3. •Brief Introduction with Mr. ullas kalale Sir(G.M.)
Kalale sir briefed me about the history of ELECTROTHERM from beginning to up till now.
I went with Mr. Mahesh yadav.
•Introduction of whole plant under guidance of Mr. Mahesh Yadav(AGM,
ELECTRICAL &. ELECTRONICS Dept.).
- First we started with paint shop then welding section, battery section ,quality control
section , production section, store and PDI dept.
•Introduction with Mr.Sandeep sing (Q.C. Dept)
- He and Mr. shrivastav informed me how different instruments can be used with
different applications.
•Observed problems of material from the vendor AUTONATION
(Mr. Deepak sharma).
•Production process observation.
4. •Involved in the prize distribution of ENVIRONMENT DAY COMPETITIONS
(poster presentation, slogan competition,)
- I found that this type of competitions enthusiast employees to do
something different and best.
•Some information about battery testing process.
- I saw how battery can be charged and the process involved in it.
5. With the meeting of vendor we observed and discussed
following :
Sr . No Model Problem Action by time line
1EXL
1. SIDE PIPE :
over size and found rusty supplier will improved it and anti rust oil will be provided from next lot
2 . SUPPORT PIPE : dim.
Should be corrected and
thickness observed under size dimentions will be corrected.
2SPEED
1. BOX PIPE STAND :
dimensions observed over size
and rusty material supplier will improved it and anti rust oil will be provided from next lot
2. PIPE SLEEV REAR FORK :
poor welding observed and
burres in the ID welding quality will be improved
3. BKT LEG LEVER MAIN STAND
: material observed
rusty anti rust oil will be provided from next lot
3 ELECTRON
1. FRONT FORK REPAIR :
matting part not passing due
to hole position shifted supplier ready to do re work.
2. MTG. PIPE CENTRE STAND :
dimentions observed uneven
and green
passivation not provided will take necessary action
3. HING BKT CENTRE STAND :
profile and angle not matched
, burrs observed in hole next supply will be corrected as perr deg. Supplier will check the scope of correction
6.
7. Went to plant with ankit sir.
Today The production was stopped due to shortage of material.
In Q.C. dept self analysis of chassis.
Data collection of different models from Mr. sandeep sir (Electric
dept.)
Meeting with vishwakarma sir and detailed discussion about batteries
and improvement.
Discussion about motors with yadav sir.
8. MODEL BATTERY MOTOR
Watt
CONTROLLER
48v,120deg/60deg
CHARGER
I/P AC 180-
240V , 50Hz
CONVERTER
YO ELECTRON 12V,20Ah 250 TC Series O/P : 48DC, 4A
I/P:
48V,2.5A
O/P:
12VDC,10A
YO ELECTRON ER 12V,24Ah 250 TC Series O/P : 48DC, 4A
YO STYLE 12V,24Ah 250 TC-M100 O/P : 48DC, 4A
YO STYLE ER 12V,38Ah 250 TC-M100 O/P : 48DC, 4A
YO SPARK 12V,33Ah 750 TC-M100 O/P : 48DC, 5A
YO XPLORE LF 12V,24Ah 250 TC Series O/P : 48DC, 5A
YO EXL 12V,40Ah 1000 TC Series O/P : 48DC, 8A,
YO SPEED 12V,33Ah 750 TC-M100 O/P : 48DC, 5A
The main parts of the e- bikes are :
•Battery
•Motor
•Controller
•Converter
•Charger
9. I discussed about batteries with vishwakarma sir and he explained me about charging and
discharging phenomena of battery , and also intro me about carbon-foam battery.
The specific gravity can be measured using a hydrometer and will have a value of about
1.250 for a charged cell and 1.17 for a discharged cell, although these values will vary
depending on the make of battery.
The specific gravity also depends on the battery temperature and the above values or for a
battery at 15°C.
Specific gravity is defined as:
mass of specific volume of electrolyte
mass of same volume of pure water
The chemical reactions that occur during charging and discharging are summarized in
figures
1 and 2.
10. Figure 1: Charging. Lead (IV) oxide is formed at the anode,
pure lead is formed at the cathode and sulphuric acid is
liberated into the electrolyte causing the specific gravity to
increase.
Figure 2: Discharging. Lead sulphate is formed at both
electrodes and sulphuric acid is removed from the electrolyte
causing the specific gravity to reduce.
Fig. 1 Fig. 2
11. • Today I went late (at 11.00am) as I was collecting data from the internet.
• Directly meet kalale sir and vishwakarma sir.
• We discussed different alternate sources to use like dynamo, solar energy etc.
• I collected data for the energy used by secondary consumers (i.e. head light, tail light, indicator,
speedometer)
-I was thinking to run all this secondary consumers(which uses about 10% of energy of motor) with
a small battery of 6v so that we can use all 4 existing battery can be used to run motor efficiently.
- we can charge it with dynamo or solar chargers.
• I met Mr.Ramsinh barad and collect some data about actual performance as he is having a yo
electron.
12. From the different suppliers I chose a latest dynamo which is having following
char.
Volt: 12v.
Power : 6w.
Current : .5A.
If it is 2-pole and 2-nos of parallel paths then we have to run it at about 200rpm. Then only we can get this
o/p.
I suggested that we can run it with the help of wind energy.
And its FOB is about 3$ per set.
The cost of design modification , 1- line operation increased , increasing a worker’s wages.
So overall cost In manufacturing will increase about 15$.
But its o/p is not that much effective.
So THIS OPTION WAS ALSO NOT FOUND FEASIBLE. SO I leave it, too.
13. SECONDARY CONSUMERS
COMPONENT POWER(W) VOLT(V) CURRENT(A)
Horn 15 12 1.25
Head light 35 12 2.85
Back light 21 12 1.60
Indicator 16 12 1.20
Meters 12 12 1.00
Total 7.90
There are following assumptions.
•The horn is blown about 20 times a day.
•Head light and tail light is used for 2 hrs .
•Indicators are used 10 time for 30 secs.
14.
15. • Directly went to Q.C. and calculated The cost, weight, dimensions of dynamo.
• Calculate the existence of solar cell, solar charger.
•Calculate that if we can use dynamo or not?
•After all these calculations I conclude that it will increase the overall cost of bike
without increasing any productive output.
•So I have to change my focus which leads to do some research about batteries.
•Then with the help of Mr. sandip prajapati(Electric department) and mr. ramsinh barad
I observe a scrape battery from inside.
•It was cylindrical battery with 6v,20Ah O/P.
16. Specifications
R15-300
(5W)
R15-600
(10W)
R15-1200
(20W)
R7 (7W) R14 (14W) R21 (21W) R28 (28W)
Operating Voltage 15.4 15.4 15.4 15.4 15.4 15.4 15.4
Operating Current 0.3 0.6 1.2 0.45 0.9 1.35 1.8
Weight (lbs./kg) 0.6/0.29 1.0/0.46 1.9/0.88
0.594/0.26
9
0.981/0.44
5
1.42/0.644 1.8/0.816
Dimensions 11.5x21 11.5x38 12x73 23x14.5 42x14.5 60.75x14.5 79.75x14.5
Rolled Dimensions
11.5x4x3.7
5
11.5x4.25x
4.25
12x4.25x4.
5
14.5x4 14.5x4 14.5x4 15.5x4
•I found the following data.
•Roll able Chargers Technical Data
With reference to this if we use , 4 set of R15-1200.
Our charging voltage will be 61.1v and current will be 1.2 A and if we charge it every day
8 hours(i.e. during our office time).
We can increase the average of yo spark up to 17kms(apx) .
its main advantage is that If we use it and with compare to our ordinary petrol vehicle
Having average of 50kms/ liter. And petrol price about 78 Rupees. Then we can save
8190 Rupees per year.
But the manufacturing cost of the vehicle will increases about 45$-50$
So it is not convenient to use this panel
18. We can see that rectangular has more volume having the same dia. Of circle.
I cal. It and find difference in volume about 21.84%
The cylindrical section should be converted into rectangular section so that we can increase its
density up to 21.84% .
Acc. To following formula
4 Vc =∏ Vr.
WHERE, Vc= Vol. of cylinder, Vr= vol. of rectangular.
Idea about modifying tubular battery
19. • Today I directly went to Thomas sir, and then I went to vishwakarma sir I
explained him why a tubular battery should be modified?
•Then I went to battery section and with Mr. Ramsinh barad we cut a scrap
battery of yo spark.
•Now I try to focus on how we can make the vehicle sturdier?
•I check all chassis, forks, and outer body then I found a fault in assemblage of
almost in all models
•I also found that handle of Exl model is little uncomfortable if we use it for a
long run we have face with back pain .
•In the afternoon section with permission of Thomas sir, I visited steel plant and
gas plant.
•And after returning from there I started making final report.
20. Yo EXL HANDLE
WE should modified its design so that a rider will not have to suffer from back pain.
It will/can also became attractive model.
21. Yo spark model
We should modified assemblage design so that it become more
sturdy and long life.
its life will be increased up to 1-2 yrs by using clamps or some
supports from inside assemblage.
22. SUGGESTIONS
1. There should not be shortage of material in any , it affects great loss of
production and efficiency.
2. Material used be used with high std. of quality so that rejection and rework
cost can be reduced.
3. PPC should be done accurately.
4. should increase service stations.
5. We should chose some(about 5-10) local garage people in a city and should
be given 1 day training so that customer can get puncture repairing easily, it
will increase our service and we wont have to invest more in our own service
stations resulting in reducing expenses of company.
6. The design of rear wheel should be such that when it punctured we wont
have to disengaged whole assembly.(if possible)
7. Should reduce price , it can be done by…
A) Reducing profit(if there is profit).
B) Reducing production cost.
C) Transportation cost etc.
23. I heartily thank you all of you (H.O. AND PLANT STAFF )to give such a good
support for my little attempt to make e-mobility more user friendly, it is my
great fate that I got such an opportunity to work with such an esteemed
company .
Really I haven’t expected that I will get this much of support and good
reward .
Its an amazing experience of my life. I also apologized If I had made any
mistakes by mistake.
It will be my privilege that if I can help our company in any field in future.
Thank you once again….
