TKAP QC CONFIDENTIAL

Overview of
Hybrid and
Electric Vehicles
Shyam Sekhar
Sheethal Kumar
 Driving Factors

CAFE
Corporate Average Fuel Efficiency

EXHAUSTION OF FAME-India
FUEL RESERVES Faster Adoption and Manufacturing of
Electric vehicles in India
 Some Interesting Data

Value of electronics > Value of mechanical components

Toshiba – Denso – Suzuki
JV for manufacturing Li-ion
batteries in India
 Shift in vehicle propulsion system

Hybrid TM

Battery

MT / AT / CVT
Internal Combustion Electric Motor
Engine

OR

Any types of transmissions

may not be required
Higher RPMs resulting in Large Speed Range
Internal Combustion High Torque Output at Low Speed
High Efficiency in wide operating range Electric Motor
Engine
No idle RPM (zero launch)
Overview of vehicle propulsion system
 Types of vehicle propulsion system
Engine

Motor
HV

Charging
Battery
PHV

EV
PCU

Fuel Cell Hydrogen

Tank
FCV
 Mode of Electrification
Connection Level
Parallel Hybrid Small electric system
Parallel Micro 2 sources powering wheels
Hybrid Hybrid Large design flexibility
Complicated control system
Series Mild E/G do no operate @ peak efficiency
Hybrid Hybrid

Full
Hybrid

Plug In
Hybrid

E/G operates @ peak efficiency range

Series Hybrid
No transmission is required
Relatively simple control system
Will need bigger motor
Will need higher battery capacity

Transmission
 Mode of
Configuration
Connection

Parallel Micro
Hybrid Hybrid

Series Mild Can run only on Engine.

Hybrid Hybrid Battery is used only for
support functions.
Full
Hybrid

Plug In
Hybrid

Type Start Stop Regen. Charge External

System Braking & Depleting Recharge
Torque Assist Mode
Micro Yes No No No
Mild Yes Yes No No
Full Yes Yes Yes No
Plug Yes Yes Yes Yes
In
 Motor connected via belt
Always mechanically connected to ICE
Uses Belt integrated Starter Generator (BiSG)
Low cost of integration
Minor changes in existing vehicle architecture
Limited torque capacity due to belt drive

Mild Hybrid Architectures P0 Architecture

P3 / P4 Architecture
P1 Architecture P2 Architecture
Motor directly connected to crankshaft Motor connected between Clutch & TM. Motor connected to TM – P3
Always mechanically connected to ICE Motor is not directly connected to engine Motor connect to Diff – P4
High cost of integration Very high cost of integration Motor is not directly connected to engine
Impact on existing architecture High energy recurpation Very high cost of integration
High torque capacity due to direct drive Additional EM for start stop assist High energy recurpation
High impact on existing architecture Additional EM for start stop assist
No losses due to TM or ICE losses
High impact on existing architecture
 Can run on Engine / Batteries or Combination
Primary Power Pack: Engine
Complimenting Power Pack: Motor
Electricity Generation: On Board
Connection: Normally Parallel

Can run on Engine / Batteries or Combination

Primary Power Pack: Motor
Complimenting Power Pack: Engine
Electricity Generation: Mainly from Grid
Connection: Series or Parallel (mainly series)
Micro Hybrid Mild Hybrid
 Full Hybrid

Plug In Hybrid
Mild Hybrid & Full Hybrid
Reduction Gear
 Full Electric

Reva / G-wiz Mahindra e20

Mahindra e-verito Tata Tigor EV

 Full Electric – Global models

Tesla Model S Nissan Leaf

BYD e-6 BAIC EC Series

 Central Drive Wheel Hub Drive
Front Wheel Drive
Independent wheel control Rear Wheel Drive
Cost Effective
No differential & drive shafts All Wheel Drive
Fewer gear pairs
Less inst. space Weight reduction All combinations are possible
Most Common High performance potential with EV
 Energy
Storage

Energy
Storage
Ecosystem
Management
System
Electric
Vehicle

Electric Power
Motor Electronics
Energy Density Power Density Energy Density

Deuterium
Gunpowder

Diesel
Battery

Plutonium
Wood

Hydrogen
Protein
Capacitor

Gasoline
Coal
Ability to store energy Ability to dissipate stored
per unit volume energy
Reservoir Utilization from Reservoir
(50km walk) (100m sprint)
Roadmap for Battery Technologies
Aluminium
Lithium Ion Solid State Zinc Air Lithium Air
Air
(270Wh/kg) (300Wh/kg) (490Wh/kg) (2000Wh/kg)
(1100Wh/kg)

BATTERIES
Li -
Ion
IDEAL
Lithium-Ion will dominated EVs for next 10-15yrs
ZONE
Energy Density Wh/Kg ->

Ni-
ULTRA CAPACITORS
MH Battery Prices are falling fast!

Lead
Acid
<90USD/kWh
Power Density W/Kg ->
 CHAdeMO GBT CCS
(CHArge de MOve)
Country: Country: Country:
Japan China USA, Europe, Korea
Automakers: Automakers: Automakers:
Mitsubishi, Subaru, Kia, Nissan, Suzuki, All Chinese Automakers VW, GM, BMW, Daimler, Ford, FCA,
Mazda, Toyota Communication: Tesla, Hyundai, Kia, Toyota
Communication: CAN Communication:
CAN PLC (Safer Encrypted Comm.) US, Canada,
Korea

Only DC Both AC & DC

Europe & Rest

of World

Charging Power upto 350kW

Charging voltage upto 1000V
Liquid cooled cables
AC Charging
Low installation cost
Low peak demand from grid
Very slow charging

AC Charging
Improved charging time than Level 1
Variety of products available
More efficient chargers
Higher peak demand from grid
More Costly

DC Charging
Fast Charging
Variety of products available
High Initial Costs
Very Costly
Multiple competing standards
 Energy
Storage

Energy
Storage
Ecosystem
Management
System
Electric
Vehicle

Electric Power
Motor Electronics
 Overview of energy management system(EMS)
Definition:
A energy management system (EMS) is any electronic
system that manages a rechargeable battery, capacitors
or other energy source on the vehicle
Basic functions:
a. Monitoring (Voltage, current, state of charge, temperature
etc.) – Rate of charging, rate of discharging
b. Communication (Motors, driver demand, sensors, batteries)
c. Optimization (Regulating the parameters as per load,
charging system) – State of charge (SOC), Cell balancing
d. Safety (Temperature, over-current, over-pressure related
interlocks) – State of health (SOH), Logbook function

Top players in EMS:

Purpose of Energy Management System (EMS):

a. Optimize battery life (Both charge and life cycle)
b. Control storage systems (Batteries, FC’s, SC’s)
c. Control power electronics and electric machines (AC-DC motors)
 Energy
Storage

Energy
Storage
Ecosystem
Management
System
Electric
Vehicle

Electric Power
Motor Electronics
 Overview of Power Electronics (PE)

Definition:
Power electronics is the application of solid-state
electronics to the control and conversion of electric
power.

Based on the type of EV/HV following power

electronics systems may be used:
• AC to DC (rectifier)
• DC to AC (inverter)
• DC to DC (DC-to-DC converter)
• AC to AC (AC-to-AC converter)

Top players in Power Electronics:

Overview
 Energy
Storage

Energy
Storage
Ecosystem
Management
System
Electric
Vehicle

Electric Power
Motor Electronics
 Overview of Electrical Machines (Motors)

Definition:
Electric machine is a general term for machines using electromagnetic
forces, such as electric motors, electric generators,

Based on the type of EV/HV following EM

systems may be used:
• AC synchronous
• AC induction
• Brushed DC motor
• Brush less DC motor

Top players in Electrical Machines:

 Overview of automotive ecosystem

TRADITIONAL ECOSYSTEM

Challenges:
1. Manufacturers must adapt to the
rapid, disruptive change in
technology
2. Current fuel infrastructure will
become obsolete
Service Fuel
3. Power production capacity and grid
must be developed to handle the
multifold increase in demand
4. Skill of the service personnel must be
developed
Power production capacity and grid must be developed to handle the
multifold increase in demand
A

A
Change in the grid
 Skill of the service personnel must be developed

IC Engines HV and EV

IC Engine have been running for more than HV and EV’s involve many electronic and
100 years (worldwide) and vastly software components which make service
experienced service personnel and wide and trouble shooting completely different to
service network has been developed the current method
Highly skilled and trained manpower
necessary to cater to the increased number of
HV and EV’s
 Energy
Storage

Energy
Storage
Ecosystem
Management
System
Electric
Vehicle

Electric Power
Motor Electronics
 CURRENT ECOSYSTEM

Challenges:
1. Dependency on software and
electronics
Power
2. Connectivity and digital content
demand by consumer
3. Battery manufacturing- Resources
Service and technology for battery
Fuel
manufacturing
Dependency on software and electronics

- This setup is for autonomous vehicle

 Battery manufacturing- Resources and technology
MATERIALS

Indian reserves
Li-Ion battery Material (use) Judgement
(Largest reserves)
Heavy dependency
Lithium (Cathode) Negligible (Bolivia)
on imports (X)
Heavy dependency
Cobalt (Cathode) Negligible (Congo)
on imports (X)
2nd largest in the
Graphite (Anode) Self sufficient (O)
world (China)

MANUFACTURERS

India has challenges both in terms of materials and technology

FUTURE ECOSYSTEM

Challenges:
1. IoT applications throughout the
system
2. Security challenges
3. Vehicle manufacturing will be a node
in the ecosystem
4. Vehicle testing and validation will
become complex
5. Shared mobility will reduce the total
no. of vehicles
 Safety Vs. Security
Safe = Protected from or not exposed to danger or risk Security = Protected against attack or other criminal activity

1. Seat belts 1. Door lock with alarms

2. Airbags 2. Central remote locking with alarms
3. ABS (Anti Lock Brakes) 3. Immobilizers
4. EBD (Electronic brake force distribution) 4. Remote tracking (using GPS)
5. Traction control 5. ……….
6. Stability control 6. ………..
7. ………. 7. ………..

Security
Safety

Advance in technology Advance in technology

 Security challenges

Security threat (Hacking) to vehicle systems

 Complexity in testing and validation

ARAI & AVL has already installed EV

Too many systems, too many standards……… Testing Systems in India
 Future of Automobiles are EVs / Fuel Cells
But “By When” is still unclear.
State of Preparedness is absolutely necessary!