DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institute affiliated to VTU, Approved by AICTE & ISO 9001:2008 Certified)
Accredited by National Assessment and Accreditation Council (NAAC) with ‘A’ grade
Shavige Malleshwara Hills, Kumaraswamy Layout, Bengaluru-560078
Department of Mechanical Engineering
(Accredited by NBA)

Final Year Project Report Phase-I 2023-24

Project Design and development of a drive train for a Hybrid Two-
Title wheeler
Batch No. 22
SN Student Name USN Signature
1 Milan Sonnad 1DS21ME435

2 Mohammed Hussain Khan 1DS21ME436

3 Mohammed Saqhib 1DS21ME437

4 Himanshu Jha 1DS20ME032

Guide Name Designation Signature

Asst.
1 Dr. P Sudhakar
Professor
 Design and Development of Hybrid Two-Wheeler

Contents
Abstract………………………………………………………………………………………………... 3
Chapter 1: Introduction ........................................................................................................................... 6
1.1 Literature Survey ........................................................................................................ 7
1.2 Problem Statement .................................................................................................... 10
Chapter 2: Objectives Of The Project ................................................................................................... 12
Chapter 3: Method And Methodology .................................................................................................. 12
Chapter 4: Analyses Details .................................................................................................................. 13
Chapter 5: Project Progress ................................................................................................................... 15
Chapter 6: Expected Outcome Of The Project ...................................................................................... 20
References ............................................................................................................................................. 22

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 Design and Development of Hybrid Two-Wheeler

LIST OF FIGURES

Figure1: Working of Parallel Hybrid Vehicle System ................................................................6

Figure 2: Block Diagram of Parallel Hybrid system..................................................................13
Figure 3: 750W BLDC Motor....................................................................................................17
Figure 4: 48V 750W controller..................................................................................................18
Figure 5: Steel 12 Tooth Spure gear..........................................................................................18
Figure 6: Belt drive....................................................................................................................18
Figure 7: Transmission without motor attachment....................................................................19
Figure 8: Transmission with pinion for motor..........................................................................19
Figure 9: Complete assembly of transmission..........................................................................19

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 Design and Development of Hybrid Two-Wheeler

LIST OF TABLES

Table 1: Specification of engine...................................................................................................14

Table 2: Specification of motor....................................................................................................14
Table 3: Specification of battery..................................................................................................14

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 Design and Development of Hybrid Two-Wheeler

ABSTRACT

The project titled "Design and Development of a Drive Train for a Hybrid Two-Wheeler" is a
groundbreaking initiative aimed at transforming urban transportation. It seeks to address the
growing environmental concerns by integrating internal combustion engines and electric
motors in a hybrid configuration, providing a sustainable mobility solution. Articulates the
project's problem statement, identifying key challenges such as optimal powertrain integration,
battery technology, smart energy management, weight distribution, affordability, regulatory
compliance, durability, and scalability. So we will introduce a hybrid two-wheeler vehicle
which will work on fuel and electric power. In this, we will attach the motor directly to the
flywheel. Addressing these challenges is paramount for developing an advanced hybrid two-
wheeler aligned with global sustainability goals. The comprehensive project, rooted in
extensive literature and addressing critical challenges, aims to contribute to developing
sustainable and efficient urban transportation solutions.

Keywords

CVT, Hybrid Vehicle, Performance, Transmission, Electrification

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 Design and Development of Hybrid Two-Wheeler

Chapter 1: INTRODUCTION

In the ever-evolving landscape of transportation, the integration of cutting-edge technologies

has paved the way for innovative solutions that cater to both efficiency and sustainability. One
such groundbreaking development is the design and development of Hybrid Two-wheelers, a
fusion of an internal combustion engine and an electric motor, each powered by a rechargeable
battery pack. This amalgamation not only signifies a leap forward in the realm of two-wheeled
mobility but also provides riders with unprecedented flexibility. The core principle of hybrid
two-wheelers lies in harnessing the strengths of both combustion and electric technologies,
allowing riders to seamlessly switch between power sources based on their specific needs and
prevailing conditions.

Parallel Hybrid Configuration:

One of the fundamental designs within the realm of hybrid two-wheelers is the parallel hybrid
configuration. In this innovative setup, an electric motor and an internal combustion engine are
intricately coupled, providing the capability to power the vehicle either individually or
collaboratively. The integration of automatically controlled clutches plays a pivotal role,
allowing for the seamless transition between the internal combustion engine and the electric
motor. During electric driving, the clutch isolates the internal combustion engine while
engaging with the gearbox, enabling efficient and eco-friendly propulsion. Conversely, in
combustion mode, the engine and motor synchronize, working in tandem to deliver optimal
performance. As we delve into the intricacies of the hybrid two-wheeler design, a fascinating
world of dual-power dynamics unfolds, promising a new era in sustainable and versatile
transportation.

Figure1: Working of Parallel Hybrid Vehicle System

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 Design and Development of Hybrid Two-Wheeler

1.1 Literature Survey

• Study on the implementation of Hybrid Two wheelers in the Indian Market by

Telidevara Venkat Sai Dhruv, Kardile Ajay Sadashiv(2015) discusses about the
comprehensive study on the implementation of Hybrid Two-wheelers in the Indian
market contributes valuable insights into the current dynamics of the automotive sector.
The literature survey conducted in this paper sheds light on the market values of hybrid
vehicles, offering a nuanced comparison with traditional petrol and diesel vehicles as
well as electric vehicles. By exploring the market capitalization of hybrid two-wheelers,
the authors provide a thorough understanding of the industry landscape, identifying key
trends and potential areas for growth. The study not only delves into the technological
aspects of hybrid vehicles but also assesses their market reception, helping stakeholders
and policymakers make informed decisions about the future of sustainable mobility in
India. Through a meticulous analysis of market trends and consumer preferences, this
research serves as a pivotal resource for those interested in the intersection of
automotive technology, environmental sustainability, and economic considerations in
the context of the Indian market.

• Development of Hybrid Two-Wheeler Vehicle (Scaled Model) by Rushi S.

Shenghani, Nayan J. Patel, Chirag K. Jain, Himanshu Rawat, B. R.
Chaudhari(2017) presents the Development of Hybrid Two-Wheeler Vehicle (Scaled
Model), the authors shed light on the various technical challenges encountered during
the manufacturing process of hybrid propulsion systems. The study delves into the
intricacies of designing a hybrid vehicle, addressing key issues that arise in the
integration of internal combustion engines and electric motors powered by rechargeable
battery packs. Through a meticulous examination of these challenges, the authors
contribute valuable insights into the complexities of hybrid two-wheeler development,
offering a foundation for future advancements in the field. The research not only
highlights the hurdles faced in the manufacturing phase but also lays the groundwork
for potential solutions, ultimately contributing to the advancement of hybrid vehicle
technology.

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 Design and Development of Hybrid Two-Wheeler

• Design and Fabrication of Hybrid Two-Wheeler by Inzamam Ul Haq Rizvi Manav

Matliwala Smit Shah Pappu Yadav and Mr. Jignesh Soni(2020) presents in their
work on the "Design and Fabrication of Hybrid Two-Wheeler" underscores the strategic
advantage of directly connecting both the internal combustion engine (IC) and the
electric motor to the drive system. This design approach empowers the hybrid two-
wheeler to seamlessly operate either the IC engine or the electric motor individually or
in tandem, dynamically adapting to varying power requirements. The authors' emphasis
on this integrated approach highlights the potential for optimal efficiency and
performance, making their study a valuable contribution to the evolving field of hybrid
vehicle technology.

• Design And Fabrication of Hybrid Two-Wheeler by N. Boopalan, Marlon Jones

Louis, A. K. Nachimuthu(2014) provides a comprehensive exploration of the
fundamental design principles and critical calculations essential for the development of
hybrid electric bikes. The study focuses on a singular, foundational design, offering
valuable insights into the integration of an internal combustion engine and an electric
motor powered by a rechargeable battery pack. Through meticulous calculations, the
authors guide readers in the selection of key components, providing a robust foundation
for the efficient and optimized performance of hybrid two-wheelers in urban mobility
scenarios.

• Design and Deployment of Hybrid Electric Vehicle by Harpreet Singh Matharu,

Vaibhav Girase, Dr. D. B. Pardeshi, P. William(2022) the authors comprehensively
explore the architecture of parallel Hybrid Electric Vehicles (HEVs). The study not
only elucidates the key components and working principles of a parallel HEV but also
provides valuable insights into the integration methodologies employed to harmonize
the internal combustion engine and electric motor systems. This research serves as a
significant resource for understanding the intricacies involved in the design and
deployment of parallel HEVs, offering a foundation for further advancements in
sustainable and efficient transportation solutions.
• Design And Development Of Hybrid Two-Wheeler by Kamatchi Kannan V,
Ponmurugan P and Chitra K(2020) - explores the design and development of hybrid
two-wheelers, focusing on the integration of battery and inbuilt ignition motor in
Hybrid Electric Vehicles (HEVs). The authors emphasize the operational efficiency of

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 Design and Development of Hybrid Two-Wheeler

HEVs, where the battery powers the vehicle during low-speed driving, while the
Internal Combustion (IC) engine provides additional force for acceleration, long runs,
or slope climbing. The paper aims to reduce the cost and complexity associated with
existing hybrid vehicles, particularly in the context of two-wheelers like scooters. The
index terms highlight key aspects such as Hybrid Electric Vehicle, Internal Combustion
Engine, Grounded Low Voltage System, Tractive System, Brushless DC motor, and
Pulse Width Modulation. The introduction underscores the increasing demand for
individual transportation on two wheels, the inefficiency of traditional vehicles using
oil-based products, and the environmental challenges associated with emissions. The
authors propose electric vehicles as a cleaner and more efficient alternative, addressing
concerns about emissions and energy consumption.

• Optimal energy management for a series–parallel hybrid electric bus by Weiwei

Xiong *, Yong Zhang, Chengliang Yin(2009) - introduces a novel post-transmission
coupled system with a unique transmission serving as the series–parallel configuration
switcher. The paper outlines the vehicle architecture, transmission scheme, and
numerical models, emphasizing an energy management system that governs mode
switching and instantaneous power distribution. Utilizing fuzzy logic, two separate
controllers, namely Mode Decision and Parallel-driving Energy Management, are
employed to enhance control. Validation through Matlab/Simulink simulations reveals
a 30.3% reduction in energy consumption compared to conventional buses under transit
driving cycles, showcasing the effectiveness of the proposed strategy. The study
highlights the potential for further research in this promising field of hybrid electric bus
technology.

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 Design and Development of Hybrid Two-Wheeler

1.2 Problem Statement

In the face of rising environmental concerns and the need for sustainable urban transportation,
there is an urgent requirement for the design and development of an innovative hybrid two-
wheeler. The current landscape lacks a comprehensive and optimized solution that seamlessly
combines traditional internal combustion engines with electric power, aiming to enhance
overall efficiency, reduce emissions, and address the unique challenges of urban commuting.

Key Challenges:

Optimal Powertrain Integration: Designing a hybrid powertrain system that seamlessly

integrates both internal combustion and electric propulsion technologies, ensuring efficient
power delivery across various riding conditions.

Battery Technology: Developing a compact, lightweight, and high-capacity battery system

that balances energy density, range, and longevity while considering factors such as charging
infrastructure and battery recycling.

Smart Energy Management: Implementing an intelligent energy management system that

optimizes the use of internal combustion and electric power sources, maximizing fuel
efficiency and minimizing emissions during urban commuting.

Weight Distribution and Handling: Balancing the weight distribution of the hybrid system
components to maintain the agility and handling characteristics of traditional two-wheelers,
ensuring a seamless and safe riding experience.

Affordability: Developing a hybrid two-wheeler that is cost-effective for the mass market,
considering manufacturing costs, maintenance, and overall affordability to encourage
widespread adoption.

Regulatory Compliance: Ensuring compliance with existing and emerging regulations related
to emissions, safety, and noise for hybrid vehicles, navigating the complexities of varying
standards across different regions.

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 Design and Development of Hybrid Two-Wheeler

Durability and Reliability: Designing a hybrid two-wheeler that can withstand the challenges
of urban commuting, including potholes, traffic congestion, and varying weather conditions,
while maintaining long-term reliability.

Scalability and Customization: Creating a design framework that allows for the scalability of
the hybrid technology, enabling adaptation to different two-wheeler models and
accommodating diverse user preferences and requirements.

Addressing these challenges will contribute to the development of an advanced hybrid two-
wheeler that offers a sustainable and efficient solution for urban mobility, aligning with the
global push towards environmentally conscious transportation alternatives.

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 Design and Development of Hybrid Two-Wheeler

Chapter 2: OBJECTIVES OF THE PROJECT

Traditional two-wheelers have drawbacks like lower fuel efficiency, emissions, and noise
pollution. Hybrid two-wheelers address these issues by combining internal combustion engines
with electric propulsion, improving fuel efficiency, reducing emissions, and providing a quieter
ride. They also offer environmental benefits, increased range with electric power, and
compliance with stricter regulations. Despite considerations like battery production impact,
hybrids present a more sustainable and efficient alternative in the evolving landscape of
transportation. making hybrid options increasingly attractive for those seeking more
sustainable and efficient modes of transportation.

Therefore, the objectives of our project are:

- To design of a drivetrain for Hybrid electric vehicle(two-wheeler).
- To simulate the designed model using software.
- Development of the vehicle: Prototype of the vehicle.
- Testing the prototype according to ARAI regulations.

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 Design and Development of Hybrid Two-Wheeler

Chapter 3: METHOD AND METHODOLOGY

Figure2: Block Diagram of Parallel Hybrid system

• Define Objectives and Requirements: Specify the requirements for your design,
including power output, range, weight, and safety standards. And aiming for better fuel
efficiency, reduced emissions, increased performance.
• Market Research: To understand consumer preferences and trends in the two-wheeler
industry. And Identify potential competitors and analyze their hybrid two-wheeler
offerings.
• Vehicle Selection: Choose a suitable two-wheeler model for the conversion based on
factors like size, weight, and compatibility with hybrid components.
• Conceptual Design: create initial concepts for hybrid two-wheeler and considering the
integration of an internal combustion engine and an electric motor and sketches and
preliminary design ideas.
• Detailed Design: create detailed engineering drawings and specifications for all
components of the two-wheeler, including the frame, engine, motor, battery, and
transmission and Selecting appropriate materials and manufacturing processes.
• Component selection: Source the necessary components, such as the internal
combustion engine, electric motor, lithium-ion batteries, and other electronic
components.
• Integration and Prototyping: Build a prototype of the hybrid two-wheeler by
integrating all the components and Test the prototype for performance, safety, and
efficiency.
• Certification and Compliance: Obtain the necessary certifications and approvals from
regulatory authorities for the hybrid vehicle.

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 Design and Development of Hybrid Two-Wheeler

Chapter 4: CALCULATIONS FOR TRANSMISSION

MECHANISM
The tables below show the engine specifications used in this project; these values are taken
from the manuals and catalogs provided by the manufacturer(Manufacturer & Model: HONDA
& Activa).

Particulars Details
Engine 109cc, 4 Stroke, Single cylinder
Power Approximately 8 bhp @ 7500 rpm
Torque 8.83 Nm @ 5500 rpm
Transmission Automatic (V-Matic)
Fuel System Carburettor
Ignition CDI (Capacitor Discharge Ignition)
Starting Mechanism Self-start and kick-start
Table 1: Specification of Engine

Particulars Details
Power 750W
Speed 1000 rpm
Power Source Battery
Voltage 48V
Table 2: Specification of Motor

Particulars Details
Voltage 48V
Current rating 18Ah
Battery type Lithium ion
Table 3: Specification of Battery

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 Design and Development of Hybrid Two-Wheeler

4.1 Calculations for power and torque requirement from the motor and
battery combination
4.1.1 Torque obtained from bike
Max Power - 7.86PS or 007.86Nm@8000rpm
Max Torque 8.90Nm@5500rpm
Torque Required
P = 2πNT/60
T = 60 x P/2πV = 60 x 7.6/2π x 1000
T = 7.123 nm
4.1.2 Torque obtained from Motor and Battery combination
Motor Specification
RPM =1000rpm
V = 48V
P = 750W
4.1.3 Power Required for electric propulsion
P=V*I
I=750/48
I= 15.625
Torque Available T = P * 60/2 πN
T = 7.16N-m
4.1.4 Battery calculation
Watts = 18Ah
V = 48V
P = V*I
I = P/V
I = 750/.864 * 1000
I=18Ah
Time = 52.08min
4.1.5 Output power from the motor to CVT
Gear ratio = 1:0.333
P = 2πNT/60
P = 2πx333xT/60
T=60x750/ 2π*333

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 Design and Development of Hybrid Two-Wheeler

T=21.48Nm
CVT efficiency is equals to 88%
Output Power from motor to CVT is equal to 0.88*750=660 Watt
Power loss is 90 watts from motor to wheel.

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 Design and Development of Hybrid Two-Wheeler

Chapter 5: PROJECT PROGRESS

This Hybrid Vehicle system consist of below mentioned Components:
1. 48V 750W BLDC Motor
2. 48V 750W Controller for BLDC Motor
3. Steel 12 tooth Spur Gear
4. Belt Drive assembly

5.1 750W BLDC Motor

48V BLDC motor 3 phase brushless DC motor with 2.39 Nm rated torque, max torque can up
to 7.16 Nm, 3000 rpm rated speed and 19.52A rated current. 750W high torque BLDC motor
runs smoothly, with little interference, long life and low maintenance cost. Motor specifications
are specified below,
Specifications:
Rated Power: 1 hp (750W)
Rated Voltage: 48V
Rated Current: 19.52A
Phase: 3 phase
Rated Torque: 2.39 Nm
Max Torque: 7.16 Nm
Rated Speed: 3000 rpm
No-load Current: ＜6.5A
Square Flange Size: 86 mm
Working Efficiency: 85% Figure3: 750W BLDC Motor

5.2 48V 750W Controller for BLDC Motor

A BLDC motor controller regulates the speed and torque of the motor; it can also start, stop,
and reverse its rotation. Electronic commutation allows for faster current switching. It results
in higher torque, effective speed control over a wide range, and hence improved motor
performance and protecting against overloads and electrical faults. Here we are using BLDC
Motor controller as specified below,

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 Design and Development of Hybrid Two-Wheeler

Specifications:
Rated voltage-DC 48V
Maximum current-25+/-1A
Embedded voltage-41+/-1V

Figure4: 48V 750W Controller

5.3 Steel 12 tooth Spur Gear

Here the spur gear is selected based on the number of tooth available on the motor sprocket
(commercially brought). This will maintain the torque availability and maximum torque
produced by the motor. The hub bore diameter of the spur gear is as same as shaft diameter of
motor. And the specification of spur gear as below,
Specifications:
No of Tooth: 12 tooth
Module: 1.5 module
Bore Diameter: 8 mm
Hub Diameter: 14 mm

Figure5: Steel 12 tooth Spur Gear

5.4 Belt Drive

A compound belt drive consists of more than two shafts with

multiple pulleys keyed to at least one of the shafts. The driving
pulley transfers power from one shaft to another through
multiple shafts. This setup improves the speed ratio without
requiring a larger driven pulley or too much extra space. Here
the belt is selected based on the length requirement for the bike
between driver and driven. Figure6: Belt Drive

3.6 Prototype design for Hybrid Vehicle system

The below images shows the engine modification for the conversion from engine to hybrid
mode. This will switch the mode based on the speed of the engine flywheel. In conventional
transmission system, the bels drive works on CVT (continuously variable transmission)
technology where power is transmitted by pulleys through belt drive. In this system, initial

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 Design and Development of Hybrid Two-Wheeler

transmission of power is done by motor till the bike catches up to the speed of 20 Kmph. Then
the bike will be shifted to engine mode.

Figure7: transmission without motor attachment

Figure8: transmission with pinion for motor

Figure9: complete assembly of transmission

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 Design and Development of Hybrid Two-Wheeler

Chapter 6: EXPECTED OUTCOME OF THE PROJECT

The expected outcome of the design and development of a Hybrid Two-wheeler, integrating
an internal combustion engine and an electric motor powered by a rechargeable battery pack,
is a highly versatile and efficient vehicle that offers a range of benefits to riders. Here are the
anticipated outcomes:

1. Optimized Efficiency: The integration of an internal combustion engine and an electric

motor enables riders to optimize efficiency based on their specific needs and riding conditions.
This versatility allows for improved fuel efficiency during regular commuting and the option
to switch to electric power for eco-friendly and cost-effective short trips.

2. Enhanced Performance: The ability to switch between combustion and electric power
sources provides an extra boost in performance when needed. This can be particularly
advantageous for acceleration, overtaking, or navigating challenging terrains. The parallel
hybrid design ensures seamless coordination between the internal combustion engine and the
electric motor, maximizing overall performance.
3. Environmental Sustainability: The inclusion of an electric motor powered by a
rechargeable battery pack contributes to reducing emissions and lowering the environmental
impact of the two-wheeler. The option to operate in electric mode promotes eco-friendly
transportation, especially in urban areas where emission regulations are stringent.

4. Adaptive Riding Experience: Riders can enjoy a customizable riding experience by

selecting the power source that best suits their preferences or the current riding conditions. The
automatic control of clutches ensures a smooth transition between the internal combustion
engine and electric motor, offering a seamless and adaptive riding experience.

5. Regenerative Braking: Hybrid two-wheelers often incorporate regenerative braking

systems, allowing the electric motor to act as a generator during braking or deceleration. This
feature helps recharge the battery pack, improving overall energy efficiency and extending the
vehicle's range.

6. Reduced Operating Costs: The combination of an internal combustion engine and an

electric motor provides cost-saving benefits. The electric mode can be utilized for shorter trips,

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 Design and Development of Hybrid Two-Wheeler

reducing fuel consumption and maintenance costs associated with the combustion engine.
Additionally, the regenerative braking system contributes to longer battery life.

7. Market Appeal: The design innovation of a hybrid two-wheeler is likely to attract

environmentally conscious consumers and those seeking a balance between performance and
efficiency. The availability of a hybrid option broadens the market appeal of the two-wheeler,
attracting a diverse range of riders.

In summary, the design and development of a Hybrid Two-wheeler, particularly with a parallel
hybrid configuration, is expected to deliver a dynamic and eco-friendly mode of transportation,
offering riders a blend of efficiency, performance, and adaptability.

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 Design and Development of Hybrid Two-Wheeler

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