HYBRID MOTORCYCLE

1) KHATRI ROHAN RAJESHBHAI 090190119004

2) THAKOR JAYRAJSINH SANTOSHSINH 090190119014

3) CHAHWALA VIJAY HARISHBHAI 090190119037

4) PATIL SAGAR KAPTAN 090190119063 UNDER THE GUIDANCE OF

Prof. M.M.MADHIKAR MECH. DEPT., G.E.C., VALSAD

HYBRID MOTORCYCLE

Petrol Engine Along With An Electric Motor

Petrol Engine

BLDC Motor

Batteries

Controller

Chain Drive

Petrol Tank

What Is Hybrid ?

Hybrid Vehicle is a an automobile which combines more than one method of propulsion system.

It can be anything from a petrol with electric motor, petrol with an hydraulic motor, diesel with electric or even solar power.

In fact, we already see around us so many hybrid cars and motorcycles running on CNG with Petrol and even Motorcycles with LPG. They are nothing but form of a Parallel Hybrid system .

The concept is to club the two technologies of an Internal Combustion Engine with the Electric main drive.

This we thrive to achieve by using the electric hub motor installed in the wheel and a programmable controller which will have the maximum speed of the motor to 50km/hr., once the motorcycle goes above 50km/hr., the controller cuts of the current to the motor and the fuel is induced into the petrol engine and then the normal commuting is possible.

Once the vehicle is running on petrol, the battery will be regenerated for further usage and can be fully charged with a 220v ac supply and Dynamo in the wheel.

The motor used is a BLDC (Brush Less DC Motor) hub motor and we target to achieve 150 km of mileage within Rs. 100 worth the fuel (combining petrol and electric power). The portability of the batteries is a high value concerned and shall be met with proper result in this project.

This project outlines the design, construction and testing of a 1000W DC brushless motor controller for use in a light electric vehicle. Specific attention was paid to the layout of the motor controller to ensure high reliability, ease of manufacture and lightweight construction without compromising efficiency.

Aim of our Project

Market assessment for the current I.C engine efficiency, Electric vehicle Efficiency and positive – negative effects.

The survey was conducted over petrol motorcycles and electric scooters available in the market. The cost per km was calculated with an assumption of the future prices and the maintenance cost of these vehicles and later compared with the hybrid motorcycle project.

Project Development Process

Bikes comparison Model name Cost/km

LPG Converted Bike Passion converted Rs 0.85/ 1km Electric Scooter YO bike Rs 0.5/ 1km Petrol Bike Passion Rs 1/ 1km Hybrid electric Bike Passion hybrid Rs 1/ 7km (for electric drive)

Although there has been development in the diesel fuel with an advent of bio diesel and LPG conversion kits in the market but still there is almost no competition in the market with this kind of hybrid motorcycle.

The sale if motorcycle is still increasing and in future so will the fuel prices, for that the hybrid concept seems quite ideal as it not only decreases the per km cost of the consumer but also enhances the range of the drive.

Below listed is an article report from www.zigwheels.com of the motorcycle sales from mid-2012. From which we can determine the future necessity of hybrid.

Feasibility of the project as per current market condition

“Two-wheeler manufacturer Honda Motorcycle & Scooter India (HMSI) today reported a 38.65 per cent growth in total sales for August at 2,22,768 units. Motorcycle sales jumped by 69.44 per cent to 1,04,316 units in August this year as against 61,562 units in the same month last year, HMSI said in a statement.”

These requirements were necessary in order to find the complete set of calculations on which the project can be made, unless we know what our need we can’t develop a good project is.

Range: 60 km to 80 km on electric power

Speed: Maximum speed 40-50km/hr. (as per the city driving condition) Torque: Enough to carry a passenger and a rider with a tank full of petrol

(300kg approximately ( + or – 30 kg).

Parameters responsible for project components based on end user Requirement terms

In order to obtain the best power from the motor, we have to have a motor with a higher watt specification, that is we need to increase the stator winding keeping the voltage constant.

For that we did a complete survey of the motors available in the market but we found none matching our need so we decided to make one by increasing the winding for the existing motor.

Motor Power V/I Range(km) No. Of Poles Price in Rs

250 W 48/24 50-65 2 10 k 300 W 48/24 60-70 2 12 k 700 W 48/24 65 4 17 k 1100 W 48/24 50-60 6 20 k +

Motors available in market along with their power and range specification:

Motor Power Study

* K =1000

What is a Hub Motor ?

It is also called wheel motor, wheel hub drive, hub motor or in-wheel motor is an electric motor that is incorporated into the hub of a wheel and drives it directly.

Hub motor electromagnetic fields are supplied to the stationary windings of the motor. The outer part of the motor follows, or tries to follow, those fields, turning the attached wheel.

In a brushed motor, energy is transferred by brushes contacting the rotating shaft of the motor which results in loss of power in the form of heat.

Energy is transferred in a brushless motor electronically, eliminating physical contact between stationary and moving parts. Although brushless motor technology is more expensive, most are more efficient and longer-lasting than brushed motor systems.

Electric Motor Defined

Brush less Direct Current (BLDC) motors in which permanent magnets on the rotor create a magnetic field which interact with synchronous stator current.

Basic Terminology Brushless motors consist of a stationary part, the stator, and a rotating part, the rotor. The space between the stator and the rotor is called the air gap. The stator carries the windings and the rotor carries the magnets. Brushless motors can have inside rotors or outside rotors. These two cases are shown in Figure. In either case, the stator and windings are stationary, allowing direct winding access without brushes or slip rings.

Motor Rotor Position

The rotation of a motor can be calculated by using EMF sensing to estimate rotor position. Field-oriented control goes a step further by using a finer rotor position estimate to calculate motor currents into the rotating frame. The rotating frame is defined by two axes, “d” for magnetic axis and “q” for rotor axis.

General equation for calculating winding angle for throttle. e =mod ( P. m.360) m- 0. ᶿ ᶿ ᶿ ᶿ

Where e= electrical angle. ᶿm= mechanical angle and 0= offset angle between electric and mechanical angle. ᶿ ᶿ

Rotor angle calculation

The rotor can be on the inside or the outside. In either case, the stator, which contains windings, does not rotate and the rotor, which contains magnets, does.

In most brushless motors, windings are placed in slots in a laminated steel structure called the CORE. The purpose of the steel is to channel more magnetic flux through the winding than would

Be possible with a non-ferrous core. The section of steel between two slots is called a tooth. Three-phase motors have a number of slots (and teeth) that is evenly divisible by three.

CORE

TOOTHDifference

Conclusion and Testing of Motor Output

The torque per unit amp of the front scooter motor at 20A, plotted within the optimal 60º rotor electrical angle for BLDC control. It remains fairly constant over this interval.

The torque per unit amp of the axial motor at 80A, plotted within the optimal 60º rotor electrical angle for BLDC control. It remains fairly constant over this interval.

The future work is to achieve the solution between the present condition and ideal condition and that’s the reason we will vary the current supply and try

to be as close as to the ideal condition.

The original motor design pursued in this case study used trapezoidal stator core wedges, wound with flat copper strips.

The stator core segment was produced by stacking H-shaped laminations of silicon steel, which were laser cut to specification. Though expensive in prototype quantities, the shapes would require only simple stamp tooling to make in large volume

Single Stator CORE developed to test the winding method

Disassembly of Motor Components

Permanent Magnets

Windings on Stator

Stator Plates

Stator Housing Cover

Rotor Plate

Assembly Of Motor

CORE, Stator and Copper wire Windings

First run test using rubber Tube on Motor

Initial CAD Modeling for small capacity

Exploded View of Assembly carried on CREO Elements 5.0

Sectional view of completed Motor design

Sectional view of motor with reduction Gear

Reduction Gear

Side View showing the motor by creating transparency on the motor housing

Assembly of motor with the wheel and braking system

Battery System

A lead acid battery goes through three life phases, called formatting, peak and decline

Formatting is most important for deep-cycle batteries and requires 20 to 50 full cycles to reach peak capacity

Peak is the state at which we can obtain the maximum power of battery.

In Decline state, the efficiency of battery goes down and then replacement is the only option available.

Controller is a brain of the complete hybrid system. Its function is to receive data from various sensors and provide Electrical power as per the throttle position and angle. It decides the fuel mode that is, to run the motorcycle on petrol or to run itOn electrical power. It checks the battery voltage and current value and notifies the user about the charging time.

Controller

Controller

Advantages and Disadvantages

Advantages Disadvantages

Lower cost/km Higher kerb weight

Higher Mileage Centre of Gravity is shifted

Practicality Speed limitation

Ease of Recharging

Very less Maintenance cost

Future Work Highlights.

1. Controller programming with optimizing parameters on Throttle Angle Motor Rotational Angle Wheel RPM Battery Discharge Brake cut-off Speed Limiter 2. Motor Optimizing 3. Load Conditions testing as per the Kerb weight (weight without rider) 4. Load conditions on maximum jerks and slippery conditions in rain 5. Maximum Torque variation as per the load 6. Dynamo Recharging Capability 7. Heat Dissipation From the motor 8. Throttle limiting position 9. I.C. Engine cut-off Threshold value 10. Optimum Evaluation and feasibility on the parameters set

Thank you