Project report template

College of Engineering

Department of Electrical Engineering

Fall 2019-2020

Learning Outcome Assessment Project Report

Design and Implementation of Electric Vehicle Using Three-phase Induction Motor

In partial fulfillment of the requirements for the

Degree of Bachelor of Science in Electrical Engineering

Team Members

Student Name

Student ID

1

Abdulaziz Alsaleh

201700157

2

Abdulaziz Alsubaie

201303093

3

Hussain Alsubaie

201300242

4

Omer Malik

201202993

Project Advisors:

Advisor Name: Mr. Saifullah Shafiq

Co-Advisor Name: Mr. Ahmed Abul Hussain

Abstract

Recently, the major numbers of transportation sector utilize fossil fuel. Moreover, the process of burning fossil fuel damages the atmosphere by adding massive amounts of carbon. In the other hand, the fossil fuel reserves are depleting which leads to an increase in the prices in the market. Additionally, new environmental rules that are being forced on the people in order to reduce carbon emissions. Thus, the rising of electric powered vehicles is seen as the top solution to reduce greenhouse emissions and save nature. This paper proposes advanced methods of assembling an electric drive system. A variable frequency drive (VFD) is implemented to drive a three-phase induction motor using a battery bank. Also, the sinusoidal pulse width modulation (SPWM) technique is used to implement the VFD. To ensure the passengers safety, a mechanical braking system is implemented into the electric drive system.

Table of ContentsAbstract21.Introduction51.1Project Definition51.2Project Objectives51.3Project Specifications51.4Product Architecture and Components61.5Applications62.Literature Review72.1Project background72.2Previous Work82.3Comparative Study93.System Design93.1Design Constraints93.1.1Design Constraints: Engineering Standards93.1.2Design Constraints: constraint name93.1.3Design Constraints: constraint name93.2Design Methodology103.3Product Subsystems and Components103.3.1Product Subsystem1: name Comm, Control …103.3.2Product Subsystem2: name Comm, Control …123.3.3Product Subsystem3: name Comm, Control …123.4Implementation134.System Testing and Analysis134.1Subsystem 1: name144.2Subsystem 2: name144.3Overall Results, Analysis and Discussion145.Project Management105.1Project Plan105.2Contribution of Team Members105.3Project Execution Monitoring105.4Challenges and Decision Making115.5Project Bill of Materials and Budget116.Project Analysis126.1Life-long Learning126.2Impact of Engineering Solutions126.3Contemporary Issues Addressed127.Conclusions and Future Recommendations137.1Conclusions137.2Future Recommendations138.References14Appendix A: Progress Reports15Appendix B: Bill of Materials15Appendix C: Datasheets15Appendix D: Program Codes15Appendix E: Operation Manual15

Introduction1.1Project Definition

Nearly everyone in the 21st century owns a petrol-powered car but having an electric car is one of a kind so we planned on making one which will help set an example for the future, which will help make the world a better place and will be more efficient than the regular one.

1.2Project Objectives

i. Increase public awareness about impact of high demand on petroleum products and finding other measures to reduce this demand.

ii. Encourage adoption of echo friendly transportation vehicles

iii. Reducing maintenance cost of vehicles.

1.3Project Specifications

i. Speed range - .ii. Three phase induction motor 4 hp.iii. Breaking Mechanism.iv. Capacity for one passenger. v. Lead Acid Batteries (9 Ah) (300 - 320 V).

1.4Product Architecture and Components

Figure 1

A. Control Unit:

The control unit is the most important component of an electric drive system. It generates all the control signals required to adjust the speed and torque of IM based on the user response. The circuit board is shown in Fig. 2. These control signals are fed to the three-phase inverter through gate driver.B. Drive System: Drive system like in conventional vehicles is responsible for driving the vehicle in forward as well as reverse direction. It consists of three-phase inverter which takes power from a DC battery bank and converts it into three phase variable frequency, variable voltage AC by means of pulse width modulation technique to drive three-phase IM.

C. Energy Source:

The electric drive system utilizes power from a dc battery bank which provides energy to drive the three phase IM.

D. Breaking Mechanism:

The breaking mechanism in this electric drive system is a mechanical break.

E. Auxiliary Load

The auxiliary load includes loads of lights, indicator, horn, fan, …etc.

1.5Applications

The proposed system can be used:

i. As a low-cost transportation vehicle.

ii. Reduce air pollution.

Literature Review2.1Project background

Fossil fuels have been an important source of energy since the Industrial Revolution in the 18th century. Nowadays, mankind depends mainly on fossil fuels as a power/energy source for machinery. Along with the increase in population drastically, the demand on fossil fuel increased along. Recent studies have shown that

resources are close to running out of the natural resource known to us as fossil fuel, which means it time that we have to start considering other options to turn to. Globally many institutes, research and development labs, and various universities are looking into renewable energy now as that seems to be the only logical and practical way. Moreover, Global Warming is turning out to be more real than expected by all, weather changes can be seen everywhere which is causing catastrophic effect not just to Earth but also to mankind. Solar vehicles and Electric vehicles are considered to be the future of automobiles. We as students want to play our role by contributing to solving these problems as much as possible. This meant for us to go completely electrical and depend on natural source of energy as much as possible. Renewable energy is vital for today’s world. Electric cars on the other hand help reduce dependency on fossil fuels hugely; they cause zero carbon emission and thus help reduce Global Warming. Geographically looking what the most obvious and essential place our project fits into is ‘VISION 2030 Saudi Arabia’, but that’s not the only place our project fits into. The project fits in line with the projects going on at Major Universities globally related to renewable energy and reduction of carbon footprint.

2.2Previous Work

The previous work to be discussed is an electric car performed by electrical engineers in Belgium Figure 2. The study was done by four senior students from Kaholieke Universiteit Leuven in Belgium. The design task was to build an electric go-kart. The performance of this electric go-kart has to be comparable to the performance of conventional go-karts for rental purposes. The final goal was an optimal power management of the go-kart, such that its velocity and acceleration is similar with that of conventional go-karts. Both the choice of components and the control of these components were part of the students’ assignment. The main components of an electric go-kart were the motor and the batteries, but peripheral equipment such as brakes and sensors were essential for a safe vehicle too. Before the motor and batteries could be selected, the necessary go-kart power, torque and energy had to be determined. However some boundary conditions, mostly of practical nature, will impose limits on the design. An empty go-kart chassis as depicted in Figure. 3 is available to the students.

Figure. 2 Figure. 3

2.3Comparative Study

As for the comparison between our Electric Vehicle and the previous Electrical Vehicle done by the students of Kaholieke Universiteit Leuven. First, the motor chosen by us is an AC three phase inductor motor while their motor was a DC motor. Second, our EV has an inverter to transform the DC coming from the battery into AC and feed the three-phase induction motor. However, the other project doesn’t need an inverter an take the DC directly to the DC motor. Third, the microcontroller used by us is STM32 which is best for motor control and 96kb RAM memory. While the microcontroller used by the previous EV is Arduino which is a lower leveled microcontroller than STM32 in term of timers and transistors.

System Design3.1Design Constraints 3.1.1Design Constraints: Economic

Saudi Arabia is the top country in producing oil in the world, our project can cause the main income of the country to be lower if our project started to be sold in the market. So, prior starting with our project, we as a group have taken into consideration whether our project will be beneficial or disastrous to the economy of Saudi Arabia.

3.1.2Design Constraints: Manufacturability

Availability of parts in local market caused us to alter our design to match the parts bought off the internet. Also, the cost off components was high comparing to the parts used by a fossil fuel vehicle.

3.1.3Design Constraints: Safety

The Electric vehicle can reach up to a speed of 50 km/h. A speed in which steering can be a little bit difficult. Moreover, the EV does not have safety materials like seat belts and airbags.

3.2Design Methodology

When building a powered prototype, there are a large number of formulas and calculations which must be met and considered to produce a sufficiently-powered, well-functioning and safe prototype. The main part of our project is the motor. The higher the power of the motor, the more work and performance our electric car can achieve and deliver. The first point that must be identified is the number of watts that the motor can deliver. Below are basic approaches and some important formulas and calculation details to determine mechanical power requirements of a AC motor, torque, etc. Figure. 4A-B-C

Figure. 4A

Figure. 4B

Figure 4C

3.3Product Subsystems and Components3.3.1Product Subsystem1: Gate Driver circuit

The signals generated by controllers are then fed to three-phase inverter through gate driver. The gate driver circuit is an intermediate stage between controller and three-phase inverter. The purpose of the gate driver circuit is to perform proper switching of low and high side switches of inverter. In addition, it ensures the proper isolation between the controller and the high voltage circuit. The isolation is done using optocouplers. Figure. 5A-B

Figure. 5A

Figure. 5B

3.3.2Product Subsystem2: Inverter

Control Signals Adjustment Algorithm:

After the ADC reads the speed signal, CSAA adjusts the frequency as well as voltage of PWM signals. It compares the required frequency with previous frequency and based on the difference between them it either starts increasing or decreasing the frequency by certain amount depending upon the pickup limitations. At the same time, voltage level is also adjusted according to the V/f principle. It is determined that whether the required frequency is greater or smaller than the rated frequency. If required frequency is less than the rated frequency, voltage level must be decreased in proportion to the frequency to avoid saturation in accordance to V/f principle. This is done by multiplying the duty cycles by a certain factor. However, if required frequency is greater than the rated frequency, the voltage should be kept constant at rated voltage. Hence, there is no need to update the duty cycles. The flow chart of CSAA is shown in Fig. 6 & Figure 7A-B-C .

Figure. 6

Figure. 7A

Figure. 7B(Bottom)

Figure. 7C3.3.3Product Subsystem3: Drive System

Drive system like in conventional vehicles is responsible for driving the vehicle in forward as well as reverse direction. It consists of three-phase inverter which takes power from a DC battery bank and converts it into three phase variable frequency, variable voltage AC by means of pulse width modulation technique to drive three-phase IM

Figure. 8A (AC motor with gear box)

Figure. 8B (Heat sink)

3.4Implementation

We now have a clear understanding on how to start the project. Despite the fact that we have a compact space in our car, we managed to decide on where to place the parts. The batteries will be placed in the back. The motor controller assemblage will be placed next to the batteries and the AC motor for an ease of connections. We have the motor connected in the rear side of the car in order to attach the motor sprocket with the rear axle sprocket. Figure. 9A-B

Figure. 9A

Figure. 9B

4System Testing and Analysis4.1Subsystem 1: Gate Driver

Figure. 10(Top)

Objective:

The gate drive circuit is used as an intermediate stage between controller and three phase-inverter. The purpose of the gate driver circuit is to perform proper switching of low and high side switches of inverter. Also, it ensures the proper isolation between the controller and the high voltage circuit. The isolation is occurred using optocouplers.

Setup:

We had bought the components of the gate driver circuit, specified to us by our advisor. We then had to put together and built the circuit on a breadboard which was then tested using a 5V dc motor weather or not the circuit was working properly.

Results:

· The signals where being sent and received decently fine.

· The gate driver was not heating up.

· There was no short circuiting.

4.2Subsystem 2: Inverter

Figure. 11 (Top)

The inverter circuit in the figure above is used to help change the voltage coming from the batteries, which is 312V dc to Ac. It consists of 6 IRF840’s which help in the reduction of voltage we tested this along with the gate driver using a 5V motor to see if it can change dc to ac.

Figure. 12 (Top)

The figure 12 shows the test that was down to check if the gate driver and the inverter are working together or not and the figure 13 shows the signals generated by the invertor.

Figure. 13 (Top)

4.3Overall Results, Analysis and Discussion

The testing for both subsystems was a fundamental way to deal with and get an unmistakable thought of how every subsystem is working as it should be. We have worked upon our testing results and decision-making procedure to change, and replace any malfunctioning component.

5.Project Management

We as a group had most extreme trust in technique and workmanship while performing

each task; this sets us in a spot where we work under the umbrella of the project management.

Project management isn't only for project managers, there is a whole other world to extend the board than is generally accepted. A project can be characterized as a short-lived endeavor planned to make a surprising thing, organization or result which is administered by fixed time duration and capital. This endeavor is planned to meet specific objectives. Project management is an order that requires arranging, controlling and execution of work

as a group to accomplish certain set objectives and targets. It is the method and development of masterminding, dealing with, motivating, and controlling resources, strategy and shows to

achieve our targets.

5.1Project Plan

Abdulaziz Alsubaie:

-Fixing motor in car.

-Finding gear to connect with motor shaft.

-Fixing chain drive system.

-Brakes etc.

Hussain Alsubaie:

-Thimbles and wires for connection

-Acquire Tools for connecting/fixing everything within car chassis.

-Thermal paste for IGBT's

-Acquire ampere meters.

Omar Malik:

-Making box for inverter.

-Cooling fan.

-Circuit breaker.

-Acquiring Fuses.

Abdulaziz Alsaleh:

-Writing progress reports.

-Writing midterm report.

-Writing final report.

The project planning was chosen once we formed our group, this comprised of thinking of appropriate and reasonable project ideas. When the subject was chosen, we began taking a shot at a point by point plan and made a rundown of the to-do assignments, each task had its very own beginning and end date. A project plan table can be seen beneath in Table 5.1

5.2 Contribution of Team Members

Task

Omer

Abdulaziz Salah

Abdulaziz Subai

Hussain

Task Total

Search & acquire components

25%

25%

25%

25%

100%

Design Subsystems 1

25%

25%

25%

25%

100%

Test Subsystems 1

25%

25%

25%

25%

100%

Design Subsystem 2

25%

25%

25%

25%

100%

Test Subsystem 2

25%

25%

25%

25%

100%

Write Reports & Presentations

25%

25%

25%

25%

100%

5.3Project Execution Monitoring

· Weekly meetings were conducted with Project Advisor (Mr. Saifullah Shafiq) and project Co advisor (Mr. Ahmad Abul Hussain).

· Weekly meetings were conducted only with team members.

· Constant communication with team members on ‘whatsapp’ for constant update on progress.

· Research & Report Making

· Making weekly drafts of progress.

· Acquiring a Chassis

· Research on required subsystems components.

· Purchase of subsystem components

· Testing on the components of subsystem

5.4Challenges and Decision Making

Because of the uniqueness of our project in this region of the world, we faced numerous difficulties and obstacles that different our group might not have encountered. These challenges and obstacles are recorded underneath and further clarified after.

· Budget

· Availability of Chassis

· Availability of Parts

· Shipment of Parts

· Cooperative Workshops / Skilled Worker

· Time Duration

· Extra load by other courses

5.4.1. Budget

As we are non-employed students, we are keeping up the financial plan to a dimension where everybody feels comfortable and keep it reasonable with other individual students was quite troublesome because of the expense of parts/subsystem components.

5.4.2 Availability of Chassis

As we were sticking to a base and sensible spending plan with quite certain measurements, we went for acquiring a used chassis. This was a hard task as most utilized body were either rusted or distorted to a level that reestablishing it would require more capital and a great deal of time or didn't match with our required measurements by any stretch.

5.4.3 Availability of Parts

Acquiring a 3 phase AC Motor with our specifications was the most difficult one among all the challenges we faced, as no company manufactures an AC Motor in Saudi Arabia or neighboring countries and neither are, they available in the local market. This forced us to go online and look for it.

5.4.4 Shipment of Parts

Shipment of parts took a very long time as the provider’s office was located in USA, but the parts had to be shipped from China as their manufacturing plant was located in China

5.5Project Bill of Materials and Budget

Item

Quantity

Unit Cost (SR)

Subtotal (SR)

Chassis

1

1500

1500

Tires

4

150

600

3-φ induction motor

1

4000

4000

STM32

1

300

300

Inverter

1

1500

1500

Batteries

24

100

2400

Total

10,300

1. Project Analysis

6.1Life-long Learning

While we are working on our senior design project, we learned so many new things especially from our adviser’s previous skills and knowledge that he had. We learned from our adviser his guidance and instruction what he had told to us to complete the task.

As a team, we learned from each other because each member has his own experience such as technical skill, presenting and communicating skills. Moreover, we looked up on the internet some ideas that have done before regarding to our project. We applied skills that we learn in the last five years from our Electrical courses such as Digital System, Electronics 1,2 and Microprocessor. In which, those classes helped us a lot to complete our Project.

As a team, we are learning from each other especially when our team leader assign the task to each member to complete in specific deadline. Called a time management where you need to manage your time to complete everything on time. If we did not manage our time, we could not finish our project and the tasks given by team leader.

In our project, we learned how to use STM 32 Microcontroller in our subsystem 1 and how to program it. In the past, we learned about Arduino but this STM 32 Microcontroller is new and advance programming printed circuit board. It help us to improve our programming skills as Electrical Engineer.

We learned about Atmel Flip software this is an advance-programming tool that help us to program by using stm 32 printed circuit board.

6.2Impact of Engineering Solutions

Our project can bring a big advantage for country for example, It can help to reduce pollution that cause of global warming. As we know that the cost of oil is increasing each day after day so it will help us to save fossil fuel and use in other equipment’s rather than using in cars or trucks or buses. It will also help to increase our economy sector.

6.3Contemporary Issues Addressed

The main issue addressed here dependency on fossil fuel and to increase the export therefore increasing the total revenue. Electric cars have a huge effect in the society economically and environmentally. If we look up on Tesla cars, they are making a trend to produce cars that works on clean energy such as Tesla or BMW or other germen cars. We as Saudi Engineers move on, and adopt the trend, and move farrowed to future as our crown prince mentioned vison of 2030.

7.Conclusions and Future Recommendations7.1Conclusions

Currently everything is still depends on fossil fuel but as price of fossil fuel increasing day by day, we need to utilize other resource like electric power instead of fossil fuel. As result, we designed an electric car that works on a three-phase induction motor using lead acid batteries.

In the past and previous project, they were using a DC motor but, in our project, we are using an AC three-phase induction motor because it fits our needs and specifications perfectly. We used lead acid battery, as comparing to the pervious projects they used lithium ion batteries. We used lead acid battery because it’s cheaper than lithium ion, generates less heat and is much safer. The most complicated challenges that we faced about programming to STM 32 because it was a new for us and different from what we had learned about Arduino. Other challenge that we faced designing a gate driver that comes in our Control Unit part. We built gate driver to control frequency as well as voltage through pulse width modulation. It was difficult for us but by taking advice from our advisers, we succeed in designing our subsystem 1. We learned about some new electronics component such as Optocoupler that used for safety for electronics circuit and some high frequency transistors that we used in our subsystem 1.

7.2Future Recommendations

· Implementation electric car using three phase induction motor in Saudi Arabia

· Using Solar panel can become a great resource to charge car batteries

8.References

1- Zachary Shahan, Electric Car Evolution, the history of solar power science, 2015, April 26th , Accessed May 2017

2- Nissan Leaf, car manufacturing forum, Business and Economy, 2010, Accessed May 2017

3- Chris Lilly, New Class Leading Renault, ZOE Z.E., zap map forum, 2016, Accessed April 2017

4- ÁnyosJedlik, Electric Vehicles History Part II, Early History, 1998, the invention of the electric vehicle, Accessed April 2017

Appendix A: Progress Reports

Progress Report (1)

Progress Report (2)

Progress Report (3)

Progress Report (4)

Appendix B: Bill of Materials

Item

Quantity

Unit Cost (SR)

Subtotal (SR)

Chassis

1

1500

1500

Tires

4

150

600

3-φ induction motor

1

4000

4000

STM32

1

300

300

Inverter

1

1500

1500

Batteries

24

100

2400

Total

10,300

Appendix C: Datasheets

Appendix D: Program Codes

Example:

· Labview codes,

· Matlab codes

· Microcontroller codes….

Appendix E: Operation Manual

Include guidelines steps that can be used to:

· Run projrct prototype,

· Run the codes

· List expected outputs

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