Mechanical · Automobile engineering · Final year project
Design & Fabrication of Unique Hubless Ebike With Suspension
A hubless electric bike with suspension. Two DC motors drive the rear rim through high-friction rollers, giving double torque, while a suspension system keeps the ride comfortable.
What is the Design & Fabrication of Unique Hubless Ebike With Suspension project?
A hubless electric bike with suspension. Two DC motors drive the rear rim through high-friction rollers, giving double torque, while a suspension system keeps the ride comfortable.
Key facts
- Branch
- Mechanical & Automobile Engineering; also suits Mechatronics
- Type
- Final year project · Advanced
- Suitable for
- Diploma capstone and B.E / B.Tech final year
- Build time
- 6 to 8 weeks
- Estimated component cost
- ₹35,100 – ₹51,600
- Guidance from
- ₹9,999 (Hardware / IoT Final Year)
How the Design & Fabrication of Unique Hubless Ebike With Suspension works
- The mild steel frame and fabrication forms the base that carries every other part, so it is designed first from the load and size of the machine.
- The DC geared motor provides the driving motion.
- Motion is transmitted through DC geared motor, chain and sprockets and ball bearings with housing, which set the speed, torque and direction at the working end.
- The Wheels / castor wheels allow the machine or vehicle to move.
Block diagram
Power
DC geared motorRechargeable batteryTransmission
DC geared motorChain and sprocketsBall bearings with housingWorking unit
Wheels / castor wheelsStructure
Frame and mountsComponents list and cost
Typical prices from Indian online stores and electronics markets (Lamington Road, Budhwar Peth, SP Road). Buy from one store where you can to save on shipping.
| Component | Qty | What it does | Approx. cost |
|---|---|---|---|
| DC geared motor | 1 | Provides the driving motion. | ₹250 |
| LEDs (assorted) | 1 | Indicate status. | ₹20 |
| Rechargeable battery (12 V 1.3–7 Ah) | 1 | Stores energy and supplies power when mains is absent. | ₹650 |
| Wheels / castor wheels | 1 | Allow the machine or vehicle to move. | ₹400 |
| Chain and sprockets | 2 | Transmit power between shafts without slip. | ₹900 |
| Ball bearings with housing | 1 | Support rotating shafts with low friction. | ₹250 |
| Mild steel frame and fabrication | 1 | Forms the main structure that holds all parts. | ₹2,500 |
| BLDC hub motor 250-350 W | 1 | Needed for this type of build. | ₹7,500 |
| Motor controller with throttle | 1 | Needed for this type of build. | ₹2,900 |
| Li-ion battery pack 36 V 10 Ah with BMS | 1 | Needed for this type of build. | ₹14,500 |
| Base frame / bicycle and fabrication | 1 | Needed for this type of build. | ₹6,500 |
| Brakes, cables and wiring | 1 | Needed for this type of build. | ₹1,400 |
| Welding, cutting and machining labour | 1 | Needed for this type of build. | ₹2,200 |
| Mounts, screws, nuts and small hardware | 1 | Enclosure, mounts and fasteners. | ₹300 |
| Paint, finishing and workshop consumables | 1 | Project overhead | ₹600 |
| Transport of material | 1 | Project overhead | ₹400 |
| Estimated total | Varies with brand, quality and city | ₹35,100 – ₹51,600 |
Prices are estimates for budgeting. We confirm the bill of materials when your design is frozen, and components are charged at actual cost with bills.
How much does this project cost?
| Option | What you get | Cost |
|---|---|---|
| Components only | You buy the parts and build it yourself | ₹35,100 – ₹51,600 |
| Hardware / IoT Final Year | Working model or guided build, Circuit diagram and bill of materials, Firmware / code with explanation | from ₹9,999 + components |
| Capstone Project (CPE) | Working project or model, Black book in MSBTE format, Step-by-step explanation | ₹9,999 + components |
| Diploma ITR | 100% working source code, Project report PDF, PPT | ₹1,999 + components |
No GST and no hidden charges. Use the cost calculator for a quote with your deadline and add-ons, or see all plans.
Download the project brief (PDF)
Summary, working, components and cost and viva questions on one branded PDF to show your guide or team. To get it developed, contact us on WhatsApp.
What you submit with this project
- Working model with circuit diagram and program code
- Project report or black book in your university's chapter order (block diagram, circuit, calculations, results)
- Presentation for the review and final viva
- Synopsis for topic approval, if your college asks for one
Mechanical viva questions on this project
What is the aim of the Design & Fabrication of Unique Hubless Ebike With Suspension project?
A hubless electric bike with suspension. Two DC motors drive the rear rim through high-friction rollers, giving double torque, while a suspension system keeps the ride comfortable.
Explain the working of your project in short.
The mild steel frame and fabrication forms the base that carries every other part, so it is designed first from the load and size of the machine. The DC geared motor provides the driving motion. Motion is transmitted through DC geared motor, chain and sprockets and ball bearings with housing, which set the speed, torque and direction at the working end. The Wheels / castor wheels allow the machine or vehicle to move.
Why is a geared motor used?
The gearbox reduces speed and multiplies torque, so a small DC motor can move a vehicle or mechanism smoothly. Torque increases roughly by the gear ratio.
Why is a resistor connected in series with an LED?
It limits the current to a safe value (about 10–20 mA). Without it, the LED would draw too much current and burn out. R = (supply voltage − LED voltage) ÷ current.
How do you calculate battery backup time?
Backup time (hours) ≈ battery capacity (Ah) × voltage × 0.8 efficiency ÷ load power (W). For example, 12 V 7 Ah at 20 W gives about 3.3 hours.
How is the wheel size selected?
From the required speed and torque: linear speed = π × D × rpm ÷ 60. A larger wheel gives more speed but needs more torque.
Why use a chain drive instead of a belt?
A chain gives a positive drive with no slip and handles higher torque, while a belt is quieter and can slip under overload, protecting the drive.
Which material did you select for the main parts and why?
Mild steel (MS) is used for the frame because it is strong, cheap, easy to cut and weld and available everywhere. Shafts are made of EN8 or bright mild steel for strength, and parts that do not carry load can be aluminium or acrylic to reduce weight.
What factor of safety did you take in your design?
A factor of safety of 2 to 3 is taken for static parts and 3 to 5 for parts under shock or fatigue loading. Allowable stress = yield strength ÷ factor of safety, and each part is checked against it.
How did you estimate the cost of the project?
The cost is the sum of raw material, bought-out parts, machining or fabrication and overheads. Our estimate for this model is about ₹35,100 to ₹51,600, depending on size, material and the workshop rates in your city.
Which manufacturing processes were used?
Cutting and grinding of sections, arc or MIG welding of the frame, drilling for mounting holes, turning of the shafts and fitting of bearings and the drive, followed by assembly, alignment and painting.
Is your system open-loop or closed-loop?
Mainly open-loop: the controller runs the actuators for a set time or number of steps. Adding a sensor for feedback would make it closed-loop and more accurate.
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Want to build Design & Fabrication of Unique Hubless Ebike With Suspension?
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