Design Aspects of EVs and HEVs

Unit I
 HEV/integration and Significance
• The concept of a hybrid electric vehicle is almost as old as the automobile itself.
• The primary purpose, however, was not so much to lower the fuel consumption
but rather to assist the ICE to provide an acceptable level of performance.
• In the early days, ICE engineering was less advanced than electric motor
engineering.
• The first hybrid vehicles reported were shown at the Paris Salon in 1899.
• These were built by the Pieper establishments of Liège, Belgium and by the
Vendovelli and Priestly Electric Carriage Company, France.
• The Pieper vehicle was a parallel hybrid with a small air-cooled gasoline engine
assisted by an electric motor and lead–acid batteries.
• It is reported that the batteries were charged by the engine when the vehicle
coasted or was at a standstill.
• When the driving power required was greater than the engine rating, the
electric motor provided additional power.
🞛A hybrid electric vehicle (HEV) augments an electric vehicle
(EV) with a second source of power referred to as the alternative
power unit (APU).
🞛 A hybrid can achieve the cruising range and performance
advantages of conventional vehicles with the low-noise, low-exhaust
emissions, andenergy independence benefits of electric vehicles
🞛 Accordingly, the hybrid concept, where the alternative power unit
is used as a second source of energy, is gaining acceptance and is
overcomingsomeof the problems of pure electric vehicles.
🞛 Any vehicle that combines 2 or more sources of power is
said to be hybrid. For example, a moped (a motorized
pedal bike), diesel-electric hybrid locomotives
◈Relies not only on batteries but also on an internal
combustion engine which drives a generator to provide
electricity and may also drive a wheel.
◈Alternative power unit to supply the power required by the
vehicle, to recharge the batteries, and to power
accessories like the air conditioner and heater.
🞛 Two types of hybrid vehicle configurations

🞛Parallel Hybrids

🞛Series Hybrids
🞛 Fuel tank, which supplies gasoline to the
engine.
🞛 Set of batteries that supplies power to an
electric motor.
🞛 Both the engine and the electric motor can
turn the transmission at the same time, and
the transmission then turns the wheels.
🞛 When the APU is off, the parallel hybrid runs like
an electric vehicle
🞛 When the APU is on, the controller divides
energy between the drive train (propulsion) and
the batteries (energy storage).
🞛 Under acceleration, more power is allocated to
the drive train than to the batteries. During
periods of idle or low speeds, more power goes
to the batteries than the drive train.
🞛 The batteries also provide additional power to
the drive train when the APU is not producing
enough and also to power auxiliary systems such
as the air conditioner and heater.
🞛 Similar to an electric vehicle with an on-
board generator
🞛 The vehicle runs on battery power like a pure
electric vehicle until the batteries reach a
predetermined discharged level.
🞛 At that point the APU turns on and begins
recharging the battery.
🞛 The APU operates until the batteries are
charged to a predetermined level.
🞛 APU never directly powers the vehicle
🞛 The length of time the APU is on depends on
the size of the batteries and the APU itself.
🞛 Since the APU is not directly connected to
the drive train, it can be run at its optimal
operating condition; hence, fuel economy is
increased and emissions are reduced relative
to a pure IC engine vehicle.
"In this system, the engine is used to supply electrical power to the motor,
which then turns the wheels"

A. Series Hybrid

B. Parallel Hybrid

C. Plug-in Hybrid

D. Series-parallel Hybrid
"The wheels are driven by both the engine and the
motor"

A. Series Hybrid

B. Parallel Hybrid

C. Plug-in Hybrid

D. Series-parallel Hybrid
Overview of vehicle development process

Theflowof car developmentuntilits completion

Software's for Automotive design
• Automotive Class A surfacing using ALIAS
• Automotive Sheet Metal Design using NX CAD
• Automotive Plastic Design using CATIA V5
• Automotive Wiring Harness using CATIA V5
• Automotive Lighting Design CATIA V5
• Automotive Seating Design using Catia V5
1. DEVELOPMENT PLANNING
The development planning department is the first step for
creating an actual vehicle based on the planning or the styling.
Image of the future bringing people inspiration.

A. BASIC LAYOUT,
B. STYLING,
C. DIGITAL DEVELOPMENT,
D. COMPETITIVE CAR ANALYSIS.
1. DEVELOPMENT PLANNING (Contd.)
A. BASIC LAYOUT
Summarize the overall vehicle’s general layout by studying the
engine room layout and a lot of functions required for cars, such
as driving performances, interior space, exterior, etc.
1. DEVELOPMENT PLANNING (Contd.)
B. STYLING
Make the car’s styling sketches, and study the styling with
computer graphics or clay models to create 3D-CAD data.
1. DEVELOPMENT PLANNING (Contd.)
C. DIGITAL DEVELOPMENT
Create a new development process by using the digital
technologies. In addition, conduct the vehicle verification
virtually to develop a process sharing the information of
designing, testing, and production engineering.
1. DEVELOPMENT PLANNING (Contd.)
D. COMPETITIVE CAR ANALYSIS
To plan the development concept or the target performances,
analyse the competitive cars’ features from various viewpoints
according to the measurement or the teardown investigation of
those to evaluate the performances or ease of use.
 2. DEVELOPMENT DESIGNING
Carry out consistently the process of the concept making
through to the production drawing fix in conformity with the
corresponding vehicle concept.
The development designing department makes the basic
concept about parts/system’s specifications and performances,
cost, etc., reviews and makes drawings of the structure and
shape, and then fixes the production drawings consistently.
The development designing department makes drawings by
optimizing the structure and shape with the digital technology,
and then feeds back the test and evaluation results, etc. of the
prototype parts to seek higher quality and performances.
2. DEVELOPMENT DESIGNING (Contd.)

A. BODY / DOOR / EXTERIOR DESIGNING,

B. INTERIOR DESIGNING,
C. ELECTRONICS / ELECTRICAL SYSTEM DESIGNING,
D. CHASSIS DESIGNING,
E. ELECTRIC VEHICLE DESIGNING,
F. POWERTRAIN DESIGNING,
G. ACCESSORIES/SPECIAL MODIFICATION VEHICLE DESIGN.
2. DEVELOPMENT DESIGNING (Contd.)
A. BODY / DOOR / EXTERIOR DESIGNING
Design body, door, exterior parts, wiper, lamp, glass, etc. by
studying various requirements of styling, performances, structure,
strength, rigidity, operability, etc. via CAD/CAE.
2. DEVELOPMENT DESIGNING (Contd.)
B. INTERIOR DESIGNING
Design instrument panel, air bag, seat, seat belt, upholstery parts,
air-conditioner parts, etc., which are the most familiar parts for
customer, by the repeated study of those structure and
performances.
2. DEVELOPMENT DESIGNING (Contd.)
C. ELECTRONICS / ELECTRICAL SYSTEM DESIGNING
Conduct control design of respective ECUs in the
body/powertrain system which are brains of cars, and of various
devices such as car navigation, audio, etc., or design
circuits/layout of harnesses which are blood vessels of cars,
meters/switches, etc.
2. DEVELOPMENT DESIGNING (Contd.)
D. CHASSIS DESIGNING
Study underbody parts concerned performances and structure
and design parts such as suspension, steering wheel, brake, tire
and wheel which are deeply related to the basic performances
“Drive”, “Turn”, and “Stop” of cars.
2. DEVELOPMENT DESIGNING (Contd.)
E. ELECTRIC VEHICLE DESIGNING
Study performances, layout/structure, and design parts such as
motor system, charger, battery pack, invertor, etc. which are the
basics of electrical vehicles.
2. DEVELOPMENT DESIGNING (Contd.)
F. POWERTRAIN DESIGNING
Analyse performances, study structure, plan layout, and design
parts such as engine, transmission, drivetrain system, fuel system,
etc. which are the heart of cars.
 2. DEVELOPMENT DESIGNING (Contd.)
G. ACCESSORIES/SPECIAL MODIFICATION VEHICLE DESIGN
Design and develop accessory parts for exterior parts, interior parts,
electronic/electrical parts, navigation/audio, etc., and design and
develop special modification vehicles such as vehicle for disabled persons.
 3. DEVELOPMENT TESTING
Improve a vehicle thoroughly to respond to our customer’s joy
for driving.
The development testing department consists largely of the
testing of function, vehicle, and powertrain, and plays a role in
evaluation, verification, and improvements of design quality with
a mutual cooperation.
If the development designing department is a parent of creating
cars, the development testing is, as it were, a foster parent who
trains and brings up the vehicles.
A. FUNCTION TESTING,
B. VEHICLE TESTING,
C. POWERTRAIN TESTING.
3. DEVELOPMENT TESTING (Contd.)
A. FUNCTION TESTING
Conduct the development related to safety such as impact
safety, braking, strength, etc. the vehicle should provide,
quietness, vehicle handling, etc.
3. DEVELOPMENT TESTING (Contd.)
B. VEHICLE TESTING
Conduct the overall vehicle development such as emission
performance in compliance with each nation’s regulation, as
well as responding to our customer’s driving pleasure for
practicality, driving performances, environmental performances
durability, etc .
3. DEVELOPMENT TESTING (Contd.)
C. POWERTRAIN TESTING
Conduct the development related to performances, function,
durability, and reliability of engines, transmissions, driveline, and
EV components that support the vehicle’s driving performances.
 4. PRODUCTION ENGINEERING
Plan/conduct/support the human and environment friendly
production line with effic iently controlled cost.
The production engineering department begins with planning
and reviewing the powertrain and vehicle production line,
designs the production facilities, machines, tools and jigs,
prepares the production plant related documents, and supports
the mass-production.
In addition, the production engineering department strives for
power and energy conservation to minimize environmental
impacts.
4. PRODUCTION ENGINEERING (Contd.)

1. PRODUCTION PROCESS PLANNING,

2. DESIGNING OF PRODUCTION FACILITIES, MACHINES, TOOLS
AND JIGS,
3. CONSTRUCTION OF PRODUCTION LINE,
4. PRODUCTION SUPPORT.
4. PRODUCTION ENGINEERING (Contd.)
A. PRODUCTION PROCESS PLANNING
Plan the production processes with the people - and
environmental - friendly production line in mind, while efficiently
keeping the cost low. Structural study, Plant layout, Process
plan/man-hour planning, Production line planning, Equipment/jig
planning.
4. PRODUCTION ENGINEERING (Contd.)
B. DESIGNING OF PRODUCTION FACILITIES, MACHINES,
TOOLS AND JIGS
Design using the latest digital technologies with the accumulated
know-how. Electrical control designing, Die designing,
Equipment/jig designing, Stamping die/plastic mold designing.
4. PRODUCTION ENGINEERING (Contd.)
C. CONSTRUCTION OF PRODUCTION LINE
Supervise and construct to enable the secure production start
within the determined period. Construction management,
Construction work.
4. PRODUCTION ENGINEERING (Contd.)

• D. PRODUCTION SUPPORT
• Conduct the quality creation and the production support to
enable
• the delivery of the stable- quality vehicle to our
customer.
• Vehicle quality build-in, Plant production related
documents, Establishment of inspection system.
4. PRODUCTION ENGINEERING (Contd.)
 MCQ
The automobile chassis consists of the engine,
frame, power train, wheels, steering and …………..
a. The doors
b. Luggage boot
c. Wind shield
d. Braking system
The power train includes the clutch,
propeller shaft, differential and …………….
a. Steering gear
b. Front axles
c. Transmission
d. Chassis
Competitive car analysis is done in which stage of
development.

A. DEVELOPMENT PLANING
B. DEVELOPMENT DESIGNING
C. DEVELOPMENT TESTING
D. PRODUCTION ENGINEERING
❑ Electric drive motors
🞛 to provide the power for propulsion
🞛 converts electric energy to mechanical energy
(motion) to drive the hybrid vehicle.
🞛 Direct Current Motors, Alternating Current Motors
🞛 The two possible configurations of electric drive
motors in a hybrid vehicle
🞛 single electric motor connected to the wheels through a
drive train and multiple electric motors, one located at
each wheel.
❑ Auxiliary Power Units
🞛 Supplies the baseline power required to the vehicle,
recharges the batteries and powers accessories such
as the air conditioner and heater.
🞛 The APU can consist of a mechanical type engine or a
fuel cell.
🞛 Spark Ignition Engine, Compression Ignition Engines, Fuel
Cells
❑ Generators
🞛 to convert the mechanical power into
electrical power when used in a series
hybrid.

❑ Energy Storage Systems

🞛 Peak power required in hybrid vehicles is met
by devices like batteries, capacitors or a
flywheel.
🞛 store energy and readily release it when
needed.
❑ Regenerative Braking
🞛 some of the energy is converted into
electrical energy and stored.
🞛 rotational energy of the braking mechanism
generates electrical power and stores it in
the batteries.

❑ Control Systems
🞛 contains two main components-command and
power components.
🞛command component manages and processes the
driver’s instructions.
🞛power component chops power flows to control
the motor’s power intake.
 Major Components Hybrid Drive Trains

• Gas Engine
• Electric Drive Motor
• Power Control Unit
• High Voltage Battery
• Generator
• Planetary Gear (Power Split Device)
Gas Engine

• The main source of power for HEV remains the gasoline engine. But these aren't your
ordinary powertrains. They're built for high efficiency and low emissions.

Electric Drive Motor

• The Electric Drive Motor is an AC synchronous-type motor using permanent

neodymium magnets and a rotor consisting of stacked electromagnetic steel plates.
• Because the magnets are arranged in an optimal V-shape configuration, the motor
produces both high output and drive torque.
Power Control Unit
• The Power Control Unit is the brains behind the hybrid system, integrating gas engine
and electric motor power in a way that is both seamless and achieves the highest levels
of performance.
• The unit contains an inverter to convert direct current from the battery to alternating
current to run the electric motor, and a DC/DC converter to produce 12V current.
• As well, the unit's high-voltage power circuit raises the voltage from the power supply,
thus allowing a reduction in current and subsequently a reduction in the size of the
inverter. More power. Less space.

High Voltage Battery

• The hybrid nickel-metal hydride HV battery never needs to be plugged in.
• That's because the battery is being constantly re-charged by either the gas engine by
way of the generator when in cruising mode, or by the electric motor during
deceleration and regenerative braking.
Generator
• The AC synchronous-type generator is just the thing to charge the battery and supply power to the high-
output electric drive motor (or motors) as needed.
• To provide the optimum power to the motor, the generator is rotated at high speeds, thus increasing the
rpm range from the conventional maximum output of 6,500 up to a whopping 10,000 rpm.
• A higher rpm rate increases power supply in the medium-speed area and improves acceleration in the
low/medium-speed range.
• The result is more power when you need it without burning extra fuel.

Planetary Gear (Power Split Device)

• By splitting power into two routes: mechanical and electrical, the planetary gear, also known as the
"hybrid transaxle," can transfer power between the engine, motor/generator, and wheels in just about any
combination you could imagine.
• Directly linked to the engine, the rotational shaft of the planetary carrier inside the gear mechanism is able
to transmit the motive power to the outer ring gear and the inner sun gear, using pinion gears.
• The rotational shaft of the ring gear, on the other hand, is directly linked to the motor.
• It transmits the drive force to the wheels, while the rotational shaft of the sun gear is directly linked to the
generator.
 Hybrid Vehicle Powertrain System
‘
• Hybrid Vehicle Powertrain Systems combine conventional
powertrain components,
• Internal combustion engine and
• Transmission,
• With new electric components,
• Electric motor,
• Power electronics and
• High voltage energy storage, such as a battery.