A Comprehensive Investigation of the Electric Two-Wheeler Fabrication Process from Conventional to Cutting-Edge Approach

India is ranked as the world's second-biggest supplier and manufacturer of two-wheelers. In relation to domestic sales and the production volume of two-wheeler vehicles, it holds the third position globally, preceded solely by China and Japan. This paper focuses on the fabrication process of an electric two-wheeler. The selection process involves choosing the chassis of a pre-existing two-wheeler, specifically a 110 cc bike. The conventional engine is substituted with a battery-motor system. The aforementioned calculations, including power, torque, battery, and motor specifications, as well as range calculation, are conducted. The wiring harness has been appropriately configured for the electric two-wheeler. The selection process involves choosing components such as the electric motor, which operates at a voltage of 60 V, and pairing it with the appropriate battery and battery management system for optimal motor performance. The components of the motor system, such as the motor controller, digital display, and electric throttle, are integrated together. The construction of the electric two-wheeler is conducted by utilizing the acquired components and employing calculations to determine the vehicle's performance. The evaluation of the vehicle is conducted and juxtaposed with the internal combustion engine.