School of Mechanical and Civil Engineering

PROJECT DESIGN REPORT

T.Y. PROJECT
(ACADEMIC YEAR: 2021-2022)
SEMESTER: V

DESIGN AN ELECTRIC MOTOR FOR ELECTRIC VEHICLE

Group ID:
Name of Project Guide:- Prof. A. B. MANE.
Project Guide Email: - archana.mane@msteams.mitaoe.ac.in
Contact No.: 9168162667

DETAILS OF THE STUDENTS

Roll No. Student Name Contact Details Email

3130 Rohan Patil 9518335912 rohan.patil@mitaoe.ac.in

3138 Saurabh Gunturkar 7756079565 saurabh.gunturkar@mitaoe.ac.in

3144 Prathamesh Dhamnikar 9518379705 prathamesh.dhamnikar@mitaoe.ac.in

3151 Pranav Malsane 7875681325 pranav.malsane@mitaoe.ac.in

Course Teacher External Examiner Head of Department

(signature) (signature) (signature)

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 CONTENT

Sr. No. Index Page No.

- Abstract 5

1. Introduction 6

2. Literature Survey 8

3. System design 10

4. Methodology 16

5. Conclusion 17

6. References 18

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 LIST OF FIGURES

SR NO NAME PAGE NO

1 DESIGN OF BLDC MOTOR 13

2 DESIGN OF GEAR COUPLING BY HAND 14

3 DESIGN OF GEAR COUPLING SYSTEM 14

4 SPUR GEARS 15

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 LIST OF TABLES

SR NO NAME PAGE NO

1 PARAMETERS OF ELECTRIC MOTOR 12

2 DIMENSIONS OF DESIGN GEARS 13

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 ABSTRACT

The future of mechanical engineering in automotive sector is going to be Electric Vehicles.

Higher efficiency, low maintenance and to emit almost zero amount of pollution, makes electric
vehicles more preferable as compared to the Internal Combustion engine powered vehicles. In new
technology of the vehicles, Electric motor is used at place of IC Engine with battery power system
instead of fuels. Now a days, the cost of fuels increase day-by-day. So, we can try to new innovation
in Electric Motor. i.e. It’s sizing, structure, performance, maximum power rating with less energy.
Rapid advancement in technology is helping vehicle manufactures to overcome the drawbacks of IC
powered vehicles. The main source of power in an electric vehicle is from its electric motor. There
are various motor are available in market. Currently, we select the motor based on its performance.
But, we can change the structure of motor and reduce its size. So, vehicle structure may not be
complex and more space is available. So, we can use that space for developing some new technology
in vehicle in future.
Instead of design of a Electric motor, we design the coupling with the help of gears structure.
So, this coupling is useful to transmit the power form motor to the wheels. This is new design which
is more useful in future of automobile sector. We can select the type of motor on the basis of
optimum power output, rated torque, etc. Mostly, we should choose the type of DC motor. Because,
there is a no need of any converter/Alternator. So, this gives the benefits in costs and reduces the
extra component.

Course Teacher External Examiner Head of Department

(signature) (signature) (signature)

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 1. INTRODUCTION

In the era of Industry 4.0, lots of inventions and new technologies have been made. Incredible
growth in the field of automobile and in other domains too. Now a day, it is clearly seen that
population over the world is increased and its effect is nothing but the increase in the number of
conventional vehicles. These rapid increases in the use of IC engine vehicles causes increase in
greenhouse gas emission. This emission is causing due to ozone layer depletion which in turn results
in global warming. By considering these things in account, an alternative option for conventional
fueled vehicle was mandatory. So as an alternative option, an electric car are invented. As we know,
there are many challenges that engineers are facing regarding the size, capacity and cost of batteries,
shortage of charging stations, time to charge the vehicle, etc.

As there are many components which are essential to make an electric car. But the most
important component of electric vehicle is an Electric Motor. It is the heart of EV. So, this project is
about “Designing an Electric motor for E-vehicle”. In this, we are going to design a motor by
considering the selection criteria required for selecting the motor. Also, we will use some software
like CATIA V5 to design a CAD model of Electric motor, Motor sizing software, ANSYS software
to check the performance of Electric motor by performing thermal and vibration analysis. Then, we
will move to compare designed motor result with the existing motor and will do the changes
accordingly to obtain the optimized output and results. Also, additionally a coupling will be designed
with some modification in the existing one which is used to transfer motion from motor shaft to the
wheels of the vehicle.

As we know there is evolution of electric vehicles. There is so much demand for electric vehicles. By
considering, this we thought about doing projects related to electric vehicles and thus we decided to
design an electric motor for Electric vehicle. By doing this project, one will be understand the
selection criteria for motor and how to compare the performance of motor with the help of software.
Purpose of this project is to increase the rate of fuels day-by-day. So, there is an alternative option of
E-vehicle. In EVs, electric motor is used. But, anybody not does the modification in electric motor for
EVs in mostly on sizing and structure phase. Based on that, there is our motive to do some innovation
in electric motor for EVs.

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1.1 Aim:
• To design an electric motor with optimum performance for E – Vehicle

1.2 Objectives:
• Categorize & selection of proper required motor by considering and assuming some parameter of EV.
• Motor election process on the basis of required optimum (maximum) power output.
• Designed a motor with compact size and enhanced performance.
• Optimization of motor towards improving performance than recent motor.

1.3 Problem Statement:

• Currently, vehicles are running on crude oils like petrol, diesel, etc. As we all know sources of oils
are less and they will vanish one day, and those vehicles are producing harmful gases which are
contaminating environment as well as harmful to human health, so to overcome from this issue
people are preferring electric motor vehicles.

1.4 Scope:
• Producing high rated output to the vehicles instead of IC Engine.
• City use more due to High mileage because of weight reduction.
• For racing car get High speed due to Optimum power output of motor.
• No vibration of motor.
• No any effect of background atmosphere on vehicle.
• Less maintenance yearly as a point of view of regular transport vehicles.

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 2. LITERATURE REVIEW

1) Khalid G. Mohammed [1] (March, 2020), conducted a study on ‘Design and selection of the
components based on their performances which are necessary to hybrid vehicle’. He had to work
on selection of motor, design the new structure of hybrid vehicle, making a converter for solar
radiation into electrical energy to be stored in batteries. He was preferred traction motor.
Traction motors need to recognize their performance: high starting torque and acceleration. Also,
he had considered the factors which affecting on components by design of electrical and
mechanical components. After that, based on methodology, he got the results and select the
components of hybrid vehicles such as the three-phase synchronous motor used, solar panel was
stored the energy in batteries like a backup system. The investigational tests on the electric motor
of the vehicle for the three different speeds, the solar panel used is considered as additional
power source.

2) T.Porselvi, Srihariharan.M.K. Ajith Kumar’s [2] (IJESC, 2017), presented ‘Selection of power
rating of an electric motor for electric vehicles’. In that experiment, they were find out the
appropriate power and other characteristics required for traction purpose. They had worked on to
find out power, proper selection of rating of electric motor for an electric car, selection of motor
by considering vehicle dynamics. They knew that Electric power flows through various
components in an electric vehicle and gets converted into mechanical power. Based on that, they
designed power rating of the motor by considering affecting parameter on vehicle dynamics: -
Rolling Resistance, Gradient Resistance. After that, they got final results to find out the results of
Rated output power, Rated voltage, Rated speed, Rated Torque. The simulation outputs of the 3
kW Brushless DC motor designed based on the rating calculation done on ANSYS. And
comparing performance with that motor, they selected a 3 kW BLDC motor and designed for
driving a 450 kg electric car.

3) Mohammad Naser Hashemnia, Behzad Asaei [3] (Researchgate, 2014), presented a

‘Comparative study of using different electric motors in the electric vehicles’. In that, the aim
was to study and compare benefits of each motor and to use one which is more suitable. They
explained the scope of this comparative study ware to help for selection of motor type. Also, why
selected the traction motor for electric vehicle system, getting all consideration of such as
efficiency, cost, reliability, power, density, maturity of technology. For that, they were used
ADIVISOR software. They were took 5 types of motor for comparison its performance.
Simulation is performing under three different driving cycles: - CYC-UDDS, Constant speed,
Nuremberg R36, etc. As compare air pollution and fuel consumption factors for selection of
motor. After their study, they conclude that the induction motors have been known as the best
candidate for the EV applications. Because they are robust, less costly, and mature in technology
and need less maintenance. Also, the permanent magnet motor had highest power density due to
presence of high power density permanent magnet.

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4) Ansh Thattil1, Sumit Vachhani2, Darshan Raval3, Piyush Patel4, Priyanka Sharma5 [4]
(IRJET), presented a ‘Comparative Study of using Different Electric Motors for EV’. In that,
the various types of electric motor all demonstrate different characteristics. Therefore, it is
necessary to conduct a throughout analysis of which motor to be used in a particular vehicle.
They were focusing on the affteing characteristics while selection of electric motor: - High
specific power, Low maintenance cost, Good control, highly efficient. Also, they had
compared the motors based on the performance such as power, efficiency. Based on that, they
concluded the BLDC motor good for any purpose such as electric vehicle. Pumping system,
transportation, etc. its advantages were less pollution, more power to volume ratio. The
induction motors have been known as the best candidate for the EV applications because they
are robust, less costly, and mature in technology and need less maintenance. it is demonstrated
that in terms of pollution and fuel consumption, the brushless DC motors have more priorities
such as less pollution, less fuel consumption and more power to volume ratio which makes
them attractive in the EV applications.

5) ‘Computer Aided Spur Gear Design and Analysis’ [5] (Edward M. Vavrek, Purdue University
North Central). The paper describes the procedure used to size and select a spur gear using a
software program. Spur gears are used in many machine design applications. The selection
process of a spur gear system involves many calculations and decisions. It helps guide the user
through the design process. The program assists the user through the design process. Most
inputs are taken from graphs, charts, or tables so the user knows where and how the
information is obtained and used. Outputs are shown with their appropriated figures or
drawings to assist the user in understanding how the output was determined and how it is used.
What this means is the user does not have to have a gear design book at his side in order to
interpret results or to get input data. The selection of spur gear material is based on two
factors, bending stress and contact stress. Bending stress in a gear is based on the concept that
gear teeth act similar to a cantilever beam with a bending force applied to them. The bending
stress is calculated based on the shape, size, width of the tooth, the force on the tooth, and
several safety factors. The program allows the student to select a gear material based on the
allowable bending stress and allowable contact stress. The procedure shown in this paper
helped as in understanding the design procedure for selection of spur gear. Also an introduction
to software has been done.

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 3. SYSTEM DESIGN

3.1. Motor calculations.

For deciding the power rating of a vehicle, the vehicle dynamics like rolling resistance,
gradient resistance, aerodynamic drag, etc. has to be considered. For illustration procedure for
selecting motor rating for an electric car of gross weight 1500 kg is considered. Let’s take the
velocity of vehicle is 65Km/hr.

Total mass = Mc + Mp

= 1260 +(240)

= 1500 kg

Where, Mc = Standard Indian mass of car = 1260 kg[ ]

Mp = Standard mass of Indian human

= {male =65 Kg} & {Female = 55 kg) ……(consider 2 male and 2 female)[ ]

Power of rolling resistance

Frolling = Crr*M*g

= 0.01 * 1500 *9.81

= 147.15 N

Prolling = Frolling * V/3600

= 147.15 *(65/3600)

= 2.65 KW

Power of gradient resistance

Fgradient resistance = M*g*sin α

= 1500* 9.81 *sin(9) ........(slope = 9)

= 2301.9 N

P(garident) = F(gradient) *(65/3600)

= 41.56 KW

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Power of aerodynamic drag

F(aerodynamic drag) = 0.5*CA*Af*ρ*(V+Vo)^2

= 0.5*0.25*0.88*1.225*(65+65)^2

= 2277.275 N

P(areodynamic drag) = F(ad) * (65/3600)

= 41.11 KW

Total Power

Total Tractive force = p1 + p2+ p3

= 2.65 + 41.56 + 41.11

= 85.32 KW

Calculate power by considering mechanical losses

The losses due transmission of power to the wheel must be included. Therefore, the
mechanical power output (Mtractive) required driving the vehicle

Mtractive = Ptotal / η

= 85.32/ 0.85

= 100.37 KW (Approx)

Where, η= efficiency of the transmission gear system.

Let us consider the efficiency of the transmission system to be 0.85. (85%)

n this way, power rating required to drive an electric vehicle of particular load is calculated

RPM of MOTOR

RPM of motor = V*(1/ 4π)

= 42650.8 (1/ 4π)

= 3394.0 rpm -- 3500 rpm

Where, inch = km * 39370 = 65* 39370 = 2559050 ……..(Convert Km to Inch)

min = 1Hr = 60 min

V = 2559050/60 = 42650.8 inch/min………( Convert velocity Km/Hr into inch/min)

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 Rated Torque

P = 2πNT/60

= [2π X 3394.0 X T] / 60

T = 239.0 --- 250 N.m

Parameters Results
Maximum Power 100.37 KW
Motor RPM 3500 RPM
Maximum Torque 250 Nm
Speed 65 Km/hr
Table(1). Main parameters of electric motor.

❖ Reasons / ideas behind the selection of BLDC Motor.

• High torque to weight ratio
• Optimum efficiency which will producing more torque per watt
• Noise factor will be totally reduced here
• Lifetime increased as in BLDC motor, we eliminating brush and commutator erosion
• Also, BLDC motor eliminates ionizing sparks from the commutator
• Coming to the main important parameter is maintenance cost, BLDC motor maintenance cost
is very low
• Also, less frequent maintenance required
• Better speed control
• No friction generated while in working
• No heating issues

By considering all Pros and Cons of various types of electric motor, we done the selection of
electric motor on the basis of our motor requirement.

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3.2. Dimensions of BLDC Motor.

Fig(3.1). Design of BLDC motor.

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3.3. Design of coupling

For transmitting the power to the wheels from motor, we have designed a coupling with the
help of gears. The Gear coupling has good reliability. In this coupling, there is a small gear
transmission system. In that, two gears are placed. One is mounted on motor shaft and another
is placed on transmission shaft which is connected to the differential. The gears mounted on
shaft with the help of keys. The advantages of the gear couplings are:

- To transmit torque between two shafts that are not collinear

- To provide long life and good reliability.
- Very high torque density.
- Moderate misalignment capacity, exceptional torsional stiffness.

Fig.(3.2) Design of Gear coupling system by hand.

Fig.(3.3) Design of Gear coupling system.

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3.4. Design of gears.

For gear coupling, we design gears on the basis of transferring the required velocity(65km/hr)
in terms of number of revolutions (N) of motor shaft. For this coupling, Spur Gear is designed.
Coupling needs two spur gears. Both the gears are same dimensions. The design calculations of gear
are as follows:

Velocity = πDN/60

D = [18 X 60]/[ π X 3394]

Dp = 101 mm………………………(so, Rp = 50.5 mm)

Let us consider,

No. of teeth (Z) = 24

Pressure angle (a) = 20 degree
Module (m) = D/Z
Addendum Radius (Ro) = Rp + m
Base circle radius (Rb) = Rp Cos(a)
Dedendum Radius (Rr) = Rp – 1.25
Circular pitch (Pc) = πD/Z Fig.(3.4) Spur gear

Sr. No. Parameters Results

1. Number of teeth 24
2. Pressure angle 20 degree
3. Module 4.2 mm
4. Pitch circle radius 50.5 mm
5. Addendum Radius 54.7 mm
6. Base circle radius 47.4 mm
7. Dedendum Radius 49.25 mm
8. Circular pitch 13.22 mm
Table(2). Dimensions of Design Gears.

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 4. METHODOLOGY

These stages are followed to achieve the output of the project:-

Understanding the basic of Electric Motor

Selection Criteria (Calculation)

Sizing and Structure

Design of Motor

Design a Coupling motor with wheels

Analysis of motor

Performance of Motor

Compare performance with other motors

Finalization of Electric Motor with optimum results

4. NAME OF SOFTWARE USED – 1] CATIA V5 R21

2] ANSYS R2021

Understanding the basics of electric motor with its different properties. Assuming some
parameters like air density, coefficient of rolling resistances, mass of driver and passengers with
vehicle. Following standard design procedure by calculating air resistances, rolling resistances,
required power, torque, battery power required, max required tractive force / effort. Based on
this calculation, we should select the type of motor. For sizing purpose, we use the MOTOR
SIZING SOFTWARE. Then, we are going to make a design of model of electric motor
in CATIA V5 design software. After designing the model, we move on to do different analysis
phase to finalize the design under different circumstances like thermal, vibrational analysis and
others which are applicable to the motors with set some boundary conditions in analysis. Then,
after getting some analysis results we can check the performance of motor. After that, we are
comparing the performance of our design and analyzed of the electric motor with other motors.
Hence, we can design an electric motor with optimum performance successfully.

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 5. CONCLUSION

So, finally we have done the calculations analytically of an electric motor (BLDC). We reach the
maximum power of electric motor above 100 KW. Maximum torque (optimum) we get 250 Nm.
Motor RPM we get near about 3500 RPM. By considering this all parameters we finalizing design of
gears, in which we select 24 teeth’s for the gear. Reason behind the selection of 24 Teeth’s of gear as
we require more revolutions for optimum power efficiency and max torque with high performance.
On the basis of motor calculations, design of gears, we finalize the rough coupling design. So finally
considering all resistances, maximum torque, maximum power, Motor RPM, we finalize the
dimensions of an Electric motor which we are going to designed. We have done one schematic of our
electric BLDC motor which you can see in this report. Successfully we ready to say that we design
an electric BLDC motor.

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 6. REFERENCES

1) ‘Design and selection of the components based on their performances which are necessary
to hybrid vehicle’ Khalid G. Mohammed [1] (March, 2020) -Intechopen.com

2) ‘Selection of power rating of an electric motor for electric vehicles’ T.Porselvi,

Srihariharan.M.K. Ajith Kumar’s [2] (IJESC, 2017) - http://ijesc.org/

3) ‘Comparative study of using different electric motors in the electric vehicles’ Mohammad
Naser Hashemnia, Behzad Asaei [3] (Researchgate, 2014) -
https://www.researchgate.net/publication/224394177

4) ‘Comparative Study of using Different Electric Motors for EV’ Ansh Thattil1, Sumit
Vachhani2, Darshan Raval3, Piyush Patel4, Priyanka Sharma5 [4] (IRJET) -
http://www.irjet.net/
5) ‘Computer Aided Spur Gear Design and Analysis’ [5] (Edward M. Vavrek, Purdue
University North Central) - https://peer.asee.org/computer-aided-spur-gear-design-and-
analysis.pdf

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