Electric Vehicle – The

future
Why Electric
Car ?

₹
Electric Ecologic Easy Economi
c
 History of Electric
Vehicles
Thomas Parker built the
first practical production
BMW E1,Ford EchoStar, Tesla,Toyota,TATA,Mahindra
electric car in London
GM EV1 MG,BYD,Audi
in 1884.

1884 1897 1990 2008 2019

Electric Taxi, William

Morrison, New York TESLA
 Electric Vehicles Benefits

Less Moving Instant

Parts Acceleration

No Exhaust Silent Drive

 What Electricity can do ?

Electricity
WHAT IS
ELECTRICITY :-
ELECTRICITY IS
DEFINED AS Chemical
Heat Electromagnet
THE FLOW OF Reaction
ELECTRIC
CHARGE.
 Working of EV
Electric cars function by plugging into a charge point and taking
electricity from the grid. They store the electricity in rechargeable
batteries that power an electric motor, which turns the wheels. Electric
cars accelerate faster than traditional fuel engines –

When the pedal is pressed

• The Controller gathers energy from
the battery.
• Controller delivers the appropriate
amount of electrical energy to the
motor.
• Motor Convert electric energy
transforms to mechanical energy.
• Wheels turn, Vehicle moves.
Electric Vehicles are eco friendly – Zero
Emission . Charging station is an element
in an infrastructure that supplies electric
energy for the recharging of electric
vehicles, Charging stations are inevitable
part of electric vehicle ecosystem.
ICE VS EV
 Electric Vehicle
Components Auxiliary system
Aux Battery ( 12V ) , Ignition system,
Infotainment,
LV harness , Coolant Pumps , Braking
System, Steering System, Chiller units,
Battery Radiator fan, Lights , Blower units and many
HV Battery pack more.

Communication CAN
CAN Harness, VECU , ECU, ABS ,
Clusters and other Communication
Dead Weight Body leads, HV cable’s
Chassis, Shell, Windshields, Seats,
Tyers and other BIW
Electronic Components
PDU, On Board Charger, DC DC
Convertor, Vacuum Pumps, E Drive
Unit, HV Cables, AC Compressor
ADVANCED DRIVER ASSIST
SYSTEM
ADAS
• ADAS stands for Advanced Driver Assistance System

• Advanced active safety and comfort features enhances driving experience and safety

• ADAS uses sensors in the vehicle such as radar and cameras to see the world around
it

• Either provides information to the driver or takes automatic action based on what it
sees.

• ADAS is not fully Autonomous Driving .

• Driver is fully responsible for safe and attentive driving and ADAS is not a replacement
for drivers control over the vehicle

• ADAS functions may not operate optimally under all driving conditions. Its
effectiveness depends
upon many factors
ADAS • Features
LDW : Lane Departure
Warning

None of these Driver Assistance

features are designed to relieve the
ACC : Adaptive Cruise LKA : Lane Keep driver of any driving responsibilities!
Control Assist

+ +

ACC AEB LKA

Collision Mitigation SPA :
System Smart
Pilot
Assist

FCW : Forward AEB : Automatic

Collision Emergency TSR: Traffi c Sign HBA : High Beam
Warning Braking Recognition Assist
ADAS Sensor
ELECTRIC VEHICLE ANTI
LOCK BRAKING SYSTEM
ADVANCED TECHNOLOGIES OF BRAKING SYSTEM
ABS- Antilock Braking System

EBD/DRP- Electronic Brake distributor, Dynamic rear proportionate valve

ESP/ESC/VDC/VSC/ASMS/DSC/DDC/VSA- Electronic Stability Program,

Electronic Stability Control, Vehicle dynamic control, Vehicle Stability
Control, Automatic Stability management system, Dynamic Stability
control, Driving dynamic control, Vehicle stability Assist

SAS- Steering Angle Sensor

SC- Sensor cluster with combined Yaw rate & Lateral Acceleration sensor

DTC/ETR- Drag Torque control/ Engine torque regulation

HBA/EBA- Hydraulic brake assist/ Engine braking control

ADVANCED TECHNOLOGIES OF BRAKING SYSTEM
LINE DIAGRAM OF AN ABS & ESP BRAKING
SYSTEM
ABS & ESP-Warning & indication tell tale lamps in cluster
Objective of Braking System
Objective of the braking system is to stop a vehicle in an efficient ,
stable &
progressive manner

Following factors influence braking efficiency:-

•The driver
•The road surface grip condition
•The tyre wear condition
•The active forces which are :- Surface contact
force
 ABS function

During emergency braking high pressure is applied at the brake pedal thereby
causing wheel lock Locking of the wheels causes a loss of vehicle stability & control

The role of ABS is to prevent wheels from

locking & maintain steerability of the vehicle
A slip value not exceeding 20% enables control
of the vehicle to be retained
BATTERY MANAGEMENT
BMS
BMS block design
The onboard charger, which is built in
your car, converting the AC power into
DC energy so that it can be stored in the
battery
DC–DC converters are used to Covert high voltage DC to
low voltage (12-28 volts) DC that can be used to charge
the 12 volt auxiliary battery and operate light load
devices such as lighting, radio, AC and windows etc. (EV
controller is operated by Aux battery )
An inverter is a device that converts DC power to the AC power used in
an electric vehicle motor. The inverter can change the speed at which
the motor rotates by adjusting the frequency of the alternating
current. It can also increase or decrease the power or torque of the
motor by adjusting the amplitude of the signal
 HV Battery Recycle / Scrapping

# As per CPBC – Every battery to be counted and reported .

Authority lays with respective OEM’s on each battery served under >
sale/repair/replacement and certify on Recycle / Scrapping per Ah value.
ELECTRIC VEHICLE BODY CONTROL
MODULE
BCM Location
 BCM Functions
Door
•Management:
Central Door Locking Safety & Security
• Remote Keyless Entry
• Antitheft System Alarm Other
• Passive Key less Entry
functions
• Rear Defogger
• Light Control
• Day time Running Lamp • Wiper Control

• Hazard on Panic braking • Rear Defogger

• Head Lamp • Warning & Buzzer

• Follow Me Home • ORVM Control

• Lead Me to Car • Tailgate Control

Reverse Park Assisted System
• Turn Indicator & Hazard
• Roof Lamps
• Backlight
Park Assisted System Architecture
Overview:
The PAS aids you in safely parking the vehicle at a speed less than 7kmph for front and
reverse parking.

The system will indicate the obstacles for a distances up to 120 cm from the rear
bumper and 60 cm from front bumper .

The system alerts you visually & through a beep alert when the obstacle is in the detection
zone.
The beep sound and visual alert increases when the vehicle gets closer to the obstacle.

4
2
RPAS Function(Reverse Park Assisted Function)

Turn the ignition to ON

Press the clutch

Change the gear to Reverse

4
2

4700c Take the vehicle behind

cmm
the vehicle by about 40
cm
•
FPAS Function
(Front Park Assisted Function)
Turn the
ignition ON
and FPAS
switch ON

Press the clutch & Change the

gear to forward gear and keep
vehicle speed <=15kmhr

Drive front towards another

40 vehicle until 40cm
•
 Sensor Mounting

Sensor location: On the rear Bumper Sensor location: On the front Bumper

•
Electronic Control Unit
Communication
 Electronic Control Unit Communication

OBC ON – Board Charger Telematics

Connected Car

DC-DCDC – DC Convertor Fully Automatic Temp. FATC

Charger Control

IPC Instrument Planel &

Cluster
VECU Automatic Driving
System
ADAS
PEPS
Passive Entry Vehicle Electric Antilock Braking ABS
Passive Start System
Control Unit
EPAS
BMSBattery Management Electronic Power
System Steering S
MCUMotor Control Unit Body Control Module BCM
DEAD WEIGHT BODY CONCEPT IN EV
D Dead Weight – BIW

Battery Pack is placed underbody

in safest distance from all other
sides, as so impact in any form will
not damage Battery
LV Architecture Powertrain Box Open
View

E
What are some of the materials used to reduce the weight of a vehicle?
Aluminum alloys, carbon fiber composites, and magnesium alloys, among others, are
some of the top materials utilized to reduce a vehicle’s weight.
ELECTRIC VEHICLE REGENERATIVE BRAKING
SYSTEM
 Brake Regeneration

Brake Regeneration:- when TCU converts POT voltage to

press the brake or release the regen command
Accelerator, Motor act as a
Alternator & produce electric Regen end
energy which is utilise to voltage Hydraulic

Regen breaking &

charge the Battery pack , TCU
convert brake /Accl. POT voltage

HydrFarueleic
to regen command.

breaking
Brake Blending
Point

Regen start
voltage Pedal Travel:-Pot in volt
for Regen
Pedal Travel in mm for
Hydraulic break
 Creep – Hill Assist

The creep function essentially enables

the car to move forward at a very slow speed
say 5 or 6 kmph when the car is in Drive
mode and the brake/accelerator pedal is
not pressed.

The creep assist in effortless driving during

bumper to bumper traffic condition.

Without With creep

It self creep function add
creep
Hill ssist in up hill condition.
A
 Basic

Principle
Regenerat
of a
ive •Basic Principle: When a vehicle equipped with
regenerative braking slows down or comes to a
stop, the electric motor that propels the
vehicle operates in reverse, converting the
Braking vehicle's kinetic energy back into electrical
energy. This electrical energy is then stored
system in the vehicle's battery for later use.
BATTERIES IN ELECTRIC VEHICLES
Battery - High Voltage Battery_ kW

Terms & Types

01 Battery Terminology
Battery Types

Chemistry &
02 CTyopemopf
Cohneemnisttsy
Various Components in
Battery
Service , Safety &Insurance
03 Safety Standards of Battery
Insurance Aspects hydrogen and
helium
Battery Specifications
Specificaton Description Measured in

Battery Type LV Architecture Battery / High Voltage Architecture Battery HV

Battery Energy (kWh) Energy Storage Capacity of Battery ( 1 kWh = 1 unit of kWh
energy consumptio )

Energy Density / Pack to Energy stored/Cell and Total Pack to Voltage Ratio kW
Voltage

Amp & Voltage Range Acceptable Ampere and Voltage Range [ measured in Amps & A&V
Voltage ]

Max & Min Cell Voltage Maximum Cell Voltage & Minimum Cell Voltage mV

Discharge Cell Amp & Lowest cell voltage/Amp and Adoption range of Cell kW
Voltage

Safety Protection rating Ingress Protection rating from external factors IP

Temperature Withstanding temperature ( -30c to 60C ) in Bpack Temp

Weight & Dimensions These can be used in the template, and their size and L * B * H & Kg
color can be edited

Communication They are sorted by theme so you can use them in all CAN
kinds of presentations
HV Battery The three primary functional

Chemistry
components of a lithium-ion battery
are the positive and negative
electrodes and electrolyte.
Generally, The negative electrode -
lithium-ion cell is made from carbon.
positive electrode is a metal oxide,
Electrolyte is a lithium salt in an
organic solvent
Lithium Iron
Lithium Nickel Phosphate
Manganese Cobalt ( LiFePo4)
Lithium
Oxide (LiNiMnCoO2)
Lithium Nickel Manganese Oxide
LFP
Cobalt Aluminum (LiMn2O4)
Oxide(LiNiCoAlO 2)
Li- NMC
Lithium
Titanate (Li2TiO3) Li-MO
Li-NCA
Li-TA

1% 4% 5% 10% 80%
 HV
Battery
Compone
• Cells and • - ve Female
nts
Modules
Connector
• MSD
• Pre • Breather
charge Plug
Resistance
• Current
• Pre charge
Monitor
Relays Sensor
• Relays & • Temp
Fuses sensor
• + • Slave BMS
Contactor -
HV Cell
• -ve Monitoring
Contactor • Master BMS –
HV Commands
• Bus Bars • Insulation
THANK YOU
ECO-FRIENDLY