Electrical Design of Two-Wheeler Electric Vehicle

Abstract

This paper presents an electrical design study of a two-wheeler electric vehicle, focusing on the major electrical and electronic subsystems required for propulsion, control, power conversion and rider interaction. The work covers the overall two-wheeler architecture, battery and electrical supply, wiring harness, brushless DC (BLDC) motor, motor controller, DC-DC converter, throttle and speed-control system. The design discussion follows the project implementation in which an electric two-wheeler uses a BLDC hub motor, an electronic controller, a DC-DC converter and a handlebar-mounted throttle. The electrical architecture is considered as an interconnected system in which the battery supplies the propulsion drive, the controller regulates motor operation, the converter supplies lower-voltage auxiliary loads, and the throttle provides the rider command. The project implementation reports a BLDC motor with a maximum speed of approximately 28 km/h and a mass of 2.1 kg, together with a 60 Vdc controller having a current limit of approximately 25±1 A and a 120° phase angle. The paper also discusses regenerative braking, protection, voltage regulation and the role of the wiring harness in reliable energy and signal distribution. The study demonstrates that coordinated selection and integration of these subsystems is essential for safe, efficient and practical electric two-wheeler operation.