Development of Electric Two Wheeler with 200 Kms range & 350 GVW.

1. Electric Two Wheeler Development
∟ 200 Kms Range /350 GVW
28th January 2018
Group-1
Ezenith Education

2. Purpose
 To develop a two wheeler for Indian Market with range 200 Kms & 350 GVW
 Identify the right combination of Battery & Motor to meet the India Market Condition
Overview
 Location: VIT,Bangalore
 Period : January 23 ~ 28th , 2018
 Project _Electric Two Wheeler [ 200KMS / 350 GVW]
 Total Members : 14
 Evaluation : Ezenith Education , Bangalore
 Project Scope & Limitation
Picture
Name BLDC Hub Motor Battery pack i-BBMC Design Integration
 Identify the Customer usage for the Two Wheeler in Urban Environment (Bangalore City)
 Summaries the Present Two Wheeler Electric Vehicles Availability in the Indian Market
 Identify the India Unique Challenges for the two Wheeler and adopt in product development .
 Limitation
 Limited exposure to a two wheeler (Electric) design and load weight balancing.
 Limited knowledge for development of In-Vehicle Communication between onboard modules.

3.  India Market Overview
Picture
Maker Honda Okinawa Indus Hero Ampere
Model Activa Praise Yo style Photon V60
Range 200km 172~200km 70-75km 80km 55km
Max
Speed
85kmph 75 kmph 25kmph 45kmph 25kmph
Battery
-
[125 CC]
VLRA
72V/45Ah
24Ah
VLRA
72V/24 Ah
60V,20AH
Kerb
weight
110kg 96 kg 75kg 111 kg 100kg
Cost 58,808 66,000 26,712 54,110 60,000
Honda,Activa offers the best Ride Quality and has the Maximum sales in Indian Market
 Okinawa,Ridge offers range of 90 Kms / 250 GVW, need to benchmark for Development

4.  India Unique Challenges
 Environment Study
Pot Holes Flooded Condition Low temperatures Hot Temperatures
 Other Requirements
Pinion Riders Local repair Over Loading
∟ -10 ⁰ C ∟ 45 ⁰ C
∟ General Tools ∟ Vehicle Stability
Riding Dressing
∟ Saress
∟ System Safety∟ Vibrations
 Market offer Unique customer driving challenges & Harsh Climatic Operating conditions

5.  Driving Cycle Consideration
International Journal of Electrical, Electronics and Data Communication, ISSN:
2320-2084
Condition
Congested
Urban
Urban Light Urban Highway
Picture
Speed 8 ~ 10 Kmph 10~25 kmph 40 kmph 45~50 Kmph
Idle Time High Moderate Low Negligible
Source: International Journal of Electrical, Electronics and Data Communication, ISSN: 2320-2084 , Volume-2, Issue-9, Sept.-2014
Develop a driving cycle to measure and record real driving behaviors
Maximum Speed 50 kmph
Avg Speed 30 kmph
Total Time / Distance 30 mins / 4 Kms
 Parameters (Approx Values)
0
15
30
45
60
0
60
120
180
240
300
360
420
480
540
600
660
720
780
840
900
960
1020
1080
1140
1200
1260
1320
1380
1440
1500
1560
1620
1680
1740
1800
S
P
E
E
D
Congested
Urban
Urban
Light
Urban
Highway
Time 
 The Driving Cycle study indicates an Average Speed of 30 kmph in Urban drive environment

6.  Vehicle Sizing : 1. Motor 2. Battery 3. Control System
 1.5 kW BLDC Motor to deliver power with high efficiency & and CVT to increase
torque output (4 times) to move the given load
Features Motor[BLDC]
 No need for inverter
 Longer life of moving parts due to electronic commutation
 Less noise and EMI, even at 10,000 RPM due to enclosed system
 Heat dissipation can be handled effectively as windings are on stator
 Jerk free torque graph by use of sinusoidal motor driver
Feature Rated Torque Rated Power Rated Efficiency Rated Current
Required
Values 4Nm 1.5 kW >= 85 % 35 – 45 A
Golden Motors Volcano Motors Volcano Motors Mechatronic Tra. Tachometric
Picture
kW 1.5 1.55 1 1.5 1
Nm 4 3.44 3.82 5.2 4.2
Options in Market
Shortlisted Motor [Golden Motor]

7.  Vehicle Sizing : 1. Motor 2. Battery 3. Control System
 ??
 Lithium – NMC selected based on good discharge rate, high energy density and good
safety
Features Lithium - NMC
 High capacity, high power
 High specific energy allows to decrease weight and dimensions
 Better Life cycle = 1000 – 2000 cycles
 Typical Discharge rate of 25C allows us to power high current
demand devices.
Nominal V Ah Life Cycle Weight (gm) Discharge Rate
Specific
Energy
Thermal
Runaway
3.60 9 1000 - 2000 147 1-2C
150 – 220
Wh/Kg
210 deg C
NMC LFP LI-ion LI-Polymer LCO
Nominal V 3.60 3.20 3.7 3.7 3.6
Ah 9 8.8 8.5 9.5 8
Life Cycle 1000~2000 1000~2000 500 500 500~1000
Weight (gm) 147 235 210 150 162
Options in Market
Shortlisted Battery [NMC- Supplier GBS]
Series Parallel
Total
Cells
Total
Energy
15 14 210 6.8kW

8.  Vehicle Sizing : 1. Motor 2. Battery 3. Control System
BMS Communicates with modules , monitors the battery Health & Manage Motor Output
Features i- BMMC Major Modules
1. Measures the cells' charge, voltage, temperature and
health
2. Diagnostics and protection for the battery
3. Controls the current among cells to avoid over or
under charging (cell balancing)
4. Communicate with Motor Controller & External Chargers
1. Data acquisition unit
2. Communication unit [CAN Interface]
3. Battery state estimation model.
4. Thermal management
5. High voltage management [safety condition]
 Block Diagram
Brakes
Cluster
Diplay
Battery Unit
Throttle
[Input]
Motor
Controller
External
Charger
OCPP
VSS
CAN
CANCAN
CAN
 Diagnosis Information
Junction
Box
Service
Plug
Item Condition Value
Battery A Ready 20A
Service Plug Ready Indication
Cell V 1 Ready 3.4 – 3.6 V
Cell V210 Ready 3.4 – 3.6 V
Battery T1 Ready 20°C - 30°C
Battery T3 Ready 20°C - 30°C
M Controller Failure Disconnect B
Charger Status Connected I/P V
∟[Battery Management & Motor Controller]
∟ External Charging
∟ Avoid Heat Pockets
∟ Customer Information
∟ In Vehicle
∟ Battery Pack

9.  Final Architecture of the vehicle
 The selected parameters are closest to the approximation for the Vehicle and Costs :
Tire Size
10’ inch
IP 67
Protection
Fr Brake
Drum
Rr Brake
Drum
Charger Socket
3.2 KW
i-BMMC
Headlamp
LED
Tail Lamp
LED
Storage Capacity
20 L
Frame
Steel Composite
GVW Range Cost
281.7
KG
202
KMs 40000
Body Material
PP TD 40
Motor BLDC
1.5 KW

10.  Challenges of the Project
The Challenges in the project due to the design were analyzed and solutions are offered keeping in
mind ease of manufacture, ease of use and cost to consumer.
 Drive Cycle decision
 Motor & Battery Selection
 i-BMMC Development
-The data was recorded manually in Cab and may not match exactly with actual usage of a two wheelers.
- No data recorder used with GPS and speed capability to accurately monitor the vehicle speed.
- The calculations was done with keeping the Average speed in mind and according to individual driving situations.
- The integrated BMS & VCU reduces the development cost of Vehicle but needs a new architecture development.
- The new module needs to communicate using multiple protocols and require high level of expertise.
- The coding of these modules to work according to design parameters for Indian roads and traffic conditions.
- Taking into considerations the drive cycle for Indian roads and designing a CVT to allow the motor to adapt effectively.
- Balancing the torque and power requirement and the capacity of motor to deliver the same for given range of 200km.
- Finding a suitable battery tech to balance the charge density and keeping the battery pack under weight specifications

11.  Vehicle Specification
Dimension Technical Specification Extra Features
Length 1761 mm Range/Autonomy 200 Kms FOB Key Single
Width 710 mm Top Speed: 55~60kmph Mobile Charing 180 W
Kerb Weight 200 Kgs Weight (GVW) 350 Kgs Speedometer Digital
Height 1149 mm Motor: BLDC Immobilizer SKU
Wheelbase 1238 mm Wattage: 3 kW External Charge
Rear LH
220 V
Ground
Clearance
153 mm Batteries:
6.8 kW
NMC
Front Suspension
Spring loaded
hydraulic type
Voltage: 48 V
Wheel Size 10-inch/10-inch Charger: 3.2 KW/14 A
Braking
Drum
ABS(Optional)

12.  Summary & Conclusion
 India offers unique challenges for an Electric two wheelers with high usage in Urban Areas
 The expected price for the two wheeler with 200 Kms/350 GVW : 40,000 (Excluding Battery)
 The Battery to power the E-Scooter is 6.78 kW with NMC Cells from GBS
 The Motor selected for the project is from Golden Motors Make with rating 1.5KW
 The Control System is developed i-BMMC as a Single Unit to monitor the Battery parameters and give input to
motor based on throttle input thus reducing the wiring & additional cost of hardware.
A digital cluster indicates the battery SOC , current speed and expected driving range ,an Eco mode Indicator.
 Summary
 Conclusion
 The Battery cost is the major challenge for the project and with newer chemistries development over the coming years
we have decided to offer the battery on lease.
 The present model is commercially developed will appeal tp the young generation to move to electric.
- The driving range of 200 Kms can be the USP and only needs single charging per week
 High GVW achieved with the state of the art motor will allow the model to be modfied for Commercial Use.

13. THANK YOU