The document discusses the key components and working principles of electric vehicle batteries and motors. It provides information on: 1) The main components of lithium-ion batteries used in EVs including the cathode, anode, electrolyte, and separator. It also discusses battery parameters like storage capacity, energy density, and cycle life. 2) The types of motors used in EVs like AC induction motors and brushed vs brushless DC motors. It provides a basic overview of how motors work using electromagnetic induction to convert electrical energy from batteries into mechanical energy. 3) The function of motor controllers to precisely control the motor based on driver input and convert battery power into vehicle motion using components like sensors and power electronics.

1. Working Principle
Battery- Fuel
Motor Controller- Fuel
Injector or Carburetor
Motor- Engine
1)In battery chemical energy gets
converted into Electrical Energy
2) Motor controller works on principle
of pulse width modulation
3) Motor works on electromagnetic
induction
4) In motor electrical energy gets
converted into mechanical energy

2. Component of Battery
1) Cathode
2) Anode
3) Electrolyte
4) Separator

3. • Cathode- determines the capacity and voltage of a Li-ion battery.
• Anode- sends electrons through a wire.
• Electrolyte- allows the movement of ions only
• Separator-the absolute barrier between cathode and anode

4. Battery Pack

5. Battery Performance Parameter
1) Storage Capacity-
• It determine the no. of hours for which battery can be discharged at constant current to
defined cut of voltage
• The value of capacity depends on ambient temp, age of battery and discharged rate.
• Higher the discharge rate lower is battery capacity
2) Cost-
• This includes initial cost of battery itself as well as cost of charging and maintaining the
battery

6. Cont…
• Energy Density
• The energy density is amount of energy that can be stored per cubic meter of
battery volume expressed in watt-hours per cubic meter(wh/m3)
• Power density
• It is power capacity per kg of battery in w/kg. Some battery offer high energy
density but low specific power which means that they can store a large amount of
energy they can supply small amount of power

7. Cont…
• In transportation terms it means that vehicle could run long distance at low speed
• Batteries with high specific power have low energy density
• Because high discharge current usually reduce the available energy rapidly ( High
Acceleration)
• State of charge
It is amount of stored energy relative to total energy storage capacity
of battery out of 100 percent is 80 percent .So state of charge is 0.80

8. • State of Discharge
• The parameter describe battery capacity that has been discharged relative to maximum
capacity.
• Self Discharge
• Reduction in energy capacity of battery under no load conditions as a result of internal
short circuit & chemical reaction
• This parameter can be affected by environmental conditions such as temperature &
humidity as well as DOD & Battery charge/discharge cycle

9. Cont…
• Cycle life
• Cycle life of rechargeable battery is no. of charge/discharge cycle it undergoes before
capacity falls to 80 percent.
• Physical requirement
• This includes the geometry of the cell, its size, weight , and shape and location of terminal
• Service life
• It is 500 to 1000 cycle for the battery, reduction in capacity is caused by depletion of
active materials by undesired reaction within cells.

10. Traction Battery
• An EV traction battery is rechargeable energy storage that supplies power to the
electric motor very quickly, giving EVs high performance & rapid acceleration.
• Traction battery used to provide motive power for EV
• High capacity to weight and volume ratio
• It require fast charging rate usually within 24 hours
• Traction battery are differ from Starting, lighting and ignition battery because they
designed to give power over certain period of time

11. Cont…
• Traction are characterized by high power to weight ratio
• Energy to weight ratio
• Energy density
• Smaller lighter batteries reduce weight of vehicle and improve performance
• Rechargeable batteries used in EV includes Lead acid, Li ion polymer
• The amount of electricity stored in batteries is measured in amp-hour

12. Cont.
• Smart solution and monitoring
• Higher Cyclic Life: 3000-4000 cycles
• Active Cell Balancing
• Temperature Cooling
• Communication
• Built-in automatic protection for
• Over Charge voltage/current Over Discharge voltage/current
• Short Circuit Over/Under temperature

13. Auxillary Battery

14. Cont…
• The auxiliary battery is not used by the traction motor but is charged by the traction
battery and is used to support all of the electrical systems on the vehicle with the
exception of: Air conditioning. Heating system.
• In an Electric Vehicle, there are two battery systems. One is the primary battery (traction
battery) while the other one is an auxiliary battery. The Vehicle Accessories are powered
by providing electricity through the auxiliary battery. It helps to power the Computer
System, Headlights, Audio System and some quintessential sensors, etc. It works in
tandem with the main battery and simultaneously reduces its load.

15. Battery Safety and maintenance
• Always handle batteries with care
• Never overfill with acid
• Always store upright
• Never allow children access to a battery
• Always charge in a well ventilated area
• Never allow battery vents to become blocked
• Always wear eye protection
• Always wear protective clothing

16. • Always charge in a well ventilated area
• Always ensure the charging leads are correctly fitted before switching on the mains
• Always ensure the mains is switched off before disconnecting the charging leads
• Always use eye protection and protective clothing
Never smoke near a battery
Never allow naked flames near a battery
Never create sparks near a battery

18. Effect of battery overheating
• At high temp. lithium ion battery produce thermal runway resulting in short
circuit, combustion explosion and safety problem
• Thermal runaway is a chain reaction within a battery cell that can be very difficult
to stop once it has started. It occurs when the temperature inside a battery reaches
the point that causes a chemical reaction to occur inside the battery.
• Internal short circuit is due to manufacturing defect or physical damage due to
mechanical deformation, manufacturing error such as burrs , misalignment of
electrode package

19. Air cooling
• It is the simplest and most cost effective way of cooling the batteries. The air cooling
allows the heat transfer from the battery pack as the air runs over its surface.
• These systems offer heating, cooling and ventilation functions as per the
requirement of the battery pack. It is one of the earliest adopted methods and it
makes use of natural as well as forced convection depending on the intake of air in
the air cooling method.
• Both of these convection methods decrease the average temperature of the battery
cell. This is mostly used for stationary battery energy storage system applications.

21. Liquid Cooling
• Liquid cooling is the most popular cooling technology. It uses a liquid coolant
such as water, a refrigerant, or ethylene glycol to cool the battery. The liquid goes
through tubes, cold plates, or other components that surround the cells and carry
heat to another location, such as a radiator or a heat exchanger. Components
carrying the liquid prevent direct electrical contact between the cells and the liquid
coolant.
• Because liquid cooling involves pumps, fans, and other devices to actively extract
and redirect the heat, it is an active form of cooling.

23. Phase change Material
• In PCM cell, cell is in direct contact with PCM, heat is conducted from cell to
PCM
• There are plate on top and bottom side of PCM to release heat absorbed by PCM
• During charging & discharging a lot of heat is generated that heat is transferred to
PCM due to conduction phenomenon
• PCM absorb a lot of heat until changing its phase temp.at this constant temp. after
changing phase temp. gradually rises.

24. SO PCM can absorb a lot of energy that energy is transferred
back to cell during relaxation period. So optimum temp. can be
maintained
Liquid cooling make
system bulky and more
space is required
Also it requires power
consumption make it less
efficient.

25. PCM
• PCM Installation cost is less
• It is non-corrosive
• Light weight, Environment friendly,
• But it is having low thermal conductivity
• If material changes its phase temp. regulation fails and become difficult to operate
continuously

26. Working Principle
Battery- Fuel
Motor Controller- Fuel
Injector or Carburetor
Motor- Engine
1)In battery chemical energy gets
converted into Electrical Energy
2) Motor controller works on principle
of pulse width modulation
3) Motor works on electromagnetic
induction
4) In motor electrical energy gets
converted into mechanical energy

27. Motor Controller
• An electric vehicle’s motor controller is a combination of power electronics and
embedded microcomputers that effectively converts the energy stored in the
batteries into motion.
• The Motor controller receives commands from interfaces such as the Throttle,
Brake, or Forward/Reverse control switches.
• The Motor controller processes these commands and very precisely controls the
speed, torque, direction, and consequent horsepower of a motor in the vehicle.

28. Block Diagram
.

29. Elements of Motor controller
• Sensor sense the motor motion and give signal to motor
• Power elements block, is essentially a bi-directional power converter. It is able to move
energy from the battery to the motor and vice versa
• Input interface block connects to the motor controller and the other vehicle components.
• The communication block,which allows the motor controller to share data with external
systems.
• Through a communication block, a motor controller can transmit data and receive
instructions.

30. AC Motor
• An AC motor is a motor that converts alternating current into mechanical power.
• The stator and the rotor are important parts of AC motors.
• The stator is the stationary part of the motor, and the rotor is the rotating part of
the motor.
• The AC motor may be single-phase or three-phase. Nikola Tesla invented the first
AC induction motor in 1887.

31. Stator
The stator is the stationary part of the motor that delivers
a rotating magnetic field to interact with the rotor.
Stator Core
The stator core is made of thin metal sheets known as
laminations. Laminations are used to reduce energy loss.
Stator Windings
Stator windings are stacked together, forming a hollow
cylinder. The slots of the stator core coils of insulated
wires are insulated.
The enclosure protects the internal parts of the motor from water
and other environmental elements. The enclosure consists of a
frame and two end brackets.

32. Rotor
A rotor
central component of a motor that is fixed to the
shaft. The most common type of rotor used in
an AC motor is the squirrel cage rotor. A
squirrel-cage rotor is cylindrical
Motor Shaft
The rotor is pressed onto a steel shaft to form a
rotor assembly.
Bearings
Bearings hold the motor shaft in place. The bearings minimize the shaft’s friction
connected to the casing, which increases the motor’s efficiency.

33. DC Motor
A DC motor is an electrical
machine that converts
electrical energy into
mechanical energy. DC motor
working is based on the
principle that when a current
carrying conductor is placed in
a magnetic field, it experiences
a mechanical force.

35. Types of DC motor

36. Brushed & Brushless DC Motor
• It uses Electrical commutation to
deliver the current.
High- because of the absense of brushes
and commutator
Construction Complex and expensive
Low Noise
Less required in absence of brushes
High Efficiency
Long Life
• It uses brushes to deliver current to the
motor windings through mechanical
commutation
• Speed range lower compared to BLDC
• Construction Simple
• Arcs in the brushes generate noise
• Periodic maintenance required
• Moderate efficiency
• Short Life

39. Factor considered in selection of motor
• 1. Vehicle characteristics
The properties of the vehicle such as size, weight, overload and aerodynamics are
crucial vehicle characteristics that will ultimately determine speed, torque and
power requirements of the electric motor.
• 2. Driving cycles
How is the vehicle being used is also very important. What will be the usual driving
cycles of the vehicle? Will it be driven in an urban area with many stops? Will it be
driven on long distances with only a few stops?

40. Cont..
• 3. Vehicle configuration (electric, hybrid)
• Is the vehicle hybrid or full electric? If hybrid, is it parallel hybrid or series
hybrid?
• 4. Maximal speed
• What is the targeted maximum speed of the vehicle ? How long does it have to be
sustained, maybe it is used only for passing?
• 5. Maximal power 6. Battery Capacity & Voltage
• 7. Cost

41. Maximum Torque
The maximum torque enables the
vehicle to start in a given slope. You
need to find the highest grade the
vehicle will need to ascend. Using that
grade, it is possible to calculate the
highest torque required by the electric
motor considering the differential and
gearbox (if using a gearbox!).
Maximal weight is also to be taken
into consideration.

42. Motor Maintenance
• Inspect the electric motor at regular time intervals.
• Remove deposits of dust, oil, and dirt in the fan cover to maintain good ventilation and allow proper cooling of the
motor.
• Observe the behavior of the seals.
• Observe the electrical, mechanical connections and the fixing bolts.
• Check oil level in bearings.
• Visually inspect commutator clamping ring.
• Check operating speed
• Motor alignments reduce the stress on the motor and driven equipment