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
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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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 2
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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 3
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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 4
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.
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 5
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.
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 6
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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 7
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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 8
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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 9
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.
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 10
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
HYBRID BIKE USING REEV TECHNOLOGY
Department of Mechanical Engineering, GMIT, Davangere Page 11
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.