ELECTRIC TWO WHEELER

[EIRI/EDPR/4080] J.C.: 2220XL

INTRODUCTION

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".

www.eiriindia.org 1
Advantages-

1. Noise less operation.

2. Cheapest way to travel.

3. Comfort and safety are really high.

4. Light weight.

5. Have cool pickup.

6. Have big storage (depends upon model but they have comparitively bigger
storage then that of petrol ones)

7. No licence.

8. No registration (only if your speed is limited till 35kmph)

9. No cost service on vehicle. Cause it's just oiling brakes and cleaning vehicle.

10. No helmet required (for low speed ones)

11. Best for age range of 16–60yrs people.

www.eiriindia.org 2
 CONTENTS
INTRODUCTION
ADVANTAGES-
DISADVANTAGES:-
TYPES OF ELECTRIC TWO WHEELER
1. E-BIKES
TYPES OF ELECTRIC SCOOTER
ADVANTAGES OF ELECTRIC TWO WHEELERS
LIMITATIONS OF ELECTRIC TWO WHEELERS
WORKING PRINCIPLE
WHAT ARE THE PRINCIPAL PARTS OF ELECTRIC TWO
WHEELERS FRAMEWORK?
BATTERY
BATTERY UP GRADATION
ALTERNATOR
WIRING HARNESS
CONTROLLERS
CHASSIS
POWER UNIT
BASE PLATE
CONE SET AND BEARINGS
SPECIFICATION
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:

www.eiriindia.org 3
(11) BATTERY INSTALLATION
(12) INSTALLATION OF ADOPTER
(13) TESTING OF ELECTRIC TWO WHEELER
(PRODUCT TESTING) E-BIKE TEST PROCEDURE
QUALITY CONTROL
MARKET POSITION
PLANT LAYOUT
SUPPLIERS OF ELECTRIC TWO WHEELER
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)

www.eiriindia.org 4
 COST ESTIMATION

Plant Capacity 800 Nos/Day

Land & Building (4000 sq.mt.) Rs. 3.90 Cr
Plant & Machinery Rs. 4.30 Cr
Working Capital for 2 Months Rs. 635.93 Cr
Total Capital Investment Rs. 644.50 Cr
Rate of Return 40%
Break Even Point 27%

www.eiriindia.org 5