Introduction: Simple Hand Made Electric Bike: DIY

About: Its all about life hacks, tools, scientific & creativity instructables ~ electron7m


In this instructable, i will teach you how to make an electric bicycle at home.

Also, this electric bike was selected and presented in the North India Solar Summit (NISS) 2016 and it remained in the news papers and web articles for many day.I would also like to share its news articles with you.

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Step 1: Stuff Needed:

1) A DC Motor = 24V ; 5A ; 120W ; Geared; Gear Ratio = 24:1 ; PMDC ; Torque 43kg-cm.

2) Battery = 4 ( 12V ;7Ah) UPS Lead Acid Batteries.

3) Battery Case

4) Multi-meter

5) 15A Power Switch

6) 15A Single Push Double Throw Switch

7) Some Wires

Video Explaination -- > Youtube

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You will also find Some NISS (North India Solar Summit) display pics in this step.

Step 2: Batteries and Motor:

As you can see in the picture, the batteries are the lead acid UPS batteries which are divided into two sets.Each set contains two batteries which are connected together in series to make up a voltage of 24 volt.

Now the function of the double throw switch that is placed on the handle of the bicycle is to connect these sets in series and parallel resulting into two output voltages with minimum voltage of 24 volt and a maximum of 48 volts.

The 24 volts battery connection system is responsible for giving it a maximum speed of 20 km per hour and the connection of 48 volts will result in attaining a maximum speed of 40 km per hour with a maximum distance coverage of 46 km under full charge.The Switching System results in achieving 2 Electronic gears without any heat loss which would certainly be there had I used a potentio-meter instead.

Video Explaination -- >

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Step 3: Connecting the Motor:

The Motor is directly connected to the wheel with the help of the chain system.The gear ratio of the sprocket attached to the motor and to the wheel is (1.5 : 1).You can see in the picture that the rear wheel is smaller than front wheel.This system serves 2 purposes.

Firstly, it increases the starting torque of the bicycle and secondly it creates some space for installing the motor which would otherwise had to be adjusted somewhere else.

It is really important that you use a geared motor because a non-geared motor will get its armature coil burnt resulting in the motor getting damaged.I have seen in many YouTube videos that for simplifying the work people's neglect the GEAR system and connect the chain sprocket directly to the wheel which seriously damages both the batteries and the motor and also reduces the efficiency of the bicycle and also they have to use a bigger motor to carry there full weight and still stand with awful and risky performance.

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Step 4: Other Connections:

You can also use a multi-meter as I have used to indicate the battery health in the form of voltage.

The connection is such that the wires from the battery are first connected to the double throw switch.Then connecting the multi-meter, they go to the main switch and after which they follow to the DC motor.This type of connection helps in getting the information on the battery health even before starting the bike.

Always remember that you have to start your bike at the speed of 20 km per hour because the starting current is really high which can only be provided by the parallel connection of the batteries which is 24 volt and 14 amperes.

So guys, that was all about this electric bike project.

Thank you for your time.

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