Electric and Hybrid Vehicles basics.pptx

Basic Introduction about Electric vehicle history, Electric Vehicle classification, hybrid Electric Vehicle, Force derivation, Laws applicable for Electric Vehicle, efficiency comparison, Fuel Cell Electric Vehicle Energy Storage Device Classification, parameters used in battery, types of battery, Ragone plot and its applications concepts are hinted in this slide for understanding the basic concept behind this topic

1. Why so much interest in EVs? EV is 4 times as energy efficiency as ICE Ex: ICE efficiency 22% to 23% EV efficiency 90% 50 times less moving parts When EV concept arise? In 1834 – First Non rechargeable battery operated EV(Tri cycle) by Thomson Devenport . After 40 years – lead acid battery arrived. In 1874 again EV reformed using Lead-acid battery by David Solomons . In 1886 – First EV trolley bus was built by Frank Sprague. In 1900 many companies started manufacturing in USA, UK, France First Electric Car Race “Clean Air car race” Between MIT and Caltech began on  August 26, 1968 , and ended on September 4 ELECTRIC VEHICLE History Phase I (1834 to 1930) Mr.C.Anandhakumar, AP / EEE, SRIT

2. Some of the important companies: Electric carriage and wagon company in US since 1884 . Pope manufacturing company (500 EVs) in US since 1898. Riker Electric motor company in US Since 1897 . London Electric cab company in UK since 1897. Bouquet, Garcin and Schivre (BGS) in France since 1899 – 1906. During 1900 the BGS company holds the world record of 290 km/Charge Nearly 34000 EV were registered in US by 1912 But in 1930 EVs are disappeared due to various reason. During 1925 Hendry ford produced one model “Ford Model T”, its price is reduced by 1/3 of previous Charles Keetring introduced automobile starter motor for ICE vehicles and its replaced for crank shaft starting. Due to this and increasing in production of fossil fuel, the ICE vehicle becomes popular after the year of 1930. ELECTRIC VEHICLE History Phase I Conti….. Mr.C.Anandhakumar, AP / EEE, SRIT

3. Some of the reason for Phase II EV revolution: In the year 1970. Oil shortage in gulf countries during 1973 . Pollution level increases in most of the countries like USA, UK and Etc.. So CARB regulations implemented in USA. Pollution level increased in UK by 1950 and in USA by 1960/1970 Awareness created using EV car race During 1968 “Great Electric car race” was organised. Race Between “BOSTON (MIT campus)” and Pasadena (Caltech university). Total Distance is 3490 miles and Total Charging stations is 53. Due to the above race more number of manufacturers jumped into EV design In USA - General Motors, Ford, US electriccat In Japan - Toyota, Nissan, Mazda, Isuzu, Subana , Honda, Mitshubishi and Suzuki In Europe - PSA peugeot , Renault, BMW, Benz, Audi, Volvo, opel , Volkswagen and Fiat ELECTRIC VEHICLE History Phase II (1970 to 1990) Mr.C.Anandhakumar, AP / EEE, SRIT

4. Some of the new arrivals in EV: General Motors (GM) designed EV1 – 144 km Nissan Allettra and Hypermini – 192 km National Institue of Environmental Studies (NIES) luciode – solar car Hong kong University (HKU – U2001) – 176 km Reva in India – 80 km Currently BMW i3, Chevy Bolt, Nissan leaf, Tesla road star and Peugeot 106 Electric Some of the HEV: Honda Accord and Insight. Toyota pirus and camry . Volvo XC60 T8 Lexus RX 450h BMW 740 The last three models are luxury sedan type in HEV ELECTRIC VEHICLE History Phase III (1990 to Till date) Mr.C.Anandhakumar, AP / EEE, SRIT

5. Interest and Research soared in 1990s Major automobile manufacturers embarking on plans for introducing their own electric and hybrid vehicles. Trends increases today as EV s are “ Zero emission vehicles ” Similarly HEVs are “ Ultra low emission vehicles ”. Basic block diagram of EV Source is portable or electrochemical Power converters are used to convert the power from one type to another Electric motors acts as a drive train Transmission and drive shaft supplies the energy from motor to wheels ELECTRIC VEHICLE Introduction Mr.C.Anandhakumar, AP / EEE, SRIT Source or charger Energy Source (Battery) Power Converter Electric Motor Transmission, Drive shaft Wheels

6. Acceleration pedal and Break pedal Battery and charger Electronic Controller Software Classical controls Modern controls Hardware Micro processors and Micro controllers Digital Signal Processor Power Electronic Converter Devices used for conversion SCR, GTO, BJT, MOSFET and IGBT. Conversion Topology DC/DC, DC/AC, AC/DC, PWM and Soft switch ELECTRIC VEHICLE Components in EV Mr.C.Anandhakumar, AP / EEE, SRIT

7. Machines used as drive train Design Finite element design CAD/CAM Materials Packaging Mechanical and Thermal Classifications DC Machines - Series, Shunt and Compound AC Machines - Induction machines, Synchronous machines Special Machines - Brushless motor, hub motor Transmission System Differential mechanism Wheels ELECTRIC VEHICLE Components in EV Conti…. Mr.C.Anandhakumar, AP / EEE, SRIT

8. Necessary to stop the Motor (Vehicle) Controlling the speed of the Motor (Vehicle) Eg : Lowering the loads under the influence of gravity Stop and reduced the speed at desired location and time To achieve the above action we need to control braking in the view of Mechanically (or) Electrically Mechanical Braking The frictional force between rotating parts and braking drums Brake linings Brake drums Electrical Braking Braking torques which oppose the rotating parts, achieved by changing the electrical connections ELECTRIC VEHICLE Braking of Electrical Motors Mr.C.Anandhakumar, AP / EEE, SRIT

9. The vehicle working with two or more energy Mainly it consists of ICE and EV components The vehicle is controlled with two different mechanism HEV provides solution for Pollution Extended range (Running distance) Classification of HEV (Based on design configuration) Series HEV Parallel HEV Series – Parallel HEV ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT Hybrid Electric Vehicle

10. In Series HEV only one energy converter provides propulsion power. The heat engine or ICE acts as a prime mover in series configuration to drive an Electric generator or that delivers power to the battery or energy storage link the propulsion. Series HEV is the simpler type, generator supplements the batteries and can charge them when they fall below a certain state of charge. The power required to move the vehicle is provided solely by the electric motor. Beyond the heat engine and the generator, the propulsion system is the same as in an EV, making electric motor power requirements the same as for in the EV. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT Hybrid Electric Vehicle Conti… Series - Hybrid Electric Vehicle

11. In Parallel HEV more than one energy source provides propulsion power. The heat engine and Electric motor are configured in parallel with a mechanical coupling that blends the torque coming from the two sources. In parallel HEV, the heat engine and the electric motor are connected to the driveshaft through separate clutches. Power requirements of the electric motor in parallel hybrid are lower than an EV or series HEV. because the heat engine complements for the total power requirement of the vehicle. The propulsion power may be supplied by the heat engine, by the battery-motor set, or by the two systems in combination. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT Hybrid Electric Vehicle Conti… Parallel - Hybrid Electric Vehicle

12. On the other hand, if the HEV is to be basically a vehicle with almost all the performance characteristics and comforts of an ICEV but with lower emission and fuel usage standards, then the choice should be a parallel configuration. Parallel HEVs have been built with performance that is equal, in all aspects of normal operation, to that of a conventional car. However, some series HEVs have also been built that perform nearly as well as ICEVs. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT Hybrid Electric Vehicle Conti… Series and Parallel - Hybrid Electric Vehicle The Series and parallel hybrids come in a variety of types. The mission of the vehicle and the optimum design for that mission dictate the choice. If the HEV is to be basically an EV with an ICE-assist for achieving acceptable range, then the choice should be a series hybrid, with the ICE ensuring that the batteries remain charged all the time.

13. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT Design – HEV and EV Drive train The drivetrain architecture and control technique for an HEV depends on the desired requirements including, but not limited to performance, range and emission. The performance requirements of initial acceleration, cruising velocity, maximum velocity, Gradability dictate the design of power and energy requirements of the engine and motor. The energy required by the drivetrain to meet the range specification dictates the choice of the energy source unit, which can be a battery pack or a combination of battery and ultra capacitors. Meeting the emission standards depends solely on heat engine emission characteristics, because the electric motor has zero emission. The power required in an HEV comes from a combination of the electric motor and heat engine outputs.

14. The basic structure of a fuel cell consists of an anode and a cathode, similar to a battery. The fuel supplied to the cell is hydrogen and oxygen. The concept of fuel cell is the opposite of electrolysis of water, where hydrogen and oxygen are combined to form electricity and water. The hydrogen fuel supplied to the fuel cell consists of two hydrogen atoms per molecule chemically bonded together in the form H2. This molecule includes two separate nuclei, each containing one proton, while sharing two electrons. The fuel cell breaks apart these hydrogen molecules to produce electricity. The exact nature of accomplishing the task depends on the fuel cell type, although what remains the same for all fuel cells is that this reaction takes place at the anode. The hydrogen molecule breaks into four parts at the anode due to the chemical reaction, releasing hydrogen ions and electrons. The flow of electrons from the anode to the cathode through the external circuit is what produces electricity ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT FUEL CELL VEHICLE A fuel cell is an electrochemical device that produces electricity by means of a chemical reaction, much like a battery. The major difference between batteries and fuel cells is that the latter can produce electricity as long as fuel is supplied. while batteries produce electricity from stored chemical energy and, hence, require frequent recharging.

15. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT FUEL CELL VEHICLE For the overall cell reaction to complete, oxygen or air must be passed over the cathode. The cathode reaction takes place in two stages. First, the bond between the two oxygen atoms in the molecule breaks and then each ionized oxygen atom grabs two electrons coming from the anode through the external circuit to become negatively charged. The negatively charged oxygen atoms are balanced by the positively charged hydrogen atoms at the cathode, and the combination produces H2O commonly known as water. The chemical reaction taking place in a fuel cell is as follows: The fuel cell was first developed for space applications as an alternative power source. The source was first used in a moon buggy and is still used in NASA’s space shuttles. There has been tremendous interest in fuel cells in recent years for applications in other areas, such as EVs and stationary power systems.

16. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT FUEL CELL ELECTRIC VEHICLE A fuel cell EV consists of a fuel storage system that is likely to include a fuel processor to reform raw fuel to hydrogen, a fuel cell stack and its control unit, a power-processing unit and its controller, and the propulsion unit consisting of the electric machine and drivetrain. The fuel cell has current source type characteristics, and the output voltage of a cell is low. Several fuel cells have to be stacked in series to obtain a higher voltage level, and then the output voltage needs to be boosted in order to interface with the DC/AC inverter driving an AC propulsion motor, assuming that an AC motor is used for higher power density.

17. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT FUEL CELL ELECTRIC VEHICLE The voltage and current values shown in the figure are arbitrary and are included to give an idea about the typical voltage ratings at different stages of the system. The power electronic interface circuit between the fuel cell and electric motor includes the DC/DC converter for voltage boost, DC/AC inverter to supply an AC motor, microprocessor/digital signal processor for controls, and battery/capacitors for energy storage. The time constant of the fuel cell stack is much slower than that of the electrical load dynamics. A battery storage system is necessary to supply the power during transient and overload conditions and also to absorb the reverse flow of energy due to regenerative braking. The battery pack voltage rating must be high in order to interface directly with the high-voltage DC link, which means that a large number of series batteries will be needed. Alternatively, a bidirectional DC/DC converter link can interface a lower voltage battery pack and the high-voltage DC bus. The battery pack can be replaced by ultracapacitors in a fuel cell EV, although the technology is not yet ready to replace batteries. Ultra-capacitors will be discussed in the next section. Fuel cell performance is sensitive to load variations because of the low voltage and high current output characteristics. The fuel cell controller using voltage and current feedback information regulates the flow of hydrogen into the fuel cell stack to achieve a reaction rate that delivers the required electrical power with minimum excess hydrogen vented.

18. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT EFFICIENCY COMPARISION

19. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT EFFICIENCY COMPARISION To evaluate the efficiencies of EV and ICEV on level ground, the complete process in both systems starting from crude oil to power available at the wheels must be considered. The EV process starts not at the vehicles, but at the source of raw power whose conversion efficiency must be considered to calculate the overall efficiency of electric vehicles. The power input P IN to the EV comes from two sources The stored power source The applied power source. Stored power is available during the process from an energy storage device. The power delivered by a battery through electrochemical reaction on demand or the power extracted from a piece of coal by burning it are examples of stored power. Applied power is obtained indirectly from raw materials. Electricity generated from crude oil and delivered to an electric car for battery charging is an example of applied power.

20. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT EFFICIENCY COMPARISION The complete EV process can be broken down into its constituent stages involving a chain of events responsible for power generation, transmission, and Usage Raw power from the applied source is fed to the system only at the first stage, although stored power can be added in each stage. Each stage has its efficiency based on total input to that stage and output delivered to the following stage. The efficiency of each stage must be calculated from input-output power considerations, although the efficiency may vary widely, depending on the technology being used. Finally, overall efficiency can be calculated by multiplying the efficiencies of the individual stages

21. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT VEHICLE MECHANICS The fundamentals of vehicle design are embedded in the basic mechanics of physics, particularly in Newton’s second law of motion relating force and acceleration. Newton’s second law states that “ the acceleration of an object is proportional to the net force exerted on it ”.

22. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT VEHICLE MECHANICS The fundamentals of vehicle design are embedded in the basic mechanics of physics, particularly in Newton’s second law of motion relating force and acceleration. Newton’s second law states that “ the acceleration of an object is proportional to the net force exerted on it ”. The object accelerates when the net force is nonzero, The term “net force” refers to the result of the forces acting on the object. In the vehicle system, several forces act on it, with the resultant or net force dictating the motion according to Newton’s second law. A vehicle moves forward with the aid of the force delivered by the propulsion unit overcoming the resisting forces due to gravity, air, and tire resistance. The acceleration and speed of the vehicle depend on the torque and power available from the traction unit and the existing road and aerodynamic conditions. Acceleration also depends on the composite mass of the vehicle, including the propulsion unit, all mechanical and electrical components, and the batteries.

23. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT VEHICLE MECHANICS A vehicle is designed based on certain given specifications and requirements. Design Involving multidisciplinary knowledge. The system-level perspective helps in mastering the design skills for a complex system, where The broad requirements are first determined and Then system components are designed with more focused guidelines. For example, first, the power and energy requirements from the propulsion unit are determined from a given set of vehicle cruising and acceleration specifications. The component-level design begins in the second stage, where the propulsion unit, the energy source, and other auxiliary units are specified and designed. In this stage, the electrical and mechanical engineers start designing the electric motors and ICE (HEVs). The power electronics engineers design the power conversion unit. The controls engineer works in conjunction with the power electronics engineer to develop the propulsion control system . The chemists and the chemical engineers have the primary responsibility of designing the energy source based on the energy requirement and guidelines of the vehicle manufacturer.

24. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT 6/14/2024 TRACTIVE FORCE A vehicle is designed based on certain given specifications and requirements. Total Power Required for the Vehicle Design Rolling Resistance Force Aerodynamic Force Hill Climbing Force Linear Acceleration Force Angular Acceleration Force

25. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ROLLING RESISTANCE Rolling Resistance Force The rolling resistance is primarily due to the friction of the vehicle tyre on the road. Friction in bearings and the gearing system also play their part. The rolling resistance is approximately constant, and hardly depends on vehicle speed. It is proportional to vehicle weight. The equation is: Where is the coefficient of rolling resistance. The main factors controlling are the type of tyre and the tyre pressure.

26. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT AERODYNAMIC DRAG Aerodynamic drag Force: This part of the force is due to the friction of the vehicle body moving through the air. It is a function of the frontal area, shape, protrusions such as side mirrors, ducts and air passages, spoilers, and many other factors. The formula for this component is: where ρ is the density of the air, A is the frontal area, and v is the velocity. Cd is a constant called the drag coefficient. The drag coefficient Cd can be reduced by good vehicle design.

27. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT AERODYNAMIC DRAG Aerodynamic drag Force:

28. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT HILL CLIMBING FORCE Hill Climbing Force: The force needed to drive the vehicle up a slope is the most straightforward to find. It is simply the component of the vehicle weight that acts along the slope. By simple resolution of forces we see that:

29. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ACCELERATION FORCE Acceleration Force: This force will provide the linear acceleration of the vehicle, and is given by the well-known equation derived from Newton’s second law, Angular Acceleration Force: The force at the wheels needed to provide the angular acceleration ( Fωa ) is found by combining gear ratio and motor torque. The gear system is 100% efficient, it causes no losses. Since the system will usually be very simple, the efficiency is often very high. However, it will never be 100%, and so we should refine the equation by incorporating the gear system efficiency ηg . The force required will be slightly larger, its given by I = Moment of Inertia a = Angular Acceleration G/r = Gear ratio

30. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ENERGY STORAGE SYSTEMS Introduction: A basic requirement for electric vehicles (EVs) is a portable source of electrical energy, It is converted to mechanical energy in the electric motor for vehicle propulsion. Electrical energy is typically obtained through conversion of chemical energy stored in devices such as batteries and fuel cells. Among the available choices of portable energy sources, batteries have been the most popular choice of energy source for EVs since the beginning of research and development programs in these vehicles. The EVs and HEVs commercially available today use batteries as the electrical energy source. The various batteries are usually compared in terms of descriptors, such as specific energy ( Wh /Kg) specific power (W/Kg) operating life. Power density Fast Charging Deep Discharging Long Cycle Low self discharging rate Safety and cost effectiveness

31. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ENERGY STORAGE SYSTEMS Types of battery: In general – Primary battery Secondary Battery Batteries are also classified as, The lead-acid battery ( Pb -acid) The nickel-cadmium battery ( NiCd ) The nickel-metal hydride battery (NiMH) The lithium-ion battery (Li-ion) Lithium-polymer (Li-poly) Sodium- sulfur ( NaS ) Zinc-air (Zn-Air) The solid-state battery

32. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ENERGY STORAGE SYSTEMS

33. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ENERGY STORAGE SYSTEMS

34. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ENERGY STORAGE SYSTEMS Electro Chemistry Negative Electrode Positive Electrode Electrolyte Nominal Voltage Li-ion Li x C 6 LiCoO2 LiPF 6 3.04V Lead Acid Pb PbO 2 H 2 SO 4 2.1V Dry cell Zn MnO 2 ZnCl 2 1.6V Alkaline Zn MnO 2 KOH 1.5V Ni-Cad Cd NiOOH KOH 1.35V Ni-H H 2 NiOOH KOH 1.5V Ni- Zn Zn NiOOH KOH 1.73V Zinc-air Zn O 2 KOH 1.65V

35. ELECTRIC VEHICLE Mr.C.Anandhakumar, AP / EEE, SRIT ENERGY STORAGE SYSTEMS Ragone Plot: A Ragone plot is a plot being used to compare the performance of various devices for energy storage. In such a chart the specific energy ( Wh /kg) is plotted versus the specific power (W/kg).