Thermal Design of Variable Frequency Drives for Hybrid and Electric Transport Applications

2021 ◽  
Author(s):  
Nikhil R. Lakhkar
Keyword(s):  
Electric Vehicle ◽  
Electric Vehicles ◽  
Hybrid Vehicle ◽  
Thermal Design ◽  
Product Development Process ◽  
Variable Frequency ◽  
Air Cooling ◽  
Electric Transport ◽  
Ic Engine ◽  
Variable Frequency Drives

Abstract The Electrification of commercial vehicles is happening at a rapid pace. Most of the major automotive corporations are pursuing this opportunity to include electric vehicles in their portfolios. The commercial trucking industry has also been exploring the use of electric vehicles for goods transport including perishables. The transition to electrically driven vehicles has led to the need for electrically driven HVAC systems. To support this evolving commercial market, we developed an electrically driven variable speed compressor platform comprising of compressor and variable frequency drive (VFD). The product platform addresses two categories of vehicles: 1) Hybrid vehicle – the vehicle in this category uses conventional IC engine and has traditional batteries that output 48VDC. 2) Electric vehicle – the vehicle in this category is electrically driven using battery bank or traction drive that gives 650VDC as output. Hence, 650V DC is input to VFD. Both these applications were addressed with two drive designs. In this paper, we discuss the thermal design aspects of both 48V and 650V variable frequency drives. In this publication, the product development process is described from product conception, to final product. The mechanical / environmental design considerations while designing these drives were, (1) The drive was expected to be mounted under the vehicle bed and hence should be strong enough to withstand shock and vibration, (2) the drive was decided to be air cooled (4) the drive was designed to be IP67 so that it can withstand harsh road conditions, (5) the desired operating temperature range was between −40°C to 85°C for 48V and −40°C to 65°C for 650V and (6) the estimated time of service was expected to be 10 years. We were able to achieve an operating margin of −40°C to 70°C at full load for hybrid vehicle drive (48VDC) and −40°C to 65°C for electric vehicle drive (650VDC) using air cooling.

A Methodological Approach for Supporting the Thermal Design of Li-Ion Battery for Customized Electric Vehicles

2014 ◽  
Author(s):  
Daniele Landi ◽  
Paolo Cicconi ◽  
Michele Germani
Keyword(s):  
Thermal Behavior ◽  
Electric Vehicle ◽  
Electric Vehicles ◽  
Combustion Engine ◽  
Thermal Design ◽  
Battery Pack ◽  
Scale Production ◽  
Li Ion Battery ◽  
Suitable Alternative ◽  
Li Ion

An important issue in the mechanical industry is the reduction of the time to market, in order to meet quickly the customer needs. This goal is very important for SMEs that produce small lots of customized products. In the context of greenhouse gas emissions reduction, vehicles powered by electric motors seem to be the most suitable alternative to the traditional internal combustion engine vehicles. The market of customized electric vehicles is a niche market suitable for SMEs. Nowadays, the energy storage system of an electric vehicle powertrain consists of several Li-ion cells arranged in a container called battery pack. Particularly, the battery unit is considered as the most critical component in electric vehicle, because it impacts on performance and life cycle cost. Currently, the design of a battery pack mostly depends on the related market size. A longer design time is expected in the case of a large scale production. While a small customized production requires more agility and velocity in the design process. The proposed research focuses on a design methodology to support the designer in the evaluation of the battery thermal behavior. This work has been applied in the context of a customized small production. As test case, an urban electric light commercial vehicle has been analyzed. The designed battery layout has been evaluated and simulated using virtual prototyping tools. A cooling configuration has been analyzed and then prototyped in a physical vehicle. The virtual thermal behavior of a Li-ion battery has been validated at the test bench. The real operational conditions have been analyzed reproducing several ECE-15 driving cycles and many acceleration runs at different load values. Thermocouples have measured the temperature values during the physical experiments, in order to validate the analytical thermal profile evaluated with the proposed design approach.

Thermal Analysis of Cold Plate for Motor Controller Based on Fluent

2012 ◽  
Vol 249-250 ◽  
pp. 691-695
Author(s):  
Gui Lin Lin ◽  
Guo Qing Xu ◽  
Wei Min Li ◽  
Bin Bin Liu
Keyword(s):  
Electric Vehicle ◽  
Optimization Design ◽  
Controller Design ◽  
Electronics Cooling ◽  
Thermal Design ◽  
High Heat Flux ◽  
Air Cooling ◽  
Material Base ◽  
Cold Plate ◽  
Motor Controller

Electronics cooling research has been largely focused on high heat flux removal from computer chips in the recent years. However, the equally important field of high-power electronic devices has been experiencing a major paradigm shift from air cooling to liquid cooling over the last decade. For example, multiple insulated-gate bipolar transistors (IGBT) used in a power drive for motor used in electric vehicle. Motor drive system plays an important impact on electric vehicle’ performance, so thermal design should be considered in the early stages during the motor controller design and layout of the devices. In this paper, a new type of water-cooled cold plate for motor controller was designed, and its cooling ability was analyzed by using different material base on Fluent. The results provide reference on the optimization design of cold plate.

scholarly journals Future of Flow Batteries in Electric Vehicle Applications

2020 ◽  
Vol 9 (7) ◽  
pp. 993-995
Keyword(s):  
Energy Storage ◽  
Electric Vehicle ◽  
Electric Vehicles ◽  
Internal Combustion Engines ◽  
Storage Systems ◽  
Hybrid Vehicle ◽  
Energy Storage Systems ◽  
Energy Storage Devices ◽  
Main Challenge ◽  
Flow Batteries

Electric vehicles are used nowadays to reduce carbon emissions and green house gases. The main challenge in the electric vehicles is the energy storage systems. For battery operated vehicles, the increase in charging time is the major concern and range of the vehicles for a single charge is not satisfied. This leads to restrict the commercialization of electric vehicles. To overcome this, researchers and industry peoples has developed a hybrid vehicle technology which contains both electric and internal combustion engines. The efficiency of the hybrid vehicle is increased when it is incorporated with IC engines. But still the energy storage issues are censorious. Now the potential area in the energy storage systems is flow batteries. The main advantage of the flow batteries is fast charging tendency. Refuelling is possible only in case of flow batteries among all energy storage devices used in electric vehicles. This paper provides the study of flow batteries used in electric vehicles and comparison of different flow batteries for electric vehicle applications

scholarly journals Design and Simulation of Electric Vehicle

2020 ◽  
Vol 9 (4) ◽  
pp. 131-133
Keyword(s):  
Electric Vehicle ◽  
Electric Vehicles ◽  
Simulation Software ◽  
Tax Credits ◽  
Rapid Urbanization ◽  
Ic Engine ◽  
Drive Trains ◽  
Torque Analysis ◽  
Ic Engines ◽  
Design Aspect

This paper is all about Design of Electric Vehicle. The growing development in the field of Electric vehicle in the need of the hour. In effort to save the environment and reduce our dependence on foreign oil, we planned of designing an Electric vehicle which can be used in conversion of any basic IC engine vehicle. Rapid climatic change, advances in renewable energy, rapid urbanization, battery chemistry and energy security are the result of developing an electric vehicle. In this paper we have consider most of the design aspect of electric vehicle and checked the results using a simulation software named modelica. This software enables us to have various drive trains, load dynamics and torque analysis. The Electric vehicles are environmental friendly, less expensive low maintenance, tend to be quiet, potential for tax credits and benefits to the utilities. IC engines automobiles emit harmful gases which are dangerous to health on other hand the electric vehicles emit hardly any harmful gases. NOMENCLATURE

scholarly journals Discontinuance among California’s electric vehicle buyers: Why are some adopters abandoning electric vehicles?

2020 ◽  
Author(s):  
Scott Hardman ◽  
Gil Tal
Keyword(s):  
Electric Vehicle ◽  
Market Share ◽  
Electric Vehicles ◽  
Lower Energy ◽  
New Technology ◽  
Hybrid Vehicle ◽  
Battery Electric Vehicle ◽  
Questionnaire Surveys ◽  
Level 2

Abstract For the market share of plug-in electric vehicles (PEVs) to continue to increase and reach 100% of the market, adopters of the technology, who initially buy PEVs, will need to continue choosing them in subsequent purchases. While much research has focused on the reasons for and barriers to initial PEV adoption, less has been devoted to the reasons for discontinuance—abandoning a new technology after first adopting it. Based on results from five questionnaire surveys, we find that PEV discontinuance in California occurs at a rate of 21% for plug-in hybrid vehicle adopters and 17% for battery electric vehicle adopters. We show that discontinuance is related to dissatisfaction with the convenience of charging, having preferences for vehicles with lower energy efficiencies, being a later adopter, not having level 2 (220-volt) charging from home, and not being male.

EV – Challenges In Going Electric

2018 ◽  
Author(s):  
Umanand L
Keyword(s):  
Mass Transport ◽  
Electric Vehicle ◽  
Electric Vehicles ◽  
Hybrid Electric Vehicles ◽  
Research Activity ◽  
Considerable Research ◽  
Hybrid Electric

This article presents a frank and open opinion on the challenges that will be faced in moving towards an electric mass transport ecosystem. World over there is considerable research activity on electric vehicles and hybrid electric vehicles. There seems to be a global effort to move from an ICE driven ecosystem to electric vehicle ecosystem. There is no simple means to make this transition. This road is filled with hurdles and challenges. This paper poses and discusses these challenges and possible solutions for enabling EVs.

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