1. Final Project
This week I worked on defining my final project idea and started to getting used to the documentation process.
This covers the final project ideas.Electric Motorcycle Conversion Kit
The project ecompases the design and production of the conversion kit for motorcycle which will be used as a mode of transport to reduce traffic jame and preserving the climate, as it will reduce the carbon footprint from fuel-powered cars.
- Project Overview
• Build a full conversion kit for the motorcycle.
• Build custom twist throttle with a Hall-effect sensor for precise control.
• Use an ESP32 microcontroller to process throttle input, toggle ECO/SPORT modes, and display battery state of charge (SoC).
• Display throttle percentage, drive mode, and fault status on an OLED.
• Enable Bluetooth connectivity for real-time data monitoring via a smartphone app (optional).
• Design 3D-printed throttle grip and display enclosure for handlebar mounting.
• Implement fault detection (e.g., throttle signal errors, low SoC) with a status LED.
• Ensure modularity for integration with a full electric motorcycle kit (e.g., CAN bus for BMS and motor controller).
A unique feature includes a custom twist throttle with Hall-effect sensor for precise torque control (0-100%), activated by the rider via a smooth twist mechanism. Built from 3D-printed PLA, aluminum, and electronic components, the module balances durability, lightweight design, and a sleek, functional aesthetic.
Construction & DesignFrame: 3D-printed PLA enclosure for the throttle grip and OLED display, providing a lightweight yet robust structure for handlebar mounting.
Throttle Surface: Made from PLA with an aluminum spring mount for smooth operation and reliable return-to-zero functionality.
Display Mounting: Secure handlebar clamp (22mm diameter) with M3 screws, ensuring stability and visibility across riding conditions.
Power: USB-powered for prototyping (5V), with integration to a 72V-to-5V DC-DC converter for the full kit, ensuring sufficient runtime for extended rides.
Throttle System: Hall-effect sensor (SS49E) and ESP32 ADC (GPIO36) ensure precise throttle control with exponential mapping for smooth response.
Interface: Controlled via a push button (GPIO21) for ECO/SPORT mode switching; the 2.8” SSD1306 OLED (I2C, GPIO4/5) displays throttle percentage, mode, SoC, and faults.
Monitoring: Bluetooth connectivity (SerialBT, “EV_Throttle”) enables real-time data tracking (throttle, mode, SoC, faults) via a smartphone app.
Fault Detection: ESP32-based fault detection identifies throttle signal errors and low SoC (10%), indicated by a red status LED (GPIO22).
Electronics: All components are housed in a custom 3D-printed enclosure, or a custom built container to protect against vibration, dust, and minor impacts during rides.
Safety Features: Includes throttle deadband (5%) to prevent jitter, exponential mapping for smooth acceleration, and fault-triggered torque cutoff for rider safety.
Gallery
Material list
| Components | Purpose | Cost |
|---|---|---|
| Seed XIAO (ESP32) | Main controller | |
| Mid-Drive motor | To drive the bike | |
| Two wheels | Mobility of the bike | |
| OLED display | Display the speed, battery, and faults | |
| Two disc | For precise braking | |
| Motor drive | Drive speed and direction of the motor | |
| Shock absorber | Absorbing impacts, adequately and comfortably overcome the irregularities of the terrain on the road | |
| Battery | Power supply | |
| Voltage regulator | Proper supply of normal voltage to components | |
| Lights | For comfortable driving in the dark and communication of the road |