Detailed Project Report on electric two wheeler

ELECTRIC TWO WHEELER

[CODE NO.3799]  

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                                    200.00 Nos./day

Land & Building (6000 sQ.mTR)      Rs 4.43  Cr.

Plant & Machinery                            Rs 2.30 Cr

Working Capital for 2 Months         Rs 38.92 Cr

Total Capital Investment                  Rs.46.02 Cr

Rate of Return                                   35%

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 131
• METHODOLOGY 131
• 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 – A:

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)