E-RICKSHAW, E-LOADER AND RETROFIT KIT CONVERTING ELECTRIC AUTO THREE WHEELER RICKSHAW
[EIRI/EDPR/3916] J.C.: 2036US$, 2400INR
Electric rickshaws (also known as Tuk Tuk, e-rickshaw) have been becoming more popular in some cities an alternative to auto rickshaws and pulled rickshaw because of their low fuel cost, and less human effort compared to pulled rickshaws. They are being widely accepted as an alternative to Petrol/Diesel/CNG auto rickshaws. They are 3 wheels pulled by an electric motor ranging from 650-1400Watts. They is mostly manufactured in China, only a few other countries manufacture these vehicles.
Battery-run rickshaws could be a low-emitter complementary transport for the low-income people, who suffer most from a lack of transport facility, if introduced in a systematic manner according to experts.
E-rickshaws are small vehicles, with three wheels and use electric power from batteries to run. They use an electric motor as engine which draws electric power from the rechargeable batteries installed in the rickshaw body. These battery operated vehicles are perfect for small distant transport, both cargo and people; they are perfect for running on narrow streets because of their small size. But the biggest reason for their popularity is low operating cost and zero pollution. They are like normal rickshaws but powered by electric motor instead of petrol or diesel motor. They are best for pollution free, environmental friendly transport system in short distances. Actually they are not capable of running long distance. E-rickshaws are now one of the preferred modes of transport in streets because of its low maintenance cost, low fuel cost, eco-friendly, no noise pollution, easy to drive and last but not the least livelihood, e-rickshaw is a boon to the common Man. Without putting in much physical efforts and without investing much amount of money, the earning is quite good for an e-rickshaw driver and hence it is an important means of livelihood for many. These e-rickshaws consist of 3 wheels with a differential mechanism at rear wheels. Basically these vehicles have a mild steel tubular chassis. The motor is brushless DC motor manufactured mostly in India and China. The electrical system used in Indian version is 48V DC can run 90-100 km/full charge. Basic seating capacity is driver plus 4 passengers.
COST ESTIMATION
Plant Capacity 30 Nos/Day
Land & Building (4000 sq.mt.) Rs. 3.13 Cr
Plant & Machinery Rs. 72.61 Lac
Working Capital for 2 Months Rs. 18.68 Cr
Total Capital Investment Rs. 22.76 Cr
Rate of Return 73%
Break Even Point 22%
CONTENTS
INTRODUCTION
CLASSIFICATION OF MOTOR VEHICLES WITH LESS THAN FOUR WHEELS
1. CATEGORY L1:
2. CATEGORY L2:
3. CATEGORY L3:
4. CATEGORY L4:
5. CATEGORY L5:
(A) E-RICKSHAW
CONSTRUCTION OF E-RICKSHAW
MAJOR PARTS AND COMPONENTS
ELECTRIC MOTOR:
ELECTRONIC MOTOR CONTROLLER:
BATTERY:
DIFFERENTIAL:
THE MAIN FUNCTIONS OF A DIFFERENTIAL ARE:
FRONT SHOCK ABSORBERS:
REAR SUSPENSION:
BRAKES:
SPEEDOMETER/INDICATOR
STEERING:
MISCELLANEOUS SPARE PARTS:
ADVANTAGES OF E-RICKSHAWS
DISADVANTAGES OF E-RICKSHAWS
TECHNICAL SPECIFICATIONS E-RICKSHAW
TECHNICAL SPECIFICATION OF PROPOSED THREE-WHEELER
SPECIFICATION CONSIDERED FOR THE PROPOSED WORK
E-LOADER
E-LOADER SPECIFICATIONS
RETROFIT OF FUEL THREE WHEELER AUTO RICKSHAW INTO ELECTRIC THREE WHEELER AUTO RICKSHAW
REASONS FOR CONVERSION
TECHNICAL SPECIFICATION OF RETROFIT THREE WHEELER ELECTRIC RICKSHAW
RETROFITTED AUTO
TECHNICAL SPECIFICATION
OVERVIEW OF DESIGN OF ELECTRIC VEHICLE
DESIGN OF CHASSIS
TABLE -: APPROXIMATE MASSES OF MAIN COMPONENTS
SELECTION OF BLDC MOTOR
FIG - BLDC MOTOR
CALCULATIONS –
SELECTION OF DIFFERENTIAL AXEL
FIG - DIFFERENTIAL AXEL
SELECTION OF BATTERY
MODELLING OF SYSTEM COMPONENTS 3-WHEELER RICKSHAW
FIG: - VEHICLE LOAD MODEL
BLOCK DIAGRAM OF ELECTRIC DRIVE SYSTEM WITH DUAL ENERGY SOURCES
MODELING OF LI-ION BATTERY
FIG:- EQUIVALENT ELECTRICAL CIRCUIT–BASED LI-ION MODEL MODELLING OF UCS
FIGURE: ELECTRICAL EQUIVALENT OF UC
SPECIFICATION OF LI-ION BATTERY BANK
SPECIFICATION OF UC BANK
B.I.S. SPECIFICATION
MANUFACTURING PROCESS
PURCHASE OF RAW MATERIAL:
CUTTING OF RAW MATERIAL:
CHASSIS SECTION
SHAPING:
FLEXING OF COMPONENTS:
FABRICATION & BODYBUILDING SHOP
BODING:
PAINTING:
HEATING:
PRE-DELIVERY INSPECTION:
PROCESS FLOW CHART FOR E-RICKSHAW AND E-LOADER
SUB ASSEMBLIES ARE:-
FABRICATION PROCESS
POWDER COATING PROCESS
ASSEMBLING PROCESS OF E-RICKSHAW AND E-LOADER
ASSEMBLING & FITTING PROCESS:
QUALITY CONTROL
A. SPECIFICATIONS OF THE 4 -SEATER E-RICKSHAW:
B. FITNESS, COMPLIANCE & TEST CERTIFICATES TO BE SUBMITTED FOR THE E-RICKSHAW:
C. TYPE OF MOTOR:
D. MOTOR CONTROLLER AND THE POWER SUPPLY SYSTEM:
E. STORAGE BATTERY:
F. MECHANICAL POWER TRANSMISSION:
G. OVERALL RICKSHAW DESIGN:
H. SUPPLIER/MANUFACTURER CONDITIONS:
I. TESTING
(B) RETROFIT PROCESS OF THREE WHEELER AUTO RICKSHAW
HERE ARE THE STEPS:
OTHER DETAILS:-
MARKET SURVEY
MAHINDRA
THUKRAL ELECTRIC BIKES
KINETIC GREEN
BABA E-RICKSHAW
JEZZA MOTORS
UDAAN E-RICKSHAW
BAHUBALI E RICKSHAW
SKYRIDE E RICKSHAW
QUEEN E RICKSHAW
GAYAM MOTOR WORKS
MARKET DYNAMICS
TRENDS
DRIVERS
RESTRAINTS
OPPORTUNITIES
COMPANIES PROFILED
DRIVER
RESTRAINT
INDIA ELECTRIC RICKSHAW MARKET COMPETITIVE LANDSCAPE
LEADING PLAYERS IN THE GLOBAL E-RICKSHAW MARKET ARE:
SAFETY AND SECURITY
ELECTRIC RICKSHAW FROM CHINA FOR INDIA AND BANGLADESH
BATTERY OPERATED E-RICKSHAWS IN THE STATE OF DELHI
THE SOCIO-ECONOMIC ASPECT INTO CONSIDERATION
BATTERY OPERATED E RICKSHAW IN DELHI
46% OF THESE MIGRATED FROM NORTHERN INDIA.
APPROVAL, VERIFICATION AND AUTHORISATION
INDIA ELECTRIC RICKSHAW MARKET OVERVIEW
INDIA ELECTRIC RICKSHAW MARKET, BY MOTOR POWER, '000 UNITS (2013-2023)
INDIA ELECTRIC RICKSHAW MARKET DYNAMICS
DRIVER
RESTRAINT
INDIA ELECTRIC RICKSHAW MARKET COMPETITIVE LANDSCAPE
ELECTRIC VEHICLES IN INDIA
BUT BEFORE WE BEGIN: NAY-SAYERS
NAY-SAYERS: POLLUTION
SO HOW DO WE ENABLE ELECTRIC VEHICLE TODAY
FOR CITY-BUSES
FOUR-WHEELERS
PUBLIC CHARGERS
TO CONCLUDE
GOVERNMENT OF KERALA POLICY ON ELECTRIC MOBILITY
INTRODUCTION
REGISTERED VEHICLE IN THE STATE 2016 ECONOMIC REVIEW
VISION
EV POPULATION TARGETS
INVESTMENT TARGETS
KEY POLICY DRIVERS
MANAGING THE ELECTRICITY GRID
UPGRADING THE BUS TRANSPORT FLEETS
INDUSTRIAL GROWTH
TRANSITION STRATEGY
TECHNICAL ADVISORY COMMITTEE
CATEGORIES OF VEHICLES
LIGHT ELECTRIC VEHICLES
TWO WHEELERS:
THREE WHEELERS:
FOUR WHEELERS
HEAVY ELECTRIC VEHICLES/ELECTRIC BUSES
ELECTRIC BOATS
EV CHARGING INFRASTRUCTURE:
STRATEGIC INITIATIVES
1. ADDRESSING THE VIABILITY GAP
2. CREATING ADEQUATE CHARGING INFRASTRUCTURE-INTEROPERABLE
3. MANUFACTURING IN THE STATE
A. DRIVE TECHNOLOGY
4. INCENTIVE AND SUBSIDIES FOR LOCALIZATION
PILOT PROJECTS AND PROMOTION
1. CREATION OF E MOBILITY ZONES (PILOT REGIONS)
THE POTENTIAL AREAS ARE:
2. SUPPORT SCHEMES FOR EARLY ADOPTION
3. HUMAN CAPACITY BUILDING
1. CENTRE OF EXCELIENCE FOR ELECTRIC AND AUTOMOUS VEHICLES:
2. CURRICULUM UPDATES FOR EVS AND AVS
3. SKILLING PROGRAMS FOR EV & AV INDUSTRY
4. CONNECTED AND AUTONOMOUS VEHICLE TESTING CORRIDOR:
FUTURE E RICKSHAWS
STRUCTURE
ERGONOMICS
SEATING POSITION AND ENTRY/EXIT
UTILITIES
PROVISION FOR LUGGAGE CARRIER
THE COMPONENTS OF THE E RICKSHAW ARE CRITICAL:
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF E-RICKSHAW AND E-LOADER
MANUFACTURERS/SUPPLIERS OF RETROFIT ELECTRIC AUTO SAURSAURABH ELECTRIC AUTO
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF HOT ROLLED SHEETS
SUPPLIERS OF M.S CHANNELS AND ANGLES
SUPPLIERS OF M.S. PLATE
SUPPLIERS OF M.S. PIPE
SUPPLIERS OF MIG WELDING WIRE ELECTRODE
SUPPLIERS OF EPOXY COATING POWDER
SUPPLIERS OF REAR AXLE
SUPPLIERS OF DIFFERENTIAL
SUPPLIERS OF WHEEL
SUPPLIERS OF LEAD ACID BATTERY
SUPPLIERS OF LI-ION BATTERY PACK
SUPPLIERS OF BATTERY CHARGER
SUPPLIERS OF LIGHT ASSEMBLY
SUPPLIERS OF BRAKES
SUPPLIERS OF T-HANDLE SET
SUPPLIERS OF STEERING SYSTEM
SUPPLIERS OF PLANT AND EQUIPMENTS
SUPPLIERS OF POWER PRESS
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF ROLLING MACHINE
SUPPLIERS OF BENDING MACHINE
SUPPLIERS OF PUNCHING PRESS
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF MIG WELDING MACHINE
SUPPLIERS OF POWDER COATING MACHINE
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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