2/3 WHEELER AUTO ELECTRONIC
SPARE PART MANUFACTURING
[CODE NO.3456]
(1) The Basics of a 2/3 wheeler Charging System
On almost every motorcycle you will find a battery, used for providing power for starting the bike and for buffering an amount of electric energy. The battery itself is charged by a generator driven by the engine, and as long as the engine is running there will be a current flowing through the battery. The no load voltage of a fully charged battery is about 13 Vdc. For charging it the charging-system should provide a voltage of about 14.4 Vdc and this should be a constant voltage at all engine-speeds.
The generator itself is located in or on the engine, and on most bikes there is a separate regulator-rectifier unit located somewhere on the frame. The reason for this is that almost all motorcycles are equipped with a three-phase AC (Alternating Current) generator, while the electrical system on the bike is a DC (Direct Current) system. The rectifier part inside the regulator-rectifier takes care of converting the AC-current to the DC-current the battery needs. The three-phase AC generator is used so often because it is much more efficient and reliable than a DC-generator. It can produce power for charging the battery even with the engine idling. The regulator part of the regulator-rectifier is used to regulate the output-voltage (to the battery) to the 14.4 Vdc that is needed.
RECTIFIER
A rectifier is an electrical device composed of one or more diodes that converts alternating current (AC) to direct current (DC). A diode is like a one-way valve that allows an electrical current to flow in only one direction. This process is called rectification.
Types of rectifiers
The rectifiers are mainly classified into two types:
• Half wave rectifier
• Full wave rectifier
Half wave rectifier
As the name suggests, the half wave rectifier is a type of rectifier which converts half of the AC input signal (positive half cycle) into pulsating DC output signal and the remaining half signal (negative half cycle) is blocked or lost. In half wave rectifier circuit, we use only a single diode.
Full wave rectifier
The full wave rectifier is a type of rectifier which converts the full AC input signal (positive half cycle and negative half cycle) to pulsating DC output signal. Unlike the half wave rectifier, the input signal is not wasted in full wave rectifier. The efficiency of full wave rectifier is high as compared to the half wave rectifier.
Regulator
It controls the generator output according to the need. It controls the current or voltage.
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%
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 – A:
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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