Hybrid E Bike or Electric Bike making & Motor Driver designing

(Last Updated On: October 19, 2019)

Hybrid E Bike or Electric Bike

Description:

Hybrid E Bike or Electric Bike- In this tutorial, you will learn how to make a low-cost Hybrid Electric Bike from an old bicycle. In this tutorial, you are going to learn a lot of things and at the end, you will be able to convert any old or new bicycle into an Amazing Hybrid E Bike or Electric Bike or Electric Bicycle.

In almost all, the electric bike projects readymade motor controllers are used, which really does not help the beginners in making their own electric bike motor controllers.

In this tutorial, we are going to make our own electric bike motor controller using mc33151 dual Mosfets driver IC, high ampere Mosfets, a potentiometer, and Arduino. To reduce the price and to explain the extreme basics I am going to use the potentiometer to control the speed of the Electric Motor.

This tutorial is divided into two parts.

In Part1 I completed the mechanical work while in Part2 I covered the motor driver circuit explanation, programming and testing. Detailed video tutorials are available at the end of this article.

 Without any further delay let’s get started!!!


The components and tools used in this project can be purchased from Amazon, the components Purchase links are given below:

12v 12AH Rechargeable Battery: https://amzn.to/30af1XU
Bike Brakes Mountain Bike V brakes kit: https://amzn.to/30cWHgS
Bicycle Sprocket Gears: https://amzn.to/30hPRGU
Silver Spray: https://amzn.to/30kaAZU
Black Spray: https://amzn.to/31GUvLn
Side kick stand: https://amzn.to/2LHpHEx
E Bike kit: https://amzn.to/2LFhj8w
MC33151 MOSFETs driver: https://amzn.to/2xh7upl
80NF70 Mosfets: https://amzn.to/2mWqI1D
Arduino Uno: https://amzn.to/2tVz1vu
Mega 2560: https://amzn.to/2ze1kdu
LM7805 Voltage Regulator: https://amzn.to/2IZEl5x
Potentiometer: https://amzn.to/2JSLbfg
330 ohm resistors pack: https://amzn.to/2NtlAeh
5v 2A adaptor: https://amzn.to/2GsNfcw
2n2222 npn transistors: https://amzn.to/2EmXsIb
10k Resistor: https://amzn.to/2KTd6OW
lm7805 Voltage Regulator: https://amzn.to/2IZEl5x
330-ohm resistors pack: https://amzn.to/2NtlAeh
LDR pack: https://amzn.to/2m2khGR
female DC power jack socket: https://amzn.to/2KEo1gt
470 uf capacitors: https://amzn.to/2xDCOzf
5×7 cm vero board: https://amzn.to/2OHGbvn
female headers: https://amzn.to/2zqmtiJ
connection wires: https://amzn.to/2DpBuW7
Super Starter kit for Beginners: https://amzn.to/2KJvmKG
Jumper Wires: https://amzn.to/2KMoVXs
Bread Board: https://amzn.to/2MS4q8X
12v Adaptor: https://amzn.to/2Ntr6h1
PCB plate: https://amzn.to/2IUwpCt
Variable Supply: https://amzn.to/2MT4Qfj
Digital Multimeter: https://amzn.to/2Nvft9i
Vero Board / strip board: https://amzn.to/2MTf9jD
Soldering iron kit: “best” You guys should definitely purchase this: https://amzn.to/2zfoNuJ
Solder wire: https://amzn.to/2ufUMWf
Wire Stripper: https://amzn.to/2KOqxfU
wire cutter: https://amzn.to/2ucIq14
PCB small portable drill machine: https://amzn.to/2Nu62XF

DISCLAIMER:

Please Note: these are affiliate links. I may make a commission if you buy the components through these links. I would appreciate your support in this way!



As part1 is about the mechanical work only in which I have practically demonstrated how to change the tires, wheel Hub and how to install the motor. For the step by step explanation, I recommend you should watch the video tutorial given at the end. In part1 the only important thing is the wheel hub selection and how to install the motor.

While part2 is about the circuit explanation, connections, interfacing, programming, and testing. Part2 is really important which I am going to explain. Let’s start with the circuit diagram.


Circuit Diagram:

Hybrid E Bike or Electric Bike

This schematic is designed in Cadsoft Eagle 9.1.0 version. If you want to learn how to make a schematic and PCB then watch my Tutorial give below.

The MC33151 Eagle library can be downloaded from my website. First, let’s start with the Power Supply.

This Power Supply is based on the famous LM7812 voltage regulator. J1 is the female power jack and this is where we connect 12 volts from the battery or solar panel. Two 470uf capacitors are connected at the input and output of the voltage regulator. 1 kilo-ohm resistor is connected in series with the 2.5v led. This is a current limiting resistor. the output of this voltage regulator is connected with the VCC pin of the MC33151 MOSFET driver.


Pin number 2 and pin 4 which are the logic input A and logic input B are connected together and will be connected with the PWM pin of the Arduino or Mega. Pin number 5 and pin number 7 are used to control the MOSFETs. As you can see the Drains are connected together and the sources of both the MOSFETs are also connected together. With motor-1 and motor-3 we connect the motor while with E_Supply-1 and E_Supply-3 we connect the 12volts. Before making the PCB I checked this circuit on a Vero board, and performed all the tests, after I was satisfied with the result, then I designed a PCB, generated the Gerber files and placed an online order on the NextPCB official website.

www.nextpcb.com

Download Gerber files: electric bike gerber files

Download Eagle PCB Board File: arduino motor driver

Download the mc33151 eagle library: MC33152

The online order placement is explained in the video tutorial given at the end.

Hybrid E Bike or Electric Bike

This is the PCB which I received from the nextpcb, as you can see the quality is really great, the silkscreen is quite clear and the blue soldermask looks amazing. I am really satisfied with their work.


Hybrid E Bike or Electric Bike

As you can see, the circuit is ready. J1 is the dc female power jack. IC1 is the LM7812 voltage regulator. Two capacitors are connected with the regulator. At the output of the voltage regulator, a 1k ohm resistor is connected in series with a 2.5v led. The 8 legged IC is the mc33152 dual Mosfets driver IC. R2 and R3 are the 100-ohm resistors connected with the gates of the Mosfet drivers; with the upper side terminal block, we connect the power supply while the motor will be connected with the lower side terminal block.

Hybrid E Bike or Electric Bike

As you can see I installed a Heatsink, this is really important, otherwise, the Mosfets will really get hot. Use a large Heatsink.



Interfacing:

Hybrid E Bike or Electric Bike

As you can see two 12v batteries are connected in parallel. The grounds of both the batteries are connected together and the positive terminals are connected together. One wire is soldered with the Ground and the other wire is soldered with the positive. The power supply wires are connected with the upper side terminal block. The two wires coming from the motor are connected with the 2nd block terminal. if the motor spins in the wrong direction you can interchange the motor wires. So, this is how the batteries and electric motor are connected with the controller board.

On the Arduino side, the connections are really simple; pin number 3 which is the PWM pin is connected with the PWM female header and the blue wire is the ground. The variable resistor or potentiometer is connected with the analog pin A0 of the Arduino while the remaining two wires are connected with the 5v and ground of the Arduino. This variable resistor will be used to control the speed of the Electric Motor.


Hybrid E Bike Arduino Programming:

Program Explanation:

This is a very simple and basic program. A variable resistor is connected with the analog pin A0 of the Arduino. Pin number 3 of the Arduino which is the PWM pin will be used to control both the MOSFETs. The PWMV is set to output while the resistor is set to input.

In the void loop function, we simply read the variable resistor, then using the map function we limit the value from 0 to 255 and then finally we use the analogwirte function which you are quite familiar with.

For the practical demonstration watch video tutorials given below.

Hybrid E Bike or Electric Bike Video Tutorials:

Hybrid E Bike or Electric Bike Part1:

 

Hybrid E Bike or Electric Bike Part2:

 

 

Recommended For You

About the Author: Engr Fahad

My name is Shahzada Fahad and I am an Electrical Engineer. I have been doing Job in UAE as a site engineer in an Electrical Construction Company. Currently, I am running my own YouTube channel "Electronic Clinic", and managing this Website. My Hobbies are * Watching Movies * Music * Martial Arts * Photography * Travelling * Make Sketches and so on...

Leave a Reply

Close