DIY E-BIKE OUT OF CAR
ALTERNATOR
DIY E-BIKE OUT OF CAR
AGENDA
ALTERNATOR
INTRODUCTION
OVERVIEW
MATERIALS NEEDED
MAKING PROCESS
TESTING
CONCLUSION
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DIY E-BIKE OUT OF CAR
INTRODUCTION
ALTERNATOR
Electric bike is a type of transportation that
has an electric motor instead of an internal
combustion engine. Electric Bikes don’t have
a tailpipe, hence no pollution. The motors on
electric bikes don’t have a lot of moving
parts due to which these vehicles are
extremely silent when operated. This
presentation guides you through the process
of building an E-Bike using an everyday
automotive component.
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OVERVIEW
Embark on the journey of constructing an E-Bike from a car
alternator with this presentation. Discover a straightforward
process that turns everyday components into an
environmentally conscious and virtually silent electric bicycle.
Experience the simplicity of assembly, eliminating the need for
advanced engineering skills. In this project, we prioritize
efficiency, cleanliness, and a peaceful ride, demonstrating that
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building your own electric bike can be both accessible and
rewarding.
MATERIALS REQUIRED
CAR B I C YC L E
B I C YC L E F R A M E A LT E R N AT O R . DC MOTOR WHEELS
MOTOR V O LTA G E
5 B AT T E RY CONTROLLER THROTTLE R E G U L AT O R
CHAIN B AT T E RY F RA M E M O U N T S
B I C YC L E C H A I N TENSIONER CHARGER A N D B RAC K E T S
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MAKING PROCESS
STEP ONE:
CONVERSION OF CAR ALTERNATOR
1. Sourcing and Modifying the Alternator:
• Choose a car alternator: 12V for moderate speeds, 24V for
higher speeds. Opt for high amperage (>100A) for better
torque.
• Remove rotor winding: Rewinding is complex. Look for
alternators with external field rotor winding (easier to connect
later).
2. Building the Motor Mount:
• Design a solid mount: Fabricate a steel mount to attach the
alternator to the rear wheel frame. Ensure proper alignment
and chain/belt drive clearance.
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• Attach a sprocket: Weld a sprocket to the alternator pulley or
shaft for chain/belt drive connection.
3. Power and Control System:
Battery pack: Choose a deep-cycle battery with the desired voltage and capacity
(consider range and weight). Lithium batteries are efficient, lead-acid are budget-
friendly.
Speed controller: A DC motor controller regulates power to the alternator,
controlling speed and braking. Size it based on battery voltage and alternator
current.
Throttle: Connect a twist grip or push-button throttle to the controller for speed
control.
4. Drivetrain and Finishing Touches:
Chain or belt drive: Connect the alternator sprocket to the rear wheel sprocket
9 with a heavy-duty chain or belt for power transmission.
Brakes and safety: Ensure existing brakes are sufficient for the increased weight
BATTERY SELECTION
Battery Types:
1. Lead-Acid:
• Pros: Affordable, widely available, high surge current
capability.
• Cons: Bulky and heavy, shorter lifespan, requires regular
maintenance
2. Lithium-Ion:
Pros: Lightweight, high energy density, long lifespan, low self-
discharge.
Cons: More expensive, requires specific charging systems,
safety concerns if damaged
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3. Lithium Iron Phosphate (LiFePO4):
Pros: Safer than Lithium-Ion, longer lifespan, good high-
Considerations:
Voltage: Match battery voltage to your motor and controller requirements
(common choices are 12V, 24V, 48V).
Capacity: Higher capacity equals longer range but more weight. Estimate your
desired range and choose accordingly.
Amperage (Ah): Determines how much current the battery can deliver. Ensure it
meets your motor's continuous and peak current needs.
Discharge Rate: Choose a battery with a discharge rate exceeding your motor's
draw to avoid damage.
Cycle Life: Refers to the number of charge/discharge cycles before battery
degradation. Higher cycles are better for long-term use.
Size and Weight: Consider space constraints and the impact of weight on your
11 bike's handling.
Temperature Range: Choose a battery suitable for your expected operating
MOTOR INSTALLATION
Choosing the right motor for your DIY electric bike with a car alternator setup involves
several considerations:
Motor Type:
• DC Brushless Motor (BLDC): Efficient, high torque, good speed control, but requires a
dedicated controller.
• DC Series Motor: Simpler but less efficient, lower torque, and harder to control speed.
Power and Voltage:
• Match the motor voltage to your battery and alternator (common choices are 12V, 24V,
48V).
• Choose a motor power (watts) that reflects your desired speed and hill-climbing ability.
RPM and Torque:
• Consider your riding style and terrain. Higher RPM motors offer faster speeds, while
higher torque motors excel at climbing hills..
13 • Ensure the motor's maximum RPM is compatible with your chosen gear ratio to avoid
overheating.
Installation:
Mount the motor securely: Fabricate a solid mount on the bike
frame, ensuring alignment with the alternator and chain/belt drive.
Connect the drive system: Use a chain or belt to connect the motor
sprocket to the rear wheel sprocket. Choose appropriate chain/belt
tensioners.
Electrical connections:
Connect the motor wires to the speed controller according to the
controller's manual.
Connect the controller to the battery and throttle.
Connect the alternator field wires to a separate power source (e.g.,
small 12V battery) with a switch for motor activation.
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MOTOR
CONTROLLER
INTEGRATION
Controller Placement:Mount the motor
controller securely on the bicycle frame,
preferably in an accessible and weather-
resistant location.
Wiring Connections:Connect the electric
motor, alternator, and battery to the motor
controller using appropriate wiring and
connectors.
Throttle Integration:Install the throttle
mechanism, ensuring a smooth and
responsive connection to the controller for
speed control.
Brake Integration:Integrate the electric
brake system with the controller,
enhancing safety by automatically cutting
power when brakes are applied.
15 Voltage Regulator:Include a voltage
regulator in the system to stabilize the
power supply, ensuring consistent
performance.
SYSTEM TESTING AND
OPTIMISATION
Initial System Test: Conduct an initial test to ensure that the controller responds
correctly to throttle inputs and that the motor engages smoothly.
Brake Safety Test: Verify that the electric brake system functions as intended, cutting
power to the motor when the brakes are applied.
Voltage Regulation Check: Monitor the voltage output from the regulator to confirm
stability under various operating conditions.
Battery Management: Implement measures to manage battery usage efficiently, such
as low-voltage protection and overcharge prevention.
Continuous Monitoring: Regularly monitor the controller and electronics for any signs
of overheating or abnormal behavior during operation.
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TESTING
Comprehensive Testing: Conduct thorough tests for all components, including the
motor, controller, throttle, brakes, and wiring.
Operational Checks: Ensure that the electric bike operates smoothly under different
conditions, such as varying speeds and terrains.
Safety Measures: Emphasize the importance of safety during testing, including the use
of protective gear and adherence to traffic rules.
Real-world Scenarios: Testing the electric bike in real-world scenarios to simulate
actual usage conditions and identify any potential challenges.
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CONCLUSION
In wrapping up this DIY E-Bike project,
we've transformed a car alternator into a
sustainable and silent electric bicycle.
Emphasizing efficiency, cleanliness, and
simplicity, this endeavor provides an
accessible way to embrace eco-friendly
transportation. Building your own electric
bike not only empowers you with a
practical solution but also contributes to
a cleaner, quieter, and more sustainable
mode of transportation.
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THANK YOU
