A SUMMER INTRENSHIP REPORT ON

ELECTRIC VEHICLE DESIGN BIST TECHNOLOGY

Submitted in partial fulfilment of Requirements for the Award of the
Degree of
BACHELOR OF TECHNOLOGY IN
ELECTRICAL & ELECTRONICS ENGINEERING
By
PURNA CHNADRA SHEKHAR AJAD KILARAPU
228T5A0207

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DHANEKULA INSTITUTE OF ENGINEERING & TECHNOLOGY

(AUTONOMOUS) GANGURU, VIJAYAWADA - 521 139

Affiliated to JNTUK, Kakinada & Approved By AICTE, New Delhi

Accredited by NBA & NAAC

Certified by ISO 9001-2015.

 DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
DHANEKULA INSTITUTE OF ENGINEERING & TECHNOLOGY

(AUTONOMOUS) GANGURU, VIJAYAWADA - 521 139

Affiliated to JNTUK, Kakinada & Approved By AICTE, New Delhi

Accredited by NBA & NAAC
Certified by ISO 9001-2015

CERTIFICATE

This is to certify that the Summer Internship entitled “Electric Vehicle (EV)
Design” is a bonafide record of Internship Presentation done by PURNA
CHANDRA SHEKHAR AJAD . KILARAPU (228T5A0207) of IV-B. Tech, I-Semester
in the Department of Electrical & Electronics Engineering, DIET, Ganguru during
the Academic year of 2024-2025 in partial fulfilment of the Requirements for the
Award of degree of Bachelor of Technology.

Guide External examiner Head of department

 ACKNOWLEDGEMENT

First and foremost, we sincerely salute our esteemed institution

DHANEKULA INSTITUTE OF ENGINEERING AND TECHNOLOGY for giving me this
opportunity for fulfilling my seminar.
We express our sincere thanks to our beloved Principal Dr. Ravi Kadiyala
Garu for providing all the library and lab facilities required for completing this
seminar successfully.
This summer internship presentation would not have been possible
without the support of many people. We wish to express my gratitude to Head
of EEE Department without whose knowledge and assistance this study would
not have been successful.
We are glad to express my deep sense of gratitude to Mr. P.T.Krishna Sai,
Assistant Professor, who were abundantly helpful and offered in valuable
assistance, support and guidance throughout this presentation.

We thank one and all who have rendered help directly or indirectly in the
completion of this summer internship report successfully.
 DHANEKULA INSTITUTE OF ENGINEERING & TECHNOLOGY
Department of Electrical and Electronics Engineering

POs/PS

List Program Outcomes

1.Engineering knowledge :apply the knowledge of mathematics ,science
,engineering fundamentals ,and an engineering specialization to the solution
of complex engineering problems.
2.ProblemAnalysis :identify ,formulate, review research literature, and analyze
complex engineering problems reaching sustained conclusions using first
principles of mathematics ,natural sciences, and engineering sciences.
3.Design/Development Of Solutions :design solutions for complex engineering
problems and design system components or process that meet the specified
needs with appropriate consideration for the public health and safety, and the
cultural ,societal ,and environmental considerations.
4.Conduct Investigations Of Complex Problems :use research-based knowledge
and research methods including design of experiments, analysis and
interpretation of data, and synthesis of the information to provide valid
conclusions.
5.Modern Tool Usage :create, select, and apply appropriate techniques,
resources, and modern engineering and IT tools including prediction and
modelling to complex engineering activities with an understanding of the
limitations.
6.The Engineer And Society: apply reasoning informed by the contextual
knowledge to assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional engineering practice.
7.Environment And Sustainability: understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate
the knowledge of, and need for sustainable development.
8.Ethics:apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
9.Individual And Team Work: function effectively as an individual, and as a
member or a leader in diverse teams, and in multidisciplinary settings.
10.Communication: communicate effectively on complex engineering activities
with the engineering community and with society at large, such as, being able
to comprehend and write effective reports and design documentation, make
effective presentations, and give and receive clear instructions.
11.Project Management And Finance: demonstrate knowledge and
understanding of the engineering and management principles and apply these
to one’s own work, as a member and leader in a team, to manage projects and
in multidisciplinary environments.
12.Life- Long Learning: recognize the need for, and have the preparation and
ability to engage in independent and life- long learning in broadest context of
technological change.

List Program Specific Outcomes

PSO 1: Ability to design solutions for identified problems by using latest

engineering tools like MATLAB, Simulink, PSPICE, plc etc.
PSO 2: Able to design and develop the Green Electrical systems.
 DHANEKULA INSTITUTE OF ENGINEERING & TECHNOLOGY
Department of Electrical and Electronics Engineering
VISION – MISSION - PEOs

Vision/Mission/PEOs

Institute Vision Pioneering Professional Education through Quality

Providing Quality Education through state-of-art

infrastructure, laboratories and committed staff.

Moulding Students as proficient, competent, and socially

responsible engineering personnel with ingenious
Institute Mission intellect.

Involving faculty members and students in research and

development works for betterment of society.

Emerge as Quality Human Resource Provider for Industry

Department and Society in the field of Electrical & Electronics
Vision Engineering.

Providing Quality Education through State-of-art

resources.
To develop innovative, proficient Electrical engineers.
Department
Mission Promoting Ethical and moral values among the students
so as to make them responsible professionals for the
society.
 Graduates of Electrical and Electronics Engineering shall
PEO1: Have strong foundation in Electrical Engineering
along with Mathematics, Sciences and allied Engineering
subjects.
PEO2: Possess good problem solving, design skills,
capability to use modern engineering tools, ability to
Program pursue higher education and research.
Educational
Objectives(PEOs) PEO3: Seek employment in various engineering or
technological positions of their interest and continue to
achieve their aspirations through lifelong learning.
PEO4: Exhibit professional and ethical attitude, effective
communication skills, Teamwork and multidisciplinary
approach.
 ELECTRIC VEHICLE DESIGN TOPICS

 Introduction of EV

 EV -merits and demerits of EV

 Components of EV

 Introduction to Vehicle Dynamics

 Types of EV

 Energy Storage requirements in EV

 Fuel cells

 Cooling methods of Battery in EV

 Safety Standards of EV
Week 1: Introduction of EV
Topic covered: Overview and History of EV
Description:
Electric Vehicles (EVs) are the vehicles that use electric motors powered
by batteries, rather than traditional Internal combustion engines. In early 1830s
the Scottish invertor Robert Anderson creates an electric carriage powered by a
non - rechargable primary cell battery. But Electric vehicles became popular in
the early 20th century, with companies like Detroit Electric and Rauch & lang
offering a range of models.

In 1910s the rise of gasoline-powered cars, led by the Ford Model T,

makes electric cars less popular due to their limited range and charging
infrastructure. In 1960s General motors and other companies done some
experiments with electric cars but they don’t gain wide spread
acceptance. But in 1990, General motors releases the EV1 which is one of
the first modern electric cars, but it’s discontinued due to limited demand.

In 2000s Tesla Motors releases the Roadster, a high-performance

electric sports car, making the beginning of the modern EV era. Today,
electric vehicles are offered by most major automakers, with models like
the Tesla Model 3, Chevrolet Bolt and Nissan Leaf leading the charge.

The first electric car Roadster, the first sport’s car

Tesla model 3 car Nissan leaf

Electric vehicle working principle:

From working principle of Electric vehicle we can say that EVs are based
on the conversion of electrical energy stored in batteries or generated
through other means into mechanical energy to propel the vehicle.

Electric vehicles functions by plugging into a charge point and

taking electricity from the grid. They store the electricity in rechargable
batteries that power an electric motor, which turns the wheels. Electric
cars accelerate faster than vehicles with traditional fuel engines – so they
feel lighter to drive.

The Pros of Electric vehicles are Highly efficient, reduced

emissions, quiet and smooth operation, faster acceleration, cheaper to
run and offers Environmental benefits .

The Cons of Electric vehicles are Battery charging which

consumes more time, range anxiety, expensive electricity storage, high
capital cost, fewer charging points on routes .

The electric vehicles are used in very wide range of applications.

They include personal transportation like commuting, sports cars, luxury
vehicles, public transportation like Buses, taxis, shuttle services,
Commercial vehicles like delivery vans, trucks, Government and Municipal
transportation like electric Rvs, Electric motorcycles, Industrial Handling
like Forklifts, Airport ground support equipment, Mining equipment,
Military and defense like communication equipment, military trucks and
other applications like Electric wheelchair’s, electric aircraft, autonomous
vehicles, electric helicopters.
Week 2: Components of EV

Topics covered:Explaining about components of EV and Vehicle dynamics

Description:

In the second week of EV design, we delve into the components of

EV. Evs have 90% fewer moving parts than an ICE car. The main
components of EV are Electric motor, on-board charger, Power electronics
controller, Battery pack, Thermal management system, battery
management system, Transmission, Wheels, etc.

The electric motor is used to convert electrical energy into

mechanical energy to propel the vehicle. Power electronics controller is
used to manage the flow of electrical energy between the battery, motor
and other components. On-board charger is used to convert AC power
from the charging station to DC power for the battery. Battery pack is used
to store electrical energy in a series of connected cells. Thermal
management system is used to regulate the temperature of the battery,
motor, and other components.

Battery Management System (BMS) is used to Monitor and

control the battery's state of charge, voltage, and temperature.
Transmission is used to transfer power to the wheels and enables gear
shifting. Wheels are used to Provide traction and support the vehicle's
weight. Steering system ensures handling and ride comfort.

Components of EV
 Vehicle dynamics :

Vehicle dynamics involves Electric Powertrain, weight

distribution, centre of gravity, Torque vectoring, Regenerative braking.

Electric power train contains Electric motor, gearbox, and battery

impact vehicle dynamics. In weight distribution battery placement affects
weight distribution, influencing handling. Coming to Center of Gravity
lowered COG due to battery placement improves the stability. Torque
Vectoring in Electric motors enable advanced torque vectoring for
improved handling. Regenerative braking affects vehicle stability and
dynamics.

The main benefits of vehicle dynamics are Improved acceleration

and performance, Enhanced handling and stability, Increased safety
features, Reduced energy consumption and Smoother ride quality.

The main challenges of vehicle dynamics are Battery weight and

placement, Electric motor thermal management, Regenerative braking
optimization and Integration with ADAS systems.

The industrial examples of vehicle dynamics are Tesla Model S,

Chevrolet Bolt EV, Nissan Leaf, BMW i3 and Audi e-tron.
Week 3: Types of EV

Topics covered: Explaining about types of EV.

Description:

In the third week of EV design, we delve into the types of EV. There
are mainly 3 types of EVs. They are Battery Electric vehicle, Plug-in Hybrid
electric vehicle and Hybrid electric vehicle.

Battery Electric vehicle :

Battery electric vehicles are fully electric vehicles

powered solely by a rechargeable battery, without the use of any internal
combustion engine. BEVs are commonly referred to as "all-electric"
vehicles because they rely 100% on electricity to operate. The key
components of Battery EV’s are Electric motor, battery pack, On-board
charging and regenerative braking.

The Electric motor is responsible for converting electrical

energy from the battery into mechanical energy to propel the vehicle.
BEVs use large lithium-ion battery packs, similar to those in smartphones
but on a much larger scale. The capacity of these batteries determines the
vehicle's range (distance it can travel on a single charge). On-board
Charger converts alternating current (AC) from the power grid into direct
current (DC) to charge the vehicle's battery. BEVs use Regenerative Braking
system to recover energy during braking and use it to recharge the battery.

Modern BEVs offer ranges between 150 to 400 miles on a single

charge, depending on the model and battery capacity. BEVs often have
faster acceleration than gasoline vehicles due to the instant torque
provided by electric motors. The charging is done through Home charging
and Public charging stations. Examples of BEVs are Tesla Model 3, Nissan
Leaf and Chevrolet Bolt EV

Plug-in hybrid Electric vehicle :

Plug-in Hybrid Electric Vehicle (PHEV) is a type of hybrid vehicle that

integrates both an internal combustion engine (ICE) and an electric motor,
which can be recharged by plugging into an external power source, like a
wall outlet or a dedicated charging station. The key components of Plug-
in hybrid EV’s are Internal combustion engine, Electric motor, battery
pack, charging port.

Just like conventional vehicles, PHEVs have a gasoline or diesel

engine that can take over when the battery is depleted, ensuring extended
driving range. The electric motor can power the vehicle independently or
in combination with the ICE, providing increased fuel efficiency and lower
emissions. It has a larger, rechargeable battery compared to traditional
hybrids. This battery can be charged externally via a plug and internally
through regenerative braking. Charging Port allows the vehicle to be
plugged into an external power source for battery recharging.

PHEVs can run solely on electric power for short distances, usually
ranging from 20 to 60 km (12 to 37 miles) depending on the vehicle and
battery size. In this mode, there are no emissions, and the vehicle
consumes no fuel. Once the electric battery is depleted, the ICE kicks in,
allowing the vehicle to operate like a traditional hybrid. It blends power
from both the electric motor and the engine.

PHEVs can significantly reduce fuel consumption. When in electric

mode, PHEVs produce zero tailpipe emissions, which contributes to lower
greenhouse gas emissions overall. PHEVs tend to be more expensive than
conventional vehicles and hybrids due to the cost of the larger battery.
While they offer an electric-only mode, the range is still limited compared
to fully electric vehicles (EVs). The examples of PHEVs are Toyota Prius
Prime, Chevrolet Volt, Ford Escape Plug-in Hybrid and BMW 330e.

Hybrid Electric vehicle :

A Hybrid Electric Vehicle (HEV) is a vehicle that combines a conventional

internal combustion engine (ICE) with an electric motor and a battery. The
electric motor supplements the ICE to improve fuel efficiency, reduce
emissions, and provide better performance. Unlike Plug-in Hybrid Electric
Vehicles (PHEVs), HEVs cannot be plugged into an external power source to
recharge; instead, the battery is charged internally through regenerative
braking and the ICE itself.
The main components of HEV are Internal Combustion Engine (ICE),
Electric motor, Battery pack and Regenerative braking. The traditional gasoline
or diesel engine that provides power to the vehicle and also charges the
battery when needed. Electric Motor works with or independently of the
engine to power the vehicle, typically during acceleration, low-speed driving, or
when additional power is needed. Battery Pack stores energy to power the
electric motor. In HEVs, the battery is recharged through regenerative braking
and energy generated by the ICE. Regenerative Braking converts kinetic energy
lost during braking into electrical energy to recharge the battery, enhancing
fuel efficiency.
The types of Hybrid EVs include Mild hybrid, Full hybrid, Series
hybrid, parallel hybrid and series-parallel hybrid vehicle. HEVs consume less
fuel than conventional vehicles by using electric power in addition to gasoline.
The electric motor reduces the workload of the gasoline engine, HEVs emit less
CO2 and other pollutants compared to conventional vehicles. The regenerative
braking system recaptures energy that would otherwise be wasted,
contributing to the vehicle's efficiency.
HEVs tend to be more expensive than traditional gasoline-powered
vehicles, although the price difference is narrowing. The examples of Hybrid
Electric vehicles include Toyota Prius, Honda Accord Hybrid, Ford Fusion Hybrid
and Toyota Camry Hybrid.
Difference between EV types:

Week 4: Energy Storage requirements in EV

Topics covered: Explaining about Energy storage requirements in EV.

Description:

In the fourth week of EV design, we delve into the energy storage

requirements in EV and fuel cells.

Energy storage requirements:

In electric vehicles (EVs), energy storage is a critical component that

directly affects their range, performance, and overall efficiency. The
primary energy storage system in most EVs is the battery, which stores
electrical energy and supplies power to the electric motor. High energy
density is important to allow the vehicle to travel longer distances on a
single charge without significantly increasing battery size or weight.

Lithium-ion batteries are commonly used in EVs due to their high

energy density. Power density, which measures how quickly stored energy
can be delivered to the motor, is essential for quick acceleration and high-
speed performance. Efficiency is another important factor, as it
determines how much of the stored energy is used to power the vehicle
without losses, directly impacting range. Cycle life, or the number of times
a battery can be charged and discharged before significant degradation, is
crucial to reducing maintenance costs.

Thermal management systems are required to prevent overheating

and maintain performance, as excessive heat can degrade the battery.
Safety considerations involve protection against overheating,
overcharging, and short-circuiting, while advanced control systems ensure
battery safety. Cost is a significant factor, with energy storage making up a
large part of the overall EV cost, and finding cost-effective solutions
without compromising performance is an ongoing challenge.

Fuel cells:
Fuel cells are an emerging technology in electric vehicles, offering an
alternative to traditional batteries. They work by converting chemical energy
from a fuel, typically hydrogen, into electricity through an electrochemical
reaction. In this process, hydrogen reacts with oxygen from the air, producing
electricity, water, and heat as byproducts.
Fuel cells offer several advantages, such as high efficiency, long range,
and rapid re-fueling, making them an attractive option for certain types of
vehicles, especially heavy-duty and long-haul transportation.
One of the key benefits of fuel cells is that they generate electricity
continuously as long as fuel is supplied, unlike batteries which must be
recharged. This leads to faster re-fueling times, similar to conventional internal
combustion engine vehicles.
Fuel cells also have the potential for higher energy density compared
to batteries, meaning vehicles powered by fuel cells can have a longer driving
range. Additionally, since the only byproduct of the reaction is water vapor, fuel
cells are a zero-emission technology, contributing to a cleaner environment.
However, there are challenges associated with fuel cells. Hydrogen
production and storage remain complex and expensive, as hydrogen must be
stored under high pressure or at very low temperatures. The infrastructure for
hydrogen re-fueling stations is still limited compared to the widespread
availability of electric charging stations, posing a barrier to widespread
adoption.
 Furthermore, the efficiency of hydrogen production, especially through
renewable methods like electrolysis, must be improved to ensure that fuel cells
are a sustainable solution.

Week 5: Cooling methods of battery in EV

Topics covered: Explaining about Cooling methods of battery in EV.

Description:

In electric vehicles, managing the temperature of the battery is

crucial to ensure optimal performance, safety, and longevity. Batteries generate
heat during both charging and discharging, and excessive heat can lead to
reduced efficiency, faster degradation, and even safety hazards. Therefore,
effective cooling methods are necessary to maintain the battery's temperature
within a safe range.
There are several cooling methods used in EVs to regulate battery
temperatures. One common approach is air cooling, where air is circulated
around the battery pack to remove excess heat. This method is relatively
simple and cost-effective but may not be sufficient for high-performance
applications, as it has limitations in terms of heat removal capacity.
A more efficient method is liquid cooling, which involves circulating a
coolant—usually a mixture of water and glycol—through channels around the
battery cells. This system is more effective at transferring heat away from the
battery compared to air cooling, providing better temperature control and
allowing the battery to operate efficiently even under heavy loads or in
extreme conditions.
 Liquid cooling systems are commonly used in modern EVs due to their
ability to manage higher heat loads while ensuring uniform cooling across the
battery pack.
Another advanced cooling technique is phase-change material (PCM)
cooling. In this method, the PCM absorbs heat as it changes from a solid to a
liquid state. This technology can be integrated into the battery pack to absorb
heat during peak temperature periods, reducing the need for active systems.

Week 6: Safety standards of EV

Topics covered: Explaining about Safety standards of EV.

Description:

Safety standards in electric vehicles (EVs) are essential to ensure that they
meet performance, environmental, and safety criteria for both users and the
general public. These standards cover various aspects of vehicle design, battery
safety, electrical systems, and crashworthiness to mitigate potential risks
associated with EV operation.
One of the primary concerns in EV safety is the battery system. Standards
ensure that the battery is protected from thermal runaway, which can occur
due to overcharging, short-circuiting, or physical damage, potentially leading to
fires or explosions. Battery enclosures are designed to protect the cells from
impact and to contain any hazardous events.
Additionally, EVs are equipped with thermal management systems to
maintain battery temperature within safe operating limits, preventing
overheating or freezing, both of which can affect performance and safety.
Electrical safety is another critical aspect. Since EVs operate at high
voltages, stringent standards govern insulation, wiring, and connectors to
prevent electric shocks. EVs must also have systems in place to automatically
disconnect the battery in the event of a crash to protect occupants and
emergency responders from electrical hazards. Crash safety in EVs follows the
same rigorous standards as conventional vehicles, with additional
considerations for the placement and protection of the battery pack. The
battery is typically located in a reinforced area to minimize damage during
collisions.