Tutorialon

ElectricVehicleDesign
TaiRanHsu,Ph.D. DepartmentofMechanicalandAerospaceEngineering SanJoseStateUniversity SanJose,California October12,2011 TaiRanHsu

Principalreferences:Build Buildyourownelectricvehicle, vehicle bySethLeitman andBobBrant, Brant 2nd Edition, Edition McGrawHill, Hill NewYork,ISBN:9780071543736,1994 SpartanZeroEmissionsHybridHumanPoweredVehicleZEMHHPV,byAmandeep Manik, ScottMacPherson,HeathFieldsandMarkRafael,SanStateUniversitystudentseniordesign projectreport,ElectricalEngineeringDepartment,May2008

Content
Part1TheBasics
HistoryofElectricVehicles AnatomyofEVs DesignforPower DriveTrain ElectricSystemandBMS DesignforVelocityandNochargeCruisingRange

Part2HybridEVsandRegenerativeBrakingSystem
RegenerativeBrakingSystems(RBS)forHybridGaselectricVehicles TheFlywheelDrivenRBS

ElectricVehicles PastandPresent

LightWeight,LowSpeed NeighborhoodandLightUtilityVehicles
(Limitedtostreetswithlowpostedspeedlimits)

HighSpeed,LongCruisingRange (Freewaylegal)

NissanLeaf(2010)

TeslaRoadster

ChevyVolt(2011)

TeslaModelS(2012)

AnatomyofEVs
BatteryMan B nagement Dr riveTrain System m(BMS)

PowerSource Charger Batteries MainController(BMS) Motor Adaptor

ThrottleController Speed p Controller

Transmission Drivewheels

ACfromPowersourcetoCharger DCfromChargertoBatteries TurnkeyclosesMaincontrollerleadstoBatteriestoSpeedcontroller ThrottlecontrolsSpeedcontroller. Morevoltsforhigherrpmandhighervehiclespeed(48vforZEM,84vforZEEN)

DesignforPower
Thevery yfirstiteminEVdesign g istodeterminehowmuchelectricp powerrequired q to drivethevehicleatatopvelocitywithexpectedpayloadsfora nochargecruising range.Asimpleformulafromrigidbodydynamicswilldothejob. AmovingrigidbodysuchasavehicletravelingatavelocityVissubjectedto thefollowingforces: 1)Thefrictionforcesbetweenthewheeltiresandtheroadsurface(Ff) 2)The Th aerodynamic d i resistance i (Fr) 3)Thedynamicforcesassociatedaccompaniedwithanyaccelerations(Fd) 4)Gravitationalforcewhentravelingalongup ordownslopes(Fg) Fr V,a Fd Ff W=mg Fg

ElectricPowerRequirement

Thep power( (P) )required q todrivethevehicleatvelocity yVis:

P=

[ (F

+ Fr + Fd + Fg ) V

wherePhastheunitofhorsepower(hp);Fin(lb);Vin(ft/s) 1hp=550ftlb/s InSIsystem:PhasaunitofWatt(W):1W=1J/s;(1J=1Nm), so1W=1Nm/s / ,and d1kW k =0.7457 0 hp h

ForcesonRunningEVs
Fr V a V, Fd Ff W=mg Fg
Thetotalweightofthevehicle(curbwt.+payload)isveryimportantinthedesign Normally weight distribution is about 45% on front axel Total weight contributes to the friction force (Ff) the primary force in determining required power for EVs with 4 wheels:

Ff =N = (W/4) where = coefficient of friction, or rolling resistance factor between wheel tires and road surface: = 0.015 on a hard surface (concrete) = 0.08 on a medium-hard surface (asphalt) = 0.3 on a soft surface (sand) The-values may vary with speed V (mph) with: = 0.012 (1 + V/100)

ForcesonRunningEVs contd
Fr V a V, Fd Ff W=mg Fg
Theaerodynamicdragforce(Fr)tothevehicleisunavoidablewhenitisrunning.Itcanbeexpressedas:

Fr =(Cd AV2)/391withnegligiblewind
whereFr isin(lb),Aisthefrontalareain(ft2)andVisthevelocityofthevehiclein(mph) ThedragcoefficientCd fortypicalEVsare: Cd =0.3to0.35forcars;0.33to0.35forvans;and0.42to0.46forpickuptrucks CoefficientCd needstobemodifiedwhenthereisarelativewindvelocityofVw present: Cw =[0.98(Vw/V)2 +0.63(Vw/V)]Crw 0.4(Vw/V) whereVw =averagewindvelocity(mph);V=vehiclevelocity(mph);Crw =relativewindcoefficient=1.4 formostsedans Totalaerodynamicdragforceonvehicleis: Fr =(Cd AV2)/391+[0.98(Vw/V)2 +0.63(Vw/V)]Crw 0.4(Vw/V)

Fr

ForcesonRunningEVs ends
V,a Fd Ff W=mg Fg

Dynamic y forces(F ( d)tothevehicleneedstobeaccountedforonly yifthevehiclechanges g itsvelocity y e.g.,inaccelerationsordecelerations.Themagnitudeoftheseforcesis: Fd = Ma where M = mass in slug or kg in SI system; and a = acceleration with (+) sign and deceleration with (-) sign in unit of ft/s2 of m/s2 in SI system Gravitational,orbodyforce(Fg)indeterminingtherequiredpoweronlywhenthevehicletravelson slopedroads.Itsmagnitudeis: Fg = W Sin in which W = the total weight of the vehicle; = is the inclination of the road surface. A +ve sign for traveling up the slope and a ve sign for down-slope traveling. NoticeAllforcesarerelatedtotheWEIGHTofthevehicle.Minimizingweightisa majorconsiderationindesign

TypicalDriveTrainofEVs

Wheel

Motor& Controller

Clutch

Manual Transmission

DriveShaft

Differential Gear

DriveAxles BatteryBanks &BMS

Wheel

DesignofDriveTrain
Threeusefulformula: hp pmotor =( (Torque q wheel xmph p xRevolution/mile)/(315120 / )/( x) for selecting g motor Torquewheel =Torquemotor x(OverallgearratioxOveralldrivetrainefficiency()
Speedwheel (mph)=(rpmmotor x60)/(Overallgearratioxrevolution/mile)

where 0.9, Overallgearratio=rpmmotor/rpmwheel

Determinethetorqueofwheels: Torquewheel =Ff R+Fh whereR=radiusofdrivingwheeltire,ft;h=distancebetweencenterofgravity(CG) ofthevehicleandthewheelaxel,ft

DesignofElectricSystemandBMS
Electricsystemanditsassociatedbatterymanagementsystem(BMS)arethecardiologysystem ofhumanbodies.MostEVscontainasystemasillustratedbelow:
BatteryCharger e.g.,48DCV,15A

BatteryBanks
e.g.48DCV,4000Wh ea. 48DCV

48DCV

DC/DC / Converter

SPDTSwitch

120VAC Power Source

ReverseContactor 400AMax

MainContactor 400AMax DashInstrumentPanel &ControlSwitching

ElectronicThrottle

Motor Controller 48DCV,250A(1hr)

DCMotor
e.g.,10hp(40hppeak) 48 72DCVserieswound

ConnectedtoMechanicalDriveSystem

MajorComponentsinElectricalSystem
ComponentName Batterycharger Picture PrincipalFunction 15Awallchargerfrom110ACVto e g 48DCVoftheEVbatterybanks e.g., Itisaheavydutysafetyswitch deliveringpowertotheDCmotor Toallowelectronically controlled forward/reversemotionofthemotor Tocontrolmotorspeedandallowssafe reversing g ThemotorthatdrivestheEV.Should deliverthemaximumdesigned power fortheEV

Main contactor

Reversecontactor

Motorcontroller

DCmotor

BatteriesforElectricVehicles
Batteriesarelikethegas gastank tank foravehiclepoweredbyinternalcombustionengine engine. Nocarcanrunwithoutgastank.Thelargerthegastankthefartherthecarruns. Batteriesarewherethevehicledrivingenergyisstored.NoEVorHEVcanrunwithoutbatteries. Themoreelectricenergyisstoredinthebatteries, batteries thefartherthevehiclewillrun run.

CommonBatteriesforVehicles
Characteristics Voltage(v) Electrolytec (Environmental merits) TheorecticalEnergyDensity (kW/kg) TheoreticalAmphr Regularchargingtime(hr) Memoryeffect Selfdischarge C Cost LeadAcid Pbacid 12 Surfuricacid 3542 45 (Discharged@1.75A) @1 75A) 4to8 Atlowvoltage 2to10%/mo L Low LithiumIon Li ion 3.2to3.6percell Lithiumsalts (nonaqueoussolution) 150250 3to12 1.5to2 No 1%/mo Hi h High NickeMetalHydride y NiMH 1.4to1.6percell Alkaline (Potassiumhydroxide) 6070 5to10 1 No >30%/mo M d Moderate

DesignforVelocity
ThevelocityoftheEVrelatestothespeedofthedrivingmotorandthedrivetrain of fthe th vehicle, hi l asshown h by b the th formula: f l

Speedvehicle (mph)=(RPMmotor x60)/(overallgearratioxrevolutions/mile)

where Overallgearratio=RPMmotor/RPMwheel Revolutions/mile=5280/(d)inwhichd=diameterofwheeltireinft Thevelocity(orspeed)ofthevehicle(V)inthefollowingformulaisalsorelatedtothe theELECTRICPOWER(P)thatthebatteriescanprovide:

Obviously,theelectricpower(P)intheaboveequationmustbegreaterthanthepower requiredtodrivethemotor(hpmotor)

DesignforNochargeRange
Thecruising Th i i rangeof fanEV(R)d depends d onh howf fastthe h vehicle hi l travels l onspecific ifi roadconditionsandthetrafficenroute. grange g ofanEV( (R) ) canbeobtainedby yusing gthefollowing gformula: Thecruising

R =nE Vav/Pmiles
where n=totalno.ofbatteriesorcells E=(TheoreticalAmph)x(voltageoutputbyeachbatteryorcell,v)from characteristicsoftheselectedbatteries(Wh) Vav =Average A vehicle hi l velocity l i ( (miles/hr) il /h ) P =Requiredpowertodrivethevehicle,W

DesignCase
A neighborhoodelectricvehiclewithacurbweightat1200lbs andisdesignedtocarrya payloadof400lbs.thevehicleisdesignedtooperateunderthefollowingconditions: 1) Thevehicleispoweredby2banksofleadacidbatterieswith12voutputbyeachbattery. Eachbankconsistsof4batteriesconnectedinseries.TheDCamphoutputis45/battery. 2)Travelsonstraightflatconcretepavedroadswithanaverageslopeav =3o. 3) MaximumspeedVmax =35mphwithanaveragespeedVav =25mph(or36.67ft/s). Thelatterisusedasthedesignedvelocity 4)Thevehicleisdesignedtoaccelerationfromzeroto25mphin30secondsaftereachstop. 5) Thevehiclehasasmallfrontsurfaceareaof8ft2 withanaerodynamicdragcoefficientCd =0.3. 6) Thevehiclewheeltirediameteris20inches.

Designforpowerrequirement:

ElectricpowerrequirementfortheNEV canbeobtainedbytheequation:

whereV=Vav =25mph=25x5280/3600ft/s=36.67ft/s Theforcesactingonthevehicleare: Thefrictionforce:Ff =W/4 =0.015x(1600)/4=6lbs

Theaerodynamicdragforce:Fr =(CdAV2)/391=(0.3x8x252)/391=1.4lbs ThedynamicforceFd =Ma=(1600/32.2)x[(36.67 0)/30]=60.7lbs

ThegravitationalforceFg =WSin =1600Sin(3o)=83.74lbs TotalforcesactingonthevehicleisF =6+1.4+60.7+83.74=151.84lbs HencetherequiredpowerP =FV=151.84x36.67ftlbs/s=5568ftlbs/s =5568/550 68/ 0hp h =10.12 0 2hp h =10.12/0.7457kW=13.58kW

SelectionofDCmotor:
Usetheformula: form la hpmotor =(Torque (Torq ewheel xmphxRevolution/mile)/(315120 Re ol tion/mile)/(315120x)

Intheaboveformula: Torquewheel =FfR +Fh withR=10/12=0.833ftandh=2ft(estimated) withforces:Ff=6lbs,Fr=1.4lbs,Fd =60.7lbs,andFg =83.74lbs, andRevolution/mile=5280(ft/mi)/(2R) (ft/rev) = 1009 rev/mi, and d = 0.9, 0 9 a common assumption, ti we h have th the h horsepower of f the th motor t to t be: b

Hpmotor =[6x10/12+(1.4+60.7+83.74)x2]x25(mph)x1009rev/mi/(315120x0.9)=26.39hp

DesignforNochargeRange R =nE Vav/P

where h n=no.of fb batteries tt i =8 E =(TheoreticalAmph)x(voltageoutputbyeachbatteryorcell,v)from characteristicsoftheselectedbatteries(Wh) =45(Amph)x12(v)=540Wh V=Vav =25mph h P=Requiredpowertodrivethevehicle=13.58kW=13580W

Hencethenochargecruisingrangeis: R=8x540x25/13580=0.318mi ThisnochargecruisingrangeRfortheEVisUNACCEPTABLYLOW!! Oneneedtoeitherusemoreandmorepowerfulbatteries(n),orcutdownthepower requirement(P)byreducingtheweight(W)ofthevehicle.

Batteriesandhighvoltagecanmakeahugedifference innochargecruisingrange:
Higherspee ed

Longercruisingrange

EVswithHigherVelocityandBetterNochargeCruisingRange
Maximumvelocity(V)andNochargecruisingrange(R)arethetwomostimportantdesign featuresforanyEV. EV ThesefeaturesaretheprincipalreasonsfortheslowemergenceofEV presenceinmarketplace. Uptillveryrecently,mostEVscouldonlybeusedforwhatistermedasneighborhood operationswithtypicalV<35mphandR<40miles. miles LowVandRareprimarilyattributedtothelimitedelectricpowerandtheenergystorage systemsusinglessthanefficientbatteries.

Electric El i V Vehicles hi l onC CurrentM Market k FordFocus MitsubishiI NissanLeaf Electric

BasePrice* Milesper charge Seats Projected P j t d availability Notavailable Upto100miles Notavailable 50to85miles $32 780 $32,780 100miles

TeslaModelS
$56 500 $56,500 160 to300miles dependto batterypack Seven E l 2012 Early

Five L t 2011 Late

Four F ll2011 Fall

Five Already Al d available

*Qualifyfor$7,500federaltaxcreditwithpossible$5,000staterebate. Source:MakeWayforElectricVehiclesSanJoseMercuryNews,April3,2011

DesignConsiderationsforIdeaEVs
Low weight g Streamline exterior Simple drive train DC to get started AC to r run n abo above e 30 mph Use more high frequency components (> 400 Hz) DC motor that gets 96 volts AC motor that gets 400 volts Matching controller and motor impedance Use high energy density batteries