Everything that you need to know about EV | Basics of an Electric Car | Certified EV Masterclass

Introduction

This tutorial provides a comprehensive overview of electric vehicles (EVs) based on a masterclass series that delves into the fundamental concepts, workings, and components of EVs. It aims to inform readers about the evolution of electric mobility, the technology behind EVs, and practical insights for understanding their operation.

Chapter 1: Why are EV numbers low today

• Historical Context: Electric vehicles have been around for over a century, but their adoption has been slow due to high costs and limited demand.
• Cost Factors: The production of electric vehicles remains low-volume, leading to higher costs. This creates a chicken-and-egg scenario—lower adoption leads to less production, which in turn keeps prices high.
• Government Intervention: Increased government subsidies and consumer education about the benefits of EVs can help shift demand and improve adoption rates.

Chapter 2: Types of Electric Vehicles

• Micro Hybrid Vehicles: Use a battery and starter motor to aid the combustion engine.
• Mild Hybrid Vehicles: Example: Maruti Suzuki Ertiga, partially powered by electric technology.
• Full Hybrid Vehicles: Example: Toyota Prius, capable of running solely on electric power without any fuel.
• Pure Electric Vehicles: Operate entirely on electric power, with no combustion engine.

Chapter 3: Fuel vs Electricity

• Efficiency Comparison:
  • Traditional internal combustion engine (ICE) vehicles convert chemical energy to thermal to mechanical energy, resulting in lower efficiency.
  • Electric vehicles directly convert stored electrical energy to mechanical energy, enhancing efficiency.
• Cost Efficiency:
  • Running costs for ICE vehicles are around 6-7 rupees/km, while electric vehicles can cost less than 1 rupee/km due to cheaper electricity.

Chapter 4: Building the Skill-Lync EV

• Mechanical Design: Understanding the basic structure, including the chassis, suspension, and wheel assembly.
• Electrical Components: Battery and motor integration for propulsion.
• Testing and Analysis: Conducting real-world experiments to gather data on performance metrics.

Chapter 5: Powertrain Architecture

• Motor Configurations:
  • Rear-wheel drive, front-wheel drive, and all-wheel drive configurations.
• Single-Speed Transmission: Most electric vehicles use a single-speed gearbox due to the motor's ability to operate efficiently over a wide speed range.
• Reverse Functionality: Achieved by reversing the current flow in the motor.

Chapter 6: Types of Motors

• Outrunner Motors: Typically used in scooters, housed in the wheel structure without requiring a transmission.
• Inrunner Motors: Require a transmission system, commonly used in conventional electric vehicles.

Chapter 7: Choosing the Best Motor for the Job

• Cost and Availability: Permanent magnet motors are more expensive due to raw material costs compared to non-permanent magnet motors.
• Torque to Weight Ratio: Permanent magnet motors provide better performance due to concentrated magnetic fields.
• Control Complexity: Permanent magnet motors are easier to control compared to non-permanent magnet motors.

Chapter 8: Cooling the Motor

• Cooling Methods:
  • Natural cooling through air circulation.
  • Advanced cooling systems may use forced air or liquid cooling for high-power motors.

Chapter 9: Electronic Control Systems

• Motor Controllers: Regulate the power supply from the battery to the motor.
• Pulse Width Modulation: Used to control the speed and torque of the motor by varying the voltage.

Chapter 10: Rechargeable Batteries

• Battery Types:
  • Lead-acid, nickel-metal hydride, and lithium-ion batteries.
• Performance Characteristics: Lithium-ion batteries offer higher energy density and longer life cycles compared to lead-acid batteries.

Chapter 11: Battery Management Systems

• Purpose: Monitor and protect battery packs from overcharging, deep discharge, and temperature extremes.
• Key Components: Include voltage, current, and temperature sensors, along with protective circuitry.

Chapter 12: Charging an EV

• Charging Methods: AC charging (using onboard chargers) and DC fast charging (using external charging stations).
• Charging Time: Dependent on battery capacity and charger output (e.g., a 100 amp-hour battery charged at 10 amps takes approximately 10 hours).

Chapter 13: Powering Auxiliary Systems

• Separation of Systems: Auxiliary systems operate on lower voltages (typically 12V) and require different batteries or converters to ensure safety.
• Wiring Harness: Connects all components, ensuring organized routing and minimizing electromagnetic interference.

Conclusion

This guide has outlined the essential concepts of electric vehicles, from their historical context to the technology that drives them today. Understanding these components not only enhances your knowledge of EVs but also prepares you for potential career paths in the automotive and engineering sectors. For those interested in pursuing a career in EV design and development, consider enrolling in specialized programs to deepen your expertise.