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ELECTRIC BIKE CONVERSION KIT SELECTION
Electric Bicycle / Electric Bike / Information / Uncategorized

Electric Bike Conversion Kit Selection

If you want to convert your bicycle into an electric bike than you are on the right track.

It is easy to convert your bicycle into an electric bike, but if you consider some  technical things during selection of an electric bike  kit  than it will ease your journey to convert the bicycle into an electric bike & running it.

As the cost of an electric bike conversion kit in comparison to a new electric cycle is half approx & not too tough to assemble, if you have time & little bit of idea about installation you have to go with an e bike conversion kit.

If you are a techie than you have to select individual parts & assemble it but if you do not know much about parts you have to go with electric bike conversion kit  & in kit all parts, design & test for smooth run of bicycle.

Before going to find out the exact  e- bike conversion kit or individual part you have to know about parts..

In electric bike conversion kit there are a number of small parts available, but we consider only three major parts ( Motor, Battery, Controller) & costly parts of kit in detail.

Electric bicycle conversion kits are generally divided into three types.

  1. Front wheel connected conversion kit- very easy to install but less popular.
  2. Rear wheel connected conversion kit – In comparison to front wheel little but tough but most popular.
  3. Mid drive connected conversion kit – less popular & tough to install.

Motor

Motor is the part that rotates the tyre through energy use from the battery pack.

Crank Drive motors
Very less use in electric bike conversion kits. Costly & more modification required.

Hub Motors
As name indicate connect in hub & maximum use in electric bicycle

Brushed & Brush less DC motors
Usually Brush less DC motors are used in electric cycles.

Friction Drive Motors
Very less use in e bike  conversion kit

Usually motors come with ratings in watts & voltage, in some countries if you use motor watts more than 250w you have to go with registration procedures.

Motors rating available as 350W 36V, 1000W 48V, 250W 24V, 250W 36V etc.

As motor ratings increase, power drawn from batteries increases & for higher capacity batteries require for higher watt motors. Select the motor as per capacity of controller & battery. Motor highest drawn current is always less than controller capacity.

In some cases, hub motors come complete with a tyre, rim & spoke. You just only change for complete assembly. In some cases you may get hub motors & spoke in kit  & fix it on your own.

Battery

Battery is costlier parts of cycle & store power to run the cycle. Try to select lithium-ion battery pack  as these batteries have higher energy density & high charge & discharge cycle.

You may also find lithium-ion phosphate batteries also in the market for cycles. Please find the difference between lithium-ion-vs-lithium-iron-phosphate.

Note :- Must consider batteries to have BMS(Battery Management System) due to BMS preventing overcharging & save battery.

If you want to design a battery pack on your own you may refer to the following book (DIY Lithium Batteries: How to Build Your Own Battery Packs) otherwise purchase a battery pack.

Battery voltage & Ah play a major role  in performance of bicycle.Battery capacity is measured in Watt-hrs.

Battery capacity Watt-hours = Amp -hrs X Volts 

Always select battery in terms of Watt-hrs, not only either voltage or Amp-hrs of battery.

Eg:- Consider Bicycle A,B & C has the same motor.

Bicycle A has a 36 Volts & 20 AH battery = 720 watt hours

Bicycle B has a 72 Volts & 10 AH battery = 720 watt hours 

Bicycle C has a 48 Volts & 10 AH battery = 480 watt hours 

Bicycle A & B has the same battery capacity, but as voltage increases, the battery simultaneously acceleration increases. In the above case bicycle B has faster acceleration in comparison to A.Bicycle C goes for a small range in comparison to A & B.

Note:- Best way to keep your battery life long is charge it often,do not  wait for complete discharge of battery.

Controller

Controller drives the motor & takes power from the battery pack.

Major cable connection in controller- For motor, battery, brake, throttle, indicator light, brake light, lock, display, PAS sensor, charging  etc.

Maximum current requested for the controller is always less than maximum allowed discharge current of BMS (Battery Management System).

Theoretically running time of the cycle = Battery capacity/Motor wattage (But i.e. not actual because number of factors decrease it).

Apart from the above parts you may find the following parts also in the electric cycle conversion kit.

Throttle

Generally two types of throttle available in kit  one is wrist control & second is thumb control.

Light

You may find inside kit Front & rear light also.

Wire harness

To transmit signal & power to & from the controller, in common language it is known as cable bunch.

Pedal assist sensor

Some kits also come with pedal assist mode for increased range of cycle when rider pedals cycle. It sends a signal to the controller.
Also find other sensors e.g.- torque sensor (Detects pedalling sensor), Speed sensor (Detects bicycle’s speed), crank sensor (Detects no. of rotations through pedalling).

Display

You may find displays also inside the kit for finding out battery condition & range, etc.

Connectors

Different connector use for connecting  cable.

Protection 

Check battery, motor protection if IP65, IP67 best for protection. 

Conclusion 

As additional features in e bike conversion kit increase simultaneously the cost  of kit increases. Before purchasing an electric bike kit you have to know the knowledge about parts & as per my opinion  go with a complete kit including lithium-ion battery.

Best Books  For Electric Vehicles.

Top 10 : Best Electric Cycle in india

Top 16 : Best Electric Bicycle Kit for 2020