The document summarizes an experimental analysis of converting a 1400 cc diesel engine car into a hybrid electric vehicle using BLDC hub motors. Key findings include: 1) The conversion achieved fuel savings of 45-61% compared to the conventional vehicle through the use of lower power hub motors and a separate battery pack for the electric motors. 2) Performance of the vehicle was retained after conversion, with no changes needed to the existing electrical or hydraulic brake systems. 3) The proposed conversion method could be easily implemented on many existing small cars with front-wheel drive to reduce emissions and fuel consumption cost-effectively.

1. Experimental analysis of 1400 cc
diesel engine car converted into
Hybrid Electric Vehicle by using
BLDC hub motors
by
Prof. Sudhir Gupte
Automobile Engineering Department
A.D.Patel Institute of Technology
IV th International Conference on
Advances in Energy Research
12 Dec' 2013
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2. Introduction
Two reasons for the need of Conversion.
Fossil fuel
resources
depleting
Environment Pollution
Global Warming
Stringent Mandatory norms
Hike in Fuel prices
Demand and supply
Newer Technologies
IV th International Conference on
Advances in Energy Research
12 Dec' 2013
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3. Introduction: What is Automotive
Industry doing ?
To achieve mandatory pollution standards
out of compulsion
Engine down sizing
Power to Weight Ratio
Reduction in Vehicular Weight
Improvement in Combustion
Air/Fuel Ratio
Study of Driving cycle
Aerodynamics
EV/HEV
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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4. Mild, Micro etc. Hybrids. But all these comes at
very high development cost and complicated &
expensive installations on the vehicle.
BUT
If per capita consumption is not reduced
drastically and if alternate energy vehicles are
not developed, they will not be able to sustain
the market conditions in the near future.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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5. Integrated holistic approach to
improve Quality of air




Improvement in Roads and traffic conditions
Fuel Quality standards
Bio Fuels & Alternate energy sources.
Electric vehicle mission plan declared by Govt. India 9th
Jan, 2012.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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6. However
Those Millions of old vehicles will be still
guzzling unwanted, harmful pollutants in the
atmosphere at an alarming rate, still
contributing towards the menace of global
warming, which will continue, if they are not
converted into hybrid electric vehicles.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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7. Hence
1400 cc diesel engine car converted
into Hybrid Electric Vehicle by using
BLDC hub motors –
An Experimental analysis
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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8. Following points were considered while attempting to contribute
towards improving the quality of air or reduce further damage
being created by the existing /old gasoline and /or diesel vehicles.
 conversion should be economical and affordable.
 Conversion
should
be
easy.
An
unskilled
worker/mechanic should be able to carry out the
conversion within 4 to 5 hours, after receiving necessary
one day training.
 Minimum requirement of special tools.
 Return on investment should be measurable and
attractive for the user.
 Convenient to use by the customer.
 Hassel free service. Ease of maintenance.
 Ease of implementation even for vehicle manufacturer
on the similar new models.
 Satisfactory performance.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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9. Concept : Proposed Hybrid system
 Using the existing IC engine as main source.
 Electric motors providing driving force as
Auxiliary power source.
 Can be used as four wheel drive as and when
necessary.
 All four wheels disc brake system.
 No/Minimum modifications in the existing drive
train.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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10. Concept : Proposed Hybrid system
…
Cont.
 On board Energy flow: Separate Battery pack
for Existing engine and for electric motors.
 Plug-in type charging system for Electric motor
batteries and existing alternator charging
system for the vehicular battery.
 Regenerative braking system not adopted,
because, under most ideal conditions,
efficiency of loop, battery to kinetic and kinetic
to battery charging is no greater than 50 %.
Also, it adds to cost, which may prohibit
customers for conversion.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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11. Models Applicable:




Maruti: M800, Alto, Zen
Tata: Indica
Hundai: Santro
All “B segment” cars with Front Transverse
Engine.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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12. Kit comprising of Parts








Permanent Magnet BLDC Hub Motors
Controller
Accelerator pedal control
Battery Pack (options to choose type of
Battery: Pb/Acid, Lithium-Ion, Lithium polymer,
etc.)
Wiring harness (inclusive of switches)
Charging system
Measuring Instruments (optional)
Brakes system
IV th International Conference on
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Dec' 2013
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17. Performance Test Results
Conventional
ICE Vehicle
Prototype
HEV
% Saving of
Fuel
in EV mode
V/s
ICE
State highway
4.65
2.29
50.8
State highway
4.83
2.62
45.8
NH 8
5.05
2.19
56.6
Express way
5.12
1.97
61.5
Parameters
Fuel Consumption,
Liters//100Km
Route
Maximum Speed
Achievable in HEV
62 km/hr
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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18. Conventional
ICE Vehicle
HEV after
Conversion
52 PS @ 5000
52PS
85 @ 2500 rpm
85 @ 2500 rpm
-
2.5+2.5 = 5 kw
-
150 Ah
150 Kg
150 Kg
Curb weight of vehicle
1050 Kg
1250 Kg
Total
1200 Kg
1400 Kg
Parameters
Engine Peak Power
Engine Max. Torque, NM
Peak Power of Motor,
PM BLDC
HEV Battery Pack, 4x12 V,
Lead Acid type
Passenger Weight
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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19. Torque at Wheels
Description
Unit
rpm @
ICE
HEV
Peak power
Ps
5000
52
5
Peak toque
Nm
2500
85
Final drive ratio
Gear Ratios
4.40
1st
Nm
3.64
2nd
Nm
1.95
3rd
Nm
1.27
4th
Nm
0.88
5th
Nm
0.64
Reverse
Nm
3.50
Tyre Size
Rolling radius
Max. Torque at wheels
165X65R14
0.272
1st
Nm
Nm
729.30
3rd
Nm
474.98
4th
Nm
329.12
5th
Nm
237.86
Reverse
Nm
1309.00
Km/hr
92
0.272
1361.36
2nd
Max. Speed
m
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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61.5
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20. Why change EV driving cycle
 Prius changes to EV during congested traffic
conditions and runs on ICE on highways. OK for
urban driving cycles in Metro cities.
 In other cities car users are driving in cities for
10 % distances and remaining on highways.
 High speed running on highway obviously fuel
consumption is high.
 With low powered, light weight PMBLDC hub
motors, it is proposed to run vehicle on ICE in
city traffic conditions and switching on to EV on
highway.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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21. Results and Discussions
 By using proposed lower power Hub Motors, up to
61 % saving is achievable on the existing cars.
 Peak performance of the available drive line is
retained / assured.
 Veh. existing electrical system is not disturbed.
 Existing Hyd. Brakes with Disc brakes in rear.
 No additional Instrumentation required.
 Power Steering and A/c are driven by ICE, hence
ICE has to run on idling while running in EV mode.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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22. Results and Discussions
…Cont.
 Appropriate torque capacity of PM BLDC hub
motors can be selected for the particular
vehicle for conversion in to HEV, for deriving
optimum results.
 Advantage of hub motors is that the output is
directly driving the wheels; hence the motors
efficiency is the only loss. Geared hub motors
add to varying torque reqyuirement.
 Well to wheel energy efficiency for Prototype
HEV is measures at 0.87 km/MJ as against
0.64 for Insight and 0.56 for Prius models but
1.14 for Tesla (pure EV).
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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23. Conclusions
 Proposed method is expected to reduce the fuel
consumption by 45 % to 61 % (with A/c & P/S).
 Results can improve further, if the high Ah, light
weight batteries are utilized.
 Possible to convert majority of the old cars with
front engine front wheel drive vehicles in to
Hybrid Electric car, without much of difficulty and
at reasonable cost.
 Easy to implement in new veh. models –
Existing/introduced in future, by the vehicle
manufacturers.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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24. Conclusions
…Contd.
 Serviceability and life of components is
improved.
 Increase Service life of ICE and driveline
components.
 Reduced maintenance cost of ICE and driveline
assembly components.
 ROI from 11 to 15 months @ 3000 km per
month.
IV th International Conference on
Advances in Energy Research - 12
Dec' 2013
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25. THANK YOU
IV th International Conference on
Advances in Energy Research - 12
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