PowerPoint Presentation

AMITY UNIVERSITY AMITY UNIVERSITY DUBAI www.amityuniversity.ae.

[Audio] Electric vehicles save money on gas, reduce pollution, and provide tax breaks. Because they cannot go too fast and have less tyre wear, they're a lot safer ride. One thing that all electric vehicles have in common is that they all employ direct current electric motors to drive the wheels. Although these motors come in a variety of speeds, sizes, and modes of operation, the torque required from the vehicle to achieve desired characteristics remains the same. Torque is a component of the force that drives the wheels and propels the vehicle forward. The torque can be defined as the motor's turning power in basic terms..

[Audio] During the conception stage, the functional analysis allows the designer or the design team to determine whether the product being developed should have one or more functions, and which of the possible functions should be added to the proposed design. Of course, it is common for a product design engineer to propose more than one solution, so there will always be more than one possible functionality configuration.

[Audio] With this constraint in mind the project must focus on what is achievable within an economically viable framework. Although cost is an important factor in the development of the project, and will ultimately influence the nature of the conversion, it must be considered in balance with environmental awareness..

Bachelors of Technology Batch 2017-2021 Semester 8.

[Audio] As we know, the Internal Combustion Engines of conventional vehicles are replaced by an Electric Motor in an electric vehicle, the first and primary component to be picked when developing an electric car is an electric motor. As a result, an electric motor used in an electric vehicle must deliver sufficient power and other qualities for traction. The most crucial duty is to choose a motor with the suitable rating for the load to be carried. Vehicle dynamics are considered while choosing an electric motor that will deliver the appropriate power and torque for traction ROLLING RESISTANCE Rolling resistance is the resistance offered to the vehicle due to the contact of tires with road..

[Audio] GRADIENT RESISTANCE The vehicle's gradient resistance is the resistance it faces when climbing a hill or flying over a bridge, or when traveling down a slope, as indicated in the diagram AERODYNAMIC DRAG The resistive force provided by the viscous force pushing on the vehicle is known as aerodynamic drag..

. Sumiya Anjum.

Motor Torque Calculations. . Sumiya Anjum.

[Audio] ACCELERATION FORCE The acceleration force is the force that assists the vehicle in reaching a predetermined speed from a standstill in a given amount of time. The acceleration force and the motor torque have a direct relationship. The higher the torque, the less time it takes for the vehicle to reach a particular speed. The acceleration force is proportional to the vehicle's mass.

[Audio] Total Tractive Effort is the net horizontal force applied by the drive wheels to the ground..

[Audio] In the car, a battery box which carries 6 packs. Each having capacity of 12V 150 Ah wired in series connection. The operational costs of an electric car may be directly compared to the costs of operating a gasoline-powered car. The energy content of a liter of gasoline is approximately 8.9 kWh. We multiply the utility cost per kWh by 8.9 to get the cost of an electrical equivalent of a liter of gasoline..

. Sumiya Anjum.

[Audio] Aerodynamics is the way objects move through air. The rules of aerodynamics explain how an airplane is able to fly. Anything that moves through air is affected by aerodynamics, from a rocket blasting off, to a kite flying. Since they are surrounded by air, even cars are affected by aerodynamics "Aerodynamics" is a branch of fluid dynamics concerned with studying the motion of air, particularly when it interacts with a moving object..

[Audio] One of the design goals of a modified vehicle body is to reduce drag. Many vehicles have a fairly steep downward angle going from the rear edge of the roof down to the trunk or tail of the car. Air flowing across the roof tumbles over this edge at higher speeds, causing flow separation. The flow of air becomes turbulent and a lowpressure zone is created, thus increases drag. Adding a spoiler at the very rear of the vehicle makes the air slice longer, gentler slope from the roof to the spoiler, which helps to reduce the flow separation. Reducing flow separation decreases drag, which increases fuel economy; it also helps keep the rear window clear because the air flows smoothly through the rear window..

Static structural Analysis of the Electric Vehicle Frame using Design Optimization.

[Audio] The exact assembly of components is defined as the subsystem for this DFMEA. The subsystem is one area where the mechanical components and the controller needs will differ significantly. Mechanical subsystems are concerned with the physical component's structural integrity, mechanical connections, wiring competency, and general design. Subsystems connected to controllers are for those whose main risks are in the development and communication with the controller or module in question..

[Audio] The graph above depicts the relationship between different instances and total spring deflection. The displacement of the spring is quite large throughout the analysis, but when the parameter ( coil diameter of the spring) is lowered, the displacement or deflection decreases. As a result, changing one of its parameters improves or enhances their efficiency..

[Audio] The rate of heat transmission increases as the surface temperature of the component rises. However, there was still space for improvement in terms of power consumption and overall design cost. The thermal management systems were designed successfully, and the project's objectives were met..

Electric Vehicle Drivetrain The electric vehicle drivetrain generally consists of an energy storage system and a motor drive. The energy available from the energy storage system is transformed into mechanical energy by the motor drive, for vehicle propulsion. A motor drive comprises of a traction motor and a power electronic converter. If a DC motor is used, a DC/DC converter is used to regulate the power flow according to the driver pedal input. Similarly, DC/AC converters are used to regulate the power flow if AC motors are used. If regenerative braking is employed, a general configuration of an electric vehicle drivetrain..

The basic formula for determining distance is: (KWh of pack / wh/m) = Distance.

CASE 1: at 20kMPH we know that a Nissan Sunny using a 72V system will draw around 150amps at 20KPH. Therefore, the Wh/km usage = 72V x (150Amps / 20KPH) = 540Wh/km The distance our Nissan Sunny will travel on this setup is: 4.752kwh / 540wh/K = 8.8 kilometre’s (at 20km/h) If we had a lithium pack of equal voltage and ah, the range would be 16 km (because Peukerts effect does not play a role) 10.8kwh x 0.8 = 8.64 kwh usable / 540 = 16 kilometre’s range CASE 2: at 40KMPH we know that a Nissan Sunny using a 72V system will draw around 150amps at 40KPH. Therefore, the Wh/m usage = 72V x (150Amps / 40KPH) = 270Wh/km The distance our Nissan Sunny will travel on this setup is: 4.752kwh / 270wh/K = 17.6kilometre’s (at 40km/h) If we had a lithium pack of equal voltage and ah, the range would be 32 km (because Peukerts effect does not play a role) 10.8kwh x 0.8 = 8.64 kwh usable / 270 = 32 kilometre’s range.

Speed-time graphs are very useful when describing the movement of an object. We can use them to determine whether or not the object is moving at any point in time. We can also use them to see what speed the object is travelling at that point in time. We can see here our speed of vehicle over time..

[Audio] Tire slip ratio is a key factor for the stability of vehicle motion. The stability boundary is captured when vehicle is cornering with different slip ratio for front/rear wheel. We investigate how the variation of - affects the vehicle motion stability for different circumstances. As shown in Figure, the influences of velocity, steering angle, friction surface, and steering system on the stable area are discussed, respectively. Corresponding to the above result, the stable area is reduced with or increasing. High-mu road surface and 4WS system are good for vehicle stability compared with low-mu and 2WS, respectively..

CarSim Simulation of the vehicle with electric motor powertrain and with a load of 240 kgs at the rear end of the vehicle of battery weight moving with a velocity of 30 km/h.

Linear Motion of the vehicle with a velocity of 40 km/h.

Disassembly.. We had to strip the car of its components which were not required during the project. Some of the components which we had to remove were:- Engine Bonnet Wheels and Tyres Front Bumper Axel’s Exhaust Dashbord HVAC.

WhatsApp Image 2021-06-30 at 8.56.27 PM (4). Removal of Dashboard.

WhatsApp Image 2021-06-30 at 8.56.27 PM (2). WhatsApp Image 2021-06-30 at 8.56.27 PM (1).

WhatsApp Image 2021-06-30 at 8.56.27 PM. WhatsApp Image 2021-06-30 at 8.56.27 PM (5).

WhatsApp Image 2021-06-30 at 8.56.27 PM (6). WhatsApp Image 2021-06-30 at 8.56.27 PM (7).

Manufacturing. For this project we have manufactured components so we can adapt the parts from the vehicle to the new parts, we have retrofitted the following parts: 1.Adapter plate for the transmission 2.Adapter for the gas pedal 3.Module for the key(ignition) and the gear knob 4.Mounting base for the motor and transmission.

Adapter plate for the transmission. A circular object with holes in it Description automatically generated with low confidence.

Adapter for the gas pedal. A machine on the counter Description automatically generated with low confidence.

Module for the key(ignition) and the gear knob For the key and the gear lever we had to 3d print the holder, we first measured the space then used CAD to model the component Computer-aided design is the use of computers to aid in the creation, modification, analysis, or optimization of a design. Then converted it to .STL format and printed it in the lab. The key and the gear knob fit in perfectly..

Mounting base for the motor and transmission. A picture containing text, floor, indoor Description automatically generated.

Assembly. First connecting all 6 batteries in series. Then connecting all the required wires to the controller from the motor. Lastly connecting the motor controller to the batteries which are connected in series. We placed the 4 batteries in the trunk and two batteries in the rear passenger leg room for the weight distribution We kept the controller in dashboard and the wires were taken to the motor through the AC line holes ..

Battery placement. (S)SUZUKI. 1 st picture is where the batteries are placed in the trunk. 2 nd picture is where the batteries are placed in the rear passenger seat. All batteries are connected in series and the batteries in rear passenger seat are taken to the Motor Controller..

Motor and Transmission Mount. 9.H15WE1.. The 1 st picture is the Motor and transmission mount in which the motor and transmission will be placed on In the 2 nd picture it is the mount for the shaft of both motor and transmission. We had to manufacture 2 different mounts for since the size of the both were different. In the 3 rd picture you can see the completely connected and perfectly placed motor and transmission and Drive shafts from the transmission connected to the wheel hub..

Battery to motor controller connection. In the dashboard is where the motor controller was placed since the wires from the motor could easily be bought to the controller through the HVAC line holes. The cables of the batteries were sent out of the car through the fuel pump space and brought back into the car through space given for the gear stick and the connected to the controller..

TESTING. INDIVIDUAL COMPONENT TESTING TESTING AFTER CONNECTING IT IN A CIRCUIT TESTING AFTER ASSEMBLING ALL THE COMPONENTS IN THE CAR TESTING OF THE VEHICLE.

COMPONENT TESTING. MOTOR 7.5 KW AC MOTOR CONTROLLER.

BATTERY THROTTLE PEDAL. Sohail Nazim.

KEY SWITCH AND STALL SWITCH. Sohail Nazim.

CIRCUIT DIAGRAM. SG1212 wring 24-96V speed Panel rogramme o o w HeatSink f' LED Status AC Motor Throttle 0 0 0 0 0 0 0 0 0 c 02 23000 coco 000013 20 0 0 0 oc o o 01 Connector 776164- I(AMP35) is Correspond to JI.

TESTING OF COMPONENTS IN CIRCUIT. Image of the full connection in series and testing of voltage across the 6 batteries..

Successful motor test. Sohail Nazim.

Vehicle testing. Sohail Nazim.

Testing of Rotation of the Axle. Sohail Nazim.

Future Scope. Solar panels can be added for a plus advantage of charging and running the auxiliary parts of the car Lithium-ion batteries can be used in place of lead acid battery Liquid cooling can be added to cool down the motor and the batteries The controller can be integrated into the bottom of the vehicle where the wiring and the controller can be undisturbed Another motor can be mounted at the rear axle to increase the power produced by the car The battery can be placed in the flooring of the car to make it nice and flat and make the center of gravity as low as possible.