Electric Vehicles – Motivation & Overview

3rd Jan 2022

By Dr. K. C. Vora
Emeritus Professor, COEP
AICTE-INAE Distinguished Visiting Faculty
Chair, ASDC Expert Group on EV
Chair, BAJA SAEINDIA & Member, SAEINDIA MC
Former Sr. Deputy Director & Head ARAI Academy, ARAI, Pune.

During FDP on EV: The Future of Mobility with Support of ATAL ACADEMY at RIT Rajaramnagar

01
 Prevailing Conditions

Economics
• Rising oil prices Policies
• Resource scarcity • Emission Standards
• Limiting CO2 emission
• International
• International policies
politics Problems of
the 21st
Century
Society Environment
• Increasing traffic • Climate change
• Urbanisation • Pollutant emission
• Increasing • Global Warming
populations

Social change, resource depletion & urbanization

characterize the future of mobility
 Motivation
Percentage of Net CO2 emission

Transportation

Electric Power

Industry Proposed Solution?

Agriculture
Zero Emission Vehicles
Commercial

Residential

0 5 10 15 20 25 30 35

Source: US Environment Protection Agency

Reduction in:
Emission,
Noise,
Fuel Consumption,
Fatigue, Source: The Times of India
Import
Resource depletion
Global Warming 08
Changing
Need ofFace
the of
Hour
Mobility
 India’s Goals for Electrification
Developments:
• National Electric Mobility Mission Plan (NEMMP 2020)
envisions sale of 6 Million Electric Vehicles.
• FAME India Scheme (Faster Adoption and Manufacturing
of (Hybrid) and Electric Vehicles in India) by NITI Aayog
incentivises EV ownership by subsidising upfront cost of
purchase combined with GST rates slashed.
• EESL (Energy Efficiency Services Ltd) has floated tenders for
4-wheeler Electric Vehicles and procured 10000 vehicles
from TATA Motors/Mahindra
• First generation public EV charger standards set. FAME scheme has 4 focus areas:
• Technology development
• Growth in EV in shared mobility sector • Demand creation
(Ola, Uber, Glyd, Ather Energy, Bajaj, Hero, BluSmart, ElectricFeel, • Pilot projects
Zbee, Revel, eBikeGo, Gen-Ze, Cow-boy, AEIV, Bird, etc.) • Charging infrastructure 25
NITI Aayog Report - Approach to Mobility Transformation

India can save 64% of anticipated road based mobility

related energy demand and 37% of carbon emissions in
2030 by pursuing a shared, electric and connected mobility
resulting in a net savings of roughly Rs 3.9 lakh crore
(approximately 60 billion USD) in 2030
 Sales of Electric Vehicles in India
India has the potential to sell Electric
Vehicles in large numbers to curb the
menaces of degrading air quality index.

OPINION POLL:
By 2030, Sale of EV in India would be:
a. 10% b. 30% c: 40% d: 80%

Source: swachhindia.ndtv.com
Source: livemint.com 24
GOVERNMENT TARGET FOR EV PENETRATION IN INDIA
 Requirement in Policy Making
Policy decisions should focus on:
• Cost reduction in battery manufacturing
• Achieve cost savings from vehicle design and manufacturing
• Adapting battery sizes to travel needs
• Supply chain and value sustainability of battery materials
• Revamp of the Energy sector to meet the demands
of electric energy by 6 million Electric Vehicles.
• Promoting battery swapping and energy trading in the
urban areas.
• Developing charging station eco-system.
27
 FAME II: Demand Incentive – Details & Distribution
➢ Implementation over a period of 3 years starting from 1-Apr-19
➢ FAME India Scheme Phase II has three broad verticals

Demand Incentive Based on

Charging Infrastructure Information, Education and
Battery Energy Content
Communication (IEC)

➢ Flexibility in fund allocation among themselves

➢ Breakup:
Total Fund
Sr. No. Component 2019-20 2020-21 2021-22 Requirement in
Crores

1 Demand Incentives 822 4587 3187 8596

2 Charging Infrastructure 300 400 300 1000

Administrative Expenditure
3 including Publicity, ICE 12 13 13 38
Activities

Total for FAME II 1134 5000 3500 9634

 FAME II: Demand Incentive – Details & Distribution

#Total
Approximate
Approxi Maximum
#Maximum Incentive @
mate Ex-Factory Total Fund
Sr. Number of 10000/kWh for
Vehicle Segment Size of Price to Support
No. Vehicles to be All Vehicles and
Battery Avail from DHI
Supported 20000/kWh for
in kWh Incentive
Buses and
Trucks
Rs. 1.5/-
1 Registered e-2 Wheelers 1000000 2 kWh Rs. 20,000/- Rs. 2000 Cr.
Lakhs
Registered e-3 Wheelers Rs. 5/-
2 500000 5 kWh Rs. 50,000/- Rs. 2500 Cr.
(Including e-Rickshaws) Lakhs
Rs. 15/-
3 e-4 Wheelers 35000 15 kWh Rs.1,50,000/- Rs. 525 Cr.
Lakhs
Rs. 15/-
4 4W Strong Hybrid Vehicle 20000 1.3 kWh Rs. 13,000/- Rs. 26 Cr.
Lakhs
Rs. 2/-
5 e-Bus 7090 250 kWh Rs. 50/- Lakhs Rs. 3545 Cr.
Crores
Rs. 8596/-
Total Demand Incentive
Crores

## The proposed amount of incentives per kWh are, however, subject to review as per the reduction in battery costs and thereby reduction in vehicle
cost and would be notified accordingly from time to time.
 Various Types of Electric Vehicles Design
• Battery Electric Vehicle (BEV)
• Hybrid Electric Vehicle (HEV)
• Plug-in hybrid vehicle (PHEV)
• Fuel Cell Electric vehicle (FCEV)

We are in a
transition
phase.
Hydrogen is the
future……..
EV: Battery Operated Vehicles/Battery Electric Vehicles

BMS
• SOC
monitoring
• Temperature
monitoring
• Cell balancing

Inverter
Converts
DC – AC for
AC Motors
Traction
Battery Pack
Traction
Motor
Integration of Key Components of Electric Vehicles
Energy Source
(Battery) Electronics/Controls Electric Machine

Mechanics
Energy Storage Source: chargedevs.com
Power
Systems like
Electronics/Controls
Batteries

Energy
Management
System
Electric Machines
i.e.
Electric Drivetrain
System Integration

Optimal Components . . .
Optimal System?
 EV Component Design & Integration

Charging Stations
Electric Motor
• High efficiency
• Performance
• Durability

• Safety /
Weatherproof
• Communication
• Interoperability
• Rollout

Battery
• Safety (Mechanical, Thermal
& Electrical Abuse)
• BMS
• Cycle Life
EV Powertrain Design & Integration

• Domain Expertise • MBD Tool Chain

• Simulation and • V – Model Process
Modeling Tool
Chain

Component
Control System
Sizing and
Development
specification

Vehicle System
Calibration Integration

• Chassis Dyno. • Configuration Design

calibration • Component Layout
• Vehicle • Harness Design
Parameterization • Packaging
 Motors in Electric Vehicles

• Traction Motors
• Auxiliary Motors:
• Power Steering
• Brake Air Compressor
• Cabin Air-conditioning System: Compressor and blowers
• Battery Thermal System: Chiller compressor, fans, and
pumps
• Power Electronics Cooling System: Fans and pumps
• Body
• Wipers
• Power window
Electric Motors
Electric Machines

13
Electric Motors
 Characteristics of Electric Motors
• Large speed ranger of EM - no need for higher
gears
• High torque output at low speed - no need for
lower gears
• Launch vehicle at zero speed-no need to idle at
low rpm
• High efficiency in the wide operating range

14
 Electric Motors
Selection Criteria: • Acceleration
• Payload • Braking
• Maximum Speed
• Cost
• Grade
Vehicle • Performance
• Range
• Durability
• Maneuverability
• RAMS

• Continuous power, torque • Volume, Weight

• Peak power, torque
Motor • Maximum speed
•
•
RAMS
Noise

• Continuous power, torque

System • Cost • Current ripple
• Efficiency • Operating temperature range
• Peak power, torque
• Maximum speed • Mounting and package
specifications •
• Cost Sensor specifications
• Insulation class •
• Efficiency Torque ripple
• Volume, Weight Motor • Voltage and Frequency •
range
Cooling system
• RAMS specifications
• Continuous power • Power factor •
• Noise Fault tolerance
• Peak power • IP Rating
• Voltage and Frequency range • IP Rating
• EMI/EMC
• Cost • Sensor system
• Voltage raise rate
•
•
Efficiency
Volume, Weight •
specifications
Cooling system
Controller • Torque Rate
• Protections
• RAMS specifications
• Current ripple
• Mounting and package specs • Fault tolerance
Source: ANSYS • Data specifications
 Electric Motors
Requirements | Challenges| Options

Challenges Design Options

Cost-Performance-Life PM | IM | SRM | ..
interdependence
Sizing & Integration Position of Magnets | Number of
Poles per Magnet
Material cost & weight
NVH, Thermal Management Solid vs Stranded | Concentrated
vs Distributed Windings
Torque | Power | Efficiency
Copper Losses & Rotor Magnet Placement
Demagnetization

https://www.ansys.com/en-in/resource-library/white-paper/overcoming-the-challenges-of-hybrid-electric-vehicle-traction-motor-design
http://www.thedrive.com/tech/17505/the-secrets-of-electric-cars-and-their-motors-its-not-all-about-the-battery-folks
 Electric Motors
Electric Motor Design

Component Electric Machine Challenges Value

Magnetic Design & Optimize Thermal

Optimization management
Thermal Management Identify NVH issues
and Performance early in the design
cycle
Initial Design Structural Integrity,
Specifications NVH and Acoustics System Analysist o
develop drive control
Reliability &
Electromagnetic Design & Opt. strategy
Manufacturability

Electric
Fluid
Dynamics
Reduced Order Model Structural

Source: ANSYS
 Electric Motors

Motor Design Workflow

Analytical Design Finite Element Analysis Thermal and System Analysis

• Motor Sizing • Detailed Study Structural Integrity • Control Optimization
• Performance Analysis • Torque Speed • Magnet • Full Drivetrain analysis
• Geometry Finalization Characteristics Demagnetization • EMI/EMC
• Efficiency Map • Motor NVH

Parametric and Optimization

Source: ANSYS
 Configuration of Motors in EV

Central Drive Wheel-hub Drive

• Simplest layout
• Absence of clutch and transmission
• Employed by almost all BEVs on the market
• Independent control of each
driving wheel
• Elimination of differential
and driving shafts.
• Popular design in electric
scooters.

Wheel-hub Drive Derivatives

Power Electronics

Ref. Power Electronics Handbook,

3rd End, M H Rashid, Elsevier, 2011

15
 Power Electronics
DC-DC Converter

• Inverter: convert DC to AC

• DC/DC converters: increase or decrease battery

voltages (Fast charging) Source: Traderscity.com

On-board Rectifiers (AC to DC)

• Rectifiers (on-board chargers): convert AC from

electric grid to DC (Slow charging).

Source: Shenzhen.com

16
 Power Electronics
Power Electronics & Control Design
Component Power Electronics Challenges Value
Busbar & Sub-system
Cables Performance Ensure short-circuit
protection
Embedded Software Component: Selection
& Adoption Virtual EMC/Power
quality validation
Efficiency,
Size/Weight, Thermal Assessment of
Magnetic Component
Mgt. Mechanical Reliability
Power Optimize Thermal
Safety, Reliability,
Module management
EMI/EMC Compliance

Busbar Electric
3.65

-5.00

-15.00
S11 and S21 Simplorer_Smatrix
Curve Info
dB20(S11)
Imported
dB20(s21)
Imported
Fluid
-25.00
S (dB)
Dynamics
Therma
-35.00

-45.00

-55.00

Control
l
-65.00

-75.00

Systems
1.00E-006 1.00E-005 1.00E-004 1.00E-003 1.00E-002 1.00E-001 1.00E+000 1.00E+001 1.00E+002
F [MHz]

Source: ANSYS
 Energy Management System (EMS)
EMS, popularly called BMS, uses hardware and software controls to optimize the
energy efficiency and drivability. BMS is the monitoring and control unit of the
battery system which performs the following functions:

Control Parameters Controlled by:

• Understanding State of Charge (SOC) • Cell status detection
• State of Health (SOH) • Cell protection and charge
• Measure Temperature management
• Aid in maintaining temperature • Cell balancing (SOC-balancing)
• Limit Current • Communication
• Control the charge scheme • Thermal Management

17
 Energy Storage System: Battery Terminologies
• Internal Resistance
• Cycle life
• Specific Energy (Wh/kg)
• Specific Power (W/kg)
• Energy Density (Wh/L)
• Power Density (W/L)
Air convection
(Natural or Forced)
• Cells, modules and pack
• Battery classification: High power or high energy
• C rates: 1C charges/discharges the battery in 1 hour
and 2C charges/discharges the battery in ½ hour
• Secondary and primary cells
• SOC (State of Charge)
• DOD (Depth of Discharge)
• Terminal Voltage
Battery Thermal Analysis
Liquid Immersion Liquid Cooling
Cooling through channels
18
 A sneak peak into the history of Batteries
• First motors in mid 1800s were DC powered by poor batteries
• Edison employees developed practical DC machines for DC grid power
• Tesla patented the AC motor and the AC grid system.
• Electric motors are revolutionizing industry and products to this day
• In 1938 the Director of the Baghdad Museum found what is now
referred to as the "Baghdad Battery" in the basement of the
museum. Analysis dated it at around 250 BC and of
Mesopotamian origin.
• The first true battery was invented by the Italian
physicist Alessandro Volta in 1800. Volta stacked discs of copper
(Cu) and zinc (Zn) separated by cloth soaked in salty water.
• Lead acid battery invented in 1859.
• In 1980, the American physicist Professor John Goodenough
invented a new type of lithium battery, in which the lithium (Li) Noble Laurete
could migrate through the battery from one electrode to the other John B. Goodenough
as a Li+ ion. He now invents Glass Battery, which is 3 times better.
 Batteries
Battery Design

Component Challenges Value

Battery
Complexity: Electrical Physics Based System
+ Thermal +Structural Simulation
+Chemistry
Design Optimization
Modul
Various Materials &
e
Design Concepts Reliability: Cell,
Pack Correct Output for Module, Pack &
Battery System System

Durability & Lifing

Cell System: using
ECM/ROM
Electric
Fluid
Dynamics
Control
Structural

Source: ANSYS
 Overall Battery Pack Requirements for xEVs
90

80 High Power

• Different vehicles need 70 Bus HEV Bus PHEV

different cell types
Intermediate Power
• High power cells needed 60

Power Capability (kW)

for Hybrid vehicles 50
Van EV

• High energy cells needed

Bus EV
40 A Seg EV

for Electric Vehicles A Seg

B Seg EV
30 REEV High Energy
• Intermediate power cells
needed for Plug-in-HEVs 20

and Pulse-charging EVs SCV REEV

10
SCV EV

3-W EV
2-W EV
0
0 10 20 30 40 50 60
Energy Capacity (kWhr) 19
 Batteries
Types of Battery Materials
• Batteries are classified based on electrochemistry
• Most common are Lithium, Lead and Nickel based
• Lithium based battery outperforms in Specific energy and power

©
Batteryuniversity.com
 Market Trends & Challenges in India

Sales figures: Three-wheeler segment

Segment FY20 FY21 % change • The 3W space is expected to be an early adopter of e-

mobility as a function of low TCO, particularly in Tier 2 and
Two-wheeler 152,000 143,837 -5 Tier 3 cities.
Three-wheeler 140,683 88,378 -37 • e3W cargos expected to do well based on interest shown by
Passenger vehicles 2,814 4,588 63 last mile delivery players –Amazon & Flipkart.
• Mahindra is a market leader in e3W –recently launched Treo
Zor
Two-wheeler segment Passenger Vehicles
• Demand expected to increase on last mile connectivity • Range anxiety and charging infrastructure remain key
• 25 OEMs retailing in India. Hero Electric, Okinawa, customer concerns –deterring a faster adoption.
Ampere, Ather & Revolt are the key High-speed players • Consumer preference towards high powered vehicles
• Low speed models comprised 72% of sales (Utility Vehicles)
• Shift seen towards advanced lithium-ion batteries, • Tata Nexon (64% of PV sales), MG ZS, Hyundai Kona and Tata
initiating growth in city-speed and high-speed categories Tigor are the top-selling models in the country.
• Ola expected to launch e2W later in 2021. • Tesla expected to launch model 3 later in 2021.
 E-mobility Ecosystem Development

Charging Infrastructure
Startups/ New entrants
• Ease of doing business • Technology Adoption
• Level playing field • Financial viability
• Collaborations with academic • New business model
• R&D Grants and funding • Payment and information

6 1
OEMs, Suppliers, Dealers
Favourable Regulations
• Socio economic impact E-mobility
• • Demand creation incentives/tax
Skill gap 5 Ecosystem 2 • State regulations
• Impact on local suppliers
• Technology transfer • Investment promotion policy
• Make in India

4 33
Availability of finance Customer Awareness
• Project financing • Economic rationale
• Angel/venture funding • Awareness campaigns
• Loans for manufacturing • Shared mobility and public transport
• Risk mitigation • Pilot projects
 E-mobility Ecosystem Development

In order to offer customers with greater options, OEMs have lined up new
launches across product segments & price categories
Govt Framework & Industry Localization
 Challenges Worldwide

Cost Anxiety Incentives

• It is true that one can save in running cost

by getting an EV.

• But the usage will define how much? A

person driving 40 km everyday will end up

saving a lot more than a person driving only

Maintenance &
3-5kms everyday. Service Charges
 Challenges Worldwide
Cost Anxiety:

• Purchasing a standard medium size EV is approx 40% more

expensive than a conventional ICE vehicle of similar size

• Total cost of ownership (TCO) for the first-time owner is higher

(life of 3-5 years).

• Scaling up the consumer adoption of BEVs in cars will require

policy support.

• Battery on lease to make 2W cost effective in India

 Challenges Worldwide

Weather Anxiety:

• Drastic differences in weather in various

places in India.

• It is very important for EV manufacturers

to consider the usage at such places.

Example: the rains in Mumbai, the heat

in Chennai, the cold in Ladakh

 Challenges Worldwide

Safety Anxiety:

• Explosion due to fire

• Short-circuit due to water penetration

• Failures due to construction quality

• Failures due to Functionality (Controller, Battery,

Motor, etc.)
 Challenges Worldwide

Range Anxiety

• Most Electric Vehicles have a driving range

between 150 kms to 250 kms.

• Range anxiety due to dynamic driving

conditions and battery efficiency.
• Incrementing driving range is related to the
battery energy capacity. This requires larger
battery packs.
• Aggressive research is being carried out to
alter battery chemistry and obtain high
energy density batteries in order to obtain
high driving range.
 Challenges Worldwide
Charging Anxiety:
• Another issue is the inadequacy of charging stations
across the cities and highways.
• Charging station network is unavailable which defers long
range driving.
• All these shortcomings have been addressed by various
methods like battery swapping, overhead wire charging
and solar charging units in all offices and buildings.
• Battery swapping network is being established worldwide
which enables replacing modular battery packs within
minutes. This helps to negate long charging times.
• Overhead wire charging has been implemented in
Germany and other European Countries to charge trucks
on the go.
• Solar charging systems like Tesla Powerwall has enabled
to harness solar energy and use it for charging vehicles.
 Challenges Worldwide
Charging Anxiety:
Addressing the charging woes will be the key for wider adoption of Electric Vehicles and customer trust

Charging Standards
• With respect to standards, the charging stations at home require no such standards.
They are used with a 230V 15A single phase plug.
• In the public EV charging station segment, Bharat EV Charger AC001 and DC001,
Chademo, CCS-2, Type 2 AC exist. The trend is however towards higher power delivering
setups.
 Challenges Worldwide

Manufacturing Anxiety: Electric Vehicle Supply Chain

One of the major speed bumps in India’s road to Electrification is the lack of availability and sustainable
supply chain of key elements required for Electric Vehicles.
Traditional Utilities /
Raw Material Battery
Supplies
Component
Manufacturers
OEMs Energy
Suppliers Infrastructure

• Setting up a strong network value chain of Electric Vehicle is possible if each step is
dealt judiciously by the Government of India and the commercial players.

• Each step involves multiple stakeholders who need to revamp their enterprise goals
so as to align with the demands of the sector to foster the ecosystem of Electric
Vehicles.

• India lags behind in manufacturing of semi-conductor devices, electric vehicle motors

and batteries.

• The energy sector should be revamped to sustain the grid loads with increased
demand for Electrical energy.
Electric vehicles available in India: E-cycles, 2W, 3W ,E-rickshaws, 4W and E-buses
Advanced Electric Vehicles in India
 Categories of Electric Vehicles in India

Off Road Vehicles….

Within campus…
Hospitals… Air ports…
universities…Resorts…

<250W Electric 2 W E-rickshaw/E-Cart 4W Passenger Vehicle (M1/N1

category)

Electric 2 W (L1/L2 E-auto (L5M & Heavy Vehicle (M2/ M3

category) L5N category) category)
Standards & Regulations of EV in India: Background
• The CMVR Technical Committee brought the BOVs under the purview of CMVR.

• A sub-committee was constituted for defining type approval procedure of BOVs,

in November 1999 comprising of members from ARAI, VRDE, ACMA, SIAM, etc.

• Automotive Industry Standards (AIS) related to type approval testing of BOVs

published in September 2003.

• Mandatory requirement from April,2005 vide SO 1365(E) dated 13 Dec 04

35
 Standards & Regulations of EV in India under CMVR
Standards for 2W, 3W, E-rickshaws, 4W and Buses
In-use gasoline/diesel vehicles
▪ Standards for Electric Vehicles can be retro-fitted with electric
▪ Standards for Hybrid Electric Vehicles kit to convert in pure electric
▪ Standards for Retro fitment
vehicle. This way older fleet can
Regulations
be converted (AIS 123)

For Retro
For OEM
fitment

Hybrid
Electric Charging
Electric
vehicles Stations
vehicles

36
 Standards & Regulations of EV in India
CMVR Homologation

Electric Traction Chargers Hybrid Vehicles Retro-fitment Others

Vehicles Battery AIS 138 AIS 102 Part 1 AIS 123 Part 1, AIS 131,
Part 1 & Part 2 and Part 2 Part 2 & Part 3 Low Speed 2
AIS 038, AIS039, AIS 048 IS 17017 Wheeler
AIS 040, GSR 291(E),
Bharat EV E-rickshaw/ E-cart
AIS 041, AIS048, Charger
AIS049 GSR 709 (E)/GSR
AC 001, DC001 2590(E)

All the standards are notified by Ministry of Road Transport & Highways (MoRTH) except EV Chargers.
G.S.R.: General Statutory Rules. S.O. Statutory Rules & Order.

37
 Standards & Regulations of EV in India
EV Safety (EVS) GTR – Circle of Safety
Water Wading

Electrical Safety for REESS

(Rechargable Energy Storage System)

EMC
Crash / Frontal Impact

45
 Standards & Regulations of EV in India
EV BATTERY TESTING AIS 048
Overall safety of battery systems:
• Chemical safety Automotive Industry
• Electric safety Standards: AIS 048 / 156
• Mechanical safety defines the safety
• Functional safety
requirements for traction
❑ Battery safety standards and regulations call for testing in
batteries used in Battery
abusive conditions. In these situations (e.g. overcharging, short
circuit, physical deformation in a vehicle crash), exothermic operated Vehicles.
reactions may be triggered (e.g. temperature rise of hundreds
of degrees within seconds) leading to thermal runaway.
❑ This can lead to the heating up of neighbouring cells within a
module, which–if sufficient heat is generated–can lead to a
chain reaction & propagation and in a worst case scenario,
develop into fire and explosion.
❑ Various tests are required like mechanical shock test, drop test,
vibration test, penetration test, immersion test, crush/crash
test, short circuit test, overcharge test, thermal stability test
and thermal shock test. Source: akinlaw.com 47
 CONCLUSION

Reference: AVL Keynote Presentation at ITEC 2021