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Electric Cars: Technology

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Electric Cars: Technology TU Delft Electric Cars: Technology DelftX eCARS2x Unless otherwise specified the Course Materials of this course are Copyright Delft University of Technology and are licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License. Content 1 Electric vehicles fundamentals ........................................................................... 3 1.1 Electric motor vs combustion engine .......................................................... 3 1.2 Comparing drivetrains ................................................................................. 8 1.3 Sizing of the EV powertrain .................................................................... 16 1.4 Types of electric motors ............................................................................ 20 1.5 Case study: Carver ..................................................................................... 28 Summary ......................................................................................................... 33 References ....................................................................................................... 36 Final Quiz ......................................................................................................... 36 2 Battery technology for EV ................................................................................ 42 2.0 Introduction ............................................................................................... 42 2.1 EV battery introduction ............................................................................. 42 2.2 EV battery parameters .............................................................................. 49 2.3 Processes and materials inside the battery............................................... 59 2.4 Case study: Carver ..................................................................................... 68 Summary ......................................................................................................... 71 References ....................................................................................................... 73 Final model quiz .............................................................................................. 74 3 Power electronics for EV .................................................................................. 78 3.1 Power electronics in electric cars .............................................................. 78 3.2 DC-DC converters: Part 1 ........................................................................... 86 3.3 DC-DC converters: Part 2 ........................................................................... 92 Summary ......................................................................................................... 96 Final Quiz ......................................................................................................... 97 4 Charging technology for EV ............................................................................ 104 4.1 Introduction to charging methods for EVs .............................................. 104 4.2 AC charging of EVs ................................................................................... 107 4.3 DC charging of EVs ................................................................................... 113 4.4 Smart charging and V2G .......................................................................... 119 1 4.5 ICT protocols for charging ....................................................................... 122 4.6 Case Study: ABB ....................................................................................... 129 Summary ....................................................................................................... 133 Resources ...................................................................................................... 135 Final model quiz ............................................................................................ 135 5 Future electric mobility .................................................................................. 140 5.1 Future trends in electric cars ................................................................... 140 5.2 Wireless charging of EVs ......................................................................... 146 5.3 Battery swap ............................................................................................ 154 5.4 Charging EV from renewables ................................................................. 160 5.5 Case Study: Nuna Solar car ...................................................................... 169 Summary ....................................................................................................... 171 Resources ...................................................................................................... 174 Final model quiz ............................................................................................ 174 2 1 Electric vehicles fundamentals Auke Hoekstra1 and Pavol Bauer2 1Eindhoven University of Technology, The Netherlands 2Delft University of Technology, The Netherlands 1.1 Electric motor vs combustion engine Most people generally do not understand the basics when it comes to comparing conventional cars with electric cars. In essence there are two fundamental characteristics that all cars have that you have to understand. If you do, everything all falls into place and the rest is details. The first fundamental characteristic is energy storage. The second fundamental characteristic is the motor. Let's start with the motor that converts potential energy into kinetic energy. You might think that there are many types of motors, but actually there are only two types when you look at the fundamentals. This has been true since the beginning of human history. So pay attention because this is going to be information that you can use forever. The first motor is the heat engine, and the second is the electric engine. Electric vehicles with the two types of motors are shown in Figure 1.1. In a heat engine, burning releases the potential chemical energy in the fuel. The heat this produces causes expansion and this, in turn, drives some rotary motion. This is true for steam engines, sterling engines, diesel engines and gasoline engines. Figure 1.2 shows how a four-stroke engine works. This is basically the modern gasoline engine and it was invented 150 years ago. On the first stroke, gasoline is injected into a chamber by opening a valve that is then closed again. On the second stroke, the cylinder moves upwards and the gasoline is compressed. On the third stroke, the energy in the fuel is harvested by igniting it. The resulting explosion drives the cylinder down and that produces a rotating motion. This is comparable to a bicycle, where pushing down the pedal moves the bicycle forwards. On the fourth and final stroke, the energy burned is emitted. It is all very ingenious but a heat engine has numerous problems. Figure 1.1 Internal combustion engine car (on the left) and electric car (on the right) 3 Figure 1.2 Four-stroke internal combustion engine sequence The entire engine requires hundreds of precisely crafted moving parts. That makes the engine heavy and expensive. Since all the heat and explosions cause a lot of wear and tear, you need a lot of maintenance, and even then it wears down pretty quickly. The heat engine also wastes a lot of energy. In theory, we could improve the efficiency to about 50%, but that would mean a couple of things. Firstly the engine would become more expensive. Secondly it would have to run at an almost constant number of explosions, which is very hard to do in the real world. Finally the motor should be run at almost maximum power. In practice, even though we've been improving the internal combustion engine for more than 150 years now, a regular car wastes more than 75% of the energy it consumes as heat. And a sports car like the Bugatti Veyron wastes more than 95% of energy if you drive it in regular city traffic. For health and climate change, the biggest problem is the exhaust fumes. These fumes are unhealthy but the biggest problem is that burning 1 liter of gasoline produces 2.3 kilogram of carbon dioxide gas. In an electric motor, it all works completely different. We will dive into all the types of electric engines later, but fundamentally they all work by using magnetic fields. You might still remember from school that magnets have poles. We say they have a north pole and a south pole, just like earth. If you put two magnets together you will see that opposites attract, as depicted in Figure 1.3. If we take a coil of wire and make electricity flow through it, it creates it is own magnetic field. It has become a magnet. If we place this magnetic coil between two magnets, one side of the coil will be pushed up and the other side will be pushed down. This makes the coil turn until it is vertical. At that moment we quickly change the polarity. The effect is rotary motion and what you are seeing here is a simplified direct current motor in action. Figure 1.3 The magnetic field rejects and attracts based on polarity 4 Table 1.1 Heat engine vs electric motor overview The advantages of the electric motor are numerous. It only has one moving part, we call that the rotor. Therefore, it can be relatively light, compact and inexpensive. And since magnetic fields are very gentle, an electric motor can last essentially forever without any maintenance. The
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