Introduction: The electric two-wheeler set-up appears a lot more promising, in the
form of research, financial acquisitions & investments, that makes the
electric vehicle segment thrilling. Well, there is also the forward push by the
government and the references of its think-tank, NITI Aayog.
Why EV’s? The innovation of internal combustion engine is one of the best creations
of humankind. The traditional vehicles with ICE provide a good performance but are
the major cause for poor efficiency and environment pollution across the
country.
Decreasing fuel
consumption and carbon emissions are the most important goal among the present-day
plan of government across the globe. Thinking about the future of a country, an
efficient and eco-friendly electric two-wheeler must be designed and manufactured.
Impact of
COVID-19 on Electric Two-wheeler market: Since the
onset of pandemic, leading authorities-imposed lockdown restrictions and
released a set of precautionary guidelines. Manufacturing units were
temporarily shut down and disruption in supply chain was observed. Workers
moved down to their native area which created shortage of workforce. The
automotive industry including electric two wheeler market faced a setback and
post COVID-19, electric two wheeler market is expected to pick up the pace
eventually.
What is the need of Electric and
Hybrid Two Wheelers?
All existing two
wheelers that are in the market cause pollution and their fuel cost is also increasing
day by day. To compensate the changing
fuel cost and curb down the high pollution levels, a good remedy is needed.
Zero tailpipe
emission technologies have long been held up as the last solution to
transportation-related pollution problems. Electric two wheelers have been
offered for several decades. Electric two wheelers, with their zero tailpipe
emissions, can significantly improve urban air quality.
Working
Principle
The working starts with a battery
connection. The battery consists of two
terminals one is positive and another one is the negative terminal. The positive terminal is linked to the stator
body of the motor on the other hand, the negative terminal is linked to the
edge of the vehicle.

The battery and
the motor are connected into series. The
wire connections were made for the flow of electrons starting with one section
then onto the next part. At the point when the engine empowers through the
current, the stator field coil gets magnetized and induces the rotor shaft to
rotate in the counter clockwise direction. Towards the finish of the engine
shaft significant conditions were made for the seating of clutch assembly.
Clutch is a power transmission gadget, which offers drive to the back wheel.
The Clutch get together is placed with the rotor shaft through needle
orientation. On the other end of the rotor shaft an alternator is settled for
the reviving framework, as it is an electrical gadget which changes over the
rotational power into the electromotive power. This alternator is connected to
revive the battery while the vehicle is in movement. This course of action is
done through V-belt pulley.
The current
flows from the battery with a guide of control framework to the stator body.
This current makes the field coil temporarily magnetized with the goal that the
rotor shaft tends to pivot in its virtual speed. As there is a V-belt drive
between the pedal shaft and the grasp gathering, the movement of the vehicle is
sufficiently attained.
The speed in the
pedal shaft is constantly lessened with the utilization of sprockets. Here the
speed decrease is in the proportion of 1:4. This game plan lessens the speed of
the engine repeatedly. To the correct side of the vehicle there lies a chain
drive for the pedal shaft. A free wheel is mounted on the back wheel to limit
the turn of the pedal under running condition.
What are the principal parts of electric
two wheelers framework?
Basically, a two-wheeler
gets its electricity from two sources –
a battery and an alternator. The function of the battery is to store
charge, it maintains a stated voltage level and keeps the electrical system
working when the engine is switched off.
On the other
hand, the alternator, produces electricity when the engine is switched on. It
provides electricity power supply to numerous electrical devices and charges
the battery on the go. Let’s go in little detail of the two:
BATTERY
A
12-volt two wheeler battery is a six-cell unit and is made of a plastic having
a set of positive and negative plates occupied in an electrolyte. When fully
charged each cell has a voltage of around 2.1 volts, which leads to a combined
voltage of around 12.6 volts. The main function of the battery is to deliver
Direct Current to the vehicles electronics when the engine is turned off. Moreover,
the battery also provides the current to crank up the engine.

Obviously,
lithium ion batteries of some kind would be the great enabler. Lithium is a now
entering the market, they are still very costly and something of a question
mark. Traditional lithium cells, as utilized in PCs, have a warm runaway
potential - meaning they tend to burst into flames, now and again like a Roman
light. New materials and sciences considering lithium are endeavouring to
address the wellbeing issue. Moreover, the prices of the lithium ion batteries
have come down and the battery manufacturers are claiming no fire problems.
Battery
Upgradation

A
ALTERNATOR
The function of the alternator is to generate electricity when the engine gets started. The alternator uses the engine’s crankshaft to turn the magnets and produce electricity. It produces alternating current (AC) which needs to be converted to direct current which is attained over a regulator which not only converts AC to DC but also regulates the amount of current that is sent to all the electronics present.

WIRING HARNESS
The current
produced on a two wheeler is channelized through a wiring harness. It plays an
essential role in connecting various electrical and electronic components on a
two-wheeler. The wiring harness is a set of wires, terminals and connectors,
designed for a two wheeler model to supply electric power.
CONTROLLERS
There are mainly
two types of controllers, one is brushed, and another is brushless. According
to the motor in use the function of the controller also varies. Because of high
efficiency, less cost and durability, the brushless motors are popular nowadays,
whereas brushed motors because of less complex controller mechanism, is still
in use fairly.
Let’s
have a look that how these two wheelers are produced/manufactured?
Manufacturing Unit Size:
The size of the unit totally depends upon the volume of business we need to do,
the quantum of assets we have available to us, and the turnover target we
intend to accomplish.
For an instance:
Hero
Electric is
considering over setting up multiple assembly plants to meet its target of
increasing sales by ten times over the next five years, including exports. The
company currently has a production capacity of 75,000 units per annum at its
Ludhiana plant.
Production Line:

In the
manufacturing unit parts like Handle bar, Frame, Fork, Swing arm, Carriers,
Centre and side stands are being manufactured.
The parts after
manufacturing are pre-treated in the plant to increase their life. At the
stages the product inspection is done. The manufacturing plant should have an in-house
paint shop facility to paint plastic parts. The electric two wheeler assembly should
be made up with modern manufacturing concepts backed by stringent quality
system.
In the
manufacturing unit, the vehicles pass through several tests like:
Reliability Test: The electric two wheelers parts/components
are being tested in the Lab for reliability test. The manufacturing plant should
have reliability testing facilities like life test for