E-Bike Design
Sustainable and Accessible E-Bike Design
Sustainable and Accessible E-Bike design
The E-Bike Design was developed during my MECH 3409: Mechanical Engineering Design course at York University. This project aimed to create a sustainable and user-friendly transportation alternative by addressing the challenges of environmental impact, accessibility, and durability.The e-bike features a triangular frame structure made from AISI 4130 steel, chosen for its superior strength, fatigue resistance, and ability to endure daily wear and tear. The design maintains a familiar bicycle aesthetic to ensure ease of use for many users. The gearbox, designed using SolidWorks and analyzed with AGMA standards, efficiently converts motor speed (700 RPM) into a maximum output of 30 km/h while withstanding significant torque and stress.
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My role involved designing the bike frame using CAD software, conducting frame stress analysis under various loading conditions, and contributing to finite element analysis (FEA). I analysed forces, moments, and safety factors to ensure the frame met endurance requirements for a daily commute of 5 km over 10 years. Additionally, I collaborated on iterative design improvements, incorporating feedback to enhance usability and efficiency.
Through this project, I gained proficiency in structural design, load analysis, and sustainable material selection. I also developed insights into integrating technical and user-focused considerations in engineering projects. Working closely with my team to troubleshoot challenges and refine the design emphasized the importance of collaboration and adaptability.
This experience reinforced my passion for applying engineering principles to real-world challenges, preparing me to contribute effectively to innovative projects as part of a professional engineering team.
E-Bike-Components
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Design Features:
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Frame: Triangular structure made of AISI 4130 steel for superior strength, fatigue resistance, and a classic bicycle aesthetic.
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Gearbox: Converts motor speed (700 RPM) to a maximum speed of 30 km/h using optimized gear ratios, designed and analyzed with SolidWorks and AGMA standards.
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Analysis:Conducted finite element analysis (FEA) to verify frame integrity under various loading conditions.Performed stress and fatigue life calculations to ensure long-term durability.
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Outcome:Designed an e-bike capable of daily use for 10 years, meeting safety standards and environmental sustainability goals.
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Enhanced my skills in finite element analysis (FEA), CAD modelling, load analysis, and sustainable designing.
Reflection [E-Bike]
The E-Bike Design project was a core experience in my journey as a mechanical engineering student, providing hands-on exposure to real-world engineering challenges and applications.
A primary challenge during the project was ensuring the frame could withstand various loading conditions, including static, vertical, horizontal, and braking loads. Designing a frame that met safety standards while remaining lightweight and durable required a detailed understanding of material properties and structural mechanics. Additionally, integrating the gearbox seamlessly with the frame while maintaining efficiency and usability presented another layer of complexity. Balancing these technical and design requirements was a tough but rewarding process.
This project taught me to use CAD modelling extensively for designing and visualizing the bike frame and gearbox. CAD tools were invaluable in creating detailed 3D models that allowed for iterative testing and refinement of the design. I also gained practical experience with finite element analysis (FEA), which proved crucial for evaluating the frame’s structural integrity and optimizing its performance under real-world conditions. These tools highlighted the importance of simulation in identifying potential issues early in the design process, saving time and resources.
Looking back, one thing I would do differently is allocate more time to the iterative testing phase. Early prototyping and additional FEA simulations could have provided more insights into the frame's performance under dynamic conditions, further improving the final design. also, I would explore alternative materials to balance weight and durability more effectively.
This project enhanced my technical skills in CAD modelling and FEA and strengthened my problem-solving abilities and teamwork. It deepened my appreciation for the role of design optimization and sustainability in engineering. Most importantly, it fueled my enthusiasm for continuous learning and innovation, motivating me to apply these skills to future projects and contribute meaningfully to a professional engineering team.