Module-5

Insight into future mobility technology; Electric and Hybrid Vehicles, Components of Electric
and Hybrid Vehicles. Advantages and disadvantages of Electric Vehicles (EVs) and Hybrid
vehicles. Introduction to Mechatronics and Robotics: open-loop and closed-loop mechatronic
systems. Joints & links, Robot anatomy, Applications of Robots in material handling, processing
and assembly and inspection
5.1 INTRODUCTION

Of all the various trends that are shaping the future of automobile industry, Electric and Hybrid electric
vehicles stands at the top, and have been considered an alternative to the fossil fuel powered vehicles. The
ever-increasing fuel problems and the requirements to maintain stringent emission standards with respect to
environment issues are the reasons behind the development of these vehicles. The present chapter deals
with the basics of Electric and Hybrid Electric vehicles.

5.2 ELECTRIC VEHICLES

An electric vehicle (EV) is a vehicle that uses one or more electric motors for propulsion. It can be powered
by a electric current collector system, with electricity from extravehicular sources, or it can be
powered autonomously by a battery (sometimes charged by solar panels, or by converting fuel to electricity
using fuel cells or a generator). The basic components of electric vehicles, their advantages and limitations
are briefed as follows:
Components of Electric Vehicles
Following are the basic components of electric vehicles:
 Traction Battery Pack is used to store the electrical energy required to power the motor. It is
equivalent to a fuel tank in a conventional IC engine. The battery pack is made up of a number of
cells that are grouped into modules, and can be charged through the use of ordinary grid electricity
at a specialized power station. Lithium ion batteries, Lead acid batteries and Nickel metal hydrate
batteries are the major battery technologies developed.
 Motor converts electrical energy into kinetic energy in the form of shaft rotation, causing the electric
transmission system to function and power the wheels of the vehicle. Usually Induction motor and
Permanent magnet synchronous motors are used in electric vehicles. Some vehicles use motor
generators that perform both the drive and regeneration*
functions.
 Electric power control unit is an efficient integration of all the devices that control the flow
of the electric power in the vehicle. It consists of the inverter, the Low voltage DC-DC
Converter (LDC), and the Vehicle Control Unit(VCU). The inverter is used to convert the
battery's Direct current (DC) into Alternating current (AC) that is required to drive the motor. The
inverter can change the speed at which the motor rotates by adjusting the frequency of the alternating
current. It can also increase or decrease the power or torque of the motor by adjusting the
amplitude of the signal.
 The DC-DC converter is a device that converts the higher-voltage DC power from the battery pack
to low-voltage DC power required to run other electronic systems of the vehicle. The vehicle control
unit oversees nearly all the vehicle's power control mechanisms, including the motor control,
regenerative braking control, air conditioning load management, and power supply for the
electronic system.
Other components include thermal system for cooling and maintaining proper temperature of the
motor and other electronic parts, charge port that allows the vehicle to connect to an external power
supply, transmission and drive systems, etc.

Working When the driver applies pressure on the accelerator pedal, a signal is sent to the
controller, which adjusts the vehicle s speed by changing the frequency of the AC power from the inverter
to the motor, which is directly connected to the transmission set up, causing the wheels to move. When the
brakes are applied, the vehicle decelerates and the motor becomes an alternator, wherein the braking
energy is captured to produce power, which is sent back to the battery that get s charged.

Advantages of Electric vehicles

1) Electric vehicles consume less energy and hence energy efficient.
2) Being light in weight, they yield more power and speed.
3) Environment friendly as they do not emit pollutants.
4) Ability for self-recharging through regenerative braking system.
5) Ability for high starting torque.
6) Electric motors can produce a consistent amount of torque at any given RPM within a
specific range. (Generally, torque output is highest during low gears to move the car from
a standstill. As the vehicle gains momentum, torque gradually decreases.)
7) Lower maintenance due to an efficient electric motor and lesser moving parts.
8) Smooth & almost noiseless due to lesser moving parts (the only moving part is the motor).
9) Electricity is comparatively cheaper than the ever growing price of liquid fuels.
Limitations of Electric vehicles
1) Electric vehicles impose increased electricity demand.
2) Battery charging consumes more time.
3) Electric vehicles have shorter range (distance) compared to vehicles powered by liquid fuels. An
average electric car can run up to 200 miles per charge. There is hence a dependency on adequate
EV charging stations, which at present are not sufficient in numbers.
4) Slightly costlier compared to vehicles powered by IC engines.
 5.3 HYBRID ELECTRIC VEHICLES
A hybrid electric vehicle is a type of hybrid vehicle that. combines a conventional internal combustion
(IC). engine, with one or more electric motors that uses energy stored in batteries to propel (power) a
vehicle. In a standard hybrid electric vehicle, IC engine is the main source of power to the vehicle,
with the electric motor chiefly used to add power during acceleration and greater torque requirements.
Hybrid electric vehicles thus combine the benefits of high fuel economy and low emissions of electric
vehicles, and the power and range (distance) of conventional fuel powered vehicles. In a hybrid
electric vehicle, the battery is charged through regenerative braking and by the internal combustion
engine. The basic components of hybrid electric vehicles, their advantages and limitations are briefed
as follows:
Components of Hybrid Electric Vehicles

Following are the basic components of hybrid electric vehicles:

 Low-voltage Battery (auxiliary) is used to start the vehicle before the traction battery is
engaged. It also powers vehicle accessories.
 Traction battery pack stores electric energy for use by the motor to propel the vehicle.
 Motor utilizes the electric energy from the battery pack to propel the vehicle. Some vehicles
use motor generators that perform both the drive and regeneration functions.
 DC-DC converter converts higher-voltage DC power from the traction battery pack to the
lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary
battery.
 Electric generator generates electricity by capturing energy during braking and
deceleration. The energy is transferred to the traction battery pack, which gets charged.
 Internal combustion (IC) engine is used to propel the vehicle by the heat energy of the
liquid/gaseous fluid. The engine is usually a spark ignited type.
 Exhaust system: The exhaust system channels the exhaust gases from the engine out through
the tailpipe. A three-way catalyst converter is designed to reduce engine-out emissions
within the exhaust system.
 Transmission system transfers the mechanical power from the engine and/or electric
traction motor to drive the wheels.
Other components include thermal system for cooling and maintaining proper temperature of the motor
and other electronic parts, fuel tank, filters, power electronics controller, etc.
Advantages of Electric hybrid vehicles

1) Hybrid electric vehicles consume less energy and provide greater mileage.
2) Lesser dependency of liquid/gaseous fuels.
3) Ability for self-recharging through regenerative braking system.
4) Less polluting when compared to conventional IC engine vehicles.
Limitations of Electric hybrid vehicles
1. Efficiency is slightly lower because neither the IC engine nor the electric motor works as
strongly as they do in conventional or electric vehicles.
2. Complex hybrid technology (IC engine + EV) makes it difficult for maintenance and
repair.
3. Slightly costlier compared to vehicles powered by IC engines& EV.
5.3.1 Electric Vehicle v/s Hybrid Electric Vehicle

Table 5.1 gives a brief comparison between electric vehicle and hybrid electric vehicle.

Sl No. Electric Vehicle (EV) Hybrid Electric Vehicle (HEY

1. Powered by electricity through battery Powered by electricity & fossil fuel (petrol/diesel)
pack Comparatively greater.
2. Have shorter range (distance) Comparatively greater.
3. Power and Fuel efficiency depends on Power and Fuel efficiency depends on
battery range. combustion of IC engine and battery range.
4. Zero emission levels Although emission levels are comparatively
higher, they are still lower when compared to IC
engine vehicles.
5. Battery charging through external Not required. Battery is self-charged through
source is required. regenerative braking system and by IC engine.

6. Low maintenance Comparatively higher

7. Technology and cost efficient Complex hybrid technology and costs higher.
8. Smooth & almost noiseless due to Comparatively greater.
lesser Moving parts
5.4 Introduction to Mechatronics
Mechatronics can be defined as the integration of mechanical engineering with electronic
engineering, electrical engineering, computer technology, and control engineering for the purpose
of design, manufacture, and maintenance of engineering products, systems, and processes. A few
examples of mechatronic systems include: Laser printers, Automatic washing machine, Automatic
oven, Modern sewing machines, Elevators and Escalators, Digitally controlled combustion engine,
machine tools with self-adaptive tools, etc.
In any mechatronic system, the mechanical element does the actual operation, the electrical
elements provide the necessary power for functioning of other elements, the electronic elements,
usually a microprocessor controls and coordinates the functions of various elements based on the
input, and the control elements control the output of the system in a desired manner.
5.4.1 OPEN LOOP CONTROL SYSTEM
An open loop control system is one in which control action is independent of the desired output. It means
the desired output is neither measured nor compared with the input.
The block diagram of the open loop control system is as shown in figure 1.1

Fig. 1.1: Open Loop control system

In this system, when input is applied to the controller which generates necessary control action
required to control the plant or process which is to be controlled to generate desired output. The accuracy
of these system depends entirely on the accuracy with which the input-output relationship is designed. If there
are any variations in the external environment or disturbance during operation, desired output will not be
accurate. These systems are to be calibrated frequently to obtain accurate results and to maintain quality of
the output.
The examples of an open loop control systems are Traffic control system, Automatic bread toaster, Electric
fan, Electric switch, Automatic washing machine and many more.
Consider a traffic control system which is used regulate the flow of traffic at cross roads. In this system,
Red, Yellow, Green lights glow according to the set duration by the timer mechanism and sequence by
the relays, which are predetermined. which do not dependent on the traffic.

5. 4.2 CLOSED LOOP CONTROL SYSTEM

A closed loop control system is one in which control action is dependent on the desired output. It means
the desired output is measured and compared with input using the feedback element.

The block diagram of the closed loop control system is as shown in figure. 1.2
 Fig. 1.2: Closed loop control system
In this system, output is measured and fed back for comparison with the reference input at the summing
point and this determines the error based on which control action is generated. The difference between the
input and corresponding output is known as error. This error signal is used by the controller to generate
manipulated signal which is used to control the plant or process so as to reduce the error and to bring the
actual output to a desired value.
The examples of a closed loop control system are Room heating system, Automobile speed control system,
Automatic tank-level control system, Temperature control system and many more.

5.4.3 Open Loop versus Closed Loop Systems

Table 5.2 gives a brief comparison between open loop and closed loop control systems.
Sl Open loop control system Closed loop control system
No
1. Control action is independent on the output of Control action is dependent on the output of the
the system. system.
2. Feedback elements and error detectors are not Feedback elements and error detectors are always
present in the system. present.
3. Simple in design and construction Comparatively complex
4. Less expensive & low maintenance costs due to Comparatively greater due to presence of
the absence of feedback elements. feedback elements.
5. Inaccurate and unreliable. Accurate and reliable.
6. Highly sensitive to disturbances Less sensitive
7. Highly affected by non-linearities Reduced effect of non-linearities