EV Design

30 Days Master Class Series

Day3 | Forces Calculation | EV
MATLAB/Simulink Introduction
 ●BE – EEE GCE Bargur - 2002
●ME – ME Power Electronics & Drives, CEG, Anna
University 2004
●R&D – 16 Years – Pantech Solutions
●Controller – 8051, PIC16/18F, dSPIC30F, TI DSP
TMS320F2812/28335
Malaiyappan.M ●Tools – MATLAB, PSPICE/CADANCE, CCS, Keil,
MPLAB
●Research Area: Advanced Power Electronics,
www.pantechelearning.com Renewable Energy, Special Electrical Machines,
Electrical Vehicle, Power Supply Design
About Pantech
● Educational Lab Equipments Manufacturer Vision
○ PE, Drives, Solar, Wind, Fuel Cell, EV
To help 10 Millions Students to
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 ● Attendance form | 7.30pm
Announcement ● E-Certificate | 25 Days
attendance is required
 30 Days Master Class
Day -1 Matlab - Simulink Introduction Day -21 Vehicle Modeling Intro
Day -2 Electric Vehicle Introduction Day -22 Power Train Modeling
Day -3 Forces on EV Calculations Day -23 Vehicle Drive and Control
Day -4 Power for EV Calculations Day -24 MCU for EV Application
Day -5 Introduction to Power Electronics Day -25 Protocols for EV Application
Day -6 Power Converter Design -1 Day -26 Sensor Circuit Design for EV Application
Day -7 Power Convert design – 2 (PFC) Day -27 Gate Drive Design for EV Application
Day -8 Inverter Design MATLAB Simulink Day -28 Arduino Based Induction Motor Control
Day -9 Introduction to Electric Motor MATLAB Simulink Day -29 EV Model Fabrication Design
Day -10 DC Motor Speed Control MATLAB Simulink Day -30 EV Model Vehicle Fabrication
Day -11 BLDC Motor Control MATLAB Simulink
Day -12 AC Induction Motor Control MATLAB Simulink
Day -13 PMSM Motor Control MATLAB Simulink
Day -14 SRM Motor Control MATLAB Simulink
Day -15 Introduction to Battery Modeling MATLAB Simulink
Day -16 Battery Management System
Day -17 SOC Estimation
Day -18 Battery Protection
Day -19 Simscape Introduction
Day -20 Simscape Fundamentals
Content
● Power Calculation
● Acceleration Time Calculation
● Matlab Simulink Examples

○ Logical Operation

○ PWM Generation
 Forces on the Vehicle

Total Tractive Force

1. Rolling Resistance Force(Frr)

2. Aerodynamic drag force(Faero)
3. Hill climbing Force(Fhc)
4. Acceleration Force(Fxi)
1. Linear Acceleration Force
2. Angular acceleration force
 Frr - Rolling Resistance Force
Total Power Required
Fad – Aerodynamic Drag Force
Total Power P = Fte . v Fhc - Hill Climbing Force
Fte Total Tractive Power = Frr + Fad + Fhc + Fla + Fwa Fla - Linear Acceleration Force
Fwa - Angular Acceleration Force
Rolling Resistance Force Frr = µrr m.g
- µrr - Rolling Resistance Constant
Linear Acceleration Force (Fla) = m.a
- m - Mass of the Vehicle
- g - Gravitational acceleration constant
𝐼 𝐺2 𝑎
Fad = ½ρCdAv2 Newtons Angular Acceleration Force F ω a= 2
Aerodynamic Drag Force 𝑟 𝜂𝑞
ρ – Air Density kg/m3 I - moment of inertia
A – Frontal Area m2 G – Gear Ratio
Cd – Drag Coefficient a - Acceleration
v - Velocity of the Vehicle m/s r – Radius of tire
- Efficiency of gear

Hill Climbing Force Fhc = m.g.Sin θ

EV Rating(2w)

Parameters Notations Value Units

Weight m 1,000.00 Kg

Width W 1.00 m Total Power = Total Tractive Force x Velocity

Velocity = kpm -> m/s
Hieght H 1.50 m
= 40 * 1000/3600
Rolling Resistance µrr 0.02

Air Density ƥ 1.25 kg/m2 Tractive Force = Rolling Resistance Force +

Aerodynamic drag force
Drag Coefficient Cd 0.30

gravitational Force g 9.80

Speed in km 40.00 kpmh

Frontal Area A 1.50 m2

Velocity v 11.11 m/sec

Total Power P = Fte . v

Fte (Total Tractive Power) = Frr + Fad

Tractive Force Fte Nm

230.72
Total Power for 40Km P 2,563.58 Watts
Effect of Load on Motive Power while Hill Climbing

g th
Len

Rise
θ
Run

Θ varies from 0 – 10 degree hill

Rise / Run

Fhc = m.g.Sin θ
Case Study
Observation
Huge Variation in Motive power
• Vehicle is fully loaded to unloaded condition
• Vehicle in hill climbing condition
• Vehicle Speed

While Vehicle Power Calculation, all the extreme conditions to be taken in to consideration

Typical Extreme Conditions

• Over load : 20% of Full load
• Grandniece : 20%
Acceleration of Force

The Vehicle will not be at constant speed.

Dynamic equation for Acceleration force (dv/dt)

m.dv/dt = Ft - (Frr + Fad + Fhc )

The Tractive Force greater than all resistance forces results into acceleration, similarly deceleration
How fast can vehicle reach the top speed?

Limiting Factors I
• Weight of Vehicle
• Motor Power of Vehicle

Limiting Factors II
• The Drive wheels will spin on the ground if, tractive effort>adhesive capability between tire and ground
• Significant Slipping on the ground for wet, icy, snow covered or soft soil.
• Irrespective of the maximum torque power train can apply on wheel

Slip S (Tire) = (1 – V/rω) * 100% for running

Slip S (Tire) = (1 – rω/V) * 100% For Breaking

V – Translatory Speed of Tire center, w – Angular speed of tire, r – Rolling radius of the tire
Motor Operating Region

Constant Torque Region

P = T. ω
Torque

Constant Power Region

ωc Speed
(Critical Speed)
Wide Open Throttle Response
Vehicle Data (Part 1)
mass : 1540 Kg
Cd: 0.19
Rolling Radius: 0.0048
Area : 1.8 Sq.Meter
Gear Ratio : 11
Radius of Wheel: 0.3m
Gear Efficiency : 95%
Motor Data (Part2)
102KW, 7000RPM, Tmax : 140 N-m

T.ω
ω = 2.pi.RPM / 60
= 2.pi.7000 / 60
= 732.66 rad/sec

The Motor will deliver the Tmax till 732.66rad/sec

The vehicle is driven by motor power though gear

T.ω Speed of the vehicle (ω) = (Velocity/Radius) x gear ratio

T.

T.

T . . 36.66
= / (T x 36.66)

= 12000 / (140 x 36.66) m/s

Critical Velocity = 19.8 m/s
 Total Power P = Fte . v
Fte Total Tractive Power = Frr + Fad + Fhc + Fla + Fwa
𝐼 𝐺2 𝑎
F ω a=
Frr = µrr m.g Fad = ½ρCdAv2 Newtons (Fla) = m.a Fhc = m.g.Sin θ 2
𝑟 𝜂𝑞

Fte = µrr m.g + 0.625CdAv2 + ma +

(G/ ) T = µrr m.g + 0.625CdAv2 + (m + ) dv/dt

The Maximum torque of an electric vehicle is a simple function of angular speed.

In most cases at low speeds, the maximum torque is a constant until the motor speed reaches a
critical value after which the torque falls.

ω < ωc or < T = Tmax

Initial Acceleration phase lets assume that T = Tmax
(G/ ) Tmax = µrr m.g + 0.625CdAv2 + (m + ) dv/dt

mass (m): 1540 Kg, Moment of Inertia(I) 1560

Cd: 0.19
Rolling Radius(µrr) : 0.0048
Area(A) : 1.8 Sq.Meter
Gear Ratio (G) : 11
Radius of Wheel(r): 0.3m
Gear Efficiency() : 95%
Motor Data:
102KW, 7000RPM, Tmax : 140 N-m

0.95x(11/0.3)x140 = 0.0048x1540x9.8+0.625x1.8x0.19xv2 +1560dv/dt

dv/dt = 3.11-0.000137v2
Once the vehicle speed reached critical velocity,

P=T.ω
Dynamic acceleration : T=P/ω
ω= (v/r)*G

0.95x(11/0.3)x2756/v = 0.0048x1540x9.8+0.625x1.8x0.19xv2 +1560dv/dt

dv/dt = 62.1/v-0.046- 0.000137 v 2

14.2 Sec : Critical Speed

 1 Month Internship
Day -1 Matlab - Simulink Introduction Day -21 Vehicle Modeling Intro
Day -2 Electric Vehicle Introduction Day -22 Power Train Modeling
Day -3 Forces on EV Calculations Day -23 Vehicle Drive and Control
Day -4 Power for EV Calculations Day -24 MCU for EV Application
Day -5 Introduction to Power Electronics Day -25 Protocals for EV Application
Day -6 Power Converter Design -1 Day -26 Sensor Curicuit Design for EV Application
Day -7 Power Convert design – 2 (PFC) Day -27 Gate Drive Design for EV Application
Day -8 Inverter Design MATLAB Simulink Day -28 Arudiono Based Induction Motor Control
Day -9 Introduction to Electric Motor MATLAB Simulink Day -29 EV Model Fabrication Design
Day -10 DC Motor Speed Control MATLAB Simulink Day -30 EV Model Vehicle Fabrication
Day -11 BLDC Motor Control MATLAB Simulink
Day -12 AC Induction Motor Control MATLAB Simulink
• INTERNSHIP E-Certificate by By Email
Day -13 PMSM Motor Conrol MATLAB Simulink
Day -14 SRM Motor Control MATLAB Simulink • Access for 30Hrs Video
Day -15 Introduction to Battery Modeling MATLAB Simulink • Download MATLAB SIMULINK Project Files
Day -16 Battery Management System • Access Period: 60 Days from login time
Day -17 SOC Estimation
Day -18 Battery Protection
• Join on VIP WhatsApp Group
Day -19 Simscape Introduction • Get Support
Day -20 Simscape Fundamentals
Internship Program
Rs 590.00 Only Limited Time Period

• INTERNSHIP Print Certificate by post

• Access for 30Hrs Video
• Download MATLAB SIMULINK Project Files
• Access Period: 60 Days from login time
• Join on VIP WhatsApp Group
• Get Support
MATLAB Demo

● Logic Function
● Sin Pulse Width Modulation (Single Phase and Three Phase)
 Q&A

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