ELECTRIC VEHICLE DESIGN

R.S.Arjun
B.Rakesh
Aneesh
V.Vinay Kumar P.Jagadeesh
Rahul Aditya
Mounish K.Brahmaji
CH.Vishnu Varma P.SivaSankar
ABSTRACT 
The title of the project is “ELECTRIC VEHICLE
DESIGN” . This project is based on the
modification of normal auto-rikshaw into an
electric vehicle by replacing its engine with a
permanent magnet DC motor. The main aim of
this project is to build a proto type for an electric
vehicle . And also to check how much it will
reduce the maintenance cost and also to
observe the performance of it. It also reduces
the pollution so that it is very useful to the
society.
 Project Motivation


Build a challenging project

Save money on commuting costs

Lower pollution

Create business opportunities
 Component Selection
• Permanent magnet DC motor
• KDH controller
• DC/DC Converter for 72V to12V volt systems
• Batteries (100AH)
• Battery charger
• Safety disconnects
Performance of EV at different loads

S.NO LOAD MILAGE( TOP CURREN WEIGHT

km) SPEED(k T(amps) (kgs)
mph)
1 No load 64 64 26 664
2 Normal 46 56 42 1130
load
3 Over 33 56 57 1400
load
S.NO SPEED(kmph) CURRENT(amps) MILAGE(km)
1 20 13 109
2 30 25 85
3 40 35 70
4 50 46 59
 Permanent Magnet DC Motor

• Mars ME0709 PMDC

• Maximum power upto 28HP
• Maximum torque 59N-m
• Speed 3600rpm
Mars ME0709 Brush-Type Permanent Magnet
Electric Motor 24-72 VDC 3700 RPM
• The ME0709 is a Brush-type Permanent
Magnet DC motor.
• Light weight, high efficiency design.
• Designed for 24-72 VDC battery operated
equipment.
• Capable of 300 amps peak and 125 amps
continuous.
• Totally open, fan cooled motor. Motor weight
of 36 pounds.
 KDH Controller
• KDH09401A,24-96V,400A (kellycontrollers)
• Voltage 24V to 96V
• Current 400A
KDHA High Voltage PM Motor Speed Controller
• It provides efficient, smooth and quite
controls for electrical vehicles like electric
motorcycle, hybrid vehicle, as well as electric
boat and industry motor speed control.
• Motor speed controller uses high power
MOSFET, fast PWM to achieve efficiency 99%
in most cases.
• Powerful microprocessor brings in
comprehensive and precise control to brushed
motor controllers.
• This programmable brushed motor controller
also allows users to set parameters, conduct
tests, and obtain diagnostic information
quickly and easily.
Features:
•Intelligence with powerful microprocessor.
•Synchronous rectification, ultra low drop,
and fast PWM to achieve very high efficiency.
•Current limit and torque control.
•LED fault code helps user debugging.
•Battery protection: current cutback,
shutdown and warning at low battery.
• Rugged aluminum housing for maximum
heat dissipation.
• Thermal protection: Current cuts back on low
temperature and high temperature to protect
battery and controller.
• High pedal protection: Disable operation if power
up with non-zero throttle.
• Brake switch is used to start regen.
• 0-5V brake signal is used to command regen
current.
• PWMable Reverse Alarm.
• Brake Switch for regeneration.
• Analog Brake Input for continuous variable
regeneration.
General Specifications:
• Frequency of Operation: 16.6kHz.
• Standby Battery Current: less than 1 mA.
• Supply Voltage, PWR, 8 to 30V.
• Supply Current, 200mA @ 12V, or 2.5W.
• Operating Voltage, B+, 18V to 120V.
• Analog Brake and Throttle Input: 0-5 Volts.
Producing 0-5V signal with 3-wire pot.
• Reverse Alarm, Main Contactor Coil Driver,
Meter.
• Full Power Temperature Range: 0℃ to 40℃
(controller case temperature).
• Operating Temperature Range: -30℃ to 90℃,
100℃ shutdown (controller case
temperature).
• Motor Current Limit,10 seconds boost:
400AMotor Current Limit, 1 minutes:
350AMotor Current Limit, continuous:180A
 Safety Systems


Manual disconnect cables

MCB B16 50HZ

Voltage 72V

Current 150A
ADVANTAGES:
• Its maintenance cost is less.
• Electric vehicles are clean and easy to use.
• More reliability.
• Fuel requirement problems are eliminated.
• The advantages of EVs have long dominated
for the heaviest vehicles.