Hand Book EV Engineering Fundamentals

Electric Vehicle Engineering Fundamentals
Handbook
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Confidential Document-Only for Intended User
About the Program
Skill gap is a major problem facing India now, and the problem just got
aggravated with the Covid-19 pandemic and the long lockdown. In the last few
years, trends suggest a rise in interest among the common masses for electric
vehicles. In coming time, there will be huge demand for Skilled Workforce in EV
Industry. In accordance with that, learning functionality of an EV is very essential
for an engineering student irrespective of his or her stream. Foundation for EVs –
this course covers all the major aspects, calculation and concepts with regards to
electric vehicles.
2
Automotive Industry 2020
Before COVID19
• Globally, the automotive industry has recovered from the economic crisis
(Automotive industry crisis of 2008–2010)
• Industry profits in 2012 (EUR 54 billion) were much higher than in 2007
(EUR 41 billion)
• By 2020, global profits could increase by another EUR 25 billion, to EUR 79

billion.
3

With COVID19

Key Challenges
• COVID Impact Recovery
• Complexity and cost pressure.
• Diverging markets.
• Digital demands.
• Shifting industry landscape

Automotive Industry India
• Annual turnover of $100 billion
• Employs 32 million people
• The two-wheeler industry in India is the largest in the world.
• India is also the largest tractor manufacturer
• The eight largest commercial vehicles manufacturer in the world.
• The automobile sector currently contributes about 50 per cent of the manufacturing gross domestic
product (GDP) in India
• 26 per cent of the industry GDP and 7.1 per cent of overall GDP
• The sector contributes approximately 13 per cent of excise revenue to the government.

Need of EVs
• Sustainable Future
• Reduce Pollution (CO2)
• Climate Change (Global Issue)
• Independent Approach
• Best operational Economics

Need of EVs
Cost Of Transportation As Constant = Rs. 5000
Nissan Leaf (121 km/24 kWh)
ICE vehicles the mileage is taken as 20 kmpl for both petrol and diesel.

Need of EVs
Transportation System
Modes Elements Impact
1. Air 1. Infrastructure 1. Economic
2. Rail 2. Vehicles 2. Planning
3. Road 3. Operation 3. Environment
4. Water 4. Policy
5. Cable
6. Pipeline
7. Space

E-mobility Roadmap
11
E-mobility Roadmap
Classification

E-mobility Roadmap
13
E-mobility Roadmap
14
E-mobility Roadmap

E-mobility Roadmap

E-mobility Roadmap

E-mobility Roadmap

E-mobility Roadmap

EV System and Subsystems
Gasoline Vehicle

Hybrid Vehicle

Hybrid Vehicle

Plug In Hybrid Vehicle

EV

Fuel Cell Vehicle

Hybridization

Hybridization

EV System & Subsystem



Weight, Power and Cost Analysis

Weight, Power and Cost Analysis
Weight Analysis CV

Cost Analysis CV & PHEV

Comparison of an EV with CV
34
E-Mobility in India
Government Supporting E-mobility Startups

Startups in EV ecosystem cheered by govt’s push for e-mobility in budget
Blueprint ready for 10 million e-mobility jobs

Government plans to create specialized workforce to support its e-mobility mission, which will generate new
jobs.
Niti Aayog’s E-mobility Plan

Only electric vehicles to be sold by 2030
Union Budget 2019

Electric Two-Wheeler Manufacturers Welcome Announcements
Future of Mobility in India
National Electric
Mobility Mission
Plan 2020
36
FAME India
(Faster Adoption and Manufacturing of Hybrid and Electric Vehicles)
Electric two wheelers: incentives will be provided for 10 lakh registered

electric two-wheelers of Rs 20,000 each.
e-rickshaws: incentives to 5 lakh e-rickshaws of Rs 50,000 each.
Electric four wheelers: An incentive of Rs 1.5 lakh each to 35,000 electric

four-wheelers with an ex-factory price of up to Rs 15 lakh.
Hybrid four wheelers: an incentive of Rs 13,000 each to 20,000 strong hybrid

four-wheelers with ex-factory price of up to Rs 15 lakh.
Phase I: April 1st 2015 -March 31st, 2019. e-buses: support to 7,090 e-buses with an incentive of up to Rs 50 lakh each
Phase II: April 1st 2019-March 31st, 2022 having an ex-factory price of up to Rs 2 crore.
37
Industry Associations
o Society of Manufacturers of Electric Vehicles (SMEV)

o Leadership in Energy and Environmental Design
o Society of Indian Automobile Manufacturers
38
Electrification Approach

GLOBAL EV MARKET
40
Global EV Market
41
Global EV Market
42
Indian EV Market

Indian EV Market
Top sales in India were from •Fuel saved in liters- 51451860

•Maharashtra with 36597 •Fuel-saving per day-52787
•Gujarat with 31577 •CO2 reduction per day-130819
•CO2 reduction in Kg-130819
•Uttar Pradesh with 28974
•Haryana with 25877
•Delhi with 20224
•Tamil Nadu with 17821
Electric Vehicles Sales Report in India till August 2019

Key Driving Factors for EV
• Stringent Emission Norms
• Fuel Economy Requirement
• High Specific Power Requirement
• High Torque back-up Need
• Low fuel consumption Need
• Improved NVH Requirement
• Enhanced Durability Presence
• High power to weight ratio Requirement

Electric Bicycle
•Elektron Cycles
•Hulikkal Electro India Pvt Ltd
•Ampere Vehicles
•BSA Motors
•Electrotherm
•Spero
•Hero Electric
•Pure EV

Electric Motor Cycle& Scooters
•Earth Energy EV •Tunwal E Vehicles private limited
•Twenty-Two Motors •BSA motors
•Ampere vehicles •BPG
•AVERA New and Renewable Energy Moto Corp •EKO
Tech Pvt Ltd •OK PLAY
•Okinawa Autotech Pvt. Ltd •Rexnamo
•Ather Energy Pvt Ltd •Thunder wind
•Heroelectric (Hero Motocorp) •Revolt Motors
•Yo-Bykes (ELECTROTHERM (INDIA) LTD.) •Tork Motors
•Lohia Auto Industries •Emflux Motors
•Palatino (Xxplore Automotive Pvt Ltd.)
•Tork Motors
•EMflux motors
•Ultraviolette Automotive

Electric Cars (Complete Electric)
•Hyundai Kona Electric
•Mahindra e-Verito
•Mahindra e2o
•MG ZS EV
•Tata Tigor EV
•Tata Nexon EV

Electric Cars (Hybrid)
•Toyota Prius
•Honda Accord Hybrid
•Toyota Camry
•MG Hector
•Suzuki Ciaz
•Suzuki Swift
•Suzuki Ertiga
•Mahindra Scorpio Intelli hybrid
•Toyota Camry Hybrid
•BMW i8

Electric Rickshaws
•CEEON INDIA
•Adapt Motors Pvt Ltd.
•Volta Motors
•Kinetic Green
•Gayam Motor Works
•REEP Industries - REEP Motors
•Mahindra electric
•Ampere Vehicles
•Go Green BOV
•OK play
•Atul Auto Ltd.

Mini Electric Pick-up Trucks
•Mahindra
•Tata Motors Ace Electric
•Ashok Leyland Dost Electric Pick-Up Truck
•ECOYAN
•Croyance Automotive, ELECTRO

Electric Boat
•NavAlt –Aditya

EV Ecosystem

EV Business Propositions
 Servicing Garage  Electric Car Washing

 Charging Station  Battery Swapping
 Painting & Spraying workshop  Battery Leasing
 Charging Station Management  Mobile EV Repair Services
 Electrical Workshop for EVs  Franchising/Reselling
 Home Charging Station Setup Service  Portable Charging Station
 Charging Station Setup Training Service  Solar Charging Station Installation Centre
 EV Rental Service  Online Shop for Electric Spare Parts
 Spare Parts Manufacturing  Online Shop for EV Reselling
 EV Manufacturing  Battery Scrapping
 EV Retrofitting  Last mile connectivity
 Spare Parts Selling  Finance Services
 EV Kits Service  Insurance Services
 EV Battery Shop  EV Skill Development
54
Servicing Garage

Charging Station

Charging Station Management

Painting & Spraying workshop

Electrical Workshop for EVs

Home Charging Station Setup Service

Charging Station Setup Training Service

EV Rental Service

Spare Parts Manufacturing

EV Manufacturing

EV Retrofitting

EV Battery Shop

EV Kits Service

Electric Car Washing

Battery Swapping

Battery Leasing

Mobile EV Repair Services

Portable Charging Station

Solar Charging Station Installation Centre

Online Shop for Electric Spare Parts

Online Shop for EV Reselling

Battery Scrapping

Last mile connectivity

Finance Services

Franchising/Reselling

Insurance Services

EV Skill Development

Supply Chain for EVs

Motor Battery and Controller



Traction Motors
Motors for Electric Vehicles
• Energy efficient
• Durable
• Compact

Traction Motors

Traction Motors

Traction Motors

Traction Motors

Motor Principle
Electrical Energy  Mechanical Energy
Stator
Motor
Rotor
Frame
AC DC
Shaft

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Principle
Flemings Left hand Rule
F
B

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Principle

Motor Types- AC and DC

Motor Types

Stator
Rotor
Stator
BDC
BLDC
Motor
Rotor Types
Commutator
Shaft
Brushes
Stator
DC Motor
PMDC Confidential Document-Only for Intended User
Single Phase Induction Synchronous Motor Motor
Types
AC Motor
Three Phase Induction Confidential Document-Only for Intended User
Motor Types
If the motor is a DC motor, then it may run on

anything from 96 to 192 volts.
If it is an AC motor, then it probably is a three-

phase AC motor running at 240 volts AC with a
300 volt battery pack
Induction: ~91%
Brush DC: ~80%
BLDC: ~93%

Motor Selection
• Motor Type (AC/DC)
• Power
• Voltage
• Cost
• Size
• Performance

Calculation for Motor Power
Mass (M): Total Mass of Vehicle (Inclusive of Driver, Body, Frame or Chassis, Power Train & Other Components) that has to
be driven by an electric motor of an EV. A typical car may require more than 770 kilograms of steel, 180 kilograms of iron,
110 kilograms of plastics, 80 kilograms of aluminum, and 60 kilograms of rubber, as well as, less significant amounts of
different materials. The total mass of an average car may be about 1500 kilograms. Addition of 400 Kg Passenger Weight &
100 Kg Luggage will give total considerable weight for motor as 2000 Kg
Gear Ratio (G): Gear ratio is simply the leverage that you have in a set of gears. It is the ratio of an output to the input. It can
be represented in usually 3 parameters: number of teeth (size of gear), force (torque), and velocity (rpm). Major use of
gears is to transmit torque or to enhance torque. Geared devices can change the speed, torque, and direction of a power
source. Gears almost always produce a change in torque, creating a mechanical advantage, through their gear ratio, and
thus may be considered a simple machine.
Transmission Efficiency: It is the ratio of the power received over a transmission path to the power transmitted. Simply it can
be defined as the ratio of the output to the input power of a system.
Coefficient of Rolling Resistance (Crr): The coefficient of rolling friction is the indication of how great the rolling resistance is
for a given normal force between the wheel and the surface upon which it is rolling. This ratio is based on the Standard
Friction Equation.

Calculation for Motor Power
Vehicle Frontal Area (Af): It is frontal area of vehicle which is exposed to aerodynamic drag For automobiles and many other
objects, Vehicle Frontal Area is the projected frontal area of the vehicle. .
Wheel Radius (Rw): The radius of a wheel measured from center to tread.
Velocity (V): Velocity at which user want to drive the vehicle.
Gradient (α): Gradient is an inclined part of a road or railway; a slope. It is Measured in terms of degree of inclination.
Vehicle's Drag Coefficient (Cd): In fluid dynamics, the drag coefficient is a dimensionless quantity that is used to quantify
the drag or resistance of an object in a fluid environment, such as air or water. It is used in the drag equation in which a
lower drag coefficient indicates the object will have less aerodynamic or hydrodynamic drag. The drag coefficient is always
associated with a particular surface area

Input Values
Mass in kg M Kg
Gear Ratio G No Unit
Transmission Efficiency η %
Coefficient of rolling resistance Crr No Unit
Acceleration due to gravity g m/s2
Vehicle's drag coefficient Cd No Unit
Vehicle frontal area Af m^2
Density of air ρ kg/m^3
Wheel Radius Rw m
Velocity, V Kmph
Gradient, α Degree
Motor Calculations
Fr [N]=M*Crr*g
Prolling [kW]= V*Fr/3600
Fgrad. [N]=M*g*Sin (α)
Pgrad. [kW]= V*Fgrad/3600
Faerodrag [N]= 0.5*Cd*Af*ρ*(V/3.6)^2
Perodrag [kW]= V*Faerodrag/3600
P Total [kw]= Prolling + Pgrad.+ Paerodrag
P Total with Eff.= Ptotal/η

Motor Calculations
Electric Bicycle

Motor Calculations
Bicycle Assembly 8
Motor and Gear 4
Power control 1
Battery 6
Cyclist 80
Auxiliary 1
Total weight 100

Motor Calculations
Drive System
• FWD 75 25
• RWD

Motor Calculations
Fp
Fd=mgsinx
mgcosx
x mg
Ff

Motor Calculations
Mass in kg M 100 Kg
Gear Ratio 6 No Unit
Transmission Efficiency 90 %
Coefficient of rolling resistance Crr 0.016 No Unit
Acceleration due to gravity g 9.81 m/s2
Vehicle's drag coefficient Cd 0.46 No Unit
Vehicle frontal area Af 0.5 m^2
Density of air ρ 1.225 kg/m^3
rw is the wheel radius 0.3 m
Velocity, V 25 Kmph
Gradient, α 1 Deg

Motor Calculations
ROLLING RESISTANCE
Frolling Crr*M*g 15.696 N
Prolling Frolling*V/3600 0.109 kW

Motor Calculations
GRADIENT RESISTANCE
Fgradient 17.120
resistance M*g*sin α 81 N
Pgradient
resistance Fgredient*V/3600 0.119 kW

Motor Calculations
AERODYNAMIC DRAG
Faerodynamic drag 0.5*Cd*Af*ρ*(V/3.6)^2 6.79374 N
Paerodynamic drag Faerodynamic*V/3600 0.047 kW

Motor Calculations
Prolling + Pgradient resistance +

Pt Paerodynamic drag 0.275
P total
with
overall
efficien
cy FT v / η 0.31

Motor RPM and Torque Estimation
Vehicle Speed [rpm]=(V*9.5493)/(3.6*Rw)
Traction Torque= P Total*1000*Rw*3.6/V
Shaft Speed [rpm]=(V*G*9.5493)/(3.6*Rw)
Load Torque= Traction Torque*G/η

Motor RPM and Torque Estimation
Motor Speed [rpm]=(V*9.5493)/(3.6*Rw)= 221 rpm
Traction Torque= P Total*1000*Rw*3.6/V= 11.88 Nm
Shaft Speed [rpm]=(V*G*9.5493)/(3.6*Rw)= 1326 rpm
Load Torque= Traction Torque*G/η=79.2 Nm

Motor Wiring Diagram
250 W
r Wiring
V=12 V I=20 A
V=24 V I=10 A
V=36V I=7 A
V=48 V I=5 A



Motor Design and Simulation Method
MATLAB is a multi-paradigm numerical computing environment and
proprietary programming language developed by MathWorks.
MATLAB allows matrix manipulations, plotting of functions and data,
implementation of algorithms, creation of user interfaces, and
interfacing with programs written in other languages




Performance Analysis of Motor

Controller for Motor
Manual Starting
Motor Controller
Manual Stopping to govern in some
Automatic Starting predetermined manner
the performance of an
Automatic Stopping
electric motor.
Selecting forward rotation
Selecting reverse rotation
Selecting Speed
Regulating speed
Regulating torque
Limiting torque
Protecting against overloads Confidential Document-Only for Intended User








Controller Selection
There are two basic types of controllers: electronic and

electromechanical.
•Electronic units are very sophisticated and include features such

as soft starting and variable frequency drives. Electronic units can be
programmed to respond to system inputs and pre-set running
conditions.
•Electromechanical units make use of electromagnetic contractors

or relays to stop, start, and reverse the motor's direction.

 Brushed motors commutation with physical  Linear motors generate force in only the direction
contacts. of travel. Common technologies include moving coil
 Brushless motors do not use physical and moving magnet designs.
contacts.  Many types of stepper motors use motor
 Induction motors induce current into the rotor controllers
windings without any physical connection to the  Full-step motors
stator windings.  Half-step motors
 Synchronous motors are non-slip devices that  Mini-motors
operate at constant speed up to full load. They  Micro-motors
include both reluctance motors  Unipolar stepper motors
and servomotors.  Bipolar stepper motors
 Pole changing motors (PCM) use pole  Pneumatic motion control systems
number control, a method for changing the  Hydraulic motion control systems
number of poles on the primary winding.
 Vector drive motors provide independent
control of both the voltage and frequency. In
some designs, encoders or resolvers are used
to provide feedback about position and speed.
•Maximum output voltage is the voltage that the device outputs. This output must match the
system's processes.
•Rated power is the maximum power to be used with the motor.
•Continuous output current is the term used to describe the current which a device will carry
continuously in air without exceeding temperature limits.
•Peak output current is the capacity current output for a short period of time
•AC supply voltage is the range of AC input voltage that will operate the drive or controller.
•DC supply voltage is the range of DC input voltage that will operate the drive or controller.

•Motor controllers use either 50, 60, or 400 Hz AC input frequency. Input frequency is the
frequency the controller will accept from the motor.
• Single-phase inputs are used for lower voltage applications and is the more
common phrase.
• Three-phase inputs are used for higher voltage applications. They can be used to
overcome high starting loads by starting the motor with higher torque. When the
initial inertial load is overcome, they switch to a more efficient low-torque delta
configuration.
•Computer-based motor controllers use many different types of buses and

communication standards.
• Bus types include advanced technology attachment (ATA), peripheral component
interconnect (PCI), integrated drive electronics (IDE), industry standard architecture
(ISA), general-purpose interface bus (GPIB), universal serial bus (USB), and
VersaModule Eurocard bus (VMEbus).
• Communications standards include ARCNET, AS-i, Beckhoff I/O, CANbus,
CANopen, DeviceNet, Ethernet, small computer systems interface (SCSI), and
smart distributed system (SDS). Many serial and parallel interfaces are also
available.
•Setup and control
• Manual controls such as

• Knobs
• DIP switches
• Jumpers
• Potentiometers
• Computer controlled or aided, including
• Joystick
• Digital control panel
• Computer interface
• Slots for PCMCIA cards

•Control programs are stored on removable, nonvolatile storage media.
•Hand held devices are designed to be programmed remotely.
•Wireless and web-enabled controls are also available.
•Configurations for motor controllers include several mounting styles. Most devices mount on a
• Chassis
• DIN rail
• Panel
• Rack
• Wall
• Printed circuit board (PCB)
• Standalone devices
• Integrated circuit (IC) chips that mount on PCBs

Controller Functionality
•Soft start is controlled circuitry, which allows the motor to ramp up to full speed over time. This is
often a safety feature for motors moving large or delicate loads, and as a preventive measure for
excessive current draw.
•Braking
o Dynamic braking is the method of the braking in which the power supply is disconnected from
the motor windings. The motor then essentially becomes a generator and the power (heat) is
dissipated through a resistor shunt across the windings.
o Injection braking is applicable to AC motors only. The AC power is disconnected and the DC
power is "injected" into the windings. This creates a magnetic field opposing the motor rotation
and slowing or stopping the motor.
o Regenerative braking is similar to dynamic braking. The motor is removed from the power and
the power generated from the rotating motor is sent back to the supply. The generated power
can be used to recharge a battery that supplies the power to the system.

•Brake output is a switch or relay designed to activate or control an external brake
•Home/limit switch inputs are used to indicate start, stop, or end-of-travel positions of the associated axes.
•Auxiliary input/output channels can be included for communications with or feedback from the device
•Status monitoring functions include an alarm and monitor one or more parameters. In the case of a fault or non-
compliant operation, such as overvoltage, overcurrent, overspeed production, and temperature changes, a signal
will be generated to alert the operator.
•Self-configuration or auto-tuning devices will detect operating conditions and automatically adjust its setting for
optimal system performance.
•Self-diagnosing motor speed controllers can detect system problems and report the problem to the operator or
control system.
•Electric vehicle design is used for control of electric motors in industrial, recreational, or other electric vehicles.
Many include application-specific features such as reverse alarm output, signal for speedometers and
tachometers.
•Soft start is controlled circuitry, which allows the motor to ramp up to full speed over time. This is
often a safety feature for motors moving large or delicate loads, and as a preventive measure for
excessive current draw.
•Braking
o Dynamic braking is the method of the braking in which the power supply is disconnected from
the motor windings. The motor then essentially becomes a generator and the power (heat) is
dissipated through a resistor shunt across the windings.
o Injection braking is applicable to AC motors only. The AC power is disconnected and the DC
power is "injected" into the windings. This creates a magnetic field opposing the motor rotation
and slowing or stopping the motor.
o Regenerative braking is similar to dynamic braking. The motor is removed from the power and
the power generated from the rotating motor is sent back to the supply. The generated power
can be used to recharge a battery that supplies the power to the system.

Controller Design and Development Method



Controller Wiring Diagram

Converters used in EVs Energy Storage
System
DC-DC converters can be used to interface the elements
in the electric power train by boosting or chopping the
voltage levels. Due to the automotive constraints, the
power converter structure has to be reliable, lightweight,
small volume, with high efficiency, low electromagnetic
interference and low current/voltage ripple.
Step Up
Step Down
Unidirectional
Bi-Directional Confidential Document-Only for Intended User
System

Non-isolated converters
System
The non-isolated converters type is generally used where the
voltage needs to be stepped up or down by a relatively small ratio
(less than 4:1).
No dielectric isolation.
• Buck
• Boost
• buck-boost
• Cuk
• Charge-pump converters

Isolated Converters System
High frequency transformer is used.
Output needs to be completely isolated from the input

Half-Bridge
Full-Bridge
Fly-back
Forward Push-Pull
All of these converters can be used as bi-directional converters
Ratio of stepping down or stepping up the voltage is high.

System
•Light weight,
•High efficiency,
•Small volume,
•Low electromagnetic interference,
•Low current ripple drawn from the Fuel Cell or the battery,
•The step up function of the converter,
•Control of the DC/DC converter power flow subject to the wide
voltage variation on the converter input.

Battery Chemistries
Battery Traction Battery/BEV/EVB
High power-to-weight ratio Nickel–

Lead–acid Ni-Cd Metal
High energy-to-weight ratio Hydride
High energy density Li-ion

Zinc Air Lithium-ion
polymer
Electrical Energy  Chemical Energy Charging
Molten Salt
Chemical Energy  Electrical Energy Discharging
Battery Chemistries

Battery Chemistries
Common
Cheapest
Pb(s) + PbO2(s) + 2H2SO4(aq) → 2PbSO4(s) + 2H2O(l)

Easy Availability
Electrical Energy  Chemical Energy Charging
Chemical Energy  Electrical Energy Discharging
Short Life Period
Shouldn’t be discharged below 50% of its capacity
Environmental Impact Confidential Document-Only for Intended User

Last up to five years from the date of manufacture
Battery Chemistries
Li-Ion Battery SOH SOC
•Internal resistance / impedance / •The battery voltage
conductance translation
High Energy Density Expensive •The battery current integration •The battery current
•Capacity integration
standard for modern battery electric vehicles

•Voltage
High Power Density Explosive •Self Discharge
•Number of C/D Cycle
High C/D Efficiency •Charge Acceptance
Battery performance testing includes the determination of

•State Of Charge (SOC)
•State of Health (SOH)
•Energy Efficiency

Battery Chemistries
Nickel Metal Hydride Battery ( Ni–MH )
Less Efficiency in Charging and Discharging
High self-discharge Poor performance
Less ideal for hotter environments High Energy Density
Molten Salt Battery
Zebra Battery
NaAlCl4
Hot salt
Molten Chloro-aluminate sodium Confidential Document-Only for Intended User

Battery Selection
Battery Chemistry
Battery Voltage
Battery Capacity
C-Rating
Battery Power
Charging Efficiency
Discharging Efficiency
BMS Confidential Document-Only for Intended User

Battery Capacity Calculations
The results show that in city driving conditions, the average
electrical consumption is:
33 Wh/km for the scooter
61 Wh/km for the 3-wheeler
84 Wh/km for the low power 4-wheeler,
123 Wh/km for the high power 4-wheeler.
For highway driving conditions, the average electrical consumption is:
133 Wh/km for the low power 4-wheeler, and 165 Wh/km for the high power
4-wheeler.
Battery Capacity Calculations
Motor Power = Pm (W)= 250 W
Motor Voltage = Vm (V)= 36 V
Battery Voltage = Vb (V)= 36 V
Vehicle Speed = V (kmph)= 25
kmph
Range = R (km)= 30 km
Battery Capacity (Ah) = P*R/Vb*V=

250*30/36*25=8.33 Ah

Battery Range Calculation
Motor Power = Pm (W)=250 W
Motor Voltage = Vm (V)= 36 V
Battery Voltage = Vb (V)=36 V
Vehicle Speed = V (kmph)= 25 kmph
Battery Capacity = C (Ah)= 14 Ah
Range = C*V*Vb/P= 14*25*36/250=50.4 km

Charging
time for
Power Max.
Battery Charging 100 km

of BEV
range
supply
Power Voltage
current
Conductive Coupling 6–8 hours Single phase 3.3 kW 230 V AC 16 A

3–4 hours Single phase 7.4 kW 230 V AC 32 A
Power Source Power Grid 2–3 hours Three phase 11 kW 400 V AC 16 A
Inductive Coupling
1–2 hours Three phase 22 kW 400 V AC 32 A
20–30
Charging Time [h] = Battery Capacity [kWh] / Charging Power [kW] minutes
Three phase 43 kW 400 V AC 63 A
20–30 Direct 400–500 V

50 kW 100–125 A
minutes current DC
Direct 300–500 V
10 minutes 120 kW 300–350 A
current DC

Comparison of Battery Chemistries

Comparison of Battery Chemistries

C Rating of Battery
A C-rate of 1C is also known as a one-hour discharge; 0.5C or C/2 is a two-

hour discharge and 0.2C or C/5 is a 5-hour discharge
Charge and discharge rates of a battery are governed by C-rates. The

capacity of a battery is commonly rated at 1C, meaning that a fully charged
battery rated at 1Ah should provide 1A for one hour. The same battery
discharging at 0.5C should provide 500mA for two hours, and at 2C it
delivers 2A for 30 minutes. Losses at fast discharges reduce the discharge
time and these losses also affect charge times.

50 amp hours Battery 10 amp charger 6 hours to recharge
Amp hour rating of the battery divide by the charger rating

(amps) and then add about 10% for the extra time to totally top
off the battery.
3-stage mode charging
First stage ( constant current ) : The charger will supply constant current for the battery
Second stage ( constant voltage ) : The voltage will be rising under the first stage, when it reach constant voltage
value, it will turn into the second stage. The current will be slowly smaller until it reduce to floating value , the CV
stage will end.
Third stage ( Floating charging ) : When the current is approaching the value of transition, the charger will cut
down to the given current gradually, that means the battery power is full and indicator light turn to green. At this
moment, the battery can be stopped charging or keep on trickle current charging for half an hour.

Charger Connectors

Charger Connectors

BMS- Principle, Function and Significance
Battery Management System (BMS) Balancing Smart Battery Pack.

Safe Operating Area Operation
Battery Pack External Communication Data Bus
State Monitoring
Data Reporting
Secondary Data Calculation

 Voltage: total voltage, voltages of individual cells, minimum and maximum cell voltage or voltage of periodic
taps
 Temperature: average temperature, coolant intake temperature, coolant output temperature, or temperatures
of individual cells
 State of charge (SOC) or depth of discharge (DOD), to indicate the charge level of the battery
 State of Power (SOP), the amount of power available for a defined time interval given the current power
usage, temperature and other conditions
 State of health (SOH), a variously-defined measurement of the remaining capacity of the battery as % of the
original capacity
 Current: current in or out of the batter
 Coolant flow: for air or fluid cooled batteries

The BMS will also control the recharging of the battery by redirecting the recovered energy
 Energy [kWh] delivered since last charge or charge cycle
 Charge [Ah] delivered or stored (sometimes this feature is called Coulomb counter)
 Internal impedance of a cell (to determine open circuit voltage)
 Maximum discharge current as a discharge current limit (DCL)
 Maximum charge current as a charge current limit (CCL)
 Total energy delivered since first use  Total number of cycles
 Total operating time since first use Confidential Document-Only for Intended User
Battery Management System (BMS) Communication

External Communication Internal Communications Battery Management System
(BMS)
Serial Communications •Isolated serial communications
Topologies
CAN Bus Communication •wireless serial communications
•Centralized •Distributed •Modular
Wireless Communication
DC-BUS Communication
Battery Management System (BMS) Load Battery Management System (BMS) Optimization
Battery ----- BMS ----- Pre-Charge ------- Load Battery Balancing --------------------- Battery Optimization
BMS- Circuit Design and Simulation Method




BMS Integration

Telematics for EVs

Telematics for EVs
eCall is a European initiative intended to bring rapid assistance to

motorists involved in a collision anywhere in the European Union. eCall
was made mandatory in all new cars sold within the EU from April 2018
The eCall initiative aims to deploy a device installed in all vehicles that
will automatically dial 112 in the event of a serious road accident,
and wirelessly send airbag deployment and impact sensor information, as
well as GPS or Galileo coordinates to local emergency agencies.

Telematics for EVs
Over-the-Air programming (OTA) refers to various

methods of distributing new software, configuration
settings, and even updating encryption keys to
devices like mobile phones, set-top boxes or secure
voice communication equipment

Telematics for EVs
Cellular vehicle-to-everything (C-V2X) will serve as the foundation

for vehicles to communicate with each other and everything around
them—providing 360º non-line-of-sight awareness and a higher
level of predictability for enhanced road safety and autonomous
driving.

EV Testing
• High Speed Emotor Dyno Testing
• EV Axle Module Testing
• Transmission Testing
• Powertrain Testing
• Charging Testing
• Coolant Testing
• Whole Vehicle Fleet Testing

Safety Measures
ELECTRICAL SAFETY MEASURES FUNCTIONAL SYSTEM SAFETY
 Electrical system safety  Brake Over Travel Switch

 Functional system safety  Kill Switch
 Energy Storage System safety  Controller
 Vehicle maintenance and operation
PROTECTION AGAINST DIRECT ELECTRIC SHOCK PROTECTION AGAINST INDIRECT ELECTRIC SHOCK
 Lugs  Fuse
 Wire Housing  Wire Tubes
 Heat Shrink Tubes  Ground Wiring
ENERGY STORAGE SYSTEM SAFETY VEHICLE MAINTAINANCE
 Battery Indicator  First Level

 Battery Box  Second Level
 Precharge  Third Level
 Battery Management System Confidential Document-Only for Intended User
Thank You
This document is intended only for the use of the individual or entity to which it
is addressed and may contain information that is non-public, proprietary,
privileged, confidential, and exempt from disclosure under applicable law or may
constitute as attorney work product. If you are not the intended recipient, you
are hereby notified that any use, dissemination, distribution, or copying of this
communication is strictly prohibited.

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Electric Vehicle Engineering Fundamentals

• By 2020, global profits could increase by another EUR 25 billion, to EUR 79

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• Complexity and cost pressure.

• Shifting industry landscape

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• Reduce Pollution (CO2)

• Climate Change (Global Issue)

• Best operational Economics

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Government Supporting E-mobility Startups

Blueprint ready for 10 million e-mobility jobs

Niti Aayog’s E-mobility Plan

Union Budget 2019

Electric two wheelers: incentives will be provided for 10 lakh registered

e-rickshaws: incentives to 5 lakh e-rickshaws of Rs 50,000 each.

Electric four wheelers: An incentive of Rs 1.5 lakh each to 35,000 electric

Hybrid four wheelers: an incentive of Rs 13,000 each to 20,000 strong hybrid

o Society of Manufacturers of Electric Vehicles (SMEV)

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Top sales in India were from •Fuel saved in liters- 51451860

Electric Vehicles Sales Report in India till August 2019

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 Servicing Garage  Electric Car Washing

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Faerodrag [N]= 0.5CdAfρ(V/3.6)^2