MOTOR DESIGN OF ELECTRIC VEHICLE

Major Project Report

Submitted in Partial Fulfillment for the requirement for the Award of

Degree of Bachelor of Technology

In
Mechanical Engineering
Submitted To
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA, BHOPAL
Submitted By
MD TAHSIN ALAM (0177ME1910 57 )
MD WAHID HUSSAIN (0177ME1910 63)
MD ZEESHAN (0177ME191060 )
MD SHAHANSA ALAM (0177ME191056)
MD DANISH (0177ME191047)

Under The Guidance of

Dr. GURJEET SINGH

DEPARTMENT OF MECHANICAL ENGINEERING

IES COLLEGE OF TECHNOLOGY, BHOPAL
 SESSION 202 2-2023

IES COLLEGE OF TECHNOLOGY, BHOPAL (M.P)

Department of Mechanical Engineering

CERTIFICATE

This is to certify that the work embodies in this Project entitled

“ MOTOR DESIGN OF ELECTRIC VEHICLE ”
beingsubmitted by “ MD TAHSIN ALAM (0177ME191057 )
MD WAHID HUSSAIN (0177ME191063)
MD SHAHANSA ALAM (0177ME191056)
MD ZEESHAN (0177ME191060) MD DANISH (0177ME1911047) ”
for partial fulfillment of therequirement for the award of
“ Bachelor of Technology in Mechanical Engineering ”
to “Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal(M.P)” during
the academic year ……. is a record of bonafide piece of work, carried
out by him under my supervision and guidance in IES COLLEGE OF
TECHNOLOGY, BHOPAL (M.P).

Guide H.O.D Principal

Dr. GURJEET SINGH Dr.GEETESH GOGA Dr. Anuprita Mishra

IES COLLEGE OF TECHNOLOGY, BHOPAL (M.P)

Department of Mechanical Engineering

APPROVAL CERTIFICATE

The Minor/Major Project entitled “ MOTOR DESIGN OF

ELECTRIC VEHICLE ” being submitted by “ MD TAHSIN ALAM
(0177ME191057) MD WAHID HUSSAIN (0177ME191063)
MD ZEESHAN (0177ME191060) MD DANISH (0177ME191047)
MD SHAHANSA ALAM (0177ME191056) ”
has been examined by us and is hereby approved for the award of
degree “Bachelor of Technology in Mechanical Engineering”, for which
it has been submitted. It is understood that by this approval the
undersigned do not necessarily endorse or approve any statement
made, opinion expressed or conclusion drawn therein, but approve the
dissertation only for the purpose for which it has been submitted.

Internal Examiner External Examiner

Date:……………. Date:………………
 IES COLLEGE OF TECHNOLOGY, BHOPAL (M.P)
Department of Mechanical Engineering

DECLARATION

We hereby declare that the work, which is being presented in Major

Project, entitled “ MOTOR DESIGN OF ELECTRIC VEHICILE ”
for partial fulfilment of the requirements for the award of
degree of Bachelor of Technology in Mechanical Engineering branch,
submitted in the department of IES College of Technology, Bhopal is an
authentic record of our own work carried under the guidance of “Dr.
GURJEET SINGH ” we have not submitted the matter embodied in report
for award of any other degree.

MD TAHSIN ALAM (0177ME191057)

MD WAHID HUSSAIN (0177ME191063)
MD DANISH (0177ME191047)
MD ZEESHAN (0177ME191060)
MD SHAHANSA ALAM (0177ME191056)
 ACKNOWLEDGEMENT

We express our deepest gratitude to our Group Director Prof. Dr.Sunita Singh
for providing us with an environment to complete our project successfully.

We are deeply indebted to our Principal Dr. Anuprita Mishra, who modelled us
both technically and morally for achieving greater success in life. He showed us
different ways to approach a research problem and the need to be persistent to
accomplish any goal. We thank him heartily.

We are extremely obliged and thankful to Dr. Geetesh Goga, Head of Department
for his keen interest, continued encouragement and precious advice for the work.
With immense pleasure I place on record, my profound sense of gratitude and
sincere thanks to Project Guide Dr. GURJEET SINGH (Associate Professor, ME
Department), for his valuable guidance, motivation, inspiring encouragement and
continuous support for this work.

We also thank all the staff members of our college and technicians for their help
in making this project a successful one.

Finally, we take this opportunity to extend our deep appreciation to our family
and friends, for all that they meant to us during the crucial times of the
completion of our project.

MD TAHSIN ALAM (0177ME191057)

MD WAHID HUSSAIN (0177ME191063)
MD DANISH (0177ME1910 47)
MD ZEESHAN (0177ME191060)
MD SHAHANSA ALAM (0177ME191056)
 ABSTRACT

Electric vehicles (EV), as a promising way to reduce the greenhouse effect, have been researched
extensively. With improvements in the areas of power electrics, energy storage and support, the
electric vehicle provides competitive driving range and fuel economy compared to the internal
combustion engine vehicle (ICEV). Operating with optimised control strategies or utilising the
concept of the energy management system (EMS), the efficiency of the EV could be
significantly improved. In this review project, the modeling of the Motor of EVs will be
explained. Battery technology will also be discussed as a possibility to increase the energy
capacity of EV.

This project presents the conversion process of a traditional Internal Combustion Engine vehicle
into an Electric Vehicle. The main constitutive elements of the Electric Vehicle are presented.
The developed powertrain uses a three-phase inverter with Field Oriented Control and space
vector modulation. The developed on-board batteries charging system can operate in Grid-to-
Vehicle and Vehicle-to-Grid modes. The implemented prototypes were tested, and experimental
results are presented. The assembly of these prototypes in the vehicle was made in accordance
with the Portuguese legislation about vehicles conversion, and the main adopted solutions are
presented.
 Content

1. Introduction

2. Literature review

3. Methodology

4. Result and discussion

5. Conclusion

6. Reference
 1. INTRODUCTION

Oil prices are growing every day, which results from the general idea that oil is a resource
that will be virtually exhausted in the next 50 years. Whereas, it is expected an increase of
the overall vehicles number from 700 million to 2.5 billion during the same period.
Alternative solutions are needed, and are being proposed. Electric Vehicles (EVs) and Hybrid
Electric Vehicles (HEVs) that main manufactures are proposing, reveals a change in cities
mobility paradigm. Furthermore, several organizations and energy experts are suggesting
new policies to encourage research, development, and demonstration projects promoting
EVs. When the subject is EVs research, generality, is made an association with new and
revolutionary vehicles. However, low cost solutions using reliable off-the-shelf components
can also be proposed. This way, the conversion of Internal Combustion Engine (ICE)
vehicles in EVs is an attractive solution for the transitory period of coexistence. This process
is called “electric vehicle conversion” . In terms of engineering, this is a challenging process
that needs knowledge about mechanics and electronics. The main systems that need to be
integrated are the electric motor and respective controller, an energy storage system and
corresponding charging system. Different solutions for the energy storage system are being
proposed, however, the most common are batteries . Therefore, a batteries charging system is
also needed. Traditionally, batteries charging systems are implemented with static power
converters. Different topologies can be used [. In order to respect batteries technology,
different charging algorithms need to be used. Batteries charging systems can also be used to
transform EVs and HEVs in an energy storage system, which receives and delivers energy,
contributing to the power grid stability. Thus, besides charging batteries (Grid-to-Vehicle,
G2V), the energy can also flow in opposite sense (Vehicle-to-Grid, V2G), in accordance with
power grid characteristics and the driver benefits. This paper addresses the conversion of an
ICE into an EV, labelled as CEPIUM (Carro Elétrico Plug-In da Universidade do Minho).
The design, and prototype implementation, of all the necessary elements is presented,
namely, the powertrain power electronics converter and batteries charging system with G2V
and V2G features.
1.1 EV CONSTITUTIVE ELEMENTS
In a conversion process the characteristic of the EVs can be defined by the owner of the
vehicle, in accordance with his needs. This specification will define the choice of the
technical solutions that best suits. The conversion presented in this paper had three main
initial objectives. The first one was to have a vehicle that could be in accordance with the
Portuguese legislation. This is very important in order to facilitate authorities’ ratification.
The second objective was to have 60 km of autonomy, to enable a round-trip between the
University’s Campus (Guimarães and Braga). The last objective, but probably the most
important one, was to only integrate new technologies whose design and implementation was
developed inside the research group.
1.2 Electric Motor
Several types of electric motor can be used in conversions. All the existing technologies have
advantages and disadvantages. Its selection should be made in accordance with the required
performances for the vehicle. Axial flux permanent magnet synchronous motors are the most
used nowadays due to technological advantage], namely: -
High efficiency;
- High power density;
- Reduced engine size for the same power;
- Low maintenance costs;
- High power factor;
- Constant speed.
The Portuguese legislation imposes the mounting of the electric motor without removing or
weakening any structural elements of the vehicle. Also, imposes that the electric motor´s
power be less than the power of the original ICE. Considering this limitations and the initial
specifications for the CEPIUM conversion was selected the AFIR-S (Axial Flux Slotted
Internal Rotor External Stator Permanent Magnet) motor whose main characteristics are presented
in Table I.
1.3 Energy Storage System
 The energy storage system is one of the main critical elements in EVs and HEVs. It defines
the vehicle autonomy and represents an important portion of the vehicle weight. According to
the storage methods different systems can be used. From such systems, batteries are the most
popular, mainly due to its cost, energy density and technology maturity. Different batteries
technologies can be found in the market. However some are more adequate for power train
applications than others. The choice of one technology also depends on the vehicle
specifications. So, for the CEPIUM conversion were chosen Absorbed Glass Matt (AGM)
batteries, due to its reduced weight, increased energy density, improved reliability, and lower
cost. Typically, AGM batteries have very low internal resistance, and are capable to deliver
high currents on demand, offering a relatively long lifespan, even with large Depth-of-
Discharge (DoD). The chosen batteries have a 50% of DoD for 1100 cycles, and are 100%
recyclable. Considering the required autonomy it was designed a 6.7 kWh battery pack.
1.4 Developed AFIR-S Motor Controller
Several manufactures have commercial solution to drive electric motors, many of them
dedicated to EVs powertrains. However, as aforementioned, one of the main CEPIUM
conversion objectives was to only integrate technologies whose design and implementation
was developed inside the research group. Therefore, the controller shown in Fig. 2 was
designed and developed. This controller includes a three phase inverter, a digital control
system, one monitoring panel, and some data acquisitions and protection systems. The power
converter is composed by three IGBTs modules (IGBTs legs), drive circuits and snubber
capacitors. The digital control system was implemented in a 32-bit floating-point Digital
Signal Controller (DSC) TMS320F28335. The monitoring panel is composed by a 20X4
display and selection buttons. The signal conditioning and command boards are used to adapt
the electric signals between the control system and the three phase inverter (sensors and
command signals).
1.5 Developed Batteries Charging System
More than just charging EVs batteries, the charging systems major role is the contribution to
a new perspective about the EVs integration in the power grid. Due to V2G operation, EVs
are not seen as a problem anymore but as a power grid asset. Therefore, for the CEPIUM
conversion was developed a batteries charging system with G2V and V2G features. Also grid
power quality issues were respected, namely, sinusoidal current and unitary power factor
[16]. Fig. 3 shows the batteries charging system prototype that was developed for CEPIUM.
This charging system is composed by an ac-dc bidirectional converter and a dc-dc
bidirectional converter. The ac-dc converter uses a full-bridge full controlled topology using
four discrete IGBTs. In the dc-dc converter are used two IGBTs. The bidirectional power
flow is obtained through an adequate control of the IGBTs.

2. Literature review

THE BIGGEST challenge of our time is to achieve industrial development while

preserving the environment [1], Manuscript received April 7, 2006; revised March 10,
2007, October 9, 2007, and November 27, 2007. First published April 18, 2008; current
version published January 16, 2009. The review of this paper was coordinated by Dr. B.
Fahimi. F. U. Syed is with the Department of Electrical and Computer Engineering,
Wayne State University, Detroit, MI 48202 USA, and also with the Hybrid Vehicle
Program, Sustainable Mobility Technologies Laboratory II, Ford Motor Company,
Dearborn, MI 48120 USA. M. L. Kuang, M. Smith, and S. Okubo are with the Hybrid
Vehicle Program, Sustainable Mobility Technologies Laboratory II, Ford Motor
Company, Dearborn, MI 48120 USA. H. Ying is with the Department of Electrical and
Computer Engineering, Wayne State University, Detroit, MI 48202 USA (e-mail:
hao.ying@ wayne.edu). Color versions of one or more of the figures in this paper are
available online at http://ieeexplore.ieee.org. Digital Object Identifier
10.1109/TVT.2008.923690 [2]. To set an example of environmental preservation
commitment stewardship for the communities and to improve air quality and fuel
economy, major automotive companies have elected to develop hybrid electric vehicles
(HEVs) as the prime candidate for achieving these goals as they do not necessarily
require external battery charging or new infrastructure. HEVs can be categorized into
three types, which are the series hybrid system [3], [4], the parallel hybrid system [3], [4],
and a more recent type of complex HEV [5] called powersplit hybrid system [5]–[8]. The
power-split hybrid system has an internal combustion engine and generator connected to
a planetary gear set, a traction motor, and a high-voltage (HV) battery [23]. This power-
split hybrid architecture requires a highly coordinated vehicle control system [23]. In
series or parallel hybrid vehicles with conventional transmissions, newly developed
control algorithms [14]–[17] are needed to perform the blending of torque, speed, and
power from multiple power sources. Since a power-split hybrid configuration is similar in
behavior to a continuous variable transmission (CVT), the blending of torque, speed, and
power of multiple energy sources becomes more critical. Fig. 1 describes the powersplit
HEV configuration and its control system. Nonhybrid vehicles require complicated
algorithms to control the engine speed only during vehicle idle conditions. Various
researches have been done on controlling engine speed for these vehicles using
conventional approaches [24], [25]. There also exist literatures on the use of nonlinear
approaches to control the engine idle speed of nonhybrid vehicles [26]–[28]. In a power-
split HEV, the engine speed is independently controlled from the vehicle speed to provide
desired driver and HV battery power, which requires a sophisticated nonlinear vehicle
system control algorithm [23]. Due to the nonlinear behavior of the engine along with the
engine response delay (which is a function of various environmental conditions) and
engine rotational inertial effect, the desired engine power is differently achieved under
different driving conditions. Conventional approaches use linear control algorithms to
control the engine power, which can result in undesired engine speed behavior. This issue
arises from the fact that a complete high-fidelity mathematical model for the power-split
HEV system along with the environmental effects cannot accurately be modeled inside
the controller. Therefore, a controller adaptable to nonlinear behaviors and not requiring
detailed knowledge of the mathematical model of the plant is required to address such
issues [29]–[33].
 3. Methodology

Fig.1- AFIR-S motor used in the Electrical Vehicle

TABLE I. MOTOR’S CHARACTERISTICS

Characteristics Value Unit

Nominal Power Pn 30 kW
Speed ω 6000 rpm
Nominal Voltage Vn 187 V
Nominal Current In 113.5 A
Torque Τ 47.7 Nm
Number of Poles p 8 -
Nominal Frequency f 400 Hz
Stator Resistance Rs 19.35 mΩ
Inertia J 5.86 mkgm2
d-axis Stator Inductance Ld 100 µH
q-axis Stator Inductance Lq 160 µH
Voltage constant ke 42.1 V/1,000 rpm

4.RESULT AND DISCUSSION

This section will describe the process undertaken in which a simulation platform was
developed for the representation of the experimental vehicle and torque vectoring control
strategy. Developing an accurate representation of the system is a critical step in developing
an accurate simulation framework. Developing a system representation and simulation aids in
the design process and allows for the inspection and verification of the strategy proposed in
this project. As such developing a system representation provides a platform which can be
used for 38 the implementation of future work on the vehicle such as implementing an
energy efficiency optimisation strategy, an alternative torque vectoring strategy or other
avenues of research utilising the experimental vehicle. V
 5. CONCLUSION

This project presented the conversion of a traditional Internal Combustion Engine vehicle
into an Electric Vehicle. The main constitutive elements that were integrated were
presented. Both the powertrain and batteries charging power converters were developed
for this conversion. The powertrain is composed by a three-phase inverter with Field
Oriented Control and space vector modulation. The developed batteries charging system
has Grid-to-Vehicle and Vehicle-to-Grid features. Also grid power quality issues were
respected, such that it operates with sinusoidal current and unitary power factor.
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