Industry Overview
The two- and three-wheeler electrical system industry plays an important role in the automotive components sector, particularly in the manufacturing of charging systems and ignition systems. These systems ensure reliable engine starting, battery charging, voltage regulation, and efficient electrical operation in motorcycles and other two- and three-wheelers.
A typical two-wheeler charging system consists of a battery, an engine-driven generator, and a regulator-rectifier unit. The generator generally produces three-phase alternating current (AC), which is converted into direct current (DC) by the rectifier to charge the battery. The regulator maintains a suitable charging voltage, approximately 14.4 Vdc, across different engine speeds. Rectifiers are primarily classified into half-wave and full-wave types, with full-wave rectifiers offering higher efficiency.
The industry also covers Capacitive Discharge Ignition (CDI) and Inductive Discharge Ignition (IDI) systems, which are essential for controlling ignition in two- and three-wheelers. Manufacturing activities include PCB preparation, component assembly, soldering, wiring, heatsink fabrication, testing, and troubleshooting. Major components include diodes, transistors, resistors, capacitors, SCRs, MOSFETs, and integrated circuits.
The project focuses on manufacturing regulator-rectifier units and CDI modules for two- and three-wheelers. It covers manufacturing processes, BIS specifications, market position, import and export data, plant layout, and suppliers of raw materials, electronic components, and manufacturing equipment. Product quality, reliable performance, and adherence to applicable standards are important considerations in this industry.
Cost Estimation
| Plant Capacity | 120.00 No./day |
|---|---|
| Land & Building (20000 Sq.Mtr) | Rent |
| Plant & Machinery | Rs. 13.00 Lacs |
| Working Capital for 2 Months | Rs. 32.05 Lacs |
| Total Capital Investment | Rs. 49.06 Lacs |
| Rate of Return | 52% |
| Break Even Point | 67% |
Content Index
- INTRODUCTION
- (1) THE BASICS OF A 2/3 WHEELER CHARGING SYSTEM
- RECTIFIER
- TYPES OF RECTIFIERS
- THE RECTIFIERS ARE MAINLY CLASSIFIED INTO TWO TYPES:
- HALF WAVE RECTIFIER
- FULL WAVE RECTIFIER
- REGULATOR
- REGULATORS FOR ALTERNATOR
- REGULATOR RECTIFIER (RR) UNIT
- WHAT IS A REGULATOR/RECTIFIER
- TYPES OF REGULATOR/RECTIFIERS
- REGULATOR RECTIFIER STANDARD WIRE COLOURS
- REGULATOR RECTIFIER WIRING BASICS
- HOW DO REGULATOR RECTIFIERS WORK?
- WHAT IS A BRIDGE RECTIFIER?
- THE PULSING ON THE DC OUTPUT IS KNOWN AS DC RIPPLE. THIS CAN BE SEEN BY PLOTTING THE DC RIPPLES AGAINST TIME ON A GRAPH:
- DC RIPPLE SMOOTHING WITH A CAPACITOR
- THE DISADVANTAGES OF HALF WAVE RECTIFIERS
- HOW DOES A VOLTAGE REGULATOR WORK?
- (2) BASICS OF 2/3 WHEELER IGNITION SYSTEMS
- CAPACITIVE DISCHARGE BASED IGNITION SYSTEM
- TYPES
- AC-CDI
- DC-CDI
- ADVANTAGES AND DISADVANTAGES OF CDI
- INDUCTIVE DISCHARGE IGNITION (IDI) SYSTEM
- BASIC OPERATIONS OF INDUCTIVE DISCHARGE IGNITION (IDI) SYSTEM
- CDI (CAPACITOR DISCHARGE IGNITION) & SOLID STATE IGNITION SYSTEMS
- CDI BOX OR BLACK BOX
- TYPES OF CDI MODULE
- THERE ARE MAJORLY TWO TYPES OF CDI MODULES:
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- (A) FOR REGULATOR RECTIFIER
- STEP 1: PREPARING THE LAYOUT
- STEP 2: CUTTING AND FINISHING THE HEATSINK
- STEP 3: SOLDERING THE MAIN PART
- STEP 4: WIRING
- ON THESE PHOTOS THE WIRES ARE:
- STEP 5: CHECKING AND TROUBLESHOOTING
- TO DO THIS:
- TO CHECK ULN2003A YOU NEED TO:
- CHECK THE OPERATION OF BTA TRIAC:
- HOW TO TEST A REGULATOR RECTIFIER
- NECESSARY MATERIALS
- INSTRUCTIONS
- (2) FOR CDI MODULE BOX
- PARTS LIST FOR THE CIRCUIT DIAGRAM
- CDI WIRING
- MARKET POSITION
- TWO-WHEELERS
- HONDA IS BIGGEST VOLUME GAINER IN FY2018
- TVS NOTCHES RECORD SALES, JUPITER SHINES BRIGHTER
- BAJAJ AUTO FEELS THE HEAT IN INDIA, BUT IS A KING IN EXPORTS
- ROYAL ENFIELD GUNS FOR SALES, IMPLEMENTS EXPANSION PLANS
- SUZUKI MOTORCYCLES INDIA: THE DARK HORSE
- MOVERS AND SHAKERS IN THE INDIAN TWO-WHEELER INDUSTRY
- THREE-WHEELER SALES TAKE A HIT IN FY2017
- HOW THE OEMS FARED
- SLACKENING DEMAND IN THE EXPORT MARKET
- ADHERING TO THE HIGHEST QUALITY STANDARDS
- A PROMISING FUTURE AHEAD
- CHALLENGES THAT NEED IMMEDIATE ATTENTION
- THE ROAD AHEAD
- EXPORT DATA OF CDI
- IMPORT DATA OF CDI
- EXPORT DATA OF REGULATOR RECTIFIER UNIT
- IMPORT DATA OF REGULATOR RECTIFIER UNIT
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF REGULATOR RECTIFIERS AND CDI FOR TWO/THREE WHEELER
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PCB
- SUPPLIERS OF TRANSISTERS
- SUPPLIERS OF DIODES
- SUPPLIERS OF RESISTOR
- SUPPLIERS OF CAPACITOR
- SUPPLIER OF SCR
- SUPPLIERS OF MOSFET
- SUPPLIERS OF INTEGRATED CIRCUIT
- SUPPLIERS OF POWER CORD
- SUPPLIERS OF COPPER WIRE
- SUPPLIERS OF SOLDER PASTE
- SUPPLIERS OF PLANT AND EQUIPMENTS
- SUPPLIERS OF HEAT WAVE SOLDERING MACHINE
- SUPPLIERS OF OSCILLOSCOPE
- SUPPLIERS OF SOLDERING IRON
- SUPPLIERS OF PCB CUTTING MACHINE
- SUPPLIERS OF PCB DRILLING MACHINE
- SUPPLIERS OF PCB ASSEMBLING MACHINE
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
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