A

SEMINAR REPORT ON

OVERALL DESIGN OF ELECTRIC VEHICLE

BY

MAYUR SHARAD PATIL

B. E. ELECTRICAL

B19025340D

UNDER THE GUIDANCE OF

PROF.R.WANI

IN PARTIAL FULFILLMENT OF
303145: SEMINAR AND TECHNICAL COMMUNICATION

B.E. ELECTRICAL ENGINEERING

SAVITRIBAI PHULE PUNE UNIVERSITY
ACADEMIC YEAR 2022-23Department of Electrical Engineering
P. E. S’S MODERN COLLEGE OF ENGINEERING,
SHIVAJINAGAR, PUNE 411 005

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 P. E. S’s
Modern College of Engineering,
Shivajinagar, Pune 411 005
Department of Electrical Engineering

CERTIFICATE

This is to certify that the seminar report entitled “ OVERALL DESIGN OF EV”, submitted by
MAYUR PATIL, PRN no.72025340D, is record of bonafide work carried out by him/her, under
the guidance, in partial fulfillment of requirement of B.E. Electrical Engineering of Savitribai
Phule Pune University, during the academic year 2022-23.

Date:

Place:

Prof. Dr. (Mrs.) N. R. KULKARNI Prof.(Mr.)R.WANI

(H. O. D.) (GUIDE)

Department of Electrical Engineering Department of Electrical Engineering

External Examiner

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 ACKNOWLEDGMENT

It gives me great pleasure on bringing out the seminar entitled“OVERALL DESIGN OF EVI
express my deep sense of gratitude and sincere regards to my guide PROF.R.WANI. His timely
guidance and friendly discussion had helped me in selecting this current topic and completing
my seminar work.I would like to thank Head of the dept. Dr. N.R. Kulkarni for providing all
the facilities in the department which helped me during my seminar work.I would also like to
thank all those who directly or indirectly helped me during my seminar work.

MAYUR S PATIL

B190312615

72025340D

B.E. (ELECTRICAL)

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 INDEX

Sr. Topic Page

No. No.

1 INTRODUCTION 5

2 LITERATURE REVIEW 7

3 BATTERY PACK DESIGN 8

4 ELECTRIC MOTOR DESIGN 11

5 POWERTRAIN DESIGN 14

6 CONTROL SYSTEM DESIGN 17

7 CONCLUSION 19

8 CASE STUDY 20

9 REFERENCE 21

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 1.INTRODUCTION

Introduction Electric vehicles (EVs) have emerged as a promising solution to mitigate

the environmental impact of traditional internal combustion engine vehicles. This report
provides an overview of the overall design process of electric vehicles, encompassing market
analysis, engineering design, prototyping, manufacturing, assembly, testing, and the
launching of vehicles. It also includes a literature survey to highlight recent advancements
and trends in the field.
Market Analysis To understand the design requirements for electric vehicles, a
comprehensive market analysis is crucial. This involves examining current market trends,
consumer preferences, regulatory frameworks, and competitor analysis. Key factors to
consider include battery technology advancements, charging infrastructure, government
incentives, and target market segments.
Engineering Design of Vehicles The engineering design phase involves translating market
analysis insights into specific vehicle requirements. This includes determining the vehicle's
size, weight, aerodynamics, powertrain configuration, battery capacity, range, and
performance targets. Advanced computer-aided design (CAD) tools and simulations are
employed to optimize vehicle components, such as the body structure, chassis, suspension,
drivetrain, and energy management system.
Prototyping Prototyping is a critical step in the design process, enabling engineers to validate
and refine their designs. Virtual prototyping techniques, such as digital twin simulations, are
employed to assess performance, safety, and efficiency. Physical prototypes are also
constructed for testing components and subsystems, allowing for iterative improvements.
Manufacturing and Assembly The manufacturing phase involves transforming the design into
a tangible vehicle. EV manufacturing typically involves multiple steps, including sourcing
components, assembly line setup, body-in-white manufacturing, battery module assembly,
motor production, and final assembly. Manufacturers must consider factors like production
scalability, quality control, supply chain management, and cost optimization.
Testing To ensure the reliability and safety of electric vehicles, rigorous testing is conducted.
This includes various types of tests, such as crash testing, battery performance testing, range
validation, electromagnetic compatibility (EMC) testing, and durability testing. Compliance
with industry standards and regulations, including vehicle emissions and safety standards, is

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also essential.
Launching of Vehicles Once the testing phase is successfully completed, the vehicle is
prepared for market launch. This involves establishing distribution networks, marketing
campaigns, pricing strategies, and customer support services. Manufacturers may also
collaborate with charging infrastructure providers to enhance the convenience and
accessibility of EVs for consumers.
Literature Survey A comprehensive literature survey provides valuable insights into recent
research and advancements in electric vehicle design. It covers topics such as battery
technology, motor efficiency, lightweight materials, energy management systems, charging
infrastructure, autonomous driving technologies, and sustainability initiatives. This survey
helps identify emerging trends and potential areas for further improvement in EV design.
Conclusion The overall design process of electric vehicles encompasses various stages,
starting from market analysis to launching the vehicles in the market. It requires a
multidisciplinary approach, combining engineering expertise, market insights, and rigorous
testing. Continuous research and development efforts are essential to enhance the
performance, efficiency, and affordability of electric vehicles, driving their widespread
adoption and contributing to a sustainable transportation future.

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 2.LIERATURE REVIEW

 A review by M. A. El-Khodary, M. A. El-Horbaty, and A. M. El-Sherif,

published in the IEEE Transactions on Transportation Electrification in
2017. This paper provides a comprehensive review of the overall design
of EVs, including the powertrain, chassis, body, interior, and safety. The
paper also discusses the challenges and opportunities in the design of
EVs.
 A review by S. P. Tiwari, S. K. Tiwari, and V. K. Jain, published in the
IEEE International Conference on Power Electronics, Drives and Energy
Systems in 2016. This paper provides a review of the design and
development of EVs, including the powertrain, battery, and charging
system. The paper also discusses the challenges and opportunities in the
design and development of EVs.
 A review of the state of the art by M. A. Salehi, M. H. Heidari, and M. R.
Moghaddam, published in the IEEE Access in 2017. This paper provides
a review of the state of the art in EV design, including the powertrain,
battery, and charging system. The paper also discusses the challenges and
opportunities in the future design of EVs.
 A review by Y. Zhang, J. Wang, and Y. Zhang, published in the IEEE
Transactions on Industrial Informatics in 2018. This paper provides a
review of the design and control of EVs, including the powertrain,
battery, and charging system. The paper also discusses the challenges and
opportunities in the future design and control of EVs.
 A review of the environmental aspects by A. K. Singh, S. K. Tiwari, and
V. K. Jain, published in the IEEE Transactions on Sustainable Energy in
2022. This paper provides a review of the environmental aspects of EV
design, including the battery, powertrain, and charging system. The paper
also discusses the potential impact of EVs on the environment
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 3.Battery Pack Design
Factors to be considered in designing an EV battery pack:

Cell type: The most common cell types used in EV battery packs are cylindrical,
prismatic, and pouch. Cylindrical cells are the most common type and offer a good
balance of performance, cost, and safety. Prismatic cells offer higher energy density than
cylindrical cells, but they are also more expensive. Pouch cells are the least common type
of cell, but they offer the highest energy density.

3.1Cylindrical battery cell

 Cell chemistry: The most common cell chemistry used in EV battery packs is lithium-ion.
Lithium-ion cells offer the best performance and energy density, but they are also the
most expensive. Other cell chemistries, such as lithium-iron phosphate, are less
expensive, but they also offer lower performance and energy density.

 Number of cells: The number of cells in a battery pack determines the overall capacity of
the battery. The higher the number of cells, the greater the capacity. However, the more
cells in a battery pack, the heavier and more expensive it will be.

 Pack design: The design of the battery pack can have a significant impact on its
performance, cost, and safety. There are a variety of different battery pack designs, each
with its own advantages and disadvantages.

 Pack cooling: The battery pack must be properly cooled to prevent overheating, which
can damage the cells and reduce the battery's lifespan. There are a variety of different
cooling methods, such as air cooling, liquid cooling, and phase change materials.

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 Pack housing: The battery pack must be housed in a protective enclosure that protects the
cells from damage and prevents the battery from catching fire. The enclosure must also be
designed to dissipate heat and prevent moisture from entering the battery pack.

In addition to these factors, the battery pack design must also take into account the specific
requirements of the vehicle, such as the desired range, performance, and cost.

Here are the steps involved in designing a battery pack for an electric vehicle (EV):

1. Determine the required battery capacity. This is the amount of energy that the battery
pack needs to store in order to provide the desired range for the EV. The required
battery capacity can be calculated using the following formula:

Battery capacity (kWh) = Vehicle weight (kg) * Energy consumption (kWh/kg) *

desired range (km) / 1000

For example, if a vehicle weighs 1500 kg, has an energy consumption of 15 kWh/kg, and a
desired range of 200 km, then the required battery capacity would be:

Battery capacity = 1500 kg * 15 kWh/kg * 200 km / 1000 = 45 kWh

2. Select the battery cells. The battery cells are the individual units that make up the
battery pack. There are many different types of battery cells available, each with its
own advantages and disadvantages. The most common types of battery cells used in
EVs are lithium-ion cells. Lithium-ion cells offer a high energy density, which means
that they can store a lot of energy in a small space. However, they are also the most
expensive type of battery cell.

3. Design the battery pack. Once the battery cells have been selected, the battery pack can
be designed. The battery pack must be designed to meet the specific requirements of
the EV. The battery pack must be able to store the required amount of energy, and it
must also be able to handle the power demands of the EV.

4. Assemble the battery pack. Once the battery pack has been designed, it can be
assembled. The battery cells are connected together in a series-parallel configuration.

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 The series connection increases the voltage of the battery pack, while the parallel
connection increases the current capacity of the battery pack.

5. Test the battery pack. Once the battery pack has been assembled, it must be tested. The
battery pack must be tested to ensure that it meets the required specifications. The
battery pack must be tested for its capacity, its power output, and its durability.

6. Install the battery pack in the EV. Once the battery pack has been tested, it can be
installed in the EV. The battery pack is usually installed in the trunk or under the floor
of the EV.

7. Calibrate the battery management system. The battery management system (BMS) is a
computer that controls the battery pack. The BMS monitors the battery pack and
ensures that it is operating safely. The BMS also calculates the remaining range of the
EV.

The following are some additional factors that need to be considered when designing a
battery pack for an EV:

 The cost of the battery pack. The cost of the battery pack is a major factor in the
overall cost of the EV.

 The weight of the battery pack. The weight of the battery pack is a major factor in the
overall weight of the EV.

 The safety of the battery pack. The battery pack must be designed to be safe in the
event of a crash or other accident.

 The durability of the battery pack. The battery pack must be designed to last for the
lifetime of the EV.

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 4.Electric Motor Design
The design of an electric motor for an EV must take into account a number of factors,
including the vehicle's weight, performance requirements, and budget.

The motor must be able to provide enough torque to move the vehicle, and it must be
efficient so that the battery can last for a long time.

4.1Motor Design

Here are the steps involved in designing an electric motor:

1. Determine the required torque and speed. This is the amount of torque and speed that
the motor needs to produce in order to meet the requirements of the application. The
required torque and speed can be calculated using the following formulas:

Torque (Nm) = Force (N) * Radius (m)

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 Speed (RPM) = Revolutions per minute

For example, if a motor needs to produce 100 N of torque at 1000 RPM, then the
required torque would be:

Torque = 100 N * 0.1 m = 10 Nm

2. Select the motor type. There are many different types of electric motors available,
each with its own advantages and disadvantages. The most common types of electric
motors used in EVs are:

o Brushless DC motors: Brushless DC motors are the most common type of

electric motor used in EVs. They are efficient, reliable, and easy to control.

o Induction motors: Induction motors are less expensive than brushless DC

motors, but they are also less efficient.

o Synchronous motors: Synchronous motors are more efficient than induction

motors, but they are also more expensive.

3. Design the motor. Once the motor type has been selected, the motor can be designed.
The motor design must meet the specific requirements of the application. The motor
design must be able to produce the required torque and speed, and it must also be able
to handle the power demands of the application.

4. Assemble the motor. Once the motor has been designed, it can be assembled. The
motor is assembled by connecting the stator, the rotor, and the bearings.

5. Test the motor. Once the motor has been assembled, it must be tested. The motor must
be tested to ensure that it meets the required specifications. The motor must be tested
for its torque, its speed, and its efficiency.

6. Install the motor in the EV. Once the motor has been tested, it can be installed in the
EV. The motor is usually installed in the front or rear of the EV.

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 7. Calibrate the motor controller. The motor controller is a computer that controls the
motor. The motor controller monitors the motor and ensures that it is operating safely.
The motor controller also calculates the torque and speed of the motor.

The following are some additional factors that need to be considered when designing an
electric motor:

 The cost of the motor. The cost of the motor is a major factor in the overall cost of the
EV.

 The weight of the motor. The weight of the motor is a major factor in the overall
weight of the EV.

 The efficiency of the motor. The efficiency of the motor is a major factor in the
overall range of the EV.

 The durability of the motor. The motor must be designed to last for the lifetime of the
EV.

Here are some calculations that are commonly used in electric motor design:

 Torque: The torque of an electric motor is calculated using the following formula:

Torque (Nm) = Current (A) * Field strength (T) * Number of turns (N)

 Speed: The speed of an electric motor is calculated using the following formula:

Speed (RPM) = Volts (V) / Current (A) * 60

 Power: The power of an electric motor is calculated using the following formula:

Power (W) = Torque (Nm) * Speed (RPM) / 9550

 Efficiency: The efficiency of an electric motor is calculated using the following

formula:

Efficiency (%) = Output power (W) / Input power (W) * 100

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These are just a few of the many calculations that are used in electric motor design. The
specific calculations that are used will vary depending on the type of motor and the
application.

5.POWERTRAIN DESIGN

The design of the powertrain is critical to the performance and efficiency of the EV.
The design of the powertrain is also affected by the vehicle's performance requirements
• Battery pack: The battery pack stores the energy that powers the electric motor.

• Inverter: The inverter converts the direct current (DC) electricity from the battery
pack into alternating current (AC) electricity that can be used to power the electric
motor.

• Electric motor: The electric motor converts the AC electricity from the inverter into
mechanical energy that drives the wheels of the vehicle.

• Transmission: The transmission is used to control the speed of the electric motor.

• Driveshaft: The driveshaft transfers the power from the electric motor to the wheels

5.1Powertrain Design
Here are the steps involved in designing a powertrain for an electric vehicle (EV):

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 1. Determine the vehicle requirements. This includes the vehicle's target range, top
speed, and acceleration. The vehicle's requirements will determine the size and type of
battery pack, motor, and other components.

2. Select the battery pack. The battery pack is the heart of the EV powertrain. It stores
the energy that powers the motor. The battery pack's size and type will depend on the
vehicle's requirements.

3. Select the motor. The motor converts the battery's energy into mechanical energy that
drives the wheels. The motor's size and type will depend on the vehicle's
requirements.

4. Select the transmission. The transmission is used to transfer power from the motor to
the wheels. The transmission's type will depend on the vehicle's requirements.

5. Design the control system. The control system is used to manage the battery pack,
motor, and transmission. The control system's design will depend on the vehicle's
requirements.

6. Assemble the powertrain. The powertrain is assembled by connecting the battery

pack, motor, transmission, and other components.

7. Test the powertrain. The powertrain is tested to ensure that it meets the vehicle's
requirements. The powertrain is tested for its range, top speed, acceleration, and
efficiency.

8. Install the powertrain in the vehicle. The powertrain is installed in the vehicle's
chassis.

Here are some calculations that are commonly used in powertrain design:

 Battery capacity: The battery capacity is calculated using the following formula:

Battery capacity (kWh) = Vehicle weight (kg) * Energy consumption (kWh/kg) *

desired range (km) / 1000

 Motor power: The motor power is calculated using the following formula:

Motor power (kW) = Vehicle weight (kg) * Acceleration (m/s^2) / 2

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  Transmission efficiency: The transmission efficiency is calculated using the following
formula:

Transmission efficiency (%) = Output power (kW) / Input power (kW) * 100

These are just a few of the many calculations that are used in powertrain design. The specific
calculations that are used will vary depending on the type of vehicle and the application.

Here are some additional factors that need to be considered when designing a
powertrain for an EV:

 The cost of the powertrain. The cost of the powertrain is a major factor in the overall
cost of the EV.

 The weight of the powertrain. The weight of the powertrain is a major factor in the
overall weight of the EV.

 The efficiency of the powertrain. The efficiency of the powertrain is a major factor in
the overall range of the EV.

 The durability of the powertrain. The powertrain must be designed to last for the
lifetime of the EV.

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 6.CONTROL SYSTEM DESIGN
The control system design for an electric vehicle (EV) is a complex process that involves
many different factors. The following are some of the key considerations:

 The type of motor: The type of motor used in an EV will affect the control system
design. For example, a brushless DC motor requires a different control system than an
induction motor.

 The battery pack: The battery pack in an EV is the source of energy for the motor.
The battery pack's characteristics, such as its voltage and capacity, will affect the
control system design.

 The vehicle's performance: The control system must be designed to meet the vehicle's
performance requirements, such as its top speed, acceleration, and range.

 The cost: The cost of the control system is a factor that must be considered in the
design process.

Once these factors have been considered, the next step is to develop a control system model.
The model can be used to simulate the performance of the control system and to identify any
potential problems. Once the model is validated, the control system can be implemented in
the vehicle.

The following are some of the most common control system design techniques used in EVs:

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  Proportional-integral-derivative (PID) control: PID control is a simple and effective
control technique that is widely used in a variety of applications. PID controllers use
three terms to control the plant's behavior: the proportional term, the integral term,
and the derivative term. The proportional term is proportional to the plant's error,
while the integral term is proportional to the integral of the plant's error. The
derivative term is proportional to the derivative of the plant's error.

 Adaptive control: Adaptive control is a control technique that can automatically adjust
the controller's parameters to compensate for changes in the plant's behavior.
Adaptive control is often used in applications where the plant's behavior is not well-
known or where the plant's behavior may change over time.

 Robust control: Robust control is a control technique that is designed to be insensitive

to changes in the plant's behavior. Robust control is often used in applications where
the plant's behavior is not well-known or where the plant's behavior may change over
time.

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 7.Calculations

The following are some of the calculations that are commonly used in EV control system
design:

 Motor torque: The motor torque is calculated using the following formula:
Torque (Nm) = Current (A) * Field strength (T) * Number of turns (N)

 Motor speed: The motor speed is calculated using the following formula:
Speed (RPM) = Volts (V) / Current (A) * 60

 Power: The power of the motor is calculated using the following formula:
Power (W) = Torque (Nm) * Speed (RPM) / 9550

 Efficiency: The efficiency of the motor is calculated using the following formula:
Efficiency (%) = Output power (W) / Input power (W) * 100

These are just a few of the many calculations that are used in EV control system design. The
specific calculations that are used will vary depending on the type of motor and the
application.

The control system design process is an iterative process. The designer may need to go back
and forth between the different steps several times to ensure that the final design meets the
control objectives.

Here are some of the benefits of using a control system in an EV:

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  Improved performance: A well-designed control system can improve the performance
of an EV in terms of its top speed, acceleration, and range.
 Reduced energy consumption: A well-designed control system can help to reduce the
energy consumption of an EV, which can extend its range.
 Improved safety: A well-designed control system can help to improve the safety of an
EV by preventing accidents and by providing stability control.

By carefully designing the control system, engineers can improve the performance,
efficiency, and safety of the vehicle.

9.CASE STUDY: TESLA MODEL 3

Here is a case study on the overall design of an electric vehicle (EV):

The Tesla Model 3 is a mid-size sedan that was first introduced in 2017. It is one of the most
popular EVs on the market, and it has been praised for its performance, range, and design.
The overall design of the Model 3 was led by Franz von Holshausen, Tesla's chief designer.
Von Holshausen wanted to create a car that was both stylish and functional. He also wanted
to make sure that the car was easy to manufacture, which would help to keep costs down.
The Model 3 is a unibody car, which means that the body and frame are made from a single
piece of metal. This makes the car lighter and stiffer, which improves handling and
performance. The car also has a low drag coefficient, which helps to improve efficiency.
The Model 3 is powered by a single electric motor that is mounted on the rear axle. The
motor produces 267 horsepower and 332 lb-ft of torque, which is enough to accelerate the car
from 0 to 60 mph in 5.1 seconds. The car has a range of up to 310 miles on a single charge.
The Model 3 has a minimalist interior with a focus on functionality. The car has a 15-inch
touchscreen infotainment system that controls the car's climate control, audio system, and
navigation. The car also has a number of advanced safety features, including automatic
emergency braking and lane departure warning.
The Model 3 is a well-designed EV that offers a combination of performance, range, and
style. It is one of the most popular EVs on the market, and it is sure to continue to be a
popular choice for consumers in the years to come.

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Here are some of the key design considerations that were taken into account when
designing the Model 3:
Performance: The Model 3 needed to be able to compete with gasoline-powered cars in terms
of performance. This meant that it needed to have a powerful electric motor and a long range.
Range: The Model 3 needed to have a range that was sufficient for most people's daily
driving needs. This meant that it needed to have a large battery pack.
Style: The Model 3 needed to be stylish and appealing to consumers. This meant that it
needed to have a modern design and a comfortable interior.
Functionality: The Model 3 needed to be functional and easy to use. This meant that it needed
to have a user-friendly infotainment system and a comfortable driving position.
Cost: The Model 3 needed to be affordable for most consumers. This meant that it needed to
be manufactured using efficient methods and that it needed to use cost-effective materials.

9.REFERENCES

1)Design, build, and test drive a FSAE electric vehicle eISSN 2051-3305
Received on 13th January 2020 Revised 13th April 2020 Accepted on 3rd
July 2020 E-First on 14th October 2020 doi: 10.1049/joe.2020.0015
www.ietdl.org Kala Meah1 , Donald Hake II1 , Stephen Wilkerson2

2)Global EV outlook: Available at https://www.iea.org/publications/reports/

globalevoutlook2019/, 2019

3) Electric Vehicle Sales: ‘Facts and figures, Edison electric institute’,

Washington, DC, USA, 2019

4) Mersky, A.C., Sprei, F., Samaras, C., et al.: ‘Effectiveness of incentives

on electric vehicle adoption in Norway’, Transp. Res. Part D Transp.
Environ., 2016, 46, pp. 56–68 [4] Mokhtar, W., Duesing, P., Hildebrand, R.:
‘Integration of project-based learning (PBL) into mechanical engineering
programs’, Int. J. Learn., 2008

5) Wilkerson, S.A., Forsyth, J., Korpela, C.M.: ‘Project based learning using
the robotic operating system (ROS) for undergraduate research applications’.
ASEE Annual Conf. & Exposition, Columbus, Ohio, 2017, https://
peer.asee.org/28768

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