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The completion of this project was subject to several coincidences at various stages. These
were the luckiest of moment form a sequence of beautiful notes in life, definitely struck by the
divine musician himself. So we thank God for gifting us with project so challenging and
fulfilling. Whatever may have been His motive, for us, it was a learning process and we have
grown in both human values and technical knowledge through the implementation of this
project. At every stage of this project this support kept us from falling back from our duty. Each
time we faced a setback, he patiently guided us forward. There is no way that we could
completely express our gratitude to him and we will always be indebted for everything he has
done for us.
We express our gratitude to Mr. Abdul Hameed .CP ( Principal Of Ma’din Polytechnic
College Malappuram).
We are very thankful for the huge contribution to our friends and family, who offered we all
kind of supports for this project
ABSTRACT
The structure of a four-wheeler electric vehicle (EV) typically comprises a chassis, which serves as
the framework supporting all components. The chassis often integrates lightweight materials, such
as aluminum or composite alloys, to enhance efficiency and range. The power train includes an
electric motor, controller, and battery pack. The motor generates propulsion, while the controller
regulates power distribution. Lithium-ion batteries are commonly employed for their energy density.
Suspension systems, consisting of shock absorbers and springs, contribute to ride comfort and
stability. Braking systems, often featuring regenerative braking to recover energy, ensure safe
deceleration. The steering mechanism facilitates directional control, and tires play a crucial role in
traction and handling. Advanced safety features like ABS and electronic stability control are
integrated for enhanced safety.
The body of the EV is designed to minimize aerodynamic drag, optimizing energy efficiency.
Additionally, the inclusion of smart electronics, sensors, and connectivity features enhances user
experience and enables data-driven functionalities. Overall, the structure of a four-wheeler EV
reflects a blend of lightweight materials, electric propulsion components, and advanced technologies
aimed at achieving sustainable and efficient mobility.
CONTENTS
1 INTRODUCTION 1
INDIA 20
11 CONCLUSION 28
12 REFERENCE 29
FIGURE NO: FIGURE NAME: PAGE NO:
4.1 EV COMPONENTS 4
4.4 CONTROLLER 7
4.8 THROTTLE 13
10.1 STAGE 1 24
10.2 STAGE 2 24
10.3 STAGE 3 24
10.4 STAGE 4 24
10.5 STAGE 5 25
10.6 STAGE 6 25
10.7 STAGE 7 25
10.8 STAGE 8 25
10.9 STAGE 9 26
10.10 STAGE 10 26
10.11 STAGE 11 26
10.12 STAGE 12 26
10.13 STAGE 13 27
10.14 STAGE 14 27
During the last few decades, environmental impact of the petroleum-based transportation infrastructure,
along with the peak oil, has led to renewed interest in an electric transportation infrastructure. Electric vehicles
differ from fossil fuel-powered vehicles in that the electricity they consume can be generated from a wide
range of sources, including fossil fuels, nuclear power, and renewable sources such as tidal power, solar power,
and wind power or any combination of those.
An electric vehicle (EV), also referred to as an electric drive vehicle, uses one or more electric motors or
traction motors for propulsion. Three main types of electric vehicles exist, those that are directly powered
from an external power station, those that are powered by stored electricity originally from an external power
source, and those that are powered by an on-board electrical generator, such as an internal combustion engine
(a hybrid electric vehicle) or a hydrogen fuel cell. Electric vehicles include electric cars, electric trains, electric
lorries, electric aeroplanes, electric boats, electric motorcycles and scooters and electric spacecraft. Proposals
exist for electric tanks, diesel submarines operating on battery power are, for the duration of the battery run,
electric submarines, and some of the lighter UAVs are electrically- powered.
Electric vehicles first came into existence in the mid-19th century, when electricity was among the preferred
methods for motor vehicle propulsion, providing a level of comfort and ease of operation that could not be
achieved by the gasoline cars of the time. The internal combustion engine (ICE) is the dominant propulsion
method for motor vehicles but electric power has remained commonplace in other vehicle types, such as trains
and smaller vehicles of all types.
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2.WHAT ARE ELECTRIC VEHICLES?
Electric vehicles are the alternative mode of transport that run on electricity instead of petrol, diesel, or
gasoline. EVs use a large battery to store electrical energy, which powers the electric motor to propel the
vehicle. In simpler terms, an electric vehicle is like a conventional car but it runs on a really big rechargeable
battery.
Instead of going to a filling station to fill up with fuel, electric vehicles are charged by plugging them into
an electric outlet or an EV charging station.
Currently, in 2023, most electric vehicles come with lithium-ion batteries having a strong battery management
system for controlling their charging and discharging.
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3.TYPES OF ELECTRIC VEHICLES
Battery Electric vehicles are fully electric vehicles that run only on electricity. BEVs are powered by large
Lithium-Ion battery packs which store electrical energy, used as an alternative to fuel.
Plug-in Hybrid Electric Vehicle (PHEV) combines the benefit of both the electric and conventional ICE.
They offer extended driving ranges compared to fully electric vehicles, as they can switch to their internal
combustion engines when the EV battery is depleted.
Hybrid Electric Vehicles combine the use of an internal combustion engine with an electric motor. However,
unlike PHEVs, Hybrid electric vehicles cannot be charged externally in charging stations. Instead, they
utilize the regenerative braking feature and the internal combustion engine to charge the battery.
Fuel Cell Electric Vehicles use hydrogen fuel cells to generate electricity, which powers the electric motor.
One of the main advantages of FCEVs is their quick refueling time
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4.ELECTRIC VECHILE COMPONENTS
4.1 COMPONENTS
The components used in this project are BLDC motor , controller unit, sealed batteries, ignition switch,
accelerator , charging circuit
The motor converts electrical energy into mechanical energy to drive the wheels and propel the car.
Motors vary hugely, some runoff direct current (DC), some off alternating current (AC). The most
common motors for electric vehicle conversions are AC due to them being more efficient. A motor is
effectively a large electromagnet that turns due to the attraction and repulsion of the magnets within.
Electric motors vary in size and power. For example, a motor that could be mounted in an average classic
car would be around 120 horsepower, whereas a Tesla large drive unit can generate upwards of 500
horsepower if required.
The motor turns the transmission (gearbox),
Which can be either the original one or a single speed unit specifically designed for electric power. Using
the original gearbox lowers the cost of converting a classic car to electric power as there is little
fabrication of new drivetrain components and only adapter plates are required.
However, if using a tesla drive unit, for example, this has to be mounted across an axle and therefore
needs custom half-shafts, differentials, and drive trains – significantly increasing cost.
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4.3 BRUSHLESS DC MOTOR
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4.5 EXPLODED VIEW OF BRUSHLESS MOTOR
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4.6 Controllers
FIG.4.4 : CONTROLLER
The electric vehicle controller is the electronics package that operates between the batteries and
The motor to control the electric vehicle‘s speed and acceleration much like a carburetor does in A gasoline-
powered vehicle. The controller transforms the battery’s direct current into alternating current (for AC motors
only) and regulates the energy flow from the battery. Unlike The carburetor, the controller will also reverse
the motor rotation (so the vehicle can go in Reverse), and convert the motor to a generator (so that the kinetic
energy of motion can be used To recharge the battery when the brake is applied).In the early electric vehicles
with DC motors, a simple variable-resistor-type controller controlled the acceleration and speed of the vehicle.
With this type of controller, full current and power was drawn from the battery all of the time. At slow speeds,
when full power was not needed, a high resistance was used to reduce the current to the motor. With this type
of system, a large percentage of the energy from the battery was wasted as An energy loss in the resistor. The
only time that all of the available power was used was at high speeds. Modern controllers adjust speed and
acceleration by an electronic process calledpulse width modulation. Switching device such as silicone-
controlled rectifiers rapidly interrupt (turn on and turn off) the electricity flow to the motor. High power (high
speed and/or acceleration) is achieved when the intervals (when the current is turned off) are short. Low power
(low speed and/or acceleration) occurs when the intervals are lon
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4.8 LITHIUM IRON PHOSPHATE BATTERY
48 v 24 AH Lithium phosphate battery is a type of rechargeable battery that uses lithium iron phosphate
(lifepo4) as the cathode material. It is also commonly referred to as LFP battery. Lithium phosphate
batteries are known for their safety, long cycle life ,and high energy density. They have a higher thermal
and chemical stability compared to other lithium-ion batteries , making them less proneto over heating
,explosion, and fire hazards.
These batteries are used in a wide range of applications , such as electric vehicles , power tools , solar
power storage, and backup power systems. They are also becoming increasingly popular in the
renewable energy sector due to their ability to store large amounts of energy from solar panels and wind
turbines.
Overall, lithium phosphate batteries are a promising and reliable technology that offers many benefits
over other battery chemistries.
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4.9 LIFE PO4 BATTERY ADVANTAGES AND DISADVANTAGES
Lithium phosphate batteries (lifepo4) are a type of rechargeable battery that have gained popularity in
recent years due to their superior performance compared to other types of batteries .Here are some
advantages and disadvantages of lithium phosphate batteries:
Advantages:
Safety :Lithium phosphate batteries are considered saferth another types of lithium-ion batteries
due to their stable chemistry and lower risk of the rmalruna way.
High cycle life: Lithium phosphate batteries can last for up to 2000 cycles, which is
significantly higher than other types of lithium- ion batteries.
High discharge rate: Lithium phosphate batteries have a high discharge rate, making them
suitable for high-power applications like electric vehicles.
Low self-discharge rate: Lithium phosphate batteries have a low self-discharge rate,which
means they can hold their charge for a long time without needing to be recharged.
Environmentally friendly :Lithium phosphate batteries are non-toxic and do not contain harmful
chemicals, making them more environmentally friendly than other types of batteries.
Disadvantages:
Low energy density : Lithium phosphate batteries have a lower energy density compared to
other types of lithium-ion batteries, which means they may not be suitable for applications
where a high energy density is required.
High cost: Lithium phosphate batteries are generally more expensive than other types of
lithium-ion batteries, which may make them less affordable for some applications.
Limited availability: Lithium phosphate batteries are not as widely available as other types of
lithium-ion batteries, which may limit their use in certain applications.
Lower voltage: Lithium phosphate batteries have a lower voltage compared to other types of
lithium-ion batteries, which means they may not be suitable for applications that require a high
voltage.
Overall, lithium phosphate batteries have several advantages that make them suitable for a variety of
applications, but they also have some limitations that may make them less suitable for certain uses.
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4.10 LCD DIGITAL DISPLAY UNIT
A display on an e-bike serves an essential purpose. While the motor is the component that
distinguishes an electric bicycle the most, the e-bike screen is the extra functionality that
highlights the benefits of the inbuilt technology that sets the electric bicycle apart from
conventional bikes. The readings of all the vital metrics you must be mindful of when riding
are tracked by the e-bike display.
The display has become an indispensable tool for all e-bike commuters in the past few decades.
Any electric bike now needs this screen, which in many forms serves the same purpose as a
vehicle's speedometer. The reason for this is simple: the e-bike display not only provides an
overview of all riding data at all times but can also check the functionality of your electric bike.
The explanation for this is straightforward: the electric bike's display not only provides a
summary of all riding data every time but can also analyze the effectiveness of your electric
bike. One benefit of e-bike screens is that they let you monitor your effectiveness and make
adjustments as necessary. Most people only have experience with e-bike speedometers. The
electricity meter, which shows the wattage in real-time, the pedal support, battery status, USB
connectivity, and other functions are a few of the additional features. If you are unaware of the
functionalities it provides and the importance of the data it reveals, a display is of no use. It is
therefore important that you are knowledgeable about the display features.
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4.11 SPECIFICATION DETAILS OF DIGITAL DISPLAY
This display is use full for any electric vehicle which works with 48v /60v /72v
accuracy is high and good quality of lcd,
Size : 155*82.55mmwire
lenght :50 cm
color : black
Material : plastic
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4.12 IGNITION SWITCH
An ignition switch is a switch in the control system of IC engine motor vehicle that activates
the main electrical systems for the vehicle. It also usually switches on power to many
accessories. The ignition switch usually requires a key be inserted that works a lock built into
the switch mechanism. It is frequently combined with the starter switch which activates the
starter motor. It may be bypassed by disconnecting the wiring to the switch and manipulating
it directly. This is known as hot wiring.
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4.13 THROTTLE
FIG.4.8 : THROTTLE
The accelerator mode is similar to how a motorcycle operates. When the accelerator is engaged
the motor provides power and propels you and the bike forward. It allows you to kick back and
enjoy a free ride. Most accelerators can be fine-tuned like a volume dial between low and full
power.
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4.14 Miniature circuit breakers (MCB)
An MCB is an automatically operated electrical switch. Miniature circuit breakers are intended
to prevent damage to an electrical circuit as a result of excess current. They are designed to trip
during an overload or short circuit to protect against electrical faults and equipment failure.
MCB Working
Mini circuit breakers are triggered by over current - electrical current that exceeds a designated
safe current and makes use of a relatively robust mechanical mechanism designed to minimize
failures and false alarms.
Excess current causes the bimetallic strip within the MCB to heat, bend, and trip. This releases
a switch that moves the electrical contact points apart to confine the arc (electrical discharge).
The arc is divided and cooled by an insulated metal strip called the arc chute. The contacts
close again once the fault has been fixed and the MCBs are reset.
An MCB is designed to protect against both overloading and short-circuiting. These are
detected differently using separate processes. Overload protection is provided by the bimetallic
strip using thermal operation, whereas short-circuit protection is provided by the tripping coil
via electro-magnetic operation.
If the discharge is especially high, the MCB will trip (activate) very quickly – within one-tenth
of a second. When the overcurrent is closer to the safety limits, the component will be slower
to respond.
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4.15 CHARGING CIRCUIT
Electric bike chargers are designed to fulfill all kind of power requirements of electric bike.
Battery charging which operates in wide ac input range (170 - 300vac) and to withstand the
adverse indian power conditions. These are designed with high frequency switching technology
that makes product highly reliable, cost effective, compact in size and light in weight when the
charge level in the charge indicator shows less, then the engine is switched on mechanically.
The power developed from the engine generates electricity through the bldcmotor and charges
the batteries through the charging circuit.
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5.ADVANTAGES OF ELECTRIC VEHICLES
The adoption of electric vehicles offers lots of advantages for the environment, economics, and the job
sector. Since their launch, EVs have gained significant popularity because of the benefits of electric
vehicles. Here are all the major advantages of electric vehicles:
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5.6 ENERGY INDEPENDENCE
Transition to electric vehicles enhances energy independence by reducing the reliance on the import of
fuels, which ideally costs 12 trillion Indian rupees yearly. One of the important advantages of electric
vehicles in India is becoming self-sufficient in meeting energy needs.
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6.DISADVANTAGES OF ELECTRIC VEHICLES
Being a new and cleaner technology, electric vehicles offer lots of environmental and economic
advantages. However, like any other new technology, electric vehicles also have their drawbacks.
Here’s a list of disadvantages of electric vehicles
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7.PROS AND CONS OF ELECTRIC VEHICLES IN INDIA
Since electric vehicles are growing exponentially in India, we identified some of their benefits and
drawbacks, along with the advantages and disadvantages of electric vehicles in India. Here are some of
the pros and cons of electric vehicles in India:
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8.SOLVING THE DISADVANTAGES OF ELECTRIC VEHICLES
Being a new technology, there are various advantages and disadvantages of electric vehicles in India.
With to vision to become carbon neutral by 2030, the government of india has identified these major
drawbacks of electric vehicles in india and worked out various models to address them. Here are some
of the major solutions rolled out by goi for the electric vehicle industry in india
8.2 FAME II
FAME II was launched to promote the adoption and manufacturing of electric and hybrid vehicles in
India with a budget of Rs 10,000 crore. It is introduced to support and incentivize 500,000 electric three-
wheelers, 7,000 electric buses, 55,000 electric passenger vehicles, and 1 million electric two-wheelers
in India.
PLI scheme was launched on June 2021 to boost the domestic manufacturing of electric vehicles and
their components in India, for the production of affordable electric vehicles with an outlay of Rs 18,100
crores.
It reduces the import duty on mineral ores, important for manufacturing Li-ion batteries. Import duty
on Nickel ores and Nickel Oxide is reduced to 0%, while the duty on Ferro Nickel is reduced from 15%
to 2.5% in India.
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8.6 SUBSIDIES ON ELECTRIC VEHICLES
Several state governments have introduced their individual EV policies to incentivize EV buyers and
manufacturers in the state. Subsidies are a major advantage of electric vehicles for the Indian market.
For electric scooters, the subsidy offered is between Rs 5,000 to Rs 10,000 per kwh of battery capacity
up to a maximum of Rs 25,000. Subsidy offered on the purchase of electric cars in India is between Rs
5,000 to Rs 10,00 per kwh of battery capacity up to a maximum of Rs 2.5 lakh.
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9.HOW ELECTRIC VEHICLES WORK ?
Electric vehicles work by the simultaneous working of interconnected ev components. Here’s how
electric vehicles work:
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10.WORKING PICTURES
24
FIG 10.5: STAGE 5 FIG.10.6: STAGE 6
25
FIG 10.9: STAGE 9 FIG.10.10: STAGE 10
26
FIG.10.13: STAGE 13 FIG.10.14: STAGE 14
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11.CONCLUSION
.
In conclusion, there are lots of advantages and disadvantages of electric vehicles for the Indian market. EVs
present a promising solution to the problems caused by conventional ice-powered vehicles. The consumer
acceptance of EVs in India is led by the environmental and economic advantages of electric vehicles.
However, they come with some disadvantages too, which we discussed in this article. After addressing these
drawbacks, the Indian electric vehicle market size of USD 4,230 million in 2023 is expected to grow at a
CAGR of 68 % to reach USD 1,52,000 million by 2030.
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12.REFERENCE
https://www.linengineering.com
https://www.academia.edu
https://afdc.energy.gov
https://www.topsoe.com
https://www.bldcmotor.org
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