EV - E-Vehicle Technology - Introduction - Unit 1

Honor Course: Electrical
Vehicles (302031MJ)
Unit 1: e-Vehicle Technology
EV Technology
Lecture 2 Key Components of EV
Working of EV
Prepared by Dr. A. R. Patil
1.1 EV Technology

1.1 EV Technology

1.1 EV
Technology

1.1 EV Technology

1.1 Key
Components of an
All-Electric Car
 Battery (all-
electric auxiliary):
In an electric drive
vehicle, the
auxiliary battery
provides electricity
to power vehicle
accessories.

1.1 Key Components of an All-Electric Car
 Charge port: The charge port allows the vehicle to connect to an external power supply in order
to charge the traction battery pack.

 DC/DC converter: This device 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 traction motor: Using power from the traction battery pack, this motor drives the
vehicle's wheels. Some vehicles use motor generators that perform both the drive and
regeneration functions.

 Onboard charger: Takes the incoming AC electricity supplied via the charge port and converts it
to DC power for charging the traction battery. It also communicates with the charging equipment
and monitors battery characteristics such as voltage, current, temperature, and state of charge
while charging the pack.

 Power electronics controller: This unit manages the flow of electrical energy delivered by the
traction battery, controlling the speed of the electric traction motor and the torque it produces.

 Power electronics controller: This unit manages the flow of electrical energy delivered by the
traction battery, controlling the speed of the electric traction motor and the torque it produces.

 Thermal system (cooling): This system maintains a proper operating temperature range of the
engine, electric motor, power electronics, and other components.

 Traction battery pack: Stores electricity for use by the electric traction motor.

 Transmission (electric): The transmission transfers mechanical power from the electric traction
motor to drive the wheels.

1.1 Working of EV

1.1 Working of Tesla EV

1.2 Significance of e-Vehicle.
● Electric powertrain in EV offeres

○ offers smoother, and quicker, acceleration
○ improves braking (reverse the energy going through the wheels, slowing down
the car with ease called regenerative braking)
● less interior noise, and vibration from the powertrain due to absence of engine
● EVs produce zero emissions.
● Solar power is a main source of renewable energy, and many external battery
chargers are fueled by this super supplier.
● EV help people save money, save the environment, and save fossil fuels from running
out prematurely

Lecture 3 & 4

1.3 Types of electric vehicles and it components
Battery Electric Vehicles Plug-in Hybrid Electric Hybrid Electric Vehicles

(BEVs) Vehicles (PHEVs) (HEVs)
Powered solely by an electric battery, Similar to a Hybrid, but with a larger Low-emission vehicles that use an
with no gas engine parts. Most BEVs battery and electric motor. Has a gas electric motor to assist gas-powered
are capable of fast charging and L2 tank and a charging port. Can charge engines. All energy comes from
charging. Zero emissions by using L2 chargers. gasoline. Cannot charge with EVgo.

1.3 Types of electric vehicles and it components
● Pure-electric vehicles
● Hybrid EVs
● Plug-in electric vehicle
● Range-extended electric vehicle
● On- and off-road EVs
● Railborne EVs
● Space rover vehicles

1.3.a Battery/All Electrical Vehicles (BEV)
Battery Electric Vehicles, also called BEVs and more frequently called EVs, are fully electric vehicles
with rechargeable batteries and no gasoline engine. All energy to run the vehicle comes from the
battery pack which is recharged from the grid. BEVs are zero emissions vehicles, as they do not generate
any harmful tailpipe emissions or air pollution hazards caused by traditional gasoline-powered vehicles.
Some popular EV models are pictured here and a full list of available fast charging EV models is available
in the chart above.

1.3.a Classification of Battery/All Electrical Vehicles (BEV)
● Neighborhood electric vehicles: small vehicles, very low range (less than 25 km)
● City electric vehicles: small vehicles, low range (less than 50 km)
● Full performance battery electric vehicles: these are the equivalent of the classic passenger
vehicles, with the range between 100 and 600 km

1.3.a Full performance battery electric vehicles (FPBEV)
● BEV architecture have the powertrain on the front axle and the high voltage battery in the floor,
between the front and rear axle which gives plenty of volume for the passenger area and boot/trunk.
● The high voltage battery, being the heaviest electric component of the vehicle, is positioned very
low, in the body floor which give advantage, a very low center of gravity, which improves the overall
stability of the vehicle.
● High performance BEVs, like Tesla Model S, have two electric motors for traction, one on the front
axle, the second on the rear axle. Both motors have their own power electronics controllers. This
configuration gives all-wheel drive (AWD) capabilities as well as very good performance in terms of
acceleration and driving dynamics (torque vectoring).

● The energy storage component in a pure electric vehicle is the high voltage (HV) battery. The
nominal voltage is, in most of the cases, between 360 and 450 V. A BEV has also a low voltage
battery, the usual 12 V battery, which is used as a power supply for the auxiliary equipment
(lightning, multimedia, etc.).
○ the range of the vehicle depends almost entierly on the HV battery
○ it is the heaviest electrical component
○ it is the most expensive electrical component
● There are different types of high voltage batteries, the chemistry being the main distinct factor.
The most common HV batteries for BEV are the lithium-ion batteries. These have also different
“flavours”:
○ metal-oxides (e.g. Lithium Manganese Oxide, LiMn2O2)
○ phosphates (e.g. Lithium Iron Phosphate, LiFePO4)
● In automotive application phosphate lithium-ion batteries are more suitable because they are
safer in terms of chemical and thermal hazard.
● The torque is provided by an electric machine. In passenger vehicle applications there are mainly two
types of electric motors already in use, with interest for the third
○ permanent magnet machines
○ inductance machines
○ switch reluctance machines
● It’s more appropriate to call them electric machines instead of motors because they can also generate
electrical energy during vehicle braking. This mechanism is called energy recuperation/regeneration.
● When the vehicle accelerates, the electric machine takes electrical energy from the HV battery and
produces torque. This is the motor phase. When the vehicle is braking, the kinetic energy of the vehicle
is used by the electric machine to produce electrical energy. This is the generator phase 1. Rectifier
● he main difference between the electric machines consists in the way they produce torque (permanent 2. DC-DC converter
3. input filter
magnetic field from magnets, induced magnetic field in the rotor windings or magnetically conductive 4. inverter
path in the rotor aligned with the stator field)

● The power electronics control module has several subsystems, each responsible with a
control function. When the vehicle is charged from a home electrical grid (e.g. 220 V), the
rectifier converts the alternating current (AC) into direct current (DC), which is fed into the
high voltage battery. The DC-DC converter is responsible with the lowering of the high
voltage (e.g. 400 V) to the low voltage network (12 V).
● The inverter controls the electric machine speed and torque by converting the direct current
from the battery into alternating 3-phase current for the electric machine. When the vehicle is
in energy recuperation phase (braking) the inverter is doing the opposite conversion, from 3-
phase AC to DC

1.3.b Plug-in Hybrid Electric Vehicle(PHEV)


Audi A3 E-Tron • BMW 330e • BMWi8 • BMWx5

xdrive40e • Chevy Volt • Chrysler Pacifica • Fiat
500e • Ford C-Max Energi • Ford Fusion Energi •
Hyundai Sonata • Kia Optima •Mercedes C530e •
Mercedes S550e • Mercedes GLE550e • Mini Cooper
SE Countryman • Porsche Cayenne S E-Hybrid •
Porsche Panamera S E-Hybrid • Toyota Prius • Volvo
XC90 TB

1.3.b Working of Plug-in Hybrid Electric Vehicle(PHEV)

1.3.c Hybrid Electric Vehicle (HEV)
Hybrid Electric Vehicles, or HEVs, have both a gas-powered engine and an electric motor to drive the car. All
energy for the battery is gained through regenerative braking, which recoups otherwise lost energy in braking
to assist the gasoline engine during acceleration. In a traditional internal combustion engine vehicle, this
braking energy is normally lost as heat in the brake pads and rotors. Regular hybrids cannot plug into the grid to
recharge and cannot charge with EVgo.

1.3.c Hybrid Electric Vehicle (HEV) : Starting From Stop
It's an advantage you'll feel in
an instant. With a firm press of
the accelerator, the powerful
electric motors combine with
the gas engine to deliver
immediate torque and seamless
acceleration off the line. When
starting from a stop under
normal conditions, only the
electric drive is used for light
acceleration, resulting in a
gentle, silent takeoff and
enhanced efficiency.
LEXUS HYBRIDS
1.3.c Hybrid Electric Vehicle (HEV) : DRIVING
Whether in city traffic or on the
highway, Using hybrid drive, the
system optimizes output from
the electric motor and gasoline
engine, allocating power to the
drive wheels as well as to an
electric generator. As a result,
you won't just enjoy a smoother
and quieter ride, you'll enjoy it
over many more miles on a
single tank of gas.
LEXUS HYBRIDS
1.3.c Hybrid Electric Vehicle (HEV) : ACCELERATING
During initial takeoff from a stop, the
high-output battery alone provides
power to the electric drive. As speed
increases, the potent gas engine is
engaged. And, when extra
acceleration is desired, power output
from both sources is optimized to
deliver an even greater boost.
Working in tandem with the
Electronically controlled Continuously
Variable Transmission, the result is
powerful acceleration without the
jarring shift points experienced in a
conventional vehicle.
LEXUS HYBRIDS
1.3.c Hybrid Electric Vehicle (HEV) : BRAKING
During initial takeoff from a stop, the
high-output battery alone provides
power to the electric drive. As speed
increases, the potent gas engine is
engaged. And, when extra
acceleration is desired, power output
from both sources is optimized to
deliver an even greater boost.
Working in tandem with the
Electronically controlled Continuously
Variable Transmission, the result is
powerful acceleration without the
jarring shift points experienced in a
conventional vehicle.
LEXUS HYBRIDS
Lecture 5 & 6

Battery Pack
 A battery pack is a set of any number of (preferably) identical batteries or individual battery cells
 A battery cell is a container to chemically store energy while battery cells are connected in series
and parallel, into a so-called battery pack, to achieve the desired voltage and energy capacity.
 The pack contains battery cells, software (battery management system) and often a cooling and
heating system, depending on where and how the battery pack is to be used
 Interconnects are also found in batteries as they are the part which connects each cell, though
batteries are most often only arranged in series strings.
 Battery cell production is primarily a chemical process, while module and pack production is a
mechanical assembly process.
Note : An electric car for example requires 400-800 volts and one single battery cell typically has 3-4 volts.

BATTERY TERMINOLOGIES – ENERGY AND POWER
 The total energy storage capacity of a cell is roughly its nominal voltage multiplied by its
nominal capacity (mWh, Wh, or kWh).
Nominal Energy Capacity = V * I
= 3.7 * 1.9
= 7.03Wh

BATTERY TERMINOLOGIES
 State-of-health (SoH) is indicator of

 Capacity, the ability to store energy
 Internal resistance, the capability to deliver current, and
 Self-discharge, reflecting mechanical integrity and stress-related conditions.
 Absolute state-of-health (ASoH), the ability to store the specified energy when
the battery is new
 Relative state-of-health (RSoH), available storage capability when battery is
broken in Note:
 Unless otherwise mentioned, RSoH refers to SoH.

 SOC, or state of charge, is the equivalent of a fuel gauge for a battery / the
level of charge of an electric battery relative to its capacity
 SOC cannot be determined by a simple voltage measurement, because
the terminal voltage of a battery may stay substantially constant until it
is completely discharged.
 Most SOC methods take into account voltage and current as well as
temperature and other aspects of the discharge and charge process to in
essence count up or down within a predefined capacity of a pack

 Absolute state-of-charge (ASoC), the ability to take the specified charge when the battery is new
 Relative state-of-health (RSoC), available charge level taking capacity fade into account.
 Unless otherwise mentioned, RSoC refers to SoC
 State-of-function (SoF) indicate usable energy by observing state-of-charge in relation to the
available capacity

State of Charge (SoC)
 Discharging cell moves lithium between negative and positive electrodes.
 Cell SOC related to average Li concentration in the negative electrode particles
 Maximum theoretical concentration of lithium in electrode particle is cs,max.
 Average concentration of Li in particle at time k is cs,avg,k.
Then, present lithium stoichiometry is
This is a kind of electrode SOC, different from cell SOC.
Where

Battery Pack Configuration
 Battery pack configurations determined by the chemistry, cell type, desired voltage and capacity,
and dimensional space constraints.
 battery cells are physically connected in series and parallel to achieve the desired power of the
pack.
 Cells come in fixed voltages and various capacities. Connecting cells in series will provide more
capacity while connecting in parallel, more voltage.
 All NiCad or NiMH cells are 1.2 volts nominal, lead acid is 2.0 volts nominal, and the various
lithium technologies are about 3.6 volts per cell
 When needed more voltage, add them in series while when need more current than a single cell can
supply, need to put cells in parallel.
 the physical configuration makes it more attractive to use many small cells rather than a few large
cells, since a large block is harder to fit than several small subunits.

 Cell capacity is rated in amp-hours(Ah) or milliamp hours (mAh) and symbol

for capacity is C
 Divide by hours and you get amps; divide by amps and you get hours
 E.g . for 5Ah ,
 when need to run for 10 hr, can get a current of 5/10 = 0.5 amps
 you need .1 amps current, then can run for 5/.1 = 50 hours.
 When used in series, the voltage is multiplied but the amp-hours stays the
same. So, three 5AH 3.6V in series would give a 5AH 10.8V pack.
 When used in parallel, the voltage stays the same and the amp-hours multiply.
So, three 5AH 3.6V cells in parallel would give a pack that is 15AH and 3.6V.




Battery Pack Configuration :Resistance of the Nickel Strip in Battery
Assembly
Multi-Row Cells Cubic

packing is in neat rows. The
size of such a pack is nD x mD
Nested Type Cells:
x H, where n is the number of This type of configuration is
cells in a row, m is the number typically supported with outer
of rows, D is the cell diameter, shrink wrap to give the cells
and H is the cell height. additional support. The
exposed ends of the cells are
Linear or F Type cubic or composite F Type typically protected with fish
paper.
configured in multiple rows

Battery Pack Configuration: Battery Configuration
Linear or L-Type Cells
Face centered Cubic Circular Type Cells

1.4 Steps in formation of battery pack and its calculation for
specific applications

1.4 Steps in formation of battery pack and its calculation for
specific applications

1.4 Case Study : Battery pack for Bicycle

Assignment 1:
Do Battery calculation with connection link configuration diagram for following demands using following
batteries
a. 18650 3.7V Li-ion 2000mAh Rechargeable Battery

b. IFR32650 3.7V 6000mAh (3c) LiFePO4 Battery
c. CR18650 3.7V Rechargeable 1200mAh Li-ion Battery
d. CR18650 3.7V Rechargeable 2600mAh Li-ion Battery
Demands:
1) Bicycle with electric demand of 10 Ah, Nominal Voltage: 24 V.
2) Bicycle with electric demand of 12 Ah, Nominal Voltage: 28 V.
3) Bicycle with electric demand of 8Ah, Nominal Voltage: 32 V.
4) Tricycle with electric demand of 6Ah, Nominal Voltage: 12 V.
5) Electric car with load of 144V with 90 Ah.

Mini Project: Electrification of TriCycle, bicycle and Handicap
Cycle
1. Prepare a group of four to five students
2. Name the group
3. Work in stages as syllabus proceed
4. Part A : Design and Develop battery system for home bicycle
a. Identify the power needed hence capacity and voltage needed
b. Identify the type of battery cell and quantity
c. Prepare the connection diagram
d. Identify the BMS system
e. Select the type of packing and dimension to make it portable depending on the space available in cycle
f. Identify the cost
5. Prepare the drawings
6. Give presentation

Lecture 7

1.5 Introduction to suspension system
Suspension is the system of tires, tire air, springs, shock absorbers and linkages
that connects a vehicle to its wheels and allows relative motion between the two.
Suspension systems must support both road holding/handling and ride quality, which
are at odds with each other.
Leaf springs Coil springs Torsion bars Air springs

1.6 Mechanical transmission
“A significant difference between conventional vehicles and EVs is the drivetrain.
Simply put, the majority of EVs do not have multi-speed transmissions. Instead, a
single-speed transmission regulates the electric motor.”
Can EV have manual transmission?
Because electric vehicles don't have a clutch or a gearbox with different speeds like a conventional diesel or
petrol vehicle, they get away with only a single gear (drive) and a reverse. The main reason why electric cars
don't have a manual gearbox is simply that they don't need one.
Based on vehicle type, it is divided into battery electric vehicle, hybrid electric vehicle, plug-in hybrid electric
vehicle, and others. Transmission systems are categorized as AMT transmissions, CVT transmissions, DCT/DHT
transmissions, and AT transmission.


“A significant difference between conventional vehicles and EVs is the drivetrain. Simply
put, the majority of EVs do not have multi-speed transmissions. Instead, a single-speed
transmission regulates the electric motor.”
Can EV have manual transmission?
Because electric vehicles don't have a clutch or a gearbox with different speeds like a conventional diesel or
petrol vehicle, they get away with only a single gear (drive) and a reverse. The main reason why electric cars
don't have a manual gearbox is simply that they don't need one.
Based on vehicle type, it is divided into battery electric vehicle, hybrid electric vehicle, plug-in hybrid electric
vehicle, and others.

“

Automated Manual Transmission (AMT)
Automated manual transmission (AMT), also known as a clutchless manual, denotes a type of
motor vehicle transmission that is closely based on the mechanical design and build of a
conventional manual transmission, but uses automatic actuation to operate the clutch and/or
the gear shift mechanism.

Continuous Variable Transmission (CVT) : CVT stands for continuously variable transmission and operates
in a similar fashion to a traditional automatic

Dual Clutch Transmission (DCT) : A dual-clutch transmission (DCT) is a type of multi-speed vehicle transmission system, that uses
two separate clutches for odd and even gear sets.

Direct Shift GearBox(DSG) : Automates two separate "manual" gearboxes (and clutches) contained within one housing
and working as one unit

Tiptronic Transmission : basically a regular automatic transmission where the driver is able to move out of
“automatic mode” and use paddle shifters to shift up or down like a manual transmission

IoT in Electric Vehicles
The Internet of things (IoT) describes physical objects (or groups of such objects) that are embedded with sensors, processing
ability, software, and other technologies, and that connect and exchange data with other devices and systems over the
Internet or other communications networks.
The IoT architecture of EV employs the information sensing equipment coupled with the wired or wireless
communications to implement the information extraction, transmission, and the scheduling for a EV charging
system.

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Honor Course: Electrical

Lecture 2 Key Components of EV

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

● Electric powertrain in EV offeres

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Battery Electric Vehicles Plug-in Hybrid Electric Hybrid Electric Vehicles

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Audi A3 E-Tron • BMW 330e • BMWi8 • BMWx5

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Nominal Energy Capacity = V * I

Prepared by Dr. A. R. Patil

 State-of-health (SoH) is indicator of

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Then, present lithium stoichiometry is

This is a kind of electrode SOC, different from cell SOC.

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

 Cell capacity is rated in amp-hours(Ah) or milliamp hours (mAh) and symbol

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Multi-Row Cells Cubic

Prepared by Dr. A. R. Patil

Linear or L-Type Cells

Face centered Cubic Circular Type Cells

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil

a. 18650 3.7V Li-ion 2000mAh Rechargeable Battery

Prepared by Dr. A. R. Patil

Prepared by Dr. A. R. Patil