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Motor Power Calculations and Controller PDF

The document discusses motor power calculations and controllers for electric vehicles. It describes factors that affect the required torque of an EV motor, including rolling resistance, grade resistance, and acceleration requirements. Equations are provided to calculate these forces and the total tractive effort. The required torque can then be determined based on the tractive effort and wheel radius. BLDC motors and motor controller wiring diagrams are also discussed. The document concludes with applications and precautions for electric vehicle motor systems.

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144 views

Motor Power Calculations and Controller PDF

The document discusses motor power calculations and controllers for electric vehicles. It describes factors that affect the required torque of an EV motor, including rolling resistance, grade resistance, and acceleration requirements. Equations are provided to calculate these forces and the total tractive effort. The required torque can then be determined based on the tractive effort and wheel radius. BLDC motors and motor controller wiring diagrams are also discussed. The document concludes with applications and precautions for electric vehicle motor systems.

Uploaded by

Rrdbjd
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Motor Power Calculations & Controller

Authors: B Kiran Kumar (9160207355, bkirran011@gmail.com )

Introduction:
To reduce the severe problem of Air Pollution in this century caused by fuel emission from
Automobiles, one answer has been developed called Zero Emission Vehicles (EV’s,HEV’s)
which are powered by onboard batteries and does not cause harmful emissions .A motor
controller is a device or group of devices that serves to govern in some predetermined manner
the performance of an electric motor.

Factors Affecting The Required Torque:-

When selecting drive motor for the electric vehicle, a number of factors must be taken into
account to determine the maximum torque required. These factors are:

1. Rolling Resistance

2. Grade Resistance

3. Acceleration Requirement

Calculating the Rolling Resistance:-

Rolling Resistance is the opposing force that the vehicle has to overcome due to the
rolling motion between the wheels and the surface of motion of the vehicle. The rolling
resistance depends on the co-efficient of rolling friction which varies depending upon
the material of tyres and the roughness of the surface of motion. The Rolling resistance
can be calculated as:

RR = GVW X Crr

RR = Rolling Resistance
GVW = Gross Vehicle Weight
Crr = Co-efficient of Rolling Resistance

Contact Surface Crr


Concrete(good/fair/poor) 0.010/0.015/0.020
Asphalt(good/fair/poor) 0.012/0.017/0.022
Macadam(good/fair/poor) 0.015/0.022/0.037
Snow(2 inch/4 inch) 0.025/0.037
Dirt(smooth/sandy) 0.025/0.037
Mud(firm/medium/soft) 0.037/0.090/0.150
Grass(firm/soft) 0.055/0.075
Sand(firm/soft/dune) 0.060/0.150/0.300

TABLE 1
Values of Co-efficient of Rolling Resistance

effi.saenis.org Drive the Future Page 1 of 5


Calculating the Grade Resistance:-
Grade resistance is the form of gravitational force. It is the force that tends to pull the
vehicle back when it is climbing an inclined surface. The grade resistance acting on the
vehicle can be calculated as:

GR = GVW X sinƟ
GR = Grade Resistance
Ɵ = Grade or inclination angle

Calculating the Acceleration Force:-


Acceleration force is the force that helps the vehicle to reach a predefined speed form
rest in a specified period of time. The motor torque bears a direct relationship with the
acceleration force. Better the torque, lesser the time required by the vehicle to reach a
given speed. The acceleration force is a function of the mass of the vehicle. Acceleration
force is calculated as:

FA = m x a

m = GVW / g

FA = Acceleration force
m = mass of the vehicle
g = acceleration due to gravity (9.81m / sec2)
a = required acceleration

Finding the Total Tractive Effort:-


The Total Tractive Effort is the total force required to move the vehicle with the desired
characteristics and is the sum of the forces calculated in above three sections. Therefore,
the Total Tractive Effort can be calculated as:

TTE = RR + GR + FA

Torque Required on the Drive Wheel:-


The torque that is required on the drive wheel will be the one that the drive motor
requires to produce so as to obtain the desired drive characteristics.

effi.saenis.org Drive the Future Page 2 of 5


The torque is:

ζ = Rf X TTE X rwheel
ζ = Torque

Rf = Friction factor that account for frictional losses between bearings, axles etc.

Rwheel = radius of drive wheel

Conclusion:-
The above results show that the motor torque for an electric vehicle can be determined if some
parameters of the vehicle like required grade ability and acceleration are known. Further, if the
required torque calculated is not produced by the available motor specifications then
modifications can be made in vehicle parameters like Gross Vehicle Weight, Wheels size,
Material of the wheels and transmission system.

BLDC Motor:-
A brushless DC motor is an electronically commuted DC motor which does not have brushes.
The controller provides pulses of current to the motor winding which controls the speed and
torque of the synchronous motor.

effi.saenis.org Drive the Future Page 3 of 5


Wiring Diagram of Controller:-

Applications:-

The simplest case is a switch to connect a motor to a power source. The switch may be manually
operated or may be a relay or contactor connected to some form of sensor to automatically start
and stop the motor. The switch may have several positions to select different connections of the
motor. This may allow reduced-voltage starting of the motor, reversing control or selection of
multiple speeds. Larger motors have a protective overload relay or temperature sensing relay
included in the controller and fuses or circuit breakers for over current protection. A video link is
attached below.

https://youtu.be/ccGljJxEm2w

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Precautions:-

 Regular Lubrication
 Regular Minor repair (if required)
 Avoid overloading over 600kg payload
 Avoid water submersion
 Avoid Short Circuit
 Avoid under-voltage & over-voltage power supply
 Only genuine KTC motor & KTC controller should be used
 Always use 48V DC battery
 Follow the colour codings of harness for connection as mentioned in description video

Reference:-

https://www.effi.saenis.org/pdf/Efficycle_2018_Information_Document_for_Motor_Kit.pdf

-Efficycle Alumni Committee

[DISCLAIMER: This document is created by members of Efficycle Alumni Committee based upon some facts and
their experiences of the event. The information included in this document must be considered only as the advice from
alumni for improvement in vehicle design, fabrication and validation. Some or all information may not be suitable for
specific designs developed by efficycle teams. These must NOT be considered as official guidelines & instruction
from Efficycle Technical Committee or the part of rulebook.]
effi.saenis.org Drive the Future Page 5 of 5

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