JETIR Research Journal - IJRAR



ASSEMBLING AND TESTING OF ELECTRIC CAR1SANDIPAN PAWAR, 2SHREEKANT WALKE, , 3VINOD BHUJBAL 4SAHIL SHINDE, 5PRITESH HALWALKAR1Professor, Department of Automobile Engineering, PHCET Rasayani, Maharashtra ,IndiaB.E. Student, Department of Automobile Engineering, PHCET Rasayni, Maharashtra, India________________________________________________________________________________________________________Abstract : The focus of this paper is to describe the future of an electric car which has a good range as well as how the electric car can be used instead of IC engine vehicle for normal passenger cars. As the emission norms are getting strict day by day there is a need to develop alternate ways in which the vehicles can be driven without polluting the environment. In this paper a review on electric cars development as well as development in the field of components of electric car such as motor, controller, battery, and chassis development are presented. Alternative solutions such as hydrogen fuel cells are also described as well as a comparison between electric power plants and IC engine vehicle emissions are also discussed along with their effects on the environment. Various features which can be incorporated in the electric car for increasing the range are also discussed in this paper. ________________________________________________________________________________________________________KEYWORDS Electric Car, Motor, Battery, Pollution , Range etc.INTRODUCTIONThis paper describes a research to modernize the pollution free electric car, aiming to improve the lifestyle and eco friendly nature. The modernized electric car used in our experiment causes no carbon emission and thus it is eco-friendly. The electrically assisted car consists of torque sensor pedal in order to reduce the overuse of battery-bank. The control system assists the human power with motor and saves energy by reducing the overuse of motor. The paper describes the data obtained from field test to determine its performance, feasibility and user friendliness. The global pollution in on rise and every effort made, being to reduce the CO2 emissions and save the planet. One such effort is the introduction of Electric Vehicle (EV). The transport sector is one of the biggest emitter of CO2 and hence it is very important to convert the sector to a green sector. Indian government has come up with ambitious plans of introducing the EVs to Indian market and keep in pace with the development of EVs globally. The National Electric Mobility Mission Plan 2020 (NEMMP 2020) has come with a detailed report on the EVs.LITERATURE REVIEWIn this paper the author (Robert et al) has described a four door, 5 passenger electric car. This car was developed in January 1967 to provide economical, pollution free transportation to urban and suburban residents where the residents are suffering from harmful effects of air pollution due to hazardous gases which were emitted by conventional IC engine operated vehicles. The battery used for powering the motor is a Tri-polar, lead-cobalt battery. The main advantage of this battery was that the harmful gases which are produced in the cells are greatly eliminated. The conventional lead acid batteries while charging process emits stibine gas, the hydride of antimony SbH3, which is a very harmful gas. To resolve the problem of overcharge of battery along with oxidation of positive grids speeds up the transfer of antimony from positive to negative plate. The sulphuric acid electrolyte of tri-polar battery consists of a solution of cobaltus sulphate which acts as a protection coat on the positive grid. Due to this the production of the toxic gas (Stibine gas) during charging of battery is eliminated. This battery also has an advantage of lower required charging voltage which helps in fast charging. According to reference of this paper and due to cost and maintenance point of you we did used lead acid gel type battery. Cost of battery is low and this is maintenance free battery. [1]In "Controllers for Electric Cars" by (Hartman et al) the Authors talk about various speed controllers along with their operation as well as various connections of batteries in series and parallel. The author has also elaborated how these connections would help in transferring nearly 100% power from battery to the motor continuously while the motor is in operation. It also includes how the freewheeling diode is used for eliminating the arcing. The contactors designed also had a longer life for smooth torque transfer. From this reference paper we did research and then preffer series connection because we require more current than voltage. [2]The paper "Selection of a Brushless DC Motor Employed to Propel an Electric Car," by (Silveira et al) gives information about an electric car is a vehicle which uses one or more electric motors for its propulsion. The authors researched to construct small automotive cars of high efficiency. The main aim was to develop and apply new technologies that allow increasing the efficiency of electric cars and to study the behavior of the efficiency of the car and the freedom of the battery, as a function of the kind of the electric motor. A brushed DC motor, connected to a 12 V, 6 Ah battery, was engaged to drive the car. Measurements showed that the electric power required by the brushed DC motor was equal to 80 W, with an efficiency of 53%, when operating at minimal conditions. Other brushed DC motors were tested and they result show small efficiency, too. The efficiency of conventional DC machines was affected by the drops in the brushes and by the sliding contact between brushes and the commutator. With the purpose of increasing the efficiency of the car, because of this reason the brushed DC motor was replaced by a BLDC motor driven and controlled by an electronic circuit. [3]The paper "Model-based Drive train Development and Rapid Prototyping for a Hybrid Electric Car" by (Andreas et al) talk about automotive industries. Now a day due to increasing demand in automotive industries, new technologies are introduced in automotive sectors for the beneficial uses. With the help of rapid prototyping the author has described how a model base can be created using executable software, it has many advantage instead of traditional development process. Energy conversion and storage at the University of UIM has developed a series hybrid electric drive train. In this base process the implementation is based on the system model additional code generation in RTW has to be adapted to specific target means of three different code generation targets which consist of few scripts and some system dependent block sets to include the target hardware. [4]LAYOUT OF ELECTRIC CARKey specification of the model:Length(mm)4500Width(mm)1725Height(mm)1445Seating Capacity(mm)5Ground Clearance Unladen(mm)173Wheel Base(mm)2600Gross Weight(kg)1150Tyre Size185/65 R14Selection of motor:-The Induction motor were tested. The Induction motor had the problem of over heating. The size of Induction motor is large, for the sama mechanical work outup over BLDC motor. The BLDC motor is smaller because its body has less heat dissipate. A BLDC motor can generate full torque at zero speed. The BLDC motor to respond much faster than induction to changing load condition. After this whole research and market survey we select BLDC motor.BLDC Motor:-We used 8HP - 6Kw - 6000W BLDC motor for running electric car. The IC Engine is replaced by BLDC motor. It is connected to clutch assembly via flywheel in the front end where engine is generally located. Motor controller and capacitor is located in the boot.Selection of battery:-We research and market survey collecting information about most of the EV batteries. Dry battery:- Lithium Ion batteryThis is maintenance free battery. Cost of the battery is to high as compared to dry and gel battery. This is light weight battery. The weight of the battery is light for same amp of other batteries. But battery is not charged for few months then this battery is dead. Life ot this battery is 8 to 10 years.Acid battery:- Lead acid batteryMaintenance is required for this battery. Cost is low as compared to dry and gel battery. Discharge rapidly if battery is not charged few months there is no starting problem. Life of battery is 3 to 5 years.Gel battery:- Lead acid gel batteryThis is maintenance free battery. Cost is more as compared to lead acid battery, charge fastly and discharged slowly as compared to acid battery. Life of this battery is 10 to 15 years.After this research we are first decide Lithium Ion battery. Performance of this battery is best and this is maintenance free but due to cost we avoid this battery. We are student and can’t afford too much cost for this project so we take decision used Gel type lead acid battery. We used total 24 batteries, each battery is 12V and 24amp-24000mah. The total voltage of batteries is 288V and total ampere is 576amp. Range is 100km in one charge. Charging time required for this batteries is around 8 to 10 hours.Location of battries:- 18 batteries are placed under the rear seat of the vehicle and remaining 6 batteries on the trunk of the vehicle.Battery management system (BMS):-There are lot of factors that are to be considered while designing a BMS. The complete considerations depend on the exact end application in which the BMS will be used. Apart from EV’s BMS are also used wherever a lithium battery pack is involved such as a solar panel array, windmills, power walls etc. Irrespective of the application a BMS design should consider all or many of the following factors.Discharging controlCharging controlState of charge(SOC) determinationState of health(SOH) determinationBMS is working like a fuse, when battery is overcharge then cut-off the current from battery, and when battery is stable then again on the current flow. BMS is most important for electric vehicle because of current flow of motor is high and due to high current flow battery is out of balance and mostly chances of battery damage.Charging system:-We used plug-in charger. There are three main types of EV charging-Rapid chargingFast chargingSlow chargingThese represent the power outputs, and therefore charging speeds, available to charge an EV. Rapid chargers:-This chargers are the fastest way to charge an EV, and this cover DC charging. Rapid charger charge at 50kw DC in 1 to 2 hours.Fast chargers:-This chargers charge power from 7kw to 22kw, which typically fully charge an EV in 3 to 4 hours.Slow chargers:-This chargers rated between 3kw to 6kw and are best used for overnight charging, usually taking time between 8 to 12 hours.CALCULATIONSCharging time of battery = Battery Ah / Charging CurrentT = Ah/AWhere,T = Time hrs.Ah = Ampere hour rating of batteryA = Current in amperesT = 240Ah/24ampT = 10 hours.But this was an ideal casePractically, it has been noted that 40% of losses occurs in case of battery charging.Then 240Ah × (40/100) = 96…(240Ah × 40% of losses)Therefore, 240 + 96 = 336Ah (240Ah + losses)T = 336Ah/24ampT = 14 hours.TESTING AND OBSERVATIONTesting Stage 1:Test of EV was performed on road.Observations:-EV running on road successfully.We check 6kw BLDC motor with 144 Volt and it worked not properly.The rpm provided during test was too medium for the process.The performance is slow .Testing Stage 2:The performance is moderate.In order to improve that, battey was changed but still the problem remained. Later it was observed that it required high voltage for running 8HP BLDC motor.The 6kw BLDC motor was tested with 288 Volt battery and it worked statisfactorily.Testing Stage 3:The entire assembled EV was tested. After assembling all the parts on the EV, the testing of controller was performed.The EV was tested and found to be statisfactory.We overcome the losses of performance of EV, the performance is statisfactorily.CONCLUSIONThe development in the electric vehicle industry has seen in recent years is not only extremely welcomed, but it highly necessary in light of the increasing global greenhouse gas levels. both developed and developing countries have become more active in EV introduction and diffusion . ICE vehicles are a major contributor to pollution in cities and their replacement with EVs will definitely improve air quality. The benefits of electric vehicles far surpass the costs. The biggest barrier to the universal adoption of electric-powered transportation is cost related, as gasoline and the vehicles that run on it are easily available, appropriate, and less costly. Similarly production of batteries is largely an expensive affair. To be able to rise above these challenges, the Indian government will also have to focus its efforts on make easier technological disturbance. We hope that over the next decade technological?advancements and policy changes will help ease the transition from?traditional fuel-powered vehicles.REFERENCEAronson, R., "The MARS II Electric Car," SAE Technical Paper 680429, 1968,?, A., "Controllers for Electric Cars," SAE Technical Paper 690127, 1969, ISSN:?0148-7191, Silveira, M., Gertz, L., Cervieri, A., Rodrigues, A. et al., "Selection of a Brushless DC Motor Employed to Propel an Electric Car," SAE Technical Paper 2011-36-0246, 2011, ISSN:?0148-7191 ? HYPERLINK "" , A., Kabza, H., Koerner, C., and Seger, P., "Model-based Drivetrain Development and Rapid Prototyping For a Hybrid Electric Car," SAE Technical Paper 2001-01-3422, 2001, ISSN: 0148-7191 . ................
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