8.

PROJECT DETAILS

a. OBJECTIVES:

 To prepare a detailed project report based on the design and development of battery charger
for E-Vehicle.

b. SCOPE OF PROJECT:

 Arriving design guidelines for level 1, level 2 & level 3 chargers for various types of EV.
 Validate the design guidelines using simulation for various cases using MATLAB.
 Fabricating a level 2 (50 kW) charger with PLC communication protocol based on the
design arrived from the design guidelines along with an user interface to provide
communication between the charging station and the consumer using 3G-LAN-WIFI with
metal cabinet.
 Validating the level 2 charger and its characteristics in terms of different parameters such as
a) Power factor
b) Frequency Response
c) Communication with BMS
d) Current THD
e) Operating Temperature.

c. JUSTIFICATION OF PROJECT:

Fuelling with electricity offers some advantages not available in conventional internal
combustion engine vehicles. EVs are often more digitally connected than conventional vehicles,
with many EV charging stations providing the option to control charging from a smartphone
app. Since the electric grid is available almost anywhere, there are a variety of options for
charging: at home, at work or on the road. Charging your EV on renewable energy such as solar
or wind minimizes these emissions even more.

d. PRODUCTS BENEFITED:

 Feasible Electric vehicle applications

e. ANTICIPATED BENEFITS: (Abstract from c. above to be provided)

 Pollution free and sustainable.

 Provides communication between consumer and charging stations.

10. TECHNICAL ASSISTANCE/CONSULTANCY FROM OUTSIDE BHEL. (Basis of estimates for the
expenses and correspondence with the agency should be given in ANNEXURE- 4)

Source Scope of Work Charges (in Rs.)

. 1
.
 NITT Design and development of battery charger for EV. 24,15,460

12. SCOPE FOR FURTHER WORK: (Include future R&D / Demonstration projects envisaged)

After the completion of the work, the design of battery charger can be modified to make it
applicable to charge different voltage and power ratings and can able to fabricate the same.

. 2
.
 ANNEXURE-6
PROJECT SCHEDULE
Project Leader: Dr. V. Sankaranarayanan (Bar Chart)
Sl. Executing Dur Engg. DURATION (Months)
atio Hrs
No ACTIVITY Agency n Dftg Hrs 1 2 3 4 5 6 7 8 9 10 11 12

1 Submission of report on overall approach to be

followed including discussions on proposed
NITT 2 432
charger design and electric circuit design of
battery charger.

2 Report on preliminary analyses. NITT 2 432

3 Fabricating level 2 (50 kW) charger based on

NITT 4 864
design guidelines.

4 Establishment and report. NITT 4 864

. 3
.
 ANNEXURE - 2

(Common for all PIRs) FORMAT NO. 3

SCOPE OF PROJECT

1. DETAILS OF WORK PROPOSED :

Work would include:
 Arriving design guidelines for level 1, level 2 & level 3 chargers for various types of EV.
 Validate the design guidelines using simulation for various cases using MATLAB.
 Fabricating a level 2 (50 kW) charger with PLC communication protocol based on the
design arrived from the design guidelines along with an user interface to provide
communication between the charging station and the consumer using 3G-LAN-WIFI with
metal cabinet.
 Validating the level 2 charger and its characteristics in terms of different parameters such as
f) Power factor
g) Frequency Response
h) Communication with BMS
i) Current THD
j) Operating Temperature.

2. APPROACH TO BE FOLLOWED :

The steps for the design and development of EV battery charger are listed as follows:

1. Designing level 1, level 2 & level 3 chargers based on the available electrical input and the
required electrical output.
2. Simulating the design obtained in MATLAB/Simulink and validating the results.
3. Steps for the fabrication of level2 (50kW) charger is listed as follows:
I. Regulation method: Deciding the efficient method used for charging the EV.
II. Ingress protection: Choosing the standards to define the levels of sealing
effectiveness of electrical enclosures against intrusion from foreign bodies such as
dirt and water.
III. Power factor: In order to get the power-factor close to unity an efficient front end
controlled converter has to be designed.
IV. Efficiency: Losses incurred by the charger circuit should be less. So, the circuit
components must be selected properly in-order to minimize the losses.
V. Choosing the charging connector cable length and cooling arrangement for the same.
VI. Connector requirements: Selecting the connector requirements as per IEC 62196
standards.
VII. Insulation (input-output): Selecting the input & output insulation requirements as
per
IEC 61851 standards.
VIII. Cooling system: Providing a proper cooling system for the EV charger to overcome
the heat generation during charging process.
IX. Display: Selecting a proper user interface and control.
X. RFID system: Selecting a proper and efficient wireless mode of payment.
XI. Charging object: Choosing the charging object as per the required charging levels.

. 1
.
 XII. BMS communication protocol: Deciding the BMS communication protocol with the
charging object.
XIII. Electrical protections: Inclusion of all electrical protection for an EV charger.
XIV. Isolation: An isolation transformer has to be selected based on the power ratings of
the EV charger.

3. AREAS OF DESIGN WORK SUCH AS COMPONENTS / SUB SYSTEM / SUB-ASSEMBLIES / CIVIL ETC
(NAME EACH AREA INDICATING WHETHER WITHIN BHEL OR OUTSIDE)
Electric Vehicle Assembly line

4. SOFTWARE NEEDED MATLAB 2018 B

5. IMPORTANT HARDWARE/EQUIPMENT
a. Electric circuit components
b. Measuring devices
c. Additional Accessories as per the approach listed in section.2 of Annexure-2.

6. PROPOSED DATA COLLECTION / EXPERIMENTS / VERIFICATIONS

Each of the main EV components has a number of technologies that are currently in use or can
become prominent in the future. EVs can cause significant impacts on the environment, power
system, and other related sectors. The present power system could face huge instabilities with
enough EV penetration, but with proper management and coordination, EVs can be turned into a
major contributor to the successful implementation of the smart grid concept. There are possibilities
of immense environmental benefits as well, as the EVs can extensively reduce the greenhouse gas
emissions produced by the transportation sector. There are many things to be considered while
assembling EV such as EV configurations, battery energy sources, electrical machines, charging
techniques, optimization techniques, impacts, trends, and possible directions of future
developments. All areas need to be carefully designed, assembled and experimentally tested for
efficient product. PLM software is used for the electric vehicle design.

7. END UTILITY OF SYSTEM/ PRODUCT / PROTO-TYPE DEVELOPED

A level 2 (50 kW) charger with PLC communication protocol based on the design arrived from the
design guidelines along with an user interface to provide communication between the charging
station and the consumer using 3G-LAN-WIFI with metal cabinet.

1.0 PROJECT ABSTRACT:

The design and manufacture of electric vehicles is becoming important with the rising cost of
petrol, and the effect of emissions from petrol powered vehicles on our environment. Operating
a battery electric vehicle will eliminate emissions inside our cities and reduce our dependence on

. 2
.
 oil. The number of electric vehicles on the roads is increasing every year as people become more
environmentally conscious and gasoline prices are volatile. This project is about design and
development of battery charger for an electric vehicle.

2.0 INTRODUCTION:

An electric vehicle gets power from one or more electric motors that use electrical energy
stored in the on-board batteries. Electric vehicles are a lot quieter than Vehicles with internal
combustion engines. They can be recharged with the use of low-emission power sources,
making them environmentally friendly. Electric Vehicles reduce the country’s dependence on
imported fossil fuel. As fossil fuels are getting depleted, electric vehicle will be the major mode
of transportation in future.

3.0 STATUS OF PRODUCT

The combined battery capacity in electric vehicles (EVs) is considered an integral part of
balancing a smart power grid in the future. In addition, EVs can reduce the usage of fossil fuels
in the transport sector because EVs can be charged using electricity from renewable energy
sources, such as wind turbines. To both enable a smart grid and the use of renewable energy, it
is essential to know when and where an EV is plugged into the power grid and what battery
capacity is available. Connection to the electric power grid allows opportunities such as
ancillary services, reactive power support, tracking the output of renewable energy sources, and
load balance. Most EV charging can take place at home overnight in a garage where the EV can
be plugged in to a convenience outlet for Level 1 (slow) charging. Level 2 charging is typically
described as the primary method for both private and public facilities and requires a 240 V
outlet. Future developments focus on Level 2; semi-fast charging provides ample power and can
be implemented in most environments. Usually single-phase solutions are used for Levels 1 and
2. Level 3 and dc fast charging are intended for commercial and public applications, operating
like a filling station, and three-phase solutions normally apply. Stations for public use are likely
to use Level 2 or 3 charger installed in parking lots, shopping centres, hotels, rest stops,
theatres, restaurants, etc.. A public charging infrastructure can address range anxiety.Many
electric vehicle chargers proposed in research are not tested for real time. The proposed work
will bring out the best out for the real time applications.

4.0 TECHNICAL DETAILS OF THE PROPOSED PROJECT:

The proposed EV battery charger circuit contains a

 Front end converter,
 Three phase inverter,
 Isolation transformer and
 Back end converter.
 Front end converter: It converts a balanced 3-phase power supply into a fixed DC supply
using power semiconductor switches such as SCR. A power-factor correction circuit is also
implemented along with the front end converter circuit.

 Three phase inverter: The inverter converts fixed DC to variable AC by using high frequency
switching techniques such as Sinusoidal Pulse Width Modulation (SPWM). The inverter
circuit may be identified as three single-phase half-bridge inverter circuits put across the

. 3
.
 same dc bus and the output from this inverter is to be fed to an isolation transformer
through a LC filter which smoothen the sine wave from (SPWM).
 Isolation transformer: Isolation transformers provide galvanic isolation of the input supply
from the output. This allows the creation of an electrical system that is independent from the
supply. Isolation transformers are also used to suppress the electrical noise that can occur on
the AC supply; this can impact the operation of EV batteries.
 Back end converter: This converter converts the obtained AC from isolation transformer to
DC and provides the voltage as per the required voltage level through proper filter
arrangements.

5.0 COMMERCIAL/MARKET POTENTIAL (To be provided by the concerned commercial dept. Cover

present market; future projections etc. with sources of information.)

Electric Vehicles like Electric Buses and Cars

6.0 BENEFITS

 Pollution free and sustainable.

 Provides communication between consumer and charging stations.

EXPLANATORY NOTE ON THE NATURE OF THE PROJECT

COST REDUCTION -

QUALITY -
I MPROVEMENT

IMPORT -
SUBSTITUTION

NEW PRODUCT -

ENHANCING -
BUSINESS
POTENTIAL

. 4
.
 Grading sheet for PIR is enclosed

. 5
.
 BENCH MARKING OF PRODUCT /CAPABILITY (PIR)
TITLE: Design and development of battery charger for E-Vehicle.
DESCRIPTION WITHIN BHEL NATIONAL INTERNATIONAL
PRESENT PROPOSED SCENARIO SCENARIO REMARKS
Technical / Not available. Not available. Available. Researches are
Features encouraged for
Innovation technological
improvement
Projected cost of Not available. Not available. Large scale project not High cost as the
product taken up due to high components are of higher
initial cost. price

Business Not available. Not available. Not developed. Available

potential

Time to market Not available. Not Available Not available. Available

Note: A comparative table specifying state of art in BHEL, National & International markets vis a vis the new product/capability being developed should be clearly brought
out with technical features/parameters, design modifications etc. This should be linked to the projected cost of the product and the potential of the new product and a
realistic estimate of the time required to market the same in line with the Rating system/evaluation sheet attached in the PIR. Justification for the various criteria may be
mentioned clearly in the PIR.

Project Leader GM (Technical committee chairman) (Product committee chairman)

. 1
.