOLOGY

4.1 Range extender

The range-extended electric vehicle technology is between plug-in hybrid vehicle

technology and pure electric vehicle technology. Compared with the pure electric

vehicles, range-extended electric vehicle adds on-board generator system (range-

extender). The range-extender consists of engine, generator, and rectifying device. The

engine can persistently charge the power battery, so the trip mileage is substantially

increased near the conventional fuel vehicle [2]. The range-extended electric vehicle can

optimize the working condition of the engine and power battery at the same time. On the

one hand the engine working area is optimized, and the engine efficiency is increased.

The high efficiency area of the internal-combustion engine can be selected by the average

power demand of the driving cycle, so the internal-combustion engine can work in low

fuel consumption and pollution and the optimum working point can realized. On the other

hand, the power battery working condition is optimized, the power battery can keep

working in good condition, avoiding over charge or discharge[12]. The utility life is

increased, the braking energy can be recovered, and the energy consumption and cost is

decreased. The range-extender solves the problems of the high power consumption of air-

condition, and other electric auxiliaries for lighting, heating, defrosting.

Figure 4.1 Range extender Configuration



4.2 Powertrain Configuration

In a series-hybrid system, the combustion engine drives an electric generator

instead of directly driving the wheels. The generator provides power for the driving

electric motors by charging batteries. In short, a series-hybrid is a simple vehicle, which

is driven only by electric motor traction with a generator set providing the electric power.

The Extended Range Electric Vehicle (EREV) is unique vehicle, where battery and

propulsion system are sized such that the engine is never required for operation of the

vehicle when energy is available from the battery. As a full-performance electric vehicle,

battery, motor and power electronics must be sized for the fullcapability of the vehicle.

An E-REV does not need to start the engine for speed or power demands and therefore

does not need to be on when battery energy is available[15]. The engine is used only

when the battery charge is low and to charge the battery in such cases. Unlike an internal

combustion engine, electric motors are highly efficient with exceptionally high power-to-

weight ratios providing adequate torque when running over a wide speed range. Internal

combustion engines run most efficiently when turning at a constant speed. An engine

turning a generator can be designed to run at maximum efficiency at constant speed.

Conventional mechanical transmissions add weight, bulk and sap power from the engine

with automatic shifting being complex. Unlike conventional transmission mechanism,

electric motors are matched to the vehicle with a simple constant-ratio gearbox hence

multiple-speed transmission can be eliminated.

Figure 4.2 Powertrain configuration of the Range-Extended Electric Vehicle



4.3 Methodology of Hybrid Vehicle

The following steps were adopted to proceed with the concept of range extension

in an electric vehicle.

Step 1: Mounting an IC engine (Petrol run, 5000rpm, and Hero Honda CD 100 engine)

on the chassis of the bike making suitable adjustments.

Step 2: Flywheel of IC engine is modified and attached with a pulley and is connected to

a PMDC Motor (110V, 15 amps @5000 RPM) mounted in line with engine using belt

drive and connections are made to the batteries through a charging circuit.

Step 3: When the charge indicator shows charge is less, IC engine will be turned ON

mechanically and PMDC Motor will produce electricity to maintain the battery level until

finding a plug in source.

Step 4: Testing the scooter for improved range.

Step 5: Procurement of electric scooter, IC engine and PMDC motor in working

condition.

Step 6:

1. Flywheel of IC engine is connected to a PMDC Motor (110V, 15 amps @5000

RPM) through a belt drive and the whole setup is mounted on the floorboard of

the electric scooter with suitable clamping [20].

2. The power developed at the flywheel was coupled to the PMDC Motor (110V, 15

amps at 5000 RPM) through the V – Belt drive and a rated power output of 900 W

(110V, 15amps).

3. The connections were given to the batteries through a charging circuit which helps

in developing the required current levels.

4. Here there is a need to charge 4 x 12V series connected batteries which require 1.2

x 48 which is equal to 57.6V and hence we made use of 60V PMDC Motor. And

this is because of voltage drop on application of load.



Stage7:

1. When the charge level comes down to a moderate level, then it is indicated by the

charge dial. Then, the engine is switched on mechanically.

2. The power developed from the engine generates electricity through the PMDC

motor and charges the batteries through the Charging Circuit.

3. Our charging circuit charges the batteries at 10Amps.



CHAPTER - 5

RESULTS and DISCUSSION

5.1 Results

Table 5.1 The specifications of the Electric - Electric hybrid scooter designed

SL NO Vehicle characteristic Value

1. Motor power 1000W

2. Number of motors 2

3. Motor Torque 33 N-m @ 150 rpm

4. Vehicle max. Speed 40 km/hrs.

5. Brake

Drum Brake

6. Motor type Brushless DC Motor

7. Battery capacity

(12 V, 24 Ah) x 4

8. Charging time

8 hours

9. Carrying capacity 1 adult

10. On board Charging Yes

11. Range 130 km



Table 5.2 Comparison between proposed and current electric scooter

Sl.no Characteristics Proposed model Current electric

scooter

1. Regenerative braking No Yes

2 Plug-in recharge Yes Yes

3. On board recharging Yes No

4. Method Discharge of charge + on

board recharge

Discharge of charge

5. Technology Extended Range Ordinary Range

6. No. of Motors 2 1

7. Hybrid system Yes No

8. Range 130 km 50 km

9. Petrol Yes No

10. Range extender Yes No

5.1.1 Cost Analysis and Distance

The below table shows the comparison between petrol bike, electric bike and

hybrid bike tested under normal conditions [25]. By absorbing the table we can clearly

say that the amount of fuel consumption using the hybrid vehicles will be less.

Table 5.3 cost analysis and distance

SL NO Mode

Person Weight

kg

Price

₹

Distance

(KM)

Price per unit

distance ₹

1. Petrol 67 68 55 1.23

2. Battery 67 6 50 0.12

3. Hybrid bike 67 74 130 0.53



5.1.2 Advantages over Other Vehicles

There are a number of high performance and even higher mileage electric vehicles

that are set to new released in a few short years (none of them coming from major auto

companies so the prices may be high) with reduce charge times (as little as an hour which

means you could recharge while you are shopping, or eating at a restaurant, watching a

movie, visiting friends and family, at the park, sport games, etc.) also the with the

implication or solar panels an lighter bodies the electric vehicles range will surpass some

of the most fuel efficient automobiles on the road today.

As for the whole longer tailpipe thing (i.e. the vast majority of electricity is produced

from polluting nonrenewable resources) we are currently making great strides to switch to

clean renewable resources for all of or power needs, also it has been proven that electric

vehicles their electric power from our polluting power grid are still better for the

environment due to their sheer efficiency [22]. The looks of the electric vehicles are

finally starting to look like normal vehicles and they perform with some of the best

supercars in the world.

5.1.3 Analysis of the recorded data

As the primary need for this work is to record the data, the method of recording

the speed is done through dynamometer provided in the vehicle. The test vehicle is driven

in stock condition through the given test route of Davangere city, India. The propulsion is

only through electric mode. The route chosen in the test area is as shown in the Figure

5.11.

The first step in developing a driving cycle is to measure and record real driving

behaviors. The obtained data has to be analyzed in forming a representative cycle from

real conditions. The obtained data is classified in different sections based on traffic

conditions.



Figure 5.1 Driving Route Chosen in the test area

The following data are recorded by making the vehicle to travel in the selected route in

anticlockwise direction from start point marked on the map. The recorded data is as given

in table 5.1.4. The total distance covered in this trip is 3 Km. the time taken for covering

this distance is 272 seconds under moderate traffic condition.

Table 5.4 Recorded Data

Route Speed(kmph) Distance(km)

Route-1 40 1

Route-2 40 0.50

Route-3 30 0.95

Route-4 40 0.55

5.1.4 SPEED CONDITION AND RECORDING METHODS

The initial need for this work is to measure and record the vehicle speed. The

measurement of speed is divided into two groups

1. Using the equipment provided in the vehicle like speedometer.

2. Usage of some additional equipment like GPS system.



5.1.5 Classification of traffic conditions

The traffic condition varies with respect to different parts of the city. In classifying the

traffic conditions the parameters used to be the average speed and percentage of idle time

for each of the trip. The four traffic conditions based on the above criteria are as follows

1. Congested urban conditions: An average speed of 8kmph to 10kmph with low to

high idle time.

2. Urban conditions: An average speed of 10kmph to 25kmph with moderate to low

idle time.

3. Extra urban conditions: An average speed of 40kmph with low idle time

4. Highways: An average speed more than 40kmph with very low idle time.

5.2 Environmental Impact by HEV’s

5.2.1 Fuel Consumption and Emissions Reductions

The hybrid vehicle typically achieves greater fuel economy and lower emissions

than conventional internal Combustion engine vehicles (ICEVs), resulting in fewer

emissions being generated. These savings are primarily achieved by three elements of a

typical hybrid design:

a. Relying on both the engine and the electric motors for peak power needs, resulting

in a smaller engine sized more for average usage rather than peak power usage. A

smaller engine can have less internal losses and lower weight.

b. Having significant battery storage capacity to store and reuse recaptured energy,

especially in stop-and-go traffic Typical of the city driving cycle.

c. Recapturing significant amounts of energy during braking that are normally

wasted as heat. This regenerative Braking reduces vehicle speed by converting

some of its kinetic energy into electricity, depending upon the power Rating of the

motor/generator.

Any combination of these three primary hybrid advantages may be used in

different vehicles to realize different Fuel usage, power, emissions, and weight and cost

profiles. The ICE in an HEV can be smaller, lighter, and more efficient than the one in a

conventional vehicle, because the combustion engine can be sized for slightly above

average power demand rather than peak power demand. The greater fuel economy of



HEVs has implication for reduced petroleum consumption and vehicle air pollution

emissions worldwide.

5.2.2 Noise

Reduced noise emissions resulting from substantial use of the electric motor at

idling and low speeds, leading to roadway noise reduction with comparison to

conventional gasoline or diesel powered engine vehicles. The reduced noise may not be

beneficial for all road users, as blind people or the visually impaired use the noise of

combustion engines a helpful aid while crossing streets and feel quiet hybrids could pose

a negative impact.

5.2.3 Pollution

Hybrid vehicles are eco-friendly, as hybrids use NiMH batteries which can be

recycled and that disposal will pose no toxic hazards and also does not release any

harmful gases that help to give green earth.



CHAPTER – 6

CONCLUSION AND SCOPE FOR FUTURE WORK

6.1 Conclusions

The powertrain efficiency of the range-extended electric vehicle is compared in

different driving cycles, energy management strategies, and range-extended control

methods the range-extender uses thermostat control method, the system efficiency is the

maximum. The energy efficiency can reach 33%, the comprehensive efficiency of the

generator and rectifier can reach above 90%.

The influence of the CD-CS and Blended strategy on the economy is compared in

different driving cycles and daily trip mileage is 130 km. Different driving cycles and

control strategies have influence on the economy of the range-extended electric vehicle.

The hybrid bike can be powered by dual source such as gasoline and electricity.

Compared to ordinary bikes this hybrid bike is more efficient and economic.

This hybrid bike will be a new innovation in automotive era, it is more eco-friendly

because it cause less pollution [28]. The hybrid bike is a better solution for hiking fuel

cost day to day.

Hybrid-electric vehicles (HEVs) combine the benefits of gasoline engines and electric

motors and can be configured to obtain different objectives, such as

1. Improved fuel economy

2. Increased power

3. Additional auxiliary power for electronic devices and power tools.

6.2 Future scope

1. An engine less than 100 cc can be used.

2. Compact battery can be used along with 36 V hub motor which requires only 3

batteries.

3. Chain pulley can placed on the bike.

4. Efficiency can be increased



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APPENDIX

Calculation of Charging Current

Battery Voltage = 48/4 = 12V

No. of batteries = 4

Battery Capacity = 26 Ah

Total time = Ah/ amps

Amp = 10% of Ah

= 2.4 (10% of 24)

Charging losses = 40% of Ah

= 40% of 24

=9.6

Total Ah = specified Ah+ losses

= 24+9.6

= 33.6 Ah

Amps supplied =5.6

Time = 33.6/5.6

= 6hrs



Calculation of V belt pulley

Design of V – Belt Drive

For power transmission between two shafts, the drive pulley operates at 5000 RPM,

Drive Pulley Diameter = 90 mm, Driven Pulley Diameter = 40mm,

Power of Engine = 1.1 kW

Power to be transmitted = 0.5kW.

Type - A V-belt is selected.

Velocity = 1 1

60

d n = 14.1372 m/s = 1V = 2V

Power Capacity:

2

0.09 4

0.45 19.62 0.765

10

VN V

V de

e p bd d F = 90mm

N* = 1.7143 kW.

Number of V- Belts:

a c di N F F F

i = 1



Pitch Length:

2

22 2

D dL C D d

L = 500 mm

maxC = 2[ d1 + d2 ] = 360 mm

Cmin= 55[ d1 + d2 ] + T = 107mm

Select C = 250mm.

Selection of V – Belt:

Cross Section symbol A,

Nominal Top Width = W = 13mm,

Nominal Thickness = T = 8mm.

hybrid bike using range extended electric vehicle (reev) technology … · combustion engine drives...

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