Unit 1 Introduction Electric Vehicle

Electric Vehicle

Prof. Praveen P. Rathod

[Link]@[Link]
Department of Mechanical Engineering

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
Historical development (root) of Automobiles

4/12/2025
Department of Mechanical Engineering, VIIT , Pune-48
 History of Automobile

The first car was built by Joseph Cugnot in 1769. It was powered by a steam engine and
was very slow.

Department of Mechanical Engineering, VIIT , Pune-48

History of Automobile
• The first car was built by Joseph Cugnot in 1769. It was powered
by a steam engine and was very slow.

• Jean Joseph Étienne Lenoir was the first to build the one cylinder
engine, internal-combustion engine, was later patent.

• Nikolas August Otto built the first four cylinder engine.

• In 1886 Gottlieb Daimler designed the first four wheeled

automobile. They also created the first v-slanted engine.

• Karl Benz, know as one of the founders of Mercedes-Benz, is the

first to build an automobile powered by an internal combustion
engine. Department of Mechanical Engineering, VIIT , Pune-48
History of Automobile
• The first hybrid commercial truck was built in 1910, and as
the gasoline engine was refined interest in hybrids died
down.

• As problems with environment and gas process continue,

Hybrids are now a hot commodity in the market place and
are now the new wave of future cars

Department of Mechanical Engineering, VIIT , Pune-48

 History of Automobile
• Gottlieb Daimler and Wilhelm Maybach with Benz’s
manufacturing firm in 1926 to create Daimler-Benz. The joint
company makes cars today under the Mercedes-Benz
nameplate, and Daimler Chrysler

• Henry Ford, a famous car company founder, designed the

world’s biggest car manufacturer, manufacturing over 15
million Model by 1927

• Hybrid cars have also been around since the 1900’s.

• In the 1900’s Ford made more steam and electric cars than it
did gasoline.
Department of Mechanical Engineering, VIIT , Pune-48
 Landmark of Indian automobile
industry
• 1897 First Person to own a car in India - Mr. Foster of
M/s Crompton Greaves Company, Mumbai
• 1901 First Indian to own a car in India - Jamsetji Tata
• 1905 First Woman to drive a car in India - Mrs.
Suzanne RD Tata
•1905 Fiat Motors
•1911 First Taxi in India
•1928 Chevrolet Motors
•1942 Hindustan Motors
•

Department of Mechanical Engineering, VIIT , Pune-48

Landmark of Indian automobile
industry
• 1944 Premier Automobiles Limited
• 1945 Tata Motors
• 1947 Mahindra & Mahindra Limited
• 1948 Ashok Motors
• 1948 Standard Motors
• 1974 Sipani Motors
• 1981 Maruti Suzuki

Department of Mechanical Engineering, VIIT , Pune-48

The automobile industry in India
• 6 th largest automobile industry and 4th in terms of sell
• 2 nd largest two-wheeler market.
• 6 th largest Passenger Cars producers.
• 4 th largest in Heavy Trucks.
• 2 nd largest tractor manufacturer.
• annual production of over 2.3million units.
• The monthly sales of passenger Cars in India exceed
100,000units

Department of Mechanical Engineering, VIIT , Pune-48

Chassis

Department of Mechanical Engineering, VIIT , Pune-48

 Frame
Frame is the basic unit to which various components are
attached and body is bolted to the frame.
Functions
1 To support the chassis components and the body
2 To withstand static and dynamic load without
deflection
Loads on the frame

1 Weight of the vehicle and passenger

2 Vertical loads when the vehicle comes across a
bump
3 Loads due to road camber, side wind while taking a
turn
Department of Mechanical Engineering, VIIT , Pune-48
4 Sudden impacts loads during a collision
5 Load due to engine torque and braking torque
Material for frame
Mild sheet steel, carbon sheet steel, sheet nickel alloy
steel

Department of Mechanical Engineering, VIIT , Pune-48

VARIOUS LOADS ACTING ON
THE FRAME:
1. Short duration Load - While crossing a broken patch.

2. Momentary duration Load - While taking a curve.

3. Impact Loads - Due to the collision of the vehicle.

4. Inertia Load - While applying brakes.

5. Static Loads - Loads due to chassis parts.

6. Over Loads - Beyond Design capacity.

Department of Mechanical Engineering, VIIT , Pune-48
 Conventional Chassis

Affects visibility
of driver

Engine is fitted in front of the driver cabin or driver seat such as

in cars.
Chassis portion can not be utilized for carrying passengers and
goods
Heavy Engine can be fitted, which can used to give more power
Department of Mechanical Engineering, VIIT , Pune-48
 Semi Forward Chassis

• Half portion of the engine is in the driver cabin & and remaining
half is outside the cabin such as in Tata trucks / Tempos

• In this arrangement a part of the chassis is utilized for carrying

extra passengers

Department of Mechanical Engineering, VIIT , Pune-48

Forward Chassis

• Complete engine is mounted inside the driver cabin, Driver seat

is just above the front wheel.

• More Boot Space Available as full utilization of chassis

Department of Mechanical Engineering, VIIT , Pune-48

INTEGRAL FRAME (FRAMELESS)
used now a days in most of the cars
no frame and all the assembly units are attached to
the body
Due to elimination of long frame it is cheaper
Only disadvantage is repairing is difficult.

Department of Mechanical Engineering, VIIT , Pune-48

SEMI - INTEGRAL FRAME
half frame is fixed in the front end on which engine
gear box and front suspension is mounted.
It has the advantage when the vehicle is met with
accident the front frame can be taken easily to
replace the damaged chassis frame.
This type of frame is used in FIAT cars and some
of the European and American cars.

Department of Mechanical Engineering, VIIT , Pune-48

LADDER FRAME:
The ladder frame is the simplest and oldest of all designs.
This design offers good beam resistance because of its
continuous rails from front to rear
o Since two dimensional structure…. Torsional rigidity is
much lower than other chassis especially with vertical
loads or bumps
One of the oldest form of chassis that is still used by most
of the SUVs till today

Department of Mechanical Engineering, VIIT , Pune-48

Chassis

Department of Mechanical Engineering, VIIT , Pune-48

 Frame
Frame is the basic unit to which various components are
attached and body is bolted to the frame.
Functions
1 To support the chassis components and the body
2 To withstand static and dynamic load without
deflection
Loads on the frame

1 Weight of the vehicle and passenger

2 Vertical loads when the vehicle comes across a
bump
3 Loads due to road camber, side wind while taking a
turn
Department of Mechanical Engineering, VIIT , Pune-48
4 Sudden impacts loads during a collision
5 Load due to engine torque and braking torque
Material for frame
Mild sheet steel, carbon sheet steel, sheet nickel alloy
steel

Department of Mechanical Engineering, VIIT , Pune-48

VARIOUS LOADS ACTING ON
THE FRAME:
1. Short duration Load - While crossing a broken patch.

2. Momentary duration Load - While taking a curve.

3. Impact Loads - Due to the collision of the vehicle.

4. Inertia Load - While applying brakes.

5. Static Loads - Loads due to chassis parts.

6. Over Loads - Beyond Design capacity.

Department of Mechanical Engineering, VIIT , Pune-48
 Conventional Chassis

Affects visibility
of driver

Engine is fitted in front of the driver cabin or driver seat such as

in cars.
Chassis portion can not be utilized for carrying passengers and
goods
Heavy Engine can be fitted, which can used to give more power
Department of Mechanical Engineering, VIIT , Pune-48
 Semi Forward Chassis

• Half portion of the engine is in the driver cabin & and remaining
half is outside the cabin such as in Tata trucks / Tempos

• In this arrangement a part of the chassis is utilized for carrying

extra passengers

Department of Mechanical Engineering, VIIT , Pune-48

Forward Chassis

• Complete engine is mounted inside the driver cabin, Driver seat

is just above the front wheel.

• More Boot Space Available as full utilization of chassis

Department of Mechanical Engineering, VIIT , Pune-48

INTEGRAL FRAME (FRAMELESS)
used now a days in most of the cars
no frame and all the assembly units are attached to
the body
Due to elimination of long frame it is cheaper
Only disadvantage is repairing is difficult.

Department of Mechanical Engineering, VIIT , Pune-48

SEMI - INTEGRAL FRAME
half frame is fixed in the front end on which engine
gear box and front suspension is mounted.
It has the advantage when the vehicle is met with
accident the front frame can be taken easily to
replace the damaged chassis frame.
This type of frame is used in FIAT cars and some
of the European and American cars.

Department of Mechanical Engineering, VIIT , Pune-48

LADDER FRAME:
The ladder frame is the simplest and oldest of all designs.
This design offers good beam resistance because of its
continuous rails from front to rear
o Since two dimensional structure…. Torsional rigidity is
much lower than other chassis especially with vertical
loads or bumps
One of the oldest form of chassis that is still used by most
of the SUVs till today

Department of Mechanical Engineering, VIIT , Pune-48

Backbone chassis

Department of Mechanical Engineering, VIIT , Pune-48

● Has a rectangular tube like a backbone
and simple in structure
● made of glass fibre is used for joining front
and rear axle and responsible for the
strength.
● Space within structure used for
positioning drive shaft in case of rear
wheel drive.
● Drive train, engine and suspensions
are connected at the ends of the
Department of Mechanical Engineering, VIIT , Pune-48
Tubular space frame chassis

Department of Mechanical Engineering, VIIT , Pune-48

● A 3-dimensional design employing number of
circular and square section tubes
● Tubes are positioned in different sections
to provide mechanical strength against
forces from anywhere
● Tubes are welded together and form
a complex structure
● Very strong when compared with ladder
and monococoque chassis of the same
weightDepartment of Mechanical Engineering, VIIT , Pune-48
Some of Problems to Switch to EV

Faculty Name(optional), Department of

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______Engineering, VIIT,Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
 Faculty Name(optional), Department of
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______Engineering, VIIT,Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
What Percentage of cars will be electrified
in the next 20 years?

By 2040
55% of cars will be electric

What does this Mean?

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Department of Mechanical Engineering, VIIT , Pune-48
The Benefits of Driving Electric
Fact:
Driving electric can save you more than 70% on fuel costs.

Fact:
Driving electric means no tailpipe emissions, helping to
preserve the environment.

Fact:
Electricity is made from largely domestic sources helping to
reduce the dependence on foreign oil.

Fact:
Electric vehicle owners tend to have higher satisfaction levels
with their cars compared to non-electric vehicle owners.

Driving electric is a win-win for utilities and their customers.

 Electric Vehicle Types

Plug-in Hybrid Electric Vehicle Extended Range Electric Vehicle Battery Electric Vehicle
(PHEV) (EREV) (BEV)
Plug-in hybrid electric vehicle Electric Electric vehicle with “Extended Range” Battery electric vehicle - Powered by
motor and ICE engine electricity only
All electric for 35-40 miles
Electric range 10-40 miles Electric range for 80-300
Gas generated for 300+ miles
Blended electric/gas at higher speeds Zero emissions
8-10 kWh
2-9 kWh 16-85 kWh
Ex: Chevy VOLT
Ex: Prius Plug-in Ex: Nissan LEAF, Tesla S

All types are considered PEVs, or plug-in electric vehicles

Today there are 25 different models of electric vehicles found in the U.S. with many
more coming to market this year.
 Electric Vehicle Charging
Infrastructure
AC Charging DC Fast Charging
Home, Fleet and Public Use Public and Large Fleet Use

Type Level-1 Level-2

200-500V, up to 40 kW 200-500V, up to 100kW
(80 amp) (200 amp)
Power 120V, 1.4 kW @ 12 amp 240V, up to 19.2 kW
120V, 1.9 kW @ 16 amp (80 amp)

Charge Time 3.3 kW – 10 to 14 miles

6.6 kW – 20 to 25 miles
(Miles of range per 40 kW – up to 120 100 kW – up to 300
3 to 5 miles 9.6 kW – 40 to 45 miles
hour of charge) miles miles
19.2 kW – up to 60
miles

Cost and complexity tends to increase the faster the charging level.

Did you know?

Most plug-in electric vehicles can be charged on a household outlet overnight.

Vehicles can be charged in a number of ways; characterized by the speed of charge.

Selection should be based on site characteristics and the typical needs of users
Charging Locations
• More than 80 percent of
residential and fleet charging is
done at “home”
– “Home refueling,” charging
overnight at home for personal
vehicles and at work for fleet
vehicles
• Workplace charging is on the rise
and supports electric vehicle
adoption
– Provides charge for those without
dedicated home charging
– Extends daily range
• Public: Allows for mass adoption
– Relieves “range anxiety”
– BEST in destination locations or
along major highway corridors

Vehicles can be charged in a number of ways; characterized by the speed of charge.

Selection should be based on site characteristics and the typical needs of users
Common Electric
MYTH: Plug-in electric vehicles can
Vehicle Myths
MYTH: Plug-in electric vehicles aren’t
only support short trips, not daily “clean.” Instead of burning gas, they
commutes. run off of dirty power plants.
FACT: The average is 40 miles or less,
FACT: Even when emissions from
and most full battery electric vehicles
power plants are taken into
are targeting close to 100-mile range
consideration, electric vehicles
on a full charge, and with plug-in
contribute significantly less green
hybrid electric vehicles, you can go
house gases than traditional cars.
even further up to 300 miles or more.

MYTH: Electric vehicles will make MYTH: Electric vehicles are far more
your energy bill go way up. expensive than the average car.

FACT: Federal tax incentives are

FACT: Slightly higher electric bills are
available, up to $7,500 as well as
offset by savings at the gas pump.
possible state and local incentives.
This would be like filling up for a few
Compared to gas-powered cars, you
cents per mile, compared to the
will save on fuel, maintenance and
average 14 cents for a traditional car.
repair costs.
4/12/2025
Department of Mechanical Engineering, VIIT , Pune-48
What about the cost of lithium ion
battery?

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What about the cost of lithium ion
battery?

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Metals and Material Demand from Li-ion packs

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Why Countries Adopt Electrification?

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 Automaker Electric Vehicle Commitments

The auto industry has committed $225 billion toward electrification.

Ford: 40 models by 2022

Chrysler: 12 models by 2022
Volkswagen: 50 percent of models by 2030
Honda: All models w/ option by 2022
Volvo: All models by 2030
GM: All models by 2035

BMW: 15-25 percent of sales by 2025

Toyota: 50 percent of sales by 2025
Source: Business Insider - Electric cars: What to expect between 2020 and 2030

Department of Mechanical Engineering, VIIT , Pune-48

Automaker Electric Vehicle Commitments

Department of Mechanical Engineering, VIIT , Pune-48

Challenges

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Department of Mechanical Engineering, VIIT , Pune-48
Ways to overcome charge anxiety

There are several practical and technological ways EV drivers can reduce their charge anxiety:
1. Electric vehicle apps
Using EV apps like Zap-Map can really help with your confidence and peace of mind when driving an
EV.
App functions can include searching your nearby location for charging points, estimating the percentage
battery used for a return journey and even making the payment for your charge. They can take into
account specific EV models, driving preferences and battery state of charge.

2. Be prepared
ensuring your EV is fully charged overnight before a long journey, and checking that your final
destination is capable of public or home charging.

3. Charge when stopped, not stop to charge

Be efficient with your time by taking any opportunities during your trip – such as coffee or toilet breaks –
to plug in and charge.

4. Pay it forward
if you see a charge point isn’t working, call it in and help resolve the problem as quickly as possible.
Sometimes it takes just a matter of minutes and the charge point will be ready for use soon.

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EV & why that is not the solution now

• High Initial Cost- Many times that of conventional vehicles

• Short Driving Range- Range anxiety
• Recharging takes much longer time than refueling gasoline-lack of
charging infrastructure
• Battery pack takes space and weight of the vehicle which otherwise is available
to the people
• Grid load

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Department of Mechanical Engineering, VIIT , Pune-48
Key Components of Electric Car?

4/12/2025
Department of Mechanical Engineering, VIIT , Pune-48
Key Components of a Electric Car

• Traction battery pack

• DC-DC Converter
• Electric motor
• Power inverter
• Charge Port
• Onboard charger
• Controller
• Auxiliary batteries
• Thermal system (cooling)
• Transmission

4/12/2025
Department of Mechanical Engineering, VIIT , Pune-48
 [Link] battery pack
• Traction battery pack is also known
as Electric vehicle battery (EVB) .

• It powers the electric motors of an electric

vehicle. The battery acts as an electrical
storage system. It stores energy in the form
DC current.

• The range will be higher with increasing kW

of the battery.

• life and operation of the battery depends on

its design.

• The lifetime of a traction battery pack is

estimated to be 200,000 miles.

• The traction battery pack delivers a constant

voltage.
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Department of Mechanical Engineering, VIIT , Pune-48
 2. DC-DC Converter

• The DC-DC convertor distributes the output

power that is coming from the battery to a
required level.

• It also provides the voltage required to

charge the auxiliary battery.

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Department of Mechanical Engineering, VIIT , Pune-48
 [Link] motor
• The motor converts the electrical energy into
kinetic energy.

• This energy rotates the wheels. Electric motor is

the main component that differentiates an
electric car from conventional cars.

• An important feature of an electric motor is the

regenerative braking mechanism.

• This mechanism slows down the vehicle by

converting its kinetic energy into another form,
and storing it for future use.

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Department of Mechanical Engineering, VIIT , Pune-48
 [Link] Inverter
• It coverts DC power from the batteries to AC
power. It also converts the AC current generated
during regenerative braking into DC current. This is
further used to recharge the batteries. The inverter
5.
canCharge
change Port
the speed of the Vehicle.
• Onboard charger is used to convert the AC
supply received from the charge port to DC
supply.

• It charges the battery pack. The charge port

is sometimes located in the front or rear part
of the vehicle

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Department of Mechanical Engineering, VIIT , Pune-48
 [Link] charger

• Onboard charger is used to convert the AC

supply received from the charge port to DC
supply.

• The on board charger is located and installed

inside the car.

• It monitors various battery characteristics

and controls the current flowing inside the
battery pack.

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 [Link]
• Power electronics controller determines the
working of an electric car.

• It performs the regulation of electrical

energy from the batteries to the electric
motors.

• The pedal set by the driver determines the

speed of the car and frequency of variation
of voltage that is input to the motor.

• It also controls the torque produced.

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Department of Mechanical Engineering, VIIT , Pune-48
[Link] batteries
• Auxiliary batteries are the source of electrical energy for the accessories in electric
vehicles.

• In the absence of the main battery, the auxiliary batteries will continue to charge
the car. It prevents the voltage drop, produced during engine start from affecting
the electrical system.

9. Thermal system(cooling)
• The thermal management system is responsible for maintaining an operating
temperature for the main components of an electric vehicle such as, electric motor,
controller etc.

• It functions during charging as well to obtain maximum performance. It uses a

combination of thermoelectric cooling, forced air cooling, and liquid cooling.

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Department of Mechanical Engineering, VIIT , Pune-48
 Unit 2 Suspension & Brakes System

Prof. Praveen P. Rathod

[Link]@[Link]
Department of Mechanical Engineering

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
 LEAF SPRINGS

Department of Mechanical Engineering, VIIT , Pune-48

• Leaf springs are formed by bending.
• They are made of long strips of steel.
• Each strip is named as Leaf.
• The long leaf is called Master Leaf, and it consists of eyes at
its both ends.
• One end is fixed to the chassis frame, the other end is fixed to
the shackle spring.
• The spring will get elongated during expansion and shortened
during compression.
• This change in length of spring is compensated by the shackle.
• The U-bolt and clamps are located at the intermediate
position of the spring.
• The bronze or rubber bushes are provided on both eyes on the
master leaf.
• Originally called a laminated or carriage spring
Department of Mechanical Engineering, VIIT , Pune-48
 Types of Leaf
Springs
There are six types of leaf springs
• Full – elliptic type
• Semi – elliptic type
• Quarter – elliptic type
• Three Quarter – elliptic type
• Transverse Spring type
• Helper Spring type

Department of Mechanical Engineering, VIIT , Pune-48

 Semi-elliptical Springs

• Semi-elliptical springs are usually used in all the vehicle. Particularly in trucks,
semi-elliptical springs are fitted in front and rear axles.

• Semi-elliptical springs are cheaper and require less repairing. They increase the
range of spring action and last for a long time.

Department of Mechanical Engineering, VIIT , Pune-48

 COIL SPRING

Department of Mechanical Engineering, VIIT , Pune-48

• The coil springs are mainly used in independent suspension,
though they have been also used in conventional rigid axle
suspension.
• They can be accommodated in restricted spaces.
• The energy stored per unit volume is almost double in coil
spring than the leaf spring.
• Coil spring do not have noise problem nor do they have static
friction.
• Spring takes shear as well as bending stresses.
• A helper coil spring also sometimes used to
provide progressive stiffness against increasing
load.
• It can not take side thrust and torsional load so that alternative
arrangement is used there.
Department of Mechanical Engineering, VIIT , Pune-48
 Brake
s slowing ,stopping & controlling the
• Brake is a device used for
vehicle.

• Braking operation based on kinetic energy of vehicle is

to converting into heat, which dissipated into
atmosphere.

• While driving the vehicle, torque of the engine produces The

tractive effort due to periphery of driving vehicle.

• When the brakes are applied it produces negative tractive

effort on wheel.

• While, this help to slow down an vehicle

Department of Mechanical Engineering, VIIT , Pune-48
 Main functions of braking
system
• To stop the vehicle
safely in shortest
possible distance in
case of emergency.
• To control the
vehicle when it is
descending along the
hills.
• To keep the vehicle
in desired position
after bringing in at
rest.

Department of Mechanical Engineering, VIIT , Pune-48

 HYDRAULIC BRAKING
SYSYTEM

construction
hydraulic braking system is mainly confined with “brake fluid” this fluid
consist of Alcohol,castor oil & [Link] braking system has
following components.
master cylinder,brake pedal,wheel cylinder,brake drum,retracting
spring,brake
shoe etc. Department of Mechanical Engineering, VIIT , Pune-48
 Working System
The brake pedal is connected to the master
cylinder by means of piston for application of
brake driver presses the brake pedal, which
moves the master cylinder.
In master cylinder pressure is instantly transferred
to all four wheels. The brakes shoe moves
against the brake drum to apply brakes.
When driver releases the brake pedal, the
master cylinder piston returns to its original
position due to return springs, dropping fluid
pressure. Brake shoe retracting spring pulls the
brake shoe from drum to their original position &
brakes are released.
ROLE OF MASTER CYLINDER:

TO BUILD THE hydraulic pressure

required to operate the system.
To bleed or force air out of brake line &
wheel cylinder.
A to act reservoir to maintain a constant volume of
fluid in system
ADVANTAGES OF HYDRAULIC BRAKE

simple in construction :Mechanical joints,

linkages & cam are eliminated.
Equal braking system: the brake fluid must
exists equal pressure.
Disadvantages of Hydraulic Brake

Fails whole system at one time: if there is

Department
leakages in system, of Mechanical
all four brakes are fail at one Engineering, VIIT , Pune-48
 Working system of internal braking
system

Internal expanding braking

system consist of brake linings are
fixed at outsides when brakes are
applied the cam is turned, the
shoe with brake lining are forced
against the Drum.
This Causes brake lining creates
friction between the rotating drum
and expanding shoes.
This force of friction opposes the
rotating drum, thereby will leads
to slowing down the vehicle.
When brake is released Retracting
springs brings the shoe back
towards its original position.

Department of Mechanical Engineering, VIIT , Pune-48

 Working of Disc
brake
The brakes are operated when friction is
being
created on friction pads by forced applying
on
it against the disc .the forces created on its
is
hydraulic pressure from master cylinder,
thereby an engaging the braking system.
When the hydraulic braking pressure is
applied
on piston will engaged an released bar
due to pressure.
When pressure is released piston will regain
its
original position. Here friction pad works
on main fundamental working process.
“CALIPER “ is added on system to balanced
two calipers by diagrammatically opposite to
each to other. In this way braking torque is
reduced.
Advantages of Disc Brake
Better heat dissipation as braking torque on surface of
exposed air.
Adjustment of pads is
automatic Renewal of pad is
quick and easy.
Disadvantages of Disc Brake.
Department of Mechanical Engineering, VIIT , Pune-48