Maintenance of GPS tracker:
Problem Identification:
Kinetic Green E-Rickshaw comes with a GPS tracking system. GPS tracking module is governed by Sensel Telematics in which fleet smart app/ Interface gives us tracking records. It provides the services like live tracking, halt reports, route reports, route playback, detailed route report, speed report, summary distance report, monthly distance reports, Geo-mapping, vehicle, and driver maintenance, etc.
To obtain these reports we just need to log in with our login ID and password, after logging in it will show the interface like shown picture.
Now you can select any of the options from the website tabs by selecting our vehicle number. You can generate all the required data in an excel sheet.
Geo Mapping: This function provides the boundary condition to our vehicle, if the vehicle crosses the boundary set by the admin, it will send a notification on registered E-mail or SMS. (For SMS service Sensel takes a monthly charge.) We can add the geofence as per our requirements and can set/ change the notification receiving details by editing the geofence. We can generate the report of the vehicle route by showing the position in the geofence.
We can set the geofence in square and polygon shapes.
The control of the Start and Stop of the vehicle present in the Sensel Interface is not working with our E-Rickshaw.
We can add driver info in the Vehicle and Driver maintenance tab where we get the monthly details of maintenance for driver and vehicle.
Problem Identification:
One of the vehicles was showing Not Reachable Status. This means the GPS tracker stopped working. GPS tracker has LED at the Bottom side, if they are ON and blinking then the GPS is working properly. If LED is off, then the GPS module is not working. If this happens, we just need to check for the loose connections of wire and joints if any. If it is ok, then check the supply voltage in the red and yellow wire of the GPS module. The supply should be more than 5 V, if it is giving 5 volts then the GPS module should be repaired by calling Sensel Telematics service support staff and the supply is not 5 V then we need to check for wiring loose connections.
Problem Detected:
It was detected that the rickshaw was not getting started even though the charging in the battery showed 58%. Then we contacted the concerned person from Vardhaman Automobile Mr. Prashant Daroi, He asked us to keep the charging on for 1 hour. After doing the same as said though the problem doesn’t resolve.
Then asked us to do some primary measures like checking the charging output voltage, battery voltage, etc. The battery voltage was only 15 V rather it should be showing 53 V, so the problem detected was in the battery. So, for this maintenance battery technician called for its repair.
The battery in the rickshaw has a BMS system inbuilt. It is an OKAYA Lithium make a battery. Which runs on software. The hardware for it is inbuilt in the battery.
This battery also consists of extra power cells which can be utilized when we travel on elevated roads. They provide extra power to vehicles to lift the load.
The problem was with the software. The software was crashed of BMS, so the technician updated the program in BMS and after updating the programmed battery again showed 53 V voltage. Hence this is how the problem is solved.
The motor controller must be failed due to a problem that occurred in the battery as the battery was showing low voltage although the motor was on, so due to this low battery voltage, it affected the circuit of the motor controller which requires a 48V supply.
The troubleshooting is done by replacing the motor controller of another vehicle and it started so this is how we detected that the motor controller failed.
Mechanical maintenance:
Brakes: the maintenance of brakes is easy, as seen in this picture there is a rachet nut that we need to adjust as per our requirement. If we want an urgent brake, then we need to rotate it anticlockwise and vice versa.
We must ensure that the drum brake handle is coupled with the lock nut of the brake wire. The lubricating oil must be used to smooth the operation of brakes.
Lubricating oil: Oil must be changed every 1000- 1500 Km. It is very hard to insert oil in the oil tank as the space kept is too small.
There are two lock nuts are present, the lower one is to remove the oil from the tank and the upper one is to fill. We can easily remove the oil but due to less space on the upper side, we must take a small bottle with small tip output.
Make sure that to fill the 250 ml of oil.
The bike was not getting started for the last week, we tried to do it charge but the charging is also not working, we tried charging by removing the battery from the bike then the battery was allowed to charge but it was fully charged.
Although the bike was not getting started, we contacted to customer service of the revolt company they asked us to check the remote control whether the LED is blinking or not, but the LED was blinking, then he asked us to try using the duplicate remote control by replacing the button cell into it and it worked, the bike started with another remote.
So, the remote has some software issues and can be solved by reprogramming it.
Mechanical maintenance(Replacement of Gradient gare cable ): 6/09/2021
Problem Detected: The gradient gare cable was found out broken on 3/9/21
the observation was due to frequent use of lever the cable fails and the wire at the one end of the attachment broke down. Then we contacted Vardhman Automobile for the replacement of the cable. They send a complete set of gradient gear drives including a lever mechanism. The whole assembly was changed on 6/9/2021.
Mechanical maintenance (Drum brakes): 15-16/9/2012
Problem Detected: The rear-wheel Drum brakes of E-Rickshaw number -MH12 SK7297- were not working properly. The observation was both the wheels got locked as brakes were applied.
Action taken :
Then we contacted the concerned person from Vardhman Automobile Mr. Prashant Daroi, He asked us to check the camshaft behind the drum brakes and make it free by hammering on it using a wooden block. but this was not working so we decided to open the drum brake.
It was difficult to open the Drum brake without a puller tool, available in the workshop. so we made one.
After opening the drum brake we observed the “S” shaped cam was completely jammed due to rust. We removed it from the drum and cleaned the rust using sandpaper and oiled it and re-assemble it as it was. The same did with the opposite wheel.
Electronic maintenance (Replacement of throttle ):
30/09/2021
Problem Detected: The acceleration throttle of E-Rickshaw number -MH12 SK7297 was not working properly. The observation was due to frequent use of the throttle, The springs in the throttle got damaged/break or it might slip from its fixed end within the throttle body resulting in its loss of stiffness and improper working on 29/09/2021.
Then we contacted Vardhman Automobile for the replacement of the acceleration throttle.
They send a complete set of acceleration throttle drives.
The throttle was changed on 30/9/2021.
Electronic maintenance: 19/10/2021
Problem Detected: on 19/10/21 problem was detected by Laxman Jadhav sir. E-rikshaw No.MH12S K7297 was not moving even though moving throttle fully. this problem occurs at the charging spot after charging the e-rikshaw.
Observations: The State of Charge( Soc) of the battery showing 99%, Throttle reverse switch working and showing indication, battery voltage showing 53V, exhaust fans of controller unit working. All the other accessories of the vehicle were working properly.
The action was taken: Based on the above observation I thought it might be some connection problem through the throttle. As Some other things were working properly. So I open and reconnect the connections of throttles to see if there is any loose connection. But the problem is not solved. Then we check the voltage of each connector pin. As I mentioned in the maintenance repairing of the throttle. the throttle connection of kinetic e-rikshaw consists of 3 connecters .1st connecter contains 2pins which acts for switch mode for reverse and forward mode which was perfectly fine.Another connector contain 3pins(Vcc,Gnd,Analog-) for potential meter .I check voltage input from Vcc and Gnd(12v) .and the third connector consists of 3pins for 3 modes on the throttle (3 pins for signal ) and the throttle was recently replaced. So we thought that there must not be any internal damage between the throttle connection and controller. After doing all this the problem was not solved.
Then we contacted Vardhman Automobile Mr. Prashant Daroi, He asked us to check the backlights of e-rikshaw whether they are started or not, checking the hand brakes (it might be the problem of a limit switch on brakes)but it was perfectly fine.
He suggests contacting Mr. Atul service engineer at kinetic e-rickshaw. After contacting him. he ask me to send pictures of BLDC Motor and Controler (BLDC Driver ) + chassis no. which I provided soon.
After that Prashant sir suggest me. It might be the failure of the motor controller and cross-check it by replacing the current motor controller with another vehicle .so I exchange the controllers and found that the same motor controller working properly in another vehicle. So it was sure that the motor controller was perfectly working. then he suggests replacing the motor of the vehicle.on 25/10/21.I receive the parcel of the motor at Vigyan ashram .it was a 1.2kw BLDC motor consisting of 3 wires (yellow, Blue, Green)and a hall effect sensor connecter.
Steps to connect the motor:
- 1st remove the main battery supply connecter from battery pack.
- Remove the wires on controles using LN key .
- attach the wires as per nomincleture on controller (yello ,green and blue).
- reconnect the main power switch again.
after doing this all the motor was not still starting. Then we connect the same motor to another vehicle and it starts. that’s sure the motor was perfectly fine. After observation this all I was sure that the problem might be in throttle itself. So we finely decided to open the newly replaced throttle and after opening it I found out one of the wires attached to variable resistance which provides an analog signal at the throttle was ditch. also, I observe that the throttle in case wiring soldering was bad and there were no heat shrink tube or protection soldered wires. And then I solder that one attach wire and its work. after reconnecting all the connections of E-rikshaw the rikshaw started to move.
Electronic maintenance(battery): 10/11/2021
E-rikshaw No.MH12S K7298 turns off in mid path while traveling from khed to shikhrapur road. It travels around 42km after charging 100% and suddenly stops.
Observations: All the other accessories of e-rickshaw were not working. The observed battery voltage of the battery was around 9.46v which was below the rated voltage range. it should be showing 53 V, so the problem detected was in the battery is cleared. Then we contacted the concerned person from Vardhaman Automobile Mr. Prashant Daroi, He asked us to keep the charging on for 1 hour. After doing the same as said though the problem solve.
Electronic maintenance(battery display problem): 14/11/2021
Observations: Display of E-rikshaw No.MH12S K7297 was not showing appropriate characters. Also E-rikshaw No.MH12S K7298 display was showing a horizontal blank line on it. regarding this problem, I contact Mr. Prashant sir from Vardhman automobile he further contacts me with Mr. Anand from the service department of Okaya lithium battery company.
On 15/11/21 he change the LCD screen module. There was a problem with software within the LCD module which has to be programmed. During troubleshooting, the display was on, which indicates the power supply to the LCD module was perfectly working and the issue was in the software of the module and not hardware. So he decided to change the whole module with a new program one which was working perfectly. Okaya lithium-ion battery company provides the 16*2 LCD display module within build controller and algorithm for indicating charging percentage(State of charge),current-voltage of battery and reading of current consume and voltage at the running condition of the vehicle. which can be shown on LCD by passing push-button on the display module. It consists of 5 pins mail jack connecter on the LCD module .which can easily be connected and disconnected from the female jack connecter which was further connected to BMS(Battery management system) of batter of e-rikshaw.
after connecting the new module the battery percentage was showing zero as we connected the module from the undefined state of charge battery also there was only one push butter in front of the LCD model to change parameters (battery %, voltage, etc) and two push buttons at the backside of module for adjusting the fingers on the display. Mr. Anand said they will start showing normal reading As the battery state of charge goes zero once.it will reset the algorithm in the LCD module.
He just replace desplay of E-rikshaw No.MH12S K7297 As he brings only one display module with him.
Electronic maintenance:(Head lights) 27/11/2021
Issue Observ: one left-hand side pair of dipper wight headlight of both e-rickshaw No.MH12S K7297 and No.MH12S K7298 was not working.
The action was taken: As both rikshaw were in warranty status. I contacted the concerned person from Vardhman Automobile Mr. Prashant Daroi for the replacement of both headlights. He sends us 2 pieces of new headlights for replacement. on 29/11/2021 we receive headlights and a pair of gradient gear levers and a cable. On 27/11/2021 we spend changing the gradient cable replacement which was done by me and Shubham Shebde. which was not done so well at that time (discuss in gradient gare & cable section).On 29/11/2021 I with help of Ghanshyam and Chechnya started working on the replacement of E-rikshaw headlights.
The whole headlight assembly consists of the plastic casing with an indicated light at the corner and the main headlight mounted on the front frame with nuts and bolts on the frame. using a screwdriver I remove the outer plastic casing of the front headlight unit. after that removing the casing we observe that the indicator light was connected with a read rectangular pin connecter and two power supply wires (brown from inside connected to read of a headlight and black from inside connected to the black of headlight attached with poor casing transparent plastic cover by connecting clips. Other than that there were two more additional wires that go direct connection with the headlight blue (middle) and wight connected at the back of the headlight. the headlight was supported with another supporting structure at the backside of the light which I remove by bolts on it. I remove all the connections of an old headlight and connect it with a new one as described in the connection diagram
After connecting all I reassemble everything. and start testing the headlights During testing I observe that the headlight of the rickshaw was operating in opposite functionality where the operator operate it for upper frontal light it works opposite and with replaced new headlight shows the dipper light on. It was the wiring issue that we solve by changing the passion of blue and wight wires on the main headlight.
Mechanical maintenance(Replacement of Gradient gare cable ): 27/11/2021
Issue: This was the second time that we found out the brake of gradient cable in e-rikshaw No.MH12S K7297 this problem occurred along with the problem of the headlight.
The action was taken: On 27/11/2021 we receive gradient gare cable and lever mechanism with two headlights from Vardhman automotive at 5:30. We decided
As both rikshaw were in warranty status. I contacted the concerned person from Vardhman Automobile Mr. Prashant Daroi for the replacement of both headlights. He sends us 2 pieces of new headlights for replacement. on 29/11/2021 we receive headlights and a pair of gradient gear levers and a cable. which we find used and the end connecting cap at cable which fix in lever mechanism broken.
As it was too long to receive the new one we decided to do some jugad for it.
