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Electric Vehicle Conversion of a Foldable Motorbike

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Electric Vehicle Conversion of a Foldable Motorbike Bjarni Freyr Gudmundsson, s042859 Electric Vehicle Conversion of a Foldable Motorbike Design state Synthesis & Special Project, Juni 2010 Bjarni Freyr Gudmundsson, s042859 Electric Vehicle Conversion of a Foldable Motorbike Design state Synthesis & Special Project, Juni 2010 Electric Vehicle Conversion of a Foldable Motorbike,Design state This report was prepared by Bjarni Freyr Gudmundsson, s042859 Supervisors Esben Larsen Department of Electrical Engineering Centre for Electric Technology (CET) Technical University of Denmark Elektrovej building 325 DK-2800 Kgs. Lyngby Denmark www.elektro.dtu.dk/cet Tel: (+45) 45 25 35 00 Fax: (+45) 45 88 61 11 E-mail: cet@elektro.dtu.dk Release date: 31. August 2010 Category: 2 (confidential) Edition: First Comments: This report is part of the requirements to achieve the Master of Science in Engineering (M.Sc.Eng.) at the Technical University of Denmark. This report represents 20 ECTS points. Rights: c Bjarni Freyr Gudmundsson, 2008 Preface This report is a part of fulfillment requirements for acquiring the course 31910 Synthesis in electrotechnology and a 10 ECTS credit special course. The aim of the project is to get familiar with electric vehicle technology and to gain understanding on what the major electrical components are needed to propel the vehicle in sophisticated way. Furthermore, the author of the paper will use this project to gain the understanding on the behavior of different DC motor types. The author wants to thank Esben Larsen for all the long discussions we had regarding the project and for the interest shown on the subject. Joachim Hjerl, David Koch Mouritzen and Christian Rottbøll at CityRiders are thanked for bringing the project to DTU, providing the opportunity of this project and thank you for being so flexible when I needed the moped for testing and measurements. Bogi Bech Jensen is thanked for the valuable comments and suggestions regarding motor types and properties. Finally, thanks to my lovingly Edda and my beautiful Freydis for the understanding and moral support after all the long working days during the project. The project was done over the summer period of 2010 and is a part of the authors MSc programme. Abstract Electric vehicles have been come more and more popular discussion and seems to be one of the most developing technology today. The society seems to be more than before aware of the influences on nature and environment combustion propelled vehicles are causing. The electric vehicle seems to be something everyone knows of but no one uses and the negative public image of electric vehicle has been less over the recent years. In this project the investigation of electric vehicle conversion is done. An Italian made foldable combustion moped is used as a test subject for the project. The main effecting factors when comes to challenges met by elec- tric vehicle designers are realized and discussed. Evaluation leads to the optimal selection on main electrical components in the electrical mopeds drivetrain. Simulation by MATLAB mathematical modeling is done using data from the electrical components considered to give the vehicle the opti- mal performance. Variable factors in the vehicle design will be manipulated to realize the effects of the different factors on vehicle performance. The re- sults of MATLAB mathematical modeling show enhanced acceleration and top speed characteristics than on current combustion mope. Contents List of Figures ix List of Tables xiii 1 Introduction 1 1.1 Background ............................ 2 1.2 ProblemFormulation. 2 1.3 DiBlasi’sR7specifications . 3 Nomenclature 3 2 Mechanics 9 2.1 Forceoftractiveeffort . 10 2.2 Forceofaerodynamicdrag. 11 2.3 Forceofrollingresistance . 13 2.4 Forceofhillclimbing. 15 2.5 Forceofacceleration . 15 2.5.1 Forceoflinearacceleration . 16 2.5.2 Forceofcircularacceleration . 16 2.6 Thetotaltractiveeffort . 17 3 Mechanical Transmission 19 3.1 BeltsandPulleys......................... 19 3.1.1 V-belts .......................... 20 3.1.2 Flatbelts ......................... 21 3.1.3 PolyV-belts ....................... 22 3.1.4 TimingBelts ....................... 22 3.1.5 Lossesinbelttransmissions . 23 3.2 Gearsratio ............................ 24 3.3 Currenttransmissionsystem . 26 3.4 Evaluationofthetransmissionsystem . 27 4 DC motors 29 4.1 Brushed DC permanent magnet electric motor . 30 4.1.1 Torque........................... 32 4.1.2 Controls.......................... 34 4.1.3 Efficiency ......................... 35 4.1.4 Regenerativebraking. 38 4.1.5 LEM-130 ......................... 41 4.1.6 PMG132 ......................... 45 4.2 WoundfieldDCelectricmotors . 47 4.2.1 Series ........................... 48 4.2.2 Shunt ........................... 52 4.2.3 Separatelyexcited . 54 4.3 Brushless DC permanent magnet electric motor . 55 4.3.1 Wheelhubmotors . 58 4.3.2 BLDCsectiondiscussion. 65 4.4 Motorcomparison ........................ 66 5 Battery 69 5.1 Li-ion ............................... 71 5.1.1 BatteryManagementSystem . 71 5.1.2 Types ........................... 72 5.2 Batterydesign .......................... 75 6 Modeling of the electric moped 77 6.1 Accelerationcharacteristics . 77 6.2 ECE-47circlesimulation. 79 6.3 LFPLi-ionvoltagecharacteristics. 80 6.4 Rangetest............................. 81 7 Discussion 89 8 Conclusion 91 References 93 Appendix 97 A Matlab codes 97 A.1 Acceleratingcharacteristics . 97 A.2 Efficiencymap .......................... 98 A.3 ECE-47circlesimulation. 99 A.4 LFPLi-ionvoltagecharacteristics. 100 A.5 Onetestcycle........................... 101 A.6 Rangesimulation . 104 B Motor and battery data 107 B.1 LEM-130 from Lynch Motor Company LTD. 109 B.1.1 MechanicalDrawing . 109 B.2 PMG132fromPERMMOTOR . 110 B.2.1 MechanicalDrawing . 110 B.2.2 Motor-curves . 111 B.3 AMGfromIskra ......................... 115 viii B.4 AdvancedMotor&Drives . 117 B.4.1 140-07-4001 ........................ 117 B.4.2 A00-4009 ......................... 121 B.5 MW-16C BLDC hub motor from Golden motor . 125 B.5.1 MechanicalDrawing . 125 B.5.2 Motorcurvesanddata. 126 B.6 HDM105E10-51SfromSEM. 128 B.7 LiFePObatteryfromGoldMotrrs . 131 C Motor Comparison 133 D Component fittings into frame 137 D.1 LEM-130 from Lynch Motor Company LTD. 137 D.2 PMG132fromPERMMOTORGMBHD.. 138 D.3 HDM105E10-51SfromSEM. 139 D.4 LFPbatteryfromGoldenMotors . 141 E E-mails 143 E.1 AdvancedMotor&Drives . 143 F Figures of the moped 147 List of Figures 1.1 The Di Blasi moped at folded and unfolded state, from [12] . 4 1.2 Data results of mopeds timing experiment. 4 1.3 Plotted results from mopeds timing experiment.. 4 2.1 The forces effecting the moped tractive effort. 9 2.2 Themopedsdrivetrain. 10 2.3 The frontal areal of the moped among driver . 12 2.4 Difference of contact area shape of narrow and wide tire, from [15]................................. 14 2.5 Tires with very different rolling resistance, from [5]...... 14 2.6 A figure of the current tire used on the Di Blasi mopeds. 15 3.1 AnexampleofaV-belt . 21 3.2 Anexampleofaflatbelt . 21 3.3 AnexampleofaPolyV-belt . 22 3.4 AnExampleofatimingbelt . 23 3.5 The efficiency of different belts at 1450[rpm]. ”Tendrem” is timing belt, ”Fladrem”is flat belt, ”Poly-V rem”is poly V-belt and ”Smalkilerem” is V-belt, figure from [29].......... 23 3.6 The moped’s accelerating characteristics for different gear ratios 25 3.7 The transmission currently on the Di Blasi moped . 26 x LIST OF FIGURES 3.8 The mopeds current transmission system. 27 4.1 Brushed DC permanent magnet electric motor, from [11]... 30 4.2 The magnetic force rotating the armature. The ”X”marks the current direction from the reader and • marks the direction towards the reader, from [35]................... 31 4.3 A theoretical description of a DC motor torque-speed charac- teristics............................... 34 4.4 Eddy current in a solid and layered armature, from [30] ... 37 4.5 An example of efficiency map of a typical brushed DC per- manentmagnetelectricmotor. 39 4.6 Regenerative braking system with a DC/DC converter, from [31]................................. 40 4.7 Increase in fuel efficiency of EVT scooter with varying size of ultracapacitor energy storage. Note: this is useful energy storage, not ultracapacitor maximum energy storage. Also, the motor/generator is rated at 1.5 kW as supplied by man- ufacturer. Figure from [23] ................... 41 4.8 Dual braking system used on the VX-1 electric motorbike, from [16].............................. 42 4.9 LEM-130 motor from Lynch Motor Company Ltd. approx weight3kg............................. 42 4.10 LEM-130 motors torque-speed characteristics . 43 4.11 The moped’s acceleration characteristics using LEM-130 motor 45 4.12 The moped’s acceleration characteristics using PMG 132 motor 46 4.13 Wound field motor’s torque-speed characteristics . ... 48 4.14 Series connected wound field DC electric motor . 49 4.15 A typical torque-speed and torque-current characteristics of a series motor, from [40]..................... 50 4.16 Modeling the mopeds top speed at different gear ratios using the 140-07 motor from Advanced Motors Inc. 52 4.17 Parallel connected wound field DC electric motor . 53 4.18 A typical torque-speed and torque-current characteristics of a shunt motor, from [40]..................... 54 LIST OF FIGURES xi 4.19 The separately excited DC motor has independent input ter- minals for the wound field and the armature . 54 4.20 TheconstructionoftheBLDCmotor. 56 4.21 ThebasicoperationofBLDCmotor . 57 4.22 VoltageappliedtotheBLDCmotor . 57 4.23 The mopeds maximum speed capabilities using
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