Introduction ae | Electric Vehicles (EVs) or Electrically Chargeable Vehicles (ECVs) usually refers to any vehicle that is powered, in part or in full, by a battery that can be directly plugged into the mains, Pure-Electric Vehicles (Pure-EVs) are electric vehicles powered only by a battery. Plug-in hybrid electric vehicles (PHEVs) use batteries to power an electri¢ motor, as well as another fael, such as gasoline o diesel, to power an intemal combustion engine. Extended-Range Electric Vehicles (E-REV) are powered by a battery with an ICE- powered generator on board. E-REVS are like pure-EVs but with a shorter battery range of around 50 miles ‘acme Hybrid Electric Vehicles (HEV) are powered by a battery and/or an ICE. The powe " source is selected automatically by the vehicle, depending on speed, engine load anc batiery charge. This battery cennot be plugged in, so charge is maintained by regenerative braking supplemented by ICE-generated power. 1 BTS Pian Hyaerbed CampaIntroduction 23 November, 2023 ME F317 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 1 BITS-Pilani, Hyderabad CampusIntroduction kx + Electric Vehicles (EVs) or Electrically Chargeable Vehicles (ECVs) usually refers to any vehicle that is powered, in part or in full, by a battery that can be directly plugged into the mains. 23 November, 2023 MEFII7 ExaiNes, Morors & Monitity Instructor Prof.N. Jalaian 1 BITS-Pilani, Hyderabad Campus:Introduction kx + Electric Vehicles (EVs) or Electrically Chargeable Vehicles (ECVs) usually refers to any vehicle that is powered, in part or in full, by a battery that can be directly plugged into the mains. * Pure-Electric Vehicles (Pure-EVs) are electric vehicles powered only by a battery. * Plug-in hybrid electric vehicles (PHEVs) use batteries to power an electric motor, as well as another fuel, such as gasoline or diesel, to power an internal combustion engine. + Extended-Range Electric Vehicles (E-REV) are powered by a battery with an ICE- powered generator on board. E-REVs are like pure-EVs but with a shorter battery range of around 50 miles. + Hybrid Electric Vehicles (HEV) are powered by a battery and/or an ICE. The power source is selected automatically by the vehicle, depending on speed, engine load and battery charge. This battery cannot be plugged in, so charge is maintained by regenerative braking supplemented by ICE-generated power. 23 November, 2023 ME FII7 ENGINES, Morons & Mositity Instructor: Prof.N. Jalaian 1 BITS-Pilani, Hyderabad CampusElectric Vehicle Layouts kx + There are several types of electric vehicles, but many look very similar to their nonelectric counterparts so look out for the badging! The following pictures show some common types: Hybrid car — Toyota Prius 23 November, 2023 ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 2 BITS-Pilani, Hyderabad CampusElectric Vehicle Layouts + There are several types of electric vehicles, but many look very similar to their nonelectric counterparts so look out for the badging! The following pictures show some common types: Hybrid car — Toyota Prius Plug-in hybrid Volkswagen Golf GTE 23 November, 2023 ME F317 ENatxes, Motors & Mosittty Instructor: Prof. N. Jalaian 2 BITS-Pilani, Hyderabad CampusLayouts ml + There are several types of electric vehicles, but many look very similar to their nonelectric counterparts so look out for the badging! The following pictures show some common types: 23 November, 2023 Instructor: Prof.N. Jalaian 2 BITS-Pilani, Hyderabad CampusThere are several types of electric vehicles, but many look very similar to their nonelectric counterparts so look out for the badging! The following pictures show some common types: Electric motorcycle (Yamaha) Commercial hybrid truck Passenger bus using electric power from a hydrogen fuel cell 23 November, 2023 ME F317 ENaixes © Instructor: Prof. N. Jalaian 2 BITS-Pilani, Hyderabad CampusElectric Vehicle Layouts + There are several types of electric vehicles, but many look very similar to their nonelectric counterparts so look out for the badging! The following pictures show some common types: Trot | | [ene 1 Charging On-board] Drive satennans|_ char = tater Drive control = etn co) Wheels sav /-—— bene p ° 2 battery | converter Generic electric vehicle layout 23 November, 2023 ME FII7 ENGINES, Morons & Mositity Instructor: Prof.N. Jalaian 2 BITS-Pilani, Hyderabad CampusElectric Vehicle Layouts + There are several types of electric vehicles, but many look very similar to their nonelectric counterparts so look out for the badging! The following pictures show some common types: Twottle Charging station’mains | ‘On-board Drive charger battery Drive control Motors) Transmission = 23 November, 2023 1224V //— converter oc/oc Generic electric vehicle layout ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 2 BITS-Pilani, Hyderabad CampusSingle Motor 23 November, 2023 MEFII7 ENaines, Morors & Monitity Instructor Prof.N. Jalaian 3 BITS-Pilani, Hyderabad Campus:Single Motor * A ‘classic’ pure-EV layout uses a single motor driving either at the front or rear wheels. VW Golf-e layout with the motor at aSheolgnt.gndshe battergATUTTIRaT cs, Morons & Mositity Instructor. Prof.N.Jalaiah 3 BITS Pilani, Hyderabad CampusSingle Motor + A ‘classic’ pure-EV layout uses a single motor driving either at the front or rear wheels. * Most EVs of this type do not have a transmission gearbox because the motor operates at suitable torque throughout the speed range of the vehicle. * Hybrid cars vary in layout, but the basic design is similar to the pure-electric car. The obvious difference being the addition of an ICE. VW Golf-e layout with the motor at Sectional view of a drive the front and the battery at the rear ~—_ motor and the basic driveline 23 November, 2023 ME F317 ENaixes, Motors & Mosittty Instructor: Prof. N. Jalailan 3 BITS-Pilani, Hyderabad CampusSingle Motor + A ‘classic’ pure-EV layout uses a single motor driving either at the front or rear wheels. * Most EVs of this type do not have a transmission gearbox because the motor operates at suitable torque throughout the speed range of the vehicle. * Hybrid cars vary in layout, but the basic design is similar to the pure-electric car. The obvious difference being the addition of an ICE. * Motor for a plug-in hybrid is shown here where it forms part of the gearbox assembly. VW Golf-e layout with the motor at Sectional view of a drive PHEV layout the front and the battery at the rear ~—_ motor and the basic driveline 23 November 1023 ME FII7 ENGINES, Morons & Mositity Instructor: Prof.N. Jalaian 3 BITS-Pilani, Hyderabad CampusWheel Motors 23 November, 2023 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 4 BITS-Pilani, Hyderabad CampusMounting the motors in the wheels makes more space available for batteries, passengers or cargo 23 November, 2023 'Y Instructor: Prof.N. Jalaian 4 — B|TS-Pilani, Hyderabad CampusProtean Electric’s in-wheel motor system is arguably simpler than a conventional electric automobile, which has constant velocity joints, drive shafts and a centrally mounted transmission and motor. 23 November, 2023 N ITY Instructor: Prof.N. Jalaiah 4 —BITS-Pilani, Hyderabad CampusProtean Electric's in-wheel motor system is arguably simpler than a conventional electri automobile, which has constant velocity Joints, drive shafts and a centrally mounted transmission and motor. 23 November, 2023 Instructor: Prof.N. Jalaian 4 BITS-Pilani, Hyderabad Campus:Wheel Motors (Cont'd) kx 23 November, 2023 ‘Gives, Morors & Mositity Instructor: Prof.N. Jalaian 5 BITS-Pilani, Hyderabad CampusWheel Motors (Cont’d) kx Protean Electric is a major player in the development of in-wheel EV motors. The drive consists of a permanent-magnet synchronous motor and integrated electronics. The electronics precisely control motor current, so each in-wheel motor can deliver the torque required in about a millisecond. In-wheel motors allow for torque-vectoring, which means different torques can be applied to different wheels. This can significantly improve handling. 23 November, 2023 MEFI17 ENaixes, Motors & Mositity Instructor: Prof. N. Jalailan 5 BITS-Pilani, Hyderabad CampusWheel Motors (Cont’d) kx + Protean Electric is a major player in the development of in-wheel EV motors. * The drive consists of a permanent-magnet synchronous motor and integrated electronics. * The electronics precisely control motor current, so each in-wheel motor can deliver the torque required in about a millisecond. * In-wheel motors allow for torque-vectoring, which means different torques can be applied to different wheels. This can significantly improve handling. * The challenge with wheel motors has always been to keep unsprung mass to a minimum. * This improves the ride quality for the driver and passengers and makes it easier for the suspension to keep the tyres in contact with the road. + Avychicle powered by in-wheel electric motors will have significantly greater unsprung mass, because the weight of a motor will be carried in each powered wheel. 23 November 1023 ME FII7 ENGINES, Morons & Mositity Instructor: Prof.N. Jalaian 5 BITS-Pilani, Hyderabad CampusHybrid Electric Vehicle Layouts | [im 23 November, 2023 ME F317 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 6 — BITS-Pilani, Hyderabad CampusHybrid Electric Vehicle Layouts | [im * Hybrid vehicles use at least one electric drive motor in addition to the internal combustion engine (ICE). * There are several different ways in which this can be combined and a number of different motors and engines. 23 November, 2023 MEFI17 ENaixes, Motors & Mosittty Instructor: Prof. N. Jalaian 6 BITS-Pilani, Hyderabad CampusHybrid Electric Vehicle Layouts | [im * Hybrid vehicles use at least one electric drive motor in addition to the internal combustion engine (ICE). * There are several different ways in which this can be combined and a number of different motors and engines. + The main objectives of a hybrid vehicle are (i) reduction in fuel consumption (and CO,), (ii) reduction in emissions, and (iii) increased torque and power. 23 November, 2023 MEFI17 ENaixes, Motors & Mosittty Instructor: Prof. N. Jalaian 6 BITS-Pilani, Hyderabad CampusHybrid Electric Vehicle Layouts | [im OOO OOO Hybrid layout (parallel): 1, ICE; 2, clutch; 3, motor; 4, transmission; 5, inverter; 6, battery 23 November, 2023 MEFII7 Exotves, Morors & Mooitity Instructor Prof.N. Jalaian 6 BITS-Pilani, Hyderabad Campus:HEV Layouts (Cont'd) _ 23 November, 2023 ORS & MOBILITY Instructor: Prof.N. Jalaian 7 BITS-Pilani, Hyderabad Campus:HEV Layouts (Cont'd) * The motors are generally permanent magnet synchronous types and work in conjunction with an inverter (converts DC to AC). * The key benefit of an electric drive is high torque at low speed, so it is an ideal supplement to an ICE where the torque is produced at higher speeds. * The combination therefore offers good performance at all speeds. 1 1, hybrid; 2, standard engine (1600ce); 3, downsized engine 4, motor (15 kW) * The following graph shows typical results. Torque —> Speed —> 23 November, 2023 ME F317 ENaixes, Motors & Mositity Instructor: Prof. N. Jalaian 7 BITS-Pileni, Hyderabad CampusHEV - Classification & Functions kx Stop/stert system y Vv Mild hybrid v v v Strong hybrid v Vv v v Plug-in hybrid N v Vv v v 23 November, 2023 MEFII7ENaives, Morons & Moniiity Instructor Prof.N. Jalaian 9 BITS-Plleni, Hyderabad CampusOperating Modes of a HEV x 23 November, 2023 ‘Gixes, Morors & Mositity Instructor: Prof.N. Jalaian 10 BITS-Pilani, Hyderabad CampusOperating Modes of a HEV kx ee Ca) me) Come) Gm CD Motor Function Reduce fuel Biel ‘consumption Efficiency by halting the Recover and store generated energy generation and load by efficient battery control 23 November, 2023 ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 10 BITS-Pilani, Hyderabad CampusOperating Modes of a HEV kx High No generation Nocharging Engine Assist wth ‘Auto stop = startup by partial load system 8 IMA & wide open = — Generate for & 12-V vehicle |_| Regeneration 3 5 3 Wide open throttle assist |_| Generate for Slartup by fechorgng - ane et No assist Generation > 23 November, 2023 ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 10 BITS-Pilani, Hyderabad CampusHEV Configurations 23 November, 2023 NES, Morons & Mositity Instructor: Prof.N. Jalaian 11 BITS-Pilani, Hyderabad CampusHEV Configurations kx * A hybrid power system for an automobile can have a series, parallel or power split configuration. * With a series system, an engine drives a generator, which in turn powers a motor. The motor propels the vehicle. 23 November, 2023 ME F317 ENaixes, Motors & Mosittty Instructor: Prof. N. Jalaian 11. BITS-Pilani, Hyderabad CampusHEV Configurations kx + A hybrid power system for an automobile can have a series, parallel or power split configuration. With a series system, an engine drives a generator, which in tum powers a motor. The motor propels the vehicle. * With a parallel system, the engine and motor can both be used to propel the vehicle. Most hybrids in current use employ a parallel system. 23 November, 2023 ME F317 ENaixes, Motors & Mosittty Instructor: Prof. N. Jalaian 11. BITS-Pilani, Hyderabad CampusHEV Configurations kx A hybrid power system for an automobile can have a series, parallel or power split configuration. With a series system, an engine drives a generator, which in tum powers a motor. The motor propels the vehicle. With a parallel system, the engine and motor can both be used to propel the vehicle. Most hybrids in current use employ a parallel system. The power split has additional advantages but is also more complex. Hybrid electric vehicles are often described as being in categories PO to P4, PS or EE as shown in figure. 23 November, 2023 ME F317 ENaixes, Motors & Mosittty Instructor: Prof. N. Jalaian 11. BITS-Pilani, Hyderabad CampusHEV Configurations SS me fp |: &s 23 November, 2023 ME F317 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 11 BITS-Pilani, Hyderabad CampusHEV Configurations kx Parallel hybrid Series hybrid Power split Transmission Electric motor / generator Transmission Transmission Engine Electric| motor Electric motor Generator eo °o Planetary gear Battery Fuel Engine Engine Fuel Battery Fuel 23 November, 2023 ME F317 ENatNes, Morors & Mosittty Instructor: Prof.N. Jalaian 11. BITS-Pilani, Hyderabad CampusFuel Cell 23 November, 2023 NEFHI7ENGiNes, Morors & Monitity Instructor Prof. N.Jalaian 12 BITS-Pilani, Hyderabad CampusFuel Cell Electrical Circuit https://americanhistory.si.edu/fuelcells/basics.htm 23 November, 2023 ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 12 BITS-Pilani, Hyderabad CampusFuel Cell * Fuel cell enables the conversion of chemical energy into electrical energy, water, and heat by undergoing electrochemical reactions 'HAO! https://americanhistory.si.edu’fuelcells/basics.htm 23 November, 2023 ME F317 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 12 BITS-Pilani, Hyderabad CampusFuel Cell * Fuel cell enables the conversion of chemical energy into electrical energy, water, and heat by undergoing electrochemical reactions * Electrochemical reactions between the fuel (hydrogen) and air (oxygen) takes place in the presence of a separating porous membrane (electrolyte). 'HAO! https://americanhistory.si.edu’fuelcells/basics.htm 23 November, 2023 ME F317 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 12 BITS-Pilani, Hyderabad CampusFuel Cell * Fuel cell enables the conversion of chemical energy into electrical energy, water, and heat by undergoing electrochemical reactions * Electrochemical reactions between the fuel (hydrogen) and air (oxygen) takes place in the presence of a separating porous membrane (electrolyte). * This results in the transfer of ions and electrons from anode to cathode across the electrolyte. https://americanhistory.si.edu’fuelcells/basics.htm 23 November, 2023 ME F317 ENGINES, Morors & Mositity Instructor: Prof.N. Jalaian 12 BITS-Pilani, Hyderabad CampusFuel Cell * Fuel cell enables the conversion of chemical energy into electrical energy, water, and heat by undergoing electrochemical reactions * Electrochemical reactions between the fuel (hydrogen) and air (oxygen) takes place in the presence of a separating porous membrane (electrolyte). * This results in the transfer of ions and electrons from anode to cathode across the electrolyte. * By connecting external load, the circuit completes and the voltage is generated through the flow of electrons. https://americanhistory.si.edu/fuelcells/basies.htm 23 November, 2023 MEFH7ENoies, Morons & Mositity Instructor: Prof. N.Jalaian 12 BITS-Pilani, Hyderabad CampusFuel Cell vs Battery kx 23 November, 2023 ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 13 BITS-Pilani, Hyderabad CampusFuel Cell vs Battery kx Hydrogen fuel cell Sect curent a 23 November, 2023 ME F317 ENGINES, Morors & MosiLity Instructor: Prof.N. Jalaian 13 BITS-Pilani, Hyderabad CampusFuel Cell vs Battery kx Galvanic cell (battery) Hydrogen fuel cell © > re 2 Fuetin_ Je’ Ait som ti = a Half] |e 2 : i: roreg g lUnused = 2ae fio 9a" a = = oa a ‘Anooe, ‘cathode Electrolyte aii ME F317 ENcixes, Morors & Mosittty Instructor: Prof.N. Jalaian 13 8/TS-Pilani, Hyderabad Campus 23 November, 2023Fuel Cell vs Battery Hydrogen fuel cell Galvanic cell (battery) 8 5 7 4 ja oe go oe Se (008 cron cane, o£” Fuel cell is an open system. * Battery is a closed system. Fuel at anode and cathode arein * Metals are used for anode and gaseous medium. cathode. Electrolyte is a porous membrane + Requires periodic charging, ~ Platinum catalyst since the reactants are internally Charging is not required, since consumed. reactants are externally supplied. MEFA17 ENatxes, Morors & Monitity Instructor: Prof. N. Jalaian 13 BITS-Pilani, Hyderabad Campus.Fuel Cell Vehicle kx 23 November, 2023 ‘Gixes, Morors & Mositity Instructor: Prof. N. Jalaian 14 BITS-Pilani, Hyderabad CampusFuel Cell Vehicle https://afide.energy.gov/vehicles/how-do-fuel-cell-electric-cars-work,Fuel Cell Vehicle Thermal Sytem (oot) 23 November, 2023 MEFi17 ENaiNes, Motors & Mosittty Instructor: Prof. N. Jalaian 14 B/TS-Pilani, Hyderabad Campus