-- Graduation Project 2017 -- Faculty of engineering university , Electrical Engineering Department , Power & Machines Section -- Our project is Electric car -- This link of our book : https://drive.google.com/file/d/0B1-PUweW3orNc2R6YWFWSzRJeDQ/view?usp=sharing -- This presentation contain 1- Introduction History Of Electric Car Difference Between Engine and Electric Car Why Electric Car and Why not? Types Of Electric Car How It Works? 2. Main Components Of Electric Car Motor Controller Batteries Transmission Braking Steering

1. Electric Car
Supervisors
Prof.Dr.Samir Deghedie
Dr. Mohamed El-Habrouk
6th July 2017

2. Presented by :
2
Aya Mohamed Ali Mohamed
Ahmed Khaled Hussin Mohamed
Ahmed Abd-Elazeem El-sayed
Ahmed Essam Ibrahim
Rogeh Wageh Essa
Karim Ragab El-sayed Mohamed
Kirollos Magdy khela
Lina Mohamed Mohamed Abdelsalam
Mayada Aladdin Mohamed
Hager Reda Mohamed Nabeh

3. Objective
3
•Spreading the field of electric cars.
•Expanding knowledge of it.
•Trend to renewable energy.
•Reducing the use of non-renewable
energy and environmental impact of it.

4. Outline
1. Introduction
• History Of Electric Car
• Difference Between Engine and Electric Car
• Why Electric Car and Why not?
• Types Of Electric Car
• How It Works?
4

5. Outline
2. Main Components Of Electric Car
• Motor
• Controller
• Batteries
• Transmission
• Braking
• Steering
3. Electric Go Kart Prototype
5

6. Outline
1. Introduction
• History Of Electric Car
• Difference Between Engine and Electric Car
• Why Electric Car and Why not?
• Types Of Electric Car
• How It Works?
6

7. 7
History Of Electric CarIntroduction

8. 8
Start of the electric carIntroduction
 By the 1900s, larger secondary batteries became available.

9. 9
 First commercial line in NYC
Introduction
The electric car of the 1970s, the Citi-car.

10. 10
 Now adays
Introduction
A recent model of the commercial hybrid electric vehicle (HEV)

11. 11
 Propagation of electric cars
Introduction

12. 12
Difference Between Engine and
Electric Car
Introduction
• But the transmission system of them is the same.

13. 13
Difference Between Engine and
Electric Car
Introduction

14. 14
Difference Between Engine and
Electric Car
Introduction

15. 15
Difference Between Engine and
Electric Car
Introduction

16. 16
Why Electric Car & Why Not?Introduction
• No Gas Required
• Savings
• No Emissions
• Safe to Drive
• Low Maintenance
• Reduced Noise Pollution
• Recharge Points
• Short Driving Range and Speed
• Battery Replacement

17. 17
Types of Electric CarIntroduction

18. 18
How It Works?Introduction

19. Outline
2. Main Components Of Electric Car
• Motor
• Controller
• Batteries
• Transmission
• Braking
• Steering
3. Electric Go Kart Prototype
19

20. 20
Transmission
Battery
Steering
Braking
Controller
Motor
Electric Car
Main Components Of Electric Car

21. Main Components Of Electric Car
Motors
21
• Classifications of
Motors
• Difference between
Ac and Dc motors.
• DC Motors.

22. 22
Classifications of MotorsComponents
Electric Motors
Alternating Current (AC)
Motors
Direct Current (DC)
Motors

23. 23
Difference between Ac and
Dc motors
Components
• A.C. motors are powered from alternating current
(A.C.) while D.C. motors are powered from direct
current (D.C.), such as batteries, D.C. power
supplies or an AC-to-DC power converter.

24. 24
Difference between Ac and
Dc motors
Components
• D.C wound field motors are constructed with
brushes and a commutator, which add to the
maintenance, limit the speed and usually reduce
the life expectancy of brushed D.C. motors. A.C.
induction motors do not use brushes.

25. 25
Difference between Ac and
Dc motors
Components
• The speed of a D.C. motor is controlled by varying the
armature winding’s current while the speed of an A.C.
motor is controlled by varying the frequency, which is
commonly done with an adjustable frequency drive
control.

26. 26
Difference between Ac and
Dc motors
Components
Dc Motor Ac Motor

27. 27
Dc motorComponents
Advantages 1- Speed control over a wide range both above
and below the rated speed.
2- High starting torque .
3- Quick starting, stopping, reversing and
acceleration.
4- Free from harmonics.
Disadvantages 1- High initial cost.
2- Increased operation and maintenance cost.
3- Cannot operate in explosive and hazard
conditions due to sparking occur at brush.

28. 28
Ac motorComponents
Advantages 1- produces less heat, friction and are lighter
and more efficient .
2- The simple design of the AC motor results in
extremely reliable, low maintenance operation.
3- Low Cost due to the simple design of the
motor.
Disadvantages 1- Inability to operate at low speeds
2- produce eddy currents due to the production
of a back emf.

29. 29
Go Kart
• In our project we decided to use a dc motor
in order to avoid using an inverter to power
the motor and to directly use dc voltage
source and to obtain high starting torque
and to have the ability to control the speed
and also to reverse its direction by reversing
armature current.

30. 30
DC MotorsComponents
An Electric DC motor is a machine which converts electric energy
into mechanical energy.

31. 31
Theory of WorkComponents
• Electric motors run by electromagnetism.
• The interaction of two magnetic fields
happens.
• These two fields result in a torque which
tends to rotate the rotor.

32. 32
Types Of DC MotorsComponents
1. Brushed DC motor

33. 33
Types of Brushed DC MotorComponents
1. Separately Excited.

34. 34
Types of Brushed DC MotorComponents
2. Permanent Magnet.

35. 35
Types of Brushed DC MotorComponents
3. Self Excited DC Motor:
• Shunt wound DC motor.
• Series wound DC motor.
• Compound wound DC motor.

36. 36
Types of Brushed DC MotorComponents
• Shunt Wound DC Motor.

37. 37
• Torque speed curve

38. 38
Types of Brushed DC MotorComponents
• Series Wound DC Motor.
The entire armature current
flows through the field
winding as its connected in
series to the armature
winding.

39. 39
Types of Brushed DC MotorComponents
• Torque speed curve

40. 40
Types of Brushed DC MotorComponents
• Reverse direction of series motor

41. 41
Types of Brushed DC MotorComponents
• Compound Wound DC Motor.
 Excitation can be obtained by
combining the operational
characteristic of both the shunt
and series excited dc motor .
 It contains the field winding
connected both in series and in
parallel to the armature winding.

42. 42
Components
• The compound wound DC motor can
further be subdivided into 2 major types
on the basis of its field winding
connection with respect to the armature
winding, and they are:

43. 43
Components
• Long Shunt Compound Wound DC Motor:
Shunt field winding is connected in parallel
across the series combination of both the
armature and series field coil.

44. 44
Components
• Short Shunt Compound Wound DC Motor:
The shunt field winding is connected in parallel
across the armature winding only. And series
field coil is exposed to the entire supply current,
before being split up into armature and shunt
field current

45. 45
Components
• The compound wound DC motor can further
be sub divided into 2 types depending upon
excitation.

46. 46
Components
• Cumulative Compounding of DC Motor:
Shunt field flux produced by the shunt
winding assists or enhances the effect of
main field flux, produced by the series
winding.

47. 47
Components
• Differential Compounding of DC Motor:
-The flux due to the shunt field winding
diminishes the effect of the main series
winding.
-The net flux produced in this case is lesser
than the original flux and hence does not find
much of a practical application.

48. Type speed control starting torque running torque
Shunt dc constant , medium ( 125 to 200 % of FLT)
Motor adjustable
Series dc varying very heavy ( 300 to 350 % of FLT)
Motor (0 to max )
Compound constant heavy (130 to 260 % of FLT)
Dc motor

49. 49
Components

50. 51
Components 2. Brushless DC Motor

51. 53
Types of Brushless DC MotorsComponents
• Inner Rotor Design
The rotor is located in the
center of the motor and the
stator winding surround the
rotor.
• Outer Rotor Design
The rotor surrounds the
winding which is located in
the core of the motor.

52. 54
Motor SelectionComponents
Rolling resistance force
Frr=Crrmg
Aerodynamic drag
Fd= .5ρACdv^2
Hill climbing force
Fd= mgsin(ψ)
Acceleration force
Fa= ma
Total tractive effort
Fte= Frr+ Fd+ Fg + Fa

53. 55
Motor SelectionComponents
To calculate the total torque and power of the motor
 Total tractive effort
Fte= Frr+ Fd+ Fg + Fa
 Traction Torque
T = Fte × r x Rf
 Traction Speed r/s
W =
𝑉
𝑟
 Calculating power
Power (KW) = (Torque (Nm) x Speed)

54. 56
Prototype CalculationsGo Kart
• M=120 kg (car + person)
• V=30 km/HR=8 m/s
• Rwheel = 0.19 m
• Rf =0.67
• Crr =0.012

55. 57
Prototype CalculationsGo Kart
• RR=120x0.012x9.81=14.1264N
• GR is neglecting for low cost
• FA=120*8/5 =192N
•  a = (final velocity−initial
velocity)/(time)

56. 58
Prototype CalculationsGo Kart
• TTE=14.1264+192=206.1264N
• T (torque) = .67x.19x206.1264 =27N.m
• Rpm = 8/(0.10472x.19)=400
• W=42 r/s
• P=27x42=1.131 kw =1.5 HP

57. 59
Our MotorGo Kart
• We choose motor 1.2 kW ,
rated current 100 A and 3000
rpm and we made gear box
to reduce the rpm from 3000
to 400.

58. 60
Go Kart
Choosing The Wire Of The Motor
** Voltage = 24 v
Max current=100A
Length =
Cable size =

59. 61
Transmission
Battery
Steering
Braking
Controller
Motor
Electric Car
Main Components Of Electric Car

60. Main Components Of Electric Car
Controller
62
• Controller and driver
• Speed Control
• Chopper
• Buck
• H-Bridge
• Closed loop Control

61. 63
Controller and Driver Function
Controller is the logic that decides upon and
specifies the driver's output.
Driver is responsible for supplying the actual
output power to the device.
Components
Components

62. 64
Controller of Electric Car
Components
Components

63. 65
Speed Control of DC Motor
• By varying the supply voltage
• By varying the field flux
Components
Components

64. 66
Speed Control of DC Motor
• By varying the supply voltage
• By varying the field flux
Components
Components

65. 67
Methods of Varying Supply
Voltage
• Chopper
Components
Components
Using ON-OFF Control
to change PWM of
Output Voltage
MOSFET ONMOSFET OFF

66. 68
Methods of Varying Supply
Voltage
• Chopper
Components
Components
Components

67. 69
Methods of Varying Supply
Voltage
• Buck (Step Down Converter)
Components
Components
Components
Components
Inductor and Capacitor
store energy to keep output
voltage constant
MOSFET ONMOSFETOFF

68. 70
Methods of Varying Supply
Voltage
• Buck (Step Down Converter)
Matlab Simulation
Components
Components

69. 71
Four Quadrant Operation of DC
Motor
Components
Components

70. 72
Direction Control of DC Motor
Components
Components
1. Relays
Once the coil is energized,
contacts change its normal
state and voltage is
reversed across the motor

71. 73
Direction Control of DC Motor
Components
Components
2. H-Bridge (Four quadrant Chopper)
Components
4 MOSFETs
4 Flywheel DiodesQ1 & Q4 ONQ2 & Q3 ONQ1 & Q2 ON
Shoot-through

72. 74
Direction Control of DC MotorComponents
2. H-Bridge (Four quadrant Chopper)

73. 75
High current H-Bridge circuit
Components
Components
• Electrical Noise
• Mosfet Driver
• Shoot-through
• Opto-coupler
• Heat sink

74. 76
Prototype ControllerGo Kart
• 100A DC motor drive Module
High Power motor speed
Control Dual Channel H-
bridge.

75. 77
Prototype ControllerGo Kart
• The module use 8 MOSFETs
for dual H-Bridge
• MOSFET model is irfb3077

76. 78
Prototype ControllerGo Kart
IR2110
High and low MOSFET driver

77. 79
Prototype ControllerGo Kart
• LM2576
3.0 A, 15 V, Step−Down
Switching Regulator

78. 80
Prototype ControllerGo Kart
• HCPL-2631
Dual Channel,
High Speed Optocouplers
f = 1 MHz

79. 81
Open Loop Speed Control
Components
Components

80. 82
Closed Loop Speed Control
Components
Components

81. 83
Closed Loop DC Motor Speed
Control
Components
Components
Matlab Model
• Circuit Diagram

82. 84
Closed Loop DC Motor Speed
Control
Components
Components
Matlab Model
• DC Motor Subsystem
Components

83. 85
Closed Loop DC Motor Speed
Control
Components
Components
Matlab Model
• Speed and Current Graphs
T = 0.5 n.m
Components

84. 86
Closed Loop DC Motor Speed
Control
Components
Matlab Model
• Speed and Current Graphs
T = 3.6 n.m

85. 87
Closed Loop DC Motor Speed
Control
Components
Current Feedback
Components
• Current feed back is
used to Control Motor
Current Besides
Speed Control

86. 88
Closed Loop DC Motor Speed
Control
Components
PID Control
ComponentsComponents
• Adjust Kp to control
rising and settling
time
• Adjust Ki to eliminate
steady state error

87. 89
Transmission
Battery
Steering
Braking
Controller
Motor
Electric Car
Main Components Of Electric Car

88. Main Components Of Electric Car
Batteries (rechargeable
batteries)
90
• Its Function In Electric
Car.
• Battery Construction.
• Battery Specifications .
• Different Types Of
Batteries For Electric Car.

89. 91
Function In Electric CarComponents
The heart of an electric car is its
battery. Unlike the batteries in most
cars, which primarily serve to start the
engine and run accessories like
the radio or air conditioner, the battery
in an electric car runs everything. Most
importantly, it runs the electric motor or
it runs a controller which in turn runs
the electric motor ,So it needs to be
powerful and long lasting enough to
take drivers where they need to go with
a minimum of recharging.

90. 92
Battery ConstructionComponents
1. Cover
2. Container
3. Terminal
4. Safety Valve
5. Negative Plate
6. Separator
7. Positive Plate

91. 93
Components
SOC=
𝑟𝑒𝑚𝑎𝑖𝑛𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑟𝑎𝑡𝑒𝑑 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
DOD=1-SOCDepth of discharge
Nominal Capacity
(Ah)
Cycle life
Nominal Voltage (V)
State of discharge
Battery Specifications
Self discharge

92. 95
Components Different Types Of Batteries
For Electric Car
Lead acid Lithium–ion
Cost Inexpensive Expensive
Self discharge 5% per month 1–2% per month
Cycle life Lower Long cycle life
Weight Higher Light weight
Pack Available in pack Form Available only in cell form
(3.7 v)
Electrolyte Can be liquid or solid No liquid electrolyte

93. 96
Lead Acid BatteriesComponents
 Nominal voltage  2.1 v/cell
 Discharge curve (for 12v lead acid battery)

94. 97
Components
97
Components
Types of Lead acid
batteries
Construction
Sealed (Dry)
(VRLA)
Flooded (Wet)
Type
Deep cycle
Starting, lighting
and ignition (SLI)

95. 99
Prototype BatteriesGo Kart
• Type: sealed lead acid
• Nominal voltage : 12 v
• Capacity : 70 Ah
• Number of batteries : 2
• Connection : series

96. Main Components Of Electric Car
Charging system
100
• Introduction
• Levels of charging
• Types of Charging
• How to stop
Charging process?

97. 101
IntroductionComponents

98. 102
Levels Of ChargingComponents

99. 103
Types of ChargingComponents
1. Conductive charging

100. 104
Types of ChargingComponents
2. Wireless Charging
 Main concept
• Wireless power is transferred via electromagnetic
waves.
• Electromagnetic wave is mainly divided into electric
and magnetic waves.

101. 105
Wireless Power transferComponents
 Principle of operation

102. 106
WPT TechniquesComponents
WPT
Reactive
Near Field
Radiative
Far Field
IPT CPT EM-WPT
Non
R-WPT
µ-
waves
LaserR-WPT

103. 107
WPT Techniques (IPT)Components
• Depends on the magnetic coupling
between 2 coils.
Field can be guided within safety limits.
 Non R-WPT
• Used in the short range transfer (< 10 cm).
• Ex: Cordless tooth brush and charging pads.
 R-WPT
• Coils are operating with their resonant frequency.
• Transfer range is extended to few meters.

104. 108
WPT Techniques (CPT)Components
• Depends on the capacitive coupling
between two electrodes.
• Limited to low-power applications; as
high voltage on electrodes can be
hazardous.
• It is simpler in design and lower in cost
than IPT systems.
• It can be used in wireless battery
charger and transferring power
between substrate layers in integrated
circuits.

105. 109
WPT Techniques (EM-WPT)Components
• It is based on the electromagnetic field
radiation in the far field region.
• It can transmit high power for long distances.
• It requires a clear line of sight to transfer
power, also there is NO safety through this
line.
 Microwaves radiation:
It uses high energy microwave source to transfer
power from the transmitting antenna to the
receiving antenna.
 Laser radiation:
It uses high intensity laser beam to transfer
power from laser source to photovoltaic cells.

106. 110
Types of ChargingComponents
3. Battery Swapping

107. 111
How to stop Charging process?Components
• Timer
• Temperature cut off
• Temperature change rate
• Minimum current
• Voltage limit
• Voltage change rate

108. 112
Prototype method to Charge
batteries
Go kart

109. 113
Transmission
Battery
Steering
Braking
Controller
Motor
Electric Car
Main Components Of Electric Car

110. 114
Transmission SystemComponents
1. Clutch
2. Gearbox
3. Driveshaft
4. Differential

111. 115
1. ClutchComponents
Types of clutch
Friction
Electromagnetic vacuam
centerfiugal

112. 116
Friction clutchComponents

113. 117
1. ClutchComponents
Types of clutch
Friction
Electromagnetic vacuam
centerfiugal

114. 118
Electromagnetic clutchComponents

115. 119
Prototype ClutchGo Kart
• To make clutch in our
prototype we used a clutch
of 12 volt air conditioner
compressor.

116. 120
2. Gear boxComponents

117. 121
Prototype GearboxGo Kart

118. 122
3. Propeller shaftComponents

119. 123
Prototype TransmissionGo Kart
High efficiency

120. 124
4. DifferentialComponents

121. 125
Prototype Transmission systemGo Kart

122. 126
Transmission
Battery
Steering
Braking
Controller
Motor
Electric Car
Main Components Of Electric Car

123. Main Components Of Electric Car
Braking System
127
• Introduction.
• Basic structure.
• Types of braking
systems

124. 128
IntroductionComponents
Braking depends mainly on friction to convert
kinetic energy to heat energy and stop the
vehicle .
• Main components of any braking system
a) Moving part around its axis
b) Fixed part mounted to the vehicle body

125. 129
IntroductionComponents
Leverage it multiplies the force of the
leg several times before transmitting it
to the braking fluid

126. 130
IntroductionComponents
Hydraulic system ,its main aim that the force applied at
a point is transmitted to another point using an
incompressible fluid

127. 131
IntroductionComponents
 Friction
It measures how hard to move an object
 Factors affecting friction
• The condition of the surfaces in contact
• The weight of an object

128. 132
Different Types of Mechanical
Braking
Components
Disc Drum Bike Vehicles drawn by
horses

129. 133
Basic StructureComponents
• Brake Pedal.
• Master Cylinder.
• Disk Brake.
• Drum Brake.

130. 134
1. Force pedal boosterComponents
At normal conditionWhen releasing the vacuum pumpWhen motors stops

131. 135
2. Master cylinderComponents

132. 136
3. Disk brakeComponents

133. 137
4. Drum brakeComponents

134. 138
Drum VS Disc Brake SystemComponents

135. 139
Why do we use disc brakes
in front and drum brakes in
rear?
Components
Disk brakes have a higher overall capacity, and drum
brakes are cheaper and take less hydraulic force to
activate. When you stop your car most of the braking
is done by the front brakes because of weight transfer

136. 140
Parking brakeComponents

137. 141
Anti lock braking system(ABS)Components
• Each wheel speed is measured
• This process is done over than
20 times /second

138. 142
Electronic Brake-force
Distribution (EBD)
Components
Load sensor is used to determine
where is the most load and gives
orders to the master cylinder.

139. 143
Braking by wireComponents
• Electro mechanical
braking
• Electro hydraulic braking

140. 144
Braking by wireComponents
• It is able to react more quickly
• It is totally silent and don’t have
vibration through the pedal due to
absence of mechanical parts
• It takes up less space than
mechanical parts
• It is less damaging to environment

141. 145
Transmission
Battery
Steering
Braking
Controller
Motor
Electric Car
Main Components Of Electric Car

142. Main Components Of Electric Car
Steering system
146
• Introduction
• Types of steering

143. 147
IntroductionComponents
The steering system converts the rotation of the
steering wheel into a swiveling movement of the
road wheels in such a way that the steering-wheel
rim turns a long way to move the road wheels a
short way.

144. 148
Types of steeringComponents
1. Rack-and-pinion steering is the most
common type of steering on cars, small
trucks and SUVs.
2. Recirculating ball steering is the most
commonly used steering system in heavy
vehicles, trucks and the larger/heavier
SUVs.

145. 149
Prototype SteeringGo Kart
• The rack-and-pinion
system

146. 150
The rack-and-pinion systemComponents

147. 151
Steering structureComponents
• Tie Rod.
• Steering Arm.
• Rack steering .
• Pinion steering.
• Steering shaft .
• Steering wheel.

148. 152
The rack-and-pinion systemComponents
• At the base of the steering column there is a
small pinion (gear wheel) inside a housing. Its
teeth mesh with a straight row of teeth on a rack
- a long transverse bar.
• Turning the pinion makes the rack move from
side to side. The ends of the rack are coupled to
the road wheels by track rods.

149. 153
The rack-and-pinion systemComponents

150. Outline
2. Main Components Of Electric Car
• Motor
• Controller
• Batteries
• Transmission
• Braking
• Steering
3. Electric Go Kart Prototype
154

151. 155
Go Kart control system and its
features
Go Kart

152. 156
System Interconnect Diagram
(SID)
Go Kart

153. 157
Car MCU (motor control unit)Go Kart

154. 158
Go Kart MechanismGo Kart

155. 159
Car MotherboardGo Kart

156. 160
Motor direction controlGo Kart

157. 161
FeaturesGo Kart
1. Voltage measurement (voltmeter)
Vout = R2/(R1+R2)* Vbattery

158. 162
FeaturesGo Kart
2. Prototype Pedal
(potentiometer)

159. 163
FeaturesGo Kart
3. Speed sensor (encoder)

160. 164
FeaturesGo Kart
4. Temprature sensor

161. 165
FeaturesGo Kart
5. Monitoring (LCD)

162. 166
FeaturesGo Kart
6. Current limiter(fuse)

163. 167
FeaturesGo Kart
7. Wireless communication(bluetooth)

164. 168
General FeaturesGo Kart
8. Dimensions 150*90 cm
9.Automatic clutch
10.Weight about 70 kg
11.Can withstand a person weight till 70 kg
12.Secured with a key to open the system
13.Can reach speed of 20 km/hr at the rated weight

165. 169
Auto-parking techniqueGo Kart
1. sensor (encoder)
1-ultrasonic sensor
2-Electromagnetic sensors

166. 170
Auto-parking techniqueGo Kart
2. Our prototype (perpendicular algorithm)

167. 171
Auto-parking techniqueGo Kart

168. Thank you