Prototyping of Electrical Systems of an Electric Vehicle(EV)

Fossil fuels are essential and primary source of energy. The global consumption of fossil fuels is on rise since the last century. The main reason is the increase in human population and the industrial growth. Environmental pollution is the most important effect of their use. Also, the earth doesn?t

Project Title

Prototyping of Electrical Systems of an Electric Vehicle(EV)

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

Fossil fuels are essential and primary source of energy. The global consumption of fossil fuels is on rise since the last century. The main reason is the increase in human population and the industrial growth. Environmental pollution is the most important effect of their use. Also, the earth doesn’t have unlimited resources and will soon ran out. The reduction in the dependency of fossil fuel is itself a big challenge for us. EVs are much efficient as compare with the internal combustion Engine vehicles, in terms of pollution, as well as the running cost. The objective to work on this project is to build a low cost Electric Vehicle using the locally available components. Electric Vehicle’s main objective is to provide a cleaner form of transportation, which should have almost no adverse effect on the environment. The EV is functioned by plug in electricity and it takes an AC source from the grid. Then batteries stores the electricity that is required to run the electric car, the higher KWh of the battery having the higher range of car. This car has single speed transmission and its drive train is coupled with the electric motor which send the power from the motor to the wheels, and in result the wheels turn. To accelerate electric car faster we made it small and lighter. The body shape and the aerodynamics can decrease the efficiency of the car, therefore design is also considered.

Project Objectives

• Build make a vehicle by using the locally available components only, which includes the mechanical design as well as the electrical charger and the motor controller.  
• Achieve the speed of 50 km/h.
• Insure the safety of driver as well as the passenger.
• Reduce vehicle’s weight by using light materials e.g. fiber glass in the body works.
• Design a vehicle which can be used in different fields, e.g, on roads, industries, indoor transportation etc.

Project Implementation Method

To make this electric car we started from the mechanical part first. We designed the chassis using engineering software’s, auto-CAD. The designed was the used to make a chassis using iron angles and all the systems were installed i.e. breaking, steering, differential, suspension systems etc. after this electrical components were installed, including a 36V, 2.5KW DC motor, which was coupled with the differential using a shaft to enhance the efficiency of the vehicle. A battery system was used consisting of 3 batteries of 72Ah and 12V each. Then a regulated voltage controlled charger of 7A was designed. A motor drive controller of 36V and 2.5KW power was designed with a cam switch of 70A between the motor and controller. Different electric components like headlights, indicators switches were installed. We distributed the load of these components on different batteries so that there is no effect on battery life. The body of vehicle was assembled using fiber glass and then finishes were done to give the car an attractive shape.

Benefits of the Project

EVs are vehicles which use electricity to run. There are a number of great benefits to Electrical Vehicles over conventional petrol/diesel cars. They have much lower running costs. EVs have less moving parts than a conventional petrol/diesel car. There is relatively little servicing and no expensive exhaust systems, starter motors, fuel injection systems, radiators and many other parts that aren’t needed in an EV. EVs help in reducing harmful air pollution from exhaust emissions. EVs have zero exhaust emissions. So, the reduced exhaust emissions are good for human health. Better air quality leads to less health problems. They are also quieter than petrol/diesel vehicles reducing the noise pollution.  EVs reduce the dependency on the fossil fuels as the number of fossil reserves is declining day by day.

One of the most positive aspect of this project is that most of the components used are either recycled which means reduction of waste on the planet.

Technical Details of Final Deliverable

We designed a mini hatchback electric car for two passengers. This car is 6ft long, 4ft wide and 5ft in height. We used the iron angles for the chassis and fiber glass for the body. We designed a battery charger, which gives the 38V after rectification, we remove the ripples in DC by regulating the voltages to get 36V regulated DC and further pass from the current limited circuit to get the 7A current and 36V DC at load side. We designed the motor driver controller with 36V, 2.5KW with soft start technology, in which MOSFET are connected in parallel, these are playing the main role to control the speed of the motor. As the input resistance from accelerator will increase the MOSFET will jump in the line one by one to achieve the speed of the motor. We used the 36V permanent magnet brushed DC motor power of 2.5KW and 2800rpm with accelerator. We used cam switch of 70A between the motor and motor controller, which change the polarity of the motor in forward and reverse direction. Further we use the front and back head lights, indicators, horn and other electric components, these components have 500W to 600W load on the batteries and in last we use the lead acid 72Ah batteries in our car.

Final Deliverable of the Project

Hardware System

Core Industry

Transportation

Other Industries

Core Technology

Clean Tech

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure, Sustainable Cities and Communities

Required Resources

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