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EVmotorcalculation 1

This document outlines the theoretical calculations for an electric vehicle powertrain. It calculates the torque required on the wheels based on the vehicle's weight and desired acceleration. It then determines the motor torque and current needed to produce that torque. Finally, it calculates the vehicle's maximum speed based on the motor RPM and battery voltage, as well as the expected travel range using sample battery specifications.

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M.Kumaresan (Thermal) Mech staff
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© © All Rights Reserved
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97 views4 pages

EVmotorcalculation 1

This document outlines the theoretical calculations for an electric vehicle powertrain. It calculates the torque required on the wheels based on the vehicle's weight and desired acceleration. It then determines the motor torque and current needed to produce that torque. Finally, it calculates the vehicle's maximum speed based on the motor RPM and battery voltage, as well as the expected travel range using sample battery specifications.

Uploaded by

M.Kumaresan (Thermal) Mech staff
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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net/publication/360427239

EV Powertrain Calculation

Method · August 2021

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Shafi Md. Istiak


Walton Hi-tech Industries Ltd.
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Shafi Md. Istiak
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EV Powertrain Calculation
Shafi Md. Istiak

Theoretical Calculation:
1. First the torque have to be calculated that will need for the vehicle (torque on the wheels):

Vehicle weight: G = 300 kg

Acceleration time from 0 km to 90 km/h (= 25 m/s ): t = 5 sec

Acceleration: 𝑎 =𝑣 /𝑡 = (25/5) m/s2 = 5 m/s2

Force for acceleration: 𝐹=300 𝑘𝑔 ∗5 𝑚/𝑠2 =150 𝑁

Torque on the wheels (wheel diameter 0,48 m): 𝑀𝑡=1500 𝑁 ∗0.48 𝑚 =720 𝑁𝑚

720 Nm is a torque on the wheels, which is needed to accelerate the vehicle (Vehicle weight is
300 kg) from 0 km/h to 90 km/h (in 5 sec)

2. Now the transmission gear (TG) ratio and calculate the torque should be considered consider:
Let,
Differential ratio is approximately 3:1
TG ratio is approximately 4:1
Therefore total ratio in the first gear is: 𝑡𝑜𝑡𝑎𝑙 𝑟𝑎𝑡𝑖𝑜=3 ∗4 =12

For example, one EMRAX 228 motor can deliver 140 Nm peak torque and 80 Nm continuous
torque. Therefore peak torque on the wheels in first gear is:

𝑡𝑜𝑡𝑎𝑙 𝑝𝑒𝑎𝑘 𝑡𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑡ℎ𝑒 𝑤ℎ𝑒𝑒𝑙𝑠 𝑖𝑛 𝑓𝑖𝑟𝑠𝑡 𝑔𝑒𝑎𝑟=12 ∗140 𝑁𝑚 =1680 𝑁𝑚

In this case close to 1700 Nm of peak torque in first gear can be expected. Which fulfills our
need. In the second gear the torque is lower.

We know, required torque on wheels is 720 nm, at first gear we actually need 60 nm torque to
fulfill the need.
As we know, for EMRAX 208,
Torque / motor current [Nm/1Aph rms] = 0.83
So,We need (60/.83)=72.29 Amps ~73 amps.

Only higher gear can deliver higher and finally end speed of EV End speed also depends on the maximal battery
voltage (Vdc) and magnetic field weakening (MFW) – more information in Item 9. Final EV speed can be even
Shafi Md. Istiak
[email protected]

higher if magnetic field of the motor is weakened. This can be done in the controller settings. Power stays the same
at higher speed. Power of EV is rising at higher speed because of the air drag.
EV needs enough high torque for starting EV and driving up the hill. 15% slope is minimal for torque calculation.

3. Torque, power calculation:


𝑷 [𝒌𝑾] = 𝒏 [𝑹𝑷𝑴]∗ 𝑴𝒕 [𝑵𝒎] / 𝟗𝟓𝟓𝟎
At lower RPM (motor rotation), you can expect lower motor power at the same torque. At
higher motor speed you can expect higher motor power at the same torque.
Mt……torque [Nm]
P………power [kW]
n………motor rotation [RPM]
Very important considerations when calculation power and torque for EV:
- acceleration
- air drag at higher speed
- driving up the hill
Usually there is no need to add higher torque for climbing up the hill, because there is enough
high torque in the first gear in the case of using TG. Only EV speed is lower. Normally we do not
need to drive up the hill at full speed.
EV must start with good acceleration even at very low RPM or at zero speed. Therefore the most
important are motor torque and reduction drive ratio (belt drive, chain drive, differential or
transmission gear etc.).

Acceleration:
Maximal torque on the front wheels:
𝑀𝑤=140 𝑁𝑚∗3=420 𝑁𝑚
Force that is needed for this torque:
𝐹=𝑀 ÷𝑟=420 𝑁𝑚 ÷0.48 𝑚=875 𝑁
Acceleration is:
𝑎=𝐹 ÷𝑚=875 𝑁 ÷ 300 𝑘𝑔=2.92 𝑚/𝑠2
Acceleration time from 0 to 90 km/h (=25 m/s):
𝑡=𝑣 ÷𝑎=25 𝑚/𝑠÷2.92 𝑚/𝑠2= 8.56 𝑠

Final EV speed:

Nominal DC battery= 470 VDC


Specific load speed (depends on the controller settings) [RPM/1Vdc] = 11 – 15 (let,11)
Maximal motor RPM according to specific load motor speed:
𝑁𝑚𝑜𝑡=470 𝑉𝑑𝑐∗11 𝑅𝑃𝑀/1𝑉𝑑𝑐=5170 𝑅𝑃𝑀
Differential gear ratio: 3 (let)
Maximal wheel rotating at full load:
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Shafi Md. Istiak


[email protected]

𝑁𝑤=5170 𝑅𝑃𝑀 ÷3 =1723.33 𝑅𝑃𝑀


Circumference of the wheel:
Diameter ,d = 0.48 m, Radius = 0.24 m
𝐶𝑟=2∗3.14∗0.24 𝑚=1.5 𝑚
Maximal EV speed without magnetic field weakening:

𝑉𝑚𝑎𝑥=1723.33 𝑅𝑃𝑀∗60∗1.5 𝑚 ÷1000=103.89 𝑘𝑚/ℎ ~104 km/h


!Note: Maximal EV speed can be much higher at the same power with magnetic field weakening (MFW). This setting can be made in the
controller software.

Battery total power and combination:


Per battery Module ,

12 V DC , 20AH/36AH [if we use 2500/3600 18650 li-ion cells available in the market]
Number of Modules per segment in series = 7
Number Of Segments in series = 6
Combination: 6S[7S[3S10P]
number of total cells: 1260
Total Accumulator will have , 504 V DC, 20Ah/36AH ,
Which will give the total power of 10.08 KWh (at,20AH) / 18.144 Kwh (at,36 AH)

Travel range with 18 kWh of battery capacity:


We know,
s=v*t
top speed, v = 104 km/h
We know , for highest torque needed(60 nm) , motor draw is 73 amps
For that, the battery will last, t= [ 18.144 KWh / (470 V * 73 amps) ] = 31.72 ~ 32 minutes
So, the car will go at a distance ,s = (104 km/h * 32 mnt) = 55 km

Therefore theoretically expected travel range is close to 55 km with one charging of the
batteries at max speed. In practice the producer of the batteries does not recommend 100%
discharging of the batteries, therefore 44 km is what can be expected in reality for 80%.

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