Unit 3 Electric Vehicle Drive Train: Department of Mechanical Engineering

Unit 3 Electric Vehicle Drive Train
Hybrid Electric Vehicle
Prof. Praveen P. Rathod

Praveen.rathod@viit.ac.in
Department of Mechanical Engineering
BRACT’S, Vishwakarma Institute of Information Technology, Pune-48
(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
Teaching Scheme: Credits:
•TH: -- 03 hrs/week
TH:--03
•PR.: - 02 hr/week OR:-- 01
Examination Scheme:
Insem-30
Endsem-30
CE-20
Competency Skill: -20
03/29/2023
Department of Mechanical Engineering, VIIT , Pune-48
Objective`
• To understand the comprehensive overview of Electric and Hybrid

Electric Vehicles.
Learning Outcome/Course Outcome
• Design electric drive train and its components.
Department of Mechanical Engineering, VIIT , Pune-48 3

Syllabus:
• Electric Drive-trains-Basic concept of electric traction,
introduction to various electric drive-train topologies,
power flow control in electric drive-train topologies, fuel
efficiency analysis. Transmission configuration,
Components – gears, differential, clutch, brakes
regenerative braking, motor sizing.
03/29/2023
What is Electric Traction System?
• A system which causes the propulsion of vehicle in which tractive or driving force is obtained from various
devices such as diesel engine drives, steam engine drives, electric motors, etc. is called as traction system .
• It can also be defined as the railway vehicle that provides the necessary traction power to move the train is
referred as the traction or locomotive. This traction power can be diesel, steam or electric power.
• Electric traction involves the use of electricity at some stage or all the stages of locomotive movement. This
system includes straight electrical drive, diesel electric drive and battery operated electric drive vehicles.
• electrical motors are used for producing the vehicle movement and are powered by drawing electricity
from utilities or diesel generators or batteries.
03/29/2023
Various types of Electric Motors used in Electric Vehicles
• DC Series Motor
• Brushless DC Motor
• Permanent Magnet Synchronous Motor (PMSM)
• Three Phase AC Induction Motors
• Switched Reluctance Motors (SRM)
Electric Motor
• An electromagnet is the basis of an electric motor
• An electric motor is all about magnets and magnetism: A motor uses magnets to create
motion.
• Opposites attract and likes repel. Inside an electric motor, these attracting and repelling
forces create rotational motion.
• A motor is consist of two magnets.
03/29/2023
The force on a current-carrying
conductor in a magnetic field:
• When a current-carrying conductor is placed in a magnetic
field, there is an interaction between the magnetic field
produced by the current and the permanent field, which
leads to a force being experienced by the conductor:

• The magnitude of the force on the conductor depends on the
magnitude of the current which it carries. The force is a
maximum when the current flows perpendicular to the field
(as shown in diagram A on the left below), and it is zero
when it flows parallel to the field (as in diagram B, on the
right):

Fleming’s left-hand rule

• The directional relationship of I in the conductor,
the external magnetic field and the force the
conductor experiences
I
B
F

Motion of a current-carrying loop in a magnetic field
F Rotation
I
N L R
S
brushes F
Commutator
(rotates with
coil)
Vertical position of the loop:
Rotation
N S

• Three Phase AC Induction Motors
03/29/2023
Brushless DC Motors
Construction
• Stator consists of stacked steel
laminations with windings placed in
the slots that are axially cut along the
inner periphery
• Rotor is made of permanent

magnet and can vary from two to
eight pole pairs with alternate North
(N) and South (S) poles. Ferrite
magnets and Rare earth alloy
magnets are used in rotor
Working
Ather Scooter BLDC In-Runner

03/29/2023
Advantages of Brushless DC motor
• Less overall maintenance due to absence of brushes
• Reduced size with far superior thermal characteristics
• Higher speed range and lower electric noise generation.
• It has no mechanical commutator and associated problems
• High efficiency and high output power to size ratio due to the use of permanent
magnet rotor
• High speed of operation even in loaded and unloaded conditions due to the absence of
brushes that limits the speed
• Smaller motor geometry and lighter in weight than both brushed type DC and induction
AC motors.
• Long life as no inspection and maintenance is required for commutator system
• Higher dynamic response due to low inertia and carrying windings in the stator
• Less electromagnetic interference
• Low noise due to absence of brushes
Limitations of Brushless DC motor

• These motors are costly
• Electronic controller required control this motor is expensive
• Requires complex drive circuitry
• Need of additional sensors
Faculty Name(optional), Department of ______Engineering,
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VIIT,Pune-48
Permanent Magnet Synchronous Motor (PMSM)
• A permanent magnet synchronous motor,

like any rotating electric motor, consists of
a rotor and a stator. The stator is the fixed
part. The rotor is the rotating part.
• The principle of operation of a synchronous

motor is based on the interaction of the
rotating magnetic field of the stator and
the constant magnetic field of the rotor.
The concept of the rotating magnetic field
of the stator of a synchronous motor is the
same as that of a three-phase induction
motor.
• The magnetic field of the rotor, interacting

with the synchronous alternating current of
the stator windings, according to the
Ampere's Law, creates torque, forcing the
rotor to rotate
03/29/2023
Direct Torque Control of Permanent Magnet Synchronous Motor
To control the permanent magnet synchronous motor, uses different types of control
systems. Depending on the task, the necessary controlling technique is used. The different
controlling methods of permanent magnet synchronous motor are,
Sinusoidal Category
Scalar
Vector: Field oriented control (FOC) (with and without position sensor)
Direct torque control
Trapezoidal Category
Open-loop
Closed-loop (with and without position sensor)

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VIIT,Pune-48
Advantages
•provides higher efficiency at high speeds

•available in small sizes at different packages
•maintenance and installation is very easy than an induction motor
•capable of maintaining full torque at low speeds.
•high efficiency and reliability
•gives smooth torque and dynamic performance
Disadvantages
•These type of motors are very expensive when compared to induction motors
•Somehow difficult to start-up because they are not self-starting motors.

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VIIT,Pune-48
Permanent Magnet Synchronous Motor vs BLDC
Permanent Magnet Synchronous Motor BLDC
These are brushless AC synchronous motors These are brushless DC motors
Torque ripples are absent Torque ripples are present
Performance efficiency is high Performance efficiency is low
More efficient Less efficient
Used in industrial applications, automobiles, servo Used in electronic steering power systems, HVAC
motors, robotics, train drives, etc systems, hybrid train drives (electrical), etc
Produces low noise Produces high noise.

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VIIT,Pune-48
DC Series Motor
• DC motor falls under the category

of self-excited DC motors
• In this case is connected internally
in series to the armature winding.
• the series field winding has fewer
turns of thick wire
• The wire is heavier, as the
diameter is considerable
increased to provide minimum
electrical resistance to the flow of
full armature current.
• In spite having fewer coil turns
the running of this DC motor
remains unaffected, as the current
through the field is reasonably
high to produce a field strong
enough for generating the
required amount of torque.
03/29/2023
Speed and Torque of Series DC Motor
Speed Regulation of Series Wound DC Motor

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VIIT,Pune-48
Advantages of DC series motors:
• It is an easy assembly and simple design.
• Vast starting torque.
• Protection is very easy.
• It is cost-effective.
• Series wound motors can use for AC or DC supply so it is also
known as universal motors.
• Compare with shunt motor DC series motor develop power for
the same construction size.
Disadvantages of DC Series Motor

• Speed regulation in the series motor is quite poor. With the increase in the load
speed of the machine decreases. ...
• With decrease in the speed torque of the dc series motor drops sharply.
• DC series motor should always require to be loaded before starting the motor.

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VIIT,Pune-48
switched reluctance motor

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VIIT,Pune-48
Advantage of SRM
• It does not require an external ventilation system as the stator and rotor slots projected. The airflow
maintained between the slots.
• The rotor does not have winding since therefore no need to keep the carbon brush and slip ring
assembly.
• Since the absence of a permanent magnet, such motors are available at a cheaper price.
• A simple three or two-phase pulse generator is enough to drive the motor.
• The direction of the motor can be reversed by changing the phase sequence.
• Self-starting and does not require external arrangements.
• Starting torque can be very high without excessive inrush currents.
• High Fault Tolerance.
• Phase losses do not affect motor operations.
• High torque/inertia ratio.
• High starting torque can be achieved.
Disadvantage of Switched reluctance motor
• Creates Torque ripple at high-speed operation.

• The external rotor position sensor is required.
• Noise level is high.
• At a higher speed, the motor generates harmonics, to reduce this, we need to install larger size
capacitors.
• Since the absence of a Permanent Magnet, the motor has to designed to carry a high input current. It
increases the converter KVA requirement.
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VIIT,Pune-48
BEV powertrain topologies
The topologies selected are
• single-motor single-axle (SM-SA) topology.

• double-motor double-axle (DMDA) topology.
• in-wheel-motor single-axle (IWMSA) topology.
• in-wheel-motor double-axle (IWM-DA) topology
Single electric machine
There are two possible technologies for a single machine vehicle are
1. a traditional powertrain formed by adapting a conventional ICE layout
2. a specialised design combining the single electric machine with a final-drive

gearbox.
03/29/2023
Single electric machine with a final drive
03/29/2023
Double electric machine with a double-axle drive
03/29/2023
Multiple electric machines with independently driven wheels
03/29/2023
In-wheel motor drive
03/29/2023
Vehicle model and simulation technique
Vehicle modelling techniques can be classified in two ways:

1. forward-facing models
2. backward-facing models
Forward-facing simulations
Forward-facing simulations present a realistic approach to vehicle simulations as they use a
driver model to control the vehicle speed, similar to a human driver controlling a car.
03/29/2023
Forward-facing simulations
1. driver model, the reference speed and the actual vehicle speed are compared, giving
an ‘error’ signal, and this is used to generate a control signal to control the torque
used to power the vehicle.
2. Driver models normally use proportional–integral controllers.
3. BEV model is used to translate the throttle and brake commands from the driver into
the torque and mechanical braking signals.
4. The torque from the motor is passed through a model of the transmission and
applied as a force at the wheels.
5. The torque from the motor is passed through a model of the transmission and
applied as a force at the wheels.
03/29/2023
Backward-facing simulations
Backward-facing simulations use the opposite approach.
Inputs and outputs of backward-facing simulations of the vehicle.
03/29/2023
Inputs and outputs of backward-facing simulations of the motor–
machine.
• The speed references can drive the system model directly, and a driver model is not
required.
• the driving profile is the speed that the vehicle is required to follow.
• Backward-facing simulations generally rely on quasistatic component maps rather than

on detailed dynamic
• Electric machines are typically modelled using motor efficiency maps.
• This simulation type cannot represent the dynamic behaviour of components
03/29/2023
Vehicle body and environmental losses
The vehicle model converts the velocity reference into the angular velocity and the torque
at the wheels
The angular velocity at the wheels can be calculated from
ωw(t)= vvehicle(t) / rw
where vw is the angular velocity at the wheel, vvehicle is the velocity of the vehicle and
rw is the radius of the wheel.
The torque at the wheels
where Tw is the torque at the wheel

Fvehicle is the traction force at the centre of gravity.
Fvehicle is calculated from the environmental force
03/29/2023
Transmission
Like ICEs, electric machines operate most efficiently within a particular speed–torque envelope.
most of the machines used in electric vehicles operate best at higher speeds and lower torques
The transmission normally includes several components but, when we consider using a single ‘lumped’
gear ratio which describes the overall behavior.
there is no need for multiple ratios, and single-ratio transmissions are common on production vehicles.
Single-speed transmissions are generally good in terms of a low drivetrain mass, a low volume, a high
efficiency and a low complexity
The calculations for the transmission are expressed as
where ωm is the angular velocity at the motor,

ωw is the angular velocity at the wheels,
TM is the torque at the motor,
Tw is the torque at the wheels
ηG is the efficiency of the transmission.
03/29/2023
Electric machine modelling
The electric machine acts as a motor–generator, providing a traction torque during acceleration
and steady state driving and then recovering the kinetic energy that is otherwise lost during
braking.
The relationship between the motor input power and the output torque–speed pair is
When motoring , the machine output power is given by
When the equation is arranged as a backward-facing model, the efficiency term appears as a
division rather than a multiplication.
03/29/2023
Electric machine modelling with efficiency maps
The starting point was the nominal machine map for the machine of the case-study
vehicle. To scale it, the torque axis was scaled in proportion to the machine’s power
rating; this principle is illustrated
03/29/2023
Modified motor map for in-wheel motors
(a) Original motor map for conventional motors (b) modified motor map assumed for in-wheel vehicles.

Mass of the vehicle
effect of different vehicle topologies, as discussed before, on the energy consumption and the
acceleration performance. One of the important vehicle parameters which impacts the energy
consumption is the mass of the vehicle.
The mass of the vehicle is calculated by considering three components: the electric machine and the
transmission (combined), the battery and the vehicle body.
Mass of the transmission and the electric machine.

Mass of the battery Case Study.
• The mass of the battery pack was estimated from the number of cells in the battery.
• The cells and the pack size used in the Nissan LEAF45 were used as the baseline.
• Each cell has a mass of 0.787 kg, and there are four cells in one module and 48 modules in a
battery pack, giving a total cell mass of 0.787 X 4 X 48 = 151.1 kg.
• It is assumed that a battery also requires 0.06 kg/kW for the mass of the thermal management
system and 0.14 kg/kW for the mass of the harness and the bus bar; this gives an effective
total cell mass of 0.975 kg per cell.
• Using these assumptions, the total mass of the case-study Nissan LEAF was estimated to be
187.2 kg.

power flow control in electric drive-train
Electric Vehicle (EV) Configurations :

Compared to HEV, the configuration of EV is flexible.
• The energy flow in EV is mainly via flexible electrical wires rather than bolted flanges or rigid shafts.
Hence, distributed subsystems in the EV are really achievable.
• The EVs allow different propulsion arrangements such as independent four wheels and in wheel
drives.
The EV has three major subsystems: The energy source subsystem consists of
• Electric propulsion
• The energy source (battery, fuel cell, ultracapacitor)
• Energy source
• Auxiliary system • Energy management unit
• Energy refueling unit
The electric propulsion subsystem comprises of:
• The electronic controller
• Power converter
The auxiliary subsystem consists of
• Electric Motor (EM)
• Mechanical transmission • Power steering unit
• Driving wheels • Temperature control unit
• Auxiliary power supply
03/29/2023
General Configuration of a Electric Vehicle
03/29/2023
In modern EV’s configuration:
• Three phase motors are generally used to provide the traction force
• The power converter is a three-phase PWM inverter
• Mechanical transmission is based on fixed gearing and a differential
• Li-ion battery is typically selected as the energy source
03/29/2023
Regenerative Braking in Electric Vehicles
The concept of regenerative braking

can be implemented in conventional
vehicles using Fly wheels.
Flywheels are disks with high inertia

which rotate at a very high speed.
In electric vehicles, we can incorporate

the regenerative braking in a much
more efficient way electronically.
This will reduce the need for heavy

flywheels, which adds extra weight to
the total weight of the vehicle.

Motor Torque and Power Flow Direction during Motoring mode
Motor Torque and Power Flow Direction when motor act as generator

Is Regenerative Braking worth to be implemented in all Electric Vehicles?
 It not advisable to use regenerative braking under fully charged conditions.
 It is because overcharging can damage the batteries, but the electronic circuit
prevents from overcharging of it.
 In this case, the capacitor bank can store the energy and help in extending the
range.
 the effectiveness of the regenerative braking is more in electric cars, buses, and
other heavy vehicles.
 the kinetic energy available is more when compared to an electric scooter

travelling at the same speed.

Differential
 Differential is an integral part of all four wheelers.

 A differential is used to allow the wheels to spin at different speeds.
 This is necessary when the vehicle turns

PART’S OF DIFFERENTIAL SYSTEM
 Pinion drive gear: transfer power from the drive shaft to the ring gear.
 Ring gear: will transfer power to differential case assembly.
 Spider gears: The spider gear lies at the heart of the differential and special mention should be
made about its rotation.
 Differential case assembly: Hold the gear and drive the axel.
 Rear drive axel: Transfer torque from differential
assembly to the drive wheels.
Case1 The vehicle moves straight

 In this case the spider gear rotates along with the ring gear but does not rotate on its own
axis.
 So the spider gear will push and make the side gears turn, and both will turn at the same
speed.

Case 2 Vehicle takes a turn(right)
 In this along with the rotation of the ring gear it rotates on its own axis.
 So the spider gear is having a combined rotation.
 When the spider gear is spinning as well as rotating, peripheral velocity at the left
side of spider gear is the sum of the spinning and rotational velocity.
 But at the right side, it is the difference of the two, since the spin velocity is in
the opposite direction at this side.
TYPES OF DIFFERENTIAL
 OPEN DIFFERENTIAL
 LOCKED DIFFERENTIAL
 LIMITED SLIP DIFFERENTIAL
 WELDED/SPOOL DIFFERENTIAL
 VISCOUS LSD
 TORSEN DIFFERENTIAL
 ACTIVE DIFFERENTIAL
 TORQUE VECTORING DIFFERENTIAL

 OPEN DIFFERENTIAL  LOCKED DIFFERENTIAL

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VIIT,Pune-48
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VIIT,Pune-48
Electronic differential in electric vehicles
 Electronic differential is advancement in
electric vehicles technology along with the
more traction control.
 The electronic differential provides the

required torque for each driving wheel and
allows different wheel speeds
electronically.
 It is used in place of the mechanical

differential in multi-drive systems.
 It is used in place of the mechanical

differential in multi-drive systems.
 When cornering the inner and outer wheels

rotate at different speeds, because the inner
wheels describe a smaller turning radius.
 The electronic differential uses the steering

wheel command signal, throttle position
signals and the motor speed signals to
control the power to each wheel
The use of Electronic Differential
(ED), replacing the conventional
gearbox and the usual configuration
of EVs with only one traction-motor
driving two wheels.
It reduces the overall mass of an EV

by replacing the conventional
mechanical differential.
The speed reference computation in

the double- driven EV can be
controlled by ED through the
torque/rotation-speed curve of an
electric motor. which is almost
perfectly adapted to the resistance-
torque/speed curve of an electric
vehicle. In case of curvilinear
trajectory or a lane change each
wheel is controlled


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Unit 3 Electric Vehicle Drive Train

Hybrid Electric Vehicle

Prof. Praveen P. Rathod

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

•PR.: - 02 hr/week OR:-- 01

• To understand the comprehensive overview of Electric and Hybrid

Learning Outcome/Course Outcome

• Design electric drive train and its components.

Department of Mechanical Engineering, VIIT , Pune-48 3

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

• Rotor is made of permanent

Ather Scooter BLDC In-Runner

Limitations of Brushless DC motor

• A permanent magnet synchronous motor,

• The principle of operation of a synchronous

• The magnetic field of the rotor, interacting

Faculty Name(optional), Department of ______Engineering,

•provides higher efficiency at high speeds

Faculty Name(optional), Department of ______Engineering,

Permanent Magnet Synchronous Motor BLDC

These are brushless AC synchronous motors These are brushless DC motors

Torque ripples are absent Torque ripples are present

Performance efficiency is high Performance efficiency is low

More efficient Less efficient

Produces low noise Produces high noise.

Faculty Name(optional), Department of ______Engineering,

• DC motor falls under the category

Faculty Name(optional), Department of ______Engineering,

Disadvantages of DC Series Motor

Faculty Name(optional), Department of ______Engineering,

Faculty Name(optional), Department of ______Engineering,

Disadvantage of Switched reluctance motor

• Creates Torque ripple at high-speed operation.

The topologies selected are

• single-motor single-axle (SM-SA) topology.

Single electric machine

1. a traditional powertrain formed by adapting a conventional ICE layout

2. a specialised design combining the single electric machine with a final-drive

Vehicle modelling techniques can be classified in two ways:

2. Driver models normally use proportional–integral controllers.

Backward-facing simulations use the opposite approach.

Inputs and outputs of backward-facing simulations of the vehicle.

• Backward-facing simulations generally rely on quasistatic component maps rather than

• Electric machines are typically modelled using motor efficiency maps.

• This simulation type cannot represent the dynamic behaviour of components

The angular velocity at the wheels can be calculated from

The torque at the wheels

where Tw is the torque at the wheel

Fvehicle is calculated from the environmental force

The calculations for the transmission are expressed as

where ωm is the angular velocity at the motor,

When motoring , the machine output power is given by