Industry Overview
Motor vehicles with less than four wheels are classified into categories L1 to L5 based primarily on the number and arrangement of wheels, engine cylinder capacity in the case of thermic engines, and maximum design speed. Category L1 covers two-wheeled vehicles with an engine cylinder capacity not exceeding 50 cm3 and a maximum design speed not exceeding 50 km/h, while Category L2 covers three-wheeled vehicles meeting the same engine and speed limits. Categories L3, L4, and L5 cover higher-capacity or higher-speed two- and three-wheeled vehicles, with L4 specifically covering three-wheeled vehicles asymmetrically arranged in relation to the longitudinal median plane, such as motorcycles with sidecars.
The report focuses extensively on electric three-wheelers, including e-rickshaws, e-loaders, and the retrofit of fuel-powered three-wheeler auto rickshaws into electric vehicles. It covers construction, major components, specifications, fabrication, powder coating, assembly, quality control, testing, compliance, and retrofit processes. It also examines the electric rickshaw market, safety and security, market dynamics, competitive landscape, electric vehicle adoption, charging infrastructure, and government policy initiatives, including the Government of Kerala policy on electric mobility. The report further addresses manufacturing requirements, suppliers, plant layout, equipment, raw materials, and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 10.00 Nos/Day |
| Land & Building (3000 Sq.Mtr) | Rs. 1.33 Cr |
| Plant & Machinery | Rs. 52.92 Lacs |
| Working Capital for 1 Month | Rs. 3.05 Cr |
| Total Capital Investment | Rs. 4.96 Cr |
| Rate of Return | 40% |
| Break Even Point | 45% |
Content Index
- INTRODUCTION
- 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
- SPECIFICATION OF E-RICKSHAW
- (B) E-LOADER
- E-LOADER SPECIFICATIONS
- (B) RETROFIT OF FUEL THREE WHEELER AUTO RICKSHAW INTO ELECTRIC THREE WHEELER AUTO RICKSHAW
- REASONS FOR CONVERSION
- TECHNICAL SPECIFICATION OF RETROFIT THREE WHEELER ELECTRIC RICKSHAW
- TECHNICAL SPECIFICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART FOR E-RICKSHAW AND E-LOADER
- 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:
- MARKET OVERVIEW
- TERRA MOTORS EYES 30,000 E-RICKSHAWS SALES IN INDIA BY YEAR-END (2016-17)
- 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
- 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
- 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
- TWO WHEELERS:
- THREE WHEELERS:
- FOUR WHEELERS
- HEAVY ELECTRIC VEHICLES/ELECTRIC BUSES
- ELECTRIC BOATS
- EV CHARGING INFRASTRUCTURE:
- STRATEGIC INITIATIVES
- ADDRESSING THE VIABILITY GAP
- CREATING ADEQUATE CHARGING INFRASTRUCTURE-INTEROPERABLE
- 3. MANUFACTURING IN THE STATE
- 4. INCENTIVE AND SUBSIDIES FOR LOCALISATION
- PILOT PROJECTS AND PROMOTION
- 1. CREATION OF E MOBILITY ZONES (PILOT REGIONS)
- 2. SUPPORT SCHEMES FOR EARLY ADOPTION
- 3. HUMAN CAPACITY BUILDING
- 1. CENTRE OF EXCELLENCE 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:
- PLANT LAYOUT 97
- MANUFACTURERS/SUPPLIERS OF E-RICKSHAW AND E-LOADER
- MANUFACTURERS/SUPPLIERS OF RETROFIT ELECTRIC AUTO
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF HOT ROLLED SHEETS
- M.S CHANNELS AND ANGLES 104
- M.S. PLATE
- M.S. PIPE
- MIG WELDING WIRE ELECTRODE
- 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 PLANT AND EQUIPMENTS
- POWER PRESS
- SHEARING MACHINE
- ROLLING MACHINE
- BENDING MACHINE
- PUNCHING PRESS
- GRINDING MACHINE
- SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
- MIG WELDING MACHINE
- POWDER COATING MACHINE
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR COMPRESSORS
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- JIGS AND FIXTURE
- SUBMERSIBLE WATER PUMP
Appendix
- 1. COST OF PLANT ECONOMICS
- 2. LAND & BUILDING
- 3. PLANT AND MACHINERY
- 4. FIXED CAPITAL INVESTMENT
- 5. RAW MATERIAL
- 6. SALARY AND WAGES
- 7. UTILITIES AND OVERHEADS
- 8. TOTAL WORKING CAPITAL
- 9. COST OF PRODUCTION
- 10. PROFITABILITY ANALYSIS
- 11. BREAK EVEN POINT
- 12. RESOURCES OF FINANCE
- 13. INTEREST CHART
- 14. DEPRECIATION CHART
- 15. CASH FLOW STATEMENT
- 16. PROJECTED BALANCE SHEET
Frequently Asked Questions
L1 to L5 classify two- and three-wheeled motor vehicles according to wheel arrangement, engine capacity, and maximum design speed.
L1 covers certain low-capacity two-wheelers, while L2 covers corresponding three-wheelers. L3 covers higher-capacity or higher-speed two-wheelers. L4 covers asymmetrically arranged three-wheelers, such as motorcycles with sidecars, and L5 covers symmetrically arranged three-wheelers. These categories provide a structured basis for vehicle classification and technical requirements.
An e-rickshaw is a three-wheeled electric vehicle powered by an electric motor and rechargeable battery system.
The battery supplies electrical energy to the motor controller, which regulates power delivered to the electric motor. Mechanical power is then transmitted through the drivetrain and differential to the driven wheels. The vehicle also incorporates systems such as steering, brakes, suspension, speedometer or indicators, and other supporting components. Proper integration of these systems is important for vehicle performance, safety, reliability, and compliance.
The major components of an e-rickshaw include the electric motor, electronic motor controller, battery, differential, suspension, brakes, steering system, and instrumentation.
The report also identifies front shock absorbers, rear suspension, speedometer or indicators, miscellaneous spare parts, and mechanical power transmission components. Each system contributes to vehicle operation and safety. Component selection should consider compatibility, load requirements, durability, electrical characteristics, and applicable technical and regulatory requirements.
Manufacturing an e-rickshaw or e-loader involves fabrication, surface treatment, component assembly, fitting, inspection, and testing.
The process described in the report includes fabrication of structural components, powder coating, assembly of the electric drivetrain and mechanical systems, and final fitting. Quality control is applied to specifications, motor and controller systems, batteries, mechanical power transmission, overall vehicle design, supplier or manufacturer conditions, and testing. Suitable plant equipment and properly organized production areas are also required for consistent manufacturing.
Retrofitting a fuel-powered three-wheeler into an electric vehicle involves replacing or integrating the conventional propulsion system with an electric drivetrain.
The process requires assessment of the existing vehicle, selection and installation of an appropriate electric motor, controller, battery and power supply system, and integration with the mechanical transmission. Structural and electrical modifications must be carried out carefully, followed by fitting, inspection, and testing. The report also addresses technical specifications, B.I.S. specifications, approval, verification, authorisation, and compliance requirements relevant to the retrofit process.
E-rickshaw quality control requires systematic verification of vehicle specifications, electrical systems, mechanical systems, safety features, and applicable certification requirements.
Important areas include the motor type, motor controller and power supply system, storage battery, mechanical power transmission, overall vehicle design, and supplier or manufacturer conditions. Testing is an essential part of the process. The report specifically includes fitness, compliance and test certificates, B.I.S. specifications, and testing requirements, highlighting the importance of validating the finished vehicle before it is placed into service.
An e-rickshaw manufacturing plant requires structural materials, electrical and mechanical components, fabrication equipment, finishing equipment, and supporting plant utilities.
The report identifies materials such as hot rolled sheets, M.S. channels and angles, M.S. plate, M.S. pipe, welding wire electrode, and epoxy coating powder. Equipment includes power presses, shearing, rolling, bending and punching machines, grinding machines, drilling and lathe machines, MIG welding equipment, powder coating machinery, air compressors, material handling equipment, fire-fighting equipment, shot blasting machines, jigs and fixtures, and submersible water pumps. Battery, motor, brake, wheel, differential, axle, charger, and lighting suppliers are also covered.
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