Detailed Project Report on electric two wheeler

ELECTRIC TWO WHEELER ( CODE NO.3732)

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Electric two-wheelers, as indicates itself, is electricity-powered two-wheelers. A battery pack and a motor are installed to store and transform the electricity. A user control is usually attached to the handle bar to brake and adjust the speed.

“Battery operated Vehicle (Two Wheeler)” means a vehicle adapted for use upon roads and powered exclusively by an electric motor whose traction energy is supplied exclusively by traction battery installed in the vehicle.

"Provided that a two wheeled battery operated vehicle shall not be deemed to be a motor vehicle if all the following conditions are verified and authorized by any testing agency specified in rule 126 namely:-

a)    Vehicle is equipped with an electric motor having thirty minute power less than 0.25 kW;

b)    Maximum speed of the vehicle is less than 25 krn/hr;

c)    Vehicle is fitted with suitable brakes and retro-reflective devices, i.e. one white reflector in the front and one red reflector at the rear;

d)    Unladen weight (excluding battery weight) of the vehicle is not more than 60 kg;

e)    In case of pedal assisted vehicle equipped with an auxiliary electric motor, in addition to above, the thirty minute power of the motor is less than 0.25 kW, whose output is progressively reduced and finally cut off as the vehicle reaches a speed of 25 km/hr, or sooner, if the cyclist stops pedaling".

COST ESTIMATION

Plant Capacity                         200 Nos/Day  
Land & Building                        Rented
Plant & Machinery                      Rs. 2.30 Cr
Working Capital for 2 Months           Rs. 38.99 Cr
Total Capital Investment               Rs. 12.41 Cr
Rate of Return                         23%
Break Even Point                       35%




INTRODUCTION    
ADVANTAGES-    
DISADVANTAGES-    
TYPES OF ELECTRIC TWO WHEELER    
1. E-BIKES    
THERE ARE MANY TYPES OF ELECTRIC BICYCLES, SOME ARE MENTIONED BELOW    
CLASS 1: PEDAL ASSIST / PEDELEC    
CLASS 2: THROTTLE    
CLASS 3: SPEED PEDELEC    
ELECTRIC BICYCLES CLASSIFICATION    
PEDAL-ASSIST    
POWER-ON-DEMAND    
THEREFORE, VERY BROADLY, E-BIKES CAN BE CLASSED AS:    
ADVANTAGES OF ELECTRIC BICYCLES    
KEY PARTS OF AN ELECTRIC BIKE    
(1) ELECTRIC MOTOR    
TYPES OF MOTOR AND DIFFERENT MOUNTING POSITIONS    
1. INDUCTION MOTOR:    
2. DC MOTOR    
PERMANENT MAGNET BRUSHLESS DC MOTOR:    
PERMANENT MAGNET BRUSHED DC MOTOR:    
MOUNTING OF MOTORS    
1. MID-DRIVE MOTOR:    
FIG 1.1: MID DRIVE MOTOR    
2. HUB MOTOR:    
I. FRONT HUB MOTOR:    
FIG 1.2: FRONT WHEEL HUB MOTOR    
II. REAR HUB MOTOR:    
FIG 1.3: REAR WHEEL HUB MOTOR    
(2) CONTROLLER OF BLDC MOTOR AND SENSORS    
CONTROLLER    
FIG 2.3: CONTROLLER    
SPEED THROTTLE    
FIG 2.4: SPEED THROTTLE    
(3) ELECTRIC BRAKE    
FIG 3.1: ELECTRIC BRAKE    
(4) BATTERY LEVEL INDICATOR    
FIG 4.1: BATTERY LEVEL INDICATOR    
BATTERY CAPACITY INDICATOR    
(5) FRAME    
FIG 5:1: FRAME DESIGN PARAMETERS    
(6) BATTERY    
BATTERY CELLS FOR E-BICYCLE BATTERY    
1. CYLINDRICAL CELL    
FIG 6.1: CYLINDRICAL CELL INTERNAL STRUCTURE    
2. PRISMATIC CELL    
FIG 6.2: PRISMATIC CELL INTERNAL STRUCTURE    
5.3 MAKING OF BATTERY PACK    
FIG 6.3: LI-ION SINGLE BATTERY    
FIG 6.4: SOLDERED BATTERY PACK    
FIG 6.5: 36 V, 13.2 AH BATTERY PACK    
FIG 6.6: BATTERY DESIGN IN FUSION360 OF 36V AND 13.2AH    
SAFETY CIRCUITS OF BATTERY    
SAFETY CIRCUITS ARE NEED BECAUSE OF FOLLOWING REASONS.    
FIG 6.7: BLOCK DIAGRAM OF WORKING OF SAFETY CIRCUIT    
SPECIFICATIONS OF BMS (BATTERY MANAGEMENT SYSTEM):    
FIG 6.8: BMS (BATTERY MANAGEMENT SYSTEM)    
2. E-SCOOTER    
ADVANTAGES OF AN ELECTRIC SCOOTER    
DISADVANTAGES    
PARTS OF ELECTRIC TWO WHEELER    
BATTERIES    
WE CAN CLASSIFY SCOOTERS ON:    
BATTERY TYPES    
RANGE AND CHARGE TIME    
BRAKES    
FRAMES AND FORKS    
BELT AND CHAIN DRIVE’S    
TYRES    
WHEEL TYPES AND SIZES    
SUSPENSION    
SPEED AND WEIGHT    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
PRODUCTION PROCESS    
ASSEMBLING PROCESS    
(1) FRONT WHEEL INSTALLATION:    
(2) HANDLEBARS INSTALLATION:    
(3) MIRRORS INSTALLATION:    
(4) PEDALS INSTALLATION:    
(5) REAR STORAGE TRUNK INSTALLATION:    
(6) THROTTLE & ACCESSORY CONTROL GRIP INSTALLATION:    
(7) SEAT INSTALLATION:    
(8) INSTALLATION OF REAR BRAKE:    
(9) TIRE INSTALLATION:    
WHEEL ADJUSTMENTS/MAINTANENCE:    
(10) DRIVE CHAIN INSTALLATION:    
CHECKING CHAIN TENSION:
TIGHTEN DRIVE CHAIN:    
LOOSEN DRIVE CHAIN:    
(11) BATTERY INSTALLATION    
(12) INSTALLATION OF ADOPTER    
(13) TESTING OF ELECTRIC TWO WHEELER    
(PRODUCT TESTING) E-BIKE TEST PROCEDURE.    
MARKET OVERVIEW FOR ELECTRIC SCOOTERS AND MOTORCYCLES    
DRIVERS    
CHALLENGES    
INDIA ELECTRIC SCOOTERS AND MOTORCYCLES MARKET - COMPETITIVE LANDSCAPE    
INDIA ELECTRIC SCOOTERS AND MOTORCYCLES MARKET    
TWO WHEELERS TO LEAD ELECTRIC VEHICLE MARKET IN INDIA    
ASIA-PACIFIC ELECTRIC SCOOTERS AND MOTORCYCLES MARKET
OVERVIEW    
DRIVERS    
CHALLENGES    
ASIA-PACIFIC ELECTRIC SCOOTERS AND MOTORCYCLES MARKET - COMPETITIVE LANDSCAPE    
ASIA-PACIFIC ELECTRIC SCOOTERS AND MOTORCYCLES MARKET SEGMENTATION    
BY VEHICLE TYPE    
BY BATTERY TYPE    
BY TECHNOLOGY    
BY VOLTAGE    
BY GEOGRAPHY    
2 & 3 WHEELER ELECTRIC VEHICLE MARKET IN INDIA & FUTURE
OUTLOOK 2022    
WHY ENINCON‘S REPORT UPON ― 2 & 3 WHEELER ELECTRIC VEHICLE MARKET IN INDIA & FUTURE OUTLOOK 2022    
BY 2022, SALES OF ELECTRIC 2W & 3W ARE EXPECTED TO REACH 1.6 MILLION IN INDIA    
2 WHEELER & 3 WHEELER SEGMENT TO DRIVE THE EV SEGMENT
IN FUTURE AS 95% OF THE TOTAL SALES COME FROM THESE SEGMENTS    
BUSINESS CASE FOR 2 & 3 WHEELER ELECTRIC VEHICLE MARKET
IN INDIA    
REPORT INSIGHTS    
KEY HIGHLIGHTS    
PRESS EXCERPTS    
MUST BUY FOR    
HYBRID AND ELECTRIC VEHICLES IN INDIA CURRENT SCENARIO
AND MARKET INCENTIVES    
STUDY OBJECTIVES    
MARKET INCENTIVES IN PLACE    
APPROACH & KEY ASSUMPTIONS    
UTILIZATION OF DEMAND INCENTIVES UNDER FAME SCHEME
FOR FY 2015-16    
TWO-WHEELERS    
INCENTIVE ANALYSIS    
CENTRAL EXCISE DUTY    
CENTRAL INFRASTRUCTURE CESS    
ADDITIONAL STATE SUBSIDIES    
TCO – TWO-WHEELERS    
LOW-SPEED ELECTRIC SCOOTERS    
HIGH-SPEED ELECTRIC SCOOTERS    
TWO-WHEELERS    
OPPORTUNITIES AND THREATS FOR THE ELECTRIC TWO-WHEELERS IN CHINA    
FIGURE 1 - THE E2W PRODUCTION NUMBER IN CHINA    
METHODOLOGY    
SWOT-FFA ANALYTICAL FRAMEWORK    
TIS ANALYTICAL FRAMEWORK    
FIGURE 2 - THE ANALYSIS SCHEME FOR TIS (BERGEK ET AL., 2008)    
THE DRIVING FORCES FOR THE CHANGE TOWARDS E2WS: SWOT-FFA    
FIGURE 3 - RESULT OF SWOT ANALYSIS OF THE E2W DEVELOPMENT    
RELATIVELY LOW COST AND COMPARABLE PERFORMANCE    
EASY ADOPTION AND UTILIZATION    
POLICY AND STANDARDS (MOTORCYCLE BAN, AIR POLLUTION AND EMISSION CONCERNS)    
EXTERNAL FACTORS    
THE RESISTING FORCES (SYSTEM WEAKNESS) OF THE E2W DEVELOPMENT: TIS ANALYSIS    
ACTORS, NETWORK, INSTITUTIONS    
SYSTEM WEAKNESS: REMARKS OF THE EVALUATION OF THE SEVEN FUNCTIONS    
FIGURE 4 - THE INDUCEMENT AND BLOCKING MECHANISMS OF E2WS CONCLUDED FROM THE TIS    
FUTURE TRANSPORT SOLUTIONS    
OVERVIEW OF THE E-BIKES & ELECTRIC TWO-WHEELERS    
ENERGY USE AND EMISSIONS OF ELECTRIC BIKE LIFE CYCLE    
ENVIRONMENTAL IMPACTS OF ALTERNATIVE MODES    
INFLUENCE OF ELECTRIC BIKES ON MOTORIZATION TRENDS    
ELECTRIC TWO-WHEELER BATTERY TECHNOLOGY STATUS    
ENERGY USE AND EMISSIONS OF ELECTRIC BIKE LIFE CYCLE    
PRODUCTION PROCESSES    
TABLE 1.1: MATERIAL INVENTORY, EMISSIONS, AND ENERGY USE OF ELECTRIC BIKE    
END-OF-LIFE    
LEAD ACID BATTERIES    
FIGURE 1.1: LEAD LOSS FLOWS FROM LEAD ACID BATTERY PRODUCTION    
TABLE 1.2: LEAD LOSSES TO THE ENVIRONMENT    
USE PHASE    
FIGURE 1.2: EMISSION RATES FROM PRC POWER PLANTS    
TABLE 1.3: REGIONAL EMISSION RATES OF TYPICAL SCOOTER STYLE ELECTRIC BIKES (UNITS AT G/100 KM EXCEPT CO2)    
TOTAL ENVIRONMENTAL IMPACTS OF ELECTRIC BIKE LIFE CYCLE    
FIGURE 1.3: POLLUTION OF BICYCLE STYLE E-BIKE OVER LIFE CYCLE    
FIGURE 1.4: POLLUTION OF SCOOTER STYLE E-BIKE OVER LIFE CYCLE    
MOTORCYCLE AND ELECTRIC BIKE OWNERSHIP GROWTH SCENARIOS THROUGH TO 2025    
METHODOLOGY    
FIGURE 3.5: REGIONAL RURAL MOTORCYCLE AND ELECTRIC BIKE OWNERSHIP VERSUS INCOME, 2005    
FIGURE 3.6: 2005 MOTORCYCLE AND ELECTRIC TWO-WHEELERS
BY REGION    
FIGURE 3.7: PROJECTIONS OF POPULATION SHARE IN DIFFERENT
INCOME BRACKETS VERSUS TIME    
TABLE 3.2: POLICY FACTORS OVER TIME IN THREE SCENARIOS    
FIGURE 3.8: PROJECTED POPULATION GROWTH BY REGION FOR
URBAN AND RURAL PEOPLE’S REPUBLIC OF CHINA    
FIGURE 3.9: ELECTRIC TWO-WHEELER AND MOTORCYCLE STOCK
OVER TIME IN THREE SCENARIOS    
FACTORS INFLUENCING FUTURE GROWTH IN ELECTRIC
TWO-WHEELER MARKET    
METHODOLOGY    
FIGURE 3.10: ELECTRIC TWO-WHEELER AND MOTORCYCLE
GROWTH IN “BUSINESS AS USUAL”    
DRIVING FORCES    
FORCE 1: TECHNOLOGY IMPROVEMENTS    
FIGURE 3.11: INDUSTRY STRUCTURE COMPARISON,
CLOSED-INTEGRAL VERSUS OPEN-MODULAR    
FIGURE 3.12: ELECTRIC TWO-WHEELER DESIGN FLEXIBILITY    
FORCE 2: LOCAL MOTORCYCLE BANS    
FORCE 3: LOCAL POLICY SUPPORT FOR ELECTRIC BIKES    
TABLE 3.4: MOTORCYCLE AND ELECTRIC-BIKE BANS IN LARGE CITIES    
FIGURE: FORCES DRIVING ELECTRIC BIKE MARKET GROWTH    
FIGURE: FORCES RESISTING ELECTRIC BIKE MARKET GROWTH    
TABLE: RANKINGS OF FORCES DRIVING AND RESISTING ELECTRIC
BIKE GROWTH    
PERFORMANCE TEST OF ELECTRIC BIKES    
TABLE 4.6: ELECTRIC BIKE AND BATTERY SPECIFICATIONS    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF ELECTRIC TWO WHEELERS    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF BLDC MOTOR    
SUPPLIERS OF MOTOR CONTROLLER    
SUPPLIERS OF LITHIUM- ION BATTERY    
SUPPLIERS OF TYRE    
SUPPLIERS OF WHEEL    
SUPPLIERS OF SPARES    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF JIGS AND FIXTURE    

APPENDIX –

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)