E-Wheelie(Electric Bike Conversion kit)

Tasks Performed:

• Brainstormed the concept design by analyzing tradeoffs between three available kit locations (front, rear and middle), type of motor(brush or brushless), and  gearing system(chain drive, planetary system, belt drive or direct drive)

• Worked on designing the battery-controller setup by comparing their voltage, current, capacity, and weight to find the most optimal battery-controller pair.

• Prepared circuitry for the connection of the battery to the controller and further to the motor for power supply.

•   Integrated the setup for the VESC controller used to its software to allow modulating the voltage difference, current and duty cycle based on the motor output speed requirement. 

• Performed mathematical analysis on the battery pack and motor to calculate the output wheel torque (balancing the force equations ), gear ratio, the power required to achieve the torque, and expected range per charge.

• Designed the sprockets for the gear train by optimizing the number of teeth, diameter, and location in the chain drive setup using Solidworks.

• Organized the bill of materials, prepared the budget for each subsystem, and set up the final purchase value for the customers.  

• Developed Validation & Verification plan for the component level, subsystem level, and system level testing.

Lessons Learned:

• Learned about the connection ports of the VESC controller and applied the knowledge from controller design courses to prepare the setup for motor-controller

• Learned to prepare budget , and analyze the cost values to meet the market value