Design and implementation of an IoT-Enabled electric motorcycle conversion platform with integrated rider heart-rate monitoring and safety functions

Abstract

The transition from conventional fuel-powered vehicles to electric mobility has become an important strategy for reducing environmental impacts and improving transportation sustainability. This study presents the design, implementation, and experimental evaluation of an IoT-enabled smart platform for converting a conventional TVS HLX 100 motorcycle into an electric vehicle while integrating rider heart-rate monitoring and intelligent safety functions. The conversion process involved replacing the internal combustion engine with a 3000 W brushless DC (BLDC) mid-drive motor powered by a 72 V, 40 Ah lithium-ion battery pack. A motor controller and battery management system were incorporated to ensure efficient power delivery, battery protection, and reliable operation. To enhance vehicle functionality, an Internet of Things (IoT) architecture based on an ESP32 microcontroller was developed for real-time monitoring and communication. The platform integrates battery voltage, current, and temperature sensing, GPS-based tracking, ultrasonic obstacle detection, accident detection, and rider heart-rate monitoring. Operational data are transmitted through a Telegram-based interface, enabling remote supervision of vehicle status and rider heart-rate information. The safety subsystem provides collision warning alerts when nearby obstacles are detected and automatically sends emergency notifications with GPS coordinates in the event of an accident. Furthermore, the physiological monitoring module supports rider safety by continuously monitoring rider heart rate and reducing motor speed when predefined abnormal heart-rate thresholds are detected. Experimental testing demonstrated reliable operation of the propulsion, communication, heart-rate monitoring, and safety subsystems. The developed prototype achieved an overall drivetrain efficiency of approximately 80%, an estimated driving range of 58–82 km per charge, and a charging time of 4–5 h. The proposed platform demonstrates the feasibility of combining electric vehicle conversion, connected heart-rate monitoring, and intelligent safety technologies within a single smart mobility framework.