Electric Vehicle, it's types and Battery Management System_Summer Internship Report.pdf

GAJJAR PARTH SUNILKUMAR
180420109009
B.E. IV ELE (M)
SEMESTER 7th
ELECTRIC &
HYBRID VEHICLES
A Report on
SARVAJANIK COLLEGE OF
ENGINEERING AND
TECHNOLOGY, SURAT
ELECTRICAL ENGINEERING
SUMMER INTERNSHIP - 3170001

Gajjar Parth Sunilkumar 180420109009
1
-: TABLE OF CONTENT :-
TOPIC Page No.
Acknowledgement 3
Company’s Details 4
Content Learned During Course 5
Types Of Electric Vehicle 6
Battery 6
Vehicle Control Unit (VCU) 7
Electrical Vehicle Safety Equipment (EVSE) 8
Comparison of Lithium-Ion Chemistries 8
Battery Assembling 9
Battery Management System 9
Balancing Battery 10
Thermal Management System 11
Report Introduction 13
Electric Vehicles 13
Battery Electric vehicle
( BEV’s )
13
Plug-In Electric vehicle
( PHEV’s )
15

2
Hybrid Electric Vehicle
( HEV’s )
17
Performance of Electric Vehicle 19
Configuration of Hybrid Electric Vehicle 21
Traction Motor 26
Motor Characteristics 27
Conclusion 30
Internship Enrolment Letter 31
Course Completion Certificate 32
Internship Completion Certificate 33

3
ACKNOWLEDGEMENT
• We live in an age of history where change is so speeded up, that we begin to
see the present only when it has already disappeared. Our training at Spark
Innovation, is somewhat like what is written in above line. Industrial training is
never an outcome of a single individual’s talent or efforts.
• Firstly, learning over a subject is very much important and that is why we were
asked to complete our briefing about Electric batteries and its Future
Technologies. This teaching was presented us through Udemy Online
Learning Platform.
• After giving ample time to complete it, we have to complete Internship
Research work over a topic of our selection within the term of 15 days.
• We humbly express our gratitude to Spark Innovation Limited, Electric
Chargers and Battery Designing Facility, Vadodara for giving us wonderful
instructions to undergo deep towards electrification of Indian Automotive
Industry.
• We are thankful to Mr. Ritul Shah for their valuable guidance throughout the
period of Internship. In spite of heavy work load they were always available to
solve our queries and curiosity about various components and processes.
They have provided us access to various study and research papers to
expand our knowledge in specific topics.
• This report includes all information about the learning course and Internship
Research Analysis of Electric Vehicle Technologies.
• We wish to express our sincere gratitude for being so supportive and helpful.

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COMPANY DETAILS
SPARK INNOVATION LIMITED
• Company is led by Mr. Ritul Shah.
• It is registered as:
Spark Innovations
9 Vudanagar Bungalows,
Near Rutansh Duplex,
Gotri Road, Vadodara, Gujarat, India – 390021
• Contact Details:
- info@sparkinnovation.in
- sparkinnovations12@gmail.com
- +91 9429832868
• Spark innovation is design and manufacturing firm for various Electronics and
Power, Electronic products used in Electric Vehicles, Solar and Other Industrial
Applications.
• Area of Focus:
- Battery Management Systems (BMS)
- Motor Controllers
- Battery Chargers

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CONTENT LEARNED DURING COURSE
• Introduction to electric vehicles
• Components inside an electric vehicle
• Lithium-ion batteries
- Various topologies - Future batteries
- Various form factors - Metal-Air batteries
- Various chemical chemistries - Aluminium-Air batteries
- Best suitable chemistry for the
batteries
- Solid state batteries
• Battery management systems
- How battery management
works
- Type of cell
balancing
- Topologies of BMS - Metal-Air batteries
- BMS ICs (Integrated Chips)
available in industries
- Key features of BMS
• Components of battery management system.
• Thermal management system,
- Methods and techniques used in cooling of the batteries
- Better efficiencies
• Design own battery packs of vehicles.

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TYPES OF ELECTRIC VEHICLE
BATTERY
• It is power house of Electrical vehicle
• Major classification of batteries
Primary batteries Secondary batteries
Single use Rechargeable batterie
Disposable
Non - rechargeable

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VEHICLE CONTROL UNIT (VCU)
• It is domain controller of EV and Hybrid EVs. VCU communicates with all other
parts of vehicle through Controller Area Network (CAN) protocol.
• CAN bus is vehicle standard robust bus systems which help in
communications of functions without host computer.
• FUNCTIONS ;
1. Charging Perspective
- High voltage coordination
- Charging control
- Balances the system Energy
2. Microcontroller And Signal
- It controls sensor signals
- OBD (On-Board Diagnostics)
- Monitoring of Data
- Thermal controls and check-ups
3. Motor Controls
- Controls motor torque and provides torque coordination
- Gear shift strategies
4. It also detects operation failures for highly automated driving functions.
5. Higher version VCU also supports interconnected functions
- Predictive and automated longitudinal guidance
- Advance driver assistance systems (ADAS) connections
- Body controller functions

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ELECTRICAL VEHICLE SAFETY EQUIPMENTS (EVSE)
• EVSE are generally called as charging stations. They sole purpose is the
safety of Car charger, car battery and Electric Vehicle. This is done with the
help of two-way communication with the charging station and EV.
- Battery data, Current battery status, Maximum battery capacity, etc
are shared with the charging station.
- This maintains the maximum charge that may not damage the battery
and charge it under safe zone.
- It also continuously monitors the temperature of the battery
- It also detects hardware faults and disconnects the battery to prevent
short circuits and fire.
• Proper connection is established so that humans don’t get current.
COMPARISION OF LITHIUM-ION CHEMISTRIES

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BATTERY ASSEMBLING
1. Battery Soldering
- Assembly of battery is required and simple way to do is Soldering.
- Most eco-friendly way with 50–75-Watt shouldering gun.
- Not use for mass production.
2. Nickel Spot Welding
- One of the cheapest and fastest methods for assembling
- It is Resistance Welding process used to connect nickel strips with
Lithium-ion cells.
- It can be manual or Automatic process.
3. Ultrasonic Wire Bonding
- It is an advanced friction welding process that is been used in
microelectronics and power electronics industries.
- During this process temperature gets up to 80-100° C
(This is lower than that of soldering process)
BATTERY MANAGEMENT SYSTEM (BMS)
1. Distributed BMS
- Individual Li-ion cell has its individual BMS
2. Modular BMS

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3. Centralised BMS
BALANCING OF BATTERY
Lithium-ion batteries are made up of different chemicals and while using the same
batteries manufacturing process it still has some irregular with same battery
composition. During multiple charging and discharging cycles there might be
major imbalance between cells in the series. Balancing is the process of maintain
equilibrium within cells.
1. Passive Balancing

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2. Active Balancing
THERMAL MANAGEMENT SYSTEM
• Controlling the temperature of the systems and protecting it using technology
based on thermodynamics and heat transfers.
• Transfer of heat can be due to:
- Conduction
- Convection
- Radiation
• TMS is required for Li-ion batteries as their data sheets tells us that best life
cycle is in rage of 20-40° C of temperature. In some weather
conditions/countries we require heating systems to warm the batteries for
better performance. In Gulf and Equatorial countries there is requirement of
Cooling systems for batteries.
1. Heat Sink
- Cheapest methods
- Aluminium or copper – metals which are thermally conductive are used to
dissipate heat in the environment using heat conduction method.
2. Air Cooling
- Cheaper solution
- External fan or vehicle dynamics are used as air cooling solution
- It cannot reduce temperature below ambient temperature

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3. Liquid Cooling
- Liquid coolants having higher heat conductivity are used for cooling which are
higher than that of air
- More effective
- Compact – complex structure required
- We can manage to reduce the temperature below ambient temperature
4. Phase Change Material
- Phase change material absorbs heat
energy by changing state from solid to
liquid. Reversing when system is cooled
down the absorbed heat is dissipated in
air and phase starts to solidify again.
- Higher the latent heat – more heat will
be stored in it. Advantage is we don’t
require any external hardware for this
method
5. Thermo Electric Cooling
- It is also called as Solid-State cooling because it has no moving element like
air or liquid
- Peltier Effect is used – it is the phenomenon which converts current into
temperature and occurs when an electric current flow through thermoelectric
device
- They are very compact in size
- Major applications are in medical instruments and pathology labs
- It has less efficiency of 20-50%

13
REPORT INTRODUCTION
We all know that the use of fossil fuels is harmful to environment and also it is limited and will soon
finished. Thus, as an alternative to this Electric vehicle are design to save environment and earth. In
this report we will see regarding the electric vehicle, it’s configuration, advantages, disadvantages
and regarding the traction motor.
ELECTRIC VEHICLES :
• An electric vehicle (EV) is one that operates on an electric motor, instead of an internal-
combustion engine that generates power by burning a mix of fuel and gases.
• There are mainly 3 configuration of electric vehicles (EV) ;
a. Battery Electric Vehicles (BEVs)
b. Plug-in Hybrid Electric Vehicles (PHEVs)
c. Hybrid Electric vehicles (HEVs)
a. BATTERY ELECTRIC VEHICLES (BEVs) :
Solely Powered By An Electric Battery.

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Working
- Power is converted to AC from DC motor for electric motor.
- Accelerator pedal sends a signal to the controller that adjusts the vehicle’s speed by
changing the frequency of the AC power from the inverter to the motor.
- Thus, the motor connects and turns the wheels.
- When the car is decelerating or brakes are applied, the motor becomes alternator which
produces power that is send back to battery.
Advantages
- Very low running costs with no petrol or diesel engine to fuels
- Typically, lower maintenance costs
- Government incentives & discounts available
- Zero emissions and no road tax
- Very quiet & enjoyable to drive
Disadvantages
- Expensive to buy
- Have a maximum range of miles
- May not be suitable for long journeys

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Example Models
- Volkswagen e-Golf - Ford Focus Electric
- Tesla Model 3 - Hyundai Ioniq
- BMW i3 - Karma Revera
- Chevy Bolt - Kia Soul
- Chevy Spark - Mitsubishi i-MiEV
- Nissan LEAF - Toyota Rav4.
b. PLUG-IN HYBRID ELECTRIC VEHICLES (PHEVs) :

16
Working
- It starts up in electric mode and operate on electricity until battery is depleted.
- Some cases when it reaches 60-70 miles per hour speed it automatically
switches to hybrid mode.
- Also, when battery is drained out, engine take over and vehicle is operated as
normal automobile (non-plug in hybrid)
- The batteries of PHEVs can also be charged internally as the combustion of
engine or regenerative braking.
- During braking, electric motor works as generator so the energy that is generated
is used to charge battery.
Advantages
- If the battery runs low the fuel powered engine will automatically kick in.
- Very low-cost motoring on short journeys using the electric battery.
- Regenerative braking technology reduces energy waste and lowers.
Disadvantages
- More expensive to buy than self-charging hybrids.
- Electric charging facilities available at owner’s home which may not be possible
for everyone.

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- If you rely on the petrol/diesel engine frequently you’ll find the fuel economy isn’t
great, especially with the extra weight of the large battery.
- Plug-In Hybrids are usually more expensive to buy than Hybrid vehicles.
- Not useful for long distance as battery will drained out
Example Models
- Porsche Cayenne S E-Hybrid - Mercedes C350e
- Chevy Volt - Mercedes S550e
- Ford C-Max Energi - Mini Cooper SE Countryman
- Ford Fusion Energi - Audi A3 E-Tron
- Hyundai Sonata - BMW 330e
- Kia Optima - Fiat 500e
c. HYBRID ELECTRIC VEHICLE (HEVs)

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Working
- It has fuel tank that supplies gas to the engine like a regular car.
- Moreover, it has a set of batteries that run the electric motor.
- Both these engine and electric motor turn the transmission at same time.
Advantages
- Less expensive than plug-in or electric cars
- Good for short journeys & city centre driving
- No plug-in point needed, good for drivers without off road parking
- No time spent on re-charging
- No “low-battery” worries on long journeys
- Use less fuel & cheaper to run than conventional cars
Disadvantages
- They’re not as environmentally friendly as plug-in hybrids or fully electric cars.
- Servicing costs can be higher.
- They’re not exempt from tax and there aren’t a many discounts or incentives
available.
- They’re not as powerful as other electric vehicles.

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Example Models
- Honda Civic Hybrid
- Toyota Prius Hybrid
- Honda Civic Hybrid
- Toyota Camry Hybrid.
PERFORMANCE OF ELECTRIC VEHICLE :
The performance of a vehicle is usually described by its maximum cruising speed, gradeability, and
acceleration.

20
Maximum Speed Of a Vehicle : The maximum speed of a vehicle is defined as the constant cruising
speed that the vehicle can develop with full power plant load (full throttle of the engine or full power of
the motor) on a flat road.
The maximum speed can be written as,
Where; npmax = max. speed of engine
ig = min. gear ratio of transmission
Gradeability : It is usually defined as the grade (or grade angle) that the vehicle can overcome at a
certain constant speed, for instance, the grade at a speed of 100 km/h (60 mph).
For heavy commercial vehicles or off-road vehicles, the gradeability is usually defined as the
maximum grade or grade angle in the whole speed range.

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It is calculated by ;
Acceleration Performance : The acceleration performance of a vehicle is usually described by its
acceleration time and the distance covered from zero speed to a certain high speed (zero to 96 km/h
or 60 mph, for example) on level ground.
CONFIGURATION OF HYBRID ELECTRIC VEHICLE :
• A HEV is a combination of a conventional ICE‐powered vehicle and an EV.
• It uses both an ICE and an electric motor/generator for propulsion.
• Following is the basic architecture components of HEV’s ;
• The performance of hybrid electric vehicle is usually given by hybridization factor (HF):
where, PEM = Power of Electric Motor
PICE = Power of IC Engine
PHEV = Total Reactive Power

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• On the based of performance HEV are classified as ;
• The purpose of HEV configurations is to achieve the optimal speed-torque characteristic from
the electric power train and to meet the operational constraints such as initial acceleration,
gradeability and maximum cruising speed with minimum power requirement.
• 3 HEV configuration are there ;
i. Series HEV
ii. Parallel HEV
iii. Series – Parallel HEV
i. SERIES HEV :
- Series HEV system has the simplest propulsion power flow mechanism among
all three configurations.
- As shown in figure, working of series HEV is like,
ICE converts gasoline to mechanical power → Mechanical power is converted to
electricity using generator → using this electricity motor moves drive.

23
CHARACTERISTICS DISADVANTAGES APPLICATION
o Optimized-Efficient
traction drive line.
o Simple power transfer
mechanism.
o Small size engine
utilization.
o Small engine with space
packaging advantages.
o Optimized efficient
power plant. Possible
zero emission operation.
o Large traction motor
drive.
o Multiple energy
conversions and energy
loss.
o High cost due to
additional generator.
o Mercedescitaro Bus And MAN-
Lions City Hybrid Bus.
o Temsaavenue Hybrid Bus.
o Tesla Ultra Light Rail.
o New Tesla Buses.
o Military Vehicles.
ii. PARALLEL HEV :
- In this configuration both engine and traction motor are connected in parallel to
regulate and blend the power transfer into the wheels.
- The electric motor can be used as a generator to recover the kinetic energy during
braking or by absorbing a portion of power from the ICE.

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o Zero emission operation
possible.
o High efficiency due to the
absence of multi
conversion of power.
o Two power sources for
better high-speed cruising
capability.
o No additional generator
and small size of traction
motor.
o Control complexity.
o Expensive system.
o Complex space
packaging
o Honda insight.
o Ford Escape Hybrid
SUV.
o Lexus Hybrid SUV
General comparison between above two configuration ;
iii. SERIES – PARALLEL HEV :
- It follows features of both series and parallel.
- The series–parallel HEV adds a mechanical link between the engine and the final
drive, so the engine can drive the wheels directly compared to series HEV.
- The series– parallel HEV adds a second electric machine that serves primarily as a
generator compared to parallel HEV.
- As It can be operated in both series and parallel mode, the fuel efficiency can be
optimized as per our vehicle needs.
CONFIGURATION
SYSTEM
VOLTAGE
(V)
TYPICAL POWER
REQUIREMENT
(KW)
ELECTRIC
FRACTION
(%)
RELATIVE FUEL
ECONOMY GAIN
(%)
Parallel Con. 14, 42, 144, 300 3~40 5~20 5~40
Series Con.
216, 274, 300, 350
550, 900
＞50 100 ＞75

25
o Improved vehicle power
capability.
o Better dynamic
performance and high
cruising speed.
o Better fuel economy with
less emissions.
o Zero emission operation
possible.
o Very expensive system.
o Control complexity
o Complex drive train
configuration.
o Nissan experimented.
o Fiat experimented.
o Toyota Prius

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TRACTION MOTORS :
• It plays an significant role in development of electrified automation industry.
• It converts electrical energy to mechanical energy in such a way that the vehicle is
propelled to overcome aerodynamic drag, rolling resistance drag, and kinetic resistance.
• Following chart shows the different DC and AC traction motors,
• Mainly four traction motors are widely used and they are,
Direct Current Motor
DC Motor
Induction Motor
IM

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MOTOR CHARACTERISTICS :
Switch Reluctance Motor
SRM
Permanent Magnet Synchronous Motors
PMSM

28

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• Following table shows the performance of above 4 traction motor,

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• Following table shows the application of traction motor in EV’s and HEV’s ;
CONCLUSION :
In this internship, I had learned regarding the “ Lithium Ion Battery and Battery Management System
for an EV ” and also for the Electric & Hybrid vehicle, it’s configuration, advantages-disadvantages,
application of different traction motor, motor characteristics.
DOCUMENT ATTACHED
- Internship Enrollment Letter
- Course Completion Certificate
- Internship Completion Certificate

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