Detailed Project Report on brushless dc motor and ac induction motor for electric vehicle

BRUSHLESS DC MOTOR AND AC INDUCTION MOTOR FOR ELECTRIC VEHICLE
[CODE NO.3578]  


(A) INDUCTION MOTOR

An induction motor or asynchronous motor is an AC electric motor in which the electric current in the rotor needed to produce torque is obtained by electromagnetic induction from the magnetic field of the stator winding

Its characteristic features are:
•    Simple and rugged construction
•    Low cost and minimum maintenance
•    High dependability and sufficiently high proficiency
•    Needs no additional starting motor and necessity not be synchronized


COST ESTIMATION

Plant  Capacity                                              :    16.00 NOS/day
land & Building (2500)Sq.Mtr)                    :    Rs. 6.83 Cr
Plant & Machinery                                         :    Rs. 1.36 Cr
Working Capital for 2 Months                     :    Rs. 1.45  Cr
Total Capital Investment                              :    Rs. 10.86  Cr
Rate of Return                                               :    19%
Break Even Point                                          :    60%


INTRODUCTION    
(A) INDUCTION MOTOR    
BASIC PARTS OF AN INDUCTION MOTOR    
STATOR    
ROTOR    
TYPES OF INDUCTION MOTORS    
(A) SINGLE PHASE INDUCTION MOTOR    
APPLICATIONS OF SINGLE PHASE INDUCTION MOTOR    
(B) THREE-PHASE INDUCTION MOTOR    
APPLICATIONS OF THREE PHASE INDUCTION MOTOR    
ADVANTAGES OF INDUCTION MOTOR    
(B) DC MOTOR    
CLASSIFICATION OR TYPES OF MOTOR    
DC MOTOR    
WORKING OF DC MOTOR    
ADVANTAGES OF DC MOTORS    
DISADVANTAGES OF DC MOTORS    
TYPES OF DC MOTORS    
THE DC MOTORS ARE DIVIDED MAINLY TO    
BRUSHLESS D.C MOTOR    
WORKING PRINCIPLE AND OPERATION OF BLDC MOTOR    
CONSTRUCTION OF BLDC MOTOR    
ROTOR    
HALL SENSORS    
TYPES OF BRUSHLESS DC MOTORS    
INNER ROTOR DESIGN    
OUTER ROTOR DESIGN    
ADVANTAGES OF BRUSHLESS DC MOTOR    
DISADVANTAGES OF BRUSHLESS DC MOTORS    
DISADVANTAGES OF BLDC MOTOR    
USES AND APPLICATIONS OF BLDC MOTORS    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
MANUFACTURING PROCESS OF BRUSHLESS D.C MOTOR    
FABRICATION PROCESS OF STATOR    
1. STAMPING    
2. STACKING    
3. SLOT INSULATION    
4. WINDING    
5. PREPPING    
FABRICATION PROCESS OF ROTOR    
ROTOR MAGNET    
1. SHAFT MACHINING    
2. HUB MACHINING    
3. HUB MAGANET GLUING    
4. BEARING PRESSING    
FABRICATION OF HOUSING AND END BELL MANUFACTURING    
ELECTRONICS MANUFACTURING    
ASSEMBLING OF BLDC MOTOR    
TESTING OF D.C MOTOR    
SHORT CIRCUIT TEST    
LOAD TEST    
METHODS FOR DETERMINING EFFICIENCY    
DIRECT METHOD (BREAK OVER TEST)    
INDIRECT METHOD (SWINBURNE TEST)    
ADVANTAGES    
DISADVANTAGE    
REGENERATIVE METHOD (HOPKINSON TEST)    
(1) VOLTAGE CONSTANT TEST    
(2) TERMINAL RESISTANCE TEST    
(3) SPEED-TORQUE TEST    
(4) DEMAGNETIZATION TEST    
(5) THERMAL RESISTANCE TEST    
(6) SAFE OPERATING AREA CURVE TEST    
(7) HOLDING TESTS    
(8) TORQUE RIPPLE    
(I) PAINTING    
(J) PACKING    
MANUFACTURING PROCESS OF INDUCTION MOTOR    
THE KEY MANUFACTURING PROCESSES ARE SUMMARISED BELOW    
(7) TESTING    
1. TYPE TESTS    
2. ROTUNE TESTS    
3. PERFORMANCE TEST    
(A) NO LOAD TEST    
(B) REDUCED VOLTAGE RUNNING UP TEST    
(D) ROTOR (SLIP RING) MOTORS    
(E) LOCKED ROTOR TEST    
(F) FULL LOAD TEST    
(8) MARKING    
MARKET POSITION    
INCREASING DEMAND FOR HVAC APPLICATIONS DRIVES THE GLOBAL
   BRUSHLESS DC MOTORS MARKET    
THE FOLLOWING ARE THE MAJOR OBJECTIVES OF THE STUDY    
BRUSHLESS DC (BLDC) MOTORS MARKET    
THE GLOBAL BRUSHLESS DC MOTORS MARKET IS CLASSIFIED
   INTO FOLLOWING CATEGORIES    
BY POWER CAPACITY    
BY DESIGN    
BY REGIONA    
ELECTRIC DC MOTOR MARKET    
TYPE INSIGHTS    
VOLTAGE INSIGHTS    
END-USE INSIGHTS    
REGIONAL INSIGHTS    
COMPETITIVE INSIGHTS    
IGARASHI MOTORS INDIA LTD MANAGEMENT DISCUSSIONS.    
AUTOMOTIVE MARKET    
AUTOMOTIVE TECHNOLOGY & CONSUMER TRENDS    
ACTUATORS & MOTORS    
ACTUATORS & MOTORS – TAM (TORQUE ACTUATOR MOTOR)    
ACTUATORS & MOTORS – CAM (COMFORT ACTUATOR MOTOR)    
LEARNINGS DURING THE YEAR    
BRUSHLESS DC MOTORS – BLDC    
NIL SPILL    
MANUFACTURING TECHNOLOGY    
NEW INFRASTRUCTURE    
PERFORMANCE 2017-18    
RISKS & CONCERNS    
SEGMENT WISE/ PRODUCT WISE PERFORMANCE    
INTERNAL CONTROL SYSTEMS & ADEQUACY    
MATERIAL DEVELOPMENTS IN HUMAN RESOURCES    
INDIA ELECTRIC MOTORS MARKET TO CROSS $ 2.25 BILLION BY 2023    
INDIA ELECTRIC MOTORS MARKET TO CROSS $ 2.25 BILLION BY 2023    
“INDIA ELECTRIC MOTORS MARKET”    
DETAILED EXPORT DATA OF DC MOTOR BRUSHLESS    
DETAILED IMPORT DATA OF BLDC MOTOR    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF BLDC MOTOR    
MANUFACTURERS/SUPPLIERS OF INDUCTION MOTOR    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF CRNGO SILICON STEEL    
SUPPLIERS OF INSULATION KRAFT PAPER    
SUPPLIERS OF COPPER WINDING WIRE    
SUPPLIERS OF PERMANENT MAGANET    
SUPPLIERS OF MOTOR SHAFT    
SUPPLIERS OF D.C MOTOR PARTS    
SUPPLIERS OF BLDC HALL SENSOR CONTROLLER    
SUPPLIRS OF PLANT AND EQUIPMENTS    
MOTOR MAKING MACHINES    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF ELECTRICAL MEASURING AND TESTING EQUIPMENT
ELECTRICAL PANEL    
COOLING TOWER    
EFFULENT TREATMENT PLANT (ETP PLANT)    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SHOT BLASTING 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