How to Employ an Electric Supercharger on a Bike

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Methodology

The aim of the project is to increase the power of bike by employing an electric supercharger.

Steps performed:

1. We procured the Hero Honda Cd Dawn as the bike for our Supercharger Project from Faridabad (belongs to one of our Group member).

We also needed the following components/ materials-

• Turbo

• Motor

• Battery

• Sprockets set

• Air Filter

2. After Procurement of above materials, We mounted the supercharger and the motor on the bike by constructing a 3 frames

• Frame for mounting the Turbo Hub On the Bike Frame

• Frame for clamping the motor to the bike frame

• Additional frame for Turbo to reduce Vibrations on Operation

We decided to use L-Iron bars for the making the frames as it is easily available and can support more load. We took accurate dimensions using Vernier Callipers and meter scale and designed a CAD model of the frame. Then we took the model to a fabricator for the fabrication work.

Cutting L-Iron to make frame members

Markings for screw holes

Welding members together

Drilling Holes for Screw

Grinding Excess Weld Metal

Completed Frame

Turbo Fixed With the Frame

3. Next we had to mount the gears on the turbo and the motor shaft.

The turbo shaft was heated and the nylon gear was slipped on the shaft and was fixed on it, as welding and other machining operation would have damaged the tubo shaft and rendered the turbo useless.

4. Construction of Motor Frame

The motor Frame was Designed and Fabricated at Welder shop.

The Final frame for supporting the Turbo assembly was welded at bike frame.

Clamp for holding the Motor

5. The frames were welded to the bike chassis to hold the assem...

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Also we found that the chain drive performed better than nylon gears as it did not incur any wear and tear.

The fuel consumption of the bike was increased slightly but the overall power delivered per unit fuel consumed was increased significantly. The best performance was achieved if the supercharger was operated after the bike crossed 60 km/h speed.

Using this process theoretically we were able to get an increase of 2hp which is a 27% increase in power as per the calculations made. Practically we gained 35 km/h with the supercharger.

As the trend of high speed vehicles catches on in India the applications of this supercharger will increase significantly. This technology allows us increase the power of a bike without making any significant changes to the engine itself. It also allows us to make the engines smaller without having to compromise on the power.

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