Design and Fabrication of Electric Bicycle with Regenerative System

Abstract

The increasing demand for sustainable and efficient transportation has led to the development of electric bicycles (e-bikes) as an alternative to traditional modes of transport. This paper presents the design and fabrication of an electric bicycle integrated with a regenerative system aimed at enhancing energy efficiency and extending battery life. The proposed system utilizes a brushless DC motor to drive the bicycle and a regenerative mechanism that recovers energy, converting kinetic energy back into electrical energy. The design considerations include optimal motor selection, battery management, and regenerative circuitry. A prototype was developed to demonstrate the functionality of the regenerative system, and experimental results show a notable improvement in energy conservation, extending the operational range of the bicycle. The integration of the regenerative system also contributes to reducing the frequency of battery recharges, offering an environmentally friendly solution for urban transportation. The paper concludes with an analysis of the system\'s performance, highlighting the potential benefits and challenges of integrating regenerative technologies into electric bicycles.

Introduction

The project proposes an electric bicycle (e-bike) enhanced with regenerative systems that utilize renewable energy sources—solar power, piezoelectric transducers, and a generator—to extend battery life and reduce dependence on external charging. The design focuses on improving sustainability, energy efficiency, and the operational range of e-bikes.

Key Features and Innovations

• Solar Panels integrated into the frame collect sunlight during the day to recharge the battery.

• Piezoelectric Transducers convert mechanical stress from road vibrations, pedaling, and drivetrain movement into electricity.

• Generator System recovers kinetic energy during wheel rotation or braking and stores it in the battery.

• Hybrid Energy Harvesting ensures continuous power through multiple sources, enhancing range and reliability.

Objectives

• Design a piezoelectric system that captures mechanical energy efficiently.

• Select suitable materials for integration and durability.

• Compare performance of piezoelectric vs. traditional regenerative systems.

• Test real-world impact on battery life, range, and user experience.

Literature Review Highlights

• E-bikes are gaining popularity as a sustainable transport solution.

• Comparative studies show lithium-ion batteries outperform lead-acid types in weight, lifespan, and efficiency.

• Regenerative braking can recover 15–20% of lost energy.

• Usage patterns of e-bikes and electric cars share similarities in sustainability motivations and user demographics.

Methodology

• When the e-bike is operated, the DC motor powers movement.

• A generator and piezoelectric system convert kinetic and vibrational energy into electricity.

• Solar panels collect sunlight, with energy processed through a rectifier to charge the battery.

• An integrated controller manages energy flow from all sources, preventing overcharging and optimizing efficiency.

Components

• DC Motor & Controller: Drive system and power regulation.

• Throttle: User input for acceleration.

• Lithium-Ion Battery & Charger: Main energy storage and charging interface.

• Piezoelectric Transducers: Embedded in frame, chain drive, and sprockets to capture vibrations.

• Sprocket & Chain Drive: Integrated with piezoelectric elements for additional energy harvesting.

• Solar Panel: Supplies energy even while stationary.

• Generator: Recovers energy from motion and braking.

Conclusion

Design and Fabrication of Electric Bicycle with Regenerative System using generator, piezoelectric transducer and solar panel is a new approach to energy recovery and sustainability in electric transportation. By integrating three energy harvesting technologies, the system can capture and store energy from mechanical motion, vibrations and solar radiation, thus increasing the overall energy efficiency of the bicycle. The generator converts kinetic energy from the bike’s movement into electrical energy, piezoelectric transducers harvest mechanical vibrations caused by road irregularities and rider movement. Solar panel captures solar energy to recharge the battery, an eco-friendly and renewable energy source. The synergy of these regenerative systems extends the bike’s range and reduces dependence on external charging. With ability to charge while riding or stationary, the bicycle becomes more self-sufficient, sustainable and cost effective. Also the integration of these technologies reduces the environmental impact, a good alternative to conventional electric bicycle and other modes of transportation. The system can harvest energy from multiple sources, future of electric vehicle technology is promising especially in urban commuting and long distance travel. Energy recovery from piezoelectric transducers is incremental and overall energy production depends on sunlight exposure, but combination of these technologies in electric bicycle enhances its performance, efficiency and sustainability. In conclusion, Electric Bicycle with Regenerative System is a new and eco-friendly solution for personal transportation. Usage of generator, piezoelectric transducer and solar panel improves the bike’s overall performance, autonomy and self-sufficiency, for more energy efficient and eco-friendly transportation in the future.

References

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Copyright

Copyright © 2025 Sanjay MP, Anshad CK, Faseela MK, Fathima Sherin MK. 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.