Cost-Effective Conversion Techniques of Scrap Bicycles into Intelligent Electric Bicycles: A Review

Year : 2025 | Volume : 12 | Issue : 02 | Page : 30 40
    By

    Ravikant Nanvatkar,

  • Anurag Ranaware,

  • Aniket Vakude,

  • Vedant Sapkal,

  1. Assistant Professor, Department of Mechanical Engineering, Sinhgad Technical Education Society’s NBN Sinhgad Technical Institutes Campus (STES’s NBNSTIC) (Affiliated to Savitribai Phule Pune University), Ambegaon, Pune, Maharashtra, India
  2. UG Student, Department of Mechanical Engineering, Sinhgad Technical Education Society’s NBN Sinhgad Technical Institutes Campus (STES’s NBNSTIC) (Affiliated to Savitribai Phule Pune University), Ambegaon, Pune, Maharashtra, India
  3. UG Student, Department of Mechanical Engineering, Sinhgad Technical Education Society’s NBN Sinhgad Technical Institutes Campus (STES’s NBNSTIC) (Affiliated to Savitribai Phule Pune University), Ambegaon, Pune, Maharashtra, India
  4. UG Student, Department of Mechanical Engineering, Sinhgad Technical Education Society’s NBN Sinhgad Technical Institutes Campus (STES’s NBNSTIC) (Affiliated to Savitribai Phule Pune University), Ambegaon, Pune, Maharashtra, India

Abstract

Over the past few years, there has been an overwhelming increase in requirement of sustainable and affordable urban mobility solutions both due to the environmental concerns along with the rising fuel prices and urban traffic jams. Electric bicycles (e-bike) have become an efficient option as a substitute to traditional modes of transport which are similar to conventional tools since they have low emissions and are energy efficient as well as easy to use. Nonetheless, the fact that new e-bikes are relatively expensive has discouraged their adoption, particularly within the developing economies. The paper discusses an affordable way of transforming the readily available but obsolete scrap bikes into intelligent electric bikes utilizing economical electric drive kits, smart control packages, and low-weight power storage options. The conversion process starts by picking up structurally good scrap bikes and assessing the mechanical good condition of the bike. Proper retrofitting would consist of installing a low cost brushless DC (BLDC) hub motor at the front or rear wheel and feeding a lightweight lithium-ion battery pack in strategic position to allow balancing and road feel. They have pedal-assist sensors, speed-monitoring sensors and battery management systems (BMS) sensor equipment that are fitted to the bike to achieve optimal user clarity in using the product to save on energy usage of the EUC bike. Moreover, it has an intelligent control interface, which enables the riders to easily alternate between pedal-assist mode and full-electric mode and get performance data in real-time using a mobile application. Compared to the market price of new commercial e-bikes, it is possible to construct such Upcycled e-bikes at a cost of less than 40 percent and still under no compromise of safety, functionality or even aesthetics. The electrical and mechanical efficiency of the converted e-bikes is then tested in an experimental trial which is aimed at testing their performance during normal urban riding condition (battery range, power output and ergonomic friendliness). The results indicate a huge potential of widespread implementation of the sustainable and scalable conversion approach, particularly in resource-limited environments.

Keywords: Urban mobility, intelligent electric bikes, retrofittement, battery management systems, mobile application

[This article belongs to Journal of Automobile Engineering and Applications ]

How to cite this article:
Ravikant Nanvatkar, Anurag Ranaware, Aniket Vakude, Vedant Sapkal. Cost-Effective Conversion Techniques of Scrap Bicycles into Intelligent Electric Bicycles: A Review. Journal of Automobile Engineering and Applications. 2025; 12(02):30-40.
How to cite this URL:
Ravikant Nanvatkar, Anurag Ranaware, Aniket Vakude, Vedant Sapkal. Cost-Effective Conversion Techniques of Scrap Bicycles into Intelligent Electric Bicycles: A Review. Journal of Automobile Engineering and Applications. 2025; 12(02):30-40. Available from: https://journals.stmjournals.com/joaea/article=2025/view=222558


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Regular Issue Subscription Review Article
Volume 12
Issue 02
Received 04/06/2025
Accepted 06/07/2025
Published 15/07/2025
Publication Time 41 Days
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