gfggj

1. Charging Circuit Design & Chassis Design of an
Light Weight EV
GUIDED BY: PRESENTED BY:
ATUL THOMAS ASWIN GOPAL A
ASSISTANT PROFESSOR VYSHAK S
DEPT. OF EEE ASWINI AMRUTHAKUMAR

2. CONTENTS
• INTRODUCTION
• LITERATURE REVIEW
• CHARGING CIRCUIT
• EV BATTERY CHARGING PROCESS
• CHASSIS DESIGNING
• ISOMETRIC VIEW OF CHASSIS
• CONSTRAINTS
• CONCLUSION
• REFERENCE
2
Charging Circuit Design & Chassis Design of
an Light Weight EV

3. INTRODUCTION
• The purpose of the charging system is to maintain the charge in the vehicle's battery.
• It generates electrical power to run the vehicle's electrical systems while the engine is
running.
• The chassis is the most important part of an electric vehicle, representing safety and life.
• The design of electric vehicles must be lightweight, durable and long-lasting.
3
Charging Circuit Design & Chassis Design of
an Light Weight EV

4. LITERATURE REVIEW
[1] Design And Analysis Of Chassis For Electric Vehicle
• The main goal is to use static and model analysis to evaluate chassis deformation to reduce weight and
improve vehicle performance in challenging low energy races. The 3D modelling and FE analysis of
the chassis was done using Catia V5 software.Battery cell characterization, having a lithium iron
phosphate (LiFeSO4) chemistry, based on first order electrical equivalent circuit (EEC).As major part
of EV have to offer high efficiency, high power density, high torque, easy control, wide speed
operating range & maintenance free operations.
4
Charging Circuit Design & Chassis Design of
an Light Weight EV

5. CONT
[2] Genetic Optimization of a Fuzzy System for Charging
Batteries
• A large variety of nickel-cadmium (Ni-Cd) batteries have been developed
to meet a wide range of user needs, ranging from low-current-level uses
like emergency power sources for semiconductor memories to very high-
power applications such as motor-operated cordless drills. The resulting
fuzzy system is able to charge high-power Ni-Cd batteries in about 10 min
with a current of 6 A
5
Charging Circuit Design & Chassis Design of
an Light Weight EV

6. CONT
[3] Designing a new generalized battery management system
• Battery management systems (BMSs) are used in many battery-operated
industrial and commercial systems to make the battery operation more
efficient and the estimation of battery state nondestructive. The existing
BMS techniques are examined in this paper and a new design methodology
for a generalized reliable BMS is proposed. The main advantage of the
proposed BMS compared to the existing systems is that it provides a fault-
tolerant capability and battery protection. The proposed BMS consists of a
number of smart battery modules (SBMs) each of which provides battery
equalization, monitoring, and battery protection to a string of battery cells.
6
Charging Circuit Design & Chassis Design of
an Light Weight EV

7. CONT
[4] Battery management system for electric vehicle
application
• A Battery management system (BMS) is proposed here to settle the critical
issues. The system includes several common modules: data acquisition unit,
communication unit and battery state estimation model. Two additional
management units are developed here, one is thermal management and the
other is high voltage management which improve the safety condition of the
battery. The BMS has been successfully used in the Qi Rui Pure Electric
Vehicle (QRPEV), the test results prove the validity and reliability of the
system.
7
Charging Circuit Design & Chassis Design of
an Light Weight EV

8. CHARGING CIRCUIT
• The battery plays a major role in electric vehicle (EV) and for that on-
board battery charger is essential.
• This charger circuit comprises of diode bridge rectifier, interleaved boost
DC-DC converter and single phase DC-AC inverter.
• Inductive power transfer (IPT) technology is used for the charging of EV
batteries.
8
Charging Circuit Design & Chassis Design of
an Light Weight EV

9. Block diagram of simple constant current regulator
battery charging circuit.
9
Charging Circuit Design & Chassis Design of
an Light Weight EV

10. • Input power to the EV charger is an AC voltage in the range of 170V to
300V.
• The EV charger uses a half-bridge LLC resonant converter design, because
of its high-power and high-efficiency characteristics, to obtain DC power for
charging the battery.
• The design utilizes a rectifier circuit for converting input AC voltage to high-
voltage DC output, and it also has an electromagnetic interference (EMI)
filter to eliminate high-frequency noise from the input power source.
10
Charging Circuit Design & Chassis Design of
an Light Weight EV

11. EV Battery Charging Process
11
The change in charging voltage and current during the charging process is graphically illustrated
Charging Circuit Design & Chassis Design of
an Light Weight EV

12. • If the battery voltage is too low when connected for charging, low
charging current will be set initially, and the charging process will start.
• When the battery voltage increases to a pre-defined level (Vu), constant
voltage (CV) and constant current (CC) are applied for charging and
continued until the battery is fully charged.
• The battery is considered to be fully charged when the voltage reaches
VOFF. When the charging current drops to Iu, the final voltage (FV) is
set. 12
Charging Circuit Design & Chassis Design of
an Light Weight EV

13. CHASSIS DESIGNING
13
Charging Circuit Design & Chassis Design of
an Light Weight EV
The chassis design procedures include choosing best material that provide maximum
security for driver and guarantee the integrity of the framework under all possible
challenging demanding situations.

14. ISOMETRIC VEIW OF CHASSIS
14
Charging Circuit Design & Chassis Design of
an Light Weight EV

15. FRONT IMPACT ANALYSIS
• Front Impact = F= m-a /t
• Time, t in sec
• Mass, m total weight of vehicle with driver, kg
• Acceleration, a As per endurance condition is concerned
• Constrain points: For front impact and rear impact suspension points of both front and rear are
fixed.
• Note: Rear impact we only change the time, t = 0 * 20 sec
Charging Circuit Design & Chassis Design of
an Light Weight EV
15

16. SIDE IMPACT ANALYSIS
• Side Impact = F = (ma)/t
• Time, t in sec
• Mass, m total weight of vehicle with driver, kg
• Acceleration, a -As per endurance condition is concerned
• Constrain points:
1. For Left side impact = Right side suspension point are fixed.
2. For Right side impact = Left side suspension point are fixed.
Charging Circuit Design & Chassis Design of
an Light Weight EV
16

17. ROLLOVER
• Rollover impact force, F = W / S
• W,workdone by vehicle, N= [ - 0.5*m * v ^ 2]
• Displacement, S
• V = sqrt(2gh)
Where,
• M = Mass of vehicle, N
• a = gravitational acceleration, 9.81 m/sec²
• h = Wheelbase, 58^ prime prime = 1473.2mm = 1.47m
• V =Velocity, m/sec
• F = rollover impact force, N
• Constrain points: For front Rollover or rear Rollover suspension points of both front and
rear are fixed.
Charging Circuit Design & Chassis Design of
an Light Weight EV
17

18. TORSIONAL ANALYSIS
• Torsional analysis, K = [T / Theta]
• T =F* L
• T =[f.w. * 3 * q] * L
• Theta =tan^ -1 [ (z1+Z2) 2L ]
• K = T / Theta
Where,
• K = Torsional stiffness, N.m/deg
• Theta = Angle of twist, deg
• T = Torque, N.m
• F = front weight =f.m.*3*g
• Z1, z * 2 = deformation, m
• L = half of track width, m
• Constrain points: For front torsional = rear suspension points fixed.
• For rear torsional front suspension points fixed
Charging Circuit Design & Chassis Design of
an Light Weight EV
18

19. Bump Analysis
For front bump analysis,
• F = (45%. ma)/t
• Time, t in sec
• Mass, m =total weight of vehicle with driver, kg
• Acceleration, a =As per endurance condition is concerned
Constrain points:
1. For front bump impact = rear suspension point are fixed.
2. For rear bump impact = Front suspension point are fixed.
Charging Circuit Design & Chassis Design of
an Light Weight EV
19

20. Constraints
20
Charging Circuit Design & Chassis Design of
an Light Weight EV
• Vehicle must have ground clearance in between 1 inch to 5 inches.
• Bumper must be installed at front, rear, and side of the vehicle such that theycover tire and
• Maximum turning radius of the kart must be 3m.
• Firewall must separate the electrical transmission from the driver.

21. COMPONENTS
Charging Circuit Design & Chassis Design of
an Light Weight EV
21

22. Charging Circuit Design & Chassis Design of
an Light Weight EV
22
• Transmission: It controls the amount of power that goes from
engine to wheels .
• Drive Shaft: It is a spinning tube that connect to the rear of the
transmission and transmit the spinning power that began in the
engine to the back of the vehicle at the differential.
• Differential: It transfers torque, causing them to spin, which in
turn moves the car

23. CONCLUSION
• The progress that the electric vehicle industry has seen in recent years is not only
extremely welcomed, but highly necessary in light of the increasing global
greenhouse gas levels.
• A DC-DC converter as a current source is employed in the charging circuit for safe
and efficient charging.
• Fast and efficient battery charging is a necessity for battery driven automobiles.
Hardware results are presented for conventional and multilevel charging methods.
• The purpose of the charging system is to maintain the charge in the vehicle's battery.
23
Charging Circuit Design & Chassis Design of
an Light Weight EV

24. References
• [1] Hartmut Surmann, "Genetic Optimization of a Fuzzy System for Charging
Batteries", IEEE Transactions on industrial electronics, vol. 43, no. 5, 0ctober
2019.
• [2] John Chatzakis, Kostas Kalaitzakis, "Designing a new generalized battery
management system," IEEE Transactions on industrial electronics, vol. 50, no. 5,
pp. 990-999, Oct 2017.
• [3] Jiaxi Qiang, Lin Yang, Guoqiang Ao, Hu Zhong, "Battery management
system for electric vehicle application," IEEE international conference on
vehicular electronics and safety,”vol.14,no.4, pp. 134-138,Aug 2016.
24
Charging Circuit Design & Chassis Design of
an Light Weight EV

25. CONT
• [4] N. Kutkut, D. Divan and D. Novotny, "Charge equalization
for series connected battery strings", IEEE Trans. ind. applicat.,
vol. 31, pp. 562-568, May/June 2018.
• [5] N. Kutkut, H. Wiegman, D. Divan and D. Novotny,
"Equalization of an electric vehicle battery system", IEEE
trans. aerosp. electron. syst., vol. 34, pp. 235-246, Jan.2017.
• [6] N. Kutkut, D. Divan and D. Novotny, "Design
considerations for charge equalization on an electric vehicle
battery system", IEEE Trans. ind. applicat., vol. 35, pp. 28-35,
Jan./Feb. 2020.
25
Charging Circuit Design & Chassis Design of
an Light Weight EV

26. THANK YOU