Overview

This project demonstrates how to convert a standard bicycle into a high-performance electric bike (e-bike) capable of reaching speeds up to 50 km/h. It involves integrating an electric motor, battery system, throttle controller, and other essential electronics. The project blends mechanical engineering, electrical systems, and DIY fabrication skills to build a cost-effective and powerful personal transportation solution.

 Project Goals

• Convert a regular bicycle into an electric-powered vehicle

• Achieve a top speed of ~50 km/h

• Ensure good range (20–40 km depending on battery)

• Maintain balance between speed, torque, and safety

• Build a system that supports throttle control and regenerative braking (optional)

 Components Used

 How It Works

1. Throttle Input: The rider uses a twist or thumb throttle to signal the motor controller.

2. Controller Logic: Based on throttle position and battery status, the controller sends power to the motor.

3. Motor Drive: The BLDC hub motor rotates the wheel, propelling the bike.

4. Speed Regulation: Speed can be limited by the controller or manually via throttle input.

5. Battery Supply: A lithium-ion battery supplies DC power to the controller and motor. Proper BMS (Battery Management System) manages charging/discharging safely.

 Build Process (Simplified)

1. Mount the Hub Motor Wheel:

   • Replace rear or front wheel with the motor-integrated hub.

   • Ensure axle fit and torque arms are installed to prevent rotation.

2. Install Battery and Controller:

   • Mount battery pack inside the bike frame or on a rear rack.

   • Mount the controller in a waterproof box near the frame.

3. Wire Everything Up:

   • Connect motor phase wires and hall sensor wires to the controller.

   • Wire throttle, brakes (cutoff), display, and battery connections.

   • Secure and weatherproof all exposed terminals.

4. Test and Tune:

   • Power on and check motor rotation.

   • Use the display to monitor voltage, current, and error codes.

   • Test ride and adjust throttle response and speed limits.

 Performance Metrics

 Advantages

• Eco-friendly personal transportation

• Customizable performance (speed, range)

• No fuel cost, minimal maintenance

• Great learning project for e-mobility and power systems

 Safety Tips

• Always wear a helmet

• Use brake cutoff switches to avoid throttle-while-braking

• Mount battery securely and away from impact zones

• Include fuses or BMS for battery protection

• Ensure legal compliance with local e-bike laws (speed/power limits)

???? Optional Upgrades

• Regenerative Braking

• Cruise Control

• Bluetooth App Integration for stats monitoring

• Solar Charging

• Smart BMS with individual cell monitoring

• LED lights and horn integration