E-BIKE MOTOR DESIGN

This thesis provides a comprehensive study on the design and evalu- ation of electric bike (e-bike) motors, focusing on both theoretical and experimental aspects. The study begins by reviewing the state of the art in e-bike tech- nology, emphasizing the electric motor as a crucial component that significantly influences overall performance and user experience. The research investigates various motor configurations and their integra- tion into e-bike systems, taking into account factors such as efficiency, torque production, and thermal management. Several commercial motors are analysed through a combination of experimental tests and finite element analysis, providing insights into their electromag- netic and mechanical properties. Motors tested include popular mod- els from manufacturers like Bosch, Shimano, and Brose, with assess- ments conducted on parameters such as cogging torque, torque rip- ple, and power delivery under various operating conditions. Through laboratory testing, the performance of these motors are determined and compared to highlight their relative advantages and limitations. The results demonstrate that various configurations offer different benefits in terms of torque density, speed range, and thermal stabil- ity. The study concludes by presenting a newly designed motor for e- bike applications, developed based on the findings from comparative analysis. The design process includes a series of parametric analy- ses and optimizations. The optimal configuration achieves a balance between performance, overall size, and manufacturability. Final mo- tor is then evaluated against commercially available motors, ensuring that the newly designed motor not only matches but potentially sur- passes the performance of existing solutions, laying a strong founda- tion for further development.