If you use a bike for commuting and from work, how to make the ride comfortable and not start work in the office with half an hour of shortness of breath, wiping beads of sweat from your face, explaining to colleagues that you came by bike over a steep climb.
There is a way out, you need to turn your bike into an e-bike - this will solve the problem when you need to quickly and comfortably get to your destination and at the same time you retain the ability to turn the pedals to maintain your sports form
And since how to turn a regular bicycle into an e-bike, what does it take?
This question was asked by my friend Alexander, after sitting in the internet, it turned out that the simplest solution to turn an ordinary bicycle into an electric bicycle is to add an electric motor that works only from a battery.
The revision kit included: an electric motor, a storage battery, a charger, a control unit (controller) and a speed regulator ("throttle stick").
In the photo, an electric drive with a chain is attached to the bike frame quite simply, the engine power is 1.2 kW
Photo 2.
During operation, the engine heats up to remove heat, cooling radiators are used, and electronic engine protection is provided, which turns it off when it heats up over 70 degrees.
The battery life is 5-7 years depending on the operating conditions.
The battery loses about 2% of its capacity in a year.
Weight 4.5 kg, charging 1.5-2 hours.
You can travel about 30-40 km on a single charge, but the distance depends on many factors:
Landscape (place for pokatuski, number and angle of inclination of slides).
The speed of the electric bike (the quieter you go - the further you will be).
The presence, speed and direction of the wind (the wind can interfere and help).
Semi-flat tires. The losses are very high. Monitor tire pressure.
Weight of the cyclist and luggage (transported cargo).
Photo 5. Battery and controller
Photo 6. Battery capacity indicator
Photo 7. Throttle grips for adjusting the speed of rotation of the electric motor.
Happy owner of an electric bike
Kitty felt sad when he heard the price of a set of 40,000 rubles. so much cost all the pleasure together with delivery.
Shl
I also rode a miracle bike and I liked it, I even thought about what is better to buy a moped or an electric bike?
Sooner or later, every biker becomes “corrupt” for a short time, and, having wound several tens of kilometers a day, begins to faintly dream of the means of “small mechanization” of an ordinary bicycle. However, after rest, these immodest desires usually pass, and the bicycle again becomes an object of desire. Nevertheless, the idea of making an electric bike with your own hands is very popular and gets more widespread every year. We will tell you more about how to do this.
From the realm of dreams:
In the photo, an extreme six-kilowatt bike, developing from a standstill speed of 60 km / h in three seconds. The peak current is 100 amperes on lithium-iron-phosphate batteries ... At the request of manufacturers, it maintains a speed of about 60 km / h for 40 km. Magicians live here: http://www.voltbikes.ru/blog/projects/E-bike-3000W-6000W-lifepo4/
Our tasks are much more modest. Immediately, we will limit ourselves to the fact that we do not mean the production of an electric bike "from scratch", but will tell you how to choose and install a special kit for alteration on your favorite bike. After this alteration, the electric bike will be able to help you out in a difficult situation.
What do you need it for?
First of all, you must think about what the bike will be used for, which has received equipment in the form of an electric motor. It will become heavier, you will not be able to do cross-country and downhill on it, because the center of gravity of the system rises, the weight increases, and besides, you should not fall on such a bike. This could damage the motor and require replacement.
Typically required for the following:
- power reserve "just in case", in case of fatigue, for a reserve. This is a very good solution for older cyclists, as well as for people suffering from cardiovascular diseases, obesity. This allows you to go on quiet walks without the danger of being exhausted on the way back, if you cannot calculate them correctly;
- constant use for climbing a hill, in the form of a connection on difficult sections of the route. For this, the electric bike must be able to move on two sources of energy at once: muscle strength and the engine.
It is better not to use an electric bike on rough terrain. His destiny is country paths, asphalt pavement. Also, an e-bike does not like jumping.
Determining the power
Before ordering a set in an online store, you need to decide how far you want to travel on one battery charge, at what average speed, which slides you can climb, how much it will cost to rebuild the bike.
Key factors will be:
- the power of the engine, which is located around the wheel hub (the speed and traction qualities of an electric bike depend on it);
- battery capacity. The autonomous riding time and the weight of additional equipment, which usually does not exceed 10 kilograms, depend on it.
Of course, additional data can be included in the assessment list, for example, the number of battery recharges (resource), the time spent on a full charge, and many other indicators.
Much depends on the rider's weight. A teenager weighing 50 kg and an overweight man weighing 125 kg apparently need different sets.
Thinking about the future
It is also important to consider whether the model of your choice can be fitted to your bike. It will be a shame if you don't succeed in remaking your bike and you need to buy a new one.
Will you be able to do this work on your own, or do you need to look for a qualified bicycle mechanic with knowledge of electrical engineering, which is a very large shortage?
Determine exactly where the battery will be placed, estimate its dimensions so that the homemade e-bike is comfortable.
What is included
In order to turn the bike into, you need the following main components (they are included in each kit):
- wheel motor. This is the heart of the electric bike, the electric motor. You just change one wheel for another;
- accumulator battery;
- battery fasteners, wires;
- control panel, or console.
In order for the disappointment not to be endless, you need to know that a sufficiently fast and long ride is possible only with a power of about 1000 W, that is, 1 kW. If you decide on the price, then an average of 20 thousand rubles will have to be paid for a wheel motor with a kilowatt engine.
An electric bike can be made with a larger or smaller battery. So, a battery with a capacity of 18 Ah will cost 30 thousand rubles.
The ideal but expensive option is a 2000 watt motor.
A cargo tricycle powered by car batteries can be considered quite an interesting and "budgetary" option. As you know, one such battery has a capacity of 55 Ah and can give very good results. Making such an electric bike with your own hands is not difficult, it is much more difficult to find a reliable cargo bike with a trolley for placing batteries. In addition, a bike with support for more than two wheels can be more comfortable for fishing, for cycling tourism within the "reach" of the outlet.
However, chargers have already been created that can power it from solar panels, charging it during the descent, and also charge it at halts using miniature steam turbine generators powered by fire energy.
Electric bicycles are in trend today. Even well-known car companies no, no, and will present a model of a futuristic bicycle of the future, the work of which is based on clean cheap energy. Well, DIY lovers also do not ignore this topic. Moreover, getting spare parts for such devices is easier than ever.
Want to see what one of the cheapest e-bikes looks like? In this article, we will not only show it, but also tell you how it works and even how much you can buy spare parts for this miracle of technology.
This model of an electric bike is so simple that anyone, even a novice master, can assemble it. This is a great opportunity to test your strength in creativity and craft skills. Well, the reward will be a completely functional and practical electric bike based on the usual sports bike.
List of materials
- Sports bike or regular bike;
- A wheel for trolleys or mobile equipment, you can completely make it yourself;
- Lead accumulator 12 V / 12 A - 2 pcs .;
- Toggle button;
- Hardware, wiring and some metal parts.
Let's start assembling the e-bike
A feature of these bicycles is the absence of a rear foot brake. They provide for manual braking of the rear wheel by means of rubber pads, and two multidirectional levers in the shape of an arc. Their compression occurs by pulling a steel cable brought to the handle on the handlebar. The principle of the driving module is based on the transmission of torque from the engine to the bicycle wheel through the auxiliary rubber-coated wheel.Engine preparation
The engine has a regular cylindrical shape, to the body of which two metal mounting angles are welded. It is necessary to fix a wheel on the engine shaft, which will transmit the torque when it comes into contact with the tire is great.In size, it should not exceed the diameter of the engine body, so as not to overload it during operation. It can be a rubberized wheel for trolleys, equipment, or even.
Installing the engine on the bike
Using plates with holes and a small piece of board, we fasten the engine to the bike frame with bolts. We center it so that the auxiliary wheel has uniform contact with the tire.
To protect against dirt and dust, bicycles are equipped with a fender, which in our case is metal. We leave it in its place, making a hole with a grinder for the wheel of the device.
Electrician
For the supplying batteries, the author chose inexpensive 12 V lead-acid batteries connected in series, suggesting, as an option, placing them in an old laptop bag. It can be attached behind the saddle, to the side of our device.
We remove the wires from the batteries, connect them in series with the engine and lead them to the toggle switch on the steering wheel. There are no speed controllers, I pressed the button - the full voltage of 24 V was supplied to the motor from the batteries. The simplest toggle switch can be fixed anywhere in a convenient place on the steering wheel.
To protect the driving mechanism of our e-bike, you can attach metal plates on both sides of the frame.
Making an e-bike with your own hands is a rather complicated process, which requires possession of good skills. In the absence of understanding the essence of the process, it is easier to buy a unit. Understanding the workflow behind the lathe, having the right tools in your arsenal, you can perform the assembly.
A set of necessary equipment
To reveal the essence of the question: how to make the desired electric bike out of an ordinary bicycle, we first prepare for work. You will need to use:
- welding machine;
- the main set of tools (meaning a hacksaw or pliers);
- lathe;
- a larger caliper;
- a drilling machine and a set of drills;
- grinding machine;
- chain puller;
- a wrench for dismantling the ratchet;
- metal-cutting objects (hydraulic shears are suitable, the use of acetylene-oxygen cutting is allowed, use a plasma cutting machine);
- the main arsenal for repair work with a bike.
You will also need aiding:
- block of V-structure;
- cutters;
- taps and dies;
- surface grinding machine.
It is supposed to work with the following materials:
- metal corner;
- ANSI # 40 sprocket with 9 teeth;
- two bearings;
- a round steel bar with a circumference of 0.5-1 inches;
- 4-inch and 1-inch V-belt pulleys;
- V-belt.
How to Convert a Normal Bike to Your Desired E-Bike
How to assemble an e-bike is a concern for many cyclists. For the purpose of economical assembly, you should look for friends who could provide a motor with a battery and a bicycle for free. It is advisable to find a bike with the maximum number of gears. This is for greater acceleration and greater electrical tolerances.
In search of an old chair with an electric motor, the Internet will help, where they often offer used motors with batteries. It is preferable to contact the wheelchair repair and sales department, as here you will be lucky for sure. It is unlikely that the technical staff will refuse help for a small amount.
We make the outer bearing ring
In the absence of the outer ring on the bike, we make it ourselves. It is not necessary to make a thread, you can do without it. The ring is secured with screws inside the carriage of a homemade e-bike.
We make an intermediate shaft
A large roller, bearings and sprockets with the size of the center hole will fit a steel blank, the size of which should be 5/8 of the circumference of the star. We approach the lathe, grind one edge of the workpiece to one inch and a diameter that is halved from the circumference of the star. The rest of the workpiece is grinded as well. The center part is 5/8 of the sprocket circle so that the intermediate shaft does not slip.
We drill holes for the bolts, having previously secured the shaft with a V-shaped block. The bolt holes must be level. The bolts are sized according to the dimensions of the shaft and other parts.
Modifying the stars
Modify an asterisk that is too wide in width. The star is machined on a lathe with a scoring tool until the part width is 0.1 inch. After that, we proceed to the installation of the cutting carriage, presumably by 10 degrees, we change the angle of the teeth until the same indicators are obtained from both edges.
Working with the main drive pulley
If there is a hole in the engine, drill an inch hole inside the workpiece, identical to the size of the shaft. Compliance with the sizes must be observed. After that, using the machine, we grind one side down to 0.5 inches, according to the dimensions of the previously processed roller.
About assembling the intermediate shaft
Having bought cylindrical pins with screws in advance, we assemble the shaft. Provided that the parts are accurately turned, the assembly will not cause any problems.
Putting the chain drive together
With the help of a puller, we proceed to dismantle the chain. We put the chain back, threading the mechanism through the speed switch at the back. We hook the chain onto the cassette middle sprocket. We check the correct position of the rear derailleur. To obtain the required chain length, place its ends side by side. Disconnect the mechanism at the fold.
Important! When disconnecting a chain, you need to make sure that the pin is attached to its end. Otherwise, there will be problems in the connection of the mechanism.
Checking work without load
We turn the homemade electric bike with the wheels upward for free rotation of the rear wheel. On a moderate gear, we start checking. To maintain tension on the bike chain, hold the motor firmly at the bottom opposite the V-belt. We connect the motor wires to the battery with our free hand.
The following factors affect chain failure:
- the width of the star is little worn off;
- in case of belt slippage, too high gear or its weak tension affects;
- poorly aligned stars.
About the layout of the motor mount
In order to save money, the layout is made of cardboard, not metal. It is much easier to transform a cardboard blank into any shape than a metal one. If possible, the motor can be inserted behind the seatpost. Then the rotating elements will be at a greater distance from the legs.
About the pre-motor mount
We cut out a metal mount on the cardboard layout, attaching the original to the iron and circling it with crayons. To cut a metal model, you will need large hydraulic shears, which allow you to exactly repeat all the contours. The rest of the tools require certain skills.
Installing the engine
We take a non-equilateral corner and start by making holes for the U-bolts and then installing them. It is necessary to prevent the bolts from slipping. With a cardboard layout, the markup will be easy. We apply it to the plate, marking one end of the slot with a center punch, then the other. Each side should receive two holes, four in total.
The holes should be normal for tightening the nuts and for the penetration of the bolts. So, for 3/8 "bolts, a 0.4" hole is assumed.
It is best to use an end mill for making the slots. In the case of plasma cutting, neat holes are cut in the iron corner for the bolts.
Installing an unequal corner
Some engines do not require this installation. If possible, we install a non-equilateral corner, due to which the engine is fixed more firmly. Alternatively, use U-bolts.
We mount the adapter bracket to the engine. Sliding the bracket maintains adequate belt tension. We make a plate and screw it to the front section of the engine. The plate suggests some offset. The small rectangle parallel to the motor is bolted directly to the main mounting plate.
Let's start welding the motor mount
We preliminarily perform a thorough sandblasting and a small cleaning with a metal brush. The bayonets must be clean. Consistency is important in welding. Having welded one edge, you need to wait until the metal cools down, and then proceed to the second part.
We direct the main heat mainly to the plate, choose a lower welding temperature, but available for welding the sheets. You can drip molten metal to better bond the two metal sheets.
Assembling the belt drive
Everything is extremely simple here. We put the belt on the pulleys, tighten it well, and tighten it with bolts. Since the use of the bike leads to a gradual stretch of the belt, we periodically check the degree of tension and adjust if necessary.
We re-check without load
In the lowest gear, we start the engine to the maximum. With sufficient fastening, we gradually increase the transmission. In the case of installing a bike computer at the back, we observe its performance. The front bike computer shows nothing. The belt should also not slip.
About the battery mount
After checking the batteries and the charger for suitability in advance, we install the battery. We make a cardboard blank of batteries, since it is easier to move. Choosing the best site for installing batteries. The recommended location is closer to the ground, away from the saddle. This placement is due to the ability to increase the grip of the rear wheel tire and lower the bike's center of gravity.
We take iron corners, make a pallet out of them for subsequent fastening of batteries with ties or elastic cords. We weld the pallet to the bike frame. The weld seam must be of high quality, since significant loads will be made on it.
The figure shows a visual diagram of an electric bike. Since the bike is already equipped with gear shifting, it is sufficient to implement a conventional shifter to control the motor. It is allowed to install a single-pole, three-position, ten-ampere switch from an unnecessary radio station. Working positions are indicated by two switches and one switch. The presented diagram shows the operation of one battery under 12-volt voltage when the first switch is set. The second switch assumes the operation of two batteries with 24-volt voltage, allowing you to use the motor at full power, and, if necessary, reduce the speed.
This is an illustrative example of a three-battery circuit. Every electrical circuit has its own pros and cons.
Testing the bike, looking for and fixing problems
Once you've finished assembling your e-bike, it's time to put it to the test. You can invite friends to show off your own invention and tell them how to build an e-bike. Be sure to protect your head with a helmet to avoid unforeseen circumstances leading to injury. It is possible that the first invention will not meet expectations, so you need to be mentally prepared for such a turn. Among the common causes of possible malfunctions are poor wire contact, incorrect calculation of the gear ratio.
When testing a unique invention, you should take with you the tools that you will need in the following cases:
- the wires are disconnected;
- subject to an exceeded gear ratio;
- battery failure.
These problems will prevent the bike from riding.
E-bike diagnostics
To diagnose suspected problems, turn on the homemade e-bike with the rear wheel up. Tire rotation is unacceptable due to excessive gear ratio. It is advisable to resort to increasing the intermediate shaft pulley or decreasing the motor pulley. This is necessary to reduce the gear ratio and increase the torque. As a result, the bike will run.
If the tire does not rotate, the wires are disconnected or the batteries are unusable. Then we provide the batteries with a full charge, and we check the voltage on them using a multimeter. The optimum full charge voltage is typically 27 volts.
We check the integrity of the electrical circuit with the same multimeter. We disconnect the wires laid to the engine, connect them to the device, and then turn on the switch. Provided that only zeros are displayed on the screen of charged batteries, the problem of the wires themselves or the switch is diagnosed.
A slow bike ride is usually caused by an incorrect gear ratio. To diagnose this problem, look at the degree of rotation of the rear wheel in the raised state. With accelerated rotation, an increase in the gear ratio is diagnosed. In this case, we reduce it by increasing the size of the felling pulley or decreasing the size of the motor pulley.
If the rotation of the tire is characterized by the same speed, both with and without load, we do the opposite. We increase the gear ratio or decrease the size of the felling pulley. You can increase the size of the motor pulley.
Coming to the theory of assembling an electric moped with knowledge of the matter, you can try to make it yourself.
Ecology of consumption. Motor: The total interest in electric transport has only been gaining momentum lately - people of all ages and occupations are increasingly puzzled by the question of "inventing" their own electric bicycle.
The total interest in electric transport has only been gaining momentum lately - people of all ages and occupations are increasingly puzzled by the question of "inventing" their own electric bicycle. Sometimes the ideas born in hot heads turn out to be incompatible with the harsh realities of life, quite often the "Kulibin" mentality bears fruit, and the result is quite worthy of the pride of its creator.
Many manufacturers have not stayed away from global trends and today in the market of components for e-bicycles it is quite common to offer so-called "whale" kits for self-creation of an e-bike based on an existing bike. In order for the bike to go without your help, you will need at least an electric motor, a battery and a controller, which is responsible for the correct operation of the first two units - all this, and much more, is included in the kit for electrifying the bike. But in order for the newly-made device to be worthy of the high rank of the bicycle hybrid, we suggest using the following tips.
Electric bike design: components and assemblies
As a theater begins with a hanger, and a dance begins with a stove, so creating an electric bike with your own hands begins with the selection of a donor. The correct solution to this issue will depend, first of all, on the goals and objectives that the future owner of the bicycle hybrid sets for the projected vehicle.
It is best to consider the risks of unavoidable high loads in advance and use a downhill-grade steel frame with two-suspension damping as the basis of the structure. This option will be preferable to others if you are going to install a powerful motor-wheel - from a kilowatt or more. A direct drive electric motor with a rated power of 1000 watts will allow a speed of 40-55 km / h. Given the high torque and own weight of the engine, such a drive is placed in the rear wheel, while it will not be superfluous to strengthen the axle mounting brackets, especially if the frame is aluminum.
When choosing a ready-made battery or creating your own battery, you need to consider parameters such as weight, dimensions, capacity and operating current. The rated operating voltage can be different (36V, 48V, or 72V) - higher voltage and higher currents will allow you to accelerate to high speeds. If you need reliability and a long service life, choose a high-capacity LiFePo4 battery. If you want to save on weight and cost - take Li-Ion. A capacity of 10 Ampere / hour is enough for about 20-40 km of track - the mileage depends on the economy of charge consumption, and for many this parameter is in no way compatible with the presence of a throttle handle.
When the light weight of the bike hybrid is more important to you and you are not chasing high speeds - the best choice is a motor-wheel with a rated power of 250-350W. These motors are lightweight, and, as a rule, have a built-in planetary gearbox, which contributes to the normal roll-off of the bike hybrid when driving on the pedals. The "cruising" speed of low-power bicycle hybrids is in the range of 25-30 km / h. Electric motors
low power is installed in both the front and rear wheels, this does not matter much, except that it is useful for a more even distribution of masses. For the same purpose, it is preferable to place the battery in the central part of the frame - the bike hybrid will have better controllability and stability. Another option for placing an electric motor - a central one (in the area of the carriage) - has not yet received widespread use in our latitudes, but many leading manufacturers of sets for electric bicycles have such proposals in their assortment.
Standard controllers in inexpensive kit kits are hardwired by manufacturers, and do not provide for the possibility of changing the operating parameters. If you don't need it, you can just enjoy the ride. If you want to tinker with the tuning and selection of the optimal parameters for your configuration, take a set with a programmable controller such as Infineon. Close attention should be paid to the switching and installation of electrical equipment - high-quality wiring designed for operation at certain currents, reliable connectors, sufficient cooling of the controller, which heats up during prolonged operation and serious loads.
Security questions
Bicycle hybrids are a relatively new type of vehicle with a fairly wide range of capabilities. In many countries of the world, legislation equates them to bicycles if the engine power does not exceed 350-500 watts. A more powerful electric bike is a different story with its own operating characteristics. Therefore, safety issues sometimes need to be paid even more attention than when driving a scooter or motorcycle. Do not forget about both protective equipment and additional equipment. Even those who are not going to bake out on downhill tracks, but simply plan to enjoy the surrounding beauty on a leisurely trip - in any case, it is worth using a bicycle helmet, gloves and other protective elements that can protect the cyclist from injury in the event of an emergency.
A headlight, a tail lamp, additional reflectors, rear-view mirrors, a loud sound signal - all this will come in handy on the road for you, and will also help other road users to notice you in time. Particular attention must be paid to brakes - they must be of high quality and capable of stopping your bike hybrid at any time, since the usual behavior of the brakes changes at high speed. And it is not at all necessary for this to be an unpleasant surprise for you. Especially considering the increased weight of the bike - the electric drive components will "pull" an additional 12-14 kilograms. And if interest in bike hybrids does not disappear after buying a starter kit with a 250-watt motor, we can assume that you will soon have a more solid and heavy two-wheeled friend.
In general, as many people as there are bicycles. Someone prioritizes cost, someone - reliability, others are interested in weight or external data. Today, ready-made solutions can satisfy the bulk of requests - among the variety of offered models, you can choose exactly the bike hybrid that will fully meet your requirements. published by
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