MOBILITY

Engineer 2030
Systems Thinking for Mobility Engineers
A SYSTEMS ENGINEERING APPROACH TO EV DESIGN – PART 1
Systems Engineering, Systems Thinking, Architectural Thinking
Electric Vehicles (EV), Automotive Product Design Pradeep Kumar Keloth, Poornendhu PT and
Dr Shankar Venugopal

1. Introduction when considered separately. The first layer of complexity

emerges from the fact that electric mobility is at the

A conscious shift to sustainable modes of mobility is

a global trend that is rapidly transforming the land-
scape of the Indian automotive industry. Electric Vehicles
convergence of multiple technologies and industries. The
EV technology, when combined with connected vehicle
and autonomous driving technologies, has tremendous
(EVs) are expected to play a key role in accelerating India’s
disruptive potential. A new mobility industry is arising at
transition to sustainable mobility. The transition to EVs is
the convergence of the traditional automotive industry,
attractive as they are intrinsically energy efficient. EVs
infrastructure industry and the power industry. EVs would
convert over 75% of the electrical energy from the grid
critically depend on the charging infrastructure and clean
to power at the wheels while conventional petrol vehicles
electricity to realise their true potential of enabling green
only convert about ~ 30% of the energy stored in fuel to
and sustainable mobility. The adaption of EVs by the Indian
power at the wheels. EVs are environmentally friendly as
customers will be greatly accelerated when their range
they emit no tailpipe pollutants. EVs are attractive from
anxiety is effectively addressed and a hassle-free charging
their performance as the electric motors provide quiet,
solution is provided through technology innovations.
smooth operation and stronger acceleration and require
less maintenance than internal combustion engines (ICEs). The central message of our paper is that the design
In an EV, instant torque is generated by the electric motor, of electric vehicles (EVs) requires systems thinking. It
whereas an ICE takes time to combust gas and turn the is evident that we cannot build a high performance EV
crankshaft. just by integrating a battery pack with maximum energy
storage capacity, an electric motor with maximum torque
The transition from ICE to EVs is quite complex due to
and power, control systems and other components. The
the multidimensional nature of electric mobility. Analysing
optimization of EV’s performance happens at the interface
the electric mobility ecosystem in India is similar to the
of these components and sub-systems. Let us consider, as
challenge faced by the six blind men who tried to describe
an example, the case of increasing the range of EV. If we
an elephant in the Indian parable. Just like the elephant,
try to achieve this goal by using a bigger battery pack,
electric mobility consists of inter-related parts that are
then we would be increasing the weight of the battery. EV
significantly more important when put together than

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batteries usually weigh 20 – 25% of the total car weight.
Beyond a limit, the additional weight will start reducing
the range of the EV. A bigger battery would also signifi-
cantly increase the cost and the charging time. If we think
of using a structural battery, then we have to consider its
impact on performance related to crash, durability, driving
dynamics NVH etc. Engineers designing EVs should be
proficient in systems thinking and multi-disciplinary opti-
mization.

2. Introduction to Systems Engineering system level (System Design Engineer) to ensure that they
achieve this. However, in reality it may so happen that
System is defined as a set of components that are inter-
these engineers are separated by different organization,
connected to achieve a desired performance from the
or by different team in the same organization or compo-
interconnected components [1]. The resultant function-
nents are imported, and in all such situations achieving the
ality at system level is more than the sum of functionality
common goal becomes difficult and challenging. Subash et
of individual components. Systems can either  be Phys-
al have elucidated how systems and architectural thinking
ical  or  Conceptual, or a combination of both. In System
can help engineers in automotive design [5].
Engineering, we deal with both physical as well as concep-
tual systems. Let us discuss, as an example, the Power Mathematical Modelling
Train System in an EV. The major components of a Power
Mathematical modelling or representation of a physical
Train System are a battery, traction inverter and an elec-
system through mathematical equations is an important
trical machine. Working of Power Train System or any of
step in the analysis of physical systems. However, the depth
its components are governed by the laws of physics and
and approach to modelling is different for both Compo-
hence are referred to as physical systems. However, these
nent and System engineers as detailed below. A Compo-
systems are designed and optimized based on the require-
nent Design Engineer uses detailed component models
ments set by the customers. Customer engineering activ-
with FEA (finite element analysis), multi physics optimisa-
ities like discussion with the customer, understanding and
tion etc. e.g.: Design of an electrical machine involves Elec-
documenting the requirements, design prototyping and
tromagnetic analysis, stator design, no of slots, shape of
upscaling etc. are a part of the conceptual system which
the slot, selection of number of poles, type of windings –
requires a human interference, and such systems are not
concentrated or distributed, selection of material, thermal
governed by law of physics. A detailed analysis of how
considerations, mechanical forces etc. A system engineer
mobility engineers can understand the customer needs
on the other hand uses a black box approach where he
and design mobility products that precisely address those
defines the system boundary and input and output. He will
needs has been described as a five step design thinking
be interested only in establishing the relationship between
process (empathize, define, ideate, prototype and validate)
input and output in a simplified manner. E.g., For the same
in a series of three papers by Sayantan and Shankar [2-4].
electrical machine, the system engineer will try to estab-
It may be noted that, the best performing components lish relation between AC power supply input to the output
integrated together will not result in best performing Viz Torque and power at various speeds. The relationship
systems. During the design of a System, it needs to be between the input and output in System Engineering is
ensured that both bottom up and top down approaches represented by set of differential equations or algebraic
are followed in tandem to make system performance equations or through look up tables. A Component Design
optimal, making full use of component functions without Engineer specifies the design limit of the components
violating any of the limiting boundary conditions at the like max temp., pressure, current, voltage, speed, torque
component level. Achieving this optimal performance etc. The system engineer on the other hand analyses the
at the system level is one of the biggest challenges in interactions between the components and try to take best
System Engineering. A team of engineers work together from each of the components without violating the above
at component level (Component Design Engineer) and design limit conditions set by component engineer.

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The activities done by a component engineer and 3. Designing an Electric Vehicle
system engineer are captured in Table below.

Component Engineer System Engineer

Detailed mathematical Mostly Differential and
models – Typically Partial Algebraic Equations
Differential Equations and
Finite Element Analysis
Multi physics simulation Abstracted information
( eg. Electromagnetic, only (e.g. Electrical
Thermal and Structural machine or battery
analysis along with pack simulation will
optimization as in case of an have only simplified
Electrical machine design) models)
Detailed understanding Mostly black or
of every part of the grey box approach
Figure 1: A Typical Electric Vehicle
components in the System (establishes input and
output relations and The System Engineering
Figure 1: Aas depicted
Typical Electricin Figure
Vehicle (EV)2 is an
interactions only) holistic approach in designing the system viz. Electric
Accuracy of simulation is Accuracy is secondary Vehicle in this case [6, 7]. There are some typical system
crucial level performance parameters that needs to be set as
Component design Simulation needs to be detailed by the customer requirements such as vehicle
simulation typically takes a fast acceleration, Power, Max speed, Gradability and Range.
lot of computation time A system engineer needs to make the correct choices
Table 1 : Activities of component engineer Vs System engineer
of various components and its combinations and create

System Requirement  Semiconductor technology

 Different inverter
Govt Policies and tax benefits topology
 Different switching

BEV system topologies

 CURRENT
 CHEMISTRY
 LIMITVOLTAGE
Power electronics
Acceleration  CURENT LIMIT

HV Battery

Range
Electric Motor

AC DC

Max Speed
Control strategy
PMSM
BLDC
Gradability
 FOC
 MTPA INDUCTION
 EMS SRM
 TMS

Powertrain topology

OTHER FACTORS
COST&WEIGHT
Thermal limits
 TEMPERATURE LIMIT OF ALL
 EV COMPONENTS

Figure 2 : System Engineering approach for Component Design

Figure 2 : System Engineering approach for Component Design

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Overall System Engineering approach to EV design, requires looking

into the problem statement from multiple perspective before designing
and finalizing on the end-product.

a design prototype of the entire system to meet these Battery: Another criterion to meet the requirement is
requirements as a part of System Engineering. Let us the selection of cell chemistry. Some parameters that need
investigate some of the design criterion that are neces- to be looked into are energy density, power density, cost,
sary to build an Electric Vehicle. safety, life span and performance of each cell chemistry.

Electric Machine: Electrical machine is the core part Electronics: Choice of power electronics consists of
of the electrical vehicle. There are several choices for selection of semiconductor technology (SiC for example),
an electrical machine like the PMSM machines, Induc- traction invertor topology, switching strategy etc.
tion machines, switched reluctance machine, Axial flux
Control algorithm: Control algorithms plays an
machines or BLDC machines. The PMSM machine is
important role in the overall operation by enhancing the
widely used and has highest torque to weight ratio, high
performance of the interconnected components.
efficiency and is compact in size for a given specification.
However, it has high cost as compared to other machines. Operational Temperature: All the EV components are
Choice of each machines has its pros and cons. The selec- very sensitive to temperature, and this is yet another crite-
tion of machine need to be done by considering all this rion to be considered during the design. Temperature at
factors. the time of operation plays an important role in case of
batteries as the temperature has performance and safety
In addition , there are many choices available for
impact on the battery pack. Any temperature beyond
connecting the motor to the wheels. Single speed drive
the design limit will have impact on the performance
systems, front or rear axial drive or even advanced
andfailure of electronic components in electronic control-
all-wheel drive are the options. These also will have an
lers. Temperature also has an impact on demagnetization
impact on the overall system performance.

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effect in case of machines having permanent magnet and the designer doesn’t have to consider analyzing every
it will affect the insulation failure as well. aspect from scratch. However along with the past design
and experience, he needs to have the analysis done for the
Size and Weight of components: Another important
present requirement with a vision for the future.
consideration in EV component design is the weight and
size of the components. Any additional weight is a load Importance of Simulations
on the battery which will impact the range of the vehicle.
Simulation plays an important role in System Engi-
Volume of components plays a role as there is limited
neering as it provides a virtual proto typing feature during
space available for packing the components in a vehicle.
the requirement finalization and high-level design itera-
The total cost of Vehicle will influence the customer’s tions in a cost-effective manner. Typically, the governing
acceptance of the product. The product designer has equations in system simulations are either differential
to control the Bill of Materials (BOM) at every stage of equations or algebraic equations. Understanding these
component design and selection. Govt policies, taxation, equations and the assumptions made in deriving such
import duties etc. are other factors while finalizing the EV equations are extremely important in interpreting the
design. It is important to keep in mind the customer expec- simulation results correctly. In many cases the non-linear
tations at every step of the product design. Surveying the equations are assumed to be linear with suitable assump-
customer requirements, understanding the needs and tions or non-linearity is incorporated through look up
implementing the same in the product design along with tables. The simulation engineer needs to follow the steps
their cost estimations are all a part of System Engineering. depicted in Figure 3 including the intermediate step of
understanding the physics and mathematics behind the
Overall System Engineering approach to EV design,
physical system, before getting into the simulation. Simu-
requires looking into the problem statement from multiple
lation tools provides abstracted standard library blocks
perspective before designing and finalizing on the
where the equations are hidden behind. System model
end-product. In reality it is possible that some of the designs
requires solvers for solving the equations and the type of
are available and past experience can be made use of and

Physical System Understanding Physics+Math Modeling and Simulation

Dynamic model of PMSM motor

Stator voltage and current in d-q frame

Electromagnetic Torque developed

Heat generation from Motor and generator

𝑞𝑞𝑞𝑞𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 = hA(𝑇𝑇𝑇𝑇𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 - 𝑇𝑇𝑇𝑇𝑐𝑐𝑐𝑐𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑚𝑚𝑚𝑚 )

𝑇𝑇𝑇𝑇_𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 = hA/ 𝑞𝑞𝑞𝑞𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 + 𝑇𝑇𝑇𝑇𝑐𝑐𝑐𝑐𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑚𝑚𝑚𝑚

Figure 3 : Approach to do Simulation

Figure 3 : Approach to do Simulation

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solvers depends on the type of governing equations. 6. Hannes Hick , Klaus Ku¨pper ,Helfried Sorger : Systems
Selection of suitable solver and appropriate time step Engineering for Automotive Powertrain Development ,
for the solver is also a crucial parameter for running the © Springer -2014.
simulations.
7. John G. Hayes, G. Abas Goodarzi : Electric Powertrain
Conclusion: Energy Systems, Power Electronics and Drives for
Hybrid, Electric and Fuel Cell Vehicles, © 2018 John
• Systems engineering skills are critical for designing
Wiley & Sons Ltd.
high performance EVs.

• System Engineering is an holistic approach of

Mr Pradeep Kumar Keloth is
getting the best from each of the components
former Head of Engineering
within defined limiting boundaries of operation for
for Electric Vehicle topics for
each component.
global customers at Bosch
• The problem statements are analyzed in depth Global Software Technology pvt
considering various aspects like performance , Ltd (former RBEI). He has more
cost, government policy and regulations, customer than 35 years of experience in
expectations etc. system engineering, Control and
• Requirement gathering, documentation, ideation simulation related topics in Automotive and Nuclear
for solution, prototyping etc are all important part Power plant related applications. He has a short stint
of system engineering. as Principle Consultant for Electric Vehicle topic at
Skill-Lync a Chennai based leading EdTech company
• Simulation plays an important role in system engi- in the education industry. Presently a freelance
neering with low-cost prototyping as the key consultant in the area of strengthening the Academia
benefit from simulation. Industry collaborations.
References

1. System Architecture - Strategy and Product Develop- Poornendhu P T is a Senior

ment for Complex Systems : Edward Crawley, Bruce Executive at the Mahindra
Cameron , Daniel Selva, © Pearson Education Limited Technical Academy at Mahindra
2016. Research Valley. She is a MTech
Postgraduate in Electronics and
2. Design Thinking for Mobility Engineers, Part 1- Empa-
Communication Engineering
thize & Define, Sayantan Mukherjee and Shankar
and has specialized in Signal
Venugopal, Mobility Engineering, Vol.9, Issue 1, Jan
Processing. She worked as
– March 2022.
Embedded System Engineer and as a lecturer
3. Design Thinking for Mobility Engineers, Part 2 - earlier. She has expertise in PIC microcontrollers and
Ideate, Sayantan Mukherjee and Shankar Venugopal, Communication Protocols.
Mobility Engineering, Vol.9, Issue 2, April – June
2022. Dr Shankar Venugopal is the Vice
4. Design Thinking for Mobility Engineers, Part 3 – President at Mahindra & Mahindra.
Prototype & Validate, Sayantan Mukherjee and He leads technology innovation
Shankar venugopal, Mobility Engineering, Vol.9, Issue and knowledge management
3, July – Sept 2022. for the automotive and farm
businesses. As the Dean of the
5. Systems and Architectural Thinking (SAT) for Mobility
Mahindra Technical Academy,
Engineers, C Subash, Srinivas Gunti and Shankar
Shankar is focused on helping
Venugopal, Mobility Engineering, Vol.9, Issue 3, July
young engineers to build future skills
– September 2022.

52 DECEMBER 2022 MOBILITY ENGINEERING