21135A0201 - EV Design MasterClass
21135A0201 - EV Design MasterClass
BACHELOR OF TECHNOLOGY IN
ELECTRICAL AND ELECTRONICS ENGINEERING
SUBMITTED BY
P Balakrishna
21135A0201
Under the esteemed Guidance of
Mr. P.Pawan Puthra
Assistant Professor
Lastly, we are grateful to one and all who have contributed either directly or
indirectly for the completion of this project.
P Balakrishna
21135A0201
ABSTRACT
Iv LIST OF FIGURES
LIST OF TABLES
CHAPTER -1 INTRODUCTION
1.2.1 MATLAB
1.2.2 SIMULINK
2.1 Principle
3.8 Prototype of EV
4.1 EV subsystem
CHAPTER -5 CONCLUSION
CHAPTER-1 INTRODUCTION
The first electric vehicle was produced by Thomas Parker in 1884, 25 years after the
invention of lead-acid batteries. After that date, many electric vehicle models appeared.
However, the development of internal combustion engine technology and the reduction in
mass production costs have left electric vehicles behind. The energy crisis that lived between
1970 and 1980 brought electric vehicles back to the forefront. But they could not reach the
high speeds and long ranges of conventional vehicles. Electric vehicles consist of various
models, which are interconnected for working of the vehicle. Initially while designing an
electric vehicle, one has to fix certain parameters like, radius of tires, type of motor, type of
battery and the dimensions of the vehicle. These factors are used in calculation of various
factors like- Resistances offered, Torque provided by tires, Charge and Discharge rate of
Battery. The design of the vehicle plays an important role in the efficiency of the vehicle. The
main components of an Electric Vehicle are the Motor and the Battery. The choice of motor
depends on the environmental conditions in which the vehicle would be driven, it also
depends on the amount of range for which vehicle is needed to be designed, different motors
provide different torques.
C. X. D. Xue, tried to determine the appropriate electric motor for electric vehicles.
Electric motors were compared according to efficiency, cost, safety and weight criteria.
The study concludes that the permanent magnet synchronous motor is the best motor
type.
Baser, an electric vehicle model with two motors, an asynchronous motor and a
permanent magnet synchronous motor. As a result of the work the asynchronous motor at
low speeds and the synchronous motor at constant speed with high speed are more
efficient.
The motor and the battery need to sync efficiently as there is constant flow of charge
between the motor and the battery. As the world is marching forward in the development
of alternate sources of energy, to support the Battery model, for running the vehicle, a
Regenerative System is introduced in the model. Through the regenerative system, when
the vehicle is braked, the tires do not immediately come to stop, there is still rotational
kinetic energy left in them. At this time, the rotational kinetic energy, which is a form of
mechanical energy, is converted into electrical energy through the generators in the
regenerative system and stored that generated electrical energy into the battery. With the
help of a regenerative system, the state of charge of the battery is improved and thereby
the range of the electric vehicle is also increased.
1.2.1 MATLAB
(an abbreviation of "MATrix LABoratory") is a proprietary multiparadigm
programming language and numeric computing environment developed by MathWorks.
MATLAB allows matrix manipulations, plotting of functions and data, implementation of
algorithms, creation of user interfaces, and interfacing with programs written in other
languages.
Although MATLAB is intended primarily for numeric computing, an optional toolbox
uses the MuPAD symbolic engine allowing access to symbolic computing abilities. An
additional package, Simulink, adds graphical multi-domain simulation and model-based
design for dynamic and embedded systems.
1.2.2 SIMULINK
Simulink is a simulation and model-based design environment for dynamic and
embedded systems, integrated with MATLAB. Simulink, also developed by MathWorks,
is a data flow graphical programming language tool for modelling, simulating and
analysing multi-domain dynamic systems.
Simulink bridges development from requirements and system architecture to detailed
component design, implementation, and testing. Capture and decompose requirements.
2.1 PRINCIPLE:
THEORY:
The vehicle uses a large traction battery pack to power the electric motor and must
be plugged into a charging station or wall outlet to charge. Because it runs on
electricity, the vehicle emits no exhaust from a tailpipe and does not contain the
typical liquid fuel components, such as a fuel pump, fuel line, or fuel tank. Both
heavy-duty and light-duty EVs are commercially available. EVs are typically more
expensive than similar conventional and hybrid vehicles, although some cost can be
recovered through fuel savings, a federal tax credit, or state incentives
The base of any car is the battery. As told earlier, the battery used for this car is very
expensive. By using lead acid batteries, the weight of the car increases a lot (>>1000 pounds).
As the number of batteries range from 50 to more, they occupy a lot of space as well. They
generate less driving power compared to gasoline cars. After a long drive, they need at least
ten hours to get recharged completely. Apart from the battery used for the car mechanism,
there is also an additional 12 V battery on board. This is needed to provide power for other
components like wipers, radio, air conditioner and so on. But the extra expense comes when
you have to recharge the battery. You will need a 300V Dc to 12V DC converter.
Thus, when the accelerator is fully pressed, the controller produces almost 96 V to the
motor. If the accelerator is released, the controller delivers 0V. Thus, the controller stands as
a buyer of power from the battery and giver of power to the motor. As the accelerator is
pressed in different modes, the controller is supposed to give an output power accordingly.
So, variable potentiometers are connected between the accelerator and the controller, so that
variable potentiometers are connected between the accelerator and the controller, so that
variable, but proportional power can be delivered to the motor. But if the potentiometer goes
wrong the result can be fatal. So, as a safety measure, there are two potentiometers connected
to the accelerator. If both show equal value, then the controller proceeds.
In most of the cars, the controller is just a normal switch with an ON position while
accelerating and an OFF position while decelerating. But this is difficult for the driver as he
will not get a flow. Thus, the controller acts as a pulsator. It notices the value of
potentiometer and rapidly switches the proportional power to the motor. The motors used in
electric cars can be AC or DC. Mostly DC motors are preferred to AC motors because they
are simple to configure and are not at all expensive. For AC motors 3-phase motors have to
be used, running at 240V AC. DC motors, on the other hand, require only (96-192) Volts. DC
motors can also be overdriven for a short period of time.
Permanent Magnet Synchronous Motor (PMSM) are most used motors in designing
Electric Vehicles because of their efficient output and less loss of energy. Permanent
Magnets produce high flux density in air gap thereby increasing power density and torque
to inertia ratio. PMSM have fast response and high efficiency. PMSM has two main
sections, Rotor and Stator. Stator consists of three phase sinusoidally distributed copper
winding. The Rotor does not have winding. The three-phase balanced supply is provided
to the stator winding which produces a rotating EMF of constant amplitude in the air gap.
The stator current is controlled by the position feedback of the rotor in order to maintain
the frequency in synchronism to the rotor. The interaction of these stator and rotor fields
results in torque development on the rotor.
As we know that there are many advantages compared with disadvantages with Electric
Vehicles.
It is one of the forces that act to oppose the motion of the vehicle.
Frr=µrr*m*g
Fad =1/2*ρ*Cd*A*V2;
A= frontal area m2 ;
The resistance offered to vehicles moving on a slope. The climbing resistance is due to the
gravity’s component.
A Battery Management System (BMS) is an electronic regulator that monitors and controls
the charging and discharging of rechargeable batteries used in Electric Vehicles.
· Protects the battery from operating outside its safe operating area.
· Control the recharging of the battery by redirecting the recovered energy (from
regenerative braking) back into the battery pack.
· To battery parameters
Infineon integrated circuits and designs help you to layout your Battery Management System.
Careful design considerations on charging and discharging processes on battery protection
and cell monitoring will support you throughout your design.
Infineon ‘s solutions and design resources for a battery management system, help you to
overcome your design challenges and support your success in developing more efficient,
longer-lasting and more reliable battery-powered applications.
From engineers to engineers, our tools will support you in every phase of your design, from
comparing the different products to simulations, and of course ready to use reference designs.
1. Active cell balancing is a more complex balancing technique that redistributes charge
between battery cells during the charge and discharge cycles, thereby increasing system run
time by increasing the total usable charge in the battery stack, decreasing charge time
compared with passive balancing, and decreasing heat.
2. Passive Balancing Allows All Cells to Appear to Have the Same Capacity. ... Using a
relatively low current, it drains a small amount of energy from high SoC cells during the
charging cycle so that all cells charge to their maximum SoC (state of charge).
· Protects the battery from operating outside its safe operating area.
1.Cell fault
3.Ageing
5.Abuse
6.External factors
4 Electrode plating
6 Reduced capacity
7 Increased self-discharging
8 Gassing
9 Pressure builds up
12 Thermal runaway
2. Operation: 4 Quadrant
4.1 EV subsystem
Fig:
Typical Subsystems
· Chassis systems
· Airbag systems
· Power train
Chassis systems.
Complexity, integration and electrification are the main drivers of modern chassis
systems development. Gain insight into recent technology developments in steering and
braking systems, suspension, tires and vehicle dynamics control. As these systems
continue to integrate more electronic components, manufacturers are adopting processes
to meet safety regulations such as the ISO 26262.
Airbag systems.
Thermoplastic olefins (TPO) can help increase the safety of a vehicle’s interior by
preventing brittle failures under high impacts like airbag deployments. By using
ENGAGE polyolefin elastomers (POE) to manufacture TPO airbag covers, you can
improve low-temperature ductility – helping important safety features like airbags to
operate properly, even at temperatures below -30°C. ENGAGE XLT POE can enable
lighter, thinner TPO parts with increased stiffness, comparable impact strength and
greater flow.Excellent toughness and flexibility, Enhanced aesthetic properties, like
surface gloss,Potential reduction in cycle time, especially in POE-rich formulations,
Fabric coatings, top coats and seam sealants. Meet your critical safety and design
objectives with silicone elastomer fabric coatings, friction-reducing top coats, and seam
sealants from Dow. Create smaller-sized, lighter-weight packages and more durable
performance in all types of airbag system designs.
Powertrain.
As the name suggests, the powertrain provides power to the vehicle. Powertrain refers to
the set of components that generate the power required to move the vehicle and deliver it to
the wheels.
Today, automotive software is getting increasingly complex due to the competitive pressure
to provide increasingly improved quality, safety, luxury, and economy. Therefore, Electronic
control units (ECUs) and controller algorithms in cars increase, vehicles are becoming more
and more complex, and development and testing of vehicle components become time
consuming.Primate has paved the way for innovation in heavy-duty vehicle ECU testing and
provided highly intuitive end-to-end automotive testing services and solutions for an
extensive range of Body and comfort electronics ECUs.
The IVI can be described as a combination of vehicle systems which are used to deliver
entertainment and information to the driver and the passengers through audio/ video
interfaces, control elements like touch screen displays, button panel, voice commands, and
more.Everything You Need to Know About In-Vehicle Infotainment Systems. Everything
You Need to Know About In-Vehicle Infotainment System. The entire automotive industry is
moving towards developing innovative technologies to enable better connectivity solutions,
improve vehicle safety, and enhance in-vehicle user-experience. One of the key technologies,
which works as a focal point of all the modern automotive systems and integrates their
functions to be controlled and monitored from one central unit, is “In-Vehicle Infotainment
System”.
Fault Tolerance, Determinism, Bandwidth, Receiver, Flexibility these five are the
main parts for the communication in EV’S
➔ Fault tolerance
It identifies the faults in the vehicle and sends it to the instrumental cluster.
➔ Determinism
We can determine our requirement through voice which is assisted at infotainment system
➔ Band width
a range of frequencies within a given band, in particular that used for transmitting a signal the
transmission capacity of a computer network or other telecommunication system
➔ Receiver
A wireless charging system can include a charging station and a charge receiver. The charge
receiver can be provided on a vehicle. The charging station can include a movable charge
transmitter. The system includes a sensor that can detect a relative position of the charge
receiver
➔ Flexibility
One of the biggest advantages of driving electric is the improvement it can make to the
environment we live in. Pure electric vehicles have no tailpipe, so they don’t emit any
exhaust gases, which reduces local air pollution particularly in congested cities.
·
➔ Security
Electric cars can also be left exposed because of their charging stations. This is because of the
combination of a physical security attack and a cybersecurity attack known as the
substitution attack. This attack gives attackers the ability to digitally clone and use an
electric car’s ‘identity.’
What is PROTOCOL?
· UART/SPI/IIC/LIN/CAN/Flex-Ray/Ethernet
· Application Protocols
· UDS/J1939/CAN-Open/MOST
· Bluetooth/Wi-Fi/USB/4G/5G/V2G
Wired Technology
· Generally used in Body and Comfort Subsystem and further with CAN/LIN Gateway
· ISO 11898 is the most commonly used fieldbus in the European automotive industry.
· US SAE J1850 plays the main role, while in the truck and bus applications J1939.
· 150Kbps.
Wireless technologies
· Bluetooth
· ZigBee
· Wi-Fi
Vehicle data:
· Vehicle type: Half Car Model
· Rider mass=80 kg
· Vehicle mass =230 kg
· CG height=254 mm
· Drag coefficient =1.2
· Front axle=1520 mm
· Rear axle=1400 mm
· Front area=1.33 m^2
Tire Parameters:
· Tire1=10
· Tire 2=1.9
· Tire3=1
· Tire4=0.97
· Tire diameter=18 inch
· Tire inertia= 1e-3 kg*m^2
· Roll resist=0.005
With the help of above parameter data, the basic vehicle diagram simulation has been
done and with a scope at the starting with zero and with positive pulse and with
negative pulse. The simulations along with the output graph are listed below.
So, on manufacturing these EV's there will be lots of benefits in savings of fuel, fast
charging system, the production cost will be lesser, control of emission takes place low
noise pollution, easy to rebuild in any damages happen, and safe to drive, by keeping all
these points EV will be boom for the future.
THANK YOU