Electric motor is a key component of EV. However, the (electric) motor of EV are essentially not the same as the motors that have been used in other conventional electric applications. But these motors are a new power source to replace the internal combustion engine (ICE) of car. The EV motor must be high power with high efficiency and compactness. Also, high-durability and low-cost are must. These tough requirements change concept of motor and change the way of design. The motor of EV cannot be designed only with designers’ experience anymore and requires deep insights of physics inside of motor as well as concept of Model Based Design (MDB). High fidelity simulation is a key technology which has become more demanding today. JMAG, which is simulation tool for electromechanical design since 1983, has been used in most of HV/EV development projects over the world from late 80’s. JMAG’s high fidelity simulation capability and high integrity with MBD have led those projects to success. The presentation will show how JMAG was used in the actual developments and explain current challenges of the coming new EV era.

This Presentation presents the analysis of Toyota Prius Motor 2004 & 2010 and 2007 Camry model. All the version of Toyota electric motor uses 48 slots and 8 pole configurations. The Toyota Prius 2004 model designed for max. Torque of 400 N-m and max speed of 6000 rpm whereas the 2010 version is designed for max. Torque of 207 N-m and max. Speed of 13,000 rpm. This presentation investigates the motoring performance of both case and show casing the magnitude of reluctance and magnet torque. How optimal inductance winding enabled to achieve max. Speed for the given voltage in case of 2010 version. Further the comparison of effficiency map of both case of motor and interpreting the impact of inductance on wide efficiency range. Other performance metrics such as flux density during the constant torque region and constant power region will be explored and addressed.

Lucas-TVS is actively working on development of Electric Motors for various EV applications such as E-Scooter, E-Rickshaw, E-Auto,etc., Permanent Magnet Synchronous Motors are best suited for these applications given their advantages over other motor types mainly higher torque density and higher efficiency. In this presentation, Design of 3kW Permanent Magnet Synchronous Motor for Electric Two wheeler application using JMAG RT is discussed. Features in JMAG RT which help to include effect of temperature rise, skewing, etc., enables to simulate the results more closer to actual conditions. This helps to predict the performance of motor more accurately which in turn reduces product development time and prototype efforts significantly. Correlation between simulation results and actual prototype test values are discussed.

The presentation explains the basic dynamics of motion of a 3 wheeler Auto Rickshaw and arrives at the necessary traction motor specifications. It then goes on to design a suitable motor for the vehicle and validates the range that can be obtained for a single charge of the battery.

Electric Powertrains play a very significant role to provide increased number of kilometres per charge, higher reliability, better user experience and lower cost, which are very critical for the success of Electric Vehicles. Hence, technology and design of powertrains to achieve high efficiency, high power density, increased robustness, intelligent control and high cost effectiveness are important. At Elecnovo, each powertrain is engineered to the requirements of every vehicle to achieve optimum performance and reliability. Design and development supports are provided on customization, operation and integration of the powertrain with the vehicle.

The product is an LED driving system inside EV and consists of 6 LEDs which can display virtual image reflected off the windshield for alerting the driver by means of warning. The LEDs are driven through vehicle ECU. The purpose of the seminar is to present the advantage of using SABER simulation tool in analysing and verifying the design for meeting the electrical requirements of the product.

The lithium ion battery has evolved as the major power source ever since it’s discovery in 1991 by Sony and represents one of the major successes of materials electrochemistry. Lithium ion batteries are becoming more and more popular in view of the multifarious applications ranging from consumer electronics to space and also for electric vehicles due to their high voltage and high power leading to light weight and smaller size cells/batteries. In view of the growing day to day demand for lithium ion batteries, intensive research is being pursued globally to develop new high performing cost effective electrode and electrolyte materials and importantly without compromising on environmental issues. Further, sodium ion batteries are also emerging as an alternative to lithium ion cells owing to its low cost and abundance. In my talk, I shall give you an overview of the recent developments on the indigenization of the lithium ion cells especially by focusing on high performing anode and cathode materials. Details regarding the synthesis and characterization of high voltage cathode materials based on layered and olivine materials shall be presented in addition to the fabrication of 18650 and pouch cells and packs for various application ranging from Solar Lantern to Energy Storage Devices and could be extended for Electric Vehicles. These cells could also be solar charged. Further, recent work on the development of electrode materials for the futuristic sodium ion batteries shall also be presented.

– Indian grid capacity and Electric Vehicle load impact on grid will be addressed and explored.

– Presents the power system case study of 1200kV circuit breaker Transient Recovery Voltage (TRV), 1200kV Transformer inrush current analysis and tapping of power from EHV ground wire, Case study on selecting the pre-inserted resistor for 400kV transmission line using EMTP-RV Software.

– Powergrid Advanced Research & Technology Centre’s capabilities for Hardware -in-loop (HIL) testing and verification of HVDC, FACTS, relay study and EV controllers are explored.

Along with the development of smart grids, the wide adoption of electric vehicles (EVs) is seen as a catalyst to the reduction of GHG emissions and ushering intelligent transportation systems. Given limited range and costs involved in charging EV, measures that will minimize costs and, at the same time, avoid users being stranded have to be sought. Aggregation of EVs need to be planned in such a way as to avoid peaks on the grid that may result in high electricity prices and overload local distribution system. In particular, EVs can augment the grid with the ability to store energy at some points in the network and give it back at others forming a vital cog in the demand management of a smart grid.

In context of large number of motor types coexisting in the commercial space would mean that there exists a sweet spot of each of the surviving motor technologies. However when we look at a traction application among the typical factors of torque, power capabilities and densities, efficiency, reliability, cost, … etc., These are factors that are agnostic criteria. A vehicular application in context brings about its own set of must haves, for instance brushless feature. There have been instances where a separately exited DC motor had been a good contender. Now that the brushless motors have come of age, from a life perspective it has become a must have feature for the traction application, thereby limiting the motor choices to Induction Machine, a BLDC, Switched Reluctance and Synchronous reluctance motors. From the application perspective there are a few aspects to be deliberated and viewed as an integrated solution.

The Development of PMSM is proceeding at a rapid phase because of the expanding range of their application. Continuous development in the area of energy products and technological ecosystems has been influential for this rapid growth. Continuous torque density & power are very critical issues in design of electric motors application for off highway, and these performance parameters are mainly driven by the rotor design in PMSM. This paper presents a shape optimal design approach where emphasis is on enhancing the torque & power output. The sensitivity of design parameters of the motor on the output characteristics are also analyzed.

Thermal management of power systems in electric vehicles is an integrated problem comprising dynamic component characteristics and varying operating conditions which are all inter-dependant. Flownex is a flow system modelling tool and SaberRD is a platform for the modelling of power electronics and systems. Saber is capable of including all electric component characteristics enabling the simulation of output changes to temperature dependant variables. Flownex allows the modelling of the thermal management system’s thermal fluid performance, based on heat input and ambient conditions. The heat load which should be removed from the power system is in turn a function of vehicle loading and internal temperature. The rate at which it can be removed again varies with vehicle speed and ambient conditions. The design and performance evaluation of therefore requires an interlinked simulation of both electrical and thermal sub-systems simultaneously. Co-simulation is possible with Flownex and Saber resulting in an accurate and robust integrated model of the power system performance for the entire operating range and life cycle. This solution enables system optimisation in a much shorter timespan and provides insights into design changes affecting the system as a whole.

Powertrain requirements for an electric commercial vehicle The growing pollution levels, reliance on imported fuel, and climate change are making faster adoption of electric vehicles mandatory. However, there are as yet no proven and practical solutions for on-board energy generation / storage that address all stake-holder requirements, such as range, charging time, safety, reliability, and cost. This talk will detail the requirements at the vehicle level for an electric commercial vehicle, and cascade them down to the subsystems.

Electric Vehicles (EVs) / Hybrid Electric Vehicles (HEVS) are emerging as promising technological solution for energy saving in transportation sectors. In this context, energy materials significantly draw the attention for the design of these vehicles. Among the energy materials, Li-ion battery and motors based on rare earth permanent magnets are the critical components of the system to realize EV / HEV technology. Lithium-ion battery has emerged as a promising candidate due to its attractive features via high energy density (both volumetric and gravimetric), high current drain, high cycle life, low self-discharge, absence of memory effect, good low temperature performance.

The performance analysis of Flux Additive DC-DC converter is proposed for electric vehicle. The flux additive dc-dc converter combines input dc sources in magnetic form by adding up the produced magnetic flux together in the magnetic core of the coupled converter and produce the output voltage with less ripple. The main advantage of this converter can draw power from two different dc sources and deliver it to the load individually and simultaneously. Multi-input converters are preferred when one of the source is diminished to obtain the regulated output, so another input is chosen to get the desired regulated voltage. This converter has been designed for 140watts in order to establish the stability and to obtain desired output voltage of 100 volts, 1.4A with multiple input voltage of 80 volts and 50volts respectively and output voltage ripple and output current ripple are 1% and 2.02% respectively. Using simulation, the performance of flux additive dc-dc converter has been validated by using PSIM software.

Electric vehicles are considered to be the most promising choice for a sustainable road transportation system . However, choice of the component technologies determine to a large extent energy and materials demand for electric mobility. For achieving true sustainability, electric vehicles need to use components and subsystems that place minimum demand for energy, materials and other resources. Thus while meeting the customer demands in terms of cost and performance is a major challenge for the designer of the electric vehicle, issues related to resource efficiency also hold significance. For example while rare earth permanent magnet motors are preferred choice for most of the electric vehicle manufacturers, concerns over cost and supply of rare earth materials have prompted efforts towards development of alternative motor topology, alternative magnets, or even alternative designs with reduced magnet content. Similarly availability of lithium to meet the future demands from batteries of electric vehicles is another critical issue and hence alternative energy storage technologies are being explored. In this paper impact of the choice and design of electric vehicle components and subsystems on the resource efficiency is discussed. Possible future scenarios are described in light of the emerging technologies and their technology readiness levels.

The present energy scenario, with depletion of fossil fuels and introduction of large scale RES has altered the conventional power system to a great extent. Energy storage is another important entity in the current scenario. Another major breakthrough is large scale introduction of Plug-in electric vehicles (PEVs), including plug-in hybrid electric vehicles (PHEVs) and Battery Electric Vehicles (BEVs) have the potential to improve Indian energy and environmental landscape of personal transportation. Charging infrastructure will play a pivotal role on EV deployment, and, in the absence of a proactive plan and schedule, is a major impediment to mass market adoption. Infrastructure limitations are particularly pertinent to BEVs due to their sole dependency on electricity. The charging infrastructure includes all of the hardware and software that ensures energy is transferred from the electric grid to the vehicle. With a projection of EVs, the effects on current, energy production, transmission and distribution scheme and emission level need to be analyzed.

Distribution systems are the most affected due to EV penetration. Distribution transformers at 11kV and 33kV will probably host bulk charging stations. Whether existing capacity is adequate or additional capacity is needed for strengthening the system is very important to analyze. Some issues reported in the literature on the probable impacts of EV penetration on distribution systems will be discussed in the talk, followed by how EMTP-RV can assist in analyzing various scenarios generation for planning, protection will be discussed.

Performance testing of the Traction motors intended to be used for Electric vehicle application differ vastly compared to the Conventional industrial motors. Although there are standards for testing the industrial motors, it does not suffice to test the motors rigorously as to simulate the unpredictable dynamic changes the Traction motors experiences when the EVs are subjected to real-world conditions and driving practices. These Traction motors are operated in their peak performance band as the vehicle is accelerating or decelerating for a fairly huge period, where industrial motors are operated at rated performance range mostly. Also, the conventional electric motor testing does not provide sufficient data needed for the characterization of the EV Powertrain and its individual components such as invertor, Control systems and batteries.

The performance of an electric vehicle should be studied before it coming into the actual practice. Laboratory test bench setup analyses the actual road load situations, energy consumption economy, static and dynamic performance of EV etc. with less personnel involvement and cost. It also gives a platform for research and development associated with electric vehicle technology. The laboratory test bench setup includes a drive motor under the test, AC dynamometer which provides actual road load situations, torque sensor, power analyzer and other measuring and interfacing equipment’s and software.