REDESIGN AND FABRICATION OF HYBRID

ELECTRIC VEHICLE AND TESTING RIG

PRESENTED BY: SUPERVISOR:

Ali Raza (180850) Dr. Shakil Rehman Sheikh

Muhammad Waseem(180928)
Noumeer Ahmad Piracha(180931)
Project No. : 1805
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 Introduction of Project

• Hybrid Electric Vehicle

• Charging Mode
• Via Plug-in
• Via generator
• Heading mode
• Stealth (silent) mode
• Parallel charging
• Power mode
• Simple power mode
• Parallel charging

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 Introduction
• Testing Rig
• Temperature
• DHT22
• Vibration
• Comparator based (digital)
• Piezoelectric based (analogue)
• Speed
• Rotary encoder based
• Optical encoder based
• Torque
• Load cell
• Dynamo based

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 Sensor Testing

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Dynamo Testing

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 Objective

• Design and fabrication of testing rig.

• Redesign of hybrid electric vehicle.

• Improvement in algorithm of control system.

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 Scope

Testing rig is capable of testing two tires at a time and generate graphs
and show values of various quantities like torque, speed, vibrations and
temperature. The hybrid vehicle is capable of caring one person. Engine
and generator are used for battery charging.

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Methodology (HEV)

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Heading Functions

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Methodology (Testing Rig)

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 ESP 32 for IOT

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 ESP 32 for IOT

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 Design Calculations
Calculations for Motor Selection:
Supposing,
Inclined Angle = = 10 degrees,
Speed = v = 30 k/h = 8.33 /s,
Time = t = 10 s,
Mass = m = 270 ,
Length of HEV = 1.57
Width of HEV = 0.97
Height of HEV = 1.17
Gravitational acceleration = g = 9.8 /
Coefficient of rolling friction force = CR = 0.02
Coefficient of drag force = CD = 0.8
Density of Air = = 1.225 /
Approx. Car Front Area = A =1.135
Tire Radius = r = 0.085

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 Design Calculations
Wheel Travel = Circumference
= 2 × × 0.085
= 0.534 m
So,𝑣
now we find acceleration by the formula;
𝑡
a = = (8.33) / 10 = 0.833 m/s2
We have to find the power:
Power = + + +
= (270 9.81 8.33 0.02) + (0.5 1.2 0.8 8.332 0.534) + (270 0.833 8.33) + (270 9.8 sin (10))
= 441.27 N 18.15 460 1873
= 2792 Watts or 2.8 kw
Now, torque can be found using the formula:
P = (2 Pi N x T) / 60
T = (Pmotor 60) / (2 Pi N)

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 Design Calculations
where,
N = Rotations per minute and can be found as:
N = Speed / circumference of tire
N = (8.33 60) / 0.534
N = 936
Now,
from Eq. (2), we get
T = (2792 60) / (2 pi 936)
T = 28.5
Now we will select motor with around 2500-3000 power, 900 to
1000 rpm rotational speed and 28-32 torque.

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 Battery Calculations
Total no. of cells = 80
Total no. of cells in series = 10
Total no. of cells in parallel = 8
Total voltage of battery = 37 V
Total current of battery = 28 Ah

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Hardware Schematics

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Hardware Schematics

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Hardware Schematics

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Rig Simulink Model

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Rig Step Response

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Rig Simulink Model Simulation

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 Hardware

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 Hardware

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Cad Model of HEV

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 Simulink Model

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Simulink Model of HEV

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Simulink Model Results
Step Input for Less Time

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HEV Signal Builder Input

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HEV Step Response

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 Timeline

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 Cost Table
Items Cost(PKR)
Rollers 2,000/-
Bearings 3,800/-
Shafts 1200/-
Sheets 5300/-
Angle iron 3000/-
Manufacturing costs 4500/-
Miscellaneous 1500/-
Total Rs 21,000

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 Sustainable Development Goals

The project goals relate with the SDGs of UN which basically ensures
access to affordable, reliable, sustainable, and modern energy for all. The
project is designed such as that it does not add CO2 and other harmful
gases to the atmosphere rather it improves the efficiency of engine and
reduce the cost of fuel. The project also ensures sustainable production
patterns by using the optimal material and cost reduction. The project relates
with the goal number 7, 12 and 13 of SDP of United Nation. [2]

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 ISO Standards
• ISO 1585:2020
This standard applies only to the vehicles with the following
characteristics:
• HEVs with an internal combustion engine (ICE) and one or more
electric motors powered by one or more rechargeable energy storage
systems (RESS) for propulsion;
• Vehicles classified as passenger cars or light duty trucks.

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 Effects on Society

• The project can reduce the amount of cars periodic testing

• Controlled Carbon emission
• Greater efficiency
• Easy to interact

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 References
[1] Gerardo Aragón-González, “Developing and testing low cost LTD Sterling engines,” 2021.
[2] N. C. K. M. Khan, “Hybrid Electric Vehicles for Sustainable Transportation: A Canadian Perspective,” World
Electric Vehicle Journal, vol. 03, p. 12, 2009.
[3] https://www.iso.org/obp/ui/#iso:std:iso:1585:ed-4:v1:en
[4] D. Workshop, DroneBot Workshop, 02 04 2020. [Online]. Available: https://youtu.be/UFCmTZUoZ1M.
[Accessed 11 2021].
[5] “How do brake testers work?,” Crypton, 2020. [Online]. Available:
https://www.cryptontechnology.com/news/how-do-brake-testers-work. [Accessed 2021].
[6] N. C. K. M. Khan, “Hybrid Electric Vehicles for Sustainable Transportation: A Canadian Perspective,” World
Electric Vehicle Journal, vol. 03, p. 12, 2009.
[7] G. C. Halit Yasar, “Performance Comparison for Series and Parallel Modes of a Hybrid Electric Vehicle,” Journal
of Science, 2019.
[8] M. P. M. R. Damiano Lanzarotto, “Energy comparison between different parallel hybrid vehicles architectures,”
International Journal of Energy Production and Management, 2017.
[9] W. Y. Y. C. e. a. H. Wang, “Overview of hybrid electric vehicle trend,” in AIP Conference Proceedings, 18th April
2018.
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