AT 19502 – Electric and

Hybrid Vehicles - I
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Syllabus

► Introduction
► DC Motors
► AC Motors
► PMSM and SRM Motors
► Vehicle Mechanics

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Textbooks and References

► Tom denton. “ Electric and Hybrid Vehicles” Routledge Publications, 2016

► Austin Hughes and Bill Drury. “ Electric Motors and Drives – Fundamentals, Types and
Applications, Newnes-Elsevier, 2013.
► Vinodh kumar, Ranjan Kumar Behera, Dheeraj Joshi “ Power Electronics, Drives and
Advanced Applications”, CR press, 2020.
► Gianfranco Pistoia. “Electric And Hybrid Vehicles Power Sources, Models, Sustainability,
Infrastructure and The Market”. Elsevier, 2010.
► Jack Erjavec. “Hybrid, Electric & Fuel-Cell Vehicles”. Cenage Learning, 2013.
► Chau. K. T. “Electric Vehicle Machines and Drives – Design, Analysis and Application”, John
Wiley & Sons Singapore Pte. Ltd., 2015

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Introduction – Why Electric and Hybrid Vehicles? 4

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India`s Crude Oil Bill

► The fuel import bill totalled about $24.7 billion in the three months ended 30
June, compared with $8.5 billion a year earlier, according to official data. Volume
growth was, however, modest at 14.7% in the June quarter at 51.4 million tonnes.
► The oil import bill has risen sharply although domestic fuel consumption still
lags pre-covid levels. With global oil prices unlikely to fall sharply in the near
future, and domestic fuel consumption on the rise in line with easing of
covid-related curbs and renewed economic activity, the oil import bill is expected
to exceed $100 billion this fiscal year through March.
► India had imported a little over 198 million tonnes of crude worth $62.7 billion in
2020-21, according to the Petroleum Planning and Analysis Cell (PPAC), the
official data keeper of the petroleum ministry.

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Electric Vehicle

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Battery

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Global Energy Scenario

Electricity demand
outlook in selected
regions/countries in
the Stated Policies
Scenario, 2019-2030

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Motors for EVs

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Change in global electricity generation by source in
the Stated Policies Scenario, 2000-2040 12

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Global energy demand and CO2 emissions trends in
the Stated Policies Scenario, 2019-2030 13

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Total final energy consumption in the transport sector, 2010-2030
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Comparison of the energy cycles for an electric drive
vehicle and a gasoline vehicle

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Common Category of Electric Drive Vehicles

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Battery Electric Vehicle

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BEV Examples

Nissan Leaf Renault Zoe BMW i3

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Tesla model 3
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Indian Models

TATA Nexon EV Hyundai Kona Electric Mahindra e2o

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Electric Vehicle Configuration 24

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EV configuration due to variations in electric propulsion
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Comparison of Electric with Gasoline 26

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 India's roadmap for electric vehicle: 27
Opportunities and obstacles
Challenges:
1.) Range anxiety - Range anxiety is one of the crucial
challenges ahead of the growth path for electric vehicles
in India. The EV customers are often worried about the
vehicles capability to reach point B from point A before
the battery runs out. This issue is closely connected to the
scarce charging infrastructure in India. The Ev charging
infrastructure in India too low compared to the petrol
pumps. Also, the available Ev charging stations are
concentrated in urban areas only. 2.) Consumer perception - The consumer perception
about electric vehicles in India is still weak compared to
ICE vehicles. The range anxiety, lack of charging
infrastructure, a wide gap between EV and ICE vehicle
prices, lack of assurance about satisfactory resale value
play key roles in that. Despite the Indian consumers are
becoming more open about adopting e-mobility than
before the negative perception about EVs is still there.
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3.) High price - There is no price parity between electric
vehicles and ICE vehicles in India. Electric vehicles are
way more expensive than their conventional 28
fuel-powered counterparts. For example, the Tata Nexon
price starts from ₹7.19 lakh, while the Tata Nexon EV
price starts from ₹13.99 lakh. This huge price difference
discourages many interested EV buyers to shy away from
making the final decision to buy a BEV. 4.) Scarce battery technology - The lithium-ion battery
is the most popular and widely used energy source for
EVs. India doesn't produce lithium. The country doesn't
produce li-ion batteries either. India relies on import for
5.) Majority of EVs are not covered under FAME EV batteries resulting in the sky-high price for these
scheme - The Indian government took an attempt to important components and eventually the EVs as well.
promote electric mobility in the country via incentivising
and discounts for EVs. The terms and conditions of the
FAME scheme doesn't support a majority of the electric
vehicles. The low-speed electric two-wheelers, lead-acid 6.) Lack of products - There are hundreds of options of
battery powered EVs are not covered under FAME. The one wants to buy a conventional fuel powered car or
highly expensive high-speed EVs on the other hand two-wheeler. The case is completely different in EV
require registration charge, driving licence. This results in segment. Only a few options are there and majority
many customers shying away from buying EVs. among them are not from established trustworthy brands.
This drives the customers away from buying EVs.
Advantages:
1.) Low cost of ownership - It is a proven fact by many
researches that EVs offer way lower cost of ownership in 29
their lifecycle compared to fossil fuel powered vehicles. At
times, the cost of ownership for an EV is as lower as 27%
than a fossil fuel vehicle. The incessant rise of petrol and
diesel costs are increasing the cost of ownership further
for the conventional vehicles. 2.) Easier to maintenance - An internal combustion
engine usually contains more than 2,000 moving parts.
An electric motor onboard an EV on the other hand
contain around 20 moving parts. The only major
components in an EV are the battery and the electric
motor. This makes the EVs much easier for maintenance,
3.) State EV policies - Several state governments reducing the cost of ownership significantly.
across India have already announced their respective
EV policies. Some of them promote the supply side,
while some promote the demand side. There are EV
policies that promote both the supply and demand side 4.) Cleaner environment - The direct and obvious
through incentives, discounts and other benefits. Delhi advantage of adopting electric mobility is the cleaner
Ev policy for example is one such state EV policy. These environment. Electric vehicles don't emit pollutants into
policies are driving the growth of the electric vehicles in the air like their ICE counterparts. The EVs are silent as
India, in a slow but steady manner. well unlike their ICE counterparts. This means EVs ensure
a cleaner and quieter environment.
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Hybrid Electric Vehicles (HEV)

► What is HEV?
► As proposed by Technical
Committee 69 (Electric Road
Vehicles) of the International
Electrotechnical Commission, a
HEV is a vehicle in which
propulsion energy is available
from two or more kinds or types
of energy stores, sources or
converters, and at least one of
them can deliver electrical
energy.

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Classification of Hybrid Electric Vehicle

► Series hybrid
► Parallel hybrid
► Series-parallel hybrid and
► Complex hybrid.

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BMW i3 Chevy Volt 26-08-2021

Power Flow Control in Series Hybrid

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Mode 1, normal driving or Mode 3, braking or deceleration

acceleration

Mode 4, vehicle at stop

Mode 2, light load 26-08-2021
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Honda Civic Chevrolet Malibu

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 Power Flow Control in Parallel Hybrid

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Mode 1, start up Mode 3, braking or deceleration

Mode 2, normal driving Mode 4, light load

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Toyota Prius Lexus RX

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Mode 1, start up Mode 2, acceleration Mode 3, normal drive

Mode 4, braking or deceleration Mode 5, battery charging during driving Mode 6, battery charging during standstill

The various operating modes of ICE dominated system 26-08-2021

 The operating modes of EM dominated system

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Mode 1, start up Mode 2, acceleration Mode 3, normal drive

Mode 5, battery charging during driving Mode 6, battery charging during standstill
Mode 4, braking or deceleration
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Power split device in hybrid vehicle
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Condition 1- Vehicle is Stationary and engine is on idle.
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1.The car always starts with the electric motor powering the
wheels.
2.But the engine is allowed to idle and run the generator which
charges the batteries and warms the engine before both of
them are put in to action.
3.For the vehicle to move the Ring Gear must move.

Condition 2- Vehicle is Moving forward:

1.The Electric Motor Drive provides power to the driving wheels.

2.Notice that the outer Ring Gear is rotating which proves that power
is being transmitted to the wheels.
3.The planetary gear carrier which is connected to the ICE is not
moving.

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Condition 3: Acceleration Above 60kmph
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1.The car accelerates and needs more power.

2.The ECU acknowledges this need for extra power.
It starts the generator which in turn starts the
engine.
3.The Engine provides driving power to the wheels.

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 COMPLEX HYBRID CONTROL

Dual-axle (front-hybrid rear-electric) complex hybrid operating modes. 49

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 Toyota Introduces New Hybrid System
New Technology Leads to World's First 4WD
Hybrid Powertrain
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Tokyo―TOYOTA MOTOR CORPORATION

(TMC), riding on the success of its
hot-selling hybrid Prius sedan, leaped two
more steps ahead of the competition
today when it unveiled its new
minivan-minded Toyota Hybrid
System-CVT (THS-C) and the world's first
hybrid 4-wheel-drive powertrain, the
"E-Four."

https://global.toyota/en/detail/8097499

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Dual-axle (front-electric rear-hybrid) complex hybrid operating modes

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Chevrolet Cadillac
Tahoe Escalade
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Electric Vehicles Timeline: 2018
– 2040
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Mild Hybrids

► A hybrid electric vehicle can perform at least one or more of the following
functions:
• engine idle stop/start
• electric torque assistance (fill and boost)
• energy recuperation (regenerative braking)
• electric driving
• battery charging (during driving)
• battery charging (from the grid)

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Idle stop/start function

► When the vehicle is stationary, the stop/start (S&S) function switches off the internal
combustion engine, without the intervention of the driver (through the ignition key).
► This function reduces the overall fuel consumption of the vehicle. When the driver shows the
intention to drive (clutch pedal pressed or brake pedal released) the engine is restarted
automatically.
► Most of the vehicles with idle stop/start function have also some sort of energy management
function, which optimizes the consumption of the low voltage (12 V) battery energy.
► In a conventional ICE vehicle, without any energy management, the primary function of the low
voltage battery is to generate the electrical energy required for the engine to start.
► After the engine is running, the electrical energy for all the electrical consumers is supplied by
the alternator (generator), which is putting a load torque on the engine.

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► If the vehicle has an energy management function, even if the engine is running,
the battery supplies electrical energy to the consumers. 56
► In this way, the alternator doesn’t have to produce electrical energy, the load
torque of the alternator is nearly zero, and the fuel consumption is reduces.
► Further, the battery is recharged when the engine is working in the most fuel
efficient points or when the vehicle is braking (through energy recuperation).

It comes with an Energy Smart

Management (ESM) function which
allows energy created under braking
and deceleration to be stored in the
low voltage battery, helping to further
reduce fuel consumption.

Renault 1.6 dCi engine (Micro Hybrid)

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(b) Micro hybrid HEVs 48 V

configuration.

(a) Micro hybrid HEVs 12 V

configuration

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Mahindra Micro Hybrid

Scorpio Micro Hybrid version which comes equipped with a

start-stop system. This system can detect when the engine is
idling in neutral gear and would automatically turn off the
engine after 2-3 seconds. To start the engine again, all that the
driver has to do is engage the clutch pedal.

Vehicles that have idle stop/start and energy management

functions are called Micro Hybrids. 26-08-2021
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Mild Hybrid - Electric torque assistance

► The electric motor can provide additional torque to the wheel, improving the overall torque
response of the powertrain. There are two types of torque assistance:
• torque fill
• torque boost
► When the drive is pressing the accelerator pedal, it requests more torque from the powertrain.
An internal combustion engine (especially diesel) has a certain delay in delivering the
requested torque. The torque response delay of the internal combustion engine has several
causes:
• the inertia of the air in the intake manifold
• the mechanical inertia of the moving parts
• the torque limitation (to prevent smoke in the exhaust)
► In these situations, called torque transients (engine is changing the operating point), the
electric motor can assist, providing additional torque, which compensates for the engine torque
response delay. This function is called torque filling.
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► An internal combustion engine has a maximum torque capability, which
depends on the engine speed. By adding the electric motor torque, additional to 60
the engine torque, the maximum overall torque of the powertrain is increased
(positive offset). This function is called torque boost and can be supplied only for
a short duration of time (order of seconds) due to battery depletion.
► The function of electric torque assistance is usually provided by mild hybrid
electric vehicles (MHEV), full hybrid electric vehicles (FHEV) and plug-in hybrid
electric vehicles (PHEV).

Honda IMA powertrain (MHEV)

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Mahindra Intelli-Hybrid

► Mahindra Scorpio 2.2-litre mHawk with

Intelli-Hybrid technology.
► Intelli-Hybrid technology reduces fuel consumption
by around seven per cent.
► It achieves this by assisting the diesel engine with
electric power during acceleration.
► The mild hybrid technology also automatically
switches off the engine within 3 seconds of the
vehicle being stationary.
► Mahindra's Intelli-Hybrid technology utilises brake
energy to charge the battery.

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► Just like the Micro Hybrid, the Intelli-Hybrid
technology also gets start-stop technology. 62
► Additionally, it offers power assist and
regenerative braking function and has a gear shift
indicator on the instrument console.
► To accommodate the Intelli-Hybrid technology, This is what Mahindra calls
Mahindra utilises a more powerful 14V battery. the 'Belt Driven Starter
Generator' or BSG
► The conventional alternator has been replaced by
an electric motor which is also mounted on the
engine.
► Mahindra calls it the 'Belt Driven Starter
Generator' or BSG and says that it performs a
power assist as well as energy re-generation
function.

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• The BSG acts like a generator by recovering the kinetic
energy which usually gets lost during braking and converts it 63
to electricity.
• This is in turn utilised to charge the battery.
• The sensors and controllers can detect when the vehicle is
braking and switches into generator mode. It then harnesses
the braking energy by working as a generator.
• This technology is effective while the vehicle is being driven
in typical rush hour stop-and-go traffic.

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• The sensors and controllers in the Intelli-Hybrid system can 64
also detect if the driver has started to accelerate hard
depending on the accelerator pedal input.
• It then goes into power assist mode, and the BSG begins to
function like a typical electric motor.
• It takes power from the re-generated energy stored in the
battery and augments the engine torque.
• It assists the diesel engine during overtaking manoeuvre by
providing additional power.
• Mahindra says that by playing this dual role and enabling
better power optimisation, the Intelli-Hybrid system improves
the engines efficiency.

This diagram represents the power flow when the BSG is

performing a power assist function 26-08-2021
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The entire battery management system has been developed
completely in-house.

The electric motor has been sourced from Valeo while Bosch has
developed the software which controls its interaction with the
diesel engine.
Compared to the Micro Hybrid system, the Intelli-Hybrid offers a bit
more technology on paper.

The powertrain has been modified to accommodate the BSG, and the
front-end auxiliary drive is revamped.
This is a schematic diagram of the Mahindra
Mahindra also says that the Scorpio Intelli-Hybrid is more
Intelli-Hybrid technology
fuel-efficient than the Scorpio Micro Hybrid.

Also, as per standard MIDC test cycles, the Scorpio Intelli-Hybrid is

around 7 per cent more efficient than the regular version.
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The ratio of power developed by an electric motor in a
hybrid vehicle to the total power consumed by the
vehicle is known as degree of hybridization.
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Power flow control

Due to the variations in HEV configurations, different power control strategies are necessary
to regulate the power flow to or from different components. All the control strategies aim
satisfy the following goals:
► maximum fuel efficiency
► minimum emissions
► minimum system costs
► good driving performance

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Power flow control

► The design of power control strategies for HEVs involves different considerations such as:
► Optimal ICE operating point
► Optimal ICE operating line
► Safe battery voltage

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 Function of the Control System in HEVs and EVs
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The major functions of the control system are:
i. to maximize the fuel efficiency
ii. to minimize the exhaust emissions.

The minor functions of the control system are component

monitoring and protection such as:
i. Battery state of charge (SOC) monitoring
ii. Battery temperature monitoring
iii. EM overheating
iv. ICE overheating

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The modes of operation of drive train

Schematics of a hybrid drivetrain

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Basic control system

Basic control system for ICE speed control

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Control system for vehicle speed control
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Control architecture of HEV
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Plug-in Hybrid Electric Vehicle

► Plug-in hybrid electric

vehicles (PHEVs) use
batteries to power an
electric motor and another
fuel, such as gasoline, to
power an internal
combustion engine (ICE).
PHEV batteries can be
charged using a wall
outlet or charging
equipment, by the ICE, or
through regenerative
braking.

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The Lohner-Porsche Mixte

Hybrid was the first
gasoline-electric plug-in
hybrid automobile

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Mitsubishi Outlander PHEV is

the world's all-time
best-selling plug-in hybrid

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Top selling highway legal plug-in hybrid electric cars between 2008 and 2020
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