CUET Automotive and Mobility Society-CAMS

Workshop on Automobile Engineering , Formula Student Racing Car & EV

CAMS Workshop : DAY -02

Topic : Engine, Electric Powertrains & EV Technology

Minhaz Uddin Midul

ME’19,CUET
Engine , Power System & Electrical System Team , Bijoy 71
What is an Engine?

A device that converts any type of

energy into mechanical force and
motion is called engine. It is an
energy-generating device or
mechanism.
Example- Heat Engine , steam
Engine , IC Engine
 • Types of Engine , Their Uses And Comparison

Engines are of two types, & these are externals combustion engines and
internal combustion engines.

External combustion engine

In externals combustion engines, the combustion of fuel takes place
outside the engines— for example, the steam engine.
Internal Combustion Engines

In internal combustion engines, the combustion of fuels takes place insides

the engine. Two-stroke and four-stroke petrol & diesel engine are examples of
an internal combustion engine.

Étienne Lenoir
Types of IC Engine

TWO-STROKE CYCLE ENGINE:

As per the name, this engine requires two piston strokes to complete an operating cycle. Those
strokes are compression and expansion strokes. Only one crankshaft rotation is required.
FOUR-STROKE CYCLE ENGINE:

This engine makes four piston strokes i.e. intake, compression, power and exhaust to
complete an operating cycle. The operating cycle requires two crankshaft revolutions(
720 degrees). It is the most common type of engine used in automotive.
TYPES OF FUEL USED

A)PETROL OR GASOLINE ENGINE

This engine generates power by burning gasoline (or other volatile liquid fuel with similar properties)
ignited by an electric spark. Generally, a mixture of fuel and air is used as a charge.

B)DIESEL ENGINE
This engine makes use of diesel as fuel, where fuel ignition takes place on its own, without any
spark. Hence, compression of the inlet air mixture takes place and then fuel is injected.

C) BI-FUEL ENGINE
This engine can run on either natural gas or gasoline which means it
follows the natural gas system and gasoline system
i.e. dual fueling system. Hence these kinds of engines are known as bi-
fuel or dual-fuel engines.
METHOD OF IGNITION
A)SPARK IGNITION ENGINE

in S.I engines, the ignition takes place with the help of a spark plug. This mechanical device called spark
plug ignites a mixture of air and fuel( charge) which is compressed and combusted in the combustion
chamber.

B)COMPRESSION IGNITION ENGINE

A CI engine follows the auto-ignition or self-ignition process where fuel charge is ignited by its own heat of
compression. Here, the air is inducted into the combustion chamber and compressed to extremely high
pressure.
NUMBER OF CYLINDERS

A)SINGLE-CYLINDER ENGINE

It is a basic piston-cylinder configuration of

an engine in which only one engine cylinder
is used. The designing of this engine is
compact and simple.

B)MULTICYLINDER ENGINE

Here, more than one cylinder system is used. It

is used to provide a more continuous flow of
power. A popular multi- cylinder engine contains
four, six, and eight engines in various
configurations.
ARRANGEMENT OF CYLINDER

A)HORIZONTALLY OPPOSED ENGINE

These engines have the cylinders configured in two banks on either side of a single crankshaft. Which means they share a
common crankshaft. The other names for this cylinder are Flat engines or “boxer” engines.example-Porsche,subaru.

B)VERTICAL ENGINE

The vertical engine is the engine in which the movement of the piston is vertical viz. vertically up and down and the placement
of the crankshaft is below the cylinder.
C)V-TYPE ENGINE
In this engine design, cylinders are placed at some angle. Due to the presence of angle in between, it forms
a “v- shape”. This angle varies from 60 degrees to 90 degrees. Usually, even numbers of cylinders are used
in this design. These are used in high-end sports bikes, high-end cars, etc.

D)RADIAL ENGINE
This is a reciprocating type IC engine. The configuration is like “wheel and spokes” in which cylinders are
placed outward from the central crankcase. It resembles a star, hence called a “star engine”.
E)IN-LINE ENGINE
In this engine, cylinders are placed in a straight line, hence it is also called “straight engine”. These engines
can have 2,3,4,5,6, or up to 8 cylinders. This engine design is conventional and quite basic.

F)X ENGINE
When two V engines are joined by a single crankshaft, we will get an X engine. Thus, this engine is made
from two V engines. This engine has its own historical Significance as They were used in aircraft during the
Second World War.
G) OPPOSEDPISTONENGINE
In this engine, pairs of pistons are co-axial which share a single combustion chamber. The cylinder
head is absent and the cylinder has its piston at its both ends.

H) WENGINE:
WANKEL ENGINE:
COOLING SYSTEM
A)AIR COOLED ENGINE

This type of cooling engine depends on the amount of airflow across their external engine surface to eliminate the heat
dissipation. We make thin cooling fins to increase the surface area.

B) WATER COOLED ENGINE

When water is used as a coolant in an internal combustion engine, then it is called the water-cooled engine. This cooling
system works on the passing of water (as coolant) through provided passages in engine blocks. We make water jackets, water
pumps, etc. for this engine.

C)OIL COOLED ENGINE

It is another liquid-based cooling system engine where engine oil acts as a coolant to reduce the heat dissipation. We make
use of the radiator (oil cooler) for this purpose where hot oil, after cooling the engine, is passed through the heat exchanger
Parts of Internal Combustion Engines
1. Cylinder
• The cylinder is made up of steel or aluminum alloys.
• In this Piston makes to and for a motion to develop power.
• It will withstand high pressure and temperature.
2. Cylinder Head
• Cylinder Head is fitted at the top of the cylinder.
• It is made up of steel or aluminum alloys.
• It is made by casting.
• A copper or asbestos gasket is provided in between the cylinder and the cylinder head to make it airtight.
3. Piston

It is made of aluminum alloys.

•The main function is to transmit force
exerted by burning of charge to connecting
rod.

4. Piston Rings
•These are circular rings made up of special
steel alloys.
•these are housed in circumferential grooves
of the piston.
• Two sets of rings are provided, with an
upper ring to prevent leakage of burnt gases
into the lower portion, while lower ring to
prevent leakage of oil into the Engine
Cylinder.
•They retain elastic properties even at a
higher temperature.
• The rings are provided with an airtight seal.
5. Valves

•These are provided on the cylinder head,

•Inlet valve is used to take the fresh mixture into the cylinder.
•The exhaust valve is used to expel burnt gases from the cylinder.
6. Connecting Rod

•It is a link between the piston and the crankshaft.

•The function of Connecting Rod is to transmit the force from piston to
crankshaft.
Camshaft
The camshaft is a rotating
object— usually made of
metal— that contains pointed
cams, which converts
rotational motion to reciprocal
motion.
7. Crankshaft

•It is made of special steel alloys.

•The function of the crankshaft is to convert the reciprocating motion of a piston
into rotary motion with the help of connecting rod.

8. Crankcase

•The crankcase is made of cast iron.

•It holds the cylinder and crankshaft of an engine.
•It also serves as a sump (storing place) for lubricating oil.
9. Flywheel

•It is a big solid wheel

mounted on a crankshaft of
an IC Engine.
•The main function of the
flywheel is to maintain speed
constant.
•It stores excess energy during
power and gives out during the
compression stroke.
10.Liner
Piston liners sit within the
cylinder and help provide a
tight seal, so it can extract
the maximum power from
the gases produced by the
internal combustion
process, reduce wear on
the cylinder
Starter Motor:
ALTERNATOR:
Carburetor:
Turbocharger:
Supercharger:
 • Power Electronics For Evs

The Main Components of Electric Vehicles

• Traction battery pack

• DC-DC Converter
• Electric motor
• Power inverter
• Charge Port
• Onboard charger
• Controller
• Auxiliary batteries
• Thermal system (cooling)
• Transmission
1. Traction Battery Pack:

Also known as Electric vehicle battery (EVB). It powers the electric motors. The battery acts as
an electrical storage system. It stores energy in the form DC current. The range will be higher
with increasing kW of the battery. The life and operation of the battery depends on its design.
The lifetime of a traction battery pack is estimated to be 200,000 miles.
 2. DC-DC Converter

The traction battery pack delivers a constant voltage. But different components of
electric vehicle has different requirements. The DC-DC convertor distributes the
output power that is coming from the battery to a required level. It also provides the
voltage required to charge the auxiliary battery.
3. Electric motor:
Electric traction motor is the main components of electric vehicles. The motor converts the
electrical energy into kinetic energy. This energy rotates the wheels. Electric motor is the
main components of electric vehicle that differentiates an electric car from
conventional cars. An important feature of an electric motor is the regenerative braking
mechanism. This mechanism slows down the vehicle by converting its kinetic energy into
another form, and storing it for future use. There are basically two types of motors DC and
AC motors.
4. Power Inverter
It coverts DC power from the batteries to AC power. It also
converts the AC current generated during regenerative braking
into DC current. This is further used to recharge the batteries.
5. Charge Port
The charge port connects the electric vehicle to an external
supply. It charges the battery pack. The charge port is
sometimes located in the front or rear part of electric vehicle
components
 6. Onboard charger
Onboard charger is used to convert the AC supply received from the
charge port to DC supply. The on-board charger is located and installed
inside the car. It monitors various battery characteristics and controls the
current flowing inside the battery pack.
7. Controller
Power electronics controller determines the working of an electric car.
It performs the regulation of electrical energy from the batteries to the
electric motors. The pedal set by the driver determines the speed of
the car and frequency of variation of voltage that is input to the motor.
It also controls the torque produced.
8. Auxiliary batteries
Auxiliary batteries are the source of electrical energy for the
accessories in electric vehicles. In the absence of the main battery, the
auxiliary batteries will continue to charge the car. It prevents the
voltage drop, produced during engine start from affecting the
electrical system
9. Thermal system(cooling)
It is responsible for maintaining an operating temperature for the main
components of electric vehicle (EV) such as, electric motor, controller etc. It
functions during charging as well to obtain maximum performance. It uses a
combination of thermoelectric cooling, forced air cooling, and liquid cooling.
 10. Transmission
The gearbox transfers the mechanical power from the electric motor to the
wheels. The advantage of electric cars is that they do not require multi-
speed transmissions. The transmission efficiency should be high to avoid
power loss.
What is motor?
A machine that changes a form of energy into mechanical energy to produce motion.
 • Electric Motors And Their Characteristics

Motor : A machine that changes a form of energy into mechanical energy to produce motion.
DC Motor

The DC motor is a type of rotary electrical motor that

converts electrical energy into mechanical energy.
This means that the input electrical energy is direct
current which is converted into mechanical rotation.

1) Shunt Motor

It is a type of DC motor where the field winding is

connected parallel to the armature winding of the
motor

2) Separately Excited Motor

The main supply is given separately to the

armature and the field winding. Separately excited
DC motors are suitable for applications that
require speed variation from low to very high
values
3) Series Motor

Series motors are a set of separately excited

motors in which the field is connected in
series to the armature winding, and thus, a
high current passes through it.

4) Compound Motor

The compound motor is a combination of

both series and shunt field coils
connected to the armature winding.

5) PMDC Motor

This type of motor is arranged with

permanent magnet poles. In this motor,
the magnets are radially magnetized and
set on the inner sides of the cylindrical
steel stator.
AC Motor

AC motor is an electric motor that uses

the electromagnetic induction
phenomenon to convert alternating
current into mechanical power.

1) Induction Motor
An electric current is required to produce
torque obtained through electromagnetic
induction from the rotating magnetic field
of the stator winding.

a) 1-Phase Induction Motor

1 phase AC motor usually works on a single-

phase power supply. It consists of single-
phase winding on the stator and cage
b) 3-Phase Induction Motor

A 3-phase induction motor uses

electromechanical energy to convert 3-
phase input electrical power into output
mechanical power.

2) Synchronous Motor

In this type, all the rotations made by the

rotor are equal to an integer multiple of
the frequency of the applied current.
• Special Types of Electric Motors

1) Brushless Motor

The motor contains an electronic controller

to change DC currents in the motor
windings creating magnetic fields which
rotate in space.

2) Stepper Motor

These motors can provide flexibility and

constant holding torque without the need
to operate the motor. They are used in 3D
printing equipment, textile machines, and
printing presses
3) Universal Motor

The motor features variable speed, and

high transmission torque and provides a
high starting torque. Universal motors are
commonly used in vacuum cleaners,
sewing machines, etc.

4)Reluctance Motor
Reluctance motors have non-permanent
magnetic poles on a ferromagnetic rotor
that does not have windings.
S
•High torque density and power density.

IDEAL REQUIREMENTOF MOTOR

CHARACTERISTICS
• High torque density and power densi
ty.
• High torque for starting, at low speeds and hill climbing, and high power for highspeed travelling.
• Wide speed range, with a constant power operating range
of around 3–4 times the base speed being a good
compromise between the peak torque requirement
of the machine and the volt-ampere rating of the
inverter.
• High efficiency over wide speed and torque ranges,
including low torque operation. Ideal Torque/power –Speed characteristics
• Intermittentoverload capability, typically twice the for EV

rated torque for short durations.

 FACTOR CONSIDER FOR SELECTINGOF MOTOR
FOR EV

1. Nature and demand of load.

2. Temperaturerange.
3. Voltage, Current,and Power rating.
4. Frame size.
5. Nature of supply.
6. Overload handling capacity.
•The electric motors used for automotive applications should have characteristics like high
starting torque, high power density, good efficiency, etc.
• THREE PHASE INDUCTION MOTOR STRUCTURE:
Torque-speed characteristics:
• PERMANENT MAGNET BRUSHLESS DC MOTOR:
PERMANENT MAGNET BRUSHLESS DC (PMBLDC)
MOTOR

• The rotor of PM BLDC motor is made of PM most commonly NdFeB (Neodymium Iron
Boron), the stator is provideda trapezoidalwave supply from a DC sourcethrough an inverter.
• As there are no windings in the rotor, there is no rotor copper loss, which makes it more
efficient motor.
• This motor is also lighter, smaller, better at dissipating heat (as it is generated in the stator) it is
more reliable because it has more torque density and specific power density.
• BLDCs are useful for use in small cars requiring a maximum 60 KW of power.

• There are two basic BLDC motor configurations: 1. Inner rotor BLDC motor
2. Outer rotor BLDC motor
TORQUE-SPEED CHARACTERISTICSOF PM BLDC
MOTOR
• Characteristics of a Permanent Magnet
Brushless DC Motor.
• The torque remains constant atthe maximum
right from the start, but starts to decrease
exponentially for speeds over the base speed.
• The obtain characteristicsof BLDC motor is
same as required characteristics so it is best
option for electric vehicle
• PERMANENT MAGNET SYNCHRONUS MOTOR:
 PERMANENTMAGNET SYNCHRONOUS
MOTOR (PMSM)

• Permanent Magnet Synchronous Motor (PMSM) or BLAC motor is same as PM BLDC

motor by construction point of view.
• PMSM has two types of configuration, inner rotor PMSMmotor and outer rotorPMSM
motor.
• Both motor carry permanent magnet on rotor side and torque is produce by interaction
of PM and commutated phase.
• Mostly, stator winding of PMSM is distributedwinding.
• The driving signal for PMSM motor is sinusoidal so PMSM is designed to have a
sinusoidal back EMF, so the rotor is shaped to a sinusoidal flux profile.
SWITCHED RELUCTANCE MOTOR:
 SWITCHED RELUCTANCE MOTORS (SRM)

• There is no permanent magnet or other external excitation in a SRM.

• Both the stator and the rotor have salient poles. Concentrated windings are usually used for
the stator.
• When stator coils are energized, variable reluctance is set up in the air gap between the stator
and the rotor.
• Rotor tends to move to a position of least reluctance thus causing production of torque.
 TORQUE-SPEED CHARACTERISTICSOF
SR MOTOR

• Switched Reluctance motor has

characteristics like high starting torque, wide
speed range and good inherent fault -
tolerance capability, which makes it suitable
for electric vehicle application.
EV Software and Simulation Tools:

• Matlab (Simulink)-

• ADVISOR

• ANSYS
• Matlab (Simulink)-
https://www.youtube.com/watch?v=tM9Akdo8
QeA&list=PLkNpfXWK1twz95zTfjzO_7FijrmzppBk
w&ab_channel=SkillLync

• ADVISOR (ADvanced VehIcle SimulatOR)

• ANSYS
EV Software and Simulation Tools:
• ANSYS
EV Software and Simulation Tools:
• ANSYS
EV Software and Simulation Tools:
• ANSYS
EV Software and Simulation Tools:
• ANSYS
Turbocharger
A turbocharger is a forced induction device that is powered by the
flow of exhaust gasses. It uses this energy to compress the intake gas,
forcing more air into the engine in order to produce more power for
a given displacement.
Supercharger
EGR
Exhaust gas recirculation is a nitrogen oxide emissions reduction technique used
in petrol/gasoline, diesel engines and some hydrogen engines. EGR works by
recirculating a portion of an engine's exhaust gas back to the engine cylinders
 Engine Tuning

Performance Chips
C old Air Intake Kit
Air Filters
Turbo/Superc hargers
EC U upgrade / remapping
Increase Exhaust Flow
Weight Reduction
Disassembly of IC Engine
• Disconnect battery cables
• Remove the hood
• Remove air c leaner
• Label all wires and vac uum lines
• Drain coolant and oil
• Remove the radiator
•Remove the distributor and spark
plug wiring
 Types of Motor Configuration in EV
According to the number of motors used in vehicle and their
configuration,
existing powertrain EVs can be classified into two types
including
• The centralized single motor driven powertrain(common
structure in modern EV) and
• the distributed multi-motor driven powertrain
 Types of Motor Configuration in EV
some EVs are focused on distributed Multi-motor driven
powertrain and it is mainly classified into three categories
1. dual motor powertrain
2. triple motor powertrain
3. four motor powertrain
 DEEP DIVE of SINGLE Motor Powertrain
• The single motor system there
is a single motor that drives
the car and that is charged and
produces torque to the engine.

• The Electric motor is mounted

as front wheel drive . AND
there is also a differential as
well that allows the wheels to
rotate at different speeds
• Advantages-
1. fewer components needed
2. cheaper to build(which is
always a good selling point for
the eager buyer)
• Disadvantages-
1. not efficient as a dual motor
system simply because it
lacks the second motor
 DUAL Motor Powertrain
1. offer more horsepower
2. efficiency and speed at a
higher altitude than SINGLE
Motor Configuration
3. all-wheel drive(AWD) systems
because of digitally control
torque to the front and rear
wheels for far better handling
and traction control.
• Advantages-
1. speed up more quickly
2. ability to stop quickly
3. little or No gear shifting feels
to the driver with a smooth
drive
• Disadvantages-
1. More expensive
2. lack of standard transmission
3. the overall control software is
going to be slightly more complex.
 Triple Motor Powertrain

• one motor is being placed on

the front axle while two
motors fitted to the rear axle
thus making the car all-wheel
drive(AWD)
• eliminates the need for a
mechanical differential.

-First EV with a three-motor

powertrain
 Four Motor Powertrain

• super handling AWD system

can precisely apply either
positive or negative torque
individually to each wheel
• Proper torque vectoring
• sharper tighter turn