The Electric Bicycle Conversion Kit Store

Engineers, all around the world, always try to achieve one particular objective: optimization. Compensating one factor for the other without reducing the efficiency has always been a tough task.  But engineers are always up to the challenge. So it should not come as a surprise to you that your electric bike is designed, optimized and manufactured in such a way that you obtain maximum performance output from bike at a very minimal input from you.   

One of the major advantages provided by electric bikes is regenerative breaking.  Any 3 phase hub motor incorporated in your electric bike can easily turn into generator whenever the motor is travelling faster than the applied drive frequency. This means whenever motor is not accelerating, it will regenerate. This regenerated energy is stored in the battery. Thus, you are recharging your battery every time your motor enters regenerative mode. As mechanical transmission systems are used, to some extent, power losses are unavoidable. These mechanical losses can cause loss of 30-40% of the regenerative energy. In order to deal with this, manufacturers prefer helical cut gears in all differential and most of the gear boxes. To add more, these gears are not designed to transmit power in two directions.

Thus optimization plays an important role in the design of an electric bike.

World has changed drastically in the last four centuries, thanks to the mechanical revolution. But more than that, we owe this day to the visionaries who saw what we never imagined. Take for example, Pythagoras, he was a wrestler. And if someone then would have said that he will establish one of the famous mathematical theorems, people would have called him “lunatic”. But still it is the fact that “The Pythagoras Theorem” is one of the most fundamental rules of mathematics. We can find many such examples but moral of the story remains the same; visionaries changed the world we live in today!

Hub motors are no exception! Wellington Adams of St. Louis dreamed of building an electric motor directly in a vehicle wheel. He not only dreamed it, but also made it a reality. He patented his hub motor in the year 1884. Albert Parcelle of Boston built the very first hub motor in the year 1890. He named it, Electro-Motor Traction Wheel. In the same year, Edward Parkhurst of Woburn invented high torque low rpm electric hub motor and successfully incorporated it in the vehicle wheel hub. It was for the very first time that an efficient hub motor was built and used.

And from here started a fairy tale which revolutionized the way people commute: electric bikes!

As discussed in the earlier blogs, optimization is the ultimate goal of any engineer. Basically, optimization includes the best use of available resource. And engineers are always in search of a perfect resource which they can use to best of its ability. As far as hub motors are concerned, unsprung weight can be a perfect candidate to optimize.

In most of the conventional hub motors, ferrous material composed of laminated electrical steel is used. This ferrous material contributes most of the weight of the electric bike. This weight comes under the category of unsprung weight. This increased unsprung weight can lead to less than optimal vehicle handling. It can even lead to reduced efficiency. That’s why engineers always try to optimize this unsprung weight.

One way to do so is to reduce the electrical steel content of the motor by utilizing a core less design. We also advise to use Litz wire coil winding to reduce eddy current losses. These two very simple measures help to reduce hub motor weight and thus unsprung weight. Various manufacturers, like General Motors, are using these measures to obtain better vehicle handling. These measures also help to increase the efficiency!

When you buy an electric bike, you either get an assembled bike or get a kit. If you opt for a kit, you have to assemble the bike on your own. Even though kit includes a guide, it is quite difficult to assemble a complete electric bike. Assembling an electric bike is no joke! That’s why we advise you to go for a pre-assembled bike. Now, what we will be discussing in the following blog? To start with, we will be discussing the scope of brushless hub motors in the electric bike industry and then we will move on to the modern trends observed in the electric bikes.

Hub motor is an important part of your E-bike. It generates and transmits the power which drives your bike. Overall performance of bike depends on the performance of hub motor. There are two options available in the category of hub motor, brushed ones or brushless. Early models of E-bikes preferred brushed motors as they were cheap and quite powerful. But they caused energy loss which was intolerable. So designer came up with another version of hub motor: brushless motor. Though they were expensive, they got the job done at very minimal loss of energy!

Present E-bike industry prefers brushless hub motors because they are efficient and requires no maintenance. So they are no-nonsense hub motors!

Ever wondered why your electric bike does weight so less as compared to other conventional bikes?  Conventional bikes use raw mechanical power to run. They include various mechanical transmission systems like gear box, differentials, axels and chains. Each and every component included in the mechanical transmission system contributes to energy loss of up to 30-40%. So what is so special about electric bikes? The answer is their mechanism. Or in particular, the mechanism of hub motor.

Hub motor consists of two magnetic coil windings, one stationary and other rotary. The power is supplied to the stationary winding which produces a magnetic field in the motor assembly. The rotary winding follows or tries to follow that magnetic field. In the process, it cuts the magnetic flux lines. As a result of which the rotor shaft rotates and we obtain some torque which drives the wheel. Now the power generated in the motor by cutting flux lines is transmitted to a brushed motor through physical contact of brushes to the rotating shaft of the motor. This physical contact results in loss of energy due to various factors like heat, friction etc.

Though they are expensive, brushless hub motors transmit power without any losses. As they transmit power electrically, there are no mechanical transmission systems required which results in no power loss!

Efficiency is of the most important benchmark that defines the performance of any instrument ever designed and built. Every engineer dreams of achieving that perfect number. This dream has inspired many to achieve the impossible. As a result, every product introduced in the market has to undergo gruesome tests to prove its worth. Hub motors are no exception. After decades of research and testing, engineers have come up with state-of-the-art hub motors. And there are various advantages that they have to offer. In the following blog we will discuss its energy efficiency.

One can ask, what is energy efficiency? To put it in simple words, energy efficiency is nothing but the ability of the motor to transmit power from the engine to the wheels with minimum energy loss. Now what makes electric hub motors so special when compared with conventional internal combustion engine (ICE) gear motor?  To start with, its energy efficiency is one major factor. Conventional ICE gear motor incorporates large number of gear ratios to compensate for engines having no usable power at engine speeds lower than 1000 rpm. Each gear contributes to power loss. The larger the number more will be the power loss.

 Basically, electric hub motors provide torque from zero rpm so it does not require as many gears as in conventional ICE gear motor. This means less energy losses. By mounting an electric motor directly inside a wheel and deleting the mechanical transmission, zero energy losses can be obtained!

Some of us like to take it safe and take each day as it come. But some of us like to take that crazy walk on the wild side. So for those who like to live dangerously, speed is life. There are various bike manufacturers who manufacture bikes which can take you for a roller coaster ride. But the world is changing. Global warming is emerging as a major threat to the world of 21^st century. So manufacturers are turning to green bikes. Research is already going on to design and build an electric bike which can charge itself in a matter of hours and can cruise at the speed of 120 KMPH.

There are many challenges that designers face. One of them is the weight considerations. In conventional bikes, mechanical transmission systems like gear boxes, differentials, drive shaft and axels are included. These components, apart from increasing the speed, help in increasing the weight. These components also result in considerable power loss. Electric bikes cannot afford to have such drawbacks.

Electric hub motor holds the answer. By incorporating electric hub motor, we are not only eliminating polluting mechanical transmission systems but also preventing power loss. Weight reduction is also an added advantage. Use of hub motors makes manufacturing an economical venture!

If you are wondering what is the component driving the wheel of your electric bike, then we have a very simple answer: a Hub Motor! In the following blog, we will discuss the modern hub motor and its uses in day to day life.

To start with, Hub motor is an electric motor which is incorporated in the hub of wheel and drives it directly. So, you know why it is called Hub motor. The invention of hub motor helped many industrialist to realize the dream of an efficient electric bike. Not only electric bikes, but also modern industries incorporated hub motors in their assembly lines in order to increase the productivity.

If you go by the history of hub motors, then you will realize that initially, they were designed to be incorporated in cars. Yet very small number of hub motors found their way to the cars. But still a few found their way to the concept cars. To name a few, we can start with Mitsubishi MIEV concept car designed in 2005. Another big name in the industry, Siemens, introduced their concept car VDO e-corner which incorporated hub motors, though a powerful one!

Simple design and efficient performance provided by hub motor is the reason why they are used even in the bus!

Car industry is fast catching up with the modern trends observed in the market. Big, powerful and smoke puffing cars are out and economical, efficient and green cars are in. As we enter the new era of engineering, we must know certain trends which are changing the world.

As far as car industry is concerned, electric hub motors are playing an important role. They are not only being used in electric bikes but also in new concept cars. We will start with Mitsubishi; the major automobile firm introduced their concept car in 2005. This model included an electronic hub motor which powered the car to an unparalleled performance. Then famous German Firm, Siemens, introduced their concept car, E-Corner, in the year 2006. This mode also included an electric hub motor. Then in the year 2006, came a bombshell. She was called Zap-X. This concept car used Electronic hub motors, thus eliminating the need of mechanical transmission systems, conventional brakes and axels. This elimination of components provided space for a giant lithium-ion battery pack which delivers power of mind blowing 644 HP!   

The moral of the story remains the same; electric hub motors are changing the way we travel!

America is crying foul over the issue of global warming. It is reducing its carbon footprints. At the same time, it is encouraging the world to follow its suit and do the same. American government offers various incentives to the industries following an environment friendly approach. Right from cars to aviation industries, America is winning the game. One of the secrets for such a success is the use of electrical energy instead of raw mechanical energy wherever possible. It is encouraging citizens to use electric vehicles. Right from electric bikes to the hybrid vehicles, people love it as they enjoy various tax incentives using such vehicles!

As far as electric bikes are concerned, hub motors play an important role in functioning. They offer various advantages when compared to conventional vehicles. Few of them are listed below;

• Energy efficiency
• Regenerative braking
• Drive by wire facility
• Weight savings
• Unsprung weight advantage

These are the very basic advantages offered by hub motors. We will discuss all these advantages in forthcoming blogs.

Use of unconventional machinery has changed the face of the industry. Hub motor has played a fundamental role in changing that face. We hope you agree!