Electric & Hybrid

Vehicle
E-Notes

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 B22EES606
Sub Code: M20PS2041 L T P C CH
Electric and Hybrid Vehicle
Duration: 14 Weeks 2 1 0 3 4
1. Explain the basics of Electric , Hybrid Electric Vehicles Architecture
& Technologies
2. Analyze various Electric Drives, Vehicle Dynamics with EV and
HEV.
3. Discuss different energy storage technologies, control and brief
Course Objectives about V2G, G2V technologies for energy management.
4. Describe various challenges in charging of EV’s, HEV’s and Design
Optimizations
On completion of this course the students will be able to:
1. Describe the configuration of a typical EV,HEV and design controls
2. Choose a suitable drive motor for EV,HEV application and
differentiate among different roadways fundamentals.
3. Choose proper energy storage system for vehicle and develop
strategies using G2V for charging various types of batteries.
Course Outcomes 4. Describe the configuration of HEV and various types of Fuel Cell
Electric Vehicles and realistically implement/ design EV,HEV and
FCV
Course Contents:

UNIT-I: Introduction to Electric Vehicles (EVs): [11 Hrs]

Historical perspective. Air pollution and global warming. EV advantages and impacts. EV market and
promotion: infrastructure needs, legislation and regulation, standardization. Comparison with Internal
combustion Engine : Technology Benefits and Challenges. Electric vehicle (EV) design options: EV
configurations: fixed v s. variable gearing, single- vs. multiple-motor drive, in-wheel drives. Types of Electric
Vehicle and components, Battery Electric vehicle (BEV), Hybrid electric vehicle (HEV), Plug-in hybrid vehicle
(PHEV) Fuel cell electric vehicle (FCEV)

UNIT-II: Vehicle Dynamics and Motor Drives: [11 Hrs]

Calculating the Rolling Resistance, Calculating the grade Resistance, Calculating, The Acceleration Force,
Finding The Total Tractive Effort, Torque Required on the Drive Wheel, EV drivetrain and components. Types
of Motors, Selection and sizing of Motor, RPM and Torque calculation of motor, Motor Controllers , Physical
locations, Mechanical connection of motor , Electrical connection of motor EV motor drive systems: DC drives,
induction motor drives, permanent-magnet synchronous motor drives, switched reluctance motor drives.
Control strategies.

UNIT-III: Batteries: [10 Hrs]

Battery parameters. Types and characteristics of EV batteries. Battery testing and maintenance; charging
schemes. Need of Battery Management System, Battery monitoring techniques, Advance Features. Open-
circuit voltage and ampere- hour estimation. Battery load levelling.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
UNIT-IV: Emerging EV Technologies: [10 Hrs]
Hybrid electric vehicles (HEVs): types, operating modes, torque coordination and control, generator/motor
requirements. Fuel cell electric vehicles (FEVs): fuel cell characteristics, hydrogen storage systems, reformers.
Alternative sources of power: super- and ultra-capacitors, flywheels.

Text Books and References:

1. C.C. Chan and K.T. Chau, Modern Electric Vehicle Technology, London: Oxford University Press
2. Iqbal Husain, Electric and Hybrid Vehicles: Design Fundamentals, New York: RC Press.
3. M. Ehsani, Y. Gao, S .E. Gay and A. Emadi, Modern Electric, Hybrid Electric, and Fuel Cell Vehicles:
4. Fundamentals, Theory and Design, CRC Press.
5. Batteryuniversity.com

Text Books and References:

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 Module -2
Vehicle Dynamics and Motor Drives

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 Concept of EV motors
Some engineers and even researchers may consider EV motors kind read or like industrial
motors.
EV motors usually require frequent start/stop, high rate of acceleration/deceleration, high-
torque low-speed hill climbing, low torque high-speed cruising and very wide-speed range of
operation, whereas industrial motors are generally optimized at rated conditions.
Thus, EV motors are so unique that they are deserved to form an individual class. Their major
differences in load requirement, performance specification and operating environment are
summarized as follows.

Expected Features of EV motors

• EV motors need to offer the maximum torque that is four to five times of the rated torque
for temporary acceleration and hill-climbing, while industrial motors generally offer the
maximum torque that is twice of the rated torque for overload operation.

• EV motors need to achieve four to five times the base speed for highway cruising, while
industrial motors generally achieve up to twice the base speed for constant-power operation.

• EV motors should be designed according to the vehicle driving profiles and drivers’ habits,
while industrial motors are usually based on a typical working mode.

• EV motors demand both high power density and good efficiency map (high efficiency over
wide speed and torque ranges) for the reduction of total vehicle weight and the extension of
driving range, while industrial motors generally need a compromise among power density,
efficiency and cost with the efficiency optimized at a rated operating point.

• EV motors desire high controllability, high steady-state accuracy, and good dynamic
performance for multiple-motor coordination, while only special purpose industrial motors
desire such performance.

• EV motors need to be installed in mobile vehicles with harsh operating conditions such as
high temperature, bad weather and frequent vibration, while industrial motors are generally
located in fixed places.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
The Design of EV Motors also depends on the system Technology of EV’s
• Single- or multiple-motor configurations-one adopts a single motor to propel the
driving wheels, while another uses multiple motors permanently coupled to individual
driving wheels.
• The single-motor configuration has the merit of using only one motor which can
minimize the corresponding size, weight and cost.
• On the other hand, the multiple-motor configuration takes the advantages to reduce
the current/power ratings of individual motors

Fig.a Single- motor configurations

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
• The Multiple-Motor one needs additional precaution to allow for fault tolerance
during the electronic differential action.
• For instance, each motor may have its own controller which is controlled by a master
controller.
• Since these two configurations have their individual merits, both of them have been
employed by modern EVs.

Fig.2 Dual motor configurations

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Classification of EV Motors

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Brushed DC Motor

Fig: Working of DC Motor

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Why BLDC

Think about This ?

▪ Brushes require frequent replacement due to mechanical wear, hence, a brushed DC
motor requires periodic maintenance. Also, as brushes transfer current to the
commutator, sparking occurs. Brushes limit the maximum speed and the number of
poles the armature can have. These all drawbacks are removed in a brushless DC
motor. An electronic control circuit is required in a brushless DC motor for switching
stator magnets to keep the motor running. This makes a BLDC motor potentially less
rugged.
▪ Advantages of BLDC motor over brushed motors are increased efficiency, reliability,
longer lifetime, no sparking and less noise, more torque per weight, etc.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 BLDC
A Brushless DC motor or BLDC motor is a type that is most suitable for applications
that require high reliability, high efficiency, more torque per weight, etc. This article
explains about BLDC motors in details.

Construction of BLDC
In this configuration, the rotor is external. i.e. stator windings are located at the core while
the rotor, carrying permanent magnets, surrounds the stator.
A commutator-brushes arrangement helps in achieving unidirectional torque in a typical dc
motor. Obviously, commutator and brush arrangement is eliminated in a brushless dc motor.
Here, an integrated inverter/switching circuit is used to achieve unidirectional torque. That is
why these motors are, sometimes, also referred as 'electronically commutated motors'.
Just like any other electric motor, a BLDC motor also consists of two main parts a stator and
a rotor. Permanent magnets are mounted on the rotor of a BLDC motor, and the stator is
wound for a specific number of poles. Also, a control circuit is connected to the stator winding.
Most of the times, the inverter/control circuit or controller is integrated into the stator
assembly. This is the basic constructional difference between a brushless motor and a typical
dc motor.
A typical controller provides a three-phase frequency-controlled supply to the stator winding.
The supply is controlled by logical control circuits and energizes specific stator poles at a

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
specific point of time. This can be understood from the below animations about working of
BLDC motors.

Advantages of BLDC Motors

Since BLDC Motors are electronically commutated, there are several

advantages over traditional Brushed DC Motors. Some of them are:

• No wear and tear (due to absence of brushes)

• High efficiency
• Better speed vs torque characteristics
• Long life
• Less noise or noiseless operation
• Significantly higher RPM

Applications of Brushless DC Motors

Some of the areas of applications of BLDC Motors are mentioned below:

• Single speed applications

• Adjustable speed applications
• Position control
• Low noise applications
• High speed applications

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Switched Reluctance Motor
The switched reluctance motor (SRM) is an electric motor that runs by
reluctance torque. Unlike common brushed DC motor types, power is
delivered to windings in the stator (case) rather than the rotor. This greatly
simplifies mechanical design as power does not have to be delivered to a
moving part, but it complicates the electrical design as some sort of
switching system needs to be used to deliver power to the different
windings.
The reluctance motor is an electric motor in which torque is produced
by the tendency of its moveable part to move to a position where the
inductance of the excited winding is maximized.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Construction of SRM

In switched reluctance motor, the stator and rotor have projected pole made
up of soft iron and silicon stampings. Silicon stamping is used to reduce
hysteresis losses.

Stator => Inward projection

Rotor => Outward projection.

The rotor does not have winding and stator only carries main field winding.
Each winding in the stator is connected in series with the opposite poles to
increase the MMF of the circuit. It is called phase winding. Refer to fig 1.1
AA’, BB’ and CC’.

Pole concern, the number of poles in the stator will be around 6 to 8 numbers.
But the rotor carries less number of poles with respect to the stator. The rotor
poles will be 4 to 8 numbers.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
By increasing the number of poles we can get a low angle of rotation from
the motor. The rotor’s shaft is mounted with a position sensor. The position
sensor is used to determine the position of the rotor by a control circuit.

The control circuit always collects the information of the rotor position and
based on that the controller gives the input to the motor.

Fig: Graph of L vs θ, I vs θ, T vs θ
The main concept is the reluctance of the magnetic circuit is depending
upon the air gap. Hence, by changing the air gap between the rotor and
stator, we can change the reluctance of the motor.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Note: reluctance is nothing but a resistance to the magnetic flux. (Opposes
the magnetic flux. For Electrical circuit it is resistance and magnetic circuit it
is reluctance).

• In future now the Electronic Controllers are advanced and due to the fast
response, the control can be accurate
• The main aim is to Replace the use of Induction Motor

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Advantage of SRM

1. It does not require an external ventilation system as the stator and

rotor slots projected. The airflow maintained between the slots.
2. The rotor does not have winding since therefore no need keeps the
carbon brush and slip ring assembly.
3. Since the absence of permanent magnet, such motors are available
at a cheaper price.
4. Simple three or two-phase pulse generator is enough to drive the
motor
5. The direction of the motor can be reversed by changing the phase
sequence.
6. Self-starting and does not require external arrangements.
7. Starting torque can be very high without excessive inrush currents.
8. High Fault Tolerance
9. Phase losses do not affect motor operations.
10. High torque/inertia ratio
11. High starting torque can be achieved.

The 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 Permanent Magnet, the motor has to designed
to carry high input current. It increases the converter KVA
requirement.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Application of SRM

High Capacity rating motors for EV Propulsion applications. Domestic

appliances such as washing machines, vacuum cleaners, fans etc.

Permanent Magnet Synchronous Motor

This motor runs at constant speed even when the load fluctuates within
the rated load.
Stator Produces – Revolving Field – Rotates at Ns
Rotor Produces – Constant Magnetic Field
Due to interaction of Ns and RMF the rotor Rotates at Ns Speed

When the stator winding is energized with 3 phase voltage, it causes a

rotating current and a magnetic field.
• The magnets of the rotor have a permanent magnetic field.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 • The rotary field of the stator interacts with the rotary field of the
rotor, this results in torque.
• The motor shaft rotates.
• Fig. 2 shows the flow of the magnetic field lines on an example of an
8-pole synchronous motor.
• As it is shown in the illustration the magnetic flux is acting mainly on
the outer diameter of the rotor. The inner diameter and shaft are
mostly field-free and therefore not coactive necessary for the
magnetic field. This matter leaves room for weight optimization in
this area.

Advantages
• Maximum efficiency
• Dynamic speed control possible
• Fast reaction to load change
• Small installation space, low weight

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 Three Phase Induction Motor Definition & Working
Principle

An electric motor is a device, which converts electrical energy into mechanical energy. Motors can operate
on ac supply, single phase as well as three phase, called as ac motors. Ac motors are further classified as
synchronous motors, single phase & three phase induction motors and some special purpose motors. Out of
all these types, three phase induction motors are commonly used for various applications in industries. The
principle of operation of three phase induction motors is based on the production of rotating magnetic field.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Construction of Induction Motor: Conversion of electrical power into mechanical power takes place in the
rotating part of an electric motor. In dc motors, electrical power is conducted directly to the armature
(rotating part) through brushes and commutator. Hence a dc motor can be called as a conduction motor.
However, in ac motors the rotor does not receive electric power by conduction but by induction in exactly
the same way as the secondary of a 2-winding transformer receives its power from the primary. That is why
such motors are known as Induction motors. An induction motor can be treated as a rotating transformer
i.e., one in which primary winding is stationary but the secondary is free to rotate.

Consider the simplified view of a 3 phase induction motor shown below.

The stator hosts a three phase winding distributed symmetrically on its

inner periphery. This stator winding is energised from a three phase
supply.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
The rotor also hosts a 3 phase winding on its periphery. But, the rotor
winding is not energised from any source and is short- circuited on itself.

(2) The rotating magnetic field cuts the rotor conductors, which as yet,
are stationary. Due to this flux cutting, emfs are induced in the rotor
conductors. As rotor circuit is short circuited, therefore, currents start
flowing in it.

(3) Now, as per Lenz's law , "the direction of induced current will be such
that it opposes the very cause that produced it " .

(4) Here, the cause of emf induction is the relative motion between the
rotating field and the stationary rotor conductors. Hence, to reduce this
relative motion, the rotor starts rotating in the same direction as that of
the stator field and tries to catch it but, can never catch it due to friction
and windage and therefore emf induction continues and motor keeps
rotating.

Thus, principle of 3 phase induction motor also explains why rotor

rotates in same direction as the rotating field and why induction motor is
self starting.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
When rotor winding is short-circuited with no resistance in series, it is
called a squirrel cage induction motor and when rotor winding is
shorted through a resistance in series, it is called slip ring induction
motor.

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
 Vehicle Dynamics

Resistances

1. Aerodynamic Resistances
2. Rolling Resistances
3. Grade Resistances

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Aerodynamic Resistance Ra
Composed of:
1. Turbulent air flow around vehicle body (85%)
2. Friction of air over vehicle body (12%)
3. Vehicle component resistance, from radiators and air vents (3%)

Rolling Resistance Rrl

Composed primarily of
1. Resistance from tire deformation (∼90%)
2. Tire penetration and surface compression (∼ 4%)
3. Tire slippage and air circulation around wheel (∼ 6%)
4. Wide range of factors affect total rolling resistance
5. Simplifying approximation:

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Grade Resistance Rg
Composed of – Gravitational force acting on the vehicle

Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru
Prepared by: Prof. Mahesh Kumar, School of EEE , REVA University Bengaluru