We have designed the plan and USP for Electric 2 wheeler for the Indian market.

Assignment Taken

Product development plan & Features (USP’s) which will be present in the vehicle and how those features will help sales.

Case Understanding

Renewable energy has great scope in India. The automobile industry is one of them, the Automobile sector has taken several giant steps in this direction around the world recently but the Indian market is still at an infant stage. As compared to other countries, the market share of electric vehicles is extremely low in India. According to some estimates, the total number of registered vehicles in India is 230 Million and the market is growing continuously. This also leads to India's dependence on fossil fuels. Taking a reformist measure, the Government of India is aiming to promote electrical vehicle usage in the country. "The government target for 30% adoption of electric vehicles by 2030 will be majorly driven by the electrification of two-wheeler, three-wheeler, and commercial vehicles. Lower rate of adoption of electric vehicles in the passenger vehicle segment is expected to have a limited impact in achieving the targets."

BCS Solution Summary

Concept ------> Construction ------> Simulations ------> Testing ------> Production

Solution

The Key Components in Electric Scooter Following are the key components in Electric Scooter:-

1. Battery Charger

In order to utilize the battery to its maximum capacity, the battery charger plays a crucial role. The remarkable features of a battery charger are efficiency and reliability, weight and cost, charging time, and power density. The characteristics of the charger depending on the components, switching strategies, control algorithms. This control algorithm can be implemented digitally using a microcontroller. The charger consists of two stages. First, one is the AC-DC converter with power factor correction which converts the AC grid voltage intoDC ensuring a high power factor. The later stage regulates the charging current and voltage of the battery according to the charging method employed. The charger can be unidirectional i.e. can only charge the EV battery from the grid or bidirectional i.e. can charge the battery from the grid in charging mode and can pump the surplus amount of power of the battery into the grid.

2. Battery

Batteries are the components that store electrical energy, allowing for the motor of the vehicle in question to run. There is already an analysis between different kinds of batteries as seen in the table.1 below, The main materials that allow recharging are nickel-cadmium, nickel-zinc, nickel-metal hydride, and lithium-ion/lithium-polymer, these are respectively listed as NiCd, NiZn, NiMH, and Li-ion/Li-Po on the battery analysis table. Specific energy is energy per unit of mass denotes a lighter battery as the value increases if the energy were to be kept constant.

➢ Battery management systems: It is also referred to as BMS. The battery system is formed by a number of battery cells. They are connected in parallel or series that is according to the design. Each of the cells should be monitoring and regulating. The conditioning monitoring includes the voltage, current, and temperature. The measured parameters are used to provide the decision parameter for the system control and protection.

3. Motor Controller

A motor controller is a device or group of devices that serves to govern in some predetermined manner of performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, limiting or regulating the torque, and protecting against overloads and fault. In this project, we are using a “sine wave vector controller”. The battery block is interfaced with the motor controller block. The motor controller controls all the functional capabilities and is the central component of the system. The basic requirement for the control is to regulate the amount of power applied to the motor, especially for motors. The motor controller can be adjusted to synchronize with other brushless motors. To drive and control the BLDC motor, the use of a motor controller was implemented. The motor controller is an essential device for any motor-driven device. The motor controller is analogous to the human brain, processing information and feeding it back to the end-user. Of course, the applications of a motor controller vary based on the task that it will be performing. One of the simplest applications is a basic switch to supply power to the motor, thus making the motor run. As one utilizes more features in the motor, the complexity of the motor controller increases. Field-Oriented Control (FOC) or sine wave vector controller is an important technology for motor systems, particularly those using permanent magnets (PM). In general, FOC provides an efficient way to control BLDC motor in adjustable speed drive applications that have quickly changing loads and can improve the power efficiency of a BLDC motor.

4. Motor

The use of permanent magnets(PM) in electrical machines in place of electromagnetic excitation results in many advantages such as no excitation losses, simplified construction, improved efficiency, fast dynamic performance, and high torque or power per unit volume.

5. DC-DC Converter

A DC-to-DC converter is an electronic circuit or electromechanical device that converts a source of direct current (DC) from one voltage level to another. It is a type of electric power converter. The different configurations of EV power supply show that at least one DC/DC converter is necessary to interface the FC (frequency controller), the Battery, or the Supercapacitors module to the DC-link. In electrical engineering, a DC to DC converter is a category of power converters and it is an electric circuit that converts a source of direct current (DC) from one voltage level to another, by storing the input energy temporarily and then releasing that energy to the output at a different voltage. The storage may be in either magnetic field storage components (inductors, transformers) or electric field storage components (capacitors).DC/DC converters can be designed to transfer power in only one direction, from the input to the output. However, almost all DC/DC converter topologies can be made bi-directional. A bi-directional converter can move power in either direction, which is useful in applications requiring regenerative braking. The amount of power flow between the input and the output can be controlled by adjusting the duty cycle (ratio of on/off time of the switch). Usually, this is done to control the output voltage, the input current, the output current, or to maintain constant power. Transformer-based converters may provide isolation between the input and the output. The main drawbacks of switching converters include complexity, electronic noise, and high cost for some topologies.

6. Vehicle Computer and Electronics

Stage 1) CONCEPT, STYLING & PACKAGING

The starting point for every new development is the concept. This is where the outlines and framework conditions for the vehicle segments, markets, technology, deadlines, cost & pricing are determined and defined. From a tech perspective, the drafting of a vehicle concept involves creating a package, conducting a potential analysis, developing a body-in-white structure concept and aerodynamics values, and defining the production technology. Styling designs are created based on an ideation process. To ensure the success of the product, technology comparisons with competitors are conducted and benchmarks defined.

Step 2) CONSTRUCTION DESIGN

After the theory comes into practice. In this phase of the Product Development Process, engineers turn the concepts into a prototype/reality. Common CAD systems are used to create detailed designs which will be used as templates for the productions of initial models. Product cost optimization also plays a crucial role in the construction design phase.

Step 3) SIMULATIONS

During this phase, vehicle characteristics and technical outlines are well understood before the actual test phase begins. This enables optimization of a variety of components and systems early in the process before the testing itself.

Step 4) TESTING

Every development step, every component, be it body, electrics/electronics, chassis, powertrain, battery, the entire vehicle is tested thoroughly for different conditions that it will undergo while in the field. 

Step 5) PRODUCTION

Production will be carried out as follows - Low Volume Production Trial (LVPT), High Volume Production Trial (HVPT), and then the actual production begins for the mass market.

The product features/USP are attached in the image below.

Conclusion

Given the well-defined product development cycle and USP we have, we will have an edge over our competitors.

Attached File Details