Development of a Concept Electric Vehicle Drivetrain
GRAD 59000
14 July 2022
Sachi Rajadnya
Dr. Mitchell L. Springer
Project Scope
The proposed design project is to develop a concept electric vehicle drivetrain. The battery material should have a good specific energy, specific power, capacity, and discharge power. Electric machine design should be optimized such that the stored energy from the battery can be delivered to the road wheels as efficiently as possible. The motor layout will ensure an optimum range and horsepower. The vehicle should have suitable performance in city, highway, high speed, and cold temperature conditions. The thermal management system must adequately and safely cool the battery pack. And finally, the battery management system but be durable, accurate, and fast.
Battery material should have a good specific energy, specific power, capacity, and discharge power.
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Electric machine design should be optimized such that the stored energy from the battery can be delivered to the road wheels as efficiently as possible.
The vehicle should have suitable performance in city, highway, high speed, and cold temperature conditions.
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Thermal management system must adequately and safely cool the battery pack.
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Motor layout will ensure an optimum range and horsepower.
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Battery management system but be durable, accurate, and fast.
Stated Requirements
Derived Requirements
Battery Material and Environment Impact
The process used to collect lithium for the Li-Ion battery packs will priotitize the limitation of air and soil contamination.
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Ride Feel
The vehicle center of gravity is low and will provide the driver a stable ride experience by having a 400V pack.
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Charging
The vehicle charging system must be AC conductive to use in present-day EV charging infrastructure.
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Derived Requirements (Cont.)
Wireless Battery Management
A wireless battery management system will be used to combat fickle internal electrical component connections.
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Smart Charging
There will be intelligent functionalities to control the charging power, charging time duration, and charging power flow direction.
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AC Induction Motor
A 3-phase AC input will be used to create a rotating magnetic field to induce a voltage and current in its windings.
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Work Breakdown Structure (WBS)
1. Concept EV Drivetrain
1.1 EV Design
1.1.1 Source Pack Materials
1.1.2 Design Electric Machine(s) and Layout
1.1.3 Research Thermal Management Method
1.2 Simulation Tests
1.2.1 Range Test
1.2.2 Module and Cell Communication Test
1.2.3 Charge Type Comparison
1.3 EV Prototype
1.3.1 Receive lab approval
1.3.2 Integrate Components
1.3.3 Pass Safety Inspection
WBS Dictionaries
The electric machine (which can be an induction, permanent magnet AC, or synchronous reluctance motor), must be designed such thatthe kinetic energy of the vehicle generates as much electrical power as possible and that the stored energy from the battery can be delivered to the road wheels as efficiently as possible. EV motors differ from industrial motors, as they generally require high low-speed torque, enabling the vehicle to meet acceleration requirements. A wide range of operating speed is also required. In contrast, industrial motors are generally optimized for specific rated conditions and have less dynamic operating conditions. With this, the motor layout (single or dual) can be decided, where one motor can drive either the front or rear axles or two motors can be used for driving both the front and rear axles.
1.1.2 Design Electric Machine(s) and Layout
The battery management system in an electric vehicle is an embedded system that protects the safety of the battery operated device’s operator, protects the cells of battery from damage in failure cases, prolongs battery life, maintains the battery in a state in which it can fulfills its functional requirements, and informs the application controller on how to make the best use of the pack at the moment. In order for this to happen, a software test will be used to see how fast and accurately the battery pack modules and cells can send the appropriate information back to the control system.
1.2.2 Module and Cell Communication Test
Responsibility Assignment Matrix
P – Primary
S - Secondary
R – Review
A - Approval
Master Schedule
Each block unit represents one week of time.
Human Resource Plan
Risk Management: Analysis to Handling
Potential Effects
Functional damage and potential self-sustaining vehicle fire
Potential Problem Battery pack overheats
Likely Causes
Overcharging during rapid charge and thermal shock
Contingent Actions
Add conductive pads around pack
Risk Monitoring System
Battery management software constantly checks pack health
Preventative Action
Use immersive cooling liquid to maintain battery temperature
Risk Analysis Results
Risk Control Actions
Reduce
Seriousness
Detect�Problem
Reduce
Probability
Provide
Status
Trigger Action