1. Non-I.C. Engines for Automotive Prime Movers
P M V Subbarao
Professor
Mechanical Engineering Department
Better Structure of an Artificial Horse to Mimic a Horse…

2. Anatomy of an Artificial Horse for Busy Roads ???

3. Conclusions on I.C. Engines
IC engines are the non-ideal form of horse.
Despite over 100 years of evolution, IC engines are far from optimized
Any new idea must consider many factors, e.g.
Where significant gains can & cannot be made
Cost
Resistance of suppliers & consumers to change
Easiest near-term change: natural-gas vehicles for fleet & commuters
Longer-term solutions mostly require improved (cheaper)
Sensors (especially in-cylinder temperature, pressure)
Actuators (especially intake valves)

4. The Type of Prime Mover for Light Vehicle Sales in Two Decades

5. The Importance of Electric Vehicles:

6. Pune Urban Drive Cycle

7. Instantaneous Kinetic Energy of Vehicle

8. Inertial Energy in A Sub Cycle Duration : 450 to 475 sec
Inertial Energy, J
Time in seconds

9. Inertial Energy in A Sub Cycle Duration :1105 to 1139 sec

10. Cumulative Kinetic Energy of Vehicle per Driving Cycle
9407.5
2538.6
4921.9
9071.9
1204.1kJ

11. RPM of engine over the drive cycle

12. Fuel Consumption over the drive cycle

13. The Importance of Electric Vehicles:
Electricity can become is cheaper than fuel.
Electricity can come from renewable resources such as solar and wind power.
Electric cars pollute less than gas-powered cars.
Electric cars are much more reliable and require less maintenance than gas-powered cars. You don't even need to get your oil changed every 3,000 miles!
By using domestically-generated electricity rather than relying on foreign oil, A country can become more independent.

14. Electric Vehicles Have A Few Downsides:
Batteries need to be charged.
Car can not be used when batteries are being charged.
Car can only go 40 Miles between charges.
Battery disposal needs to be carefully managed.

15. Early Electric Cars
1914 Detroit Electric car.
Limited range.

16. GM EV1

17. Solectria Force

18. Corbin Sparrow PTV

19. Honda Civic
The hobbyist says “If I can’t buy one, I’ll build my own…

20. More Hobbyist EV’s
My Escort

21. More hobbyist EV’s
Ford Ranger

22. Major Components of an Electric Vehicle
What is out there that you need to have to build an EV (besides batteries)?
Motor
Controller
Charger
DC/DC Converter
Heater
Instrumentation
Contactor(s)
Safety Equipment

23. OEM’s: typically AC drive
AC Motors
OEM’s: typically AC drive
Fail-safe design
Low initial torque, higher at speed
requires complicated electronics package
AC speed control (similar to industrial)
Inverter (convert DC to AC)
High voltage ( VDC)
Bearings only mechanical maintenance item

24. DC Motors Hobbyist: typically brushed DC series wound
Motors are available and inexpensive
100% torque at 0 RPM
Controllers are dirt cheap compared to AC
No inverter stage required
Lower voltage system ( VDC)
Bearings and brushes are potential maintenance items (change brushes every 100,000 hours or so)

25. Motors
“Advanced DC” 9” diameter motor
Others include GE, Prestolite

26. Controllers In General, Volts = Speed, Amps = Torque Curtis
to 144 VDC, 500 Amps
Auburn Scientific
to 192 VDC, 1200 Amps
DCP
to 336 VDC, 600/1200 Amps
EVCL
“GODZILLA” to 336 VDC, 1200 Amps

27. Controllers
All use PWM technology.

28. Chargers
OEM: uses weird connectors like inductive “paddle” or AVCON “gas pump” nozzle.
Hobbyist: How about something everyone already has, like 120 VAC household outlets and 240 VAC dryer outlets?
Simple (voltage regulated) to complicated (computer controlled charging algorithms)
More advanced charging required for advanced batteries (AGM)

29. DC/DC Converters
Uses PWM to step traction pack voltage down to 12V to run car accessories.
Common in electronics use
Not widely available in the voltages required

30. Heater Ceramic - Self-regulating temperature of about 180° F.
As temp. increases, resistance increases, decreasing power and stabilizing temp.
Therefore, more air across the element = more heat.
Typically 1500W. Can be stacked for more heat.

31. Heater
The right type can be “harvested” from an AC ceramic heater.

32. Instrumentation
Instrumentation can be as simple as an expanded scale voltmeter, but can be sophisticated, and include:
Traction Pack Voltmeter
Battery Current Ammeter
Motor Current Ammeter
Amp-hour/kWh meter (“E-Meter”)

33. Contactors
BIG relays for switching traction pack

34. Safety Inertia switch to deactivate contactor(s)
same as is used to shut off fuel pumps in ICE cars
AGM batteries - no spillage
Service disconnects - BIG circuit breakers
Fuses, of course
Traction pack is electrically isolated from frame
8 G crash load rating recommended for battery boxes

35. Performance Acceleration and speed About the same as ICE
Ranges from “economy car” to “muscle car”.
DC motors great for drag racing
Current NEDRA record seconds in the 1/4 mile by “Current Eliminator”

36. Performance
tZero by AC Propulsion

37. Performance - tZero
AC Propulsion's tzero out-accelerated a Ferrari F355, a new Corvette, and a Porsche Carrera 4 in a series of impromptu 1/8 mile drag races held on January 22, 2000 at Moffett Field in Mountain View, California, and at Calstart's northern facility at the former Alameda Naval Air Station.

38. Performance Range - typically 30-60 miles
somewhat dependent on if you have a lead foot
great for commuting, which is where people use the most gas anyway.
Use an ice vehicle for long trips - the right tool for the right job.
Over 100 miles attainable with purpose-built EV’s or using advanced batteries

39. Performance
John Wayland’s 120 mile range “Red Beastie”

40. Performance
“Red Beastie’s” battery pack

41. Emissions Common claim is EV’s just move the pollution
Point taken, but power plant emissions are scrubbed to a point not possible on a vehicle.

42. Emissions
Belfast electric bus project (4 year duration of monitoring)

43. The Energy Storage System
Electric motors have high power density and good control.
A car needs to store energy for range.
Alternatives:
Capacitors or inductors
Flywheels or springs
Compressed air tanks
Batteries
Liquid fuel
Figures of merit:
Useful storage per unit mass
Useful energy rate (power) per unit mass
A 90 HP electric motor based on automotive duty.

44. Selection of Storage Technology
Energy density
Lead-acid batteries
100 kJ/kg (30 W-h/kg)
Lithium-ion batteries
600 kJ/kg
Compressed air, 10 MPa
80 kJ/kg (not including tank)
Conventional capacitors
0.2 kJ/kg
Ultracapacitors
20 kJ/kg
Flywheels
100 kJ/kg
Gasoline
43000 kJ/kg

45. Battery Vs Fuel Tank
Lead-acid battery energy density is only about 1% of the usable energy in gasoline.
Sample test car: 275 kg battery pack  equivalent to 4 L of gas!

46. Energy and Power Needs Rate is a problem.
Example: refill a gas tank with 15 gal in 5 min.
The energy rate is roughly that of 20 major campus buildings!
It is costly and problematic to fill batteries quickly.