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    Detailed Project Report on 2/3 wheeler auto electronic spare part manufacturing

    Detailed Project Report on 2/3 wheeler auto electronic  spare part manufacturing
    Detailed Project Report on 2/3 wheeler auto electronic spare part manufacturing
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      2/3 WHEELER AUTO ELECTRONIC
      SPARE PART MANUFACTURING
      [CODE NO.3456]  


      (1) The Basics of a 2/3 wheeler Charging System

      On almost every motorcycle you will find a battery, used for providing power for starting the bike and for buffering an amount of electric energy. The battery itself is charged by a generator driven by the engine, and as long as the engine is running there will be a current flowing through the battery. The no load voltage of a fully charged battery is about 13 Vdc. For charging it the charging-system should provide a voltage of about 14.4 Vdc and this should be a constant voltage at all engine-speeds.

      The generator itself is located in or on the engine, and on most bikes there is a separate regulator-rectifier unit located somewhere on the frame. The reason for this is that almost all motorcycles are equipped with a three-phase AC (Alternating Current) generator, while the electrical system on the bike is a DC (Direct Current) system. The rectifier part inside the regulator-rectifier takes care of converting the AC-current to the DC-current the battery needs. The three-phase AC generator is used so often because it is much more efficient and reliable than a DC-generator. It can produce power for charging the battery even with the engine idling. The regulator part of the regulator-rectifier is used to regulate the output-voltage (to the battery) to the 14.4 Vdc that is needed.


      RECTIFIER

      A rectifier is an electrical device composed of one or more diodes that converts alternating current (AC) to direct current (DC). A diode is like a one-way valve that allows an electrical current to flow in only one direction. This process is called rectification.


      Types of rectifiers

      The rectifiers are mainly classified into two types:

      •    Half wave rectifier

      •    Full wave rectifier


      Half wave rectifier

      As the name suggests, the half wave rectifier is a type of rectifier which converts half of the AC input signal (positive half cycle) into pulsating DC output signal and the remaining half signal (negative half cycle) is blocked or lost. In half wave rectifier circuit, we use only a single diode.

      Full wave rectifier

      The full wave rectifier is a type of rectifier which converts the full AC input signal (positive half cycle and negative half cycle) to pulsating DC output signal. Unlike the half wave rectifier, the input signal is not wasted in full wave rectifier. The efficiency of full wave rectifier is high as compared to the half wave rectifier.

      Regulator

      It controls the generator output according to the need. It controls the current or voltage.

      COST ESTIMATION

      Plant  Capacity                                            :    120.00 No./day       
      land & Building (20000 Sq.Mtr)                :    Rent
      Plant & Machinery                                      :    Rs.    13.00 Lacs
      Working Capital for 2 Months                   :    Rs.    32.05 Lacs
      Total Capital Investment                            :    Rs.    49.06 Lacs
      Rate of Return                                             :    52%
      Break Even Point                                        :    67%


      INTRODUCTION    
      (1) THE BASICS OF A 2/3 WHEELER CHARGING SYSTEM    
      RECTIFIER    
      TYPES OF RECTIFIERS    
      THE RECTIFIERS ARE MAINLY CLASSIFIED INTO TWO TYPES:    
      HALF WAVE RECTIFIER    
      FULL WAVE RECTIFIER    
      REGULATOR    
      REGULATORS FOR ALTERNATOR    
      REGULATOR RECTIFIER (RR) UNIT    
      WHAT IS A REGULATOR/RECTIFIER    
      TYPES OF REGULATOR/RECTIFIERS    
      REGULATOR RECTIFIER STANDARD WIRE COLOURS    
      REGULATOR RECTIFIER WIRING BASICS    
      HOW DO REGULATOR RECTIFIERS WORK?    
      WHAT IS A BRIDGE RECTIFIER?    
      THE PULSING ON THE DC OUTPUT IS KNOWN AS DC RIPPLE. THIS CAN
         BE SEEN BY PLOTTING THE DC RIPPLES AGAINST TIME ON A GRAPH:    
      DC RIPPLE SMOOTHING WITH A CAPACITOR    
      THE DISADVANTAGES OF HALF WAVE RECTIFIERS    
      HOW DOES A VOLTAGE REGULATOR WORK?    
      (2) BASICS OF 2/3 WHEELER IGNITION SYSTEMS    
      CAPACITIVE DISCHARGE BASED IGNITION SYSTEM    
      TYPES    
      AC-CDI    
      DC-CDI    
      ADVANTAGES AND DISADVANTAGES OF CDI    
      INDUCTIVE DISCHARGE IGNITION (IDI) SYSTEM    
      BASIC OPERATIONS OF INDUCTIVE DISCHARGE IGNITION (IDI) SYSTEM    
      CDI (CAPACITOR DISCHARGE IGNITION) & SOLID STATE IGNITION SYSTEMS    
      CDI BOX OR BLACK BOX    
      TYPES OF CDI MODULE    
      THERE ARE MAJORLY TWO TYPES OF CDI MODULES:    
      USES AND APPLICATION    
      B.I.S. SPECIFICATION    
      PROCESS FLOW CHART    
      MANUFACTURING PROCESS    
      (A) FOR REGULATOR RECTIFIER    
      STEP 1: PREPARING THE LAYOUT    
      STEP 2: CUTTING AND FINISHING THE HEATSINK    
      STEP 3: SOLDERING THE MAIN PART    
      STEP 4: WIRING    
      ON THESE PHOTOS THE WIRES ARE:    
      STEP 5: CHECKING AND TROUBLESHOOTING    
      TO DO THIS:    
      TO CHECK ULN2003A YOU NEED TO:    
      CHECK THE OPERATION OF BTA TRIAC:    
      HOW TO TEST A REGULATOR RECTIFIER    
      NECESSARY MATERIALS    
      INSTRUCTIONS    
      (2) FOR CDI MODULE BOX    
      PARTS LIST FOR THE CIRCUIT DIAGRAM    
      CDI WIRING    
      MARKET POSITION    
      TWO-WHEELERS    
      HONDA IS BIGGEST VOLUME GAINER IN FY2018    
      TVS NOTCHES RECORD SALES, JUPITER SHINES BRIGHTER    
      BAJAJ AUTO FEELS THE HEAT IN INDIA, BUT IS A KING IN EXPORTS    
      ROYAL ENFIELD GUNS FOR SALES, IMPLEMENTS EXPANSION PLANS    
      SUZUKI MOTORCYCLES INDIA: THE DARK HORSE    
      MOVERS AND SHAKERS IN THE INDIAN TWO-WHEELER INDUSTRY    
      THREE-WHEELER SALES TAKE A HIT IN FY2017    
      HOW THE OEMS FARED    
      SLACKENING DEMAND IN THE EXPORT MARKET    
      ADHERING TO THE HIGHEST QUALITY STANDARDS    
      A PROMISING FUTURE AHEAD    
      CHALLENGES THAT NEED IMMEDIATE ATTENTION    
      THE ROAD AHEAD    
      EXPORT DATA OF CDI    
      IMPORT DATA OF CDI    
      EXPORT DATA OF REGULATOR RECTIFIER UNIT
      IMPORT DATA OF REGULATOR RECTIFIER UNIT    
      PLANT LAYOUT    
      MANUFACTURERS/SUPPLIERS OF REGULATOR RECTIFIERS AND CDI
      FOR TWO/THREE WHEELER    
      SUPPLIERS OF RAW MATERIALS    
      SUPPLIERS OF PCB    
      SUPPLIERS OF TRANSISTERS    
      SUPPLIERS OF DIODES    
      SUPPLIERS OF RESISTOR    
      SUPPLIERS OF CAPACITOR    
      SUPPLIER OF SCR    
      SUPPLIERS OF MOSFET    
      SUPPLIERS OF INTEGRATED CIRCUIT    
      SUPPLIERS OF POWER CORD    
      SUPPLIERS OF COPPER WIRE    
      SUPPLIERS OF SOLDER PASTE    
      SUPPLIERS OF PLANT AND EQUIPMENTS    
      SUPPLIERS OF HEAT WAVE SOLDERING MACHINE    
      SUPPLIERS OF OSCILLOSCOPE    
      SUPPLIERS OF SOLDERING IRON    
      SUPPLIERS OF PCB CUTTING MACHINE    
      SUPPLIERS OF PCB DRILLING MACHINE    
      SUPPLIERS OF PCB ASSEMBLING 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      
       

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