IRJET - Design of EV with Fault Detection and Monitoring in Low Voltage System
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This document describes the design of an electric vehicle (EV) with fault detection and monitoring capabilities for the low voltage electrical system. The key components of the EV include a 48V, 110Ah lithium-ion battery, a 4.5kW BLDC motor, an motor controller, and a DC-DC converter. Calculations are shown to select the motor based on vehicle dynamics. A monitoring system is developed using Arduinos with I2C communication to monitor parameters and detect faults. The system uses a master-slave architecture to communicate faults and shut down the main contactor if any parameters exceed limits. The monitoring system interface is designed to support 3D rendering of fault locations to aid in troubleshooting.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2189
Step 1. Master initiate slave.
Step2 . Slave check system parameters and connected
component
Step 3. Send Data back to master.
Step 4. Master setup USB serial communication with
monitoring device.
Step 5. Master Sending serial data packets to monitoring
device.
Step6. Based on the received data UI elements and 3d
environment are constantly changed.
Flowchart:
5. CONCLUSIONS
From this we can concludethebasicrequirementsof
electric vehicle electrical system.
We can also conclude the procedure to be followed
for motor selection based on the dynamics of
vehicle.
Additionally more control is provided over the
system by developing an algorithm by
implemented I2C communication by using
Arduino, so we can detect fault in system.
REFERENCES
[1] Selection of Power Rating of an Electric Motor for
Electric Vehicles T.Porselvi1, Srihariharan .M. K 2,
Ashok.J3, Ajith Kumar.S4 Associate Professor1,
Student2, 3, 4 Department of Electrical and
Electronics Engineering Sri Sairam Engineering
College, Anna University, Chennai, India
[2] https://www.electronicwings.com/arduino/arduin
o-i2c
[3] Kadlag Sunildatta Somnath, Mukesh Kumar Gupta
"Implementation on Single Phase Electric Vehicle
Battery Chargers “ Published in International
Journal of Engineering and Advanced Technology
(IJEAT) ISSN 2249-8958,Volume-9Issue-1,October
2019
[4] Kadlag Sunildatta Somnath, Mukesh Kumar Gupta
“Review Paper on Electric Vehicle Charging and
Battery Management System” Published in
International Conference on Communication and
Information Processing (ICCIP-2019) Available on
Elsevier-SSRN
[5] Kadlag Sunildatta Somnath, Mukesh Kumar Gupta "
Charging Power Station for Electric Vehicles “
Published in International Journal for Research in
Engineering Application & Management (IJREAM)
ISSN:245-9150Special Issue- TIMRI - 2019
BIOGRAPHIES
“Mr. Sunildatta Somnath Kadlag
did B.E in electrical engineering
from Dr. B.A.M.U. Aurangabad in
1997 and M.E in Electrical
Engineering (Control System)from
College of Engineering Pune (Pune
University) in 2005. He is
Currently pursuing Ph.D. in
Electrical EngineeringfromSuresh
Gyan Vihar University Jaipur
(Rajasthan). His researchfieldarea
is Electric Vehicle. “
“Mr. Shinde Sagar Balasaheb”,
Appearing in BE Electrical(2020)
from AVCOE, Sangamner,
Maharashtra, India.](https://image.slidesharecdn.com/irjet-v7i4417-210209121115/85/IRJET-Design-of-EV-with-Fault-Detection-and-Monitoring-in-Low-Voltage-System-4-320.jpg)
IRJET - Design of EV with Fault Detection and Monitoring in Low Voltage System
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2186 Design of EV with fault detection and Monitoring in low voltage system Sagar Shinde1, Sairaj Deshmukh2, Akash Waghmare3, Shubham Suryawanshi4, Prof. S.S. Kadlag5 1-4Student, Dept. of Electrical Engineering, AVCOE, Sangamner, Maharashtra, India. 5Head of Department, Dept. of Electrical Engineering, AVCOE, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract - Electric vehicles first appeared in the mid-19th century. An electric vehicle held the land speed record around 1900. Thehigher prize, small rangeofbatteryelectric vehicles, compare to combustion of engine vehicles, Causes worldwide decline in their use; although electric vehicles have continued to be used in the form of trains and other uses. Taking considerations of recent events of major resources and facilities at their disposal, over increasing traffic, snags problem of parking and the need to make automobile a more environmental friendly, to overcome from that, designer came with new conceptsandideasthatiselectricvehicle.The required amount of torque which is required for vehicle, For designing electric vehicle the most important component to be selected is motor, which depends on the traction power require for the vehicle. The size of the motor is also an important consideration which depends on the rating of the motor. Therefore, to achieve all thetractioncharacteristicsin compact size, a proper selection of motor rating should be done based on the load. Key Words: 1.E-Vehical. 2. BLDC motor. 3. Lithium ion Battery. 4.Bldc Controller. 5. Monitoring system. 1. INTRODUCTION: Electric vehicle are environment friendly technology which helps in reducing pollution of harmful gases. In electric vehicle there are many components like Traction motor, Motor controller, Traction batteries and other ECU’s which monitor vehicle parameters such as SOC, SOH, battery voltage, motor and battery temperatureetc.electricalsystem of vehicle is divided in to two major categories tractive system and control system. Traction system consist of High voltage components such as battery, motor, motor controller, main contactors. Above block diagram shows the electrical power transmission and conversion to mechanical power, from battery to the wheels of the vehicle (power train). Section 2 explains the selection of battery, motor controller. Section 3 explains the calculation of traction motor form vehicle dynamics parameters such asrollingresistanceforce, grad ability, aerodynamic drag, etc. the calculation is performed by considering the vehicle top speed as 50km/hr. Section 4 explains the monitoring system of the vehicle. In this all the vehicle parameters are feed back to the monitoring device. It here also explained about I2C communication protocol used. And finally Section 5 concludes the report. 2. DESCRIPTION OF THE PROJECT In this design the hardware components that we use are: Battery BLDC Motor Controller Converter Monitoring System using Arduino and I2C protocol 2.1 BATTERY (48V, 110 AH) Fig: Battery 48V, 110Ahr Li-Ion Battery
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2187 Table-1: Specification of Battery. 2.2 BLDC MOTOR (4.5KW) The BLDC motor is extensivelyusedinapplicationsincluding Different types of vehicles and other application which is related to the motor. Table-2: Specification of Motor. TYPE BLDC Motor POWER 4500 watt VOLTAGE 48 volts CURRENT 94 Amp TORQUE 10.7 Nm RPM 4500 Torque vs speed characteristics Advantages: Higher efficiency and reliability Smaller and lighter Greater dynamic response Better torque vs speed characteristics 2.3 Controller Generally all new E-Vehicles are developed with the help of controller. Different types of controllers used in E-Vehicles. The motor controller allows the motorto rotateatdiffspeed. It takes input from battery and gives ouput to the motor. We use KLS 7245H Motor controller Battery Pack Compatibility: Works with 48 Volt Battery Packs Motor Compatibility: Works with 4500 Watt Brushless DC Motors Current Limit: 94 Amps (94 Amps Maximum Current Output) Low Voltage Protection: 39.2Volts Dc 2.4 Converter A DC-DC Converter is a category of power converter and it is an electric circuit which convert a source of direct current from one voltage level to another (48v to 12v). Specifications Input Voltage: 48 Volt to 72 Volt Output Voltage: 12 Volt Block dia. of DC-DC converter 3. CALCULATIONS 1)Aerodynamic drag can be calculated using the following formula. Fdrag=0.5CdA*1.225*(V+V0)² Where,1.225=Density of air
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2188 Cd-Coefficient of drag A-Frontal area of vehicle in m² V-Speed in m/s. 2)Rolling resistance can be calculated as follows: Frr=Crr*g*m Where, Crr-Coefficient of rolling resistance g-Acceleration due to gravity(9.81m/s²) m-Mass in kg. 3)Gradient force can be calculated as follows: Fg=m Where, m-Mass in kg -Road or hill climbing angle FT=Fdrag +Frr +Fg Where, FT-Total Force Total power required to travel electric scooter PT= FT*V Where, PT- Total Power, V-Velocity (m/s) Table-3: Specification of Vehicel. Coefficient of drag 1.28 Rolling resistance 0.030 Mass with rider 318kg Frontal area 2.25 m² Density of air 1.225 Road or hill climbing angle 25º Velocity 50kmph Radius of tire 11.5”=0.2921m Fdrag=0.5*1.28*2.25*1.225*50=88.2N Frr=0.030*9.81*318=93.58N Fg=318*sin(25)=134.394N FT=88.2+93.5+134.39=316.09N PT=316.88*13.88=4387.32Watt (Approximately= 4.5KW) 4. Data and Fault monitoring system: To monitor system parameters and fault and their location, we have developed a sub system that will take parameters from our high voltage system and display it on display or smart phone or desktop monitor. Initially I2C communication is established between two Arduino Uno. From this two Arduino one Arduino act as master and another as slave. Depending on parameters required we can increase the no of slave Arduino in the system. Arduino Master is placed at the front side of the vehicle; it will perform the action of initiation of slave arduino’s. Based on the algorithm programmed on slave it will perform parameters check. If all the parameters are within limit it will start main contactor which starts the system. If any parameter exceeds beyond the limit them it will display error on monitor and shutdown main contactor. The monitoring system is developed in such a way that it support 3d rendering. As is showninabovefigure.Ifthefault occurs and system shutdown then if user clicks on any ofthe button, then the application shows the location of that fault and associated components within the circuit. Development flow: 1. Initially I2C communication is established between master and slave. 2. Than slave is connected to system and algorithm is developed. 3. User Interface of Android application is developed in Unity 3d. 4. Java library is developed in Android Studio for establishing USB serial communication between android phone and Arduino master. 5. Library is then imported to unity 3D and final application is developed. Algorithm of Slave Arduino. Step 1. Establish I2C communication.
- 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2189 Step 1. Master initiate slave. Step2 . Slave check system parameters and connected component Step 3. Send Data back to master. Step 4. Master setup USB serial communication with monitoring device. Step 5. Master Sending serial data packets to monitoring device. Step6. Based on the received data UI elements and 3d environment are constantly changed. Flowchart: 5. CONCLUSIONS From this we can concludethebasicrequirementsof electric vehicle electrical system. We can also conclude the procedure to be followed for motor selection based on the dynamics of vehicle. Additionally more control is provided over the system by developing an algorithm by implemented I2C communication by using Arduino, so we can detect fault in system. REFERENCES [1] Selection of Power Rating of an Electric Motor for Electric Vehicles T.Porselvi1, Srihariharan .M. K 2, Ashok.J3, Ajith Kumar.S4 Associate Professor1, Student2, 3, 4 Department of Electrical and Electronics Engineering Sri Sairam Engineering College, Anna University, Chennai, India [2] https://www.electronicwings.com/arduino/arduin o-i2c [3] Kadlag Sunildatta Somnath, Mukesh Kumar Gupta "Implementation on Single Phase Electric Vehicle Battery Chargers “ Published in International Journal of Engineering and Advanced Technology (IJEAT) ISSN 2249-8958,Volume-9Issue-1,October 2019 [4] Kadlag Sunildatta Somnath, Mukesh Kumar Gupta “Review Paper on Electric Vehicle Charging and Battery Management System” Published in International Conference on Communication and Information Processing (ICCIP-2019) Available on Elsevier-SSRN [5] Kadlag Sunildatta Somnath, Mukesh Kumar Gupta " Charging Power Station for Electric Vehicles “ Published in International Journal for Research in Engineering Application & Management (IJREAM) ISSN:245-9150Special Issue- TIMRI - 2019 BIOGRAPHIES “Mr. Sunildatta Somnath Kadlag did B.E in electrical engineering from Dr. B.A.M.U. Aurangabad in 1997 and M.E in Electrical Engineering (Control System)from College of Engineering Pune (Pune University) in 2005. He is Currently pursuing Ph.D. in Electrical EngineeringfromSuresh Gyan Vihar University Jaipur (Rajasthan). His researchfieldarea is Electric Vehicle. “ “Mr. Shinde Sagar Balasaheb”, Appearing in BE Electrical(2020) from AVCOE, Sangamner, Maharashtra, India.
- 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 04 | Apr 2020 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2190 “Mr. Deshmukh Sairaj Sambhaji”, Appearing in BE Electrical(2020) from AVCOE, Sangamner, Maharashtra, India. “Mr. Waghmare Akash Sadgurunath”, Appearing in BE Electrical(2020) from AVCOE, Sangamner , Maharashtra, India Mr. Suryawanshi Shuubham Dattatrya”, Appearing in BE Electrical (2020) from AVCOE, Sangamner, Maharashtra, India.