Design and Implementation of Hybrid Electrical Vehicle with regenerative braking and multiple sources
Earth has limited amount of energy resources which is very soon going to extinct. As the population is increasing the demands of people is also increasing. The question is whether the earth?s resources are sufficient to sustain that population at a high standard of living for all in this key issue i
2025-06-28 16:31:43 - Adil Khan
Design and Implementation of Hybrid Electrical Vehicle with regenerative braking and multiple sources
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryEarth has limited amount of energy resources which is very soon going to extinct. As the population is increasing the demands of people is also increasing. The question is whether the earth’s resources are sufficient to sustain that population at a high standard of living for all in this key issue is energy. Secondly Noise is another big issue for humanity. Or aim is to build vehicle which is friendly for our environment.
EVs do not have charging points so when they will be covered with solar panels on the body of vehicle, during parking and travelling they will be able to restore much energy. Cost of electricity is high so solar can benefit is this regard.
In Series plug in Electric vehicles engine and other sources are related to each other during operation while in Parallel PEVs both (Engine and other sources) are separately operated.
The follwing figure shows the different types of vehicles with their sources
Typically, EVs consists of DC or AC motors (along with convertors), motor controllers, Batteries, charge controller and other mechanical structure. We will use additionally Super Capacitors which will be charged by the regenerative Braking System and will provide the peak voltages to the DC bus, because the energy provided at the start is not sufficient to provide the peak energy demand. Additionally, we will use solar energy which will provide energy to the batteries which will store in them and provide the DC bus energy.
The controller will be used to control the power flow from different sources to the DC bus which will combine energy from all source s and provide power to motor controller and finally to the traction (DC motors).
Our Solar (PV module) will be connected to the Boost converter topology and Ultra-capacitor will be connected to Buck-Boost converter.
We aim to design an Energy Management system which will monitor the overall energy exchange between multiple sources and state of charge of battery and Ultra-capacitors.
The extension of our project is to design a controller to control the SOC of battery and UCs and regulate the DC- bus voltage and currents to their optimal reference values.
Lithium Ion battery is used in this project. PID control is used for electrical and fuzzy logic is for mechanical control of vehicle.
Project ObjectivesThe “Design and Implementation of Hybrid Electrical Vehicle with Regenerative and Multiple Sources” aims to design and implement the Electrical and Mechanical system of Hybrid Electrical Vehicle incorporating with Regenerative braking system with Ultracapacitor, Battery, Solar on the roof.
The Project aim is to improve the efficiency of the vehicle by designing the sophisticated control system and the Energy Management System which will control the incoming power from sources.
Problems in Conventional Vehicles- Conventional Vehicles are dangerous to our environment.
- Fossil fuel resources are limited.
- FFVs (Fossil Fuel Vehicles) are expensive.
- PEVs (Plug in Electric Vehicles) don does not use renewable energy sources such as Solar.
- PEVs wastes energy in friction during braking.
- Incorporation of renewable source to make it cost effective and environment friendly
- Designing and implementation of Regenerative braking System to conserve energy
- Design of and implementation of EMS of Multiple sources
- Design of and implementation of Control System for varying load conditions
- The proposed project of “Design and Implementation of Hybrid Electrical Vehicle with Regenerative and Multiple Sources” contains multiple sources with Battery being the primary source of Energy and ultra-capacitors shall be used as auxiliary source.
- Ultra-capacitors will harvest the energy through regenerative phenomenon. We will have a battery for storage of extra energy as well.
- Our Solar (PV module) will be connected to the Boost converter topology and Ultra-capacitor will be connected to Buck-Boost converter.
- We aim to design an Energy Management system which will monitor the overall energy exchange between multiple sources and state of charge of battery and Ultra-capacitors.
- The extension of our project is to design a controller to control the SoC of battery and UCs and regulate the DC- bus voltage and currents to their optimal reference values.
We have divided our project in following milestone. Following are the implementation methods for each milestone.
- Selection of motor and its rating
The Selection of most efficient traction motor is the main part in the designing of vehicle. We selected BLDC motor for its high-power density, no brushes involved, high efficiency 85 to 80 percent over induction motor which is 75 to 80 percent. For the calculation of rating first we made our estimate that there will be weight of 500kg of overall vehicle. Then by Calculating the torque required and assuming speed of 40 km/h we calculated the power ratings of 1kw with gear ratio of 21/9 to drive the Vehicle.
- Design of mechanical structure (only Length, width, shape)
We have designed our Iron frame which are the basis and will bear all weight, as the scope of our project is not to design the every parameter related to mechanical part so we only specify how much there will me length, width and what will be the shape of vehicle. Keeping all in mind that the weight will not increase than 300 Kg (assuming 200 Kg weight for passengers).
- Design of Regenerative braking system
We selected Series Regenerative Braking system.
The control of the braking is PID for electrical System and Fuzzy Logic for the mechanical System.
PID control will involve Primary and Secondary Control to define that how much capacitor will be charged.
The rating of Supercapacitor is determined by calculating the torque, then current generated by this torque and finally Capacitance of Capacitor.
- Design of battery
We have selected Lithium-Ion battery and the ratings is based on the current requirement to drive the motor and for how long we will provide the current. Each Lithium-Ion cell have Voltage 3.7V and Current of 2.5A. By Series and parallel combination of cells we have designed battery of 48V and 50AH.
- Design of Energy management system
We have 48V bus which will be used to deliver power to motor and receives the power from sources. The Block Diagram for the EMS is as follows
- Main control of complete process
Our Solar (PV module) will be connected to the Boost converter topology and Ultra-capacitor will be connected to Buck-Boost converter.
The extension of our project is to design a controller to control the SoC of battery and UCs and regulate the DC- bus voltage and currents to their optimal reference values.
The control process is explained by the following diagram
- Designing of Solar system
The Area of roof is approximately 2 m2 so accordingly we designed that 3 150W plates will cover our roof.
- Implementation of Hardware
We have completed our 70% of hardware yet the following pics are of hardware.
The “Design and Implementation of Hybrid Electrical Vehicle with Regenerative and Multiple Sources” has much benefits in the automobile sector.
Our HEV is Cheaper to run, Cheaper to maintain, produces less pollution, uses Renewable energy sources , all these are Environment and pocket friendly factors.
- Regenerative Braking extends the battery charge
The electricity is used to replace car batteries until the energy is captured by the regenerative braking. Because this energy is typically wasted, any automobile will encounter a lengthy charge when driving.
Too braking in city regenerative braking has been shown to contribute to improved fuel economy – by as much as 20%.
- Using a supercapacitor will improve the peak supply needed to start the motor, so less current will be provided by the battery which will improve its life.
- The peaks in the regenerative braking can reduce the battery life but when we will use the supercapacitor the sudden peaks have no effect on its life and will benefits overall Energy management system.
As the electric transmission mechanism is part of the system, the greater stopping efficacy contributes to a lower wear on the vehicle's brakes. There is no way to obtain this advantage for normal friction braking.
- 80 % of EVs have at least 75% battery level at the end of their charging session. So if we will install solar panels on the roof it will significantly improve the timing to use the battery during day time.
- We have chosen parallel Configuration of motor and Engine. A decreased traction motor size, the absence of a generator and efficiency losses reduction in the various power transfer processes between electrical devices and the battery are some of the benefits of parallel configurations.
- During Night from some reasons, if we have not charged battery then we can drive our vehicle through Engine.
So there are lots of benefits, applications and advantages of this project in commercial automobile sector.
Technical Details of Final DeliverableThe “Design and Implementation of Hybrid Electrical Vehicle with Regenerative and Multiple Sources” will be complete model of Vehicle as shown in below
- The model shown above is not completed yet. It will also include outer body of the car and whole Electrical system will be attached to it.
- The model has 11 feet length and 4.5 feet width.
- Solar will be installed at the roof of this model.
- The ratings of the motor is 48V BLDC .
- The ratings of the Battery is 48 V 50AH
- The Voltage of the DC bus is 48V.
- The voltage produced by solar will be 12 V and will be boost to 48V to store into the battery.
- Super Capacitor will be attached by buck boost converter to DC bus and then power will go or taken through battery to bus and finally to motor.
- State of Charge will be measured and according to state of charge the energy management system will be controlled.
- HMI will show the speed and SOC of battery on screen.
- 100CC Engine is used in this model.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 80000 | |||
| 48V 1000W BLDC Motor | Equipment | 1 | 23000 | 23000 |
| 48V 1000W BLDC Motor Controller | Equipment | 1 | 2000 | 2000 |
| Bidirectional DC-DC (Buck Boost Converter) | Equipment | 2 | 800 | 1600 |
| Lithium Ion BMS and Charge Controller | Equipment | 1 | 8000 | 8000 |
| Super Capacitor 12 V | Equipment | 1 | 12000 | 12000 |
| Model Body | Equipment | 1 | 10000 | 10000 |
| Solar Pannel | Equipment | 3 | 4000 | 12000 |
| SOC monito , Arduino, microcontroller, | Equipment | 1 | 1400 | 1400 |
| HMI LCD scree , Copper wires , Remaining Body Parts | Miscellaneous | 1 | 10000 | 10000 |