Design and Manufacture of Advanced Electric Bicycles with Speed Control Function and Battery Monitoring Mechanisms

Abstract

The Advanced Electric Cycle project focuses on designinganddevelopinganefficient,eco-friendly,andcost-effective electric bicycle to reduce fuel dependency and environmental pollution. The system integrates a Brushless DC (BLDC) hub motor, motor controller, lithium-ion battery, throttle control, pedal assist sensor (PAS), and digitaldisplay unit to provide smooth and intelligent riding assistance.Thecycleisdesignedtosupportaloadofup to 100 kg with improved stability and performance. The BLDC hub motor ensures high efficiency, low noise operation, and reduced maintenance. A 36V battery system is used to provide sufficient power and extended travel range. The motor controller acts as the brainofthesystem,managingpowerflow, speed control,andsafety features such as overload protection. The inclusion of pedal assist technology enhances energy efficiency by supplying power only when required. The developed system demonstrates reliable performance, reduced carbonemissions, andeconomicaloperation compared to conventional fuel-based vehicles. The project successfully achieves the objective of creating a sustainable and smart transportation solution suitable for urban and semi-urban environments.

Introduction

The Advanced Electric Cycle is a sustainable and energy-efficient transportation solution developed to address increasing fuel consumption, traffic congestion, and environmental pollution. By combining traditional bicycle mechanics with an electric propulsion system, the cycle offers an eco-friendly and economical alternative for short-distance travel. Key components such as a BLDC hub motor, 36V lithium-ion battery, motor controller, throttle, and LCD display work together to provide smooth operation, better torque, improved efficiency, and enhanced rider comfort.

The system is designed using a centralized architecture where the motor controller acts as the core control unit. The architecture consists of five main sections: Power Supply, Control, Drive, Input, and Output. The battery supplies power to the controller, which regulates current and voltage to the hub motor based on throttle inputs. The LCD display provides real-time information such as speed and battery status, while the lighting system improves rider safety.

The project aims to support higher load capacity while maintaining safety, reliability, and cost-effectiveness. A review of existing electric bicycle systems revealed that most focus on solar charging and regenerative braking but still face challenges such as heavy batteries and limited integration of multiple energy sources. The proposed design addresses these limitations through efficient component integration and power management.

Experimental testing demonstrated successful operation under various conditions. The electric cycle achieved a maximum speed of 35 km/h, an average range of 30 km per charge, and a battery charging time of 4–5 hours. The system supported loads of up to 100–120 kg and achieved an overall efficiency of approximately 85–90%. Smooth acceleration, stable speed control, effective power regulation, and reliable display and lighting performance were also observed.

Conclusion

The Advanced Electric Cycle project was successfully completedandtested.Allthecomponentssuchasthebattery, motor controller, hub motor, throttle, and display worked properly together. The cycle achieved a maximum speed of 35 km/h and gave a range of 30 km on a single full charge. The battery took around 4–5 hours to charge completely, which is suitable for daily use. The system efficiency was around 85–90%, which means most of the battery power was properly used without much energyloss.Thecyclewastestedwithaloadofupto120kg and it worked smoothly without any major problem. Speed control was stable and there were no sudden jerks during operation. Thisprojectshowsthatanelectriccycleisagoodalternative to fuel vehicles. It saves fuel, reduces pollution, and is economical for short-distance travel. Overall, the project achieved its main objectives and proved that electric transportationissimple,useful, andenvironmentallyfriendly.

References

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Copyright

Copyright © 2026 Dr. A. S. Shirkande, S. B. Dolase, G. M. Mastud, S. R. Deshmukh, R. A. Dagade. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.