Detailed Project Report on brushless dc hub motors used in electric vehicles

BRUSHLESS DC HUB MOTORS USED
IN ELECTRIC VEHICLES
[CODE NO.3591]  



In simple words we can say a device that produces rotational force is a motor. The very basic principal of functioning of an electrical motor lies on the fact that force is experienced in the direction perpendicular to magnetic field and the current, when field and current are made to interact with each other.

In any electric motor, operation is dependent upon simple electromagnetism. A current carrying conductor generates a magnetic field, when this is then placed in an external magnetic field, it will encounter a force proportional to the current in the conductor and to the strength of the external magnetic field.It is a device which converts electrical energy to mechanical energy. It works on the fact that a current carrying conductor placed in a magnetic field experiences a force which causes it to rotate with respect to its original position.




COST ESTIMATION

Plant  Capacity                                           :    100.00 NOS/day
land & Building (2500)Sq.Mtr)                 :    Rs. 2.19 Cr
Plant & Machinery                                      :    Rs. 1.36 Cr
Working Capital for 2 Months                  :    Rs. 10.55  Cr
Total Capital Investment                           :    Rs. 14.33  Cr
Rate of Return                                            :    20%
Break Even Point                                       :    55%


INTRODUCTION    
CLASSIFICATION OR TYPES OF MOTOR    
DC MOTOR    
BRUSHLESS DC MOTORS WORK    
WORKING OF DC MOTOR    
ADVANTAGES OF DC MOTORS:    
DISADVANTAGES OF DC MOTORS    
TYPES OF DC MOTORS:    
THE DC MOTORS ARE DIVIDED MAINLY TO:    
BRUSHLESS D.C MOTOR    
WORKING PRINCIPLE AND OPERATION OF BLDC MOTOR    
CONSTRUCTION OF BLDC MOTOR    
ROTOR    
HALL SENSORS    
TYPES OF BRUSHLESS DC MOTORS    
INNER ROTOR DESIGN    
OUTER ROTOR DESIGN    
ADVANTAGES OF BRUSHLESS DC MOTOR    
DISADVANTAGES OF BRUSHLESS DC MOTORS    
DISADVANTAGES OF BLDC MOTOR    
USES AND APPLICATIONS OF BLDC MOTORS    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS OF BRUSHLESS D.C MOTOR    
FABRICATION PROCESS OF STATOR    
1. STAMPING    
2. STACKING    
3. SLOT INSULATION    
4. WINDING    
5. PREPPING    
FABRICATION PROCESS OF ROTOR    
ROTOR MAGNET    
1. SHAFT MACHINING    
2. HUB MACHINING    
3. HUB MAGANET GLUING    
4. BEARING PRESSING    
FABRICATION OF HOUSING AND EEND BELL MANUFACTURING    
ELECTRONICS MANUFACTURING:    
ASSEMBLING OF BLDC MOTOR    
TESTING OF BLD.C MOTOR    
CLASSIFICATION OF TEST    
1. TYPE TESTS    
2. ROTUNE TESTS    
3. PERFORMANCE TEST    
(A) NO LOAD TEST    
(B) REDUCED VOLTAGE RUNNING UP TEST    
(C) OPEN CIRCUIT VOLTAGE RATIO 'REST FOR WOUND    
(D) ROTOR (SLIP RING) MOTORS    
(E) LOCKED ROTOR TEST    
(F) FULL LOAD TEST    
(8) MARKING    
MARKET POSITION    
INCREASING DEMAND FOR HVAC APPLICATIONS DRIVES THE GLOBAL
  BRUSHLESS DC MOTORS MARKET    
THE FOLLOWING ARE THE MAJOR OBJECTIVES OF THE STUDY.    
BRUSHLESS DC (BLDC) MOTORS MARKET    
THE GLOBAL BRUSHLESS DC MOTORS MARKET IS CLASSIFIED INTO
   FOLLOWING CATEGORIES:    
BY POWER CAPACITY    
BY DESIGN    
BY REGIONA    
ELECTRIC DC MOTOR MARKET    
TYPE INSIGHTS    
VOLTAGE INSIGHTS    
END-USE INSIGHTS    
REGIONAL INSIGHTS    
COMPETITIVE INSIGHTS    
IGARASHI MOTORS INDIA LTD MANAGEMENT DISCUSSIONS.    
AUTOMOTIVE MARKET    
AUTOMOTIVE TECHNOLOGY & CONSUMER TRENDS    
ACTUATORS & MOTORS    
ACTUATORS & MOTORS – TAM (TORQUE ACTUATOR MOTOR)    
ACTUATORS & MOTORS – CAM (COMFORT ACTUATOR MOTOR)    
LEARNINGS DURING THE YEAR    
BRUSHLESS DC MOTORS – BLDC:    
NIL SPILL    
MANUFACTURING TECHNOLOGY    
NEW INFRASTRUCTURE    
PERFORMANCE 2017-18    
RISKS & CONCERNS    
SEGMENT WISE/ PRODUCT WISE PERFORMANCE    
INTERNAL CONTROL SYSTEMS & ADEQUACY    
MATERIAL DEVELOPMENTS IN HUMAN RESOURCES    
INDIA ELECTRIC MOTORS MARKET TO CROSS $ 2.25 BILLION BY 2023    
INDIA ELECTRIC MOTORS MARKET TO CROSS $ 2.25 BILLION BY 2023    
“INDIA ELECTRIC MOTORS MARKET”    
DETAILED EXPORT DATA OF DC MOTOR BRUSHLESS    
DETAILED IMPORT DATA OF BLDC MOTOR    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF BLDC MOTOR    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF CRNGO SILICON STEEL    
SUPPLIERS OF INSULATION KRAFT PAPER    
SUPPLIERS OF COPPER WINDING WIRE    
SUPPLIERS OF PERMANENT MAGANET    
SUPPLIERS OF MOTOR SHAFT    
SUPPLIERS OF D.C MOTOR PARTS    
SUPPLIERS OF BLDC HALL SENSOR CONTROLLER    
SUPPLIRS OF PLANT AND EQUIPMENTS    
MOTOR MAKING MACHINES    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF ELECTRICAL MEASURING AND TESTING EQUIPMENT
ELECTRICAL PANEL    
COOLING TOWER    
EFFULENT TREATMENT PLANT (ETP PLANT)    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SHOT BLASTING MACHINE    



APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET