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Jeep Report
Jeep Report
In this new era of industrialization and globalization, all we need to look at is to work upon a
clean, emission-free, and green environment. The tail pipe emission from vehicles is a major
contributor in air pollution in india. Hence with day by day increase in number of vehicles on
road the tailpipe emission contribution is also increasing. Also Our main objective to initiate the
autonomous electric jeep (E-jeep) research project was to develop a high torque electric vehicle
that can replace conventionally used IC engines so that carbon footprint can be reduced and can
work upon sustainability. Our main work in this report will intensely discuss all the aspects of
developing an electric vehicle while converting an IC engine-based vehicle.
Also, considering the driver/passenger safety and comfort as major concerns, our next phase of
this project will be to automate the E-jeep and develop a fully functional self-driving car using
sensors for image capturing and mapping along with specific algorithms to process all the data
simultaneously.
But as science further progressed, it created another problem of pollution and IC engines are the
major contributor in it. From the early 21st century, scientists again start looking for electric
vehicles because today clean and green energy production is much easier.
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[1] .
Also for a country like India with a large number of existing automobiles, it would not be a good
idea to scrap them completely in one go. Hence EV conversion kits are better suited. So further
seeing this scope in electric vehicles with advanced motors and controllers available. We decided
to convert the Mahindra Thar diesel engine into an electric motor car. We used a BLDC motor to
run the powertrain and remove the engine with its assemblies. We used a Kelly controller to
control the motor. For the source of energy, we used Lead Acid batteries to run our motor instead
of pre-existing diesel tanks.
The conversion of any vehicle is guided by the objectives of its owner and his needs.
Hence all the designs and specifications of the used technology is in accordance with some basic
initial objectives that were:-
First one was to design a kit which fits well inside Indian Government norms and regulations.
This was quite important for having a useful actual road legal kit. Secondly the kit must allow
the vehicle to propel for at least 120 mins to create optimal testing conditions. The last and one
of the most important objectives was to have a kit which will be affordable. Therefore the whole
project looked for low cost but effective ideas.
The article by Jeffin Francis[4]etal. helps us to identify the changes in electric drive lines and the
driveline of Mahindra diesel thar. It guides us in calculations regarding the power required in the
driveline of our Mahindra Thar and its range.
Thesis by Abkenar[6]etal. Gives deep understanding about working of Brushless DC motor its
various configurations and controller required for it. Helps us in understanding faults diagnostic
of the Brushless DC motor. It gives insight about modeling of the BLDC Motor Drive for EV
Application.
METHODOLOGY
The project started with the aim of converting an I.C. driven vehicle to an autonomous Electric
vehicle in various phases. These phases can be categorized into three parts
Phase one:
METHODOLOGY (MECHANICAL)
Study of the dynamometer was carried out covering various types like Rope pulley dynamo,
Prony brake dynamo, Hydraulic dynamo, and Eddy current dynamo. A final design of the
dynamometer was developed and its analysis was carried out on CREO software. The existing
throttle was disassembled and its working was studied.
Meanwhile, load testing was carried out on the vehicle chassis for loading of the forklift battery.
Loading was carried out with a 640 kg deadweight along with a live weight totaling 986 kg.
Fig 2Load Testing
The engine was dismantled and removed from the vehicle with the help of a crane.
Measurements of the chassis were taken and the mounts of the main motor were fabricated and
mounted keeping in view the constraint of utilizing existing drill holes and engine mounting
points. The motor was mounted by resting the motor mounts on engine mounting points at one
end and another end on the transmission face. The existing transmission was directly coupled to
the motor using a jaw coupling. Initially, vacuum inside the brake booster for the power braking
mechanism was created by the rotation of brake vacuum pump by the engine which was also
responsible for pumping the fluid for the power steering mechanism, after removal of the engine,
power brakes and power steering operation were achieved by employing a separate BLDC motor
for running the brake booster vacuum pump and hydraulic steering pump. The stock flywheel
was removed from the engine camshaft and fitted onto the motor shaft using bolts configuration.
For power steering, the vehicle’s stock hydraulic steering pump was dismantled from the engine
and coupled to the secondary motor using V-belt drive. The vacuum pump for power brakes was
stock attached to the alternator shaft so the whole assembly had to be removed from the engine
and was coupled to the motor using a ribbed belt drive. A separate mount was fabricated for the
alternator, secondary motor, and power steering pump and was fitted on the radiator grill
mounting points.
Since initially our vehicle i.e., Mahindra Thar 2017 had an internal combustion-based engine and
during our Phase-I, modification of IC engine based vehicle to the set-up of the electric motor
was required, the engine was forklifted and the transmission was jacked for support and
installation process for the electric motor was initiated hence proper mounting location and
design of the mount was finalized after several iterations for the primary motor(main motor
installed to deliver power to the wheels). Software used for designing and load analysis were
Creo parametric 7.0 and.
hence mounting for this system was also designed and manufactured after performing several
tedious iterations.
Note: For both primary and secondary mounts, pre-manufactured mounting points were used by
us and no modifications in chassis or frame were made.
Motor Specifications:
Primary Motor
2. Power (W)
12000
7. Speed (rpm)
3000
8. Motor weight (kg)
45
9. Insulation class
F
11. Protection
IP 65
Secondary Motor:
1. Motor type
BLDC (Brushless Direct
Current Motor)
7. Speed (rpm)
3000
8. Motor poles
20
9. Insulation class
F
10. Protection
IP 55
Modeling:
CREO 7.0 is a powerful tool for modeling 3D shapes and assemblies. Creo Parametric was
employed for modeling the primary motor mount using various features like Extrude,
Weldment, Hole, Mirror, etc and load analysis was carried out using Ansys 2021R1.
After taking all the preliminary steps like measuring the dimensions of the required working
space using vernier scale, measuring tape, modeling of the primary motor mount was initiated.
Mount was modeled in such a way that it was easier to manufacture within a certain set of
constraints like availability of material, robustness and ease of fabrication.
Primary Motor Mount:
For analysis, Ansys 2021 was preferred which is a very helpful and efficient software for various
types of analysis. Static structural analysis was done for the primary motor mount.
Img 5 showing the geometry imported in Ansys
Img 10 shows the placement of forces applied by motor and the transmotion on the mount
Img 11 showing momentum that occurs due motor and transmission
Img 18 shows isometric view of motor mount containing auxiliary motor steering fluid pump and
brake booster vacuum pump
This structure is used to support the auxiliary motor, steering fluid pump and brake booster
vacuum pump alternator. The auxiliary motor runs the brake booster vacuum pump by a flat belt
drive system and steering fluid pump by V belt drive system.
Img 19 shows meshing of structure contain auxiliary motor, steering fluid pump and brake
booster vacuum pump
Img 20 shows placement of forces applied by auxiliary motor, alternator and steering fluid pump,
showing fixed placement constraint positions.
Material Assignment
Factor Of Safety
The Factor of safety for Thar mount comes out to be 11.9
Factor of safety for structure comes out to be 5.87
METHODOLOGY (ELECTRICAL)
Initially, in this phase an old electric forklift was to be utilized for various electrical components
like motor, controller, foot throttle, and batteries.
Img 27Fig Forklift
The charger, initially of 48V and 70 amp was found to be damaged and since it was
manufactured in 1995, its circuit diagram could not be retrieved for repair purposes.
The onboard ironclad battery was rated to be of 48V DC with a capacity of 443 Ah, comprising
24 cells each rated at 2V with its specifications according to its nameplate given as follows:
1. No. of cells 24
The motor, after the inspection of internal terminals was found to be a brushed DC motor and its
specifications are found to be as follows:
2. B.S. 1727/1971
5. Voltage (V) 48
7. Rating 1 hour
8. Type TENV
9. Insulation class F
The initial controller of the forklift was found to be damaged so it was decided to design and
fabricate an FoC controller of the desired requirement. For that NE555 circuit was studied and
simulation was done on LT Spice software for generation of PWM signal, further calculations of
snubber circuit were also carried out. The controller circuit was designed using IGBTs and its
simulation was carried out on MATLAB Simulink using 20-24 IGBTs with 0.3Ω resulting in a
voltage drop of 47.2V and output current of 118.2 Amp.
Fig 31 NE555 circuit diagram
For testing purposes, 6 E-rickshaw batteries of rating 12V dc 100 Ah were connected in series
thus totaling a 72V 100Ah battery pack. A mount was designed and fabricated for the battery
pack and fitted at the rear part of the vehicle thus insulating the battery pack from the vehicle
body.
3. C5 capacity (Ah) 80
For the main motor, a BLDC motor controller was used with specifications as follows:
For the secondary motor and the switches operation, a DC-DC buck converter of rating 72-48V
DC, 25 amp was used.
Fig 37 DC-DC Converter 72-24V
For headlights, instrument cluster lights, and hall sensor for rpm measurement, another DC-DC
buck converter of rating 48-12V DC, 20 amp was used.
Both the motor controllers were mounted at the left side of the vehicle keeping in mind the
reduction in the length of thick power wires in order to reduce the I^2 R losses and improving
thermal and wire management. The stock throttle was replaced with an electric vehicle foot
throttle and the wires were adequately insulated and connected to the controller. For driver
assistance, a three-way key switch was used for driver assistance to turn ON/OFF the whole
electrical system. Dc contactors of the rating 48V coil voltage 200 amp and 48V coil voltage 150
amp were retrieved from the forklift for switching purposes both controlled using a key switch.
For motor protection, ANL fuses of rating 250 amp and 35 amp were used. For contactor coil
protection, glass tube fuses of rating 2 Amp and coil suppression or freewheeling diodes were
connected in antiparallel fashion across both contactor coils. The controller protection was done
using pre-charging wire-wound resistors of rating 1kΩ 10W were connected across the contacts
in order to prevent heavy inrush of current in the controller. Further, a 300 amp ANL fuse was
also connected across the positive terminal of the main motor controller for its protection. All the
switches, contactors, and fuses were mounted on a grade P3 electrical Bakelite sheet and were
fitted at the site of the glovebox. The whole switch panel area was then duly covered with a
transparent acrylic shield to give a clear view of the switches and contactors. The existing stereo
system plate was replaced with a custom stereo system plate fitted with an aluminum plate on
which driver assistance items like the key switch, motor rpm display, FNR (Front Neutral
Reverse) switch, potentiometer, and led indicators were mounted. The key switch has three
positions (off, 1, and 2). On turning the switch at ‘1’ position the 48V system and secondary
motor contactor gets turned ON along with the whole 12V supply (hall sensor, headlights,
taillights, and brake lights) and at ‘2’ position, 72V supply gets turned ON resulting in the
closing of main motor contacts.
The 48-12V buck converter had common ground with the 48V voltage supply and initially the
vehicle’s negative was ground to the body itself, so connecting the 48V ground to the body was
not done since it could lead to short-circuiting at the motor ends. The wiring diagrams of lights,
windshield wipers, and cockpit lights were referred from the vehicle’s wiring manual. The
negative wire was back-traced from all the required electrical accessories and the common body
ground was removed from the vehicle’s body. A separate ground wire was added and connected
to the common 48V ground. All the high-power-consuming light bulbs were replaced with less
wattage LED lamps for adequate illumination and reduced power consumption. In the whole
process, the vehicle’s ECU (Electronic Control Unit) was completely isolated and not used as per
the constraints. In case of emergency situations, a battery-disconnect kill switch was connected
between the contactors and battery. The whole wire selection was made according to the
American Wire Gauge system. For main motor and 72V connections, 50 mm^2 wires crimped
with 50 no. Wire lugs were used. For 48V connections, 16 mm^2 and 10 mm^2 wires were used.
All the wires, lugs, thimbles, and terminal nut-bolts were selected of copper material for better
conductivity and reduced losses. All the wire connections were covered with layers of
high-tension tape, insulating rubber tape followed by heat shrink tubes for increased insulation
and proper cable management was done using wire conduits and sleeves. A separate terminal
box was fabricated for the main motor terminals in which three layers of grade P3 Bakelite
sheets were sandwiched together using epoxy resin and bolted down to the main motor mount.
Three terminals made of copper bolts were protruded out from the box and separated using
Bakelite ribs to prevent short-circuiting. The whole terminal box was then concealed using a
custom 3-D printed cover. All the high voltage areas were marked using standard triangular high
voltage stickers.
RESULTS AND DISCUSSION
In the case of the secondary motor, the starting current was going beyond the current rating of
72-48V DC-DC buck converter which resulted in automatic tripping and beeping of the
converter at the time of motor starting even at no-load conditions. So, a 5kΩ variable resistance
or potentiometer had to be connected to its controller acting as a throttle instead of direct
starting.
The whole apparatus of the auxiliary motor was tested. The testing was first performed on power
steering pump alone with half-inflated tyres with the vehicle in a stationary position in order to
simulate heavy loading on the motor and current drawn was noted. According to the motor
performance characteristics, maximum torque could be achieved between 1200-1500 rpm. A
potentiometer was used to set the motor rpm within this range, and the current was noted.
Afterward, the brake pump was also coupled, and final readings of current drawn by the motor
turned out to be 18-19 amp in regular turning and surges of about 28 amp at the extreme end of
steering turns.
During testing in the case of power bakes, an issue of vacuum pump overheating was
encountered. Lack of proper oil flow in the pump body was assumed to be the cause since oil
was fed into the pump at pressure from the engine. So, the whole troubleshooting was carried out
in a series of iterations as follows:
Iteration 1: In this iteration, a high-pressure vessel (small gas cylinder) was modified with
adequate inlet and outlet hydraulic hoses and fitted at a certain height in order to allow the oil
flow under the effect of gravitational force. It was noted that in spite of feeding oil from height, a
very little volume of oil was coming out of the return pipe resulting in foaming of oil and heating
of hose pipe. The pump’s temperature also grew quite high. The brake pedal was working in
normal condition and very less resistance was felt while pressing as it is in the case of power
brakes.
Iteration 2: In this iteration, the pump was removed from the alternator and the vacuum body was
opened. The body was carefully examined for any foreign substances which could cause
excessive friction between the vanes and outer body but the body was clear. On further
inspection, it was noted that the inlet oil valve diameter was very small since initially oil was
getting pumped into the body under pressure. So in conclusion, it became evident that the pump
was getting heated due to lack of oil flow inside the body which acted as a lubricant along with
coolant for the vanes. The team had to make a decision between two alternatives:
1. Either install a pressure pump between the reservoir and the vacuum pump which would
pump the oil at pressure inside the body or replace the existing system with an
electronic 12V DC vacuum pump.
2. Increase the diameter of the inlet valve so that oil could easily flow in and out of the
body.
The second alternative was selected as the first one required replacement of existing 12V and
48V supply and further, it would have led to increased power load on the battery pack. On
testing, it was noted that the oil volume from the return hose increased substantially and the
pump heating was reduced drastically without any effect on the vacuum produced inside the
brake booster.
Iteration 3: In this iteration, the reservoir mount was designed and fabricated. The reservoir was
fitted with the required hydraulic pressure hoses and mounted at an appreciable height keeping oil
spillage and aesthetics in mind. The whole assembly of brake pump and steering pump was tested.
A negative pressure gauge was used to measure the vacuum generated inside the brake booster.
Firstly, readings were taken without the stock vacuum canister, which resulted in a vacuum value
of 398 mmHg. Secondly, the vacuum canister was attached to the pump which pushed the
generated vacuum value to 600 mmHg and smooth application of brakes. Further temperature
readings of the vacuum pump, corresponding motor rpm, and current values were noted. It was
observed that initially, temperature grew in a non-linear fashion and after a span of continuous
running (12 minutes), the temperature value got saturated up to 73°C. A graph was plotted as
shown.
Fig 41 Temperature/Pressure vs run time graph for cooling oil
Further, these values were again noted for another working Mahindra THAR of the same variant
and year of manufacturing. Both the readings upon comparison showed a significant similarity.
CONCLUSION
Phase one of this project is completed in which Mahindra Thar CRDe BS-IV converted into an
electric vehicle. Mahindra Thar engine is replaced with BLDC motor to run the driveline. The
motor's output shaft is coupled with the gearbox input shaft using flexible jaw coupling. The
power source to run the motor is electric batteries. The motor is controlled by a Kelly controller.
Auxiliary BLDC motor is used to run the brake booster vacuum pump and steering fluid pump.
Thar is ready for road testing in direct drive. The acceleration of the motor is controlled by the
same foot pedal stock throttle is replaced by an electrical throttle .
Annexure/appendix
calc
REFERENCES
[2]S. Kaleg, A. Hapid, and M. R. Kurnia, “Electric Vehicle Conversion Based on Distance,
Speed and Cost Requirements,” Energy Procedia, vol. 68, pp. 446–454, Apr. 2015, doi:
10.1016/j.egypro.2015.03.276.
[3]Bhatt, Pooja and Mehar, Hemant and Sahajwani, Manish, Electrical Motors for Electric
Vehicle – A Comparative Study (April 3, 2019). Proceedings of Recent Advances in
Interdisciplinary Trends in Engineering & Applications(RAITEA) 2019, Available at SSRN:
Electrical Motors for Electric Vehicle – A Comparative Study or
http://dx.doi.org/10.2139/ssrn.3364887
[6]Abkenar, Alireza Tashakori. "BLDC Motor Drive Controller for Electric Vehicles." Faculty of
Science, Engineering and Technology Swinburne University of Technology, Doctor of Philosophy
Thesis (2014). Available at:
https://researchbank.swinburne.edu.au/file/f63fd114-1fc2-431d-b038-64838f9751be/1/Alireza%
y20Tashakori%20Abkenar%20Thesis.pdf