Internship Report

On
EV Powertrain and
Integeration
Submitted To
Dr. Ravi Mohan Saxena Sir

Discipline
Mechanical engineering 7th
Sem
Submitted by
Gagan Patankar
0108ME211030
 Acknowledgement
We hereby thank the management for
providing an opportunity to study in their
esteemed institution . We thank the
company ‘ISIEINDIA’ and trainer’s for
giving a broad idea and knowledge about
“Electric vehicle powertrain and
integeration”. We express sincere gratitude
to principle of LNCT institute for his
encouragement towards student’s attitude .
We are thankful to trainer representative
Vinod Gupta for his kind encouragement
and motivation .
Electric Vehicle
Powertrain and
Integration
Electric vehicles (EVs) are gaining popularity worldwide. The heart
of any EV is its powertrain, which converts electrical energy into
mechanical motion.
Introduction to EV
Powertrains
1 Energy Source 2 Energy Conversion
EV powertrains utilize An electric motor
batteries to store and converts electrical energy
deliver electrical energy. into mechanical power.

3 Drivetrain
The drivetrain transmits power from the motor to the wheels.
Overview of EV Powertrain
Components
1 Electric Motor 2 Battery System
Converts electrical Stores electrical energy,
energy into mechanical powering the motor and
motion, driving the providing range.
wheels.

3 Power Electronics 4 Drivetrain

Manages and controls the Transmits power from the
flow of electrical energy motor to the wheels,
throughout the system. including gears and axles.
Electric Motors: Types and Characteristics
Type Advantages Disadvantages

Induction Motor Simple, reliable, and cost-effective. Lower efficiency, limited torque.

More expensive, can be affected by

Permanent Magnet Motor High efficiency, high torque,
high temperatures.
compact size.

High efficiency, precise speed Complex design, higher cost.

Synchronous Motor
control, high torque.
Battery Systems:
Technology and Trends
1 Lead-Acid Batteries
Mature technology, low cost, but low energy density.

2 Lithium-Ion Batteries
High energy density, long lifespan, but can be
expensive.

3 Solid-State Batteries
Emerging technology with potential for higher
energy density and safety.
Vehicle Control Units
Features Architecture Protocols

• Motor control VCUs typically use a distributed • CAN bus

• Battery management architecture, with multiple • LIN bus
controllers interconnected via
• Braking system control • Ethernet
communication networks.
• Climate control
• Infotainment system
Power Electronics and Motor Controllers
DC-DC Converter
Converts battery voltage to the required motor voltage.

Inverter
Converts DC power to AC power for the electric motor.

Motor Controller
Regulates motor speed and torque, providing precise control.
Vehicle Dynamics and Control
Motor Control Braking System
Regulates the motor's speed and torque, optimizing Combines regenerative braking with conventional friction
performance and efficiency. brakes for efficient energy recovery.

1 2 3

Battery Management
Monitors battery health, charging status, and discharge rate,
ensuring optimal battery life.
Drivetrain and
Transmission Integration
Single-Speed Multi-Speed
Transmission Transmission
Simple and cost-effective, Improves efficiency,
but may limit efficiency. especially at high speeds,
but adds complexity.

Electric Axle
Integrates motor, transmission, and differential into a single unit.
Thermal Management Strategies

Air Cooling
Simple and cost-effective, but less efficient than other methods.

Liquid Cooling
More efficient than air cooling, but more complex and expensive.

Heat Pump
Uses a closed loop system to manage temperature effectively.
Vehicle-to-Grid (V2G) and
Charging Infrastructure

Level 1 Charging Level 2 Charging

Slowest charging method, using a Faster charging using a dedicated
standard household outlet. outlet with higher voltage.

Level 3 (DC Fast Charging) Vehicle-to-Grid (V2G)

Fastest charging method, utilizing Enables EVs to feed energy back
high-power DC chargers. to the grid, providing grid stability
and potentially generating
revenue.
Trends and Future
Developments in EV
Powertrains
1 Solid-State Batteries 2 Wireless Charging
Higher energy density, Convenient and efficient
faster charging, and charging without physical
improved safety. connections.

3 Advanced Motor 4 Integration with

Control Autonomous Driving
Improved efficiency, Seamless integration of
performance, and powertrain and
responsiveness. autonomous systems.
Safety and Regulatory Considerations

Fire Safety Crash Safety

High-voltage batteries pose a fire risk, requiring EVs must meet stringent safety standards for occupant
stringent safety measures. protection in collisions.
EV Safety & Standards
High-voltage isolation Prevents electric shock

Battery thermal management Protects against overheating

or fire

Crashworthiness Ensures occupant safety in

the event of a collision
Advantages
1 Zero Emissions 2 Energy Efficiency
EVs significantly reduce Electric motors convert
greenhouse gas more energy into motion
emissions, contributing to compared to internal
cleaner air. combustion engines.

3 Quiet Operation 4 Low Maintenance

EVs produce minimal EVs have fewer moving
noise, making them ideal parts, requiring less
for urban environments. frequent maintenance
compared to gasoline
vehicles.
Disadvantages
Limited Range Charging Infrastructure
Battery capacity limits the Limited availability of
distance an EV can travel on charging stations can pose a
a single charge. challenge for long journeys.

Higher Initial Cost

EVs generally have a higher purchase price compared to
conventional vehicles.
Application
Passenger Vehicles
EVs are becoming increasingly popular for personal
transportation, offering an eco-friendly and efficient
driving experience.

Commercial Vehicles
Electric trucks and buses are gaining traction in urban
areas, reducing emissions and noise pollution.

Off-Road Vehicles
Electric vehicles are well-suited for off-road
applications, providing quiet operation and high
torque.
Challenges in EV
Powertrain Integration
1 Battery Range and 2 Thermal Management
Efficiency
Managing heat
Balancing energy density, dissipation effectively to
weight, and cost while ensure optimal
maximizing efficiency. performance and
longevity.

3 Cost Optimization
Balancing performance, durability, and cost to make EVs
affordable.
Conclusion and Key
Takeaways
EV powertrain integration is crucial for the success of electric
vehicles. By understanding the key components and challenges,
we can continue to innovate and drive the transition to sustainable
transportation.
THANK
YOU