Why electric motorcycles need a fresh engineering approach? • EVreporter

Electric motorcycles are no longer a futuristic concept--they are here, and they are transforming urban mobility. But designing an electric motorcycle isn't as simple as swapping out an engine for a battery. It requires a completely fresh engineering approach, much like how smartphones revolutionized communication compared to landlines.

From rethinking the frame to optimizing power distribution, every aspect of an electric motorcycle needs to be re-engineered. The market for electric motorcycles in India alone is expected to grow at a CAGR of over 40% in the coming years, driven by increasing fuel costs and government incentives. In 2023, global electric motorcycle sales exceeded 10 million units, signaling strong consumer demand.

However, a well-designed electric motorcycle must go beyond just sustainability--it must meet rider expectations for performance, durability, and ease of use.

The Shift from Mechanical to Electrical & Electronics Engineering In traditional automobiles, internal combustion engine (ICE) vehicles are primarily mechanical machines. Almost every component, from the engine to the transmission, is mechanically driven.

However, electric vehicles (EVs) represent a fundamental shift, much like how smartwatches replaced traditional wristwatches with digital technology. In EVs, approximately 50% of the engineering focus is on electronics and electrical systems, while only 50% remains mechanical. This transformation impacts every part of the vehicle, requiring a different approach to design, development, and integration.

The transition also means that software and digital capabilities play a much larger role, making an electric motorcycle function more like a smart device on wheels. With the reduction in the number of moving parts in EVs, vibrations are significantly reduced, creating a very smooth driving experience.

The Need for Bigger and Custom Components Unlike ICE vehicles with an established supply chain ecosystem, electric motorcycles require a new set of essential, larger sub-components.

The engine is replaced by the motor, the fuel tank is replaced by the battery, and petrol is replaced with electricity, making the battery pack and motor the most crucial components. It's not just about fitting a battery and a motor, but also the BMS and Inverter to safely perform with precise customization and calibration. Each component must be uniquely designed to match performance needs, as most parts are not readily available in the market.

The BMS, which regulates battery performance, is entirely different from a Power Distribution Unit (PDU), which manages power flow across the vehicle. Since off-the-shelf solutions often don't meet the unique requirements of electric motorcycles, companies must develop and design these components specifically to align with market needs. This makes EV engineering highly specialized and requires a ground-up approach rather than simple modifications of ICE designs.

Rethinking the Motorcycle Chassis and Design

A traditional motorcycle is like a typewriter--built around mechanical components, where every keypress moves a lever to strike ink on paper. Switching to electric is like moving to a computer, where typing is digital, and the entire system operates on different principles. When transitioning to electric, it's not like removing the engine entirely and replacing it with an advanced battery system--but, the entire structure, weight balance, and functionality need to be rethought.

Engineers must reconsider weight distribution, ensuring the battery is positioned strategically to maintain balance and stability. Structural integrity is another crucial factor, as the frame must be strong yet lightweight to counterbalance the added battery weight. Ergonomics play a vital role in ensuring rider comfort while accommodating a completely different power system.

Additionally, the heavier electric powertrain means that suspension and braking systems need to be recalibrated to maintain optimal safety and handling, making the engineering process more intricate than simply swapping an engine for a motor.

Optimizing the Electric Powertrain An electric motorcycle's powertrain functions differently than a petrol-powered bike. Instead of multiple gears and an exhaust system, an electric motor provides instant torque with minimal moving parts, much like an automatic sliding door compared to a manual one.

High-efficiency motors are preferred for their compact size and superior power-to-weight ratio. Since electric motors have a broad powerband, a single-speed transmission is sufficient, eliminating the need for complex gear shifts. Additionally, energy efficiency is improved through features like regenerative braking, which helps recapture energy and extend range.

However, integrating these components requires deep customization to ensure seamless power delivery and optimal battery consumption.

Battery and Energy Management Challenges If the electric motor is the engine of the motorcycle, then the battery is its powerhouse--determining how far and how efficiently it can go. However, designing an optimal battery system comes with several challenges.

There is a constant trade-off between energy density and weight, as increasing battery capacity extends range but also adds significant weight. Efficient thermal management ensures consistent performance, preventing overheating and allowing the battery to operate at its best, just like a well-ventilated laptop runs smoothly even under heavy usage. Charging compatibility is another crucial factor, with advanced systems enabling fast charging while maintaining long-term battery health--much like optimized charging algorithms in smartphones that extend battery life.

Adapting Traditional Motorcycle Components

Although the powertrain in an electric motorcycle is entirely different, traditional mechanical components like suspension, brakes, frame, and chassis are still essential. However, these components must be adapted to work in harmony with the new power train. The increased battery weight may necessitate stronger suspension, while regenerative braking requires coordination with conventional braking systems.

A simple switch from ICE to electric isn't enough--each component must be re-engineered to match the vehicle's new power dynamics.

The Integration of Software and Digital Features Unlike ICE motorcycles, EVs incorporate advanced software and digital features, making them function almost like a smartphone on wheels. Riders can access features such as document storage, Bluetooth call features, and ride analytics.

This level of connectivity enhances the overall user experience, ensuring riders stay informed and connected while on the move. Just as smartphones have evolved beyond mere communication devices into smart assistants, electric motorcycles offer far more than basic transportation.

Addressing Range and Cost Optimization One of the biggest hurdles for electric motorcycles is ensuring they can travel long distances without making them prohibitively expensive.

Imagine buying a suitcase: a bigger one can fit more items but is harder to carry. Similarly, adding more battery increases range but also adds weight and cost. To address this, engineers focus on aerodynamics to reduce wind resistance, much like how cyclists lean forward to cut through the air.

Lightweight materials such as aluminum and composites help maintain strength while keeping the weight down. Offering scalable battery configurations allows different customers to choose the right balance between cost and range based on their commuting needs. Electric motorcycles are not just a modified version of traditional bikes; they require a ground-up redesign.

Much like how electric cars aren't just fuel-powered cars without an engine, electric motorcycles need a new engineering approach to maximize performance, efficiency, and affordability. By integrating advanced design principles, efficient powertrains, and smart energy management, manufacturers can create a motorcycle that isn't just good for the environment--it's better for the rider, too. The future of two-wheel mobility belongs to those who embrace innovation.

The question isn't if electric motorcycles will take over--it's how fast we can engineer them to be the best they can be.

About the author

Mr.

Phunith Kumar V, CPO & Co-Founder, Raptee.HV

Also read: Raptee aspires to address low e-motorcycle adoption in India[1]

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References

1. ^ Raptee aspires to address low e-motorcycle adoption in India (evreporter.com)