VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama Belagavi-590014

A PROJECT REPORT ON
“ELECTRIC VEHICLES BASED ON REGENERATIVE POWER
TECHNOLOGY”
Submitted in partial fulfilment of the requirement for the award of degree of
BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING
Submitted by,

HEMANTH KUMAR S (1BO17ME012)

KAREEM KHAN (1BO17ME015)
MANOJ K R (1BO17ME018)
MOHAMMAD IMDAD PASHA (1BO17ME023)
MAHTAB ALAM (1BO15ME049)
Under the Guidance of, Prof.

Hasansab Jamadar
Mechanical Engineering, Brindavan collage of engineering.

BRINDAVAN COLLAGE OF ENGINEERING

Dwarka Nagar, Bagaluru main road, Yelahanka, Bengaluru -560063.

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 CERTIFICATE

This is to certify that the project work entitled “ELECTRIC VEHICLES BASED ON REGENERATIVE POWER
TECHNOLOGY” carried out by Mr.HEMANTH KUMAR S (1BO17ME012), Mr.KAREEM KHAN (1BO17ME015),
Mr.MANOJ K R (1BO17ME018), Mr.MOHAMMAD IMDAD PASHA (1BO17ME023) Mr.MAHTAB ALAM
(1BO15ME049), bonafide student of BRINDAVAN COLLAGE OF ENGINEERING during the academic year
2020-21, are submitting the project report in partial fulfilment for the award of Bachelor of Engineering
in Mechanical Engineering during the academic year 2020–21. The project report has been approved as it
satisfies the academic requirements in respect of Project work prescribed for the said Degree.

Signature of guide with date Signature of HOD with date

____________________ ___________________

Hasansab Jamadar Dr. TILAK SR

Professor. Professor,HOD

Brindavan collage of engineering. Brindavan collage of engineering.

Yelahanka, Bengaluru-63. Yelahanka, Bengaluru-63

Name of the Examiner with affiliation Signature with Date

1.

2.

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 DECLARATION

We,
Mr.HEMANTH KUMAR S (1BO17ME012),
Mr.KAREEM KHAN (1BO17ME015),
Mr.MANOJ K R (1BO17ME018),
Mr.MOHAMMAD IMDAD PASHA (1BO17ME023),
Mr.MAHTAB ALAM (1BO15ME049),
Students of Bachelor of Engineering at Brindavan collage of engineering, declare that this Project
Report entitled “ELECTRIC VEHICLES BASED ON REGENERATIVE POWER
TECHNOLOGY” is the project work done by us under the supervision of Prof. Hasansab Jamadar
Mechanical Engineering department at Brindavan collage of engineering)

We are submitting this Project Report in partial fulfilment of the requirements for the award of
the degree of Bachelor of Engineering in Mechanical Engineering by Brindavan collage of
engineering, Bengaluru-63 during the academic year 2020-21.

I declare that this project report satisfies the academic requirements in respect of Project work
Prescribed for the said Degree.

I further declare that this project report or any part of it has not been submitted for award of any
other Degree / Diploma of this University or any other University/ Institution.

(Signature of the candidates)

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Signed by us on:
Certified that this project work submitted by Mr.HEMANTH KUMAR S (1BO17ME012),
Mr.KAREEM KHAN (1BO17ME015), Mr.MANOJ K R (1BO17ME018), Mr.MOHAMMAD
IMDAD PASHA (1BO17ME023) Mr.MAHTAB ALAM (1BO15ME049) has been carried out
under my guidance and the declaration made by the candidate is true to the best of my knowledge.

Signature of Guide Signature of Head of Department

Date: ………. Date: ……….

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 ACKNOWLEDGEMENT

We are extremely grateful to all professors and staff of Mechanical Engineering, Brindavan collage
of engineering, for guiding me througut the project.

We are extremely thankful to Prof. Hasansab Jamadar Mechanical engineering at

Brindavan collage of engineering for his constant encouragement, direction and support
throughout the course.

We are grateful to our parents and all members of family for their constant encouragement given
to us. We also thank our friends for their cooperation.

Above all, we thank the almighty, for giving us the resource and strength to do this project.

HEMANTH KUMAR S - 1BO17ME012

KAREEM KHAN - 1BO17ME015

MANOJ K R - 1BO17ME018

MOHAMMAD IMDAD PASHA - 1BO17ME023

MAHATB ALAM - 1BO15ME049

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 ABSTRACT

Electric power is widely used in electric traction for many reasons, it is easy to control the
speed of an electric motor, the absence of exhaust gases, free of noise, it has high starting torque,
and it needs less maintenance than its mechanical counterpart. In the current project, modern
hybrid car is designed and manufactured using a 220 volt AC electric power to charge a series
batteries, each battery has 12 VDC (35-50A/h) to supply totally 60 VDC input voltage for the
electronic inverter which converts 60 VDC to 60 VAC (three-phase voltage) as a controllable
voltage source to three-phase synchronous motor (SM) type (BLDC-YG1-ZZ-1000-1200 W).

A self power generating electric vehicle disclosed relates to the field of mechanical engineering.
The self power generating electric vehicle is a self-charging vehicle comprising an electric motor,
a charging unit, and a battery. A driving wheel, coupled to the electric motor, receives torque there
from to displace the vehicle. A driven wheel is coupled to the vehicle, and rotates as a result of
the displacement of the vehicle. The charging unit is coupled to the driven wheel to receive torque
there from. The charging unit is configured to facilitate conversion of the received torque into
electrical energy, which is further stored in the battery. The battery stores the electrical energy
received from the charging unit, and supplies the same to the electric motor. The electric motor is
configured to convert the electrical energy received from the battery into torque which is further
provided to the driving wheel to displace the vehicle.

The electrical system for an electric automobile or vehicle whereby the storage batteries are
recharged whenever the accelerator control is in a predetermined position and the vehicle is in
motion or the batteries are being recharged from an exterior source of voltage. In one
embodiment, the motor mechanically drives an alternator which produces alternating current
which is rectified to recharge the storage batteries. The motor may also be excited by an external
source to drive the alternator and recharge the batteries.

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 INDEX

Certificate

Declaration

Acknowledgement

Abstract

Table of contents

CHAPTER
NO. CONTENT/TITLE PAGE NO.
1.

15
CHAPTER 1
15
1.0. INTRODUCTION
16
1.1. Working Principle of Electric Vehicles
1.2. Electric vehicle working 17

1.3. Scope of EV 18
1.4. Electric charging 19
1.5. Electric batteries 20

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2. CHAPTER 2
LIRATURE REVIEW
2.0.Components of Electric Vehicles
2.1.Motor 21
21
2.2.Alternator
21
2.3.Motor controller 22
23

2.4.Gear ratio converter 24

2.5.Battery 26

2.6.Advantages of Electric Vehicles 27

30
2.7.Disadvantages of Electric Vehicles

3.

CHAPTER 3
OBJECTIVES
3.0.Electric vehicle Batteries and Characteristics
3.1.Lithium-ion battery
33
3.2.Hybrid Nickel-Metal (NiMH) Batteries
35
3.3.Lead-Acid (SLA) Batteries 37
3.4.ZEBRA battery 39
40
3.5.Battery Management system 42

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4. CHAPTER 4
4.0. Types of Electric Vehicles and Principle 44
4.1. Types of Electric Vehicles 44
4.2. Battery Electric Vehicle (BEV) 45
46
4.3.Basicnprinciple of BEV 47
48
4.4.Hybrid Electric Vehicles(HEV) 49
51
4.5. Plug-in Hybrid Electric Vehicle (PHEV)

4.6.Fuel Cell Electric Vehicle (FCEV)

5.
CHAPTER 5 53
5.0. Electric car components and functions 53
5.1. Traction battery pack 55
5.2. Power inverter 56
5.3.Controller 57
5.4.Electic traction Motor 58
5.5.Charger 59
5.6.Transmission 60
5.7.DC to DC converter 61
5.8.Battery 63
5.9.Battery cooling system 64
5.10. Charging ports
65

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6. CHAPTER 6
METHODOLOGY 67
6.1.Energy storage system 67
6.2. Outline of Energy Storage Methods 68
6.3. Battery energy storage 69
6.4. Battery management system (BMS) 70
6.5.Methods of energy storage system
71
6.6.Vehicle Range and Charge Capacity
71
6.7.Vehicle safety and reliability

7. CHAPTER 7
EXPERIMENTAL WORK
7.0.Design and frame drawing
72
7.1. Regeneration process 72
7.2.Other components 73
81
7.3.Frame and assembly 83
7.4.Cutting and fitting 85

8.
CHAPTER 8
86
Results and discussion
CHAPTER 9 87
Scope for future
88
CHAPTER 10
Conclusion 89
Reference

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“ELECTRIC VEHICLES BASED ON REGENERATIVE POWER TECHNOLOGY”

CHAPTER-1

INTRODUCTION

Millions of electrical vehicles and other electric transportation systems are coming to market which
require constant charging. All Such devices have large slow charging batteries and other storage
devices of electrical charge which need to be plugged into DC or AC power sources to be recharged.
For some of these a slow charge of several hours is required to complete charge the slow-charging
NiMH or Li-ion or Led acid batteries. For many consumer devices and Electrical Vehicles (EV) the size,
weight and cost of the large battery is a major design and cost problem which prevents the company
producing the devices or cars from achieving the optimal design and performance characteristics
they would like. Most design solutions provide for either a very large battery which can provide for
range of over 100 miles or an on board engine which uses fossil fuels to recharge Such batteries. The
added cost makes EV more expensive than gasoline cars and require high maintenance for both
motors.

Since most batteries are made from rare earth metals a shortage of Such elements and high prices
require a solution that will enable billions of people to own EV or use electrical public transport
options without the industry running out of such resources. Currently Electrical Vehicles (EV) require
a plug-in solution with a dedicated high Voltage and amperage alternating current (AC) outlet with
expensive rectifiers in order to pro vide the device with proper conditioned DC electrical charge to
fill out the DC batteries. While many attempts are known in the art for wireless charging all Such
innovations require very Small gap of no more than few inches or touch between the transmitting
coil and receiving coils to transfer power from the source to a device and they do not solve the issue
of rapid transfer of vast amounts of energy or the automated configuration ration, security,
authentication and conditioning of the power to the specific device which needs the charge. Other
system provide for removable EV battery solutions or induction based continuous charge which
needs the EV to be very close or touching the road or charge track.
In our project the power can be generated during running condition and braking condition. When
the car is switched on the motor takes current from the battery. The motor then converts electrical
energy into mechanical energy. The mechanical energy moves the vehicle forward, when the car
starts moving then generation takes place. The dynamo setup attached to the back wheels starts
generation. This process is called as self generation. The power can also be generated with the help
of regenerative braking system. The RBS system converts the mechanical energy into electrical
energy during braking operation. In automobiles whenever the brakes are applied the vehicle comes
to a halt and kinetic energy gets wasted due to friction in the form of kinetic energy.

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Working Principle of Electric Vehicle

“An electric vehicle works on a basic principle of science conversion of energy. Electrical energy is
converted into mechanical energy. There is a motor used in the electrical system to carry on this duty
of conversion”.

Fig.1.1

How does the electric engine work?

Electric cars function by plugging into a charge point and taking electricity from the grid. They store
the electricity in rechargeable batteries that power an electric motor, which turns the wheels. Electric
cars accelerate faster than vehicles with traditional fuel engines so they feel lighter to drive.

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How does charging work?

You can charge an electric vehicle by plugging it into a public charging station or into a home charging
unit. There’s plenty of charging stations around the UK to stay fully charged while you’re out and
about. But to get the best deal for home charging, it’s important to get the right EV electricity tariff,
so you can spend less money charging and save more on your bill.

What’s their range like?

How far you can travel on a full charge depends on the vehicle. Each model has a different range,
battery size and efficiency. The perfect electric car for you will be the one you can use for your normal
journeys without having to stop and charge up halfway through. Explore our EV leasing options.

What types of electric cars are there?

There are a few different types of electric vehicle (EV). Some run purely on electricity, these are called
pure electric vehicles. And some can also be run on petrol or diesel, these are called hybrid electric
vehicles.

Plug-in electric – This means the car runs purely on electricity and get all their power when they’re
plugged in to charge. They don’t need petrol or diesel to run so don’t produce any emissions like
traditional cars.

Plug-in hybrid – These mainly run on electricity but also have a traditional fuel engine so you can use
petrol or diesel too. If you run out of charge, the car will switch to using fuel. When it’s running on
fuel, these cars will produce emissions but when they’re running on electricity, they won’t. Plug-in
hybrids can be plugged in to an electricity source to recharge their battery.

Hybrid-electric – These run mainly on fuel like petrol or diesel but also have an electric battery too,
which is recharged through regenerative breaking. These let you switch between using your fuel
engine and using ‘EV’ mode at the touch of a button. These cars cannot be plugged in to an electricity
source and rely on petrol or diesel for energy.

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What are the inner parts of an EV?

EVs have 90% less moving parts that an ICE (Internal Combustion Engine) car. Here’s a breakdown of
the parts that keep an EV moving:

Fig.1.2

• Electric Engine/Motor – Provides power to rotate the wheels. It can be DC/AC type, however,
AC motors are more common.
• Inverter – Converts the electric current in the form of Direct Current (DC) into Alternating
Current (AC)
• Drivetrain – Evs have a single-speed transmission which sends power from the motor to the
wheels.
• Batteries – Store the electricity required to run an EV. The higher the kW of the battery, the
higher the range.
• Charging – Plug into an outlet or EV charging point to charge your battery.

EV batteries – capacity and kWh

Kilowatts (kW) is a unit of power (how much energy a device needs to work). A kilowatt-hour(kWh)
is a unit of energy (it shows how much energy has been used), e.g. a 100 watt lightbulb uses 0.1
kilowatts each hour. An average home consumes 3,100 kWh of energy a year. An electric car
consumes an average of 2,000 kWh of energy a year.

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When breaking in a traditional car, the kinetic energy caused usually goes to waste. However, in an
electric car braking converts and stores thermal energy from brake pads and tyres’ heat friction and
reuses it to power the car. This is called regenerative braking and it’s pretty clever!

Electric car charging

Fig.1.3

How to charge an EV?

You can charge an electric vehicle either by plugging it into a socket or by plugging into a charging
unit. There are plenty of charging stations around the UK to stay fully charged while you’re out and
about. There are three types of chargers:

Three pin plug for electric car charging

• Three pin plug – a standard three-pin plug that you can connect to any 13 amp socket.
• Socketed electric car charger
• Socketed – a charge point where you can connect either a Type 1 or Type 2 cable.
• Tethered electric car charger
• Tethered – a charge point with a cable attached with either a Type 1 or Type 2 connector.

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How long does it take to charge and electric car?

There are also three EV charging speeds:

Slow – typically rated up to 3kW. Often used to charge overnight or at the workplace. Charging time:
8-10 hours.
Fast – typically rated at either 7Kw or 22kW. Tend to be installed in car parks, supermarkets, leisure
centres and houses with off-street parking. Charging time: 3-4 hours.
Rapid – typically rated from 43 kW. Only compatible with EVs that have rapid charging capability.
Charging time: 30-60 minutes.

How far can you travel on one full charge?

An EVs range is dependent on the battery size (kWh). The higher the EV battery kWh, more power,
the further you travel. Here are examples of how far some electric cars charge will go:

Volkswagen e-Golf – range: 125 miles – equivalent to a journey from Bristol to Snowdonia National
Park.
Hyundai Kona Electric – range: 250 miles – equivalent to a journey from London to the Lake District.
Jaguar I-Pace – range: 220 miles – equivalent to a journey from Edinburgh to Birmingham

Fig.1.4

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LIRATURE REVIEW
CHAPTER-2
Components of Electric Vehicle

The important components in electric vehicle are:

• Motor
• Alternator
• Motor controller
• Gear ratio converter
• Battery

Motor

The main function of motor is to convert supplied electric energy current in to mechanical energy.
Brushless DC motor (BLDC) have been much focused for many motor manufacturers. These are more
effective in term of System cost, size, higher in efficiency, excellent controllability and also power
saving than other motor. It has only two basic main parts Rotor and stator. The rotor is rotating part
which carry permanent magnet and stator is stationary part and containing stator winding. The
structure of stator is similar to the induction motor. It is made up of steel lamination with axially cut
for winding.

Fig.2.1 BDC Motor Fig.2.2 BLDC Motor

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Alternator
This is a part of car and it is also belongs to electrical generator category that converts mechanical
energy into current. Because the magnetic field goes forward and forward through the field cooler,
there is an alternate current. In the alternator, the rotor moves around the magnetic flux. It produces
the electric current from the mechanical energy. This is known as an alternator. In the vehicle it runs
with the wheel friction and produces the electricity to charge the vehicle battery. When the electric
vehicle is in running motion than the alternator produces 13.8V to 14.8V.This ratio is without power
loss due to friction but with friction power loss, the remaining power is 11.9V to 12.7V. Alternator
works on the 1200 rpm to 8000 rpm (approximately).

Fig.2.4
Fig.2.3

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Motor controller

In most of the electric vehicle, Brushless DC motor is used which is better than brushed DC motor,
permanent magnet DC motor. Brushless DC motor does not have brush and commutator, the electric
vehicle which uses brushless DC motor has to use motor controller which helps to control various
properties of motor to take sufficient current and voltage applied to motor. When accelerating pedal
is press, this linked variable resistor type controller gives signal to the motor controller to adjust
speed as per our needs. The motor controller has no power when vehicle is at rest position.

Fig.2.5 Controller

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Fig.2.6

Gear ratio converter

Planetary gear systems, also known as epicyclic gear systems, are important components in modern
engineering. They are useful for speed variation and can be found in everything from automatic car
transmissions and industrial food mixers to operating tables and solar arrays. With four core
components – the ring gear, the sun gear and the planetary gears connected to the carrier – the idea
of calculating the gear ratio of a planetary system may sound daunting. However, the single-axis
nature of the system makes it easy. Just be sure to note the state of the carrier in the gear system.

Fig.2.7

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To make calculating planetary gear ratios as simple as possible, note the number of teeth on the sun
and ring gears. Here the sun gear has 20 unit diameter and the ring gear has 100 unit diameter, the
planetary gear has 40 unit diameter. The next steps depend on the state of the planetary gears
connected to the carrier, although all use the same formula. Calculate gear ratio by dividing the
number of teeth on the driven gear by the number of teeth on the driving gear.

If the carrier is standing still in the planetary gear system while the ring gear rotates the sun gear,
divide the number of teeth on the sun gear (the driven gear) by the number of teeth on the ring gear
(the driving gear).

i.e.
Ring gear (R)=50 teeth
Planet gear (P)=20 teeth
Sun gear(S)=10 teeth
i=1+(Zr/Zs)
i=1+(50/10)
i=6
This answer is correct, when we use sun gear as input gear and ring/planet gear as output but, here
we are considering the Sun gear (connected to the alternator)as output and the ring /planet gear as
input (connected to the wheel).
Hence the gear ratio will be 1:6.

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Fig.2.8
Fig.2.9

Battery
The main function of battery is to store electric energy. Most Hybrid and electric vehicle used lithium
ion batteries. This storage system is usually essential for hybrid electric vehicle, Plug in hybrid electric
vehicle and all types of electric vehicles. Due to advancing technologies, most of automobile
manufacturer uses rechargeable batteries. The differenttype of batteries along with their
characteristics are shown in table below.

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Fig.2.10

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Advantages of Electric Vehicles

An electric car can be a great way for you, as a consumer, to save a lot of money on gas. However,
there are so many different reasons why you should invest in an electric car in the modern-day of
technology.

1. No Gas Required
Electric cars are entirely charged by the electricity you provide, meaning you don’t need to buy any
gas ever again. Driving fuel-based cars can burn a hole in your pocket as prices of fuel have gone all-
time high.
If most people charge their cars in the garage installing a few solar panels, that price can get cut even
further, offering savings on powering your entire home. With electric cars, this cost of $2000 – $4000
on gas each year can be avoided.

2. More Convenient
The electric vehicle is easy to recharge, and the best part is you will no longer need to run to the fuel
station to recharge your car before hitting the road! Even a normal household socket could be used
for charging an electric car.

3. Savings

These cars can be fuelled for very low prices, and many new cars will offer great incentives for you
to get money back from the government for going green. Electric cars can also be a great way to save
money in your own life.

4. No Emissions
The biggest advantage of an electric vehicle is its green credential. Electric cars are 100 percent eco-
friendly as they run on electrically powered engines.
It does not emit toxic gases or smoke in the environment as it runs on a clean energy source. They
are even better than hybrid cars as hybrids running on gas produce emissions. You’ll be contributing
to a healthy and green climate.

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5. Popularity
EV’s are growing in popularity. It is nearly three times as efficient as cars with an internal combustion
engine, according to Wikipedia. With popularity comes all new types of cars being put on the market
that are unique, providing you with a wealth of choices moving forward.

6. Safe to Drive
Electric cars undergo the same fitness and testing procedures test as other fuel-powered cars. An
electric car is safer to use, given their lower center of gravity, which makes them much more stable
on the road in case of a collision.
In case an accident occurs, one can expect airbags to open up and electricity supply to cut from the
battery. This can prevent you and other passengers in the car from serious injuries. They are even
less likely to explode in the absence of any combustible fuel or gas.

7. Cost-Effective
Earlier, owning an electric car would cost a bomb. But with more technological advancements, both
cost and maintenance have gone down.
The mass production of batteries and available tax incentives further brought down the cost, thus,
making it much more cost-effective. Consult a tax specialist to learn more about any tax credits that
might be available to you on the state or federal level.

8. Low Maintenance
Electric cars run on electrically powered engines, and hence there is no need to lubricate the engines,
anything related to the combustion engine or a ton of maintenance tasks that are usually associated
with a gas engine.
Other expensive engine work is a thing of the past. Therefore, the maintenance cost of these cars
has come down. You don’t need to send it to the service station often as you do for a standard
gasoline-powered car.

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9. Reduced Noise Pollution

Electric cars put a curb on noise pollution as they are much quieter. Electric motors are capable of
providing smooth drive with higher acceleration over longer distances. Many owners of electric cars
have reported positive savings of up to tens of thousands of dollars a year.

10. Battery Life & Cost

Batteries are an integral part of an electric vehicle. Most electric vehicle batteries are lithium ones,
and their costs are improving every year.
The full capacity of a lithium-ion battery cell should be good for 300 to 500 cycles. A good battery
could last you up to ten years. With the improving technologies, the cost of these batteries is
expected to come down even more.

11. Easy Driving

In the world of automobiles, electric cars have the simplest driving method. Commercial electric cars
come with a transmission comprising of only one really long gear and also don’t suffer from the
stalling problem as petrol cars do.
Considering the demand for oil will only be going up as the supplies run out, an electric car will most
likely be the normal mode of transportation in the coming future.
Companies like Nissan and Tesla offer great electric models with an outstanding amount of benefits
for people who decide to invest. You’ll be saving not only yourself but also your family a huge amount
of money.
The environmental impact of an electric car is zero, as well, meaning you’re reducing your carbon
footprint and positively affecting the economy.

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Disadvantages of Electric Vehicles

Although the evidence of the positives has become very clear, there are also some downsides that
each individual needs to consider before they decide to make an electric car their next big
investment. These reasons are:

1. Recharge Points
Electric fuelling stations are still in the development stages. Not a lot of places you go to on a daily
basis will have electric fuelling stations for your vehicle, meaning that if you’re on a long trip or decide
to visit family in a rural or suburban area and run out of charge, it may be harder to find a charging
station. You may be stuck where you are.
However, until charging stations are more widespread, be sure to have a charging station maps
where you live and where you frequently go so that you’ll be able to charge your new EV when you
need to.

2. The Initial Investment is Steep

As EVs are very new, you may be surprised when you take a look at the sticker price for EVs. Even the
more affordable brands can be around $30,000 to $40,000.

If you’re looking for a luxury option, you may be paying $80,000 or even more. Though technology is
advancing and the price to produce electric cars continues to drop, you still have to pay $10,000 to
$50,000 more for an EV than for a gas-powered car.

3. Electricity isn’t Free

Electric cars can also be a hassle on your energy bill if you’re not considering the options carefully. If
you haven’t done your research into the electric car you want to purchase, then you may be making
an unwise investment.

4. Short Driving Range and Speed

Electric cars are limited by range and speed. Most of these cars have a range of about 50-100 miles
and need to be recharged again. You just can’t use them for long journeys as of now, although it is
expected to improve in the future.

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5. Longer Recharge Time

While it takes a couple of minutes to fuel your gasoline-powered car, an electric car takes about 4-6
hours and sometimes even a day to get fully charged.
Therefore, you need dedicated power stations as the time taken to recharge them is quite long. Thus,
the time investment and necessary planning do put some people off.
There are some kits that can cut the charging time down. But again, that is going to be an additional
investment. So consider that, too.

6. Silence as a Disadvantage
Silence can be a bit disadvantage as people like to hear the noise if they are coming from behind
them. An electric car is, however, silent and can lead to accidents in some cases.

7. Normally 2 Seaters
Most of the electric cars available today are small and 2 seated only. They are not meant for the
entire family, and a third person can make a journey for the other two passengers a bit
uncomfortable.

8. Battery Replacement
Depending on the type and usage of battery, batteries of almost all electric cars are required to be
changed every 3-10 years.

9. Not Suitable for Cities, Facing Shortage of Power

As electric cars need the power to charge up, the cities that already facing acute power shortages
are not suitable for electric cars. The consumption of more power would hamper their daily power
needs.

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10. Lower Amount of Choices

The market today for electric cars is expanding, with no signs of slowing down. However, the truth is
that there are fewer options to customize and choose the aesthetics of your EV.
At the same time, the vast amount of customization is available with traditional cars. This is likely to
change over time, but for many people, it is going to be a disadvantage.

11. Minimal Amount of Pollution

Electric vehicles are also not 100% emission-free; they cause a little amount of pollution indirectly.
The batteries and electricity needed for charging are not necessarily generated from renewable
energy sources.

12. Some Governments Do Not Provide Money Saving Initiatives to Encourage You to Buy an
Electric Car

Just because there is a variety of factors doesn’t mean they have to be overwhelming. Doing a fair
bit of research into different models, and maybe even hybrids will help you make an accurate
decision moving forward. However, no matter how you look at it, an electric car can save our precious
environment.

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OBJECTIVES
CHAPTER-3
ELECTRIC CAR BATTERIES AND CHARACTERISTICS

Electric car batteries

Electric car batteries are one of the most important components in a car system. In BEV cars, batteries
are the only “life”. Because, only electrical energy stored in the battery is the only source of energy
driving the BEV car. There are no other sources. The types of electric car batteries are also depends
on the car system. The most popular electric car battery used is lithium-ion. Batteries that are
considered zero emission abbreviated as ZEBRA. The most suitable battery for hybrid electric cars is
NiMH. This article will explain at a glance about the different types of electric vehicle batteries and
their characteristics along with a little about the Battery Management System (BMS)of an electric
car.

Types of Electric Car Batteries

Electric car batteries are different from SLI batteries (starting, lightning and ignition). SLI batteries
are batteries that are usually installed in gasoline or diesel cars. This type of electric cars battery is
designed as an energy storage system, capable of delivering power for long and sustainable periods.

There are 5 types of electric vehicle batteries to be discussed in this article:

• Lithium-Ion (Li-On)
• Nickel-Metal Hybrid (NiMH)
• Lead Acid (SLA)
• Ultra capacitor
• ZEBRA (Zero Emissions Batteries Research Activity).

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Fig.3.

The comparison of the first four types of electric car batteries can be seen as follows:

Fig.3.2

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Lithium-Ion Battery (Li-On)

This type of electric vehicle battery is most widely applied is the Li-On battery. This battery may
already be familiar to us because it is also used in many portable electronic equipment such as
cellphones and laptops. The main difference is a matter of scale. Its physical capacity and size on
electric cars is much greater – this is often referred to as a traction battery pack.

Li-on batteries have a very high power to weight ratio. This type of electric car battery is high energy
efficiency. Performance at high temperatures is also good. The battery has a greater energy ratio
per weight – a parameter that is very important for electric car batteries. The smaller the battery
weight (same kWH capacity) means the car can travel further with a single charge.

This battery also has a low “self-discharge” level, so the battery is better than any other battery in
maintaining its ability to hold its full charge.

In addition, most parts of Li-on batteries can be recycled, making it the right choice for those
interested in environmentally conscious electric cars. BEV cars and PHEVs use the most lithium
batteries.

Fig.3.3Lithium-ion battery

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Fig.3.4 Lithium-ion battery parameters.

Li-on battery Types

• Lithium Iron Phosphate(LiFePO4) — LFP

• Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO2) — NCA

• Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO2) — NMC

• Lithium Titanate (Li2TiO3) — LTO

• Lithium Manganese Oxide (LiMn2O4) — LMO

• Lithium Cobalt Oxide(LiCoO2) — LCO

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Hybrid Nickel-Metal (NiMH) Batteries

NiMH batteries are more widely used by hybrid-electric vehicles (HEV), but are also used
successfully in some BEV cars. This type of hybrid electric car battery does not get power from
outside (can be recharged from an outside source of the car system). The recharging of hybrid
electric car batteries depends on engine speed, wheels and regenerative braking.

Fig.3.5 Hybrid Nikel metal battery

NiMH batteries have a longer life cycle than lithium-ion batteries or SLA batteries. NiMH batteries
are safe and tolerant of incorrect usage.

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The biggest disadvantages of NiMH batteries include:

• The price is relatively more expensive

• High self-discharge rate

• Generate significant heat at high temperatures.

These deficiencies make NiMH less effective as a battery for electric cars whose batteries must
be able to be recharged from outside the system, such as from the PLN network. That is why the
car battery is the most widely applied by hybrid cars.

Fig.3.6 NiMH Battery parameters

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Lead-Acid (SLA) Batteries

SLA (lead-acid) batteries are the oldest rechargeable batteries. Compared to lithium and NiMH batteries,
lead-acid batteries do lose capacity and are much heavier, but the price is relatively cheap and safe. There
are large capacity SLA electric car batteries under development, but SLA batteries are now only used by
commercial vehicles as a secondary storage system.

Fig.3.7 Lead-acid battery parameters

Ultra-capacitor Batteries

The ultra-capacitor battery is not like the general definition of a battery. In contrast to other
electro-chemical batteries, this type of electric vehicle battery actually stores polarized liquid
between the electrode and the electrolyte. As the surface area of the liquid increases, the energy
storage capacity also increases.

Like SLA batteries, ultra-capacitor batteries are very suitable as secondary storage devices in
electric vehicles. This is because the ultra-capacitor helps electro-chemical batteries increase their
load levels. In addition, ultra-capacitor can provide extra power to electric vehicles during
acceleration and regenerative braking.

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Fig.3.8 Ultra-capacitor battery

ZEBRA Battery

The battery for ZEBRA electric cars is a low-temperature variant of sodium-sulfur (NaS)
batteries and is a development of ZEBRA (originally “Zeolite Battery Research Africa” then
became a “Zero Emissions Batteries Research Activity” battery) in 1985. From the
beginning ZEBRA batteries were indeed developed for electric vehicle applications. The
battery uses NaAlCl4 with Na + -beta-alumina ceramic electrolyte.

Characteristics of ZEBRA batteries

• High power cell so that it fits as an electric car battery

• High temperature batteries operate at more than 270 °

• The chemical Sodium Nickel Chloride (NaNiCl) provides a nominal operating cell voltage of
2.58 Volts

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Fig.3.9 ZEBRA Battery

Advantages of ZEBRA battery

• High energy density (5 times higher than SLA batteries).

• Large cells (up to 500Ah) allow.

• Life cycle> 1000 cycles.

• Short circuit tolerance.

• Safer than Sodium Sulfur cells.

• The typical cell failure is shorted but does not cause the battery to fully damage.

• Low cost ingredients

Disadvantages of ZEBRA battery

• Suitable for large capacity batteries (> 20KWh).

• Limited size and capacity range.

• Only one factory in the world produces this battery.

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• High internal resistance.

• Liquid sodium electrode.

• High operating temperature.

• Preheating is required to get the battery up to an operating temperature of 270 ° C (up

to 24 hours from cold conditions).

• Uses 14% of its own capacity per day to maintain temperature when not in use.

• Thermal management is required

Battery Management System

Battery management system or Battery Management systems (BMS) is a technology system that
functions to maximize the life of electric vehicle battery and its characteristics. It is strongly
recommended that all battery powered electric vehicles be installed BMS. The aim is to ensure
the battery stays within the ideal working parameters. Some battery chemicals (such as lead acid)
are quite tolerant of misuse, but lithium and NiMH can both be permanently damaged by a misuse
such as over charging, over discharging, or overheating. All types of electric car batteries will
benefit greatly by installing a BMS.

Fig.3.10 Battery Management

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Some special functions of the battery management system include:

• Charge balancing, to ensure all cells complete charging at the same time then to prevent
damage through overcharging.

• Active balancing, in which energy is transferred from stronger cells to weaker cells, to
ensure all cells reach the maximum discharge point at the same time.

• Temperature monitoring (temperature monitoring), to avoid damage due to overheating.

• Low-voltage cut-off, a way to isolate a battery when any cell reaches the recommended
minimum voltage, and to avoid damage due to overuse.

• State of charge (SOC) monitoring of all battery cells for electric cars. Through monitoring
voltage and current, the remaining capacity of each cell can be calculated.

Fig.3.11 Battery Management System flow chart.

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CHAPTER-4

TYPES OF ELECTRIC CAR AND WORKING PRINCIPLES

Types of Electric Cars

Different types of electric cars changed and are developed continuously giving users and
potential users choices. Today the world is increasingly familiar with the terms BEV, HEV,
PHEV and FCEV. How does an electric car work? How an electric vehicle works is depend
on the type. This article will briefly discuss the types and working principles of electric cars or
vehicles marketed in the World and Indonesia today.

An electric car is a vehicle that is fully or partially propelled by electric motors, using energy
stored in rechargeable batteries. The first practical electric cars were produced in the 1880s.
Electric cars were popular in the late 19th century and early 20th century. Innovation and
advanced development in internal combustion engines (ICE) and mass production of cheaper
gasoline vehicles has led to a decline in the use of electric vehicles.

Fig.4.1

The development of energy storage technology, especially battery technology, makes electric
cars become more popular again at this time. So how an electric car work really?

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How Does An Electric Car Work?

When pedal of the car is pressed, then:

• Controller takes and regulates electrical energy from batteries and inverters.

• With the controller set, the inverter then sends a certain amount of electrical energy to
the motor (according to the depth of pressure on the pedal).

• Electric motor converts electrical energy into mechanical energy (rotation).

• Rotation of the motor rotor rotates the transmission so the wheels turn and then the car
moves.

Types of Electric Cars

There are 4 (four) types of electric cars, with the following outline:

• Battery Electric Vehicle (BEV)

• Hybrid
Hybrid Electric Vehicle (HEV)
Plug-in Hybrid Electric Vehicle (PHEV)
• Fuel Cell Electric Vehicle (FCEV)

In brief, the system architecture of the four types of electric cars above can be seen in the
following figure:

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Fig.4.2

Battery Electric Vehicle (BEV)

A Battery Electric Vehicle (BEV), also called All-Electric Vehicle (AEV), runs entirely on a battery
and electric drive train. This types of electric cars do not have an ICE. Electricity is stored in a large
battery pack that is charged by plugging into the electricity grid. The battery pack, in turn, provides
power to one or more electric motors to run the electric car.

Architecture and Main Components

Components of BEV

• Electric motor
• Inverter
• Battery
• Control Module
• Drive train

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Working Principles of BEV

• Power is converted from the DC battery to AC for the electric motor.

• The accelerator pedal sends a signal to the controller which adjusts the vehicle’s speed by
changing the frequency of the AC power from the inverter to the motor.

• The motor connects and turns the wheels through a cog.

• When the brakes are pressed or the electric car is decelerating, the motor becomes an
alternator and produces power, which is sent back to the battery.

Fig.4.3

Examples of BEV

Volkswagen e-Golf, Tesla Model 3, BMW i3, Chevy Bolt, Chevy Spark, Nissan LEAF, Ford Focus
Electric, Hyundai Ioniq, Karma Revera, Kia Soul, Mitsubishi i-MiEV, Tesla X, Toyota Rav4.

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Hybrid Electric Vehicle (HEV)

This type of hybrid cars is often called as standard hybrid or paralel hybrid. HEV has both an ICE
and an electric motor. In this types of electric cars, internal combustion engine gets energy from
fuel (gasoline and others type of fuels), while the motor gets electricity from batteries. The
gasoline engine and electric motor simultaneously rotate the transmission, which drives the
wheels.

The difference between HEV compared to BEV and PHEV is where the batteries in HEV can only
charged by the ICE, the motion of the wheels or a combination of both. There is no charging port,
so that the battery cannot be recharged from outside of the system, for example from the
electricity grid.

Architecture and Main Components of HEV

Fig.4.4

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Working Principles of HEV

• Has a fuel tank that supplies gas to the engine like a regular car

• It also has a set of batteries that run an electric motor

• Both the engine and electric motor can turn the transmission at the same time

Examples of HEV
Honda Civic Hybrid, Toyota Prius Hybrid, Honda Civic Hybrid, Toyota Camry Hybrid.

Plug-in Hybrid Electric Vehicle (PHEV)

PHEV is a type of hybrid vehicle that both an ICE and a motor, often called as series hybrid.
This types of electric cars offers a choice of fuels. This type of electric cars is powered by a
conventional fuel (such as gasoline) or an alternative fuel (such bio-diesel) and by a
rechargeable battery pack. The battery can be charged up with electricity by plugging into an
electrical outlet or electric vehicle charging station (EVCS).

PHEV typically can run in at least two modes:

• All-electric Mode, in which the motor and battery provide all the car’s energy

• Hybrid Mode, in which both electricity and gasoline are employed.

Some PHEVs can travel more than 70 miles on electricity alone.

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Architecture and Main Components of PHEV

Components of PHEV:

• Electric motor
• Engine
• Inverter
• Battery
• Fuel tank
• Control module
• Battery Charger (if onboard model)

Fig.4.5

Working Principles of PHEV

PHEVs typically start up in all-electric mode and operate on electricity until their battery pack is
depleted. Some models shift to hybrid mode when they reach highway cruising speed, generally
above 60 or 70 miles per hour. Once the battery is empty, the engine takes over and the vehicle
operates as a conventional, non-plug-in hybrid.

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In addition to plugging into an outside electric power source, PHEV batteries can be charged by
an internal combustion engine or regenerative braking. During braking, the electric motor acts as
a generator, using the energy to charge the battery. The electric motor supplements the engine’s
power; as a result, smaller engines can be used, increasing the car’s fuel efficiency without
compromising performance.

Examples of PHEV

Porsche Cayenne S E-Hybrid , Chevy Volt, Chrysler Pacifica, Ford C-Max Energi, Ford Fusion Energi,
Mercedes C350e, Mercedes S550e, Mercedes GLE550e, Mini Cooper SE Countryman, Audi A3 E-
Tron, BMW 330e, BMW i8, BMW X5 xdrive40e, Fiat 500e, Hyundai Sonata, Kia Optima, Porsche
Panamera S E-hybrid, Volvo XC90 T8.

Fuel Cell Electric Vehicle (FCEV)

Fuel Cell Electric Vehicles (FCEVs), also known as fuel cell vehicles (FCVs) or Zero Emission Vehicle,
are types of electric cars that employ ‘fuel cell technology’ to generate the electricity required to run
the vehicle. In this type of vehicles, the chemical energy of the fuel is converted directly into electric
energy.

Architecture and Main Components of FCEV

Fig.4.6

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Components of FCEV

• Electric motor
• Fuel-cell stack
• Hydrogen storage tank
• Battery with converter and controller
• Working Principles of FCEV

The working principle of a ‘fuel cell’ electric car is different compared to that of a ‘plug-in’ electric
car. This types of electric cars is because the FCEV generates the electricity required to run this
vehicle on the vehicle itself.

Examples of FCEV

Toyota Mirai, Hyundai Tucson FCEV, Riversimple Rasa, Honda Clarity Fuel Cell, Hyundai Nexo.

Fig.4.7

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CHAPTER-5

ELECTRIC CAR COMPONENTS AND FUNCTIONS

Electric Car Components

Electric car or vehicle component and function depend on the car type. There are
at least four types of electric cars currently sold commercially and operates in the
world. This article will discuss various common main electric car components or
parts or elements and their function such as traction batteries, inverters (DC-DC
converters), traction motors, on-board chargers and controllers. The different types
of electric car components determines how the car works. Electric cars (vehicles)
components and functions can be explained by means of picture below.

Fig.5.1

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How Does An Electric Car Work?

When the car pedal is pressed, then:

• Controller [C] takes and regulates electrical energy from batteries [A] and inverters [B].

• With the controller set, the inverter then sends a certain amount of electrical energy to
the motor (according to the depth of pressure on the pedal).

• Electric motor [D] converts electrical energy into mechanical energy (rotation)

• Rotation of the motor rotor rotates the transmission so the wheels turn and then the car
moves.

Note: The working principle above is for battery electric vehicle (BEV) type.

Fig.5.2

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Electric Vehicle Components

Basic Main Components of Electrical Vehicle

The basic main elements of electric cars installed in almost all types of electric cars are as
follows:

Traction Battery Pack (A)

The function of the battery in an electric car is as an electrical energy storage system in the form of
direct-current electricity (DC). If it gets a signal from the controller, the battery will flow DC electrical
energy to the inverter to then be used to drive the motor. The type of battery used is a rechargeable
battery that is arranged in such a way as to form what is called a traction battery pack.

Fig.5.3 Traction battery pack

There are various types of electric car batteries. The most widely used is the type of lithium-ion
batteries. Please read above “Electric Car Batteries and Their Characteristics” to get a little idea about
batteries for electric. There are various types of electric car batteries. The most widely used is the
type of lithium-ion batteries.

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Power Inverter

The inverter functions to change the direct current (DC) on the battery into an alternating current
(AC) and then this alternating current is used by an electric motor. In addition, the inverter on an
electric car also has a function to change the AC current when regenerative braking to DC current
and then used to recharge the battery. The type of inverter used in some electric car models is
the bi-directional inverter category.

Fig.5.4 Power inverter

Controller

The main function of the controller is as a regulator of electrical energy from batteries and
inverters that will be distributed to electric motors. While the controller itself gets the main input
from the car pedal (which is set by the driver). This pedal setting will determine the frequency
variation or voltage variation that will enter the motor, and at the same time determine the car’s
speed.

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Fig.5.5 Controller

In brief, this unit manages the flow of electrical energy delivered by the traction battery,
controlling the speed of the electric traction motor and the torque it produces. This component
will determine how electric car work.

Electric Traction Motor

Because the controller provides electrical power from the traction battery, the electric traction
motors will work turning the transmission and wheels. Some hybrid electric cars use a type of
generator-motor that performs the functions of propulsion and regeneration. In general, the type
of electric motor used is the BLDC (brushless DC) motor

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Fig.5.6 Electric traction motor

Other Electric Car Components

Charger is a battery charging device. Chargers get electricity from outside sources, such as the
utility grid or solar power plants. AC electricity is converted into DC electricity and then stored in
the battery. There are 2 types of electric car chargers:

On-board charger: the charger is located and installed in the car

Off-board charger: the charger is not located or not installed in the car.

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Fig.5.7 Charger

Transmission

The transmission transfers mechanical power from the electric traction motor to drive the
wheels. Electric cars don’t require multi-speed transmissions because of the so-called “engine” in
an electric car, an electric motor. … Electric motors deliver power instantly, meaning, the process
of building up torque through revving as in internal combustion engines is unnecessary.

Electric vehicles don’t feature a multi-speed gearbox like conventional petrol or diesel vehicles.
Instead, they have just one gear. … The gears allow you to keep the power between a set amount
so that you can gradually speed up and slow down while still having enough torque to do so.

Single speed Transmission and Multi-speed Transmission are two types of transmission mostly
used in electric vehicles. The key factors affecting on the transmission are fuel efficiency, motor
efficiency, speed- torque variation, power, cost, weight etc.

As a result of this, a transmission system is not needed in an electric car. Instead, an EV will just
have a fixed-ratio gearbox which aims to strike the right balance between acceleration and the
top-speed. And since there’s no transmission, there’s no transmission fluid required in an EV
either.

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Fig.5.8 Transmission

Researchers at Cornell University are developing technology that can charge an electric car while
its in motion. US highways could embed the roads with metal plates that charge the cars as they
drive over them. The project is about five years away from a roll out, but can already power most
electric vehicles.

DC/DC Converter

This one of electric car parts that to converts higher-voltage DC power from the traction battery
pack to the lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary
battery.

A full-bridge DC/DC converter is the most frequently implemented circuit configuration for fuel-
cell power conditioning when electrical isolation is required. The full bridge DC/DC converter is
suitable for high-power transmission because switch voltage and current are not high.

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Fig.5.9

Overview: The DC/DC converter effectively replaces the alternator on an Internal Combustion
Engine (ICE) car. Instead of taking energy from the rotation of the ICE motor to charge the 12V
battery, it pulls power from the main High Voltage (HV) battery pack and converts it down to 12V.

A basic DC-DC converter takes the current and passes it through a switching element, which turns
the DC signal into an AC square wave signal. This wave is, then passes through another filter which
turns it back into a DC signal of the required voltage.

Fig.5.10 DC converter

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In electric vehicles which use a DC motor, actually running the motor can use up to three times
the voltage provided by the battery.DC/DC converters constitute an entire subcategory of
electrical engineering. There are many different ways to get the job done, all of which are based
on the principles of Ohm’s Law.

Battery

In an electric drive vehicle, the auxiliary battery provides electricity to power vehicle accessories.
An electric-vehicle battery is a battery used to power the electric motors of a battery electric
vehicle or hybrid electric vehicle. These batteries are usually rechargeable batteries, and are
typically lithium-ion batteries. These batteries are specifically designed for a high ampere-hour
capacity.

Fig.5.11 Lithium-ion battery setup

A Lithium-ion (Li-ion) battery is a type of rechargeable battery used in electric vehicles and a
number of portable electronics. They have a higher energy density than typical lead-acid or nickel-
cadmium rechargeable batteries.

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Fig.5.12 Batteries

In light of the explanation I gave above, the simple answer is that most likely yes, your EV is losing
some amount of charge while parked and idle. If you’re still plugging your car in each day and
maintaining the charge level between 20 and 80 percent, then the amount you’ll lose to vampire
drain will be minimal.

Thermal cooling system

This system maintains a proper operating temperature range of the engine, electric motor, power
electronics, and other components. The developed battery thermal management system is a
combination of thermoelectric cooling, forced air cooling, and liquid cooling. The liquid coolant
has indirect contact with the battery and acts as the medium to remove the heat generated from
the battery during operation.

Four different cooling systems:

• Phase Change Material (PCM)

• Fin Cooling.
• Air Cooling.
• Liquid Cooling (both Direct and Indirect)

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Fig.5.13 Cooling system

There are 3 common battery thermal management methods used today:

• Convection to air either passively or forced.

• Cooling by flooding the battery with a dielectric oil which is then pumped out to a heat
exchanger system.
• Cooling by the circulation of water-based coolant through cooling passages within the
battery structure.

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Fig.5.14 Cooling system

Charge Port

Fig.5.15 Charging ports

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The charge port allows the vehicle to connect to an external power supply in order to charge the
oktraction battery pack.

Fig.5.16

In short, all electric car brands use the same standard plugs for normal-speed charging (Level 1
and Level 2 Charging), or will come with a suitable adapter. However, different EV brands use
different standards for faster DC charging (Level 3 Charging).

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METHODOLOGY
CHAPTER-6
Energy Storage Systems

Energy Storage Systems are the set of methods and technologies used to store energy. The stored
energy can be drawn upon at a later time to perform useful operation.

For instance, many renewable energy sources (such as wind, solar energy or solar energy, tides)
are intermittent. Sometimes the use of renewable energy is not direct when the energy is
available, but at other times. Then we need energy storage so that energy can be used when
needed.

Energy is available in various forms including radiation, chemical, gravitational potential, electrical
potential, electricity, elevated temperature, latent heat and kinetic.

There are various methods and technologies to store various forms of energy. The choice of
energy storage technology is typically dictated by application, economics, integration within the
system, and the availability of resources.

Energy storage systems are also involved in converting energy from forms that are difficult to
store to forms that are more convenient or economical.

Fig.6.1

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Outline of Energy Storage Methods

Methods of Energy Storage Systems

• Electrochemical Energy Storage

• Flow battery
• Rechargeable battery
• Ultra battery

Electrical Energy Storage Systems

• Capacitor
• Super capacitor
• Superconducting magnetic energy storage (SMES)

Five Key Energy Storage Technologies

• Electrochemical Energy Storage

• Chemical Energy Storage
• Thermal Energy Storage
• Mechanical Energy Storage
• Electrical Energy Storage

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Fig.6.2 Methods of energy storage system

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Battery Energy Storage

Energy Storage Technology Center provides the automotive and power generation industries
with science and engineering expertise to research, develop and evaluate batteries, battery
chemistries, battery cells and battery packs used in electric vehicles (EV) and grid storage
applications.

• Batteries
• Battery Development
• Battery Technology
• Electric Vehicle Battery & Electric Car Research
• Energy Storage System Development
• Energy Storage System Evaluation & Safety (ESSES)
• Energy Storage Technology Center

Battery Management Systems (BMS)

A battery management system (BMS) closely monitors and manages the state of charge and state
of health of a multicell battery string. For large, high voltage battery packs, such as in an electric
vehicle, accurate monitoring of each individual battery cell and the overall pack parameters is
critical for achieving maximum usable capacity, while ensuring safe and reliable operation. The
quality of the battery management system directly impacts the miles per charge an EV can deliver,
maximizes the batteries overall lifetime, and as a result lowers the cost of ownership.

As electric vehicles continue to grow in popularity, the industry is demanding increased

performance from technology providers. Our battery management systems deliver best-in-class
voltage and current measurement to drive innovation in EVs.

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Vehicle Range and Charge Capacity

ADI’s outstanding BMS measures accuracy whether the cells are charging or discharging, which
allows the vehicle to charge more fully and discharge more completely. Simply put, BMS
maximizes the usable capacity—key to maximizing vehicle range, cost, weight, and size.

Vehicle Safety and Reliability

Overcharging and over-discharging cells can lead to damage, resulting in battery fires, capacity
reduction or reduced lifetime.Analog Devices’ BMS devices address safety and reliability concerns
by providing measurements that ensure each cell is functioning within a constrained operating
range.

Fig.6.3

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EXPERIMENTAL WORK

CHAPTER-7

Design and Frame drawing

• The dimensions of the vehicle would be, 8 feet long and 4 .5feet wide. (excluding the
length of wheel )
• The seating space will be for two people.
• The stearing mechanism will be on the right.
• The self generation and the motor setup will be in the back.

Fig.7.1

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Fig.7.2

Regeneration process.

In the electric vehicle, we mainly use an electric power and their supply is indicated from the
battery. Battery is installed in an electric car and also to be mounted with the vehicle. The
performance of an electric vehicle is more as compared to another type of vehicle. It also has a
maximum output efficiency rather than to that of internal combustion engine. Whenever the
electricity is used in the vehicle, it produces a zero percentage of emission while it is running or
in the initial condition. This process is totally emission-less. It has power to carry the vehicle at
minimum time. An electric car has totally different work from that of internal combustion engine.

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In an electric vehicle, all the circuit and switch are controlled by the controller. Controller is
directly connected to the motor, battery and another lighting system. The motor drives to the
accelerator pedal that is controlled through the controller. In the electric vehicle, re-chargeable
batteries are mostly used. The battery is charged with the charging system. In the electric vehicle
the main component that we use is battery, controller, motor and another more components.
Battery is charged through the charger to be plugged in with the house electricity. Electric car can
be changed to kinetic energy; electricity can be converted from kinetic energy to electric energy.
It has a minimum power loss and maximum output efficiency rather than the internal combustion
engine which has less output efficiency. The motor is installed at the rear differential between the
rear wheels. Alternator works on the principle of electromagnetic induction and italso moves
around its axis to produce electricity. With the installation of the alternator it increases the range
of battery and it provides the battery charging while the electric car is in running condition than
the alternator produces electricity.

Fig.7.4

This generator works on the principle of induced EMF (Electromotive force) by the motion of a
conductor through a magnetic field. This means that two essential parts of a DC generator are
the magnetic field and conductors which can move in the field.

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When conductor slashes magnetic flux, an emf will be generated based on the electromagnetic
induction principle of Faraday's Laws.

One dynamo can produce less electricity, hence in order to produce maximum amount of
current the dynamo can be arranged in the form of series arrangement as shown.

The axial of the rod in the centre will act as axial for the rear wheels.

In the regeneration setup alternators can be used instead of dynamos.

In our project the power can be generated during running condition and braking condition.
When the car is switched on the motor takes current from the battery.The motor then converts
electrical energy into mechanical energy.

The mechanical energy moves the vehicle forward, when the car starts moving then generation
takes place. The dynamo setup attached to the back wheels starts generation. This process is
called as self generation.

The power can also be generated with the help of regenerative braking system. The RBS system
converts the mechanical energy into electrical energy during braking operation. In automobiles
whenever the brakes are applied the vehicle comes to a halt and kinetic energy gets wasted due
to friction in the form of kinetic energy.

Fig.7.5

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Fig.7.6

External Components

Speedometer

The electronic speedometer depends on an electronic rotation sensor placed near the engine's
transmission. A speedometer is a measuring device for a vehicle's speed and normally measures
that speed by having a needle move along a circular path, like a clock hand, indicating how fast a
motor is propelling a vehicle. Fig.7.7

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Acceleration and Braking system.

When the driver of the vehicle presses down on the gas pedal, the controller detects the position
of the pedal and sends a signal to the motor to increase its speed. ... By pressing down on the gas
pedal, the driver of the electric vehicle is capable of accelerating as fast as the engine power will
allow the vehicle.

The accelerator pedal sends a signal to the controller which adjusts the vehicle's speed by
changing the frequency of the AC power from the inverter to the motor. ... When the brakes are
pressed or the car is decelerating, the motor becomes an alternator and produces power, which
is sent back to the battery.

Fig.7.8

Battery level indicator

A battery indicator (also known as a battery gauge) is a device which gives information about a
battery. This will usually be a visual indication of the battery's state of charge. It is particularly
important in the case of a battery electric vehicle.

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Fig.7.9

Belt pulley

helps in power transmission using a cable or belt. In a belt and pulley system, a belt runs along a
pulley's groove so that the power can be transfer either from one pulley to another or from the
pulley directly to the application that requires power.

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Fig.7.10

Motor and Controller kit

Fig.7.11

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AAlternator

Fig.7.12

Battery

Fig.7.13

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Stearing kit

Fig.7.14

Frame and Assembly of the Vehicle

Fig.7.15

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Fig.7.16

Fig.7.17

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Cutting and fitting

Fig.7.18

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Fig.7.19

Fig.7.20

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Fig.7.21

Fig.7.22

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CHAPTER-8

Results and Discussion

In the current project, modern hybrid car is designed and manufactured using a 220 volt AC electric power
to charge a series batteries, each battery has 12 VDC (35-50A/h) to supply totally 60 VDC input voltage for
the electronic inverter which converts 60 VDC to 60 VAC (three-phase voltage) as a controllable voltage
source to three-phase synchronous motor (SM) type (BLDC-YG1-ZZ-1000-1200 W).

A self power generating electric vehicle disclosed relates to the field of mechanical engineering. The self
power generating electric vehicle is a self-charging vehicle comprising an electric motor, a charging unit,
and a battery. A driving wheel, coupled to the electric motor, receives torque there from to displace the
vehicle. A driven wheel is coupled to the vehicle, and rotates as a result of the displacement of the vehicle.
The charging unit is coupled to the driven wheel to receive torque there from. The charging unit is
configured to facilitate conversion of the received torque into electrical energy, which is further stored in
the battery. The battery stores the electrical energy received from the charging unit, and supplies the same
to the electric motor. The electric motor is configured to convert the electrical energy received from the
battery into torque which is further provided to the driving wheel to displace the vehicle.

The electrical system for an electric automobile or vehicle whereby the storage batteries are recharged
whenever the accelerator control is in a predetermined position and the vehicle is in motion or the
batteries are being recharged from an exterior source of voltage. In one embodiment, the motor
mechanically drives an alternator which produces alternating current which is rectified to recharge the
storage batteries. The motor may also be excited by an external source to drive the alternator and recharge
the batteries.

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CHAPTER-9

Scope for further

With battery prices reportedly falling 73% since 2010, electric cars are expected to be as
cheap as fuel-powered cars in the foreseeable future. The International Energy Agency
cites that by 2020 up to 20 million electric vehicles will ply the road, a number that is
expected to go up to 70 million by 2025.

The coming decade is expected to be the decade of the fully electric car. With battery
prices reportedly falling 73% since 2010, electric cars are expected to be as cheap as fuel-
powered cars in the foreseeable future. The International Energy Agency cites that by
2020 up to 20 million electric vehicles will ply the road, a number that is expected to go
up to 70 million by 2025. Countries around the world are waking up to the potential of e-
mobility. While China is incentivising e-mobility with tax breaks, EV credit policies,
research subsidies and more, countries like the UK, France, Norway and India are looking
to adopt e-mobility at a larger scale, having expressed the desire to phase out petrol and
diesel engines entirely in the coming decades.

India has a lot to gain from the widespread adoption of e-mobility. Under the Make In India
programme, the manufacturing of e-vehicles and their associated components is
expected to increase the share of manufacturing in India’s GDP to 25% by 2022. On the
economic front, large-scale adoption of electric vehicles is projected to help save $60
billion on oil imports by 2030 – currently 82% of India’s oil demand is fulfilled by imports.
Price of electricity as fuel could fall as low as Rs 1.1/km, helping an electric vehicle owner
save up to Rs. 20,000 for every 5,000km traversed. Finally, electrification will help reduce
vehicular emissions, a key contributor to air pollution which causes an average 3% GDP
loss every year.

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CHAPTER-10

Conclusion

It reduces the pollution from the cities. The city has been defined to develop a battery power vehicle for
daily use and to change eco-friendly methods for daily short-term basis within the cities. In conventional
work, the concept of self-charging has been found in conventional battery power vehicles, which was the
goal of changing the concept of plug-in charging. This work started with the study of technology, the use
of components and future of the battery power for electric car. For many trials, the battery was checked
for the supply of resources from the DC-DC converter. It shows successful results of a conductor for
charging rotational energy from the wheels to charge the batteries in the series. On the basis of their
special applications used in the automobiles field, alternative systems, motor, motor controllers, DC-DC
converters were selected. From the results, we can conclude that when the vehicle system has been
adopted, the vehicle travels for a long time.Alternator produces 12V-14V, which uses rotational energy
from the wheel under the fast motion. DC-DC Convertor receives as a 12V DC to 54V DC; the result is to
charge the batteries.

The electric vehicle is driven by the battery. On switching the car the motor takes current from the battery.
The motor converts the electrical energy into mechanical rotation and hence the vehicle moves
forward.When the car starts running then generation takes place.The synchronous generator attached to
the wheels starts generation.Here synchronous generator has been used because it can operate at low
power.When the driving speed of the car increases then generation also increases.Hence the generation
depends upon the driving condition.The output of the generator is alternating type.Hence it canbe
converted into DC with the help of rectifier circuit. The rectifier circuit converts this Alternating current
into pulsating DC .The pulsating DC component is passed through the filter circuit which removes
harmonics .Then the DC is stored in the ultracapacitor.Hence the power can be generated without any
external forces and this process iscalled self generation.

The energy can be generated using self generation and regeneration principle and both the methods does
not produce any pollution to the system .Using these systems the driving range of the vehicle can be
improved. The energy storage can also be done with the help of Hybrid Energy Storage system. This
method can improve the battery life of the system. It is also possible to boost the overall efficiency if the
system is properly sized and controlled.Future work related to this paper will focus on analyzing the system
under high voltage conditions.

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