Battery Circuit

IGNATION CIRCUIT

The Ignition system consists of magneto assembly, ignition lock, AC Digital CDI unit (Alternating Circuit Capacitor Discharge
Ignition unit), ERCU (Electronic Control Unit) TPS (Throttle Position Sensor), Ignition coil assembly and a spark plug.

The Voltage produced in the source coil is connected to the CDI which will activate the ignition coil
The CDI is equipped in the source coil is connected to the CDI which will activate the ignition coil.

The CDI is equipped with a microcontroller which gives the input to the ignition coil primary winding. When the ignition switch is
turned ON and vehicle stored, AC voltage passes to the digital CDI. A black white earth wire (BW) from common junction is
connected to digital CDI.

The pulsar coil produces the signals whenever the pip in the magneto periphery passes. Based on the signals, the microcontroller will
give input to the primary winding (thicker turns in the coil) of ignition coil where voltage will collapse in fraction of seconds. This in
turn develops high voltage across the secondary winding (thinner turns in the coil) of ignition coil due to mutual induction. This high
voltage is given to sparkplug through HT lead of ignition coil. The ignition coil is earthed through a black white wire.
The TPS is fitted below the fuel tank and is operated through throttle cable. TPS has a slider over the PCB (Printed Circuit Board) that
has variable.

Precautions: -

1) When connecting terminals to the battery, connect the negative terminal last
2) If any terminal is found corroded, remove the battery pour the warm water over it and clean with wire brush
3) Apply the petroleum jelly on the terminals after the completion of the connection and cover positive terminal with the boot.

4) DC Machines: - Dc machine is a highly versatile energy conversion device. It can meet the demand of loads requiring high
starting torques, high accelerating and decelerating torques. At the same time, DC machine is easily adaptable for drives.
a) The constructional diagram is as shown in figure.
Generator and Motor are said to be DC Machines.

Circuit Model of DC Machine: In DC machines all parallel paths in the armature are Symmetrical.
DC Shunt Motor : For constant Supply voltage the field current is constant. At small values of armature current the demagnetizing
effect of armature reaction is almost negligible and therefore the air gap flux is unaffected. For larger values of armature currents,
the demagnetizing effect of armature reaction decreases the air gap flux slightly.

Wm = Ea/Ka Ø
Ea = Vt – Ia ra
Wm = Vt – Ia ra / Ka Ø

Speed Current Characteristics: - For constant supply voltage Vf and constant field current If, the motor Speed is affected by Ia Ra
drop and demagnetizing effect of armature reaction. With increase of Ia, Voltage drop Ia Ra increase as and the numerator (Vt – Ia
ra) decreases – therefore the motor Speed tends to decrease. Torque – Current characteristics : - The expression Te = Ka Ia Ra
reveals that if the flux is constant in the DC shunt motor, torque would be increase linearly with armature currents.

Speed torque characteristics : - The speed – torque characteristics is also called as mechanical characteristic and under steady
state conditions.This means speed drops more rapidly with the increase of torque in the shunt motor. Because of shunt motor
characteristics shunt motor is best fitted for the electric two-wheeler.
Assume the highest speed is 22/7x 18 = 0.5657m
Rating of the wheel = 50x 103/ 0.567 x 60 = 1473.10 rpm
The motor speed with gear ratio 5.09: 1 = 7500 rpm
 (7500 is the maximum rpm of motor)
O/P power = 2 IIN /60 x torque
5500 = 2 II (7500) / 60 x torque.
Torque = 5500 /785. 398 = 7.003 N-m
COST ANALYSIS WEIGHT ANALYSIS
Sl.No Equipment Cost (Rs) S.No. Equipment Weight (Kg)
1 Battery (72 V, 100A) 6,600.00 1 Battery 10
2 Motor 6,600.00 2 Motor 6
3 Transmission 3 Generator 1.1/2
i)Ideal gear 168.50 4 Transmission equipments 25
ii) Gear lever 132.00 5 Electricals 25
iii) Gear shaft 188.90 6 Wheels 25
iv) Camgear shift 194.50 7 Seats 2
v) Shift counter 297.77 8 Total Weight 94.1/2
4 Electricals
i) Mageneto 300.00
ii) Head lamp 395.00
iii) Tail Lamp 130.00
iv) Break Lamp 30.00
v) Horn 150.00
vi) Battery (12v, 50 A) 550.00
5 Generator 2,200.00
6 Wheels 2,280.00
Total Cost : 20,016.00
- : ADVANTAGES: -

The electric two wheeler has so many advantages over a two wheeler. One should assign the great advantages of electrical two
wheelers those are:-
1) Save money (cheap cost) 2) Save environment (No pollution) 3) Save strength (less weight)

Coming to our first advantages save money, it is already cleared in the cost analysis, as engine,
 Silencer, oil tank are replaced by Motor, Generator, battery. Hence it is a nice offer to consumer.
In common two wheelers are running with fuel (Petroleum), commonly used engine is four engines. The working method of
four stroke engine is as mentioned below:-
The 4 – stroke engine contains four stages
1) Suction 2) Compression 3) Power 4) Exhaust.

When air comes in to the cylinder the piston is ready to move downwards. In the suction stage the air contains pressure,
when the piston move down wards the pressure of the air increases now it is in compression stage. These two stages are
considered as two strokes when the air contains high pressure, it is in power stage our will Brunt. The burned air is considered
as smoke it will come out from the silencer in exhaust. Stage.

These four stages are changing in cyclic order. This is the working principle of common two wheelers. The smoke
contains dangerous gas (co) which affects the zone. But electric two wheelers does not consists smoke. Hence no pollution.

Third advantages is save strength at present all vehicles are available 200 -300 kgs but electric two wheeler is less
weight vehicle consisting up to 100 kgs. The electric start will be there hence the consumer strength will be saved.

DISADVANTAGES

The battery continuously charges with generator. But there is no guarantee for Vehicle to have a high speed Means (0 – 40 KMPH)
with in 10 seconds. 72 V. 100 A battery takes more place so seat size will be reduced. It is complex to maintain electric two
wheeler.
REFERENCES

www.google.com
www.bajajauto.com
www.tvsvictor.com

Some important matter is collected from Sri Rama Engineering Co., Mahabubnagar.
Books : - Electric Machinery, Bhimra, Thereja.
APPENDIX
 TECHNICAL SPECIFICATIONS

Maximum power : 7.5 (bhp) or 5.5 Kw

Torque : 7.00 Nm
Drive : Automatic CVT with torque sensor

Electricals : -

I. Magneto : 12V, 50W

II. Head Lamp : 12V, 35 W
III. Tail Lamp : 12V, 5 W
IV. Brake Lamp : 12 V, 10 W
V. Horn : 12 DC type
VI. Battery : 12 V 5 Ah

Dimensions & Weight : -

i) Tyre (Front) 2.75 x 18 Cm

ii) Tyre (Rear) 3.0 x 18 Cm.
iii) Wheel base 1220 mm
iv) Weight 100 kg

Battery: -
Battery : 72 V, 100A
CLUTCH

Standard Service limit

1. Lever clutch free play at lever eng. 10 – 15

2. Plate clutch drive thickness 2.90 – 3.10 2.60
3. Plate Clutch driven distortion -- -- 9.30
4. Plate Clutch driven distortion -- -- 0.10
5. Spring Clutch free length 32.00 31.50

Transmission
Service limit
1. Primary reduction ratio 3.722 (67/18)
2. Final reduction ratio 2.857 (40/14)
3. Gear Ratios

First gear 3.273 (36/11)

Second gear 1.750 (40/14)
Third gear 1.283 (26/21)
Fourth gear 0.958 (23/24)

Standard Service limit

1. Drive Chain 254.00 259.40
2. Drive Chain Slack 20.30 ------The Electric two
wheeler, which runs with battery, is the new technology which is under development. Present technology is handled with
mechanical energy conversion. Mechanical energy converted into rotatory motion by piston arrangement. At present available
engines are 4 stroke engine it has four stages. Suction, X Compression, Power & Exhaust. These stages are repeated in cyclic
manner. Such type of arrangements are not required in electric two wheeler. The battery is directly connected to the motor
(Which converts electric energy in to rotatory motion) then after transmission. The electric two-wheeler is light weight,
cheapest vehicle which is best fitted for present environmental conditions.

Technical Specifications
Block Diagram of Electric Two Wheeler
CAD Diagram of Vehicle
Detailed information about Battery, Motor
Specifications of Motor, Transmission, Battery
All necessary calculations.
Complete Cost and Weight analysis
 Advantages of Electric Two Wheelers
Comparison of working methods of two wheeler and Electric Two Wheeler.
At present the two wheelers are handled with mechanical energy conversion, but it is really surprising, that the two
wheeler can run with battery arrangement, of course, it is complex to maintain a battery for running of the vehicle, still it is on
developing. But coming to environmental considerations the “Electric two Wheeler” is awaiting Technology.Battery
Arrangement

The battery has 72 V, 50 A. The oil tank in two wheeler is replaced by battery arrangement. This battery is used to
starting the motor. Always ensure
battery in fully charged
conditions. This arrangement
consists 12 V, 50 A.

Motor

The Motor is a device which

converts electric energy into
rotatory motion. Motor are
basically three types.

1) Series Motor

2) Shunt Motor

3) Compound
Motor.

In our electric tow –

wheeler we are using shunt
motor because of its characteristics.

BATTERY
 Battery (72 V, 100 A) Consists of twelve 12 V, 50 A batteries, Battery is used to start the motor. Check and top up at
initial 1000 km and at very 3000 km thereafter. Visually inspect the surface of the battery assembly container. If any sign of
cracking of electrolyte leakage from sides of the battery assembly noticed, replace the battery assembly with a new one. If the
battery assembly lead terminals are found rusty with an acidic white powdery substance, then clean them with sand paper. Add
only distilled water, as necessary to keep the electrolyte above the lower level line but not above the upper level line.
Periodically check the electrolyte for specific gravity by using a hydrometer to find the state of charge. If the battery assembly
is getting discharged frequently check the charging system.

The output current from the generator passes through the white red wire and connected to the regulator (RR unit)
through red white wire (RW). A black white earth wire (BW is connected to regulation (RR) unit RR unit regulates the voltage
as well as converts AC to DC current. The DC current from AS to DC current. The DC current from Regulator (RR unit)
passes through the Red wire, to the battery for charging one output wire from Battery connected to ignition system. One Black
white earth wire is connected to battery when ignition system is in on position the output current from the ignition switch
passes through orange wire.