Program on EV Technology and Policy – Day 1

7th May 2022

R.Muruganandam, VP-R&D
Sona Comstar Automotive Technology, Chennai
Objectives
• To learn the environmental impact and history of Electric Vehicles
• To understand the concept of Electric Vehicle and its types
• To study the configurations of Electric Vehicles
• To acquire knowledge about Energy Storages, Charging System, Effects and Impacts
• To appreciate the Electric Mobility Policy Frame work India and EV Policy Tamil Nadu 2019.

Outcomes
• Appreciate the need of an Electric Vehicle
• Compare the different EV vehicle specifications in the market
• Choose the right motor, inverter and battery systems for EVs
• Workout the benefits of EV cost based on the Govt policy
Environmental impact and history

• Environmental Impact of Conventional Vehicle

• Air Pollution
• Petroleum Resources
• History of Electric vehicles & Hybrid Electric Vehicles
• Conventional Drive-train System
• Rear Wheel, Front Wheel and All wheel Drive-train System
• Parts of Drive-train system
Air Pollution
On Board Diagnostics
Petroleum Resources

Top countries with the largest oil reserves in 2019

1. Venezuela – 304 billion barrels. ...
2. Saudi Arabia – 298 billion barrels. ...
3. Canada – 170 billion barrels. ...
4. Iran – 156 billion barrels. ...
5. Iraq – 145 billion barrels. ...
6. Russia – 107 billion barrels. ...
7. Kuwait – 102 billion barrels. ...
8. United Arab Emirates – 98 billion barrels.
Diesel Price Movement
What Mobility Was Supposed to Mean…
What It In Fact Came to Mean…
Paved Roads, Highways,
Gas Stations, Motels, …
Suburbia, Fast-Food Restaurants, Taxis, Dealerships, Mechanics, …
All This Was Preceded by ‘The Great Horse Manure Crisis’ of 1890s.
But Innovators Were Already at Work…

Gottlieb Daimler in a motor vehicle constructed by himself in 1886. Karl Benz seated on the 1885 Benz Motorwagen.
…Resulting the First Disruption in Mobility.

Horse Carriages

2000
Source: Nakicenovic, N., 1986. The automobile road to technological-change - Diffusion of the automobile as a process of technological substitution. Technological Forecasting and Social Change 29 (4), 309–340.
Why Was the Model T Successful?

Convenience Safety
• Horses needed • Frightened and
time to prepare out-of-control
• Space for stable horse could
SOCIETAL
• Difficult to CONCERNS
create havoc
maintain and ADDRESSED BY • Overturning of
MODEL-T
operate. carriages used
to be common

• Manure on the street

Environment • Dead horses left behind
• Fear of epidemics
Drivers of the First Disruption in Mobility

Internal High-
Combustion Strength
Engine Alloy Steel
TECHNOLOGICAL
ADVANCES OF
1900s

Mass
Production
Drivers of the New Disruption in Mobility

Unprecedented Virtually Free

Computing Data Storage
Power DATA
DATA TECHNOLOGICAL
STORAGE
ANALYTICS ADVANCES OF
2000s

Sensors, Cameras
DATA COLLECTION and other IoT Devices
Thomas Edison aboard his own 1902 Studebaker Electric in the left
photo. Edison and his camping buddy Henry Ford also tried their
hand at an electric car and built at least one prototype before both
decided that the gasoline engine had a more promising future. One
factor was that electricity was not yet widely available outside city
centers, severely limiting the market for cars tied to that
infrastructure. Drivers could carry spare cans of gasoline for long
journeys, but spare batteries were a lot heavier per unit of energy.

History of Electric vehicles

& Hybrid Electric Vehicles
1923-1966
Electric Vehicles
Parts of Drive train system
Key parts of Drive train system
 • Pros:
Front Wheel Drive (FWD) • Extremely efficient in terms of cost,
mass, space, and fuel consumption
• locating engine mass in front of the
passenger compartment might improve
crash safety.
• Cons:
• Tires tasked with acceleration have less
friction available for turning and can
wear out more quickly; heavy front
weight bias compromises handling
responsiveness.

1.Mauti Suzuki Alto

2.Chevrolet Beat
3.Hyundai Verna
4.Hyundai i10
5.Honda City
6.Honda Civic
7.Toyota Corolla
8.Mitsubishi Outlander
9.Maruti Suzuki Ciaz
10.Volvo S40
Rear Wheel Drive (RWD)
• Pros: improves both steering feel and
ultimate cornering grip; (mid- or rear-
engine): engine weight over drive
wheels plus dynamic rearward weight
shift during acceleration optimizes
accelerative traction.
• Cons (Front engine): added mass, cost,
friction, rotational inertia of driveshaft,
and gearing

•Mahindra TUV300. ...

•Mahindra Bolero. ...
•Mahindra Scorpio. ...
•Tata Safari Storme.
•Toyota Innova.
•Ford Endeavour.
•Toyota Fortuner....
•MG Gloster.
AWD Pros And Cons:
•Mahindra Thar.
•Mahindra Alturas.
•Toyota Fortuner. ...
•Ford Endeavour. ...
•Jeep Compass. ...
•MG Gloster.

• Pros: Inherent traction advantage in all conditions, especially accelerating

through turns and as engine power approaches or exceeds a level that can
overwhelm two driven tires.
• Cons: Added cost, weight, rotational inertia, and friction reduce efficiency
in all driving situations
End of Session-1

Any Questions?
Types of Electric Vehicles

• Introduction to Battery Electric Vehicle (BEV)

• Definition BEV
• Necessity BEV
• Different between BEV and Conventional Vehicle
• Advantages of BEV
• Block diagram of BEV
• Hybrid electric Vehicle(HEV)
• Plug-in Hybrid Electric Vehicle (PHEV)
• Fuel Cell Electric Vehicle (FCEV)
Introduction
to Battery
Electric
Vehicle
 Motor

Electric Car !!
Inverter
• Infrastructure development
• Bike friendly
• More public transports
• metro, train, e-bus
• V2x enabled

• Personal Mobility
• E-bike
• E-vehicles
• Car sharing
Different between BEV and Conventional Vehicle
Block diagram of BEV
Hybrids
Plugin Hybrid electric Vehicle(PHEV)
Plug-in Hybrid Electric
Vehicle (PHEV)
Fuel Cell Electric Vehicle (FCEV)
End of Session-2

Any Questions?
Electric Vehicles

• Configurations of Electric Vehicle

• Performance of Electric Vehicles
• Tractive Effort in Normal Driving
• Energy consumption.
• Concept of Hybrid electric drive trains
• Architecture of Hybrid Electric Drive trains
• Series, Parallel and Series & Parallel
Configurations of Electric Vehicle
Performance of Electric Vehicles
Tractive Effort in Normal Driving
Power flow efficiency
Hybrid Topologies
Hybrid Topologies & features
Power Split Hybrid
Electric Propulsion Systems

• Types of EV motors
• DC motor drives
• Permanent Magnetic Brush Less -DC Motor Drives (BLDC)
• – Principles, Construction and Working
• Hub motor Drive system
• Merits and Demerits of DC motor drive, BLDC motor drive
Digital Validation -
Multiphysics
Motor Types

D.C. Motor

Permanent Magnet
Motor

Reluctance Motor

Induction Motor
SERIES DC MOTOR

✓ Falls under the category of self-excited DC motors, and

it gets its name from the fact that the field winding in
this case is connected internally in series to the
armature winding.

✓ PRINCIPLE : Whenever the magnetic field is formed

approximately, a current carrying conductor cooperates
with an exterior magnetic field, and then a rotating
motion can be generated.

https://www.youtube.com/watch?v
DC MOTOR : =LAtPHANEfQo
WORKING
BRUSHLESS DC MOTOR

✓ A brushed DC motor has permanent magnets on the

outside of its structure(STATOR), with a spinning
armature on the inside (ROTOR, containing
electromagnet).

✓ A brushless DC motor is essentially flipped inside out,

eliminating the need for brushes to flip the
electromagnetic field.

✓ The control of the speed and torque is done by an

‘electronic controller’.

https://www.youtube.com/watch?v
BLDC MOTOR :
WORKING
=bCEiOnuODac
PM SYNCHRONOUS MOTOR

✓ The principle of operation of a synchronous motor is

based on the interaction of the rotating magnetic field
of the stator and the constant magnetic field of the
rotor.

✓ The magnetic field of the rotor, interacting with the

synchronous alternating current of the stator windings,
according to the Ampere's Law, creates torque, forcing
the rotor to rotate.

https://www.youtube.com/watch?v
PMSM :
WORKING
=Vk2jDXxZIhs
SWITCHED RELUCTANCE MOTOR

✓ Based on the variable reluctance principle.

✓ By changing the air gap between the rotor and stator,

we can change the reluctance of the motor.

✓ Reluctance is nothing but a resistance to the magnetic

flux. (Opposes the magnetic flux)

✓ As the magnetic flux have a tendency to flow through

lowest reluctance path, therefore rotor always tends to
align along the minimum reluctance path.

https://www.youtube.com/watch?v
SR MOTOR : =23i0prqMfT0
WORKING
INDUCTION MOTOR

✓ Based on the principle of electromagnetism. It is

called a ‘squirrel cage’ motor because the rotor
inside of it – known as a ‘squirrel cage rotor’ –
looks like a squirrel cage.

✓ The main difference is that there is no electrical

connection from the rotor winding to any source of
supply. The required current and voltage in the
rotor circuit are provided by induction from the
stator winding. This is the reason to call is as an
induction motor.

https://www.youtube.com/watch?v
INDUCTION
MOTOR: WORKING =AQqyGNOP_3o
CONTROL ALGORITHMS FOR MOTORS
N vs T
Control Methods for Motors
Trapezoidal Control
 PERFORMANCE COMPARISON OF MOTOR DRIVE TECHNOLOGIES
• EV applications demand high efficiency, high torque density, high reliability,
and wide speed range while reducing weight, complexity, efficiency and cost.
Motor Drives Pros Cons Application

✓ Uses DC supply from the battery in vehicles ✓ Large and inefficient, maintenance requirements
DC Motors ✓ Danavolt of Peugeot Citroen
✓ Motor drives, speed and torque control is simple ✓ Limited regenerative braking capacity

✓ Silverado of Chevrolet
Induction ✓ Renowned for their simplicity, ruggedness, cheapness and ✓ Low efficiency, low power factor, and low inverter ✓ Durango of Daimler Chrysler,
Motors reliability usage ✓ X5 of BMW
✓Kangoo of Renault

✓ Tino of Nissan
Permanent ✓ High torque and power density, high controllability, low weight ✓ Limited reserve and high cost of rare earth
✓ Insight of Honda
Magnet Motors and size materials
✓ Prius of Toyota

Reluctance ✓ High reliability and speed potential ✓ High torque ripples, acoustic noise, and high
✓ Commodore of Holden
Motors ✓ Can withstand high temperatures and mechanical stresses Electromagnetic Interference
Summary of Performance Comparison

Performance DC PM IM SR
Cost Comparison of Controller on scale of 1-5
6
Power Density Low High Low Medium
5
Torque Ripple Low Medium Low High
4

Acoustic Noise Medium Low Low High 3

2
Overload Capacity High Medium High Low
1
Controllability High Medium High Low
0
Max Speed Medium Low High Very High DC Brushless PM IM SR

Speed Range Medium Low Medium High

Cost Comparison of Motor on Scale of 1-5
Size Medium Small Medium Large
5
Reliability Low Medium High High 4.5
4
3.5
Efficiency Low High Medium Medium 3
2.5
2
1.5
1
0.5
0
DC Brushless PM IM SR
Hub Motor
Top EV Cars

• https://www.topgear.com/car-
news/electric/top-gears-top-20-
electric-cars
End of Session-4

Any Questions?
Thank You!