TECHNICAL SEMINAR ON

“RECENT ADVANCEMENTS IN ELECTRIC VEHICLE

TECHNOLOGISE”

Submitted in partial fulfilment of the requirement for the award of

BACHELOR OF ENGINEERING
IN
INDUSTRIAL ENGINEERING AND MANAGEMENT

BY

TEJAS T R
(IDA21IM406)

Under the guidance of

Dr.S K RAJENDRA
Professor

Dr, AMBEDKR INSTITUTE OF TECHNOLOGY,

(An Autonomous Institute Affiliated to visvesvarya Technological University,Belgaum)
Recognized by AICTE and Accredited by NBA, New Delhi
2023-24

1
 Dr, AMBEDKR INSTITUTE OF
TECHNOLOGY,
(An Autonomous Institution Affiliated to Visvesvaraya Technological University-Belagavi, Approved by AICTE, Program
Accredited by NBA, New Delhi& ISO 9001:2015 Certified)
Bengaluru-560056, Karnataka India

DEPARTMENT OF INDUSTRIAL ENGINEERING AND

MANAGEMENT

CERTIFICATE

This is to certify that the Technical Seminar entitled “RECENT ADVANCEMENTS IN

ELECTRIC VEHICLE TECHNOLOGIES” is carried out by TEJAS T R (1DA21IM406)
bonafide students of Dr, Ambedkr Institute of Technology, Bengaluru, have submitted in
partial fulfilment of the requirement for the award of Bachelor of Engineering in industrial
Engineering and management of Visvesvaraya Technological University, Belagavi during the
year 2023-24. It is certified that all corrections/suggestions indicated for Internal Assessment
have been incorporated in the report and same is deposited in the departmental library. The
Technical Seminar report has been approved as it satisfies the academic requirements in
respect of Technical seminar prescribed for the said degree.

Dr. S K RAJENDRA Dr N MOHAN

Professor Professor & HOD
Dept. of IEM
Dr.AIT Dept.of IEM
Dr.AIT

External Examiners:

1. .........
2. .........
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 ACKNOWLEDGEMENT

Seminar of this kind can be triumphed, only by constant guidance and support of many people,
involved with it. I am using this opportunity to thank all those, without whom, the completion of
this seminar would have been impossible. I thank them for their inspiration, guidance,
constructive criticism and friendly advice during the technical seminar.

I would also like to thank our beloved Dr. Nanjundaswamy, Dr.AIT Bengaluru. for their kind
support.

I would Also like to thank Dr. N. Mohan, Head of the Department, Industrial Engineering and
Management Department, for giving this opportunity to work on this technical seminar.

I would also like to thank our guide Dr. S R Rajendra, Professor Industrial Engineering and
Management Department, who has been a source of motivation, support, guidance and
encouragement.

I would like to express gratitude to the faculty members of Industrial Engineering and
Management Department for their intellectual support throughout the course of this work.

I would like to express gratitude to my family members for their moral support, and my friends
with whom I shared my day-to-day experience and received lots of suggestions that improved
my quality of work.

TEJAS T R
8th Sem,
Industrial Engineering and
Management
Dr.ambedkar Institute of
Technology

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 TABLE OF CONTENTS

Chapter No. Chapter Name Page No.

1. Introduction 6

2. Literature Review 7-18

3. Case study- 1 11-20

4. Case study- 2 21-27

5. Conclusion 28

6. References 29

LIST OF FIGURES
Figure No. Figure Name Page No.

1. Emissions of different types of vehicles 8

2. Core parts of powertrain 15

3. Ultra-flywheel electric vehicle 16

4. Rear wheel drive (RWD) 16

5. All wheel drive 17

6. Four wheel drive 18

7. 19
Raven powertrain technology

8. 23
The Main Parts of Electric Vehicle (Power train)

9 23
Types of battery

4
 CHAPTER 1

INTRODUCTION

Electric vehicles (EVs) have gained significant attention in recent years as a sustainable and
environmentally friendly mode of transportation. The increasing demand for clean energy and
the need to reduce carbon emissions have led to the development of various technologies that
improve the performance and efficiency of EVs. Increasing the use of electric vehicles (EVs)
has been offered as a double option to decrease fuel energy consumption and greenhouse gas
emissions (GHG), in a wide effort to mitigate the bad environmental impact and climate
change. Recently, the EV industry has been known as a huge development.

This report covers a broad array of subjects linked to EV technology, such as the main
categories of these vehicles and their technical characteristics: fuel energy economy,
environmental impact and market evolution. Particularly, three principal categories of EV,
mainly hybrid electric vehicles (HEVs), plug-in electric vehicles (PHEVs) and battery
electric vehicles (BEVs) are presented in detailed. Moreover, this Report analyses and
compares these types of vehicles and both summarizes and discusses the recent
advancements, challenges and environmental impacts of EV technology. We can conclude
that HEVs can play an important part in preparing for the transition to fully EVs. The
progress at the battery level will accelerate this transition as long as issues of autonomy,
durability, and cost are resolved.
In parallel, this report addresses the critical role of EVs in the evolving energy ecosystem,
emphasizing their environmentally friendly attributes and their capacity to absorb excess
power from renewable sources. A focal point of discussion revolves around the dynamic field
of Electric Vehicle Smart Charging (EVSC), a critical aspect in meeting the charging
demands of EVs while minimizing adverse impacts on the power grid.
Furthermore, this report explores the latest developments in Wireless Power Transfer (WPT)
technologies for EV charging, providing a detailed examination of capacitive,
electromagnetic field, and magnetic gear principles. It offers insights into the advantages and
limitations of each technology and discusses key technical challenges and state-of-the-art
research, presenting a comprehensive overview of the current landscape of wireless charging
solutions.
5
 BENEFITS OF ELECTRIC VEHICLES

Lower running costs

The running cost of an electric vehicle is much lower than an equivalent petrol or diesel
vehicle. Electric vehicles use electricity to charge their batteries instead of using fossil
fuels like petrol or diesel. Electric vehicles are more efficient, and that combined with the
electricity cost means that charging an electric vehicle is cheaper than filling petrol or
diesel for your travel requirements. Using renewable energy sources can make the use of
electric vehicles more eco-friendly. The electricity cost can be reduced further if charging
is done with the help of renewable energy sources installed at home, such as solar panels.

Low maintenance cost

Electric vehicles have very low maintenance costs because they don’t have as many
moving parts as an internal combustion vehicle. The servicing requirements for electric
vehicles are lesser than the conventional petrol or diesel vehicles. Therefore, the yearly
cost of running an electric vehicle is significantly low.

Zero Tailpipe Emissions

Driving an electric vehicle can help you reduce your carbon footprint because there will be
zero tailpipe emissions. You can reduce the environmental impact of charging your vehicle
further by choosing renewable energy options for home electricity.

Electric Vehicles are easy to drive and quiet

Electric vehicles don’t have gears and are very convenient to drive. There are no
complicated controls, just accelerate, brake, and steer. When you want to charge your
vehicle, just plug it in to a home or public charger. Electric vehicles are also quiet, so they
reduce noise pollution that traditional vehicles contribute to.

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Petrol and diesel use is destroying our planet

The availability of fossil fuels is limited, and their use is destroying our planet. Toxic
emissions from petrol and diesel vehicles lead to long-term, adverse effects on public
health. The emissions impact of electric vehicles is much lower than petrol or diesel
vehicles. From an efficiency perspective, electric vehicles can covert around 60% of the
electrical energy from the grid to power the wheels, but petrol or diesel cars can only
convert 17%-21% of the energy stored in the fuel to the wheels.

No noise pollution

Electric vehicles have the silent functioning capability as there is no engine under the
hood. No engine means no noise. The electric motor functions so silently that you need to
peek into your instrument panel to check if it is ON. Electric vehicles are so silent that
manufacturers have to add false sounds in order to make them safe for pedestrians.

DISADVANTAGES OF ELECTRIC VEHICLES

Limited Battery Range

The average petrol car can easily do four or five hundred miles on a tank of petrol. A diesel
car might do closer to 700 miles. The all-electric Peugeot e-208 on the other hand needs
recharging every 217 miles.

Battery Lifespan Concerns

Many people worry about how long their EV’s battery will last. The general consensus is
that it should last around 10-20 years and up to 150,000-miles. A measured driving style
and careful charging habits both help extend your battery’s service life, and if you are
buying a new car every few years then you will be covered by the manufacturer’s warranty
anyway.

Charging Infrastructure Worries

Worries about the location and availability of EV charging points may deter you from
considering an electric car. While the rollout of charging points hasn’t always been

7
 trouble-free, the fact is that the UK’s EV charging infrastructure is improving at a rapid
pace.

Long Charging Times

Filling up your petrol or diesel car can take just 5 minutes. Charging your EV can take
anything from 30 minutes to an hour using the latest public rapid chargers. You may be
twiddling your thumbs for an entire day if you are using a standard domestic socket. This
can seem like an instant deal-breaker, until you dig a little deeper.

APPLICATIONS OF ELECTRIC VEHICLES

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8
 CHAPTER-2

LITERATURE REVIEW

SL.
NO. PAPER NAME AUTHOR

01 Recent Advancements and Developments for Haji Zakaria, Mounir Hamid, El

Electric Vehicle Technology. Marjani Abdellatif, Amarir Imane.

02 Study of electric vehicle battery reliability Shubham mishra, shrey verma,

improvement subhankar chowdary, ambar gaur,
subashree mohaptra.

03 Wireless Charging Technologies for Electric Ching T. W, Wong Y.S.

Vehicles.

04 Trends and Emerging Technologies for the Tiande Mo , Yu Li 1,Kin-tak Lau, Chi
Development of Electric Vehicles Kin Poon , Yinghong Wu ,and Yang
Luo.

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 Case study 1:- Evolution and Recent Advancements in Electric
Vehicle (EV) Technology

This paper presents the main components of electric vehicles (EV) and the evolution of
technologies used in them. The electric vehicles are gaining importance globally as it is
seen as a factor of reducing air pollution and smog. This paper focuses on advantages of
EVs compared to internal combustion engine (ICE)-based vehicles, different types of EVs
and their greenhouse gas emissions, different types of EV motors and their developments,
evolution of batteries and their advanced technologies, different types of battery
management system (BMS), different types of powertrains and challenges encountered by
different types of EVs. EVs are diversified and sophisticated, with different elegance
options, but all with the reliability and power of conventional, gasoline-powered vehicles.
The main aim of this paper is to give a general image of the present EV innovation and the
ways for further improvement to aid future researches in this area.

1.1 Dark Period of Electric Vehicles

As the motor vehicles gained popularity around 1900 A.D, the electric cars were greater in
number when compared to diesel/petrol cars. The development of electric starter for petrol
cars eliminated the conventional drawback of utilizing a hand crank to get the car moving.
After the huge production of Model T by Henry Ford, the era of electric car had come to
an end as the price of petrol car is half of the price of an electric car. So, the manufacturing
of electric cars was stopped by the year 1935

1.2 Come Back of Electric Vehicles

There was resurgence in electric cars due to the shortage of oil in Gulf countries in 1970s
and 80s. With the accessibility and cost of oil being demonstrated to be progressively
unstable, people could optically recognize the possible advantages of battery-powered
cars. The chance of getting aids and strict regulations made the auto manufacturers of
USA, Japan and Europe to develop EVs. Most of the companies in Japan and Europe have
developed their EVs around 1960s. The experimental EVs like Electrovair in 1966,
10
Electrovan in 1968, Electrovette in 1979 were launched by General Motors. Following the
general motors, many companies started producing different kinds of EVs in late 90s.

1.3 Importance of Electric Vehicles

Currently, the global population is 6 billion, and if it increases with the current trend, it
may become 10 billion by 2050. This will pave the way for increase in the usage of
vehicles 700 million (as per reports in 2000) to 2.5 billion by 2050, and if all these
vehicles are IC engine-based vehicles, then most likely all the cities will be covered with
permanent smog with extreme air pollution. This will bring severe health issues. Hence, it
is essential to shift the attention towards pollution-free transport. One of the promising
solutions is sustainable transport. It means the use of low or zero emission vehicles for
public transport. Hence, the captivation of fossil fuels will be less as it is the major source
of pollution. So, to better apprehend the benefits and shortcomings of EV, the comparison
among different types of EV and ICE-based vehicles can be done on following parameters

The parameters considered for comparison are energy sources; pollution, energy
diversification, efficiencies, performance capital and operating cost are listed in Table

Fig :- Emissions of different types of vehicles

The graph shown in Fig.1.3 illustrates about the emissions of different types of vehicles.
On analysing the figure, it is evident that ICEV-based vehicles have greater percentage of
emissions compared to BEV. The other types of vehicles such as HEV, PHEV and REV
are in the middle of these two ICEV and BEV.

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 1.4 Motor Drive Technologies of Electric Vehicles

1.4.1 Evolution of EV Motors

The interesting facts about EV motors are that in 1831, Joseph Henry used
electromagnetism for oscillatory motion of beam motor, and this was considered as one of
the most primitive motors of the present DC motor. This invention has shown the way for
the introduction of the first actual electric motor in 1834 by Thomas Daven port.
Following this, Frank J. Spague developed a non-sparking constant-speed motor fixed with
brushes. This motor maintained constant speed under varying loads One of the remarkable
inventions in scientific world is the induction motor. Speed regulation, high efficiency and
the significant distance dispersion of power conceivable make the induction motor more
popular in industries. The induction motor was first invented by the Nikola Tesla in 1887.
In EVs, motor plays a vital role in the drive train.

1.4.2 Main Requirements of an EV Motor

 Maximum torque and high speed

 High power and energy density
 High speed constant power region.
 Low speed constant torque region.
 High reliability and robustness.
 Good voltage regulation in wide speed and High efficiency
 Controllability, steady state and dynamic response

1.4.3 Classification of EV Motors

EV motors are generally classified into brushed DC motors and brushless motors. Brushes
and commutator will be present in brushed DC motors and are absent in brushless motors.
Generally, all DC motors are commutator-based motors. As the construction of DC motors
provides symmetrical control of flux and torque, they offer very simple control.
Furthermore, the DC motors provide high torque only at low rpm, and the efficiency is
only 75–80%. Also, the DC motors require regular maintenance, and life span is short due
12
to the deterioration of brushes. Thus, DC motors are not taken into consideration in EVs
AC motors are normally brushless motors. Among them, induction motors and permanent
magnet motors are commonly used in EVs. Brushless DC motors (BLDC) and permanent
magnet synchronous motors (PMSM) are categorized under permanent magnet motors.
BLDC motors are mostly preferred in two wheelers. Thus, the induction motors and
PMSM are gaining importance in EVs as they provide high torque at all speed, require less
maintenance, and the efficiency is between 85–90%. The comparisons of brushless motors
based on different parameters are shown in Table

Table :- Brushless motors based on different parameters

1.5 Powertrain Technologies

Powertrain embraces of set of components that generate the required power to rotate the
wheels and to move the vehicle. In an EV, the powertrain comprises fewer components

13
than internal combustion engine-based vehicles. It includes battery pack, DC-AC
converter, electric motor, motor control mechanism and on-board charger Along with the
core parts, there are also several software and hard ware components in the powertrain.
Electronic control units (ECUs) are generally software programs combined with the
powertrain components to aid data transfer and processing. There are some other several
small ECUs like battery management

system, DC-DC converter, thermal management system and body control module in an EV
that executes particular functions. The communication between different ECUs is normally
carried over by CAN protocol. The core parts of powertrain are shown in Fig.1.3
A juncture of emanations guidelines, advancements in core technologies and competitions
in creating market is making automakers forcefully put resources into new “EV powertrain
technologies” and “E-Mobility” solutions. The different architectures of powertrain like
front wheel drive, rear wheel drive, all wheel drive and four wheel drive are vying for
noticeable quality in different sections of the market

Fig:- Core parts of powertrain

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1.5.1 Ultra-flywheel electric vehicle

Fig 1.4 :- Ultra-flywheel electric vehicle

 The most common driven cars on the road today

 The mass of the engine and transmission is balanced directly on top of the front
wheels, providing better traction than rear wheel Drive (RWD) when climbing
hills or on slippery roads
 Highly stable and efficient

1.5.2 Rear wheel drive (RWD)

Fig:- Rear wheel drive (RWD)

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 • This framework utilizes a long driveshaft that transmits power from the engine
to the differential at the back hub
• Better weight distribution
• More number of components
• Better in dry surface

1.5.3 All wheel drive

Fig:- All wheel drive

• AWD provides better clutch and control under all road conditions
• Gives sportier dealing with and footing to a more extensive scope of vehicles
• Reduces fuel economy • Increases the complexity and weight of vehicles

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1.5.4 Four wheel drive

Fig 1.6 :- Four wheel drive

• Can be used only off-roading and not in everyday life

• With 4WD, the vehicle’s capacity is part between each of the four wheels,
giving the driver the greatest footing and control on the lopsided landscape.
This will be helpful when climbing on steep slopes, rolling over rocks and
stones or attempting to get the vehicle out of a snowbank

1.6 Advanced Powertrain Technologies

It will be always an interest fact to have an inside look of Tesla cars. As Tesla is the pioneer in
EVs, the technologies used by them will be always differing from other cars. Recently, two
powertrain technologies namely Raven powertrain and Plaid powertrain have been introduced in
Tesla cars. The main details about these technologies have been explained below.

1.7 Raven Powertrain Technology

The Raven powertrain shown in Fig. 1.4 is currently available in the Model S and Model
X, but only in performance and long-range guises. This Raven powertrain technology
couples the battery available in a Model S or X with the permanent magnet synchronous
reluctance motor at the rear side. Compared to induction motor,

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 Fig :- Raven powertrain technology

Permanent magnet synchronous reluctance motor is more efficient and powerful than the
induction motor. Around 824 lb-ft of torque and 690 horse power is likely to be the total
system output

1.8 Challenges Faced by EV

Even though the development in the design, construction and performance of EV is

increasing day by day, the challenges faced by EV in the aspect of cost, range, oversizing
and energy density cannot be denied. Explains about the challenges faced by different
types of EVs

SL.No Type of EV Challenges of the vehicle

 Lower energy storage capacity due to
low specific energy and low energy
density of battery
 Limited driving range
1 Battery electric vehicle  Increase in number of batteries leads
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 to oversizing and high cost
 Lack of charging infrastructure
 (e) Charging time can be reduced by
increasing the voltage, but it creates
stress
 No zero emissions
 Dependence on liquid fuels and
2 natural gas
Hybrid electric vehicle  Fuel economy can be achieved by
variable transmission system, but it
requires complex coordinated system,
and it creates heavy losses and lot of
noise
.
 Capacity of the battery should be high
3 Grid-able HEV  High cost
 Constraints are similar to HEV

 High cost of fuel cell

4 Fuel cell electric  Lack of infrastructure for hydrogen
vehicle (FCEV) storage and refuelling
 Requirement of high safety concerns

 High cost
Ultra-capacitor electric  Low specific energy
5 vehicle  Requirement of battery as hybrid
energy source

Fig :- Challenges Faced by EV

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1.9 Conclusion

The objective of this paper is to concentrate on the key parts of EV. As EVs become
progressively pervasive, pioneering solutions will be essential to create them and their
powertrain segments, battery technologies, battery management system, thermal
management system and charging system proficiently. The challenges faced by different
types of EV presented in this paper will be helpful to concentrate in various domains of
EV to improve their efficiency. Also, different types of optimization techniques and power
electronic configurations have to be focused in future to simplify the controlling methods.

CASE STUDY 2 :- Electric Vehicle Battery Infrastructure Present

Scenario Of India

This paper presents the optimal design and development of an EVs , which includes the
selection of the motor, the battery, charger, Battery Management System(BMS) and the
motor control system. Battery is a significant component in the EV and its selection is
20
mainly based on its compatibility in both charging& discharging characteristics. When
safeguarding battery-operated devices, BMS are also essential for choosing the right
materials for the batteries. Due to high torque, small size, brushless commutation and
lower maintenance among other motors Permanent Magnet Brushless Direct Current
motors (PMBLDC) are currently the preferred option among researchers and the
automotive industry. This EV prototype consists of PMBLDC motor, Li-ion battery,
Battery management
1918, there have been electric vehicles (EVs) on the road [1–5]. The use of electric
vehicles for road transportation has decreased as a result of internal combustion engines'
(ICE) quick development and viability. However, current issues namely air pollution, a
lack of oil resources and their rapid price increment, as well as energy independence, have
prompted a reorganization of electric vehicles as another mode of transportation. Variable
speed drives that operate on both direct and alternating current were frequently used in
applications of electric vehicle. Yet, in the twenty first century, permanent magnet
brushless direct current (PMBLDC) motors were comes into the market that are highly
efficient and have a high power density. Neodymium-iron-boron (Nd-Fe-B) and
Samarium-Cobalt (Sm-Co) are two examples of these materials [6–9]. Unlike brushes in
DC motor the PMBLDC motor mainly utilizes electronic commutation this creates
complexity in the control algorithm

2.1 SYSTEM ENLARGEMENT

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In general, batteries are used to store energy. It is charged with the help of charger from

the mains electricity. To run the electric motor, the power electronic controller converts
the battery's DC voltage into a switched-mode signal. DC-DC converter, which down the
voltage from the battery pack like 20V-5V, the remaining parts in a vehicle can be
powered from the battery. It is simple in structure. The propulsion parts are key
components. The configuration is shown in Figure
Fig:- The Main Parts of Electric Vehicle (Power train)
2.2 BATTERY
Batteries are the parts of the car that store electrical energy, enabling the motor to run.
The table shows that a comparison of several battery types has previously been done.

According to the battery analysis table, the elementary components that enable recharging
are Nickel Metal Hydride, lithium-Polymer Lithium-ion, Nickel Cadmium, Nickel Zinc,
which are listed as NiMH, Li-Po/Liion, NiCd and NiZn respectively. if the energy were

22
held constant, the value of specific energy, which is defined as energy per unit of mass,
would rise
Fig:- Types of battery

2.3 BATTERY FAILURE TYPES

Possible failure modes of EV battery can be categories as battery operating conditions and
also chemical process. Battery operating conditions failures, which cover
charging/discharging depth, high/low temperature and vibration, are grid corrosion, grid
growth and discharging of negative plate. Salloux and Mc Hardy (2007) have discussed
that dry-out and sulfation are common failures in chemical process in their research on
Valve Regulated Lead Acid (VRLA) battery. The leading cause of battery failure is grid
corrosion in which the life expectancy of the battery is limited due to corrosion of the
positive grid. As the battery cycles and ages, the conductivity of the grid is gradually
reduced in which the material corrodes from the plate and accumulates at the bottom of the
cell container. This accumulation of the material develops a conductive path and reduces
the capacity of the cell. The rate of the corrosion grid can be reduced by applying low
porosity thicker grids manufactured using bottom-pour casting. Grid growth is the
common premature battery failure due to crack of the battery container especially at
weakest link which is the terminal posts. The plates grow in size during the battery life in
which puts pressure from within the container. The current design of the battery which
integrates extra space to have room for the expansion could overcome this phenomenon.
Discharging of the negative plate over a period of time is another common failure.
Negative plate take in oxygen release by positive plate during charging process in which
prevents the negative plate to reach fully charged state. A catalyst that recombines the
oxygen and the hydrogen has been introduced in new battery design which reduces oxygen
diffusing at negative plate. As a result, negative plate will be maintained at full state of
charge. Dry-out is occurred due to extensive overcharging or overheating of the battery
which leads to water lost from the cell and the separator loses conductivity. This condition
will shorten the life of the battery. By adding catalyst that recombines the oxygen and the
hydrogen, it will help to recover water lost and prevent dry-out. Sulfation takes place when
the lead sulphate crystals formed and gradually build up and fail to re-dissolve back to
active material during charging. This will reduce the capacity of the battery. Moseley and
23
 Rand (2004) have studied on VRLA batteries that are plagued by a tendency to accumulate
sulphate on the negative plate. To counter this problem, appropriate design of the plate
grid can enhance the ability of the battery to improve

Core Battery To determine the sustained (30s)

Performance Test discharge power capability of a
battery at 2/3 of its open circuit
voltage at each of various depths
of discharge.
Peak power To perform a sequence of constant
power discharge/ charge cycles
that define the voltage versus
power behaviour of a battery as a
function of depth of discharge.
Core Variable power To produce the effects of electric
Battery discharge vehicle driving behaviour
Performance (including regenerative braking) on
Test the performance and life of a
battery
To produce the It is a demanding profile with
effects of electric respect to the frequency of
vehicle driving occurrence of high power peaks
behaviour (including and ratio of maximum regenerative
regenerative charging to discharge power.
braking) on the
performance and life
of a battery
Dynamic stress test Can effectively simulate dynamic
regime discharging and can be
implemented with equipment at
most test laboratories and
developers
Special

24
Performance Partial discharge, Stand loss, Sustained hill-climb power, Thermal
Test performance, Battery vibration, fast charging
Safety and To address conditions associated
Abuse Test Safety and Abuse with government regulations or
Test expected accident related
exposures exposures
Based on mechanical, electrical
Safety and Abuse testing and environmental exposure for
Abuse Test worse-case scenarios
To accelerate relevant failure
Accelerated aging modes and degradation
mechanisms to permit rationally
precise aging factors to be
determined.
Life Cycle To simulate the conditions that EV
Test Actual-use battery may experience in the
simulation actual operation and the result
from these tests will validate the
accelerated life-cycle test
performed.
To determine the battery life
Baseline life test achieved under a ‘reference’ or
baseline set of test conditions, for
comparison with the results of
accelerated life testing under any
other set of test conditions.

Table :- Lists of battery test procedures manual

2.4 BATTERY TESTING METHOD

United States Advanced Battery Consortiums (USABC) has developed EV battery test
procedures manual (second revision) dated on January 1996 in which summarizes the
procedural information needed to perform the battery testing. USABC has been formed by
the U.S. Department of Energy (DOE) to develop EV advanced batteries. The aim is to
develop EV that is competitive with conventional IC engine vehicles in terms of

25
performance and price. Based on USBC EV battery test procedures manual, typical battery
test flow includes the following areas which are core battery performance test, special
performance testing, safety and abuse test, and life cycle testing. Core battery performance
testing consists of mandatory electrical performance tests. Special performance testing is
optional depends on the requirements of the manufacturer. Safety and abuse testing is to
make sure the systems are safe for customers and comply with government regulations. It
also discovers any design deficiencies that may jeopardize the safety of the public.
Standard procedures are used in life cycle testing to determine if the expected service life
of EV batteries will satisfy USABC requirements. Accelerated aging and normal use
conditions are used to characterize degradation in electrical performance as a function of
life and to identify relevant failure mechanisms. Table 3.1 shows details of the tests that
are applied by USABC for battery testing. Some other researches also propose battery
testing methods specifically for certain type of battery for EV. Poscoe and Anbuky (2003)
have developed the architecture of an automated battery test system which was designed
for VRLA battery behavioural research with three most significant battery parameters:
voltage, current and temperature. This testing technique comprises quality assurance,
design verification and performance assessment purposes for battery manufacturers,
validation purposes for battery users, and battery behavioural research purposes for
engineers developing behavioural prediction algorithms

2.5 LIFE PREDICTION METHOD.

Lifetime prediction of batteries is widely discussed by researches around the world. Some
of the battery lifetime prediction model proposed by the researches based on type of
batteries and parameters. Rahmatov and Virudhula (2001) have come up with analytical
expression to estimate battery lifetime for various time-varying loads by taking into
accounts the changes in the concentration of the electro active materials inside the battery.
Sauer and Wenzl (2007) have discussed three different approaches for lifetime prediction
for VRLA batteries which are physico-chemical ageing model, weight Ah ageing model
and event-oriented ageing model. Then these three approaches are compared between
parameter identification, model complexity and calculation speed. Marano et al (2009)
have used different approaches for lifetime estimation of Li-ion battery which are
performance-based models and weighted Ah-throughput model. Performance base models
simulate the change of performance values of the battery.
Agarwal et al (2010) have developed a nonchemically based partially linearized input-
output battery model for lead-acid batteries. This model can be extended to different types
of batteries if the parameters are properly tuned.

2.6 WAYS OF IMPROVEMENT

The reliability of the battery can be improved by integrating these criteria into the design
of the battery which must perform their functions as expected (Lukic and Emadi, 2008)

2.6.1 Thermal protection

Both charge capacity and life cycle can be optimized when the battery is kept within a
recommended operating temperature range between + 20°C to +30°C. Therefore to keep
the temperature within that range, the system may need both heating and cooling elements
to get optimal performance. If the temperature is too high or too low, it can cause poor
performance and finally failure to the batteries. Jarrett and Kim (2011) have written a
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research paper on design optimization of EV battery cooling plates for thermal
performance which help in temperature control.

2.6.2 Cell equalization (balancing) on cell

EV batteries consist of long strings of cells in series in order to achieve higher operating
voltage. Equalization is used to prevent large long term unbalance rather than small short
term deviations. It is also help to protect the cell from overstress. By using balancing
method in which charge from one or more high cells are removed to lower charge cells
will help to reduce the cells from overstress

2.6.3 Tolerance setting

Premature failure of the battery can cause by over stress of individual cells in a series due
to uneven temperature distribution and difference in aging. The best way is to select cells
from the

same manufacturing batch to minimize variability of traits in a group. If there are some
degraded cells in the chain with diminished capacity, there are tendency to over charging
the battery. The reliability of a battery will be improved with tight tolerance and strict
process control.

Other improvement that could be made on the EV battery also have been highlighted in
which related to battery management systems. Meissner and Richter (2005) have discussed
that further technical improvement of EV batteries and procedures are needed for optimum
use of the batteries resources, i.e., knowledge of actual SOC, power capability, and
quantification of the degradation of the batteries performance as an input for energy
management. Karden et al (2005) have mentioned that battery monitoring systems allow
for more efficiently and effectively battery operating strategies which will improve the
reliability of the battery in EV.

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2.7 CONCLUSION

Reliability of the EV battery can be improved by understanding the failures occurred,

types of testing conducted and method of prediction lifetime. Using the proposed
approaches, the reliability of EV battery systems or components can meet the expectation
values and also capable of prolong the battery life where as the battery selection depends
on the application requirement. On the other hand, field data, usage and environmental
profile are important in further improving the reliability of the EV battery. Unfortunately,
EV car manufacturers hardly discuss on the current issues on problem occurred regarding
the reliability of the battery.

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 REFERENCES

• Agarwal, V. And Uthaichana, K. (2010) Development and Validation of a Battery Model

Useful for Discharging and Charging Power Control and Lifetime Estimation IEEE
Transactions On Energy Conversion

• Chan, C.C. (2007) The state of the art of electric, hybrid and fuel cell vehicles, Proc. IEEE

• Karden, E., Shinn, P., Bostock, P., Cunningham, J., Schoultz, E. And Kok, D. (2005)
Requirements for future automotive batteries - a snapshot, Journal of Power Sources

• Lukic, S.M. and Emadi, A. (2008) Charging Ahead: The Development of Adequate
Energy Storage Systems in Electric, Hybrid Electric and Plug-In Hybrid Vehicles

• Moseley, P.T. and Rand, D.A.J. (2004) Changes in the demands on automotive batteries
require changes in battery design, Journal of Power Sources,

• Rakhmatov, D.N. and Vrudhula, S. (2001) An Analytical High-level Battery Model for
Use in Energy Management of portable electronic systems,

• Tollefson, J. (2008) Car Industry: Charging Up the Future, Nature News

• Wang, J., Cao,B., Chen, Q. And Wang, F. (2007) Combined State of Charge Estimator for
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• Pascoe, P.E. and Anbuky, A.H. (2003) Automated battery test system, Measurement

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