Code #3799
Industry Overview
Electric two-wheelers are road vehicles powered exclusively or primarily through an electric motor and an onboard battery pack. The battery stores electrical energy, while the motor converts it into mechanical power for vehicle propulsion. User controls, generally mounted on the handlebar, allow the rider to regulate speed and braking. Battery-operated two-wheelers may include electric bicycles, pedal-assisted bicycles, electric scooters, and other electric two-wheeler configurations.
The report covers the classification, components, battery technologies, motor types, controllers, braking systems, frames, suspension, tyres, wheels, and other major systems used in electric two-wheelers. It also discusses battery-pack assembly, battery-management and safety circuits, production and assembly procedures, product testing, BIS specifications, and plant layout considerations.
The report further examines market drivers and challenges for electric scooters and motorcycles in India and the Asia-Pacific region, including vehicle, battery, technology, voltage, and geographic segmentation. It addresses market incentives, total cost of ownership, environmental impacts, battery technology, production processes, end-of-life considerations, future transport solutions, and factors influencing market growth. Supplier categories, plant and machinery requirements, raw-material sources, and supporting industrial equipment are also covered.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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/MAINTENANCE:
- (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)
Frequently Asked Questions
Electric two-wheelers are two-wheeled vehicles powered by an electric motor and onboard battery system. They include configurations such as electric bicycles, pedal-assisted bicycles, electric scooters, and motorcycles. The main systems generally include the battery, electric motor, controller, braking system, frame, wheels, tyres, suspension, and user controls. Their design and specifications vary according to vehicle type, intended speed, range, battery technology, and application.
The main components of an electric two-wheeler include the electric motor, battery pack, motor controller, sensors, throttle or other user controls, braking system, frame, wheels, tyres, suspension, and electrical indicators. Depending on the vehicle design, the drivetrain can use a hub motor or a mid-drive arrangement. Battery systems may incorporate cylindrical or prismatic cells together with a battery-management system and safety circuits.
Electric two-wheelers can use several motor technologies, including induction motors and DC motor configurations. The report specifically discusses permanent-magnet brushless DC motors and permanent-magnet brushed DC motors. Motors may also be installed in different positions, particularly as mid-drive motors or hub motors. Hub motors can be positioned in the front or rear wheel, while mid-drive motors are located closer to the drivetrain and frame structure.
A battery management system is important because it helps monitor and manage the electrical operating conditions of a battery pack. It can support functions associated with battery protection, cell monitoring, charging control, and safe operation. The report also covers dedicated battery safety circuits and their working principles. Proper battery management is an important part of electric two-wheeler design because the battery is a central energy-storage component and must operate within appropriate electrical and safety limits.
Production and assembly involve integrating the frame, wheels, tyres, handlebars, brakes, drivetrain, electrical controls, battery, and associated accessories. The report describes individual installation stages such as front-wheel, handlebar, mirror, pedal, seat, brake, tyre, chain, battery, and adapter installation. Final testing is also included to verify the completed electric two-wheeler. A suitable process flow, plant layout, equipment arrangement, inspection procedures, and product-testing methodology support consistent manufacturing and assembly operations.
The electric two-wheeler market is influenced by technology development, vehicle cost, performance, charging requirements, battery technology, infrastructure, consumer adoption, regulations, and policy support. The report also discusses local motorcycle restrictions, environmental and emissions concerns, market incentives, and technology improvements as factors affecting market development. At the same time, system weaknesses, infrastructure limitations, institutional factors, and other market challenges can influence the pace and pattern of adoption.
An electric two-wheeler manufacturing project may require sources for raw materials, BLDC motors, motor controllers, lithium-ion batteries, tyres, wheels, spare parts, plant and machinery, and supporting industrial equipment. The report also identifies supplier categories for air pollution control equipment, air-conditioning equipment, air compressors, material handling equipment, fire-fighting equipment, and jigs and fixtures. Supplier selection generally depends on technical specifications, quality requirements, compatibility, service support, delivery capability, and applicable standards.
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