Electric car presentation 2017

1. Electric Car Supervisors Prof.Dr.Samir Deghedie Dr. Mohamed El-Habrouk 6th July 2017

2. Presented by : 2 Aya Mohamed Ali Mohamed Ahmed Khaled Hussin Mohamed Ahmed Abd-Elazeem El-sayed Ahmed Essam Ibrahim Rogeh Wageh Essa Karim Ragab El-sayed Mohamed Kirollos Magdy khela Lina Mohamed Mohamed Abdelsalam Mayada Aladdin Mohamed Hager Reda Mohamed Nabeh

3. Objective 3 •Spreading the field of electric cars. •Expanding knowledge of it. •Trend to renewable energy. •Reducing the use of non-renewable energy and environmental impact of it.

4. Outline 1. Introduction • History Of Electric Car • Difference Between Engine and Electric Car • Why Electric Car and Why not? • Types Of Electric Car • How It Works? 4

5. Outline 2. Main Components Of Electric Car • Motor • Controller • Batteries • Transmission • Braking • Steering 3. Electric Go Kart Prototype 5

6. Outline 1. Introduction • History Of Electric Car • Difference Between Engine and Electric Car • Why Electric Car and Why not? • Types Of Electric Car • How It Works? 6

7. 7 History Of Electric CarIntroduction

8. 8 Start of the electric carIntroduction  By the 1900s, larger secondary batteries became available.

9. 9  First commercial line in NYC Introduction The electric car of the 1970s, the Citi-car.

10. 10  Now adays Introduction A recent model of the commercial hybrid electric vehicle (HEV)

11. 11  Propagation of electric cars Introduction

12. 12 Difference Between Engine and Electric Car Introduction • But the transmission system of them is the same.

13. 13 Difference Between Engine and Electric Car Introduction

16. 16 Why Electric Car & Why Not?Introduction • No Gas Required • Savings • No Emissions • Safe to Drive • Low Maintenance • Reduced Noise Pollution • Recharge Points • Short Driving Range and Speed • Battery Replacement

17. 17 Types of Electric CarIntroduction

18. 18 How It Works?Introduction

20. 20 Transmission Battery Steering Braking Controller Motor Electric Car Main Components Of Electric Car

21. Main Components Of Electric Car Motors 21 • Classifications of Motors • Difference between Ac and Dc motors. • DC Motors.

22. 22 Classifications of MotorsComponents Electric Motors Alternating Current (AC) Motors Direct Current (DC) Motors

23. 23 Difference between Ac and Dc motors Components • A.C. motors are powered from alternating current (A.C.) while D.C. motors are powered from direct current (D.C.), such as batteries, D.C. power supplies or an AC-to-DC power converter.

24. 24 Difference between Ac and Dc motors Components • D.C wound field motors are constructed with brushes and a commutator, which add to the maintenance, limit the speed and usually reduce the life expectancy of brushed D.C. motors. A.C. induction motors do not use brushes.

25. 25 Difference between Ac and Dc motors Components • The speed of a D.C. motor is controlled by varying the armature winding’s current while the speed of an A.C. motor is controlled by varying the frequency, which is commonly done with an adjustable frequency drive control.

26. 26 Difference between Ac and Dc motors Components Dc Motor Ac Motor

27. 27 Dc motorComponents Advantages 1- Speed control over a wide range both above and below the rated speed. 2- High starting torque . 3- Quick starting, stopping, reversing and acceleration. 4- Free from harmonics. Disadvantages 1- High initial cost. 2- Increased operation and maintenance cost. 3- Cannot operate in explosive and hazard conditions due to sparking occur at brush.

28. 28 Ac motorComponents Advantages 1- produces less heat, friction and are lighter and more efficient . 2- The simple design of the AC motor results in extremely reliable, low maintenance operation. 3- Low Cost due to the simple design of the motor. Disadvantages 1- Inability to operate at low speeds 2- produce eddy currents due to the production of a back emf.

29. 29 Go Kart • In our project we decided to use a dc motor in order to avoid using an inverter to power the motor and to directly use dc voltage source and to obtain high starting torque and to have the ability to control the speed and also to reverse its direction by reversing armature current.

30. 30 DC MotorsComponents An Electric DC motor is a machine which converts electric energy into mechanical energy.

31. 31 Theory of WorkComponents • Electric motors run by electromagnetism. • The interaction of two magnetic fields happens. • These two fields result in a torque which tends to rotate the rotor.

32. 32 Types Of DC MotorsComponents 1. Brushed DC motor

33. 33 Types of Brushed DC MotorComponents 1. Separately Excited.

34. 34 Types of Brushed DC MotorComponents 2. Permanent Magnet.

35. 35 Types of Brushed DC MotorComponents 3. Self Excited DC Motor: • Shunt wound DC motor. • Series wound DC motor. • Compound wound DC motor.

36. 36 Types of Brushed DC MotorComponents • Shunt Wound DC Motor.

37. 37 • Torque speed curve

38. 38 Types of Brushed DC MotorComponents • Series Wound DC Motor. The entire armature current flows through the field winding as its connected in series to the armature winding.

39. 39 Types of Brushed DC MotorComponents • Torque speed curve

40. 40 Types of Brushed DC MotorComponents • Reverse direction of series motor

41. 41 Types of Brushed DC MotorComponents • Compound Wound DC Motor.  Excitation can be obtained by combining the operational characteristic of both the shunt and series excited dc motor .  It contains the field winding connected both in series and in parallel to the armature winding.

42. 42 Components • The compound wound DC motor can further be subdivided into 2 major types on the basis of its field winding connection with respect to the armature winding, and they are:

43. 43 Components • Long Shunt Compound Wound DC Motor: Shunt field winding is connected in parallel across the series combination of both the armature and series field coil.

44. 44 Components • Short Shunt Compound Wound DC Motor: The shunt field winding is connected in parallel across the armature winding only. And series field coil is exposed to the entire supply current, before being split up into armature and shunt field current

45. 45 Components • The compound wound DC motor can further be sub divided into 2 types depending upon excitation.

46. 46 Components • Cumulative Compounding of DC Motor: Shunt field flux produced by the shunt winding assists or enhances the effect of main field flux, produced by the series winding.

47. 47 Components • Differential Compounding of DC Motor: -The flux due to the shunt field winding diminishes the effect of the main series winding. -The net flux produced in this case is lesser than the original flux and hence does not find much of a practical application.

48. Type speed control starting torque running torque Shunt dc constant , medium ( 125 to 200 % of FLT) Motor adjustable Series dc varying very heavy ( 300 to 350 % of FLT) Motor (0 to max ) Compound constant heavy (130 to 260 % of FLT) Dc motor

49. 49 Components

50. 51 Components 2. Brushless DC Motor

51. 53 Types of Brushless DC MotorsComponents • Inner Rotor Design The rotor is located in the center of the motor and the stator winding surround the rotor. • Outer Rotor Design The rotor surrounds the winding which is located in the core of the motor.

52. 54 Motor SelectionComponents Rolling resistance force Frr=Crrmg Aerodynamic drag Fd= .5ρACdv^2 Hill climbing force Fd= mgsin(ψ) Acceleration force Fa= ma Total tractive effort Fte= Frr+ Fd+ Fg + Fa

53. 55 Motor SelectionComponents To calculate the total torque and power of the motor  Total tractive effort Fte= Frr+ Fd+ Fg + Fa  Traction Torque T = Fte × r x Rf  Traction Speed r/s W = 𝑉 𝑟  Calculating power Power (KW) = (Torque (Nm) x Speed)

54. 56 Prototype CalculationsGo Kart • M=120 kg (car + person) • V=30 km/HR=8 m/s • Rwheel = 0.19 m • Rf =0.67 • Crr =0.012

55. 57 Prototype CalculationsGo Kart • RR=120x0.012x9.81=14.1264N • GR is neglecting for low cost • FA=120*8/5 =192N •  a = (final velocity−initial velocity)/(time)

56. 58 Prototype CalculationsGo Kart • TTE=14.1264+192=206.1264N • T (torque) = .67x.19x206.1264 =27N.m • Rpm = 8/(0.10472x.19)=400 • W=42 r/s • P=27x42=1.131 kw =1.5 HP

57. 59 Our MotorGo Kart • We choose motor 1.2 kW , rated current 100 A and 3000 rpm and we made gear box to reduce the rpm from 3000 to 400.

58. 60 Go Kart Choosing The Wire Of The Motor ** Voltage = 24 v Max current=100A Length = Cable size =

60. Main Components Of Electric Car Controller 62 • Controller and driver • Speed Control • Chopper • Buck • H-Bridge • Closed loop Control

61. 63 Controller and Driver Function Controller is the logic that decides upon and specifies the driver's output. Driver is responsible for supplying the actual output power to the device. Components Components

62. 64 Controller of Electric Car Components Components

63. 65 Speed Control of DC Motor • By varying the supply voltage • By varying the field flux Components Components

64. 66 Speed Control of DC Motor • By varying the supply voltage • By varying the field flux Components Components

65. 67 Methods of Varying Supply Voltage • Chopper Components Components Using ON-OFF Control to change PWM of Output Voltage MOSFET ONMOSFET OFF

66. 68 Methods of Varying Supply Voltage • Chopper Components Components Components

67. 69 Methods of Varying Supply Voltage • Buck (Step Down Converter) Components Components Components Components Inductor and Capacitor store energy to keep output voltage constant MOSFET ONMOSFETOFF

68. 70 Methods of Varying Supply Voltage • Buck (Step Down Converter) Matlab Simulation Components Components

69. 71 Four Quadrant Operation of DC Motor Components Components

70. 72 Direction Control of DC Motor Components Components 1. Relays Once the coil is energized, contacts change its normal state and voltage is reversed across the motor

71. 73 Direction Control of DC Motor Components Components 2. H-Bridge (Four quadrant Chopper) Components 4 MOSFETs 4 Flywheel DiodesQ1 & Q4 ONQ2 & Q3 ONQ1 & Q2 ON Shoot-through

72. 74 Direction Control of DC MotorComponents 2. H-Bridge (Four quadrant Chopper)

73. 75 High current H-Bridge circuit Components Components • Electrical Noise • Mosfet Driver • Shoot-through • Opto-coupler • Heat sink

74. 76 Prototype ControllerGo Kart • 100A DC motor drive Module High Power motor speed Control Dual Channel H- bridge.

75. 77 Prototype ControllerGo Kart • The module use 8 MOSFETs for dual H-Bridge • MOSFET model is irfb3077

76. 78 Prototype ControllerGo Kart IR2110 High and low MOSFET driver

77. 79 Prototype ControllerGo Kart • LM2576 3.0 A, 15 V, Step−Down Switching Regulator

78. 80 Prototype ControllerGo Kart • HCPL-2631 Dual Channel, High Speed Optocouplers f = 1 MHz

79. 81 Open Loop Speed Control Components Components

80. 82 Closed Loop Speed Control Components Components

81. 83 Closed Loop DC Motor Speed Control Components Components Matlab Model • Circuit Diagram

82. 84 Closed Loop DC Motor Speed Control Components Components Matlab Model • DC Motor Subsystem Components

83. 85 Closed Loop DC Motor Speed Control Components Components Matlab Model • Speed and Current Graphs T = 0.5 n.m Components

84. 86 Closed Loop DC Motor Speed Control Components Matlab Model • Speed and Current Graphs T = 3.6 n.m

85. 87 Closed Loop DC Motor Speed Control Components Current Feedback Components • Current feed back is used to Control Motor Current Besides Speed Control

86. 88 Closed Loop DC Motor Speed Control Components PID Control ComponentsComponents • Adjust Kp to control rising and settling time • Adjust Ki to eliminate steady state error

88. Main Components Of Electric Car Batteries (rechargeable batteries) 90 • Its Function In Electric Car. • Battery Construction. • Battery Specifications . • Different Types Of Batteries For Electric Car.

89. 91 Function In Electric CarComponents The heart of an electric car is its battery. Unlike the batteries in most cars, which primarily serve to start the engine and run accessories like the radio or air conditioner, the battery in an electric car runs everything. Most importantly, it runs the electric motor or it runs a controller which in turn runs the electric motor ,So it needs to be powerful and long lasting enough to take drivers where they need to go with a minimum of recharging.

90. 92 Battery ConstructionComponents 1. Cover 2. Container 3. Terminal 4. Safety Valve 5. Negative Plate 6. Separator 7. Positive Plate

91. 93 Components SOC= 𝑟𝑒𝑚𝑎𝑖𝑛𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑟𝑎𝑡𝑒𝑑 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 DOD=1-SOCDepth of discharge Nominal Capacity (Ah) Cycle life Nominal Voltage (V) State of discharge Battery Specifications Self discharge

92. 95 Components Different Types Of Batteries For Electric Car Lead acid Lithium–ion Cost Inexpensive Expensive Self discharge 5% per month 1–2% per month Cycle life Lower Long cycle life Weight Higher Light weight Pack Available in pack Form Available only in cell form (3.7 v) Electrolyte Can be liquid or solid No liquid electrolyte

93. 96 Lead Acid BatteriesComponents  Nominal voltage  2.1 v/cell  Discharge curve (for 12v lead acid battery)

94. 97 Components 97 Components Types of Lead acid batteries Construction Sealed (Dry) (VRLA) Flooded (Wet) Type Deep cycle Starting, lighting and ignition (SLI)

95. 99 Prototype BatteriesGo Kart • Type: sealed lead acid • Nominal voltage : 12 v • Capacity : 70 Ah • Number of batteries : 2 • Connection : series

96. Main Components Of Electric Car Charging system 100 • Introduction • Levels of charging • Types of Charging • How to stop Charging process?

97. 101 IntroductionComponents

98. 102 Levels Of ChargingComponents

99. 103 Types of ChargingComponents 1. Conductive charging

100. 104 Types of ChargingComponents 2. Wireless Charging  Main concept • Wireless power is transferred via electromagnetic waves. • Electromagnetic wave is mainly divided into electric and magnetic waves.

101. 105 Wireless Power transferComponents  Principle of operation

102. 106 WPT TechniquesComponents WPT Reactive Near Field Radiative Far Field IPT CPT EM-WPT Non R-WPT µ- waves LaserR-WPT

103. 107 WPT Techniques (IPT)Components • Depends on the magnetic coupling between 2 coils. Field can be guided within safety limits.  Non R-WPT • Used in the short range transfer (< 10 cm). • Ex: Cordless tooth brush and charging pads.  R-WPT • Coils are operating with their resonant frequency. • Transfer range is extended to few meters.

104. 108 WPT Techniques (CPT)Components • Depends on the capacitive coupling between two electrodes. • Limited to low-power applications; as high voltage on electrodes can be hazardous. • It is simpler in design and lower in cost than IPT systems. • It can be used in wireless battery charger and transferring power between substrate layers in integrated circuits.

105. 109 WPT Techniques (EM-WPT)Components • It is based on the electromagnetic field radiation in the far field region. • It can transmit high power for long distances. • It requires a clear line of sight to transfer power, also there is NO safety through this line.  Microwaves radiation: It uses high energy microwave source to transfer power from the transmitting antenna to the receiving antenna.  Laser radiation: It uses high intensity laser beam to transfer power from laser source to photovoltaic cells.

106. 110 Types of ChargingComponents 3. Battery Swapping

107. 111 How to stop Charging process?Components • Timer • Temperature cut off • Temperature change rate • Minimum current • Voltage limit • Voltage change rate

108. 112 Prototype method to Charge batteries Go kart

110. 114 Transmission SystemComponents 1. Clutch 2. Gearbox 3. Driveshaft 4. Differential

111. 115 1. ClutchComponents Types of clutch Friction Electromagnetic vacuam centerfiugal

112. 116 Friction clutchComponents

113. 117 1. ClutchComponents Types of clutch Friction Electromagnetic vacuam centerfiugal

114. 118 Electromagnetic clutchComponents

115. 119 Prototype ClutchGo Kart • To make clutch in our prototype we used a clutch of 12 volt air conditioner compressor.

116. 120 2. Gear boxComponents

117. 121 Prototype GearboxGo Kart

118. 122 3. Propeller shaftComponents

119. 123 Prototype TransmissionGo Kart High efficiency

120. 124 4. DifferentialComponents

121. 125 Prototype Transmission systemGo Kart

123. Main Components Of Electric Car Braking System 127 • Introduction. • Basic structure. • Types of braking systems

124. 128 IntroductionComponents Braking depends mainly on friction to convert kinetic energy to heat energy and stop the vehicle . • Main components of any braking system a) Moving part around its axis b) Fixed part mounted to the vehicle body

125. 129 IntroductionComponents Leverage it multiplies the force of the leg several times before transmitting it to the braking fluid

126. 130 IntroductionComponents Hydraulic system ,its main aim that the force applied at a point is transmitted to another point using an incompressible fluid

127. 131 IntroductionComponents  Friction It measures how hard to move an object  Factors affecting friction • The condition of the surfaces in contact • The weight of an object

128. 132 Different Types of Mechanical Braking Components Disc Drum Bike Vehicles drawn by horses

129. 133 Basic StructureComponents • Brake Pedal. • Master Cylinder. • Disk Brake. • Drum Brake.

130. 134 1. Force pedal boosterComponents At normal conditionWhen releasing the vacuum pumpWhen motors stops

131. 135 2. Master cylinderComponents

132. 136 3. Disk brakeComponents

133. 137 4. Drum brakeComponents

134. 138 Drum VS Disc Brake SystemComponents

135. 139 Why do we use disc brakes in front and drum brakes in rear? Components Disk brakes have a higher overall capacity, and drum brakes are cheaper and take less hydraulic force to activate. When you stop your car most of the braking is done by the front brakes because of weight transfer

136. 140 Parking brakeComponents

137. 141 Anti lock braking system(ABS)Components • Each wheel speed is measured • This process is done over than 20 times /second

138. 142 Electronic Brake-force Distribution (EBD) Components Load sensor is used to determine where is the most load and gives orders to the master cylinder.

139. 143 Braking by wireComponents • Electro mechanical braking • Electro hydraulic braking

140. 144 Braking by wireComponents • It is able to react more quickly • It is totally silent and don’t have vibration through the pedal due to absence of mechanical parts • It takes up less space than mechanical parts • It is less damaging to environment

142. Main Components Of Electric Car Steering system 146 • Introduction • Types of steering

143. 147 IntroductionComponents The steering system converts the rotation of the steering wheel into a swiveling movement of the road wheels in such a way that the steering-wheel rim turns a long way to move the road wheels a short way.

144. 148 Types of steeringComponents 1. Rack-and-pinion steering is the most common type of steering on cars, small trucks and SUVs. 2. Recirculating ball steering is the most commonly used steering system in heavy vehicles, trucks and the larger/heavier SUVs.

145. 149 Prototype SteeringGo Kart • The rack-and-pinion system

146. 150 The rack-and-pinion systemComponents

147. 151 Steering structureComponents • Tie Rod. • Steering Arm. • Rack steering . • Pinion steering. • Steering shaft . • Steering wheel.

148. 152 The rack-and-pinion systemComponents • At the base of the steering column there is a small pinion (gear wheel) inside a housing. Its teeth mesh with a straight row of teeth on a rack - a long transverse bar. • Turning the pinion makes the rack move from side to side. The ends of the rack are coupled to the road wheels by track rods.

149. 153 The rack-and-pinion systemComponents

151. 155 Go Kart control system and its features Go Kart

152. 156 System Interconnect Diagram (SID) Go Kart

153. 157 Car MCU (motor control unit)Go Kart

154. 158 Go Kart MechanismGo Kart

155. 159 Car MotherboardGo Kart

156. 160 Motor direction controlGo Kart

157. 161 FeaturesGo Kart 1. Voltage measurement (voltmeter) Vout = R2/(R1+R2)* Vbattery

158. 162 FeaturesGo Kart 2. Prototype Pedal (potentiometer)

159. 163 FeaturesGo Kart 3. Speed sensor (encoder)

160. 164 FeaturesGo Kart 4. Temprature sensor

161. 165 FeaturesGo Kart 5. Monitoring (LCD)

162. 166 FeaturesGo Kart 6. Current limiter(fuse)

163. 167 FeaturesGo Kart 7. Wireless communication(bluetooth)

164. 168 General FeaturesGo Kart 8. Dimensions 150*90 cm 9.Automatic clutch 10.Weight about 70 kg 11.Can withstand a person weight till 70 kg 12.Secured with a key to open the system 13.Can reach speed of 20 km/hr at the rated weight

165. 169 Auto-parking techniqueGo Kart 1. sensor (encoder) 1-ultrasonic sensor 2-Electromagnetic sensors

166. 170 Auto-parking techniqueGo Kart 2. Our prototype (perpendicular algorithm)

167. 171 Auto-parking techniqueGo Kart

168. Thank you