Electric Vehicles

- An Introduction
Why so much interest in EV?
14 Of the 20 most Polluted
Cities in the World

36 % of NOx emission due to

Vehicles

40 Times increase in import bill

of petroleum products

4x EV is 4 time more energy

efficient that ICE

50 Times lesser moving parts in

EV that ICE
Issues in switching to EV
Energy Storage: Battery
• Weight, Volume and cost on the higher side
• Energy Density (Weight & Size)
• Unit of Energy : Watt-hour
• Gravitational Energy Density (Watt-hour/Kg)
• Volumetric Energy Density (Watt-hour/liter)
Why Li - ion Battery
• Gravitational ED of Battery (NMC, NCA) is around 250 - 300 Wh/Kg today
• Expected to reach 400 - 500 Watt-hr/Kg in the Future (NMC battery with Graphite - Silica Anode)
• Volumetric ED of NMC is reaching around 500 Watt-hr/liter
• The Cost (Cell-Price) per Kwh is decreasing
• As the ED is increasing - size, volume and cost
decreases (Cost is inversely proportional to ED)
• More energy in small area
• Material Used - Lithium, Nickle, Manganese, Cobalt,
Aluminum, Graphite

Your Text Here

Li - Ion Battery vs Petrol
• Energy Density of Petrol - 12,500 Wh/Kg
• Even with 4 time higher drive efficiency,
- Battery weight per km is 10 -12 times higher that petrol weight per km
- Battery size per km is 5 - 6 times higher
Drive Train for Petrol Vehicle
• Fuel from Fuel Tank to engine in controlled manner (Petrol Injection value)
• Required Torque and Speed
• Hydraulics vs Battery
• Engine shaft coupled to dynamometer
• Auxiliary power for Electric Power Steering, Sensors,
lights, motors, air-condition, Power brakes etc
• Battery assisted Drive - Mild Hybrid
• Regenerative braking
• Petrol pump to fill fuel tank
Drive Train for Electric Vehicle
• Motor and Controller (required power and speed)
• Electric energy from Battery (Current I from battery - more/ less energy to
motor)
• Nearly constant battery voltage (P=V*I)
• DC-DC converters convert the battery voltage to the
required level for auxiliary devices like power steering,
power brakes, air- condition unit etc
• Battery Charger to fill electricity in battery
• Regeneration during deceleration and climbing down
Petrol Vehicle to Electric Vehicle
Petrol Vehicle Electric Vehicle
Engine and Engine Control Motor and Controller
Fuel tank + Petrol - Petrol injection pipe Battery + Charge : Current controls the drive
Hydraulic or Electric Battery (Lead Acid) -
DC - DC converters
drives the auxiliary units
Petrol pump to fill fuel tank Battery charger to fill (charge/electricity) battery
Regeneration possible - used to charge battery
No Regeneration
(Motor as Generator)
Drive Specifications
• Torque, Speed, Power, Energy
• Engine/Motor will generate certain torque and rotate at certain rpm
• Controller will control the Torque and speed
• Vehicle Torque (Nm) = Force (N) x rtyre (m)
• Force will over come:
- Rolling resistance
- Aerodynamic resistance
- Acceleration for vehicle
- Over come gradient
Vehicle Speed
• Vehicle speed (Kmph) is defined by motor/engine rpm
𝑆𝑝𝑒𝑒𝑑 (𝑘𝑚𝑝ℎ)
𝑆𝑝𝑒𝑒𝑑 (𝑚Τsec) =
3.6
𝑟𝑝𝑚
𝑆𝑝𝑒𝑒𝑑(𝑚Τsec) = 2𝜋𝑟𝑡𝑦𝑟𝑒
60
𝑟𝑝𝑚 ∗𝑟𝑡𝑦𝑟𝑒
𝑆𝑝𝑒𝑒𝑑 (𝑚Τsec) =
9.55

3.6 ∗𝑟𝑝𝑚∗𝑟𝑡𝑦𝑟𝑒
𝑆𝑝𝑒𝑒𝑑 𝐾𝑚𝑝ℎ =
9.55
Vehicle Power
• Power in Watts = Force (N) x Velocity (m/sec)

𝑇𝑜𝑟𝑞𝑢𝑒 𝑟𝑝𝑚∗𝑟𝑡𝑦𝑟𝑒
Power W = 𝑥
𝑟𝑡𝑦𝑟𝑒 9.55

𝑇𝑜𝑟𝑞𝑢𝑒 ∗𝑟𝑝𝑚
Power (W) =
9.55
Gears
• An IC engine or Motor gives less torque than vehicle requirement
• Gear is used to multiply the torque by gear ratio ‘n’
𝑉𝑒ℎ𝑖𝑐𝑙𝑒 𝑇𝑜𝑟𝑞𝑢𝑒 = 𝑛 ∗ 𝐸𝑛𝑔𝑖𝑛𝑒 𝑜𝑟 𝑀𝑜𝑡𝑜𝑟 𝑇𝑜𝑟𝑞𝑢𝑒
• However, the speed (rpm) reduces by ‘n’
𝐸𝑛𝑔𝑖𝑛𝑒 𝑜𝑟 𝑀𝑜𝑡𝑜𝑟 𝑇𝑜𝑟𝑞𝑢𝑒
𝑉𝑒ℎ𝑖𝑐𝑙𝑒 𝑆𝑝𝑒𝑒𝑑 𝑟𝑝𝑚 =
𝑛

• Vehicle Power will be same as engine/motor power

• Gear is a must for ICE and an option for EV
• EV uses a single fixed gear
Vehicle Performance Parameters
• Characterized by Vehicle Torque (Nm), speed (Kmph/rpm) and Power (W)
- Determined by IC engine or Motor
- Gears multiply torque at the rate of speed
• Nominal and Peak values
- Continuous or Cruising values of torque, speed and power
- Peak Value of torque, speed and power
Specifications of Motor and Controller
• Motor Specifications
1) Torque - Speed Characteristics
- Nominal Torque and Speed
- Peak Torque and Speed
2) Power
- Nominal Power
- Peak Power
3) Thermal
- Components like magnet are impacted by high temperature
4) Mechanical
- Vibration, Size, Weight
Energy Storage
• Petrol tank for ICE and Battery for EV
Energy storage sizing
• How much petrol/battery energy is used per Km of the drive (Avg)
• How much do the vehicle drive every day
• How much do the vehicle drive per week
• What is the convenience for fuel tank/Battery change

Wear and tear of Energy Storage

• Life of fuel tank/ Battery
• Fuel tank - Low cost, Long life
• Battery - Very high cost, Limited life
Battery Life
• Capacity reduces for every charging cycle
• Replacement happens when 20 - 25 % capacity (EOL) is lost
• Calendar Life - Even if the battery is not used, the capacity deteriorates (6 -10
years)
• Cost Rs. 12,000 - 15,000/- per KWhr
• Significantly contribute the cost of EV
Cost of Fuel/Energy
• Petrol cost is very high
• Depends on the type of Vehicle, Vehicle energy efficiency (Mileage - Km/liter),
typical drive cycle (speed, acceleration, deceleration, up hill/ down hill etc)

• Electricity cost is very low (Rs. 5 - 8 per unit)

• Energy for charging depends on type of vehicle, vehicle efficiency (Wh/km) and
typical drive cycle
• Medium sized EV can drive 8 km/ KWhr
• Battery cost is high, but charging cost is low, battery need replacement
Rate of Petrol/Charge injection
• Petrol can be injected at any rate
• Does not add cost or wear and tear

• For EV, rate of current injection to (Charge rate) or extraction from (discharge rate) a battery
impacts battery life
• As voltage is constant, rate of current is proportional to power in/ out
• Life of battery depends on
✓ Charge - discharge rate (C_rate)
✓ Temperature of charge, discharge and storage
✓ Depth of discharge (DoD) - extend to which battery is emptied and filled up in each cycle
Battery Power and Range
• Electric power is continuously used by Motor
• Gradients consumes higher power/ energy usage
• Inefficiencies in Motor/ Controller add to Power/ Energy consumed
• Power consumed by auxiliary units need to be considered

𝑃𝑜𝑤𝑒𝑟 𝑢𝑠𝑒𝑑 𝑃𝑎 = 𝑃𝑀𝑜𝑡𝑜𝑟 + 𝑃𝑀_𝑖𝑛𝑒𝑓𝑓 + 𝑃𝐶𝑜𝑛𝑡𝑖𝑛𝑒𝑓𝑓 + 𝑃𝐴𝑢𝑥

• Battery to be designed to provide energy over a range, as well as peak power

Battery Energy Capacity
𝑉 ∗𝐴ℎ
Battery capacity (C) in KWhr =
1000
• Defined in terms of nominal voltage and cell capacity (Ampere hour)
• For longer life of battery, it is never fully emptied of fully charged
• Useful energy in each charge cycle is typically 𝑥 % (eg. 85%) of fully capacity - referred as
Depth of Discharge (DoD)
• Battery capacity reduces with every charge - discharge cycle
• If the battery capacity remaining is 𝑦 % (eg.80%) of the initial capacity, the range gets
proportionally reduces
• At the End of Life (EoL), Usable Capacity = 𝑥 ∗ 𝑦 ∗ 𝐶
Battery Life
Battery life (No. of charge - discharge cycles) depends on
• Battery Chemistry used
• Rate of Charging - discharging
• Usage temperature (25⁰ C - Ideal)
• Operation region of charge - discharge (DoD)
• Calendar Life

State of Health (SoH) - A measure of battery capacity (remaining) as compared to initial capacity
• End of Life (EoL) - When the battery capacity reduces to 75 - 80% of initial capacity
• Will limit the range to 75 - 80% of the initial range
Vehicle Control Unit (VCU / MCU)
• Communicates Battery and controller
• Manages Motor and controller
ICE to EV : Common Parts
• Body/ Frame
• Doors & Power windows
• Wheels (Rim, hub, Knuckles, Tyres )
• Suspension System (Lower arm and Struts)
• Power Steering system
• Power Breaking system
• Safety systems - Airbag, parking sensors
• Wipers and Fluid pumps
• Mirrors
• Interiors - Seats, Seat belts AC vents, Cabin Lights
ICE to EV
Parts to be modified
• Air conditioning systems - Integration of Variable speed DC drive to run AC
• Cooling system
• Dash board

Parts to be removed
• Fuel Tank
• Engine and associated connections
• Clutch and transmission system
• ECU and associated sensors
• Fuel pump and other engine subsystem
ICE to EV : To be added
• Electric Motor - High performance electric motor for traction
• Motor Controller - for closed loop feed back control of motor
• Transmission system - High efficient
• Battery pack with BMS and CAN communication support
• IoT and telematics - Vehicle data collection to monitor and manage the vehicle
• DC - DC converters - For powering auxiliary devices
• Vehicle control unit / Master control Unit
• Isolation circuits - Vehicle and user safety
• Charging Infrastructure - Ports, On board charger, external charger
• Software and remote monitoring
1) A vehicle needs to run continuously at 60 kmph and should have a peak torque of 150 Nm. The motor
used in the vehicle gives peak torque of 25 NM at 3000 rpm.
a) What is the gear ratio required to generate the required torque?
b) What should be the minimum tyre radius (in m) of the vehicle?
2) A EV battery has a capacity of 15 kWh. Assuming effective capacity used in the beginning is 85% and
end of life is 70% of capacity,
a) What is the range (km) that the vehicle (using 80 Wh/km) can support, when the battery is new?
b) What range (km) will it support at the end of life?

Assume auxiliary power used is 500 W continuously and the average speed of vehicle is 40 kmph.

c) What would be the range (in km) in beginning of life of battery?

d) What would be the range (in km) in end of life of battery?
3) A Battery is of 48V, 30Ah is designed to power an Electric two wheeler. Battery is designed to
operate at 80% DoD and end of life is considered when the capacity falls to 70% of its initial capacity.

a) Compute the total energy content in the battery (in kWh).

b) What maximum amount of usable energy available for each cycle at beginning of life (in kWh)
c) What maximum amount of energy available for each cycle at end of life (in kWh)
4) A Petrol vehicle consume 15 kms per litre and the Equivalent EV consume 150 Wh / km with battery
cells being 250 Wh/kg and 500 Wh/l. Energy density of Petrol 12,500 Wh/Kg and 9375 Wh/Lit.

a) Compute the ratio of Energy Efficiency of EV Vs ICE (Internal Combustion Engine) vehicle
b) Compute Ratio of Battery weight and petrol weight per km of travel by two vehicles
c) Compute Ratio of Battery volume and petrol volume per km