ABSTRACT

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The increasing demand for sustainable and cost-effective transportation solutions has led to significant interest in electric bicycles (e-bikes). Converting conventional bicycles into e-bikes offers an economical alternative while promoting the reuse of existing bicycle structures. This project focused on the design and 3D modelling of an e-bike chassis capable of accommodating essential components such as the battery pack, electric motor, and mounting systems while maintaining compatibility with standard bicycle configurations. Detailed CAD models of the chassis were developed using SolidWorks to ensure effective component integration, ergonomic considerations, and manufacturability. Although structural simulations were not performed, the final design provides a foundation for future analysis, optimization, and prototype development, demonstrating the application of CAD techniques in sustainable mobility solutions.

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INTRODUCTION

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In conjunction with RUNNAM, a team focused on developing an eco-friendly delivery network using bicycles, this project was initiated to support the transition from conventional bicycles to electric bicycles (e-bikes). As RUNNAM sought to improve delivery efficiency and reduce rider fatigue, plans were made to convert their existing fleet of bicycles into e-bikes rather than acquire entirely new units.

Leveraging my expertise in Computer-Aided Design (CAD), I was responsible for designing a chassis structure capable of integrating essential e-bike components, including the battery pack and electric motor, into the existing bicycle configuration. Using SolidWorks, a detailed 3D model was developed to ensure proper component accommodation, structural compatibility, and ease of integration. The resulting design provides a foundation for future development, analysis, and fabrication of the conversion system.

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CAD Modelling Methodology

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Several design concepts were considered based on component placement, structural compatibility, and ease of installation. Different battery and motor mounting arrangements were evaluated to determine the most practical configuration. The final concept was selected based on its ability to provide adequate support for the electrical components while maintaining the original bicycle functionality.

The chassis design was developed using SolidWorks CAD software. The modelling process involved creating individual structural members, defining component mounting locations, and assembling the complete chassis system. Dimensions and geometries were refined iteratively to ensure proper fitment and compatibility with the existing bicycle structure.

Major Components of the Bicycle Assembly

The e-bike conversion design was developed based on the existing bicycle assembly. The major components considered during the modelling and integration process are listed below:

Frame
Front Fork
Handlebar