Self-Sustaining E cycle with Integrated Pedal Energy Recovery System

The growing demand for sustainable urban mobility has led to the evolution of electric bicycles (e-bikes). However, a major limitation remains the fixed capacity of the battery and the lack of on-board energy production. This paper presents a novel approach to energy recovery through a 'Pedal-to-Charge' mechanism. The system integrates a secondary DC generator coupled to the pedal sprocket, enabling the rider to charge the onboard battery while pedaling. Unlike conventional e-bikes where pedaling provides direct mechanical drive to the wheel, this system converts manual labor into electrical energy, which is then stored in a Lithium-ion battery pack to power a BLDC hub motor. Experimental evaluation focuses on the efficiency of the human-to-electric energy conversion, the impact of gear ratios on generator output, and the overall range extension. Results indicate that steady pedaling at 60-70 RPM can provide significant trickle charging, extending the battery life by 15-20% and providing a 'fitness-mode' for the rider.